Hydraulic Top Drive System

Model DQ40YA-JH

User Manual

Daqing Jinghong Petroleum Equipment Manufacturing Co., Ltd

 Daqing Jinghong

Prologue

The users should read this manual before use the equipment. In order to prevent the
accident happened, 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 including the relative technical information about the operation usage and
maintenance of the top drive drilling system. The others technical instructions of this
product are including in the following manuals:《operation manual》《electric manual》
《hydraulic manual》《maintenance manual》
《electrical diagram manual》《mechanical
drawing manual》.

Refers to other contents which aren’t 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：[email protected]
Address： No.3-2，Nanyuan Road, Nanyuan Investment Zone, Longsha district, Qiqihar
City, Heilongjiang
Zip code： 16100

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Summary

The top drive drilling system has a great advantage in increase the drilling speed and
accident handle ability, especially in the deep well, complex technologies well’s
exploration and development, the top drive drilling system has become an indispensable
device. But at present, the top drive drilling system which product in China and other
countries still has some shortage except satisfied the functions. In order to improve the
top drive drilling system’s performance in every respect, fulfill the higher requirements of
the market, Jinghong company developed the DQ40YA-JH top drive drilling system with
indigenous intellectual property rights. It integrated the mechanical, electric and
hydraulic control technology. Our top drive drilling system has the advantage of simple
structure, easy to adjust and long service life, etc.

The main technical features are:

1. Main components adopt diesel motor from Caterpillar, pump and motor from
HAGGLUNDS, solenoid valve from WANDFLUH, etc. which has simple structure, reliable
and safe.

2. PLC as the control center is from Siemens, ensure accurate and steadily control.

3. The patented couple cylinders opposite clamping backup tong, easy and simple
operating, save energy and time while make up and break out.

4. Hydraulic control IBOP adopts patented structure of rack and gear. Besides, the
hydraulic pipe is embedded into the body of structure in order to avoid the damage of the
hydraulic pipe for bump, what makes the operation of IBOP more reliable.

5. The guide beam adopts side-insert foldable structure; it is quick, convenient and safe
Compare with the other brand top drive, JH top drive save 2-3 hours in installing.

6. Driller panel is equipped with touch screen which displays the condition of system
operation and can also monitor emergency point of equipment in time; this increase the
reliability of equipment operating.

7. Single tooth panel anti-loose structure, bear larger toque, easily installing and
disassembling.

8. All cables are protected, enhance the mechanical strength, increase its reliability.

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Contents

Prologue .................................................................................................................................................1
Summary ................................................................................................................................................2
Contents .................................................................................................................................................3
Part I DQ40YA-JH Top Drive Structure and Specification ...................................................................6
Chapter I DQ40YA-JH Top Drive Structure and Specification .........................................................6
I. Hydraulic top drive drilling system components ............................................................................ 6
II. Hydraulic top drive working principle ............................................................................................. 6
III. Specification ..................................................................................................................................... 7
IV. Drilling Data ...................................................................................................................................... 7
V. Pipe Handler...................................................................................................................................... 7
VI. Hydraulic Top Drive System specification.................................................................................... 7
VII. Working Curve of Top Drive DQ40YA-JH ................................................................................... 8
VIII. Top Drive DQ40YA-JH Dimension .............................................................................................. 9
Part II Mechanical Manual ............................................................................................................................ 10
Chapter I Structure and function Introduction ......................................................................................... 10
I. Power Swivel .....................................................................................................................................11
II. Pipe Handler Device....................................................................................................................... 13
III. Guide beam and carriage ............................................................................................................. 15
Part III Electrical Manual ............................................................................................................................... 16
Chapter I Safety Operation Specification ................................................................................................ 16
I Safety Notice................................................................................................................................... 16
Chapter II Electrical System Components............................................................................................... 17
I. PLC Integrated control system....................................................................................................... 19
II. Relay box ......................................................................................................................................... 23
III. Driller Panel .................................................................................................................................... 24
IV. Touch Screen.................................................................................................................................. 27
V. Control Cable................................................................................................................................... 31
VI. Other Cable .................................................................................................................................... 31
Chapter III PLC System Software and Hardware................................................................................ 32
I. PLC Program Structure................................................................................................................... 32
II. The Switch and Indicator light of CPU......................................................................................... 33
III. Module installation, Power Distribution and Indicator .............................................................. 34
IV. Program Upload and Download .................................................................................................. 34
V. ET200M Remote Station................................................................................................................ 34
VI. Indicator on Interface Module ...................................................................................................... 34
VII. Remote station ET200M, Module installation, Power Distribution and Indicator................ 35
Chapter IV Installation, Commissioning and Maintenance ................................................................... 35
I. Electric installation and commissioning notices .......................................................................... 35
II. Electric system reinstallation......................................................................................................... 36

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III. Examination before power on ...................................................................................................... 36
IV. Daily maintenance ......................................................................................................................... 37
Appendix I System Initial state .................................................................................................................. 38
I. PLC integrated cabinet initial state................................................................................................ 38
II. Driller panel initial state .................................................................................................................. 38
Part IV Hydraulic Manual ................................................................................................................................... 39
Chapter I Safety Operation Specification ............................................................................................. 39
I Safety operation notification ............................................................................................................ 39
II Electric system operation notification............................................................................................ 40
III Hydraulic system operation notification....................................................................................... 40
Chapter II Hydraulic System Overview .................................................................................................... 42
I. Hydraulic system main technical specifications .......................................................................... 43
II. Components and principle of the hydraulic station .................................................................... 43
III. Hydraulic System Working Principle ........................................................................................... 45
IV. Hydraulic system component....................................................................................................... 48
V Control Valve Block and Executing Agency................................................................................. 54
VI. Hydraulic Pipe................................................................................................................................ 59
Chapter IV Adjustment and Maintenance of Hydraulic System pressure...................................... 60
I. Hydraulic system pressure adjusting ............................................................................................ 60
II. Daily Maintenance of hydraulic system ....................................................................................... 61
III. Hydraulic Oil Selection and Change ........................................................................................... 62
Part V Installation and Commissioning ............................................................................................................ 64
Chapter I Safety Operation Specification ............................................................................................. 64
I Safety operation notice .................................................................................................................... 64
Chapter II Installing Preparation ....................................................................................................65
Top Drive well field facade layout ..................................................................................................... 68
Chapter III Installation................................................................................................................................. 69
I. Installing the guide beam................................................................................................................ 70
II. Hydraulic pipe and Cable installation........................................................................................... 81
III. Auxiliary Device Installation.......................................................................................................... 81
Chapter IV Inspect after installation....................................................................................................... 82
Chapter V Test Running............................................................................................................................. 83
I. The inspection before starting........................................................................................................ 83
II. Electric Device Test-running.......................................................................................................... 83
III. Main hydraulic system testing...................................................................................................... 84
IV. Auxiliary Function Test Running .................................................................................................. 84
Attachment I Top Drive System Electric Wiring Installation Inspecting list ............................ 91
Attachment II Top Drive System mechanical installation inspecting list................................. 92
Attachment III Top Drive System Installation and Commissioning Record............................ 93
Part VI Operation Manual.............................................................................................................................. 95
Chapter I Safety operation practice.......................................................................................................... 95
I. Safety operation notification ........................................................................................................ 95
II. Operator safety operation notes ................................................................................................... 95
Chapter II Main Hydraulic system operation ........................................................................................... 97
I. Inspection Before start .................................................................................................................... 97
II. Start procedures.............................................................................................................................. 97

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III. The start procedure of main hydraulic system .......................................................................... 98
IV. Auxiliary Hydraulic Pump Operation ........................................................................................... 99
V. Washing Pump Operation ............................................................................................................. 99
VI. Radiator cooler operation........................................................................................................... 100
VII. Drilling Operation........................................................................................................................ 101
VIII. “Make up/ Break out” operation .............................................................................................. 106
IX Drilling ahead by single ................................................................................................................112
X. Drilling ahead by triple ..................................................................................................................114
XI. Backreaming............................................................................................................................117
XII. Pulling out operations .................................................................................................................117
XIII Well Control................................................................................................................................. 121
XIV Jarring operation ........................................................................................................................ 122
Appendix I Driller Panel initial state ............................................................................................. 123
Appendix II PLC Cabinet Initial State ............................................................................................. 124
Part VII Operation Manual .......................................................................................................................... 125
Chapter I Safety Operating Rules........................................................................................................... 125
I Safety Operating Rules .................................................................................................................. 125
Chapter II Daily Inspection....................................................................................................................... 126
I. First week daily inspection............................................................................................................ 127
II. Daily check before equipment start............................................................................................ 127
III. Daily inspection ............................................................................................................................ 127
Chapter III Maintenance Items and period ......................................................................................... 128
I Daily maintenance Items................................................................................................................ 128
II Weekly Maintenance Items .......................................................................................................... 129
III Monthly Maintenance Item .......................................................................................................... 132
IV Maintenance Items in each quarter ........................................................................................... 134
V. Maintenance Items in half year................................................................................................... 135
VI Maintenance Items every year ................................................................................................... 135
VII. The maintenance of diesel motor refers to Series-C motor operation and maintenance.137
VIII. Please contact with technical dept of Jinghong for further maintenance and repairing. 137
Appendix I Recommend inspection ................................................................................................ 138
Appendix II Recommend lubrication............................................................................................... 139
Appendix III Torque value of thread hastening ............................................................................. 140
Appendix IV Recommendation of Greases selects...................................................................... 140

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Part I DQ40YA-JH Top Drive Structure and

Specification

Chapter I DQ40YA-JH Top Drive Structure and

Specification

I. Hydraulic top drive drilling system components

Hydraulic top drive drilling system is composed of parts as follow:

1. Diesel motor: CAT C15 diesel engine, provides power for whole hydraulic system.

2. hydraulic power: includes main hydraulic pump which produce main hydraulic power,
charging pump, washing pump which supply the initial oil press for pipes of closed loop
system and cool the main motor, oil filter and oil tank which provide clean hydraulic oil for
whole circuit, assistant pump which provide power for assistant system, circulating pump
and electric cooling fan which provide power for hydraulic oil cooling, and etc.

3. Hydraulic pipe system: closed main loop, washing loop, assistant hydraulic system loop,
and etc.

4. Top Drive Drilling system body: radial plunger type hydraulic motor effected as
executive mechanism of hydraulic pump, main valve block, gear box, principal axis,
controlling valve block, assistant hydraulic executive mechanism, and etc.

5. Controlling system: controlling centre basic on Siemens PLC system, include: CPU,
analog valve transform block, digital valve input/output block, remote communication
block, and etc.

II. Hydraulic top drive working principle

The main hydraulic system has two parts: one part is hydraulic oil self-cycling system
composed of oil tank, washing pump, cycling pump, cooler and filter, mainly to cool and
wash the motor, meanwhile to complete the hydraulic oil self-cycling cooling, control oil
temperature, filter and clean the hydraulic oil. The other part is a closed loop system
composed of proportional variable piston pump, hydraulic motor, control valve panel
produced by Haggluds to control the rotary speed and torque while drilling.

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III. Specification
Drilling Depth: 4000M (φ114mm drill pipe)
Max. Loading: 2250 kN(250ton)
Main channel: φ62mm
Rated Circle pressure: 35Mpa (5000psi)
System Weight: 5.5t (main body)
Working Height: 4.4m
Input Power: 380VAC 50HZ
Rated Power: 403KW

IV. Drilling Data

Rotary speed scope: 0～180r/min adjustable
Working torque: 35KN·M Continually
Max. torque: 49kN·M Interrupted
Hydraulic motor working pressure: 35Mpa

V. Pipe Handler
Upper IBOP (Remote) 6 5/8" API REG box～pin，70MPa
Lower IBOP (manual) 6 5/8" API REG box～pin，70MPa
Backup tong path φ210mm
Backup tong clamp scope φ89～φ216mm
Link 2740mm，250t
Leaning angle Forward 35°，Backward55°

VI. Hydraulic Top Drive System specification

Power 380VAC/50Hz
Diesel Power 403kW
Hydraulic motor working pressure 0-35MPa
Hydraulic motor max. pressure 40MPa
Hydraulic main pump working flow 900L/min
Washing pump motor power 11KW
Auxiliary hydraulic pump motor power 5.5KW
Cooling fan motor power 2.2KW
Solenoid valve control voltage 24 VDC
Oil tank container 1500L
Explosion-proof grade EXdⅡBT4

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VII. Working Curve of Top Drive DQ40YA-JH

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VIII. Top Drive DQ40YA-JH Dimension

DQ40YA-JH Top Drive Dimension

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Part II Mechanical Manual

Chapter I Structure and function Introduction
The Top Drive works on the top of drilling string and makes up or breaks out by itself.
At the same time, the top drive can trip along the guide beam to complete drilling
operation.

Mechanical structure of Top Dive Drilling System includes:

¾ Power swivel
¾ Pipe handler device

¾ Guide Beam and Carriage

DQ40YA-JH Top Drive Dimension

Bail

Washing pipe assembly

Box

IBOP Control Device

Link
Anti-loosing device
Lower IBOP

Backup Tong

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I. Power Swivel

The Power swivel consists of counterbalance device, bail, washing pipe

assembly, box and other spare parts. The main function of power swivel is to drive
the main shaft rotate to drill, make up and break out, as well as circulating mud to
ensure the drilling work regularly.

Counterbalance System

Bail
Washing pipe assembly

Box body

1. Gooseneck
The lower of gooseneck is connected with drilling hose, it is the
inlet of drilling mud. Gooseneck is installed and connected with
the washing pipe. The gooseneck is the transmission channel of
mud circulation. The top of gooseneck is sealed. After open the
top, the fishing and logging can be carried out.

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2. Washing pipe assembly

The washing pipe assembly is installed between main
shaft and goose neck, the four seal collar in lower
packing box rotate driven by main shaft, inspect and
maintenance the washing pipe assembly regularly is
necessary to prolong its service life. The washing pipe
used on this top drive is same to the one used for normal
swivel, which ensure the universal and easily
maintenance.

3. Bail Counterbalance device

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 protect the connection thread
from being damaged when drilling pipe making up and
breaking out while using top drive, It works as the
hook-compensate spring， balance the weight of main body.
The top drive produced by Jinghong adopts double hydraulic
cylinder counterbalance, increase its reliability and safety in
working.

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II. Pipe Handler Device

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

Leaning device
IBOP controller

Thread anti-loosen
device
Lower IBOP
Link
Saver sub
Backup Tong

1. IBOP

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

than the pressure in drilling string, shut off the channel
inside of drilling string by close up the IBOP to avoid well
kicking or blowing out. IBOP is installed between the
saver sub and main shaft. It is composed of remote IBOP
upside and manual IBOP in low part. Remote (upper)
IBOP is connected with the main shaft of power swivel,
the manual (lower) IBOP in low part connects with saver

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sub, the saver sub is connects with drilling stem while drilling. The inner and outer
threads of IBOP are 6 5/8REG.

Double hydraulic cylinder control remote IBOP on or off. The cylinder control the
on/off sleeve to slid, the rack of on/off sleeve control the gear rotating of ball valve
to realize the open or close of IBOP. The Top drive adopts gears and rack, process
the advantages of simple structure, driving accuracy, and
high transmission reliability.

2． Side-hanging Backup Tong

The function of Backup Tong is to make up and break out
during a trip. The couple cylinder clamp backup tong of
Jinghong Top Drive system is operated only once on
driller panel directly to make up and break out without
locking rotating link adaptor. This design is convenient to
change tong dies, 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.

The Backup Tong is composed of clamping system,

centralizer system and suspending system. Clamping
system includes hydraulic tank, piston, tong teeth seat
and tong teeth. Centralizer system is composed of
centralize guide, anti-wear ring and bell mouthing.
Suspending system includes guide frame, torque bearing
panel, floating spring

3． Drilling string anti-loosen device

Install anti-loosen device between the joints of main shaft

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

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III. Guide beam and carriage

The main function of the guide beam is to bear reactive 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 guide beam inside adopts steel rope pull structure, increase its safety, ensure it
works reliably and safely. It also save the guide beam installing time.

Carriage

Bearing wheel

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Part III Electrical Manual

Chapter I Safety Operation Specification

Before install, set up, operate and maintain Top Drive Drilling System, please read
this manual first.
The Top Drive Drilling System installing, debugging, operation and maintenance
must be done by professional or specially trained people, if not, it maybe cause
personal injury or machine damage.

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

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

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite

risk of injury to rig personnel.

I Safety Notice

The following safe notices are very important for correct installation, using,
maintenance of the Top Drive, all the operator and the attendant must read it
carefully and understand it:
1. Forbidden livewire work, electric system maintainer and operator must be
qualified and follow close to safety operation specification.

2. When working, do not maintenance or remove any electric element, do not pull
out/connect wire with current.

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

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4. Cut off the mechanical interlock switch Q1, test the electric current with
Electroscope and make sure no voltage before replace the PLC electric elements in
cabinet.

5. Keep protective gas pressure when turn the driller’s console on. If the driller’s
console protective gas pressure lost, it is required to resume quickly or turn off the
driller’s console controlling power.
6. Integrated control cabinet connects with ground line correctly.
7. Check the electric control board if there is dewing before starting, when main
power was off more than 30 minutes.

Chapter II Electrical System Components

Electrical system is mainly composed of Coil-in electric energy power splitting

protect system, PLC combination control system and solenoid valve executing
device.The generator supplies 380V main power to the primary air switch NSX 160F,
produced by Schneider in electrical control room. The air switch is perfect in bearing
powerful current produced when switch, output 380V auxiliary power, and supply
power to PLC cabinet. Below is the picture of main air switch Q1.

Schneider NSX 160F

As the center of driving control system, the PLC produced by Siemens is responsible
for the top drive controlling. The PLC system is connected with driller panel 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

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

S7-300 315-2DP

ET200M

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I. PLC Integrated control system

PLC cabinet inside includes: motor control loop, PLC control system, Currency
enlarge loop, and DAC module etc.

Currency enlarge loop

Q1
DAC module
PLC Control System

Control Power
Motor control loop

Currency enlarge loop

Solenoid valve
Intermediate relay
terminal blocks

Motor control loop Sensor / Transmitter

Terminal Block

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PLC Integrated control panel:

1. Indicator light

a. Power indicator light: after switching on the system, the AC is ready and the
indicator light is on.
b. DC power indicator light: after switching on the system, the DC is ready and the
indicator light is on.
c. Major pump indicator light: the indicator light is on while major pump running.
d. Heating valve indicator light: the indicator light is on while the heater of the
major pump.
e. Assistant pump indicator light: the indicator light is on while the assistant pump
running.
f. Fault/alarm indicator light: while system alarm, the indicator flashes every one
second; while reversal, the indicator light flashes every three seconds; while
fault, the indicator light keeps on.
g. Diesel engine indicator light: the indicator light is on while the diesel engine
running.
h. Washing pump indicator light: the indicator light is on while the washing pump
running.
i. Cooling air blower indicator light: the indicator light is on while the cooling air

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blower running.
j. Hydraulic oil heater indicator light: the indicator light is on while the heater
running.
K. Diesel motor indicator light: check the errors according to its flash.

2. Manual Switch

a. Reset/Mute button: when system alarm, the indicator flashes, the Warner
alarms. Press silence button, the alarm sound disappear, the fault/alarm
indicator light keeps lighting. Pressing the button for three seconds can test the
indicator light.
b. Mud pump interlock switch: use for mud pump link-control. On interlock
position, if the IBOP shut down, the composite control cabinet gives a signal to
prevent or disconnect to the mud pump running. On un interlock position, the
composite control cabinet give no signal.
c. Thermal compensator valve switch: while switch onto “on” position and the
temperature is lower than 25 ℃ and the washing pump run, the valve on;
while switch onto “stop” position, the valve off.
d. Diesel engine controlling switch: while the engine is ready, switch to “start”
position, the diesel engine starts; switch to “stop” position, the engine stop.
e. Washing pump switch: switch to “start” position, the washing pump start;
switch to “stop” position, the washing pump stop.
f. Cooling air blower switch: switch to “start” position, the blower start; switch to
“stop” position, the blower stop; switch to “auto” position, the blower is
controlled by the PLC output signal, and while the hydraulic unit temperature is
over 35 ℃ monitored by PLC, the blower start; while the hydraulic unit
temperature is below 25℃, the blower stop.

3. Electric controlling major loop of Hydraulic source unit

Electric controlling major loop of hydraulic source unit are comprised of hydraulic
pump electric motor (5.5KW), washing pump electric motor (11KW) and cooling air
blower electric motor (2.2KW), which are controlled by driller’s panel or composite
control cabinet. All electric motor are three-phase asynchronous of explosion
prevention.

1). The switch of auxiliary hydraulic pump has two positions: (1) start, (2) stop.

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2). Washing pump have two states: (1) start, (2) stop.
3). Cooling air blower have three states: (1) auto, (2) stop, (3) start.

4. Hydraulic resource unit controlling loop

Hydraulic resource unit controlling loop include of major flowing controlling loop,
pressure controlling loop, temperature detecting loop and hot oil controlling loop.

1. The flow controlling loop is PLC output through the Hagglunds amplifiers
controlling the proportional solenoid valve acting, output flow is stepless adjusting,
the amplifier of this control loop is used to realize the main shaft CCW, soft stop,
and emergency stop.

Flow controlling
currency amplifiers

2. Pressure control loop is output by PLC system completed the closed loop system
pressure adjusting through the currency amplifier controlling the proportional
relief valve.

Pressure control
currency amplifier

3. Speed detecting loop: the speed signal transmitter through the speed sensor
installed on motor connects with PLC to realize the active monitor for hydraulic

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motor rotary. Supply the feedback to PLC control system.

Speed Signal transmitter

4. Temperature detecting loop: Controlling and monitoring the hydraulic oil

temperature by temperature sensor on oil tank to control the automatic cooling
system work.

5. Hot oil control loop: it is mainly used in cold area. When the surround temperature
is low, oil heating valve pre-heats the hydraulic oil in closed loop and washing the
motor shell. The oil heating valve could only be started when the hydraulic oil
temperature is lower than
25℃.

II. Relay box

Relay box is set on the body of top drive, the function is providing power for detecting
element, feedback detection signal, and provide control power signal for control valve.

Rotary sensor signal

Valve control power signal

A B port pressure signal

It can monitor the pressure signal and rotary speed on site A/ B of the
major motor, and etc.

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III. Driller Panel

The Driller panel has all functions for drilling operation and any other auxiliary
operation for driller; it can set top drive rotary speed, torque, operation mode.

The driller panel is positive pressure type explosion-proof, it can be operated only
while safety gas working.

The functions of Driller Panel Indicator Light and Operate Button/ Rotary Knob are
as follows:
No Name Type Function

1 Emergency stop button Squagging When the hydraulic system is

fault, press this button an d
then the system stops.
2 Ready Indicator Light Green Indicator When systems all are ready, it
Light lights.
3 Fault/alarm indicator light Red When system alarms, it flash
indictor light once a second; when system is
fault, it keeps lighting.
4 IBOP Indicator light Red When IBOP closed, it lights.
indictor light
5 IBOP Two positions At close positions, IBOP closes.
closed/open button
6 Well Control Red button When well blowout, press this
button to establish interlock
with other equipments.

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7 Fault reset button Green Indicator When alarm or fault, press this
Light button for mute, and when
alarm or fault disappear, press
this button for resetting.
Pressing the button for three
seconds can test all of the
indicator lights.
8 Hydraulic pump running Green indicator When hydraulic pump running
indicator light light normally, it lights up.
9 Hydraulic pump switch Two positions At stop position, hydraulic
stop/start button pump stop; at start position,
hydraulic running.
10 Link suspension Button When press it, the link is over
the well hole and keep
suspending.
11 Link leaning Three position A resetting rotary knob with
backward/forward rotary knob spring. leaning cylinder will be
locked, when it’s on center
positions. Turn it on “forward”,
leaning cylinder will push the
links and elevator to the rat
hole or Kelly board; when
“backward” ， will make the
elevator be off the drilling tool
when drilling.
12 Motor direction Three positions Control the rotary direction of
FWD/stop/REV rotary knob hydraulic motor.
13 Operation mode Two positions Choose the operation mode
drill/make up and breakout button and set the max. torque.
14 backup tong two position When turn right, backup tong
Loose/Clamp button starts to clamp drill pipe. When
turn left, backup tong is
released.
15 makeup torque Potentiometer In makeup operation, set Max.
makeup torque.

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16 Drilling torque Potentiometer In drilling operation, set Max.

drilling torque.
17 Throttle Potentiometer When normal drilling, set the
Max. rotary speed that drilling
string limited.
18 Torque Meter Meter Indicator actual torque of Top
driver output with unit kN.m
（Kft.lb）.
19 Rotary Meter Meter Indicate actual rotary speed
output valve of main shaft. Unit
r/min.
20 Fast/Slow two position When turn right, motor run
button slow. When turn left, motor run
fast.

1. Throttle hand wheel

Speed setting hand wheel is the major tool for main shaft speed setting (in addition,
assistant speed setting include generator speed setting and high or low speed
selective switch). The scale of hand wheel is only to consult, and the real rotary
speed is test by rotary speed detector. When turn the hand wheel to CCW, the rotary
speed will decrease to “0” step by step. When turn the hand wheel to CW, the rotary
speed will increase to the Max. value to 180r/min progressively.

2. Drilling Torque hand wheel

The scale of “drilling torque” handle is used for setting system torque. When turn to
CCW, the torque will decrease progressively to “0”. When turn to CW, the torque will
increase progressively to 35 kN·m.

The full range of drilling torque matching with the rated torque to main shaft is 35
kN·m (set in factory).

Drilling torque hand wheel only works in “drilling” mode but not in “make up and
breakout” mode。

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3. Makeup Torque Hand Wheel

The scale of “drilling torque” handle is used for setting system torque. When turn to
CCW, the torque will decrease progressively to “0”. When turn to CW, the torque will
increase progressively to 35 kN·m.

The full range of drilling torque matching with the rated torque to main shaft is 35
kN·m (set in factory).

Makeup torque limited is the torque value when makeup and breakout. In making
up, this value controls the proportional relief valve and limits the closed loop
pressure. In Breaking out, when all the breaking conditions are allowed, the system
would output anti-torque for 20s at the largest torque 49KN.m, the makeup torque
reduce to makeup torque limitation after 20s.

IV. Touch Screen

Touch screen is made by Siemens, and the type is M277 8”. Generally, all operation
interface can be divided into 3 areas, display information separately.

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 monitoring 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.

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1. Main Frame

Display output torque, output speed, and the parameters of auxiliary motors,
including: hydraulic motor work mode, major motor input/output oil pressure, top
drive work state, hydraulic motor running/fault, air blower indicator, and etc.

2. Auxiliary Frame

Include information about hydraulic system, lubrication oil system and other
system.

Elevator link system includes: elevator link forward, elevator link backward,
elevator link suspending.
Hydraulic system includes: hydraulic pump running, hot oil valve heating and
hydraulic oil temperature indication.
Motor washing loop includes: washing pump running/heating and hydraulic oil
temperature indication.

Other system includes the indication of IBOP valve opening, IBOP valve closed,
backup tong clamping, backup tong loosening, and include other working state

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indication of top drive drilling system.

3. Alarm Frame

Recording all alarm events when running.

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4. Senior management

Frame can only enter after login; user name ‘JH’ and password ‘8888’ can login
through flashing window and keyboard.

Frame is as follow after login. Green is current state. User can decide to inspect
temperature and CCW.

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V. Control Cable
The function of Control Cable is to send the control signal of the main control cabinet
to hydraulic motor controlling valve at the top of the Top Drive system.
For installing and connecting easily, a 52m cable was used to connect the controlling
cabinet to all controlling valve and detection signal feedback line on the top drive
body.
The controlling cable uses the same one protection hose ofΦ75 with two hydraulic
pipes. One section of 18m is traveling cable, which tapped for 0.6m. The joint near
the controlling cabinet tapped for 1.5 m.

The joints of cable and controlling cabinet all adapt CIRCULAR

CONNECTOR, which is operated easily outside.

VI. Other Cable

1. Driller panel Control Cable

4 cables are used for Driller panel controlling and communicating.

1. One 10-core cable is for driller panel control power.
2. One 10-core cable is for dynamo data line.
3. 2-core communicate cable
4. 7-core logging signal cable.

2. Cable of Relay Box

The relay box is set on top drive body. Its function is transit the control signal to the
function element on body, and feedback the function element actuating signal and
detectable signal to the composite controller cabinet.

The Cable between coil control cabinet is one piece 28-core cable.

Most of them are 24v power, nine control power line of solenoid pilot
actuated valve, feedback line of detectable signal, and etc.

3. Repeat Earth electrode

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

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system. On bottom right corner of the Integrated cabinet set the earth terminal. The
earth terminal connects to earth electrode with copper wire of 70 mm2.

The earth electrodes is 1.8m long, outer layer galvanized. The earth terminal
connects to earth electrode with 3m 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 PLC System Software and Hardware

I. PLC Program Structure

The PLC system adopts Siemens S7-300, CPU is CPU315-2DP.

Master station is composed of power module, CPU, switching value input module,
switching value output module, analog input module, analog module.

Power module CPU

Analog output
module
Switching value output module

Switching value input module Analog input

module

The remote station is composed of ET200M (IM153-1 interface module), switching

value input module, switching value output module, analog input module, analog

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module.

IM153-1

Switching value input module Analog output module

Switching value output module Analog input module

II. The Switch and Indicator light of CPU

1. Indicator light of CPU

SF System fault Normally ON (red) Hardware or software error or fault

BUSF Bus Fault Normally ON/flash Network fault or site lose
red)
DC5V Inner power Normally ON (green) CPU power normal
FRCE Forced Normally ON (green) Programming unit pushed output
output
RUN CPU running Normally ON (green) CPU running state
STOP CPU stop Normally ON/flash CPU stop state
yellow)

2. The switch of CPU

Upper
Running+programme CPU running and improving programme online
positon
Middle
Stop CPU stop
Position
Lower
Clear Memory Clear RAM
Position

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III. Module installation, Power Distribution and Indicator

1. All modules of PLC system are installed on installation frame. When replace the
module, the fastening screw should be loosen first, and fixing the module from front
to back one by one, and unload as opposite. Operation in detail can be seen in
manual S7-300 about hardware installation.

2. Every channel of switching value input/ switching value output module has one
indicator, green light means channel in ‘1’ logic state.

3. Analog input/ analog 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.

IV. Program Upload and Download

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

When replace the CPU or memory of CPU damaged, the following 2 methods can be
used for recovery: one method is insert the memory to the new CPU while no power,
when power up, the program will load to CPU automatically. The other method is to
download the program online by PLC. The encoder operation is in STEP7 Manual.

Upload and download program should be only done by professional.

V. ET200M Remote Station

The remote station of control system is set on the driller panel. The remote station
has 8 wave bands Code Switch for setting 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.

VI. Indicator on Interface Module

The work state of interface module showed by ET200M interface module indicator

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SF System fault Normally ON (red) Hardware configuration or

software error or damaged
BF Bus fault Normally ON/flash Communication fault with CPU
(red)
ON Inner power Normally ON (green) Control power normal
DC24V Input/output Normally ON (green) Input/output power normal
power

VII. Remote station ET200M, Module installation, Power

Distribution and Indicator

1. ET200M and module are both installed on installation frame. When replace the
module, first loose the fastening screw at the bottom, then fix the module from front
to back one by one, and unload as opposite. Operation in detail can be seen in
manual S7-300 about hardware installation.
2. Every channel of switching value input/ switching value output module has one
indicator, green light means channel in ‘1’ logic state.
3. Analog input/ analog 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.

Chapter IV Installation, Commissioning and

Maintenance
After carried to the well site, installing and commissioning are as follow. This manual
mainly provides general requirements and notices about electric system installing
and commissioning.

I. Electric installation and commissioning notices

Notices before installation
1). Before unload electrical system, mark the cables and joints, to benefit for
reconnection correctly.
2). Before confirm everything is OK, keep power off and hang ‘ Machine be working
with, Do not switch it on’ mark.

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3). Generally, after installation finished completely and examined, then connect the
power cable, to ensure people and equipment safe.
4). Install worker must wear labor protection appliance.
5). While equipment unloading, confirm that power off, forbidden working while
power on.
6). Wearing safety belt while working aloft, tools and spares should put into tool bag,
in order to prevent to drop off.
7). Forbidden working outside in high windy, thunderstorm or sleet weather.
8). Pay attention to pressure level and insulating property, select suitable
protection.
9). Read the 《electric manual》 carefully, master electric theory and circuit diagram.
10). Electric controlling room is designed of non-explosion proof, therefore, around
of room should have not any flammability or explosive dangerous gas.

II. Electric system reinstallation

1). Turn off the 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. The cable box outlet should face to derrick.
3). In the position off the electric room cape on the cross 4m, knock in earth pole,
earth resistance should smaller than 4Ω.
4). Notice plug direction while fix the cable, first insert electric and relay box plug
while connect cable, then insert traveling cable and ground cable plug, last insert
room plug.
5). All cable plug should screw down to prevent drop off or water inlet.
6).Measure insulativity of motor and cable before connect the cable to the electric
controlling room.
7). Examine cables before turn on the power.
8). Examine the element and strut of electric controlling room if where disrepair or
get loose.
9). Check and confirm selection switch in original position.

III. Examination before power on

All cable connect right, element no disrepair, and 600v main power is preparing, the
top drive drilling system power can be turn on.

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1). Check if the main power inlet cable is 380v±10%, turn on the main Power witch
Q1.
2). Give power to all units from high level to low level switch.
3). Turn on the power of supervisory system.
4). Start washing pump, hydraulic pump and cooling air-blower on driller panel, and
check them rotary direction and running state.
8). Check if the hydraulic motor 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
1MΩ. 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). Driller panel is explosion-proof of positive pressure system, and need provide air
filter and oil-water separator to confirm air dry and clean, not have explosive and
flammable gas

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Appendix I System Initial state

I. PLC integrated cabinet initial state

Before system start, make sure that PLC integrated original button or switch in the
state as follows:

Button or switch Initial state Explanation

Emergency Stop button is normal
【Emergency Stop】 Loosen
closed ( not pressed )
【Diesel control】 stop

【Radiator air blower】 Stop Meso-position

【Washing pump】 Stop Meso-position

【Heating valve】 Stop Left-position

【Mud pump interlock】 Interlock with the mud pump
interlock
（Optional） while system running
【Hydraulic oil heating】
Stop Meso-position
(Optional)

II. Driller panel initial state

Before system start, make sure that driller’s panel button or switch in the state as
follows:
Button or switch Initial state Explanation
Emergency Stop button is normal
【Emergency Stop】 loosen
closed ( not pressed )
【Rotary speed setting】 zero
【High/low speed】 Low speed Double motor work
【 Rotary direction Meso-position
No direction selection
setting】 (stop)
【Backup tong】 Loosen Backup tong loosen
【Mode setting】 Drilling
【IBOP】 loosen
【Hydraulic pump】 stop

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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.

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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 “Machine be working
with, Do not switch it on” when carrying through all sorts of electric operation.
5) Before dismantling electric joint, please make out the mark to wire(cable) and
connection terminal to assure reconnect properly.

III Hydraulic system operation notification

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

following proceedings:

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

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

2) Use relief valve in system, and discharge all system pressure slowly, and affirm

no oil pressure in system pipeline and accumulator;

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

to assure reconnection correctly;

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

electric and machinery parts.

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

stability or stiffness may not be sure.

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

running.

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

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

stability, executing agency running condition, condition of action element Tracking

Signal, etc.

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

prepare suitable container, oil plug, cotton, silk and so on, in order to avoid the

flow out of residual hydraulic liquid in pipeline, which will pollute equipment

and ambience.

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

hurt personal safety, which can reach the temperature approached by person only after

a period of time cooling.

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

accurate fitting surface on it.

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

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

release the pressure of all system accumulators.

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

replacing components and parts except having special explain in this manual.

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

other risks to operators.

When system is operating, the temperature of hydraulic equipment and

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

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

pressure in accumulator thoroughly before maintaining hydraulic system, and

then operate it.

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

sure to seal the hydraulic pipeline unloaded in time. The dust is harmful to

hydraulic system, and may result in equipment operating malfunction and even

personal injury.

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

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

and pipe fittings is of damage or abrasion or not. In Addition, when detecting,

screwing down or replacing any pipeline connection of leak, please clean away

the dirt on hydraulic components and parts in time.

Chapter II Hydraulic System Overview

Hydraulic drive system is important component of top driven system. 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. So using and maintenance the hydraulic system in a right way is the most

important thing to keep the top drive working well.

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The top drive hydraulic system including the following parts:

1）Hydraulic source (ground pump station )

2）Hydraulic valve group

3）Actuating mechanism (brake cylinder, balancing cylinder, rotary head oil motor,

backup tong cylinder, hydraulic elevator cylinder, in BOP control oil cylinder

and so on).

4） Hydraulic pipeline (Ground hydraulic pipe, derrick hydraulic pipe)

5） Other accessories

I. Hydraulic system main technical specifications

Power 380VAC/50Hz

Diesel engine power 403kW

Hydraulic motor working pressure 0-35MPa

Max. Hydraulic motor pressure 40MPa

Main hydraulic pump working flow 900L/min

Flush pump motor power 11KW

Auxiliary hydraulic pump motor power 5.5KW

Cooling fan motor power 2.2KW

Solenoid valve control voltage 24 VDC

Oil tank volume 1500L

Explosive-proof grade EXdⅡBT4

II. Components and principle of the hydraulic station

The whole hydraulic system are explosion-proof design, motor, liquid level control,

temperature alarm system are adopt explosion-proof part. In order to avoid the

high oil temperature cause the high system temperature, the whole hydraulic

control system equipped forced air cooler. Lower the hydraulic source temperature

by the oil line circulate.

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Radiator
Hydraulic oil tank
Top Drive Control Cabinet

Washing pump
and motor Diesel motor

Auxiliary Main hydraulic pump and

Pump and charging pump
motor
1．Diesel motor: CAT C15 diesel, supply the power to hydraulic devices.

2．hydraulic power source including:

a. Main hydraulic pump---- supply the inlet oil pressure for the main hydraulic

system.

b. Charging pump: fill oil to the main hydraulic system.

c. Auxiliary pump : supply hydraulic power to the auxiliary system.

d. Flushing pump: flushing cooler the main motor, lubrication main hydraulic

pump, supply the power for the hydraulic oil cycle and cooler.

e. Hydraulic oil filtration unit: keep the hydraulic oil clean.

f. Oil tank: hydraulic oil tank.

g: Air cooling device: cooling the hydraulic oil.

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h. Other auxiliary devices.

3．Hydraulic pipe line system: including closed major loop, flush loop, auxiliary

hydraulic system loop.

a. closed major loop--- the closed working system including proportional axial

variable displacement piston pump, hydraulic motor, control valve plate to

finish the drilling required speed and torque control.

b. Flush loop--- hydraulic oil self-circulation system is including oil tank, flush

pump, circulation pump, cooling pump and oil filter. It main function is

flushing and cooling motor, circulation and cooling hydraulic oil, keep the oil

temperature and filter the hydraulic oil.

c. Auxiliary hydraulic system--- the auxiliary hydraulic system including

auxiliary pump, oil filter, solenoid valve and their actuator. It uses to achieve

the different movement of the top drive.

4. Top drive main body: including hydraulic pump actuator radial plunger type

hydraulic motor, main valve unit, driving box, main shaft, carrier bearing, control

valve, auxiliary hydraulic actuator and so on.

5. Control system: The control center is Siemens PLC system, including CPU,

analogue value translator, digital value I/O module, remote data communication

module.

III. Hydraulic System Working Principle

1. Closed main hydraulic loop and flush loop

DQ40YA-JH top drive main hydraulic pump power supplied by diesel motor, the

power line including diesel motor, main pump, charging pump, flush pump, filter,

radiator, oil tank and so on.

The main hydraulic system including two parts: one part is axial variable

displacement piston pump, control valve plate, hydraulic motor, it use to control the

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drill speed and torque. The other part is oil tank, flush pump, circulating pump,

cooler and oil filter of the hydraulic oil self-circulation system, it main function is

flush and cooling the motor, and control oil temperature and filtrate the oil.

The power of the hydraulic top drive supplied by CAT C15 diesel, the output shaft

drive the plunger-type variable hydraulic pump directly. Before first use, it should

start the flushing pump to fill the oil in main closed loop then start the main

hydraulic pump; after the main pump started, the charging pump through filter,

overflow valve(30bar) and one-way valve to fill the hydraulic oil in the main loop and

control return circuit. The unnecessary oil in main loop could back to oil tank

through three-way valve, overflow valve, filter, and radiator. When the major loop is

overloaded, the overflow valve will connect the in and out pipeline to protect the

major loop, at the same time, the high pressure oil will open the relevant sequence

valve to adjust the main pump swash plate angle in order to decrease the flow

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capacity. When the closed system is working, the pump capacity could adjusted by

change the swash plate angle, the working pressure could adjusted by the overflow

valve.

The motor is CA140 actuator radial plunger type hydraulic motor, it transfer the

hydraulic oil pressure to power on the main shaft, the main shaft rotating with the

drill tools. The motor controlled by the half/all displacement solenoid valve. When

running under half-insulated, the max. speed could be 180r/min, the output torque

is half of the rated value; when running under all-insulated, half the speed and twice

the output torque.

2. Auxiliary circuit

DQ40YA-JH top drive auxiliary circuit powered by 7.5Kw three-phase asynchronous

motor.. The circuit includes motor, auxiliary pump, oil filter, valves and actuators.

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z Auxiliary pump schematic diagram

This cylinder should be out ,when others act

Backup Tong Cylinder of Counter Balance Tilt Cylinder IBOP

Nitrogen Pressure of Accumulator
9 MPa

G1 G2 MP2 G3 MP3 MP4 G4 G5 MP5 G6 G7 MP7

M18×1.5 M18×1.5 M14×1.5 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 (Electromagnet Power On )

Tilt Cylinder in Float Situation

ab
o

b
a
③ ①
③
②
Pressure:10MPa
③ ① ②

①
②

Pressure:17MPa
①
②
②
b

a
a

a
b

b
①
b

a
b

Pressure:12MPa

① ① ①
8MPa 8MPa 8MPa

③ ③ ③

② ② ②

T M14×1.5
M22×1.5
MPT
P M14×1.5
M22×1.5
MPP

Auxiliary pump powered by 5.5Kw three-phase asynchronous motor. The power

goes through hydraulic pipe line reach top drive body. One-way valve, filter to the
hydraulic valve group, and the top drive movement realized by hydraulic valve
group.

IV. Hydraulic system component

1. Oil tank

Hydraulic oil tank make by stainless steel, the volume is 1500L, the oil tank
equipped with heater, hydraulic oil temperature gauge, hydraulic oil leveler.

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The main function of the oil tank:

1) Storage the system needed oil

2) Radiating the system working heat.

3) Separate the gas and precipitate in the oil.

The hydraulic oil connect with fresh air, in order to avoid the pollution, we set an air
filter on the oil tank cover. Pay attention to the clean of the air filter and change it.

2. Oil pump

1).Major variable pump (see the right)

Model: SP500

Powered by diesel motor and it give power to closed

system pressure, control the flow rate drill torque and
make up and break out torque by the hand wheel.

2). Flush pump (See the right)

Model: PVL13-12-125-1RUU-10

Rated working pressure: 21/16MPa

Flow rate: 1222/122 ml3/r
It mainly use to flush and cooling the major motor, lubricate the main hydraulic
pump; supply the cooling power for the hydraulic oil self-circulation.

3).Auxiliary oil pump

Model: A37-F-R-01-H-S-K-32
Max. Pressure: 21 MPa
Working pressure: 13MPa
Max. Flow rate: 36 ml3/r

It mainly used to supply the auxiliary hydraulic loop power.

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3. Hydraulic motor

Model: CA140

It transfers the hydraulic oil pressure to kinetic energy

on the main shaft, the main shaft rotating with drill
tools. By the control of all/half-insulated solenoid valve,
the system could run with single or double motor.

4. Oil filter

Hydraulic system equipped filter, it makes the hydraulic source have the
self-cleaning ability. The oil goes through oil inlet filter and oil return filter to remove
the foreign particle, protect hydraulic parts.
Filter features:
1) It is easy to replace, clean filter or repairs the system; when replace, clean filter,
it just need turn on the filter cover to do it.
2) Equipped with filter display device with bypass-valve, when the filter blocked by
pollutant and the pressure reach -0.018MPa, if the operator cannot clean or replace
the filter in time, the bypass-valve will open automatically (opening pressure) to
protect oil pump.

1). Inlet filter

The inlet filter installed besides charging pump and flushing pump,
it used to removal the bigger foreign particle to protect the pump
and other hydraulic parts.

2).Scavenge filter

The scavenge filter installed beside the hydraulic system circuit, it makes
the hydraulic source have the self-clean ability. The scavenge filter used to
removal the bigger foreign particle to protect the pump and other

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hydraulic parts.

5. Air filter

The hydraulic source oil tank cover equipped with air filter, the filter is also an oil
inlet.
Air filter main technical specification:

Model QUQ3—20X1
Air filter precision 20μm
Air flow 1 m3/min
Filter net hole 0.5 mm

6. Radiator

In the hydraulic power transmission system, normally, the highest oil temperature is
55℃, the hydraulic system equipped radiator for coolant. To make heat dissipation
easier, the ambient temperature needs lower the radiator oil outlet temperature.
The radiator needs periodic cleaning, and pay attention to the fan deformation
during the running.

Main technical specification of radiator

Fan diameter: 600 mm

Fan speed: 1420 rpm

Radiator maintenance: Running under dust occasion, it need clean the radiator
with the banister brush to avoid damage the cooling fin.

7. Liquid Indicator and Thermometer

Direct reading type liquid indicator and thermometer is set

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

of the oil tank can be read out directly.

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Model： YWZ-150

8. Explosion-proof motor

1. Main technical specification of the motor:

1) Flushing pump motor M2JA160M4A (ExdⅡBT4)
Voltage: 380 VAC/50Hz Power: 11KW
2)Auxiliary pump motor M2JA132M4A (ExdⅡBT4)
Voltage: 380 VAC/50Hz Power: 7.5KW
3) Radiator motor YB2-100L1-4 (ExdⅡBT4)
Voltage: 380 VAC/50Hz Power: 2.2KWx2

2. Explosion-proof motor installation:

1) Check the following item before installation:

a. Check the Ex-mark and explosive-proof certification, motor protection level

and group should meet the requirement.
b. Fix all the fastener with spring washer, all the fastener should without crack
and other indications.
c. Electric resistance between stator winding and main case should not lower
than 0.38MΩ whiling 380V rated voltage.
d. The motor adopt flexible coupling transmission, motor shaft center and
transmitted pump center should in a same line, otherwise, it will cause the bearing
damage.

Check the items above before installing, forbid to use if not qualified.

3. Maintenance of the explosion-proof motor:

1) Seat of the motor should check and clean on fixed days, keep the shell clean
and cannot use the water blower to clean the motor.
2) Motor bearing could resist temperature no more than 95℃, check the bearing
every 2500 hours at least, change the grease in time, before change the
bearing, it should clean the bearing with petrol. The grease is special grease
（GB7324-87），for small motor. Fill 2/3 of the bearing box volume. When
dismounting the motor, the stator can only take off from the fan side. When

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installing the motor, the flameproof joint should painting 204-1 rust grease.
3) If the motor become damp, it must have drying treatment, it could adopt
drying oven or short-circuit current. In the drying process, motor winding
temperature should not over 155℃.
4) When motor cable entry seal ring degradation, should replace it in time.

9. Overflow valve
Proportional electromagnetic relief valve, this valve controls closed loop system
pressure. Control and adjust the overflow valve pressure opening by make up
torque and drill torque potentiometer.

Main technical features:

Model: BVPSA06-A-350-G24

10. Proportional directional valve

Proportional solenoid directional valve is used to control the output flow of the
variable pump. Turn the hand wheel to adjust the proportional solenoid directional
valve, then control the variable pump tilting tray angle thereby change the delivery
capacity of the pump.

11. Solenoid directional valve

It controls the liquid flow open, close and flow direction, the valve group including
valve body, one or two explosion-proof electromagnet, control valve and one or two
returning spring. Under the non-operation status, the control kept in the center or
initial position by the returning spring. The electromagnet controls the valve.

When no electric on the electromagnet, the control valve pushed to the initial
position by the returning spring, three position four-way directional control valve
manual operation could move the valve.

Note: in order to the valve working well, it must fill enough oil in the pressure
chamber.

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12. Oil filled pressure gauges

YN series Oil filled pressure gauges has a high measurement accuracy and
antifatigue ability. It also could resist a strong vibration and pulse influence.

Oil filled pressure gauges including transmit pressure system (joint, bourdon tube,
flow controller), gear drive, display device (indicator and disk) and shell (watch case,
watch cover, glasses). The shell could resist the working liquid goes into the gauge.

13. Accumulator

Accumulator has the function of stored energy, steady pressure, lower the power
consumption, compensate the leak, absorb pressure pulse and impact force.

Main technical specification of accumulator:

Working medium: Nitrogen-Petroleum base hydraulic oil

Working temperature: －35℃—＋70℃
Working pressure: 35 MPa
Pre-charge Nitrogen pressure: 18MPa
Before charging the Nitrogen, the accumulator needs inspection, charging gas with
the supplied special tools, the tools used for charging, air exhaust, testing and
adjust the charging pressure. The accumulator can only fill with Nitrogen, while
charging, open the nitrogen cylinder valve slowly.

When the hydraulic system need maintenance, it should open the accumulator
safety valve.

Accumulator is forbid to charging oxygen, compressed air or other

inflammable gas.
Must keep the accumulator pressure in a suitable level.

V Control Valve Block and Executing Agency

The Control Valve Block of DQ40YA－JH Top Drive Hydraulic System is composed of
2 parts: one part is to realize the top drive CW/CCW and single motor or double

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motor running by half flush and full flush of solenoid valve on control valve panel.
The other part divides the
auxiliary loop of hydraulic system into 4 control loops to realize the functions of Top
Drive.

1. The Main Control valve block

In the main closed loop of Top Drive System DQ40YA-JH, Main control valve block is
composed of two position 4-way reversing valve, hydro-control two position 3-way
reversing valve, hydro-control two position five-way reversing valve (valve panel
inside), Relief valve and hydro-control one-way valve (valve panel inside). Two
position 4-way reversing valve, hydro-control two position 3-way reversing valve,
hydro-control two position five-way reversing valve are used to realize the running
of single motor or double motor. Six pcs of hydro-control one-way valve are used to
control top drive CW/CCW, Relief valve protects the main motor from high pressure
damaging.

2. Auxiliary Control Valve Block

Cylinder of Counter Balance
Nitrogen Pressure of Accumulator

The auxiliary loop of top drive DQ 40YA-JH is divided 9 MPa

into 4 control loops to realize the function of Top

Drive.

G3 MP3
M18×1.5 M14×1.5

1) Counter Balance System Hydraulic Loop

②

This hydraulic loop is composed of relief valve,

③ ①

压力:10MPa

one-way and accumulator. The counter balance

① ②

system is to balance the main body weight, its main

function is similar to hook counterbalance spring, ①
压力:17MPa

protect the thread is not wore during make up and

②

break out. The main function of relief valve is to 压力:12MPa

adjust the work pressure of counter balance cylinder,

①

compatible with the main body weight, keep security

8MPa

protection against shock loading.

T M14×1.5
M22×1.5
MPT
55 P
M22×1.5
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Note: Release the relief valve or connect the oil return port T with the
pressure test port MP2 of valve block, make sure the pressure in
accumulator is released before dissembling.

Backup Tong

G1 G2 MP2
2) Backup Tong Clamp Hydraulic loop M18×1.5 M18×1.5 M14×1.5

This hydraulic loop is composed of the three

③
position 4-way solenoid reversing valve of Y type ①
②
median function and hydro-control one-way valve.
The pressure for backup tong is supplied by relieve
valve. The function of hydro-control one-way valve
is to prevent tong head frictionate drilling tools a
b

a
b

when the backup tong releases.

①
8MPa

T
M22×1.5

P M14×1.5
M22×1.5
MPP

When the actions of backup tong clamp, breakout and make up are
finished, don’t forget to transfer the backup tong clamp state to release.

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3) Link leaning hydraulic loop

This hydraulic loop is composed of the three position 4-way solenoid reversing valve
of O type median function, four position 3-way solenoid reversing valve, relief valve
and hydro-control one-way throttle valve. The function of solenoid reversing valve is
changing direction, three position 4-way solenoid reversing valve control leaning
tank to forward and backward, four position 3-way solenoid reversing valve to
control the leaning tank to float, two relief valves control the oil-feeding pressure
when move forward and backward. One-way throttle valve has two functions: one is
to keep the leaning arm and connected ring and elevator could stay in any position,
and the action element has back pressure to keep balance with gravity loading.
Adjust the throttle valve to change the speed of leaning arm (link). The other
function is to realize the two learning arms (link) move in same speed, Swing
distance is relative to the link length (see the hydraulic manual), neutral position is
free.
Tilt Cylinder

MP4 G4 G5 MP5
M14×1.5 M18×1.5 M18×1.5 M14×1.5

此位置时(电磁铁均得电)
倾斜油缸处于悬浮状态
ab
o

b
a

定阻尼
3mm
a
b

a
b

T
M22×1.5

P
M22×1.5

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4）BOP On/Off hydraulic loop
Remote IBOP System Control loop is composed of the three position 4-way solenoid
reversing valve of M type median function, hydro control one-way valve, pressure
reduce relief valve. The function of solenoid reversing valve is changing direction,
three position 4-way solenoid reversing valve control the IBOP executing device to
realize IBOP ball valve off/on. Pressure reduce relief valve has the function of
pressure reduce valve, which adjust the BOP hydro executing device pressure. And
it also has the function of relief valve, which prevent executing device produce
over-high pressure when have Load resistance. The hydro control one-way valve
locks the cylinder up move position to prevent declining and return hydraulic oil
back to oil tank when the BOP open.
This cylinder should be
out ,when others act

IBOP

G6 G7 MP7
M18×1.5 M18×1.5 M14×1.5

③
②
a
b

a
b

①
8MPa

T
M22×1.5

P
M22×1.5

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VI. Hydraulic Pipe

Hydraulic pipe connects hydraulic resource and valve block, totally 5 pipes: Main
Motor High pressure output pipe and low pressure oil return pipe, loop washing
output pipe, auxiliary loop output pipe and oil release loop pipe. Main motor high
pressure output and low pressure oil return make closed working loop. Loop
washing output pipe go through filter and get into motor, carry the heat produced by
motor go through oil release loop pipe and oil return filter, get into oil tank. The
auxiliary loop output pipe go through filter and get into the auxiliary valve panel and
pass the valves to realize top drive actions. Return oil go through the oil release loop
pipe back to oil tank.

Hydraulic pipe includes: ground hydraulic pipe, derrick trip hydraulic pipe and
hydraulic control pipe.

1. Ground hydraulic pipe

Ground hydraulic pipe is the pipe between hydraulic resource and derrick line
connecting panel, totally 2 pipes, length 46m. One is composed of the main motor
high pressure output pipe and system leakage oil return pipe. The other pipe is
composed of washing loop output pipe, auxiliary hydraulic loop output pipe and
control cable fixed with a wearable cover.

2. Derrick trip hydraulic pipe

Derrick trip hydraulic pipe is between the derrick line connecting panel and top drive
mainbody valve block, totally 2 trip pipes. It connect with ground hydraulic pipe on
the derrick line connecting panel, the other end is connect with top drive mainbody,
total length is 18.6m.It is same to the ground hydraulic pipe. One is composed of the
main motor high pressure output pipe and low pressure oil return pipe, oil release
pipe fixed with a wearable cover. The other pipe is composed of washing loop output
pipe, auxiliary hydraulic loop output pipe and control cable fixed with a wearable
cover.

3. Control Pipe

Control pipe includes 2 parts: one is pipe between hydraulic station inside pumps
and oil tank, valve and other hydraulic part. The other part is the pipes between

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valve on top drive main body and executing element, distribute the power from
hydraulic resource to the executing device. The valve block and every cylinder,
motor are connected by soft pipes for easily installing and disassemble, others are
hard pipe.

Inspection before installation: Inspect the soft pipes before installing. Inspect the
shape, size, model, and length of all elements. Check the soft pipe clearance, check
blocks or foaming. Check the cover station. Soft pipe and joint assemble: Do not
connect the soft pipe with non-indicated joint.

Do not over bend the soft joint.

Chapter IV Adjustment and Maintenance of

Hydraulic System pressure

I. Hydraulic system pressure adjusting

1. Hydraulic station pressure adjusting

1). The pressures in hydraulic main pump station are adjusted before delivery, it is
fixed do not need adjust pressure.

2). The normal work pressure of washing pump has a 8bar one-way valve control,
do not need adjusting. When the hot fill valve working, reversing valve works, the
hydraulic oil go through 60bar relief valve, fill to main loop after the hydraulic oil

heating up.

3) Auxiliary hydraulic pump work pressure adjusting

The system pressure of auxiliary hydraulic pump is adjusted by the short bolt on
pump body. The initial system pressure of auxiliary hydraulic pump is 13.5 before
delivery. Release the back nut when adjusting, fixed the short bolt after adjusting.

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2. Hydraulic valve block pressure adjusting

1）Leaning cylinder is double-acting cylinder, its pressure is supplied by auxiliary
hydraulic pump, control the work pressure of forward and backward through
adjusting two relief valves.

2）Clamp cylinder is double-acting cylinder, its pressure is supplied by relief valve.

3）BOP cylinder is double-acting cylinder, its pressure is supplied by relief valve.

4）Counter Balance cylinder is single cylinder, its pressure is the pressure supplied
by auxiliary hydraulic pump acts on cylinder directly. Connect an accumulator
on the counter balance cylinder to keep the pressure stably. Connect another
relief valve on this loop to prevent the over high input pressure.

II. Daily Maintenance of hydraulic system

1. Basic request
1）Oil tank level is not lower than the lower oil level line, oil temperature is not higher
than 55℃.
2) Check the filter block device on filter, clean or replace filter in time.
3）Hydraulic oil must be clean, change it according to its replace principle
4）The oil inlet must be open, the outlet pipe must be connect with system before
start the pump,
5）Pipe connecting must be reliable, attention to the Compound Gaskets and O Type
Seal Collars.
6）Cut off the electrical control part, and make alarm.
7）Release all the system pressure by releasing valve slowly, make sure not any
pressure in system pipes.
8 ） Marks on the connecting part before disassembling to ensure re-connect
correctly.
9） Take effective measures to prevent hydraulic oil omit into other electronic or
mechanical elements.

Close the system valve before disassemble hydraulic pipes, and

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prepare suitable container, oil plugs and cotton to prevent the left
hydraulic oil flow out when open the pipe, pollute the equipment
and surrounding.

The temperature of Hydraulic equipment and hydraulic oil might be

high, it need some time to cool down.

III. Hydraulic Oil Selection and Change

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

1 Selection of hydraulic oil

In order to meet the requirements of hydraulic driving, recommend to use the 46#
hydraulic oil in winter, use 68# anti-wear hydraulic oil in other seasons (recommend
to use the 100# anti-wear hydraulic oil in the area where the lowest temperature is
higher than 20 degree). Recommend principle is use the high viscosity grade
hydraulic oil in permitted temperature scope.

The quality of hydraulic oil is important for the hydraulic system running, so we
recommend Shell, Mobil.

2. Hydraulic oil Changing

Change the hydraulic oil following the principles below:

a. Change the hydraulic oil after 3 months for the first use of the new system.
b. In normally using period, recommend to change the oil in 6-12 months.
c. Change the oil according to the analyzing result or experiences.

Feed or change hydraulic oil should notify the following items.

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

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same to the precious oil brand and grade.

b. Keep the clearance of oil drum mouth, oil tank mouth and filter input/output

oil pipe while feeding, oil must through a filter cart before putting into oil tank,

filtration shall not be less than system filtration.

c. Oil in the tank should be in the allowed oil level when system filled with oil.

d. Before oil feed in tank, disassemble the main oil return pipe, connected with

the temporary oil drums. Start the motor of oil pump, push the old oil out of the pipe

by new oil. Operate the reversing valve of hydraulic cylinder when oil pump running,

the old oil in hydraulic tank can be replaced.

Forbid to mix oil in different brands or grades.

Do not 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 put on it, and selecting the famous

brand products is necessary.

The replace of hydraulic oil should follow the principles below:

1. Replace oil after using half year for first time, replace once every year.

2. The oil clearance is quite important, please use same brand and grade hydraulic

oil, do not mix with debris or water into system.

Forbid to mix oil in different brands or grades.

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Part V Installation and Commissioning

Chapter I Safety Operation Specification

I Safety operation notice

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

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

“caution” and “note” three level of information.

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

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

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite

risk of injury to rig personnel.

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

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

carefully before operation. Working personnel and other personnel who enter the

working area of the system should have got the training of drilling operation and safe

knowledge.

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

get a badly hurt of person or get damage of the device.

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

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

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

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

on”.

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

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

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

glove, helmet, etc.

This manual only includes the basic safety knowledge which operator should

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

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

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

technology personnel and safety personnel.

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

manual> to get a well known of the electric circuit diagram.

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

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

Chapter II Installing preparation

1. Before installing the top drive drilling system, the relevant personnel should

prospect the working site and have a meeting to confirm the installation plan.

2. Installation person should check all the equipment according to the packing list,

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confirm that all the devices, accessories and installation tools are prepared and in

a good condition to avoid the stoppage in the process of installation.

3. The installation technical staff and safety staff should arrange a technical

discussion to ensure that everyone who participates in the installation knows the

installation scheme and safety measure. Set out a detailed working schemes and

working site layout to increase the working efficiency. We suggest carrying out the

working according to <installation reference table>.

Installation reference table

Item Device needed Staff Working time

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

Note:
1). Installation time is about 4 hours (reference time)
2). The working time is not fixed; it will change with the practical conditions
of each well.
3). Training time is depends on the situation of the operator, but the total
training time is no less than 16 hours.
4. Well site arrangement

Before installing the top drive drilling system, please consider carefully the

arrangement of site, including:

1) Put the hydraulic station on the flat ground.

The ground where the control house placed must be flat.

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2) Put the hydraulic station on the back right side of the derrick ramp.
3). Put the A.B pipeline box and cable box on the right of derrick.

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

body (with transport frame), guide beam (with transport frame) and moveable

cable box on the place which is convenient to install.

It should be consideration the layout position of guide beam, main body,

cable box and installation accessories when the item reach the well site. Try
to put them on the suitable place in order to convenient to hoisting, avoid
repetitive operation, save installment time.

5. Turn off the limiting device of the travelling crane; make sure the hook block could

reach the top of the rig.

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Top Drive well field facade layout

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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 adjusting unit

Set up the Sliding-insert folding type guide beam and top drive

Set up the anti-torque beam

Set up the pipeline and cables

Set up the auxiliary devices

Testing and commissioning the system

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I. Installing the guide beam

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

on the top of rig for first time. General, we adopt welding or bolting. The material of

the lifting lug is Q345B. Take care of the direction when welding (see the chart

below). It must use high strength bolt and the bolting joint should be safe and

reliable.
Crane Top View

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

The welding staff must be qualified the welder test.

The connecting bolt must be the M30 grade 12.9. After it being fixed, it must
locked with the pin.

Connection (welding) must firm and reliable, take care when working at the
high position.

2. Lifting the guide beam adjust unit and guide beam docking assembly to the drill
floor by the crane.

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3. Install the guide beam adjust unit. Before the derrick uprights, connect the U ring
of guide beam adjust panel with the lug on derrick and insert the pins.

The U ring connected with lug

Guide beam adjust panel

There are 2 types of adjust panel with top drive system, chose the panel
according to the derrick height or connect both to use.

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4. The installation staff climbs to the travelling crane to assistance and operate the
guide beam and main body installation process.

5.Using the traveling block lift the guide beam to drill floor, put them under the hook
block in order to install conveniently.

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6. Using the supplied track cable and U shape ring fix the dolly with the hook block
(the wire rope connect with the traveling block), lifting the traveling block slowly
until the five sections upright, move the guide beam hook 0.8m above the drilling
floor.

Bearing steel rope

U Ring

Hook is 0.8m above drilling floor

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7. Lift the transport frame and top drive body to the drilling floor, aligning the
connector of transport frame with the hook on the bottom of 5th guide beam.

Top drive body and transport frame position drawing

8. Connect the hook on1st guide beam with the connector of transport frame.

Hook
Connector of transport frame

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9. A: Rise up the crane to upright the transport frame. Use the crane to draw the
transport frame, help the frame and guide beam in vertical station.

Transport frame

10. Lift the hook to move the 5th guide beam to the guide beam adjust compounds,
connect the adjust panel with compounds by U ring, and insert the pin.

Adjust compounds

U ring

Nut Shaft

Guide beam adjust panel

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11. Lower the traveling block, carriage moves down, make the guide beam adjust
component bear the weight, the guide beam will connect together automatic by its
weight and keep vertical.

Install State

Vertical State

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12、Put the fixed pin into the guide beam limited seat, tight the nut and insert
the pin to make sure the transport frame and guide beam are vertical.

Fixed pin

Limited seat

Nut

13、Fasten the centralizer block shaft of top adjust panel of guide beam.

Centralizer Block Centralizer block shaft

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14. Lower the crane to the bottom of guide beam, disassemble the carriage.

A. Low down the crane, let the carriage touch the top of top drive. Get the
carriage wire rope from the hook, connect the wire rope with the air winch,
hang the carriage by air winch.

B. Disassemble the install pin on carriage, operator moves the wheels away
from guide beam by rotating the wheel frame some angles.

C. Lift the carriage to the indicated position by the air winch.

Install pin

The position of wheel

frame after rotating.

15. Connect the hook with the bail.

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16. Disassemble the fixed pin between carriage and transport frame. Rise up the
crane to lift the top drive.

Fixed pin

17. Install the guide beam and anti-torque beam.

A. Connect the anti-torque base with beam, connect the beam with derrick
beam by the studs, press panel and nuts.

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B. Connect the anti-toque frame and bottom guide beam by fix pin.

Fix pin

18. Adjust the flexible distance of reactive torque through guide screw. Preset
the center of guide beam to the center distance of installed guide beam.

Rotate the guide screw in CW

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

All the connects must be reliable and safe.

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19. Inspect the top drive moving in the range by rising and lowering slowly.

No block while the top drive move up and down.

20. Connect the “Limit anti-collision device” when the sliding is regular.

II. Hydraulic pipe and Cable installation

1. Lift the cable box and pipes onto drilling floor, put it on the right front of drilling

floor.

2. Inspect the bolts and card condition on the movable section cable, install it on

the derrick by pneumatic crane (position refers to well site plan), hang the frame

to derrick.

3. Inspect the bolts and card condition on the A, B pipe and hanging frame, install

it on the derrick by pneumatic crane (position refers to well site plan), move the

cable box.

III. Auxiliary Device Installation

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

personnel to start the following install at the same time.

1. Install the elevator link on Top Drive body.

2. Connect the trip A port pipe, B port pipe, cable, oil return pipe, auxiliary power

cable plug with the cable of top drive body (Distinguish from color).

3. Install drilling hose (position according to the well site layout)

4. Install hydraulic station, stab steel into ground at 1.6m. One end of connect steel

connects with ground cable, and the other connects with general control box.

Hydraulic station must connect with earth to ensuring operator and equipment

safe.

5. Move the Driller’s panel from electric control room to drilling floor, put it in a wide

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place in the driller house for easily operating.

6. Connect the cable of driller panel (include 10 core control cable (400513),

10-core generator data wire, 2-core communication wire, 7-core logging signal

cable).

All cables are connected by push fit, Marks on the joint of plug and
jack.
7. Connect air pipes, adjust input air pressure, ensures the air pressure on driller

panel is lower than 0.2Mpa, higher than 0.12 Mpa.

8. Connect the power of generator group and the control house.

Chapter IV Inspect after installation

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

every installation is correct, all the transport and fixing device has been removed,

each part are ready for test-running.

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

3. Installation should be carried out according to attachment I < Top Drive System

Installation Line Connecting Inspect list >, attachment II <Top Drive System

Installation Inspecting list>.

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

Inspection must be carried out by professional operator.

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Chapter V Test Running

I. The inspection before starting

1. Inspect the cool oil level and lubricate oil level in diesel motor, inspect the diesel

motor spare parts, air cooler, electrical control system and meters. Refill the diesel

motor by refill cart before start.

The operation and maintenance of diesel motor refer to Series-C motor operation

and maintenance.

2. Check the hydraulic oil tank level, top drive pipe connections, Check the hydraulic

station pipe connections.

3. Inspect all the operate elements and meters on the electric system, PLC cabinet

and drill panel, set them into initial state, the auxiliary pump and washing pump

stop, the diesel motor is in stop state.

4. Inspect the power indicator.

II. Electric Device Test-running

1. Switch on the main power switch.

2. Power on the accessory transformer switch in power switch box and power switch

of PLC which is from auxiliary transformer or wire feeding switch in PLC box.

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

Connect the main switch Q1

Disconnect the main switch Q1, check

Phasesequence relay
the phase sequence, Q1 re-connect

Connect the control power Q2~Q7

Connect the motor power QF2~QF4

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III. Main hydraulic system testing

1. Start the washing pump, observe the A, B port pressure on driller panel.

2. Start the diesel motor after the washing pump starts 1 min. For first using, the

diesel motor could be started only when the A.B port pressure raise more than 5

bar.

3. When the diesel starts, its rotary speed should be stet lower than 1000r/min.

when the diesel motor works regularly, adjust its rotary to 1500-1700r/min,

start the hydraulic operating functions.

4. When the ready indicator works, operate the throttle, 0-180r/min speed up

slowly, observe its running station.

5. Operate the hand wheel on driller panel, 0-35kN·m increase gradually, observe

its torque.

Note: In first using, there are not any oil in the pipes, the washing pump starting

need more than 20 mins, please be patient.

IV. Auxiliary Function Test Running

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

function.

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

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

3. Inspect IBOP switch.

Please fill the form in operate manual.

Attachment III <Top Drive Device Installation and Commissioning Record >

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Chapter VI Top Drive Disassemble

Top Drive disassemble procedure

Cut off the once power and each function block

Dissemble Auxiliary Equipment

Dissemble pipeline and Cables

Dissemble anti-torque beam

Dissemble Top drive main body and slid-insert type foldable guide beam

Dissemble the guide beam connection device

Dissemble adjusting components of guide beam

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I Accessory equipments disassemble

1. Cut off the ONCE power switch.

2. Switch off all function units.

3. Shut down the active force power switch.

4. Pressure release, turn on the manual switch near to the oil return tank pipeline,

release the pressure in pipeline, turn the switch to original position.

5. Disconnect the pipelines of port A, B, auxiliary pipeline, washing pump pipeline,

oil return pipeline and protect the pipeline connectors.

6. Disconnect the driller panel’s cables (24V power line, diesel signal line,

telecommunication cable)

7. 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

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8. Fix the leaning cylinder by the press panel.

9. Disassemble drilling hoses and top drive mud pipe.

II Cables disassemble
1. Disassemble all the pipelines and cables on top drive.

2. Coil the pipeline and cables, and lift them into boxes. put the cable box in position

convenient for delivery.

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III Disassemble Top Drive Main Body

1. Fix the top drive mainbody and transport frame by the fixed pin shaft.

Fixed pin

2. Disassemble the hook and bail of top drive main body.

3. Install the carriage on the guide beam by air winch.

4. Connect the hook with the wire rope of carriage.

5. Open the tong of anti-torque beam. Disassemble the compounds of anti-torque,

lift it to the position convenient for transport.

6. Disassemble the fixed pin between transport frame and 1st guide beam hook.

Fixed Pin

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7. Lift the crane to guide the carriage move to the top of guide beam. Open the

wirerope of the guide beam butt device, the crane bear the weight of guide beam

and main body.

8. The air winch assist the bottom of transport frame, lower down the crane, the two

corporate to disassemble the guide beam main body and the frame. Lift to the

position convenient for transport.

9. Lift the guide beam frame to drilling floor.

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

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

Air winch assists

this part guide
beam

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

12. Hang the adjusting back panel, guide beam and transport frame under the

drilling floor for packing.

13. Packing the dissembled top drive and auxiliary components.

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Attachment I Top Drive System Electric Wiring Installation

Inspecting list

No. Item Inspect Content Result

Electric 1. Through the inspecting, Check the
1 leakage equipment cabinet has electricity or
Inspect not.
1. The phase sequence light in general
cabinet is not light (means the phase
sequence is correct, light up phase
sequence is opposite )
Hydraulic 2. PLC system working well, no alarm.
2
station 3. The enlarger indicator and
exchange module runs well.
4. Then sensor and general cabinet
outside cable connect correctly and
reliable.
1. stable laying, reasonable
arrangement.
2. Cable plugging connected
3 Driller’s panel correctly and locked well.
3. Air Pressure is regular.
4. Panel lights works well, meters
display regularly.
Remarks:

Record： Check：

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Attachment II Top Drive System mechanical installation

inspecting list

No. Item Inspect Content Result

1. Guide beam 1. Check the connection between U
hang ring and guide beam.
2. Check if the affix connection is
reliable.
2. Guide beam 1. Whether the guide beam is vertical
body and and neat.
connection 2、Whether the bolts locked tight.
3. Lifting ring 1. Inspect the connection between
connects with lifting ring and hook, whether the
crane or hook anti-off device installing is in place
4. Reactive 1. Whether the bolt is fastening.
torque beam 2. Whether the joint pin with guide
beam is in place.
5. 1. Whether all auxiliary devices are
taken off.
Top Drive main
2. Whether the liquid level of Lube oil
body
and hydraulic oil normal.
3. Is there any crash between each part
on top drive body.
4. Inspect the components of top drive.
5. No obstacles in top drive’s routine.
6. Main shaft’s Inspect the bolts of anti-loose block.
three anti-loose Whether the anchor is firm.
blocks.
7. Pulley Inspect whether the back of pulley
friction with guide beam.

Remark

Record： Check ：

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Attachment III Top Drive System Installation and

Commissioning Record
No. Item Testing Technical Request Result
Washing pump
motor , auxiliary 1. Normal voice
1 pump motor and 2. Motor rotating direction is correct

air blower rotate 3. Air pressure is normal

direction
1. Hydraulic lubricating system runs
Hydraulic, well, pump sound is normal.
2
lubricating system 2. Gear oil, hydraulic oil pressure,
temperature is normal.
1、 indicator works well.
Indicator on Driller’s
3 2、 indicating correctly.
panel
3、 no alarming.
Button switch hand
All the button switch hand wheel
4 wheel on driller’s
work well.
panel
1. Start and run regularly without
Diesel Motor starts sluggish and crawl.
5
and stops 2. Normal stopping and delay breaks is
regular.
1. No noise in gear box, running
sound is normal.
6 No-loading testing
2. No omit, smell or block.
3. No calibration while test-running.
Temperature of Motor raises lower
Load test and than rated temperature in limited
7 make up and time. (Note: Torque value and curve
break out test displayed on the win CC screen in
electric control house)

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Link leaning,
1、 act well
8 neutral floating test
2. moving smoothly

1. Clamp and loosen correctly

Back-up tong test
9 2. No omit

1、 Make up and breakout is

Counterbalance
10 normal, top drive upward
device movement
jumping is realizable.
test
1. Act flexibly, no blocks.
11 IBOP function test
2. Signal outputting correctly.

Remark:

Record： Check：

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Part VI Operation Manual

Chapter I Safety operation practice

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.

1. 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.
2. Working personnel and other people who enter the working area of the system
should have got the training of drilling operation and safe knowledge.
3. Working personnel should wear suitable protective articles, such as glove,
clothes，and etc.
4. In this manual, signal【】means it is the operate elements of electric control
system, such as buttons, switches etc. Non-professional staff and non-qualified
personnel could not install, test-run, operate or maintain the top drive system avoid
physical and equipment injuring.
5. Repairing and maintenance could not be carried out while the system working.

II. Operator safety operation notes

1. Electric system operating notes

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

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2) Before confirm each works, please hang the signal of “Working state, switch-on is
forbidden”
3) Use professional tools and protective facility.
4) Maintenance while switch-on is not allowed or disassemble any electric elements,
don’t pull any plugs while power on.
5) Remark the cable and cable ends before disconnecting the electrics to ensure
correct reconnecting.
6) Keep the protective air pressure while powering on the driller’s panel. When the
protective air lose pressure, recovery the pressure quickly or stop drilling and cut
the power supplied to driller’s panel.
7) Don’t turn the transfer cabinet or driller’s panel in dangerous gas.
8) 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.
9) 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 meet with the
high pressure oil layer or gas with H2S、SO2.
3) Keep equipments in good working station while drilling in the oil layer, carry out

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while shaft handing over. For instance: the Inspection and testing of IBOP, well
control operation, handle with the problems in time.

Chapter II Main Hydraulic system operation

I. Inspection Before start

1. Diesel motor inspect: Inspect the cool oil level and lubricate oil level in diesel

motor, inspect the diesel motor spare parts, air cooler, electrical control system and

meters. Refill the diesel motor by refill cart before start.

2. Hydraulic system inspect: Check the hydraulic oil tank level, top drive pipe

connections, Check the hydraulic station pipe connections.

3. Electrics start inspect: Inspect all the operate elements and meters on the electric

system, PLC cabinet and drill panel, set them into initial state, the auxiliary pump

and washing pump stop, the diesel motor is in stop state.

4. Top Drive body and guide beam inspect: check the gear oil level in gear box,
check whether there is any blocks in the top drive running scope, check the top drive
liquid tank pipes.

Do not start the diesel before the washing pump pressure reaches to
8 bar (washing pump start 1 min).

II. Start procedures

1. Start the electric system first, start the PLC and touch screen to check the whole
electric system, find the electric problem.
2. Commissioning the auxiliary motor. Start the wash pump motor, feed oil and wash
lubricate to the main system loop.
3. Start the diesel motor, drive the main pump running, feed enough oil into the
closed system, be ready for drilling functions.
4. When the above procedures are ready, start the top drive drilling, main pump
output power, the main motor running to start drilling.

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III. The start procedure of main hydraulic system

1). Start

1. Switch off the general power switch Q1, switch on the DC power switch.
2. Inspect the touch screen functions, ensure the sensor and communication
function are normal.
3. Switch off the auxiliary motors’ switch sequently, test their working state.
4. Put the switch on START when all the auxiliary motors are normal. Put the
washing pump switch on START, and radiator air cooler switch is on Auto.
5. Connect the diesel motor start button. Start the diesel motor according to
《Caterpillar diesel motor operation manual》to start the main hydraulic system.

Check and confirm the driller panel when finish the operations above.
a. Push the mute/return for 3s, test the indicator light on driller panel.
b. The drilling work could be carried out only when the ready indicator lights
up.

2). Stop
1、Put the 【Throttle】 on “Zero”, 【Turning】button on “Stop”, 【Hydraulic pump】
is on “Stop”, stop auxiliary pump running.

Hydraulic pump Throttle

2. Stop the diesel motor

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3. Stop the washing pump
4. Stop the air-blower
5. Turn off the DC Power and diesel motor
6. Cut the main power.

IV. Auxiliary Hydraulic Pump Operation

1. Start

a. Turn on the main switch Q1 in PLC cabinet, turn on the power switch of auxiliary
pump.
b. Move the 【Stop/Start】of hydraulic pump on driller panel to START position, the
hydraulic pump running indicator lights up.

Hydraulic pump

2. Stop
Move the 【Stop/Start】of hydraulic pump on driller panel to STOP position, the
hydraulic pump running indicator is off.

V. Washing Pump Operation

1. Start

a. Turn on the main switch Q1 in PLC cabinet, turn on the power switch of washing
pump.

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b. Move the 【Stop/Start】of washing pump on PLC panel to START position, on Start
position, start the washing pump directly, the washing pump running indicator lights
up.

Washing Pump

2. Stop
Move the 【Stop/Start】of washing pump on driller panel to STOP position, the
washing pump running indicator is off.

Washing pump motor controls the main motor and the temperature of hydraulic
oil, so it could be on START position except inspecting or main system stops.

VI. Radiator cooler operation

1. Start

a. Turn on the main switch Q1 in PLC cabinet, turn on the power switch of radiator
cooler pump.

b. Rotate the button【Radiator Cooler】to start or auto position, on START, start the
radiator cooler directly. On AUTO, controlled by PLC, when the hydraulic oil
temperature is lower than 35 ℃ , cooler starts, indicator lights up. When the

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temperature is lower than 20℃, the cooler stops, indicator is off.

2. Stop
Rotate the button【Radiator Cooler】to stop position, The cooler stops.

When the cooler stops, the temperature of hydraulic oil might rise up, so when the
closed loop or auxiliary pump runs, it’s better to be on START avoid hydraulic oil is
over hot.

Radiator Cooler

VII. Drilling Operation

1. Before drill operation, Make sure the ready indicator light is lightening.

The lightening condition:

a. Diesel motor is running
b. Major loop hydraulic oil pressure is normal.
c. Flushing pump is running.
d. Hydraulic oil temperature is normal.
e. Speed sensor is normal.
f. Major valve unit I/O pressure sensor is normal.
g. PLC system working normal.

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2. Drill torque set

a. Turn 【Mode switch】to “drill”.

Mode switch

b. Turn 【Direction】to “Stop”.

Direction

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c. Turn 【Direction】to “low”. (In normal drilling in, if do not have to drill in high
speed, we suggest to stay in low speed, the double motor work to protect
themselves)

Rotary Speed

d. Turn【Drilling torque】slowly, check the torque meter value, set the torque to
the required value.
Drilling torque

Note: the set torque is vary base on the different【High speed/low speed】
position. Low speed torque is twice of high speed. Check the torque when turn the
【High speed/low speed】switch.

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3. Drilling operation
a. Turn【Operation】to “drill”.

Mode switch

b. Turn【Direction】to “CW”.

Direction

c. Turn【Rotary Speed】to “high” or “low”.

Rotary Speed

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Note: High speed, single motor is running, the Max. speed is 180r/min; at low
speed, the Max. speed is 90r/min, under the same drill torque set, the low speed torque
is twice of high speed.

d. Turn 【Throttle】hand wheel slowly, the main shaft will turn CW, turn the hand
wheel CW slowly to increase the major motor speed.

Throttle

During the drilling process, the drilling torque is changing in the range of set drilling
torque. It will block when the drill tool meet high counter torque. At this time, major
proportional throttle valve will move to maintain the major loop pressure, and
adjust the major pump output flow. When the counter torque is larger than the set
torque value, major motor self-locking will move to prevent motor reversing. If the
counter torque keeps rising to the safety pressure of the self-locking loop, major
motor will turn CCW to release the dangerous pressure.

If the drilling blocks, release the torque gradually till to 0. Return

【Throttle】 to Zero, release the anti-torque and carry on the next step.

4. Stop drilling
When need stop, first turn 【Throttle】hand wheel back to zero until the tachometer
is zero, turn【Direction】to stop, the drilling process is finished.

When confirm top drive direction, rotate the main shaft, hand wheel

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return to 0 slowly, then keep the 【 Direction 】 ”CW” to confirm the
direction.

VIII. “Make up/ Break out” operation

1. Inspect system before making up/Breaking out

The mainly inspecting items are as follows:

a. Make sure the ready indicator light is lightening.
b. All the buttons on drill panel in the initial status.
c. Before push the backup tong button, make sure there isn’t any drill tool in the
backup tong; otherwise, the backup tong may damage the saver sub thread.
d.【high speed/low speed】switch should turn to low.

On this position, 【high speed/low speed】switch is on high speed

position, makeup/break out is failed.

2. Set drilling torque

a. Turn 【Mode switch】to “strain at”.

Mode switch

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b. Turn 【Direction】to “CW”.

Direction
c. Turn【Rotary speed】to low speed.

Rotary speed
d. Turn 【Makeup torque】slowly, check the torque value, set the torque to the
needed valve.

Makeup torque

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If in the makeup and break out state, 【fast/slow】 is on the “fast”, make up and
break out is impossible.

3. Makeup and break out operation

a. Turn【Direction】to “CW”, the system will be CW mode.

Direction

b. Turn【Rotary speed】to “low”.

Rotary speed

c. Turn【Mode switch】to “Strain at”. The main shaft will turn to working mode,
and the speed is 10r/min, first connect the main shaft with the drill tools, then the

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main shaft will output the torque under the set value of 【Makeup torque】

Mode switch

d. Turn【Tong】to “on” (Start the auxiliary hydraulic pump first), or using B tong
to clamp the drill tools, so that they can bear the counter torque. Turn “drill-makeup
& breakout” to “makeup & breakout”, when the toque meter indicator increase to
the makeup toque limited value, rotate 【mode switch】 to drill. When the torque
meter is 0, release the tong, the makeup is finished.

Mode switch Tong

Release the Backup tong when the toque value is zero, avoid the anti-toque
releases. Put the 【Tong】 to “clamp” and keep 10s, then start the makeup operating
prevent from the backup tong loosing.

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Before operate the backup tong to clamp, the saver sub must be into the bottom
drill tools. The first reason: if there is not any drill tool, the saver sub might be damaged.
The second reason: The backup tong fixes the drilling tool, if make up moves large, the
length of compensate spring is not enough, have to open and clamp again.

4. Breakout operation
a. Turn【Tong】to “on”, or using other tools to clamp the drill tools.

Tong

b. Turn【Rotary speed】to “low”.

Rotary speed

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c. Turn 【Direction】to “CCW”, the system will be CCW mode.

Direction

d. Turn【Mode switch】to “Strain at”, the output torque will increasing until reach the
max. torque of the top drive to breakout the thread. Note: if the breakout torque
reach 49KN·M, and the thread still not broke, the operator should turn【Operation】
back to “drill”, using other way to breakout.

Mode switch

e. After the breakout, the main shaft will turn out at 12r/min.

f. After screw out, turn 【Mode switch】back to “drill”, main shaft will stop. The
balance system returns to the drilling in state automatically. Turn 【Direction】to

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“stop”; turn 【Tong】back to “off”, the breakout process is finished.

Mode switch Tong

When the 【Tong】is “on”, make sure the drill tool inside the backup tong,
otherwise, it will damage the saver sub thread.

When the 【Tong】is “on”, system will set the reverse torque as the top drive
maximum value, keep one minute and the set back to set value automatically.

IX Drilling ahead by single

1. Set slip on the connection in the drilled well, stop mud circulation
2. Start the auxiliary pump, switch 【hydraulic pump】to start.

Hydraulic Pump

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3. Switch the 【IBOP】 to close.

IBOP

4. Breakout according to the procedures in VIII-4.

5. Rise the top drive system up, move the elevator away from the drill pipe
connector.

6. Lower down the top drive, switch the 【Link incline】to Forward, move the
elevator to the mouse hold connector and fasten it.

Link incline

7. Rise up the single from mouse hole, press 【suspension】as well, move the

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single to the well center under gravity.

suspension

8. Low the crane slowly, drillers put the drill pipe connector right above the well,
lower the top drive (to avoid elevator friction), connect the single and drilling tools
by hydraulic tong.
9. Move the hydraulic tong away, lower the top drive, when the upper of single
goes into the guiding shoe, follow the spin operation in Chapter VII-II
10. When stop spinning, follow the fasten operation in Chapter VII-2.
11. Lift the traveling crane, pull the slip, open IBOP, start pump to circulate the
mud.

Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.

Before single drilling, open IBOP, then start mud pump.

X. Drilling ahead by triple

Drilling ahead by triples is the normal drilling method of top drive drilling system. If

there aren’t the existent triples on the well frame, it can be connected by winch and

hydraulic tong in mouse hole during the course drilling or at the leisure time. In

addition, when drilling by making a connection, the triples left in the well frame can

also be used for drilling by making up in triples after drilling start.

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There is the procedure for drilling ahead by triples as followed:

1. Set slip on the single connection in the drilled well, stop circulating mud.

2. Start the auxiliary pump, the switch of 【Hydraulic Pump】is “on”.

Hydraulic Pump

3. Rotary knob of 【IBOP】is “off”.

IBOP

4. Break out according the VIII-4 instructions.

5. Pull the top drive drilling system upward to make the elevator goes off the joint
of drilling rod, lift the top drive drilling system to the Kelly board.

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6. Put the 【Link incline】on “forward” and keep, move the elevator to the needed
position.

Link incline
7. Well workers will make up the triples into the elevator.

8. Push the button of【Suspension】, lift the crane, drill worker catch the triple
bottom prevent from crashing.

Suspension
9. Lower the crane to proper height, the driller helps to put the triples into the
box threads of the drilling rod;
10. Connect the triple and drilling tool by hydraulic tong.
11. Put the top drive drilling down slowly to put the upper side of the triples into
the guiding shoe.
12. Lock tight by Top drive according to Chapter VII-2.

13. Pull out the slip, open BOP, start pump to circulate the mud.

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Shut off the mud pump to lower down the pressure in tube to safe
pressure before stop drilling and breaking out, then close the IBOP.

Before single drilling, open IBOP, then start mud pump.

XI. Backreaming

During the course of pulling out, if the drilling devices are blocked, connect them

with the top drive drilling system at once, and circulate mud. Lift the drilling and

backreaming at the same time to avoid drill rod being clamped and key box being

reamed though.

Procedures of backreaming are as follows:

(1) Circulating mud and rotating to pull the drilling devices out until one triple is
lifted outside;
(2) Stop mud circulating and rotating, set the slip;
(3) Unlink the connection of top drive and triples following the procedure in chapter
VII-3, and unlink the connection of triple and drill tool;
(4) Pull out the triples, arrange the triples into the drilling rod box;
(5) Set the top drive drilling system down to of drilling floor.
(6) Lift the drilling rod to pull the slip out. Spin and fasten following the VIII-4.
(7) Loosen the elevator, operate the【Link incline】 to slope it backward a little and
deviate it from the drilling rod. Lift the traveling crane to the kelly board. Repeat the
above operations.

XII. Pulling out operations

Pulling out runs in conventional ways, in order to save time, the link leaning device
helps elevator close to derrick worker.

1. Tripping in
1. Move the top drive to Kelly board by lifting system, switch【Link incline】 to
“Forward”, move elevator close to request position, then workers will put the drilling

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rod into the elevator and buckle door bar;

Link incline

2. Push【Suspension】and lift the crane, the leaning cylinder is suspending, the triple
back to the center automatically under gravity, in this process, driller should hold
the bottom of drill string back by rope, release slowly avoid crashing the connector
of drill pipe , protect the bottom of triple as well.

Suspension

3. Put the traveling crane down, buckle the carried drilling rod with the drilling rod
of the rotary face, spin and fasten by hydraulic tong;

4. Lift the drilling rod to pull the slip out. Set the drilling rod down to the head of the
well and set it onto the slip.

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5. Loosen the elevator, switch【Link incline】 to “backward” to move elevator away
from the neck of triple, lift the crane to Kelly board, repeat the action above.

Link incline

2. Tripping out

(1) Loosen the connecting thread between the main shaft and drilling rod, and lift
the top drive drilling system. Operate the 【Link incline】to slop it forward in order
to buckle the main shaft of the lift sub into the joint of the drilling rod;

Link incline

（2）Lift the top drive drilling system above the Kelly board. Set the slip on the
drilling floor, put the top drive drilling system under the slip;
（3）Breakout with hydraulic tong;
（4）Pull the top drive drilling system, operate the 【Link incline】to “front” in order
to make the elevator close to the Kelly board. Drilling workers pull the triples’ to the

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arranging area, lower down the top drive to put the triples steady. Workers open the
elevator and put the drilling rod into the triples box;

Link incline

（5）Operate 【Suspension】, set the top drive drilling system down to the joint of
the drilling platform. Operate 【Link incline】 to “backward” a little, then “forward”
in order to buckle the elevator into the joint of the drilling rod.

Link incline Suspension

（6）Repeat the procedures from 2 to 5.

If there are reducing radius or key groove during the course of round-trip, connect
the drilling rod with electric engine of the top drive drilling system at any height of
the well frame, and starting the circulation and rotating removable drilling tools
immediately to make the drilling tools pass the blocking position. Greatly reduce the
labor intensity and improve operational efficiency

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XIII Well Control

1. When the top drive drill system is on the stop status, turn the rotary knob of

【IBOP】 could open or close the IBOP. In the drilling process or the mud pump

running status, it is not allowed to close the IBOP (except the well control status).

IBOP

2．Under the urgent condition such as well blowout, push the 【well control】switch

will enter the well control status, operating procedure showed as follows:
well control

a. Start the auxiliary hydraulic pump (Ignore the state before)

b. Stop the mud pump (Give the connect point signal, connect the control to mud

pump)

c. Stop top drive system (Fast stop)

d. Shut the IBOP off.

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e. Operators should replace all switches to original position. (Attachment I)

f. After obviating the urgent situation, and insuring there are no trouble alarm in

system, push the 【reset】 switch, then the well control statue is cancelled

Reset/Mute

XIV Jarring operation

Because every well has special condition, and the parameters, such as drilling depth,
drill pipe weight, bumper jarring type and so on, are not decided, so it is impossible
to give a standard rule or specification, in addition, the damage of jarring in various
conditions to the Top Drive Drilling System is not predictable. For these reasons, we
suggest that don’t jarring while equipping Top Drive Drilling System and forbidden
using surface bumper sub, otherwise it may cause damage to the Top Drive Drilling
System.

If jarring with Top Drive Drilling System can not avoid, please assess
comprehensively about the possible damage of jarring to the Top Drive Drilling
System.

After jarring, do a comprehensive examine of Top Drive Drilling System according to

following guideline. A detailed examine and maintenance plan should be made to
ensure all functions of the Top Drive Drilling System well and convenient for next
time using.

1. Take a general visual inspection to Top Drive Drilling System to ensure no

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damages.
2. Check the safety wire rope and connecting bolts. If any bolt loosing, please
tighten it and refasten the safety wire rope.
3. Check all cable joints, electric cabinet terminals, and device connectors of Top
Drive Drilling System. If any loosing, fasten again.
4. Inspect the station of main hydraulic pipe, auxiliary pipe, and all the valves on
valve panel, pipe connector, ensure no damages or deforming.
5. According to jarring intensity to decide if disassemble load-carrying components
on loading path (including lifting pin, elevator link, rotating hanging ear and main
shaft) and inspect them.
6. According to jarring intensity to decide if do further examination to Top Drive
Drilling System.

Appendix I Driller Panel initial state

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

Button or Switch Initial Remarks

position
【Emergency Stop】 Loose Emergency stop button is NC contact

【Throttle 】 Zero
【High Speed/Slow
Slow Double Motor Work
Speed】
Center
【Direction Select】 without CW or CCW selection
(Stop)
【Backup Tong】 Loose Backup Tong is free

【Mode Switch】 Drilling

【IBOP】 Open

【Hydraulic Pump】 Stop

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Appendix II PLC Cabinet Initial State

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

Button or Switch Initial Position Remarks

【Emergency Loose emergency-stop switch button is NC

Stop】 contact
【Diesel Motor Stop
Control】
【Radiator Stop Center
Motor 】
【Wash Pump】 Stop Center

【Heat valve】 Stop Left

【Mud Pump interlock The system interlock with mud pump when
Interlock】 running.
（Optional）
【Mud Pump Stop Center
Interlock】
（Optional）

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Part VII Operation Manual

Chapter I Safety Operating Rules

I Safety Operating Rules

Note This sign provides additional information on procedures

involving little or no risk of injury to personnel or equipment

damage.

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

personnel or equipment damage.

Warning This sign warns the user of procedures involving a definite

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

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

revise the safety working plan and guarantees all in involved working personal
knows about the maintenance term so that it could ensure all the working staff’s
safety and the devices are in a good condition.

1. Every time before the maintenance, it needs the safety analysis, guarantee all the
power switch is on the “switch off” status. When lubricating, checking or replacing
the system, it should cut off the power supply.
2. During the maintenance and repair period, the operator must be equipped with
suitable protective equipment, such as glove, helmet.
3. When the system is running, it not allowed to maintenance and repair.
4. Before repairing the hydraulic system, should release the pressure in the
accumulator.
5. Check the hydraulic oil leaks by hand is forbidden, hydraulic oil leaked from the
hole is almost invisible in the high pressure. Hydraulic oil is not only high
temperature but also it could penetrate the skin and cause injury, use wood,

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inspecting should be carried out by bamboo and other hard-board, and wear
protecting appliance.
6. Don’t try to repair the part which you aren’t familiar with.
7. Before repairing the top drive drilling system, please read the related manual
carefully.

8、Inspect the motor, the inner power station and pipes are not omit.

9、The legs of Motor torque arms could not be covered, clear it regularly.

10、The motor cover and other metal connect parts forbids welding work.

Fill oil into the special oil port in power station, and the discharged oil is not
allowed to re-use.

12、Fill oil by the special oil refill cart, do not mix the different brand oils, replace the
filter element in the cart.

13、All the oil in system should be same brand, same type.

14、Clean the radiator panel of water cooler and air cooler regularly.

15、Inspect the blocks and wires in electric system regularly.

16、Record the maintenance, repairing information detail.

Chapter II Daily Inspection

In order guarantee the top drive running smoothly, avoid the unforeseeable
accidents. It requires checking the top drive status and key parts in any time of daily
operation. We suggest that this inspection should carried out by the specialized
technical personnel everyday.

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I. First week daily inspection

a. oil omitting
b. Oil level in oil tank.
c. Working temperature
d. System pressure
e. System performance and general station
f. Abnormal noise.
g. Filter pollution indicator.

II. Daily check before equipment start

a. Oil omit
b. Oil level in oil tank.
c. Inlet valve and all the relief valves are open
d. Filter pollution indicator
e. Whether there is WARNNING or ALAEM on Spider screen. Check its information
and record, report to responsible people.
f. oil temperature.

III. Daily inspection

a. Whether it has abnormal vibration.
b. Whether it has abnormal noise.
c. Pipe oil omit
d. Oil level in oil tank.
e. Power station clearance, the top cover is blocked or not.
f. Work and oil refill pressure is stable or not.
g. Equipment running station
h. Hydraulic oil temperature and motor temperature
i. Drive system running
j. Spider screen display.
k. Air cooler and radiator clearance.

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Chapter III Maintenance Items and period

I Daily maintenance Items

1. Washing pipe

Oil point:
Glib 1 on the side of washing pipe
beneath stuffing box.
Lube method:
Feed grease into the glib by grease gun.
Inspecting Item:
Washing pipe omits.

2. Remote IBOP Control Structure

Oil Point
4 pieces of roller spindle glib on side.
Sleeve and switch gear joggled joint
Lube Method
Feed grease into the glib by grease gun.
Scribble grease on the joggled joint of sleeve and switch.

Inspect Item:
a. Whether the guide plate and wheel bolts loose, wear out or lost.
b. BOP pulley situation of lubricates and slanted and wear out.

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Centralizer Ring
3. Centralize Ring

Oil Point
Inside surface of Centralize Ring
Lube Method
Feed grease into the glib by grease gun.
Inspect Item
Inspect the wear out of centralize ring, change it regularly.

4. Hydraulic station
The inspect items includes：
a. Observe the level meter in oil tank, level should not be lower than the middle
line.
b. Observe the hydraulic oil temperature, it should not higher than 70℃.
c. Relief valve and ball valve position.
d. Observe the filter clearance indicator, find out its blocks.
e. Work pump working state: abnormal shaking, noise and heating.
f. Inspect the hydraulic pipe omit.
g. Inspect the hydraulic pipe surface station.

II Weekly Maintenance Items

1. Pin Roll of Lifting ring

Oil point:
2 points on pin roll of bail
Lubricate method
Feed grease into the glib by grease gun.
Inspect Item
a． Lubrication of bail pins.
b． Baffle of bail pin and screw.

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2. Guide beam and carriage.

Oil point
4 points on the bottom of tackle.
16 points on each side of tackle.

Lubricate method:
Feed grease into the glib by grease gun, 2
washes for each point.

Inspect Item
a．Inspect wheels working situation. No
Blocks.
b. Check the wearing situation of the
wheel,
replace it when necessary.
c. Inspect the fixed bolts on wheels
check whether the lock washer lock well.

3. Leaning Device

Inspect Item:
a. Wearing situation on bolts of link
leaning hydraulic tank.
b. The position and clamps of lock
collar clamp on link.
c. The lubrication and lock of joint bearing.
Lubricate Point:
Connecting pins of Joint bearings and rings.
Lubricate method:
Feed grease into the glib by grease gun
Lock collar
clamp of link

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4. Reactive torque inspection

Inspect Item:
a. Inspect fixture of bolt.
b. Inspect the drift of reactive torque. It is necessary to adjust the reactive torque if
it drifts away more than 3mm.

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.

Remote IBOP
Manual IBOP

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6. Loosen proof Device

Inspect Items:
a． Bolt fixture.
b． Safety lock rope.
Installation of anti-loosing device
a. Cover molybdenum lubricating grease below bolt head
on the surface of locking bolt.
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 pairs of anti-loosing device on the joint.
e. Put the tong dies on the center of connection.
f. Fasten bolts by torque wrench, till the torque to
350 N·m.
g. Fix all bolts by steel wire.
Hanging Lug

III Monthly Maintenance Item

Fixed Pin
1. Drape hanger of crane, U ring and fixed pin

Inspect Items: U Ring

a. Inspect the welding point and welding line.
b. Inspect the safety pins of Connect Pin
fixed pins and connect pin of U rin

2. Gooseneck

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

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3. Main motor and air cooling motor

Inspect Item
a. Inspect the damage on the outlet cable of motor.
b. Inspect the damage and loose of the bolts and lock line.
c. Inspect damages on uptake blind and filters.
d. Whether the debris attach to Heat exchanger.

Maintenance Item:
a. Clean the heat exchanger regularly.

4. Back-up Tong

Inspect Item:
a. Check the abrasion of tong teeth.
b. Inspect the looseness of bolts on tong teeth seat.
c. Check trumpet fixed bolts, wear ring bolts and fixed pins
and other fasteners whether there is loose and damages,
the reliability of locking.

Maintenance Item:

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), Fixed
4 oil seals in the Left side fixed pin. pin

e. While changing tong key, replace the 4 at the

same time to ensure geometry and mechanical strength
same.

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5. Accumulator

The accumulator of counterbalance cylinder is a pressure container of pre-filled

nitrogen, its main function is to assist the hydraulic source to supply amount of
pressure oil to meet the system speed and pressure request.

1) Inspect the nitrogen pressure

Inspect Period: every month or every well, the shorter one.
(1) Omit:
Use the filling tool to increase the nitrogen pressure.
(2) If the device is not used for long time, close the stop valve between oil inlet
and pressure oil pipe, keep the oil pressure in accumulator is higher than the air
pressure.
2) Nitrogen filling
The filling tool is equipped with this machine, if choose other tools, make sure the
connection with air valve and nitrogen source is safe. The nitrogen source is closed
before filling, connect the air pipe with the nitrogen bottle.

Fill with Nitrogen, etc noble gas only.

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.

2．Motor insulation inspection.

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3．Hydraulic station maintenance requires:
a. Clarify the oil clearance level by the sample from oil tank.
b. Inspect the pressure gauge.
c. Inspect the pressure in accumulator.
d. Inspect the heat exchanging capacity of air cooler, the oil temperature at inlet
should be higher than the outlet’s.
e. Inspect and clean the air filter.
f. Inspect the rubber connector.

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.

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
abrasion exceeds 2mm, lower the bearing weight, replace it when exceeds 3mm.
Detect the wear-out of guide rail clasp.
3. Detect the wear-out of bail and the lift lug of rotate head.
4. Inspect the washing pump and auxiliary pump, adjust it according to the result.
5. Inspect the pressure of washing pump, if the pressure is not fit, find out the
reason, replace it when necessary.
7. Hydraulic station inspect
a. Examine the oil sample, replace and change the oil when necessary, the pipes
wash for 24 hrs.
b. Re-adjust the system.

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c. Replace the relative elements and parts.
d. Inspect the electric wire, communication, interlock etc.
e. Inspect the hydraulic cylinder sealing, replace the seal ring when necessary.
f. Clarify the oil clearance level by the sample from oil tank.

Hydraulic station and system maintenance notice:

a. When the hydraulic station is failed, analyze and decide its position and
reason.
b. When disassemble the error elements, check the media connection between
elements and high pressure oil loop. Check the elements has pressure or not,
if yes, discharge the pressure before disassemble it.
c. Plug the oil let of hydraulic system by clean plugs when repairing, avoid the
dust get into the system.
d. Replace the elements when worn or old.

8. Hydraulic pipe maintenance

Check the hose and connector, stop the system when whichever the following
happens

a. connector slides on the hose.

b. The cover is damaged, scratched or wear out.
c. Hose is hardened, heated or carbon.
d. The connector is burst, damaged or rusty.
e. The connector or hose omits.
f. The hose is squeezed or twisted
g. The cover is foamed, soft, rusty or scached.

9. The steel rope of guide beam

Inspect Item:
Inspect the steel rope at the guide beam connections whether damaged or squeeze
out when the guide beam is folding. If the diameter of steel rope reduced 30%, it
must be tested again to confirm whether it needs to change a new rope.

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Maintenance:
Grease the steel rope at the guide beam connections when it’s folding.

VII. The maintenance of diesel motor refers to Series-C motor

operation and maintenance.

VIII. Please contact with technical dept of Jinghong for further

maintenance and repairing.

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Appendix I Recommend inspection

Inspect Items Period

Gear box oil level Day

Hydraulic accumulator oil level Day

Loose equipment and parts Day

Washing pipe omit Day

Pipe omits Day

Lock wire Day

Guide beam connections Week

Link ring diameter Month

Main shaft redial move 3 months

Accumulator station 3 months

Pump connect components wear 12 months

Goose neck inner surface wear 6 months

BOP wearing Whenever stops

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Appendix II Recommend lubrication

Lubricate item Point Cycle Name

Lubricate washing pipe
1 Day Usual Grease
assembly
Lubricate IBOP executive Usual Grease
4 Day
wheel
Lubricate slid beam centralize Usual Grease
4 week
wheel
Lubricate slid beam guide Usual Grease
12 week
wheel
Lubricate IBOP ball valve 1 week Usual Grease

Lubricate backup tong arm week Usual Grease

Replace the gear oil and

3 months Gear oil
analyze the oil sample
Replace the gear box oil filter 3 months
3 months or
Analyze the oil sample of
according to the Hydraulic oil
hydraulic system
analyze result

Replace the hydraulic system 3 months or

filter according to the
filter indicator

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Appendix III Torque value of thread hastening

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

Appendix IV Recommendation of Greases selects

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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