Pneumatic Control System of ZJ40DBT

Drilling Rig

User's Manual
ZJ325.51-SC

Sichuan Honghua Petroleum Equipment Co., Ltd.

August, 2011

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（注：本页不发给用户，仅作公司存档用）

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 Foreword

ZJ325.51.00 pneumatic control system is one of the main supporting

components of ZJ40DBT drilling rig, is designed and manufactured as per
users' requirements of related API specifications, and can meet the requirement
on supporting ZJ70LDB drilling rig.
In order to make users use this pneumatic control system better, we make
User's Manual of ZJ325.51.00 Pneumatic Control System. This user's manual
generally describes the technical parameters, the working principle, the
maintenance and the repair of the pneumatic control system. Operators must
read this manual carefully before installation and operation.
There is a recommended spare parts list attached to this manual as a
reference for users ordering spare parts.

Contact information:
Sichuan Honghua Petroleum Equipment Co., Ltd.
Address: South section 2, Zhongshan Road, Guanghan, Sichuan
Postal code: 618300
Telephone:
Fax:
Website:
After service telephone:
Telephone of home marketing department:
Telephone of aboard marketing department:

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 Contents

warnings........................................................................................ 1
1 Safety warnings
General....................................................................................................... 1
2 General
components......................................................................1
3. Purposes and components
Purpose.................................................................................................... 1
3.1 Purpose
Components............................................................................................ 1
3.2 Components
parameters...............................................................................2
4 Technical parameters
commissioning............................................................ 2
5 Installation and commissioning
Installation............................................................................................. 2
5.1 Installation
Commissioning...................................................................................... 3
5.2 Commissioning
Lubrication................................................................................................ 6
6 Lubrication
system......................................... 6
7. Maintenance of pneumatic control system
7.1 Cautions for maintenance of pneumatic control syste
systemm .............. 6
maintenance................................................................................ 7
7.2 Daily maintenance
maintenance........................................................................... 8
7.3 Periodic maintenance
troubleshooting............................................... 9
8 Common troubles and troubleshooting
list............................................................. 11
9 Recommended spare parts list
9.1 Recommended one year spare parts list for pneumatic
control cabin valves
valves................................................................................... 11
9.2 Recommended one year spare parts list for peripheral
valves
valves............................................................................................................ 11
10 Attached drawing
drawing................................................................................. 13

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG

1 Safety warnings

1.1 Only trained and qualified persons can install, operate and maintain the
pneumatic control system with qualification certificates.
1.2 The main personnel engaged in installation, operation and repair shall have
corresponding experiences and experience.
1.3 There shall be a general principal and a principal for work division assigned
for installation, operation and repair.
1.4 Persons on duty shall wear labor protection articles as required.
1.5 In the operation process, strictly execute the operation specifications of all
equipment and follow the technical safety rules.

2 General

Pneumatic control technique of drilling rig uses compressed air as a

working medium for transferring power or signal, cooperates with main
pneumatic elements of a pneumatic control system and forms a loop with part or
all of mechanical, hydraulic, electric, electronic (including PLC controller and
microcomputer) etc, thereby achieving needed action control.

3. Purposes and components

3.1 Purpose

The pneumatic control system of drilling rig mainly has the following
purposes:
Startup and stop of power package;
Braking of Rtbrakeclutch, engagement and unengagement
Collision electric protection of traveling block and positive and reverse
rotation control of swivel etc.

3.2 Components

It mainly comprises the following components:

Air supply system: air compressor and air supply processing unit;

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
Control components: including all valves and sensors;
Air accessories: including all air supply pipelines and connecting valves.
Actuating mechanism: including pneumatic clutch, pneumatic winch,
swivel and pneumatic motor etc.

4 Technical parameters

Max. working pressure of system 1MPa

Max. working pressure 0.8MPa
Max. working pressure 0.65 MPa
Working media: Compressed air after filtering

5 Installation and commissioning

5.1 Installation

5.1.1 Make sure that power and air-supply house, mast (cantilever mast),
substructure, drawworks and driller's control cabin are installed in place or not.
5.1.2 Connect all parts with the rubber tubes supplied and according to the
pneumatic control system schematic diagram and the installation drawings for
drill floor airlines. The connecting sequences of the rubber tubes shall follow
that ground equipment first and then equipment of drill floor; the main airlines
first and then control airlines. The detailed installation sequences are shown in
the following picture:

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
DW

DW pneumatic
control box
HPU

DW
Drill floor pneumatic
Air Cable cylinder control box
source trough
room

Diesel Left air Ri St ai H Swive R

motor wench gh an r yd l T
t d- w ra
ai by en ul
r po ch ic
w rt to
en ng
ch

Note：The dotted line as shown in the picture indicates connections for the
Note
control airlines.

5.2 Commissioning

5.2.1 Preparation for debugging

5.2.1.1 Make sure that the compressors, dryers in the power and air-source
house and all electromagnet- valves in the driller's control cabin are properly
powered or not.
5.2.1.2 Start one of compressors and dryers and charge the air tank in the air-
source house and the air tank hung under the drill floor.
Note: The pressure of the relief valve installed on the air tank has already
been set before it leaves the factory and it is strictly forbidden to reset unless
some special circumstances.
5.2.1.3 When the pressure of the air tank is up to 1Mpa, engage all clutches; and
the pressure drop in pipelines shall not be more than 0.10Mpa within 30 minutes.
5.2.1.4 Coordinate with driller and check the following items:
Item Contents to check
Auto-bit-feed drilling All bolts are complete and tightened.

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
Air swivel joint and pipelines have no leakages; and
air release valve is agile and reliable.
2-position 3-way pneumatic control valve and
pipelines have no leakage, and air release valve is
rig clutch agile and reliable
Friction blocks have no abnormal worn, damaged or
lost etc.
Air tube is in good condition and without oil-
contaminates.
All bolts are complete and tightened.
Air control valve (two-position, three-way) and
pipelines have no leakage; and air release valve is
agile and reliable.
Rotary table brake
Friction blocks have no abnormal worn, damaged or
lost etc.
Air tube is in good condition and without oil-
contaminates.
Its’ actions shall be agile and reliable and it has no
Toggle valve
leakage.
All pipelines are connected well and have no
leakages; and the ‘valve terminal’ acts sensitively.
Pneumatic control Whether the adjustable pressure switch has
cabinet electrical signal output or not at setting value and
display of pressure sensor signal is correct or no
System pressure is 0.65～0.8MPa
5.2.2 Debugging
5.2.2.1 Confirm input air source of pneumatic control box has already connected;
switch valve of bigeminy input is open.
5.2.2.2 Rise up the turn-knob of pressure-relief valve on the 3 in 1 unit and
watch pressure gauge; rotate the turn-knob anticlockwise and press it down
when the gauge pressure is up to 0.8 Mpa, and finally lock up the set pressure.
5.2.2.3 Observe the air-source pressure on the touch screen, if it does not

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
correspond with the actual pressure, it must be adjusted by multiplying a factor
on the basis of the gauge pressure.
5.2.2.4 Click the pneumatic control button on the touch screen, the solenoid of
the corresponding pneumatic control is powered; various functions shall be
adjusted one by one on the touch screen "hyd & air control" interface.
5.2.2.4.1 Click the “automatic bit-feed” button, and indicating the automatic bit-
feed clutch on the touch screen has been engaged. At this time, the ‘rotary table
brake’ button will not function when clicked.
5.2.2.4.2 Start RT motor (without rotary speed), RT brake in pneumatic control
is powered, relieve RT brake; preset rotary speed to RT, RT starts to run, click
“RT brake” button, RT stops running, “auto bit feed” button is not working now.
5.2.2.4.3 Start the rotary table and cut off the power supply to the motor, the
motor will stop running, and at this time, the ‘rotary table clutch’ can
automatically stop the rotate table.
5.2.2.4.4 When the touch screen is at the status of ‘drilling’, turn the drawworks’
crown protector toggle valve, the drawworks motor will stop running; the
drawworks’ drum is braked through the hydraulic disk brake, at the same time
the indicator lamps of “over wind valve” and “drum brake” on the status bar of
the touch screen are lighted; reset the toggle valve and press the ‘brake air
release ’ button several times, the indicator lamps of “over wind valve” and
“drum brake” will automatically go out.
5.2.2.4.5 When the touch screen is at the position of ‘automatic bit-feed’, repeat
the actions as mentioned above. At this time, the “automatic bit-feed” will stop
running. Other functions are the same as above-mentioned.
5.2.2.4.6 When the touch screen is at the position of ‘drilling’ or ‘automatic bit-
feed’, cut off the power supply to the motors of drawwork and automatic bit-
feed separately, the hydraulic disk brake will be actuated and stop the draw
work’s drum. The indicator lamp of ‘drum brake’ in the status bar on the touch
screen is illuminated.
5.2.2.4.7 If click ‘forward-reverse ’ control button and click the ‘swivel spinner’
on/off button again, the Swivel will start rotating counter clockwise.
5.2.2.4.8 Click the ‘horn’ knob, the horn will sound.
5.2.2.4.9 Adjust reducing valve in pneumatic control cabin until pressure is

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
lower than 0.65MPa, touch screen displays low-pressure alarm, and drum brakes.

6 Lubrication

Pneumatic working medium is compressed air, air doesn’t have lubricity

and always have moisture. So, lubrication is needed.
Lubracation of pneumatic control mainly use fog lubrication, which mix
fog atomized by lubricators and compressed air, and then sent to pneumatic
control system.
Because FESTO pneumatic control valve parts have self-lubricating
function, it's not necessary to lubricate in additional.
Lubricators lubrication is required except FESTO valve parts (mainly are
pneumatic DW, pneumatic motor of swivel), lubricating oil is 10＃ automobile
oil.
Oil consumption of pneumatic control system is usually 1 drop/1000L.

7. Maintenance of pneumatic control system

7.1 Cautions for maintenance of pneumatic control system

7.1.1 Prevention of the loss of compressed air.

For ensuring the normal work of pneumatic control system, provide a
certain flow of compressed air under certain pressure, otherwise, the accidents
of action fault or insufficient force etc may be caused.
For reducing air leakage, it must pay attention to the seal of all pneumatic
control components and pipeline joints.
7.1.2 Pay attention to cleaning of pipelines
If there are dirt and impurities entering air pipes, valves will go wrong, and
in the assembly and disassembly of pipelines, prevent dirt and impurities from
entering air pipes.
When pneumatic control valves go wrong, analyze reasons carefully.
There are many reasons for failure of pneumatic control valves, sometime
the pneumatic control valves are good, but air pipelines are blocked or air
pressure is too low. Therefore, check section by section. Check method: firstly

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
check control valve, control pipelines and actuating valves, open air joints
section by section, check for air smoothness, if air is not smooth, check the air
inlet pipelines of the valves for smoothness, if the air is smooth, the valve goes
wrong, replace with standby valve, and check the replaced valve.
The pneumatic control valves (particularly the pneumatic control valves
mounted in control cabin) are good in working condition during continuous
working period but suddenly go wrong after being not used for a few days. That
is because the valve chamber generates scale when being not used, the resistance
of the rotating part of the valve is increased, and then the valve goes wrong and
leaks air. In this case, completely plug the air vent of the pneumatic control
valve, if no air is exhausted, the pneumatic control valve is rusted, and the valve
can work normally after repeatedly rotating the valve core for several times. If
the valve leaks air continuously, open and check the valve.

7.2 Daily maintenance

The main task of daily maintenance work is to discharge condensate water,

check lubrication oil and manage air compressor system. The discharge of
condensate water relates to the whole pneumatic control system, from air
compressor, air tank and pipeline system to air filter, dryer and automatic water
discharger etc. After finishing work, discharge condensate water at all positions
to prevent the condensate water from icing as the temperature at night is lower
than 0 DEG C. As the temperature in pipe at night decreases, condensate water
can be further separated out. Therefore, before running pneumatic devices every
day, discharge condensate water. Pay attention to observing the automatic water
discharger for normal working, and water in water cup cannot be excessive.
When pneumatic device runs, check the oil drop amount of oil sprayer for
conformity with requirements and oil color for normality, namely, dust and
water etc cannot be mixed in oil.
The daily management work of air compressor system is to check air
compressor for abnormal sound and abnormal heat generation, lubrication oil
level for normality and air compressor for automatic startup and stop
performances.

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
7.3 Periodic maintenance

The weekly maintenance work is to check oil leakage and manage oil
sprayer, aiming at discover symptom of accidents. Air leakage can be checked
after machine is stopped. Immediately treat the places which leak air seriously,
such as cracked hose and seriously loose joint etc. Record other places leaking
air. The leakage reasons are listed in following table. When supplementing oil to
oil sprayer, pay attention to the reduction of oil amount. If oil consumption is
less, readjust the oil drop amount. If the oil consumption is still less or oil is not
full after adjustment, check oil passage of oil sprayer for blockage.

Leakage positions Leakage reasons

Joints of pipe and pipe
connector
Hose
Water drain valve of filter
Water cup of filter
Reversing valve body
Loose joint and connector
Hose is cracked or pulled off
Embedding of dust
Water cup cracks.
Unfavorable sealing and loosen screw

The monthly or quarterly maintenance work shall be more careful than the
daily and weekly maintenance work, but is also limited in the range that the
external parts can be checked. The main contents comprise: check leakage
conditions at all positions, loose screw and pipe joint, check the air discharged
from reversing valve for quality, check all adjusting parts for flexibility, check
the indicator for correctness, check the switching action of electromagnetic
valve for reliability and the contents which can be checked externally.
See maintenance work in following table for details.
Elements Maintenance contents
Observe whether the values of all pressure gauges in
Pressure gauge
specified range or not.
Enable pressure to be higher than set pressure, observe
Safety valve
whether the safety valve works or not.
Air outlet of reve Check for oil fog displacement, condensate water discharge

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
rsing valve and air leakage.
Electromagnetic Check magnetic coil for temperature rise and switching
valve action of valve for normality.
Air compressor Check mesh of suction filter for blockage.
In air leakage check, coat soap solution at checked places, as the effect of
displaying air leakages is more sensitive than listening of sound.
Pay attention to the following three aspects while checking the air
discharged from the reversing valve for quality:
Know whether lubrication oil amount contained in discharged air is proper
or not by the method of placing clean white paper near air outlet of reversing
valve, and it indicates that the lubrication is favorable if light spots are on the
white paper after the valve works for three to four circles.
Know whether the discharged air contains condensate water or not.
Know whether the air outlet which cannot leak air leaks air. A little leakage
means early damage of components.
If lubrication is unfavorable, consider whether the oil drop amount of oil
sprayer is adjusted reasonably and the management method accords with
requirement or not. If there is condensate water discharged, consider whether
management of condensate water accords with requirement or not. The main
reason for leakage is the unfavorable seal in valves, rusting and breakage of
return spring and insufficient air pressure.
As safety valve is used seldom, in periodic check, make ensure its reliable
action.

8 Common troubles and troubleshooting

Trouble phenomenon Reasons Troubleshooting

No response while Press down power start
operating change- No power button on power
over switch and switching cabinet
clutch

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG
Open main air supply
Main air supply switch switch (air supply start
is not opened. valve) in pneumatic
control box
Too low pressure of
Increase air pressure
compressed air
Clean pipeline after
Pipeline blockage
check
No response in control Repeatedly rotate valve
of two-position three- core for several times,
way pneumatic control otherwise repair or
vale of clutch replace air relay
Wrong connection of Correct connection
control pipe method of control pipe.
Loose connecting wire
Rewire
of circuit
Damaged magnetic coil Replace magnetic coil
Release action of toggle
valve and press brake
Toggle valve had worked.
discharge button to
discharge air
Damaged quick relief Repair or replace quick
valve relief valve
Damaged pneumatic Repair or replace
control valve pneumatic control valve
Damaged Replace electromagnetic
electromagnetic valve valve

9 Recommended spare parts list

9.1 R ecommended one year spare parts list for pneumatic control cabin
valves

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG

Recommended two year spare parts list for DW pneumatic control cabin

No. Model/code Description Qty.

1 QSL-1/2-12 Plug-in joint 8
3 in 1 air supply treatment
2 FRC-1/2-D-MIDI-A device 2
3 KD5-1/2-I,KS5-1/2-I Quick-change connector 6
4 QSSF-1/2-12 Bulkhead joint 2
5 SDET-22T-D10-G14-I-M12 Ex-proof pressure sensor 2
6 SIE-WD-TR L type connection seat (EXP) 2
7 QSL-1/4-10 Plug-in joint 24
8 QSK-1/4-10 Self-sealing quick joint 6
9 PEV-1/4-B－EEX EX-proof pressure switch 4
Two-position three-way ex-
10 MFH-3-1/4－MSFG-24-EEX proof solenoid valve 10
11 OS-1/4-B Shuttle valve 2
Normally open pneumatic
12 VL/O-3-1/4 control valve 2
13 QSSF-1/4-10 Bulkhead joint 10
14 KD3-1/4-A,KS3-1/4-I Quick-change connector 14

9.2 R ecommended one year spare parts list for peripheral valves

Recommended two year spare parts list for peripheral pneumatic components
No. Model/code Description Qty.
1 CL1-24V DC (R412000144) Coil 6
CD12-3/2NC-G012-N0NE Open explosion-proof
2 2
(5724555202) solenoid valves(1/2")
3 QY32A.00 Quick release valve 4
CD07-3/2NC-G014-NONE Closed explosion-proof
4 4
(5772075302) solenoid valves(1/4")
Normally closed pneumatic
5 QY22 2
control valve
6 Q11F-16 Stainless steel ball valve: 2'' 10
7 QSLd-L50 Filter 2
8 Q11F-16 Stainless steel ball valve: 1'' 2
9 Q11F-16 Stainless steel ball valve: 11/ 10

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 PNEUMATIC CONTROL SYSTEM OF ZJ40DBT DRILLING RIG

2"
10 Straight joint 2" 8
Inner joint with different
11 2
diameter: 2"/1/2"
12 Straight joint 1/2" 2
13 Straight joint 1 1/2" 2

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10 Attached drawing

Attached drawing 1: Schematic diagram

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SN Description Qty.
1 Pre-filter 1
2 Post-filter 1
3 Ball valve 30
4 Ball valve 2
5 Ball valve 7
6 Connector 4
7 3 in 1 air source treatment device 2
8 Filter installation frame 2
9 Quick connector 4
10 Clapboard connector 4
11 Connection hose 1
12 L connection socket（EXP） 1
13 EXP pressure sensor 1
14 Plug 1
15 Air dividing block 1
16 Connection hose 1
17 Connector 12
18 Self-sealing quick release joint 3
19 Electromagnetic valve frame 1
20 EXP pressure switch 2
21 Connction bolt 6
22 Air horn 1
23 Shuttle valve 1
24 Pneumatic Control Box 1
25 Two-position three-way electromagnetic valve（EXP） 3
26 Quick connector 9
27 Clapboard connector 9
28 Anti-crush valve of crown block 1
29 Normal close electromagnetic valve(1/4") 3
30 Normally open air control valve 1
31 Quick Release Valve 4
32 Crown-O-Matic 1
33 Single direction air guide bibcock 1
34 Normally closed pneumatic valve 1

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Attached drawing 2: Pipe layout drawing

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SN Description Qty.
1 Hose 1
2 Hose 1
3 Ball valve 2
4 Ball valve 4
5 Hose 1
6 Air manifold left 1
7 Pneumatic control pipe layout drawing of DW 1
8 Hose 1
9 Check valve 2
10 T-joint 1
11 Hose 1
12 Hose 1
13 T-joint 1
14 Hose 2
15 Steel pipe 1
16 45°elbow 3
17 Hose 5
18 Hose 1
19 Hose 2
20 Ball valve 10
21 Hose 1
22 Air manifold right 1
23 Hose 1
24 Pneumatic pipe layout drawing of mast 1
25 Steel pipe 1
26 45°elbow 2
27 Hose 2
28 Ball valve 7
29 Hose 1
30 Flow diagram of pneumatic control 1

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Attached drawing 3: Pipe layout drawing of mast

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SN Description Qty.
1 Hose 1
2 Elbow 7
3 Stainless steel ball valve 6
4 Inner connector 3
5 Lubricators 2
6 Elbow 2
7 Hose 1
8 Elbow 3
9 Hose 1
10 Seamless steel tube 1
11 Inner connector 4
12 Straight joint 4
13 Seamless steel tube 1
14 Seamless steel tube 1
15 T joint 2
16 Reducing female joint 1
17 Stainless steel ball valve 1
18 Inner connector 5
19 Straight joint 6
20 Pipe clamp 9
21 Pipe clamp 6
22 Adjustable joint 1
23 Adjustable joint 1
24 Pipe clamp 18
25 Adjustable joint 1
26 135\U+00B0 Elbow 1

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Attached drawing 2: Pipe layout drawing of DW

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SN Name Qty.
1 Hose 1
2 Adaptor 1
3 Clapboard connector 3
4 Quick release joint 3
5 Hose 2
6 Quick release joint 1
7 Clapboard connector 1
8 Pipe clamp 3
9 Cooper pipe 1
10 Round steel pipe 1
11 Hose 2
12 Hose 12
13 Hose 1
14 Installation frame of pneumatic control box 1
15 Ai horn 1
16 Clapboard angle coupling 10
17 T-joint 4
18 Inside and outside connector 2
19 Hose 3
20 Straight joint 16
21 T-joint 3
22 Straight joint 6
23 Cooper pipe 1

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