zp-275 rotary table.pdf

ZP-275 ROTARY TABLE

Operation and maintenance manual

AG27500100-SM

March, 2006

Foreword ZP-275 Rotary Table is an important component of drilling rig. During drilling, the rotary table turns the Kelly; the Kelly turns the string and bit to drill the hole. The rotary

table is designed to conform to the Standard SY/T 5531 Rotary Table for Drilling Rig

and API 7K Spec.

In order to make operators know the rotary table well, this manual shows the

details about the rotary table. Before running the rotary table, the administrators,

technicians and operators related to this drilling job must carefully read the manual

and relative documents to master the safety-operation procedures and skills.

Meanwhile, you are also requested to abide by the rules and regulations specified in

your unit.

During application, if the parameters and information of other matched equipment

are needed, see the instruction manuals and relative documents for the matched

equipment.

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Contents

FOREWORD............................................................................................................................................................ I

1. GENERAL............................................................................................................................................................1

1.1 FUNCTIONS AND FEATURES..........................................................................................................................1 1.2 TECHNICAL PARAMETERS.............................................................................................................................1

2. CONSTRUCTION DESCRIPTION ...................................................................................................................1

3. INSTALLATION AND ADJUSTMENT .............................................................................................................3

3.1 INSTALLATION................................................................................................................................................3 3.2 ADJUSTMENT ................................................................................................................................................3

4. OPERATION AND USE .....................................................................................................................................4

4.1. HOW TO LOCK THE MASTER BUSHING AND TURNTABLE BUSHING ..............................................................4 4.2. THE BRAKE OF THE TURNTABLE ..................................................................................................................4 4.3. THE MATCHING OF THE ROTARY TABLE AND ROLLER BUSHING ..................................................................4

5. MAINTENANCE..................................................................................................................................................5

5.1 LUBRICATION ................................................................................................................................................5 5.2. ROUTINE MAINTENANCE AND CHECK ITEMS ................................................................................................5 5.3. PERIODIC MAINTENANCE AND CHECK ITEMS ...............................................................................................6

6. PACKING, TRANSPORTATION AND STORAGE.........................................................................................6

6.1 PACKING AND TRANSPORTATION..................................................................................................................6 6.2 STORAGE ......................................................................................................................................................6

7. LIST OF BEARINGS, LISTS OF SPECIAL TOOLS AND SPARE PARTS ..............................................7

7.1 BEARINGS .....................................................................................................................................................7 7.2 SPECIAL TOOLS ............................................................................................................................................7 7.3 SPARE PARTS ...............................................................................................................................................7

8. ATTACHED DRAWINGS ...................................................................................................................................8

8.1 CONFIGURATION DRAWINGS.........................................................................................................................8 8.2 PARTS LIST OF ZP-275 ROTARY TABLE.....................................................................................................10

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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

1. General

1.1 Functions and Features

During drilling, the rotary table turns the Kelly and the string hanging under the

swivel to drill the hole. On trips and running casing, the string is latched to the top

rotary table, which can receive the maximum load permitted in the drilling rig and the

long service life of the table bearings should be guaranteed in load condition. The

rotary table can transmit the enough torque and horsepower through the bevel gear

and pinion.

1.2 Technical Parameters

Model ZP-275

Table opening 698.5 mm (271/2 ) Max. Static load 4500KN

Max. Table speed 300 r/min

Gear ratio 3.67

Distance between the center of rotary table and the center of the 1st row of sprocket

1353mm (53-1/4)

Overall dimensions (LWH): 2380mm1670mm685mm Weight 6122 kg

2. Construction Description

The rotary table realizes reduction through a pair of spiral bevel gear and pinion,

i.e. it can obtain necessary revolutions and torques to drive the drill string for drilling

operation.

The rotary table is mainly composed of master bushing, turntable, spiral bevel

gear and pinion set, input shaft assembly, locking device, table base and top cover,

etc.

The spiral bevel gear and pinion are used to provide smooth transmission, small

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contacting stress and high load capacity. The gear and pinion are both made of high

alloy steel through heat treatment. The meshing clearance between the gear and

pinion can be adjusted by shim (19) and shim (20.6) which is positioned on the lower

main bearing and the flange end of input shaft.

The turntable14 is a turning part to output the speed and torque in the rotary table. The turntable bore diameter is in conformance with the regulation of API 7 K, the

gear12 is tightly matched with the turntable, the loading bearing and prevent jump bearing(40) all adopt angle contact thrust bearing, the contact thrust bearing as main

bearing not only receives maximum drill string load and casing load, but also

withstands the impact load from well bottom during drilling and tripping operations. It

has a compact construction. The bottom support ring (27) is connected with the

turntable by bolts to support the main bearing, the shims (22 are used to adjust the

axial clearance of the main bearing, the turntable is positioned on the table base by

loading bearing

The input shaft assembly is cartridge type construction, a component to input the

power to the rotary table. It consists of bearing race (20.7), bearings (20.15 and

(20.16), input shaft (20.5) and pinion (20.1), etc. The input shaft is supported in the

bearing house with a radial short cylindrical roller bearing and a radial spherical roller

bearing, the shaft assembly is mounted in the table base. The input shaft end diameter

and the key sizes conform to the regulation of No.5 shaft end specified in API 7K.

The rectangular type table base (10) is made of steel casting and welded

structure; it can withstand the maximum static load. There is a lube pool in the

chamber for lubricating the bevel gears and bearings. The table base is equipped with

left and right Z-blade locking devices, which can stop the table from forward and

reverse rotation to meet the needs of down-hole drill tool and special drilling

operations. The top cover (12) welded by riffled steel plate is a rectangular face plate

and fixed to the table base with inner-hex screws.

The master bushing (18) is split type construction, 5-1/4 four-pin-drive roller

bushing or Kelly bushing is used for drilling operation, the master bushing is

connected with the turntable and Kelly bushing by brake block (15). this rotary table

also can adopt big Kelly bushing ,the Kelly bushing device is whole type substructure,

after the relevant bushing device is put into the bore, 5-1/4 four-pin-drive roller

bushing is used for drilling operation

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The splash lubrication is applied to gear and bearing; the grease lubrication to the

pin shaft of the locking device.

The labyrinth seal is used between turntable and table base as dynamic seal; the

spring seal ring between input shaft and bearing cap; O-ring is applied to the other

static seal areas.

There are two transmission methods through the input shaft end in the rotary

table, they are sprocket which is generally integral type two-row one, and flange. The

rotary table is provided with tree sizes of sprockets which are respectively 19, 21 in

teeth and 2 in pitch, also a flange to be connected with Cardan shaft for customers

choice(Please specify the transmission method when ordering the rotary table). We

can supply customer with other specific sprocket and transmission connection so long

as the customer put forward to the requirement.

Note: Sprocket and flange are excluded in our supply scope of the rotary table. If

needed, customers should order them additionally.

3. Installation and Adjustment

3.1 Installation

The rotary table is generally mounted on the rotary table beam in rig substructure,

the top cover of rotary table should be leveled with the drill floor, after being positioned

and aligned, the rotary table should be tightened by the setting block and bolts or other

fastening ways.

NoteLocating block and connecting bolt are excluded our supply scope of the rotary table.

3.2 Adjustment

When being installed, the rotary table should be aligned as per following request.

Transmission method Installation and alignment position Permit

Sprocket Flatness error between the input sprocket of high speed shaft and the output sprocket of drawworks.


Parallelism error between the input flange of high speed shaft and the output flange of transmission device (Progressively measure 4 points adjacent to 90 degree).


and API 3# bushing are excluded in our supply scope of the rotary table. If needed,

customers should order them additionally.

5. Maintenance

5.1 Lubrication

5.1.1. The bevel gears and the bearings are splash-lubricated by the oil pool. The

sulphur-phosphorus type90 # extreme-pressure oil filled with 10 % of 4# anti-rust

complex agent shall be used as lubricant. The lubricating oil shall be changed every

two months. The oil level is subject to the highness when the rotary table stops

working for 5 minutes. When the oil level lowers to the down limitation, should fill the

lubricating oil up to the upper limitation and try to avoid overfilling, otherwise, it causes

the labyrinth seal of the low turntable leakage.

5.1.2. The pin shaft of turntable locking device shall be lubricated once a week

with 2# lithium base grease by means of grease gun.

4Lubricating points

Fig. turntable locking device

5.2. Routine maintenance and check items

5.2.1. Check oil level, oil temperature and oil quality for normal once a shift.

5.2.2. Check the spring seal ring on input shaft once a shift and the labyrinth seal

of the low turntable for leakage.

5.2.3. Check the voice and vibration of running table once a shift to make sure no

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abnormal condition will happen.

5.2.4. Check the table locking device for flexibility and reliability once a shift and

for the position requested by drilling operation.

5.2.5. Check the master bushing and turntable, bushing lock pin and brake block

for flexible and reliable rotation once a shift.

5.3. Periodic maintenance and check items

5.3.1. After completing one well, should check the lower set ring (27) and bolt (24)

for looseness, if yes, they must be tightened at 690N.m of force moment.

5.3.2. After completing one well, should check input sprocket for axial play, if

found, tighten the screws on shaft end closure.

5.3.3. After completing one well, should check input sprocket for worn-out and

deformation, if found larger, the sprocket must be repaired or replaced.

5.3.4. After completing one well, should check the bushing for worn-out and

deformation, if found larger, the bushing must be repaired or replaced.

5.3.5.When the cumulative drilling depth reaches 90000-100000 meters, should

check the bevel gear and pinion and bearing raceway for worn-out and pit corrosion, if

exceed the allowance value, they must be replaced.

6. Packing, Transportation and Storage

6.1 Packing and Transportation

During packing, the rotary table should be in brake condition; the shaft end is

coated with lubrication grease and packed as per the regulation.

The rotary table is shipped in naked packing. When moving the rotary table,

necessary crane and transportation facilities should be used, and the rotary table shall

be lifted by the four lower corners. It is not allowed to tug or pull it on the ground.

6.2 Storage

When the rotary table stops running more than 2 months, it should be stored

properly. First, unscrew the plug (21) on the table base and emptying the lubricating oil

and clean the oil pool; then, wash the gears, bearings, turntable, input shaft assembly

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and bushing; finally, apply the rust grease to all part surfaces and fitting surfaces, and

fill in the fitting clearance of moving components with rust grease.

If a long-term storage, the rotary table should be kept in dry, ventilation and

non-corrosion warehouse and make a periodic anti-rust check.

7. List of Bearings, Lists of Special Tools and Spare Parts

7.1 Bearings

Table 2 Bearings for Rotary Table Model Description Qty per unit Weight(kg)

91682/800 bearing 8001060155 1 293

1681/800 bearing 800950120 1 120 NU2330 (32630)

Centripetal short cylinder roller bearing 150320108 1 45

22330 (3630)

Centripetal globe roller bearing 150320108 1 43

7.2 Special Tools

Table 3 Special tools for Rotary Table Drawing No. Description Qty per unit Weight(kg)

AG27500134 Bushing lifting dog 2 6.82

7.3 Spare Parts

Table 4 Spare parts for Rotary Table Drawing No. Description Qty per unit Weight (kg)

HG4-692 Spring seal ring SG18022018 1

0.178

AG27500123 O-seal ring 8008.6 1 0.14

AG2750012003 O-seal ring 4208.6 2 0.072

AG27500129 O-seal ring 10008.6 1 0.16

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8. Attached Drawings

8.1 Configuration Drawings

See following drawing 2, 3, 4, and table 5.

Fig2. 275 rotary table

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Fig3. 275 rotary table

Fig4. Input shaft assembly of 275 rotary table

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8.2 Parts list of ZP-275 Rotary Table

Table 5 Parts List of ZP-275 Rotary Table

No. Drawing No. Name Qty. ZP 275rotary table (see fig.2 and fig.3)

1 AG27500101 Left pawl 1 2 AG27500102 Right pawl 1 3 AG27500103 Control rod pin 2 4 AG27500104 Pawl pin 2 5 AG27500105 Screw plug 1/8 2 6 AG2750010600 Control plug 2 7 AG27500107 nameplate 1 8 AG2750010800 Oil pointer 1 9 AG27500109 Screw plug 1 1/2 2 10 AG2750011000 Forge welding substructure 1 11 AG27500111 Wall scraper 2 12 AG2750011200 Upper cover 1 13 AG27500113 Big rig gear 1 14 AG27500114 Turntable 1 15 AG27500115 Slipper 4 16 AG27500116 pin 4 17 AG27500117 5master bushing 2 18 AG27500118 Break out block 2 19 AG27500119 Washer 6 20 AG2750012000 Input shaft assembly 1 21 AG27500121 screw plug 1 1 22 AG27500122 Lower seal set 1 23 AG27500123 O seal ring 1 24 AG27500124 Bolt M2470 12 25 AG27500125 Washer demand 26 AG27500126 Washer demand 27 AG27500127 Lower seal set 1 28 AG27500128 stopper 1 29 AG27500129 O seal ring 1 30 AG27500130 Double bank chain wheel

P=50.8 Z=19 1

31 AG27500131 Double bank chain wheel P=50.8 Z=21 1

32 AG27500132 Baffle 1 33 AG27500133 Flange 1 34 AG27500134 Main bushing lifting dog 2 35 GB1152-74 Oil cup M101 4 36 GB70-85 Allen screw M2475 4 37 GB827-86 Rivet 310 4 38 91682/800 Bearing 8001060155 1

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No. Drawing No. Name Qty. ZP 275rotary table (see fig.2 and fig.3)

39 GB91-86 Cotter pin 535 4 40 1681/800 Bearing 800950120 1 41 GB93-87 Spring washer 24 12 42 GB30-76 Bolt M1640 24 43 GB93-87 Spring bolt 16 24 ZP 275rotary table input shaft (see fig4 )

20.1 AG2750012001 Small bevel gear Me=18 Z=21 1

20.2 AG275001200200 Left Bearing cover 1

20.3 AG2750012003 O-seal ring 4208.6 2 20.4 AG2750012004 spacer 1

20.5 AG2750012005 shaft 1

20.6 AG2750012006 Washer 4265200.5 4 20.7 AG2750012007 Bearing sleeve 1

20.8 AG2750012008 Washer 3224001 1 20.9 AG2750012009 Check ring 150 1

20.10 AG2750012010 Right Bearing cover 1

20.11 AG2750012011 Shaft sleeve nut 1

20.12 AG2750012012 Key 1

20.13 AG27500121 screw plug NPT 1 1

20.14 HG4-692-67 Oil seal 18022018 1 20.15 GB283-64 Bearing 32630 1

20.16 GB286-64 Bearing 3630 1

20.17 GB5782-86 Bearing M2060 16 20.18 GB93-87 Spring washer 20 16

20.19 GB32-86 Bolt M1635 8 20.20 Iron wire 1 demand

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Foreword 1. General 1.1 Functions and Features 1.2 Technical Parameters 2. Construction Description 3. Installation and Adjustment 3.1 Installation 3.2 Adjustment

4. Operation and use 4.1. How to lock the master bushing and turntable bushing 4.2. The brake of the turntable 4.3. The matching of the rotary table and roller bushing

5. Maintenance 5.1 Lubrication 5.2. Routine maintenance and check items 5.3. Periodic maintenance and check items

6. Packing, Transportation and Storage 6.1 Packing and Transportation 6.2 Storage

7. List of Bearings, Lists of Special Tools and Spare Parts 7.1 Bearings 7.2 Special Tools 7.3 Spare Parts

8. Attached Drawings 8.1 Configuration Drawings 8.2 Parts list of ZP-275 Rotary Table

zp-275 rotary table.pdf

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