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DQ70BS-JH Top Drive Drilling System

User Manual

Heilongjiang Jinghong Petroleum Equipment

Manufacturing Co., Ltd.

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

In case of injury and the accident, the operator should use the equipment with
adequate safety awareness and take the right protection measure during the
operation. For the safety and the working efficiency , take precaution against
some potential safety hazards.

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 consists of top drive electrical system, hydraulic system, mechanical
structure and installation, commissioning, operation, and maintenance. And the
contents of the book is suitable for the equipments built for certain period . for the
revision and some contents which aren’t included in the manuals and other
problems during the process of installation, usage and maintenance, if it is
necessary, please contact us:

Tel： 86-452-2340601
Fax： 86-452-2340601

E-mail： [email protected]
Address： No.24，Delong 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 is developed instead of traditional rotary table. And is also
an important petroleum drilling equipment developed since late 1980’s. The use
of the top drive drilling system could greatly decrease the accident of pipe
stuck , Improve the working performance and working security. The top drive
drilling system is honored as one of three great technical revolutions of drilling
equipments sine 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 client’s demands . The novel design and structure ,reliable
performance ,easy manatinace make it the desirable drilling equipment at rig site
even with the complex geological structure. It is perfect equipment for deep well,
super deep well, horizontal well and directional well.

The main technical features are:

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

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

3. The patent slid-inserting type foldable structure is used in the guide beam. It is
quick, convenient and safe to install and dismantle. Comparing with the other
brand top drive drilling system, it takes 2~3 less hours to install and dismantle
the track.
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4. The patent structure of reversed oil cup structure is used on the main shaft
seal at the bottom of the gear box, which guarantees that the lubrication will not
leak during the working process even the seal on the main shaft lose
effectiveness.

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

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

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

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

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

improved the mechanical strength of cable and increased the reliability.

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

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 Contents
Prologue.................................................................................................................................................1
Summary................................................................................................................................................2
Contents.................................................................................................................................................4
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
IXWorking Curve of Top Drive DQ70BS-JH..............................................................................10
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.................................................................................................... 20
V Guide beam and carriage............................................................................................. 26
Part III Electrical Manual................................................................................................................... 27
Chapter I Safety Operation Specification..................................................................................... 27
I Safety Notice.....................................................................................................................27
Chapter II Electric System Component........................................................................................ 29
I. Incoming Line Power Distributor and Protect System..............................................30
II. AC Frequency Converter Driving System...............................................................30
III. PLC Comprehensive Control System....................................................................... 31
IV. terminal Box.................................................................................................................. 32
V. Hydraulic Lubrication station....................................................................................... 32
VI. Driller console............................................................................................................ 33
VII. Touch Screen...............................................................................................................36
VIII. Main Power Cable......................................................................................................40
IX. Other Cable................................................................................................................... 40
Chapter III Monitoring System (WINCC)....................................................................................42
I. Screen introduction.........................................................................................................42
II. System Structure........................................................................................................... 43
III. Top Drive Drilling System............................................................................................44
IV. Network Topology........................................................................................................ 45
V. Auxiliary Interface..........................................................................................................46
VI. Alarm History.................................................................................................................47
VII. Trend of the working curve........................................................................................48
VIII. System Login.............................................................................................................. 50

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 IX. Logout System..............................................................................................................51
Chapter IV PLC System Software and Hardware........................................................................ 52
I. PLC Program Structure..................................................................................................52
II. The hardware Structure of PLC System.................................................................... 53
III. Switches and indicators on CPU module................................................................. 53
IV. Module installation, Power Distribution and Indicator............................................54
V. Programmer Upload and Download...........................................................................54
VI. ET200M Remote Station.............................................................................................54
VII. Indicators on Interface Module................................................................................. 55
VIII. Remote station ET200M ,power configuration and indicators........................... 55
IX. Communication system...............................................................................................56
Chapter VI Main Electric Motor Drive System............................................................................56
I. Main Electric Motor and Frequency Converters........................................................ 56
II.Transmission Unit Structure and Operate Principle................................................. 56
III. Main Circuit and Control Circuit diagram..................................................................57
IV. Connection of Standard Control Line....................................................................... 58
V. Extensive Characteristic of Software Provide Protection for Transmission, Motor
and Process........................................................................................................................ 58
VI. Adjustable Power Limitation....................................................................................... 58
VII The “master/slave” control..........................................................................................59
Chapter VII Installation, Commission and Maintenance............................................................. 59
I. Electric installation and commission notice................................................................59
II. Electric system re-installation...................................................................................... 60
III.inspection before power on..........................................................................................60
IV. Daily maintenance........................................................................................................61
Part IV Hydraulic Manual.................................................................................................................. 62
Chapter I Safety Operation Specification..................................................................................... 62
I Safety operation notification...........................................................................................62
II Electric system operation.............................................................................................. 63
III Hydraulic system operation..........................................................................................63
Chapter II Hydraulic system structure and Principle................................................................... 65
I Hydraulic System Structure and Working Principle................................................... 66
II. Control valve unit and executive device.................................................................... 70
III Control Loop on Hydraulic mainifold.......................................................................... 74
Chapter III Hydraulic oil...............................................................................................................81
I Selection of hydraulic oil................................................................................................. 81
II Hydraulic oil Changing................................................................................................... 81
Chapter IV Hydraulic system Commissioning and Maintenance................................................ 82
I System pressure adjusting............................................................................................. 82
II Pre-setting and adjusting of hydraulic system pressure.......................................... 83
III Hydraulic system daily maintenance requirement................................................... 83
Part V Installation and Commissioning...........................................................................................85
Chapter I regulations for installation and commissionning..........................................................85

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 I Safety operation note...................................................................................................... 85
Chapter II preparation for installation.................................................................................. 87
Chapter III Installation..................................................................................................................90
I. Installing the guide beam...............................................................................................91
II. Installation of Top Drive Main Body..........................................................................101
III. Cable installation........................................................................................................ 107
III Auxiliary Device Installation....................................................................................... 113
Chapter IV Inspection after installation......................................................................................115
Chapter V commissioning...........................................................................................................116
I Electric Device commissioning.................................................................................... 116
II auxiliary function commissioning................................................................................118
Chapter VI Top Drive Disassembly............................................................................................119
I auxiliary equipments disassembly.............................................................................. 120
II disassemble Cables.................................................................................................. 122
III Disassemble Top Drive Main Body.......................................................................... 122
IV Disassemble the guide beam....................................................................................125
Attachment I Top Drive System Electrical Installation Inspecting list................ 129
Attachment II Top Drive System mechanical installation inspection list.................130
Attachment III Top Drive System Installation and Commissioning Record............131
Part VI Operation Manual.......................................................................................................... 133
Chapter I Safety Operation Rules............................................................................................... 133
I. Safety operation notification....................................................................................... 133
II. Operator safety operation notes................................................................................134
Chapter II Operating Procedure..................................................................................................136
I. Inspection before starting the device.........................................................................136
II． Hydraulic system operation....................................................................................139
III. heating the main motor..............................................................................................141
IV. cooling fan for the main motor..................................................................................141
V. Braking mode selection.............................................................................................. 142
VI. Drilling operation........................................................................................................ 145
VII. Backup tong operation............................................................................................. 151
VIII. link tilt operation....................................................................................................... 153
XI. Make Up and Breakout Operation...........................................................................154
X Drilling ahead by single............................................................................................... 161
XI. Drilling ahead by triples.............................................................................................161
XII. Back reaming............................................................................................................. 162
XIII trip in and trip out the hole....................................................................................... 163
XIV Running Casing........................................................................................................ 165
XV Well Control Operation............................................................................................. 165
XVI Jarring operation.......................................................................................................166
XVII Release drilling torque operation.......................................................................... 167
XVIII Emergency stop operation....................................................................................168
XIX Reset/ silence............................................................................................................168

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 XX Stop System............................................................................................................... 168
ENDIX I System Initial State.................................................................................................. 169
Attachment I. Driver cabinet initial state.......................................................................169
Attachment II Driller panel initial state.......................................................................... 169
Attachment III PLC Cabinet Initial State.......................................................................170
Attachment IV Monkey board operation box initial state........................................... 170
Part VII Maintenance Manual........................................................................................................171
Chapter I Safety Operating Rules............................................................................................... 171
I Safety Operating Rules.................................................................................................171
Chapter II Daily Inspection.........................................................................................................172
I It is important to inspect the following items..............................................................172
Chapter III Maintenance Items and period................................................................................. 174
I Daily maintenance Items.............................................................................................. 174
II Weekly Maintenance Items......................................................................................... 175
III Monthly Maintenance Item......................................................................................... 180
IV Maintenance Items in each quarter..........................................................................183
V. Maintenance Items in half year................................................................................. 184
VI Maintenance Items every year..................................................................................185
Attachment A Torque value of thread hastening......................................................... 188
Attachment B Recommendation of gear oil................................................................. 188
Attachment C Recommendation of Greases...............................................................188

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I General Data

Rated Drilling Depth: 7000 m（φ114 drill stem）

Max. Load capacity: 4500 kN (350ton)
Main channel: φ76mm
Rated circulating pressure: 35MPa（5000psi）
System Weight: 15t（Main body）
Working Height: 5.9m (Bail surface to elevator upper surface)
Electric Volt: 600VAC
Rated Power: 315KWX2 422HPX2
Ambient Temperature: -35℃～55℃
Altitude: ≤1200m

II Drilling Parameter

Rotary speed: 0～220r/min adjustable

Work torque: 55kN·m (continuous)
Max. Torque: 82kN·m（discontinuous）

III Main Motor Parameter

Related Power: 315KW X2 continuous

Related Rotary speed: 1200r/min
Max. Rotary Speed: 2400r/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: 68kN·m (50,000ft-lb)

Cylinder Work Pressure: 10MPa

VI Electric Control System

VFD Input Volt: 600VAC

VFD Output Frequency: 0～121Hz
Motor alarm temperature: 200℃
Lube oil temperature alarm: 85℃
Hydraulic source oil temperature alarm: 75℃

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 box～pin，70MPa
Lower of IBOP (manual): 6 5/8" API REG box～pin，70MPa
Backup Tong Diameter: φ216mm
Backup tong retaining range: φ87～φ216mm
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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 Chapter I Structure and function Introduction

The Top Drive System could drive the drilling pipe string at the very top of drilling
string directly, also make up or break out the connection at the joint part ,
move along the guide beam up and down to finish drilling.

Top Drive DQ70BS-JH Dimension

Bail
Air cooling Device

Brake Device
Main Motor

Wash pipe packing

assembly Counterbalance device

Gear Box
Cover Assembly

Rotating Link Adapter

Link IBOP Control Device

Anti-loosen Device
Manual IBOP

Back-up Tong

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I. Structure and function introduction

Mechanical structure of Top Dive Drilling System includes different components,

which are as follows:
 Power swivel
 Pipe handler System
 Guide Beam and carriage

II. Top Drive DQ70BS-JH Working Curve

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III. Power Swivel

The Power swivel consists of main motor, breaker at the top of the main motor and
air cooling system , counterbalance device, bail, washing pipe assembly, gear box
and other components. The main function of power swivel is to drive the main
shaft , make up and break out the pipe connection, make a mud circulation to
ensure the drilling work avaliable.

Brake and air

Bail cooling Device

Main Motor
Counterbalance device

Wash pipe Assembly

Gear Box

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1. Main motor
2 sets of Main motors are installed on top of the gear box. Each Motor has a main
shaft ,the bottom part of the shaft connects to a gear in transmission box, the
top part of the shaft connects to braking disc.

Each main motor could supply 315KW power continuously. The rated rotary speed
is 1200r/min at 60.6Hz frequency, stepless speed is adjusted by AC speed
adjusting system. The rated output torque could be set by current , and is
proportional to current. The motor is cooling down by the compulsory air which
goes through the main motor and comes out from the air outlet.

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2. cooling motor and Braking Device

Cooling motor is installed on top of the brake system, driven by the

explosion-proof 3P AC ansynchronous motor with the power 5.5KW. cooling air
goes in from air inlet at the top of the brake unit , goes through the the main
motor ,then comes out through the outlet at the bottom of the main motor . the
simple structure make cooling effective.
The hydraulic disc brakes is installed on top of the main shaft driven by the
hydraulic oil. The brake force is proportional to the pressure of the hydraulic oil,
the wearing of brake disc is supplemented by extension of the hydraulic cylinder.
There are 2 springs on each braking unit which can be pressured and goes back
automatically . The braking device has 3 functions while the top drive system
working.
A. hold the reversed torque of drilling tools down the hole.
B. When the pipe is stuck, if the motor torque is equal to the reversed torque down
the hole , the drilling tool could start to run backwards, so the brake is necessary
to prevent the drilling tool from disconnecting due to reversal rotating.
C. works as brake while the motor runs out of order

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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 with large transmition torque, weak noise. Bearing are SKF bearing
with the capacity against the vibration and shock.

The lubricate system in gear box is by the compulsory force driven by motor of
1.1KW which is produced by ABB. The oil going through the cooling device and
filte sprays on the lub-parts inside the gear box then returns to oil cabinet. This
way makes bearing and gear lubricated sufficiently to ensure the reliability of
lubrication. There are pressure detector and temperature cell in the lube pipes,
which can inspect a the pressure and temperature of lube system. And give the
alarm signal once there is something wrong .

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4. Wash Pipe Assembly

Washing pipe assembly is installed between the mail shaft and gooseneck, it is
same as the regular one, 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 top end is connected to the mud house ,where is the inlet of the
mud .the top cover can be removed for logging and fishing job

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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 . Balance
cylinder is fixed on bail, the main function is to balance the weight of main body.
Jinghong top drive system adopts double hydraulic cylinders to ensure the system
works more safe and reliable.

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 IV. Pipe Handler Device

Pipe handler device is the important element of top drive system, it consists of link
tilt, back-up tong assembly, anti-loose device, IBOP, rotating adapter and other
components. It could highly improve the function of automatic drilling.

Rotating Link Adaptor

Link tilt

Thread Anti-loosen Device

IBOP

Backup Tong

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1. Rotating Link Adaptor

Rotating Link Adaptor is set on the shaft sleeve whicn is connected to the
bottom part of the gear box, so it can run separately.The rotation of Rotating
Link Adaptor is driven by hydraulic motor, it could rotate CW and CCW, it propels
the adapter to rotate 360º, it is easy to grap the pipes in mouse hole. It is also
convenient to grap the drilling pipe in pipe stand box while the top drive is moved
up to Kelly board. The rotary speed normally is set at 8 r/min. It could be
adjusted according to the customer requirements.

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2. IBOP
The Function of IBOP: when the pressure in the hole is higher than the pressure in
drilling string, the IBOP can shut down the flow inside 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.

OFF

ON

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The remote IBOP can move up and down by the moment of the executive sleeve
driven by hydraulic cylinders. The rack on the executive sleeve match up with the
gears connected to the ball valve inside the IBOP .The turn of the ball valve can
open and close the IBOP . the advantages of this kind structure is simple,
driving accurately , and high transmission reliability.

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3. Side hanged back up tong

Backup tong is designed for make-up or break out the pipe ,it is not necessary
to lock the rotating adapter before clamping the pipe. This design is convenient to
change tong dies .. Oil pipe lines are embeded inside the clamp body. No pipe lines
is exposed to avoid scratching as well as improving work reliability.

24
4. anti-loosing assemble

anti-loosing assembly geoes between the joints of main shaft , IBOP joint and
the saver sub in order to prevent them from loosing when the top drive system
breakout. See the structure on the right.

25
V Guide beam and carriage

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

Carriage

Bearing Wheel

26
 Part III Electrical Manual

Chapter I Safety Operation Specification

Before installation, commissioning, operation and maintenance , please read

this manual first.
All the job mentioned above must be done by professional or specially trained
personnel, otherwise , it maybe cause personal injury or machine damage

Note It is a sign that means something about the safety of the

equipment and personnel

Caution It is a sign that means personnel injury or equipment

damage maybe occure

Warning It is a sign that means personnel injury or equipment

damage is at high risk

I Safety Notice

The following safety notices are very important for correct installation, usage,
maintenance of the Top Drive, all the operator and the maintenance personnel
must read it carefully and fully understand it:

1. it is Forbidden to work with the electricity .maintenance and operation

must be done by qualified personnel and the safety regulation must be
followed
2.don’t remove the safety cover on the high-voltage equipment, do not
maintenance or remove any electric shield element, do not pull out/ insert wire
cable with electricity.

3. don’t open the terminal box, driller consol or pull the wire with the
electricity in the environment full of explosive gas

27
 4. Before working on Frequency Converter or variable-frequency motor, turn
off the power of the Frequency Converter, test the electric current and hang the
sign” DO NOT shut the switch, people working”. Do not maintain major loop,
before DC bus voltage drop within the safety range (under DC 24V), (normally it
takes 30 minutes).
5. switch on the mechanical interlock switch 1QF or 2QF, test the electric
current with tester and make sure no voltage before replace the PLC electric
elements in cabinet.

6. Keep protective gas pressure stable in the driller console ,try to restore the
gas pressure if the protective gas pressure lost, or turn off the driller’s console
controlling power.

7. Electric control house must be grounded correctly.

8. it is Forbidden to remove the interlock of software and hardware. If have to

do so ,restore it as soon as possible after get everything normal

9. If the temperature is higher than 40℃, or the humidity is over 95% or there
is dews, do not start the frequency converter or other control power before start
air conditioner to cooling and dehumidify.

10. Check the electric control board before starting the divece to find out if
there is dews

11. When the temperature outside is high, do not let the air conditioning run
at low temperature to prevent dewing.

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 Chapter II Electric System Component

Electric control system is mainly composed of power incoming and distribution unit ,
frequency conversion driving system and PLC combination control system.

The main power supplies(600v) from the generator goes to the frame breaker
(MT12N2) produced by Schneider. The breaker is perfect against the electrical
shock . The frame breaker then make power supply to frequency converter. And to
auxiliary transformer, which provides power (400v)to the PLC cabinet

Frequency-converter system consists of 2 sets of separate frequency inverter, which

drives 2 sets of 315KW AC motor separately. These 2 motors can work separately or
together (primary and slave), with self-detecting and protection function.

the core device of driving control system is two sets of PLC units produced by
SIMENSE .one set is working ,the other one is spare part just for the reliability .. This
mode is: when one system is working, another same system is stand by, and when
the running system collapse , another system can work immediately, so the drilling
job can’t be interrupted . The PLC system is connected to driller consol and drilling
system by the PROFIBUS line. The system main PLC control unit is S7-300 system
programmable controller produced by Siemens, and the CPU is 315-2DP, the remote
control station is ET200M.

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I. Incoming Line Power Distributor and Protect System

This function is undertook by the Incoming cabinet which includes frame breaker,
auxiliary transformer, controlling transformer, and electric relay etc.

The frame breaker Q1 is the master

switch of the Top Drive Drilling System
produced by Schneider, model:MT12N2;
auxiliary transformer power is 70KVA,
and its function is to transform the
three phases alternating current from
600 V to 380 V . T1 is control station, and
the power capacity is 518VA.
Transforming 600 V AC to 220V
AC,.works as the power to control the
main air switch. HL1 is the indicator of
switch on, HL2 is the indicator of switch
off. SA is the general control of switch on and off. SB is the emergency button.

II. AC Frequency Converter Driving System

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

frequency motors. and the model is ACS800. Three-phase alternating current of
600V is fed into frequency converter，and three-phase variable frequency power
is used to drive the AC variable frequency motor. They can work separately and
together . the master/slave mode is adopted when they work together.
The AC power goes into the converter , the frequency power comes out via
rectify and invert unit .so the motor can get the various frequency power that
makes the motor run at diffident speed .
AC frequency motor is produced by WARDLEONARD in U.S.A, which power is
315KW, with rated currency 405 A. This system has the function of anti-stuck.
When the drill pipe is stopped because of the torque down hole , the motor
speed will drop rapidly . When the torque output by he motor is bigger than the
anti- torque from down hole , the motor will speed up to setting speed.

30
 The electric motor is equipped with cooling fan and preheating unit. These helps
solve the problem of cooling in hot area and heating in cold area.

III. PLC Comprehensive Control System

This part Includes logic control system and AC distribution system. PLC
Integrated Control Panels is as follow

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

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

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 c. Motor heater: used for controlling major motor tempreture . This switch
can work independently. The indicator displays the working state of heater.
After turning on the power of the frequency converter, the inter lock
function will stops heating
d. Reset/silence button (SB1): when system alarms, the indicator flashes,
Press silence button, the beeper stops beeping , but the fault/alarm
indicator still stay on .
e. Mud pump interlock switch (SA6): used for mud pump interlock control.
In interlock state, only stop the mud pump first , the IBOP can be close .if
well control button is press down , the mud pump will stop and the IBOP
close. In un-interlock state, the IBOP can open and close freely

IV. terminal Box

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

It can send back some signals to PLC system such as air pressure signal of main
cooling motor, temperature signal of main motor, over temperature alarm signal ,
temperature signal of hydraulic oil, pressure signal of lubricating oil, main motor
encoder etc.

V. Hydraulic Lubrication station

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

lubricating pump motor (1.1KW), etc. It is controlled by driller’s console. The
motor is explosive-proof three-phase ansynchronous motor. Lubrication station
is set on top drive body.
1. Hydraulic pump switch has three positions: 1). auto, 2). start, 3). stop.
1). Auto: switch at auto, the system will run based on the PLC program.
2). start: switch at start, the hydraulic pump will run.
3). Stop: switch at stop, the hydraulic pump will stop.

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

32
VI. Driller console

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

33
1). Indicator, Button/Knob Switch’s Functions Showed as Followed:
No name Type Function

1 emergency 1SB1 When the invert or main motor break down,

button self-locking press this button ,and the system will stop
working. After clearing all faults , just
reset it (CW rotation)
2 Ready light 1HL2 green light When systems all are ready, it on .
3 Fault/alarm 1HL3 red light When alarms happen , it flash at every one
light second; when fault s appears , it on all the
way
4 Brake light 1HL5 red light When brake works , it on
5 Brake mode 1SA10 three At brake mode, the brake solenoid works,
Brake/off/auto positions switch and the brake indicator is on . At auto mode,
the brake is controlled by PLC . At off mode,
solenoid valve releases, main shaft rotate
freely.
6 IBOP light 1HL4 red light When IBOP closed, it is on.
7 IBOP 1SA11 two At closed positions, hydraulic valve close the
closed/ope positions switch IBOP, the mud circulation is not aviliable
n switch
8 Well control 1SB2 red button When kickoff occurs, this button is
interlocked with other functions.
9 Motor 1SA1 3 Select motor of top drive: M1 or M1+M2 or M2
selection positions
A/A+B/B button
10 Hydraulic 1HL1 green light When hydraulic pump running normally, it
pump running lights.
light
11 Hydraulic 1SA6 three At stop positions, hydraulic pump stops; at
pump positions button start positions, hydraulic keeps running; at
switch auto positions, pump is controlled by PLC
auto/stop/st programe.
art
12 Link tilt float 1SB4 button This button activates the floating solenoid ,
which keep the link tilt at the center position
just over the well head.
13 Link tilt ISA9 Three It is a self –reset switch.. When it is at
adapter positions “counterclockwise” positions, the link tilt
Counterclockw Self-reset adapter rotates counterclockwise; when it at
ise/clockwise “clockwise” positions, it runs clockwise; when
it is release, it spring back to center
positions automatically.

34
14 Link tilt switch 1SA7 three A self –reset switch . when it is set at
backward/for positions, forward ,the link tilt will move forward to the
ward resetting key mouse hole or to the monkey board .,when it
is set at backward ,the link tilt will move
backward , the elevator will get off the pipe.
15 Hydraulic 1SA8 2-position Open or close the elevator
elevator button
open/close
16 motor cooling 1SA2 3-position For control the cooling fan running. At “on”,
fan button cooling fan start running, at “off” cooling fan
auto/off/on stops running. At “auto”, cooling fan is under
control of the PLC programe.
17 motor rotary 1SA3 three Control the direction of main motor
direction positions button
backward/stop
/forward
18 operation 1SA4 three Choose the working mode for top drive
mode positions switch
drill/spin/torqu Right position
e spring back
19 backup tong 1SA5 two Work together with the mode switch , when it
Release/Lock position button is turned right , the clamp close and bite the
Right side spring pipe , that make break out possible . when it is
back released ,the clamp can’t work
20 makeup torque potentiometer Set the maximum torque value , for making a
set connection .
21 Drilling torque potentiometer Set the maximum torque value , for drilling
Set mode .
That is the max which the top drive can output
22 setting speed potentiometer In normal drilling operation, set limit in
of drilling transducer, and set max speed.
23 Torque Guage indicator Show torque out put by the Top driver with
KN·m unit.
24 Rotary Gauge indicator Show the speed of the top drive with r/min
unit.
25 Reset /slience 1SB3 Green Reset the equipment ,when some faults takes
button place. And make the beeper slince
26 counterblance 1SB5 Green Press this button, the counterbalance cylinder
button lift the top drive upwards automatically about
7cm.this can prevent the pipe thread from
damaging.

35
2). Throttle for speed control
The Throttle is used for setting rotary speed that is output by the invert. The scale
on the throttle can help to set the max- speed . When turning right ,the rotating
speed will goes up until to the max 220r/min. when turning down the
throttle ,the running speed will decrease until to the zero .the rated speed is 110
r/min.

3). Drilling Torque throttle

The throttle is used to set the drilling torque. Turning the throttle
counterclockwise will reduce the drilling torque limitation until to zero . Turing
the dial clockwise, will increase the drilling torque limitation up to the max
55KN.M
The maximum drilling torque limitation is 55kN.m (set at workshop).

4). Makeup Torque throttle

The throttle is used to set the make up torque. Turning the throttle
counterclockwise will reduce the make up torque limitation until to zero . Turn
ing the handle clockwise, will increase the make up torque limitation up to the
max 55KN.M
The maximum ,making-up torque limitation is 55kN.m (set at workshop).

VII. Touch Screen

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

36
1). Main Frame
show output torque, output speed, both motor parameters including: motor
speed, running frequency, motor current, motor power, motor temperature,
alarm, cooling fan running etc.

2). Auxiliary Frame

Show link tilt state , hydraulic system state, lubrication system state, other
information
Link tilt state: tilt forward tilt backward link tilt adapter rotate clockwise link
tilt adapter rotate anti-clockwise ,link tilt float

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 running , low pressure signal, high
temperature alarm, heating state and lubrication oil temperature

Other system include: IBOP valve open, IBOP valve closed, backup tong clamping,
backup tong loosen, brake state.

37
And other working state of top drive drilling system.

3). Alarm screen

Recording all alarm events .

38
4). Senior management screen
The user can enter the screen by feeding in the user name ‘JH’ and password
‘8888’ .

You can choose the soft key board which appears on the screen .

39
VIII. Main Power Cable

The function of main power cable is to send power supply from inverter to main
motor on Top driver.
For easy installation, the cable is divided into three segments:
1. The first segment is ground cable; it’s 26m, from main control cabinet to
derrick cable.
2. The second segment is derrick cable; it’s 48m, from the base of the derrick to
derrick terminal board.
3. The third segment is service cable, it’s 26m , and one end is connect to the main
motor, another to derrick cable.

For the main cable ,each end has four quick connectors which are labeled
separated by U (yellow)k, V (green), W (red) . When making connection , make
sure they are matched up very well, U to U, V to V, W to W.
The quick connectors at both end of the cables ,and at the control house and main
motor .makes the installation of the cable much easier .

Stick in the male part into the female part in place , and lock the nut firmly
The length of the cable is decided by the distance between top drive electric
control room and derrick,. If the service cable and the derrick cable (total 74m) is
long enough, the ground cable can work as the spare part.

the ground cable has the same length as the traveling cable, they can be
exchanged .each other.

IX. Other Cable

1. Driller panel Control Cable

There is one cable for the drilling console.
There 12 conductors inside the cable : 4 for the power of the driller console, 1 for
emergency control ,2 for communication .and the othe 5 works as spare part
2. terminal box cable
The terminal box is set on the body of the top drive . Its function is transit the

40
auxiliary power, control power and control signal to the function unit , and send
the feedback signal to controller cabinet or frequency inverter.

There are two cables running from cabinet to the terminal box.
1. 15 conductor cable: cable size 3×6+6×4+5×2.5
2 2
3×6 mm is for hydraulic pump ,to 2 sets of main motor fan is 6×4 mm is for
2 2
the cooling fan motor , 3×2.5mm is for the lub motor , 1×2.5mm is for heating
hydraulic and lub oil.
2. 60 conductor control cable: cable size 30×2×1
Including 24v power, solenoid power line, feedback signal and encoder singnal.
2. The two cable is divided into three sections: ground cable 26m; derrick cable
48m; service cable 26m.

3. ground electrode
The Electric control system of top drive adopts three phase four-wire system.
on the diagonal corner there are two ground bar which are connected to the

cabinet via a cable of 70 mm2.

The two ground electrodes are 1.8m long, with the galvanized layer . there is a
5 meters long cable running between the cabinet and electrode . the ground
bar is as follow, the connection part is hit 300MM down into the earth.

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

41
 Chapter III Monitoring System (WINCC)

I. Screen introduction

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

Title bar: show name.

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

Auxiliary interface screen

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

42
II. System Structure

Chick on ‘system structure’ to enter screen as follow:

In this screen, the basic information and construction can be seen as follow:
Running state of A Cooling fan , Running state of B Cooling fan
Running state of A Main electric motor, Running state of B Main electric motor
Running state of hydraulic and lubrication pump, IBOP state as well as link tilt
state
In any function module, red color means closed and green color means open

43
III. Top Drive Drilling System

Chick on the top drive drilling system button , the following screen is 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 the state of top drive drilling system.

In this screen, operator can know:

A main motor parameter: Motor current, voltage and other 8 parameters
B main motor parameter: Motor current, voltage and other 8 parameters
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 color means closed and green color means open

44
IV. Network Topology

Chick on the ‘network topology’ to open the screen as follow:

In this screen, operator can know all networks state that helpful to diagnose
malfunction.

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

45
V. Auxiliary Interface

Chick on ‘auxiliary interface’ to enter interface as follow:

In this screen, it show the work state of any other auxiliary units except for the top
drive system parameters. 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 fault information.
3. Lubrication system, show on/off of lubrication pump, current temperature,
as well as fault information.
4. Auxiliary system, show state of IBOP, electric house temperature, state of
backup tong.
5. Show the working state, include drilling waiting, drilling and 7 other
parameters
6. Control panel indicator, including A/B system running, and some

46
 synchronous informations
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 information includes date, time, number, state and messege text.
When alarming comes up , characters and background is shown by red color ,and
a mark of ‘+’ will appear
When alarm disappeared, characters and background color change back to
regular color, the status bar appears ‘-’.
Alarm confirm the alarming can be confirmed by the button
Chick ‘recent pigeonhole’ or ‘future pigeonhole’ can see alarm history.

Chick on ,some alarming record can be shown.

is used to show the alarming records by different order ,the first one

47
show the first piece of information ,and the second one show the last piece.

VII. Trend of the working curve

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

In this interface, there two mode to show working curves ,history and real .you
can get what you want by hit the buttons on the left upper conner.

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

48
49
VIII. System Login

Chick on ‘system login’ in toolbar to enter interface:

All buttons in this screen can function only after the user successfully login.

50
 According to different authority grade, the buttons which can be used are
different. But in any state
By pressing ‘ctrl+A’ can go back to login screen.
The contents in this area Including: Reverse rotate allowed; Reversal rotate
forbidden; change to Chinese language ;change to English language

IX. Logout System

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

In this interface, you can choose the way to log out

Including:
Logout and return to WINDOWS: logout and go to WINDOWS.XP
Log off system: logoffr and return to welcome interface.
Reset compute,
Turn off computer

51
 Chapter IV PLC System Software and Hardware

I. PLC Program Structure

OB1: Main loop block, it can be executed periodically . and the emergency
operation mode is implemented here. Call some subroutines and
communication drive program.
OB82、OB85、OB86、OB87、OB121、OB122：Diagnostic and interruption
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: deaingl with the emergency stop l , send out the signals to control the
equipment.
FC4: pump control functions including hydraulic and lubrication pump
automatic mode.
FC5: the link tilt control to realize the functions: such as tilt forward ,tilt
backward ,rotate clockwise ,rotate anti-clockwise.
FC6: control functions of backup clamp.
FC7:the brake control block to realize the control of the main shaft.
FC8: well control state and IBOP control.
FC11: the motor selection, according to working conditions, select the
working state of motor.
FC12: the cooling fan control function. choose the cooling fan mode
according to the state of the main motor.
FC13: the invert control block , send the control signal to keep the inverter
in a standby state.
FC14: deal with the signal to control the invert to get it run or stop.
FC15: the speed reference signal to invert
FC16: the torque reference signal to invert.
FC17: make a choice of different working procedure
FC18: set the speed and torque limitation
FC19: speed and torque output indication.
FC20: write and read the processing data between the invert an PLC

52
 FC21: over temperature alarming for hydraulic an lubricating oil
FC22: the indicating function of system failure.
FC23: the communication failure function.
FC24: over temperature alarm for main motor .
FC25: the additional function of program.
FC26: the encoder mode choice
FC27: show the working state

II. The hardware Structure of PLC System

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

Master control station consists of power supply module, CPU, switch input, the
switch output, analog input, analog output module.

The remote control station consist of : ET200X (IM153-1 interface module), the
switch input, the switch output, analog input, analog module.

III. Switches and indicators on CPU module

1. State light on CPU

SF System fault Normal on (red) Hardware or software error
or fault
BUSF Bus Fault Normal light on/flash Network fault or station lose
ed)
DC5V Inner power Normal light on (green) CPU power normal
FRCE Output Normal light on (green) Force output
force
RUN CPU Normal light on (green) CPU running state
running
STOP CPU stop Normal light on /flash CPU stop state
yellow)

53
2. CPU Work mode select switch
Up Running+programme CPU running , can revise programme online
Middle Stop CPU stop
Down memory clear Clear RAM

IV. Module installation, Power Distribution and Indicator

1). All modules of PLC system are set on guide beam, remove the fastening screw
at the bottom of the module before replacing the modules . Installation of the
modules is done from the front to the end . remove the modules in the reverse
order.
2). Each channel of input/ output module has one indicator, if the light is on that
means the logic state is ‘1’ . there is a input or output signal.

3). Analog input/output module is set to 0-10V working state. If there is a

hardware configuration fault or DC24V power breakdown, the red light SF will be
on.

V. Programmer Upload and Download

The software of PLC system can be uploaded to host computer or downloaded to

CPU .
If replace the CPU module or memory card, the follow two methods can be choosn:
one is insert the memory to the new CPU module ,and the program will be read
automatically after the power is on again. The other way is to down load the
program by the computer
* Upload and download program should be only done by professionals

VI. ET200M Remote Station

The hydraulic system is set on the body of the top drive drilling system, and the
monkey board control is optional , so there is only one remote station. With this
design, the communication fault can be reduced greatly . The remote station has
8 Code Switch used for setting Profibus station address. There is a switch On the

54
 Profibus plug which can make the terminal resistance In on or off state .for the
last station the switch must be put on..

VII. Indicators 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 Communication fault with CPU
(red)
ON Inner power Normal light on Control power normal
(green)
DC24V Input/output Normal light on Input/output power normal
power (green)

VIII. Remote station ET200M ,power configuration and

indicators

1). ET200M and module are set on guide beam, remove the fastening screw at the
bottom of the module before replacing the modules . Installation of the modules
is done from the front to the end . disconnection of the modules in the reverse
order.
2). Each channel of input/ output module has one indicator, if the light is on that
means the logic state is ‘1’ . there is a input or output signal.

3). Analog input/output module is set to 0-10V working stae. If there is a

hardware configuration fault or DC24V power breakdown, the red light SF will be
on.

55
IX. Communication system

工 控 机 电 气 室 A系 统 PLC DP 电 气 室 B系 统 PLC DP 1#主 电 机 变 频 器 2#主 电 机 变 频 器 司 钻 房 A系 统 PLC DP 司 钻 房 A系 统 PLC DP

1#网 络 接 头 2#网 络 接 头 3#网 络 接 头 4#网 络 接 头 5#网 络 接 头 6#网 络 接 头 7#网 络 接 头
CZ12 CZ22
DP1 DP2 DP3 DP4 DP5 1 1 DP6 DP7
2 2
3 3
ON OFF OFF OFF OFF ON ON

CZ13 CZ23
A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 A1 B1 A2 B2 1 1
2 2 A1 B1 A2 B2 A1 B1 A2 B2
3 3

KA1 KA2 KA3

Chapter VI Main Electric Motor Drive System

I. Main Electric Motor and Frequency Converters

Top drive drill system has 2 sets frequency converting units that control two set
motor separately. The transmission units mode are ACS800-07-0610-7.

II.Transmission Unit Structure and

Operate Principle

1). Protection grade of transmission unit is IP 21;

2). Components in transmission unit:

Fuse (main switch/ breaker)
Auxiliary circuit fuse
Inlet contactor
EMC Filter with +E202 ,control unit (RDCU,RMIO)
Transmission control units (RDCU, RMIO);
Frequency conversion module;
Profibus-DP adapter;
Interface port for encoder;
Communication adapter. RDCO-02

56
 3）apparatus on the swing door
optional control panel
fuse-switch operating handle
switches for contactor and
emergency stop button.

III. Main Circuit and Control Circuit diagram

Communication Model Port 1:

Control Panel
RPBA,
Connector

Communication Port 2: RATA-02C

External control by Motor Control
analog/digital inputs/outputs I/O Panel Communication optional Module:
signal. RDCO-02

AC Power Supply Frequency Convertor

~ = = ~ Output

Brake Unit

Brake Resistance

57
IV. Connection of Standard Control Line

3 programmable difference input port: 1 voltage s signal, 2 current signal.

6 programmable digital input port
2 programmable analog input port
3 programmable relay input port

V. Extensive Characteristic of Software Provide Protection

for Transmission, Motor and Process

1). Environment Temperature

2). DC Overvoltage
3). DC Undervoltage
4). Transform Temperature
5). One phase missing
6). Overcurrent
7). Power Limitation
8). Short Circuit
9). Programmable protection

VI. Adjustable Power Limitation

1). Control signal monitor;

2). Danger frequency leap over;
3). Current and torque amplitude limitation;
4). ground fault protection;
5).EXTERNAL FAULT;
6). MOTOR PHASE LOSS;
7). Stall Protection
8). Electric motor Over-temperature protection;
9). Under load protection;
10). Control PANEL LOSS.

58
VII The “master/slave” control

“master/slave” is designed for multi-transmission, which is composed of

several ACS 800 units , the main shafts are connected each other via gear, chain
and convey belt. Working load can be allotted evenly among the motors. The
outside control signal is only sent to master one ,and the slave one gets the
control signal from the master via the fiber.

Master motor is typical speed control, other transmission units follow the torque
or speed of master motor. Normally, the two units are connected by gear or
chain, the slaves should adopt torque control mode to synchronize the speed of
the master motor.

This control system has single motor mode (A or B) and double motor mode
(A+B). Double motor mode adopts the control way of “master/slave ”

Chapter VII Installation, Commission and Maintenance

After shipped to the well site, installation and commission should be carried out
as follow. This manual mainly provides general requirements and notices about
electric system installation and commission.

I. Electric installation and commission notice

Notices before installation

1). Before disassemblying electrical system, mark the cables and connection
joints for the installation next time
2). Before confirming everything is OK, keep power off and hang ‘no switch on,
people working’ sign.
3). Generally, after competing all the installation and examination is done , then
switch on the power to ensure safety of people and equipment
4). The personnels must wear labor protection wares.
5). It is forbidden to work on the equipments with electricity.

59
6). Wearing safety belt while working at high position , tools and spares should be
put into tool bag, in order to prevent from dropping down.
7). Forbidden to work outside in the bad weather condition such as windy,
thunderstorm or sleet weather.
8). Pay attention to the insulating grade for the tools , the adequate protection is
necessary .
9). Read the electric manual carefully, be familiar with the circuit diagram.
10). Electric controlling room is designed with no anti-explosion function,
therefore, there should be no explosive gas around.

II. Electric system re-installation

1). Turn off the main power switch, auxiliary transformer power switch 600v
power and 380v roompower switch before installing.
2). Electric controlling room should placed horizonal and off the ground, to
prevent water coming in and erosion . outlet socket should face to the mast.
3). Hammer in the ground bar 4 meters from the control room at the diagonal
corner ,the resistance should less than 4Ω.
4). Notice direction while fixing the cable, first motor cable and terminal box
cable , then traveling cable and ground cable, the control room connection is
the last one.
5). All cable plug should screw in tightly to prevent from coming off and water in
6). Do measure the electric motor and cable before connect the cable to the
electric controlling room.
7). Examine the cable before turnning on the power.
8). Examine the elements in control cabinet ,try to find out if there is damage or
loosen parts.
9). confirm selection switch at original position.

III.inspection before power on

All cables are connected correctly , no damage apparatus, and 600v main power
is ready , the top drive drilling system power can be switch on.
1). Check if the main power i is 600v±10%, switch on the main breaker (Q1)
2). Turn on the auxiliary transformer inlet switch Q2 in power cabinet and auxiliary

60
transformer outlet switch 1QF in PLC cabinet. .or you can choose to switch on the
inlet switch 2QF from the rig generator.
3). Switch on PLC cabinet and socket. If there humidity or high temperature, it is
necessary to start air condition to dehumidify or get temperature down
4). Engage the power to all units from top to bottoml
5). Turn on the frequency invert
6). Turn on the supervisory system.
7). Start lubrication pump, hydraulic pump and cooling fan on driller’s console,
and check direction and running state.
8). Check the motor of A, B, A+B
9). Check if the auxiliary function works normally.

IV. Daily maintenance

Daily maintenance is a necessary for electrical unit running normally. Therefore, it

is necessary to make regular maintenance, examine

1). The main maintenance for the electrical device is to keep them clean and dry ,
if the device is left idle for a long time ,just get it clean and dry out the humidity
by a heater. Make sure the insulating resistance is right . for 380v or less system
the resistance is above 1MΩ and 380-600v the insulating resistance above 5MΩ.
if condensation appears, stop the electric system and dehumidify.

2). The connection on all parts should be tight, the screw on electric device should
stay firmly, plug connector should not loosen.

3). Check the cable regularly, it will be changed every 4-6 years

4). Pay attention to current and torque when motors are in running state

5). Driller’s console is equipped with explosion-proof device such as air filter and
oil-water separator to ensure the air is dry and clean and no explosive and
flammable gas come in

61
 Part IV Hydraulic Manual

Chapter I Safety Operation Specification

I Safety operation notification

Note some notices to personnel injury or equipment damage

Caution This sign means a risk of personnel injury or equipment

damage.

Warning This sign mean personnel injury or equipment damage

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

repairing on hydraulic equipment in order to avoid personal injury and equipment

damage.

Except for the main contents in this manual ,there are some signs of “notes”,

“caution” and “warning” . they are used to warn the operator of the risk of

personnel injury or equipment damage please pay enough attention to these

sings ,.

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

maintaining of hydraulic system should be done by the qualified people. Please

read this manual and the related technical documents carefully before operation.

The above people and other people working close to the equipment should given

proper training and work with proper protective appliances.

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

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

operator. Strictly forbid to do any maintaining, repairing and adjusting on

62
equipment in running state. Strictly forbid any testing on unfamiliar parts. Please

read and understand all safety warning before start working on the equipment

II Electric system operation

The hydraulic system includes electric control loop and elements. Before
operation on the electrical components, please note the following proceedings:
1) Read electric manual carefully, and be familiar with electric circuit diagram and
equipment demand for power and voltage;
2) Using special instrument for electrical parts . and make sure the tools suitable
for the voltage grade requirements;
3) During any operation, make sure wearing right safety ware.
4) Please disconnect all power supply, and hang sign “operating, not switch on”
5) Before dismantling electric joint, please make the mark on wire (cable) and
connection terminal to assure re-connection job correctly next time

III Hydraulic system operation

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

the following proceedings:

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

hydraulic system and the structure, function

2) discharge all system pressure slowly, and make sure no oil pressure in system

pipeline and accumulator;

3) Before dismantling pipeline, please make marks on the hose to assure correct

reconnection next time

4) Take effective measure to prevent hydraulic oil from leaking into other electric

and machinery parts.

5) Before starting hydraulic system, air should be discharged. That is harmful

to stabilization..

6）System commissioning should be carried out before hydraulic system put into

use.

63
7) After hydraulic system is put into use , examination and recording job should

be done regularly, including oil temperature, oil pressure, oil pollution level,

stability. etc.

Before disconnecting hydraulic pipeline, please shut down valve ,

and prepare suitable container, oil plug, cotton, silk and so on, in
order to avoid the oil leakage, which will pollute equipment and ambience.

The temperature of equipment and hydraulic oil may be high

enough to personal injury , make sure the temperature goes
down and low enough to approach the device

when dealing with the hydraulic components and parts, take

enough care to avoid surface damage.

Before installing and maintaining hydraulic equipment , please cut

off the power, hydraulic oil and compressed air, and release the pressure
in accumulators.

Please lock main source of power correctly before greasing, testing

and replacing components.

Please wear protective glasses.

When system is in operation, the temperature equipment and

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

Do not try to examine hydraulic oil leakage with your hand. Please
release pressure in accumulator thoroughly before maintaining

64
 hydraulic system
Before opening hydraulic system, please clean operating area
thoroughly. Be sure to seal the hydraulic pipeline in time. The dust
is harmful to hydraulic system, and may result in equipment
malfunction and personal injury.

Please check hydraulic system everyday to confirm whether there is

pipe leakage; damage or wear out on the hose .and the dirty stuff
should be cleaned out ,when replacing the hose , fittings

Chapter II Hydraulic system structure and Principle

This chapter mainly describes the structure and working principle of hydraulic
system, it would help operator work correctly. Detailed principle of hydraulic
system refer to “hydraulic manual”.

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

shaft movement driven by main electric motor, other functions such as make up
and break out, link tilt moment, IBOP control ,brake and counterbalance are all
controlled by hydraulic unit

The hydraulic system includes Counterbalance system, brake system, link tilt
control system, link tilt adapter rotation system, IBOP ,backup tong ,hydraulic
elevator
The hydraulic system consists of
1) hydraulic source
2) Hydraulic mainfold

3) executive device (braking cylinder, balancing cylinder, rotating link adaptor

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

4) Hydraulic pipe

5) accessories

65
Hydraulic system main technical specifications are as follows:
Rated pressure 13.5 MPa
Rated flow 37L/min
Power 380 VAC / 50 HZ
power of hydraulic pump 5.5 Kw Level 6
volume of tank 110 L
Control voltage of solinoid valve DC24 V
Explosion-proof grade EXdIIBT4
Clearness grade Level 7 (NAS1638), 16/13(ISO4406)
Filter accuracy: Oil sorbent filter 100 um,
Highpressure filter 10 um,
lubricate filter 100 um

I Hydraulic System Structure and Working Principle

1. Hydraulic source
Hydraulic source consists of oil tank, oil pump motor, and etc, which provide
hydraulic power for the system The oil tank and pump unit are mounted on the
top drive body which bring on some advantage such as energy saving,
integration structure , short pipeline, rapid response .

2. Oil tank
The oil tank is made of stainless steel, and its volume is 100L; in addition to
storage of hydraulic oil, it also has the functions of dissipating some heat
produced in system operation, separating gas and sediment in oil.
Oil in the tank should connect with atmosphere. An air filter is set on top of the
tank for reducing oil pollution.
The oil level and temperature gauge are set at the side of tank, so as to show the
oil level and temperature conveniently.

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

66
Type ： M2JA132M6B
Explosion-proof grade： (ExdⅡBT4)
Rated power： 5.5KW
Rated speed： 950r/min
Pressure limited variable flow ram pump (produced by Japanese YUKEN):
A37-F-R-01-H-S-K

Work condition and parameter description:

A. In order to make the pump last longer, we adopt 6 poles motor because it can
reduce the runnin g speed of the motor
B. Pump features: When the system pressure increases and is close to the preset
pressure , pump flow automatically decrease, but keep the pressure stable, and
the pressure and flow can be adjusted manually . This pump is with good
chocking character , reduce the energy consumption,
And heat emission.

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

32
101.6 -0.05 -
202

58.7

30.2

Inlet
6.35 +0.03
0

Outlet

67
4. Thermometer

Direct reading type liquid indicator and thermometer is mounted

at the side of the oil tank, and the level and temperature
of the oil tank can be read out directly.
Model： YWZ-150

5. inlet Oil filter

Filter is the element to clean the oil, oil filter is
mounted inside oil tank by thread
Oil filter parameters:
Model: WU-100X100J
Rated flow: 100L/min
Filter accuracy: 100μm
THE indicator on driller’s panel can remind you of
replacing the filter when the light is on
6 hydraulic oil level guage
Model: UHK-30-200BD explosion proof floating
level controller
Explosion-proof sign：ExdIICT4-T6

Environment Temperature: -40℃-70℃

68
Liquid level controller is mounted at the bottom of oil tank by screw thread. The oil
level and temperature can be seen freely, and alarm signal will appear when the
level is too low or the oil temperature is too high.

7. radiation fin
The highest oil temperature on
hydraulic system is no more than
80 ℃ , when over 35 ℃ , it can be
cooling down by the air going
through the radiation .the radiation
should be cleaned regulaly.

8. three-way ball valve

There are two pieces of 3-way ball valve on Top Drive body. One is installed

outside of manifold , the other is installed on the side of oil-return filter. Operators

could choose to cooling down the hydraulic oil, lubricate oil or not by changing

the handle position on the valve. (before shipment ,t the 3-way ball valve was set

to let the oil go through the radiator, when the working temperature is low,

enough (below-5℃ )r, switch the valve to the by-pass

9. Air Filter
Air filter is set on the top of the tank

Main function
1. Exchange air so that keep the same pressure with atmosphere.
2. Filter the impurities in the air

69
10. High Pressure oil filter
Main specifications of pressure oil filter:
Model：ZU-H63×10
Normal flow rate ：63L/min
Filter fineness：10um

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

11.the cooling of the hydraulic oil

There is not separate cooling fan for the hydraulic system, the hot oil is cooled by
going through the radiator mounted on the motor cooling fan . that means the
save of the energy.

II. Control valve unit and executive device

The control valve unit is composed of 7 control loops in charge of different

operational function. Each loop has a pressure testing point to monitor the
pressure, meanwhile, it could also discharge the gas in tank, keeping system work
steadily.

70
 1. Hydraulic system schematic diagram and element list
Brake Cylinder of Counter Balance Rotating Link Adapter Backup Tong Hydraulic Elevator Tilt Cylinder IBOP
Nitrogen Pressure of
Accumulator 8 MPa
6
12

13

11
G1' G1 MP1 T1 G2' G2 MP2 G3 G4 G5 G6 G7 G8 MP8 MP9 G9 G10 MP10 G11 G12 MP12
M18×1.5 M14×1.5 M14×1.5 M18×1.5 M18×1.5 M18×1.5 M14×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5 M18×1.5 M14×1.5 M14×1.5 M18×1.5 M18×1.5 M14×1.5 M18×1.5 M18×1.5 M14×1.5

On this point(Electromagent Power On)

Tilt Cylinder in Float Situation

(102) ② (103) ② (38) 4

(208) ①
1.1

ab
1.2

b
a
7 ③
Nitrogen Pressure of ③ ① ③ ① (39) (37) ②
Accumulator 5 MPa 7MPa (203) ③ (205)
① ② ① 10
②
8.4
M14x1.5

16 MPa 16 MPa

15.5 MPa (204)

8.2 8.3
② ② ① ① ②
① ②
(201)
(8) (6) 2.1 (18) (16) (28) (26) (58) (56)
① 2.2 3.1 9
8.1 (206) (207)
b

a
a

a
b

b
(9) (7) (19) (17) (29) (27) (59) (57)
②
(202)
①
Fixed Damping
1.3mm

① ① ① (48) (46)
3.2
(101) 8.5 MPa (104) 12.5 MPa (105) 8MPa (106) ① 6 MPa

a
b
5.1 ③ 5.2 ③ 5.3 ③ (49) (47) 5.4 ③

② ② ② ②

(222) (242)
T
M22×1.5
MP T
M14×1.5
(221) (241)
P
M22×1.5
13.5MPa MPP
M14×1.5

2. Distribution of port on manifold

P： oil input port

T： oil return port

MPP: system pressure test point

MPT: Oil return pressure test point

4 pieces of installing screw: M16

71
 T1 G5 G12
G3 G8
G1

G2
G9
G13 G4 G7
G6
G10 G11

MVSPM22 BASPM22 MP8 BASPM22

IBOP pressure reduce MVSPM22
Counterbalance Low
Pressure control Leaning relief
MVSPM22 MVSPM22
Brake pressure reduce
MP1 RNXPM22
MP2 Counterbalance PC10 BASPM22
pressure reduce Hydraulic elevator
BASPM22 pressurereduce

Leaning relief
Counterbalance High
Pressure control MP9 MP10 MP12

Detailed control valve units specifications:

T1：Braking cylinder oil return port.
G1: Braking cylinder
MP1: pressure testing point on cylinder
G2: Balance cylinder
MP2: pressure testing point on Balance cylinder
G3： Rotating Link Adaptor
G4： Rotating Link Adaptor
G5： Rodless chamber of Back up tong cylinder
G6： Rod chamber of Back up tong cylinder
G7： Rod chamber of hydraulic elevator

72
G8： Rodless chamber of hydraulic elevator
MP8： Pressure Testing Point in Rodless chamber of hydraulic elevator
G9: Rod chamber of link tilt cylinder
MP9: Pressure Testing Point in Rod chamberr
G10：Rodless chamber of link tilt cylinder
MP10: Pressure Testing Point in Rodless chamber
G11: Rod chamber of BOP cylinder
G12: Rodless chamber of BOP cylinder
MP12: Testing point in Rodless chamber of BOP cylinder
G13 Brake accumulator
MPP: testing port for system pressure
MPT: testing port for return oil

73
III Control Loop on Hydraulic mainifold

There are seven control loops to realize different operation separately.

1. Braking cylinder control loop

The Braking cylinder is the kind of spring back one way cylinder .the brake unit
consist of four cylinders .The pressure of the cylinder is less than system pressure,
so one pressure –relief valve is mounted on the control loop with the pre-set
value 7.5Mpa In workshop (This valve could be tested on the pressure testing port
MP1).for the safety and reliability , so we adopt the electromagnetic ball valve as
the directional change valve, set a check valve on P port to keep the pressure ,
and put an accumulator on the port of cylinder to ensure the brake bites tightly In
the braking state. The high return pressure could make the brake work
incorrectly so we bypass the oil return port of braking cylinder back to the oil tank
to ensure there is no high returning pressue .

Brake

11
G1' G1 MP1 T1
M18×1.5 M14×1.5 M14×1.5 M18×1.5

(102) ②
1.1

Nitrogen Pressure of ③ ①
Accumulator 5 MPa

M14x1.5

②
(201)
①

①
(101) 8.5 MPa

5.1 ③
②

T
M22×1.5

P
M22×1.5
13.5MPa MPP
M14×1.5

74
2. Counterbalance System Control Loop
The main function of counterbalance system is
to balance the weight of equipment. It works as
the hook-compensate spring to protects the
Cylinder of Counter Balance
thread from wearing while making up and Nitrogen Pressure of
Accumulator 9 MPa
12
breakout. There are 3 kinds of pressure in
counterbalance loop: system pressure 13Mpa, 13

sub-pressure 8 MPa, safe pressure 17Mpa. The

electromagnetic ball valve could switch the G2' G2 MP2

pressure inside the cylinder

The pressure requirements is very critical , we ②
1.2

use the following elements such as accumulator, ③ ①

10 MPa
① ②

no leakage electromagnetic ball valve, and 8.4

check valve at P port to eansure the stable 15.5 MPa

① ②

pressure . 8.1

②
The accumulator is a pressure container which ①

should be charge by the special tool which is ①

7 MPa

used for feeding, releasing, measuring of 5.2 ③

②

accumulator and . Only nitrogen gas could be

charged into the accumulator, other kinds of gas T
MP T

are not acceptable. The function of accumulator

P

is cushion, shock-absorbing and keeping stable

pressure.

Safety valve in the counterbalance system loop is not lower than the
system pressure. Otherwise, it could not be safe and would lead to
produce much heat which would cause serious fault ..

75
3. Rotating link adaptor control loop

Rotating link adaptor loop adopts a hydraulic motor. Although the loop uses the
system pressure, a fixed damper is installed on the P port to control the
pressure and speed of hydraulic motor. This design meet the function
requirements without having to do some adjustment

G3 G4
M18×1.5 M18×1.5

(8) (6)
b

a
b

(9) (7)

T
M22×1.5

P
M22×1.5
18MPa

76
4. Backup tong control loop

Backup tong uses the system pressure, the hydraulic one-way valve could keep
the jaw at random position for a long time . It is mainly designed to protect
tong dies from crashing during drilling operation.

G5 G6
M18×1.5 M18×1.5

③ (205)
①
②

(18) (16)
b

a
b

(19) (17)

T
M22×1.5

P
M22×1.5
18MPa

77
5. Hydraulic elevator control loop

The pressure of this loop is lower than system pressure, for there is a pressure
relief valve set in the loop. The value is 8MPa set at workshop (This valve could
be tested on the pressure testing port MP8), the pressure could be set according
to different situation.

G7 G8 MP8
M18×1.5 M18×1.5 M14×1.5

(28) (26)
a
b

a
b

(29) (27)

①
(105) 8MPa

③
②

T
M22×1.5

P
M22×1.5
18MPa

78
6. IBOP Control Loop

The Pressure for this loop is lower than system pressure, because there is
pressure relief valve set in the loop. The value is 5MPa before delivery (This
valve could be tested on the pressure testing port MP12), the pressure could be
reset according to different situation. The directional changing valve in loop is M
type. when this loop is in idle state, this valve stay in the neutral position which
will bleed the hydraulic system pressure . Please note: only the solenoid of this
valve is energized in advance ,the other hydraulic action is available . The
function of hydraulic check valve in loop is to lock the cylinder to stop it from
sliding down.

G11 G12 MP12

M18×1.5 M18×1.5 M14×1.5

(208) ①
③
②

(58) (56)
b

a
b

(59) (57)

(106) ① 5MPa

③
②

T
M22×1.5

P
M22×1.5
18MPa

79
7. link tilt control loop
The link tilt loop is supported by system pressure, while the O type explosion-
proof directional change valve stays in the neutral, the link tilt and the elevator
could stay in any position. The function of 2 overflow valves: This valve prevent
over flow when incorrect operating happens (such as crash other parts etc),
ensure the link tilt cylinder could not be distorted. While both of the 2 electric
magnetic valves are energized , the link tilt can stay in the nature position which
protect elevator from wearing.

MP9 G9 G10 MP10

M14×1.5 M18×1.5 M18×1.5 M14×1.5

(38)
ab
o

b
a

(39) (37)

② ① ① ②

(206) (207)

(48) (46)
a
b

a
b

(49) (47)

T
M22×1.5

P
M22×1.5
18MPa

Do not adjust the preset pressure of adjusting valve without

permission.

80
Chapter III Hydraulic oil

Hydraulic oil is the important component of hydraulic system. The quality of the oil
affects the system life span ,nature and reliability. So high attention should be
paid to.

I Selection of hydraulic oil

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

Recommend hydraulic oil and specialized temperature

Hydraulic oil

Specialized temperature range

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

ISO Viscosity Grade 10 32 46

Mobil Mobil Mobil
Mobil
DTE21 DTE24 DTE25

II Hydraulic oil Changing

1. Change the hydraulic oil following the principles below:

a. Change the hydraulic oil 3 months after putting it into use for the fisrt
time
b. In normally condition , recommend to change the oil every 6-12 months.
c. Change the oil according to the analyzing result or experiences.
2. some notices for feeding hydraulic oil
a. make sure the oil is up to the specification, the feeding oil must be same
as the original one
b. While feeding oil, let the oil go through a filter with accuracy is 20um, must
keep the hose ,bucket and the cart clean
c. make sure the oil level is within the right rang on the window

81
 d. before feeding the new oil , disconnect the returning hose to the oil tank ,
so the original oil can be pushed out and bleed out which can be collected into a
bucket . energizing the directional control valve also help to displace the
original oill

it is not allowed to mix different brands of oil

Do you use the fuel oil instead of hydraulic oil.

Hydraulic oil is the important component of hydraulic system. The hydraulic oil
performance affects the system performance and life time directly, as well as the
system reliability, so high attention should be paid on it.

The oil should be replaced 6 months later for the first time, then change it once
every year. The cleaness of oil is very important, keep using one brand of oil, don’t
let the impurity and water enter into the system.

Forbid to mix oil in different brands

Chapter IV Hydraulic system Commissioning and

Maintenance

I System pressure adjusting

The system pressure can be adjusted on the pump which is connected to the
manifold , meanwhile. There is a overflow valve in the system . please note: the
valve is mainly to protect the whole system ,once the system pressure is much
high than the set pressure on this valve. If this valve is set incorrectly, the
adjusted pressure is lower than pump pressure, which would increase the system
temperature and cause problems.

82
II Pre-setting and adjusting of hydraulic system
pressure

1) pressure setting for each cylinder

 link tilt cylinder is two-way cylinder, the pressure is equal to the system
pressure .
 Braking cylinder is one-way cylinder, its pressure supplied by a pressure relief
valve.
 Rotating adapter is driven by hydraulic motor, its steady pressure is gained by
adjusting pressure relief valve
 Backup clamp cylinder is two-way cylinder, its pressure is gained by adjusting
pressure relief valve.
 IBOP Oil tank is two-way cylinder, its pressure is gained by adjusting pressure
relief valve.
 Counterbalance tank is one-way cylinder, its pressure is gained by adjusting
pressure reducing spillover valve. an accumulator is set to keep the pressure
stable. In order to prevent the pressure in accumulator is too high , a pressure
relief valve is set in the loop to limit the pressure.
2) Commissioning Hydraulic system
(1). Before start the any loop of the hydraulic system , by-pass the
counterbalance loop ,Make sure pressure relief valve on this loop is open,
start the motor of hydraulic pump, inspect running direction of the motor.
(2) Test the hydraulic system under the circumstance of right motor
direction, including IBOP loop , Back-up Tong loop . Braking loop l, link tilt adapter
loop l, link tilt loopl, counterbalance loop.

III Hydraulic system daily maintenance requirement

1) Daily inspect Items

Inspect the hydraulic source, the items include:

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

83
(3) Inspect the system pipe leakage.
2) Regular inspect (every 3 months)
(1) Fasten the bolts on motor.
(2) Inspect the air pressure of accumulator.
(3) Inspect the heat exchange capacity of air radiator, oil temperature at inlet
should be higher than outlet’s.
(4) Inspect and clean the air filter.
3) Braking device maintenance
1. Inspecting
1) Wear of pad on Brake unit
2) wear on the pad is Symmetrical or not
3) leakage of the brake hose.
2. Exhaust of brake loop
1) Put Press on the braking system
2) Open the cover on the top of hydraulic brake , discharge the air then cover
it again.
3) Same Operation to other brake cylinder.
3. Replacement of the brake pad
Replace the brake pad when its thickness is less than 2mm. a running –in
period is needed to reach the rated torque
Replace procedure:
1). Release the oil pressure of the hydraulic system.
2). Loose the bolts and spring pins.
3). Slide out the brake pad.
4). Slid in the new pad
5). Install the bolts and spring pins.
6). Fix the bolts.

84
 Part V Installation and Commissioning

Chapter I regulations for installation and

commissionning

I Safety operation note

In order to avoid personal injury or equipment damage during the installation and
disassembly of the top drive drilling system, this manual includes signs of
“warning”, “caution” and “note”

Note some notices to personnel injury or equipment damage

Caution This sign means a risk of personnel injury or equipment

damage.

Warning This sign mean personnel injury or equipment damage

The top drive drilling system should be installed and tested by the
qualified operator with experiences. This manual and related technical
data should be read carefully before operation. Working personnel and
other personnel who enter the working area of the system should have got
the training of drilling operation and safe knowledge.

When the system is running, do not touch the rotating parts of

the device, to avoid the injury or damage of the device.

Before installation and maintenance of the hydraulic system, cut

off the power supply, close the valve and release the pressure of
accumulator.

85
during the installation, dismantle and maintenance process, the
power switch must keep “off” state and hang sign of “No
Switching On”.

Before dismantle the electricity connection, the operator must

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

The working personnel should wear the suitable protective articles,

such as glove, helmet, etc.

This manual only includes the basic safety knowledge which

operator should understan, other knowledge should be collected,
judged by the operator.

All the installation work should meet the requirements of the

related standards and specifications inside this manual, and
should be confirmed by the installation technology personnel and
safety personnel.

Before operating the electric system, the operator should read the
<electrical manual> to get familiar with the electrical diagram.

Before operating the hydraulic system, the operator should read

the <hydraulic manual> to get familiar with the hydraulic system
principle.

86
 Chapter II preparation for installation

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

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

Installation reference table

Item Device needed Staff Working time

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

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

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

87
 4. layout at rig site
Before installing the top drive drilling system, please consider layout at the rig
site carefully including:
1) the placement of the control cabinet

The area where the control house is placed must be flat.

2) Put the electrical control house, rig cable box behind the the drilling
platform.
3) According to the layout , place the top drive (with transport frame), guide
beam (with transport frame) and moveable cable box in the area where is
convenient to get.

When unloading all the stuff, place guide beam, main body, cable
box and installation accessories in the right place for the easy
hoisting .try to avoid the repeated operation ,saving the installment time.
4) Measure the derrick beam for installation of anti-torque beam , according to
the width of the derrick beam, weld " sliding block" beneath anti-torque beam
5. Remove the anti-collision device to let the traveling block move up to the
crown .

88
Top Drive layout on well site

89
 Chapter III Installation

Procedure of Top drive Installation

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

Adjust the guide beam adjustable unit

Install the guide beam

Set up the anti-torque beam

Set up the top drive

Set up the cable

Set up the auxiliary devices

Switch on the power

Testing and commissioning the system

90
I. Installing the guide beam

1. According to situation of the derrick , the pad eye should be installed beneath
the crown for first time. General, we can weld the pad eye on the derrick . The
material of the pad eye is Q345B. pay attention to welding orientation(shown as
follow)

Welding requirement: doing the job by the technical staff

The welding staff must be a qualified one

the welding must be reliable and use care when work at high
position.

91
2. The length of track adjusting plate can be calculated from height of rig, lengt
h of track and height of padeye. The track adjusting plate has seven rows of hol
es and the length between adjacent rows is 200mm. So the adjusting length is
1200mm altogether.

92
Confirm the length of the hang-off link according to the height of the derrick. You
can choose the different adjustable plate for the different rig and assembly them .

Used to derrick 43m

Hang-off link For Derrick 45m

Adjusting Plate

Connect different positioning point to meet different height rig requirements.

93
3. Fix the adjusting plate to the padeye, and be sure to put locker of connecting
pin back.

4.Sent a technician climb onto the crown so he can conduct the installation of tr
ack.

5.Hoist the track onto the rig floor with a crane and put it on a proper position.

94
6 .Connect pulling dolly to travelling block. Be sure to fix both its connection set
and safe cable to travelling block for safety. Pull the track up slowly and stop
before it gets the padeye. All the 6 sections of track should be up in the air now.

Traveling block

Hook device
Safety cable

95
7. Remove the transporting frame from the rig floor
8. Connect the top hole of track to the track adjusting plate with a shackle, and
put its locker back at last.

96
9. move the tracks up all the way until the hole on top of the guide beam line up
with the hole on the shackle ,then pin these two parts together by the derrick
man.

Install
7th Guide Beam

Vertical State

2nd,3rd,4th,5th,6th
Guide Beam

1st Guide Beam

97
10. measure the guide beam safe distance (The distance from guide beam bottom
to the drilling floor is 2-2.2m), come down the traveling block and the cart will
slide down along the track . when the cart come off the track, move it away by
the crane or winch

Lift Locking

Wire rope

This State is dangerous

98
11. install the tieback beam .put the base plate on the anti-torque beam and
Bolt them together by the screw rods ,then put the tieback beam on the base plate
And fix it on the plate by the long bolts .don’t lock all the bolt , because
Later we will get the top driver right at the center of the wellhead.

Tong Arrester

Reactive Torque Base

99
 12. turn the screw rod embedded in the tieback beam ,move the beam back and
forth ,try to find the right place for the track ,at this moment , the top driver right
above the center of the wellhead.

Rotate the guide screw in CW

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

100
II. Installation of Top Drive Main Body

Chart of top drive main body and transport frame

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

101
2.Lower the hook to right level. Connect the hook ( 3 points :2 points on the

transport frame, 1 point on bail) to the transport frame. And hold the frame by the

crane( 2 points on the bottom of transport frame)

3. Upright the transport frame by Hook and crane, the back of frame just lean

against guide beam..

Crane and hook work together while uprighting the frame, avoid
crashing.

102
4. Dismount the locating pin on bottom guide beam, regulate screw rod on it,

ensure bottom part of the guide beam and the track of transport frame in the

same vertical plane.

Guide Pin

Adjust Screw rod

5. Dismount the locating pin , disconnect the transport frame and top drive.

Locating pin

103
6. Connect the hook with the bail, come up the hook slowly, top drive moves

upward along with guide beam.

104
7.screw back the bottom part of the guide beam . put back the guide pins.

Adjust Screw

8. Re-adjust the tieback beam, keep the main shaft of top drive and wellhead in

the same line. Fix all the bolts, insert pins.

Rotate guide screw CW and CCW,

All connection parts must be reliable and safe.

105
 9. move the top drive up and down the track all the way , make sure no

scratch and bump

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

10. If the top drive slides up and down without problem, then testore the

anti-collision device.

106
III. Cable installation

1. put the traveling cable box on the rig floor. On the right and front side

107
 2. lift the cable up one by one by the air winch and put it in the clamp and

lock it. The clamp is fixed on the cable terminal plate mounted on the derrick.

108
3. Install another the cable terminal plate on rear beam of derrick (keep the

same height with traveling cable hanger)

Cable terminal plate

Derrick Back Beam

109
4. Hang cable in derrick cable box up , connect it to the cable terminal plate and
lock it . the cable goes down from derrick to the ground ,don’t get them crossed .

110
 5. Connect the traveling cable and derrick cable by the quick connectors. Shown

as follows:

Derrick Side Beam

Derrick Power Cable

Trip Auxiliary Power Cable

Derrick Back
beam

Trip General Control Cable

Derrick Power Cable

Derrick General Control Cable Trip Power Cable Trip Power Cable

Derrick Auxiliary Power

All cables are connected by quick connector, Marks on the joint

(label and color), align the mark before connection

Connection must be safe and reliable.

111
6. Lay the cable on ground from control cabinet to derrick. Place the cable on
ground to derrick bottom. And connect with the derrick cable.

note: Ground cable length is 26m. If the derrick cable length (48m) is long
enough , the ground cable can be used as backup. Depend on the well
site condition

Keep the cable properly when ground cable Is a spare

112
III Auxiliary Device Installation

After finishing installation of guide beam, Top Drive , and cable, the
follow work can be done by different person at the same time.

1. Install the elevator link on Top Drive body.

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

Control House must grounded properly , ensuring operator and equipment

safe.

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

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

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

All cables are connected by push fit, Marks on the joint of plug and
jack.
7. , feed the pressured air into the driller console ,adjust air pressure, ensure

the air pressure IN driller panel is lower than 0.2Mpa, higher than 0.12 Mpa.

113
8. Feed lubrication into gearing box by oil cart. Feed hydraulic oil into hydraulic

oil tank.

Lubricate oil inlet

Hydraulic oil inlet

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

generator and the control cabinet .

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 Chapter IV Inspection after installation

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

confirm every installation is correct, all the transport and fixing device has been
removed, each part is ready for test-running.
2. Inspection should be carried out by technical personnel
3. Installation should be carried out according to attachment I < Top Drive System
Installation Line Connecting Inspect list >, attachment II <Top Drive System
Installation Inspecting list>.
4. Inspecting procedure and methods refer to <Operating Manual>.

Inspection must be carried out by professional .

115
 Chapter V commissioning

I Electric Device commissioning

1. Switch on the main power switch.

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

Phase
sequenc
e relay

Operator must ensure the phase sequence is correct before

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

116
4. While the temperature is higher than 40℃ and the air humility is higher than
95% or dew is found in the control cabinet , start air conditioner to remove
dampness or drop temperature.
5. Supply power to each function unit. Processes are as follows:

6. Start the lubricate pump, hydraulic pump and cooling fan on driller’s panel,
inspect rotating direction and running condition.

7. The pressure of hydraulic system is already set before delivery. Re-adjust on

site is not allowed . In special case , this must be done by professional personnel
who is familiar with the principle of top drive hydraulic system. The detailed

117
adjusting procedure refers to <hydraulic manual>.

8. Start the main motor, check the running condition. Operating procedure refers
to <Operate manual>

II auxiliary function commissioning

Start the hydraulic pump to get ready for commissioning the hydraulic auxiliary
function

1. inspect the link tilt adapter ,run CW and CCW

2. Check the link tilt, let it move forward, backward and float
3. Check the Back-up tong
4. check the brake unit
5. Inspect IBOP unit
6. press “well control” button, the main motor should stop running and IBOP
close.

Please fill the form in operate manual.

Attachment III <Top Drive Device Installation and Commissioning Record >

118
 Chapter VI Top Drive Disassembly

Top Drive disassemble procedure

Cut off the power

Disassembly Auxiliary Equipment

Dissemble Cables

Dissemble anti-torque beam

Dissemble Top drive main body

Dissemble the guide beam

Dissemble the guide beam connection device

Dissemble adjusting components of guide beam

119
I auxiliary equipments disassembly

1. Disassemble the elevator.

A. Release the bolts and shafts on the elevator shelter and joints, move the
elevator.
B. Fix these bolts and shafts on Top drive main body.
C. Lift the elevator link to the easily delivery position.

Elevator
shelter
bolt

Elevator

Joint shaft

120
2. fix the link tilt cylinders to main shaft by the plate shipped with the top drive.

3． Reset the link tilt adapter

4．Disconnect the powe for the function units
5．Disconnect the main power
6．Disassemble the driller console cable
7．Remove the ground cable if it is put into use
8．the main power cable，auxiliary power cable，comprehensive control cable
should be took away from the top drive and cover it for the protection
9．take off the mud hose 。

121
II disassemble Cables

1. Disconnect the joints of the traveling cable and derrick cable. Disconnect the
main power cable, auxiliaryl control cable and comprehensive control cable.

2. dismantle the traveling cable and the derrick cable and put them in the cable

box . put the cable box in area convenient for delivery.

III Disassemble Top Drive Main Body

1. Lift the transport frame to drilling floor and get it upright , lean against the
guide beam.

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

rod , make the bottom part of the guide beams and transport frame align up

3. come down the traveling block ,when top drive is very close to the transport

frame ,come down slowly until the track on the transport frame slide into the

rollers . come down further slowly .get the top drive rest on the frame .

122
4. put the location pin back to lock the top drive .disconnect the hook and bail of

the top drive

Lock pin

5. connect the transport frame with the hook of traveling block ,(three point ) by

the cables. And hold the transport frame by the crane .and get the transport frame

lay down horizontally on the rig floor

6.Adjust screw rod and restore the bottom of guide beam.

123
7.Lift the top drive main body to the easily delivery position

124
IV Disassemble the guide beam

1. Lift the hoist carriage to the drilling floor, connect them with the hook by rope

and U shackle .

During the process , use the air hoist to lift the front part of the hoist carriage to

keep balance .to prevent it fall over .

Lift locking
Wire rope

This state is dangerous!

2. come up the hoist carriage ,,make it run upwards along the guide beam.

3.open the tieback beam ,let the track move freely .and remove the tieback

beam ,put it somewhere it is easy to pack

125
4. put the track cradle on the rig floor .

126
5. the derrick man climb up to right place to watch the whole process and give

the right order to the driller . move the hoist carriage up until all the weight of the

track is bore on the carriage .all the joints parts of the track will open ,and the pin

slide out from the box. The derrick man take off the shackle to disconnect the

track and the hang-off link.

127
6. Lower the hook, with the help of the crane ,lay the track into the track cradle.

And fold up all the track.

Crane assists this

part guide beam

7. Disconnect the hook of the traveling block and the hoist carriage . the track

now is on the rig floor

8. crane down the track to the ground and place them in area where it is easy to

pack

9. Packing the dissembled top drive and auxiliary components.

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Attachment I Top Drive System Electrical Installation

Inspecting list

No. Item Inspect Content Result

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

1. Power cable is connected correctly

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

1. Power cable is connected correctly

Auxiliary
4 2. Cable plugging device is locked correctly.
Powercable
3. Trip cable does not scratch other devices.

1. Control cable is connected correctly

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

1. ,console is stably placed

2. Cable plugging connected correctly and locked
well.
6 Driller console
3. Air Pressure is regular.
4. Panel lights works well, the gauge is in good
situation
Remarks:

Record： Check：

129
Attachment II Top Drive System mechanical installation

inspection list

No. Item Inspect Content Result

1. Guide beam hang 1. Check the connection between U shackle
and guide beam.
2. Check if the pin is reliable.
2. Guide beam body 1. Whether the guide beam is vertical and
and connection neat.
2、Whether the bolts locked tight.
3. Bail connects 1. Inspect the connection between bail and
with hook hook

4. Tieback beam 1. Whether the bolt is fastening.

2. Whether the joint pin with guide beam is in
place.
5. 1. Whether all auxiliary devices are taken off.

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

body hydraulic oil normal.

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

7. Traveling block Inspect whether the traveling block bump into

the track

Remark

Record： Check ：

130
Attachment III Top Drive System Installation and

Commissioning Record

No. Item Testing Technical Request Result

Rotating direction of
1. Running without noise
lube pump, motor of
1 2. Motor rotating direction is correct
hydraulic pump and
3. Air pressure is normal
air‐blower
1. Hydraulic lubricating system runs well,
Hydraulic, lubricating pump sound is normal.
2
system 2. Gear oil, hydraulic oil pressure,
temperature is normal.
1、 Indicator works well.
Indicator on Driller
3 2、 Indicating correctly.
panel
3、 No alarming.
Button switch hand
All the button switch hand wheel work
4 wheel on driller’s
well.
panel
1. Every function unit works well.
5 Control cabinet 2. Air conditioner runs well.
3. indicators work well.
1 running at the right drection.
2. normal start ,and running in good
6 Motor starts and stops situation, without . stall and wriggle
3. stop normally and break works in right
delay time
1. No noise in gear box,
7 No‐loading testing 2.No leakage
3. No resonance while test‐running.
Temperature varies within the normal range
8 Load test and make up (Note: Torque value and curve displayed on
and break out test the win CC screen in electric control house)

131
 1. Rotate smoothly
9 Rotating link adaptor 2. Direction changing without shock.
CW and CCW test 3. No leakage

Link tilt, neutral 1. Act well

10
floating test 2. moving smoothly

1. act with good accuracy.

11 Breaking device testing
2. brake the main shaft in right way
1. Clamp and loosen correctly
12 Back‐up tong test
2. No leakage

1. Make up and breakout is normal, top drive

13 Counterbalance device
can be lift in right way
movement test
1. Act flexibly, no stall.
14 IBOP function test
2. Signal outputting correctly.
Remark:

Record： Check：

132
 Part VI Operation Manual

Chapter I Safety Operation Rules

I. Safety operation notification

Note some notices to personnel injury or equipment damage

Caution This sign means a risk of personnel injury or equipment

damage.

Warning This sign mean personnel injury or equipment damage

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

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

before operation.

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

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

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

glove, clothing etc.

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

system, such as buttons, switches etc. Non-professional staff and non-qualified

personnel could not install, test-run, operate or maintain the top drive system

avoid physical and equipment injuring.

133
4. Repairing and maintenance could not be carried out while the system working.

II. Operator safety operation notes

1. Electric system operating notes

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

circuit diagram.

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

is forbidden”

3) Use professional tools and protective facility.

4) Maintenance while switch-on is not allowed or disassemble any electric

elements, don’t pull any plugs while power on.

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

correct reconnecting.

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

protective air lose pressure, recovery the pressure quickly or stop drilling and cut

the power supplied to driller’s panel.

7) Don’t open the driller console in dangerous gas.

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

convert, avoid dangerous.

134
9) While the temperature is higher than 40℃, humidity larger than 95% or have

dew, don’t start the drive and other control powers before air conditioner lower

the temperature and humidity.

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

any dew in electrical control cabinet.

2. Hydraulic system operating notes

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

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

confirm there is not any pressure in the system pipe lines.

3) Cut power off before disassembling the pipe lines.

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

correctly.

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

hydraulic pipe lines, avoid the rest hydraulic oil releasing and pollute the

equipment and space when open the pipe line.

3. Well control Operating Notes.

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

requirements of well control.

2) Carry out the industry standard, stipulation and recommends when the top

drive is working is a situation with the high pressure and harmful gas , H2S,SO2.

135
3) Keep equipments in good working station while reaching the oil layer, carry out

the following activities during shift change .For instance: the Inspection and

testing of IBOP, well control operation, handle with the problems in time.

DQ70BS-JH Top Drive Drilling System is composed of power swivel, pipe handler,

guide beam and carriage, electrical control system, hydraulic control system, and

auxiliary device.

The following is the draft of main body of top drive system

Chapter II Operating Procedure

Only qualified, experienced and trained personnel can operate the Top Drive
Drilling Equipment.
Reading carefully and understanding the manual and relevant technical
documents before operation.
Before operating, the operator should check the following items:
a. Check the running record to check the working situation of last shift.
b. do the maintenance job according to the maintenance regulations
c. Check the condition of saver sub and the tong dies.
d. do the regular inspecting items by professional personnel.

I. Inspection before starting the device

1. Inspecting before starting

Before starting electrical system, should check the following items:
a. make sure that the machine and hydraulic system is ready.
b. Check the electrical components on the driller console l and PLC cabinet, make
them in initial status.
c. All indicators of the electronic system can be tested by pushing the button of
【MUTE/TEST】.
d. Confirm the AC380V/50Hz is supplied by the assist transformer or drilling
electrical control room. If supplying by assist transformer, switch on 1QF, cut 2QF
off. Otherwise, cut off 1QF and switch on 2QF. 1QF and 2QF adopt mechanical
chain control.
136
2. Procedure of power on

a. Turn on the general power switch Q1, then close the primary power switch of
converter and the switch of assist transformer Q2. After that close all the power
switches (except the spares), and check the power work condition.

b. Inspect whether the 24V power light (HL1) on PLC cabinet panel works well,
【Fault/Alarm】indictor should be off ,that means no alarm singnal

24V Power Indicator Fault/Alarm

137
 c ． 【 Fault/Alarm】indicator 1HL4 on Driller’s panel shows no fault, 【Ready】
indicator 1HL1 stay on constantly which demonstrates electric system are ready
for drilling and assist operation.

Fault/Alarm

3． Stop System Work

a. Turn the speed 【THROTTLE】on Driller console to the “zero” position, and put
the【MOTOR DIRECTION】 to the “stop” position

Motor Direction Throttle

138
b. Turn off the power of invert and assist transformer, turn the main power off, the
whole electric system stops.

II． Hydraulic system operation

1. Start/stop operation of hydraulic system

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

(1) Auto: When 【Operate Selection】switch is put on “Drill” and at the same time
brake signal occurs , or 【Operate Selection】 is on spin or torque . hydraulic pump
starts automatically, and the indicator is on.
When 【Operate Selection】switch is on “Drill” and the speed throttle is off the
“zero position” for 20s, the hydraulic pump stops and stays in dormancy state.
When speed throttle is turned back to Zero, the speed drops around Zero,
hydraulic pump starts
Automatically to provide with the hydraulic pressure.

Operate Selection

(2) Start: put the hydraulic pump【Stop/Start】to “start”, hydraulic pump keeps
running , indicator is on.

(3) Stop: Turn the hydraulic pump【Stop/Start】to “stop”, hydraulic pump stops,
indicator is off. In this state, even there is a brake signal , hydraulic pump could not
start, but it could work when well control button is pressed down.

139
 (4) put the switch on “Auto” position during the drilling operation , lay it on “start”
when trip in or trip out of the hole.

Hydraulic Pump

b. the run or stop state of the Lubricate Pump is synchronous with main

shaft.
c. stop the hydraulic system : put the switch on stop position , the hydraulic pump
stops, the indicator is off.
d. Lubrication oil pump stops and starts at the same pace with main motor.

2. Inspection of the Hydraulic System

Inspect the hydraulic system

by the information shown on
Driller console
Hydraulic system inspection
items:
1. Hydraulic oil temperature
inspect Pt100
2. Hydraulic oil level and
alarming inspection
3. Lube oil pressure
inspection
4.Lube oil temperature
inspection Pt100

140
III. heating the main motor

1. if the heating power is ok and the invert is not energized , switch the
【Motor Heat】 to “ON”, the motor is now being heated ,and the indicator
is on ..

Motor Heater

2. There is interlock between heater and invert control system. If the invert is
working ,the heater can’t start . if the heater is already in working state ,
it will stop once the invert is put into use.

IV. cooling fan for the main motor

‘Motor fan’ switch has three positions: 1). Auto; 2). Start; 3). stop.
1). Auto: cooling motor starts automatically according to the state of main motor
temperature, hydraulic oil temperature, lubrication oil temperature.
(1) When one of the three temperature mentioned above is over 35℃, the
cooling motor will start automatically.
(2) When three temperature mentioned above is all below 25℃, the cooling
motor stop running automatically
2). Start: if Switch is put on this position, the cooling motor keep running ,once the

141
feedback signal of air pressure is lost , the alarm signal will appear.

3). Stop: the cooling motor stops and Main motor can not start.

Motor aire-blower

When there is not feedback signal of air pressure , main motor can
not start. If the main motor is already in running state ,it will stop because
of the fault signal.

V. Braking mode selection

1. Automatic position
(1) Normal brake: during drilling operation ,if there is a need to stop the top
drive ,just turn down the speed throttle to zero ,when the speed of the main
shaft drops below 3 rpm ,the brake solenoid will be activated ,and the main shaft
will stop.
(2)anti- torque brake: in some special case , the torque down hole is more than
the torque output by the main motor , so the main shaft will run reversely ,
although the speed throttle is not turn down to zero . when the reverse speed
is less than -3 RPM, the brake will be actuated and stop the main shaft.
(3) Emergency stop: when push down the emergency button, the invert enable
signal will stop ,and the brake will stop the main shaft ,no matter whatever
situation the top drive is in.
(4) Fault brake: when the top drive is stop by the fault signal , the brake will work
as it is in the normal situation .

142
2. Brake position
i. if the top driver is not working ,and a brake signal will stop the main shaft . the
solenoid of the brake will be energized all the time.
ii. if the top driver is running , the switch is put on the “break” position ,the brake
unit will work as the same way the emergency brake does .
3. loosen position
The brake solinoed will lose the power and stop working . no matter
whatever position the ‘operation switch’ is on .the brake will not work .
execept that the “well control “ button is pressed down .

Break Mode

4. In braking state, hydraulic pump intermittent working manner

1). Hydraulic intermittent working manner : while given brake signal, hydraulic
pump start working for 5 minutes , then stops for 30 minutes and resume
working for 2 minutes. .and works in this cycle repeatedly.
2). During the intermission period of the brake .the IBOP solenoid will be
energized because the existence of the brake signal .so the hydraulic pressure
will be supplemented ,and the accumulator will get the Supplementary
pressure.
3). During the intermission period of the brake ,if any one of the solenoids is
actuated , the solenoid of the IBOP will get the power., the hydraulic pump start
running for 5minutes . then enter into the intermittent working cycle .
5.Relations between Operate select and braking
While 【Brake mode】switch is put on ‘auto ’ and 【operation select】 is put on

143
“drilling”, the brake is aviliable , if “Spin” or “torque “ is choosen , the brake will
not work
① In “drilling” state. The switch of【brake mode】is normally put on ‘auto’.
② In directional drilling state, if this process lasts less than 40 minutes , the
switch【operate select】should be put on “drilling“state, and the switch 【brake
mode】 on ‘auto’ . if the process is longer than 40 minutes , put the switch
【direction select】 on ‘stop’, 【brake mode】 on ‘brake’. At this time the invert
doesn’t get the “enable run” signal . there is no current goes through the main
motor.
③ if the Switching【brake mode】is put on “brake”, the brake signal is
available all the times .and the hydraulic pump will work at intermittent state .no
matter what position the 【operation mode】is put on .
6. While trip in or trip out the hole , hydraulic pump switch is set on ‘start’
position. The intermittent work mode doesn’t apply to the pump any more.

if the Switch 【 brake mode 】 is put on ‘off’, top drive can start
running, but brake will not work when system stops.

When emergency stop happens, system will stop rapidly, brake pad
would
Worn out seriously, so it is forbidden to use emergency stop instead
of the normal stop function .
While system is in “spin” or “torque” state,, brake will open
automatically, no matter what position the 【brake switch】is on . brake
does not work any more .

144
VI. Drilling operation

Inspection before Drilling operation

Check the system before drilling operation, and get it in the initial l stated
showed in appendix 1. it includes:
A. Put the speed ‘THROTTLE’ on ‘ZERO’ position and ‘DIRECTION’
switch on “stop” position.

Motor Direction Throttle

B. Put the “Motor Selection” on the position you want , you can choose A motor,
A+B motor, or B motor

Motor Selection

145
C. Before system doesn’t run and “THROTTLE” is at “zero” positions, choose the
“ROTATION DIRECTION” switch to FORWARD

Motor Direction

If “speed THROTTLE” is not at “zero” positions, and 【motor

direction】 is not at “stop”, the 【motor selection】

can’t work .only the requirement(“speed THROTTLE” at

“zero” , and 【motor direction】on “stop”) is met , the

【motor selection】is now effective

The speed throttle is not on “zero” , the 【motor direction】

can’t work

During the drilling operation , if you put 【motor direction】

on “backward”. the motor will not run reversely.

146
2. Operation rules
a. Cooling motor is chosen at “Auto” or “Start”

Air Motor

b. Choose 【operation select】 switch to “drilling” mode.

Operation

147
c. use the “Motor Select” to choose the motor you want (A motor, A+B motor,
B motor)

Motor Selection

d .put the 【motor direction】at “forward”, at the same time if the speed
throttle is at “zero” and the invert is in good situation ,the indicator “ready
“ will goes on

Motor direction

148
 e. turn the dial 【drilling torque】off zero slowly to set the torque you want

Drilling Torque

f. turn the dial 【drilling torque】off zero slowly to set the speed you want .

Throttle

149
3．Constant Torque and Constant Power
1. Turning the “ speed THROTTLE” clockwise, then the speed of the
main shaft will increase , before the top driver reach the rated power, the
motor will keep running within the torque range set by the “drilling
torque” dial. Which is called constant torque .

Drilling Torque Throttle

2. when the top driver reaches the rate power, if the speed keeps going
up , the torque output by the top driver will decrease .which is called
constant power

4．Speed Control and Torque Control

a. During drilling operation , when the torque output by the top driver is
less than the torque set on the” drilling torque” dial , main shaft will run
at the speed set by the speed throttle.

Throttle

150
 c. If the torque on the drill pipe is over the limitation torque, the main shaft
will stop rotating but the torque is still maintained when the torque down
hole goes down ,the speed will restore and goes up to the speed set by the
speed throttle . and the device is now running at speed control mode.

VII. Backup tong operation

After the hydraulic system starts running , the back-up tong can be operated
1. clamp close
put the speed throttle is at “Zero” and the real speed of the main shaft is
also at zero .put the ‘backup tong’ switch at close . the backup tong will
close

Motor Direction Operation Backup Tong Throttle

Once the clamp close ,it is not allowed to run the main shaft ,or the tong dies
or the pipe will be damaged

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 2. clamp open
If the torque shown at the torque gauge is zero . turn the backup tong switch
down to open ,the clamp will loose

Back up Tong

Don’t try to loose the clamp. if the torque shown on the gauge is not
zero .or just at the moment ,the main will run backwards , the pipe or tong
die will be damaged

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VIII. link tilt operation

After hydraulic system starts, the link tilt operation is available . the switches
related include: tilt forward, tilt backward, float and turn left ,turn right
1. Turn “link tilt forward” ,the link tilt will move forward to mouse hole or monkey
board to grab the pipes with the maximum angle of 35°. If the switch is put
“link tilt backward “ the link tilt will move backwards with maximum angle 55°, so
the top drive can go down until the stabbing guide touch the rig floor ,making the
top drive more efficient.

Link leaning

2. Put down “float” button, the solenoid will make the rod chamber and rod-less
chamber of the cylinder connected with oil tank. Link tilt and the elevator will stay
free as the result of the selfweight.

Elevator suspend

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3. Push down “float ” button, the link tilt adapter could run left and right freely.

‘ there is a interlock between “link tilt forward/backward” and “link

tilt left/right” that means if you tilt out ,you can’t turn the link tilt adapter. If
you want to do so , you have to press the “float” first . but you can
change the working mode by reset the interlock on the touch screen .
that is change the interlock state . but once you get
Everything done ,we recommend trying to restore the setting

Elevator and link tilt could hold the weight no more than 3Tons .if
the weight exceeds 3 Tons, push the “ float ” button to prevent from
the damage of the cylinder.
Once the “float “ is pressed down , make sure that the link tilt
should be at the neutral position . then you can turn the link tilt
adapter left/right .

XI. Make Up and Breakout Operation

1. Make Up and Breakout Operation

a. Put the ‘speed THROTTLE’ at zero and ‘ motor DIRECTION’ switch at stop
position.

Motor Direction Throttle

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b. Turn the “Motor Select” to A+B mode.

Motor Selection

c. “Operation mode ” is at drilling position.

Opeartion

d. Hydraulic pump control switch is on “Auto” or “Start”

e. Air Motor is on “ Auto” or “Start”.

If “speed THROTTLE” is not at “zero” position, or “motor

DIRECTION” switch is at other position, the “operation mode ”
switch is inactive ( you can’t choose spin mode ).

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2. Make Up Operation
Spin:

Motor Direction

b. put “Operation mode ” to spin , system will spin at fixed speed 12r/min,
fixed torque 6kN·m. When the torque reach 6 kN·m, top driver will start to slow
down and stop

Speed Throttle

When the “speed THROTTLE” is not at Zero, the “operation

mode “ is inactive.
When the top driver is spinning , If the “speed THROTTLE”
handle goes off “zero” position, or “operating DIRECTION” is
incorrectly set .the speed and torque reference will be
reset at zero.

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Torque :
This operation should be carried on when the main shaft stops, the output torque
is equal to the torque you set by the “make up torque limitation”
a. Put ‘ speed THROTTLE’ at zero position, and ‘ DIRECTION select ’ at forward.

Motor direction Throttle

b. Set the torque you want by the “make up torque” dail

Makeup Torque

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c. put the ‘OPERATION mode ’ at torque by left hand and ‘backup tong’ at close
by right hand ,hold the two switch for a while ,5 seconds later, they will both start
to work together ,the top drive will run at the torque set before hand .and will
keep the torque ,once it reach the set value . after the operation is done , release
the two switches and the ‘OPERATION mode ’ switch will spring back to spin
position , the top drive output the spin torque

Operation Backup Tong

d. Turn the “Operation mode” switch from “Spin” to “Drilling”.

Operation

Keep the hydraulic pump running when making a torque

connection.
When the top drive is still spinning , don’t try to torque the pipe . the
running main shaft will damage the pipe or the tong dies .

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3. Breakout operation
Before breaking out the connection , Support the drilling tools (seat the slip ) , in
case the drilling tool will come off ,and something wrong happen.

Check out if the switch position is consistent with the requirement of the item

a. Put “Motor direction” on backward position

Motor direction

b. Press down the “counterbalance “ Button

Counterbalance

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c. put the ‘OPERATION mode ’ at torque by left hand and ‘backup tong’ at
close by right hand ,hold the two switch for a while ,5 seconds later, they will
both start to work together ,the top drive will run at the maximum torque (set
at workshop before delivery) . when the shaft speed reach 6RPM , release
the two switches and the ‘OPERATION mode ’ switch will spring back to spin
position , the top drive output the spin torque

Operation

d. After the break out is done ,Turn the “Operation mode” switch to
“Drilling”.

. during the break out process .once the “counterbalance” is

pressed down , the counterbalance cylinder will be actuated by the
hydraulic system . the lifting force will overcome the weight of the
top drive . top drive will move upwards . so the thread at jont part
will be protected very well. The whole process will last one
minute .then the hydraulic pressure will bleed .and top driver will
come down again . all this process will be done automatically.
when breaking out the connection, The torque output by the top
driver is the maximum torque ( normally is 150% of normal output
torque ). So if the top drirve can’t break out the connection. the top
driver will enter into stall state. Don’t let this process last more
than one minute. Try to take some other measures to break out the
connection .

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X Drilling ahead by single

1. Procedure for drilling ahead by single

（1）Set slip in the wellhead , stop mud circulation and close remote IBOP;

（2）Break out the connection according to the instructions described in XI-3

（3）come up the top drive ,Make the elevator go off the joint of pipe ;
（4）tilt out the link tilt to the mouse hole to grab the single pipe and close the
elevator
（5）move the top drive upwards ,Lift the single pipe out of the mouse hole, then
tilt back to the well head .get the pipe right in the center of well head.
（6）come down the top drive , stab the pin of the top pipe into the box of the
bottom pipe . at the same time ,the top of the pipe will enter into the stabbing
guide .
（7）spin the top driver ,let the pin goes into the box completely.
（8）hold the pipe strings in the hole . now you can make up the joints at the
torque set up beforehand (one joint is between saver sub and signal , another one
is between the signal and pipe string). Refer to VII-1.
（9）take out the slip ,open the IBOP and circulate the mup.

stop the mud pump until the pressure in the mud hose drops to the
safety range, break out the connection.

after making up the single , open IBOP then start mud pump.

XI. Drilling ahead by triples

Drilling ahead by triples is the regular way of DQ70B drilling system. If there
aren’t the existing triples on the floor , it can be done in the mouse hole during the
course of drilling or at the leisure time. In case of security the pipes should be kept
in the same vertical plane to stab in easily .just let the pin screw into the box , that
is enough. Because all the joints should be tighten late.
procedure for drilling ahead by triples:
1）Set slip in the wellhead , stop mud circulation and close remote IBOP;

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 （2）Break out the connection according to the instructions described in XI-3
（3）come up the top drive to monkey board , tilt out the link tilt to grab the triple
（4）close the elevator by the derrick man. move the top drive upwards And tilt
back the link tilt ,don’t forget press the “float”
（5）get the triple right in the center of well head.
（6）come down the top drive , the floor man stab the pin into the box at the
wellhead . at the same time , try let the triple enter into the stabbing guide .
（7）spin the top driver ,let the pin goes into the box completely.
（8）hold the pipe strings in the hole . now you can make up the joints at the
torque set up beforehand , Refer to VII-1.
（9）take out the slip ,open the IBOP and circulate the mud .start drilling again.

stop the mud pump until the pressure in the mud hose drops to
the safety range, break out the connection.

after making up the triple , open IBOP then start mud pump.

XII. Back reaming

During the course of tripping out of the hole , if the drilling pipes get stuck ,
connect the pipe with the top drive right away and make a circulation. Come up
the top driver while back reaming the pipes is case of the adhesion at the bottom
of the hole.

Procedures of back reaming are as follows:

(1) lift the pipe string while Circulating the mud ,until one triple is pulled out of
the hole.
(2) Stop mud circulation and set the slip;
(3) disconnect the joint by the hydraulic tong at rig floor. Break out the
connection between the save sub and pipe
(4) Pull out the triples , put them into the pipe box of the derric;
(5) come down the top drive to the rig floor.
(6) stab the saver sub into the pipe while ,spin the thread completely ,then
make up the pipe.

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 (7) restore the mud circulation, run the top driver ,continue back reaming.

XIII trip in and trip out the hole

Tripping hole is done in regular way , with the help of pipe handler , it could
reduce worker’s labour intensity and improve working efficiency.
A． Trip in
（1）Move the top drive upward to kelly board , turn the link tilt adapter to the
right direction the derrick man want the top drive is torward.

（2）tilt out the link tilt to grab the pipe ,and the derrick man close the elevator
（ 3 ） come up the top driver ,tilt back the elevator and press the
button ”float” ,the link tilt cylinder is in float state.

Link incline Link center

（4）lift the pipe stand , it will go back to vertical position , during the process ,the
floor man should hold the bottom of the pipe stand by the rope .and let it stay
right over the well head.
（5）come down the top driver , stab the pin into the box at the rig floor and

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torque it by the hydraulic tong.
（6）Lift the pipe string , take out the slip , let it go down into the hole and put
back the slip again.
（7）open the elevator, tilt back the link tilt , come up the top driver to the
monkey board . Repeat the above operations.

Link incline

B. Trip out of the hole

（1）disconnect top drive and the pipe string . come up top driver . open the
elevator and tilt forward the link tilt to grab the pipe then close elevator again.
Let the elevator hold all the pipe string.

（2）Lift the top drive above the monkey board. Set the slip .

（3）Breakout the pipe with hydraulic tong at the rig floor.

（4）come up the top driver to the monkey board , tilt forward to push the pipe
stand to pipe stand box. At the same time ,the floor man push the bottom of the
stand to where they want. Open the elevator .the derrick man get the pipe stand
in good orde .

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 （5）tilt back the link tilt and press the “float “, come down the top driver to rig
floor ,open the elevator ,grab the pipe close the elevator .

Link incline Link center

（6）Repeat the procedures from 2 to 5.

During the process of tripping out of the hole , if the hole get contracting neck or
key groove . connect the top driver with the drilling pipes .start the mud
circulation. Run the top driver. Come up the top driver to let it pass the stuck
point.

XIV Running Casing

Running casing with the top drive drilling system can improve the operating speed,
Jinghong top drive is different from others brand, a special device for running
casing is adopted , the main function is that when the stuck down the hole or well
kicking happens , the top drive can be connected with the casing quickly and star
the mud circulation, rotating the pipe to Prevent the well kicking and realese the
stuck in time. Enhancing the safety and speed of running casing.

XV Well Control Operation

1. When the top drive stops working, turn the IBOP can be opened or closed. Once
the top driver is running or the mud circulation is on, it is not allowed to close the
IBOP (except for the well control ).

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2．In case of the emergency ,press down the “emergency “ button. The top driver
now is in emergent situation. Shown as follows:
a. Start the hydraulic pump (no matter it is running or not at that monent)
b. Stop the mud pump (Give the interlock signal to the control circuit of the mud
pump)
c. Stop top driver
d. close the IBOP .
3. Operators should RESET all the switches to original position (refer to
Attachment I)
4. once the emergent situation is over , and no faults or alarms appear , press
the “reset” on driller console to relieve the well control status.

IBOP Well Control

Reset

XVI Jarring operation

Because of different situation of every rig and different parameters such as : well
depth, the type of the drilling tools ,the type of the jarring assembly .so it is
different to set up the standard instructions for the use of the jar. And it Is hard
thing to predict the damage to the equipment caused by the use of the jar so we
don’t recommend to use the jar connected with top drive during the operation and
other shocking tools on the rig floor..

If it is not avertable to use the jar connected with Top Drive Drilling System,
please assess comprehensively the possible damages to top driver caused by the

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use of the jar.
After the operation is done, a complete inspection is necessary and give the
comprehensive maintenance to top driver before putting it into use again .

1. give the complete and visual check to Top Drive Drilling System to ensure
there is no sign of damage .
2. Check the safety wires and all the fixing bolts. Once something
abnormal ,just fix it
3 .check all the cables ,terminal box ,and other electrical connections , if
something is loosening ,just fix it
4, check all the hydraulic hose if there is leakage ,cracks or deformed parts
5, according to the intensity of the shocking job ,some loading parts should be
detected for defection including loading eyes ,link tilt , main shaft..
6. According to jarring intensity to decide if the further examination is
necessary .

XVII Release drilling torque operation

Generally, when the torque down hole is bigger than the torque of the main
motor, the main shaft will stall ,in this case ,it is necessary to release the
anti-torque,.
Please note that the incorrect way to release the anti- torque will lead to the
accident , putting the pipe at the risk of being disconnected .so the operation
must be done strictly following to the guiding rules. Which are as follow.
Once the main shaft stall happens, lift the drilling tools in order to release the
anti-torque ,so the main shaft can continue drilling . when the method above
can’t make it .please choose one of the two methods to release the anti-torque
Just leave the “speed throttle” and “brake” switch untouched to ensure the
continuous output torque . turn down the “drilling torque limitation” dial to
slow down the torque output by the top driver. The main shaft will move
backwards little by little .(don’t let the main shaft run backward fast.) .until the
dial is turned down to zero . lift the top driver , then turn off the “speed throttle”
to zero . and start the top driver again.
If the method above is no effective , and top drive works incorrectly ,we will
choose the following one .

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 Leave the “drilling torque limitation” untouched , put the “brake “ switch on
brake . turn down the “speed throttle “ to zero . put the “brake “ on off .the main
shaft will start to run backwards slowly , then put the “brake “ on again ,the main
shaft stops , then off and on again ,just let it work in this way repeatedly ,until the
anti-torque on the shaft is released completely . then lift the drilling tools .and
start the top driver angin.

XVIII Emergency stop operation

1.In something emergent happens , the operator can push down the any one of
the emergency switches , all equipments of system would stop. Operator should
put all the switches to initial position.

2.once the system is back to normal state ,and there is no faults s and
alarms ,reset the emergency switch and press down the “reset” on the drill
console .

XIX Reset/ silence

When something fault occurs , the indicator of fault is on and the beeper goes off
at the same time. . Push “Reset/slience” the beeper will stop ,but the indicator is
still on until the fault is got rid of .

XX Stop System

Turn off the “speed throttle “ to zero and put the “direction switch” on stop
position on driller console .the come down to the PLC cabinet to switch off the
380v breaker or auxiliary switch .turn off the invert power and stop the main
power breaker ,the whole system stops.

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ENDIX I System Initial State

Attachment I. Driver cabinet initial state

Before starting system, make sure that all switches or buttons of driver cabinet
are in the following initial state.

Button or switch Initial position Note

Emergency stop Open Emergency-stop button is NC
contact

Attachment II Driller panel initial state

Before starting system, make sure that all switches or buttons of driver cabinet
are in the following initial state.

Button or switch Initial Note

position
Emergency stop Loose Emergency stop button is NC contact
Brake mode Auto Brake by PLC system
HPu Stop Stop the hydraulic system
Link rotation Center rotator is in inactive state
Link incline Center Link is in balanceable state
IBOP Open When drilling normally
Fan Close In initial position, it is in “close” position
Motor select A+B Select motor according to need
Operation Spin Initial position
Backup tong Loose Initial position
Motor Select
direction Stop Switch Initial position
Makeup torque Zero Set the value of torque before makeup
operating
Drilling torque Zero Set the value of torque before drilling
operating
Speed Zero Set the value of speed before drilling
operating.

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Attachment III PLC Cabinet Initial State

Before starting system, make sure that all switches or buttons of PLC/MCC
cabinet are in the following initial state.

Button or switch Initial position Note

Emergency-stop Loose emergency-stop switch button is NC

contact

Doghouse control emergency On the left side, allowed the doghouse

stop use the emergency stop operation

Motor heat Stop Use only under the low temperature or

high humidity

Mud pump linkage linkage The system linkage with the mud pump

Attachment IV Monkey board operation box initial state

Before starting system, make sure that all switches or buttons of monkey board
operation box are in the following initial state.

Button or switch Initial Note

position
Link rotation Center Rotator is in inactive state
Link incline Center Link is in balanceable state

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 Part VII Maintenance Manual

Chapter I Safety Operating Rules

I Safety Operating Rules

Note This sign provides additional information on procedures

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

Caution This sign alerts the user to procedures involving a risk of

personnel or equipment damage.

Warning This sign warns the user of procedures involving a

definite risk of injury to rig personnel.
Before maintenance work, the operator should make a safety maintenance plan;
make the safety analysis and take the training .

During the maintenance period, if the maintenance plan is changed, it needs to

revise the safety working plan and guarantees all in involved working personal
knows about the maintenance term so that it could ensure all the working staff’s
safety and the devices are in a good condition.
1. Every time before the maintenance, it needs the safety analysis, guarantee all
the power switch is on the “switch off” status. When lubricating, checking or
replacing the system, cut off the power supply.
2. During the maintenance and repair period, the operator must be equipped with
suitable protective equipment, such as glove, helmet.
3. When the system is running, it not allowed to maintenance and repair.
4. Before repairing the hydraulic system, should release the pressure in the
accumulator.
5. Check the hydraulic oil leaks by hand is forbidden, hydraulic oil leaked from the
hole is almost invisible in the high pressure. Hydraulic oil is not only high
temperature but also could penetrate the skin and cause injury, inspection should
be carried out by bamboo and other hard-board, and wear protecting appliance.

171
6. Don’t try to repair the part which you aren’t familiar with.
7. Before repairing the top drive drilling system, please read the related manual
carefully.

Chapter II Daily Inspection

In order to ensure that the top drive drilling system is in a good condition, prevent
the unforeseeable accident from happening . it is necessary to perform the daily
inspection to get familiar with the running state of the top drive .and deal with the
unexpected thing , all this should be done by the professional .

I It is important to inspect the following items

Item Term
Fastener Visual check all the fastener, lock wire no rust ,no slack .
cables connection Visual check the cables protect sleeve and cables connector
no slack
Hydraulic pipe line Visual check the hydraulic pipe line ,no break, the
and connector Connector no slack and leakage
Oil level of the Check the oil level ,conform to the requirement.
hydraulic tank
Hydraulic mainfold Check the hydraulic valve unit, no leakage
Gear box lubrication Check the level of the lubrication oil in the gear
oil Box. The level is ok
Explosion-proof Check the air filter , air pressure is ok
driller console
Driller’s panel cable Check the panel cables joint. No loose, no bend too hard and
so on.
Driller’s panel Check the driller’s panel indicator ,works normally
indicatror
electrical cabinet Check the electrical cabinets, in/out is fine, Ground is fine.
electrical cabinet air Electrical control house air condition in normal condition,
condition

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Roller of the carriage No rust ,no worn out ,rotate well .the lock nut is good
Guide beam joint Vertical no bent , the lock pin is good.

Pad eye Visually check the hang-off link ,the lug ,the pin . no wear ,lock
pin i
Is good
Top driver running All the motor and transmission no abnormal noise

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 Chapter III Maintenance Items and period

I Daily maintenance Items

1. Washing pipe
Grease fitting :
On the outside of the washing pipe
. the bottom part
Greasing method:
Grease gun , 2-4 pumps
Inspecting Item:
Washing pipe leakage.

2. Remote IBOP
Grease fitting
4 pieces of roller
Gear and rack
Grease Method
Feed grease fitting 1 pump .
Put some grease on gear and rack
Inspect Item:
a. Whether the guide plate and roller . bolts, loose, wear out or lost.
b. if the gear in the center or wear out.

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3. stabilizer
Grease Point
Inside surface of stablizer
Centralizer Ring
Grease Method
Use grease gun to Feed grease
Inspection Item
If the stabilizer is worn out ,change it .

II Weekly Maintenance Items

1. Pin of Bail
Grease point:
2 points on pin of bail
Grease method
Feed grease by grease gun.
Maintenance Item
Inspect Item
a． Lubrication of bail pins.
b． the lock plate and the bolts

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2. carriage with rollers
Grease point
4 points on the bottom of plate
16 points on each side of roller.
Lubricate method:
Feed grease into the fittings by grease gun, 2 washes for each point.
Inspection Item
a．Inspect rollers working situation. No Blocks.
b. Check the wearing situation of the roller. replace it when necessary.
c. Inspect the fixed bolts on wheels, check whether the lock washer lock well.

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3. Linlk tilt

Inspect Item:
a. Wearing situation on bolts of link
hydraulic cylinder
b. The position and clamps of lock
clamp on link.
c. The connection pins.
Grease Point:
Connecting pins of Joint bearings and rings.
Lubricate method:
Feed grease by grease gun

4. tieback beam
Inspection Item:
a. Inspect bolt.
b. Inspect the deviation . if the deviation is more than 3MM ,adjust it .

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5. Anti-loosen Device
Inspect Items:
a． Bolt fixture.
b． Safety lock rope.
Installation of anti-loosing device
a. put grease (molybdenum ) on bolt and nuts.
b. Make sure all the connecting joints are locked to the required torque before
installing the anti-loose device.
c. Clear the surface of IBOP, main shaft and protecting connector. Ensure surfaces
are bright and clean without any grease.
d. Put anti-loosing device in pair on the joint.
e. Put the tong dies on the center of connection.
f. Fasten bolts by torque wrench, the torque up to 400 N·m.
g. Fix all bolts by safety wire.

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6. Back-up Tong

Maintenance Item
a.Smear grease on fixed pins while installing.
b.Please disconnect the right side fixed pin only (initial
position of back-up tong, refers to the direction facing
to the top drive),
c. 4 oil seals in the Left side fixed pin.

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III Monthly Maintenance Item

1. Brake Device
Inspect Item:
a．break pad wear out evenly
b．the extent of worn
c．Inspect where there is leakage on Hydraulic hose

if The brake pad is contaminated by the oil or grease ,the friction

force could be reduced , the brake should be changed..

Maintenance Items:
if the thickness of the pad is less than 3mm , just change it out
Note: It takes a certain time to run in the new pad , the pad can’t offer the rated
force before running in.
Change the brake pad.
a) Release the oil pressure of braking device.
b) remove the cover and M14 bolts , and disconnect the brakes pipe lines,

180
remove the brake assembly entirely.
c) Release the guide pin and spring.
d) Replace to new pad.
e) Install the guide pin and spring.
f) Lock the screws, install the guide pin.
g). Fix the brake assembly by M14 bolts , connect the pipe lines, install the cover.

Keep the friction material away from oil or grease.

2. pad eye U shackle and fixed pin

Inspect Items:
a. Inspect the welding point
b. Inspect the keeper of
fixed pins and connect pin of U ring.

Drape hanger

Fixed Pin

U Ring

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3. Gooseneck
Inspect Item
a. Whether there is any dent , abrasion or corrosion.
b. Check for leakage.

4. Main motor and air cooling motor

Inspect Item
a. Inspect the damage to the cable of motor.
b. Inspect the damage and loose of the bolts
and lock line.
c. Inspect damages to window-blind and
screen.
d. Whether some dirty thing attached to
Heat exchanger.
Maintenance Item:
a. The heater of main motor would work
automatically when the main motor stops,
shut off it if it is idle for a long time.
b. Inspect the air-blower preliminary, if there
is some part damaged during
transportation ,or long time stock . if there
are some sundries in the passageway of the
cooling motor
c. Clean the heat exchanger regularly.
5. Back-up Tong
Inspection Item:
Check the abrasion of tong dies.
Inspect the looseness of bolts on the jaw.
c. Check trumpet fixed bolts, wear ring bolts and fixed pins and other fasteners
whether there is loose and damages, the reliability of locking.

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Maintenance Item:
Clear the dirt on the surface and gash of tooth in time.
Smear grease on fixed pins while installing.
Please disconnect the right side fixed pin only (initial position of back-up tong,
refers to the direction facing to the top drive),
4 oil seals in the Left side fixed pin.
e. While changing tong key, replace the 4 at the
same time to ensure geometry and mechanical strength same.

IV Maintenance Items in each quarter

1. Lubrication on bearings of main motor

Oil site
2 points on the top of main motor, 2 points on the below (inside).
Lube method:
Feed grease into glib by grease gun. Release the blockage on the position potion
of glib which is on the back of motor while feeding grease. Re-block it until grease
squeezed out.

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2、Motor insulation inspection.
3、AC preshoot pressure detects.
a、The pressure of balanced AC is 9MPa.
b、The pressure of Brakes AC is 3MPa.
4、Big gear of Rotating link adaptor and small gear of drive motor.
Grease point
gear and teeth
lube method
put the grease on the joint and teeth.
Maintenance Items:
Check the fixed bolts on motor frame often, lock it tight if there is any loose.

5. BOP Maintenance
Oil Site
Remote control IBOP glib point 1, manual IBOP glib point 1.
Lubricating mode
Feed lubricating grease into glib by grease gun, twice for each points.

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V. Maintenance Items in half year

1. Hydraulic oil
Inspect item:
Fluid level, pressure, temperature, cleanse of Hydraulic oil
Maintenance method:
Feed or change hydraulic oil according to the well site situation.
a. The time is continuous used 3 months for first changing.
b. After that, change the hydraulic oil every 6 month or according to the oil sample
analyzing.
c. Replace the filter while changing oil. Meanwhile, clean the filter of HX-63X10
and WU-100X100J.
2. Gear oil
Inspect Item
Fluid level, pressure, temperature, cleanse of Hydraulic oil
Maintenance method
Feed or change gear oil according to the well site situation.
a. The time is continuous used 3 months for first changing.
b. After that, change the hydraulic oil every 6 month or according to the oil sample
analyzing.
c. Replace the filter while changing oil.

3. Big gland sealing

Oil points:
Glib on Big gland sealing
Lubricate Method:
Feed grease into the glib by grease gun.

VI Maintenance Items every year

1. Detect the wear-out of hanging lift lug, U ring, and fixed pins by disconnecting.
2. Inspect the bail and clasp, recommend to detect the wear-out. If the bail bolt

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abrasion exceeds 2mm, lower the bearing weight, replace it when exceeds 3mm.
Detect the wear-out of guide rail clasp.
4. Detect the wear-out of bail and the lift lug of rotate head.
5. Inspect the lube pump of gearing oil and hydraulic oil pump, adjust it according
to the result.
6. Inspect the pressure of gear pump, if the pressure is not fit, find out the reason,
replace it when necessary.
7.Guide rail wire rope
Check item:
When the guide rail body in the folded state, check whether the rope core near
the joints of the guide rail is extruded and whether there is structural damage c
aused by breaking of the whole rope. Diameter of the wire rope decreases whe
n it is been worn. When the wear more the 30% of the diameter, it should be ch
ecked roundly or carried out strength test to confirm whether need to replace t
he wire rope.
Maintenance methods:
When the guide rail body in the folded state, grease the wire rope near the joint
s of the guide rail.

8、Rotating Link Adaptor

1）link tilt adaptor

Grease point
3 points grease fitting.

Lubricate method
Feed grease into the fitting by grease gun，
4 pumps for each
Maintenance Item
a、lock pin wear out or not
b、lf there is leakage outside.

Note. Please contact with technical dept of Jinghong for further

maintenance and repairing.

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 Tel: 0452-2340601
Fax: 0452-2340601
Email: [email protected]
Add: No.24, Delong Road, Nanyuan Investment Zone, Longsha District,
Qiqihar, Heilongjiang, China.
Zip: 161005

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 Attachment A Torque value of thread hastening

Recommend forc
Recommend forc Recommend forc
Thread Type e
e（N.m）10.9 e（N.m）12.9
（N.m）Level 8.8
M8 22 30 37
M10 45 63 75
M12 78 109 131
M16 193 271 325
M20 328 531 637
M24 653 906 1101
M30 1300 1828 2193
Remarks: The fasten torque of M20 on locking device is 400 N.m

Attachment B Recommendation of gear oil

Gear Oil

Scope of ambient temperature

Manufacturer
-35℃ to -6℃ to 21℃ to
-7℃ 20℃ 55℃
ISO viscosity (International
Organization for 32 68 220
Standardization)
Mobil Mobil Mobil
Mobil
SHC624 XMP68 XMP220

Attachment C Recommendation of Greases

Name Extreme Synthesis of lithium-based Precision

pressure grease Instrument
lithium based Grease
grease
Type 0 1 2 3 ZL-1H ZL-2H ZL-3H ZL-4H ZT-53-7
Remarks GB7323-87 Use in
Winter

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