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Drillmec SpADrilling Technologies
12, Via 1 MaggioI-29027 Gariga di Podenzano
PIACENZA (Italy)
Corporate web site: http://www.drillmec.comMailbox: [email protected]
Ph +39.0523.354211Fx +39.0523.524418
TRAININGMR8000
CAREFULLY READ THIS MANUALBEFORE OPERATING THE MACHINE
!
Drilling rig semitrailer mounted
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zilianiCasella di testo
zilianiCasella di testo
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DRILLING RIGMR 8000
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IDENTIFICATION
This equipment is identified through the serial number and/or the identification numbers on main components.
EQUIPMENT IDENTIFICATION PLATE
The equipment identification plate shown in the picture re-ports all identification data for the machine. The label islocated on the lefthand side of the equipment, on the mastsupport. Always check that the equipment part number(N. MATR.) stamped on the plate matches with that re-ported on the front cover of this manual.
Piacenza - ITALY
Machine type
Serial Number
Year of manufacturing
Nominal Power
Weight
0953-3682E
[Kg]
[Kw]
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NOMENCLATURE OF THE MAIN COMPONENTS
CROWNBLOCK
MONKEYBOARD
TRAVELLINGBLOCK
POWERTONG
SERVICEWINCH
SUBSTRUCTURESEMITRAILER
DIESELENGINE
OILTANK
DRAWWORKS
COMPOUND
DRAWWORKS
STAIR
DIESELENGINE
WALKWAYS
TRANSMISSION
SUBSTRUCTURE
SERVICEWINCH
DRILL PIPE RAMPAND STAIR
ROTARYTABLE
DRILLFLOOR
POWER TONG
HYDRAULICBRAKE
TELESCOPICSECTION MAST
FIXEDSECTION
MAST
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TECHNICAL SPECIFICATION
Semitrailer mounted mobile rotary drilling rig DRILLMEC MR 8000 model, suitable for -20C to +40C range temperature.The rig is manufactured in accordance with API standards.
MAST
Technical Data (Ratings to API 4F)
Static Hook load (w/10 lines) : 200 metric tons (440,000 lbs)Clear height : 35.97 m (118 ft) from ground levelClear height to rotary beams : 4.17 m ( 15.11/16 ft) from ground levelRacking Board Elevation : 16.76 m (55 ft) from drill floor levelCrown Block Sheaves : 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;
Hydraulic Catheads Break-out : max pull 12,000 kilos (26,400 lbs)/ stroke 1.3 mHydraulic Catheads Spinning : 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
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SUBSTRUCTURE
- Max. Rotary Table Load (Casing Capacity) : 200 metric tons (440,000 lbs)- Max. Setback Capacity : 113 metric ton (250,000 lbs)- Simultaneous Capacity : 313 metric tons (690,000 lbs)- Drill Floor Height : 5,180 mt (17 ft)
Two steel skids are placed below the semi-trailer body levelling jacks and are part of the substructure auxillary equip-ment.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 ofseveral 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: 15psi- Max speed: 1550 rpm- Brake capacity: 5000 Hp- Volume: 13-1/2 gal- Hydromatic brake air clutch: 26 CB 525
TRAVELLING BLOCK - HOOK
- Load capacity: 500,000 lbs (250 metric ton)- Sheave: five 30 (76.2 cm)- Grooved for drill line OD: 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 collarsup 9.1/2, consisting of:- Double hydraulics clamps. Top one rotating with max torque: 101,000 lb-ft (14,000 kg-m).
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- 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 1Description EExd Obstruction Red Light with XenoFlash 230V-60HzType EVX4070
XF2J1FE110A3Supplyer Cortem Sirena
MONKEY BOARD:
Q.ty 1Description EExd Floodlight 230V-60Hz 400W with Metal Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
MAST:
Q.ty 6Description EExd Floodlightwhit Energy Saver Lamp 230V - 60Hz 23W (130Watt)Type EVGC 3070
Plet-23Supplyer Cortem
DRILLING FLOOR & SUBSTRUCTURE
Q.ty 5Description EExd Floodlight 230V-60Hz 400W with Metal Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
TRAILER:
Q.ty 2Description EExd Floodlight 230V-60Hz 400W with Metal Jodure Lamp 400WType FLSA40Supplyer ITALSMEA
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MAIN DIMENSIONS
WORKING CONFIGURATION
TORNELLO MANOVRA
TORNELLO SERVIZIO
440
890
500
3030 1825
1033
20500 (67'-3")
30785 (101')
16764 (55')
35966 (118')
2020
2950 (9'-8")
7000 (23')
5182 (17')
1570 4170
12000 (40')
4616 (15')
5233 (17')
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KG 73000
KG 12000
KG 12000
KG 12000
KG 12000
KG 25000
3406
2500
7000
15
1375
4860
21075
5951
2374
1360
1360
1360
8670
TRANSPORT CONFIGURATION
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MAST GUYLINE LAYOUT
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zilianiCalloutWIRE ROPE 22 mm
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A-3.4.4 HOIST WIRE ROPE REEVING DIAGRAM
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111
8
12
8
7
3
9
6
10
5
4
2
7 1
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Item Code Q.ty Description
1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS
2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS
3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS
4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS
5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS
6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS
7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS
8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS
9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS
10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS
11 4059 0116 2 CARDAN JOINT
12 4059 0126 1 CARDAN JOINT
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13 4100 1122 1 ROPE D.28.57 (1.1/8")
A-3.4.5 POWER FLOW DIAGRAM
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118
10
440 000
83
61
6,627
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440 000
250 000
690 000
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18500
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SAFETY DEVICES
Both the complete machine, and its individual parts, arefitted with built-in safety devices.
- All cylinders are equipped with check valves. In case ofbreaking of connecting pipes or pressure drop or fail-ure, the cylinders will be locked thus preventing anyunwanted movements.
The machine is fitted with the following buttons for emer-gency stop and mechanical locking devices:
WARNINGIn case of engine stop for a long time, it is mandatoryto switch off the batteries Q1 and Q2.
- C20 emergency on the main control panel stops drill-ing rig operation.
- Engine start up, and therefore machine operation, canonly be performed by pressing start button on dieselengine control board and battery breaker is on.
- Emergency control board near diesel engine stops onlydiesel engine.
Q1
Q2
C20
Emergency
Emergency
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- C29 and C30 emergency is located on draw work andstops drilling rig operation.
C29
C30
Safety mechanical block stabilizer (Fig. B-3.7).
- The drilling rig is equipped with a limit switch for properoperation.
- The machine is also equipped with protective panelsand fixed guards (fitted with the following plate: Safetydevice - Do not remove) in order to avoid coming intocontact with drive gears in motion or hot hydraulic com-ponents.
HAZARDBefore operating the machine, verify all safety devicesare present and properly working.
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DIAGRAM OF SAFETY DEVICE FOR EMERGENCY STOP
C30
C29
Q1 Q2
C20
Emergency
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RPM
RSSTE
ES
CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (LEFT HAND FROM FLYWHEELSIDE)
RPM Diesel engine hour-counter and RPM indicator
ES Emergency push buttonTE Diesel engine hour counterRSS Start - Stop switch
Q1 Battery breaker
DEE Diesel engine engage
DEE
Q1
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Fig. C-1.5
R2
Fig. C-1.6
R3
R2 Throttle knob on control panel
R3 Throttle pedal on drill floor
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CONTROL AND INSTRUMENTS FOR DIESEL ENGINE (RIGHT HAND FROM FLYWHEELSIDE)
TE Diesel engine hour-counterES Emergency push buttonRPM RPM IndicatorRSS Start - Stop switch TE
R2
DEE Diesel engine engage
Q2 Battery breaker
RSSRPM
ES
DEE
Q2
R2 Throttle knob on control panel
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zilianiCasella di testo
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POSITIONING CONTROLS
A10 Stabilizers oil pressure gaugeC18 L.H. Rear stabilizer remote controlC19 R.H. Rear stabilizer remote controlC20 L.H. Front stabilizer remote controlC21 R.H. Front stabilizer remote controlC22 Mast raising cylinder remote controlC23 Mast telescopic remote controlC24 Telescopic locking remote controlC25 Stabilizers distributor shut-off ball valve
C18
A10
C25
C19 C20 C21 C22 C23 C24
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DRILLING CONTROLS AND INSTRUMENTS
A4 Compressed air gaugeA6 Main drum compressed air gaugeA7 Drum brake cooling water pressureA8 Drawworks lubricating oil pressureA9 Lubricating oil pressure gauge for transmission compoundA11 Cathead spinning pressure gaugeC14 Main drum clutch controlC15 Crown - O - matic controlC16 Speed selector engineC17 Pneumatic system feedingC18 Rotary table clutchC20 Emergency stopC21 Hydromatic brake controlC27 Auxiliary equipment remote controlC28 Spinning cathead controlC29 Break-out cathead controlHW1 Engine warning lampHW2 Engine warning lampR2 Throttle knobR6 Torque regulator spinning cathead
C15
A4 A9 A8 A7 A11
C16
C20
A6
R6
C21HW1
HW2R2
C27 C17
C18 C28 C29 C14
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A17 Weight indicatorA18 RPM Rotary tableA19 SPM Mud pump 1A20 SPM Mud pump 2A21 Torque Rotary tableA22 Mud pressureA23 Digital pump stroke counter and totalizerA24 Tong line pullC31 Main drum brake lever on drill floorR3 Throttle pedal
C31
R3
A17
A18
A24
A21
A22
A20
A19
A23
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DEVICE INSTALLED IN OTHERLOCATIONS
A26 Draw works lubricating oil pressure manometer
A25 Transmision lubricating oil pressure manometer
C29 Emergency lever on L.S. draw works
Fig. C-1.16
Fig. C-1.17
Fig. C-1.19
A26
A25
A24
Fig. C-1.18
C29
A24 Visual level oil tank transmission
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C30 Emergency lever on R.S. draw works
Fig. C-1.20
C30
A12 Hydraulic oil temperature meterA13 Visual level on oil tank
Fig. C-1.21
A13A12
Fig. C-1.22
A28
C31
Fig. C-1.23
A28 Visual level oil tankC31 Main drum brake lever
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C27 Ball-Valve hydraulic pump suctionC28 Ball-Valve hydraulic pump suction
FUEL LEVELPILOT ALARM
C27
C28
C30
C30 Service winch control on drill floor
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Mud system instrumentation is mounted inside dog house, for information of this system you can see commercialdocuments.
C26
SERVICE WINCH ONMONKEY BOARD
C26 Service winch control on monkey board.
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DIESEL ENGINE STARTING (POWERPACK)
C-2.1.1 COLD STARTING
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 minimumrpm.
4) Rotate clockwise start key RSS. This way the motorstarts the diesel engine as soon as this is started, re-lease the push-button.
5) Few minutes of operation at minimum load are suffi-cient to reach engine working temperature.
IMPORTANTThe first machine positioning does not require press-ing the throttle.Movements are performed at minimum rpm.
IMPORTANTMax. engine rotation is set at 2100 rpm ( 50 rpm).When giving full power, always remenber to check rpmcounter and make sure that max. rpm are never ex-ceeded. (RPM)
RSS
RSS
C24
C47
C48
R2
C17
RPM
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DIESEL ENGINE STOPPING (POWERPACK)
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 Diesel engine hour-counterRSS Starting button on diesel engineRPM RPM indicatorQ1/Q2 Battery breaker
OPERATING INSTRUCTIONS
PRELIMINARY CHECKS
1. Before starting work, make sure you have performedall necessary checks and servicing operations as re-quired by the hours worked by the machine.
IMPORTANTFor the complete machine, refer to hour-counter TE
2. It is recommended that you always refuel the hydrau-lic power pack diesel engine before starting theworkshift. This will prevent the machine from forcedstopping during operation.
Fig. C-3.1
TE
Fig. C-2.5
Fig. C-2.7
RSS
RSS
TE
RPM
Fig. C-2.6
Q2
Q1
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PRELIMINARY OPERATIONS
1. Set the skids according to Fig.
2. Set skids 1-2 under the four hydraulic levelling jacks ofthe semitrailer.
3. Start the hydraulic oil circuit: Start engine at Iow speed Operate C25 ever on the hydraulic control panel in
the installation postion.
4. Lower the two front and rear jacks of semitrailer bymeans of distribution valves levers on the hydrauliccontrol panel located in the rear left side ofsemitrailer.
5. Apply the side walkways to the semitrailer.
NOTEBefore shipment, lubrication oil is drained from oilreservoirs (except for the one of the auxiliaires trans-mission oil circuit).
RSS
RSS
C25
C18 C19 C20 C21
1 2
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LEVELLING OF RIG
1. Make sure that handle of speed selector C19 on con-trol panel is in neutral position.
2. Check that main air tank is full by means of the relatedgauge (A- 4).If it is not, fill it by an engine compressor or a hoseconnected to external compressor.
3. Start engine at low speed
4. Run engine at low speed until both the engine water,speed selector and converter oil reach the work tem-perature
5. By operating distributors levers on the hydraulic con-trol panel properly level rig.To avoid frame twisting, simultaneously operate the twofront handles and then the two rear handles. Semitrailerfloor must be 1.650 mm. high from ground floor.
6. When rig is properly levelled, lock levelling jacks bymeans of safety ring nuts.
IMPORTANTHook may be loaded only after rig is mechanicallylocked by means of safety ring nuts.
7. Anchor to plinths the two tighteners fixed to the frontsides of semitrailer.
SUBSTRUCTURE SETUP
NOTE:
Substructure is made up of two main elements: the ro-tary part (skids, bearers, floors, etc...) and the setbackpart (part (skids, bearers, floors, etc...).Rotary skid , as well as setback rotary on the oppositedrillers side, can be either transported indipendently fromthe 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 accord-
ing the related drawing. In case of separate transpor-tation, connect the skid of drillers opposite side torotary 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.
5. Settle the four telescopic bearers at working heightby means of safety pins.
6. Place the setback element skid at drillers side nearthe rotary skid. In case of separate transportation,connect the skid of drillers opposite side to the set-back element by means of suitable bearers.
7. Hook a crane to the four ears of setback frame andraise it up to the working position
8. Settle the four telescopic bearers to the working heightby means of safety pins.
9. Anchor the rotary working floor to setback floor.10. Pin the two rotary skids with the two setback skids.11. Connect the substructure rear skid with the two set-
back skids.12. Set the four braces of above drawing and pin them to
substructure skids.13. To make substructure more stable set the six
tighteners between working floor and front and rearskids of substructure.Lock tighteners at correct height by means of jamnuts.
14. Install the B.O.P. trolley guides and fix them with pins.Install the B.O.P. trolley.
15. By means of truck crane install pipe ramp and sideladders.
16. Install working floor safety handrails.
INSTALLATION OF DRIVE CHAINBETWEEN ROTARY TABLECOUNTERSHAFT AND ROTARY TABLE
A) Fix the two swinging chain housing as per drwg SpareParts Catalogue.
B) Mount chain and tension it through tighteners (SpareParts Catalogue).
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11
74
1010
5
9 6
2-3
1
POS. CODE Q.ty DESCRIPTION
1 01902240 1 DRIVE BAR STORAGE HOLE FIXTURE2 01906175 1 PROBE ANCHORS AND TRANSMISSION ASSY3 01906177 1 SIDE PLATFORMS ASSEMBLY4 01906178 1 B.O.P. SERVICE TROLLY5 01906180 1 SUBSTRUCTURE STAIRWAYS6 01906181 1 DRILL PIPE RAMP7 01906182 1 SUBSTRUCTURE FRAMES8 01906191 1 DOG HOUSE GROUP9 01906258 1 DRILLING PIPE SUPPORT FOOTBOARDS10 01906312 1 MAIN SKID FRAME11 01908104 1 DRILL FLOOR HANDRAILS ASSY
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Fig. C-3.6
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 com-
pletely full;- screw the plugs.
2. Run engine at approximately 1200 RPM
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3. By means of valve lever on the hydraulic control panel gradually raise mast in working position and lock it by meansof 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 theinstructions 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 telescopemast.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 triggeringvalue 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 theupper 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 takesright position, pins of handrails must be inserted .
6. Anchor guylines lower ends to tighteners of trailer and substructure skids. Slightly tension tighteners (Spare Parts
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Manual).See also the API recommended guying patterns table.
NOTEMake sure that mast inclination angle is correct, by checking that the distance between well center and mast pinis 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 rigto operate at the maximum power.
a) ENGINEFollow the manufacturer s instructions.
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TORNELLO MANOVRA
TORNELLO SERVIZIO
440
890
500
3030 1825
1033
20500 (67'-3")
30785 (101')
16764 (55')
35966 (118')
2020
2950 (9'-8")
7000 (23')
5182 (17')
1570 4170
12000 (40')
4616 (15')
5233 (17')
b) RIGAfter 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 adjust-
ment to remove slacks caused by initial elongations.
RECOMMENDATIONIn order to prevent personal injury during the perform-ance of any maintenance procedure, make sure thatcomponent to be overhauled is not working.
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MAIN CONTROL PANEL
OPERATING INSTRUCTIONS
All air gauges, oil gauges and controls are mounted onmain control panel, positioned on the drillfloor.Before starting drilling operations and at frequent intervals,while rig is in operation, check gauges and controls toensure that the correct air and oil pressures are suppliedto each point (see the related tables in the following pages).Operating instructions are indicated here below and arealso illustrated on panel.
WARNINGNever stop the engine abruptly when operating at fullload (unless required for emergency conditions).
1. Crown-o-matic push-button C15
ENGAGINGThe crown-o-matic is a safety device, wich automaticallycontrols the tripping of the drilling travelling block, preventigit from clashing against the crown block.This system senses when the travelling block is within apreset distance of the crown block. It disengages the clutch,then simultaneously applies the brakes to the drawworks.
DISENGAGINGPush C15 button and simultaneously release the brake:the drilling travelling block comes down due to its ownweight. In the meanwhile, the driller assistant must go nearthe drawworks and put the crown-o-matic toggle valve inits rest position.
Item DescriptionStandard Crown Block Safety System
1 Track
2, 3 Short Toggle Valve Assembly
(P/N 50640652)
4, 5, 7 Clutch Assembly
6 Air Cylinder Assembly
BRAKELEVER
31
2
5
47
6
TOCONTROLPANEL
C15
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2. Speed selector engine control valve C16
3. Engine emergency shut-down-control valve C20For 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 R2Turning clockwise the control knob increases RPM of die-sel engine.Turning ccw the control knob decreases RPM of dieselengine.
5. Spinning cathead torque regulator-control valveR6
6. Auxiliary winch-remote control C30 (hydraulicwinch mounted on drill floor)
7. Auxiliary winch-remote control C26 (on monkeyboard)
8. Hydraulic brake clutch-control valve C21The upward movement of this valve handle engages thehydraulic brake clutchThe downward movement disengages the hydraulic brakeclutch.
9. Rotary table fender sliding control valve C18The upward movement of this valve handle the rotary tableopening fenderThe downward movement the rotary table closing fender.
10. Hydraulic catheads-control valves C28 and C29The upward movement of control valve C28 actuates thespinning cathead.The upward movement of control valve C29 actuates thebreak-out cathead.This handles automatically return to neutral position whenreleased.Also the cylinders of catheads return automatically to fullextended position.Turning clockwise the control knob increases torque ofmake-up cathead.Turning ccw the control knob decreases torque of make-up cathead.
C16
C 20
C21
R6R2
C18C29
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11. Main drum clutch-control valve C14The upward movement of this valve handle engages themain drum clutch.The downward movement disengages the main drum clutch.
12. Auxiliary equipment remote control valve C27Auxiliary equipment (tongs or hydraulic motor, etc) areactuated by means of handle C27.
C27
C14
40
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13. Main air pressure-gauge A4This gauge indicates the air pressure in the control panel(7.7 bar steady-scale 0-16 bar)
14. Drawworks oil pressure-gauge A8It indicates lubricating oil pressure of drawworks. In work-ing condition it shall be 0.7 bar-(scale 0-6 bar)
15. Brake rim cooling water pressure-gauge A7It indicates cooling water pressure of internal circuit. Thewater flow must be costant and its value is 189 lit/min(gauge scale 0-6 bar)
WARNINGBe sure that no water leakage is falling on brake band.In case of failure, repair immediately.
16. Main drum clutch air pressure-gauge A6 low speedIt indicates air pressure inside drum low speed clutch.
17. Spinning cathead oil pressure-gauge A11It indicates the pressure inside spinning cathead cylinder.Pressure: 0-250 bar (scale 0-400 bar)Pulling force. Up to 6 Ton
18. Lubricating oil pressure gauge for transmissioncompound A9This gauge indicates lubricating oil pressure insidetransmission compound
A4 A9 A8 A7 A6A11
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POWER TONG CONTROLS
Remote control panel
A15 Power tong clamping forceA16 Torque power tongC36 Lifting up-downC37 Tilt open-closeC38 Torque make up-returnC39 Torque break out-returnC40 Lower clamp open-close
Fig. C-4.7
A15A16 R10
R11
C36C39
C38 C40 C37
POWER TONG
ROTARY TABLE
POWER TONG
DRILL FLOOR
DRILLFLOOR
Fig. C-4.8
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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 TABLE2) CHECK CONDITION OF DRIVE CHAINS, HOSES, DISCHARGE LINES, ETC. AND REPLACE WHEN NECESSARY.3) KEEP OIL PRESSURE BETWEEN 0.4-1.75 BAR4) 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 CONTAMI-NATED 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 TABLE6
7
3
1113
114
2
15
8
16 10 9 12
18
1745
18
46
-
FREQUENCY N IN DESCRIPTION TYPE OF GREASEFig. D-1.2
EVERY 1 DRAWWORKS:DAY STUFFING BOX OF WATER SWIVEL SHELL SUPER GREASE EP2
JOINTEVERY 2 MAST:
DAY WIRELINE GUIDE ROLLERS OF SHELL SUPER GREASE EP2HYDRAULIC CATHEADS
EVERY 3 WIRELINE LAZY FULLEYS FOR SHELL SUPER GREASE EP2DAY HYDRAULIC CATHEADS
EVERY DAY 18 POWER TONG SHELL SUPER GREASE EP2
EVERY 7 DAYS 4 DRAWWORKS:MAIN GREASING PLATE SHELL SUPER GREASE EP2
EVERY 7 DAYS 5 BRAKE LEVER PINS SHELL SUPER GREASE EP2
EVERY 7 DAYS 6 CROWN AND TRAVELLING BOX:BEARINGS AND JOINTS SHELL SUPER GREASE EP2
EVERY 7 DAYS 7 HOOK:UPPER SEALS AND JOINTS SHELL SUPER GREASE EP2
EVERY 7 8 MAST:DAYS ROPE ROLLERS SHELL SUPER GREASE EP2
ON THE INTERMEDIATE SECTIONEVERY 30 DAYS 9 DRAWWORKS: SHELL SUPER GREASE EP2
IDLE GEARSEVERY 30 DAYS 10 TRANSMISSION:
UNIVERSAL SHAFT CROSS SHELL SUPER GREASE EP2IDLE GEARS
EVERY 30 DAYS 11 ROTARY TABLE TRANSMISSION:UNIVERSAL SHAFT CROSS SHELL SUPER GREASE EP2
AT EVERY RAISING 12 DRAWWORKS:OR LOWERING OF WIRELINE GUIDE ROLLER OF SHELL SUPER GREASE EP2
MAST DRAWWORKSAT EVERY RAISING 13 MAST:OR LOWERING OF PINS; SHELL SUPER GREASE EP2
MASTAT EVERY RAISING 14 RAISING JACK PINS;OR LOWERING OF SHELL SUPER GREASE EP2
MASTAT EVERY RAISING 15 TELESCOPING SECTION LOCKOR LOWERING OF SHELL SUPER GREASE EP2
MASTSEE 16 ENGINE CATERPILLAR SEE MANUFACTURERS
MANUFACTURERS INSTRUCTIONS INSTRUCTIONS
SEE 17 PARMAC HYDRAULIC BRAKE SEE MANUFACTURERSMANUFACTURERS INSTRUCTICNS INSTRUCTIONS
47
-
OIL LUBRICATION
4
611
8 9 11 2 1
310597
48
-
YCNEUQERF NIN.giF3.1-D
NOITPIRCSED YT.Q.TIL
.DIEAS EPYTLIO
YADYREVE 1 :SKROWWARDLEVELLIOKNAT-
RETLIFLIO-
052 03EAS 001ALAMOLLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
2 ELGNATHGIRXOBRAEG
081 001ALAMOLLEHS
YADYREVE 3 LIO:ELBATYRATORLEVEL
5 022ALAMOLLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
4 KOOHXELPIRT 5 LIOSULLETLLEHS64TS
EESS'RERUTCAFUNAM
SNOITCURTSNI
5 SROSSERPMOCRIA 5.2+5.2 NPCNOSAES30973298
DNARLLOSREGNI
YADYREVE 6 :TIUCRICCILUARDYHLEVELLIOKNAT-
RETLIFLIO-
LIOSULLETLLEHS64TS
EESS'RERUTCAFUNAM
SNOITCURTSNI
7 ENIGNELESEID 05+05 ALUMIRLLEHS04W51X
EESS'RERUTCAFUNAM
SNOITCURTSNI
8 ROTAIDARENIGNE 59+59 EZEERFITNALLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
9 XOBRAEGNOSILLAEUQROTHTIW
RETREVNOC
08+08 IIINORXEDFTALLEHS
EESS'RERUTCAFUNAM
SNOITCURTSNI
01 GNIKARBMURDNIAMMETSYS
57 DIULFADISSACLLEHS23FH
)425CHSLIBOM(
EESS'RERUTCAFUNAM
SNOITCURTSNI
11 DNUOPMOC 081 001ALAMOLLEHS
49
-
AIR CLUTCHES
The clutches, highly reliable in any working conditions (illustrated in section other manufacturers equipment of thismanual).
Regarding clutch maintenance, it is recommended to:
a) provide the proper air pressure to each ctutch - see the air pressure tableb) 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 amonth.
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, rustor machine cuttings stuck under the seat.Due to improper valve operations, the clutch may disengage incompletely and therefore cause overheating anddamage to the diaphragm. Overheating may also be due to clutch dragging.
50
-
NOITPIRCSED ERUSSERPLANIMON
ISP rab
HCTULCSKROWWARD 721 8,8
ERUSSERPGNIDEEFLARENEGLENAPLORTNOC01AEGUAG
011 95,7
YCNEGREME 521 26,8
HCTULCELBATYRATOR 111 7,7
HCTULCEKARBCILUARDYH 111 7,7
AIR PRESSURE
51
-
ERUSSERPLIO
TNENOPMOC .LYTICAPAC LEVELROTACIDNI
FOECALPLORTNOC
)mc/gK(ERUSSERP
XAM .MON .NIM
KROWWARDDNA
NOISSIMSNART052 KCITSPID LORTNOC
LENAP52
)67,1(01
)07,0(5
)53,0(
ERUSSERPRETAW
TNEMELE NOITISOP FOECALPLORTNOC
YTICAPACnim/l
ERUSSERP)rab(ISP
TELNI TELTUO
MURDNIAMEKARB
S'RELLIRDEDIS
LORTNOCLENAP
981 57-05)2,5-5,3(
sag"4/1.1 sag"4/1.1
LEERDNASEKARB
S'RELLIRDEDIS
LORTNOCLENAP
021 57-05)2,5-5,3(
sag"2/1 sag"2/1
CILUARDYHEKARB
S'RELLIRDEDIS
LORTNOCLENAP
002 57-05)2,5-5,3(
TPN"3 TPN"2
METSYSEKARBNIRETAWDLOCESU:GNINRAW
OIL AND WATER PRESSURE
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. Improper release of brake bands.2. Kinked or out-of-round brake bands.3. 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 thesuggested maximum for average applications.Normally, horizontal and inclined drives should be installed with an initial sag equal to approximateiy 2% of sprocketcenter 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 manufacturers 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 considerablesaving by detecting any major trouble that might be developing and allowing the necessary repairs to be made on aplanned or normal rig downtime.
The following is a guide to some of the key points which should be observed during routine inspection. The prevailingoperating 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
IMPORTANTIf clogged or damaged, replace grease nipples with new ones. (for fubricant specifications, see paragraph D -1.3).
54
-
111
8
12
8
7
3
9
6
10
5
4
2
7 1
11
Item Code Q.ty Description
1 0190 6758 2 CHAIN 1.1/4" 100-3 ASA 78 LINKS
2 0190 6760 1 CHAIN 1.1/4" 100-4 ASA 86 LINKS
3 0190 6761 1 CHAIN 1.3/4" 140-2 ASA 158 LINKS
4 0190 6762 1 CHAIN 1.3/4" 140-2 ASA 86 LINKS
5 0190 6764 1 CHAIN 1.3/4" 140-2 ASA 108 LINKS
6 0190 6765 1 CHAIN 2" 160-1 ASA 114 LINKS
7 0190 6767 2 CHAIN 3/4" 60-2 ASA 84 LINKS
8 0190 6768 2 CHAIN 5/8" 50-1 ASA 68 LINKS
9 0190 6766 1 CHAIN 2" 160-1 ASA 120 LINKS
10 0190 7950 1 CHAIN 2" 160-1 ASA 122 LINKS
11 4059 0116 2 CARDAN JOINT
12 4059 0126 1 CARDAN JOINT
13
13 4100 1122 1 ROPE D.28.57 (1.1/8")
55
-
TRAP YCNEUQERF NINGWD
NOITPIRCSED FOEPYTTNACIRBUL
TSAM
DNANWORCGNILLEVART
KCOLB
SYAD03YREVE *8 SECIVEDNRUTER,STROPPUSESAERGSNIAHCDNA
LLEHSSAERGREPUS
2PE
GNISIARYREVETAGNIREWOLDNA
TSAMFO
SYAD7YREVE
*31 SNIPESAERG LLEHSSAERGREPUS
2PE
*41
*7
SNIPKCAJGNISIARESAERG
SGNIRAEBLLAESAERG
LLEHSSAERGREPUS
2PELLEHS
SAERGREPUS2PE
*6 SGNIRAEBLLAESAERG LLEHSSAERGREPUS
2PE
GIREHTNISEVAEHSGNILLEVARTDNANWORCEHTFOGNINOITISOPEHT:ETONSUOIVERPEHTTAHTOSNOITAREPOPU-GNIGGIRHCAEHTIWDESREVEREBDLUOHSNORAEWSETUBIRTSIDSIHT.EVAEHSENILTSAFEHTSEMOCEBEVAEHSENIL-DAED
YEHTNEHWDECALPEREBDLUOHSHCIWFOHTOB,SEVAEHSDNASGNIRAEBEHTNROWEMOCEB
YRATORELBAT
YADYREVE **3 .LEVELLIOEHTKCEHCLEVELLIONIEGNAHCLACIDARYNA
EBDLUOHS,EMITTROHSAREVOEHTEBYAMSIHT.DETAGITSEVNI
RORETAW,LAESGNIKAELFOTLUSERELBATYRATOREHTOTNIYRTNEDUMTI,ESACRETTALEHTNI.CTE,GNISUOHGNISUOHNIARDOTDEDNEMMOCERSILIONAELC,HSERFHTIWTILLIFERDNA
ALAMOLLEHS022
SYAD7YREVE *11 TEKSAGREWOLDNAREPPUESAERG LLEHSSAERGREPUS
2PE
D-6.2 ROUTINE MAINTENANCE
56
-
TRAP YCNEUQERF NINGWD
NOITPIRCSED FOEPYTTNACIRBUL
NOISSIMSNART SYAD03YREVE *01 STNIOJLASREVINUESAERG LLEHS2PESAERGREPUS
SKROWWARD YADYREVE **1 LEVELLIORIOVRESERKCEHC LLEHS001ALAMO
SYAD7YREVE *4 GNIRAEBNIAMESAERGETALP
LLEHS2PESAERGREPUS
SYAD03YREVE *9 SRAEGELDIESAERG LLEHS2PESAERGREPUS
SHTNOM3YREVE ,SEPIP,KNAT(METSYSNOITACIRBULEHTKCEHC.1TCATNISITIERUSSAOT).CTE,SLAESROTOR,SEGUAG
.SNOITCURTSBOROEGAMADMORFEERFDNA,STNIOJ,SEPIP,SEVLAV(METSYSRIAEHTKCEHC.2
).CTE,KNAT,SNEERCS,SEGUA).CTE,RAEWGNINIL(METSYSGNIKARBEHTKCEHC.3
'SRERUTCAFUNAMREHTO"EHTEES(SEHCTULCKCEHC.4)LAUNAMETARAPESFONOITCES"TNEMPIUQE
NEKORB,SNIPRETTOCGNISSIM(SEVIRDNIAHCKCEHC.5.CTE,SRELLORFONOITACIRBULETAUQEDANIROSKNIL.SSENTHGITREPORPROFSTUNDNASTLOBLLAKCEHC.6
.SLAESDNASREBBUR,STEKSAGLLAKCEHC.7
0001YREVESRUOH
**1 RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
DNUOPMOC YADYREVE
0001YREVESRUOH
**11
**11
LEVELLIORIOVRESERKCEHC
RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
ELGNATHGIRXOBRAEG
YADYREVE
0001YREVESRUOH
**2
**2
LEVELLIORIOVRESERKCEHC
RETLIFDNALIOTNEMECALPER
LLEHS001ALAMO
* Grease lubrication** Oil lubrication
IMPORTANTThe first lubricating oil replacement must be carried out after the first 400 working hours, then observe theindications supplied in the routine maintenance table.
57
-
HYDRAULIC SYSTEM - OIL LEVEL CHECK
For hydraulic oil level check, set the machine to haulageconfiguration. This way, all jack are cIosed and the oil inthe tanks is at its maximum level. The machine shouldalso be perfectly Ieveled.Oil level should be closed to the maximum.
lf occasionally (due to operating reasons) the machinecannot be set to the haulage configuration, the oil levelmust be checked by means of the oil level visual indicator.With machine in working canfiguration, oil level should neverbe lower than the indicator on the see-through glass. Topup if oil level is too low.
(for hydraulic oil specifications, see paragraph D-1.4)
WARNINGWhen topping up, do not exceed maximum oil level(with machine in haulage configuration)
HYDRAULIC SYSTEM - REPLACE OILFILTER AND TANK AIR BLEEDINGCARTRIDGES
IMPORTANTThese components should be replaced at the time speci-fied even if not required by the clogging checkingdevices.
Access to hydraulic oil filter (on return line) is from thetank top through screws A.
WARNINGThese operations should be performed in clean areasto avoid that any earth, dirty and impurities can enterin the tank and in the system.
IMPORTANTOnce the component is replaced, check hydraulic oillevel as described in item D-6.3.
A
58
-
HYDRAULIC SYSTEM - OIL CHANGE
For hydraulic oiI change (as for oil Ievel check), the ma-chine should be set to haulage configuration. With thisconfiguration, all jacks are closed and the oil in the tanksis at its maximum level. The machine should also be per-fectly Ieveled.Oil Ievel should be closed to the maximum.
To ease up drainage, oil should be warm. This with preventresidual 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.
IMPORTANTThis tank contains apprax. 800 Iiters of hydraulic oil.
2. Close valves B cutting off the tank from the hydraulicsystem.
3. Undo plugs A and open the two bali valve C. To easeup oil outflow, also undo the bleeding cartridges on topof the tank. Let the oil drain.
WARNINGDo not disperse old oil in the environment as this causespollution.
4. Close valves C and retighten plugs A.5. FilI up through the return filter.
WARNINGAIways remember that the hydraulic oil, even whennew and delivered in drums, contains pollutants. WhenfilIing oil up, use special pumps provided with fllteringsystem.
6. Check that max. oil level is reached through level indi-cator D.
WARNINGWhen fiIling up with oil, do not exceed max. oil levelshown by indicator D.
Fig. D-6.3
Fig. D-6.4
C
A
B
B
Fig. D-6.5
D
59
-
7. Refit and retighten two new air bleeding cartridges.
(for hydrauIic oil specifications, see chapter D - 1.4)
WARNINGThese operations should be performed in clean areasto avoid that any earth, dirty and impurities can enterthe hydraulic oil tank
ROPES - WEAR CHECK
VisuaIly check hoisting and drilling wire rope, sand reelrope, 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 meas-ures to be taken with reference to the information containedin the standards ISO 4309.
Always refer to ISO 4309 standards for all what concernsthe ropes, their maintenance and replacement.
COMPLETE MACHINE - GENERALINSPECTION
Inspect the whole machine to make sure that it is in goodworking order.
In particular, check the drilling fluid circulation system fit-tings, high pressure couplings and seals. Inspect the wholemachine for Ieakage.
Check good operation conditions and correct assembly andclosing of protection hoods and guards.
HAZARDIn case of malfunctioning and/or faults, promptly eli-minate the problem and stop any works until the ma-chine is in good order again
Fig. D-6.6
60
-
BOLT TIGHTENING SPECIFICATIONS
61
-
HOSE FITTING SPECIFICATIONS
For best operation of the hydraulic system, always keepin mind some important rules for hose fitting.
Hose fitting nuts shall be tighten until no leakage occursthrough the coupling. Exceeding that point, does not im-prove tightness and damages the coupling!
A hose should never be subject to torsion! When fitting thehose, consider that during operation, the hose is subjectto changes in length with consequent torsional effects.Therefore, hoses should not be too short and the propersettling should be checked with hose in resting position(see Fig. D-8.1).
If hoses routing requires the hose to bend, make sure thatthe bending radius are correct (see Fig. D-8.2 and D-8.3).A bending radius too small can cause restrictions in thesection and therefore load losses. Moreover, these bendscan cause torsional stress and even breakage of the hose!
For correct fitting of hoses , elbow fitting can be used forinstallation in restricted space without impairing hose effi-ciency and life (see Fig. D-8.3 and D-8.4).
62
-
63
-
Functional group: Semitrailer group Table Number Revision
Hydraulic power unit 1 01170400 - 1 0 (12-2006)
Functional group: Semitrailer group Table Number Revision
Hydraulic power unit 1 01170400 - 1 0 (12-2006)
Position Part Number Quantity Description Notes
1 RI01170400-01 1 Electric pump -2 RI01170400-02 1 Pump by hand -3 RI01170400-03 1 Distributor -4 RI01170400-04 1 Exclusion manometer -5 RI01170400-05 1 Manometer -6 RI01170400-06 1 Filter -7 RI01170400-07 1 Tank -8 RI01170400-08 1 Retaining valve -9 RI01170400-09 1 Control panel -10 RI01170400-10 1 Frame -
64
-
Functional group: Semitrailer group Table Number Revision
Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)
Functional group: Semitrailer group Table Number Revision
Hydraulic oil reservoir 1 01906232 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906235 2 Description not available -2 01908758 1 Tank -3 01908759 1 Tank -4 01908760 2 Gasket -5 40690045 2 Thermometer -6 50310022 2 Pn 10 1" 1/2 ball valve -7 50310195 4 Valve -8 50510019 2 Connector -9 50520046 2 Cap -10 50530025 2 Air breather -11 50540178 2 Level indicator -12 50540181 2 Level indicator -13 50590007 2 Nipple -14 50590009 2 Nipple -15 50630073 4 A.f.l. connector -16 50630077 8 3" art.280 nipple -17 50630079 2 A.f.l. connector -18 50630182 2 A.f.l. connector -19 50971117 2 Filter -20 52030045 2 Washer -21 70351004 40 Screw -22 70351610 8 Screw -23 70661613 8 Nut -24 70911017 40 Elastic washer -25 70911627 8 Elastic washer -
65
-
Functional group: Mast group Table Number Revision
Monkey board handrails 2 01907330 - 1 0 (06-2007)
Functional group: Mast group Table Number Revision
Monkey board handrails 2 01907330 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01907649 1 Description not available -2 01907915 1 Description not available -3 01907916 1 Description not available -4 01907917 1 Description not available -5 40630123 6 Shear pin -6 71191616 15 Pin -7 71300018 9 Split pin -
66
-
Functional group: Mast group Table Number Revision
Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)
Functional group: Mast group Table Number Revision
Cylinder for extracting mast 2 01907331 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906950 1 Description not available -2 01906951 1 Description not available -3 01907931 2 Description not available -4 01908883 1 Description not available -5 50470576 1 Plate -6 51040304 1 Hydraulic piston -7 52104075 1 O-ring -8 70351614 8 Screw -9 70311624 4 Screw -10 70351612 8 Screw -11 70370824 4 Screw -12 70611618 20 Self-locking nut -13 70901648 4 Washer -14 70910814 4 Elastic washer -15 71050812 2 Split pin -16 71204009 2 Pin -
67
-
Functional group: Substructure group Table Number Revision
Machine base frame 3 01906312 - 1 0 (06-2007)
Functional group: Substructure group Table Number Revision
Machine base frame 3 01906312 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906896 1 Front skid -2 01907096 1 Skid -
68
-
Functional group: Draw works group Table Number Revision
Swivel joint for water 4 01902248 - 1 0 (06-2007)
Functional group: Draw works group Table Number Revision
Swivel joint for water 4 01902248 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01902619 1 Body -2 01902620 1 Manifold -3 01902621 1 Cover -4 01902622 1 Flange -5 01902623 1 Bushing -6 01902624 2 Ring -7 40630186 1 Spring -8 01902625 2 Spacer -12 52700471 2 Gasket -13 52700470 4 Gasket -14 52104081 2 O.ring packing -15 01902626 2 Gasket -16 70351010 8 Screw -17 70911017 8 Elastic washer -18 61000006 2 Lubricator -19 50520037 2 Cap -
69
-
:puorg lanoitcnuF puorg skrow warD noisiveR rebmuN elbaT
01 - 70370910 4tfahsretnuoc tupni rewoP )7002-60(
Functional group: Draw works group Table Number Revision
Power input countershaft 4 01907307 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906521 1 Description not available -2 01906522 1 Description not available -3 01906524 1 Description not available -4 01906526 1 Description not available -5 01906527 2 Description not available -6 01906528 2 Description not available -7 01906529 1 Description not available -8 01906530 2 Description not available -9 01906531 2 Description not available -10 01907427 1 Description not available -11 01907428 1 Description not available -12 019011621 1 Spacer -13 61070142 2 Description not available -14 70351609 12 Screw -15 70351610 20 Screw -16 70351614 24 Screw -17 70611618 24 Self-locking nut -18 71073236 2 Tang -
70
-
Functional group: Draw works group Table Number Revision
Installation of the travelling block limit switch 4 01906106 - 1 0 (06-2007)
Functional group: Draw works group Table Number Revision
Installation of the travelling block limit switch 4 01906106 - 1 0 (06-2007)
Position Part Number Quantity Description Notes
1 01906517 1 Description not available -3 01906518 1 Description not available -4 01906519 1 Description not available -8 50640721 1 Cylinder -10 50640546 1 Hinge -11 50640723 1 Description not available -12 70390062 2 Screw -13 70351205 4 Screw -14 70911221 4 Elastic washer -15 50640722 1 Fork -16 50640652 1 Valve -
71
-
DRILLING RIGHTD 250 TOP DRIVE
72
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 5
TOP
BOTTOM
OFFDRILLERSIDE
DRILLERSIDE
DWWKS SIDE
OFF DWWKS SIDEFig. A1
A - 1 ORIENTATION
Front and rear sections of the equipment, as other parts of the equipment on side, shall be conventionally placedas shown in the following diagram (unless specified otherwise).
73
-
Operation and Maintenance ManualGENERAL INFORMATION
Section A page 6
Fig. A2
Machine Type
Serial Number
Year of Manufacturing
Nominal Power [kw]
Weight [kg]
Piacenza - Italy
A - 2 IDENTIFICATION
This equipment is identified through serial number and/oridentification numbers on main components.
A - 2.1 EQUIPMENT IDENTIFICATIONPLATE
The equipment identification plate shown in the pictureprovides all identification data for the machine. Alwayscheck that the equipment part number (N. MATR.)stamped on the plate, matches with that reported on thefront cover of this manual.
IMPORTANT
Always specify the equipment technical code and partnumber (N MATR.) when you require information ortechnical assistance.
A - 2.2 MANUFACTURER
DRILLMEC Drilling Equipment Div. - 12 Via 1 Maggio - LocalitGariga 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 electricalcomponents which are not manufactured by DRILLMEC(pumps, motors, etc.) are fitted on the componentsthemselves, in the locations assigned by the manufacturers.
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 7
MAXIMUM WORKING PRESSUREMAXIMUM WORKING PRESSURE
MAXIMUM DYNAMIC LOADMAXIMUM DYNAMIC LOADCAPACITY AT 100 RPMCAPACITY AT 100 RPM
MAXIMUM STATICMAXIMUM STATICLOAD CAPACITYLOAD CAPACITY
CUSTOMERCUSTOMER
MANUFACTUREDMANUFACTURED
SERIAL NUMBERSERIAL NUMBER
POWER SWIVELPOWER SWIVEL
SPECIFICATION SPECIFICATION 8C L.E. (EDITION 4)8C L.E. (EDITION 4)AUTH. 8C-0041 PSL1AUTH. 8C-0041 PSL1
BARBAR
MTMT
MTMT
MODELMODEL
TOP DRIVETOP DRIVE
09533652E09533652E
2 SPEED2 SPEED
1 SPEED1 SPEED
200
RPM
200
RPM
146
RPM
146
RPM
109
RPM
109
RPM
80 R
PM80
RPM
10400 ftlb10400 ftlb
14235 ftlb14235 ftlb
19030 ftlb19030 ftlb
26000 ftlb26000 ftlb
ftlb
ftlb
TORQ
UE
TORQ
UE
RPMRPM
2212522125
1475014750
73757375
2002001501501001005050
Fig. A3
0953-3720E0953-3720E
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Fig. A4
TORQUE WRENCHTORQUE WRENCH
ftlb TORQUEftlb TORQUE
BREAK-OUTBREAK-OUTMAKE-UPMAKE-UP
PRES
SURE
- PS
IPR
ESSU
RE -
PSI
35603560
21402140
49904990
42754275
28502850
14251425
81130811305180051800
4425044250
36880368802950029500
2213022130
1475014750
73757375
09533658E09533658E
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 9
1
14
13
7
9
4
15
12
11
10
86
5
3
2
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. ACTUATOR10 - ELEVATOR11 - ELEVATOR LINKS12 - TORQUE WRENCH13 - WEIGHT COMPENSATOR SYSTEM14 - WASHPIPE15 - GUIDE
Fig. A5
A - 3 MAJOR COMPONENT DESCRIPTION - TOP DRIVE
The following section describes the component parts, and defines terms used throughout this service manual.
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 10
DRI
LLIN
G M
OD
E
TRIP
PIN
G M
OD
E
LOAD PATH
TRIPPING MODEDRILLING MODE TRIPPING MODEDRILLING MODE
ELEVATORLINKS
DOUBLE HOOKLOAD SHOULDER
DOUBLE HOOK
ROTARY DRILLINGHOOK
TOP DRIVESUSPENDING
LINKS
WASH PIPEPACKING ASS.Y
MAIN SHAFTLOAD SHOULDER
SWIVELTHRUST BEARING
TRANSMISSIONBODY
COUNTERBALANCESYSTEM
MAIN SHAFT(DRILL SYSTEM)
BONNET
GOOSE NECK
LINK PIN
Fig. A6
A - 3.1 HTD 200 LOAD PATH
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 11
HYDRAULIC MOTORS
HYDRAULIC MOTORS
MAIN BODY
Fig. A7
A - 3.2 HYDRAULIC MOTORS
The uses four (4) HYDRAULIC MOTORS mounted vertically side by side on top and on bottom of themain body to power the The ports of the motors are connected each other with a rigid pipe and finally connected to an interface block withquick couplings.
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 12
HYDRAULICCALIPER
BRAKEDISC
Fig. A8
Two hydraulic caliper disc brakes, mounted between each top hydraulic motor and the main body, hold torque inthe drill string and assist in positioning during directional work.An electrical solenoid valve remotely operates the hydraulic caliper disc brakes.
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 13
TRANSMISSION/MOTOR HOUSING
MAIN BODY
Transmission/motor housing (main body) and swivel assembly
Fig. A9
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 drillstring. Inside the transmission/motor housing main body is a single-speed double-reduction sput gear system thatprovides 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 bypassesthe 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 constantlycirculates 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-pipeweldment. The bonnet supports the S-pipe weldment. Two upper links serve to attaching to standard rotary drillinghooks.
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Section A page 14
FIXED PART
MOVING PARTS
SUPPORT BRACKETS
AIR SPRING
Counterbalance system
Fig. A10
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 hangsfrom the crown block and extends within 26,88 meters of the drill floor. The guide beam attaches to a torque reactionspreader 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 comesin 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 atime, 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 movingup and down on the guide beam. There are four rollers that run inside the guide beam flanges to counter the drillingtorque and four guide rollers that run on the inside of the guide beam flanges. Both the guide and bogie rollers arethrough-hardened and run on grease lubricated bearings.
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Section A page 15
GUIDEBEAM
CONNECTINGLINK
GUIDEBEAM
CARRIAGEASSEMBLY
TORQUE WRENCH
ELEVATOR LINKS
DRILLINGHOOK
LINKS
MAINBODY
GUIDE BEAM (ASSEMBLED)
TORQUE REACTION SPREADER BEAM
FRONT
Carriage and guide beamFig. A11
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 16
IBOP
FRONT
DOUBLE HOOKROTATION GEAR
TWO WAYLINK TILT CYLINDERS
CLAMP
ELEVATORLINKS
MOUSE HOLEPOSITION
DRILL DOWNPOSITION
WELL CENTER(FLOAT POSITION)
TORQUEWRENCH
ROTATINGDOUBLE HOOKLINK ADAPTER
PINIONREDUCER
HYDRAULICDRIVE MOTOR
Fig. A12
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
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 17
The Rotating Double Hook combined with ahydraulic motor for 270 clockwise/counterclockwiserotation in order to position the elevator to pick uppipes and to assist the derrick man. The free rotationmode also allow the pipehandler to rotate with the mainshaft.The two-way link tilt cylinder assemblies consist ofthe cylinder body pinned to the rotating link adapterand the cylinder rods pinned to the links through a setof clamps.Pressurizing the cylinder assemblies by operating theswitch on the drillers console extends the drill pipeelevator to the mouse hole or the drill down position. Afloat position allows the links to return to well center.
The Elevator Links can be moved to mouse hole ordrill down position by means of the tilt cylinders, re-mote controlled from the operators panel.
The Torque Wrench for make up/break out of pipe,is connected to the pipe handler by means of asuspension beam. The torque wrench can be locatedin two different positions on the suspension beam,depending on which connection to be broken. Thetorque wrench includes torque cylinders, clamp jawsand a guide funnel.
The Remote Operated I.B.O.P. (10.000 PSI) isoperated by two hydraulic cylinders remote controlledfrom the operators panel.
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Operation and Maintenance ManualGENERAL INFORMATION
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A - 4 TOP DRIVE SPECIFICATIONS
A - 4.1 TOP DRIVE SPECIFICATIONS
MODEL:
LOAD CAPACITIES
MAXIMUM STATIC LOAD CAPACITY: 200.000 kgMAXIMUM DYNAMIC LOAD CAPACITY AT 100 RPM: 115.000 kgMAXIMUM PASSAGE DIAMETER: 76 mmMAXIMUM WORKING PRESSURE: 350 barsLOWER THREAD: NC 50 API - 4 IFMAX TORQUE: 3525 daNmMAX SPEED: 200 RPM
PERFORMANCE DIAGRAM:
Fig. A13
TOP DRIVETOP DRIVE
09533652E09533652E
2 SPEED2 SPEED
1 SPEED1 SPEED
200
RPM
200
RPM
146
RPM
146
RPM
109
RPM
109
RPM
80 R
PM80
RPM
10400 ftlb10400 ftlb
14235 ftlb14235 ftlb
19030 ftlb19030 ftlb
26000 ftlb26000 ftlb
ftlb
ftlb
TORQ
UE
TORQ
UE
RPMRPM
2212522125
1475014750
73757375
2002001501501001005050
TOP DRIVE POWER OUTPUT: 295 kwDOUBLE HOOK CAPACITY: 200.000 kgELEVATOR LINK CAPACITY: 226800 kg (250 Short ton.)LENGHT: 108 (2743 mm)LINK SIZE: 2.x108
WEIGHT: 6500 kg approx.
* TOP DRIVE includes guide dolly and connection link to travelling block
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 19
PIPE HANDLER - COUNTERBALANCE SYSTEMUTILITY REQUIREMENTS RIG AIR SUPPLY: 8 bar
TORQUE WRENCH:The TORQUE WRENCH can handle pipe from 4 to 6.5/8 ODMAXIMUM MAKE-UP TORQUE: 4400 daNmMAXIMUM BREAK-OUT TORQUE: 5925 daNm
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Operation and Maintenance ManualGENERAL INFORMATION
Section A page 20
AIR
INTA
KE
FUEL
TA
NK
OIL
TA
NK
DRA
INA
GE
BALL
VA
LVESU
CTI
ON
BALL
VA
LVE
HYD
RAU
LIC
PU
MPS
MU
LTIP
LE P
UM
P D
RIVE
UN
ITBA
SE S
KID
TRA
NSM
ISSI
ON
SH
AFT
RAD
IATO
R
AIR
INTA
KE
INSU
LATI
ON
HO
OD
DIE
SEL
ENG
INE
AIR
FIL
TER
PUM
P D
RIVE
LU
BRIC
ATIO
NC
IRC
UIT
HEA
T EX
CH
AN
GER
AIR
DIS
CH
ARG
E
AIR
DIS
CH
ARG
E
QU
ICK
COU
PLIN
GCO
NN
ECTI
NG
BLO
CK
OIL
TA
NK
INSP
ECTI
ON
CO
VER
AIR
FIL
TER
FUEL
TA
NK
HYD
RAU
LIC
CIR
CU
ITH
EAT
EXC
HA
NG
ER
FILT
ERH
YDRA
ULI
C O
IL T
AN
K
EXA
UST
MU
FFLE
R
DIE
SEL
ENG
INE
RAD
IATO
R
Fig. A14
A - 5 MAJOR COMPONENT DESCRIPTION - HYDRAULIC POWER UNIT(HPU) FOR
The following section describes the HPU component parts and defines terms used throughout this service manual.
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Operation and Maintenance ManualGENERAL INFORMATION
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A - 6 HYDRAULIC POWER UNIT (HPU) SPECIFICATIONS
Model: 1 x Caterpillar 3408 DITA EPA-CARB
Arrangement drawing: 0190 3398
Transmission circuit:Pressure range: 0 - 350 barFlow range: 0 - 800 l/min
Replenishment circuit:Pressure min: 16 barFlow: 90 l/min
Pipehandler circuit - Torque Wrench:Pressure: 350 barFlow: 0 - 113 l/min
Link Tilt:Pressure: 180 barFlow: 0 - 30 l/min
Diesel engine:Max power output: 376,5 bkw (505 bhp) @1800 RPMMax fuel consumption: .....l/hour at ..... kw ..... (..... gph at ..... hp) (see engine manuals)Max rated RPM: 1800 RPM
Tank capacities:Hydraulic oil tank: 950 ltr.Diesel tank: 600 ltr.
Weights:Total weight HPU: 11830 kgs
Painting:All items painted, where relevant, with DRILLMEC procedure.
Service loop hydraulic hoses:
PILOT PRESSUREFlex. SAE 100 R2AT 1/2 pilot pressure
CLOSED LOOP CIRCUITFlex. SAE 100 R13 2 motor deliveryFlex. SAE 100 R2AT 2 drainage
PIPEHANDLER - TORQUE WRENCHFlex. SAE 100 R13 1 1/4 services deliveryFlex. SAE 100 R2AT 1 1/4 services return
COUNTERBALANCE SYSTEMFlex. SAE 100 R1AT 3/4 air pressure
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 3
Fig. C2
A1 P1 H1 H2 H3
SP1
H4
SC10
R7 R8 SC12 SC9 SC3 SC7 SC1
SC6
SC5
SC8SC4
SC11
C - 1.1 CONTROLS AND INSTRUMENTSON TOP DRIVE CONTROL PANEL
P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake ControlSC7 Torque Wrench Automatic Sequence ControlSC8 Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12 Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1 Return Filter Clogging Indicator LampH2 Discharge Filter Clogging Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive Torque Regulator
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 4
C - 1.2 CONTROLS AND INSTRUMENTSIN THE HYDRAULIC POWER UNIT
Fig. C3
A58
A62
A61
A60
A59
Fig. C4
A54 A55 A53 A52 R52
Fig. C5
A63
C60 C61 C62
A58 RPM meterA59 Oil pressureA60 AmmeterA61 Water temperatureA62 Fuel pressure
A53 Piloting oil pressureA52 Compensator air pressureR52 Compensator pressure regulatorA54 Replenishing pressure (CLOSED CIRCUIT)A55 Replenishing pressure (CLOSED CIRCUIT)
A63 Oil temperature thermometerC60 Ball valve on hydraulic system suction lineC61 Ball valve on hydraulic system suction lineC62 Ball valve on hydraulic system suction line
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 5
Fig. C6
C63
Fig. C7
A64
Fig. C8
A65
C63 Ball valve on reservoir oil drain
A64 Oil visual level
A-65 Fuel visual level
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 6
C - 2 HYDRAULIC POWER UNITSTARTING 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 properlamp signals the reaching of the minimum allowed pointof 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 thebattery cables are correctly connected. Such cablesare usually disconnected during transport.
- Check that the suction valves of the pumps, placedon the hydraulic oil reservoir, are properly opened.
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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
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 8
Fig. C10
A54 A55 A53 A52 R52
Fig. C11
A61
A59
Fig. C12
SC10
SP1
C - 2.3 CHECKS AFTER START-UP
- After having executed all the operations described atthe preceding point, check that the pressure displayedon the "supercharging" pressure gauges A54 and A55is stabilized on 16 18 bar.
- Check the piloting pressure displayed on the pressuregauge A53. The pressure has to be 25 30 bar.
- Check the air pressure to supply the counter-balancesystem of the top drive. Such a pressure can beadjusted through the pressure regulator R52 readingthe value displayed on the pressure gauge A52.
- Warm-up the engine (the warm-up time depends onthe climatic conditions).
- Check on the engine instruments that the pressuresand the temperatures are the correct ones accordingto the indications provided by the manufacturer of theengine.
- Now it is possible to increase the speed of the dieselengine. Access to the top drive control panel on thedrill floor.
- Press the push-button SP1 = Control authorization.
- Turn the selector SC10 from Min position to Maxone.
- With the top drive near the drill floor, exercise eachcontrol on the driller's console following the operatinginstructions of paragraph C-3 and the operatingprocedures of paragraph C-4.
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Fig. C13
A1 P1 H1 H2 H3
SP1
H4
SC10
R7 R8 SC12 SC9 SC3 SC7 SC1
SC6
SC5
SC8SC4
SC11
C - 3 OPERATING INSTRUCTIONS
P1 Top Drive Rpm Analog MeterA1 Top Drive Torque Pressure GaugeSC1 Hook Rotation ControlSC3 Link ControlSC4 Link-On Free ControlSC5 Ibop Valve Open-Close ControlSC6 Top Drive Brake ControlSC7 Torque Wrench Automatic Sequence ControlSC8 Make-Up/Break-Out ControlSC9 Top Drive Emergency StopSC10 Throttle Min-Max For Top Drive HpuSC11 Top Drive Rotation Speed SelectorSC12 Top Drive Rotation Fwd/Rev ControlSP1 Controls AuthorizationH1 Return Filter Clogging Indicator LampH2 Discharge Filter Clogging Indicator LampH3 Minimum Oil Level Indicator LampH4 Controls Authorization LampR7 Top Drive Rotation Rpm RegulatorR8 Top Drive Torque Regulator
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 10
C - 3.1 DRILLERS CONSOLE AND TOP DRIVE CONTROL PANEL
LOBMYS ROTACIDNI/LORTNOCEMAN
NOITCNUFDNANOITPIRCSED
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noitisop"EMOH"ehtotsetatoryllacitamotuahcnerweuqrot
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 11
LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED
8CS lortnoctuo-kaerb/pu-ekaM naetavitcaottcelesuoy,noitisop"PU-EKAM"othctiwsehtgninruTpu-ekmaotsetatorhcnerweuqrot(ecneuqespu-ekamcitamotua
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.noebtsum4HthgilehT.)1PSnottub("NOITAZIROHTUA.enigneleseidehtnonruT.noitcurtsnignitratsUPHehtwolloF
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gnihsinelperspmupciluardyhnodetacolsretliftahtmralalausivasevigtIdeggolcerastiucric
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 12
LOBMYS ROTACIDNI/LORTNOC EMAN NOITCNUFDNANOITPIRCSED
3H rotacidnilevelliomuminiMpmal
muminimehtnwoddeppordlevelliotahtmralalausivasevigtI
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C - 3.1.1 WARNING LAMP SWITCHING-ON
The measures to be taken when the warning lamp comeson depend on the type of fault detected.
In principle, the engine should be immediately turned offwhen the following warning lamps come on:
H1 Clogged hydraulic oil filter - RETURNH2 Clogged hydraulic oil filter - DISCHARGEH3 Hydraulic oil - MINIMUM LEVEL
WARNING
Working with H3 warning lamp on is forbidden, as itcan cause damage to other parts of the system.Also check OIL THERMOMETER A-63 on HPU oiltank.
WARNING
An hydraulic oil overtemperature is a sign ofmalfunctioning of some part of the system, cloggedfilter or heat exchanger.
Once the machine is turned off, find the cause of malfunctionand repair it. If you are unable to solve the problem, contacta service center or DRILLMEC S.p.A. directly (full addressis printed on cover and first page of this manual).
At regular intervals, also check instruments for DIESELENGINE in sound proof hood.
The engine should be immediately turned off when thesesituations occurr:
- Low engine oil pressure- Engine water over temperature- Low battery charge
WARNING
When above warning lamps are turned on, stop theengine; leaving the engine running can cause seriousdamage to the engine.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 13
Fig. C14
P1A1
R7 R8 SC12
SC11
C - 4 OPERATING PROCEDURES
C - 4.1 TOOL ROTATION
The power swivel rotation (drilling tool) is controlled withlever SC12: push the lever down for clockwise rotation,pull the lever up for anticlockwise rotation.
IMPORTANT
Lever SC12 can be locked in full stroke positionallowing the operator to control other drillingparameters such as pull/push regulation, rpm or torque.
Rpm (speed) is controlled by R7; torque is controlled byR8. Rpm and torque control can be turned clockwise fromleft (min.) to right (max).
Read torque on A1 gauge, read rpm on P1 rpm meter.Another kind of speed and torque control can be performedby means of selector SC11 (2-position selector).
IMPORTANT
During the drilling, if the stops locking the rotation ofthe power swivel, do not move the rotation command
lever setting it in neutral position, but turn the torqueregulator in anticlockwise direction setting the pressureto zero (see pressure gaugeof power swivel rotationtorque) them set lever again to neutral position.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 14
MAIN SHAFT
IBOP ACTIVATORSHELL
UPPER IBOPACTIVATOR CYLINDER
CRANK ASSEMBLY
OPEN
CLOSE
IBOP
Fig. C15
C - 4.2 IBOP SAFETY VALVES
Turning the IBOP switch on the drillers console to theCLOSE position extends the hydraulic actuatorcylinders, moving the actuator shell body downward (seefollowing figure). This downward movement rotates thecrank assemblies 90, closing the IBOP ball valve.
Turning the switch to the OPEN position retracts thecylinders rod, pulling the IBOP actuator shell upward-opening the IBOP. Full hydraulic pilot pressure isapplied to fully open or close the valve, mantaining theshell position.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 15
Fig. C16
A1 P1
SC12 SC7
SC6
C - 4.3 ACTIVATING TOP DRIVE BRAKE
Turning the switch SC6 to the ON position, apply brakeand in the same time the automatic sequence of torquewrench is disabled.Also Top Drive rotation is disabled (cutting the pilotpressure). Turning the switch to the OFF position, releasethe 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 mainbody, hold torque in the drill string and assist in positioningduring directional work.
For safety reasons, Top Drive rotation and torque wrenchautomatic sequence are disabled.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 16
DOUBLE HOOK
LINKS
DRILL PIPEELEVATOR
CW
CCW
WELLCENTER
TORQUE WRENCH
HYDRAULICMOTOR
POSITIONINGGEAR
PINION
Fig. C17
C - 4.4 PIPE HANDLER OPERATION
C - 4.4.1 ROTATING DOUBLE HOOK AND LINKS
The rotating double hook supports the weight of thedrill string through a set of links that hang from thehook.
The positioning gear is an integral part of the rotatingdouble hook. The positioning gear, meshed with ahydraulic motor driven pinion gear, rotates thepipehandler.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 17
Fig. C18
SC4
SC3
SC1
C - 4.4.2 LINK TILT
The link tilt consists of two double-rod assemblies with thecylinder body pinned to the rotating double hook and rodend of the cylinder pinned to the elevator link. Moving thelink tilt lever upward, SC3 on the drillers console, extendsthe drill pipe elevator to the MOUSE HOLE position.
WARNING
Rotate pipe handler 90 with SC-1 before to move thelever downward SC-3 to reach the DRILL-DOWNposition.Be sure not to interfere with guide beam.
Moving the link tilt lever downward retracts the drill pipeelevator to the drill down position. Turning the link tilt floatswitch SC4 to free position allows the elevator to return towell center.
Elevator travel is adjustable. If it is necessary to adjust themousehole position, relocate the clamps on the links asrequired.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 18
FRONT
DOUBLE HOOKROTATION GEAR
HYDRAULICDRIVE MOTOR
REDUCER
PINION
ROTATINGDOUBLE HOOKLINK ADAPTER
GUIDE BEAM
TORQUEWRENCH
DRILL DOWNPOSITION
WELL CENTER(FLOAT POSITION)
ELEVATORASSEMBLY
MOUSE HOLEPOSITION
CLAMP(ADJUSTABLE)
ELEVATORLINKS
TWO WAYLINK TILT CYLINDER
WARNING!ROTATE PIPE HANDLER 90
Fig. C19
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 19
Fig. C20
SC8
SC7
C - 5 TORQUE WRENCH
C - 5.1 TORQUE WRENCH BREAK-OUTSEQUENCE
Turn the selector SC8 on BREAK-OUT position.To activate the automatic (break-out) sequence, move thelever SC7 upward and hold it in position till the sequenceis 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 SC7to return in neutral position.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 20
Fig. C21
Selector SC8 in BREAK-OUT position
HOME position for BREAK-OUT sequence
Lever SC7 upward1st phase of automatic sequence
LOWER CLAMP CLOSE
UPPER CLAMP CLOSE
Lever SC7 upward2nd phase of automatic sequence
UPPER CLAMP ROTATES C.C.W
Lever SC7 in neutral position1st phase of automatic return to HOME position
UPPER AND LOWER CLAMPS OPEN
Lever SC7 in neutral position2nd phase of automatic return to HOME position
UPPER CLAMP ROTATES C.W.
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Operation and Maintenance ManualOPERATING INSTRUCTIONS
Section C page 21
Fig. C22
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 SC7upward 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 SC7to return in neutral position.
Selector SC8 in MAKE-UP position
HOME position for MAKE-UP sequenceLever SC7 upward1st phase of automatic sequence
LOWER CLAMP CLOSE
UPPER CLAMP CLOSE
Lever SC7 upward2nd phase of automatic sequence
UPPER CLAMP ROTATES C.W
Lever SC7 in neutral position1st phase of automatic return to HOME position
UPPER AND LOWER CLAMPS OPEN
Lever SC7 in neutral position2nd phase of automatic return to HOME position
UPPER CLAMP ROTATES C.C.W.
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Operation and Maintenance ManualINSTALLATION
Section D page 4
BRACKETSAND PINS
BRACKETSAND PINS
COLLAR
Fig. D3
Fig. D4
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.
The HYDRAULIC POWER UNIT has a proper container with old field supporting frame.
The pipehandler, the links, guide beam group, service loop and other accessories, are supplied in separate properpackages.
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Operation and Maintenance ManualINSTALLATION
Section D page 5
At the reception of the machine, be extremely careful duringthe down-loading procedures of the fixtures; it is necessaryto check all the received materials and the status of thefixtures themselves in such a way to ensure their perfectstatus after the transport.
IMPORTANT
Every dispute, comment or claim has to be immediatelypointed out to the transport company. The claimsforwarded with delay will not be taken into account.
D - 1.1 LIFTING DEVICE
The hoist or the lifting crane for the machine installation isalways under the customer's responsibility. However, itsloading capacity has to be not lower than 15 Ton.
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Operation and Maintenance ManualINSTALLATION
Section D page 6
1 2 3 4
5
PHASE 1
NOTE:
1 - Assemble the guide beam composed by nr. 4 elements (ref. 1-2-3-4) and its lower attachment ref. 5
Fig. D5
D - 2 INSTALLING THE GUIDE BEAM AND LOWER ATTACHMENT
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Operation and Maintenance ManualINSTALLATION
Section D page 7
7 8 9
16
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