Top Drive Drilling Equipment

HSE Manual
Model： DQ40BC
Serial No： 06027

Beijing Petroleum Machinery Factory

January 2006
 Top Drive Drilling Equipment

HSE Manual
Model： DQ40BC
Serial No： 06027

The technical and patent information covered in this manual is forbidden used as manufacture without
permission

Any company or individual can not pirate or copy this document without any permission or authorization

Original Documents
 Preface

Top drive drilling equipment (hereinafter referred to as Top Drive) is a piece of new oil drill
equipment in the place of rotary boring.

Top drive is a piece of complex equipment integrating mechanical, electrical, hydraulic and
information features, operating with a voltage of 600VAC and high pressure liquid in a field
well drilling environment and liable to contact flammable and explosive substances at any
time. During transit, installation, trouble shooting and service of the equipment, priority shall
be given to health, safety and environmental protection.

The most important resources in the world are mankind and the natural environment on which
the mankind is living. Maintaining the health, preventing accidents and protecting the
environment are one of our vital works. Continuously improving the health, safety and
environment management and heightening the level of the health, safety and environment
management are the objective we are driving at.

We would like to continuously improve the HSE performance of the company by means of
the effective operation of the HSE management system. To improve the quality of products
for customers and in the hope to provide safety, health and environmental protection for
people operating on site and equipment, operators shall carefully read this manual before the
operation of this equipment so as to use the equipment safely and assist you with the
satisfactory completion of the expected drilling operation.

This manual is not the only guidance for people in manufacture, operation, maintenance and
management of Top Drive to follow. On top of this manual, the above people shall comply
with related national, local and professional laws, regulations and standards.

For information not covered by the accompanying documents and other problems arising
from the installation, operation and maintenance, contact the manufacturer if necessary:

BPM Beijing Petroleum Machinery Factory

Ads: No.41, Zhixin Road, Haidian District, Beijing P.R China

Postcode: 100083

Tel: （010）62097381

Fax: （010）62097613

E-mail: Bpm.zhaojing@vip.163.com
 Contents

1. Overview ............................................................................................................................. 1
2. Regulation for safe operation on well site........................................................................... 2
3. Regulation for safe installation of Top Drive...................................................................... 3
4. Regulation for safe electric operation ................................................................................. 5
5. Regulation for safe hydraulic operation .............................................................................. 8
6. Regulation for safe operation of Top Drive ...................................................................... 11
BPM Top Drive HSE Manual

1. Overview

Top drive is a set of equipment integrating mechanical, electrical, hydraulic, and information
features, characteristic of high voltage and high pressure liquid and other hazards as well as
overhead operations. During operation, trouble shooting and maintenance, abnormal
operation will lead to serious bodily injuries and damage to equipment and causing
unforeseeable serious outcome.

Personnel involved in the installation, trouble shooting, operation and maintenance of Top
Drive shall be properly trained to get relevant qualification, and carefully read this manual
and related operating manuals.

Safety is the paramount element on site that all personnel working on site shall pay special
attention to and place emphasis on. Safety of personnel is the most important. In whatever
operations, top priority shall be given to the safety of personnel.

Always keep the data on site complete and clear.

Always check if the identification of equipment is complete and clear.

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BPM Top Drive HSE Manual

2. Regulation for safe operation on well site

1) Operators at the well site must wear all necessary articles for labor protection.

2) Hot line repair operation must be monitored. In principle, the operation shall be
performed with the power off. If this is impracticable, the supervisor shall work at a
place where he can see the operator and quickly switch off the power. Before hand, the
signal for communication should be defined.

3) For overhead operations, always wear properly safety belt. The clothes and footware
shall comply with the requirements for overhead operations. During the operations,
the safety belt should be attached to a reliable point. All tools must be provided with
safety ropes and the small tools should be kept in the pouch at any time after use to
prevent them from falling.

4) To perform maintenance of the equipment, first stop the equipment and wait till it
comes to a standstill before starting the operation.

5) While dismantling the hydraulic loop, to prevent the residual pressure from injuring
people, slowly release the pressure before starting the work so as to avoid damage to
people and equipment resulting from operation with pressure.

6) After power shuts down in the circuits, first check if the circuits are not live.
Discharge if necessary before starting the work.

7) To remove parts with spring construction in the mechanical portion, care shall be
exercised to release the load of the spring before starting the work.

8) For all parts, the safety pins, chains or ropes are indispensable and shall be subject to
frequent inspections. When something is missing, fill it promptly.

9) To lift Top Drive main body, special bail complying with standard must be used with
the diameter of the wire hope not less than 7/8” and held firm and level. Also, special
care shall be exercised in lifting the electric house.

10) For whatever operations, safety plan shall be made before hand to cover all fortuitous
events and provide all measures to the greatest extent possible to prevent any
accidents.

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BPM Top Drive HSE Manual

3. Regulation for safe installation of Top Drive

Installation and removal of equipment should be conducted to comply with related

regulation and attention shall be given to the following items:

1) Operators must wear articles for labor protection as per related regulation (e.g. gloves,
hardhat, etc.).

2) For overhead operations, always wear properly the safety belt. All tools must be
provided with safety ropes or kept in the pouch to prevent them from falling.

3) The removal and installation of the equipment shall be performed with the power off.
Hot line operation is not allowed in any cases.

4) In case of strong wind, lightning, rain, snow and other weather conditions, stop the
installation or removal.

5) The electric house must be placed horizontally and off the floor to prevent water from
ingress through the bottom.

6) All cables must be first connected to motors or the external terminals. All cable plugs
must be tightened to prevent loosening or ingress of water.

7) To connect the cables, always note the colors of the cable connectors (red, white,
black). Those connectors with the same color shall match.

8) The connectors linking to the electric room must be connected after all pieces of
equipment are installed to prevent accidental electric shock during the installation.

9) The main earth pole with a maximum of 4Ω must be provided near the electric house
and fully and reliably earthed, which are provided normally at 2 points and connected
to the main earth bus for the electric house so as to ensure bodily and equipment
safety.

10) Before connection to the electric house, motors and cables must be subject to
inspection for insulation.

11) Each motor and control box must be correctly connected to the PE bus bar or PE line.

12) Check the element part and supporter in the control cabinet and the supports and make
sure that there is no damage or loosening resulting from transit.

13) The location for HPU shall be well ventilated to facilitate heat emission of the
hydraulic system, and away from other heat-emitting equipment (e.g. diesel engine).

14) The lifting ear for guide rail must be firm and reliable to prevent breakage and
loosening during drilling. In the case of thread joint, high-strength bolts supplied from

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BPM Top Drive HSE Manual

the manufacturer must be used.

15) Special sling must be used to lift the room to lift from the 4 trapezes of the base.
Never lift by using trailing bars or by holding other parts of the room. To replace the
damaged sling, never change the size and length.

16) The distribution for the room shall be provided in strict compliance with the
description. Never increase freely the power of the electric house and change the
circuits in the house.

17) Switch off the power when the electric house is not in use.

18) Before switch on the power, careful inspection must be conducted to the correctness
of the cable connection.

Before normal startup system, the following items must be inspected:

1) Check the operation record of the equipment and see if there is anomaly of equipment
operation in the previous shift.

2) Check the level in the oil tank of the reduction box, which shall not be excessively
low or high. In case of low level, fill in oil with reference to the <Maintenance
Manual>.

3) Check the level in the oil tank for the hydraulic system and the filter.

4) Charge at the lubricating points supposed to be filled with lubricating oil (grease) on
daily basis.

5) Check if there is oil leakage.

6) Check the condition of the hydraulic hose.

7) Check if the gooseneck and connector are damaged.

8) Check visually if suspended cables of Top Drive are not twisted.

9) Check if the safety lockwire and safety pin are missing.

10) Check the wear of backup tong tooth.

11) Check if any bolt in the locking device of the main shaft is loosened.

12) Check if the equipment other than Top Drive is normal.

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BPM Top Drive HSE Manual

4. Regulation for safe electric operation

Before the operation of the equipment and the electric system, attention shall be given to
the following items:

1) Carefully read the <Electric Manual> and be familiar with the electric circuit diagram.

2) Make available suitable tools and provide proper protection.

3) Before confirming that all works are completed, switch off the power and hang the
sign of “Do not Switch On”.

4) Connect the power cables only after the installation is all completed and the inspection
shows conformity to ensure bodily and equipment safety.

5) Never conduct hot line repair or removal of any electric component, nor pull out/plug
in cable plugs live.

6) Rectifier is repaired and replaced only by technical staff of related disciplines.

7) Inverter is repaired and replaced only by technical staff of related disciplines.

8) Parameters of Rectifier and Inverter are set only by related technical staff.

9) During the operation of the Rectifier or before the voltage of the DC bus drops below
the safe limit (24V DC), never attempt to replace the DC fuse between the DC bus and
the Inverter. Otherwise, it may endanger the human body and equipment.

10) To repair the Rectifier, Inverter or motor, turn rightward the key switch (to the locking
position) on the main air switch （3WN6）to prevent faulty operation.

11) For Rectifier and Inverter, the insulation should not be inspected with megameter.
Otherwise, the high test voltage may damage the equipment.

12) Never open the explosion proof control box or Driller Console live in a flammable
atmosphere.

13) The Driller Console is a positive pressure explosion proof electric control box where
clean compressed air must be fed in and certain pressure (approx. 0.05~0.2MPa)
maintained in normal service. In case of pressure loss of the protective gas for the
Driller Console, stop drilling and switch off the control power for the Driller Console
and restore the pressure as soon as possible.

14) Relief of safety interlock in software and hardware is prohibited. After removal of
faults, restore the bypassed interlock allowed by functions as soon as possible.

15) Revision of the set parameters in the Rectifier and Inverter by unprofessional is
prohibited to avoid risks.

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BPM Top Drive HSE Manual

16) When the main power of the system is re-energized after shutdown for 30 minutes or
more than, always makes sure that there is no condensate in the electric control
cabinet.

17) In case of high temperature and humidity and of condensate, never start the drive and
other control power before starting the air conditioning for cooling and
dehumidification.

18) In damp environment, when the temperature in the electric house is lower than that of
the outside environment, leaving the door of the electric house open for a long time is
prohibited. Otherwise, it may lead to condensation on the electric equipment.

19) During the operation of the air conditioning, all doors of the air conditioning chamber
must be closed and only internal circulation is provided to prevent the outside air with
high humidity from ingress into the electric house.

20) The upload and download of the control program is performed only by related
professionals.

21) The electric modules are replaced only when power is off.

22) The dial switch on the OLM module in the electro-control system for Top Drive must
not be tampered.

23) Before the DC voltage drops below 24V, never touch any DC bus or devices.

24) Short circuiting of single phase to ground will endanger equipment and human bodies.

25) When multimeter is used for the inspection of the network, the control power for all
stations must be switched off and the connectors pulled off.

26) Cables for all parts shall be firmly connected, and the thread crimp connection shall
not be loosened and the welded parts shall be free of dry joints.

27) Cables will age as a result of exposure to light and oxidation in air. After a service of 2
years, care must be exercised to check if there is cracking, peeling and other aging
signs. Generally, cables shall be replaced after 4 years in service.

28) Always note to prevent damp and dust and make sure that they are not operating in
environment of high temperature (45℃ and above) or low temperature (－13℃ and
below).

29) Before the system restarts after idling for some time, always remove the dust built up
on the components with vacuum cleaner followed by drying with electric dryer.
Finally, measure the resistance of insulation, which shall be min. 1MΩ and generally
over 5MΩ.

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BPM Top Drive HSE Manual

30) With complex natural conditions at the well site and operating condition for drilling,
all cable connectors and cables shall be subject to regular inspection and maintenance
(max. 5 days) depending on the specific operating condition for drilling to prevent
loosening or even breakdown of the connectors.

31) Before electric disconnection, the terminals for wires (cables) must be marked to
ensure correct reconnection.

32) In case of rain for long time or if Top Drive lays idle for long time, before starting Top
Drive, first heat the 2 main motors to ensure dryness and insulation so that they could
operate normally and safely.

33) The trouble shooting of the main motors must be performed with single motor in
operation to prevent accident resulting from the 2 motors rotating in different
directions.

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BPM Top Drive HSE Manual

5. Regulation for safe hydraulic operation

The HPU shall be subject to routine inspection, which includes:

1) Check the liquidometer of the oil tank and the level shall not be lower than the middle
line of the liquidometer.

2) Check the temperature of the hydraulic liquid, which shall not be more than 70℃.

3) Check the switches for stop valve and ball valve properly located.

4) Check the cleanliness indicator for the filter and judge the blockage of the filter.

5) Check if there is abnormal vibration, noise and heating in the operating pumps.

6) Visually check the leakage of the pipe ways for the hydraulic system.

7) Visually check the surface condition of the hydraulic cables. In any of the following
cases, stop the operation immediately and replace the hose assembly promptly.

— Slippage of connector is found on the hose.

— Damage, cut or abrasion of outer covering.

— Hardened hose, heat cracking or carbonization.

— Cracked, damaged or seriously corroded connector.

— Connector or hose leakage.

— Hose bent, bruised or twisted.

— Foaming, softening, erosion or delaminating of outer covering.

Before the repair and operation of the equipment and hydraulic system, attention
shall be given to the following items:

1) Carefully read the <Hydraulic Manual> and familiarize yourself with the operating
principle of the hydraulic system and construction, function and action of the
hydraulic components.

2) Before the installation, maintenance and other operations of the equipment in the
hydraulic system, switch off the power and shut off the hydraulic oil, compressed air
and other energies and release the pressure in all system accumulators.

3) Shut off and lock the hydraulic, power and control sections and attach signs for
warning.

4) Slowly release all pressure in the system with the pressure relief valve in the system.

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BPM Top Drive HSE Manual

5) Before dismantling the hydraulic lines, release the pressure in the accumulators so that
all oil pressure is released and make sure that there is no oil pressure in the system
pipes and accumulators. High pressure oil penetrates the skin, leading to serious
damage.

6) Before dismantling the pipe ways, mark the connection parts for correct reconnection.

7) Take effective measures to prevent the hydraulic oil from leakage and ingress into
other electric or mechanical parts.

8) Before dismantling the hydraulic pipe ways, close the valves in the system and get
ready proper containers, oil blinds, cotton yarn, etc. to prevent the residual hydraulic
liquid flowing out of the pipe ways from contaminating equipment and the
surrounding environment when the pipe ways are opened.

9) During the operation of the system, the temperature of the hydraulic equipment and oil
may be high and injure the human bodies, which will take some time to cool down to
an accessible temperature. Carefully take protection.

10) To avoid harm to the operators resulting from the high pressure oil or other hazards,
wear the safety goggles.

11) Inspection of the leakage of the hydraulic lines must not be performed freehand. The
high pressure oil leaking out of small holes is hard to be detected visually and likely to
penetrate the skin, which causes serious damage. Conduct inspection with chips or
cards.

12) Handle the parts and components with care to prevent damage to some precision
matching faces of the parts and components.

13) Before lubricating, testing or replacing parts and components, correctly lock the main
power source.

14) Before opening the hydraulic system, thoroughly clean the work area. For the
dismantled hydraulic lines, always seal them promptly. Dust is definitely detrimental
to the hydraulic system, and may lead to the malfunction of the equipment and even
bodily injury.

15) Check the hydraulic system on daily basis for leakage from the pipe fittings, damaged
surface layer of the hydraulic hose, interleaved hose, cracking from pressure or
hardening and damaged or worn pipe fittings. In addition, to test, tighten or replace
any leaking pipe connectors, promptly remove the dirt on the hydraulic parts and
components.

16) Test on unfamiliar parts must not be conducted. Before maintenance and test, always
read and understand all safety warnings.

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BPM Top Drive HSE Manual

17) When seriously worn or aged, components shall be promptly replaced to ensure the
operating performance and reliability of the hydraulic system.

18) Never use the mixture of hydraulic oils of different brands.

19) Hydraulic oil must not be substituted by fuel.

20) For the overflow valve of the system, the set pressure at shipment is 18MPa, which
shall not be freely adjusted.

21) Accumulators shall be charged only by nitrogen and other inert gases. They must not
be charged by oxygen, compressed air or other flammable gases to prevent explosion.

22) When accumulators with pressure exist, the system shall not be repaired.

23) To dismantle the accumulators for repair, first discharge the pressurized oil and
discharge the nitrogen in the rubber bladder with gas filling tool before dismantling
the parts and components.

24) If the pressure in the accumulators is excessively high, reduce the pressure
appropriately. If the pressure is lower than the setting, charge with nitrogen.

25) Maintenance and repair and any trouble shooting of the equipment must not be
performed during the operation of Top Drive.

26) To fill the oil, note the cleanliness of the ports of the oil barrel and tank and the inlet
and outlet oil pipes of the filter press.

27) There is an overflow valve on the distribution valve block. Although allowing
pressure regulation, this valve in the system functions as a relief valve. The correct
method of application is that the set pressure value of this valve is higher than the set
pressure value of the pressure limiting variable output plunger pump. Otherwise, the
temperature of the system will continuously rise, leading to the paralysis of the
system.

28) When the oil pump starts for the first time, air must be carefully and totally evacuated
from the hydraulic system.

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BPM Top Drive HSE Manual

6. Regulation for safe operation of Top Drive

During the operation of Top Drive, check the pressure in the strata, well control
requirements and operating condition of Top Drive at all time and note the following
items:

1) Fan must not be switched off during the operation of Top Drive.

2) The power for the electric house shall not be switched off until the main air switch of
the electric system is off.

3) In any cases, never use surface bumper sub. Otherwise, it may damage Top Drive
equipment.

4) After each jarring operation, all cable connections for Top Drive shall be subject to
inspection. Proceed with prompt reconnection where loosening is found.

5) Before starting up the main motor, always check if the braking condition and the
limited value for drilling torque are correct.

6) During the startup of the main motor, to ensure the equipment safety, the limited value
for drilling torque is preferably not excessively high. Operator could increase the
limited value for drilling torque after the main shaft rotates.

7) In reverse running of the drilling mode, note the setting of the drilling torque to
prevent accident resulting from drill pipe loosening or back out.

8) When the reactive torque is released, there is the risk that the drill string is thrown out.
Always operate by strictly following the operating regulation. During the operation,
strict control over the reverse running speed of the drill string must be provided to
prevent accidents.

9) Backup tong must be operated after the rotating head is locked and confirmed to fully
ensure the equipment and bodily safety.

10) IBOP must not be closed during drilling or running of the mud pump (except in the
well control condition).

11) In manual mode, the manual control the multi-core cable of the Local Control Box to
transfer above the pure manual terminal for the operation of the magnet valves of the
auxiliary equipment, which is not interlocked for safety. Operators must carefully
operate to prevent damage to the equipment.

12) In the running mode of system, operating the 【System Start】 switch may cause stop
due to failure.

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BPM Top Drive HSE Manual

13) The maximum bearing capacity of the link tilt oil cylinder is 2 ton. To lift drill collar
and other heavy objects, the middle position status of the elevator link must be
maintained, that means the link tilt oil cylinder is in a state without strength.

14) In case of blowout and other emergencies, press the 【WELL CONTROL】switch and
the system enters the well control state.

15) In case of emergency in the system where emergency stop is required, operators could
press any 【E-STOP】button nearby and all pieces of equipment in Top Drive come to
a fast stop.

16) When the PROFIBUS communication is interrupted for some causes at the Local
Control Box of Top Drive system, the system may switch to emergency operation
mode.

17) When CPU in the PLC/MCC cabinet does not work normally due to fault, the
emergency operation mode for Driller Console shall be followed while the CPU shall
be replaced by a new one to ensure the return to normal operation in a short time.

18) When the communication at the HPU fails, operator could start the hydraulic pump
locally and the HPU will keep on normal operation. Now, the 【HYDRAULIC PUMP
RUN】 indicator light at the Driller Console become off. Solve the trouble as soon as
possible so that the system returns to normal.

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