DQ450DBZ 直驱顶驱

DQ450DBZ Top-Drive
Service & Manual
DQ004-SC

2014 年 01 月
 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Operating instruction
Manual conventions

This instruction contains the conventions used throughout this manual. Please

pay close attention to these notes, cautions and warnings during reading the manual.

Note: ◆supplementary instructions for operation, personnel and equipment.

Caution: promptings involving a risk of personal injury or equipment

damage.

Warning: promptings involving a definite risk of personal injury or

equipment damage.

Safety requirements

DQ450DBZ top drive drilling equipment is installed and operated in a controlled

drilling rig environment that involves potential hazards such as high voltage, high

pressure liquid and aloft work. To avoid injury to personnel or equipment damage,

carefully read the notes, cautions and warnings before installation, disassembly,

commissioning, maintenance, operation and inspection.

Personnel training

All personnel installing, disassembling, testing, maintaining, operating and

inspecting equipment, or those in the vicinity of the equipment, should be trained in

drilling operation, drilling safety knowledge and top drive operation, and should read

this manual and relevant technical documents carefully.

Non-specialized person or untrained person is not allowed to install or

test the top drive device.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Safety operation specification in the field

1. Personal should wear protective equipment in the drilling field.

2. Live working should be operated in the supervision, in principle it should be

operated when power is failed. If live working is necessary, supervisor should be at

the place that not only can see operator, but also can make power failed quickly, and

make communication signal clear in advance.

3. Fasten safety belt when work high above the ground, and wear proper clothes

and shoes. During working, fasten the safety belt properly. All tools must have safety

ropes, small tools should be put into working bags to avoid objects falling from high

attitudes.

4. During maintenance, make devices stop running, and maintain them after

stopped completely.

5. Safety programs should be made in advance, eliminate accidents that may

happen in operating as far as possible.

Installation and disassembly specifications of top drive device

1. Operator should wear protective equipment such as gloves and safety helmet

according to related regulations.

2. Fasten the safety belt when working high above the ground, tools and parts

should be fastened by safety ropes or put into working bags to avoid falling.

3. Cut off the power before dismantling and never try to perform live-wire work.

4. Stop installation and dismantlement in strong windy, thundering, rainy and

snowy day.

Safety operation specification of electrical system

1. Commissioning and maintenance of electrical system should be carried out by

professionals.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2. Carefully read user manual and part drawing of electrical system and know

wiring diagrams of DQ450DBZ top drive before operation.

3. Cut off the power switch before operation, and hang the signboard of

'non-switch on'.

4. Prior to disconnecting electrical connections, verify that wires (cables) and

connecting terminals are properly labeled to ensure proper reconnections.

5. Live working is forbidden. Never try to open safety shelters at the position

with high voltage, never try to repair or remove any electrical elements, and pull out

or insert the cable plugs with electricity.

6. Never try to open the anti-explosion control cabinet or driller’s station with

electricity under the circumstance of flammable gas.

7. Never replace the DC fuse between DC bus and inverter before rectifier

running and DC bus voltage dropped to under safety range (DC 24V), otherwise, it

may cause human injury and equipment damage.

8. To avoid faulty operation, separating the switch to main circuit breaker of

rectifier cabinet when repair the rectifier, inverter or motor.

9. Do not detect the isolation of rectifier and inverter by megger, otherwise, high

testing voltage will damage the equipment.

10. Keep the pressure of protective gas when driller’s control cabin powered on,

recover the pressure as soon as possible or stop drilling and cut off the power supply

of driller’s control cabin when the protective gas lose pressure.

11. It is forbidden to relieve safety chain locks of any software and hardware.

Recover functions of linkage by bypass after troubleshooting.

12. Do not start actuator and other power supplies before temperature reduction

and dehumidification of air conditioner when the temperature is exceeding 40℃,

humidity more than 95% or there is condensation.

13. Ensure that there is no condensation in electric control cabinet when main

power supply is powered on again after cut off for half an hour.

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14. It is forbidden to open the electric control room for a long time or be opened

frequently when the temperature of it is under external environment temperature in

humid condition; otherwise, there is condensation on electrical equipment.

Safety operation specification of hydraulic system

1. Operator should be professional and know safe operations.

2. Before operation, carefully read user manual of hydraulic system for

DQ450DBZ top drive, and know operating principles, hydraulic component structures

and related electrical connections of the hydraulic system well.

3. During maintain or repair the system, cut off the power supply, operate mode

selection valve to ‘unloading’, and operate it after system pressure is zero.

◆ Before hydraulic pipeline disassembly, mark all connection positions so

as to ensure correct reconnection. Meanwhile, close ball valves of system as per

different maintenance positions and inspection positions to reduce outflow of

hydraulic fluid, prepare the proper container, cotton yarn and greasy blockage

to avoid outflow of hydraulic fluid polluting equipment and environment when

open the pipeline.

Temperature of hydraulic system components and hydraulic oil will rise

after working, and operate after temperature is cooled to accessible temperature

before repair.

Before maintain the hydraulic system, cut off the power supply,
operate mode selection valve to ‘unloading’, and operate it after there is no

pressure in the system.

Safety operation specification of top drive device

1. Never tray to close cooling fan during top drive running.

2. The power supply of electric control cabin should be cut off after main air

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

switch of electric control system cut off.

3. In any case, ground jar knocker is not allowed to use. Otherwise, the top drive

device may be damaged.

4. During start main motor, drilling torque limitation shall not be too high, and

increase drilling torque limitation value after main shaft rotates.

5. When reverse torque is released, the danger that the drill tool is thrown off

exists, operate as per operation regulations strictly, and strictly control reversed speed

of the drill tool to prevent accidents during operation.

6. Except well control, it is forbidden to close IBOP during drilling or mud pump

running.

7. If the system needs emergency stop when emergency situation happened,

operator can press down E-STOP button, and all equipment of top drive stop quickly.

Safety operation specification for well control

Pay attention to following items in installation and application of top drive

device, and understand the condition of strata pressure and requirements of well

control at any time.

1. Read carefully and understand drilling design requirements and technical

requirements of well control.

2. Carry out related requirements of industrial standards, regulations and

recommended practices under the circumstance of hi-pressure hydrocarbon reservoir

or harmful gas such as H2S, SO2 etc during drilling.

3. During drilling in the hydrocarbon reservoir, keep the equipment in good

condition, check and drill the operation of IBOP etc operation of well control during

shift every day, and process it timely if there are problems.

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MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Contents

1. Lubrication of DQ450DBZ top drive ........................................................................ 1

1-1 Lubrication description .................................................................................... 1

1-2 Lubrication of wash pipe ................................................................................. 2

1-2 Lubrication of bail ........................................................................................... 3

1-3 Lubrication of link tilting mechanism ............................................................. 4

1-4 Lubrication of back-up tong ............................................................................ 5

1-5 Lubrication of BOP ......................................................................................... 7

1-6 Lubrication of carriage .................................................................................. 10

1-7 Lubrication of guide rail ................................................................................ 11

1-8 Lubrication of power transmission system .................................................... 12

1-8-1 Composition of power transmission system....................................... 12

1-8-2 Lubrication of main thrust bearing ..................................................... 14

1-8-3 Lubrication of thrust bearing .............................................................. 15

2. Check and maintenance ........................................................................................... 16

2-1 Check and maintenance ................................................................................. 16

2-1-1 Daily inspection and maintenance...................................................... 16

2-1-2 Weekly inspection and maintenance .................................................. 18

2-1-3 Monthly inspection and maintenance ................................................. 19

2-1-4 Half-yearly inspection and maintenance ............................................ 21

2-1-5 Yearly inspection and maintenance .................................................... 22

2-2 Inspection and maintenance of bail ............................................................... 24

2-3 Inspection and maintenance of wash pipe assembly ..................................... 26

2-3-1 Structure of wash pipe assembly ........................................................ 26

2-3-2 Maintenance of wash pipe assembly .................................................. 27

2-3-3 Replacement of wash pipe assembly.................................................. 27

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2-4 Check and maintenance of brake device ....................................................... 34

2-4-1 Check of brake device ........................................................................ 34

2-4-2 Replacement of brake block ............................................................... 35

2-5 Check and maintenance of gooseneck ........................................................... 37

2-6 Check and maintenance of rotating head ....................................................... 28

2-7 Check and maintenance of elevator link tilting mechanism .......................... 39

2-7-1 Check and maintenance description of elevator link tilting mechanism

...................................................................................................................... 39

2-7-2 Position adjustment description of elevator link clamp ..................... 41

2-7-3 Replacement of elevator link tilting oil cylinder ................................ 42

2-8. Check and maintenance of BOP assembly ................................................... 43

2-8-1 Check and maintenance description of BOP assembly ...................... 43

2-8-2 Check and maintenance description of shutoff sleeve and rocker arm

mechanism of upper IBOP ........................................................................... 44

2-8-3 Structure and check and maintenance description of upper IBOP ..... 46

2-8-4 Check and maintenance of torque booster ......................................... 48

2-9 Check and maintenance of back-up tong ....................................................... 49

2-9-1 Check and maintenance description of backup tong .......................... 49

2-9-2 Replacement description of jaw assembly seat and tong dies ............ 54

2-9-3 Replacement of jaw assembly seat and jaw assembly of open type

tong .............................................................................................................. 55

2-10 Check and maintenance of balancing device ............................................... 58

2-11 Check and maintenance of carriage ............................................................. 60

2-12 Check and maintenance of guide rail .......................................................... 61

2-12-1 Check and maintenance of hanger plate assembly ........................... 62

2-12-2 Check and maintenance of guide rail main body ............................. 65

2-12 Check and maintenance of reverse torque beam ......................................... 68

2-13 Check and maintenance of power drive system .......................................... 70

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2-13-1 Check and maintenance description of rubber umbrella .................. 70

2-13-2 Check and maintenance of main shaft.............................................. 71

2-13-3 Check and maintenance of rotating head ......................................... 72

2-13-4 Check and maintenance of lifting box body..................................... 73

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MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

1. Lubrication of DQ450DBZ top drive

1-1 Lubrication description

Lubrication of DQ450DBZ top drive mainly includes lubrications for bail, wash

pipe assembly, carriage, link tilting mechanism, IBOP, back-up tong and motor.

Lubrication position and lubrication cycle are shown in table 1-1.

Table 1-1 Lubrication position and lubrication cycle

Lubricating positions Qty. Lubrication cycle Lubricating oil type

Wash pipe assembly 1 daily

Lifting bail 2 Every week

Link tilt mechanism 4 Every week

Aligned roller of back-up tong 4 daily

Movable post of back-up tong 1 Every week

Extreme pressure
Rear post of back-up tong and
1 Every week lithium base
spring seat
grease(GB/T 7323) with
Connecting pins of front and
2 Every week viscosity (00, 0, 1, 2)
back jaw body of back-up tong
or synthesized lithium
IBOP roller 4 daily
base grease(SH/T 0380)
Rocker arm assembly of IBOP 1 Every week
with viscosity(1, 2, 3, 4)
Bearing wheels of carriage 16 Every week

Guide wheel of carriage 4 Every week

HPU motor, main motor fan and

3 Monthly
motor impeller

Guide plate of guide rail 2 Every week

Main thrust bearing 1 Every half year Mobilith SHC-200# (ISO

VG 220) low-temperature
Thrust bearing 1 Every half year synthetic lubricating grease

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Lubricating grease for motion friction pairs of power transmission system is

Mobilith SHC-200# (ISO VG220) low-temperature synthesis grease.

1-2 Lubrication of wash pipe

Daily

Lubricating nozzle (1 place)

of wash pipe assembly

Lubricating nozzle

Fig.1-1 Lubrication of wash pipe assembly

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1-2 Lubrication of bail

Weekly

Lubricating nozzle
(2 places) of bail pin

Bail

Bail pin

Lubricating nozzle

Fig.1-2 Maintenance of bail

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1-3 Lubrication of link tilting mechanism

Weekly

1. Lubricating nozzle at connection of

oil cylinder body and support plate

2. Lubricating nozzle at connection of

oil cylinder piston rod and elevator

link clamp

Lubricating nozzle

Fig.1-3 Lubrication of link tilting mechanism

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1-4 Lubrication of back-up tong

Back-up tong of DQ450DBZ top drive is divided into closed type back-up tong

and open type back-up tong, the lubrication is shown in fig.1-4 and 1-4a.

Daily

Lubricating nozzle (4 places) of

alignment roller of back-up tong

Weekly

Movable post of back-up tong and movable

frication surface of rear post (1 place)

Rear post

Movable post
Lubricating nozzle

Fig.1-4 Lubrication of back-up tong

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MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Weekly

1. Rear post of back-up tong, spring

seat and frication surface of rear jaw

Rear post
body (1 place); 2. Lubricating nozzles

on connecting pins between front and

back jaw bodies (2 places).

Spring seat

Lubricating nozzle

Fig.1-4a Lubrication of back-up tong

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1-5 Lubrication of BOP

Lubricating nozzle

Daily

Lubricating nozzle (4 places) of roller

of BOP turn-off oil cylinder support

Fig.1-5 Lubrication of BOP

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The DQ450DBZ is provided with shutoff sleeve with two different structures and

corresponding rocker arm mechanism, and its lubrication and maintenance ways are

similar.

Weekly

Rocker arm assembly of turn-off sleeve (2 places)

Turn-off sleeve

Rocker arm assembly

Fig. 1-6 BOP shutoff sleeve and rocker arm lubrication description I

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

1. Shutoff sleeve and rocker

arm assembly (2 positions)
2. Rocker arm assembly
lubrication nozzle (2 positions)

Shutoff sleeve

Rocker arm assembly

Lubrication nozzle

Fig. 1-6a BOP shutoff sleeve and rocker arm lubrication description II

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1-6 Lubrication of carriage

Weekly

1. Lubricating nozzle of bearing

wheel assembly (16 places)

2. Lubricating nozzle of guide

wheel assembly (4 places)

Guide wheel

Lubricating nozzle

Bearing wheel

Guide wheel
Bearing wheel

Lubricating nozzle

Fig. 1-7 Lubrication description of carriage

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1-7 Lubrication of guide rail

Guide plate of guide rail

Weekly

Lubrication of guide plates (guide

plate of section V, guide rail)

◆Lubrication method of guide rail:

1. Complete it by smearing lubrication

grease on guide plate;

2. Smear lubrication grease on bearing

wheel and guide wheel, and move

carriage up and down.

Fig.1-8 Lubrication of guide rail

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1-8 Lubrication of power transmission system

1-8-1 Composition of power transmission system

Rubber umbrella

Two-lip seal
Distance ring

Frication sleeve 1
Main shaft
Packing box

Bearing

Case cover
Main thrust
bearing
Oil seal, gland assembly

Oil seal, gland

Encoder group assembly

Disc brake device

Lifting box body group

Main motor

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Sealing gland

Bearing

Adjustable gasket

Thrust bearing

Lower barrel body Force bearing nut

Oil seal,
Bearing
gland assembly

Crankset

Locking hoop
subassembly
Rotating head

Fig.1-9 Composition of power transmission system

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1-8-2 Lubrication of main thrust bearing

Lubricating grease is at
position which is above the 1/3
position of big shaft shoulder
of main shaft.

Plug

Remove plug and fill

lubricating grease, and plug

filling port after filling.

Semiannual

Lubrication of main thrust

bearing (symmetrical two

places)

Detect the quality and level of lubricating grease semiannually, and

the lubricating grease shall be higher than the 1/3 position of the shaft

shoulder of the main shaft.

Replace with new lubricating grease biennially necessarily as required,

Fig.1-10 Lubrication of main thrust bearing
and lubricating grease shall be higher than the 1/2 position of the big shaft
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shoulder of the main shaft.
 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

1-8-3 Lubrication of thrust bearing

Plug

Remove plug and fill

lubricating grease, and plug filling

port after filling.

Semiannual

Lubrication of thrust bearing

(symmetrical two places)

Fig.1-11 Lubrication of thrust bearing

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2. Check and maintenance

2-1 Check and maintenance

2-1-1 Daily inspection and maintenance

No. Check positions Contents Maintenance measure

Check wash pipe assembly Replace packing or

1 Wash pipe assembly
for mud leakage wash pipe assembly

Leakage of hydraulic Replace pipeline and

2 Disc brake device
pipeline. tighten nut

Wear condition of brake Replace brake pad

3 Disc brake device
pad (thickness≤4mm)

4 Rotating head Check it for looseness Retighten bolts

Looseness of connecting
5 Elevator link tilt Tighten bolt
bolt of support plate

Flexible rotation of knuckle

bearing of connections

between link tilting oil

Replace knuckle
6 Elevator link tilt cylinder and support plate,
bearing
and between link tilting oil

cylinder and elevator link

clamp

Oil leakage of end cover of Replace link tilting oil

7 Elevator link tilt
oil cylinder cylinder

Check bolt of elevator

Check whether forward and
link clamp for looseness
8 Elevator link tilt backward tilting angles
and adjust the elevator
meet the requirements
link clamp

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Leakage of turn-off oil Replace oil cylinder or

9 BOP assembly
cylinder seal

Abrasion and lubrication of

Replace roller, and fill
10 BOP assembly upper and lower rollers of
lubricating grease
turn-off oil cylinder

Looseness of flange disc

Retighten bolt and
bolt of torque booster, and
11 BOP assembly install locking steel
crack and falling of locking
wire
steel wire

12 BOP assembly Abrasion of saver sub Replace saver sub

Flexible movement, Check sleeve and

sufficient lubrication and rocker arm assembly,

13 BOP assembly abrasion of rocker arm fill lubricating grease,

assembly of remote control or replace rocker arm

IBOP assembly if required

Tighten bolt, washer or

Looseness of bolt, nut and
14 Back-up tong washer, crack of safety pin nut, and reinstall safety
and locking steel wire pin or locking steel wire

Hydraulic oil leakage at

Check sealing ring, and
15 Back-up tong connection between jaw
replace it if required
body and end face

Guide cover and movable Clean internal mud and

16 Back-up tong
guide cover dirt

17 Back-up tong Abrasion of tong die plate Replace die plate

Cleanliness of tong die Clean mud and dirt in

18 Back-up tong
plate tong die plate

19 Back-up tong Bolt of guide cover Retighten bolt and

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

replace it if necessary

Looseness of connecting
Tighten connecting bolt,
bolt and nut between
20 Carriage and reinstall locking
carriage and motor, and
steel wire
crack of locking steel wire

Check safety rope of Reinstall or replace

21 Carriage
carriage for good condition safety rope

Sufficient lubrication of

22 Carriage guide wheel and bearing Fill lubricating grease.

wheel

Check whether safety pin

Reaction torque
23 for claw of fixed beam I is Reinstall safety pin
beam
lost

Check fixed bolts and nuts

Reaction torque
24 of fixed beam I for Retighten nuts
beam
looseness

Check whether the drill

Reaction torque Adjust position of fixed
25 pipe is located at wellhead
beam beam I
centre

2-1-2 Weekly inspection and maintenance

No. Check positions Contents Maintenance measure

Smear lubricating grease

Sufficient lubrication for
1 Rotating head on the crankset and tooth
crankset and motor pinion
surface of pinion

Check sealing gland and Check sealing of

2 Rotating head
contact surface of force connection between

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

bearing nut for rotating head and force

transudatory oil grease bearing nut

Check abrasion, closure

3 BOP assembly and leakage of upper and Replace BOP

lower IBOP

Check abrasion of upper Fill lubricating grease

4 BOP assembly cover plate of turn-off and replace upper cover

sleeve plate

Fill lubricating grease

Lubrication and abrasion
5 Back-up tong and replace alignment
of alignment roller
roller

Abrasion of guide wheels Replace bearing wheel or

6 Carriage
and bearing wheels guide wheel

Abrasion of guide ring,

7 Back-up tong and abrasion of tong body Replace guide ring

and DP

Visually check weld of Replace hanging

8 Balance device hanging beam of balance beam of balance oil

oil cylinder for crack. cylinder

2-1-3 Monthly inspection and maintenance

No. Check positions Contents Maintenance measure

Clean gooseneck and

1 Gooseneck check it for sinking, Replace gooseneck

abrasion and corrosion

2 Gooseneck Perform bulge test for Replace gooseneck if

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

gooseneck necessary

Abrasion of lifting lug of

3 Elevator link tilt Replace the elevator link
elevator link

Abrasion and crack of Replace the pear-shaped

4 Balance device
pear-shaped ring ring

Abrasion of pin for

pear-shaped ring (hanging

5 Balance device Replace pin
beam) of balance oil

cylinder

Check fixed bolt of baffle Retighten bolt and install

6 Balance device
plate for looseness locking wire

Check whether split pin of

7 Balance device Replace split pin
cylinder pin is lost

Visually check weld seam

Replace the crown block
8 Guide rail assembly of crown block padeye for
padeye
cracks

Replace the shackle as

9 Guide rail assembly Abrasion of shackle
per requirements

Check whether split pin of

10 Guide rail assembly Reinstall split pin
shackle is lost

Abrasion of padeye hole

Replace the hanging
11 Guide rail assembly of hanging plate of guide
plate
rail

Check hanging plate for Replace the hanging

12 Guide rail assembly
cracks plate

Check hanging plate and Replace sections of guide

13 Guide rail assembly
connecting padeye hole of rail

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

section V for cracks

Abrasion of hanging plate

and connecting pin of Replace pin, shear pin

14 Guide rail assembly section V, guide rail; and and safety pin as per

missing of shear pin and actual situation

safety pin

Abrasion of connecting

padeye and padeye hole Replace it if abrasion is

15 Guide rail assembly
between sections of guide serious.

rail

Abrasion of connecting

16 Guide rail assembly pins between sections of Replace pins

guide rail

Check whether shear pins

Reaction torque Supplement shear pins
17 and safety pins of fixed
beam and safety pins
beam II are lost or not

Check fixed bolts and nuts

Reaction torque
18 of fixed beam II for Retighten nuts
beam
looseness

2-1-4 Half-yearly inspection and maintenance

No. Check positions Contents Maintenance measure

1 Lifting bail Abrasion of bail Reduce load or replace

2 Bail pin Abrasion of bail pin Replace bail pin

Replace brake disc

3 Brake disc Abrasion of brake disc
(thickness≤10mm)

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2-1-5 Yearly inspection and maintenance

No. Check positions Contents Maintenance measure

1 Lifting bail Magnetic powder inspection of Replace it if necessary

bail

2 Guide rail assembly Magnetic powder inspection of Replace it if necessary

crown block padeye

3 Guide rail assembly Magnetic powder inspection Replace it if necessary

for connecting padeye hole of

hanging plate and section V,

guide rail

4 Guide rail assembly Magnetic powder inspection Replace pin

for pin of connecting padeye

hole of hanging plate and

section V, guide rail

5 Guide rail assembly Magnetic powder inspection Replace pins

for connecting pins between

sections of guide rail

6 Guide rail assembly Magnetic powder inspection Replace connecting pin,

for connecting pin, connecting and replace guide rail if

dual padeye and connecting necessary

slotted hole position

7 Reaction torque Magnetic powder inspection Replace parts of fixed

beam for weld seams of fixed beam I beam I as per actual

situation

8 Reaction torque Magnetic powder inspection Replace parts of fixed

beam for weld seams of fixed beam beam II as per actual

II situation

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

9 Hanging beam of MT for all welds Replace hanging

balance oil cylinder beam of balance oil

cylinder

10 Check bearing parts Carry out magnetic testing annually and ultrasonic testing

quinquennially on exposed surfaces of parts.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-2 Inspection and maintenance of bail

As the integral swivel bail, it is the main bearing part of top drive. During

working, weights of top drive body and drill string shall be borne by the bail, upper

part of the bail connected with the hook, and lower part connected with main motor

by lifting box body.

The lifting capacity of bail for DQ450DBZ top drive conforms to the

hook load of 4500kN (500tons) of API8A/API8C, and performance indicators

reached safety lifting load standard of API.

Fig.2-1 Parameters of bail

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Yearly

Magnetic powder inspection of bail

Semiannual

Every 5
Abrasion of bail
years

Carry out ultrasonic

Semiannual
testing on bail
Abrasion of bail (2 places)

bail

bail pin

Fig.2-2 Inspection and maintenance of bail

Reduce load if abrasion loss of bail and bail pin exceeds 2mm, and

replace if it exceeds 4mm.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-3 Inspection and maintenance of wash pipe assembly

2-3-1 Structure of wash pipe assembly

Lower bushing
ring
Gooseneck seal

Spring ring
Distance ring

Upper sealing
pressing sleeve

Mud packing
Mud packing
Upper bushing ring

Distance ring
Upper packing box

Mud pipe
Lower sealing
pressing sleeve
Lower packing box

Lubricating nozzle
Main shaft
sealing ring
Set screw

Fig.2-3 Wash pipe assembly of DQ450DBZ top drive

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2-3-2 Maintenance of wash pipe assembly

Daily

Check wash pipe assembly

for mud leakage

Fig.2-4 Inspection of wash pipe assembly

2-3-3 Replacement of wash pipe assembly

1. Clean mud and dirt at outer side of wash pipe, and remove lubricating nozzle

of wash pipe assembly;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2. Remove upper packing box gland and lower packing box gland of wash pipe

assembly;

Threads of upper packing box gland and lower packing box gland

connected with gooseneck and main shaft are left-handed ones.

Fig.2-5 Replacement step 1 for wash pipe assembly

During lower packing box gland is removed, manually start HPU if the

lower packing box gland and main shaft rotate simultaneously, and then break

out operation is carried out by disc brake.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

At the end of
disassembly of upper packing

box gland, pay attention to

sudden falling of gland and

personal injury.

Fig.2-6 Replacement step 2 for wash pipe assembly

3. Clean mud at connections between upper packing box and gooseneck, and

between lower packing box and main shaft;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Ensure upper and lower

packing boxes are not

imbedded into gooseneck and

main shaft before knocking.

Fig.2-7 Replacement step 3 for wash pipe assembly

4. Pull upper packing box and make it separate from gooseneck, and upper

sealing pressing sleeve and gooseneck contact surface are exposed.

5. Lift lower packing box and make it separate from main shaft of motor, and

then lower sealing pressing sleeve and contact surface of motor main shaft are

exposed.

6. Knock packing box glands up and down until connections between upper and

lower parts of wash pipe and gooseneck and main shaft are loose, and then remove

wash pipe assembly wholly;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Fig.2-8 Replacement step 3 for wash pipe assembly

7. Remove old wash pipe, clean end face and screw threads of main shaft and the

end face and screw threads of gooseneck;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Fig.2-9 Replacement step 3 for wash pipe assembly

8. Before installation, check the new wash pipe assembly, check whether O-rings

of upper and lower end faces are installed in channel; if necessary, remove O-rings,

and then smear lubricating grease in the channel to avoid O-ring falling;

Before install new wash pipe assembly, check whether grease nipple is

screwed into lower packing box or not, if it is screwed into, please remove it to

avoid the grease nipple damaging during installation.

9. Place new wash pipe assembly between gooseneck and main shaft, and align it

with centre, and then make upper and lower packing boxes embedded on the

gooseneck and the main shaft.

During place new wash pipe assembly, make sure O-rings at upper and

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

lower ends are pressed into seal groove correctly.

10. Lift upper packing box gland, and tighten the upper packing box gland

manually, similarly, tighten lower packing box gland, and then preliminary fixation of

the wash pipe assembly is finished;

Threads of upper packing box gland and lower packing box gland

connected with gooseneck and main shaft are left-handed ones.

11. Rotate main shaft for 1~2 circles, and make packing box is at normal

position;

12. Start top drive HPU motor, and make disc brake knob at BRAKE position;

13. Tighten upper and lower packing box glands by spanner;

14. Loosen disc brake, rotate main shaft and knock flange of upper and lower

packing box glands until glands are tightened, reinstall lubricating nozzle, fill general

purpose lithium base lubricating grease or high-temperature molybdenum base grease,

and then clean installation site;

Main shaft shall not rotate too quickly, pay attention to safety when
knock the flange, otherwise, it may cause personal injury;

15. Do not open mud pump, rotate main shaft of top drive at rotation speed of

about 50r/min for 1 minute, and then open mud pump and check leakage. If leakage

occurs, disassemble, check and repeat the assembly and the installation of wash pipe

assembly.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-4 Check and maintenance of brake device

2-4-1 Check of brake device

Every half a year

Every day Wear condition of brake disc

1. Check disc brake hydraulic

pipeline for leakage
2. Wear condition of brake block

Replace brake disc in

time when its thickness is less
than 10mm.

Replace brake block in

Brake block
time when its thickness is less
than 4mm.

Brake disc

Fig. 2-10 Check description of brake device

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

The braking capacity of the brake block loses due to the pollution of oil

or grease. Replace the friction block which absorbs excessive grease in time.

Keep the friction block and the brake disc clean at ordinary time, and

prevent them from adhering the oil or the grease.

2-4-2 Replacement of brake block

The brake block in the disc brake caliper belongs to quick-wear parts, and the

thickness of the new brake block during delivery is about 8mm. Due to the friction

during the long-tem use, the thickness of the brake block can be worn to different

extents. Therefore, in the use process, check the thickness of the brake block

frequently, the damage to the oil cylinder of the brake caliper is possibly caused and

the brake failure is even caused when the brake block is excessively worn.

When the thickness of the brake block is less than 4mm, it should be

replaced immediately.

◆ Replacement method of brake block:

1. Confirm the power cutoff of the main motor, and the whole hydraulic system

stops working, and further, the system has no pressure;

2. Confirm the cleanliness of the disassembly mesa, and remove the peripheral

hydraulic pipelines of the disc brake assembly;

3. First, take down eight fixing bolts for fixing the disc brake arrester and the

arrester carrier plate, and integrally extract the disc brake assembly from the lifting

box body;

4. Take down reset spring screw and guide dowel (Fig. 4-5) on the disc brake

arrester by using spanner, take down the old brake block, replace with the new brake

block, and tighten the reset spring screw and the guide dowel;

5. Reinstall the replaced disc brake assembly on the arrester carrier plate, and

recover the installation of the hydraulic pipelines and the joint;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

6. Integrally send the installed disc brake assembly into the installation position

of the lifting box body, tighten the fixing bolts of the arrester carrier plate, and reeve

anti-loosing wire, thereby completing the replacement.

When the brake block of the disc brake arrester generates vertical

asymmetric wear in the use process, the distance between the brake block and

the brake disc can be adjusted by regulating the position of the fixing bolt of the

disc brake arrester on the arrester carrier plate.

Disc brake arrestor

Arrestor carrier

Disc brake arrestor fixing bolt

Arrestor carrier fixing bolt

Fig. 2-11 Exploded view of disc brake assembly

Brake block carrier

Brake block

Reset spring screw

Guide dowel

Fig. 2-12 Disc brake arrester

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-5 Check and maintenance of gooseneck

Union disc (3”-1002)

Every month
Union plug (3”-1002)

Carry out bulge test

Union seal (3”-1002)
on gooseneck with
rated pressure
Female union (3”-1002)

S-pipe

Gooseneck

Every month

Clean gooseneck and S-pipe inner hole,

visually check for indentation, wear or
corrosion (note: use flashlight and mirror for
visual check, and the endoscope is optimal)

If the indentation, wear or

Female union
corrosion exists in the visual (4”-FIG1002)
check, check by ultrasonic flaw

detection

Fig. 2-13 Check and maintenance description of gooseneck

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-6 Check and maintenance of rotating head

Every week
每 周

Check big fluted disc of rotating head and

motor pinion for adequate lubrication.
Big fluted disc
of rotating head
Motor pinion

Seal gland

Bearing nut

Every day Every week

Check anti-loosing clamp Check contact face of seal gland

assembly for looseness and bearing nut for fat effusion.

Fig. 2-14 Check and maintenance description of rotating head

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-7 Check and maintenance of elevator link tilting mechanism

2-7-1 Check and maintenance description of elevator link tilting mechanism

Every day

Check connecting bolt of

supporting plate for looseness

Every day

Check joint of dual padeye of cylinder

block of elevator link tilting oil cylinder,
the end part of piston rod and knuckle
bearing for flexible rotation.

Every day

Check end cover of cylinder block of elevator link

tilting oil cylinder for oil leakage (2 positions)

Every month

Check wear condition of elevator

link lifting lug (4 positions).

Fig. 2-15 Check and maintenance description I of elevator link tilting mechanism

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every day

1. Check U-bolt and nut of elevator

link clamp for looseness.
2. Check forward tilting and
backward tilting angles of elevator
link for conformity with
requirement.

Fig. 2-16 Check and maintenance description II of elevator link tilting mechanism

The looseness of the U-bolt and nut of the elevator link clamp can cause

the change of the forward and backward tilting angles of the elevator link tilting

mechanism and can influence the normal use of equipment, and the service

performance of the elevator link tilting mechanism can be greatly improved by

periodically checking and tightening the U-bolt and nut.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-7-2 Position adjustment description of elevator link clamp

◆ Position adjustment method of

elevator link clamp seat of elevator
link tilting mechansim:
1. Loosen U-bolt and nut of elevator
clamp, check and clean contact face of
elevator link clamp seat and elevator
link;
2. Adjust the center of the elevator link
clamp seat (the center of the padeye hole
of clamp seat) and the bottom of the
upper lug hole of the elevator link to
1170mm, and the extension length of the
oil cylinder is about 1250mm;
3. Retighten U-bolt and nut to complete
adjustment.

Elevator link clamp

The adjusted size is the

reference position size during the
adjustment when the DQ450DBZ
is matched with DH350 elevator
link, and can be adjusted
according to the method as per the
actual condition during field
adjustment. The DH500 elevator
link clamp can be also adjusted as
per the method.

Fig. 2-17 Position adjustment description of elevator link clamp

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Do not operate the whole mechanism during measurement when the

length of the oil cylinder is adjusted in step 3, otherwise, personal injury and

death are caused possibly.

When the rotating pin is installed in step 4, if the hole cannot be aligned,

the position of the elevator link clamp can be properly adjusted for hole

alignment, and the dimensions shows in the figure are reference dimensions only.

2-7-3 Replacement of elevator link tilting oil cylinder

◆ Replacement method of elevator
link tilting oil cylinder:
1. Take down dowel of rotating pin and
washer at end part of piston rod of
elevator link tilting oil cylinder, slightly
knock the end part of the rotating pin,
and draw rotating pin out from the lug
ring of the piston rod;
2. Take down the dowel of rotating pin
Dowel and washer at the dual padeye at the tail
of the cylinder block of the oil cylinder,
slightly knock the end of the rotating pin,
and draw rotating pin out from the lug
hole of the supporting plate;
3. Replace with new oil cylinder, install
rotating pin at dual padeye at tail of
Rotating cylinder block of oil cylinder, and install
pin washer and dowel;
Retainer ring
4. Install retainer ring and rotating pin at
piston rod of oil cylinder, and install
washer and dowel;
Washer 5. Decide whether or not to adjust the
position of elevator link clamp according
to actual condition after the replacement
of the oil cylinder, and adjust the position
as per section 2-7-2 if necessary;
6. Fill lubricating grease for lubricating
from lubricating oil nozzle.

Fig.2-18 Replacement description of elevator link tilting oil cylinder

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-8. Check and maintenance of BOP assembly

2-8-1 Check and maintenance description of BOP assembly

Every day

1. Check shutoff oil cylinder for

leakage
2. Check upper and lower rollers
of oil cylinder for wear and
lubrication
3. Check shutoff sleeve for flexible
action

Every week

Check upper and lower

IBOPs for wear and leakage.

Every day

Check bolt of ring flange of torque

booster for looseness (3 positions)

Every day

Check thread of saver sub for wear

Fig. 2-19 Check and maintenance description of BOP assembly

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-8-2 Check and maintenance description of shutoff sleeve and rocker arm

mechanism of upper IBOP

The DQ450DBZ top drive is provided with shutoff sleeve with two different

structures and corresponding rocker arm mechanism, and its check and maintenance

are similar.

Every week

Check upper cover plate of

shutoff sleeve for wear condition

Every day

Lubrication of rocker arm of

shutoff sleeve of upper IBOP

Every day

Wear condition of rocker arm assembly and flexible rotation of crank

Fig. 2-20 Check and maintenance of upper IBOP shutoff sleeve and rocker arm

mechanism

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every week

Check upper cover plate of shutoff sleeve for wear condition

Every day

Lubrication of upper IBOP

shutoff sleeve rocker arm

Every day

Check rocker arm assembly for wear and crank for flexibility

Fig. 2-21 Check and maintenance of upper IBOP shutoff sleeve and rocker arm

mechanism

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-8-3 Structure and check and maintenance description of upper IBOP

Body

Elastic
retainer ring

Upper ball sat

Ball valve

Liner

Switching
knob
Lower valve
seat

Wavy spring

6-5/8” REG API

Fig. 2-22 Structural drawing of IBOP

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

◆ Use requirements of IBOP for DQ450DBZ top drive:

1. Carry out strength and leakage tests on top drive valve as per table 2-1 before

the lowering to the well, and stabilize pressure for 5 min without leakage;

Table 2-1 Max. working pressure and test pressure (unit: MPa) of IBOP

Max. working Leakage test pressure Strength test

pressure value value pressure value

35 ≥35 70

70 ≥70 105

105 ≥105 157.5

2. Rotate the switch knob by using special spanner before use, and check the ball

valve for flexible and in-position rotation;

3. Test the rotation flexibility extent of the knob by using the special spanner

again after the connection with the top drive, and then, lower to the well;

4. When the well kick or blowout occurs in the well, immediately close the ball

valve of the IBOP;

5. In the normal operation, close the remote IBOP of the top drive before the DP

is broken out, thereby preventing the drilling fluid splashing on the drill floor.

Do not use switching knob of ball valve of IBOP in semi-open

condition, check the opening condition of the IBOP before use, and stop using

and replace it if the incomplete opening and closure occur.

The recommended service life of the IBOP for the top drive is 180
days (continuous working time).

One person uses special spanner to close and open the ball valve of the

IBOP under static pressure easily, if the cocket torque is obviously increased

during the opening or closure under the static pressure in the use process,

replace and repair the parts with obvious damage defect.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Periodically run the IBOP for the top drive in the field use process,

ensure the flexible action and the reliable sealing of the knob of the ball valve,

and run once each week and open and close 3-4 times each time.

2-8-4 Check and maintenance of torque booster

Every day

Check bolt and locking wire for looseness

Bolt disassembled from torque

booster cannot be reinstalled, and

replace with new bolt and tighten it.

Fig.2-23 Check and maintenance description of torque booster

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-9 Check and maintenance of back-up tong

2-9-1 Check and maintenance description of back-up tong

Back-up tong is divided into closed type back-up tong and open type back-up

tong, inspection and maintenance are shown in following drawing.

Every day

Check bolt and locking wire for looseness

Every week

Correct roller's lubrication and wear condition.

Every day

Check sealing face of end cover of tong

body of backup tong for leakage.

Fig. 2-23 Check and maintenance description of back-up tong

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Daily

1. Check bolt and locking steel

wire for looseness;
2. Check nut, washer and safety
pin for looseness.

Weekly

Check abrasion of guide ring,

and whether there is abrasion
for tong body and DP or not.

Daily

Check sealing face of end

cover of back-up tong for
leakage.

Fig. 2-23a Check and maintenance description of back-up tong

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every day Every day

Check guide cover, guide cover Remove mud and dirt in fixed
mounting seat fixing bolt, regulating guide cover and movable guide
rod and nut for looseness.
cover.

Fig. 2-24 Check and maintenance description of back-up tong guidance system

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Daily Daily

Check guide cover, guide cover Remove mud and dirt

mounting seat fixing bolt, in fixed guide cover
regulating rod and nut for and movable guide
looseness. cover.

Fig. 2-24a Check and maintenance description of back-up tong guidance system

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every day

1. Remove mud dirt at tooth

ditch and surface of tong dies;
2. Check tong dies for wear
condition

Fig. 2-25 Check and maintenance description of backup tong jaw assembly

User should clean the dirt on the tong dies every day and check the
jaw assembly for wear condition in the use process, otherwise, the clamping

performance of the backup tong can be influenced.

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-9-2 Replacement description of jaw assembly seat and tong dies

◆Back-up tong includes closed type and open type, when open type one is

used, replacement of jaw assembly seat and jaw assembly shall refer to item

2-9-3.

Fig.2-25 shows the structure of the jaw assembly of the back-up tong, the jaw

assembly of the backup tong of the DQ450DBZ top drive fixes the left and right jaw

assemblies on piston respectively by two fixing bolts, and the piston pushes out the

jaw assembly to complete clamping during work. The jaw assembly comprises jaw

assembly seat and two tong dies fixed on the jaw assembly seat, the upper part is

limited and fixed by two tong die limiting bolt, and lower end is fixed by tong die stop

dog and bolt.

Jaw assembly seat

Tong dies limiting bolt

Piston Tong dies

Jaw assembly
Tong dies stop dog fixing bolt

Fixing bolt

Fig. 2-27 Replacement description of jaw assembly seat and tong dies of back-up tong

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

◆ Replacement method of jaw assembly for DQ450DBZ: take down two

jaw assembly fixing bolts by using inner hexagon spanner, and then take down

the jaw assembly integrally to replace it.

◆ Replacement method of tong dies for DQ450DBZ: take down three

fixing bolts at the lower part of the tong dies stop dog and the tong dies stop dog,

and draw the tong dies out for replacement.

In the operation process, the top drive needs to use different saver subs and jaw

assemblies for cooperative use for drill pipes of different models. Table 9-1 shows the

model description of the DP matched with the saver sub for DQ450DBZ top drive and

jaw assembly.

Table 9-1 Description of DP matched with saver sub for DQ450DBZ top drive

and jaw assembly

Saver sub model Jaw assembly model Clamping range of DP model

(thread spec.) (spec.) backup tong (mm)

DQ005.02.01 DQ004.01.17.00 Φ160-Φ185 5in

(NC50) (4-1/2”)

DQ005.02.07 DQ004.01.18.00 Φ175-Φ195 5-1/2in

(5-1/2FH) (5-1/2”)

DQ005.02.08 DQ005.01.11.00 Φ115-Φ145 3-1/2in

(NC38) (3-1/2”)

2-9-3 Replacement of jaw assembly seat and jaw assembly of open type tong

Clamping system and tong die structure are shown in fig.2-26a, back-up tong

body is divided into front and back tong bodies, pistons are installed respectively in

front and back jaws, tong dies are fixed on the piston by two fixed bolts, and tong dies

are pushed out by the piston to achieve clamping operation during working. Front and

back jaw bodies are connected by two pins, remove one pin, front jaw body can rotate

around the other pin to open jaw body. Tong die comprises tong die seat and two jaw

assemblies fixed on the seat, upper part is limited and fixed by two limited bolts of
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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

jaw assembly, and lower part is fixed by tong die baffle and bolts.

Baffle plate
Pin

Front jaw
Tong die
body

Rear jaw body

Limited bolt of jaw assembly

Piston
Fixed bolt of jaw assembly
Jaw assembly seat
Jaw assembly

Baffle plate of jaw assembly

Fixed bolt

Fig. 2-26a Replacement description of jaw assembly seat and jaw assembly of
back-up tong

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

◆ Replacement of tong die

1. Remove two fixed bolts of baffle plate, remove baffle plate and one pin

connecting front and back jaw bodies, and then rotate front jaw body for 90 degree to

open jaw.

2. Remove two fixed bolts of tong die by internal hexagon spanner, and then

replace tong die wholly.

◆ Replacement of jaw assembly

1. Open jaw as per first step of replacement method of tong die.

2. And then remove three fixed bolts at lower part of jaw assembly baffle and the

jaw assembly baffle, and then replace jaw assembly.

During working, different saver subs and tong dies are needed for different drill

pipes for top drive. Table 9-1a is specification of drill pipes for saver subs and tong

dies

Table 9-1a Specification of drill pipes for saver subs and tong dies

Model of saver sub Model of tong die Clamping range of Model of

Screw thread spec. Spec. back-up tong (mm) assorted drill pipe

DQ005.02.01 DQ004.01.17.00
Φ160-Φ185 4-1/2in /5in
(NC50) (4-1/2＂)

DQ005.02.07 DQ004.01.18.00
Φ175-Φ195 5-1/2in
(5-1/2FH) (5-1/2＂)

DQ005.02.08 DQ005.01.11.00
Φ115-Φ145 3-1/2in
(NC38) (3-1/2＂)

Manual IBOP
DQ004.01.19.00
Remote control Φ185-Φ205
(6-5/8)
IBOP

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-10 Check and maintenance of balancing device

Balance systems with hanging beam and without hanging beam are included into

balance system, its inspection and maintenance are shown in following drawing.

Every month

Check pyriform ring for wear and

crack (2 positions)

Dowel Baffle plate

Pyriform ring

Every month

1. Check pin for installing

pyriform ring on piston rod
of balancing oil cylinder for
wear and baffle plate fixing
bolt for looseness (2
positions).
Split pin
2. Check split pin of pin of
cylinder block for loss (2
positions).

Fig.2-27 Check and maintenance description 1 of balancing device

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Weekly
Yearly

MT for all welds of

Check weld of hanging beam
hanging beam
for crack

Traveling block Baffle plate Hanging beam

Balance oil cylinder

Monthly

1. Check pin for pear-shaped ring on piston rod of balancing

oil cylinder for wear and baffle plate fixing bolt for looseness
(2 positions).
2. Check split pin of cylinder body for missing (2 positions).

Fig.2-27a Check and maintenance description 2 of balancing device

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-11 Check and maintenance of carriage

Every day

1. Check bolt and nut

connecting carriage with
Safety rope
motor base for looseness
and locking wire for good
condition;
2. Check safety rope of
carriage for good condition;
3. Check guide wheel and
bearing wheel for adequate
lubrication.

Every week

Check all guide wheels

and bearing wheels for
wear condition,
asymmetric wear or loss,
and replace immediately if
necessary.

Fig.2-28 Check and maintenance description of carriage

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-12 Check and maintenance of guide rail

Hanger plate
assembly

Guide rail
section V

Guide rail Fixed beam II

section IV

Guide rail
section III

Guide rail
section II

Guide rail
section I

Fixed
beam I

Fig. 2-29 Description of DQ450DBZ top drive guide rail and reverse torque beam

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

2-12-1 Check and maintenance of hanger plate assembly

Every year
Crown block padeye

Magnetic powder inspection for crown

block padeye

Every month

Check weld on crown block padeye

for crack by naked eyes.

Shackle
T(8)-BX30
Every month

Shackle Check split pin for loss (2 positions)

S(6)-BX35

Every month

Check shackle for wear (2 positions)

Hanger plate

Every month

Check lug hole of guide rail hanger

plate for wear condition (2 positions)
Check guide rail hanger plate for crack

Fig. 2-30 Check and maintenance description I of hanger plate assembly

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Fig. 2-31 Shackle and hanger plate lug hole size of hanger plate assembly

Table 2-2 Shackle and hanger plate lug hole size description of hanger plate assembly

d1(mm) d2(mm) d3(mm) R4(mm) R5(mm)

T(8)-BX30 42 41 39 ╳ ╳

S(6)-BX35 60 61 53 ╳ ╳

Hanger plate ╳ ╳ ╳ 80 32

Note: R4 and R5 in table 2-2 are radius dimensions.

The rated load of shackle T(8)-BX30 is 30t, and the rated load of

shackle S(6)-BX35 is 35t.

◆ Operation cautions for shackle:

1. Discard immediately if there is crack when any position of the shackle body

and the pin are observed by naked eyes;

2. Discard immediately when there in crack during magnetic powder inspection

and ultrasonic flaw detection;

3. Discard immediately when the shackle body has obvious deformation and the

pin has deformation and cannot rotate;

4. Discard immediately if the sectional wear extent at any position of the shackle

body and the pin exceeds 10% of the specified size;

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

5. Discard immediately if the shackle body and the pin have large-area corrosion

or rusting.

Every month

Check split pin for loss (4 positions)

Every month

Check shear pin for wear condition

and safety pin for loss (2 positions)

Fig. 2-32 Check and maintenance description II of hanger plate assembly

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2-12-2 Check and maintenance of guide rail main body

Hanger plate assembly

Guide rail section V

Connection manner diagram of guide rail sections (taking

guide rail sections II and III for example):

Guide rail section III

Lock cylinder

Pin

Guide rail section II

Fig. 2-33 Connection description of guide rail sections

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every month

1. Check lug hole of hanging plate for crack;

2. Check connecting lug hole of guide rail for
crack.

Every month

1. Check dowel for wear condition and

shear pin and safety pin for loss (2
positions)

Every year

1. Carry out magnetic powder inspection on

dowel;
2. Carry out magnetic powder inspection on
guide rail connecting dowel hole and hanger
plate connecting lug hole.

Fig. 2-34 Check and maintenance description I of guide rail

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every month

Wear condition of lug hole of

connecting padeye of guide rail
pin (4 positions for each joint)
Every month

Wear condition of pin

Every year

1. Carry out magnetic powder inspection on pin;

2. Carry out magnetic powder inspection on
connecting dual padeye of guide rail connecting
pin and connecting kidney hole position joint.

Fig. 2-35 Check and maintenance description I of guide rail

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2-12 Check and maintenance of reverse torque beam

Every day

Check safety pin for loss

Every day Every year

1. Check DP for location at wellhead center Magnetic powder

2. Check stud nut for looseness (16 positions) inspection for all welds

Fig. 2-36 Check and maintenance description of fixed beam I

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 MAINTENANCE MANUAL OF DQ450DBZ TOP DRIVE

Every month

1. Check all shear pins and

safety pins on fixed beam
II for loss (10 positions);
2. Check fixing bolt and
nut of fixed beam for
looseness (16 positions).

Every year

Magnetic powder
inspection for all welds

Fig. 2-37 Check and maintenance description of fixed beam II

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2-13 Check and maintenance of power drive system

2-13-1 Check and maintenance description of rubber umbrella

Gooseneck bracket

Every month
Washpipe assembly

Check rubber umbrella for

Rubber umbrella wear or corrosion, and
replace it if wear or
corrosion is discovered.

Fig. 2-38 Check and maintenance description of rubber umbrella

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2-13-2 Check and maintenance of main shaft

Every 5 years

Carry out ultrasonic testing on main shaft

Every year

1. Check thread of main shaft and thread of

bearing nut for crack or wear; Carry out
magnetic testing
2. Magnetic powder inspection for groove of
anti-loosing clamp assembly on main shaft

Every 5 years

Carry out ultrasonic testing on

load-carrying nut

Fig. 2-39 Check and maintenance description of main shaft

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2-13-3 Check and maintenance of rotating head

Every 5 years

Carry out ultrasonic testing

on whole rotating head

Every year

1. Carry out magnetic powder inspection on cambered surface area;

2. Carry out ultrasonic flaw detection in 90°range.

Fig. 2-40 Check and maintenance description of rotating head

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2-13-4 Check and maintenance of lifting box body

Every 5 years

Carry out ultrasonic testing on whole

lifting box body

Every 2
year

Carry out ultrasonic flaw detection on annular area

Every year

Check area of lug hole of lifting ring for wear and carry out magnetic
powder inspection

Fig.2-41 Check and maintenance description of lifting box body

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◆ Explanation:

It is suggested to carry out magnetic powder inspection on the external surfaces

of all main bearing components every year (or the top drive works more than 3000

hours), check the external surfaces of the main bearing components for damage or

crack, and replace the main bearing components if above phenomena occur. When the

top drive works five years (more than 15000 hours), carry out magnetic powder

inspection on the integral main bearing components (internal surfaces and external

surfaces), check for damage or crack, and meanwhile, carry out ultrasonic flaw

detection to confirm whether or not the bearing parts have defects inside. The main

bearing components mainly comprise lifting ring, lifting box body, main shaft, lifting

ring shaft and rotating head.

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