ZP-275 ROTARY TABLE
Operation peratio n and and ma m aintenance in tenance manua manu al AG27500100-SM AG27500100-SM
March, Marc h, 2006
Foreword ZP-275 Rotary Table is an important component of drilling rig. During drilling, the rotary table turns the Kelly; the Kelly turns the string and bit to drill the hole. The rotary table is designed to conform to the Standard SY/T 5531 “Rotary Table for Drilling Rig” and API 7K Spec. In order to make operators know the rotary table well, this manual shows the details about the rotary table. Before running the rotary table, the administrators, technicians and operators related to this drilling job must carefully read the manual and relative documents to master the safety-operation procedures and skills. Meanwhile, you are also requested to abide by the rules and regulations specified in your unit. During application, if the parameters and information of other matched equipment are needed, see the instruction manuals and relative documents for the matched equipment.
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Contents FOREWORD ....................................................... ............................................................... ...................................... I 1. GENERAL ............................................................................................................................................................1 1.1 FUNCTIONS AND FEATURES ..........................................................................................................................1 1.2 TECHNICAL P ARAMETE RS.............................................................................................................................1 2. CONSTRUCTION DESCRIPTION ...................................................................................................................1 3. INSTALLATION AND ADJUSTMENT .............................................................................................................3 3.1 INSTALLATION................................................................................................................................................3 3.2 A DJUSTMENT ................................................................................................................................................3 4. OPERATION AND USE .....................................................................................................................................4 4.1. HOW TO LOCK THE MASTER BUSHING AND TURNTABL E BUSHING ..............................................................4 4.2. THE BRAK E OF THE TURNTABL E ..................................................................................................................4 4.3. THE MATCHING OF THE ROTARY TABLE AND ROLLER BUSHING ..................................................................4 5. MAINTENANCE..................................................................................................................................................5 5.1 L UBRICATION ................................................................................................................................................5 5.2. ROUTINE MAINTENANCE AND CHECK ITEMS ................................................................................................5 5.3. PERIODIC MAINTENANCE AND CHECK ITEMS ...............................................................................................6 6. PACKING, TRANSPORTATION AND STORAGE.........................................................................................6 6.1 P ACK ING AND TRANSPORTATION..................................................................................................................6 6.2 STORAGE ......................................................................................................................................................6 7. LIST OF BEARINGS, LISTS OF SPECIAL TOOLS AND SPARE PARTS ..............................................7 7.1 B EARINGS .....................................................................................................................................................7 7.2 SPECIAL TOOLS ............................................................................................................................................7 7.3 SPARE P ARTS ...............................................................................................................................................7 8. ATTACHED DRAWINGS ...................................................................................................................................8 8.1 CONFIGURATION DRAWINGS.........................................................................................................................8 8.2 P ARTS L IST OF ZP-275 ROTARY T AB LE .....................................................................................................10
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
1. General
1.1 Functi ons and Features During drilling, the rotary table turns the Kelly and the string hanging under the swivel to drill the hole. On trips and running casing, the string is latched to the top rotary table, which can receive the maximum load permitted in the drilling rig and the long service life of the table bearings should be guaranteed in load condition. The rotary table can transmit the enough torque and horsepower through the bevel gear and pinion.
1.2 Techni cal Parameters Model
ZP-275 698.5 mm (271/2 )
Table opening Max. Static load
4500KN
Max. Table speed
300 r/min
Gear ratio
3.67
Distance between the center of rotary table and the center of the 1 st row of sprocket 1353mm (53-1/4”) Overall dimensions (L×W×H):
2380mm×1670mm×685mm
Weight
6122 kg
2. Construction Description The rotary table realizes reduction through a pair of spiral bevel gear and pinion, i.e. it can obtain necessary revolutions and torques to drive the drill string for drilling operation. The rotary table is mainly composed of master bushing, turntable, spiral bevel gear and pinion set, input shaft assembly, locking device, table base and top cover, etc. The spiral bevel gear and pinion are used to provide smooth transmission, small
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
contacting stress and high load capacity. The gear and pinion are both made of high alloy steel through heat treatment. The meshing clearance between the gear and pinion can be adjusted by shim (19) and shim (20.6) which is positioned on the lower main bearing and the flange end of input shaft. The turntable(14) is a turning part to output the speed and torque in the rotary table. The turntable bore diameter is in conformance with the regulation of API 7 K, the gear (12) is tightly matched with the turntable, the loading bearing and prevent jump bearing(40) all adopt angle contact thrust bearing,
the contact thrust bearing as main
bearing not only receives maximum drill string load and casing load, but also withstands the impact load from well bottom during drilling and tripping operations. It has a compact construction. The bottom support ring (27) is connected with the turntable by bolts to support the main bearing, the shims (22 are used to adjust the axial clearance of the main bearing, the turntable is positioned on the table base by loading bearing The input shaft assembly is cartridge type construction, a component to input the power to the rotary table. It consists of bearing race (20.7), bearings (20.15 and (20.16), input shaft (20.5) and pinion (20.1), etc. The input shaft is supported in the bearing house with a radial short cylindrical roller bearing and a radial spherical roller bearing, the shaft assembly is mounted in the table base. The input shaft end diameter and the key sizes conform to the regulation of No.5 shaft end specified in API 7K. The rectangular type table base (10) is made of steel casting and welded structure; it can withstand the maximum static load. There is a lube pool in the chamber for lubricating the bevel gears and bearings. The table base is equipped with left and right Z-blade locking devices, which can stop the table from forward and reverse rotation to meet the needs of down-hole drill tool and special drilling operations. The top cover (12) welded by riffled steel plate is a rectangular face plate and fixed to the table base with inner-hex screws. The master bushing (18) is split type construction, 5-1/4” four-pin-drive roller bushing or Kelly bushing is used for drilling operation, the master bushing is connected with the turntable and Kelly bushing by brake block (15). this rotary table also can adopt big Kelly bushing ,the Kelly bushing device is whole type substructure, after the relevant bushing device is put into the bore, 5-1/4” four-pin-drive roller bushing is used for drilling operation
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
The splash lubrication is applied to gear and bearing; the grease lubrication to the pin shaft of the locking device. The labyrinth seal is used between turntable and table base as dynamic seal; the spring seal ring between input shaft and bearing cap; O-ring is applied to the other static seal areas. There are two transmission methods through the input shaft end in the rotary table, they are sprocket which is generally integral type two-row one, and flange. The rotary table is provided with tree sizes of sprockets which are respectively 19, 21 in teeth and 2” in pitch, also a flange to be connected with Cardan shaft for customers’ choice(Please specify the transmission method when ordering the rotary table). We can supply customer with other specific sprocket and transmission connection so long as the customer put forward to the requirement. Note: Sprocket and flange are excluded in our supply scope of the rotary table. If needed, customers should order them additionally.
3. Installation and Adju stment
3.1 Installation The rotary table is generally mounted on the rotary table beam in rig substructure, the top cover of rotary table should be leveled with the drill floor, after being positioned and aligned, the rotary table should be tightened by the setting block and bolts or other fastening ways. Note:Locating block and connecting bolt are excluded our supply scope of the rotary table.
3.2 Adjust ment When being installed, the rotary table should be aligned as per following request. Transmission method Sprocket
Installation and alignment position Permit Flatness error between the input sprocket <1.5mm of high speed shaft and the output sprocket of drawworks.
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
Cardan shaft
Gear coupling
Parallelism error between the input flange of high speed shaft and the output flange <1mm of transmission device (Progressively measure 4 points adjacent to 90 degree). Auxiliary error between high-speed shaft 3 mm and the output shaft of transmission device. Auxiliary error between high-speed shaft <1.5mm and the output shaft of transmission device.
4. Operation and us e
4.1. How to lock th e master bushi ng and turn table bus hing Pin (32) end should arrow to the strike plate of brake block, when the pin end arrow to the turntable and bushing, it shows that the master bushing and the turntable bushing are locked, per contra, they are separated.
4.2. The brake of th e turn table The locking device is used to lock the turntable and bear the reaction torque during down-hole drill tool and special operations. When the rotary table is used for drilling operation, it should be in open position. When braking the turntable, drive the turntable by low speed, lift control level (6) and put left and right brake shoes (1, 2) into the turntable recess, the control handle to be in the front end (near to well bore) means braked; to be in the back end (near to input shaft end), open. Caution: Starting the braked rotary table may cause the table parts severe damage.
4.3. The matchin g of t he rotary table and ro ller bus hing During drilling operation or running 7” casing, install API 3# bushing in master bushing. While running 9-5/8” casing, install API 2# bushing in master bushing. While running 13-3/8” casing, install API 1# bushing in master bushing. Notice: above-mentioned 5-1/4” roller bushing, API 1# bushing, API 2# bushing
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
and API 3# bushing are excluded in our supply scope of the rotary table. If needed, customers should order them additionally.
5. Maintenance
5.1 Lubr ication 5.1.1. The bevel gears and the bearings are splash-lubricated by the oil pool. The sulphur-phosphorus type90 # extreme-pressure oil filled with 10 % of 4# anti-rust complex agent shall be used as lubricant. The lubricating oil shall be changed every two months. The oil level is subject to the highness when the rotary table stops working for 5 minutes. When the oil level lowers to the down limitation, should fill the lubricating oil up to the upper limitation and try to avoid overfilling, otherwise, it causes the labyrinth seal of the low turntable leakage. 5.1.2. The pin shaft of turntable locking device shall be lubricated once a week with 2# lithium base grease by means of grease gun. 黄油润滑点(共4处) Lubricating points
Fig. turntable locking device
5.2. Rout ine maintenance and ch eck it ems 5.2.1. Check oil level, oil temperature and oil quality for normal once a shift. 5.2.2. Check the spring seal ring on input shaft once a shift and the labyrinth seal of the low turntable for leakage. 5.2.3. Check the voice and vibration of running table once a shift to make sure no
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
abnormal condition will happen. 5.2.4. Check the table locking device for flexibility and reliability once a shift and for the position requested by drilling operation. 5.2.5. Check the master bushing and turntable, bushing lock pin and brake block for flexible and reliable rotation once a shift.
5.3. Periodic maintenance and check items 5.3.1. After completing one well, should check the lower set ring (27) and bolt (24) for looseness, if yes, they must be tightened at 690N.m of force moment. 5.3.2. After completing one well, should check input sprocket for axial play, if found, tighten the screws on shaft end closure. 5.3.3. After completing one well, should check input sprocket for worn-out and deformation, if found larger, the sprocket must be repaired or replaced. 5.3.4. After completing one well, should check the bushing for worn-out and deformation, if found larger, the bushing must be repaired or replaced. 5.3.5.When the cumulative drilling depth reaches 90000-100000 meters, should check the bevel gear and pinion and bearing raceway for worn-out and pit corrosion, if exceed the allowance value, they must be replaced.
6. Packing, Transp ortation and Storage
6.1 Packi ng and Transpor tation During packing, the rotary table should be in brake condition; the shaft end is coated with lubrication grease and packed as per t he regulation. The rotary table is shipped in naked packing. When moving the rotary table, necessary crane and transportation facilities should be used, and the rotary table shall be lifted by the four lower corners. It is not allowed to tug or pull it on the ground.
6.2 Storage When the rotary table stops running more than 2 months, it should be stored properly. First, unscrew the plug (21) on the table base and emptying the lubricating oil and clean the oil pool; then, wash the gears, bearings, turntable, input shaft assembly
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
and bushing; finally, apply the rust grease to all part surfaces and fitting surfaces, and fill in the fitting clearance of moving components with rust grease. If a long-term storage, the rotary table should be kept in dry, ventilation and non-corrosion warehouse and make a periodic anti-rust check.
7. Lis t of B earin gs, Lists of Special Tools and Spare Parts
7.1 Bearings Table 2 Bearings for Rotary Table Description Qty per unit
Model
Weight(kg)
91682/800
bearing 800 ×1060×155
1
293
1681/800
bearing 800 ×950×120
1
120
NU2330 (32630)
Centripetal short cylinder bearing 150×320×108
1
45
1
43
22330 (3630)
roller
Centripetal globe roller bearing 150 × 320×108
7.2 Special Tools Drawing No. AG27500134
Table 3 Special tools for Rotary Table Description Qty per unit Bushing lifting dog
2
Weight(kg) 6.8 ×2
7.3 Spare Parts
HG4-692
Table 4 Spare parts for Rotary Table Description Qty per unit Spring seal ring SG180 × 1 220×18
AG27500123
O-seal ring 800 ×8.6
1
0.14
AG2750012003
O-seal ring 420 ×8.6
2
0.07×2
AG27500129
O-seal ring 1000 ×8.6
1
0.16
Drawing No.
7
Weight (kg) 0.178
INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
8. Attached Drawings
8.1 Confi gur ation Drawings See following drawing 2, 3, 4, and table 5.
Fig2. 275 rotary table
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
Fig3. 275 rotary table
线 心 中 盘 转
Fig4. Input shaft assembly of 275 rotary table
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
8.2 Parts list of ZP-275 Rotary Table Table 5
Parts List of ZP-275 Rotary Table
No. ZP 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 26 27
Drawing No. Name 275rotary table (see fig.2 and fig.3 ) AG27500101 Left pawl AG27500102 Right pawl AG27500103 Control rod pin AG27500104 Pawl pin Screw plug 1/8″ AG27500105 AG2750010600 Control plug AG27500107 nameplate AG2750010800 Oil pointer Screw plug 1 1/2 ″ AG27500109 AG2750011000 Forge welding substructure AG27500111 Wall scraper AG2750011200 Upper cover AG27500113 Big rig gear AG27500114 Turntable AG27500115 Slipper AG27500116 pin 5″master bushing AG27500117 AG27500118 Break out block AG27500119 Washer AG2750012000 Input shaft assembly screw plug 1″ AG27500121 AG27500122 Lower seal set AG27500123 O seal ring Bolt M24×70 AG27500124 AG27500125 Washer AG27500126 Washer Lower seal set AG27500127
Qty.
28
AG27500128
stopper
1
29
AG27500129
O seal ring
1
30
AG27500130
Double bank chain wheel
1 1 2 2 2 2 1 1 2 1 2 1 1 1 4 4 2 2 6 1 1 1 1 12 demand demand 1
P=50.8 Z=19 P=50.8 Z=21
1
31
AG27500131
Double bank chain wheel
32
AG27500132
Baffle
1
33
AG27500133
Flange
1
34
Main bushing lifting dog
2
35
AG27500134 GB1152-74
36
GB70-85
Allen screw M24×75
4
37
GB827-86
Rivet 3×10
4
38
91682/800
Bearing
M10×1
Oil cup
10
800×1060×155
1
4
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INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE
No. ZP 39
Drawing No. Name 275rotary table (see fig.2 and fig.3 ) GB91-86 Cotter pin 5×35
Qty.
4
40
1681/800
Bearing
41
GB93-87
Spring washer 24
12
42
GB30-76
Bolt M16×40
24
43
GB93-87
Spring bolt 16
24
ZP
800×950×120
1
275rotary table input shaft (see fig4 )
AG2750012001
Small bevel gear Me=18
20.2
AG275001200200
Left Bearing cover
1
20.3
AG2750012003
O-seal ring 420×8.6
2
20.4
AG2750012004
spacer
1
20.5
AG2750012005
shaft
1
20.6
AG2750012006
Washer
20.7
AG2750012007
Bearing sleeve
20.8
AG2750012008
Washer
20.9
AG2750012009
Check ring 150
1
20.10
AG2750012010
Right Bearing cover
1
20.11
AG2750012011
Shaft sleeve nut
1
20.12
AG2750012012
Key
1
20.13
screw plug NPT 1
1
20.14
AG27500121 HG4-692-67
Oil seal 180×220×18
1
20.15
GB283-64
Bearing
1
20.16
GB286-64
Bearing 3630
1
20.17
GB5782-86
Bearing M20×60
16
20.18
GB93-87
Spring washer 20
16
20.19
GB32-86
Bolt M16×35
8
Iron wire φ1
demand
20.20
426×520×0.5 322×400×1
11
32630
Z=21
1
20.1
4 1 1