Training foraj

TRAINING MR8000 Drilling rig semitrailer mounted

Drillmec SpA Drilling Technologies 12, Via 1° Maggio I-29027 Gariga di Podenzano PIACENZA (Italy)

!

Corporate web site: http://www.drillmec.com Mailbox: [email protected] Ph +39.0523.354211 Fx +39.0523.524418

CAREFULLY READ THIS MANUAL BEFORE OPERATING THE MACHINE

1

DRILLING RIG MR 8000

2

IDENTIFICATION Piacenza - ITALY

This equipment is identified through the serial number and/ or the identification numbers on main components. Machine type

EQUIPMENT IDENTIFICATION PLATE

Serial Number Year of manufacturing

The equipment identification plate shown in the picture reports all identification data for the machine. The label is located on the lefthand side of the equipment, on the mast support. Always check that the equipment part number (N°. MATR.) stamped on the plate matches with that reported on the front cover of this manual.

3

Nominal Power Weight

[Kw] [Kg]

0953-3682E

NOMENCLATURE OF THE MAIN COMPONENTS

CROWN BLOCK

TELESCOPIC SECTION MAST

FIXED SECTION MAST

MONKEY BOARD

TRAVELLING BLOCK

POWER TONG

DRAWWORKS

OIL TANK

SERVICE WINCH

DIESEL ENGINE SUBSTRUCTURE

SEMITRAILER

DRAWWORKS COMPOUND

POWER TONG DRILL FLOOR

STAIR

ROTARY TABLE

DIESEL ENGINE

DRILL PIPE RAMP AND STAIR

SERVICE WINCH

TRANSMISSION WALKWAYS

HYDRAULIC BRAKE

4

SUBSTRUCTURE

TECHNICAL SPECIFICATION Semitrailer mounted mobile rotary drilling rig DRILLMEC MR 8000 model, suitable for -20°C to +40°C range temperature. The rig is manufactured in accordance with API standards.

MAST Technical Data (Ratings to API 4F) Static Hook load (w/10 lines) Clear height Clear height to rotary beams Racking Board Elevation Crown Block Sheaves

Hydraulic Catheads Break-out Hydraulic Catheads Spinning

: 200 metric tons (440,000 lbs) : 35.97 m (118 ft) from ground level : 4.17 m ( 15.11/16 ft) from ground level : 16.76 m (55 ft) from drill floor level : four cluster sheaves OD 36” grooved for 1.1/8” cable; one fast line sheaves OD 36” grooved for 1.1/8” cable; one deal line sheaves OD 20” grooved for 1.1/8” cable; : max pull 12,000 kilos (26,400 lbs)/ stroke 1.3 m : max pull 6,000 kilos (13,200 lbs)/ stroke 4.6 m

Racking board capacity

: 2850 m

5” OD - 6.5/8” TJ OD

DRAWWORKS

Main Drum: - Diam. x Lenght: 26” x 42.1/2” - Spooling Capacity: 700 m (2,300 ft) of 1.1/8” OD wire line - 42 VC 650 Fawick air clutch - Brake diameter x lenght 1168.4x203.2 mm (46” x 8”) - Raising speeds: 5 forward, 1backward - Parmac hydraulic brake V80

Chains: - Main drum chain: 1 3/4” double ASA The drawworks is complete with water cooling system and PARMAC V80 hydromatic brake composed as follows:

DIESEL ENGINE AND TRANSMISSION -

2 diesel engine CAT C15 Output power: 402kW (540 Hp) at 2,100 rpm Pneumatic starter Automatic Allison transmission S 5610 H model Compound: 2 chain transmissions ASA, oil lubrication. Heavy duty right angle gear box 2 pumps for hydraulic system 2 air compressors with T30 IR ( max displacement 710 l/min) Pneumatically operated inertia brake

5

SUBSTRUCTURE -

Max. Rotary Table Load (Casing Capacity) Max. Setback Capacity Simultaneous Capacity Drill Floor Height

: 200 metric tons (440,000 lbs) : 113 metric ton (250,000 lbs) : 313 metric tons (690,000 lbs) : 5,180 mt (17 ft)

Two steel skids are placed below the semi-trailer body levelling jacks and are part of the substructure auxillary equipment. A remarkable feature of the proposed substructure is the length of the base skids that is 40’ (12 m) approximately. The mast front guylines together with those of the monkey board are fixed at the end of each skid avoiding the need of several external anchors driven into the ground. Two anchors only placed at the rear of the semi-trailer. Hydraulic winch mounted on drill floor with max pull load 3000 kg ( 2943 daN) SEMITRAILER -

Four hydraulic levelling jacks with an additional mechanical safety locking device. Lighting and road signs according to international standards. Folding walkways with handrails. Ladders. N. 2 skids to be placed under the hydraulic levelling jacks. Single tyres. 2” and 3.1/2” king pin One spare tyre

ROTARY TABLE -

27.1/2” opening Complete with master bushing, adapter plate, bit breaker and lifting slings safety pads “anti-slipping” type Max speed: 300 rpm Max static hook load on table: 770000 lbs (320 metric ton) Rotary clutch: 20 CB 500

AUXILIARY HYDROMATIC BRAKE -

Parmac V80 Max pressure: Max speed: Brake capacity: Volume: Hydromatic brake air clutch:

15psi 1550 rpm 5000 Hp 13-1/2 gal 26 CB 525

TRAVELLING BLOCK - HOOK -

Load capacity: Sheave: Grooved for drill line OD:

500,000 lbs (250 metric ton) five 30” (76.2 cm) 1.1/8 “

HYDRAULIC POWER TONGS One (1) Hydraulic Power Tongs DRILLMEC, operated from a panel , to make-up and break-out drill pipes and drill collars up 9.1/2”, consisting of: - Double hydraulics clamps. Top one rotating with max torque: 101,000 lb-ft (14,000 kg-m).

6

-

Set of hydraulic cylinders for swinging the power tongs in/out from well center to parking position.

LIGHTING SYSTEM TOP OF THE MAST: Q.ty Description Type Supplyer

1 EExd Obstruction Red Light with XenoFlash 230V-60Hz EVX4070 XF2J1FE110A3 Cortem Sirena

MONKEY BOARD: Q.ty Description Type Supplyer

1 EExd Floodlight 230V-60Hz 400W with Metal Jodure Lamp 400W FLSA40 ITALSMEA

MAST: Q.ty Description Type Supplyer

6 EExd Floodlight whit Energy Saver Lamp 230V - 60Hz 23W (130Watt) EVGC 3070 Plet-23 Cortem

DRILLING FLOOR & SUBSTRUCTURE Q.ty Description Type Supplyer


TRAILER: Q.ty Description Type Supplyer


7

2950 (9'-8")

8 4170

5182 (17')

500

12000 (40')

1570

3030

7000 (23')

TORNELLO MANOVRA

TORNELLO SERVIZIO

4616 (15')

890

440

1033

5233 (17')

35966 (118')

16764 (55')

30785 (101')

MAIN DIMENSIONS

WORKING CONFIGURATION

1825

20500 (67'-3") 2020

9 4860 3406

5951 1375

KG 25000

8670

7000

21075

2500

KG 73000

KG 12000

1360

KG 12000

1360

KG 12000

1360

KG 12000

2374 15°

TRANSPORT CONFIGURATION

MAST GUYLINE LAYOUT

WIRE ROPE 22 mm

10

A-3.4.4 HOIST WIRE ROPE REEVING DIAGRAM

11

A-3.4.5 POWER FLOW DIAGRAM

11

7

7

1

11

1

8

8 12

2

4 3

13

5

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Code 0190 6758 0190 6760 0190 6761 0190 6762 0190 6764 0190 6765 0190 6767 0190 6768 0190 6766 0190 7950 4059 0116 4059 0126 4100 1122

Q.ty 2 1 1 1 1 1 2 2 1 1 2 1 1

Description CHAIN 1.1/4" 100-3 ASA 78 LINKS CHAIN 1.1/4" 100-4 ASA 86 LINKS CHAIN 1.3/4" 140-2 ASA 158 LINKS CHAIN 1.3/4" 140-2 ASA 86 LINKS CHAIN 1.3/4" 140-2 ASA 108 LINKS CHAIN 2" 160-1 ASA 114 LINKS CHAIN 3/4" 60-2 ASA 84 LINKS CHAIN 5/8" 50-1 ASA 68 LINKS CHAIN 2" 160-1 ASA 120 LINKS CHAIN 2" 160-1 ASA 122 LINKS CARDAN JOINT CARDAN JOINT ROPE D.28.57 (1.1/8")

12

9

6

10

118

10 440 000 83 61 6,627

13

440 000 250 000 690 000

14

18500

15

SAFETY DEVICES Both the complete machine, and its individual parts, are fitted with built-in safety devices. -

All cylinders are equipped with check valves. In case of breaking of connecting pipes or pressure drop or failure, the cylinders will be locked thus preventing any unwanted movements.

The machine is fitted with the following buttons for emergency stop and mechanical locking devices:

Q1

WARNING In case of engine stop for a long time, it is mandatory to switch off the batteries Q1 and Q2.

Q2

-

C20 emergency on the main control panel stops drilling rig operation.

-

Engine start up, and therefore machine operation, can only be performed by pressing start button on diesel engine control board and battery breaker is on.

-

Emergency control board near diesel engine stops only diesel engine.

C20

Emergency

Emergency

16

-

C29 and C30 emergency is located on draw work and stops drilling rig operation.

C29

C30

Safety mechanical block stabilizer (Fig. B-3.7). -

The drilling rig is equipped with a limit switch for proper operation.

-

The machine is also equipped with protective panels and fixed guards (fitted with the following plate: “Safety device - Do not remove”) in order to avoid coming into contact with drive gears in motion or hot hydraulic components.

HAZARD Before operating the machine, verify all safety devices are present and properly working.

17

DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP

C20

C29 C30

Q2

Q1

Emergency

18

CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (LEFT HAND FROM FLYWHEEL SIDE) RPM

Diesel engine hour-counter and RPM indicator

RPM

ES TE RSS

Emergency push button Diesel engine hour counter Start - Stop switch RSS

ES

TE

DEE

Diesel engine engage

DEE

Q1

Battery breaker

Q1

19

R2

Throttle knob on control panel

R2

Fig. C-1.5 R3

Throttle pedal on drill floor

R3

Fig. C-1.6

20

CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (RIGHT HAND FROM FLYWHEEL SIDE) TE ES RPM RSS

Diesel engine hour-counter Emergency push button RPM Indicator Start - Stop switch

TE

RSS RPM

DEE

Diesel engine engage

DEE

Q2

Battery breaker Q2

R2

Throttle knob on control panel

R2

21

ES

POSITIONING CONTROLS

C25

A10

C18

A10 C18 C19 C20 C21 C22 C23 C24 C25

C19

Stabilizers oil pressure gauge L.H. Rear stabilizer remote control R.H. Rear stabilizer remote control L.H. Front stabilizer remote control R.H. Front stabilizer remote control Mast raising cylinder remote control Mast telescopic remote control Telescopic locking remote control Stabilizers distributor shut-off ball valve

22

C20

C21

C22

C23

C24

DRILLING CONTROLS AND INSTRUMENTS A4 A6 A7 A8 A9 A11 C14 C15 C16 C17 C18 C20 C21 C27 C28 C29 HW1 HW2 R2 R6

Compressed air gauge Main drum compressed air gauge Drum brake cooling water pressure Drawworks lubricating oil pressure Lubricating oil pressure gauge for transmission compound Cathead spinning pressure gauge Main drum clutch control Crown - O - matic control Speed selector engine Pneumatic system feeding Rotary table clutch Emergency stop Hydromatic brake control Auxiliary equipment remote control Spinning cathead control Break-out cathead control Engine warning lamp Engine warning lamp Throttle knob Torque regulator spinning cathead

C16

C15

A4

C20

A9

A8

A7

A6

A11 R6

C21

HW1 HW2

R2

C27

C17

C18

C28

23

C29

C14

C31

R3

A23 A17

A19 A18 A20 A24 A22 A21

A17 A18 A19 A20 A21 A22 A23 A24 C31 R3

Weight indicator RPM Rotary table SPM Mud pump 1 SPM Mud pump 2 Torque Rotary table Mud pressure Digital pump stroke counter and totalizer Tong line pull Main drum brake lever on drill floor Throttle pedal

24

DEVICE INSTALLED IN OTHER LOCATIONS A26

Draw works lubricating oil pressure manometer

A26

Fig. C-1.16 A25

Transmision lubricating oil pressure manometer

A25

Fig. C-1.17 A24

Visual level oil tank transmission

A24

Fig. C-1.18 C29

Emergency lever on L.S. draw works

C29

Fig. C-1.19

25

C30

Emergency lever on R.S. draw works

C30

Fig. C-1.20 A12 A13

Hydraulic oil temperature meter Visual level on oil tank

A12

A13

Fig. C-1.21 A28 C31

Visual level oil tank Main drum brake lever

A28

Fig. C-1.22

C31 Fig. C-1.23

26

FUEL LEVEL PILOT ALARM

C27 C28

Ball-Valve hydraulic pump suction Ball-Valve hydraulic pump suction C27

C28

C30

Service winch control on drill floor C30

27

C26

Service winch control on monkey board.

SERVICE WINCH ON MONKEY BOARD

C26

Mud system instrumentation is mounted inside dog house, for information of this system you can see commercial documents.

28

DIESEL ENGINE STARTING (POWER PACK) C-2.1.1 COLD STARTING

C24

1) Check, that valve C24, C47 and C48 is open. 2) Switch on key C17. 3) With machine already in working configuration, bring throttle control R2 (drill floor control panel) to minimum rpm. 4) Rotate clockwise start key RSS. This way the motor starts the diesel engine as soon as this is started, release the push-button. 5) Few minutes of operation at minimum load are sufficient to reach engine working temperature.

C48 C47

IMPORTANT The first machine positioning does not require pressing the throttle. Movements are performed at minimum rpm.

R2 C17

IMPORTANT Max. engine rotation is set at 2100 rpm (± 50 rpm). When giving full power, always remenber to check rpm counter and make sure that max. rpm are never exceeded. (RPM) RSS

RSS

RPM

29

DIESEL ENGINE STOPPING (POWER PACK) The correct diesel engine turn-off procedure is as follows. 1. Bring engine rotation speed to minimum, with no load, for approx. two minutes to stabilize the temperature. 2. Stop the engine by switch RSS key. TE RSS RPM Q1/Q2

Q1

Diesel engine hour-counter Starting button on diesel engine RPM indicator Battery breaker

Fig. C-2.5

OPERATING INSTRUCTIONS PRELIMINARY CHECKS 1. Before starting work, make sure you have performed all necessary checks and servicing operations as required by the hours worked by the machine. Q2 IMPORTANT For the complete machine, refer to hour-counter TE Fig. C-2.6 2. It is recommended that you always refuel the hydraulic power pack diesel engine before starting the workshift. This will prevent the machine from forced stopping during operation.

RSS

RSS

Fig. C-2.7 TE

TE

RPM

Fig. C-3.1

30

PRELIMINARY OPERATIONS 1. Set the skids according to Fig. 2. Set skids 1-2 under the four hydraulic levelling jacks of the semitrailer.

RSS

3. Start the hydraulic oil circuit: • Start engine at Iow speed • Operate C25 ever on the hydraulic control panel in the installation posìtion. 4.

Lower the two front and rear jacks of semitrailer by means of distribution valves levers on the hydraulic control panel located in the rear left side of semitrailer.

5.

Apply the side walkways to the semitrailer.

RSS

C25 NOTE Before shipment, lubrication oil is drained from oil reservoirs (except for the one of the auxiliaires transmission oil circuit). C18

1

2

31

C19

C20

C21

5.

LEVELLING OF RIG 1. Make sure that handle of speed selector C19 on control panel is in neutral position. 2. Check that main air tank is full by means of the related gauge (A- 4). If it is not, fill it by an engine compressor or a hose connected to external compressor.

6.

7. 8.

3. Start engine at low speed

9. 10. 11.

4. Run engine at low speed until both the engine water, speed selector and converter oil reach the work temperature

12. 13.

5. By operating distributors levers on the hydraulic control panel properly level rig. To avoid frame twisting, simultaneously operate the two front handles and then the two rear handles. Semitrailer floor must be 1.650 mm. high from ground floor. 6. When rig is properly levelled, lock levelling jacks by means of safety ring nuts.

14. 15. 16.

IMPORTANT Hook may be loaded only after rig is mechanically locked by means of safety ring nuts. 7. Anchor to plinths the two tighteners fixed to the front sides of semitrailer.

SUBSTRUCTURE SETUP

INSTALLATION OF DRIVE CHAIN BETWEEN ROTARY TABLE COUNTERSHAFT AND ROTARY TABLE A) B)

NOTE: Substructure is made up of two main elements: the “rotary” part (skids, bearers, floors, etc...) and the “setback” part (part (skids, bearers, floors, etc...). “Rotary” skid , as well as “setback” rotary on the opposite driller’s side, can be either transported indipendently from the related elements, or connected to them. 1. Place the skid below the two rear jacks of the trailer. 2. Place the skid of rotary element driller side according the related drawing. In case of separate transportation, connect the skid of driller’s opposite side to rotary part by suitable supports. 3. Set the two side floors of rotary frame. 4. Hook a crane to the four ears of the rotary frame and lift it up to the working position.

32

Settle the four telescopic bearers at working height by means of safety pins. Place the setback element skid at driller’s side near the rotary skid. In case of separate transportation, connect the skid of driller’s opposite side to the setback element by means of suitable bearers. Hook a crane to the four ears of setback frame and raise it up to the working position Settle the four telescopic bearers to the working height by means of safety pins. Anchor the rotary working floor to setback floor. Pin the two rotary skids with the two setback skids. Connect the substructure rear skid with the two setback skids. Set the four braces of above drawing and pin them to substructure skids. To make substructure more stable set the six tighteners between working floor and front and rear skids of substructure. Lock tighteners at correct height by means of jam nuts. Install the B.O.P. trolley guides and fix them with pins. Install the B.O.P. trolley. By means of truck crane install pipe ramp and side ladders. Install working floor safety handrails.

Fix the two swinging chain housing as per drwg Spare Parts Catalogue. Mount chain and tension it through tighteners (Spare Parts Catalogue).

11

7

10

10

4

1

5

9

2-3

POS. CODE 1 2 3 4 5 6 7 8 9 10 11

01902240 01906175 01906177 01906178 01906180 01906181 01906182 01906191 01906258 01906312 01908104

Q.ty 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION DRIVE BAR STORAGE HOLE FIXTURE PROBE ANCHORS AND TRANSMISSION ASSY SIDE PLATFORMS ASSEMBLY B.O.P. SERVICE TROLLY SUBSTRUCTURE STAIRWAYS DRILL PIPE RAMP SUBSTRUCTURE FRAMES DOG HOUSE GROUP DRILLING PIPE SUPPORT FOOTBOARDS MAIN SKID FRAME DRILL FLOOR HANDRAILS ASSY

33

6

RAISING OF MAST 1. Make sure that no air is contained in the three stage raising jacks by: - unscrewing breather plugs located in the upper section of each stage of the jack; - operating the valve lever on the hydraulic control panel, gradually pour oil into the breathers until they are completely full; - screw the plugs. 2. Run engine at approximately 1200 RPM

Fig. C-3.6

34

3. By means of valve lever on the hydraulic control panel gradually raise mast in working position and lock it by means of lower pins. 4. Anchor fixed section guylines to tighteners of semitrailer and to the substructure skids.

TELESCOPING OF MAST UPPER SECTION 1. Make sure that no air is contained in the telescopic jack (Drwg. 0190 7331 - Spare Parts Manual) as per the instructions given in the Raising of mast” paragraph, point 2. 2. With engine at approximately 1200 R.P.M., operate valve lever on the hydraulic control panel and gradually telescope mast. During this operation, the oil pressure in the jack is about 180/200 bar. When telescoping of the mast upper section is completed, pressure is 210 bar (3000 P.S.I.) which is the triggering value for the operation of the safety valve on the hydraulic circuit. 3. By means of valve lever on the hydraulic control panel, lock the safety pins between the intermediate section and the upper section of mast. 4. By means of valve lever on the hydraulic control panel, slightly lower the telescopic section on the above safety pins. After that, pins are actually locked (drwg. No. 0190 4192 - Spare Parts Manual). 5. Monkey board takes position with auto system of folding,during mast raising ( Fig. C-3.7). After monkey board takes right position, pins of handrails must be inserted . 6. Anchor guylines lower ends to tighteners of trailer and substructure skids. Slightly tension tighteners (Spare Parts

35

Manual). See also the “API recommended guying patterns” table. NOTE Make sure that mast inclination angle is correct, by checking that the distance between well center and mast pin is 2020 mm. )

BREAKING - IN PERIOD A correct breaking-in period ensures a long working life to your rig. It is suggestable therefore not to require to the new rig to operate at the maximum power. a) ENGINE Follow the manufacturer’ s instructions.

36

16764 (55')

35966 (118')

30785 (101')

b) RIG After approximately the first 200 working hours: at the maximum power. - drain flush and refill the oil circuits with new oil - with reference to chain tension, make an adjustment to remove slacks caused by initial elongations.

1825

500

890

1570

440

1033

4170

5182 (17')

3030

2020 20500 (67'-3")

37

7000 (23')

12000 (40')

TORNELLO MANOVRA

TORNELLO SERVIZIO

4616 (15') 2950 (9'-8")

5233 (17')

RECOMMENDATION In order to prevent personal injury during the performance of any maintenance procedure, make sure that component to be overhauled is not working.

MAIN CONTROL PANEL OPERATING INSTRUCTIONS All air gauges, oil gauges and controls are mounted on main control panel, positioned on the drillfloor. Before starting drilling operations and at frequent intervals, while rig is in operation, check gauges and controls to ensure that the correct air and oil pressures are supplied to each point (see the related tables in the following pages). Operating instructions are indicated here below and are also illustrated on panel.

WARNING Never stop the engine abruptly when operating at full load (unless required for emergency conditions).

BRAKE LEVER

C15

1. Crown-o-matic push-button C15 ENGAGING The crown-o-matic is a safety device, wich automatically controls the tripping of the drilling travelling block, preventig it from clashing against the crown block. This system senses when the travelling block is within a preset distance of the crown block. It disengages the clutch, then simultaneously applies the brakes to the drawworks. DISENGAGING Push C15 button and simultaneously release the brake: the drilling travelling block comes down due to its own weight. In the meanwhile, the driller assistant must go near the drawworks and put the crown-o-matic toggle valve in its rest position. Item

1

3

2

TO CONTROL PANEL

5

Description Standard Crown Block Safety System

1

Track

2, 3

Short Toggle Valve Assembly (P/N 50640652)

4, 5, 7

Clutch Assembly

6

Air Cylinder Assembly

6

38

7

4

2. Speed selector engine control valve C16 3. Engine emergency shut-down-control valve C20 For drilling rig emergency stop, push the lever upward. This emergency lever stops also the mud pumps. To restart, pull the lever C20 downward. 4. Diesel engine throttle-control valve R2 Turning clockwise the control knob increases RPM of diesel engine. Turning ccw the control knob decreases RPM of diesel engine. 5. Spinning cathead torque regulator-control valve R6 6. Auxiliary winch-remote control C30 (hydraulic winch mounted on drill floor) 7. Auxiliary winch-remote control C26 (on monkey board)

8. Hydraulic brake clutch-control valve C21 The upward movement of this valve handle engages the hydraulic brake clutch The downward movement disengages the hydraulic brake clutch. 9. Rotary table fender sliding control valve C18 The upward movement of this valve handle the rotary table opening fender The downward movement the rotary table closing fender. 10. Hydraulic catheads-control valves C28 and C29 The upward movement of control valve C28 actuates the spinning cathead. The upward movement of control valve C29 actuates the break-out cathead. This handles automatically return to neutral position when released. Also the cylinders of catheads return automatically to full extended position. Turning clockwise the control knob increases torque of make-up cathead. Turning ccw the control knob decreases torque of makeup cathead.

C16

C 20

R2

R6

C21

C18 C29

39

11. Main drum clutch-control valve C14 The upward movement of this valve handle engages the main drum clutch. The downward movement disengages the main drum clutch.

12. Auxiliary equipment remote control valve C27 Auxiliary equipment (tongs or hydraulic motor, etc) are actuated by means of handle C27.

C27

C14

40

13. Main air pressure-gauge A4 This gauge indicates the air pressure in the control panel (7.7 bar steady-scale 0-16 bar)

16. Main drum clutch air pressure-gauge A6 low speed It indicates air pressure inside drum low speed clutch.

14. Drawworks oil pressure-gauge A8 It indicates lubricating oil pressure of drawworks. In working condition it shall be 0.7 bar-(scale 0-6 bar)

17. Spinning cathead oil pressure-gauge A11 It indicates the pressure inside spinning cathead cylinder. Pressure: 0-250 bar (scale 0-400 bar) Pulling force. Up to 6 Ton

15. Brake rim cooling water pressure-gauge A7 It indicates cooling water pressure of internal circuit. The water flow must be costant and its value is 189 lit/min (gauge scale 0-6 bar)

18. Lubricating oil pressure gauge for transmission compound A9 This gauge indicates lubricating oil pressure inside transmission compound

WARNING Be sure that no water leakage is falling on brake band. In case of failure, repair immediately.

A4

A9

A8

A7

41

A11

A6

POWER TONG CONTROLS Remote control panel A15 A16 C36 C37 C38 C39 C40

R10

A16

R11

A15

Power tong clamping force Torque power tong Lifting up-down Tilt open-close Torque make up-return Torque break out-return Lower clamp open-close

C36

C39

C38

C40

C37 Fig. C-4.7

POWER TONG POWER TONG ROTARY TABLE DRILL FLOOR

DRILL FLOOR

Fig. C-4.8

42

LUBRICATION SYSTEM Proper Iubrication is essential for the correct functioning and Iong working Iife af your rig. -

GREASING POINTS FREQUENCY TYPE OF GREASE

Greasing points are either Iocated on two centralized grease panels or on the single elements. Use- SHELL SUPER GREASE EP2 or equivalent

OIL LUBRICATION For oil Iubrication, refer to D - 1.4 and follow the instructions on the respective table regarding: - Components te be Iubricated - Frequency - Quantity and type of oil. - SAE regulations Chains and bearings of transmission, are oil pressure lubricated from two pump. Lubrication compound : pump Bosch cod.50700292 delivery= 45 l/min. Lubrication drawworks: pump Bosch cod.50700253 delivery= 63 l/min. Oil pressure is checked by gauge located on control panel. Oil pressure 0.4-1.75 bar. A filter unit is located on the discharge line of the pump Bosch. Clean carefully the filter cartidge before the complete congestion. CHECK AND MAINTAIN LUBRICATING SYSTEM AS FOLLOWS: 1) DAILY CHECK THE OIL LEVEL AS INDICATE IN THE TABLE 2) CHECK CONDITION OF DRIVE CHAINS, HOSES, DISCHARGE LINES, ETC. AND REPLACE WHEN NECESSARY. 3) KEEP OIL PRESSURE BETWEEN 0.4-1.75 BAR 4) DRAIN, FLUSH THE TANK AND CHANGE OIL AT THE END OF THE BREAKING - IN PERIOD. AFTERWARDS, CHANGE OIL EVERY 4000 WORKING HOURS OR MORE OFTEN, IF OIL BECOMES CONTAMINATED WITH ABRASIVE PARTICLES OR CORROSIVE COMPOUNDS.

43

CENTRALIZED GREASE PLATE ON DRAWWORKS (DRWG 01908094)

44

LINE No.

DESCRIPTION

1

PLATE

10

GREASE FITTING

11

SLEEVE COUPLING

12

ELL

13

SLEEVE

14

FLEXIBLE PIPE

15

NUT

45

D-1.3 GREASE LUBRICATION TABLE 6

8

15 7

2 1

3

14 18

13

16

10

9

11

12 18

5

4

17

46

FREQUENCY

N° IN Fig. D-1.2

DESCRIPTION

TYPE OF GREASE

EVERY DAY

1

DRAWWORKS: STUFFING BOX OF WATER SWIVEL JOINT

SHELL SUPER GREASE EP2

EVERY DAY

2

MAST: WIRELINE GUIDE ROLLERS OF HYDRAULIC CATHEADS


EVERY DAY

3

WIRELINE LAZY FULLEYS FOR HYDRAULIC CATHEADS


EVERY DAY

18

POWER TONG


EVERY 7 DAYS

4

DRAWWORKS: MAIN GREASING PLATE


EVERY 7 DAYS

5

BRAKE LEVER PINS


EVERY 7 DAYS

6

CROWN AND TRAVELLING BOX: BEARINGS AND JOINTS


HOOK: UPPER SEALS AND JOINTS


EVERY 7 DAYS

7

EVERY 7 DAYS

8

EVERY 30 DAYS

9

DRAWWORKS: IDLE GEARS

EVERY 30 DAYS

10

TRANSMISSION: UNIVERSAL SHAFT CROSS IDLE GEARS

EVERY 30 DAYS

11

MAST: ROPE ROLLERS ON THE INTERMEDIATE SECTION

ROTARY TABLE TRANSMISSION: UNIVERSAL SHAFT CROSS DRAWWORKS: WIRELINE GUIDE ROLLER OF DRAWWORKS

SHELL SUPER GREASE EP2 SHELL SUPER GREASE EP2



AT EVERY RAISING OR LOWERING OF MAST

12


13


14


15

SEE MANUFACTURER’S INSTRUCTIONS

16

ENGINE “CATERPILLAR”



17

PARMAC HYDRAULIC BRAKE

SEE MANUFACTURER’S INSTRUCTICNS

MAST: PINS;



RAISING JACK PINS; SHELL SUPER GREASE EP2 TELESCOPING SECTION LOCK SHELL SUPER GREASE EP2

47

OIL LUBRICATION

4

11

8

9

7

6

11

9

1

2

5

10

3

48

FR EQU EN C Y

N ° IN Fig. D -1.3

D ESC R IPTION

Q.TY LIT.

SAE ID .

S A E 30

OIL TYPE

EVERY D AY

1

D RAWWORKS: - TANK OIL LEVEL - OIL FILTER

250

SEE MANUFAC TURER'S INSTRUC TIONS

2

RIGHT ANGLE GEAR BOX

180

SHELL OMALA 100

EVERY D AY

3

ROTARY TABLE: OIL LE V E L

5

SHELL OMALA 220


4

TRIPLEX HOOK

5

SHELL TELLUS OIL ST46


5

AIR C OMPRESSORS

2.5+2.5

SEASON C PN 89237903 INGERSOLL RAND

EVERY D AY

6

HYD RAULIC C IRC UIT: - TANK OIL LEVEL - OIL FILTER


7

D IESEL ENGINE

50+50

SHELL RIMULA X15W40


8

ENGINE RAD IATOR

95+95

SHELL ANTIFREEZE


9

ALLISON GEAR BOX WITH TORQUE C ONVERTER

80+80

SHELL ATF D EXRON III


10

MAIN D RUM BRAKING SYSTEM

75

SHELL C ASSID A FLUID HF 32 (MOBIL SHC 524)


11

C OMPOUND

180

SHELL OMALA 100

49

SHELL OMALA 100

SHELL TELLUS OIL ST46

AIR CLUTCHES The clutches, highly reliable in any working conditions (illustrated in section “other manufacturer’s equipment” of this manual). Regarding clutch maintenance, it is recommended to: a) provide the proper air pressure to each ctutch - see the air pressure table b) see table - models of clutches - minimum allowable lining thickness When inspecting clutches check: 1) Condition of linings. Lining wear Is automatically balanced to a certain extent by a rubber diaphragm. Check Iining wear at least once a month. 2) Condition of clutch drum. The clutch drum surface should always be smooth. If it is badly warped or grooved, it should be remachined. 3) Operation of quick release valves. Check all quick release valve at Ieast once a month.The most common cause of quick release valve failure is dirt, rust or machine cuttings stuck under the seat. Due to improper valve operations, the clutch may disengage incompletely and therefore cause overheating and damage to the diaphragm. Overheating may also be due to clutch dragging.

50

AIR PRESSURE NOMINAL PRESSURE

DESCRIPTION

PSI

b ar

DRAWWORKS CLUTCH

127

8,8

CONTROL PANEL GENERAL FEEDING PRESSURE GAUGE A10

110

7,59

EMERGENCY

125

8,62

ROTARY TABLE CLUTCH

111

7,7

HYDRAULIC BRAKE CLUTCH

111

7,7

51

OIL AND WATER PRESSURE OIL PR ESSU R E C OMPON EN T

D RAWWORK AND TRANSMISSION

C APAC ITY L.

LE V E L IN D IC ATOR

250

D IPSTIC K

PLAC E OF C ON TR OL

C ONTROL PANEL

PR ESSU R E (K g/cm²) MAX

N OM.

MIN .

25 (1,76)

10 (0,70)

5 (0,35)

WATER PR ESSU R E ELEMEN T

POSITION

PLAC E OF C ON TR OL

C APAC ITY l/min

PR ESSU R E PSI (bar)

IN LET

OU TLET

MAIN D RUM BRAKE

D RILLER'S SID E

C ONTROL PANEL

189

50-75 (3,5-5,2)

1.1/4" gas

1.1/4" gas

SAND REEL BRAKE

D RILLER'S SID E

C ONTROL PANEL

120

50-75 (3,5-5,2)

1/2" gas

1/2" gas

HYD RAULIC BRAKE

D RILLER'S SID E

C ONTROL PANEL

200

50-75 (3,5-5,2)

3"NPT

2"NPT

WAR N IN G: U SE C OLD WATER IN B R AK E SYSTEM

DRILLING DRUM BRAKES SHOULD A REDUCTION IN THE BRAKING CAPACITY OCCUR, CHECK FOR: 1. Improper band brake adjustment. 2. Water, oil or other rig wash solutions sprayed on and around the brake rims, reducing the coefficient of friction of the linings.

IN CASE OF KICKING BRAKES, CHECK FOR: 1. 2. 3.

Improper release of brake bands. Kinked or out-of-round brake bands. Brake system adjustment.

GENERAL RECOMMENDATIONS The following precautions should be taken in connection with proper brake maintenance. a. Do not paint brake blocks or inside of brake bands (paint retards heat transfer between blocks and band). b. Do not pull brake blocks bolts too tight or allow them to Ioosen. c. Do not Ieave brake blocks or relined bands out in weather. d. Do not install new brake blocks without cleaning brake bands of rust, etc. e. Check the brake rims at regular interval of time. The maximum allowed wear on the rims is equal to 12 mm. f. In case of maximum wear of rims, it must change the nms. g. The main brake drum is water cooled by means of an internal circuit. Water circulation flow is equal to 189 Lit/min. Check every six month the good state of fittings and piping of water circuit. Always use original spare parts. h. Check the brake system at Ieast once a month. i. Check the main handles once a year with Magnaflux (N.D.T.)

52

BRAKE WEAR

WATER COOLING CIRCULATION

53

DRIVE ROLLER CHAINS (DRWG. N° 0190 7387) Make sure that roller chains are always well Iubricated. As oil cleanliness is an essential factor in chain Iubrication, accurately clean every chain before mounting it, to reduce the amount of foreign contaminants in the oil. Clearance of chain links should never exceed 0,1 - 0,2 mm. Check clearance al Ieast once a month. When possible use a chain length with an even number of pitches to eliminate the need for an offset Iink. To obtain maximum chain life, maintain proper chain tension. Make an adjustment after approximately the first 200 hours of operation to remove slack caused by initiai elongation. Thereafter, the frequency of periodic adjustment Is governed by operating conditions. Sprocket center distance must be more than half the sum of the sprocket outside diameters to avoid tooth interference. A center distance equal lo the diameter of the large sprocket plus one-half the diameter of the small sprocket is the suggested maximum for average applications. Normally, horizontal and inclined drives should be installed with an initial sag equal to approximateiy 2% of sprocket center distance. Check gear tooth wearing once every six months (especiaily the pinion teeth). Clearance between tooth space and roller should not exceed 0,3 mm.

BREAKING-IN PERIOD A correct breaking-in period ensures a Iong working Iife to your rig. a) Engine follow the manufacturer’s instructions. b) Rig After approximately the first 200 working hours: - drain, flush and refill the oil circuits with new oil; - with reference to chain tension, make an adjustment to remove slacks caused by initial elongation.

ROUTINE MAINTENANCE Routine inspection of components is the most important form of preventive maintenance and with result in considerable saving by detecting any major trouble that might be developing and allowing the necessary repairs to be made on a planned or normal rig downtime. The following is a guide to some of the key points which should be observed during routine inspection. The prevailing operating conditions surrounding each individual rig wiIl dictate the frequency at which the inspections should be made; however, the intervals listed below are recommended for optimum performance from the equipment.

MECHANICAL PARTS - GREASING

IMPORTANT If clogged or damaged, replace grease nipples with new ones. (for fubricant specifications, see paragraph D 1.3).

54

11

7

7

1

11

1

8

8 12

2

4 3

13

5

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Code 0190 6758 0190 6760 0190 6761 0190 6762 0190 6764 0190 6765 0190 6767 0190 6768 0190 6766 0190 7950 4059 0116 4059 0126 4100 1122

Q.ty 2 1 1 1 1 1 2 2 1 1 2 1 1

Description CHAIN 1.1/4" 100-3 ASA 78 LINKS CHAIN 1.1/4" 100-4 ASA 86 LINKS CHAIN 1.3/4" 140-2 ASA 158 LINKS CHAIN 1.3/4" 140-2 ASA 86 LINKS CHAIN 1.3/4" 140-2 ASA 108 LINKS CHAIN 2" 160-1 ASA 114 LINKS CHAIN 3/4" 60-2 ASA 84 LINKS CHAIN 5/8" 50-1 ASA 68 LINKS CHAIN 2" 160-1 ASA 120 LINKS CHAIN 2" 160-1 ASA 122 LINKS CARDAN JOINT CARDAN JOINT ROPE D.28.57 (1.1/8")

55

9

6

10

D-6.2 ROUTINE MAINTENANCE PART

FREQUENCY

N° IN DWG

DESCRIPTION

TYPE OF LUBRICANT

MAST

EVERY 30 DAYS

8*

GREASE SUPPORTS, RETURN DEVICES AND CHAINS

SHELL SUPER GREAS EP2

AT EVERY RAISING AND LOWERING OF MAST

13*

GREASE PINS


14*

GREASE RAISING JACK PINS

7*

GREASE ALL BEARINGS

SHELL SUPER GREAS EP2 SHELL SUPER GREAS EP2

6*

GREASE ALL BEARINGS

CROWN AND TRAVELLING BLOCK

EVERY 7 DAYS


NOTE: THE POSITIONING OF THE CROWN AND TRAVELLING SHEAVES IN THE RIG SHOULD BE REVERSED WITH EACH RIGGING-UP OPERATION SO THAT THE PREVIOUS DEAD-LINE SHEAVE BECOMES THE FAST LINE SHEAVE. THIS DISTRIBUTES WEAR ON THE BEARINGS AND SHEAVES, BOTH OF WICH SHOULD BE REPLACED WHEN THEY BECOME WORN ROTARY TABLE

EVERY DAY

3**

CHECK THE OIL LEVEL. ANY RADICAL CHANGE IN OIL LEVEL OVER A SHORT TIME, SHOULD BE INVESTIGATED. THIS MAY BE THE RESULT OF LEAKING SEAL, WATER OR MUD ENTRY INTO THE ROTARY TABLE HOUSING, ETC. IN THE LATTER CASE, IT IS RECOMMENDED TO DRAIN HOUSING AND REFILL IT WITH FRESH, CLEAN OIL

SHELL OMALA 220

EVERY 7 DAYS

11*

GREASE UPPER AND LOWER GASKET


56

PAR T

FR EQU EN C Y

N ° IN D WG

D ESC R IPTION

TYPE OF LU B R IC AN T

TRANSMISSION

EVERY 30 D AYS

10*

GREASE UNIVERSAL JOINTS


D RAWWORKS

EVERY D AY

1**

C HEC K RESERVOIR OIL LEVEL

SHELL OMALA 100

EVERY 7 D AYS

4*

GREASE MAIN BEARING PLATE


EVERY 30 D AYS

9*

GREASE ID LE GEARS


EVERY 3 MONTHS

C OMPOUND

RIGHT ANGLE GEAR BOX

* **

1. C HEC K THE LUBRIC ATION SYSTEM (TANK, PIPES, GAUGES, ROTORSEALS, ETC .) TO ASSURE IT IS INTAC T AND FREE FROM D AMAGE OR OBSTRUC TIONS. 2. C HEC K THE AIR SYSTEM (VALVES, PIPES, JOINTS, AUGES, SC REENS, TANK, ETC .) 3. C HEC K THE BRAKING SYSTEM (LINING WEAR, ETC .) 4. C HEC K C LUTC HES (SEE THE "OTHER MANUFAC TURERS' EQUIPMENT" SEC TION OF SEPARATE MANUAL) 5. C HEC K C HAIN D RIVES (MISSING C OTTER PINS, BROKEN LINKS OR INAD EQUATE LUBRIC ATION OF ROLLERS, ETC . 6. C HEC K ALL BOLTS AND NUTS FOR PROPER TIGHTNESS. 7. C HEC K ALL GASKETS, RUBBERS AND SEALS.

EVERY 1000 HOURS

1**

OIL AND FILTER REPLAC EMENT

SHELL OMALA 100

EVERY D AY

11**


SHELL OMALA 100

EVERY 1000 HOURS

11**


EVERY D AY

2**


EVERY 1000 HOURS

2**


SHELL OMALA 100

Grease lubrication Oil lubrication

IMPORTANT The first lubricating oil replacement must be carried out after the first 400 working hours, then observe the indications supplied in the routine maintenance table.

57

HYDRAULIC SYSTEM - OIL LEVEL CHECK For hydraulic oil level check, set the machine to haulage configuration. This way, all jack are cIosed and the oil in the tanks is at its maximum level. The machine should also be perfectly Ieveled. Oil level should be closed to the maximum. lf occasionally (due to operating reasons) the machine cannot be set to the haulage configuration, the oil level must be checked by means of the oil level visual indicator. With machine in working canfiguration, oil level should never be lower than the indicator on the see-through glass. Top up if oil level is too low. (for hydraulic oil specifications, see paragraph D-1.4)

WARNING When topping up, do not exceed maximum oil level (with machine in haulage configuration)

HYDRAULIC SYSTEM - REPLACE OIL FILTER AND TANK AIR BLEEDING CARTRIDGES

IMPORTANT These components should be replaced at the time specified even if not required by the clogging checking devices.

A

Access to hydraulic oil filter (on return line) is from the tank top through screws A.

WARNING These operations should be performed in clean areas to avoid that any earth, dirty and impurities can enter in the tank and in the system.

IMPORTANT Once the component is replaced, check hydraulic oil level as described in item D-6.3.

58

HYDRAULIC SYSTEM - OIL CHANGE C For hydraulic oiI change (as for oil Ievel check), the machine should be set to haulage configuration. With this configuration, all jacks are closed and the oil in the tanks is at its maximum level. The machine should also be perfectly Ieveled. Oil Ievel should be closed to the maximum. A

To ease up drainage, oil should be warm. This with prevent residual sludge inside the tank. Then, proceed as follows: 1. Prepare a system for collection of the used oil to be connected to draining plugs A.

Fig. D-6.3

B IMPORTANT This tank contains apprax. 800 Iiters of hydraulic oil. 2. Close valves B cutting off the tank from the hydraulic system. 3. Undo plugs A and open the two bali valve C. To ease up oil outflow, also undo the bleeding cartridges on top of the tank. Let the oil drain.

B Fig. D-6.4

WARNING Do not disperse old oil in the environment as this causes pollution. 4. Close valves C and retighten plugs A. 5. FilI up through the return filter.

WARNING AIways remember that the hydraulic oil, even when new and delivered in drums, contains pollutants. When filIing oil up, use special pumps provided with flltering system. 6. Check that max. oil level is reached through level indicator D.

WARNING When fiIling up with oil, do not exceed max. oil level shown by indicator D. D

Fig. D-6.5

59

7. Refit and retighten two new air bleeding cartridges. (for hydrauIic oil specifications, see chapter D - 1.4)

WARNING These operations should be performed in clean areas to avoid that any earth, dirty and impurities can enter the hydraulic oil tank

ROPES - WEAR CHECK VisuaIly check hoisting and drilling wire rope, sand reel rope, wear conditions. In particutar, check what follows: - rope end connections - rope stretches going through pulleys or blocks during use - rope stretches that can be subject to friction or rubbing against external parts. Make sure that ropes do not show: - broken strands - dents - twists - permanent bends - signs of wear or deterioration that could impair safety. If any of these conditions are found, consider the measures to be taken with reference to the information contained in the standards ISO 4309. Always refer to ISO 4309 standards for all what concerns the ropes, their maintenance and replacement.

Fig. D-6.6

COMPLETE MACHINE - GENERAL INSPECTION Inspect the whole machine to make sure that it is in good working order. In particular, check the drilling fluid circulation system fittings, high pressure couplings and seals. Inspect the whole machine for Ieakage. Check good operation conditions and correct assembly and closing of protection hoods and guards.

HAZARD In case of malfunctioning and/or faults, promptly eliminate the problem and stop any works until the machine is in good order again

60

BOLT TIGHTENING SPECIFICATIONS

61

HOSE FITTING SPECIFICATIONS For best operation of the hydraulic system, always keep in mind some important rules for hose fitting. Hose fitting nuts shall be tighten until no leakage occurs through the coupling. Exceeding that point, does not improve tightness and damages the coupling!

A hose should never be subject to torsion! When fitting the hose, consider that during operation, the hose is subject to changes in length with consequent torsional effects. Therefore, hoses should not be too short and the proper settling should be checked with hose in resting position (see Fig. D-8.1).

If hoses routing requires the hose to bend, make sure that the bending radius are correct (see Fig. D-8.2 and D-8.3). A bending radius too small can cause restrictions in the section and therefore load losses. Moreover, these bends can cause torsional stress and even breakage of the hose!

For correct fitting of hoses , elbow fitting can be used for installation in restricted space without impairing hose efficiency and life (see Fig. D-8.3 and D-8.4).

62

63

Table Number

Functional group: Semitrailer group

Hydraulic power unit

1

01170400 - 1

1

01170400 - 1

Hydraulic power unit

Part Number

1 2 3 4 5 6 7 8 9 10

RI01170400-01 RI01170400-02 RI01170400-03 RI01170400-04 RI01170400-05 RI01170400-06 RI01170400-07 RI01170400-08 RI01170400-09 RI01170400-10

Quantity

1 1 1 1 1 1 1 1 1 1

(12-2006)

0

(12-2006)

Table Number


Position

Revision

0

Description

Notes

Electric pump Pump by hand Distributor Exclusion manometer Manometer Filter Tank Retaining valve Control panel Frame

-

64

Revision

Table Number


Hydraulic oil reservoir

1

01906232 - 1

1

01906232 - 1

Hydraulic oil reservoir

Part Number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

01906235 01908758 01908759 01908760 40690045 50310022 50310195 50510019 50520046 50530025 50540178 50540181 50590007 50590009 50630073 50630077 50630079 50630182 50971117 52030045 70351004 70351610 70661613 70911017 70911627

Quantity

2 1 1 2 2 2 4 2 2 2 2 2 2 2 4 8 2 2 2 2 40 8 8 40 8

(06-2007)

0

(06-2007)

Table Number


Position

Revision

0

Description

Notes

Description not available Tank Tank Gasket Thermometer Pn 10 1" 1/2 ball valve Valve Connector Cap Air breather Level indicator Level indicator Nipple Nipple A.f.l. connector 3" art.280 nipple A.f.l. connector A.f.l. connector Filter Washer Screw Screw Nut Elastic washer Elastic washer

-

65

Revision

Table Number

Functional group: Mast group

Monkey board handrails

2

01907330 - 1

2

01907330 - 1

Monkey board handrails

Part Number

1 2 3 4 5 6 7

01907649 01907915 01907916 01907917 40630123 71191616 71300018

Quantity

1 1 1 1 6 15 9

(06-2007)

0

(06-2007)

Table Number


Position

Revision

0

Description

Notes

Description not available Description not available Description not available Description not available Shear pin Pin Split pin

-

66

Revision

Table Number


Cylinder for extracting mast

2

01907331 - 1

2

01907331 - 1

Cylinder for extracting mast

Part Number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

01906950 01906951 01907931 01908883 50470576 51040304 52104075 70351614 70311624 70351612 70370824 70611618 70901648 70910814 71050812 71204009

Quantity

1 1 2 1 1 1 1 8 4 8 4 20 4 4 2 2

(06-2007)

0

(06-2007)

Table Number


Position

Revision

0

Description

Notes

Description not available Description not available Description not available Description not available Plate Hydraulic piston O-ring Screw Screw Screw Screw Self-locking nut Washer Elastic washer Split pin Pin

-

67

Revision

Table Number

Functional group: Substructure group

Machine base frame

3

01906312 - 1

3

01906312 - 1

Machine base frame

Part Number

1 2

01906896 01907096

(06-2007)

0

(06-2007)

Table Number

Functional group: Substructure group

Position

Revision

0

Quantity

Description

Notes

1 1

Front skid Skid

-

68

Revision

Table Number

Functional group: Draw works group

Swivel joint for water

4

01902248 - 1

4

01902248 - 1

Swivel joint for water

Part Number

1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19

01902619 01902620 01902621 01902622 01902623 01902624 40630186 01902625 52700471 52700470 52104081 01902626 70351010 70911017 61000006 50520037

Quantity

1 1 1 1 1 2 1 2 2 4 2 2 8 8 2 2

(06-2007)

0

(06-2007)

Table Number


Position

Revision

0

Description

Notes

Body Manifold Cover Flange Bushing Ring Spring Spacer Gasket Gasket O.ring packing Gasket Screw Elastic washer Lubricator Cap

-

69

Revision


Power input countershaft

Table Number

4

01907307 - 1

4

01907307 - 1

Power input countershaft

Position

Part Number

Quantity

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

01906521 01906522 01906524 01906526 01906527 01906528 01906529 01906530 01906531 01907427 01907428 019011621 61070142 70351609 70351610 70351614 70611618 71073236

1 1 1 1 2 2 1 2 2 1 1 1 2 12 20 24 24 2

(06-2007)

0

(06-2007)

Table Number


Description

Notes

Description not available Description not available Description not available Description not available Description not available Description not available Description not available Description not available Description not available Description not available Description not available Spacer Description not available Screw Screw Screw Self-locking nut Tang

-

70

Revision

0

Revision

Table Number


Installation of the travelling block limit switch

4

01906106 - 1

4

01906106 - 1

Installation of the travelling block limit switch

Part Number

1 3 4 8 10 11 12 13 14 15 16

01906517 01906518 01906519 50640721 50640546 50640723 70390062 70351205 70911221 50640722 50640652

Quantity

1 1 1 1 1 1 2 4 4 1 1

(06-2007)

0

(06-2007)

Table Number


Position

Revision

0

Description

Notes

Description not available Description not available Description not available Cylinder Hinge Description not available Screw Screw Elastic washer Fork Valve

-

71

Revision

DRILLING RIG HTD 250 TOP DRIVE

72

Operation and Maintenance Manual GENERAL INFORMATION Section

A-1

A

page

5

ORIENTATION

Front and rear sections of the equipment, as other parts of the equipment on side, shall be conventionally placed as shown in the following diagram (unless specified otherwise).

TOP

DRILLER SIDE

OFF DRILLER SIDE

DWWKS SIDE

BOTTOM

OFF DWWKS SIDE Fig. A1

73


A-2

A page 6

IDENTIFICATION

This equipment is identified through serial number and/or identification numbers on main components.

Piacenza - Italy

A - 2.1 EQUIPMENT IDENTIFICATION PLATE

Machine Type Serial Number Year of Manufacturing

The equipment identification plate shown in the picture provides all identification data for the machine. Always check that the equipment part number (N°. MATR.) stamped on the plate, matches with that reported on the front cover of this manual.

Nominal Power

[kw]

Weight

[kg]

Fig. A2 IMPORTANT Always specify the equipment technical code and part number (N° MATR.) when you require information or technical assistance.

A - 2.2 MANUFACTURER DRILLMEC Drilling Equipment Div. - 12 Via 1° Maggio - Località Gariga I-29027 Podenzano (PC) - ITALY Tel. +39 0523 354211 - Telefax +39 0523 524418;

A - 2.3 MODEL AND VERSION TOP DRIVE model:

with hydraulic power pack.

A - 2.4 OTHER IDENTIFICATION PLATES The plates for all major mechanical, hydraulic and electrical components which are not manufactured by DRILLMEC (pumps, motors, etc.) are fitted on the components themselves, in the locations assigned by the manufacturers.

74


A

page

7

SPECIFICATION 8C L.E. (EDITION 4) AUTH. 8C-0041 PSL1

POWER SWIVEL MODEL SERIAL NUMBER MANUFACTURED CUSTOMER

MAXIMUM STATIC LOAD CAPACITY

MT

MAXIMUM DYNAMIC LOAD CAPACITY AT 100 RPM

MT

MAXIMUM WORKING PRESSURE

BAR

0953-3720E

09533652E

26000 ftlb 1° SPEED 22125

TOP DRIVE 19030 ftlb

TORQUE ftlb

14750

2° SPEED

14235 ftlb

10400 ftlb

50

100

200 RPM

146 RPM

80 RPM

109 RPM

7375

150

200

RPM

Fig. A3

75


A page 8

TORQUE WRENCH 4990 4275 3560 2850

PRESSURE - PSI

2140 1425

7375

22130 14750

36880 29500

51800

81130

44250

MAKE-UP

BREAK-OUT

ftlb TORQUE

09533658E

Fig. A4

76


A-3

A

page

9

MAJOR COMPONENT DESCRIPTION - TOP DRIVE

The following section describes the

component parts, and defines terms used throughout this service manual.

NOTE: 1 - LINKS 2 - GOOSNECK 3 - HYDRAULIC MOTOR 4 - DOLLY 5 - GEAR BOX 6 - PIPEHANDLER ROTATION GEAR 7 - DUPLEX HOOK 8 - LINK TILT CYLINDER 9 - I.B.O.P. ACTUATOR 10 - ELEVATOR 11 - ELEVATOR LINKS 12 - TORQUE WRENCH 13 - WEIGHT COMPENSATOR SYSTEM 14 - WASHPIPE 15 - GUIDE

1 2 14 4 3

13

5

7 6 8 15 9

12

11 10 Fig. A5

77


A page 10

DRILLING MODE

ROTARY DRILLING HOOK TOP DRIVE SUSPENDING LINKS WASH PIPE PACKING ASS.Y

GOOSE NECK

TRIPPING MODE

A - 3.1 HTD 200 LOAD PATH

BONNET

MAIN SHAFT LOAD SHOULDER

LINK PIN

SWIVEL THRUST BEARING TRANSMISSION BODY DOUBLE HOOK

MAIN SHAFT (DRILL SYSTEM)

DOUBLE HOOK LOAD SHOULDER ELEVATOR LINKS COUNTERBALANCE SYSTEM

DRILLING MODE

TRIPPING MODE

TRIPPING MODE DRILLING MODE

LOAD PATH

Fig. A6

78


A

page

11

A - 3.2 HYDRAULIC MOTORS The uses four (4) HYDRAULIC MOTORS mounted vertically side by side on top and on bottom of the main body to power the The ports of the motors are connected each other with a rigid pipe and finally connected to an interface block with quick couplings.

HYDRAULIC MOTORS

MAIN BODY

HYDRAULIC MOTORS

Fig. A7

79


A page 12

Two hydraulic caliper disc brakes, mounted between each top hydraulic motor and the main body, hold torque in the drill string and assist in positioning during directional work. An electrical solenoid valve remotely operates the hydraulic caliper disc brakes.

BRAKE DISC

HYDRAULIC CALIPER

Fig. A8

80


A

page

13

A - 3.3 TRANSMISSION, MOTOR HOUSING (MAIN BODY) AND SWIVEL ASSEMBLY The transmission, motor housing and swivel assembly transfers the power produced by hydraulic motors to the drill string. Inside the transmission/motor housing main body is a single-speed double-reduction sput gear system that provides a 13,54:1 ratio from the motors to the main shaft. The main thrust bearing located inside the motor housing supports drilling loads, while the load stem, which bypasses the thrust bearing and provides support for the rotating link adapter and pipehandler, carries the tripping loads. The main body of the motor housing provides a sealed oil lubrication reservoir for the transmission gears and bearings. Bearings and gears are force fed by an oil pump that is integral with the main body. The filtered lubrication oil constantly circulates through the main thrust bearing, take-up bearing, lower radial and compound gear bearings. An industry standard wash pipe packing box assembly is located between the main shaft/swivel stem and the S-pipe weldment. The bonnet supports the S-pipe weldment. Two upper links serve to attaching to standard rotary drilling hooks.

TRANSMISSION/ MOTOR HOUSING MAIN BODY

Transmission/motor housing (main body) and swivel assembly Fig. A9

81


A page 14

FIXED PART

MOVING PARTS SUPPORT BRACKETS AIR SPRING Counterbalance system A - 3.4 CARRIAGE AND GUIDE BEAM The travels vertically along a guide beam on a carriage attached to the main body. The guide beam hangs from the crown block and extends within 26,88 meters of the drill floor. The guide beam attaches to a torque reaction spreader beam mounted across the lower section of the mast/derrick, approximately 2 meters above the drill floor. The guide beam counters the drilling torque produced as the transmission turns the drill string. The guide beam comes in 24,64 meters sections and requires brackets for mounting to the crown. The guide beam sections are pinned toghether in such a way that they hinge and can be assembled one section at a time, at the ground level, and raised to the crown attachment using the drilling hook. The carriage consists of four roller brackets that mantains alignment of the mainshaft with the drill string while moving up and down on the guide beam. There are four rollers that run inside the guide beam flanges to counter the drilling torque and four guide rollers that run on the inside of the guide beam flanges. Both the guide and bogie rollers are through-hardened and run on grease lubricated bearings.

Fig. A10

82


GUIDE BEAM CONNECTING LINK GUIDE BEAM

A

page

15

DRILLING HOOK

LINKS MAIN BODY FRONT CARRIAGE ASSEMBLY

TORQUE WRENCH ELEVATOR LINKS

GUIDE BEAM (ASSEMBLED) TORQUE REACTION SPREADER BEAM

Carriage and guide beam

83

Fig. A11


A page 16

A - 3.5 PIPEHANDLER The Pipehandler consists of the following components: · · · · ·

Powered rotating double hook link adapter Torque wrench Two way link tilt Internal blowout prevention (IBOP) Elevator links and drill pipe elevator

HYDRAULIC DRIVE MOTOR DOUBLE HOOK ROTATION GEAR REDUCER PINION FRONT TWO WAY LINK TILT CYLINDERS

ROTATING DOUBLE HOOK LINK ADAPTER

CLAMP TORQUE WRENCH

ELEVATOR LINKS

IBOP MOUSE HOLE POSITION

DRILL DOWN POSITION WELL CENTER (FLOAT POSITION)

Fig. A12

84


·

The Rotating Double Hook combined with a hydraulic motor for 270° clockwise/counterclockwise rotation in order to position the elevator to pick up pipes and to assist the derrick man. The “free rotation” mode also allow the pipehandler to rotate with the main shaft. The two-way link tilt cylinder assemblies consist of the cylinder body pinned to the rotating link adapter and the cylinder rods pinned to the links through a set of clamps. Pressurizing the cylinder assemblies by operating the switch on the driller’s console extends the drill pipe elevator to the mouse hole or the drill down position. A float position allows the links to return to well center.

·

The Elevator Links can be moved to “mouse hole” or “drill down” position by means of the tilt cylinders, remote controlled from the operator’s panel.

·

The Torque Wrench for make up/break out of pipe, is connected to the pipe handler by means of a suspension beam. The torque wrench can be located in two different positions on the suspension beam, depending on which connection to be broken. The torque wrench includes torque cylinders, clamp jaws and a guide funnel.

·

The Remote Operated I.B.O.P. (10.000 PSI) is operated by two hydraulic cylinders remote controlled from the operator’s panel.

85

A

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17


A-4

A page 18

TOP DRIVE SPECIFICATIONS

A - 4.1 TOP DRIVE SPECIFICATIONS MODEL: LOAD CAPACITIES MAXIMUM STATIC LOAD CAPACITY: MAXIMUM DYNAMIC LOAD CAPACITY AT 100 RPM: MAXIMUM PASSAGE DIAMETER: MAXIMUM WORKING PRESSURE: LOWER THREAD: MAX TORQUE: MAX SPEED:

200.000 kg 115.000 kg 76 mm 350 bars NC 50 API - 4½” IF 3525 daNm 200 RPM

PERFORMANCE DIAGRAM:

09533652E

26000 ftlb 1° SPEED 22125

TOP DRIVE 19030 ftlb

TORQUE ftlb

14750

2° SPEED

14235 ftlb

10400 ftlb

50

100

200 RPM

146 RPM

80 RPM

109 RPM

7375

150

200

RPM

Fig. A13

TOP DRIVE POWER OUTPUT: DOUBLE HOOK CAPACITY: ELEVATOR LINK CAPACITY: LENGHT: LINK SIZE:

295 kw 200.000 kg 226800 kg (250 Short ton.) 108” (2743 mm) 2.¼”x108”

WEIGHT:

6500 kg approx.

*

TOP DRIVE includes guide dolly and connection link to travelling block

86


PIPE HANDLER - COUNTERBALANCE SYSTEM UTILITY REQUIREMENTS RIG AIR SUPPLY:

8 bar

TORQUE WRENCH: The TORQUE WRENCH can handle pipe MAXIMUM MAKE-UP TORQUE: MAXIMUM BREAK-OUT TORQUE:

from 4” to 6.5/8” OD 4400 daNm 5925 daNm

87

A

page

19

AIR INTAKE

88

HYDRAULIC CIRCUIT HEAT EXCHANGER

FUEL TANK

SUCTION BALL VALVE DRAINAGE BALL VALVE

OIL TANK

AIR FILTER

QUICK COUPLING CONNECTING BLOCK

RADIATOR

RADIATOR

AIR INTAKE

INSULATION HOOD

TRANSMISSION SHAFT BASE SKID MULTIPLE PUMP DRIVE UNIT HYDRAULIC PUMPS

AIR FILTER

EXAUST MUFFLER FILTER DIESEL ENGINE HYDRAULIC OIL TANK

OIL TANK INSPECTION COVER

FUEL TANK

AIR DISCHARGE

A-5

AIR DISCHARGE

Section

PUMP DRIVE LUBRICATION CIRCUIT HEAT EXCHANGER DIESEL ENGINE

Operation and Maintenance Manual GENERAL INFORMATION

A page 20

MAJOR COMPONENT DESCRIPTION - HYDRAULIC POWER UNIT (HPU) FOR

The following section describes the HPU component parts and defines terms used throughout this service manual.

Fig. A14


A-6

HYDRAULIC POWER UNIT (HPU) SPECIFICATIONS

Model:

1 x Caterpillar 3408 DITA EPA-CARB

Arrangement drawing:

0190 3398

Transmission circuit: Pressure range: Flow range:

0 - 350 bar 0 - 800 l/min

Replenishment circuit: Pressure min: Flow:

16 bar 90 l/min

Pipehandler circuit - Torque Wrench: Pressure: 350 bar Flow: 0 - 113 l/min Link Tilt: Pressure: Flow:

180 bar 0 - 30 l/min

Diesel engine: Max power output: Max fuel consumption: Max rated RPM:

376,5 bkw (505 bhp) @1800 RPM .....l/hour at ..... kw ..... (..... gph at ..... hp) (see engine manuals) 1800 RPM

Tank capacities: Hydraulic oil tank: Diesel tank:

950 ltr. 600 ltr.

Weights: Total weight HPU:

11830 kgs

Painting: All items painted, where relevant, with DRILLMEC procedure. Service loop hydraulic hoses: PILOT PRESSURE Flex. SAE 100 R2AT 1/2” pilot pressure CLOSED LOOP CIRCUIT Flex. SAE 100 R13 2” motor delivery Flex. SAE 100 R2AT 2” drainage PIPEHANDLER - TORQUE WRENCH Flex. SAE 100 R13 1 1/4” services delivery Flex. SAE 100 R2AT 1 1/4” services return COUNTERBALANCE SYSTEM Flex. SAE 100 R1AT 3/4” air pressure

89

A

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21

Operation and Maintenance Manual OPERATING INSTRUCTIONS Section

C

page

3

C - 1.1 CONTROLS AND INSTRUMENTS ON TOP DRIVE CONTROL PANEL P1 A1 SC1 SC3 SC4 SC5 SC6 SC7 SC8 SC9 SC10 SC11 SC12 SP1 H1 H2 H3 H4 R7 R8

Top Drive Rpm Analog Meter Top Drive Torque Pressure Gauge Hook Rotation Control Link Control Link-On Free Control Ibop Valve Open-Close Control Top Drive Brake Control Torque Wrench Automatic Sequence Control Make-Up/Break-Out Control Top Drive Emergency Stop Throttle Min-Max For Top Drive Hpu Top Drive Rotation Speed Selector Top Drive Rotation Fwd/Rev Control Controls Authorization Return Filter Clogging Indicator Lamp Discharge Filter Clogging Indicator Lamp Minimum Oil Level Indicator Lamp Controls Authorization Lamp Top Drive Rotation Rpm Regulator Top Drive Torque Regulator

A1

P1

SC10

H1

H2

H3

SP1 SC4

SC8

H4

SC11

SC6 SC5

R7

R8

SC12

SC9

SC3

SC7

SC1 Fig. C2

90


C page 4

C - 1.2 CONTROLS AND INSTRUMENTS IN THE HYDRAULIC POWER UNIT A58 A59 A60 A61 A62

RPM meter Oil pressure Ammeter Water temperature Fuel pressure

A58

A62 A59

A61 A60

Fig. C3 A53 A52 R52 A54 A55

Piloting oil pressure Compensator air pressure Compensator pressure regulator Replenishing pressure (CLOSED CIRCUIT) Replenishing pressure (CLOSED CIRCUIT)

A54

A55

A53

A52

R52

Fig. C4 A63 C60 C61 C62

Oil temperature thermometer Ball valve on hydraulic system suction line Ball valve on hydraulic system suction line Ball valve on hydraulic system suction line

A63 C60

C61

C62

Fig. C5

91


A64

C

page

5

Oil visual level

A64

Fig. C7

A-65 Fuel visual level

C63

Ball valve on reservoir oil drain A65

C63

Fig. C6

92

Fig. C8


C-2

C page 6

HYDRAULIC POWER UNIT STARTING INSTRUCTIONS

C - 2.1 CHECKS BEFORE STARTING The easiest checks have to be manually executed: -

Diesel engine oil level check.

-

Visual check of the hydraulic oil level (however, a proper lamp signals the reaching of the minimum allowed point of this level).

-

Water level check into the radiator.

-

Fuel level check (A65).

-

Oil level check into the pump driving unit.

-

At the first start-up of the Power Pack, check that the battery cables are correctly connected. Such cables are usually disconnected during transport.

-

Check that the suction valves of the pumps, placed on the hydraulic oil reservoir, are properly opened.

93


C

page

7

C - 2.2 DIESEL ENGINE STARTING C - 2.2.1

WARM-UP / STARTUP

1)

Turn on the diesel engine.

2)

Set diesel engine to minimum rpm for 15/20 min.

3)

Increase the number of rpm up to 800/1000.

Fig. C9

94


C page 8

C - 2.3 CHECKS AFTER START-UP -

After having executed all the operations described at the preceding point, check that the pressure displayed on the "supercharging" pressure gauges A54 and A55 is stabilized on 16 ÷18 bar.

-

Check the piloting pressure displayed on the pressure gauge A53. The pressure has to be 25 ÷30 bar.

-

Check the air pressure to supply the “counter-balance system” of the top drive. Such a pressure can be adjusted through the pressure regulator R52 reading the value displayed on the pressure gauge A52.

-

Warm-up the engine (the warm-up time depends on the climatic conditions).

-

Check on the engine instruments that the pressures and the temperatures are the correct ones according to the indications provided by the manufacturer of the engine.

-

Now it is possible to increase the speed of the diesel engine. Access to the top drive control panel on the drill floor.

-

Press the push-button SP1 = Control authorization.

-

Turn the selector SC10 from “Min” position to “Max” one.

-

With the top drive near the drill floor, exercise each control on the driller's console following the “operating instructions” of paragraph C-3 and the “operating procedures” of paragraph C-4.

A54

A55

A53

A52

R52

Fig. C10

A59

A61

Fig. C11

SP1 SC10

Fig. C12

95


C-3 P1 A1 SC1 SC3 SC4 SC5 SC6 SC7 SC8 SC9 SC10 SC11 SC12 SP1 H1 H2 H3 H4 R7 R8

C

page

9

OPERATING INSTRUCTIONS

Top Drive Rpm Analog Meter Top Drive Torque Pressure Gauge Hook Rotation Control Link Control Link-On Free Control Ibop Valve Open-Close Control Top Drive Brake Control Torque Wrench Automatic Sequence Control Make-Up/Break-Out Control Top Drive Emergency Stop Throttle Min-Max For Top Drive Hpu Top Drive Rotation Speed Selector Top Drive Rotation Fwd/Rev Control Controls Authorization Return Filter Clogging Indicator Lamp Discharge Filter Clogging Indicator Lamp Minimum Oil Level Indicator Lamp Controls Authorization Lamp Top Drive Rotation Rpm Regulator Top Drive Torque Regulator

A1

P1

SC10

H1

H2

H3

SP1 SC4

SC8

H4

SC11

SC6 SC5

R7

R8

SC12

SC9

SC3

SC7

SC1 Fig. C13

96


C page 10

C - 3.1 DRILLER’S CONSOLE AND TOP DRIVE CONTROL PANEL SYMBOL

CONTROL/INDICATOR NAME

DESCRIPTION AND FUNCTION

P1

Top drive RPM analog meter

Displays the RPM of drill pipe.

A1

Top drive torque pressure gauge

Displays the drill pipe torque reading on the plate around the gauge hydraulic pressure in the closed circuit is directly proportional to drill pipe torque

SC 1

Double hook rotation control

There are three lever position: NEUTRAL, LEFT (ccw) and RIGHT (cw). Move the lever upward to move the DOUBLE HOOK + D.P.E. to the left. Move the lever downward to move the DOUBLE HOOK + D.P.E. to the right

SC 2

Torque wrench up/down control

The torque wrench can be located in two positions on the suspension beam, depending on wich connection to be broken. MOVE THE LEVER UP ---> UPPER POSITION MOVE THE LEVER DOWN ---> LOWER POSITION

SC 3

Link control

Activates the link tilt cylinder. The neutral position is off, moving the lever upward extends the elevator links to "pick up" (mouse hole) position. WARNING: Rotate pipehandler 90° and then moving the lever downward retract the elevator links to "drill down" position

SC 4

Link on-free control (Link tilt float)

The links "float" to the center (neutral) position when turning the switch to the "free" position

SC 5

IBOP valve open-close control

Activates the upper IBOP valve. Turning the switch to the left retracts the IBOP activator cylinder to open the valve. Turning the switch to the right extends the cylinders to close the valve

SC 6

Top drive brake control

Turning the switch to the "ON" position, apply brake and in the same time the automatic sequence of torque wrench is disabled. Also Top Drive rotation is disabled cutting the pilot pressure. Turning the switch to the "OFF" position, release brake.

SC 7

Torque wrench automatic sequence control

Moving the lever upward activate the automatic sequence: LOWER CLAMP CLOSE, UPPER CLAMP CLOSE, UPPER CLAMP ROTATE. * In the same time DOUBLE HOOK ROTATION IS FREE and TOP DRIVE ROTATION IS FREE. When the lever is in neutral position, the torque wrench automatically rotates to the "HOME" position

97


SYMBOL


C page 11


SC 8

Make-up/break-out control

Turning the switch to "MAKE-UP" position, you select to activate an automatic make-up sequence(torque wrench rotates to amke-up connection). Turning the switch to "BREAK-OUT" position, you selectto activate an automatic break-out sequence (torque wrench rotates to break-out connection).

SC 9

Top drive emergency stop

Emergency stop shuts down all Top Drive operations. Pressing the stop button will cause Top Drive rotation to stop and will cause shut down of HPU diesel engine. EMERGENCY RESET: Rotate button and release. Press "CONTROL AUTHORIZATION" (button SP1). The light H4 must be on. Follow the HPU starting instruction. Turn on the diesel engine.

S C 10

Throttle Min-Max for Top Drive HPU

Turning the switch to left will cause the diesel engine minimum RPM (~1000 RPM). Turning the switch to right will cause the diesel engie maximum rated RPM (1800 RPM)

SC11

Top Drive rotation speed selector

Controls the displacement of the hydraulic drilling motors "LOW" position means the drilling motor in maximum displacement and therefore LOW SPEED-MAX TORQUE "HIGH" position means the driling motor in minimum displacement and therefore HIGH SPEED-LOW TORQUE

S C 12

Top Drive rotation Forward/Reverse control

There are THREE positions on the lever: - NEUTRAL POSITION with safety latch - FORWARD POSITION with detent - REVERSE POSITION hold to run FORWARD and REVERSE are used with drilling or making/breaking connections

SP1

Controls authorization

This button must be pressed always at starting or after an emergency intervention. It activates all function only if levers or switches with detent are returned to NEUTRAL POSITION (safety rules); in the same time H4 lamp lights on

H1

Return filter clogging indicator lamp

It gives a visual alarm that filters located on oil tank of HPU are clogged

H2

Discharge filter clogging indicator lamp

It gives a visual alarm that filters located on hydraulic pumps replenishing circuits are clogged

98


C page 12

SYMBOL



H3

Minimum oil level indicator lamp

It gives a visual alarm that oil level dropped down the minimum

H4

Controls authorization lamp Activating control authorization button, H4 lamp illuminates indicating you can start to work

R7

Top Drive rotation RPM regulator

Controls the displacement of closed loop hydraulic pumps. This means flow control and finally hydraulic motors RPM control. Drill pipe RPM is displayed an the RPM meter A42

R8

Top Drive Torque regulator

Sets the hydraulic pressure of closed loop in drilling or make-up/brakeout operations. Hydraulic pressure in the closed circuit is directly proportional to drill pipe torque

The measures to be taken when the warning lamp comes on depend on the type of fault detected.

Once the machine is turned off, find the cause of malfunction and repair it. If you are unable to solve the problem, contact a service center or DRILLMEC S.p.A. directly (full address is printed on cover and first page of this manual).

In principle, the engine should be immediately turned off when the following warning lamps come on:

At regular intervals, also check instruments for DIESEL ENGINE in sound proof hood.

H1 H2 H3

The engine should be immediately turned off when these situations occurr:

C - 3.1.1

WARNING LAMP SWITCHING-ON

Clogged hydraulic oil filter - RETURN Clogged hydraulic oil filter - DISCHARGE Hydraulic oil - MINIMUM LEVEL

-

Low engine oil pressure Engine water over temperature Low battery charge

WARNING Working with H3 warning lamp on is forbidden, as it can cause damage to other parts of the system. Also check OIL THERMOMETER “A-63” on HPU oil tank.

WARNING When above warning lamps are turned on, stop the engine; leaving the engine running can cause serious damage to the engine.

WARNING An hydraulic oil overtemperature is a sign of malfunctioning of some part of the system, clogged filter or heat exchanger.

99


C-4

OPERATING PROCEDURES

C - 4.1 TOOL ROTATION

C page 13

lever setting it in neutral position, but turn the torque regulator in anticlockwise direction setting the pressure to zero (see pressure gaugeof power swivel rotation torque) them set lever again to neutral position.

The power swivel rotation (drilling tool) is controlled with lever SC12: push the lever down for clockwise rotation, pull the lever up for anticlockwise rotation.

IMPORTANT Lever SC12 can be locked in full stroke position allowing the operator to control other drilling parameters such as pull/push regulation, rpm or torque. Rpm (speed) is controlled by R7; torque is controlled by R8. Rpm and torque control can be turned clockwise from left (min.) to right (max). Read torque on A1 gauge, read rpm on P1 rpm meter. Another kind of speed and torque control can be performed by means of selector SC11 (2-position selector).

IMPORTANT During the drilling, if the stops locking the rotation of the power swivel, do not move the rotation command

P1

A1

SC11

R7

R8

SC12 Fig. C14

100


C page 14

C - 4.2 IBOP SAFETY VALVES Turning the IBOP switch on the driller’s console to the CLOSE position extends the hydraulic actuator cylinders, moving the actuator shell body downward (see following figure). This downward movement rotates the crank assemblies 90°, closing the IBOP ball valve. Turning the switch to the OPEN position retracts the cylinders rod, pulling the IBOP actuator shell upwardopening the IBOP. Full hydraulic pilot pressure is applied to fully open or close the valve, mantaining the shell position.

MAIN SHAFT UPPER IBOP ACTIVATOR CYLINDER

OPEN

CRANK ASSEMBLY IBOP ACTIVATOR SHELL CLOSE

IBOP

Fig. C15

101


C page 15

C - 4.3 ACTIVATING TOP DRIVE BRAKE Turning the switch SC6 to the “ON” position, apply brake and in the same time the automatic sequence of torque wrench is disabled. Also Top Drive rotation is disabled (cutting the pilot pressure). Turning the switch to the “OFF” position, release the brake. SC7 Torque wrench automatic sequence SC12 Top Drive rotation When applying brake, two hydraulic caliper disc brakes, mounted between each top hydraulic motor and the main body, hold torque in the drill string and assist in positioning during directional work. For safety reasons, Top Drive rotation and torque wrench automatic sequence are disabled.

A1

P1

SC6

SC12

SC7 Fig. C16

102


C page 16

C - 4.4 PIPE HANDLER OPERATION C - 4.4.1 ROTATING DOUBLE HOOK AND LINKS The rotating double hook supports the weight of the drill string through a set of links that hang from the hook. The positioning gear is an integral part of the rotating double hook. The positioning gear, meshed with a hydraulic motor driven pinion gear, rotates the pipehandler.

DOUBLE HOOK TORQUE WRENCH LINKS

HYDRAULIC MOTOR CCW

DRILL PIPE ELEVATOR CW WELL CENTER

POSITIONING GEAR PINION

Fig. C17

103


C page 17

C - 4.4.2 LINK TILT The link tilt consists of two double-rod assemblies with the cylinder body pinned to the rotating double hook and rod end of the cylinder pinned to the elevator link. Moving the link tilt lever upward, SC3 on the driller’s console, extends the drill pipe elevator to the “MOUSE HOLE” position.

SC4 SC1

WARNING Rotate pipe handler 90° with SC-1 before to move the lever downward SC-3 to reach the ‘DRILL-DOWN’ position. Be sure not to interfere with guide beam. Moving the link tilt lever downward retracts the drill pipe elevator to the drill down position. Turning the link tilt float switch SC4 to free position allows the elevator to return to well center. Elevator travel is adjustable. If it is necessary to adjust the mousehole position, relocate the clamps on the links as required.

104

SC3

Fig. C18


C page 18

HYDRAULIC DRIVE MOTOR DOUBLE HOOK ROTATION GEAR REDUCER PINION

FRONT TWO WAY LINK TILT CYLINDER

ROTATING DOUBLE HOOK LINK ADAPTER

GUIDE BEAM CLAMP (ADJUSTABLE) TORQUE WRENCH

ELEVATOR LINKS

MOUSE HOLE POSITION

DRILL DOWN POSITION

ELEVATOR ASSEMBLY

WELL CENTER (FLOAT POSITION)

WARNING! ROTATE PIPE HANDLER 90° Fig. C19

105


C-5

C page 19

TORQUE WRENCH

C - 5.1 TORQUE WRENCH BREAK-OUT SEQUENCE Turn the selector SC8 on “BREAK-OUT” position. To activate the automatic (break-out) sequence, move the lever SC7 upward and hold it in position till the sequence is completed. In the same time: -

SC8

SC7

DOUBLE HOOK ROTATION IS FREE TOP DRIVE ROTATION IS FREE

Fig. C20

to permit freely upper clamp rotation. When the sequence is completed, release the lever SC7 to return in neutral position.

106


C page 20

Selector SC8 in “BREAK-OUT” position “HOME” position for BREAK-OUT sequence

Lever SC7 upward 1st phase of automatic sequence LOWER CLAMP CLOSE UPPER CLAMP CLOSE

Lever SC7 upward 2nd phase of automatic sequence UPPER CLAMP ROTATES C.C.W

Lever SC7 in neutral position 1st phase of automatic return to “HOME” position UPPER AND LOWER CLAMPS OPEN

Lever SC7 in neutral position 2nd phase of automatic return to “HOME” position UPPER CLAMP ROTATES C.W.

Fig. C21

107


C page 21

C - 5.2 TORQUE WRENCH MAKE-UP SEQUENCE Turn the selector SC8 on “MAKE-UP” position. To activate the automatic (make-up) sequence move the lever SC7 upward and hold it in position till the sequence is completed. In the same time -

DOUBLE HOOK ROTATION IS FREE TOP DRIVE ROTATION IS FREE

to permit freely upper clamp rotation. When the sequence is completed, release the lever SC7 to return in neutral position. Selector SC8 in “MAKE-UP” position “HOME” position for MAKE-UP sequence Lever SC7 upward 1st phase of automatic sequence LOWER CLAMP CLOSE UPPER CLAMP CLOSE

Lever SC7 upward 2nd phase of automatic sequence UPPER CLAMP ROTATES C.W

Lever SC7 in neutral position 1st phase of automatic return to “HOME” position UPPER AND LOWER CLAMPS OPEN

Lever SC7 in neutral position 2nd phase of automatic return to “HOME” position UPPER CLAMP ROTATES C.C.W.

Fig. C22

108

Operation and Maintenance Manual INSTALLATION Section

D page 4

The HTD 200 is supplied in a shipping and handling skid. The HTD 200 is supported by two brackets on carriage and by collar on main shaft.

BRACKETS AND PINS BRACKETS AND PINS COLLAR

Fig. D3 The HYDRAULIC POWER UNIT has a proper container with old field supporting frame.

Fig. D4

The pipehandler, the links, guide beam group, service loop and other accessories, are supplied in separate proper packages.

109


At the reception of the machine, be extremely careful during the down-loading procedures of the fixtures; it is necessary to check all the received materials and the status of the fixtures themselves in such a way to ensure their perfect status after the transport.

IMPORTANT Every dispute, comment or claim has to be immediately pointed out to the transport company. The claims forwarded with delay will not be taken into account.

D - 1.1 LIFTING DEVICE The hoist or the lifting crane for the machine installation is always under the customer's responsibility. However, its loading capacity has to be not lower than 15 Ton.

110

D

page

5


D-2

D page 6

INSTALLING THE GUIDE BEAM AND LOWER ATTACHMENT

NOTE: 1 - Assemble the guide beam composed by nr. 4 elements (ref. 1-2-3-4) and its lower attachment ref. 5

1

2

3

4

5 PHASE 1

Fig. D5

111

112 1

6

GUIDE SUPPORTED BY THE SERVICE CRANE

NOTES: ASSEMBLE ON THE GUIDE (ref. 1) THE UPPER ANCHOR. ITEM (ref. 6) AND THE OTHER ITEMS (ref. 7-8-9) WITH THE RELEVANT ACCESSORIES TO LIFT THE GUIDE WITH THE TRAVELING BLOCK AND THE HELP OF THE SERVICE CRANE

9

8

7


D page

7

PHASE 2

Fig. D6


D page 8

7 6

8 7 9

8 9

NOTES: FIX THE UPPER ANCHORING ELEMENT (ref. 6) INTO ITS COUPLING SEAT AND LOWER DOWN THE TRAVELING BLOCK IN SUCH A WAY TO RELEASE THE TENSION OF THE ROPE (ref. 7). EXTRACT THE LIFTING PIN (ref. 9) FROM ITS SEAT LEAVING ALL THE COMPONENTS (ref. 8-9) AND THEIR RELEVANT ACCESSORIES CONNECTED WITH THE ROPES (ref. 7). THEN, LOWER DOWN THE WHOLE ASSEMBLY WITH THE TRAVELING BLOCK ON THE DRILL FLOOR.

PHASE 3

Fig. D7

113


D

page

9

PHASE 4

FRAME FOR TOP DRIVE TRANSPORT AND INSTALLATION

10

GUIDE ON ITS INSERTED POS.

NOTES: AFTER HAVING INSERTED NEWLY THE GUIDE INTO THE MAST, INSTALL THE LINKS (ref. 10) ON THE TRAVELING BLOCK. POSITION ON THE CENTER OF THE WELL THE FRAME WITH THE TOP DRIVE AND CONNECT THE LINKS (ref. 10) WITH THE TOP DRIVE. THEN, LIFT THE ASSEMBLY AND FREE THE CENTER OF THE WELL FROM THE TRANSPORT FRAME OF THE TOP DRIVE.

Fig. D8

114

Operation and Maintenance Manual INSTALLATION D page 10

PHASE 5

13

12

WELL CENTER

Section

11

13

14

NOTES: LOWER DOWN THE TOP DRIVE INTO THE ROTARY TABLE WITH MAX. PASSAGE 27" ½. RETURN THE GUIDE ON ITS WORKING POSITION AND THEN, DURING THE GOING UP PHASE, SLOWLY INSERT THE ROLLS OF THE DOLLY INTO THE GUIDE. NOW, FIX THROUGH THE PINS (ref. 13) THE CROSS BEAM (ref. 11) WITH ITS ANCHORING JOINT (ref. 12) ALREADY FIXED. INSERT THE PIN (ref. 14) AND EXECUTE THE FINAL INSERTION OF THE SHIMS. Fig. D9

115


D page 11

PHASE 6

15

NOTES: MOVE UPWARD THE TRAVELING BLOCK AND THE TOP DRIVE IN SUCH A WAY TO BE ABLE TO EXECUTE THE INSTALLATION OF THE TORQUE WRENCH (ref. 15). THEN, EXECUTE THE INSTALLATION OF THE HYDRAULIC OIL SERVICE LOOP AND OF THE MUD ROTARY HOSE.

Fig. D10

116


D-3

D page 12

INSTALLING THE ROTARY HOSE

Rotary hose supplied by DRILLMEC is pre-arranged with WECO 4” Fig 602 hammer union, female one end and male on the other end. It is convenient to connect rotary hose to the stand pipe when the mast is horizontal, before raising the mast. Install the female end of rotary hose to the hammer union of the stand pipe and tighten. Temporarily tie the rotary hose to the mast. After the installation of top drive on the guide beam (see par. D - 2), procede to connect the rotary hose to the goosneck.

SEE DETAIL A MALE

FEMALE

ROTARY HOSE 3½ I.D. 5000 psi W.P DETAIL A L = 55 ft (16,674 m) with integral hammer union WECO 4" FIG. 602

By means of the service winch, lift the male end with hammer union of rotary hose and connect it to the female end of the goosneck and tighten. Verify that the orientation of the rotary hose does not cause interference in the rig.

Fig. D11

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DRILLING RIG MUD PUMP 9T1000

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POWER SLIP

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TECHNICAL DOCUMENTATION PSA 150

Oil Tool Division

Blohm + Voss PSA 150 Power Slip for 2 3/8” – 7 5/8” RSX - Standard Slips

Air Operated

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Oil Tool Division

2 Introduction The inspection and maintenance procedure described is based on API – Recommended practice and Blohm+Voss Repair GmbH experience in the design of power slips. This recommended practice outlines a procedure for methods of inspection and maintenance of Power Slips to help prevent injury to personnel and irreparable damage to equipment. This technical documentation contains instructions of safety, installation, operation and maintenance for the PSA 150. This technical documentation must be studied before working with the PSA 150. In the event of problems which cannot be solved with the aid of this manual, please contact one of the addresses listed at the end of this documentation. The Blohm+Voss Type PSA 150 Air operated Power Slip is designed to enhance safety by eliminating personnel on the Rig floor when operations require the use of slips. The PSA 150 can be operated by using a foot valve at a safe distance from the Rotary Table. In case of a loss of air pressure, a safety device is installed to prevent the lifting arm from engaging. Under such circumstances, the PSA 150 can be operated manually. The Power Slip accommodates B+V Standard (Rotary) Slips in the range of 2 3/8” to 7”, as well as most other brands.

Fig. 4: Power Slip installed with Master Bushing and Rotary Slip, air operated

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Oil Tool Division

Fig. 5: Power Slip installed with Master Bushing, Slips raised

Fig. 6: Power Slip installed with Master Bushing, Slips set

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3

Technical Data of Power Slip PSA 150

3.1 Dimensions ( see also page 25 ) width length height weight ( without Slips )

582 mm 1251 mm 541 mm 270 kg

3.2 Slip Adapter Hand slips are connected to the PSA with an Adapter (see Pos. 16, page 17/18 slip Fastening Link). Two different Adapters are available: For B+V Slips: For Access:

P/N 88208 P/N 88208-A

3.3 Power Required Working pressure Flow rate

7 bar / 100 psi 6,8 qm / min or 240 cfm

The air supply should be equipped with a maintenance unit ( Lubricator, Air Regulator, Filter) to ensure that devices are operated with clean compressed air. An air regulator ensures constant working pressure. The air regulator guards the pneumatic parts against break down. The maintenance unit should be operated with Antifreeze Oil to prevent freezing of air operated devices at temperatures down to –20°C or –4°F. This oil forms a film of lubrication on the plain surface and guarantees that all air operated devices connected are working to full capacity even at –20°C or –4°F.

3.4 Identification You find the identification plate on the left side from Power Slip, when you look from behind the PSA 150.

Part Number Serial Number

Fig. 7: Identification plate

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Oil Tool Division

4 Installation and operation 4.1 Installation (1) To install Power Slip: Tilt the “ Quick Locking Pin Assembly „ into vertical position first unlocked

Fig. 9 Locking assembly

Fig. 10: Locking assembly, unlocked ( vertical position )

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Oil Tool Division

(2) Place the Power Slip on the Rotary Table by lifting with a crane and close the Locking Assembly

Fitting for the crane First tilt the “ Quick Locking Pin Assembly „ into vertical position Fig. 11: Place the Power Slip on the Rotary Table (Quick Locking Pin Assy. showed in horizontal position)

locked

(3) Lock the Power Slip by turning the lever back in horizontal position

Fig. 12: Locking Pin Assembly, locked ( horizontal position )

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(4) Connect the foot valve with pneumatic air.

to PSA (see also Fig.14)

Connection Air Supply

Fig. 13: Pneumatic valve with connection to air supply

Foot valve with threaded connection G ¼” (see technical data sheet, at page 27and 22) Foot valves with detent are actuated by means of a foot lever with mechanical detent. The valve engages when it is first actuated, and when the foot lever is actuated again, the valve returns to it is initial position. (5) Put the nipple on the clutch hose coupling from the PSA 150. ( see page 20, pneumatic air, exploded view ) Nipple Clutch hose coupling

Fig. 14: Connection pneumatic set outside from PSA

Fig. 15: Connection pneumatic set inside from PSA

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4.2 Operation of PSA Pressure will be applied to the air operated Power Slip by using the foot valve. The pneumatic Cylinder extends and lifts the connected rotary slip. To reduce the lifting height of the slip screw-in the adjustment screw. When you unscrew the adjustment screw the lifting distance is larger. Fig. 16: Adjustment Screw (see Pos. 14, page 25)

4.3 Manual Lifting in Case of Emergency If the Power Slip PSA 150 can not be lifted by compressed Air, use the retaining link to lift up the Power Slip manually, ( operated with a loop lever ). Please disconnect air hoses before.

Fig 17: lift up the Power Slip manually

Lift up

Fig. 18: lift up

Lift down

Fig. 19: lift down

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5 Lubrication Per Week :

Lubricate any movable pins ( see spare parts : 5; 8 ; 9; 19-3 )

Per ½ Year :

Lubrication as above and visual inspection of pneumatic cylinder and air hoses

Lubrication points for moveable pins:

Grease point

Grease point

Grease point Grease point

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ROTARY TABLE AND TRAVELLING BLOCK

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TRAVELLING BLOCK : Manufacturer : American Block Product Description : 250 T Unitized Block / Hook Assembly Maximum laod rating – Block / Hook Assy Weight of Block/Hook Assembly

250 Short tons (227 Metric Tons) 11,000 lbs (4990 Kg)

Block : Number of sheaves Sheaves diameter (OD) Wire rope diameter

5 30" (962 mm) 1"⅛

Hook : Hook stroke Hook components oil specification Design factor

8" (203 mm) SAE 30 W 3/1

ROTARY TABLE : Manufacturer : DRILLMEC Product Description : 27"½ Maximum laod rating Maximum output torque Maximum output speed Weight Gear ratio Opening diameter (ID) Overall length Overall width Overall height Center of table to center of sprocket teeth Pinion shaft extension Lubrication oil capacity

500 Short tons (450 Metric Tons) 17,300 ft-lb (2390 m- Kg) 400 rpm 11,500 lbs (5,220 kg) 3.16 27,5 "(699 mm) 93.8 " (2380 mm) 63.0 " (1600 mm) 28.0 " (711 mm) 53.25 " (1352 mm) 4.938 " (125 mm) (API # 5 standar) 10,0 gallons (37.8 liters)

Design and dimensions

API 7K

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HYDROMATIC BRAKE

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MUD SYSTEM

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150

Training foraj

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