ZG103-35S Circulating Manifold of Drilling

Fluid

User's Manual
GH232-SC

Sichuan Honghua Petroleum Equipment Co., Ltd.

August, 2011
 Table of Contents

1. SAFETY WARNINGS ..................................................................................1

2. PURPOSES AND APPLICABILITY............................................................... 1
3 THE STANDARDS...................................................................................... 2
4 TECHNICAL PARAMETERS.........................................................................2
5. WORK FLOW DIAGRAM (FIGURE 3)........................................................ 2
6. BASIC STRUCTURE (FIGURE 2)................................................................3
7. INSTALLATION AND COMMISSIONING ...................................................... 4
8. OPERATION AND REPAIR.......................................................................... 5
9. LUBRICATION .......................................................................................... 6
10. MAINTENANCE......................................................................................6
11. COMMON FAULTS AND TROUBLE-SHOOTING ..........................................7
12. ATTACHED TABLES AND DRAWINGS....................................................... 7

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

1. Safety warnings

� Only trained and qualified persons can install, operate and maintain the mud
pump set with qualification certificates.
� Operators must read related operation manuals before operation and can
operate or maintain equipment after the familiarity with its functions and
operation.
� There shall be a chief principal designated for installation and maintenance,
the persons participating in work shall be assigned with clear work, and
detailed and reliable safety measures shall be available.
� In the operation process, strictly execute its operation specifications and
follow technical safety rules.
� Do not run equipment in the dark except that there are proper lighting
facilities.
� Persons on duty shall wear labor protection articles as required.
� The used lifter and handling equipment must adapt to related weight to be
operated.
� Make sure to release pressure to zero in disconnection of any high pressure
pipelines or hoses. Follow similar procedure during electrical equipment
connection; make sure power is off before maintenance.
� It is forbidden to maintain and repair equipment during its operation.
� Do not overload equipment.

2. Purposes and applicability

ZG103-35S circulating manifold of drilling fluid is an important equipment

of circulating system. It is connected to the position between mud pump and
swivel or top drive, and provides the well bore with HP drilling fluid during
drilling operation. The special operations such as cementing, well killing, cement
plug and reversal circulation etc can also be done when it is connected to
cementing truck, choke line manifold and well killing manifold.

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

3 The standards

SY/T5244 “Drilling fluid circulating manifold”

The 5th,API 7K “Specification for drilling and well servicing equipment”

4 Technical parameters

Bore diameter: 4″
Max. working pressure: 35MPa
Hydraulic strength test: 53 MPa
Applicable temperature: -18°C ~+50°C（with Max. working pressure）
The height of gooseneck: 19m
The length of rotary hose: 23m
Weight: 6728kg
Working medium: clear water, drilling fluid, fracturing fluid and crude oil

5. Work flow diagram (Figure 3)

ZG103-35S drilling fluid circulating manifold can carry out 4 work circulations
during the whole drilling operation.
5.1 During drilling circulation, the HP drilling fluid discharged from mud pump
gets into well bore through ground manifold, standpipe manifold of mast,
rotary hose, and top drive for drilling circulation operation.
5.2 During tripping out, the manifold, via 2″port of the control valve set on the
floor, is connected to well annulus space for mud-fill operation.
5.3 When you carry out well-killing operation, the 2″port of the control valve set
on the floor is connected to kill line, open the 2″control gate valve; the killing
operation can be done by mud pump.
5.4 When the mud pump is used for displacing mud reversely, connect the floor 2″
port to the entrance of wellhead cementing device, the mud pump injects the
mud into the wellhead by the gate valve control to displace the cement in the
well bore.

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

6. Basic structure (Figure 2)

The basic structure of ZG103-35S drilling fluid circulating manifold: it mainly

consists of the ground manifold and single standpipe manifold at mast.
6.1 For the structure and components of single standpipe manifold at mast, please
refer to figure 1:

Fig.1：Single standpipe manifold of mast

1. gooseneck pipe 2. rotary hose ： 23m

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

3. top drive adaptor 4. elbow component

5. hose：4.5m 6.drill floor valve set 7.
pressure gage 8. elbow component 9.
S elbow component
6.2 For the structure and components of ground manifold, please refer to figure 2:

Fig.2：Ground manifold
1.90° bent pipe subassembly 2.S bent pipe subassembly 3. straight pipe subassembly
4. ground valve set 5. 2” union type mud valve gate 6. straight pipe subassembly
7.S bent pipe subassembly 8. straight pipe subassembly 9. hose：4.5m
10. welded male union 11. T-joint assembly 12. female union

7. Installation and commissioning

Installation should be carried out in turn according to installation diagram

(attached drawing 1) and manifold diagram (attached drawing 2):
Install the manifold according to the size requirements of the diagram strictly. First
install the part at the mast and then the part on the ground.
Warning: pay attention to the union trapezoidal thread and sealing
surface during installation, damage is not allowed.
7.1 Grease the union spherical surface, sealing groove and thread slightly with No.2
lithium base grease after clean them with detergent.
7.2 Before lifting the mast, connect and install the manifold supports one by one
reliably according to its diagram; then install mast standpipe manifold, be sure to
align the center of connecting pin on the mast section with the end surface
(locating base) of female union. Install gooseneck first, and then install all parts
on mast. After the gooseneck height and angle be adjusted, tighten their fixing
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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

bolts and install thrust pin finally.

7.3 After the mast being erected, install ground manifold. First install all manifolds of
the substructure base seats and fix the pipe clamp holder preliminarily. When all
connections have been made properly, tighten all pipe fittings.
7.4 After the installation being completed, check if all parts have been installed
reliably, and all installation sizes are in conformity with the requirements. Then
clean the system by blowing air with air compressor to clean the internal of
pipes, clear out eye winker for ensuring smooth passage. Be sure to prevent eye
winker, which may affect the performance of the instruments, getting into the
instruments on cleaning them. So the instruments should be taken off or a blind
plate can be used to plug the passage into instruments.
7.5 Dynamic hydraulic test:
Increase the pressure gradually to 35MPa with clear water step by step
(7MPaeach step) for dynamic hydraulic pressure test. Keep the pressure of every
step for at least 15 minutes; when the pressure reaches 35MPa, keep it for 30min.
It must be qualified if there is no leakage.

8. Operation and repair

8.1 When ZG103-35S drilling fluid circulation manifold is used for mud high pressure
circulation, its operation procedure is as the following (see Figure 3):
⑴When #1 drilling pump is used for drilling fluid circulation on drilling, turn on
the gate valves 2, 3, 4, and turn off the rest gate valves. The same with #2
drilling pump.
⑵When #1 drilling pump and #2 drilling pump are used for drilling fluid
circulation on drilling, turn on the gate valves 1, 2, 3, 4, and turn off the rest
gate valves.

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

Gate
valve
Hose
Steel pipe
Pressure gauge
4

1号泵 No. 1 pump

6
2
2号泵 No. 2 pump

1 5

Fig.3 Working flow chart

8.2 It is simple and convenient to operate ZG103-35S drilling fluid circulating
manifold. You just need to disconnect the union at each connection position when
repair is required. And check union thread, O ring and each part; if the O ring is
damaged, replace it with a new one, then grease connection union thread and tighten
the union. The O ring should be replaced every time when you disassemble the
manifold for ensuring no leakage during operation. It is required to conduct anti-
corrosion treatment after the manifold being operated for a period of time in order to
prolong the manifold’s operating life.

9. Lubrication

9.1 Lubricate mud gate valves according to their manuals.

9.2 Lubricate the connection surface of union with No.2 lithium base grease.

10. Maintenance

10.1 Check if the split pin at each position is damaged at each well completion;
replace it if it is damaged.

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

10.2 Check the corroded status of various pipe fittings every half a year; if there is any
seriously corroded, test its thickness with ultra-sonic device. Replace it timely if the
thickness is less than 15.2mm.
10.3 Clean and grease the whole set of the manifold once every 2 years.
10.4 Pay special attention to the trapezoid thread of each union, and prevent the
sealing surface from being damaged and prevent eye winker getting into pipe.
10.5 Maintain Z63Y-35 mud gate valves according to their manuals.

11. Common faults and trouble-shooting

11.1 Trapezoid thread (union) can not be tightened: check if thread of each female
union (external trapezoid thread) is damaged, repair it with file (file away the bulge)
11.2 Serious vibration: check if any one of adjacent related pipe clamp and holder is
loose, tighten it timely if any.
11.3 Leakage: cut off the drilling fluid source which is concerned with leakage, check
if the union connection is tight, and tighten it as required. Then disconnect the union
connection, check if there are any seal rings damaged or aged. Replace them timely if
any.
11.4 Troubleshooting for mud gate valves should be done according to the manual of
the valve.

12. Attached tables and drawings

� Attached table 1 Recommended spare parts list

� Attached table 2 Spare parts supplied with equipment
� Attached drawing 1 Installation GH232.00
� Attached drawing 2 Manifold GH232.01.00

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

Attached Table 1 Recommended spare parts list

No. Name Spec. Qty. Remarks

For 4″Fig1003
1 O-ring φ145×10 30 pcs
Union
For 4″Fig1002
2 Union sealing ring 4″Fig1002 10 pcs
Union
For 2″Fig1502
3 Union sealing ring 2″Fig1502 4 pcs
Union
Welding metal-to-metal seal
4 ID4" 2 sets
mud gate valve ID4"
Welding metal-to-metal seal
5 ID2" 1 set
mud gate valve ID2"

6 Union type mud valve ID2" ID2" 1 set

7 Welded union 4″Fig1003 5 set 4″Fig1003

8 Welded union 2″Fig1502 2 set 2″Fig1502

9 Welded union 4″Fig1002 3 set 4″Fig1002

Length as per
10 HP hose assembly 4”Fig1002/4.5m/35MPa 1 pc
API 7K

11 Bolt M24×90 GB/T5782 30 grade 8.8

12 Pin: 5×50 GB/T91 30 Q235

13 Nut M24 GB/T6179 30 grade 8.8

14 Washer 24 GB/T97.1 30 grade 200H

15 Bolt M20×40 GB/T5783 10 grade 8.8

16 Washer 20 GB/T93 10 65Mn

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

Attached table 2: Parts supplied with equipment

No. Name Spec. Qty. Remarks

1 O-ring φ145×10 5 For 4″Fig1003 Union

Union sealing
2 4″Fig.1002 5 For 4″Fig1002 Union
ring
Union sealing
3 2″Fig.1502 5 For 2″Fig1502 Union
ring

4 Bolt M24×90 GB/T5782 20 grade 8.8

5 Pin: 5×50 GB/T91 20 Q235

6 Nut M24 GB/T6179 20 grade 8.8

7 Washer 24 GB/T97.1 20 grade 200H

8 Bolt M20×40 GB/T5783 10 grade 8.8

9 Washer 20 GB/T93 10 65Mn

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

Attached drawing 1 Installation GH232.00

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 ZG103-35S CIRCULATING MANIFOLD OF DRILLING FLUID

SN Description Qty.
1 Manifold 1
2 Standpipe Clamp Seat 1 1
3 Clamp 30
4 Bolt 60
5 Nut 60
6 Washer 60
7 Pin 60
8 Standpipe Clamp Seat 2 2
9 Connection plate 1 7
10 Standpipe Clamp Seat 3 4
11 Pin 28
12 Bolt 28
13 Nut 28
14 Washer 28
15 Standpipe Clamp Seat 4 1
16 Connection plate 2 3
17 Standpipe Clamp Seat 5 2
18 Bolt 20
19 Washer 20
20 Connection plate 2
21 Washer 8
22 Bolt 8
23 Ground Seat 2 2
24 Ground clamp seat 14
25 Ground valve set support 1
26 Ground valve set support 1
27 Hose safety device assembly 8

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Attached drawing 2 Manifold GH232.01.00

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SN Description Qty.
1 Gooseneck 1
2 Rotary hose 1
3 Top drive adaptor 1
4 Straight pipe assembly 1
5 Hose 3
6 Drill floor valve set 1
7 Straight pipe 1
8 S-pipe 1
9 90° S-pipe 1
10 S-pipe 1
11 Straight pipe 1
12 Ground valve set 1
13 S-pipe 1
14 Straight pipe 1
15 Straight pipe 1
16 Union flange 2
17 Welded male union 2
18 Female union plug 2
19 Union flange：2″Fig1502 1
20 Male union plug：2″Fig1502 1
21 Dual-scale shockproof pressure gauge 1
22 Union type mud valve 2
23 T-joint 2
24 Female union plug 2

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编制：

校核：

审定：

2011 年 8 月 23 日

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