( 2J30/1700CZ Drilling Rig Operation Manual Pe AB_MGBAS (FB) BRAS === RG Petro-machinery (Group) Co.,Ltd.Z330/1700CZ. Tk Mounted dling Rig Instruction Mana Preface Thank you for choosing products of Nanyang RG Petro-machinery (Group) Co., Ltd.! The instruction of ZJ 30 /1700CZ truck-mounted drilling rig is written by the professional engineers in our technology center, according to the module of function and based on the product design and service experience in oil field. To ensure your products run safely and steadily, please read carefully the instruction and other informations attached to the products. For that the drilling rig is consisted of man parts but only a few parts are mentioned here, it is required for users to study the special instructions for other ones, so as to get some necessary knowlege on structure, usage and maintenance and etc., and much attention is required to pay on the clauses about the safty caution.PG am sac oe ag hy mS Important safety statement Any operation, management, maintenance and repair personnel of the product must know very well of the relative content of the instruction and abide by the regulation related to operation, management, maintenance and repair, especially for the content such as safety warning and notes prompted by the instruction and national law, regulation, industrial regulation and common-sense safety regulation and matters needed attention in and to prevent the human injury and damage of the equipment. ‘The instruction could not list all safety warning information in detail, so when select a method to operate, it must affirm the method neither can endanger the human safety nor damage the equipment. Correct maintenance is the key factor for the safe and reliable operation of the product. The maintenance person should maintain the equipment according to the method instruction introduced. ‘The correct repair of the product and replacement of the components original factory manufactured is the key factor for safe and reliable operation of the equipment. The user must maintain and replace the component within the range manufacturer authorized. Please read carefully when the instruction uses the following title and markt A ‘Warning: using for the condition which can cause human injury or dead if does not abide by the operation procedure and method; Caution: Using for the condition which can cause the damage or destruction 0 of the equipment if does not watch the operation procedure and method carefully. 0 ‘Note: using for attention or independent explain condition. RG Peiro- Machinery (Group) Co, Lid: Standard Operation! Safety First ! 4 The engine before adjust and overhaul the drive systems such as the engine, hydraulic torque convertor, transfer case and drawworks ete. And engage or disengage each clutch handle. 4 The operator should wear the safety hat and protective articles before enter into the well field 4 Smoking and naked light is prohibited strictly when fill of the engine fuel oil or alcohol into air system. 4 It must check the shift valve for in free position before the start. Starting the engine in engaged status is prohibited strictly. + It is improper to run the engine in heavy load immediately after startup. It should operate in no-load or light load for a period and can be run in heavy load after the temperature of all parts is normal and lubrication is well. 4 The speed of the engine is no less than 1200r/min during the operation to provide enough lubrication oil to the hydraulic transmission box. It is prohibited strictly that pill out the drilling rig by engaging the reverse gear. It should adopt the two-engine combination when the hook block load is more than 1150KN(258000Ibf). It must stop the engine before the engagement and disengagement of the engine joint device, 4 The hydraulic transmission box adopts the pneumatic shifting methods. The main machine is installed with several types of electric clement. When the main machine need welding repairing, it must power off the vehicle to prevent the burnout of the electric elements. 4 Does not wet the electric control box and various wires (cables) plug when each the wagon, 4 It must pull each tension rope in position after the derrick is installed vertically to ensure the safety of the derrick. Under no circumstance should the tension rope be RG Petro-machinery(Group) Co,LtdPE. Ine Tak ot Dig ess en released during the operation, It is strictly prohibited to act the leg cylinder when the derrick is in vertical status to prevent the heavy accident due to tumover of derrick. Each device must operate correctly during the extension and retraction of the derrick (only for upper derrick). It must clean up the fuel, remove the foreign material on the cylinder piston and piston rod and make each tension rope in order before the rising, lowering and extension of the derrick. ‘It must discharge the air in hydraulic system, hoisting and extension cylinder before the rising, lowering and extension of the derrick; the hook block should be in the place under the derrick and the righting device is opened completely during the extension process of the derrick. ‘There must not be personnel on the derrick, in front of or behind of the derrick during the rising, lowering and extension of the derrick. After the heavy load operation, the engine should be in idle-speed for 5 minutes before the extinguishments. It should check the safety of the derrick if the load of the hook block nearly equals to the Max.hook block load. Pay attention to the oil level of the hydraulic oil tank and add the oil immediately after found the lack of oil to prevent the damage of the hydraulic elements such as the oil pump etc. RG Petvo- Machinery (Group) Co, Lid1330/1 700CZ. Truck Mounted dling Rig Instruction Manual Fresca Under any condition such as manufacture, running and work, the tightness condition of the transmission bolts, axle bolts and tyre bolts in this device are crucial to the safety of the equipment. So we remind the users to check all the bolts in relevant positions before DP ase and in use, avoid the slack, crack, distortion of the bolts. The relevant requirements refer to the following list: ro ———— = — | { Item Tightening torque | Remark smission shaft M10X1 25Kg.n | Plate spring bolt of axle 42~48Kg.m le 55~60Kgm __| According to | | | suspension » |__ bot of Tiema a “T5Kem —_|_theaxles_| Tire bolts of Suoma axle items in this » other relevant operation manuals.ZI30/700CZ ‘Truck-Mounted Drilling Rig Instruction Mant Content Chapter 1 Summary of Drilling Rig— 1.1 Constitution of the Drilling Rig. 1.2 Basis parameter of drilling rig— 1.3 Performance parameter of main parts ~ 1.4 Load characteristics of hook (6%5 rope system )-————-——-—— 1.5 Transmission Path of rig Chapter? Technique brief of parts — 2.1 Power set 2.2 Draw works (Model: JC28/11) 2.3 Compounding gear box-——-—~ 2.4 Drop gear box 2.5 Rotary drive box — 2.6 XD70/14%8 Carrier 2.9 ‘Transmission system =------ 2.10 Substructure ~ 2.13 Swivel — 2.14 Rotary hose 2.15 Hydarulic system ———- 2.16 Pneumatic system Chapter 3 Operating instruction and regulation ---———---- Preparation for Transportation: 3.2 Locating the main unit. 3.3 Location installation of drilling rig ~ 3.4 Working phase ——-— 3.5 End of Workin— 3.6 Pack and seal. Chapter 4 Packing and transportation— 4.1 Model of product transportation 4.2 Oil filed locating transportation of mian unit ——-———— RG Peiro- Machinery (Group) Co, Lid26am ’T00C%2 Truck: Mounted drilling Rig Instmction Manual Chapter 1: Summary of Drilling Rig 1.1 Constitution of the Drilling Rig (SY/T5609-1999Model and Basic Parameters of Oil Drilling Rig) and related technical criterions such as API are followed in the design, manufacture and production of 73 30/1700CZ truck-mounted drill rig, The constitution of drilling rig: raising system. rotating system, power system. transmission system. control system. Cye system, assistant system and substructure, As a block of truck-mounted drilling rig, all its systems are mounted on @ high-power truck except that the Cye system and assistant system are collocated singly. So the complete set of drilling rig has excellent mobile capability as well as drilling function which can effectively reduce the time cost for moving and improve the efficiency. We mainly introduce the carrier and the upper part of the platform. 1.2 Basis parameter of drilling rig (1) Model Z330/1700CZ, (2) Service depth: Nominal service depth 2l_"EUE 8700m (285438) Nominal work over depth 3!/a"DP 5700 m (187008) Drilling depth: Nominal drilling depth S"DP 2500 m (8200ft) 4'/2"DP 3000 m (9800ft) (@) Max. load of hook 1800KN (404000 Ibs) ® Engine power 403KW (540hp) /2100r/min (Dual) © Mast height 38m 6) Traveling system Qty. of effective rope 10 (5x6 rope system) ameter of lifting rope 932mm(1-1/4") Lifting speed of hook 0.2~1.5mi/s @ Open diameter of rotary table 9698.5mm (27-1/2") (8) Height of drilling platform 6m RG Peiro-machinery(Group) Co.Ltd ae¢ ° BrT‘eD (Enosp) Assunyoeu-oned OW 6 BuyjUp pesunow-yon4j wWO0E Jo e[djouLd uojssjwisued, |B = — Si “ — i ————— strat | age (4 I =z ro or wet | | ' | m oni) | + ! PS) a eeoat ER RAMAN AEE ZO00L 08714 Buqap payunow-yon.sy wopoE Jo B7e38 BuLAoyy ZH “ByPGom moines nse Di Lat nd fo a Fig.3 Working state of 3000m truck-mounted drilling rig. 1.3 Performance parameter of main parts 1.3.1 Engine Model CAT C15 Power 403kW (540hp) /2100r/min (Dual engine) 1.3.2 Transmission box Model Allison $5600 z RG Peiro-Machinery (Group) Go, Lid2330/1700C2 ‘Truc k- Mounted Drilling Rig Tnsiuction Manual - Max. net input power Max. input rotary speed 410KW (550hp) 2500r/min Max. net input torque 2732N'm (2021 Ibff) ‘Transmiaaion ratio of gears 0.6751 1:1 1.35:1 2.0131 2.68:1 4:1 5.12:1 (reverse) 1.3.3 Compouding box Model BZX260 Max. input rotary speed 2100r/min Max. out torque 18000N-m 1.3.4 Draw works Model JC28/11 Main drum fast line pull 280KN (62921 Ibf) Max. rotary speed 450r/min Diameter Width of main drum brake rim: @1168%267mm (@46"*10.5") Clutch model of main drum clutch Pull of sand drum Dia. x width of sand drum brake rim ‘Model of sand drum clutch 1.3.5 Angle gear box Model Max. inpu rotary speed Max. output torque 1.3.6 Auxiliary brake Model Max. sliding rotary speed Max. free wheel rotary speed Brake torque Heating power Discharge capacity of cooling water Axile thrust disc ATD330H 110KN(24719 Ibf) 997021 0mm (p38.2"*8.3") Axile thrust disc TPQ124 1X240 2100r/min 24000N.m WCB324 7ASthnin 1190¢/min 33900N-m (25086 Ibfft) Air pressure 0.55MPa(78psi) 604k W(810hp) 307L/min (81 US gal/min)1.3.7 Rotary drive box Max. input rotary speed 1500r/min ‘Max. input torque Clutch model 2330/1 700CZ, Truck Mounted Driling Rig Instruction Manual 5400N-m. Axial thrust dise ATD318H 1.3.8 Mast (pitch, front open. guy lines, hydraulic telescoping) Model 18038 Max. load 1800kN Height | 38m Height of racking platform 23m /24m /22m Capacity 3000m (98008) (4'/."DP) Wind capacity 130km/h (70knot) (Full set back without hookload) e- 1.3.9 Crown block Model Max, load Qty. of pulley 1.3.10 Substructure TC180 1800KN (404494 Ibs) Tea. (5x6 rope system) | Max. load of rotary beam 1800KN (404494 Ibs) Working height Structure Sm (16.4ft) or 6m (19.78) Parallelogram Working space of upper platform —7.2x6m(24x20f) Working space below rotary beam 3.9m or 4.9m(12.8ft or 16.1ft) e 1.3.11 Hook Model YG225 Max. load 2250KN (500000 Ibs) 1.3.12 Rotary table Model Max. working torque Max. static load Open diameter 2205 2P275 22500N-m 27S00N-m 7 16650 Ibfit 20350 Ibttt 3150kN 4500KN 707865 Ibs 10112361bs 9520.7mm (20-1/2") g698.5mm (27-1/2") RO Peiro-Machinery (Group) Co, Lid13.13 Hydraulic winch Model Rated pressure Max. lifting power 1.3.14 Hydraulic system Rated pressure Discharge capacity 1.3.15 Pneumatic system Rated pressure Discharge capacity 1.3.16 Carrier Drive type Max. speed limitied) Climbing gradient Approach/Departure Min, ground clearance Steering radius YBBC YISB 14MPa (2000psi) 14MPa (2000psi) 30KN (6742 Ibs) SOKN (11236 Ibs) 14 MPa (2000psi) 208L/min (54 US gal/min) 0.85MPa (120psi) 700L/minx2 (185 US gal/minx2) 14x8, 45km/n (28mile/h) 26% 26°/18° 311mm (12.2") 19.5m (64ft) Tyre Single tyre of front axle Dual tyre of rear axle Model 18-22.5 (without inner tyre) 12-20. Cwith inner tyre) Model 14-20 8.5V20PG. ms 2330/1700CZ Truck-Mounted Drilling Rig Instruction Manual 1.4 Load characteristics of hook (6x5 rope system) -& first gear <8 second gear =4 third gear #8 fourth gear a8 fifth gear Sooo 0 02 04 06 08 10 12 14/8 KARE EBS, HOOK SPEED-LOAD CHARACTERISTIC 1. Use single or dual power for lifting and droping drilling tools of traveling system EMTl 7 ts AGB E2tT2 | ecm SB ——— can vp op Some HPP pp ae eg ety 2. Use singe or dual power for rotary work = TRG Paro Machinery (Group) Oo, UiZ330/1700C2 True Mounted Driling Rig Instruction Manoal Ett rs. TS CHAIN rm = 1G SHAN, ‘CLUTG — -Is_, cB >» RIGB CLUTCH CHAIN Org CHAN pp BB xprry 3. Use singe power for road drive Ets rf Ts | i,m E2a+t2 J {FDA ——+{ (RDA E: engine T: transmission box CB : compounding box AG! r B: angle gear box ansmission shaft MD: main drum RGB: rotary table transmission box FR: fast rope CB: crown block DD: elevator DI levator links W! Wireline system DP: drilling pipe RD: rotary drive CLUT k Hi: clutch rotary table KB: Kelly bushing GB: gear box CT center transmission shaft FDA: front drive axle RDA: 1] Notice: When drill is moving, only the set on the right side (1#) are allowed to use, instruments in the cab will show their behaviour, In particular cases, the set on the left side(24) can be temporarily used (people should face the flywheel),2+ set are not allowed to use for a long time when the drill s moving RG-Petro-Machinery (Group) Co., Ltd. 9.PGom smc mt tgs Chapter 2 Technique brief of parts 2.1 Power set ‘The power unit of Z130/1700CZ truck-mounted drilling rig is consisted by two engine and two transmission cases. 2.1.1 Engine The engine is American CAT series diesel engine, which has 6 cylinders, "I" arrangement, four stroke, and water-cooled turbocharging aftercooling charisteristics. The complete machine is light and compact and with wide power range and economic in fuel-burning, the response speed of variable-speed governor to change in load is very fast. The relative parameter of the motor used on ZJ30/1700CZ truck-mounted drilling rig. Performance Parameter: Engine model CAT CIS Engine power 403 kW(S40HP) /2100rpm Direction of rotation (watch from flywheel) Counterelockwise ‘Temperature range 25 ~455'C For detail specification,please read the equipment list.) 2.1.2 Transmission box Allison $5600 type transmission box is consisted by torque converter and planetary gearing case. When drilling, the digger can shift by using the gearshift valve in the digger case, As main drive of the drill assorted with engine, the following advantages have been attained: -Reduced the shock load, Slaked the impact of torsion shaken from power machine and dynamic load from working machine; ‘Make the transmission of the complete machine more calm, the accelerate decelerate more smooth, so the installed power can be fully used, and so that the engine is often work at the economical rotation rate; Reduction gear for declivity is included, which can assist the main brake when the drill is moving down declivity. Torque converter is consisted by hydrokinetic machine, pump impeller, turbine and idler shaft. Power transfer is completed by circulation dubbing flow which come from the 7 RG Paro-Machinery (Group) Co, LidZ1B0/1700C2 ‘Truc k- Mounted Driling Rig Instruction Manual turbine and change its flow direction when flow by tail pulley, the turbine is driven by dubbing and the dubbing is pumped by pump blade driven by engine. The transmission in planetary gearing case is constant mesh transmission, controlled by hydraulic pressure multiple disk clutch, w' can relieve and join under load state to complete power gearshift. Performance parameter: ‘Transmission case type Allison $5600 Maxima bending moment ratio 25 Maxima import rotation rate 2500 rpm Maxima net input torque 2732N:m (2021 Ibfit) ‘Transmission ratio of each velocity stage 0.67:1 (closed) 1.35:1 2.01:1 2.68:1 4:1. 5.12:1 (Reverse gear) 2.2 Draw works(Model: JC28/11) we drawworks, which is installed on the car deck as well as power package, is mainly used to complete the elevating of the travelling system and assisting job done by sandline drum through the trassmisson of power. The drawworks system are formed of home roll assembly, sandline drum assembly, home roll brake cireuit, sand brake, hydrodynamic retarder, crownblock protector, brake hub cooling water circulation system, drawworks chassis and shield assembly, nput/output chain case shield and so on. The power deferented by power unittrasfer to sandline drum ax through the chain in the parallel operation case, and then to the home roll by chain. At the same time, on the other side of the home roll, the hydrodynamic retarder is driven by chain, so the gradual transfer of power is completed, There are many kinds of security protection and auxiliary operation device in the drawworks system, which can ensure the safety of operation According to API Spec 7K and oil lifting equipment criterion 2.2.1 Main drum assembly The main drum assembly of JC28/I1 drawworks is consisted by drum shaft, roller, brake hub, connecting dise, axial direction thrust dise clutch, input/output chain wheel and so on, The drum shaft is made of high quality alloy steel by solid forging,beared byBG soe stow it cS self-aligning bearing on both sides;the brake hub is made of alloy stee! by integral incusing, Jebus rope groove is included, which can reduce the loss due to frietion caused by the cut-in of fast line and make the drilling line tide and swift. The power is imported by treble chain, which can control the rotation of home roll by using at 330h axial direction push tray clutch ‘The cooling of brake hub is circulating water cooling, with the water jacket and water-circulation pipe on it, the brake hub can be cooled by circulation of cooling water ‘come from water diversion faucet on the two terminal of drum shaft, so that the chap of hub exteriority or veneering with brake staple caused by extra-hige temperature can be prevented, The circulating water is from the same water tank of hydrodynamic retarder’s circulating water, but the watercourse is different. Performance parameter: Diameter * length of drum body 9560 * 11045mm (p22”*41") Brake hub diameter * width {p1168%267mm (946"*10.5") Wire rope diameter used 932mm (1 1/4") Maximum pull of fast line 280KN (62921 Ibf) Maximum rotation speed of roller 450 rpm Model of clutch ATD330H Axial thrust dise type = RO Paro Machinery (Group) Co, Lid{S12 aod eng ia Ma PG.m BPW: sandreel HH: control valve HAA: brake system =H: main drum ARBLA: ouxiliary brake SUES: air cock Ae: clutch FIG.4 Structure of JC28/11 draw works 2.2.2 Sand drum JC28/11 draw works consists of sand shaft, drum doay, brake rim, axile thrust disc ‘RG-Petto- Machinery (Group) Co.. Lid. aPou si nena th iain‘ clutch, input and output chain wheel, ete. The excellent alloy steel forging drum shaft and the alloy steel integral casting brake rim are used in the sand drum. Use the axile clutch for making sand drum working. Technique parameters: Dia. x Length of drum 9360%945mm(o14.2"*37.2") \ Dia, x width of brake rim 9970210 mm(938.2"%8.3") Clutch model ATDI24 | Max. pull (The second floor) _110kN(24719 Ibf) Cooling type Wind cooling Diameter of drilling line 914.5 mm (9/16" ) Rope capacity 3000m (9842ft) e 2.2.3 Brake system Brake system mainly consists of brake steel strap, brake block, brake shaft, adjusting device, balanced device, bend crank and crank arm, etc. Perforamnce parameters Frietion system of brake block 120°C, F05~06 250°C, £0.25 Angle of brake band 340° See the instruction manual of draw works for details. 2.2.4 Auxiliary brake WCB324 js installed on the head of the main drum shaft directly e ‘The relation between the brake capacity and the compressed air in the air bag is direct ratio, and to be independent of hook load. - Not only can be used as the auxiliary brake, but the complete brake in the max brake torque area of the brake, } Circulating water compulsory cooling brake dise Perforamnce parameter: ‘Max. sliding rotary speed 7150/min Max. free wheel rotary speed 1190r/min Brake torque 33900N-m (25086 Ibfft) Pressure 0.5SMPa(78psi) = RG Patro-Machinery (Group) Ca, Lad2330/1 700CZ, True k- Mounted Drilling Rig Instruction Manual Heating power 604kW(810hp) Discharge capacity of cooling water _-307L/min (81 US gal/min) See the instruction manual of auxiliary brake for details. 2.2.5 Crown o-matic and emergency brake FIG. 5 Crown saver principle Crownblock saver is consisted by valve of crownblock elbow, air container, shuttle valve, crownblock control valve and so on. When the rotary hook of traveling block came up to a certain height, the fast line on the roller mise en place and the valve stem of crownblock elbow valve is bump agley,so that the normally closed valve is open,the main air get into normally closed air container through crownblock elbow valve and make the container open,so the air contained in air pocket get into pneumatic auxiliary piston cylinder and brake cylinder,the pneumatic assist brake and brake cylinder work at the same time to brake the roller. Meanwhile,another part of air control the normal open air container to cut of the air getting into valve on diggerand complete the deflation of drum clutch,then the drawworks stop and the impact is prevented. Driller control is controled by the digger, which make the braking mechanism of pneumatic assist brake and main brake air cylinder work at the same time to brake the drawworks.There is scram control valve on the driller's station, whenever the digger think it is necessary to make a emergency braking,what he need todo is to. push down the valve,the home roll will stop rotating in minimum duration to scram.PG. it gi il 2.2.6 Water circulating cooling system The system consists of two sets of unattached water circulating devices using the same water box. It consists of motor, water pump, pipe line and water tank respectively, one for cooling the drum brake device and one for cooling auxiliary brake. 1, Cooling device of brake rim pump: SLRS50-1001 flux: 25m*/h(6605 US gal/h) power of motor: —1.IkW (two sets) (1.Shp) 123 4567 L.straight pipe sub 2.A crimping hose sub 3. out sub 4. inner sub S.elbow 6. Auxiliary brake 7 shaft S.hard water pipe 9.drum body 10. brake rim U1. spring 12.lutch 13.steel pipe 14Right angle sub 1Sight angle elbow FIG 6 Cooling system of brake rim Te RG Petro Machinery (Group) Co., Lid£Z1B0/1700CZ ‘True k- Mounted Drilling Rig Instruction Manual FIG.7 Auxiliary brake cooling system 2. Auxiliary brake cooling device Two water circulating systems use the same set consisting of motor and water pump and, the other is used for the emergency equipment making the system safely. 2.3 Compounding gear box The compound box'is a gear compound device. It consists of two sets of angle gear box with dynamic clutch on-off device and universal transmission shafts. Angle gear box mainly contains input shaft, output shaft, spiral bevel gear, dynamic clutch on-off device, case, bearings and other spare parts. The compound box is characterized with transmitting stability, lower noise, easy operation and maintenance. Performance paramete Model BZX180B Transmission ratio 1: 1 (Drawworks, travelling crane) Max. input rotary speed 2500r/min Max. output torque 18000N-m See the instruction manual of compounding box for details. RG-Petro-Machinery (Group) Co., Lid.PG ms 2330/1700CZ_ Truck-Mounted Drilling Rig Instruction Manual 1, input shaft 2, output shaft 3, output shaft (Rotary table gear box) 4, output shaft (front axle) 5s output shaft (rear axle) 2.4 Angel gear box ‘Angel gear box mainly consists of input and output shaft, big and small helix prick gear, box body, bearings and other accessories. Performance paramete! Model JX240B Speed ratio 1s 1.346 Max. input rotary speed 21001pm ‘Max. output torque 24000N.n See the instruction manual of drop gear box for details. 7 RG Pairo-Machinery (Group) Co, Lid2330/1 700CZ ‘True k- Mounted Deilling Rig Instruction Manal 1, output chain pulley 2 output bearing box 3, big gear 4, small gear 5. oil dipstick 6, oil hole Fig 9. Drop gear box drawing 2.5 Rotary drive box The rotary table is mainly used to transmit the power to the rotary table, achieve the clutch of the power transmission, change the gear and release the power of the anti-torque. It is composed of the gear box, lower chain box, middle transmission shaft, the upper chain box, ATD318H axial push disc clutch and the inertia brake device. Power is inputed by the transmission shaft and shifted by the gear box. It is transmited to the input shaft of the lower chain box though the ATD318H axial push disc clutch and the input shaft of the lower chain box is connected with the mid transmission shaft directly. Then the power is transmited to the upper chain. A set of the anti-torque release device is installed on the input shaft head of the upper chain box, the use of which is to release the distortion power of the drill pipe slowly preventing the emergent reverse turn of the drill pipe after the disengagement of the clutch, Rotary table torque transducer interface is installed on the upper chain box. The whole device is lubricated by the oil pump set on the gear box. Performance parameter: Model ZI30CZ-04 RG-Petro-Machinery (Group) Co, Lid, 19-PE w ZI30/1700CZ,‘Truck-Mounted Drilling Rig Instruction Manual Max. output torque 14000N-m Transmission ratio 136:1 Gear: cone forward one reverse Model of clutch ATD318 Axial thrust dise See the instruction manual of rotary drive box for details. 1, rotary gear box 2, lower chain box 3 rotary table clutch 4 . anti-torque brake 5. shaft 6, ‘upper chain box Fig 10 Rotary drive box drawing 2.6 XD70/14x8 Carrier See the instruction manual of carrier for details, 2.7 Derrick Derrick system is consisted by lower part and upper part, Crown system, carrying device, hydraulic catwork device, different kinds of guy line. riser, ladder, racking platform ar RG Pewo-Machinery (Group) Co, LidZS30/1700CZ. True k- Mounted Drilling Rig tuction Manual work platform, bracket of rotary hook and so on. Derrick is binodal set pitch flex Derrick, the flex of Derrick is completed by two telescopic oil cylinders and can ensure stability when Derrick is flexing. The elevating and dropping down of Derrick is completed by two elevating oil cylinder connected to the lower part of crossbeam and Derrick. The Derrick and rear support bracket of carrier loader is connected by wrench bearing, the inclination of Derrick can be adjusted by the lead screw between Y type bracket and carriage to ensure rotary hook and estuarine are well aligned. At normal operating conditions, inclination of Derrick is 3°. There is angle indicator instrument on the Y type bracket, when the Derrick is in place and well installed on the bracket, the angle indicated on the instrument is the very inclination of Derrick. Derrick adopt the structure of pitch, open front,with guy line, Its stability can be surely ensured when full stands, without hook load and the wind speed is 130km/h. Meet the demand of API Spec 4F and structure criterion of mast and substructure Perforamnce parameters: Max. load 1800KN (404494 Ibs) Qty. of crown block sheave Tsets (5x6 rope system) Capacity of monkey board 3000m(4'/"DP) (9842ft) (Ine. 7"DC 10 setbacks) Max. wind capacity 130km/h (70knot) (Pull set back no hook load) Wind guy line of upper section 919mm (3/4") its models 6*19S-FC-19-IPS- mutual twist Load guy line 922mm (7/8") its Model: 6*19S-FC-22-IPS- mutual twist Guy line of monkey board gi9mm (3/4") 2s Model: 6%19S-FC-19-IPS- mutual twist Wind guy line of lower section 19mm (3/4") 4its Model: 6*19S-FC-19-IPS- mutual twist See the instruction manual of mast for details, RG-Petro-Machinerv (Gronn) Cn 194 =lower section owes ZI3O/TOUCZ Trvck-Mounted Drilling Rig Instruction Manual load mechanism Fig.11 Structure of mast RG Peiro-Machinery (Group) Co, Lid2130/1 7002, ‘Truc k- Mounted Drilling Rig Instruction Manual 2.8 Crown block Crown block assembly in multi-shaft structure mainly consists of base, sheaves, sheave shaft, bearings and so on. There are two rope systems 4*5 and 5*6 for user’s choice. Sheave group is connected with base through bolts. Sheaves are cast steel member and have passed through dynamic balancing test. Sheave grooving arc is in conformity to API RP9B, suitable for the matched wireline. Sheave groove is surface-hardened. Heat treatment and non-destructive test are conducted for crown block shaft. Fixed sheave group of the crown block (5%6) is a multi-shaft structure, consists of seven sheaves. Fastline sheave, deadline sheave and sandline sheave have their own individual shaft and the others are tandem, supplied with wireline stopper to prevent drill line out of groove. There is a grease nipple on shaft end of the sheave in order to lubricate rings. Crown floor with handrail is inte Performance parameters: Model TCI80 Max. load 1800KN (404494 Ibs) Dia. of sheave 915mm (36") 760mm (30") Dia. of sand pulley 500mm (20") See the instruction manual of crown block for details. 2.9 Transmission system The dynamical system of ZJ 30/1700CZ, truck-mounted drilling rig is fluid power come from engine and transmission case and mechanical drive device. The engine is concatenation of C15 and Allison SS610HR transmission case, which drive the home roll and sandline drum through transmission shaft, parallel operation case and chain drive to achieve rountrip of travelling system and asisting work of sandline drum.Power transfer to table driven device from the mian drum through chain drive and then to the rotary table through transmission shaft and sloping chain so that the rotation of drill is completed. The whole transmission agent is consisted by fluid drive, planetary gearing, transmission shaft, helical beval teeth drive, and roller chain drive and so on, Performance parameter: RG-Peine Machinery (Grn Co TaRG re si ai i ies vn Model of transmission shaft from transmission box to compounding box CDZ150-1428 Model of transmission shaft from transmission box to drop gear box Dz150-400 Model of transmission shaft from drop gear box to compounding box CDZ150-460 Model of compounding box transmission shaft cDzZ150-400 Model of transinission shaft from lower climbing box to rotary table drive SWC225BH-800+60 Model of transmission shaft between two climbing box SWC-DH225.2-470410 Chain from compounding box to sand drum 248-4-116 Chain from sand drum to main drum 288-3-134 Chain from main drum to rotary table drive box 288-2-182 Lower climbing chain 288-2-72(6m substructure) 288-2-62(5m substructure) Upper climbing chain 288-2-116(6m substructure) 288-2-84 (Sm substructure) 2.10 Substructure ‘The drill floor is a main wos platform when the drilling rig is working. Upper level surface of the working platform is mainly used to install the rotary table, provide operational working area and provide place for setbacks and tools. BOP is installed under the working platform, The substructure mainly consists of the rotary table, pipe setback, drill floor, drill pipe sliding way, stair assembly, safe escape sliding way, load roller chain box, cartier mat, etc. The substructure adopts six legs and foldable structure. The rotary table seat and setback seat is designed with an integral body. Overall height of the substructure is less than 2.95m when integral moving. The Hook-block or a crane can lift the substructure to the ‘working position. The load roller chain box is designed with two bodies, one is connected with another by a transmission shaft, One is fixed on the substructure, it can be moved together with the substructure, no need to disassemble. Another is fixed on the Y-support, it can be moved together with the main unit, Please disassemble the transmission shaft of the ae RG Paro Machinery (Group) Oo. Lid.PA Jam ZIBO/1700CZ ‘True k- Mounted Drilling R ion Manoal load roller chain box when moving. There are two 10T poor-boy wheelbarrows on the lower level surface of table beam. One can move outside of the substructure along the orbit, so installation of BOP and wellhead device is easy under the guidance of the wheelbarrows. ‘Meet the demands of API Spec 4F and the criterion of mast and substructure. Performance parameter Model: ZZT180 Structure: parallelogram Max. load of rotary beam: 1800KN (404494 Ibs) Working height: 6'm Working area of upper platform: 7.2x6m (24208) Working area below rotary beam: 4.9m hoister manual and single-rail ladder °2tt eng lle ladder ‘for dfiler / ' catwalk way adjusting \. guide screw mast PES ving board Fh tig base \ i slideway Fig.12 structure of substructure 2.11 Rotary table The rotary table consists of rotary table seat, main & auxiliary bearing, level axle RG-Petro- Machinery (Group) Co, Lid 25ZI30/N700CZ, Truck-Mounted Drilling Rig Instruction Manual assembly, locking device, rotary table, upper cover and so on. ‘A double-segment bushing is offered in the drilling rig due to its light weight and easy operation. A sealed oil tank is provided in the substructure. Both main & auxiliary bearing use radial ball bearing, The main bearing bear the axle force resulted from sliding of the drill pipe as well as the radial force. Maze mechanical seal is used for rotary table and substructure. Both large and small gear transmission all utilize helical tooth bevel gear transmission which provides a even transmission, high load-carrying capability. Performance parameter: ‘Model 72205 Max. working torque 22500Nm 16650 Ibftt Max. static load 3150KN 707865 Ibs Open diameter 9520.7mm (20-1/2") ZP275 27500N-m 20350 bit 4500kN 1011236 Ibs 9698.5mm (27-1/2") Fig. 13 Structure of rotary table 2.12 Hook block With travelling block and hook integrated, the hook block assembly is compact in Te RG Petro-Machinery (Group) Ca,2330/1700C2 True k- Mounted Dailing Rig iesiruction Manual RGus structure, 18% shorter than the length of travelling block and hook separated structure, It mainly consists of top cover, sheave, sheave shaft, left and right side plate, double row taper roller bearing, center shaft, springs, inter unit, locking unit, hooking, ring protection device, location block, and double row thrust cylinder roller bearing and so on. All load-bearing members of hook block are made from high strength alloy material. Key middle unit and hook body will be inspected for (-ray non-destructive test and static tension test, The hook block may automatically reset and buffer shock with the internal, middle and external springs. The locking unit can make the hook block locked at demanding positions with equal distances between them or rotate freely. The main hook mouth of hook block can. automatically close and lock when, on which, swivel is hung, and does not slide and open during its running. The hook block is designed, made, tested in strict accordance with API Spec 8A. Model YG180 Working load 1800KN (404494 Ibs) Qty. of sheave 5 (5x6 rope system) Dia. of sheave 915mm (36") Dia. of drill line 32mm (1 1/8") Dia. of main hook 190mm (7.5") Dia, of assistant hook 150mm (6") Working length of spring 180mm (7") Rotary angle of hook body 45°*8=360° Fig. 14 structure of hook RG-Petre- Machinery (Gemini Cn Td ~ —_ *PE om Z330/1700CZ,‘Truck-Mounted Driling Rig Instruction Manual 2.13 Swivel ‘The swivel is used to realize fluid circulation during the drilling operation. It consists of two parts: fixed part achieves purpose of lifting the hook-block, rotary part connects with drill string. Fixed part includes swivel bail, case, cover, swivel gooseneck and stuffing box. 7 wash pipe adopts quick disassembly structure, it can move up and down and self align Rotary part includes swivel stem, main bearing, aligning bearing and mud pipe, etc. S\ center. Tapered roller bearing is used for main bearing. Design and manufacture of swivel gooseneck and swivel bail is in accordance with API. Spec 8A. Model SL225 Max. load 2250kN(505618Ibs) Max. rotary speed 300rpm Max. working pressure 35Mpa(5000psi) Inner diameter of central pipe ©76mm(3") Thead of connector 6%" REG Fig. 15. Structure of swivel ae RO Petro Machinery (Group) Co., Lid2130/1 700C2 Tre ke Mounted Drilling Rig Tastuction Manual PCom 2.14 Rotary hose The rotary hose consists of reducing joints, union, joints and rubber hose. It is a mud connecting part between standpipe and swivel. ‘The rotary hose is made of four-layer high-strength steel wire, twine or multi-layer glue canvas. Good synthetic rubber is used as inner and outer layers which possess best wear property and acid resistance, ‘A cross over joint is provided in between rotary hose and swivel with 4"NPT standard hammer union. Model sGa" Full bore 89mm (3 1/2") 35Mpa (5000psi) 1250mm (50") Working pressure Min, bending radius Length 16.5m(S4it) Working pressure <100° Connecting thread 4"NpT 2.15 Hydarulic system Hydraulic system include hydraulic tank, filtrator, main oil pipe, elevating fluid-cylinder device, flex fluid-cylinder device, tongs fluid-cylinder device, landing leg fluid-cylinder device, hydraulic drawworks, hydraulic pressure spinner assembly, derrick floor flex fluid-cylinder device and different kinds of hydraulic control valve ( for detail,please see schematic diagram) . Filtrator should be inspected periodly and replace if necessary to ensur the working reliability of liquid path system. Hydraulics component performance parameter: 1. Main oil pump 208L/min (54 US gal/min) 14MPa(2000psi) Diacharge capacity of oil pump System pressure 2, Hydrulie winch (3t, St Each 1) Model YC YISB 14MPa (2000psi) —-14MPa (2000psi) 30KN (6742 Ibs) SOKN (11236 Ibs) Rated pressure Max. lifting power 3. Cat head oil cylinder Max. pull Effective length 150kN(33708Ibs) 1600mm(63") TAlneibtnenitonsth UR 9Gem ‘System pressure Z330/1700CZ, ‘Truck-Mounted Deiling Rig Instruction Manat 14MPa (2000psi) 4, Hydraulic jack Model 3030 Working length 300mm(11.8") System pressure 14MPa_(2000psi) 5, Lifting cylinder of mast Model: Y(3)74/446 Max. thrust of single cylinder TAQKIN(166292Ibs) Max. pull of single cylinder 246KN(55280lbs) 14MPa (2000psi) 4460mm(175.5") System pressure Total working length 6. Telescoping eylinder ‘Max. lifting power of single cylinder System pressure ‘Total working length 7. Oil tank Capacity il suction filter of main oil pump Oil circulating filter of main oil pump Oil suction filter of steering pump Oil circulating filter of steering pump Oil is to be recommended 158kN(355061bs) 14MPa (2000psi) 14800mm(583") 1200L (317 US gal) LXZ-400*180F LXZ-400*30F LXZ-160*100 LXZ-160*10 ‘N68 anti-worn hydraulic oil in the summer N32 anti-worn hydraulic oil in the winter Hydraulic tank, which is shared by truck-mounted hydraulics and chassis steering system, has a transparenee liquid level sight gauge on the side and a air filtrator on the top. Hydraulic oil get into the oil pump by blotter filter, Blotter filter and scavenge oil filter are outer self-sealing structure. So when replace/tinse filter element or maintaining tank system,all needed is to unscrew the end cover of filter.The self sealing valve will close to isolate the oil way of tank so that oil in the tank won't set out anymore. ‘The oil pump is high pressure gear wheel pump, driven by the pump box installed on ALLISON transmission case. The connection and scparation of pump box is pneumatic controlled, when working,the gear pump is driven by pump box which is controlled by the pneumatic control valve on driller consol. When the drill is in location, the quad valve in = RG Pew Machinery (Group) Co, LRGus The rotary hose consists of reducing joints, union, joints and rubber hose. It is a mud 2330/1 TOOCZ. True k- Mounted Deiling Rig Instruction Manual 2.14 Rotary hose connecting part between standpipe and swivel. ‘The rotary hose is made of four-layer high-strength steel wire, twine or multi-layer glue canvas. Good synthetic rubber is used as inner and outer layers which possess best wear property and acid resistance. A cross over joint is provided in between rotary hose and swivel with 4"NPT standard hammer union. Model sca" Full bore 89mm (3 1/2") w@ Working pressure ipa (5000psi) Min, bending radius 1250mm (50") Length 16.5m(S4ft) Working pressure <100° Connecting thread 4"NPT 2.15 Hydarulie system Hydraulic system include hydraulic tank, filtrator, main oil pipe, elevating fluid-cylinder device, flex fluid-cylinder dev , tongs fluid-cylinder device, landing leg fluid-cylinder device, hydraulic drawworks, hydraulic pressure spinner assembly, derrick floor flex fluid-cylinder device and different kinds of hydraulic control valve ( for detail,please see schematic diagram) . Filtrator should be inspected periodly and replace if mp ecessary to ensur the working reliability of liquid path system. Hydraulics component performance parameter: 1. Main oil pump Diacharge capacity of oil pump 208L/min (54 US gal/min) System pressure 14MPa(2000psi) 2, Hydrulie winch (3t, St Each 1) Model YIBC YISB 14MPa (2000psi) _ 14MPa (2000psi 30KN (6742 Ibs) SOKN_ (11236 Ibs) Rated pressure Max. lifting power 3. Cat head oil cylinder Max. pull 150KN(337081bs) Effective length 1600mm(63") RG.Prten-Marhinery (Gremnl Gn Tad 29.RG er ZG ae one ting tin ad System pressure 14MPa_(2000psi) 4, Hydraulic jack Model Y3030 Working length 300mm(11.8") System pressure 14MPa (2000psi) 5. Lifting cylinder of mast Model: Y(3)74/446, Max. thrust of single cylinder 740KN(166292Ibs) Max. pull of single cylinder 246KN(55280Ibs) ‘System pressure 14MPa (2000psi) Total working length 4460mm(175.5") 6. Telescoping cylinder Max. lifting power of single cylinder __158KN(35506Ibs) System pressure 14MPa (2000psi) ‘Total working length 14800mm(583") 7. Oil tank Capacity 12001 (317 US gal) Oil suction filter of main oil pump LXZ-400*180F il circulating filter of main oil pump LXZ-400*30F Oil suction filter of steering pump LXZ-160*100 Oil circulating filter of steering pump LXZ-160%10 Oil is to be recommended N68 anti-worn hydraulic oil in the summer ‘N32 anti-worn hydraulic oil in the winter Hydraulic tank, which is shared by truck-mounted hydraulics and chassis steering system, has a transparence liquid level sight gauge on the side and a air filtrator on the top. Hydraulic oil get into the oil pump by blotter filter. Blotter filter and scavenge oil filter are outer self-seali structure. So when replace/rinse filter clement or maintaining tank system,all needed is to unscrew the end cover of filter.The self sealing valve will close to isolate the oil way of tank so that oil in the tank won't set out anymore, The oil pump is high pressure gear wheel pump, driven by the pump box installed on ALLISON transmission case. The connection and separation of pump box is pneumatic controlled, when working,the gear pump is driven by pump box which is controlled by the pneumatic control valve on driller consol. When the drill is in location, the quad valve in 30 RG Pairo- Machinery (Group) Oo, Lidsn Tas Non ig imi Rem hydraulic control box can be operated, the height and levelness of drill can be adjusted by hydraulic ram. The elevating, laying down and flexing of mast can be achieved by operating the dual valve in hydraulic control box. (For detail information,please read "working instructions of mast") . ‘The digger can operate the pneumatic control scale rein on the digger control case, utilize compressed air to control the commutation of the seven united valve so that the control of hydraulic drawworks, hydraulic pressure spinner assembly, hydraulic catwork and tongs compensating cylinder can be achieved. 2.16 Pneumatic system ‘The pneumatic control system of drill is consisted by home roll on-off control loop, sandline drum control loop, ae control loop, urntable control loop, assist brake control loop, air slips control loop and so on. 1, Control circulation of main drum The leave-joint, separate and magnitude of engine throttle of home roll on-off is controled by combination pressure control valve. The valve has the function of three-position four-way valve and two-way pressure control valve. When the rein of valve is in meso-position, home roll push tray clutch disengage, engine throttle is at idle speed;, home roll push tray clutch joint, keep on upthrusting, engine throttle opening can be aggrandized and the engine speed can be increased. If the rein is pulled down, it ean control engine gun so that it has the action of hand throttle. ‘Admission of combined pressure control valve is controled by normal open pneumatic control valve 1 which is in ac position of ac restoration valve, so that the operation of home roll is available when the ac valve is open, when the elbow valve is open to brake, normal ‘open pneumatic control valve | is shut and the air supply of combination pressure control valve is cut down so that home roll clutch exhaust from delivery valve, clutch out. When begin drilling, hitch the suitable velocity stage potential, upthrust the rein of combination valve on home roll for 10%, home roll incorporated,home roll won't rotate with Joad,the torque converter now is in a behaviour of derricker clutch off; keep on upthrusti increase engine speed, home roll begin to rotate and rotary hook began to rise. When rotary hook need to stop, loosen the rein of control combination valve on home roll by left hand,the rein return to meso-position automotively, home roll clutch out, engine return to tickover, impact the brake handle by right hand to make the rotary hook still. on 31PG. shied tg My st Ht ‘Warning: When the air pressure is lower than 0.7Mpa(100PSD,clutch not, 2. Control circulation of sand drum The leave-joint,separate and magnitude of engine throttle of sandline drum is ‘controled by combination pressure control valve,when rein upthruste for 10°,the clutch hitch, keep on upthrusting, the throttle will raise. 3. Crown saver and control circulation of emergent brake ‘The reset control, valve of Crown system is dual three position four way diverter valve,when the gadding machine is working normally,the rein should be upthrusted to hitch position,when the rotary hook of traveling block elevate to the set height, cylinder number of wire rope which enwinded on the roller reach to a certainty height,the knockout pin of elbow valve will be repelled so that the control gas can pass the shuttle valve to open normally closed pneumatic control valve,air get into the brake cylinder through valve to brake. Meanwhile, air get into normal open pneumatic control valve and make it shut, cut down the air getting into the home roll control valve. After the failure recovery, the ac elbow valve follower should be restored, pull the rein of restoration valve to the off-position,the assist brake and air cylinder plunger are restored, brake cylinder involute,brake released. At this time, the rein of control valve should be put to the ac position to ensure the safe handling next time. ‘The digger can also operate the emergeney brake valve,in hazardous condition, put the rein of this valve down to the braking position to brake the home roll. The operation principle of emergency brake valve is the same as the elbow valve. A Warnning: This system is prevention system, frequent operation is inadvisable, please prevent the rotary hook over working, 4, Control circulation of auxiliary brake Auxiliary brak is controled by a two position three way valve, operate the rein of valve to hitch or release the hydrodynamic retarder. The digger can operate the pressure control valve by stamp on the pedal and, control the magnitude of waterflow by using compressed air to achieve the adjustment of braking torque. 5. Control circulation of rotary table One set of three position and four way valve is used to control rotary table for clutching the rotary drive. Driller control the hand pressure valve to control the throttle a RO Pero Machinery (Group) Co. Lid330/1700C2, ‘Truc k- Mounted Driling Rig Instuction Manual Frac through the compressed air and, the anti-torque inertia brake control can be achieved by another hand pressure valve. 6. Control valve for air slip The control valve of air slips is three-position four-way valve,when the tripping operation require to chuck drill stem in downhole,push the rein of valve,the air slips at shaft collar will chuck the drill stem. When the air slips need to be rel eased, just pull the handle backwards. RG-Petro-Machinery (Coun Ca ViaRGom orc Tot! Day fan Na Chapter 3 Operating instru ion and regulation The third chapter briefly introduces the operating requirements and regulations of 2530/1700CZ truck-mounted drill. In order to ensure a safe operation of the equipment and keep the personnel safe, users should strictly obey the operation regulations stated in the text. Before operating the equipments, operating personnel should get familiar with the drill ‘well including the structure, performance and scope of application. Naturally the knowledge of the correlative techniques is required for operating personnel. When starting the machine make sure every part of the drill runs regularly, otherwise you should stop it for check and restart it afler trouble removal. Owing to the complicated structure of the drill, we cannot completely mention in every detail So you can contract our technical service department, when you encounter some certain cases which are not list in the text. In the following text, we will introduce operation regulations of the drill in detail. It contains some steps as drill transportation, operating preparation, operation period and the cend of operation. 3.1 Pepa ‘ion for Transportation 3.1.1 Inspection item 1) check the cooling water container of the engine , and make sure that water is enough. 2) check the engine fuel, and make sure that it is enough; 3) check engine mobile oil , and make sure that itis at standard oil level as marked. 4) check mobile oil of the gear box , and make sure that it is at standard oil level as marked. 5) check the oil level of the compound box 6) check the detaching and attaching of compound box , and make sure that it runs well. 7) check the steering hydraulic box , and make sure that it is enough 8) check the steering rod system. 9) check every filter. 10) check ,quality and quality of the oil in every gearbox and chainbox ;PE on 11) check each clique in digger box , and make sure that it is in a midposition ,and the gearshift clique whether it is ina neutral position. 12) check the tire pressure (Chart.1 &.2); Charging pressure of tyre @ | 2130/1700CZ Truc k- Mounted Drilling Rig Instrction Manu | ‘Tyre Dual 12-20 Single 18-22.5 | Pressure (kPa) 630(90psi) 700(100psi) | (1) Attention: ‘The pressure should be not higher than the above pressure when charging. s The pressure for different load @) Load pressure psi_| 55 | 60 | 65 | 70 | 75 | 80 | 85 | 90 | 95 | 100 Spec. kgiom? | 39 | 42 | 46 | 49 | 53 | 56 | 60 | 63 | 67 | 70 _ Spen._ko z : 16-225 | s | 9320 | 3530 | 3730 | 3925 | 4115 | 4295 | 4470 | 464s | 481s | 4975 | 13) check locking apparatus of upper hull and lower hull on oil derrick , and make sure that they hang proper (at back of mast); 14) check the gas-driven reversing valve of gas-suspension and make sure that it is open(one lays in the liquid control box, the other lays at the back of fuel tank which is on the opposite side of drill runner.) (D):Attention: ‘The pressive of air suspenting should be not more, than the rated pressure 0.42MPa. 3.1.2 Operation of engine 1) If it is the first time to start the engine or the engine has been not used for a long time, you should use the hand oil pump to suffuse the diesel into the pressure chamber prior to start the engine .So the remnants air can be drained away from the fuel oil pipe or any intracavity of the pump. 2) Firstly turn on the ignition lock, turn the power on, switch on hand shank of pause(if’ air pressure has already existed, push the controler of pause air clique to switch on ), Then push the START button. The engine should tick over for 3-Smins till the water temperature of engine and air pressure has a normal value. RG-Petro-Machinery (Group) Co. Ltd aePGem rere tena eg reine [1] warming: When the engine is in the idle operation, judge the sound, exiting eas, and heat of the engine, make sure that itis in a normal condition.» Only after checking can we start the load.. When operating in winter air, the no-load operation should keep longer time, and load operation should be taken at a condition of normal oil pressure and warm water... ae x : 3) The engine STOP control valve is located at control pan beside ‘The engine or on the drill runner box .Before stopping the engine we must switch wheel box into neutral then tum the stop control. [1] Notice: The engine mustn't be stopped while sunning highly/It is recommended that siop | @) the engine after Smins of no-load running. (1) Notice: ‘The detail operation of engine and transmission box ean be found in the manual ‘books appended in the last. 3.1.3 Operation in the winter We regard that the operation under S°C (13°F )_as winter operation. The following task is necessary for winter as change of season. 1. Check oil forewarmer and make sure it is in order; 2, Add alcohol into alcoholic antifreeze case of the gas path system, ( applied under O'C for recommendation); 3. Check the air heater’s conditions; « 4. Use the antifreeze engine that is used in winter; 5. Use the antifreeze fluid in the water circulation system; 3.14 Transportation of Main unit 1. The main unit is 144 for driving when running at a normal road, engage the handle of rear axle of gear box. A warning: when running at anormal road, the and back s can’t be attached togethers and the front hand shank can be attached only in some place like mire or desert where the adhesion between the tyre and floor is low. (1) Attention: The engine can’t be stopped when the main unit is moving. - ery Coron Co2. When running at muddy road , we can append both front and rear axle as required, but the rear axle should be prior to the front axle. Appending front axle demands lange-angle to stir transmission shaft because the modulus of spline much higer wehn ‘Appending the front axle, ( At a general situation, To engage demands 10 - 20 degree) 3. When running at a highway, the tire pressure is in a normal pressure. While running in the desert, the ire pressure should be kept at 4.2kg/em” (60 psi) as required. So that, adhesion between the tyre and floor will be enhanced. 4, When running at frozen snow, mire or desert region, we can joint differential lock to avoid the wheel-slip problem, 5. The mast should remove to transport when meeting some high restricts. POLPrisnAAachiners (Caran TadHe (BH) Bal ae Aqurasse pue Supyy Ise 91 BL “suey tps tons0s somo] LT OZ ur wont sn orp Supoou09 “Bun a0}00"Z WAL SEITLATS HEH “odosay puw ooya Buea, ‘amy Surpnjoxs sf yseur JO wBOM TOL Ur : 0N Do a | / 7 sun ace 430 WoRIBE Io} Jo ope eee Pe EPR Pd bo om eatery oat wee pine Spee eee | — / Ce ee / vase \ / \ > \ # sodaryo sovard mog || 391 _/ \ Vv MEEM TL EER | Tenney wononnsay Ty SoA PAUNOWPALL ZOVLIOELZ2130dkiling rig instruction manual 3.1.5 Emergency treatment for malfunction at running time Stop the machine immediately when malfunctions are found. Check and estimate the position, scale, cause, extent of injury restore plan and hardness degree of the malfunction, and then determine whether to carry on driving or dispose on-site. Waiting for succor or repairing at near place is also solvable. 1. If the drill is troubled by power malfunction, we should keep the engine on as far as possible, This is because that engine could kept a certain capability of comering and braking 2. If an inner malfunction occurs to the rear axle (or intermediate axle) , we should unhook appending device of rear axle, After that we append front axle so as to keep running. 3. If both the rear axle and front axle have problems, we should unhook appending device of rear axle as well as the front axle's. 4, If some rear axle differential of front and rear axles has problems, we should pull out half rear axle before drive the drill 3.2 Locating the main unit 3.2.1 Clean up Well Site i i , Choose the probable field and tidy Ne? seledtien it up. The well site location demands at least 2100m?(22592f*), 70m(230ft) in Jength, and 30m(98.4ft) in width. The SEB os < [Seg marginal ascent between well top and drill site should be at 0.5%~ 1.0%. A well water drained system is also © 9 required The ground loadability of the place which is around well top within the Sm(16.4f), should be not less than 0.29MPa(4Ipsi).We should fill up the sandstone instead, if the loadability is less than 0.29 MPa(4Ipsi),choose the right location to establish the drill according to the practical situation of the RG Pei zchninery (Group) CodPE. 1a si ki ite nt well site. At first, establish the bed in terms of well top position, then connect derrick foundation and boat-shaped bed. After that the drill can be poured to boat-shaped bed. By that mainframe is perched already. Dig four ground anchor holes as guy line fig required, they are supposed to be 1.8m(5.9f%) in deep, 1.3m(4.38t) in top length, 0.8m(2.6ft) in bottom width, 1.6m(5.2ft) in bottom length. The londability of each anchor hole fixed by guy rope should higher than 98kn at the guy rope direction .We aslo can fix a steel precasted block as showed in the Fig. The size is 3m(9.84f) long, 1.5m(4.92f) wide and 0.5m(1.64ft) high. Then prefabricate a steel tube remained at the 1/3 position, which has inside diameter of 50mm(in), pin the wire rope on it, so that 1 movable anchor was made .This is most benefit for move drill but not for digging, £ i Ti a a (FE DOR 3 t & } A rh Ri x ian man = i nn omensZ130dkiling rig instruction manual Fig. 17 Well head and guy anchor load 3.2.2 Lifting and installation of sub structure 3.2.2.1 Substructure lifting and installation: ‘The substruct can be lifted by a 307 crane with wirelines overg22mm, four lifting eyes. When the substructure is vertical, fix all bevel tension bars around the substr The ture, nter of the rotary table can align the wellhead through the bevel tension bars. The substructure can also be lifted by the hook-block of rig, with wirelines over 922, and four lifting eyes. Operate the drawworks to lift the substructure. When the substructure is vertical, fix all bevel tension bars around the substructure. The center of the rotary table can align the wellhead through the bevel tension bars. When the substructure has been lifted, lift all floating boards around the substructure and fix all rails. Install all ladders, the escape sliding way, the sloping way and the catwalk. Install all pipe racks. Install two 10T manual trailers under the rotary table beam. Install orbit of the flatbed trailer on the ground and the flatbed trailer. The flatbed trailer must move on orbit. RG Petro-machninery (Grown) Goh. aePG em 3.2.3Working after locating rig: a. Park the drill on a exact workplace Z33001700CZ, truck-mounted drilling rig instruction manual b. Switch on the boxes” hand shank (the double lock valve will pump the gas to the vehicle coming with movement of hand shank, and air supply of underpan will stop). c. Switch on the latching control valve of Torque Convener on the working position. d. When the air pressure reach 0.7mpa ot even higher, turn the wheel box into neutral, and tum off the hydraulic pump. ce. Adjust the hydraulic leg in order to keep the complete machine in a horizontal position and keep the each tyre endure a probable load. Connect sloping chain after the oil derrick rising then lock the hydraulic legs. f. Adjust jack which is under the oil derrick, so as to keep transmission shaft in a horizontal position . g. Adjust screws which are connected boat-shaped bed of frant vierele and derrick foundation of back vehicle, then load them in. (it has 10 screws in all, 2 in the front of the vehicle ,8 in the back ) h. Firstly put down the pedal, then install it in the winch clutch, connect support bar between the pedal boat-shaped bed, lastly install the ladder . i. Drive up the brake handle to loosen the brake. 3.2.4 Lifting mast operation Mast for Z530/1700CZ, DRILLING RIG is front tilt, face open, telescoping, hydraulic raising and telescoping. Do according the follow methods before raising the mast. (1) Clean the mast, lightening parts of the mast loosen is forbidden, Check all main wireline of the travelling system and all wireline of hydraulic winches, they must be normal. dW S guy line ADRS from wellhead to ancl ha SA eas TeoPG em Z130dsilng vie instruction manual (2) Pull out fast line and dead line from the mast hook. Caution: Do strictly according the requirement, otherwise, there will have equipment and personal in danger. (3) Disassemble all mast lights and explosion-proof switches before mast raising and telescoping. (4) Check hydraulic system and pneumatic system before mast raising ensure no leakage. The following methods referred: Turn on PTO, fill air for pipelines and some hydraulic cylinder, keep 5 minutes when pressure reaches 14Mpa,then reduce pressure but leakage are forbidden, keep 5 minutes when pressure reaches 0.7~ 0.8Mpa. If user fill air for pneumatic system with any pneumatic components, reduction of pressure must be less than 0.03Mpa. (5) Exhaust air for hydraulic system before mast raising and telescoping. Mast raising and telescoping with cylinder air is forbidden. (6) Tighten and lock all bolts between the mast and the Y-shaped stand when the mast raise to correctly position, install and tighten wind-proof guylines for mast lower section, Maximum deflection of guyline is 100mm. (7) When the mast upper section is stretched out, make Hook-block near the substructure surfac is possible as you can. Hook-block must lie down on the Hook-block support frame when the mast has been put down. After the mast upper section has been stretched out, tighten two load guylines, four windproof guylines and two racking platform guylines Canti (1) Mast raising and telescoping when wind speed is over force 4(including force 4) is forbidden; (2) Mast front tilt angle is 3°after the drilling rig has completed all working preparations, The center of the hook-block is aligned the center of the wellhead. Mast ig procedure: (1) Pull the handle of the control valve for the raising cylinder to increase pressure till pressure reaches 2Mpa. Open the discharge valve of the raising cylinder, repeat the motion till the cylinder hasn’t any air. Close the discharge valve, move the handle of the control valve to the middle position, open the cross stop valve of the piston rod oil-return circuit. (2) Push the control valve handle of the raising cylinder slowly to ensure approximate 200mm distance from the mast to the front stand. Push the handle to the middle position, mast is static, Observe each parts of the raising cylinder for hydraulic “RG Petro-machninery (Group) Contd.PG em ei men ag ici leakage, normal indication of pressure gauges no interference and no mast sliding case, then drop the mast. (3) Push the control valve handle of the raising cylinder again, raise the mast slowly. Observe the raising cylinder carefully during the periods of mast raising, is raising procedure of the cylinder correct? Raising procedure for the cylinder is as follows: First, the first step piston, second, the second step piston, finally, the third step piston (piston rod). Caution: the hydraulic cylinder must draw back immediately if the hydraulic cylinder doesn’t siretch out according correct procedures, resolve all troubles immediately to ensure mast correctly stretched out, otherwise, there will have equipment and personnel in danger. Maybe, the mast will abnormally fall down. (4) Operation must be slow in order to prevent equipment from shock during stretching transition period for each step piston, When the raising mast is near vertical position, appropriately reduce the handle open degree and open degree of the cross stop valve for the piston rod oil-retumn circuit, When the mast raises across 90%position, operate the cross control valve to put the mast on the Y-shaped stand slowly, then lock all bolts, fix and tighten all windproof guylines. (5) Push the handle of the control valve to the middle position and open the discharge valve to reduce pressure of the raising hydraulic cylinder. (© Loosen the lower brake without delay during the period of mast raising, so main Wirelines and wirelines of hydraulic cylinder doesn't tighten too tight. ‘Caution: A mast doesn’t lie down for a long time after a mast raises. Cover all piston rod surfaces with lubrication grease. The best way is a protective cover, which can cover all piston rod surfaces. ‘The following operations for telescoping the upper section of mast: When the mast upper section stretched out, operator must do strictly according the flows procedures: 1. User must exhaust air of the telescoping cylinder before the mast upper sectior stretched out, Then close the cross valve, open the top discharge cap of the telescoping cylinder, slightly push the handle of the control valve, keeps pressure no more than IMpa, exhaust all air of the telescoping cylinders, push the handle to the middle position, screws on all discharge caps. 2. Pull the handle of the control valve of the telescoping cylinders to raise the mastZ72Odriling rig instruction manual See upper section slowly, please repeat No.1 procedure if the cylinder has any air, is the mast stuck Does the centralizer support the cylinders? Operation with troubles is forbidden, Do after all troubles are resolved 3. Reduce the handle open degree and the mast raising speed if the mast is near the working position. Observe the mast upper section til it is higher than the loading place, and the loading block must be normally stretched out. Push the handle of the control valve to the middle position, open the needle valve, and drop the mast lower section slowly. After the load block has been completely puted on the loading seat, close the needle valve 4. Use bolts to tighten all loading guylines in the front of the mast lower section, and the place of the front support. Install four windproof guylines of the mast upper section and two racking platform guylines. 5. Please loosen brake without relay while the upper mast section has been stretched out, so the Hook-block can descend till it approaches the substructure upper surface. 6. One person with a safety belt climbs to the mast to lock the loading device, insert electric explosion proof plugs into sockets and turn on lighting and alarm electric circuit. 7. Install the high driller’s console, connect the high brake tension bar, and install the high brake. 8. Install all rails for the racking platform. QS Warning: Unconcemed persons on the mast, the front of the mast and the back of the mast when the mast is raising is forbidden... a Warning: The stabilizer on the mast must open without relay when the mast raising. 3.2.5 Water circulating system installation Install the water tank on the side of driller place along direction of drawworks shaft central line, or install it in a middle place between the doghouse and the diesel engine house. Connect all pipelines. Output pipelines of a water pump should be connected to the cross input joint between the two-direction joint and the auxiliary brake. Another pump is used as an auxiliary pump, the water-return joint aligns the place of the pump Turn on electrical switch to start hydraulic pumps before trippin operation. RG Petro-machninery (Group) Co, 45~PG. 110 cme ing atin 3.2.6 Auxiliary parts installation 1. Install PTO, escape and connecting guy line. 2. Install the adjustable platform of the upper section of sloping chainbox, insert rails, 3. Instrall the union of mud stand pipe and, connect the rotary hose. 4. Install the balanced hydraulic lifting rope. 3.3 Location installation of drilling rig. Our company has provided a plan of site layout ( display in the chart),but it is not exclusive one,, The users also can arrange the plan by themselves as their favors. 3.4 Working phase 3.4.1 Draw works system 1. Clutch of compounding box Power should be reasonable matched with actual load. Only need to turn on single engine if rig load is less than 1150KN (257600 Ibf) or rotary operation, No.2 engine is the best choice. Choose an engine what you want to use, operate the manual clutch on-off device to clutch on the angle gear box connected with the engine in engine kill situation, or the transmission in neutral position, but engine working situation, mean while, another angle gear box must be clutched off. Two engines works simultaneously is the best choice if rig load over I1SOKN (257600 Ibf) . Operation method is as above. (1) Attention: Another angle gearbox must be clutched off if single engine is working. 2. Main drum operation and working The main drum is used to drive the hook-block by the methods of swirling wirelines of the travelling system. The clutch control valve in the driller’s console controls the main drum, it is a combination pressure-regulating valve, and it not only controls the clutch but also controls the throttle of the engine, Push up the control handle of the combination pressure regulating valve through about 10°, the clutch is clutched on, and the main drum starts to rotate. Push the handle continually, it can control throttle to increase speed of the engine. Push the handle to the top, the engine speed is maximum. The handle can be stop in any position from the 10%position to the top to control engine speed according actual necessity. Loosen the control handle, it can be reset automatically to clutch off the clutch. The oF TH himakion Gas is Wi2 0dsng rig instruction manual RG. procedure is as followings: at the first, reduce the speed of the engine, then clutch off the clutch Push down the handle of the combination pressure-regulating valve, it only controls, the throitle of the engine, and has no effect for the clutch, If make up and break out drill pipe, or only need to control engine speed in another operation, the operation methods is used. 3. Auxiliary brake operation and working WCB324 auxiliary brake directly mounted on the shaft of the main drum, and near the driller, The auxiliary brake can be controlled by the hand wheel pressure-regulating valve on the driller’s console. Rotate the hand wheel to adjust compressed air pressure in the air bag of the auxiliary brake. Brake capacity of the auxiliary brake is proportional to pressure of compressed air. The hand wheel of the pressure-regulating valve is rotated to control speed of the main drum to realize running of drilling tools at a constant speed. The hand wheel, in case of emergency, can be rotated clockwise to the end to quickly stop the main drum. Heat of the auxiliary brake can be quickly radiated by circulating water of the alloy steel water pipes. The explosion proof motor, which is used to drive the centrifugal pump, supplies power for circulating water. The explosionproof motor is mounted on the side of the water-cooling tank, and under the lower base. All explosion proof switches are installed in the doghouse. When operating, only need to turn on the switch of the explosionproof motor, 50 circulating coo! water can flow smoothly, Attention: If the auxiliary brake needs to work, first of all, the motors for water- circulating cool system must starts to ensure that circulating water flow smoothly, otherwise, internal parts of the auxiliary brake should be damaged. 4. Brake system for the main drum ‘The brake system for the main drum consists of brake handle, steel belts, brake block, adjusting screw bars, pulling bars and so on. It is used to brake the main drum. Before delivery, the brake system has been adjusted, and it has the best brake performance and effect. The brake block will be worn if the brake belt has been used for some time. Some adjustment, in accordance with actual situation of the brake block, must do without relay. Adjusting method is as follows: ‘Tighten the brake belt, and tighten all housing screws on the Drawworks frame and the protective cover. Rotate counterclockwise each screw three circles. The distance ftom the brake block to the brake rim should be about Smm_(0.2in) RG Petro-machninery (Group) Co.td. aPG sory este ig iy annem Fig.19 Clearance adjustable structure for brake band ‘After adjust the brake band, in the tightened condition as the above picture, the distance from C to AB should be about 30mm (1.2in) , for if it is more than 38mm (1.5in) , the performance of brake is not good and, if it is less than 25mm (Jin) , not only the abnormale brake, but the accident would happen. Fig.20 Brake adjustment (Adjust here) Wr eee ieee Hee‘After brake the band tightened, check the drawing for details of the demands of dead head and the correct positions. If it not met the demands, adjust it immediately. When the height of the brake bar is not in the position needed, adjust the length of the tension bar, at first release the spare nut, rotate the tension bar until the brake bar on the suitable position and then, make up the tension bar and tighten the spare nut. If the replacement needed for the brake rim, take care, control the distortion of the brake and, at the same time, pay more attention to the worn of the wheel rim of the brake edge. See the below for the worn limitation Original dia, of brake rim: $1168mm (46in) b, Max. wor allowed: 10mm (0.4in) Min. allowed worm dia: 148mm (45.2in) Fig.21 Worn drawing of braker rim T] Attention: Change the brake rim immediately if the surface of the brake rim has a crack with length of over 100mm. 1} Attention: First of all, start motors of water-circulating cool system when operation. Water-circulating cool system for the brake rim and water-circulating cool system for the auxiliary brake are designed as a same system with one water tank, individual loops. Motors drive the centrifugal pump to transfer circulation water with some pressure to water joints on the end of the main drum shaft, the two water chambers of the brake rim. Finally, circulation water returns to the water tank through another end of the water joint on the main drum shaft. Ex-proof control switches of the motor are mounted on the side of the water tank. RO Petro-machninery (Group) Co, 35.PG cm cat 5, Rotary table operation and working ‘The rotary table drive box can control the rotary table. The rotary table drive box not only supplies power for the rotary table, and it is also a control part of the rotary table. The rotary table control valve on the driller’s console can control the rotary table, it is three-position four- way valve. Push the valve handle to forward direction, clutch of the rotary table is clutched on, the rotary table starts to rotate. Push the valve handle to backward direction, clutch of the rotary table is clutched off, the brake cylinder of the rotary table starts to work, the rotary table stop. Beside, the rotary table drive box equips with a manual rotation direction change device, push its handle to forward direction, the rotary table normal motion, pull its handle to backward direction, the rotary table back motion. So the rotary table can meet the requirements of a left-hand DP or a right-hand DP. QA Waring: When the clutch of the rotary table is clutched on, change the rotation direction is forbidden, otherwise, clutches and parts ofthe gear will be damaged. ‘The rotary table drive box equips with an anti-torque release device. Brake control valves of the rotary table on the drillers console can control it. The brake pneumatic system of the rotary table consists of a three-posi ion four-way valve and a manual pressure-regulating valve. Push the handle of the control valve of the rotary table according the upper direction, it supplies air for the brake cylinder through the three-position four-way valve and handwheel pressure-regulating valve. So it can prevent the rotary table and corresponding transmission parts from back motion when the DP distortion power is releasing, and prevents the transmi jon parts from damaged. Clockwise rotating angle of the handwheel is bigger, the brake force is bigger. If rotate the handwheel with counter clockwise, drill pipes distortion power can be slowly released. ‘The pressure-regulating valve of the hand wheel is in open position in normal condition. QQ Warning: When the rotary table is rotating or clutches of the rotary table doesn’t clutch off, operating the brake control valve of the rotary table is forbidden, otherwise, clutches and the brake device will be damaged. 6, Sand drum and sand drum brake ‘A combination pressure- regulating valve, which can control clutches and throttle, is = TY Wacoew Weel Ga ALPC used to control the sand drum and the main drum. The pressure-regulating valve is mounted ‘Z130dkiling rg instruction manual on the drawworks frame, the side of the driller place. So brake operation is done in here. Brake control and adjustment principle for the sand drum is as the same as the main drum. 3.4.2 Hydraulic, pneumatic and electric system 1. Hydraulic system This drill is based on the principle of central control, and it put all the hydraulic winch, hydraulic pressure spinner assembly, upper hydraulic break-out cylinder control valve attach to the driller case where it is easy to be controlled by the driller, and is centrally controlled by the drill. Because the pick- litre fluid-cylinder device, the dilatating fluid-cylinder device and the hydraulic ram do not move when they are at task, its control valve is attached in the liquid-control case on the vehicle, and the two functional positions adopt the interlock loop. As the operation of the derrick telescoping and the operation of the dilatating flui |-cylinder device have been described in the previous chapters, we will only describe the operation of the hydrauli system. ‘A. On the driller case, there is a three-position four-way valve that controls the shut of the hydraulic pump; push the valve upwards, the oil pump on the left side will work; push the valve downwards, the oil pump on the right side will work; push the valve to the middle position, the oil pump will not work. B. The hydraulic winch diverter valve controls the direction of rotation of the hydraulic winch drum; life the operation handle of the valve, the hydraulic winch drum will rotate in the clockwise way, and the load will be lifted up; thrust down the operation handle of the valve, the hydraulic winch drum will rotate in the counterclockwise way, and the load will be lowered down. C. The makeup and breakout fluid-cylinder device control valve controls the protrusion and the retraction of the makeup and breakout hydraulic cylinder piston perch; lift the operation handle of the valve, the piston perch will protrude; loosen the operation handle of the valve, the handle will return to the middle position automatically; thrust down the operation handle of the valve, he piston will retract. D. The fuel induction of the hydraulic tong is controlled by a setting handle on the control case of the drill The pressure in the overflow cock and other pressure regulation positions of the hydraulic system has already been adjusted before it leaves the factory, and usually it does not need to be re-adjusted in everyday service. The filtrator should be checked and cleaned RG Potro-machatnery (Cmant Ga eT 7PGuxs strc eee iy ac eed at fixed periods, so that it can guarantee the functionary soundness of the hydraulic system. ‘The replacement of the hydraulic oil should be decided by the pollution level of the hydraulic oil, if the moisture limit proportion by weight has exceeded 0.05%, and the pollution level has exceeded 7 ~ 10mg/100ml, it is required to replace the hydraulic oil. (T)Attention: Pay more attention to add and change hydraulic oil for preventing the damage of system components. 2. Pneumatic system ‘The compressed air of the gas system is provided by the air compressor which lies in one side of the engine, and it has been tuned in to a limited pressure before it leaves the factory, but if the user finds the pressure to be a little lower, he can also adjust it, Unburden the shell cover, and rotate the stud in it in an counterclockwise way will raise the pressure, while rotate the stud in a clockwise way will lower the pressure. There is an automatic unloading gear in the inner part of the air compressor, and as soon as the internal pressure in the air pocket reaches to a standardized value, the pressure will feed back to the inner part of the air compressor through the pressure control valve, and make the compressed air flow between the two cylinders, so that the air compressor will work with no load. ‘The two air compressors of the two sets are connected paralleled, and each air outlet of each air compressor has been installed a one-way valve, in case the compressed air may bunch backward. ‘The total capacity of the air pocket is 200L, and the set pressure of the safety valve of the air pocket is 1.IMPa (160Psi) .At the bottom of the air pocket there is a water drain valve, and it is required to discharge once every day, but in winter itis required to discharge twice everyday. Main gas upper suppose with telescope get tri-link piece, fasten in turn for pressure control valve, air cleaner, oil mist cyclone, abaft oil mist cyclone return be furnished with protection of frost pump, leave factory fronts pressure control valve have tune in to assignment air pressure, user general not require nouveau adjust for on done into ‘The working pressure of the air cleaner is 1MPa, and its maximum operating temperature is 52.At the bottom of the air cleaner, there is a discharge valve, and the discharge valve can be either excretion or manual excretion. If it was manual excretion then require at fixed periods excretion, maintenance cleaner time, respond priority shut intake port, lead vessel and/or pipeline medium voltage force demote to zero, can but with lukewarm water purge plastic container, with lukewarm water or soap water flush Gir Keamteeee Scar Tn2130drilling rig instruction manual FES miscellaneous part out of to that if. Puff to the filter element in the opposite direction of the air current, remove the contamination on the surface, and blow-dry the parts and the clear ‘opening in the inner part of the shell with clean and dry compressed air. This apparatus is made of three pieces, gas system, purification, and it adopts festo air and supplies cleaning treatment, the type is LFR - 1 - D - MAXI, an oil systemic purification, and the other is the type MA - 50 - 16 - 1/4. ‘The relief valve and the filter box compose a single loading suit, on one hand it can mist cyclone of gas guarantee the stability of the working pressure of the gas system, on the other hand, it can filter the contamination in the upstream compressed air, the pipe scale, the rust and the condensation water: The degree of accuracy of the system is 40um (0.0016in) The oil mist cyclone adopts the automatically changeable baffling structural shape, and it can spray the oil mist evenly to the compressed air.The regulator can guarantee the quantity of the oil mist and the quantity of the compressed-air flow form a proportion, and when the compressed air passes by the Venturi nozzle, it will produce drop of pressure, and forces the oil liquid to enter the view oil cyclone through the oil cup, and then enter the delivery outlet along with the compressed air, at the same time, it is being atomized. You can adjust the quantity of the dripping oil by way of adjusting the screw nail, if it is ordinary air, 1 - 12 drop in 1000L air will be enough, The Oil Recommended to Use with the Tri ‘Type of the viscosity Festo special oil 32 mm2/s Aral Vitam GF 32 (cSt) temperature40'C BP Energol HLP 32 ISO standard VG 32 Esso Nuto H 32 1803448 standards Mobil DTE 24 Shell Hydrol DO 32 - (1) Attention: Before alcohol is filled, the ball valve in front of the freeze protection pump must be closed, and pneumatic system of the freeze protection pump must be cut off. Don't open the input joint to fill alcohol till the freeze protection pump has no pressure, RG Petro-machainery (Group) Go, .id aPG Ot toa i ita a All pneumatic control valves are installed in the driller’s console. Function is as follows: ‘A. Main drum combination pressure-regulating valve ‘The valve controls the main drum and the throttle of the engine, itis a three-position four-way valve. It has bi-directional regulating function. The handle is in middle position, and thrust plate clutch of the main drum is clutched off, the engine idling run, Push up the handle through about 10°, clutch is clutched on. Push the handle continuously, it can control the throttle of the engine, engine runs with a bigger speed. Push down the handle, it has ‘manual control throttle funtion. When tripping operation, select speed and push up the handle of the main drum combination valve through about 10°, clutches of the main drum are clutched on. The main drum with load doesn’t rotate, hydraulic torque converter is working as the same situation as one main clutch clutched off, push the handle continually, the engine runs with a bigger speed, the main drum starts to rotate, the hook ~block is lifted. Loosen the handle of the main drum combination valve with left hand, the handle returns to middle position automatically, clutches of the main drum are clutched off, the —s Gi Keeaeir ies PhZ130deilking rig instruction manusl Fars engine idling run. Press the brake handle with right hand, so the hook-block stops. The hook-block can be fallen by its weight, dropping speed of the hook-block can be control by the brake handle. B. Transmission speed change valve The change valve of the hydraulic transmission can control the eight-position pneumatic cylinder; six speeds are forward, one neutral, and one speed reverse. When tripping operation, Operation with reverse speed is forbidden, otherwise, the hydraulic transmission will be damaged. It is forbidden for the transmission to change speed with load. Tripping operation in cach speed with overload is forbidden. Please change speed on time according to stand actual situation. When the drilling rig is working, engine must run with a speed of over 1200z/min in order to ensure the transmission has enough lubrication oil ‘The drilling rig adopts hydraulie& mechanical transmission method. A torque converter can ensure that the drilling rig has high effective starting characteristic. The engine connects with the transmission with flexible connecting method. Because the engine hasn’t counter brake function, reverse speed is forbidden when tripping operation, otherwise, the torque converter and the engine are damaged. A ‘Wanring: When tripping operation. The engine and the transmission will be damaged if operating with reverse speed. Crown block saver reset valve and emergency valve ‘The crown block saver reset valve is a three-position four-way change valve. Push the handle according upper direction to the crown block saver position. A saver toggle valve on the drawworks is opened by wirelines when the hook-block reaches a waming position under the crown block, at the same time, compressed air comes into a pneumatic auxiliary brake cylinder, the main drum is braked. Compressed air closes the normal open air relay, ‘compressed air of the control valve of the main drum is cut-off, compressed air of clutches for the drawworks exhausts quickly from the quick valve, clutch is clutched off, and air in the throttle cylinder is cut off, the engine idling runs. At the same time, driller’s control valve hasn’t any effect. After all troubles are resolved, pulling rod of the saver toggle valve must be reset, and push down the handle of the crown block saver valve to the reset position, and piston of the pneumatic auxiliary RG Petro-machninery (Group) Oo a 5sPb ce 233017007. truck-mounted diling rig instruction manual brake cylinder is reset, the brake cylinder is reset, release the brake, The handle of the control valve must be pushed to the saver position to ensure itis safe for next time. [1] Attention: ‘The device is a safely device, fequent operation is forbidden, Prevent the hook-block from lifting too high as possible as you can. ‘The emergency valve is two-position three-way air pilot valve and, it is often in normal close condition. Please push up the handle of the control valve of the emergency brake in case of the brake failed and there has the rig in danger. Compressed air transfers directly to the pneumatic auxiliary brake cylinder and the brake cylinder brake the drum quickly. Pneumatic system works as the same principle as the erown block saver device. ‘After all troubles has been resolved, please reset the handle, exhaust air of the brake cylinder to loose brake, and push the handle of the crown block reset valve to reset it, then the piston of the pneumatic auxiliary brake is drawn back. The handle of the crown block saver valve must be pushed to the saver position to ensure it is safe for next time. Warning: This “system i ian apparatus for protection, it is inadvisable to fiequienily and’ we should prevent the rotary hook form rising excessively as much as you can... C. Throttle dump valve ‘The handle dump valve is mainly used to control the rotary speed of engine for control the speed of hook and working components of hydraulic system. D. Engine kill valve ‘There are two engines’ pneumatic kill valves in the driller’s console. If the engine needed to stop, at first of all, the transmission must be putted in NEUTRAL position, and push the handle of the kill valve to STOP position. ‘The stop valve sent a sign to the stop cylinder pull the pulling rod of the stop cylinder to the STOP position to stop the engine. If the engine needed to start, only need to put the valve to the START position. pneumatic ki E. Sand drum combination pressure regulating valve The valve can control clutches of the sand drum and throttle, it is a three-position four-way valve and has bi-direotional pressure regulating function, When the handle is in NEUTRAL position, the clutch of the sand drum is clutched off and the engine idling runs. ee2130drilling rig instruction manual Saas Push up the handle through about 10°, the thrust plate clutch of the sand drum is clutched on. Push the handle continually can control throttle of the engine, and the engine can run with a bigger speed. Pushing down the handle can control the throttle of the engine and, it has manual control throttle function, F. Auxiliary brake valve ‘The auxiliary brake valve is a handwheel pressure-regulating valve. The auxiliary brake airbag’s pressure can be regulated by the handwheel to control braking force of the auxiliary brake, to realize drill too! automatically pulled out with a constant speed. G Rotary table control valve ‘The rotary table control is achieved by a setting combination pressure control valve to realize the operation of the shut, gas pedal, decohesion of the counter rotation tray and the operation of the reaction torque inertia brake . Push upwards the valve handle for 10 degree, make the rotary table shut, keep on pushing the handle upwards, it will enlarge the span of the engine throttle, and increase the engine speed. Push the handle downside, then the turntable rotary table tray retard air cylinder will prevent the rotary table from quickly reversal turning , which may be caused by the release of the deformation energy of the drill stem or the confirmative dive components, and will avid the damage of the driving medium. If is required to release the arrest, make the combination pressure control valve handle return to the mesa-position slowly, make the rotary table rotate slowly, and make the rotary table release slowly in a reactive torque way, Clutch control valve of hydraulic oil pump The hydraulic pressure system oil pump pluck and shut control valve is a three-po: ion four-way valve. It you pull upwards the three-position four-way valve handle, the tank of the left side of the transmission case will operate, if you pull downside the three-position four-way valve handle, the oil pump on the right side of the transmission case will operate, if you pull it back to middle-position, then the two oil pumps both will stop operation. H, Control valve of mud pump Dual sets of mud contro! device are installed on the ler console for achieving the remote operation. The pump system can be not only working separately, but working as two pumps combination. The clutch of 1# mud pump and control of throttle of engine can be achieved though one set of three position and four way vavle and handle dump vavle on the left and, the clutch of 2# mud pump and control of throttle of engine can be achieved though RG Petvo-machninery (Group) Co, id aePGaus 2330/1700CZ_ truck-mounted drilling rig instruction manual cone set of three position and four way vavle and handle dump vavle on the right. I. Air slip valve ‘The air slip valve is three-position four-way valve. When tripping operation and the drill string needed to hold, push the handle according to the forward direction, so that the air slip can hold the drill string, Operator only needs to pull the handle according to the backward direction if the air slip were needed stop. J. Air spinner vavle ‘The air spinner valve is a three-position four-valve, push up the handle, the air spinner can rotate with forward direction. Push down the handle, the air spinner can rotate with backward direction. 3. Electric system lectrie system consists of a light system and an alarm system, electric motors and motor’s control system for the auxiliary brake and the water-circulating cool system for the brake rim. Power source is 220V, SOHZ. Light and alarm system consists of 220V, SOHZ ex-proof and waterproof electric connector, some ex-proof light lamps, flame-retardant cable, etc. All lighting and distributing equipment is for outdoor condition. There are three electric branches, one is for mast lighting and alarm system, one is for substructure lighting system, and one is for lighting system on carrier. Electric circuit for the water- circulating cool system of the auxiliary brake and the brake rim consists of a 220V, SOHZ electric distribution box with two electric branch circuits, ex-proof motors, flame-retardant cable, etc. Each water pump is controlled by an electric circuit. When the drilling rig is normally working, two water pumps generally are in normal working condition. 3.4.3 Spare drilling line The method to judge the service life of the drilling line: The three methods to judge the service life of the main drilling line wire rope are as follows: 1, When the number of the torque break thread is three or the brake threads is five in the three torques, the part cutting should be done. The torque is one loop of the center line. 2. The wireline use life in accordance with ton-mile. (1) calculate and record the following " ton-mile ": © Pull-drill ton-mile @ton-mile @Coring ton-mile @easting ton-mile Wit Peenewiiecs Nima GorAll the above attenuations can be got a "ton-mile value in the * drilling handbook of the United States of America ", according to different hole depth, different load and different msg. When the summation of all the above attenuation reaches 600 - 900 ton-mile, you should cut eighty feet, in order to obtain the maximum service life of the wire rope, you should make a choice of cutting plan, it should be regulated between 600 ton-miles to 900 ton-miles, until you find the optimal point. 3. the wire rope is calculated (1) the following thimble ton-kilometer (the weight of the casing string that is drilled in the air mud flotage quotiety+ 1000 combination weight )X hole depth 1000 1000 (2) the trip-in ton-kilometer (the weight of the drill collar and drill pipe in the air mud flotage quotiety + 1000 combination weight ) hole depth 1000 1000 (8) the ton-kilometer of the drilling and coring Drilling:3*(ton-kilometer of wire rope drilled this time—ton-kilometer of wire rope tripped-in last time) Coring: 3*(ton-kilometer of wire rope drilled this time—ton-kilometer of wire rope tripped in last time) 4, Demodulate the summation of all the above values with the _ton-mile between 600 and 900, the amount of the ton-kilometer is within the range between 875 and 1313 ton-kilometer, Every time when mute 80 feet, it means to mute 24 to 25 meters according to metric system metric system. 3.4.4 Mud circulation system and auxiliary equipments See the operation manual of the system for details and, the system can be displayed in the other ways according to the drilling requirements by user. 3.5 End of Workin 3.51 Integral traction of drilling rig: When a drill is drilling cluster wells at a same block, and move from one well to RO Peiro-machninery (Group) Co.PGom 7 vied i ee another, you can use the fumetion of the whole traction of the drill, the steps are as follows: 1. Unwound all the back guys on the derrick, and retract the upper part of the derrick , then put down the lower hull of the derrick (detailed operation is shown in the section of 3.5.2.1); 2. Remove the derrick floor ladder escape runner, ramp, sludge pipe, aqueduct and other bridge pieces that connect the derrick floor with the floor or other systemic systems; 3. Tie the rope at the back of the bulldozer traction handspike to the traction handspike at the back of the drilling floor, and use four bulldozer towing aircraft to move the drill to the new well position. 4, Hhoist the derrick, tie a fixed knot of the back guy, join the derrick floor derrick ladder, escape runner, ramp and other bridge pieces tightly, connect the derrick floor add the floor. 5. Lengthen the slurry-out tube, tie the mud circulation system and the well-control system pipeline tightly. 3.5.2 Move of drilling rig: ‘After the end of the task, prepare for the movement. First of all, dismount the bridge pieces between mainframe and solid control as well as well-control systems, dismount the turn-back slurry tube, slung down the blowout preventer, dismount the movable platform between drilling floor and the derrick. Then lower the drilling floor, utilize the crane with the capacity of more than 30 tons when lower the drilling floor, Hitch the lug on the drilling floor with the wire rope whose diameter is greater thang22mm, When the wire rope is strained under the stress, dismount the joint lead screw between the drilling floor and the derrick foundation, between the upper part of the drilling floor and the foundation of the drilling floor, Make the drilling floor to deflex correctly, and lower the drilling floor slowly to the lowest position. When the drilling floor has been lowered to the lowest position, it is required to dowel the guide pin and the pins. Then dismount the handrail, lower the wing platform, at the same time put the several holdfast-tail stakes which are on the drilling floor to their transportation position. 1. drawing back and dropping operation for the mast upper section 1) Drawing back operation for mast upper section Drawing back operation procedure for the mast upper section accords to contrary ate RG Pero-machinery (Group) Co idZ830drilling rig instruction manual FE SEare stretched out operating procedure. One person with a safely belt climbs on the mast, disassembly all lighting equipment plugs and mast load-bearing locking device. Caution: Safely pins must be pulled when the mast is dropping, otherwise, telescoping cylinders will be damaged and there will have personal in danger. Loosen all guylines. Close all cross valves for the telescoping cylinder to rise the handle of the control valve for the telescoping cylinder to stretch the mast out about 250mm. When the load-bearing block has been completely drew back, open all cross valves to realize the mast upper section drew back smoothly. ‘When the mast upper section has been drew back, close the cross valve. ‘Caution: The drawworks must be operated continuously during the period of the mast. upper section drew back to ensure that the hook-block can be in suitable position. After the Upper mast section has been drew back, if the mast needn't drop, make the hook-block near the surface of the substructure and fix it as possible as you can, otherwise, put the hook-block in the hook-block frame position, 2) Mast lay down Before the mast dropping, disassemble engine’s cover and move the driller’s brake handle from the upper position to the lower, disassemble the brake level, the mast dropping operation procedure is as follows: A. Open the discharge valves of the raising cylinder and operates the handle of the change valve to exhaust all air in the cylinder. Put the handle of the control valve to the neutral position. B. Loosen all locking bolts between the mast and the Y-shaped support. C. Open the high-pressure stop valve. Press down the handle of the change valve slowly to ensure that the mast can be drew back slowly and smoothly. Observe raising cylinders carefully, it must be drew back according to a correct procedure. Correct procedure is as follows: first, the piston rod, second, the internal cylinder, third, the middle oylinder. QQ Warning: ‘The mast will abnormally fall by itself and there will have personal and equipment in danger if raising cylinders aren’t drawn back according to a correct procedure. RG Petro-machninery (Group) Co, anPom soar mc nd high i in ‘When the mast near the front support about 200mm~300mm, dropping speed of the rast should be limited to ensure that the mast can align the front support correctly E. Tie fastlines and deadlines near the engine on hooks of the mast to prevent the water tank and paint of the engine from damaged by wirelines when the drilling rig is running on road. (1) Attention: The drawworks must be operated continuously to ensure that the hook-block can lie downon the hook-block frame during the period of the mast dropped. QN caution: ‘The engine must idling run during the period of the mast drew back and laid down, the engine kill is forbidden. Otherwise,there will have personl and equipment danger. ‘After all operation, the change valve must be in neutral position, and dimp valve closed to the minimum, and handles for other hydraulic and pneumatic valves in middle position, then stop the engine. BS warnin has been raised, mo : When wind force is over 4, raising the mast is forbidden. After the mast jack is forbidden. ig a hydraul 2. Transportation ‘Actual road condition must be considered when the drilling rig is travelling. Height of the main unit is 4.5m (151) . The racking platform must be disassembled if height is limited. The mast must be disassembled if necessary. When the drilling rig is moving, user had better use a flat-bed trailer. The engine and pump group, each tank for the solid control system, the water tank and the doghouse can be carried on the trailer by a crane or a special trailer. If moving distance no more than 40~60km (25-37mile) and user adopts reliable transportation method, the 3000M drilling rig can complete moving from one place to another place and installation within one day. Sarees Nias TRLHider ng msirncion man 3000m truck-mounted drilling rig transportation table Item Description ‘Truck No. 1_| Main unit 1 2_| Engine and pump group 2 3__| Solid control system 3 4 _| Water and doghouse 1 s Generator’s house 1 6 _| Combination house 1 7 Oil tank 1 g_| Substructure and spare part including carrier’s mat P and heavy-duty beam_) wv. 9 _| Catwalk and pipe rack 2 10 _| BOP and spare part 1 11_| Wellhead tool 1 | Total 16 3.6 Pack and seal When it is a long time before the reuse of the drill, required to fill up some lubricating oil to relevant driving medium, and to maintain the engine regularly, the part of the power package should be covered with canvas hood, when parking the main frame, it is required to protrude the hydraulic jack, so that the tires can avoid being pressed for a long time. [RG Petre-machninery (Group) Co, eoPGorn snr sii yt oe Chapter 4 Packing and transportation 4.1 Model of product transportation 2330 truck-mounted drilling rig mainly consists of the main unit and the accessories. Highroad, railway and waterage can be chosen by users. ‘The railway is for line-haul, the highroad is for near transportation and the railway and the waterage are used fro the international transportation. 4.1.1 Highroad transporation ‘The naked rig driven by itself with the mast and the hook block to the destination is recommended forthe road transportation no more than 1000 km and the other standard = @® accessories need two 15 trucks and one 30T half trailer for transportation. The speed when running is 35knv/h and the clearance head height is 4.52, the load of the front axle is no more than 107, and the load of single rear axle is no more than 12T, for meeting the demands of road height and the road load, When moving, the length of the main unit is 16m, the width is 3.3m, the min.steering radius is 19.5m and the sloping degree is 26%. 4.1.2 Rail way transportation The rail way transportation is used for the long distance transportation. Usually, the main unit can be separated in to three parts, the main unit including chassis and the working parts on the carrier, the mast and the accessories including hook block, swivel, sub structure, rotary table and rig base, ete. which will use 5 or 6 train wagons, The naked mast, main unit and the big accessories is to mark the lifting tags, also eo the packing board can be used for preventing the main parts of the unit from the lose and damage and the small part can be packed in the wooden box. When lifting for transportation, the main unit the single weight is 507 can be to put in the platform or lift by the lifting equipments, The 30T lifting equipment is to be used for the mast and, the single weight of it is 2ST.

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