Professional Documents
Culture Documents
Maintenance Instruction
Contents
1 Safety cautions..................................................................................................................1
2 Periodic maintenance........................................................................................................2
2.1 Daily maintenance positions..........................................................................................2
2.2 Weekly maintenance positions.......................................................................................3
2.3 Monthly maintenance positions.....................................................................................4
2.4 Seasonal maintenance positions.....................................................................................5
2.5 Semi-annual maintenance positions...............................................................................5
2.6 Annual maintenance.......................................................................................................5
3 Lubrication........................................................................................................................6
3.1 Lubrication of pulley bearing wheel..............................................................................6
3.2 Lubrication of pulley guiding wheel..............................................................................6
3.3 Lubrication of washpipe assembly................................................................................7
3.4 Lubrication of upper gland seal.....................................................................................7
3.5 Lubrication of bail pin...................................................................................................7
3.6 Pin of tilting oil cylinder................................................................................................8
3.7 Lubrication of backup tong............................................................................................8
3.8 Lubrication of remote control IBOP control mechanism..............................................9
3.9 Lubrication of remote control IBOP..............................................................................9
4 Check and maintenance of mechanical system...............................................................10
4.1 Main motor and air cooling motor...............................................................................10
4.2 Brake device................................................................................................................10
Maintenance Instruction
II
Maintenance Instruction
III
Maintenance Instruction
IV
DQ450DBZ Direct Driving Top Drive
Maintenance Instruction
1 Safety cautions
Before maintenance, carry out safety education and guidance to all workers engaged in
maintenance.
During maintenance, if original maintenance schedule is changed, revise safety
operation regulations, educate and guide all workers again, and ensure all workers know the
change of the maintenance schedule so as to guarantee the safety of workers.
Warning
2 Periodic maintenance
2.1 Daily maintenance positions
Maintenance Instruction
Lubricating positions
Lubricating
No.
Positions
Washpipe assembly
2
3
points
1
mechanism
Backup tong alignment wheel
Lubricant
Lubricating
grease
Lubricating
grease
Lubricating
grease
Positions
Washpipe assembly
Manual IBOP
Pipe handler
Backup tong
7
8
9
10
11
12
Measures
Repair or
etc
replace
Repair or
replace
Repair or
lubrication
Reliable operation and adequate
replace
Repair or
lubrication
Bolt, safety locking wire, split pin
replace
Repair or
etc
replace
Adjust or
Looseness condition
drive
Hydraulic system
Contents
Bolt, safety locking wire, split pin
Pipes of hydraulic
system
Looseness condition
Cables
replace
Replace
Refasten
Add or replace
Repair or
replace
Adjust or
replace
Repair or
damage etc
replace
Maintenance Instruction
Lubricating positions
No.
Positions
Lubricating points
Bail pin
16
Lubricant
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease
Lubricating
grease
Positions
Air outlet of main motor
Contents
Damage condition of shutter
Damage condition
Fan assembly
Floating brake
IBOP
7
8
Pulley
10
11
Measures
Replace
Repair or
replace
Adjust or
replace
Replace
Repair or
wear condition
replace
Repair or
Wear condition
Damage and wear conditions
Crack condition of weld joint
Wear condition of bearing wheel
and guide wheel
Looseness or loss of fastener
Looseness or loss of fastener
replace
Replace
Repair welding
Replace
Adjust or
replace
Adjust or
replace
Positions
Maintenance Instruction
Contents
Corrosion generated due to
washpipe leakage
Measures
Replace
3
4
Wear
Replace
Wear
Replace
Repair
welding
Replace
Replace
Replace
Repair or
replace
Positions
Hydraulic oil of hydraulic
Contents
Oil sample analysis (se reemplaza el
system
Filter
Measures
Replace
Replace
Positions
Bail and bail pin
Main shaft
Contents
Damage
Offset
Accumulator
Nitrogen pressure
Measures
Replace
Adjust
Replace air bag or
accumulator
Maintenance contents
Flaw detection of main bearers (such as guide rail, trolley, bail and bail pins
etc)
Lubricating grease replacement of main motor
Equipment repair
Equipment overhaul
2 years
3 years
4 years
Notice
Maintenance Instruction
3 Lubrication
3.1 Lubrication of pulley bearing wheel
Positions:
8 positions on two sides of pulley
respectively (16 positions in total).
Method:
Fill lubricating grease.
Maintenance Instruction
Maintenance Instruction
(4
Maintenance Instruction
grease
is
completed,
and
(2
Maintenance Instruction
Maintenance Instruction
When the thickness of brake friction block is less than 4mm, replace friction block.
During replacement of friction block, release pressure of brake oil line, and then
open brake guard, withdraw friction block, replace with new friction block, and
finally install the brake guard.
Note
of running-in.
Notice
Keep friction block clean and does not attach oil or grease at ordinary
time.
3. Replacement of brake disk
When the thickness of brake disk is less than 10mm, replace the brake disk in time.
4.3 Bail and bail pin
Check:
1. Wear of bail and bail pin.
2. Adequate lubrication of bail pin.
3. Looseness of baffle and screw of bail pin.
Maintenance:
1. Fill lubricating grease in lubricating grease
nozzle in bail pin periodically.
2. Periodically check wear conditions of bail and
bail pin, and decrease bearing weight when
wearing capacity is more than 2mm. Replace
when the wearing capacity exceeds 4mm.
4.4 Gooseneck
Check:
1. Periodically check the wear and
corrosion of gooseneck.
10
Maintenance Instruction
In
movement
and
check
of
Maintenance Instruction
1. Assembly
1) Put upper end of lower packing box downwards, install lower sealing pressure
sleeve, packing, distance ring and lower bushing ring in lower packing box, align
upper and lower distance ring grooves during installation, and install flat holding
screw and lubricating grease oil cup.
2) Manually coat all seals with universal lithium base or high-temperature
molybdenum base lubricating grease, and prevent lubricating grease from being in
contact with external surface of distance ring.
3) Install mud pipe in lower packing box assembly (grooved end is upward), and
make tail end of washpipe be flush with lower packing box.
4) Install lower packing box gland and upper packing box gland on washpipe.
5) Install packing and bushing ring in upper packing box.
6) Manually coat all seals with universal lithium base or high-temperature
molybdenum base lubricating grease, and prevent lubricating grease from being in
contact with external surface of distance ring.
7) Install upper sealing pressure sleeve, packing and upper bushing ring in grooved
end of mud pipe.
8) Install spring ring.
9) Install upper O-ring and lower O-ring and keep them at proper positions with
lubricating grease.
2 Installation
2) Coat thread oil at threads, install washpipe assembly on top drive, manually
tighten upper and lower packing box glands.
2) Manually rotate main shaft for 1-2 turns, and centralize packing box of mud pipe.
3) Start brake of top drive.
4) Hammer each flange until the packing box is tightened.
5) Release brake, rotate main shaft, and hammer each flange (release brake for each
hammering) until packing box does not rotate.
6) Slightly hammer flange to tighten packing box gland. Mud leakage cannot be
caused by hammering.
7) Fill universal lithium base or high-temperature molybdenum base lubricating
grease at grease nozzle.
8) Do not open mud pump, rotate main shaft of top drive at rotation speed of about
50r/min for 1 minute, and then open mud pump and check leakage. If leakage
occurs, disassemble, check and repeat the assembly and the installation of washpipe
12
Maintenance Instruction
assembly.
4.6 Pipe handler
Check:
1. Check the rotation flexibility of rotating head.
2. Check the conformity of forward tilting
angle and backward tilting angle of elevator link
with requirement.
3. Check the oil leakage of oil line of tilting oil
cylinder.
4. Check the movement flexibility of tong jaw
block.
Maintenance:
1. Periodically fill lubricating grease in 2
grease nozzle of rotating head.
2. Periodically fill lubricating grease in grease
nozzles (4 positions) of left and right tilting oil
cylinders.
3. Periodically fill lubricating grease in guide
wheel and clamping frame of backup tong.
4. Visually inspect depression or wear of
elevator link, and if any, carry out flaw detection
with ultrasonic wave. Replace elevator link if
necessary.
5. Visually inspect wear condition of tong dies,
and replace with new tong dies if wear is
excessive.
13
Maintenance Instruction
Maintenance Instruction
The flexible action of remote control IBOP is the premise for safe drilling,
15
Maintenance Instruction
4.11 IBOP
Check:
1. Check the adequate lubrication of positions
needing lubrication.
2. Check leakage.
3. Check the wear condition of IBOP.
The weekly check of the wear condition
Notice
Maintenance:
Ensure the reliable sealing of two IBOPs (a
16
Maintenance Instruction
turn, avoid deflection and blockage of flange, and then gradually loosen
17
Maintenance Instruction
Notice
2. Installation
1) Coat molybdenum disulfide lubricating grease on
thread surface of locking bolt and internal surface of
taper sleeve.
2) Clean surfaces of main shaft, IBOP and protecting
joint, and remove grease and dirt on surfaces.
3) Install thread locking device as per the sequence of
upper flange, upper taper sleeve, lower taper sleeve and
lower flange, and complete the installation of the thread
locking devices of main shaft, BOP and protecting joint.
Notice
device
and
clamping
device,
and
Maintenance Instruction
19
In
Maintenance Instruction
the
Maintenance Instruction
4) Install the left or right pulley plate on gear box as per the steps reverse to above
steps, and embed guide plate on guide rail between two rows of bearing wheels
during installation.
21
Maintenance Instruction
7) Slowly release all system pressure by using load release valve in system, and make sure
no pressure in pipe.
8) Before pipe disassembly, mark all connection positions so as to ensure correct
reconnection.
9) Take effective measures to prevent hydraulic oil from leaking and entering other
electric or mechanical components.
Before disassembly of hydraulic pipe, close valves in system, prepare
Note
proper containers, oil plugs, cotton silks etc, and prevent residual
hydraulic fluid in pipe from flowing out to pollute equipment and
environment around when the pipe is opened.
Notic
e
Maintenance Instruction
5) Check the heat exchange capacity of air cooler, and inlet oil temperature is higher than
outlet oil temperature.
6) Check and clean air filter.
Check hose joint for air bubbles.
5.2.3 General spot check (once a year)
1) Sample and assay oil liquid, partially or completely replace with new oil if necessary,
and circularly clean pipe for 24h.
2) Readjust system.
3) Replace relative elements and parts as per circumstances.
4) Check electric wiring, signaling and interlocking functions.
5) Check sealing of hydraulic cylinder, and replace ineffective sealing ring.
Sample and assay oil liquid in oil tank, and determine the cleanness grade of oil
liquid.
5.2.4 Precautions in maintenance of hydraulic source and system
1) When HPU goes wrong, analyze and judge faulted positions and reasons.
2)
When faulted element on hydraulic system is disassembled, first judge the medium
connection between the faulted element and high-pressure oil line, judge whether the
element to be disassembled has pressure before disassembly, and if the element has pressure,
try to release pressure, and then disassemble faulted element.
3) When faulted element is repaired, plug exposed oil port outside hydraulic system with
special part or clear object to prevent impurities from entering hydraulic system.
When element is worn or aged seriously, replace in time to ensure the working
performance and reliability of hydraulic system.
5.3 Maintenance of accumulator
Accumulator of balancing oil cylinder is a nitrogen-precharged pressure container, the
nitrogen leaks to influence usage performance as the piston is worn after the accumulator is
used for a long time. Therefore, periodically check the pressure of precharged nitrogen,
supplement nitrogen if necessary, or replace and reinstall seals.
5.3.1 Check of nitrogen pressure
Check period: check every month or check for each well, and take the shortest period.
1) Check of air leakage
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Maintenance Instruction
a) Check charging pressure with charging tool. As air is released a little for the check
each time, the method is not suitable for the accumulator with small capacity.
b) Install pressure gauge near oil port of accumulator, fill oil liquid in accumulator fully
with pump, stop the pump, and flow the pressure oil slowly from accumulator through valve
connected with the accumulator. In the oil discharge process, observe charging pressure
gauge, the pointer of pressure gauge descends slowly, close the lift valve of accumulator
when the charging pressure valve of the accumulator reaches, and the pointer of the
pressure gauge reaches zero quickly. The read value on the pressure gauge before the
pressure gauge descends quickly is the charging pressure of the accumulator.
2) When the device is not used for a long time, close cut-off valve between oil port and
pressure oil pipe, and keep the oil pressure in accumulator above charging pressure.
3) If accumulator does not play a role in the device, please check the reason of air leakage
of the air valve, and supplement nitrogen if necessary. If no nitrogen is the air cavity of the
accumulator, oil pours from the air valve, please disassemble and check the piston for
damage. If Oil leaks outside the accumulator, please screw up connection part. If oil leakage
occurs still, please disassemble and replace relevant parts.
4) In disassembly, discharge pressure oil, release nitrogen in air cavity with charging tool,
and then disassemble all parts.
5) As per the characteristics of accumulator, assemble the oil inlet valve in the following
way of first putting oil inlet valve, rubber support and supporting ring in shell, installing
rubber support and supporting ring on the valve in the shell in sequence, and then pull outlet
end of valve out of large opening of shell, finally assemble in sequence.
6) Supporting ring is designed so that it can be put in the shell, cut off two sides of the
supporting ring. In assembly and disassembly, flatwise put the cut position of the supporting
ring, and align it with large opening of shell for assembly and disassembly.
5.3.2 Charging of nitrogen
Notic
e
The charging tool is provided along with the top drive, and the safety connection
between the air valve and the nitrogen source shall be ensured. Ensure whether the nitrogen
source is closed before charging, and then connect charging pipe on nitrogen bottle.
24
Maintenance Instruction
Note
oil or grease. Brake pad loses friction force if being polluted by oil or
grease, and replace the brake pad.
25
Maintenance Instruction
26
Troubleshooting
Repair or regulate stroking
mechanism
Increase inclination angle of
inclined tray
Replace return disk
Replace spring
27
Trouble
Trouble diagnosis
types
High noise Insufficient oil liquid in oil tank
Troubleshooting
or
serious
Bad sealing of pump, leakage of contact
pressure
surface or pipe joint, air mixing
fluctuation
Impact of coupling of pump and motor
pointer
Tighten connectors and
replace seals if necessary
Elastic element in coupling
requirement
during
installation
Screw up mounting screw of
pump
Unsmooth oil suction of pump due to Dredge and clean oil suction
impurity accumulation in oil suction line line of pump
of pump
Air suction of pump as valve on oil Check and open valve on oil
suction pipe of pump is not opened
suction line
Unsmooth oil suction of pump as valve Check and open valve on oil
Inflexible
rotation
jamming
pump
pump
Reassemble
Adjust axiality
28
temperature
Actual rotation speed of pump exceeds Replace with high-speed
shall
be serviceable range
pump or decrease rotation
lower
65)
than
speed of pump
Too high speed of oil in pipe and too Thicken oil pipe and adjust
large pressure loss
system layout
Trouble
types
Pressure
fluctuation
Trouble diagnosis
Troubleshooting
Replace spring
8.3 Reinstallation
Regulation
failure
Replace spring
Deformation of spring
Replace spring
29
Trouble types
Trouble diagnosis
Troubleshooting
Trouble types
Trouble diagnosis
No working
output
Troubleshooting
pressure No
charged
air
for Charge accumulator with air
accumulator
as per working parameter
Trouble of oil charging Repair and replace
valve of accumulator
Fracture of capsule in Repair and replace
accumulator
Oil valve of safety ball Check oil valve of safety
valve of accumulator is not ball valve of accumulator.
opened.
Insufficient output flow
Too high charging pressure Charge accumulator with air
of accumulator, and small as per working parameter
volume of pressure medium
in accumulator
Too low charging pressure Charge accumulator with air
of accumulator, and small as per working parameter
volume of pressure medium
discharged
from
accumulator (small volume
change of air bag)
Small total volume of Enlarge total volume of
accumulator
accumulator
6.1.6 Common trouble diagnosis and troubleshooting of explosion-proof electromagnetic
reversing valve
30
Trouble types
Power up electromagnet,
but valve core does not
reverse, and cut off
power, but the valve core
does not return
Trouble diagnosis
Troubleshooting
Trouble types
Trouble diagnosis
Measures
31
of Overflow
closed.
valve
is
Trouble types
Electromagnetic
does not work.
Reasons
valve Whether PLC works or not.
Measures
32
Trouble types
Reasons
Measures
Trouble types
Reasons
Measures
Trouble types
Reasons
Measures
33
Trouble types
Reasons
Measures
Replace with new die plate
(or slip assembly)
Clean groove with wire
brush
Increase pressure properly
Replace the sealing ring
Replace slip
Replace die plate
of
Trouble types
Reasons
Measures
of
Trouble types
Brake disk is
released.
Brake disk does
work or slips
Reasons
Measures
not Complete
jamming
reversing valve
not Low system pressure
Complete
jamming
of
reversing valve
Leakage of hydraulic brake
pipe
Wear inefficiency or fall of
friction plate
Pressure reducing valve
changes in set valve or is
jammed completely.
Abnormal sound in brake Contact between pipe and
rotating member
Looseness of screws of
brake plate
Insensitive braking of Excessive wear of friction
brake
plate
Low pressure of brake oil
35
cylinder
Notic
e
36
37
38
connector, =cooler.
39
40
41