Operation Manual (Eng

Top Drive Drilling Equipment
Operation 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
Beijing Petroleum Machinery Factory
Ads:
No.41, Zhixin Road, Haidian District, Beijing P.R China
Postcode:
100083
Tel:
( 010) 62097381
Fax:
( 010) 62097613
E-mail:
Bpm.zhaojing@vip.163.com
-I-
Contents
Safety Notice ............................................................................................................ 1
HSE instruction ........................................................................................................ 2
2.1
Electric safety operation indication ........................................................................... 2
2.2
Hydraulic safety operation indication........................................................................ 3
2.3
Well control safety operating indication .................................................................... 3
Main Specification.................................................................................................... 4
3.1
Basic specification .................................................................................................... 4
3.2
Drilling Parameter .................................................................................................... 4
3.3
Motor Specification .................................................................................................. 5
3.4
Cooling fan............................................................................................................... 5
3.5
Hydraulic disc brake ................................................................................................. 5
3.6
Electric control system.............................................................................................. 5
3.7
Gearbox.................................................................................................................... 5
3.8
Pipe handler device................................................................................................... 5
3.9
Hydraulic control system .......................................................................................... 6
Structure and operating principle............................................................................... 7
4.1
Power swivel ............................................................................................................ 8
4.1.1
Main motor and cooling fan ...................................................................................... 9
4.1.2
Brake device ........................................................................................................... 10
4.1.3
Gearbox.................................................................................................................. 11
4.1.4
Wash pipe assembly................................................................................................ 12
4.1.5
Lifting bail.............................................................................................................. 13
4.1.6
Gooseneck .............................................................................................................. 13
4.2
Pipe handler............................................................................................................ 14
4.2.1
Rotating head.......................................................................................................... 15
PDF "pdfFactory Pro" www.fineprint.com.cn
4.2.2
IBOP ...................................................................................................................... 16
4.2.3
Upper IBOP control system .................................................................................... 17
4.2.4
Link tilt device........................................................................................................ 18
4.2.5
Backup Tong........................................................................................................... 19
4.2.6
IBOP locking device ............................................................................................... 22
4.3
Guide rail and carriage............................................................................................ 22
4.4
Electric drive and control system ............................................................................ 23
4.4.1
Composing of electric system ................................................................................. 24
4.5
Hydraulic drive and control system......................................................................... 29
4.5.1
HPU ....................................................................................................................... 29
4.5.2
Control valve manifold ........................................................................................... 30
4.5.3
Hydraulic pipelines ................................................................................................. 40
Operating procedure ............................................................................................... 41
5.1
Inspection before startup......................................................................................... 41
5.2
The startup/shutdown of electric system.................................................................. 42
5.2.1
Startup system ........................................................................................................ 42
5.2.2
Stop system............................................................................................................. 42
5.3
Start/stop of hydraulic system ................................................................................. 43
5.4
Main motor heating................................................................................................. 44
5.5
Motor cooling fan ................................................................................................... 44
5.6
Driller Console ....................................................................................................... 45
5.6.1
Drilling operation procedure ................................................................................... 45
5.6.2
Reverse drilling under Drill Mode........................................................................... 47
5.6.3
Stop drilling ............................................................................................................ 48
5.6.4
Make-up/break-out operation .................................................................................. 48
5.6.4.1. Make-up operation.................................................................................................. 49

5.6.4.2. Break-out operation ................................................................................................ 50
5.6.5
Rotating head lock operation................................................................................... 51
5.6.6
Elevator link operation............................................................................................ 51
5.6.7
IBOP operation ....................................................................................................... 52
5.6.8
Emergency stop operation....................................................................................... 52
5.6.9
Fault/Alarm ............................................................................................................ 53
5.7
Special operation .................................................................................................... 55
5.7.1
Encoder switch ....................................................................................................... 55
5.7.2
Running without encoder ........................................................................................ 55
5.7.3
PLC control operation............................................................................................. 56
5.7.4
Driller Console emergency operation ...................................................................... 57
Operation procedure of drilling ............................................................................... 58
6.1
Trip in/out operations.............................................................................................. 58
6.1.1
Trip in..................................................................................................................... 58
6.1.2
Trip out................................................................................................................... 58
6.2
Operation of make-up ............................................................................................. 59
6.3
Operation of break-out ............................................................................................ 59
6.4
Drill ahead .............................................................................................................. 59
6.5
Drilling by single .................................................................................................... 61
6.6
Drilling by stand ..................................................................................................... 61
6.7
Backreaming........................................................................................................... 62
6.8
Running casing ....................................................................................................... 62
6.9
Jarring operation ..................................................................................................... 63
Inspect .................................................................................................................... 64
7.1
Visually Inspect ...................................................................................................... 64
7.1.1
Inspect the main body ............................................................................................. 64
7.1.2
Inspect the hydraulic system ................................................................................... 64
7.1.3
Inspect electrical system ......................................................................................... 65
7.1.4
Inspect guide rail and carriage................................................................................. 65
7.1.5
Disassembly inspection........................................................................................... 65
7.1.6
Nondestructive evaluation....................................................................................... 65
7.2
Wear limit ............................................................................................................... 66
Appendix 1 DQ70BSC well site layout............................................................................ 67

Appendix 3 DQ70BSC main body structure sketch.......................................................... 69
Appendix 3 DQ70BSC main body structure sketch.......................................................... 70
Appendix 4 DQ70BSC main body planform.................................................................... 71
Appendix 5Drill pipe tool joint dimension........................................................................ 72
BPM Top Drive
Operation Manual
1 Safety Notice
Only qualified and experienced personnel can operate Top Drive Drilling Equipment.
Carefully reading and understanding the manual and relevant technical documents before
operation.
The personnel mentioned above and closed to the equipment should be trained on well
drilling operation and well drilling safety knowledge, and should wear the glove, uniform and
other protections.
Besides the contents in this manual, it contains the notecaution and warning which
are used to direct the personnel to avoid of the injury during operating the equipment. They
are:
Notes:
This sign is used for additional notes for matters relating to

bodily and equipment safety.
Caution:
This sign is used for prompting a condition that may lead to

bodily or equipment damage.
Warning:
This sign is used for prompting a condition that will most

likely lead to bodily or equipment damage.
In this manual, the words withindicates that it is an operating parts of

the electric system.
As for the installation, trouble shooting, operation and maintenance of Top
Drive Drilling Equipments electric system, the operator should read the
manual before operating. For continuous improvement and changing, you
must check the product serial number printed in the cover of this manual to
ensure that the product confirming to the technical manuals.
Unprofessional person not being specially trained can not do the work of
installation, trouble shooting, operation and maintenance. It may lead to
the injury to the body or equipment. During operation, it is not permitted
to repair and maintain.
-1-
BPM Top Drive
Operation Manual
2 HSE instruction
This manual mainly introduces Top Drive component parts and each parts function. On
trouble shooting and detail repair, please refer to <Electric Manual> and <Hydraulic Manual>.
2.1 Electric safety operation indication

Please read below carefully before doing any operation of electric system:
a) Only professional person have permit to debug or repair for electrical system.
b) Read the <Electric Manual > and <Electric Drawing>carefully, familiar with the electric
circuit diagram.
c) Use suitable tools, and take suitable protection measures.
d) Hang forbid mark board like Do Not Switching On, and make sure shut off power
switch before each parts of work has been finished.
e) Before disassemble the electric connections, mark the electric wires (cables) and
connection terminals, so as to ensure the correct reconnection.
f) Dont repair or dismantle any electrical unit with power on, dont plug in/out each cable
connector with power on.
g) Dont open the junction box or Driller Console under having flammable gas environment.
h) Do not try to change the DC insurance between DC bus and Inverter when Rectifier is
working or DC voltage on bus is above safety range (DC 24V), It is dangerous for human
safety and electrical equipment!
i) If need maintain Rectifier, motor or Inverter, please turn main switch (3WL) to right side
(lock position), in order to prevent faulty operation.
j) The insulation of Inverter and Rectifier cant be checked by megameter, or else the high
test voltage will damage the equipment.
k) Driller Consoles protection air must keep pressure when power on! When air lost, filling
gas as quickly as possible or shut down the control power of Driller Console!
l) Forbid to free the safety interlocks of Top Drive System. If necessary, recover bypass
function as soon as possible after having solved the problem.
m) When temperature is higher than 40, and humidity percent is higher than 95% or dew
exists, dont start drivers and control power supplies before starting air conditioning to
lower down the temperature and decrease wet.
n) When system main power shut down by accident for more than half an hour, before restart
the system, must make sure that there is no dew in electrical control cabinets.
o) Under the moist environment, when electric house temperature is lower than the outside,
forbid long time opening the electric house door, otherwise may produce dew on the
electric equipments!
-2-
BPM Top Drive
Operation Manual
2.2 Hydraulic safety operation indication

Before operating the equipment and hydraulic system, please take the following as the
attention:
a) Read <Hydraulic Manual> and <Hydraulic Drawing> carefully, and acquaint the
hydraulic schematic diagram.
b) Switch off electric control system.
c) Use relief valve in system, and discharge all system pressure slowly, till no oil pressure in
system pipeline.
d) Before dismantling pipeline, please make marks to connection locations in order to insure
reconnection correctly.
Before disconnecting hydraulic pipeline, please close valve in system,

and prepare suitable container, oil plug, and cotton silk, etc. to avoid
pipelines residual hydraulic liquid flowing out, which will pollute the
equipment.
The temperature of hydraulic equipment and hydraulic oil may be so
high as to hurt personal, which could reach the approachable temperature
only after a period of times cooling.
2.3 Well control safety operating indication

During the course of installation and operation, operators should know the condition of
formation pressure and well control requirements. Paying attention to the following items:
a) Reading and understanding the drilling requirement and well control technical
requirements.
b) When meeting the high pressure hydrocarbon reservoir or poisonous gas including H2S,
SO2, etc. please follow the relevant standard, criteria, recommended practice and
requirements.
c) When drilling hydrocarbon reservoir, keep the equipment in good condition. Operate
IBOP with well control, etc. functions when changing operators. If any problems exist,
repair as soon as possible.
-3-
BPM Top Drive
Operation Manual
3 Main Specification
3.1 Basic specification
Nominal drilling depth
7000m (4 1/2 drill pipe)
Max. Loading
4500kN
Waterway
ID76.2mm (3)
Rated circulation pressure 35MPa (5000psi)
System weight
12t
(Main body, not include guide rail and migration supporter)
Working height
6.1m (from top lifting bail to upper face of elevator)
Supply voltage
600VAC
Rated power
400HP x 2
Ambient temperature
-35 ~ +55
Altitude
1200m
3.2 Drilling Parameter

Scope of rotating
0~220r/min (continuous, adjustable)
Working torque
50kN.m (0~110r/min continuous)
Max. Torque
75kN.m (discontinuous)
Power (kW)
1 min torque (kN.m)
Continuous torque (kN.m)
DQ70BSC Top Drive Drilling Equipment Working Curve
-4-
BPM Top Drive
Operation Manual
3.3 Motor Specification

Rated power
Rated rotating speed
Max. Rotating speed
400HP x 2
1150r/min
2400r/min
continuous
3.4 Cooling fan

Type
Rated power
Rated power
Rated frequency
Rated current
Rated rotating speed
YB132S1-2-H WF1
5.5kW (7.5HP)
380VAC
50Hz
11A
2900r/min
3.5 Hydraulic disc brake

Brake torque
50kN.m36,900ft-lb
Oil cylinder working pressure
8~9Mpa
3.6 Electric control system

VFD input voltage
Motor temperature alarm (adjustable)
Gearbox oil temperature alarm (adjustable)
HPU oil temperature alarm (adjustable)
600VAC/3AC
recommended value 110
3.7 Gearbox
Reduction gear ratio
Lubrication
10.5:1 bipolar speed reduction

gear oil pump compulsory lubrication, filter air cooling
3.8 Pipe handler device

Rotating head speed
4~6r/min
(adjustable)
Hydraulic motor working pressure 14Mpa
Upper IBOP (remote)
6 5/8 API REG box~pin, 70MPa
Lower IBOP (manual)
6 5/8 API REG box~pin, 70MPa
Backup Tong ID
220mm
-5-
BPM Top Drive
Scope of clamping by Backup Tong

Max. Break-out torque
Lower elevator link
Tilt angle
Operation Manual
2 7/8DP ~ 6 5/8DP
75kNm
3048mm, 350t
Front rake 30, back rake angle 55
3.9 Hydraulic control system

Working Pressure
Working flow
Motor voltage
Motor power
Motor rotating speed
16Mpa
40L/min
380VAC
15kW
1450r/min
-6-
BPM Top Drive
Operation Manual
4 Structure and operating principle

Top Drive is composed of Power Swivel, Pipe Handler Device, Electric drive and control
system, Hydraulic system, Driller Console, Auxiliary Control Box, guide rail, carriage, and
migration supporter, etc.
Power swivel
Guide rail
Pipe handler device
x 3
DQ70BSC Top Drive Main Body

-7-
BPM Top Drive
Operation Manual
4.1 Power swivel

Power swivel is composed of gearbox, two AC motors, lifting bail, wash pipe packing
assembly, and brake devices situated upon motor. Swivel lifting bail is fixed on the main body
by pins, and connected with block. The main function of the power swivel is to ensure normal
drilling operation, through AC motor driving the main shaft, make-up/break-out, and circulate
mud.
Hydraulic control valve manifold
Air cooling device
Heat exchange
Brake assembly
Lifting bail
Main motor
Wash pipe assembly
Gearbox
Power swivel
-8-
BPM Top Drive
Operation Manual
4.1.1 Main motor and cooling fan

Two main motors are abreast installed on
the gearbox. The motor is designed with
two shafts, its lower shaft connects with
the main drive small gear, and its upper
shaft connects with brake device.
Every main motor could provide 400HP
continuous power. In the condition of
50Hz frequency, the rated rotating speed
is 1150r/min.
The main motor is an AC VFD motor,
which could bear the vibration of 6g.
Adopt steel to weld the shell of motor,
reduce the vibration when motor
working. The design includes Class F
insulation and 100% epoxy resin vacuum
pressure soak, also adopts open grease
lubrication antiwear bearing.
On upper main motor, there is a cooling
fan, which is driven by 5.5kW explosion
proof triple-phase AC asynchronous
motor. When cooling fan is running, it will suck the air from disc brake air inlet into the
main motor air inlet mouth, then go through inner main motor and go out from bottom air
outlet. This design is more reliable for ventilation.
There is temperature sensor inside the main motor, which is used to detect and protect motor.
-9-
BPM Top Drive
Operation Manual
4.1.2 Brake device

On the upper shaft terminal of each motor, there is a disc brake. Clamp the brake disc through
two brake oil cylinders could realize Top Drive brake operation. Its power of applying the
brake and the pressure being exerted are in direct ratio.
The installation of brake device showed as follows:
Cooling fan base
Encoder
Disc brake
Brake disc
Brake hub
Brake closing board
Brake closing board
Disc brake
Heat radiator
Brake installation map

Every brake is equipped with two reset springs, which could auto reposition the brake
friction disc when it loosening the brake.
When motor runs galloping, brake device could stop the system.
- 10 -
BPM Top Drive
Operation Manual
4.1.3 Gearbox
Gearbox is an important part of Top Drive,
which adopts two-class gear drive. The
gear ratio is 10.5:1. Two gears are all bevel
wheels, which could meet the requirement
of big torque when motor breaks out. All
bearings adopt SKF shaft, vibrationresistance. Please refer to this picture for
the structure.
The lubrication system of gearbox adopts
oil pump to lubricate compulsorily. The
design of the lubrication pump is cycloidal
gear structure, reversible, driven by a main
motor output shaft. The lubricating oil
from the pump being sprinkled into the
gears and bearings, through the filter, flow
rate switch and radiator to all lubricant
points, then return to the oil tank through
main shaft.
The lubrication pipe of the gearbox is
equipped with flow rate switch and
temperature sensor which are used to give
alarm and to detect the oil temperature in
gearbox and circulating oil pumps flow
rate.
Gearbox
When main shafts speed is below 40rpm, flow rate switch will be off, and control screen also
indicates off. When main shafts speed is over 40rpm, flow rate switch will be on, and control
screen also indicates on. When main shafts speed is over 60rpm, flow rate switch will be
controlled by program (Siemens program)
Notes: The lubricant used in winter and summer is different. Low viscosity lubrication oil is
used in winter. In winter, when start the main motor, circulating in lower speed about 10
minutes first, and then do the drilling operation. High viscosity of the lubricant used in
summer. The over high oil temperature will wear and tear the gear shaft. Stop drilling when
the oil temperature alarm, then, rotate Top Drive system in lower speed and unload condition
about 10~15minutes until the lubrication oil temperature drops to the normal range.
- 11 -
BPM Top Drive
Operation Manual
Gearbox structure
Inspect the oil level of gearbox timely. Lower oil level will result in absorbing oil
insufficiency, gearbox and bearing cooling or lubrication not enough, and life loss of Top
Drive. It is necessary to add lubrication oil to gearbox in time.
The adjusting pressure of lubrication oil pumps safety valve (relief valve) is 1MPa. If
lubrication oil pumps pipe is blocked, the gearbox and bearing will become lack of cooling
and lubrication, and finally result in life loss of Top Drive. Operators must inspect the
lubrication system timely, changing the filter, and keep the oil clean.
4.1.4 Wash pipe assembly
Wash pipe assembly is equipped between
main shaft and gooseneck. Maintain the wash
pipe assembly timely could prolong its life.
Metric
- 12 -
Inch size
Wash pipe
assembly
BPM Top Drive
Operation Manual
Do not tighten up union too much, tighten till no leakage is enough, or else
may lead to packing and wash pipe wear and usage time become short.
4.1.5 Lifting bail
Lifting bail, an integral swivel lifting bail, is an important bearing part of Top Drive Drilling
Equipment, which bears the whole weight of the system. Swivel lifting bail is fixed on the
main body with the pin, and connected with block hook.
The lifting bail in this Top Drive is larger and thicker than the normal standard 500 tons
swivel lifting bail. Its performance reaches API requirements.
4.1.6 Gooseneck
Gooseneck is a channel of drilling liquid; it is equipped in the wash pipe supporter. The lower
gooseneck is connected with wash pipe and its upper could do fish operation and well log
work after opening. The mouth of gooseneck is connected with rotary hose through S-pipe as
the inlet opening of drilling liquid.
Gooseneck
Lifting bail
- 13 -
BPM Top Drive
Operation Manual
4.2 Pipe handler

Pipe handler is an important part of Top Drive Drilling Equipment. It could improve the
automatic degree of drilling. Pipe handler is composed of Backup Tong, IBOP and its control
system, link tilt device, rotary device, elevator links, elevator, etc.
Rotating head
IBOP
Link tilt device

Backup Tong
x 3
Pipe handler device
- 14 -
BPM Top Drive
Operation Manual
4.2.1 Rotating head

Upper rotating head is connected with gearbox and its lower is connected with Backup Tong
hanger. Rotating head could rotate independently, not along with the main shaft. Hydraulic
motor speed is adjusted by speed regulating valve, the hydraulic motor make the rotating head
rotates through drive the gear directly. Rotational speed is usually 3~5r/min. Rotating head
could rotate clockwise and counterclockwise.
In particular, the rotating head in the DQ70BSC Top Drive is different from other Top Drives.
Its hanger is located on the inner housing directly, and inside it there are one thrust bearing
and two alignment bearings. Therefore, when tripping or setting casing, it could directly bear
350t or 500t weight of elevator link. The DQ70BSC is a dual load path, which could prolong
the life of main shaft.
Rotating head
- 15 -
BPM Top Drive
Operation Manual
4.2.2 IBOP
The function of the IBOP is: when pressure in the well is higher than in the drill pipe, operator
could close the IBOP to prevent well from well kick or well blowout.
It is composed of upper remote IBOP and lower manual IBOP. Upper IBOP is connected with
power swivels main shaft, and lower IBOP is connected with the saver sub. When drilling,
saver sub connects with drill pipe. IBOP box/pin is 6 5/8 REG. The structure of upper IBOP is
same with lower IBOP, it including valve body, upper valve seat, wavy spring, valve core,
operating handle, crosshead, taper knob, lower matching retainer ring, lower valve seat, upper
matching retainer ring, support ring, retainer ring used for bore, O-ring etc. Operator could
turn the ball valve handle to 90to realize close/open inner drill pipe.
As for the high/low
pressure sealing, high
pulling strength, high
tensional strength, IBOP
is very effectively. IBOP
is matched with lower
adapter and drill string
joint. IBOP is located on
the crossover coupling,
and used to close the
main drill hole and bears
the recoil force.
IBOP could be used as
mud saver, if continual
use of it will result in the
abrasion, also the loss of
the life.
Retaining
ring
Upper
matching retainer ring
Support
ring
Upper
valve seat
Lower
matching retainer ring
Handle
seat
Handle
cover
Float
ball
Lower
valve seat
Operation
handle
Valve
body
IBOP
- 16 -
BPM Top Drive
Operation Manual
4.2.3 Upper IBOP control system

Upper IBOP realizes reversing by operating the hydraulic cylinder; it is convenient to
open/close IBOP on Driller Console. Upper IBOP operation mechanism is composed of a
couple of oil cylinders hanged under the rotating head, sleeve and wrench etc.
Oil cylinder supporter
Oil cylinder
Baffle
Rotating pin
Roller
Axle
Support
Bolt
Sleeve
Crank
Cover plate
Upper IBOP Control Device
When Driller Console send electric control signal to IBOP return circuit, oil cylinder will
upward push the IBOP sleeve to drive the crank and swivel pin rotary close the IBOP ball
valve; pushing downward could open the IBOP ball valve. The lower connection between oil
cylinder and sleeve is roller contact, which could ensure the sleeve move with roller upon the
oil cylinder piston rod, when rotating along with the main shaft.
Note: In normal drilling condition, when main shaft is rotating, it is not permitted to
operate IBOP, or else, suppressing pump may take place. Only when meeting well kick or
- 17 -
BPM Top Drive
Operation Manual
well blowout, could it be closed. Generally, it is not recommended to close the IBOP when
tripping. Because after a frequent use of IBOP, it may lead to not tight when close, and may
result in big accident meeting actual well kick or well blowout. Inspect all indicator lights on
Driller Console before drilling, inspect the IBOP button and make it in the open position.
Notes: open the IBOP first and then open the mud pump.
As for the applied high flow rate and high pressure sealing on drill pipe, upper IBOP is a very
good switch device.
4.2.4 Link tilt device
The tile oil cylinder pushes the elevator link and elevator to make the movement at two
directions, which could realize pitch and pit back, and resetting automatically. Pitch to the rat
hole or monkey board to hold or put drill pipe; pit back is to reset the elevator; the maximum
pit back could make the elevator more far away from the derrick floor.
Front rake is 30and back rake angle is 55. Swing horizontal distance is relevant with the
length of elevator links.
- 18 -
BPM Top Drive
Operation Manual
4.2.5 Backup Tong
Backup tong structure
Backup tong
The Backup Tong is composed of clamping system, hanging system and centralization parts.
The clamping system, function part of Backup Tong, consists of hydraulic cylinder, end cover,
piston, tong tooth seat, and tong body, etc. When clamping, oil flows into the hydraulic
cylinder, and pushes the piston up to the up-right. When tong tooth contacts the drill pipe, the
piston will stop, and the hydraulic force will push the hydraulic cylinder to the left and make
the right tong tooth clamps the drill pipe. The main shaft rotates, and then completes the
make-up/break-out operation.
The hanging system consists of rack, support seat and spring. The weight of Backup Tong is
squatted on the support seat through spring, finally lightens the shock coming from drilling,
and also could realize float function. The support seat could be hanged on different height by
changing hanging pin, so it is possible to disassemble the saver sub and IBOP .
The centralization system consists of stabilizer and spring. When Backup Tong is not working,
the front and back stabilizers will clamp the saver sub and make the Backup Tong tooth and
drill pipe keep a certain distance; when Backup Tong is clamping, owing to the front stabilizer
is hold out against the drill pipe, it could not move backward along with tong, so the spring
will be compressed. When Backup Tong is loosened, the spring will push the Backup Tong
hydraulic cylinder forward to reset, and keep the distance of tong tooth and drill pipe.
When disassembling Backup Tong, dismount the Backup Tong supporter and hanging pin first,
then put the Backup Tong down to ground or platform. Dismount the two pins and front tong
body. Dismount back tooth seat installed on the piston. The front and back end cover are all
limited by three semi-rings, after disassembling the retainers, and taking off the semi-rings,
- 19 -
BPM Top Drive
Operation Manual
then operator could take out the piston from back. Please pay attention to avoid damaging the
sealing parts.
The advantage of Backup Tong:
Big clamp range: 87mm~197mm (2 7/8~6 5/8).
Easy to maintain: simple structure, easy to disassemble and change.
Slide up and down: Backup Tong could slide upwards along the Backup Tong supporter.
It is easy to dismount crossover coupling and upper/lower IBOP. Select suitable parts as
below:
Tooth Seat Clamping Range
Chart no.
Name
9703641048
Front tooth seat 187
9703641045
Back tooth seat 187
9703641046
9703641043
Back tooth seat 168
9703641047
9703641044
Back tooth seat 127
Clamp dia.in
6 5/8
5 1/254 1/2
3 1/22 7/8
Note When using, do not exceed the tooth seat range.

Use Backup Tong to dismount the lower or upper IBOP and saver sub
a When use Backup Tong to dismount the saver sub, the first step is to breakout the
IBOP locking device, which between the saver sub and lower IBOP. Then, pull out
the hanging pin of Backup Tong, and lift the Backup Tong by hook to a suitable
height, insert the hanging pin to fix the Backup Tong. Finally, operator could
dismount the saver sub with Backup Tong directly.
b When use Backup Tong to dismount the lower IBOP, the first step is to replace front
and back tooth seat assembly 187, dismount centralization sleeve 187 and guide ring
203, breakout the IBOP locking device which between the saver sub and the lower
IBOP. Then, lift the Backup Tong by hook to suitable height, to dismount the saver
sub, and dismount the IBOP locking device which between the lower and upper IBOP.
Finally, lift Backup Tong, and dismount the lower IBOP.
c When dismount the upper IBOP with Backup Tong, there are three methods below:
- 20 -
BPM Top Drive
Operation Manual
l Firstly, replace Backup Tongs front and back tooth seat assembly 187, dismount
centralization sleeve 187 and guide ring 203, dismount saver sub and lower IBOP
IBOP locking device, and the IBOP locking device between the lower and upper
IBOP. Secondly, lift the Backup Tong by hook to a suitable height, and do break-out
operation while avoiding spin. Thirdly, tighten the IBOP locking device between the
lower and upper IBOP, and dismount the IBOP locking device between upper IBOP
and mainshaft, keep the Backup Tong still while break-out with upper IBOP drived
by the lower IBOP, and then operator could dismount the parts below upper IBOP.
Finally, dismount the upper IBOP directly by unscrewing the IBOP locking device
between lower and upper IBOP, which avoid operation of dismounting the IBOP
remote system.
l Breakout the IBOP locking device between the upper IBOP and mainshaft, then,
dismount the upper and lower IBOP, saver sub as an entirety. Finally, operator could
breakout the upper and lower IBOP easily.
l Dismount the IBOP remote system, and then dismount the IBOP locking device
between upper IBOP, lower IBOP and main axle ordinal. After dismount the lower
IBOP and saver sub, operator could dismount the upper IBOP.
Notewhen unscrew the loose device, please take care to avoid dropping of the lock
tooth plate.
- 21 -
BPM Top Drive
Operation Manual
4.2.6 IBOP locking device

In order to avoid the screw thread between main shaft and IBOP joint and saver sub
disconnecting when break-out, IBOP locking devices are installed among these joints.
Refer to the chart:
Upper tooth tong body
Tooth plate
Bolt
Lower tooth
tong body
4.3 Guide rail and carriage

The main function of guide rail is to bear reactive torque when Top Drive is running. The
guide rail used in DQ70BSC Top Drive system adopts double-pin connection. The carriage,
slid along with Top Drive and transmit torque to guide rail, is connected with guide rail by
pins. The upper guide rail is connected with crown pad by U-ring. Lower guide rail is
connected with torque beam of derrick leg, so the torque will be transmitted to the lower
derrick directly, this could avoid upper derrick bearing all the torque. See below picture:
- 22 -
BPM Top Drive
Operation Manual
Nut
Load-bearing wheel body
Carriage
Guide rail assembly
4.4 Electric drive and control system

The main drive of DQ70BSC Top Drive is controlled by AC VFD. It is composed of Rectifier
cabinet, Inverter cabinet, PLC/MCC control cabinet, Driller Console, cable, auxiliary control
cable, etc.
Driven by Rectifier and Inverter, two 400 hp AC VFD motors rotates main shaft by driving
gearbox, finally realize drilling and torque operation. Therefore operators could select one
motor or double motors working mode.
PLC could logically control whole system, inspect each parts movement, give fault diagnosis
- 23 -
BPM Top Drive
Operation Manual
alarm, and interlock procedure to prevent from fault operation. PLC is linked with drive
system via PROFIBUS field bus, with high reliability and powerful anti-interference. PLC is
connected with LCB by optical fiber with swift signal transmit speed and powerful antiinterference. PLC could self-diagnose and quickly inspect faults through WINCC monitoring
system, through which realize alarm, found data file and running curve, and seeking history
data.
This electric system is easy to operate. It has interlock protect function to prevent system from
fault operating. E.g.: switch operation mode, brake or Backup Tong misoperates during
drilling, etc.
There is a manual signal circuit, which could improve systems reliability.
For derail information of electric system, please refer to <Electric Manual > and <Electric
Drawing >.
4.4.1 Composing of electric system
The electric system is composed of drive system and control system.
4.4.1.1
Drive system in electric house and PLC
Drive system: including Inverter and Rectifier.

PLC/MCC system: including DC and AC distribution system of all functional units.
PLC system is linked with drive system via PROFIBUS, connected with LCB by optical fiber
and with each station by two twist-wire shielded cables. PLC is a serial programmable
controller designed as SIMENS S7-300. Its CPU is 315-2DP. Droller Console substation use
ET200M module.
4.4.1.2
Control stations outside the electric house
Including Top Drive Local Control Box, HPU and Driller Console.
a) Local Control Box: Local Control Box is installed on carriage. It could monitor system
by reading signal of cooling fan, gearbox (e.g. Oil temperature) and control hydraulic
valve (e.g. IBOP).
b) HPU Control Station: This control station controls two hydraulic pumps (one is working,
another is backup) and hydraulic oil cooling pump. Two hydraulic pumps and cooling
pumps could be started locally or remotely through PLC.
c) Driller Console: Driller Console could operate all functions required for well drilling. It
- 24 -
BPM Top Drive
Operation Manual
could set the speed, torque, operating mode and all assistant operations. The Driller
Console is positive pressure explosion-proof ExpniaIIT4, which could electrify only when
pressure of protecting air is in normal condition. When the pressure in cabinet is lower
then 5kPa, it will give alarm.
The buttons and indicator lights in Driller Console show as follows:

No
Indicator light
Type
Function
If hydraulic pump runs normally, it will on.
Pump Running
green indicator light
If pressure lower than normal value, it will flash.

If communication is interrupted or hydraulic pump
stop running, it will off.
This indicator light (2HZ) will become flash quickly
Locking
red indicator light
when the switch is in lock.

This indicator light will become on after finish
locking operation.
If the indicator light is on, it means IBOP is closed.
IBOP
red indicator light
Brake
red indicator light It lights when PLC send brake order.
If the indicator light is off, it means IBOP is opened.

This indicator light will flash when Driller Console
Ready
green indicator light is power on but system not ready. When system start
and everything is ready, it will on constantly.
6
7
8
Through combination, these three are used to

Fault/Alarm
red indicator light indicate alarms and faults. For detail information,
please refer to Fault/alarm section of Chapter 5.
- 25 -
BPM Top Drive
Operation Manual
No
Meter
Type
Torque
meter
10
Speed
meter
No
Switch
Type
HPU
three-position
11
12
Function
Show actual output torque of main shaft with unit
being kN.m and Klb.ft.
Show actual output speed of main shaft with unit
being r/min.
Function
Turn to run, pump will run.
Turn to stop, pump will stop running.
Run/Stop
switch
E. Stop
mushroom button
Turn to autopump will run according to pressure.

If press this button, drive unit will stop running, after
a short time, main air switch will be closed.
Turn to lock means lock the rotating head.
Turn to unlock means unlock the rotating head.
13
Locking Pin
unlock/lock
two-position switch
Lockingindicator light could show the status of

rotating head.
Link Rotation is invalid if already operate
Lock Pin.
Spring reset key, turn back to middle position
Link Rotation
three-position
ccw/stop/cw
switch
15
Clamp
two-position switch
16
Auxiliary
17
Link Center
black button
Link Incline
three-position
Rear/stop/Front
switch
14
18
two-position
switch
automatically. This switch is used to operate rotating

head: ccw/stop/cw
Turn this switch to clamp, Backup Tong will keep
clamp, it will reset when loose.
If this switch is on, the monkey board operator could
operate the Pipe Handler Device. Otherwise not.
Press this button, the elevator link will keep on float
status.
Spring reset key, turn back to middle position
automatically. The switch is used to realize the
elevator rear/front operation.
This switch is used to control main motors cooling
19
Air Cooling
three-position
fan. Turn to auto, main motors air cooling fan will
On/Off/Auto
switch
be controlled by procedure in PLC. Turn to on,

cooling fan will start. Turn to off, it will stop.
20
IBOP
Open/Close
Combination with the mud pump switch on signal.

two-position switch On open position, means open the IBOP valve gate.
On close position, means close IBOP valve gate.
- 26 -
BPM Top Drive
Operation Manual
Select motors work mode of Top Drive.

21
Motor
A/AB/B
three-position
switch
Turn to A, motor A will work.

Turn to B, motor B will work.
Turn
to
A+B,
two
motors
will
work
simultaneously.
22
23
Break
off /Auto/ On
Operation
Drill/Spin/Torque
three-position
switch
three-position
switch
on means brake is working; off means brake is

not working; and auto means brake will work
according to system procedure.
Be used to choose the operation mode: drill, spin or
torque. Drill is the null value (initial state).
When alarm, press this button will stop the sound.
24
Reset/Silence
black button
After resolving system faults, press this button again

will reset the alarm or fault. Keep on press it for
three seconds will test all indicator lights.
25
Direction
three-position
Ccw/Stop/Cw
switch
Be used to choose the motors direction. Stop is

the null value (initial state).
Be used to set a max torque for make-up operation.
Clockwise rotates hand wheel could increase limit
torque, under two motors working condition, full
26
Makeup Torque
potentiometer
range torque is 50kN.m; and under one motors

working condition, full range torque is 25kN.m. If
set value is higher than 25kN.m, systems output
torque will keep on 25kN.m.
Be used to set a max torque for drilling operation.
Clockwise rotates hand wheel could increase limit
torque, under two motors working condition, full
27
Drilling Torque
potentiometer
range torque is 50kN.m; and under one motors

working condition, full range torque is 25kN.m. If
set value is higher than 25kN.m, systems output
torque will keep on 25kN.m.
Be used to set drilling rotation speed.
Clockwise rotates hand wheel could increase preset
28
Throttle
Potentiometer
rotating speed. Speed range is 110rpm or 220rpm.

Different rated speed could be realized bySpeed
Rangeswitch on the Wincc system.
- 27 -
BPM Top Drive
4.4.1.3
Operation Manual
Main power cable and auxiliary control cable
The main power cables are used to connect the control cabinets output variable frequency
with Top Drives two main motors.
For easy install, the cable is divided into 3 parts:
a)
Ground cable (self-select part): 38m, from electric house to the bottom of derrick.
b) Derrick cable: 38m, from the derrick bottom to supporter nearby monkey board.
c)
Traveling cable: 30m, from the supporter to main motor.
Quick connectors are used among three-cables, between main power cable and main motor,
also between main power cable and main control cabinet. This is very convenient for install
on local well site.
The auxiliary control cable is the multicore cable and connected by quick connectors.
The auxiliary control cable between Main Control Cabinet and Top Drive is divided into two
parts: derrick pipeline (68.6m) and grounding pipeline (38m). The grounding pipeline (38m)
contains two pieces: one is 12-core, and the other is 67-core. Main power cable is placed
beside the auxiliary control cable.
- 28 -
BPM Top Drive
Operation Manual
4.5 Hydraulic drive and control system

The hydraulic system of DQ70BSC Top Drive includes: lifting bail balance system, brake
system (used to brake the main motor and mainshaft), rotating system of rotating head in pipe
handler device, elevator link tilt system, IBOP control system, Backup Tong system, etc. PLC
controls all actions. Hydraulic system is composed of below items:
a) HPU (ground pump station)
b) Hydraulic valve manifold
c) Actuator (counterbalance cylinder, brake oil cylinder, IBOP control oil cylinder, rotating
head motor etc.)
d) Hydraulic pipeline (service loop, extended loop etc.)
e) Accessories
4.5.1 HPU
The function of HPU is to provide hydraulic power, including oil tank, oil pump, motor, valve
block, electric control parts etc.
HPU adopts redundancy design, namely, two motors drive two hydraulic pumps respectively.
In normal condition, just startup one pump and another is for back-up. Hydraulic is equipped
with remote control system, operators could either start/stop the A, B pumps or cooling pump
on the pump station, or do the same operation on the Driller Console. The working pressure
value of hydraulic pump is set to 16Mpa, depending on pressure control valve. In addition, the
system has another relief valve used as safety valve, usually set its value to 19 MPa.
The hydraulic pump of HPU is pressure compensating type, that is, when system pressure is
lower than 16Mpa, the pump will give full flow, when system pressure reaches to the set
value, the pump will work with approximately zero flow and output very few of liquid.
HPU is equipped with an independent cooling fan (it has two select: auto and manual), which
is used to cool the hydraulic oil. This device is equipped with a temperature controller, if
select auto, when oil temperature is higher than set value, the cooling fan will startup
automatically; when the oil temperature is lower than set value, it will stop.
All circuit system in the HPU is explosion proof design. The electric control cabinet, motor,
liquid level control, temperature alarm system are all adopt explosion proof parts.
Equipped with side filter system, which give the HPU function of self-cleaning. The side
liquid flow through a high accuracy filter to wipe off the harmful impurity.
- 29 -
BPM Top Drive
Operation Manual
4.5.2 Control valve manifold

Control valve manifold is installed between two motors, and it is composed of main control
valve manifold, balance mechanism valve manifold, and accumulator block etc.
Main Control valve manifold is modular integrated valve manifold, it consists of explosion
proof electromagnetic valve, pressure reducing valve, multiple balance valve, pilot operated
check valves, flow control valve, multiple relief valve, double throttle check valve, modular
flow restrictor valve, relief valve, check valve, etc.
Valve port distribution:

P1Main valve block oil inlet port
T1Main valve block oil return port
L1Main valve block oil drain port
PACounterbalance cylinder A port
PBCounterbalance cylinder B port
BABackup Tong cylinder A port
L1
BBBackup Tong cylinder B port
T1
FAKelly valve cylinder A port
PA
BA
FA
PB
BB
FB
SA
HA
QA 1
QA 2
HB
QB1
QB 2
P1
FBKelly valve cylinder B port

SABrake cylinder A port
SBBrake cylinder B port
- 30 -
BPM Top Drive
Operation Manual
HARotary motor A port

HBRotary motor B port
QA1Link tilt cylinder A1 port
QB1Link tilt cylinder B1 port
QA2Link tilt cylinder A2 port
QB2Link tilt cylinder B2 port
XARotary lock cylinder A port
XBRotary lock cylinder B port
The main control valve manifold is composed of seven control systems
that control seven actuators separately.
Each system has pressure measure point to monitor actuators working
pressure. Also the pressure measure point could help system work reliably by exhausting gas
for hydraulic system and actuator.
First: Elevator link tilt system

This system consists of explosion proof magnetic valve, balance valve, double throttle check
valve, explosion proof lock valve, modular flow restrictor valve, two-way flow control valve.
This system could help actuator keep certain back pressure, and balance the weight load.
Elevator link tilt systems working pressure is 14MPa, which is set by the multiple balance
valve.
Timely inspect elevator link tilt systems pressure could avoid operating pressure over low or
high. If over low, the elevator link tilt system can not load weight or can not stay at random
locations. If over high, mechanical parts may be damaged due to the speed is too fast.
- 31 -
BPM Top Drive
Operation Manual
5126040100
Two way flow control valve
5126000560
Explosion proof magnetic valve
Link tilt system pressure

measure point
5126000581 Balance valve
5126000540 Explosion proof lock valve

5126000330 Double throttle check valve
5126000551 Modular flow restrictor valve
- 32 -
BPM Top Drive
Operation Manual
Second: Rotary system

It consists of explosion proof magnetic valve, flow control valve, and multiple relief valve.
Flow control valve could adjust the speed of rotating head randomly, and speed of rotating
head is usually controlled below 3~5rpm so as to prevent it from excessive movement inertia.
Working pressure of circuit is 14MPa, controlled by multiple relief valve.
Timely inspect rotary systems pressure could avoid operating pressure over low or high. If
over low, the rotary system can not runs nimbly. If over high, mechanical parts may be
damaged.
5126000560
5126000500 Flow control valve
5126000310 Multiple relief valve
Rotary system pressure

measure point
- 33 -
BPM Top Drive
Operation Manual
Third: Brake system

It consists of Explosion proof magnetic valve and pressure reducing valve. The pressure
reducing valve has the function of reducing secondary loops pressure, and is used to adjust
actuator pressure. SA port pressure is 0MPa, and SB port pressure is 8~9MPa.
Timely inspect brake systems pressure could avoid operating pressure over low or high. If
over low, may result in open or close brake cylinder not in time. If over high, the mechanical
parts may be damaged.
It is strictly prohibited to brake when main motor is running normally.
5126000480
Pressure reducing valve
5126000670
Brake system
pressure measure point
- 34 -
BPM Top Drive
Operation Manual
Fourth: IBOP system

It consists of explosion proof magnetic valve, pilot multiple check valve and pressure
reducing valve. The pressure reducing valve has the function of reducing secondary loops
pressure, and is used to adjust IBOP actuator pressure 12MPa.
Pilot operated check valves function is close and lock IBOP upgoing stroke (prevent oil
cylinder from down sliding). Or else, actuators malfunction may happen.
Timely inspect IBOP systems pressure could avoid operating pressure over low or high. If
over low, may result in open or close IBOP cylinder not in time. If over high, the mechanical
parts may be damaged.
5126000560
5126000480
5126000320
pilot multiple check valve
- 35 -
BPM Top Drive
Operation Manual
IBOP system
measure point
pressure
Fifth: Backup Tong system

It consists of explosion proof magnetic valve, P port pressure reducing valve, A port pressure
reducing valve, and pilot multiple check valve. The pressure reducing valve has the function
of reducing secondary loops pressure, and is used to adjust Backup Tong actuator pressure.
Timely inspect Backup Tong systems pressure. Normally, B port pressure is set to 12 MPa. If
over low, may result in tong tooth could not clamp drill pipe effectively. If over high, the
mechanical parts or drill pipe may be damaged.
When adjusting, correctly connect pressure tools and correspondent pressure measure
points.
Before operating the Backup Tong, it is important to lock the rotating head firstly. This
could make sure equipments and personnels safety.
- 36 -
BPM Top Drive
Operation Manual
5126000670
5126000320
Pilot multiple check valve
5126000480 P port pressure

reducing valve
5126000680 A port
pressure reducing valve
Backup Tong system

pressure measure point
- 37 -
BPM Top Drive
Operation Manual
Sixth: Balance system

It consists of reduce relief valve 5126000471 , problem board and accumulator
components connected with the problem board. Accumulator components consist of Sub-plate
relief valve, check valve and accumulator. The pressure reducing valve has the function of
reducing secondary loops pressure, and is used to adjust counterbalance cylinder actuator
pressure 10.5MPa. Sub-plate relief valve is used to protect system and restrict its pressure, its
set pressure is 2~3MPa higher than the pressure reducing valves.
Notice: when maintaining or dismounting, it is important to loose accumulators relief valve
firstly, because accumulator has 8~9MPa pressure.
Balance system pressure

measure point
5126000471 Reduce relief valve
- 38 -
BPM Top Drive
Operation Manual
5126000600
Pressure
measure point
5126000600 Relief valve
Seventh: Rotary lock system

It consists of explosion proof magnetic valve(Y), and pressure reducing valve. Pressure
reducing valve is used to adjust the rotary lock cylinder pressure, and it is used to lock the
rotating head and connect main shaft and Backup Tong, and prepare for make-up and breakout. The adjusting device is on the upper of rotating head, upon the rotating supporter.
Pressure reducing valves set pressure is 4MPa.
5126000562 Explosion proof magnetic
valve(Y)
5126000480
Pressure
measure point
- 39 -
BPM Top Drive
Operation Manual
4.5.3 Hydraulic pipelines

Hydraulic pipeline is used to connect HPU and valve manifold, totally 3 oil tubes, that is, high
pressure outlet, low pressure return and leakage hydraulic circuit. The return oil pass through
the filter first (precision is 10), and then flow back into oil tank, but the leakage oil will flow
back to oil tank directly, that is no back pressure exists.
Hydraulic pipeline consists of following parts: extended loop and service loop.
Hose connection is adopted among valve manifold, each oil cylinder, and motor, etc. actuator
elements. These kinds of connection are good for installation and dismantle.
- 40 -
BPM Top Drive
Operation Manual
5 Operating procedure
Only qualified and experienced personnel being trained could operate Top Drive system.
Please read and learn this manual and other relevant document before operating.
5.1 Inspection before startup

The personnel mentioned above and closed to the equipment should be trained on well
drilling operation and well drilling safety knowledge. Wearing the glover, uniform and other
protection are necessary.
If it is the first time to install, please refer to the <Installation and Trouble Shooting Manual>
to debug.
Inspecting the following item before startup the system:
a) Inspecting the running records and if any unmoral phenomenon happened during latest
operators working period.
b) Inspecting the liquid level of gearbox, please refer to <Maintenance Manual> when filling
oil. The liquid level should be neither too high nor too low.
c) Inspecting the oil tank liquid level of hydraulic system and filter.
d) Filling the oil to the lubricant point every day.
e) Inspecting the hydraulic oil to see whether it is leak or not.
f)
Inspecting the hydraulic hose.
g) Inspecting the gooseneck and joints, if any damage occurs.

h) Visually inspect the cable hanged on Top Drive. Make sure that no entangling happens.
Inspect whether cable joints are loose or not.
i)
Inspecting the safety lockwire and safety pin.
j)
Inspecting the Backup Tong head arresting pin and bolt.
k) Inspecting the wearing of Backup Tong tooth.

l)
Inspecting the main shaft IBOP locking device, inspect if the bolts have loosed.
m) Inspecting other equipments besides the Top Drive.
- 41 -
BPM Top Drive
Operation Manual
5.2 The startup/shutdown of electric system

5.2.1 Startup system
Before startup electric system, making sure that the mechanical and hydraulic systems have
been ready, inspecting the electric system about the following items:
a) Inspect the mechanical and hydraulic system first. Make sure that they are ready.
b) Inspect all operation cabinets and meters of electric system and Driller Console; ensure
they are in initial status. (Refer to <Electric Manual> appendix 1).
c) The indicators on Driller Console could be tested by press the button of
Reset/Silencefor three seconds.
TurnSystem Startswitch on PLC/MCC cabinet to on, the system ready indicator light
will flash, and then the Rectifier begins to run, after a short time, the corresponding Rectifier
cabinets main air switch will power on. 600V power supplied to Rectifier, Inverter will run
when Driller Console gives an enable signal, and then Top Drive is ready.
When electric system is ready, at the same time the system ready and ready indicator light
on Driller Console will on constantly. Enable signal from Driller Console will startup the
Inverter.
The operation of system start will invalid if the system is not in initial status!
When system is running, operating System Start switch on PLC/MCC
cabinet will cause fault stop.
5.2.2 Stop system
Stop electric system:
a)
Turn Throttlehandle of Driller Console to zero, and turnDirection switch to

the Stop position. Inverter will stop and Top Drive will stop running.
b) TurnSystem Startswitch to off. The main air switch will disconnect when Rectifier
accept system stop signal, then, the system will stop running.
The power only can be shut off after the main air switch was opened.
- 42 -
BPM Top Drive
Operation Manual
5.3 Start/stop of hydraulic system

Start HPU locally:
a)
Operating thePump Selectswitch on HPU to A or B.
b)
Turn HPU Control Box Powerto on.
c)
When Power On indicator light is on, turn HPU Pumpto on, the selected pump will run, and
Pump A Running or Pump B Running indicator light will on. When communication is well,
Pump Runningon Driller Console will on.
Stop HPU locally:

a)
Turn the HPU Pumpswitch to off, the pump will stop running, and indicator light will off.
b)
If HPU pump keep stop for a long time, operator should turn Poweron HPU Control Box to off.
Compared with remote operation by Driller Console, local operation on HPU has priority.
When checking or repairing, it is important to disconnect power supply to ensure
personnel and equipment safety.
When HPU pump on local control mode, E_Stopoperation cant stop the HPU
pump.
Start HPU remotely:

When communication is well, Driller Console remote control HPU procedure:
a)
Turn HPU Control Box Powerto on.
b) Use HPU panel to select pump A or B.

c)
Turn HPU Pump to auto, set HPU pump to remote control.
d) Turn HPU on Driller Console to run, could start the selected pump. Turn
HPUon Driller Console to stop, could stop the selected pump. If turn to auto, the
pump will run automatically when pressure is lower than 14Mpa, while pump will stop
automatically when pressure is higher than 16Mpa.
e)
If HPU keep stop for a long time, operator should turn HPU Control Box Powerto
off.
When HPU pump on remote control mode, E_Stopoperation will stop
the HPU pump. If need pump running, control the pump locally.
- 43 -
BPM Top Drive
Operation Manual
5.4 Main motor heating

When main motors are not running, switch Motor Heaterof PLC/MCC cabinet to on
could startup the heater of two main motors. The Heat on PLC/MCC will show the status of
motor heater.
In PLC logic, heater and motors running are interlocked. Namely when main motors are
running, heater is forbidden to work; if start main motor when heater is working, the heater
will stop automatically.
If it has been rained for a long time outside or Top Drive has not been worked
for a long time, it is necessary to start heaters to enhance motors insulation
before starting motors. So that two motors could work safely.
5.5 Motor cooling fan

Two air cooling fans are installed on the top of main motors.
The on position of Air Coolingon Driller Console could startup the air cooling fan
directly. If Air Coolingswitch is on off position, after delay time, the main motors
cooling fan will stop. But when motors are running, no matter which position ofAir
Cooling, the air cooling fan will not stop.
When Air Coolingswitch is on auto position, before Top Drive start running, system
preset main motors corresponding cooling fan will start.
A cooling pressure monitor is located at air in port of motor to measure the winds pressure of
cooling fan. If the monitor measures the pressure is low after motor is startup, the system will
give sound/light alarm shows the cooling fan is not normal. Please check the cooling fan and
the monitor as soon as possible to avoid damaging of the equipment. The status of monitor is
displayed at Top drive system of WinCC.
- 44 -
BPM Top Drive
Operation Manual
5.6 Driller Console

5.6.1 Drilling operation procedure
Inspect the system before operating; make sure that system is in following status:
Name
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
Follow below items:

a)
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
b) Set speed range on the Wincc system.

c)
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
d) Slowly turn Drilling Torqueswitch to a need torque.

e)
Operating the Direction switch to select cw position.
f)
Turn Throttleslowly away from zero position, the main motor will rotate clockwise
with the speed given by Throttle.
Only system is not working and Throttle is on zero position,
Operationswitch is valid. Otherwise, Operationswitch is invalid.
- 45 -
BPM Top Drive
Operation Manual
Only system is not working and Throttle is on zero position,

Directionswitch is valid. Otherwise, Directionswitch is invalid.
Only system is not working, Direction is on stop position, and
Throttleis on zero position, theMotorswitch is valid. Otherwise,
Motorswitch is invalid.
If the operation of Motoror Operationhas a mistake, the system
will give a three seconds sound alarm but no light alarm; After system
returning to normal, this sound will disappear.
Throttle, Drilling torqueandMakeup torquehandle back to zero
position, means set these switches to left end (throttle no input data).
When startup main motors, for safety, the presetDrilling Torquevalue
shouldnt be very high. After the main shaft begin to rotate, operator could
increase Drilling Torquevalue at this time.
Before startup the main motor, make sure that Brake is in right status
and Drilling Torquevalue is right.
- 46 -
BPM Top Drive
Operation Manual
5.6.2 Reverse drilling under Drill Mode

In normal condition, it is not permitted to do drilling ccw. But in order to solve some complex
working conditions, Top Drive has the function of drilling ccw, which needs to do some
setting in the Wincc system.
Check the system before this operation, startup system correctly. Make sure that system is in
following status:
Name
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Driller Console
Drilling Torque
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
Zero position
Reverse drilling follow below items:

a)
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
b) Set speed range in Wincc system. After logon, operate DRILLING_CCW

SETTINGbutton could realize drill ccw under Drill Mode. If successful, this button
will become red color.
c)
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
d) Slowly turn Drilling Torqueswitch to a need torque.

e)
Turn Directionswitch to ccw when Throttleis on zero position and system is

- 47 -
BPM Top Drive
Operation Manual
not running.
f)
Turn Throttle slowly away from zero position, the main motor will rotate
counterclockwise with the speed given by Throttle.
g) Logout Ccw Mode on Wincc after finishing ccw drill operation.

When drilling ccw under Drill Mode, take care to preset drill torque
carefully, in order to avoid drill pipe backing out happens.
5.6.3 Stop drilling
Under Drill Mode, turn Throttle to zero position and Directionswitch to Stop
position, Top Drive will stop running normally. If break is on auto position, the brake will
work when the speed is suitable.
When system is running under Drill Mode, if incorrect operateDirection
switch away from Cw position, or incorrect operate theBrakeswitch, or
some electric faults occur, the system will decrease the speed and finally stop
running.
5.6.4 Make-up/break-out operation
Inspect the system before this operation; make sure that system is in following status:
Name
Button or Switch
Status
Driller Console
Motor
A+B
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
- 48 -
BPM Top Drive
Operation Manual
Name
Button or Switch
Status
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
5.6.4.1. Make-up operation

1
a)
Make-up with stand
Make sure that HPU is in good condition. When communication is well, Pump Running
indicator light will on.
b) Turn Makeup Torqueto a preset value.

c)
SelectDirectionswitch to Cw position and Operationswitch to Spin . At this

time system will work clockwise under Spin Mode, with fixed speed and torque.
d) When system keep 15% of rated torque and direction of rotation keep clockwise, turn
Operationswitch to Torque, the make-up operation will be finished automatically
with the preset torque ofMakeup Torque.
2
a)
Make-up with single
Make sure that HPU is in good condition. When communication is well, Pump Running
b) Turn Makeup Torqueto a preset value.

c)
TurnLocking Pinon Driller Console to Lock to do locking operation. When the

locking indicator light become on, means locking operation has finished. Clamp
operation should be done after finishing the clocking operation.
d) Turn Direction switch to CW position, Operation to Spin will realize

clockwise Spin Mode. System will clockwise spin with fixed speed and torque.
e)
After finishing spin, ensure rotating head is locked, then turnClampto lock by left
hand, and turnOperationto Torque at the same time, system will switch to Make-up
Mode. After a short time, system will Make-up with value given byMakeup Torque.
Before operating clamp, confirm that the rotating head locking operation has completed, namely,
has already detected the locking pin insert ready signal, the Locking indicator light will become
on.
Before Make-up operation, pay attention to Torque meter, make sure that the actual Make-up
torque reaches to the preset value given byMakeup Torque.
- 49 -
BPM Top Drive
f)
Operation Manual
When torque reach to preset value, left hand release theClamp, right hand turn
Operationswitch to Drill, this finish the make-up operation.
g) TurnLocking Pin switch to Unlock position to let the locking pin out. If the
locking indicator is off, means unlock operation has finished.
5.6.4.2. Break-out operation
a) Make sure that HPU is in good condition. When communication is well, Pump Running
b) TurnLocking Pinon Driller Console to Lock to do locking operation. When the
locking indicator light become on, means locking operation has finished. Clamp
operation should be done after finishing the clocking operation.
c) Turn Directionswitch to ccw.
Before operating clamp, confirm that the rotating head locking operation has
completed, namely, has already detected the locking pin insert ready signal, the
Locking indicator light become flickering slowly.
d) Turn Clamp to lock, and turnOperationto torque. Backup Tong will close
firstly, after a short time system will counterclockwise rotates with a speed not more than
Max torque value 75kN.m. When speed is faster than value of spin speed, the system will
stop automatically. Left hand release the Clamp , right hand away from
Operationswitch, then finish the break-out operation.
When Top Drive under Torque Mode, release Clamp switch or release
Operationswitch, PLC system will stop the drive unit.
e) TurnOperationswitch to spin, then the system will switch to counterclockwise Spin
Mode with fixed speed and torque.
f) When drill pipe tool joint loosen completely, turnDirectionswitch to stop and
Operationswitch to drill, system will stop running.
g) Turn Locking Pin switch to unlock position to do the unlock operation. When the
indicator is off, means unlock operation has finished.
When the drive is running under Spin Mode, if incorrectly operateDirection
or electric faults happens, the system will stop running.
- 50 -
BPM Top Drive
Operation Manual
5.6.5 Rotating head lock operation

After starting the HPU, operateLocking Pinswitch of Driller Console could realize lock
and unlock of rotating head. Before operating the clamp, operator should operateLocking
Pinswitch to complete rotating head lock operation firstly.
Turn Locking switch to lock position, the rotating head will rotate with a small
increments and the locking pin will act. After locked, the Locking indicator light will on,
means lock operation has completed. If the indicator light does not on, turn Locking Pin
switch to unlock, do lock operation again.
Locking Pinand Link Rotationswitches are interlocked.
In order to keep equipment and personal safe, after finishing rotating head lock
operation, then operator could operate clamp.
5.6.6 Elevator link operation
After starting the hydraulic system, when making sure that the rotating head locking device
has unlocked, turnLink Rotationswitch could control the elevator link clockwise or
counterclockwise rotation.
Driller Consoles Link Inclineswitch could realize the control of elevator link front/rear.
Link Rotation and Link Inclinecan not operate at the same time.
PressLinks Centerbutton could operate the elevator link back to center position. Pay
attention to avoid colliding drill string when operating.
Before the link rotation operation, make sure that the lock pin has unlocked; otherwise link
rotation operation is invalid.
If the master computer system has set the interlock between link rotation and link incline,
after finishing link incline operation, press Link Center,then a few times later the link
rotation operation will be valid.
Locking Pinand Link Rotationare interlocked. When operating link
rotation operation, locking pin operation is invalid; when operation locking pin
operation, the link rotation operation is invalid.
When Driller ConsolesAuxiliaryswitch is on and the Auxiliary Control Box indicator
lights is on, operate the switch on Auxiliary Control Box could realize the same function
mentioned above. Auxiliary Control Box and Driller Console are interlocked.
- 51 -
BPM Top Drive
Operation Manual
Max. Load weight of tilt oil cylinder is 2ton, when hoisting overweight things
such as drill collar, make sure that elevator link is in floating status, namely tilt oil
cylinder runs without strength.
5.6.7 IBOP operation
When system stops running, IBOPcould control IBOPs movement.
When operates such as logging, etc. turn PLC/MCC cabinets IBOP Disableto Disable
for protect cable in the well, the operating procedures shown as follow:
a) Turn IBOP to Open ,open the IBOP.
b) Turn PLC/MCC cabinetsIBOP Disableto Disable.
The well testing finished, turnIBOP Disableto Enable, IBOP could be controlled by
Driller Consoles IBOP
During well testing etc., turn PLC/MCC cabinets IBOP Disableto Disable
for protect cable in the well.
After well testing finished, please turn PLC/MCCs IBOP Disableto Enable
for IBOP control reliability, it could be controlled by Driller Consoles IBOP.
5.6.8 Emergency stop operation
When urgent condition taking place, operator could press any ofE. Stopswitch, then, all
equipments of Top Drive will stop quicklyif HPU. Pump on remote contorl mode.
After pressE. Stop, it is forbidden to do any further operations, except that operator has
finished below procedures:
a)
Turn Throttle handle back to zero position; turn Direction to stop; turn
Operationto Drill.
b) Turn PLC/MCC cabinetsSystem Startto off.

c)
Solve the emergency, and make sure that there is no fault or alarm in system.
d) Reset E. Stop.
e)
PressReset/Silenceto silence the alarm, then press again to reset.
f)
Turn System Startto on, restart the system.
- 52 -
BPM Top Drive
Operation Manual
5.6.9 Fault/Alarm
The error can be divided into 4 types:
a)
System fault: The drive system faults, the system will stop quickly.
b) Communicating fault: either of PROFIBUS substation communication is interrupted,

(under cable mode, it will not give alarm when Top Drive Local substation
communication is interrupted), the system will stop quickly.
c)
Electric fault : Such as main air switch, auxiliary power supply, I/O power supply,
Driller Console power supply, E-stop, etc. the system will stop quickly.
d) Electric fault : Such as UPS power supply, HPU power supply, etc. the system will
normal stop automatically.
There are three Fault/Alarm indicator lights on Driller Console, which could notice different
kinds of alarm/faults through different kinds of combinations.
H1
H2
H3
- 53 -
BPM Top Drive
H1
H2
off
flash
flash
off
on
flash
off
on
flash
off
flash
H3
Operation Manual
Alarm type
Top Drive description
off
flash
off
other alarms
encoder loss alarm
Alarm
air pressure loss alarm
flash
main motors over temperature
off
other communication faults
flash
off
communication fault of Inverter
Communication fault
communication fault of Rectifier.
flash
communication fault of Local Control Box (LCB)
off
other equipment faults
flash
off
Rectifier fault
System fault
Inverter fault
flash
braking unit over temperature
off
flash
off
other electric faults

on
auxiliary power fault
Electric fault
emergency stop
flash
air cooling power fault
When fault or alarm happens, sound will on.

After system stop running, operator should turnThrottlehandle back to zero position,
Directionto stop,Operationto Drill, and turnSystem Starton PLC/MCC
cabinet to off.
After fault or alarm happens, press Reset/Silenceto stop sound, but Fault/Alarm
indicator lights will keep on its status. At this time, operator could search for alarm record in
the Wincc system. After solving the fault, pressReset/Silenceagain to reset the system
and extinguish Fault/Alarm indicator lights.
- 54 -
BPM Top Drive
Operation Manual
5.7 Special operation

5.7.1 Encoder switch
If the encoder of main motor was damaged, the Wincc system will give record of alarm. At
this time, switchEncoder Selectswitch could realize system work with the other encoder.
a)
TurnThrottleto the zero position, turnDirectionswitch to stop position, turn

Operationswitch to drill, and turn theSystem Startto off.
b) Turn ENCODER SELECTon Inverter 1 cabinet.

c)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
At this time, change the encoder or solve the problem immediately.

Switch Encoder Selecttimely, not more than two weeks, this kind of
alternately run of encoder could enhance systems reliability.
Use the corresponding encoder for the stability, when running in single motor.
5.7.2 Running without encoder
If the encoder of two motors were damaged, switchEncoder Faultswitch to fault could
realize system running without encoder.
a)
TurnThrottleto the zero position, turnDirectionswitch to stop position, turn

Operationswitch to drill, and turn theSystem Startto off.
b) Turn PLCs Encoder Faultto fault. This time, Without Encoder indicator light
will power on.
c)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
At this time, change the encoder or solve the problem immediately.

System running without encoder, the control definition for torque was reduced;
Please change the encoder for systems credibility.
- 55 -
BPM Top Drive
Operation Manual
5.7.3 PLC control operation

5.7.3.1 Start Cable operation
In case of PROFIBUS optic fiber of Top Drive system was interrupted, the system can be
switched to the Cable operating mode.
a)
TurnSystem Startto off, and reset all switches of Driller Console to initial position.
b) Turn Control Modeswitch on PLC/MCC cabinet to Cable, and System Start

switch to on, switch system to Cable operation mode.
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
When switch the System Startto off, operation mode changing should
be done after the main air switch is off.
5.7.3.2 Stop Cable operation
a)
After the communication of LCB has recovered, reset all switches on Driller Console to
the initial position (refer to appendix 1), then, turn System Start to off, and turn
Control Modeto Profibus..
b) Press the Reset/Silencebutton when system has no alarm or fault. After that
electric system will switch back to normal communication mode.
the
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
- 56 -
BPM Top Drive
Operation Manual
5.7.4 Driller Console emergency operation

5.7.4.1 Start Em-operation
When the CPU cant work due to some faults, emergency operation should be adopted. But
please replace a new CPU as soon as possible.
a)
TurnSystem Startto off, and reset all switches of Driller Console to original
position.
b) Turn ON OFF AUTOswitch on HPU to on.

c)
Turn Control Modeswitch on PLC/MCC cabinet to Bypass, switch system to

manual emergency operation mode.
d) Turn Air Coolingto on to start main motors cooling fan.

e)
Turn System Startswitch to on, drive unit will ready.
f)
After ensuring the cooling fan has started, turn Directionto cw or ccw.. The
main shaft will rotate clockwise or counterclockwise with a fix speed.
Under this mode, operator should manually operate Brake, HPU pump, HPU
cooling fan, auto is invalid.
5.7.4.2 Stop Em-operation
a)
After system has recovered from faults, turnDirectionswitch to stop, system will
stop running.
b) Turn all switches of Driller Console back to original position first, then turn System
Startto off, turnControl Modeto Profibus at last.
c)
Press Driller ConsoleReset/Silence, Top Drive will run in normal status.

Under manual operation mode, it is possible to do some simple magnet valve
operation. But under this mode, although main shaft could rotate, Top Drive
could run only with the rotating speed and torque preset by system.
Under manual operation mode, system work without CPU. So that all the
interlocks, alarms and protections in program can not be realized.
Under manual operation mode, all the interlocks are invalid, so the operator
should be more carefully, avoid damaging equipment or any person.
- 57 -
BPM Top Drive
Operation Manual
6 Operation procedure of drilling

6.1 Trip in/out operations
Trip in/out is conducted in conventional ways, with pipe handler device, Top Drive could help
operator work less labor and more effectively.
6.1.1 Trip in
a) Move Top Drive to monkey board by hoisting system, operateLink Rotationto move
the elevator link incline arm to the operator required direction.
b) SwitchLink Inclineto front, move elevator near to drill pipe, then operator put the
drill pipe into elevator and lock its bar.
c) SwitchLink Inclineto rear, move back to mouth of well, then, operateLink
Center. At this time, the link tilt cylinder is in floating state.
d) Lift and move drill string back to center position, during this period, operators should hold
the lower end of drill string with a rope and release it slowly in order to avoid damaging
the joint of drill string.
e) Lower down the block, align the hoisted drill pipe with wells, then, spin with hydraulic
tongs.
f)
Lift the drill string and move away slip. Place the drill string down to the mouth of well
and seat it onto the slip.
g) Loosen the elevator, move elevator link away from drill pipe by switchLink Inclineto
rear a little. Lift block to monkey board and repeat the above motioned steps.
6.1.2 Trip out
a) Disconnect the main shaft and drilling string thread, and then lift Top Drive. Operate
Link Inclineto front to make elevator catch the drill pipe tool joint.
b) Hoist Top Drive to monkey board. Seat slip on derrick floor well mouth, and then lower
down Top Drive.
c) Break-out with hydraulic tongs.
d) Hoist Top Drive, switchLink Inclineto front to make the elevator near to monkey
board, then operator open the elevator and put the drill string inside pipe setback.
e) OperateLink Incline, lower down Top Drive to the joint point of derrick floor. Switch
- 58 -
BPM Top Drive
Operation Manual
Link Inclineto front to make the elevator catch the drill pipe tool joint.
f)
Repeat the procedures from two to five.
If reducing radius or key seat occurs during trip in/out process, connect the drill string with
Top Drive motor at any height, and then circulating and rotating active drill string
immediately to free stuck pipe.
6.2 Operation of make-up

After finishing trip out, and aligning the hoisted drill pipe with wells and shoulder up tightly,
operator should connect Top Drive with drill string and cycle mud to prepare for rotating drill
ahead. (Operator should grease drill pipe internal thread with lubricant of threads)
First inspect whether all the operation buttons on the Driller Console are in right position and
HPU has been started. Observe the indicator light state and inspect whether the ready
indicator light is on. The operation procedure, please refer to chapter 5.
When lower down Top Drive slowly, pay attention to extension parts location
of piston rod of counterbalance cylinder, do not squat all weight of Top Drive
onto drill pipe tool joint, avoid damaging the thread when spin.
6.3 Operation of break-out

Operate break-out when separate Top Drive and drill string, and the procedure please refer to
chapter 5.
6.4 Drill ahead

a) ResetThrottleof Driller Console to zero, and turnDirectionto the stop.
b) OperateMotor to choose work mode (electric A, A or B, or B). When make-up and
break-out must choose A+B: two motors work simultaneously. When drilling, in general,
choose two motors work simultaneously.
c) WhenThrottleis zero, and Top Drive is stop, turnDirectionto cw (under Drill
Mode, ccw is invalid). WhenThrottleis in other states, it is also invalid to switch
Direction.
d) TurnOperationto drill. WhenThrottleorDirectionis in other states, it is
invalid to turnOperationto drill.
- 59 -
BPM Top Drive
Operation Manual
e) TurnDrilling Torqueslowly away from zero position, and set to a need value.
f)
TurnThrottleslowly away from zero position, set to a need value, and then system
will start running.
g) When the load torque is larger than preset torque, drill pipe may be jammed and could not
drill; two methods are recommended shown as below to release the reactive torque.
Keep the Throttle handle and the brake switch position, ensure the master motor
can output torque continually. Decrease the setting value of Drilling Torque
handle. It makes the master motors output torque down slowly. The drill reverses
slowly until the Drilling Torque handle to Zero; The reverse velocity of drill is
down to Zero.
Keep the value of Drilling Torque handle and the Throttle handle goes back to
ZERO position when the drill torque is limited. The system brakes down when the
motor stop to output. Operation Mode and Direction switches hold their status.
The drill starts to reverse slowly after releasing the brake switch. Based on the
reverse velocity, the operator will apply the brake in suitable situation to ensure the
drills interface can not be thrown off. Repeated the above process until the drills
reverse velocity cuts down to Zero.
The second method depends on disc breaks capability and drillers experience, so BPM only
recommend the first method. The second method could only be use when the drive unit cant
work normally.
To avoid drill pipe thread off happens during the release reactive torque
operation, all operations should strictly follow the routine procedure. To avoid
the accident, the ccw rotate speed should be strictly controlled during release
reactive torque operation.
h) Under Drill Mode, turnThrottleto zero could normally stop Top Drive. IfBrake
switch is on auto position, system will brake automatically after reducing its speed.
- 60 -
BPM Top Drive
Operation Manual
6.5 Drilling by single

Procedures are as below:
a) Seat slip on the single which has just finished drilling in, stop circulating mudoperator
could close IBOP.
b) Break-out in terms of procedures of chapter 5.
c) Hoist Top Drive, till elevator away from drill pipe tool joint.
d) Start elevator link tilt device, move elevator to rat hole single tool joint.
e) Use elevator lifts the single away from mousehole, operate elevator link tile device, move
single to the center well.
f)
Align the tool joints, low down Top Drive, make upper single inside the bell guide and
connect it with saver sub.
g) Spin and make-up in terms of chapter 5.

h) Move away slip, open BOP, startup pump to circulate mud.
6.6 Drilling by stand

Drill by stand is the most popular drilling method of DQ70BSC Top Drive Drilling
Equipment. If there isnt stand on the well derrick, operator could connect stand at mousehole
during the leisure time. For safety, the drill string in mousehole must be put vertical to ensure
connect in vertical plane.
a) Seat slip on the drill string tool joint which has just finished drilling in, then stop
circulating mud (operator could close IBOP)
b) Break-out in terms of procedure of chapter 5.
c) Hoist Top Drive to make the elevator away from drill pipe tool joint and raise it to
monkey board. Then, start elevator link tilt device, and make the elevator link near to the
waiting stand.
d) Put the stand into elevator, move elevator link tilt device back to well mouth.
e) Move the stand into drill string internal thread.
f)
Slowly lower down Top Drive, till upper stand could connect with saver sub.
- 61 -
BPM Top Drive
Operation Manual
g) Spin and shoulder up in terms of procedure of chapter 5.

h) Move away slip, open BOP, startup pump to circulate mud, then, begin to drill in.
6.7 Backreaming
During drilling, if the drill string was blocked, operator should connect drill string with Top
Drive immediately, and then circulate mud. Lifting while backreaming to avoid occurring of
drill string jam or key seat damage.
a) Circulate mud and rotary lift drill string simultaneously, till one stand is out of well.
b) Stop circulating mud and rotating, and then seat slip.
c) Disconnect tool joint by hydraulic tongs, and disconnect saver sub thread by Top Drive.
d) Hoist stand, put it inside pipe setback.
e) Lower down Top Drive to the derrick floor, rear incline the tilt arm, and then open the
elevator.
f)
Connect saver sub with drill string internal thread, use Top Drive motor to spin and
shoulder up.
g) Circulating the mud and rotating the active drill string. Continue backreaming operation.
6.8 Running casing

When running casing with DQ70BSC Top Drive, 500 tons and longer than 3.8m elevator link
should be prepared to leave enough space to install cement head.
Running casing could be conducted by conventional method: install a crossover coupling
between Top Drive saver sub and casing, circulate pressure during the course of running
casing, so as to decrease frictional resistance on reducing radius well section. When running
casing, Top Drive tilt arm could be used to grip casing and centralization when spinning.
Therefore, it is efficient to running casing with Top Drive Drilling Equipment.
a) Operate elevator link, lift casing to connect with wells casing.
b) Operate pipe handler devices tilt device and rotating head, adjust to align the two casings.
c) Shoulder up by use of hydraulic tongs.
- 62 -
BPM Top Drive
Operation Manual
d) Lift casing string, and open the slip.

e) Place down the casing string, and seat the slip.
f)
Open the elevator, and front inclines tilt arm to catch a new casing.
g) Repeat the above mentioned operations.
6.9 Jarring operation

Jarring operation will impose bad influence on Top Drive Drilling Equipment. However, it is
difficult to estimate the influence extent on Top Drive because of the uncertainty of jarring,
which will change according to the well depth, drill string, neutralization point, the type of jar,
etc. and the different situation of every well.
Anyway, it is forbidden to use ground jar, or else it will damage Top

Drive seriously.
When each times jarring has finished, Top Drive should be examined carefully. The
examined items include:
a) Visually inspect the whole Top Drive, and make sure no break or damage exists.
b) Visually inspect the upper mud pipeline.
c) Examine all connections between the cable and pipeline, reconnect those loosening ones.
d) Examine all the connections of exposed bolts and nuts, reconnect or replace those
loosening ones.
e)
Examine if there is loosing happens on all shelters, cover plates, etc.
- 63 -
BPM Top Drive
Operation Manual
7 Inspect
7.1 Visually Inspect
In order to ensure Top Drive runs undamaged and reliable, it is required to pay attention to the
running state of Top Drive Drilling Equipment, and visually inspect all parts such as electric
parts, hydraulic parts, mechanical parts, etc.
These kinds of visually inspects should be conducted at any time, by specially appointed
person every day.
7.1.1 Inspect the main body
Inspect item
Inspect content
Visually inspect all fasteners. Make sure that there isnt loosing
Fastener
ones, and rust or break on locking steel wire.

Visually inspect all cable covers, make sure that they are in good
cable and electrical connection
condition, reliably fixed, and no loosing exist on cable

connections.
Hydraulic
pipeline
connections
and
Visually inspect if the hydraulic pipelines are damaged, inspect the

connections, if leak or loose exist.
Visually inspect, make sure that there isnt loosing bolts on IBOP
IBOP locking devices
locking device of main shaft, and the interspaces between the

locking rings are equal.
Lubricant oil of gearbox
Observe lubrication oil level of gearbox; make sure that the

lubrication oil is enough and its temperature is normal.
7.1.2 Inspect the hydraulic system

Inspect item
HPU oil tank liquid level
HPU working pressure
HPU oil temperature
Inspect content
Examine liquid level of oil tank, whether it could meet the
specified requirement.
Examine pressure meter of HPU, whether it could meet the
specified requirement.
Examine oil temperature of HPU, whether it could meet the
specified requirement
HPU running
Observe HPU, whether it runs stably, and no abnormal noise exist.
HPU connector
Observe whether oil leakage happens on every HPU connector.
Hydraulic valve manifold
Observe and make sure that there isnt oil leakage on the
connectors of the hydraulic valve manifold.
- 64 -
BPM Top Drive
Operation Manual
7.1.3 Inspect electrical system

Inspect item
Explosion
proof
of
Inspect content
Driller
Console
Inspect the air supply disposal parts and clean accumulated water
in order to make sure that the output voltage could meet
requirement.
Joint of Driller Console

Display of Driller Console
Electric cabinet
Air conditioning unit of electric
cabinet
Inspect cable joint of Driller Console, whether the joint is reliable,

no abnormal phenomenon such as loose, big bend, etc.
Observe indicator light and meters of Driller Console, inspect
abnormal phenomena.
Observe the electric cabinet; inspect input, output and ground
connection.
Inspect whether the air conditioning and fan inside electric cabinet
runs well, and whether the filter gauze of ventilation opening on
the cabinet door is clear.
7.1.4 Inspect guide rail and carriage

Inspect item
Inspect content
Inspect roller of carriage and locking nuts, make sure that there is
Carriage roller
no loose exist, and there is no obvious abrasion on roller, and the

roller rotates well.
Observe the location of guide rail connecting pin, and make sure
Guile rail connection
that the locking pin is good. Observe the interspaces between guide
rails; make sure that there is no obviously inequable interspaces
exist.
Guide rail hanging
Observe the hanging plate of guide rail and connecting pin, make
sure that there is no abnormal phenomena, such as abrasion, etc.
7.1.5 Disassembly inspection

If necessary, the dismounting examination should be conducted for Top Drive to find and
solve the problem, replace quick wear parts, etc.
The inspect item, method and periodicity of dismounting examination, please refer to
<Maintenance Manual>.
7.1.6 Nondestructive evaluation
Nondestructive evaluation should be conducted periodically for loaded parts of Top Drive,
such as lifting bail, elevator link, etc.
Nondestructive evaluation could be applied by methods as ultrasonic testing (UT), magnetic
- 65 -
BPM Top Drive
Operation Manual
particle examination (MT) or other suitable methods, and it should be conducted in

accordance with the related technology standard and requirements of specification.
7.2 Wear limit

Timely examine the wear degree of loaded parts, such as lifting bail, elevator link, etc. Those
that have reached wear limit should stop use and replace at once.
If Top Drive uses normally, the wear degree should be examined after each well. As to
abominable work condition, such as bit bounce, deep well, etc, the wear degree should be
examined in terms of the abrasion condition.
Please refer to <Maintenance Manual> for details.
- 66 -
BPM Top Drive
Operation Manual
Appendix 1 DQ70BSC well site layout
25500
- 67 -
BPM Top Drive
Operation Manual
RIG LAYOUT
- 68 -
BPM Top Drive
Operation Manual
Appendix 2DQ70BSC migration supporter sketch
x M1 .
5 M x 1 x.
5 1 .
5
x 1
. 5
M M x
x1
5
.
x 1
. 5
M1
5
.
. 5
1
. 5
1
5
.
1
x 1
. 5
- 69 -
BPM Top Drive
Operation Manual
Appendix 3 DQ70BSC main body structure sketch
x 1 .
5
x 1
. 5
x 1 .
5
x 1
. 5
x 1 .
5
x 2
- 70 -
BPM Top Drive
Operation Manual
Appendix 4 DQ70BSC main body planform
M 2 4 x 3
20
x 2.5
- 71 -
BPM Top Drive
Operation Manual
Appendix 5Drill pipe tool joint dimension
Drill pipe tool joint
Specification
OD of inner and outer thread joint

0.8
D(mm)
85.7
2 7/8IF
2 7/8EU
104.8
111.1
120.7
3 1/2IF
3 1/2EU
4FH
3 1/2EU
4IU
133.4
4EU
152.4
4 1/2IU
152.4
4IF
4 1/2IEU
4 1/2IF
127.0
139.7
158.8
158.75
4 1/2EU
168.28
5IEU
168.28
5IEU
5 1/2FH
177.80
184.15
177.80
5 1/2IEU
184.15
190.50
203.20
6 5/8FH
6 5/8IEU
209.55
215.90
- 72 -

Operation Manual (Eng

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Manual (Eng

Uploaded by

Copyright:

Available Formats

Top Drive Drilling Equipment

Beijing Petroleum Machinery Factory

No.41, Zhixin Road, Haidian District, Beijing P.R China

Safety Notice ............................................................................................................ 1

HSE instruction ........................................................................................................ 2

Electric safety operation indication ........................................................................... 2

Hydraulic safety operation indication........................................................................ 3

Well control safety operating indication .................................................................... 3

Basic specification .................................................................................................... 4

Drilling Parameter .................................................................................................... 4

Motor Specification .................................................................................................. 5

Hydraulic disc brake ................................................................................................. 5

Electric control system.............................................................................................. 5

Pipe handler device................................................................................................... 5

Hydraulic control system .......................................................................................... 6

Structure and operating principle............................................................................... 7

Power swivel ............................................................................................................ 8

Main motor and cooling fan ...................................................................................... 9

Brake device ........................................................................................................... 10

Wash pipe assembly................................................................................................ 12

PDF "pdfFactory Pro" www.fineprint.com.cn

Upper IBOP control system .................................................................................... 17

Link tilt device........................................................................................................ 18

IBOP locking device ............................................................................................... 22

Guide rail and carriage............................................................................................ 22

Electric drive and control system ............................................................................ 23

Composing of electric system ................................................................................. 24

Hydraulic drive and control system......................................................................... 29

Control valve manifold ........................................................................................... 30

Hydraulic pipelines ................................................................................................. 40

Operating procedure ............................................................................................... 41

Inspection before startup......................................................................................... 41

The startup/shutdown of electric system.................................................................. 42

Startup system ........................................................................................................ 42

Start/stop of hydraulic system ................................................................................. 43

Main motor heating................................................................................................. 44

Motor cooling fan ................................................................................................... 44

Driller Console ....................................................................................................... 45

Drilling operation procedure ................................................................................... 45

Reverse drilling under Drill Mode........................................................................... 47

Stop drilling ............................................................................................................ 48

Make-up/break-out operation .................................................................................. 48

5.6.4.1. Make-up operation.................................................................................................. 49

Rotating head lock operation................................................................................... 51

PDF "pdfFactory Pro" www.fineprint.com.cn

Elevator link operation............................................................................................ 51

IBOP operation ....................................................................................................... 52

Emergency stop operation....................................................................................... 52

Special operation .................................................................................................... 55

Encoder switch ....................................................................................................... 55

Running without encoder ........................................................................................ 55

PLC control operation............................................................................................. 56

Driller Console emergency operation ...................................................................... 57

Operation procedure of drilling ............................................................................... 58

Trip in/out operations.............................................................................................. 58

Operation of make-up ............................................................................................. 59

Operation of break-out ............................................................................................ 59

Drill ahead .............................................................................................................. 59

Drilling by single .................................................................................................... 61

Drilling by stand ..................................................................................................... 61

Running casing ....................................................................................................... 62

Jarring operation ..................................................................................................... 63