Académique Documents
Professionnel Documents
Culture Documents
Maintenance Manual
Model DQ70BSC
Serial No
06032
Preface
The design, manufacture and service of this product are based on the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000 Quality Management System-- Requirements
API Spec Q1 Specification for Quality Programs for the Petroleum and Natural Gas Industry
This manual contains information relating to Top Drive operation, service and maintenance.
The technical information of this product is included respectively in the following documents:
<Operation Manual>
<Electric Manual>
<Hydraulic Manual>
< Installation and Trouble Shooting Manual>
<Maintenance Manual>
<Electric House Manual>
<HSE Manual>
<Data Backup and Recovery Manual>
<Electric Drawing>
<Mechanical Drawing>
<Hydraulic Drawing>
With individualized design provided for the Top Drive based on the service operating
condition and special requirements of the customers, the technical document for this product
may not be suitable for the other products of the same type. Product type and No. shall be
checked when the technical document is used.
For information not covered by the accompanying documents and other problems arising
from the installation, operation and maintenance, contact the manufacturer if necessary:
BPM
Ads:
Postcode:
100083
Tel:
( 010) 62097381
Fax:
( 010) 62097613
E-mail:
Bpm.zhaojing@vip.163.com
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Contents
1.
Introduction ..............................................................................................................1
2.
3.
3.1.
3.2.
3.3.
Monthly maintenance................................................................................................5
3.4.
Quarterly Maintenance..............................................................................................6
3.5.
3.6.
4.
Lubricating position..................................................................................................7
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
4.8.
4.9.
4.10.
5.
5.1
5.2
5.3
Bail.........................................................................................................................16
5.4
Gooseneck ..............................................................................................................16
5.5
Gearbox..................................................................................................................17
5.6
5.7
5.8
Upper IBOP............................................................................................................23
5.9
IBOP ......................................................................................................................24
5.10
5.11
Backup Tong...........................................................................................................26
5.12
Guide rail................................................................................................................27
5.13
Carriage ..................................................................................................................28
6.1
Accumulator ...........................................................................................................29
1.
Maintenance Manual
Introduction
DQ70BSC Top Drive is composed of power swivel, pipe handler device, electric and
hydraulic transmission control system, driller control, single guide rail and carriage, migration
supporter. Top Drive main body:
Valve manifold
Air cooling
device
Lifting bail
Brake
Wash pipe
Main
motor
Gearbox assembly
Tilt device
M
x 3
Backup tong
Elevator link
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Maintenance Manual
2. Safety Notice
It is necessary to do the safety analysis and safety education work before maintaining.
Whenever changing the original plan, please revise the safe operation application in time to
ensure the safety of operators.
Warning Shut off the power before operation. Except for special notation, please shut
off the power before lubricating, Inspection or changing.
Warning Forbid to maintain and repair when the equipment is running, do not adjust the
equipment when its working.
Warning Please wear the protection tools when maintain and repair the equipment.
Wearing safety goggles to protect the eyes.
Warning Operators may do the maintenance work on high place, which may bring the
danger of bodily injury.
Warning Pay attention to the scald when evacuating the hydraulic oil. It is forbidden to
check the leakage by hands. The hydraulic oil can bring the injury to skin,
operators should use the spill or board to check and wear the safety goggles.
WarningReleasing the pressure in accumulator before repairing the hydraulic system.
WarningPlease do not repair the parts which you dont know much better.
WarningPlease read and learn the safety notice and warning before maintaining.
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Maintenance Manual
Item
Lubricating Item
Measure
1.
grease
2.
grease
grease
Item
Inspection Item
Measure
1.
motor assembly
2.
3.
IBOP
proper operation
4.
5.
hydraulic oil
cleanness etc.
demand
Inspection Item
No.
6.
repair or replace as
per demand
repair or replace as
per demand
repair or replace as
per demand
repair or replace as
per demand
hydraulic pipelines
repair or replace as
per demand
tube
8.
9.
cable
demand
repair or replace as
-3-
No.
Maintenance Manual
Item
Inspection Item
Measure
per demand
repair or replace as
10.
cable joint
break, loose
11.
clamping device
loose
Item
Lubricating Item
Measure
1.
bail pin
grease
2.
rotating head
grease
3.
carriage assembly
18
grease
grease
grease
grease
per demand
3.2.
Weekly maintenance
Lubricating Item:
No.
4.
5.
6.
Inspection Item:
No.
1.
Item
guide ring and
centralization sleeve
Inspection Item
Measure
damage, wear
2.
lock device
3.
IBOP
4.
5.
wear
seam etc.
demand
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No.
Maintenance Manual
Item
Inspection Item
Measure
6.
Carriage roller
wear
7.
8.
fan assembly
9.
motor cable
break
10.
brake disc
wear
Item
Lubricating Item
Measure
main motor
grease
demand
repair or replace as per
demand
hydraulic pump
motor
Inspection Item:
No.
1.
2.
3.
4.
Item
Inspection Item
upper mainshaft
bushing
leakage
Measure
replace as per demand
wear
Maintenance Manual
Item
Inspection Item
Measure
1.
gearbox oil
replace
2.
replace
jam
replace
3.
Item
Inspection Item
mechanical pitting, wear and
Measure
1.
gear teeth
2.
wear or damage
3.
mainshaft
4.
wear or damage
5.
accumulator
backlash
replace capsule or
accumulator
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4.
Maintenance Manual
Lubricating position
Lubricating method:
Filling choke with grease by grease gun.
2 chokes on stabilizer
Lubricating method:
Filling choke with grease by grease gun.
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Maintenance Manual
Lubricating method:
Filling choke with grease by grease gun.
Filling motors with lubricating grease: fill
choke at front side of main motor with special
used lubricating grease, till the lubricating
grease spill over from the screw plug at back
side of main motor.
The lubricating grease used for main motor is
special used, which is recommended to use
Aeroshell No.7 or better ones.
-8-
Maintenance Manual
2 points at two sides of gearbox (Totally 2 points, one side has 1 point)
Lubricating method:
Filling choke with grease by grease gun.
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Maintenance Manual
Lubricating method:
Filling choke with grease by grease gun.
Lubricating method:
Filling choke with grease by grease gun.
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Maintenance Manual
Lubricating method:
Filling choke with grease by grease gun.
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4.9.
Maintenance Manual
Lubricating position:
a
Lubricating method :
Filling choke with grease by grease gun.
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Maintenance Manual
- 13 -
Maintenance Manual
Exhaust Process
a
Maintenance Manual
Equipped with a hose on the air discharge, then open it carefully, close it when the
air has been drained off.
IllustrationThe brake disc will lose the friction force if it is polluted by oil or grease.
The brake disc should be replaced if the friction material sucks the oil or
grease.
Replace the brake friction disc.
Replace the brake friction disc when the friction material
is 6mm left. Note: the new brake friction disc can reach
the rated torque after running in period.
a Discharge the system oil pressure of brake
device.
b Remove the shot pin and return spring screw.
c Sliding the brake disc upward and outward.
d Slip in the new brake friction disc
e Install the shot pin and r return spring screw.
f Tighten up the screw
Note: keep the friction materials clean; dont touch any of oil or grease.
Replace the brake disc.
Replace brake disc when it remains 10mm.
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Maintenance Manual
5.3 Bail
Inspection item:
a The lubrication condition of bail pin.
b The wear condition of bail and bail pin.
c Bail pin baffle and screw.
Maintain item:
a Fill choke in the bail pin with grease regularly.
b Inspect the wear degree of lifting bail and bail pin
regularly; replace when necessary.
5.4 Gooseneck
Inspection item:
a Inspect the fixed bolt and safety lockwire of
gooseneck and wash pipe support regularly.
b Inspect the gooseneck regularly (if there are
concave, wear or corrosion)
c Regularly bulge test for the gooseneck.
Maintain item:
a Dismount the bolts used to fasten the
gooseneck and fix device, in order to fix and
move the gooseneck.
b Clean the inner hole of gooseneck; visually measure and ensure no concave, wear and
corrosionIf exists, please use ultrasonic flaw detection.
c Paint the thread grease to the thread before reinstalling.
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Maintenance Manual
5.5 Gearbox
Inspection item
a
b
c
d
Maintain item:
IlluminationBPM Top Drive could work in the condition of widely changeable
ambient temperature. Before changing the oil, select the oil according to the
prognostic circumstance temperature.
NoteIt is recommended to replace oil every six (6) months or replace according to
practical inclement situation.
warning
Using oil viscosity degree over than environment requires will lead to
damage of gears and bearings.
Using oil viscosity degree lower than environment requires could not create
effective oil film, and finally lead to wear and tear.
Make sure that the lubrication oil is clear enough before filling into the
gearbox. Prevent contaminants, such as mud or grains of sand from going
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Maintenance Manual
into the gearbox, and finally result in blocking up of lubrication oil way or
damaging the bearing and gear, etc.
a The oil level of gearbox should keep a certain height. Charging the oil when the level
is over low to prevent the bearing gear from wearing.
NoteOil level of gearbox should between the lowest and highest scale. The oil level
is over low, which will lead to less of lubrication cooling. The oil level is
over high, which will lead to leakage of lubrication oil.
b Clear up mud after replacing wash pipe. Keep gearboxs cover, wash pipe bracket,
and mud umbrella clean all the time. Inspect oil pointer once a day at least, if colour
of lubricating oil is unusual, check in time by below items:
Clean gearbox by gasoline. To avoid blocking oil circuits, do not use cotton
kinds of things to erase.
Replace sealing, ring, and V water sealing nearby the mud umbrella. Smear
flange sealant on K-face when assembling.
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Maintenance Manual
c Please contact the BPM Top Drive centre when dismounting the gearbox lubricating
pump.
d Please contact the BPM Top Drive centre when dismounting the gearbox.
e Please select the proper gear oil refers to appendix B.
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Maintenance Manual
- 20 -
Maintenance Manual
x 3
Maintenance Item:
a Lubricate the elevator link eye with pipe
lubricant of threads.
b Lubricate the lubricating points.
c The installation and
elevator link.
disassemble of
- 21 -
Maintenance Manual
inch
inch
2 3/4
350
4 13/16
2 9/16
300
4 5/8
2 3/8
225
4 7/16
2 3/16
175
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Hoist capability
ton
Maintenance Manual
Baffle
Rotating pin
Roller
Axle
Support
Bolt
Sleeve
Crank
Cover plate
Maintenance Manual
5.9 IBOP
Inspection Item
a Inspect the lubricating position everyday.
b Ensure working normally and no leakage.
c Inspect the wear status of IBOP weekly.
Illuminationit is important to inspect the wear status of IBOP weekly.
Maintain item:
Two IBOP (upper and lower) should be
sealed well; test pressure should be
70MPa; open or close totally when
operating.
retaining
ring
upper
matching
ring
support
ring
upper
valve seat
It is recommended to do magnaflux
handle
seat
operation
handle
than 1.6mm, it is necessary to replace at
once.
lower
matching ring
ball
float
lower
valve seat
valve
body
- 24 -
5.10
Maintenance Manual
Inspection item
a If the bolts loose or not.
b Inspect the safety lockwire
Noteplease replace the loosened bolts as soon as possible.
Disassemble the IBOP locking device
a Dismantle the lockwire.
upper lock
ring
tooth plate
bolt
Maintenance Manual
flange plate, and make sure that the flange interspaces are equal.
g Tighten the bolts with torque wrench clockwise or counterclockwise till all tighten
torque of bolts reach to 200Nm.
h Fix all bolts with steel wire.
Illustrationthe IBOP locking device should be put in the connection position between
two parts of upward and downward in equidistance. The tooth plate should
be distributed in the connection position between two parts of upward and
downward in equidistance.
Noteplease do not tighten the lock bolts before the IBOP locking device is put
correctly.
NoteIt is forbidden to tighten the lock bolts on diagonal direction.
NoteEnsure all bolts to be tightened correctly; The interspaces between IBOP
locking device flange plates should be consistency.
5.11
Backup Tong
Inspection item
Inspect the fastener of bolts timely to make sure
they have fasten-locked and no damage happens.
Replacing is needed when they are broken, and
please avoids the fastener parts loose or drop off.
Maintain item
a Clean the oil contamination and sundries in the
tooth plate groove and surface in time.
b Fill grease to choke every day.(refer to the
picture)
c Paint enough grease on the tong tooth seat
when replacing it.
Disassemble and installation of Backup Tong
When disassemble and install the Backup Tong, firstly, please dismount the hanging pin
which connecting the Backup Tong bracket and supporter connection. Then, dismount the
Backup Tong bracket, put the Backup Tong down onto the ground or workbench, disassemble
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Maintenance Manual
the two pins and front Backup Tong and the back tooth seat which connecting on the piston.
Because the front and back covers are all fixed by three semiannular rings, operator could
take out the piston at backside when disassemble the semiannular rings stop collar and
semiannular rings itself. Please take care of avoiding breaking the seal parts when take out the
piston and covers.
Replace tong tooth
a Dismount the pin which connecting the front tong with hydraulic cylinder
(disassemble one is enough), then, rotate to pull apart the front tong 90.
b Dismount the tong tooth fixing plate, and replace the tooth plate, then, install the
fixing plate and pins.
c Replace the tong tooth seat does the same first step as changing the tong tooth. You
must open the front tong firstly, then dismount the front and back tooth seat, and
replace the relevant tooth seat.
5.12
Guide rail
Inspection item
a Inspect the guide rail joint pin, lock pin and split pin.
b Inspect the welding spot damage and fracture status
of adjustable plate and guide rail junction block.
c Inspect the loose status of fix bolts of guide rail
reactive torque supporter.
Maintain item
a Inspect the guide rail connecting pin shaft, lock pin
and split pin.
- 27 -
5.13
Maintenance Manual
Carriage
Inspection item
a Inspect the loose status of roller nut.
b Inspect the wear status of roller surface.
Maintain item
a Fill grease to the choke of two-side roller shaft and carriage up/down face.
Replace the roller
It is forbidden to dismantle the roller when the carriage is on the slide position (the normal
working position) of guide rail; to replace roller, operator must slide Top Drive body and
carriage out from guide rail.
a Fix the body and the first guide rail under the guide rail with pins.
b Dismantle the joint pin of the first guide rail, and then dismantle this guide rail from
Top Drive body.
c Separate the first guide rail from the body and pull it out from the carriage.
d Dismantle the old roller and install a new one.
e Install the body onto the guide rail as per contrary processes.
Round nut
Stop ring
Wheel body
Loaded wheel
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Maintenance Manual
6.1 Accumulator
The accumulator of counterbalance cylinder and HPU is a pre-filled nitrogen pressure
container. Long time use will lead to capsule break so that the nitrogen will out. Therefore, it
is necessary to inspect the pressure of pre-filled nitrogen and refill the nitrogen or replace the
capsule.
NoteClose the stop valve between oil mouth and pressure oil tube, keep the
accumulator oil pressure higher than the gas filling pressure.
Inspection item
If accumulator is error, inspect the following items:
a If the gas valve is leak out; refill nitrogen if necessary.
b If there is no nitrogen in the capsule, while the gas valve position is leaking oil, please
inspect the capsule.
c Please shoulder up the connecting parts if the accumulator is leak out. If it still can
not work, please replace the relevant parts.
Inspect the nitrogen pressure
Inspect the gas filling pressure with filling tools.
Fill nitrogen with charging tools when the pressure is lower than the preset pressure.
- 29 -
Maintenance Manual
- 30 -
Maintenance Manual
Diameter
Min. torque
(ft-lb)
Max. torque
(ft-lb)
1/4
20
7.6
8.4
2020
5/16
18
16
18
3340
3/8
16
29
32
4940
7/16
14
48
53
6800
1/2
13
71
79
9050
9/16
12
105
116
11600
5/8
11
143
158
14400
3/4
10
247
273
21300
7/8
409
452
29400
608
672
38600
1-1/8
760
840
42300
1-1/4
1064
1176
53800
1-3/8
1387
1533
64100
1-1/2
1843
2037
78000
- 31 -
Maintenance Manual
Diameter
Min. torque
(ft-lb)
Max. torque
(ft-lb)
1/4
20
5.7
6.3
2020
5/16
18
12.1
13.4
3340
3/8
16
21.4
23.6
4940
7/16
14
36
39
6800
1/2
13
53
59
9050
9/16
12
78
87
11600
5/8
11
107
118
14400
3/4
10
185
205
21300
7/8
306
339
29400
456
504
38600
1-1/8
570
630
42300
1-1/4
798
882
53800
1-3/8
1040
1150
64100
1-1/2
1382
1582
78000
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Maintenance Manual
Diameter
Min. torque
(ft-lb)
Max. torque
(ft-lb)
1/4
28
9.5
10.5
2320
5/16
24
18
20
3700
3/8
24
33
37
5600
7/16
20
52
58
7550
1/2
20
86
95
10700
9/16
18
114
126
12950
5/8
18
162
179
16300
3/4
16
285
315
23800
7/8
14
447
494
32400
14
665
735
42200
1-1/8
12
836
924
47500
1-1/4
12
1178
1302
59600
1-3/8
12
1596
1764
73000
1-1/2
12
2090
2310
87700
- 33 -
Maintenance Manual
Diameter
Min. torque
(ft-lb)
Max. torque
(ft-lb)
1/4
28
7.1
7.9
2320
5/16
24
13.5
15.0
3700
3/8
24
25
28
5600
7/16
20
39
43
7550
1/2
20
64
71
10700
9/16
18
86
95
12950
5/8
18
121
134
16300
3/4
16
214
236
23800
7/8
14
335
370
32400
14
499
551
42200
1-1/8
12
627
693
47500
1-1/4
12
884
977
59600
1-3/8
12
1197
1323
73000
1-1/2
12
1568
1733
87700
- 34 -
Maintenance Manual
thread spec
10.9 grade
12.9 grade
M8
22
30
37
M10
45
63
75
M12
78
109
131
M16
193
271
325
M20
328
531
637
M24
653
906
1101
M30
1300
1828
2193
- 35 -
Maintenance Manual
Winter
7--30
Summer
2EP
4EP
6EP
68
150
320
Castrol
Alpha LS-68
Alpha LS-150
Alpha LS-320
Chevron
NL Gear 68
NL Gear 150
NL Gear 320
Exxon
Spartan EP68
Spartan EP150
Spartan EP320
Gulf
EP Lube HD68
EP Lube HD150
EP Lube HD320
Mobil
Shell
Omala 68
Omala 150
Omala 320
Statoil
Loadway EP68
Loadway EP150
Loadway EP320
Texaco
Meropa 68
Meropa 150
Meropa 320
Total
Carter EP 68
Carter EP 150
Carter EP320
Union
GB7323-87
Precision
instrument grease
ZT-53-7
Be used in winter
- 36 -
Maintenance Manual
Service personnel
Date
Detail Work
- 37 -
Remark
Date
Maintenance Manual
Detail Work
- 38 -
Remark
Date
Maintenance Manual
Detail Work
- 39 -
Remark
Date
Maintenance Manual
Detail Work
- 40 -
Remark
Maintenance Manual
Group number:
Contact person:
Contact
Well number:
Phone:
Mobile phone:
Fax:
Email:
Well location:
Top Drive model/serial no:
Installation time:
Present task:
Hole configuration
Next task:
Drilling
parameter
Maximum speed:
Maximum torque:
Mud density:
Hook weightaverage:
Failure
description
Signature:
Date:
Note Please fax this list to: Beijing Petroleum Machinery Factory Top Drive Center
Tel.:0086-10-62097381 Fax: 0086-10-62097613 Email: bpm.zhaojing@vip.163.com
- 41 -