Post on 25-Sep-2015
DQ70BS-JH Top Drive Drilling System
User Manual
Daqing Jinghong Petroleum Equipment Manufacturing Co., Ltd.
1
Prologue The users should read this manual before using the equipment.
In order to prevent the accident, the operator should pay more attention to the safety
all the time.
The design, manufacturing and service of this product comply with the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000 Quality Assurance System
API SPEC Q1 Quality Program Specification for Petroleum and Natural Gas Industry,
This manual includes top drive electrical system, hydraulic system, mechanical
structure and installation, test-running, operation, and maintenance. Refers to other
contents which arent included in the manuals and other problems during the course of
installation, usage and maintenance, if necessary, please contact us:
Tel 86-452-2345069 Fax 86-452-2340601 E-mail clb@jh-pm.com Address No.3-2Nanyuan Road, Nanyuan Investment Zone, Longsha district, Qiqihar City, Heilongjiang
Zip code 161005
2
Summary Top drive drilling system (hereafter referred to as top drive) is a new type of drilling
equipment that instand of traditional rotary table. The top drive is an important
petroleum drilling equipment developed since late 1980s. Using the top drive drilling
system could greatly decrease the accident of drill pipe sticking. Improve the working
performance and working security. The top drive drilling system is honored as one of
three great technical revolutions of drilling equipments in modern time.
Jinghong company developed the DQ70BS-JH top drive drilling system with
independent intellectual property rights. It integrated the mechanical, electrical and
hydraulic control technology. Our top drive drilling system takes a fully consideration of
operation while drilling, Our top drive drilling system has the advantages of simple
structure, easy operations and long service life, etc. All above features fully satisfy the
technological requirements on site. It is an important equipment for the drilling of deep
well, super deep well, horizontal well and controlled directional well in complex geologic
condition.
The main technical features are:
1. Adopt the double cylinder opposite clamping type backup tong, it could makeup and
breakout without lock the rotating link adaptor. It is more applicable, convenient and
easier to handle, makeup and breakout is fast and easy.
2. The patented structure of rack and pinion is used in IBOP of hydraulic control; the
hydraulic pipe is embedded into the body of structure in order to avoid the damage of
the hydraulic pipe for bump, which makes the operation of IBOP more reliable.
3. The patent slid-inserting type foldable structure is used in the guide beam. It is quick,
convenient and safe to install and dismantle. Comparing with the other brand top drive
drilling system, installment time of our guide beam could save 2~3 hours.
4. The patent structure of reversed oil cup is used in the main shaft seal of the gear box,
which guarantees that the lubrication will not leak in the process because the seal of the
3
main shaft is out of order.
5. Driller panel is equipped with touch screen which displays the condition of system
operation and can also monitor emergency point of equipment in time, increase the
reliability of equipment operation.
6. The counterbalance system with patent technology adopts single cylinder, it has
good balance performance.
7. The system equipped with double PLC control systems which backup each other. This
design has a great improvement of the reliability of top drive drilling system.
8. The hydraulic system is integrated on the main body of top drive, it is convenient to
installment.
9. The device of anti-loosen device with single direction tong dies, this device can load
more torque and be installed and disassembled easily.
10. The materials of cable is low-temperature resistible and wearable, which improved
the mechanical strength of cable and increased the reliability.
11. The rotating link adaptor connects with the gear box through shaft sleeve. When
tripping of raising and lowering or making a break off with bumper jars, there is no force
on the main shaft, which increases the service life of the main shaft bearing.
12. Patent technology of casing running tool, during the casing running, when the pipe
sticking or well kicking happens, it could realize the fast connection of top drive and
casing pipe, cycling the mud, avoid accidents (customer optional)
13. Equipped with the trolley of slip with pneumatic lift device, reduced the labor
intensity, and increased drilling speed (optional).
4
Contents Prologue......................................................................................................................................................... 1 Summary........................................................................................................................................................ 2 Contents......................................................................................................................................................... 4 Part I Technical Parameters of Top Drive DQ70BS-JH.......................................................................... 8
I General Data ...................................................................................................................................... 8 II Drilling Parameter ............................................................................................................................... 8 III Main Motor Parameter ....................................................................................................................... 8 IV Cooling Air-blower ............................................................................................................................ 8 V Hydraulic Disc Brake .......................................................................................................................... 9 VI Electric Control System ..................................................................................................................... 9 VII Reducing gear box ............................................................................................................................ 9 VIII Pipe Handler system........................................................................................................................ 9 IX Working Curve of Top Drive DQ70BS-JH...................................................................................... 10
Part II Mechanical Manual......................................................................................................................... 12 Chapter I Structure and function Introduction....................................................................................... 12
I. Structure and function introduction ....................................................................................... 13 II. Top Drive DQ70BS-JH Working Curve............................................................................... 13 III. Power Swivel ......................................................................................................................... 14 IV. Pipe Handler Device ............................................................................................................. 17 V Guide beam and carriage ...................................................................................................... 20
Part III Electrical Manual............................................................................................................................ 21 Chapter I Safety Operation Specification.............................................................................................. 21
I Safety Notice ............................................................................................................................. 21 Chapter II Electric System Component................................................................................................. 22
I. Incoming Line Power Distributor and Protect System ....................................................... 23 II. AC Frequency Converter Driving System........................................................................ 24 III. PLC Combination Control System...................................................................................... 24 IV. Relay Box............................................................................................................................... 26 V. Hydraulic Lubrication station ................................................................................................ 26 VI. Driller Panel ........................................................................................................................... 27 VII. Touch Screen ....................................................................................................................... 30 VIII. Main Power Cable .............................................................................................................. 33 IX. Other Cable ........................................................................................................................... 34
Chapter III Monitoring System (WINCC) ............................................................................................ 35 I. Screen Instruction ................................................................................................................... 35 II. System Structure.................................................................................................................... 36 III. Top Drive Drilling System .................................................................................................... 37 IV. Network Topology................................................................................................................. 38 V. Auxiliary Interface .................................................................................................................. 39 VI. Alarm History ......................................................................................................................... 40 VII. Curvilinear Trend ................................................................................................................. 41
5
VIII. System Login ...................................................................................................................... 43 IX. Logout System ...................................................................................................................... 44
Chapter IV PLC System Software and Hardware ................................................................................. 45 I. PLC Program Structure .......................................................................................................... 45 II. The hardware Structure of PLC System ............................................................................. 46 III. Switch Position and State Light Meaning on CPU ........................................................... 46 IV. Module installation, Power Distribution and Indicator ..................................................... 47 V. Programmer Upload and Download.................................................................................... 47 VI. ET200M Remote Station ..................................................................................................... 48 VII. Indicator on Interface Module ............................................................................................ 48 VIII. Remote station ET200M and module remove as well as power deploy and indicator....................................................................................................................................................... 48 IX. Communication system ....................................................................................................... 49
Chapter VI Main Electric Motor Drive System .................................................................................... 49 I. Main Electric Motor and Frequency Converters ................................................................. 49 II. Cupboard Transmission Unit Structure and Operate Principle ....................................... 49 III. Main Circuit and Control Circuit Sketch Plan .................................................................... 50 IV. Connection of Standard Control Line ................................................................................ 50 V. Extensive Characteristic of Standard Software Provide Protect for Transform, Electric Motor and Process ..................................................................................................................... 51 VI. Adjustable Power Limiter ..................................................................................................... 51 VII The primary / secondary control of Transmission ......................................................... 51
Chapter VII Installation, Commission and Maintenance ...................................................................... 52 I. Electric installation and commission notices ....................................................................... 52 II. Electric system reinstallation ................................................................................................ 53 III. Galvanization examine ......................................................................................................... 53 IV. Daily maintenance ................................................................................................................ 54
Part IV Hydraulic Manual........................................................................................................................... 55 Chapter I Safety Operation Specification.............................................................................................. 55
I Safety operation notification ................................................................................................... 55 II Electric system operation notification ................................................................................... 56 III Hydraulic system operation notification .............................................................................. 56
Chapter II Hydraulic system structure and Principle............................................................................. 58 I Hydraulic System Structure and Working Principle............................................................. 59 II. Control valve unit and execute device ................................................................................ 63 III Control Loop on Hydraulic valve block................................................................................ 66
Chapter III Hydraulic oil ....................................................................................................................... 70 I Selection of hydraulic oil.......................................................................................................... 70 II Hydraulic oil Changing............................................................................................................ 70
Chapter IV Hydraulic system Commissioning and Maintenance.......................................................... 71 I System pressure adjusting...................................................................................................... 71 II Pre-setting and adjusting of hydraulic system pressure.................................................... 72 III Hydraulic system daily maintenance request..................................................................... 72
Part V Installation and Commissioning ................................................................................................... 74
6
Chapter I Safety Operation Discipline .................................................................................................. 74 I Safety operation note............................................................................................................... 74
Chapter IIInstalling preparation............................................................................................................................................................... 76 Chapter III Installation .......................................................................................................................... 79
I. Installing the guide beam ....................................................................................................... 80 II. Installation of Top Drive Main Body..................................................................................... 89 III. Cable installation ................................................................................................................... 95 III Auxiliary Device Installation .................................................................................................. 98
Chapter IV Inspect after installation ................................................................................................... 100 Chapter V Test Running...................................................................................................................... 101
I Electric Device Test-running ................................................................................................. 101 II Assist Function Test Running.............................................................................................. 103
Chapter VI Top Drive Disassemble .................................................................................................... 104 I Accessory equipments disassemble ................................................................................... 104 II Cables disassemble.............................................................................................................. 106 III Disassemble Top Drive Main Body ................................................................................... 106 IV Disassemble the guide beam............................................................................................. 110 Attachment I Top Drive System Electric Wiring Installation Inspecting list ................. 113 Attachment II Top Drive System mechanical installation inspecting list........................... 114 Attachment III Top Drive System Installation and Commissioning Record ..................... 115
Part VI Operation Manual ................................................................................................................... 117 Chapter I Safety Operation Rules........................................................................................................ 117
I. Safety operation notification ............................................................................................. 117 II. Operator safety operation notes ........................................................................................ 118
Chapter II Operating Procedure .......................................................................................................... 121 I. Inspection before starting ..................................................................................................... 121 II Hydraulic system operation............................................................................................. 124 III. Main Motor Heater .............................................................................................................. 126 IV. Main Electric Motor air Cooler........................................................................................... 126 V. Braking mode selection ....................................................................................................... 127 VI. Drilling operation ................................................................................................................. 129 VII. Backup tong operation ...................................................................................................... 134 VIII. Elevator link operation ..................................................................................................... 134 XI. Make Up and Breakout Operation.................................................................................... 136 X Drilling ahead by single ........................................................................................................ 141 XI. Drilling ahead by triples ..................................................................................................... 142 XII. Backreaming...................................................................................................................... 143 XIII Pulling out operations ....................................................................................................... 144 XIV Running Casing ................................................................................................................. 146 XV Well Control Operation ...................................................................................................... 146 XVI Jarring operation ............................................................................................................... 147 XVII Release drilling torque operation ................................................................................... 148 XVIII Emergency stop operation............................................................................................. 149
7
XIX Reset/Mute ......................................................................................................................... 149 XX Stop System ........................................................................................................................ 149
Appendix I System Initial State........................................................................................................... 150 Attachment I. Driver cabinet initial state................................................................................ 150 Attachment II Driller panel initial state ................................................................................... 150 Attachment III PLC Cabinet Initial State................................................................................ 151 Attachment IV Monkey board operation box initial state .................................................... 151
Part VII Maintenance Manual ............................................................................................................ 152 Chapter I Safety Operating Rules........................................................................................................ 152
I Safety Operating Rules ......................................................................................................... 152 Chapter II Daily Inspection ................................................................................................................. 153
I It is important to inspect the following items....................................................................... 153 Chapter III Maintenance Items and period.......................................................................................... 154
I Daily maintenance Items ....................................................................................................... 154 II Weekly Maintenance Items.................................................................................................. 155 III Monthly Maintenance Item.................................................................................................. 159 IV Maintenance Items in each quarter................................................................................... 162 V. Maintenance Items in half year .......................................................................................... 162 VI Maintenance Items every year........................................................................................... 163 Attachment A Torque value of thread hastening .................................................................. 164 Attachment B Recommendation of gear oil selects............................................................. 164 Attachment C Recommendation of Greases selects .......................................................... 164
8
Part I Technical Parameters of Top Drive DQ70BS-JH
I General Data
Rated Drilling Depth: 7000 m114 drill stem Max. Load capacity: 4500 kN (350ton)
Main channel: 75mm
Rated circulating pressure: 35MPa5000psi System Weight: 12.5tMain body Working Height: 5.9m (Bail surface to elevator upper surface)
Electric Volt: 600VAC
Rated Power: 315KWX2 422HPX2
Ambient Temperature: -3550 Altitude: 1000m
II Drilling Parameter
Rotary speed: 0230r/min adjustable Work torque: 55kNm (continuous) Max. Torque: 82kNmdiscontinuous
III Main Motor Parameter
Related Power: 315KW X2 continuous
Related Rotary speed: 1150r/min
Max. Rotary Speed: 2600r/min
IV Cooling Air-blower
Model: M2JA132S2A
Rated Power: 5.5kW
Rated Volt: 380VAC
Rated Frequency: 50Hz
Rated Currency: 10.7A
Rated Rotary Speed: 2905r/min
9
V Hydraulic Disc Brake
Braking Torque: 68kNm (50,000ft-lb) Cylinder Work Pressure: 7.5MPa
VI Electric Control System
VFD Input Volt: 600VAC
VFD Output Frequency: 0121Hz Motor alarm temperature: 200 Lube oil temperature alarm: 80 Hydraulic source oil temperature alarm: 80
VII Reducing gear box
Ratio of velocity: 10.97:1 double grades speed reducing
Lube: Gear pump forced lubrication, air cooling
VIII Pipe Handler system
Rotate Head adapter rotating Speed: Factory set 3r/min
Hydraulic motor work pressure: 13.5MPa
Upper of IBOP (remote control): 6 5/8" API REG boxpin70MPa Lower of IBOP (manual): 6 5/8" API REG boxpin70MPa Backup Tong Diameter: 216mm Backup tong retaining range: 87216mm Link: 2740mm, 350t
Leaning angle: forward 35, backward 55
10
IX Working Curve of Top Drive DQ70BS-JH
11
Top Drive DQ70BS-JH Dimension
12
Part II Mechanical Manual
Chapter I Structure and function Introduction
The Top Drive System used on oil drilling rig could drive the drilling drill string rotate
from the top of drilling tool directly, it also could rotate and release the drilling bit, it
could move along with the guide beam up and down to finish drilling.
Top Drive DQ70BS-JH Dimension
Counterbalance device
Cover Assembly
Gear Box
Air cooling Device
Wash pipe packing assembly
Bail
Link
Back-up Tong
Anti-loosen Device
IBOP Control Device
Manual IBOP
Main Motor Brake Device
Rotating Link Adapter
13
I. Structure and function introduction
Mechanical structure of Top Dive Drilling System includes assembly and
components as follows:
Power swivel Pipe handler System Guide Beam and tackle
II. Top Drive DQ70BS-JH Working Curve
14
III. Power Swivel
The Power swivel consists of main motor, break above the motor and air cooling system
on the top of motor, balance device, bail, washing pipe assembly, gear box and other
components. The main function of power swivel is to drive the main shaft rotate to
drill, make up and break out, as well as circulate mud to ensure the drilling work
carrying on regularly.
1. Main motor 2 sets of Main motors are installed on the gear box. Motor
has double axles, the lower axle connects with main
transmit gear, upper axle connects with braking system.
Each main motor could supply 315KW power
continuously. The rated rotary speed is 1200r/min in
60.6Hz frequency, stepless speed is adjusted by AC
speed adjusting system. The rated output torque value of
motor could be set by currency, Output torque is
proportional to currency. The motor is protect type
compel air, cooled air pass through the motor inside and
discharge from the air outlet.
Main Motor Bail
Wash pipe Assembly
Gear Box
Brake and air cooling Device
Counterbalance device
15
2. Air-blower and Braking Device Air-blower is installed above brake system, driven by the flameproof 3P AC
asynchronous motor which power is 5.5KW. Air blower starts to absorb air from air inlet
on cooler shell, release it from the air outlet on the lower part, this simple and strong
guarantee reliable airy.
The hydraulic operating disc brakes installed on the upper axle of motor, it brakes via
the brake disc on hydraulic oil tank. The brake energy is proportional to the pressured
pressed by hydraulic system, the wearing of brake disc is compensated by increasing
the movement of hydraulic cylinder. There are 2 self reset springs on each braking
disc, springs could reset when the braking discs release. The braking device has 3
functions while the top drive system working.
A. Bearing the reversed torque of drilling tools in well.
B. When touch sticking, if the motor torque is equal to the reversed torque, the drilling
tool would bounce, so take measures to brake the main shaft to prevent the drilling tool
drop out while reversal rotating.
C. It works as brakes while the motor galloping.
Brake Body
Brake Pad
Brake Disc
Brake Fix Seat
Main Motor
Protect Cover
Encoder
Encoder Frame
16
3. Gear Box Gear Box adopts double-geared drive,
transmission ratio is 10.97:1, the gears are all
helical gear, large transfer torque, little noise.
Bearing are SKF bearing, strong anti-seismic
capability and anti-attack capability.
The lubricate system of gear box is gear pump
force lubrication. The lube pump is driven by
motor of 1.1KW produced by ABB. The motor
spreads lubricate oil on oil points of double filter
and cooling device, via main shaft return to oil
cabinet. DQ70BS-JH top drive system adopts
force lubricate mode, bearing and gear could
contact the oil sufficiently to ensure the
reliability of lubrication. Install the pressure
detector and temperature cell in the lube pipes,
inspect and alarm the pressure and oil temperature of lube system.
4. Wash Pipe Assembly Washing pipe assembly is installed between the mail
shaft and gooseneck, the mail shaft rotating drives the
four loops of sealing ring in washing pipe packing to
rotate, so regular inspection and maintenance is
necessary to prolong its service life.
5. Gooseneck Gooseneck is installed on the washing pipe frame, bottom
is connected with washing pipe, the sealed top is the
transmission channel of mud circling, open the top to start
fishing and well logging. Its top is connected with drilling
hose, it is the inlet of drilling fluid.
17
6. Bail balance system
Bail is the importance bearing component of Top
Drive System. The bail is connected with gear box
via bail pin, its top is hanged on the hook of crane.
Balance cylinder is fixed on bail, the main function is
to balance the weight of main body. Jinghong top
drive system adopts single hydraulic cylinder
balance mode to solve the problem of unfair force
on connecting rod in double cylinder system. Single
hydraulic cylinder designing ensure the system
works more safe and reliable.
Bail could connect with crane as well as the hook,
ensure enough well sites requires.
IV. Pipe Handler Device
Pipe handler device is the important element of top drive system, it consists of leaning
unit, back-up tong assembly, thread loose-proof device, IBOP, rotate head and other
components. It could highly improve the automation of drilling.
Rotating Link Adaptor
Leaning Device
IBOP
Thread Anti-loosen Device
Backup Tong
18
1. Rotating Link Adaptor
Rotating Link Adaptor is installed on the fixed shaft
connected with gear box, and moving independently
from main shaft, the structure as the draft.
The rotation of Rotating Link Adaptor i is driven by
hydraulic motor, it could rotate CW and CCW, it
propels the link to rotate 360, it is easy to catch the
drilling stem in mouse hole. It is also convenient to
catch the drilling pipe on rack frame while the main
body is moved to Kelly board. The rotary of rotate
head normally be set at 3 r/min. It could be adjusted according to the customer
requirements.
2. IBOP The Function of IBOP: when the pressure in well is higher than
the pressure in drilling string, cut down the channel inside of
drilling string by close up the IBOP to avoid well kick or blowout.
IBOP is installed between the saver sub and main shaft. It is
composed of remote IBOP upside and manual IBOP in low part.
Remote IBOP upside is connected with the main shaft of power
swivel, the manual IBOP in low part connects with saver sub, the
saver sub is connects with drilling stem while drilling. The inner
and outer threads in IBOP are 6 5/8REG.
The remote IBOP changes direction operated by hydraulic
tank. The gears work with rock running drives the ball valve
to rotate 90 opening and closing the IBOP. The Top drive
adopts gears and rack to realize the open and close of IBOP,
process the advantages of simple structure, driving accuracy,
and high transmission reliability.
19
3. Side-hanging couple clamp
Backup tong serves for Strain at during a trip. The couple
clamp backup tong on Jinghong Top Drive system operates
only once on drillers panel directly to make up and breakout
without locking rotating head. This design is convenient to
change clip tooth, it clamps tightly. Oil pipe lines are
designed inside the body. Not any pipe lines explored to
avoid scratching as well as improving work reliability.
4 Drilling string anti-loosing assemble Install anti-loosing assemble between the joints of main
shaft and IBOP joint and the thread of saver sub in order to
prevent them from loosing when the top drive system
breakout. See the structure on the right.
20
V Guide beam and carriage
The main function of the guide beam is to bear reverse torque when top drive system
working.
The carriage connects with gear box inputs in the guide beam, and slide along with top
drive, transmits the torque to the guide beam. The upper guide beam is connected with
the bottom beam of crown block. Lower guide beam is connected with spreader beam
of the derrick. The torque can be directly transmitted to the lower derrick. The main
point is guide beam produced by JH is folding structure without install lock pins, which
makes installation convenient and reduces risk and cost.
Carriage
Bearing Wheel
21
Part III Electrical Manual
Chapter I Safety Operation Specification
Before install, set up, operate and maintain Top Drive Drilling System, please read this
manual first.
The Top Drive Drilling System installing, debugging, operation and maintenance must
be done by professional or specially trained people, if not, it maybe cause personal
injury or machine damage.
Note It is a sign that used to the additional note about safely item with personal and equipment.
Caution It is sign that used for to causing the suggestion of personal or equipment injury.
Warning It is a sign used for to extremely easy to cause personal or equipment damage.
I Safety Notice
The following safe notices are very important for correct installation, using,
maintenance of the Top Drive, all the operator and the attendant must read it carefully
and understand it:
1. Forbidden livewire work, electric system maintainer and operator must be
qualified and follow close to safety operation specification.
2. When working, do not open the safety cover over the high-voltage equipment,
do not maintenance or remove any electric element, do not pull out/connect wire with
current.
3. Forbidden open the relay box, driller consol or pull out/connect wire under
combustible gas environment.
22
4. Before maintain Frequency Converter or variable-frequency motor, turn off the
power of the Frequency Converter, test the electric current and hanging the caution
sign DO NOT shut the switch, people working. Do not maintain major loop, before DC
bus voltage lower in the safety area (DC 24V), (normal after 30 minutes). It is
dangerous for human safety and electrical equipment!
5. Cut off the mechanical interlock switch 1QF or 2QF, test the electric current
with Electroscope and make sure no voltage before replace the PLC electric elements in
cabinet.
6. Keep protective gas pressure when turn the drillers console on. If the drillers
console protective gas pressure lost, it is required to resume quickly or turn off the
drillers console controlling power.
7. Electric control house should be connected to ground wire correctly.
8. Forbidden relieve the link of software and hardware. If really needed, resume as
soon as possible after clearing fault.
9. If the temperature higher than 40 , or the humidity higher than 95% or there is dewing, do not start the frequency converter or other control power before start air
conditioner to cooling and dehumidify.
10. Check the electric control board if there is dewing before starting, when main
power was off more than 30 minutes.
11. When the temperature outside is high, do not set the air conditioning too low to
prevent electric equipment to dewing.
Chapter II Electric System Component
Electric control system is mainly composed of Coil-in electric energy power splitting protect
system, frequency conversion driving system and PLC combination control system.
The generator supplies 600V main power to the primary air switch (EIN1000) produced by
ABB in electrical control room. The air switch is perfect in bearing powerful current
23
produced when switch. The major switch connects the major power to 2 sets of frequency
converter. The other circuit is connected to auxiliary transformer, which provides main
power to the PLC cabinet of 380V.
Frequency-converter driver system is component of 2 sets of separate frequency-converter,
they drive 2 sets of 315KW AC motor separately. These 2 motors work separately or drive
together (primary and secondary mode), could self-detect and protect.
As the center of driving control system, the PLC produced by ABB adopt the mode of one
using and one preparing to ensure system working safely and reliably. This mode is: when
one system is working, another same system is prepared always, and when the running
system work wrong, another system can work immediately, so drilling will not be delayed.
PLC integrated control cabinet is needed to control the Top Drive Drilling System. The PLC
system is connected with driller consol and drilling system with the help of PROFIBUS line.
The system main PLC controller is S7-300 system programmable controller produced by
Siemens, and the CPU is 315-2DP, the remote control station is ET200M.
I. Incoming Line Power Distributor and Protect System
This system is mainly component of Income
cabinet. The Income Cabinet includes main air
switch, auxiliary transformer, controlling
transformer, and electric relay etc.
The major air switch is the master switch of the
Top Drive Drilling System produced by ABB;
auxiliary transformer power is 80KVA, and its
function is transforming the three phases
alternating current from 600 V to 380 V and
supply to integrated cabinet as power station. T1
is control station, and the power is 630VA.
Transform 600 V AC to 220V and 24V AC, as to
scram and no-voltage protection, and control the
main air switch. SB1 is installed on the integrated
cabinet, 1SB3 is the dead-stop button, installed on the drillers panel.
24
II. AC Frequency Converter Driving System
It is mainly composed of 2 sets of frequency converter and 2 AC variable frequency
motors. The frequency converter is produced by ABB, and the model is ACS800.
Three-phase alternating current of 600V is input frequency converterrectified and inversed to transform to three-phase variable frequency power, and used to drive the
AC variable frequency motor.
AC frequency motor is produced by WARDLEONARD in U.S.A, which power is 315KW,
and rated currency is 405 A. This system has the foundation of anti-rotate. When the
drill pipe locked, the motor speed will reduced rapidly; when reactive torque is bigger
than the drive torque, the motor stop rotary, and this is called motor-blocking. When
the drive torque is bigger than the reactive torque, the motor will speed up to setting
speed.
The electric motor is added cooling fan and preheating unit. These solve the problem of cooling and working in cold area.
III. PLC Combination Control System
Include logic control system and AC distribution system of all units. PLC Integrated
Control Panels is as follow
25
A. Indicator light
a. Power indicator light of 24V: switch on the system, then power of all units is OK;
system is ready, indicator lights.
b. Hydraulic oil heating light: light on while heating hydraulic oil.
c. Motor hearting indicator: light on while motor heater working.
d. Fault/alarm light: while system alarm, light flashes (1 Hz); while fault, light
keeps.
e. Back up indicator.
B. Hand switch
a. A/B system select switch : at A position, first PLC work; at B position, second
PLC work.
b. Hydraulic oil heater switch
c. Motor heater: used for controlling major motor heater. This switch can work
independent upon PLC. The indicator displays the working state of heater. After
turn on the power of the frequency converter, the link-control is added, and the
main motor stops to be heated.
d. Reset/silence button (SB1): when system alarm, the indicator flashes, the
Warner alarms. Press silence button, the fault/alarm indicator keep state.
26
e. Photoelectric encoder of the main electric motor (SA5): when drilling normally,
switch to normal, and this can control the rotary torque accuracy. When fault of
encoder appears, switch to unmoral, and this can stop the efficient of drilling
rate.
f. Mud pump link switch (SA6): use for mud pump link-control. In link-control state,
if the mud pump did not give the stop order, when switch the IBOP to close, the
IBOP can not close. If well blowout happen, press well control button, the mud
pump will stop and the IBOP close. In unlink-control state, operate the IBOP
switch on drillers console can control the IBOP.
g. Back up switch
IV. Relay Box
Relay box is set on the body of top drive, the function of it is providing power for
detecting element, feedback detection signal, and provide control power signal for
control valve.
It can read out air pressure signal of main cooling motor, temperature signal of main
motor, over temperature alarm, temperature signal of hydraulic oil, pressure signal of
lubricating oil, pulse signal of main motor encoder, and etc.
V. Hydraulic Lubrication station
Lubrication station of hydraulic is composed of hydraulic pump motor (5.5KW),
lubricating pump motor (1.1KW), etc. It is controlled by drillers console. The electric
motor adopts flame-proof type three-phase asynchronous motor. Lubrication station
is set on top drive body.
1. Hydraulic pump have three tap positions: 1). auto, 2). start, 3). stop.
1). Auto: switch to auto, the system will run based on the PLC program.
2). start: switch to start, the hydraulic pump will run.
3). Stop: switch to stop, the hydraulic pump will stop.
2. Lubrication pump start and stop the same time as the main electric motor.
27
VI. Driller Panel
The Driller panel has all functions for drilling operation and any other auxiliary
operation for driller; it can set top driver speed, torque, operation mode.
The Driller panel is EX type; it can only be powered on when driller panel inter pressure
is normal, otherwise, it would indicate air pressure losing on touch screen.
1). Indicator, Button/Knob Switchs Functions Showed as Followed:
No name Type Function
1 frequency conversion emergency stop button
1SB1 self-locking
When the frequency conversion or main motor break down, press this button and then frequency conversion stop. After eliminated the fault, should reset (CW rotation)
28
2 Ready light 1HL1 green light When systems all are ready, it lights. 3 Fault/alarm
light 1HL4 red light When system alarm, it flash once a second; when
break down, it lighting. 4 Brake light 1HL2 red light When braking, it light. 5 Brake mode
Brake/off/auto 1SA10 three positions switch
At brake mode, when electron magnetic valve work, system braking and it light. At auto mode, PLC control system braking auto. At off mode, solenoid valve releases, main shaft rotate freely.
6 IBOP light 1HL3 red light When IBOP closed, it lights. 7 IBOP
closed/open
1SA11 two positions switch
At closed positions, hydraulic valve close the IBOP, so as to close the mud circulatory system.
8 Well control 1SB2 red button When well blowout, press this button to link with other equipment.
9 Motor selection A/A+B/B
1SA5 3 turn button
Select motor of top drive: M1 or M1+M2 or M2
10 Hydraulic pump running light
1HL5 green light When hydraulic pump running normally, it lighting.
11 Hydraulic pump switch auto/stop/start
1SA6 three positions button
At stop positions, hydraulic pump stop; at start positions, hydraulic running; at auto positions, run as the PLC result.
12 Elevator link centre
1SB3 button This button controls the electric valve of link center. When press it, the link is over the well
13 Elevator link rotary Counterclockwise/clockwise
ISA9 Three positions resetting key
It is a resetting key with spring. When turn it on counterclockwise positions, the link rotate counterclockwise; when turn it on clockwise positions, the link rotate clockwise; when unclench it, it go back center positions automatically.
14 link incline backward/forward
1SA7 three positions, resetting key
A resetting key with spring. Oil case will be locked, when its on center positions. Turn it on forward, incline oil case will push the links and elevator to the rat hole; when reclinedwill make the elevator be off the drilling tool when drilling.
15 Hydraulic elevator
1SA8 three positions button
Shut/pen elevator
16 motor cooling fan auto/off/on
1SA2 three positions button
For control the cooling fan running. At on, fan starts, at off fan stops. At auto, according to PLC output result.
17 motor rotary direction
1SA3 three positions button
Control the direction of main motor
29
backward/stop/forward
18 operation mode drill/spin/torque
1SA4 three positions switch resetting on right
Setting according to the value of the limited max torque.
19 backup tong Release/Lock
1SA4 two position button Reset to left
Rotary to right, start backup tong tight the drill pipe. Leaving hand reset to left automatic, backup tong loose.
20 makeup torque potentiometer In makeup operation, set limit in transducer, and set max torque.
21 Drilling torque potentiometer In drilling operation ,set limit in transducer, and set max torque
22 setting speed of drilling
potentiometer In normal drilling operation, set limit in transducer, and set max speed.
23 Torque Guage indicator Show true torque of Top driver output with KNm unit.
24 Rotary Gauge indicator Show true rev of master axis with r/min unit. 25 Return/Mute Green button Back to start and mute 26 Break out jump Green button Press this button, hydraulic pump increase press to
balance oil tank, lift top drive 7cm, protect from damaging the connect thread of pipe.
2). Throttle hand wheel
Throttle hand wheel is used for set normal drilling rotary speed limiting on frequency
converser. Handle scale is set. When rotate hand wheel inverse hour, the drilling speed
low down, and the minimum is zero. When rotate hand wheel clockwise, the drilling
speed increase, and the maximum is 230r/min. The rated speed is the main shaft
output speed 110r/min.
3). Drilling Torque
The scale of drilling torque handle is set by system. Turn the handle counterclockwise,
will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn
the handle clockwise, will increase the limit torque, while getting to the limit positions,
the limit torque the rated torque (55kN.m).
The full quantity torque of MAKEUP TORQUE is 55kN.m (set in factory).
30
4). Makeup Torque
The scale of drilling torque handle is set by system. Turn the handle counterclockwise,
will reduce the limit torque, while getting to the limit positions, limit torque is zero. Turn
the handle clockwise, will increase the limit torque, while getting to the limit positions,
the limit torque the rated torque (55kN.m).
The full quantity torque of MAKEUP TORQUE is 55kN.m (set in factory).
VII. Touch Screen
Generally, all operation interface can be divided into 3 areas, each of them display
separate information.
Toolbar: at the bottom of the screen, frame switch, data and time are all in toolbar.
Display area: in the centre of the screen, it is used for oversee and controlling.
Title panel: display name
Chick on the button to enter interface as follow:
1). Main frame; 2). Auxiliary frame;
3). Alarm frame; 4). Senior management.
1). Main Frame
Display output torque, output speed, as well as both motor parameters, include: motor
speed, running frequency, motor electric current, motor power, motor temperature,
alarm, fan running order, and etc.
31
2). Auxiliary Frame
Include elevator system, hydraulic system, lubrication system, other system notes.
Elevator system includes elevator co-rotation, elevator reversal, elevator incline back
and elevator middle position.
Hydraulic system includes: hydraulic pump run, hydraulic system oil low, oil
temperature high alarm, oil heating as well as oil temperature note.
Lubrication system include: lubrication pump run, low pressure, temperature high
alarm, heating and lubrication temperature notice.
Other system include: IBOP valve open, IBOP valve closed, backup tong clamping,
backup tong loosen, braking notice.
And include other working state notice of top drive drilling system.
32
3). Alarm Frame
Recording all alarm events when running.
4). Senior management
Frame can only enter after login; user name JH and password 8888 can login
through flashing window.
33
Frame is as follow after login. Green is current state. User can decide by self
whether test and whether turn back.
VIII. Main Power Cable
The function of main power cable is to send the frequency conversion output of main
control cabinet to master motor on Top driver.
For installing and connecting easily cable has three segments:
1. The first segment is ground cable; its 26m, from main control cabinet to derricks
base.
2. The second segment is derrick cable; its 48m, from derrick base to top.
3. The third segment is traveling cable, its 26m, and one joint connect to the main
electric motor, another to derrick cable.
Every cable joint have four plugs, and there are labeled separated by U (yellow)k, V
(green), W (red) and zero curve (white). When joint the plugs, be sure joint U to U, V
34
to V, W to W, zero curve to zero curve.
The joint of three cable and the joint between main motor and coil out cabinet adapt
CIRCULAR CONNECTOR, and operate conveniently outside.
Pay attention of insert enough and lock reliably.
According to distance between top drive electric control room and derrick, the power
cable length is chosen. If the traveling cable and the mast cable (total 74m) is enough,
the ground cable is not need.
If the ground cable length is the same to the traveling cable, it is allowed to exchange.
IX. Other Cable
1. Driller panel Control Cable
Driller panel control and communicate totally adapt three cables.
1. Ten core driller panel control cable: Four cores for drillers console control
power, two cores for stop emergency control, two cores for transform of A/B
system, and other two cores are spare.
2. Two core communicate cable: total 2 cable, one for A system communicates,
and another for B system communicates. There are marked on joints and
sockets.
2. Cable of Relay Box
The relay box is set on top drive body. Its function is transit the assist power, control
power and control signal to the functor on body, and feedback the functor actuating
signal and detectable signal to the composite controller cabinet or frequency converser.
Cable between coil output cabinet and relay box is two.
1.15 core assist power cable: cable size 36+64+52.5
Among of them, provide to hydraulic pump power is 36 mm2; to 2 sets of main motor
fan is 64 mm2; to lubricate pump motor is 32.5mm2; to hydraulic oil heater is 12.5mm2, lubricate heater is 12.5mm2
2. 60 core composite control cable: cable size 3021
Most of them are 24v power, thirteen control power line of solenoid pilot actuated valve,
35
feedback line of detectable signal, signal line of motor encoder, and etc.
3. The two cable is divided into three section: ground cable 26m; mast cable 48m;
travelling cable 26m.
3. Repeat Earth electrode
Electric controlling system of top drive drilling system adopts three phase four-wire
system. on the cross position set the earth terminal. The earth terminal connects to
earth electrode with copper wire of 70 mm2.
The two earth electrodes are 1.8m long, outer layer galvanized. The earth terminal
connects to earth electrode with 5m long lead. The state of picture is as follow, earth
electrode is knock into ground 300mm.
All cable joint adapt fast plug connection, the plug and socket both
mark, take care when connecting or the plug may be damaged. Ensure that
lock the nut.
Chapter III Monitoring System (WINCC)
I. Screen Instruction
Each operate panel can be divide into three areas as follow to give different
information.
Toolbar: displayed at the bottom of the screen, usually used to exchange button in the
area and show current date and time.
Display area: in the central section of the screen, it is main area for monitoring and
operation.
36
Title bar: show name.
Chick on the icon on toolbar to enter corresponding screen:
System structure screen
Top drive drilling system screen
Network topology screen
Auxiliary interface screen
Alarm history screen
curvilinear trend screen
System login screen
System logout screen
II. System Structure
Chick on system structure to enter screen as follow:
In this screen, the basic information and construction frame can be seen as follow:
37
Running state of A Cooling fan of electric motor, Running state of B Cooling fan of
electric motor
Running state of A Main electric motor, Running state of B Main electric motor
Running state of hydraulic pump; running state of lubrication pump; valve of IBOP as
well as elevator link state
In any function module, red state means closed and green means open
III. Top Drive Drilling System
Chick on the top drive drilling system in toolbar to enter interface as follow
In this screen, it is mainly show the top drive drilling system running state and data,
this is helpful for operator to know well of the state of top drive drilling system.
38
In this screen, operator can know:
A main motor parameter: Motor current, motor pressure and others totally 8 data.
B main motor parameter: Motor current, motor pressure and others totally 8 data.
Running state of A cooling fan, Running state of B cooling fan
And also top drive drilling real torque and speed
In any function module, red state means closed and green means open.
IV. Network Topology
Chick on the network topology to enter screen as follow:
In this screen, operator can know all networks state well of system, so as to make
decision fast.
In this screen, it shows remote I/O module, and network state of NO. 1 and 2 frequency
converter
39
V. Auxiliary Interface
Chick on auxiliary interface to enter interface as follow:
In this interface, it show the work state of any other auxiliary units exept top drive
driling system. General speaking, it can be divided into six parts.
1. Elevator system, show the work state of elevator.
2. Hydraulic system, show the on/off of hydraulic pump, current temperature, and
if there are fault.
3. Lubrication system, show on/off of lubrication pump, current temperature, as
well as fault.
4. Auxiliary system, show state of IBOP, electric house temperature, state of
backup tong.
5. Show body working state, include drilling waiting, drilling and others, totally 7
items.
6. Control panel indicator, include show A/B system running, and items showed
40
with panel synchronously.
In each function module, red state means closed and green means open.
VI. Alarm History
Chick on alarm history button in toolbar, enter interface as follow:
The alarm contents include date, time, number, state and messege text.
When alarming, characters and background is the color of red, the status bar appears
a mark of +.
When alarm disappeared, characters and background color change to general color,
the status bar appears -.
Alarm confirm when alarming, button in alarm toolbar can be used to confirm.
Chick recent pigeonhole or future pigeonhole can see alarm history.
Chick on then scrollbar will appear on right when the history too long, then
alarm history can be seen totally.
41
the first button is for given the first alarm, and the second one is for
the last alarm.
VII. Curvilinear Trend
Chick on curvilinear trend in toolbar to enter interface as follow:
In this interface, include two mode: realtime curvilinear and history curvilinear, these
two modes can be cut over by button of realtime curvilinear and history curvilinear.
Output torque and speed of the top drive drilling can be seen though curvilinear.
42
43
VIII. System Login
Chick on system login in toolbar to enter interface:
All buttons in this interface can operate only by people login. According to different
user grade, the operation limited is different. No matter in which interface, press
44
ctrl+A can login.
Include: Reversal rotary allowed; Reversal rotary forbidden; Cut over to Chinese
interface; Cut over to English interface; User manage
IX. Logout System
Chick on logout button in toolbar, enter interface as follow
In this interface, follow mode can be used to logout, include:
Logout and return to WINDOWS, logout current monitoring system, and return to
WINDOWS.
Logoff system, logoff current user and return to welcome interface.
Reset compute,
Turn off computer
45
Chapter IV PLC System Software and Hardware
I. PLC Program Structure
OB1: Main loop block, periodic cycle execute main program, switch over the
implementation system emergency operation mode, use function block
required to complete the driver communication and control, to achieve the
work requirement of Top Drive process control.
OB82OB85OB86OB87OB121OB122Diagnostic interrupt organization block, it is used for the PLC system in the I / O access error, OB errors, rack failures,
communication errors, programming errors and module errors to provide
diagnostic information, and to prevent the CPU shut down.
FC3: emergency stop signal of implementation system, according to requires to
control the emergency stop signal.
FC4: control functions of implementation pump; complete the automatic control of
hydraulic pump and lubrication pump.
FC5: The ability to control the rings, to realize the control function of ring moving
forward, backwards, forward, reverses control functions.
FC6: Implement the control functions of back clamp.
FC7: Implement the spindle drive brake control functions, based on options,
achieve the shaft brake control as required.
FC8: Realize the well control state and IBOP control.
FC11: Implement the motor selection, according to working conditions, select the
working condition of spindle motor.
FC12: implement the main motor fan control function, based on selection state of
the spindle motor, control ventilation motor and spindle motor.
FC13: implement the output signal to the spindle motor inverter, select according
to the spindle motor, output signal to the converter to keep the inverter in a
standby state.
FC14: implement the data transfer functions, based on control instructions to
control the inverter to run / stop.
FC15: implement the speed of a given data conversion.
FC16: implement the torque limiter of a given data conversion.
FC17: implement the drilling process memory.
FC18: implement the given function of main inverter rotary speed and torque
46
limiter.
FC19: Implement the main inverter speed and torque output indicator.
FC20: implement the read and write capabilities of the inverter and PLC.
FC21: implement the alarm function when hydraulic oil, lubricating oil temperature
is over.
FC22: Implement the indicating function of system failure.
FC23: implement the communication failure function.
FC24: implement the warning function of main motor temperature over.
FC25: implement the additional function of program.
FC26: implement the transformation function of the main inverter "There encoder
run / non-encoder run".
FC27: Implement the indicating function of work state.
II. The hardware Structure of PLC System
A PLC system adopts Siemens S7-300 series of products, CPU is CPU315-2DP.
Master is composed of power supply module, CPU, switch input, the switch output,
analog input, analog module.
The remote station by: ET200X (IM153-1 interface module), the switch input, the
switch output, analog input, analog module.
III. Switch Position and State Light Meaning on CPU
1. State light on CPU
SF System fault Normal on (red) Hardware or software error
or fault
BUSF Double Bus
Fault
Normal light on/flash
ed)
Network fault or site lose
DC5V Inner power Normal light on (green) CPU power normal
FRCE pushed
output
Normal light on (green) Programming unit pushed
output
47
RUN CPU
running
Normal light on (green) CPU running state
STOP CPU stop Normal light on /flash
yellow)
CPU stop state
2. CPU Work mode select switch to three position
Up Running+programme CPU running and can revision programme online
Middle Stop CPU stop
Down memory dump Clear inner RAM
IV. Module installation, Power Distribution and Indicator
1). All modules of PLC system are set on guide beam, when replaced loosen the
fastening screw at the bottom of the module. Install modules from front to behind one
by one, and remove the opposite order.
2). Each channel of switch valve input/ switch valve output module has one indicator,
green light means channel in 1 logic state.
3). Analog quantity input/ analog quantity output module is set to 0-10V input/output.
If the hardware configuration fault or DC24V power breakdown, the red light on module
will turn on.
4). Logging signal is analog output, factory set to 4 ~ 20mA current output signal.
V. Programmer Upload and Download
The software of PLC system can be uploaded to CUP or downloaded to CPU upper
computer. If replace the CPU or memory of CPU damaged, the follow two methods can be used for
return routine: one is insert the memory to he new CPU while no power, then reapplied
power, the program will load to CPU automatically. * Upload and download program should be only done by professional.
48
VI. ET200M Remote Station
The hydraulic system is set on the body of the top drive drilling system, this reduce one
remote station, as well as assistance floor control is option, so the top drive drilling
system electric system has only one remote station. With this design, the fault rate
reduces. The remote station has 8 wave bands Code Switch used for set Profibus station
address. On the Profibus plug has switch, the last station of the system must connects
to a terminal resistance. While switch to on position, the Profibus plug connects to
terminal resistance.
VII. Indicator on Interface Module
The work state of interface module showed by ET200X interface module indicator
SF System fault Normal light on (red) Hardware configuration or
software error or damaged
BF Bus fault Normal light on/flash
(red)
Communication fault with CPU
ON Inner power Normal light on
(green)
Control power normal
DC24V Input/output
power
Normal light on
(green)
Input/output power normal
VIII. Remote station ET200M and module remove as well as
power deploy and indicator
1). ET200M and module are both installed on guide beam, when replace the
module first loosen the screw at the bottom of the module. While install from
front to behind one by one; while remove from behind to front one by one. The
detail can be seen jin S7-300 hardware installation manual.
2). Each channel of switch valve input/ switch valve output module has one
indicator, green light means channel in 1 logic state.
3). Analog quantity input/ analog quantity output module is set to 0-10V
49
input/output. If the hardware configuration fault or DC24V power breakdown,
the red light on module will turn on.
IX. Communication system
1 #
B 2A 2B 1A 1
O N
B 2A 1 B 1 A 2
2 #
O F F
A P L C D P
B 2A 1 B 1 A 2
3 #
O F F
B P L C D P
B 2A 1 B 1 A 2
4 #
O F F
1 #
B 2A 1 B 1 A 2
5 #
O F F
2 #
B 2A 1 B 1 A 2
6 #
O N
A P L C D P
B 2A 1 B 1 A 2
7 #
O N
A P L C D P
D P 1 D P 2 D P 3 D P 4 D P 5 D P 6 D P 71122
C Z 1 2
C Z 1 3
C Z 2 2
C Z 2 31122
3
3 3
3
K A 1 K A 2 K A 3
Chapter VI Main Electric Motor Drive System
I. Main Electric Motor and Frequency Converters
Top drive drill system has 2 frequency conversion transmission units, control electric
motor separately. The transmission units mode are ACS800-07-0490-7.
II. Cupboard Transmission Unit
Structure and Operate Principle
1). Protection grade of cupboard transmission unit is
IP 21;
2). Cupboard transmission unit components:
Fuse cutout (main button/);
Auxiliary circuit fuse plug;
Inlet contactor;
EMC Filter cupboard with +E202;
Transmission control units (RDCU, RMIO); Frequency
conversion module;
Internal braking carrier;
Profibus-DP adapter;
Pulse coder port;
50
Communication adapter.
3. Swing-door structure installed optional control panel
fuse-switch operating handle
contactor control the operation
of switches and emergency
stop button.
III. Main Circuit and Control Circuit Sketch Plan
IV. Connection of Standard Control Line
3 programmable difference mimic input port: 1 voltage source signal, 2 current source
signal.
Communication Model Port 1:
RPBA,
Communication Port 2: RATA-02C Motor Control I/O Panel Communication optional Module:
RDCO-02
External control by analog/digital inputs/outputs signal.
Control Panel Connector
~ = =
Brake Unit
AC Power Supply Frequency Convertor Output
Brake Resistance
~
51
6 programmable digital input port
2 programmable mimic input port
3 programmable relay input port
V. Extensive Characteristic of Standard Software Provide
Protect for Transform, Electric Motor and Process
1). Environment Temperature
2). DC Overvoltage
3). DC Undervoltage
4). Transform Temperature
5). Input Shortage
6). Overcurrent
7). Power Limiter
8). Short Circuit
9). Defencive Function of Programmable
VI. Adjustable Power Limiter
1). Control signal oversee;
2). Danger frequency step over;
3). Current and torque amplitude limiting;
4). ground fault protection;
5).EXTERNAL FAULT;
6). MOTOR PHASE LOSS;
7). Protection of locked-rotor;
8). Electric motor Over-temperature protection;
9). Electric motor buffer under run protection;
10). Control PANEL LOSS.
VII The primary / secondary control of Transmission
Primary/secondary is designed for multi-transmission, which is composed of many
ACS 800 frequency conversion transmissions, meanwhile, motor shifts connect each
other via gear, chain and convey belt. Loading could be divided in to transmission units
52
fairly due to the primary/secondary function. The outside control signal could only
connected with Primary Motor. Primary motor controls the secondary by Optical fiber.
Primary motor is typical speed control, other transmission units follow the torque and
speed of primary motor. Normally, when the motor shaft of primary and secondary
motor is connected by gear or chain, the secondary should adopt torque control mode
to delete the speed gap between transmission units.
This transmission drive system has single motor mode (A or B) and double motor mode
(A+B). Double motor mode adopts the control of primary/secondary
Chapter VII Installation, Commission and Maintenance
After carried to the well site, install and commission as follow. This manual mainly
provides general requirements and notices about electric system installing and
commission.
I. Electric installation and commission notices
Notices before installation
1). Before unload electrical system, mark the cables and joints, to benefit for
reconnection correctly.
2). Before confirm everything is OK, keep power off and hang no switch on, people
working mark.
3). Generally, after installation finished completely and examined, then connect the
power cable, to ensure people and equipment safe.
4). Install worker must wear labor protection appliance.
5). While equipment unloading, confirm that power off, forbidden working while power
on.
6). Wearing safety belt while working aloft, tools and spares should put into tool bag, in
order to prevent to drop off.
7). Forbidden working outside while high windy, thunderstorm or sleet weather.
8). Pay attention to pressure level and insulating property, select suitable protection.
9). Read the electric manual carefully, master electric theory and circuit diagram. 10). Electric controlling room is designed of anti-explosion, therefore, around of room
53
should have no flammability or explosive dangerous goods.
II. Electric system reinstallation
1). Turn off the main power switch, auxiliary transformer power switch 600v power and
380v room coil in power switch before installing.
2). Electric controlling room should placement level and off the ground, to prevent
water inlet through floor. Socket of coil-out cabinet is face to the mast.
3). In the position off the electric room cape on the cross 4m, knock in earth pole, earth
resistance should smaller than 4.
4). Notice plug direction while fix the cable, first insert electric and relay box plug while
connect cable, then insert traveling cable and ground cable plug, last insert room plug.
5). All cable plug should screw down to prevent drop off or water inlet.
6). Do measure the electric motor and cable before connect the cable to the electric
controlling room.
7). Examine the cable before turn on the power.
8). Examine the element and strut of electric controlling room if where disrepair or get
loose.
9). Check and confirm selection switch in original position.
III. Galvanization examine
All cable connect right, element no disrepair, and 600v main power is preparing, the top
drive drilling system power can be turn on.
1). Check if the main power inlet cable is 600v10%, joint the main Power switch Q1
over.
2). Turn on the assistant transformer Q2 and assistant transformer coil in 1QF of PLC
composite controlling cabinet.
3). Switch on PLC composite controlling cabinet and socket. If the air damp or
temperature high, it is needed to start air controlling system to dehumidify or reduce
temperature.
4). Give power to all units from high level to low level switch.
5). Turn on the frequency converser.
6). Turn on the supervisory system.
7). Start lubrication pump, hydraulic pump and cooling fan on drillers console, and
check them rotary direction and running state.
54
8). Check if the motor of A, B, A+B runs normally.
9). Check if assistant function works normally.
IV. Daily maintenance
Daily maintenance is a necessary guarantee for electric running normally. Therefore, it
is necessary to maintenance, examine and go around regularly.
1). The most important is deducting and damp proof for electric system maintenance.
After a period of time deposited, deducting with cleaner then blow-dry with air-dryer
before start electric system. If needed, measure the insulating resistance ,ensure that
when voltage below 380v the insulating resistance above 1M and when 380-600v the
insulating resistance above 5M. According to working condition, clean dust regularly,
if condensation appears, stop the electric system and dehumidify.
2). The connection of all parts should be firm, the screw of electric element should not
be loosen, plug connector should not drop.
3). Check the cable regularly, generally 4-6 year once.
4). Pay attention to current and torque when motor running.
5). Drillers console is explosion-proof of positive pressure system, and need provide air
filter and oil-water separator to confirm air dry and clean, not have explosive and
flammable gas.
55
Part IV Hydraulic Manual
Chapter I Safety Operation Specification
I Safety operation notification
Note This sign provides additional information on procedures involving little or no risk of injury to personnel or equipment
damage.
Caution This sign alerts the user to procedures involving a risk of personnel or equipment damage.
Warning This sign warns the user of procedures involving a definite risk of injury to rig personnel.
Please read this hydraulic manual before operating, testing, maintaining and repairing
of this hydraulic equipment in order to avoid personal injury and equipment damage.
This manual contains notes, caution and warning and so on besides text. These
contents are to prompt the influence of the related operation to the safety of personal
and equipment. Please give sufficient importance to these important advices.
To avoid the damage to personal and equipment, the installing, operating and
maintaining of hydraulic system should be finished by the qualified people with the
corresponding experience. Please read this manual and the related technical
documents carefully before operation.
The above people and other people close to system equipment should accept the
training of well drilling operation, well drilling safe knowledge and using tool, and use
proper protective appliances.
56
It is impossible that this manual involves all safety knowledge with which operator
should be equipped, so such knowledge should be collected, judged and used by
operator. Strictly forbid any maintaining, repairing and adjusting equipment in the
course of top driven operating. Strictly forbid any detecting unfamiliar parts. Please
read and understand all safety warning before maintaining and detecting.
II Electric system operation notification
The hydraulic system contains electric control loop and element. Before operating
equipment and its electrical system, please notice the following proceedings:
1) Read electric manual carefully, and acquaint electric circuit diagram and equipment
demand to power and voltage;
2) Using special instrument of electric operation, and affirm the instrument with
suitable stand voltage grade and eligible protection;
3) During any operation, make sure wearing right safety ware.
4) Please disconnect all power supply, and hang sign board someone operating, not
switch on when carrying through all sorts of electric operation.
5) Before dismantling electric joint, please make out the mark to wire(cable) and
connection terminal to assure reconnect properly.
III Hydraulic system operation notification
Before operating equipment and its hydraulic system, please pay attention to the
following proceedings:
1) Read hydraulic manual carefully, and acquaint the operating principle of hydraulic
system and the structure, function and action of hydraulic component;
2) Use relief valve in system, and discharge all system pressure slowly, and affirm no oil
pressure in system pipeline and accumulator;
3) Before dismantling pipeline, please make marks to connection locations in order to
assure reconnection correctly;
4) Take effective measure to prevent hydraulic oil leakiness from going into other
electric and machinery parts.
57
5) Before hydraulic system run formally, gas should be discharged. Otherwise, the
stability or stiffness may not be sure.
6System commissioning should be carried out before hydraulic control system
running.
7) After hydraulic control system run formally, several examine and record should be
done regularly, including oil temperature, oil pressure, oil pollution level, run stability,
executing agency running condition, condition of action element Tracking Signal, etc.
Before disconnecting hydraulic pipeline, please shut down valve in
system, and prepare suitable container, oil plug, cotton, silk and so on,
in order to avoid the flow out of residual hydraulic liquid in pipeline, which will
pollute equipment and ambience.
The temperature of hydraulic equipment and hydraulic oil may be so high
as to hurt personal safety, which can reach the temperature approached
by person only after a period of time cooling.
When taking and putting components and parts, take care to avoid hurt
certain accurate fitting surface on it.
Before installing and maintaining hydraulic system equipment and so on,
please cut off the energy source of electric power, hydraulic oil and
compressed air, and release the pressure of all system accumulators.
Please lock main source of power correctly before greasing, detecting
and replacing components and parts except having special explain in
this manual.
Please wear eye protector for avoiding the damage of the high voltage oil
58
and other risks to operators.
When system is operating, the temperature of hydraulic equipment and
hydraulic oil may be very high, and please take care of protection.
Do not try to examine hydraulic oil leakiness with your hand. Please
release pressure in accumulator thoroughly before maintaining hydraulic
system, and then operate it.
Before opening hydraulic system, please clean operating area
thoroughly. Be sure to seal the hydraulic pipeline unloaded in time. The
dust is harmful to hydraulic system, and may result in equipment
operating malfunction and even personal injury.
Please check hydraulic system everyday to confirm whether pipe fittings
is of leak; hydraulic pose surface layer is of damage; pose is of snarl,
split or harden; and pipe fittings is of damage or abrasion or not. In
Addition, when detecting, screwing down or replacing any pipeline
connection of leak, please clean away the dirt on hydraulic components
and parts in time.
Chapter II Hydraulic system structure and Principle
This chapter mainly describes the structure and working principle of hydraulic system,
it would help operator operate and maintain correctly. Detailed principle of hydraulic
system is at hydraulic atlas.
Hydraulic drive system is important component of top driven system. Besides main
revolve driven by main electric motor, other functions such as up-shackle, hanging ring
declining and gyrating, IBOP switching, main electric motor braking, main body weight
balancing and so on are controlled and realized by Hydraulic drive. Therefore
maintaining and using hydraulic system correctly is crucial to run top driven properly.
59
The hydraulic system of top drive well drilling includes Counterbalancing system,
braking system, rotary head gyrating system, hanging ring declining system, inner
blowout preventer control system, hydraulic elevator, back up tong and so on, which is
made up of the following parts:
1) Hydraulic source
2) Hydraulic valve block
3) Actuating device (braking cylinder, balancing cylinder, rotating link adaptor motor,
backup tong cylinder, Leaning cylinder, IBOP control cylinder and so on).
4) Hydraulic pipe
5) Auxiliary
Hydraulic system main technical specifications are as follows:
Rated pressure 13 MPa
Rated flow 37L/min
Power 380 VAC / 50 HZ
Electric motor power of oil pump 5.5 Kw Level 6
Effective volume of oil tank 100 L
Control voltage of magnet valve DC24 V
Explosion-proof grade EXdIIBT4
The media clearance Level 7 (NAS1638), 16/13(ISO4406)
Filter accuracy: oil sorbent filter 100 um, High pressure
filter 10 um, lubricate filter 60 um
I Hydraulic System Structure and Working Principle
1. Hydraulic source
Hydraulic source consists of oil tank, oil pump motor, and etc, which supplies hydraulic
power for the system and actuating units of operating system. The oil tank and pump
unit are both installed on the top drive system body, with this design there are several
advantage: energy saving, strong property of integration, short pipeline, rapid
response of actuator element.
60
2. Oil tank
The oil tank is made of stainless steel, and its effective volume is 100L; in addition to
storing hydraulic oil, it also has the functions of dissipating some heat produced in
system operation, separating gas and sediment in oil.
Oil surface of the tank should connect with atmosphere. An air filter is set on the tank
in to reduce oil pollution. When working, pay attention to cleaning and replacement of
filter.
The oil level gauge and oil thermograph are set at