User Manual of Drilling Fluid Circulating Manifold

ZG103-35S Drilling Fluid Circulating Manifold

GH290Ⅱ-SC
April, 2014

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 User Manual of Drilling Fluid Circulating Manifold

Contents

1. Safety warnings ······················································································ 1

2. Purposes and applicability ········································································· 1
3. Standards ······························································································ 1
5. Workflow (Fig. II) ··················································································· 2
7. Installation and commissioning ··································································· 4
8. Operation and repair················································································ 4
9. Lubrication ···························································································· 6
10. Maintenance ························································································· 6
11. Common troubles and troubleshooting ························································ 6
12. Attached lists and drawings ······································································ 6
Attached list 1 Recommended one year spare parts list
Attached list 2 Complimentary spare parts
Attached drawing 1 Installation diagram GH290.00 II
Attached drawing 2 Manifold GH290.01.00 I

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 User Manual of Drilling Fluid Circulating Manifold

1. Safety warnings
 Only trained and qualified persons can install, operate and maintain equipment 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 procedures in wiring of electric appliances and make sure to
cut off power supply before trying repair.

 It is forbidden to maintain and repair equipment during its operation.

 Do not overload equipment.

2. Purposes and applicability

ZG103-35S drilling fluid circulating manifold is important equipment for circulating
system. It is connected between drilling pump and swivel or top drive and used for
conveying high-pressure drilling fluid to wellhole in drilling operation. Secondly, it is
further connected with cementing truck, choke manifold and kill manifold to perform
special operations of well cementation, well killing, cementing plug hammering and
reverse circulation etc.

3. Standards
SY/T5244 Drilling Fluid Circulating Manifold

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th
API 7K, 5 edition, Specification for Drilling and Well Service Equipment

4. Technical parameters
Nominal diameter: 4″
Maximum working pressure: 35MPa
Water pressure test for strength: 53MPa
Temperature grade: PU
Height of gooseneck: 17.5m; 21.5m
Length of rotary hose: 19m; 23m
Weight: 11866 kg
Working medium: clear water, drilling fluid, fracturing fluid and crude oil

5. Workflow (Fig. II)

ZG103-35S drilling fluid circulating manifold can complete four working circulations in
drilling process.
5.1 During drilling circulation, high-pressure drilling fluid discharged from drilling pump
is pumped into well through ground manifold, mast standpipe manifold, rotary hose, swivel or
top drive to perform drilling circulation operation.
5.2 During trip out, connect manifold with wellhole annular space through interface 2'' of
control valve bank on drill floor to perform mud grouting operation.
5.3 During well killing, connect interface 2'' of control valve bank on drill floor with
well-killing line, open 2'' control gate valve, and implement well killing with drilling pump.
5.4 When drilling pump is used for displacing mud reversely, connect interface 2'' on drill
floor with inlet of wellhead cementing device, the drilling pump injects mud into wellhole
under gate valve control to displace the cement paste in wellhole.

6. Basic structure (please refer to Fig. 2 for details)

Basic structure of ZG103-35S drilling fluid circulating manifold:

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Fig.1 Basic structure of manifold

1. Upper gooseneck 2. Lower gooseneck 3. Straight pipe subassembly

S type elbow Drill floor valve
4. 5. 6. S type elbow subassembly
subassembly bank
7. Tee subassembly 8. Tee subassembly 9. S type elbow subassembly
10. Union flange 11. Welded union (male) 12. S type elbow subassembly
S type elbow
13. 14. Ground valve bank 15. Adapter
subassembly
16. Hose 3.5m 17. Elbow subassembly 18. Straight pipe subassembly
Straight pipe
19. Elbow subassembly 20. 21. Elbow subassembly
subassembly
22. Elbow subassembly 23. Rotary hose 23m 24. Top drive adapter
25. Rotary hose 19m 26. Swivel adaptor 27. Cementing manifold

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7. Installation and commissioning

Installation shall be carried out in sequence as per installation diagram (attached drawing
1) and manifold diagram (attached drawing 2):
Install the parts strictly as per the sizes marked on diagram. First install the mast
standpipe manifold, and then install the ground manifold.
Warning: do not damage union trapezoidal threads and sealing
surface during installation.
7.1 Coat union spherical surface, sealing groove and threads thinly with 2# lithium base
grease after cleaning them with detergent.
7.2 Before mast lifting, connect and install its manifold supports one by one reliably as
per diagram, and then install mast standpipe manifold, and ensure the center of connecting
pins of the sections of mast to be flush with end surface of female union (positioning
reference) during installation; install gooseneck, and then install pipes on mast in sequence.
Adjust the height and angle of gooseneck, then screw up its fixing bolt, and finally install
thrust pin.
7.3 After mast is lifted, install ground manifold, install manifolds of basements of
substructure, and preliminarily fixing pipe clamp seats.
When all connections are performed properly, tighten all pipes.
7.4 After the installation is completed, check all parts for firmness and reliability and all
installation sizes for accordance with requirements. Blow the parts systemically. During
systemic blowing, blow inner holes of pipe with air compressor to remove foreign matters. It
needs to take down instruments and meters or seal pipelines entering the instruments and the
meters with blind plates to prevent foreign matters are blown in the instruments and meters to
influence their performances.
7.5 Dynamic pressure test:
Pressurize to 35MPa with clear water step by step (7MPa each step) for dynamic pressure
test; keep the pressure for at least 15min at each step; and when the pressure reaches 53MPa,
keep it for 30min. It is qualified if there is no leakage.

8. Operation and repair

8.1 When ZG103-35S drilling fluid circulating manifold is used for mud high-pressure

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 User Manual of Drilling Fluid Circulating Manifold
circulation, its operation procedure is as follows (Fig. II):
(1) In the drilling circulation operation with 1# drilling pump, open gate valves 3, 5,
11,12, or 3, 5, 11, 10, 9, close other gate valves. In the drilling circulation operation with 2, 3#
drilling pump, do it similarly.
(2) In the drilling circulation operation with 1#, 2# and 3# drilling pumps, open gate
valves 1, 2, 3, 4, 6, 7, 8, 9, or 1, 2, 3, 5, 6, 7, 11 and 12, close other gate valves.

Fig. II Workflow diagram

8.2 It is simple and convenient to use ZG127-35S drilling fluid circulating manifold.
During repair, remove all unions of connecting parts, and check union threads, O-ring and all
components; if O-ring is damaged, replace with a new one, then grease connecting union
threads and tighten the unions. Replace O-ring after each removal. Ensure that there is no
leakage during use. Perform antiseptic treatment on manifolds which is used for some time.

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Thus, the service life of the manifolds is prolonged.

9. Lubrication
9.1 The lubrication of mud gate valve shall be carried out as per the instruction of its
valve.
9.2 The lubrication of union connection surface: 2# lithium base grease.

10. Maintenance
10.1 After each well is drilled, check split pins for damage, if any, replace them;
10.2 Check corrosion of all pipes half a year, if the corrosion is obvious, measure
thickness with ultrasonic wave, and then replace the pipes the measured thickness of which is
less than 15.2mm with new ones.
10.3 Recoat whole manifolds every 2 years.
10.4 In the movement and installation, pay attention to prevent all union trapezoidal
threads and sealing surface from damage, and prevent foreign matters entering pipes.
10.5 The maintenance of mud gate valve shall be carried out as per the instruction of
valve.

11. Common troubles and troubleshooting

11.1 Trapezoidal thread (union) cannot be tightened: check if there is any damage to
threads (external trapezoidal threads) of all female unions, if any, repair them through filing
protrusion.
11.2 Serious shock: check pipe clamp and pipe seat adjacent to the trouble for looseness,
and if any, tighten in time.
11.3 Leakage: first cut off drilling fluid source of the trouble, check union joint for
tightening, if not, tighten the union joint; and then, disconnect union joint, check sealing ring
for damage or aging, and if any, replace with a new one.
11.4 The troubleshooting of mud gate valve shall be carried out as per the instruction of
valve.

12. Attached lists and drawings

 Attached list 1 Recommended spare parts list

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 Attached list 2 Complimentary spare parts
 Attached drawing 1 Installation diagram GH290.00 II
 Attached drawing 2 Manifold GH290.01.00 I

Attached list 1 Recommended one year spare parts list

No. Description Spec. Qty. Remarks

1 Union sealing ring 4” Fig1003 30 pcs For 4'' Fig1003 union

2 Union sealing ring 4” Fig1002 20 pcs For 4'' Fig1002 union

3 Union sealing ring 2” Fig1502 20 pcs For 2'' Fig1502 union

Union type metal-to-metal seal

4 Z23Y-35-DN100 2 sets
mud gate valve: 4''
Union type metal-to-metal seal
5 Z23Y-35-DN50 2 sets
mud gate valve: 2''

6 Welded union 4” Fig1003 5 sets 4″Fig1003

7 Welded union 2” Fig1502 2 sets 2″Fig1502

8 Welded union 4” Fig1002 2 sets 4”Fig1002

9 HP hose assembly 4″1002/3.5m/35MPa 1 pc

10 Bolt M24×90 GB/T5782 40 8.8 grade

11 Pin 5×50 GB/T91 40 Q235

12 Nut M24 GB/T6179 40 8 grade

13 Washer 24 GB/T97.1 40 Grade 200HV

14 Bolt M20×40 GB/T5783 30 8.8 grade

15 Washer 20 GB/T93 30 65Mn

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Attached list 2 Complimentary spare parts
No. Description Spec. (drawing No.) Qty. Remarks

1 Union sealing ring 4” Fig1003 5 pcs For 4'' Fig1003 union

2 Union sealing ring 4”Fig1002 5 pcs For 4'' Fig1002 union

3 Union sealing ring 2”Fig1502 5 pcs For 2'' Fig1502 union

4 Bolt M24×90 GB/T5782 20 8.8 grade

5 Pin 5×50 GB/T91 20 Q235

6 Nut M24 GB/T6179 20 8 grade

7 Washer 24 GB/T97.1 20 Grade 200HV

8 Bolt M20×40 GB/T5783 10 8.8 grade

9 Washer 20 GB/T93 10 65Mn

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