TC450-7 Crown Block

INSTRUCTION MANUAL
AA450104-00SM

Sep., 2007
 Preface

TC450-7 Crown block, the important match component of drilling rig, is

designed for land/offshore drilling rig and installed on the mast of drilling rig,
services for tripping in & tripping out drill stem pole, and casing during drilling
operation together with traveling block, drawworks and hook.

TC450-7 crown block is designed and manufactured according to API SPEC

4F and API SPEC 8A.

This manual introduces structure、 technical parameters、 operation and

maintenance of crown block in order that the operators can know well and
master the use method of crown block. The details of relative document about
structure parameter of complete equipments (or components) and
maintenance when using can be found in the instruction manual (see details in
other matched equipments manuals and relative documents of drilling rig).

Before using ， all managers, technicians and operators must study the
complete operation manual and related technical documents for knowing well
all details. In addition, they must have safety operation techniques. All
operation should be done according to HSE requirements.

All administrative work and specific operation should be carried out according
to requirement of regulations of this system and department.
 CONTENT
1. General ..................................................................................................................1

1.1 Simple introduction .......................................................................................1

1.2 Technical Parameters ...................................................................................1

2. Structure instruction .............................................................................................3

2.1 Crown block frame ........................................................................................4

2.2 Main sheave assembly.................................................................................4
2.3 Guide sheave assembly...............................................................................4
2.4 Sand sheave assembly ................................................................................4
2.5 Auxiliary sheave assembly ..........................................................................4
2.6 Crown block crane........................................................................................4
2.7 Top drive lifting eye .......................................................................................5
2.8 Crown block saver ........................................................................................5

3. Repair and maintenance .....................................................................................5

3.1 The maintenance check before working: ..................................................5

3.2 The maintenance check during the operation:.........................................6

4. Installation .............................................................................................................7

5. Transportation and Storage ................................................................................8

5.1 Transportation ...............................................................................................8

5.2 Storage ...........................................................................................................8

6. Bearings List .........................................................................................................8

1. General

TC450-7 Crown block is an important matched component of drilling rig, which

services for tripping in & tripping out drill stem pole, and casing during drilling
operation together with traveling block, drawworks and hook.

1.1 Simple introduction

Crown block is a pulley assembly fixed on the top of the mast. Through the
wire line, it is connected with traveling block and make up of the hoisting
system of the drilling rig. It bears the Max. Hook load, the pull of fast line and
dead line; then transfers these loads to mast and substructure. Because the
more the number of line is, the less the pull of the fast line is, which will relieve
the load of drawworks during the drilling operations (tripping in and tripping out,
casing and drilling, hanging drilling tool) and reduce the allocated power of
engine set. Crown block frame is welded together by high-quality structural
steel. Crown block and its main shaft are designed to meet the requirements of
API 4F Specification; the main sheaves and bearing are designed to meet the
requirements of API 8F Specification. See fig.1 for Crown block details and
table 1 for crown block parts list.

1.2 Technical Parameters

1. Model TC450-7
2. Rated hook load 4500kN (500Us tons)
3. Wireline diameter Ф38mm (1 1/2 in)
4. OD of sheave Ф1524 mm (60 in)
5. OD of guide sheave Ф1524 mm (60 in)
6. Primary sheaves number 6 sets
7. Guide sheaves number 1 set
8. OD of sand sheave Φ762mm (30 in)
9. Sand sheaves number 1 set
10. Sand sheave wireline diameter Φ14.5mm (9/16 in)

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 11. Max. Load of crane 49kN
12. OD of auxiliary sheave Φ400mm (15 5/8 in)
13. Auxiliary sheaves Number 4 pieces
14. Wireline diameter of Aux. sheave Φ19mm (3/4 in)
15. Overall dimensions (LxWxH) 3410mmx2753mmx2938mm
16. Theoretical weight 11012kg
17. Mast model JJ450/45-K mast

Fig.1 TC450-7 Crown Block

Table 1 Parts list of TC450-7 crown block

Parts list of TC450-7 crown block Drawing No.: AA19009-00
ERP: AA45010400
Item Drawing No. ERP Code Name Qty. Material Note
1 AA19009-01.00 AA4501040100 Crane 1
2 AA19009-02.00 AA4501040200 Safe guard 1
3 AA19009-03 AA4501040300 Jumper frame 1
4 AA19009-04 AA4501040400 Jumper frame 1

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5 AA19009-05.00 AA4501040500 Crown block frame 4
6 AA19009-06 AA45010406 Name plate 1
7 AA19009-07 AA4501040700 Support 1
8 AA19009-08 AA4501040800 Support 1
9 AA19009-09.00 AA4501040900 Enclosing 1
10 AA19007-01.00 AA4501020100 Guide sheave Assy. 1
11 AA18007-01.00 AA3151030100 Crown block saver 1
12 AA18006-05A.00 AA3151020500 Jumper frame 2
13 AA19007-02.00 AA4501020200 Main sheave Assy. 1
14 T203-001.00 Auxiliary sheave Assy. 4
15 T206-001.00 Sand sheave assy 1
16 T206-002.00 Jumper frame 1
17 GB6170-86 Nut M24 20

18 GB6172-86 Thin nut M24 20

19 GB5782-86 Bolt M24×110 12

20 GB5782-86 Bolt M18×35 8

21 GB93-87 Spring washer 18 8

22 GB847-85 Self-threading screw 4

ST3.5X13-C-H
23 GB5782-86 Bolt M24×130 8

24 T43-02 Mini pin 16

25 GB5782-86 Bolt M12×35 4

26 GB5782-86 Spring washer 12 4

2. Structure instruction

TC450-7 crown block mainly consists of crown frame, primary sheave

assembly, guide sheave assembly, sand sheave assembly, auxiliary sheave
assembly, crane, crown block saver, jumper frame, enclosing and etc.

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2.1 Crown block frame

Crown block frame adopts integral welded structure. Primary sheave shaft seat,
guide sheave shaft seat and sand sheave assembly on the top of crown frame
are respectively connected with bolts. The lower of crown frame is connected
to the mast with M30 bolts.

2.2 Main sheave assembly

Main sheave assembly consists of main shaft, support seat, 6 sheaves,

bearings, and so on. There is a pair of bearings in each of the sheaves. At the
end of the bearing an M10x1 nozzle is fitted to inject lubricating grease into
bearings easily. Outside rim of sheave there is jumper frame which can avoid
wireline jumping from sheave groove. Safe guard is installed on main sheave.

2.3 Guide sheave assembly

Guide sheave assembly consists of sheave shaft, support seat, sheave,

bearings, and so on. At the end of shaft is fitted with M10x1 nozzle in order to
add grease into bearings freely. Pin is installed in sheave frame to avoid
wireline jumping from sheave groove.

2.4 Sand sheave assembly

Sand sheave assembly consists of sheave shaft, support seat, sheaves,
bearings, and so on. At the end of shaft there is an M10x1 nozzle to inject
grease easily into bearings. Pin is installed in sheave frame to avoid wireline
jumping from sheave groove.
2.5 Auxiliary sheave assembly

Four sets of auxiliary sheave assembly are installed in crown block, at the end
of sheave shaft there is an M10x1 nozzle. Auxiliary sheave assembly can be
used by two air winches to derrick up weight, drill pipe and to hang the
hydraulic tong.

2.6 Crown block crane

Crown block crane is used to repair the crown block. Crown block crane is a

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kind of girder construction. Its maximum load is 49KN, which can hoist the
heaviest part of crown block (main sheave assembly). Details see fig. 2.

Fig. 2 Girder construction crown block crane

1-Left frame; 2-Top frame; 3-Rear frame; 4-Pin; 5-Right frame;

6-Support seat; 7-Pin; 8-Mini pin; 9-Bolt; 10-Nut; 11-Thin nut;
12-Cotter pin; 13- 5t hand monorail trolley

2.7 Top drive lifting eye

On Crown block it is equipped with lifting eye installing beam of top drive rail.
This lifting eye is fit for Varco TDS-11SA top drive.

2.8 Crown block saver

Crown block saver below crown block beam plays a buffer part when traveling
block clashes crown block.

3. Repair and maintenance

3.1 The maintenance check before working:

In order to ensure crown block can work smoothly for a long time, the operator

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should maintain it correctly and in time. All the failures must be eliminated
before installing. Check as follows before crown block starts to work:

1) All the connection must be fixed well and no loose.

2) Rotation of each sheave should be flexible and no block. When rotating

one sheave, the adjacent should not rotate with it.

3) Each sheave shaft should be injected grease periodically and be

checked lubrication nozzle and grease way to ensure they are clear.
Each sheave bearing should be injected ZL-3 lithium lubrication grease
(SY1412-75) twice every week.

4) Temperature rising of all sheave bearings should be not more than 40℃;
the highest temperature is not more than 70℃; and meanwhile perform
normally with out abnormal noise.

5) Check if each jumper frame is damaged and bent.

3.2 The maintenance check during the operation:

1) According to the requirements of lubrication, add lubricating grease on

schedule.

2) Change the lubricating grease and find out the reason if the
temperature rising of all sheave bearings is 40℃ more than the
surrounding’ s.

3) During long service, especially in the circumstance of bad lubrication,

bearing of sheave would make noise and make sheave vibrate because
of enlarged clearance and wearing, which will reduce service life of
wireline, so worn bearing should be replaced in time in order to avoid
accidents.

4) Change the sheaves in time and it is strictly forbid to continue using if

there is any crack or defection.

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 5) Check often wearing of sheave groove and details see table 2. Shape of
sheave groove has a great effect on the life of wireline and should be
measured with the template at regular intervals. Manufacture and use of
the template is according to API Spec. 8A and RP 9B.

Table 2 Radius of sheave groove bottom

Wireline Size of groove bottom template

Nominal Min. radius of Max. radius of Min. radius of
Diameter new groove groove bottom
worn groove
bottom
bottom

38 mm (1 1/2) 20.19mm 20.96mm * 19.53mm

Note：The sheave worn to this size is bad for the use of wireline. The sheave
groove should be updated or repaired (details see Fig. A and B).

Fig. A Fig. B
Fig. A: Sheave groove has been worn to the allowable minimum Radius.
Fig. B: Severe worn sheave groove

4. Installation

Installation of wireline between crown block and traveling block adopts method
of reeving uncross.

Crown block frame and mast should be connected with 30M bolts. To ensure
the normal performance of crown block, please keep the crown frame bottom
be horizontal and make the crown block center align with the mast center, and
then connect them with bolts.

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5. Transportation and Storage

5.1 Transportation

1) Crown block is shipped as a whole and nude packing. The crane frame,
auxiliary sheaves, and other components of crown block should be
attached tightly before shipping. Pins of crane frame and mini pins are
packed in boxes.

2) When lifting, use the crane hang four lifting eyes on crown block beam.

Attention: Dragging crown block is not permitted when being transportation.

5.2 Storage

1) Before storing, clean the product surface, coat the sheave grooves with
the lubricating grease, each bearing should be injected grease. Crown block
should be covered completely with oilskin.

2) The whole crown block must be stored in the dry, ventilating and no
corrosive warehouse.

6. Bearings List

Bearings for crown block see table 3

Table 3 Bearings list for crown block

Name Code Specification (mm) Qty (pcs/set)

Primary sheave block L357049/L357010D Φ304.8×Φ393.7×107. 6

(37961K) 95 1
Guide sheave block

Sand sheave block 42238 Φ190×Φ340×55 2

Auxiliary sheave block 42316 Φ80×Φ170×39 8