Foreword Safety warning General Function Technical parameters: Structure and main components

Transcription

1 MAST TRAILING DEVICE OF ZT40DT RIG December, 2008

2 Table of Contents Foreword Safety warning General Function Technical parameters: Structure and main components main structure and description Installation of mast trailer Debugging Lubrication Maintenance Frequent trouble and trouble shooting Precautions Recommended spare parts lists Attached drawings...11

3 Foreword In order to help our user operate the mast trailing device properly we have compiled Operation manual of Mast trailing device. This operation manual generally described the technical parameters of the device, its structural features, installation, lubrication, maintenance, transportation etc. Please read the operation manual carefully before the installation and operation. There is a recommended spare parts list attached to the operation manual for your reference when you order spare parts. If the parts which the user needs are beyond the recommended list, please refer to its drawings booklet. There is an ex-factory code for each mast trailing device, please point out its model and the code when you order spare parts or inquire about the related things. 1

4 1. Safety warnings 1.1 The personnel who is occupied in installation, transportation and maintenance of the mast trailing device should be trained and qualified, and carryout the work with operation certificate. 1.2 The operators can operate or maintain the equipment only when he knows well the control functions and operation procedure of the equipment, and reads the operation manual. 1.3 The operator for operation and maintenance should wear proper safety wares. And tie safety belt properly while working in high up. 1.4 The equipments should be used strictly in accordance with their operating rules and related safety regulations. 1.5 The lifting and moving devices for the mast trailing device should meet the requirement of load capacity. Warning: there should be enough craning equipments to be used and observe strictly all safety operation rules and regulations. Be sure to release the pressure of hydraulic system and hang a warning plate shows dangerous operation forbidden the equipment is in repairing before start to adjust and repair the device. Warning: When you install the mast trailing device, lift and lower mast onto the mast trailing device, a special safety rules and regulations should be worked out and followed, there should be a special person responsible to command the operation. 2. General 2.1 Function The mast trailer is one of the important components of ZJ40DT rig. It is used for moving the mast specially. You don t need to disassemble the mast for moving. 2.2 Technical parameters Overall size (L W H): (m) Min. height from ground (in moving status): 0.62(m) The height from towing plate lower surface to ground: 1.676(m) Total weight of the mast trailer: 90T Towing device load capacity (in transportation status) 30T Load capacity of axle: 60T Tire model Wheel rim model 26.00/5.0 Axle model ZD

5 OPERATION MANUAL FOR MAST TRAILING DEVICE OF ZJ40DT RIG Tow pin model 3½ Lifting cylinder stroke 580(mm) Rated work pressure of lifting cylinder. 18(MPa) Support cylinder stroke 900(mm) Rated work pressure of supporting cylinder. 18(MPa) Max. Traveling speed 10km/h 3. Structure and main components 3.1 Main structure and description The mast trailer basically consists of chassis frame, support frame, top frame, side beam, lifting and supporting cylinders, tow device, and tire, axels, wheel rims of suspension etc. For the overall size of the trailer, please refer to following figure 1. Figure 1 Overall size of mast trailer Chassis frame The chassis frame is one of the important components of mast trailer. It is welded of I steel and cylinder support frame etc. and is a part which is connected to suspension frame, and used to emplace rope spooler and fixing support frame. 3

6 3.1.2 Support frame It consists of support frame beam, lifting cylinder fixing frame, cylinder bottom support, external guide pipe etc. and it is used to support and guide top frame moving up and down Top frame The top frame is composed of cross beam, vertical beam (longeron), lug seat, cylinder upper support, internal guide pipe etc, used to connect and support mast side beam and emplace traveling hook while moving mast Side beam It consists of beams, positioning plate, locating pin etc., used for supporting and fixing the mast Suspension system The suspension system adopts 135T axle, model tires and model 26.00/5.0 wheel rim; for maintenance and trouble shooting of the axle, refers to its operation manual Tow device Tow device consists of tow seat, inclined support, vertical post, inclined post, mast single lug support and crown block single lug support etc., and used to support mast top end and to connect tractor mainly. 3.2 Installation of mast trailer Assemble tires, rims and axle suspension properly Installation of chassis frame and suspension: Connect the chassis frame to suspension with M42 lock screw bolts, install support cylinders, and then install the rope spooler on the chassis frame according to the position shown in the figure. It is shown in figure 2 after it is installed. 4

7 Figure 2 Suspension and chassis frame After the suspension and chassis frame have been assembled, install the support frame, and connect the lifting cylinders lower end to support frame Assemble the top frame, side beam and lifting cylinder upper support. It is shown in figure 3 as it is assembled. Figure 3 Mast trailer back part sketch Weld crown block single lug seat, mast single lug seat respectively to the crown block and mast as per the position shown in the figure; the tow device is shown in figure 4 as it is assembled by welding. 5

8 Figure 4 Tow device 3.3 Debugging Safety and equipment status inspections should be carried out completely before you put the trailer into transportation of mast. Main items to be inspected are as following: A. Check the tire wearing condition and if the tire pressure meets the regulation requirement. B. Check if there is any surface distortion and crack with axles and rigid suspension; if rotating parts are lubricated properly and can rotate actively, and installed reliably. C. Check if there is any damage with the trailer frame welded parts, if all connection pins have their safety pins installed, and all bolts, nuts, spring washers and split pins are installed completely. D. Check if the hydraulic control system works sensitively, the connections of pipelines and quick release joints are correct and reliable. E. Check if the mast trailer module is disconnected from other modules of the rig completely before put the trailer into transportation. Pay attention to check if the mast is disconnected from substructure completely When trailer is used for moving mast integrally: before the mast lowering down, the trailer chassis frame should be emplaced exactly at the position in right ahead of the drilling rig. The distance between trailer axle and wellbore center is and its concrete layout is shown in figure 5. Figure 5 The layout position of the mast trailer 6

9 3.3.3 When the mast is emplaced in horizontal position and on tall stand, jack up the top frame of mast trailer with the lifting cylinder and install (insert) the positioning pins of the left and right side beams in mast fixing plate; fix the mast with eyelet bolts, press plate and nuts; and fix the tow device to the crown block and mast with pins and safety pins To jack up the trailer, jack up the mast, remove the tall stand; connect the tow device to tractor. Check if the hook of tow saddle is open completely. Generally the saddle has automatic connection function. It can automatically be hooked when tow pin reaches to its position. But attention should be paid that when the saddle and tow pin being connected completely check if the saddle rod is locked, and remove the raising line and drilling line then Remove the connection pins between mast and substructure, retract support legs, fix the top frame and support frame withφ80 connection pins. After all carry out safety inspection and equipment status inspection again Before the mast trailer transportation, the road condition should be completely inspected, such as the road flatness, accessible status, road load-bearing capacity and steering radius etc, they should be evaluated After the mast being moved to a new well site, put the mast trailer at the position right ahead of substructure. Removeφ80 connection pins between support frame and top frame, jack up the top frame together with the mast with lifting cylinders. Let the trailer close to the substructure slowly then, and adjust the mast position rightward and leftward. Connect the front legs and bracket withφ pins when their bracketφ120 holes are aligned Install the raising line and put tall stand under the mast upper part. Remove the connection pins from the tow device to mast and crown block (now the tractor and tow device are unhooked); remove the eyelet bolts between the trailer side beams and mast. For the detail please refer to the related instruction for the mast raising. When the trailer and the mast are completely disconnected,move away all trailer components and maintain the equipment for storage. 4. Lubrication Be sure to lubricate all rotating parts and contacting surfaces properly. Grease or oil the work surfaces of tow pins and tow plate, knuckle bearings of lifting cylinders, spherical surfaces of lifting cylinders, internal of guide pipe of support frame and top frame before and after the operation of the trailer. Use NLGI2 lithium base grease for ambient temperature 20 ; lubricate before each operation of the trailer, and once in every 3 months. For the lubrication of axles and the rigid suspension refer to the related operation manuals. 7

10 5. Maintenance 5.1 Periodically check the paint quality of the trailer surface, repair paint in time if there is any damage. 5.2 The main load-bearing parts are chassis frame, support frame, top frame, side beam and tow device etc. if there is any crack or damage or distortion, repair and rectify it in time. 5.3 Before each operation, check the nut of tow pin, tire bolts and the installation bolts of axles and suspension, tighten the loose one if any. Select the correct bolts for axle, suspension and tire etc according to the requirements of general assembly drawing. It is not allowed to replace them with common ones. 5.4 Before each operation, check hydraulic cylinders, pipe lines and hydraulic control valves, if there is any default and leakage, eliminate or replace it timely. 5.5 For the maintenance of hydraulic cylinders, axles and suspension, refer to the related operation manuals. 5.6 If the trailer is not in use, it should be treated for anti-water, anti-humidity and anti-rust; when disconnect it or lift it pay attention to avoid it from being bumping and damage. 6. Frequent troubles and trouble shooting Frequent troubles of hydraulic cylinder Phenomenon Reasons Troubleshooting Piston rod damaged due to bumping or pulling Grind it with fine sand paper or oily stone, or replace it if it can not be repaired. Cylinder internal surface pulled. Same as piston rod External leakage The sealing part of piston rod Replace the sealing part worn or damaged. The piston rod can not extend smoothly. Disassemble and check if it is installed properly There is air in cylinder or bubble Loosen the joint and in oil. release the air. Hydraulic cylinder is not Check if the installation Piston rod crawl and creeping installed in the right position direction is in conformity with moving direction. It is bent fully or partially with piston rod. Correct the linearity of the full length of the piston rod, or replace it. 8

11 Phenomenon Reasons Troubleshooting Cylinder internal rusted or Remove the rust and burr, pulled. or replace the cylinder barrel if too serious. In addition, if there is any partial distortion with structural component happened during the trailer operation, it can be corrected or reinforced partially. If it is happened at the main structural component you should consult the manufacturer before you solve the problem. 7. Precautions 7.1 There should be a special person for inspection and maintenance of the trailer, for some fault eliminating you have to contact the professional vehicle department. 7.2 On the trailer installation there should be a special person for operation, special person for command. For solving the problems appeared in installation and operation, the reasonable recommendation from transportation department should be taken into the consideration. 7.3 The connection of hydraulic lines should be carried out in accordance with the marks on operation control box, hoses and cylinders, the self sealing quick release joints in lines should not be false connected. During installation pay attention to avoid hydraulic pipe lines and joints from being extrusion. 7.4 The maximum traveling speed 10km/h for the trailer 8. Recommended spare parts lists Support cylinder (HG / ) No. Code Name Qty. 1 HG Cylinder block 1 2 GB/T894.1 Retainer ring for shaft HG key way 1 4 HG Shaft clamp 1 5 K01-P( ) Piston seal ( ) O ring 1 7 K08-D( ) Piston seal 1 8 F01( ) Guide ring 2 9 HG Piston 1 10 HG Piston rod 1 9

12 11 HG Guide sleeve 1 12 F01( ) Guide ring ( ) O ring 1 14 S09-E( ) Piston rod seal 1 15 S01-P( ) Piston rod seal 1 16 A01 ( /7) Dust ring 1 17 HG Spherical cover plate 1 18 GB70-76 Hex. Screw M GB93-76 Spring washer HG Spherical seat 1 21 Z2S16 Hydraulic check 1 valve, stacked 22 HG Valve cover 1 23 GB/T70.1 Hex. Screw M GB93-76 Spring washer GB/T70.1 Hex screw M GB93-76 Spring washer 10 4 Lifting cylinder (HG / R/R) No. Code Name Qty. 1 GB/T Hole retainer ring JB/T Nozzle M GE80ES Knuckle bearing 2 4 HG Cylinder block 1 5 HG piston 1 6 K01-P( ) Piston seal 1 7 F01 ( ) Guide ring 2 8 F08-D( ) Piston seal ( ) O ring 1 10 HG Piston rod 1 11 HG Guide sleeve 1 12 F01( ) Guide ring 2 10

13 ( ) O ring 1 14 HG Hole key 1 15 S09-E( ) Piston rod seal 1 16 HG Press plate 1 17 GB70-76 Hex screw M GB93-76 Spring washer S01-P( ) Piston rod seal 1 20 A01( /10) Dust ring 1 21 HG Rod end 1 9. Attached drawings Attached drawing 1 Mast trailing device Attached drawing 2 Chassis frame Attached drawing 3 Support frame Attached drawing 4 Top frame Attached drawing 5 Side beam Attached drawing 6 Tow device Translated by : Date: Proofread by: Date: Finalized by: Date: 11

14 Attached drawing 1 Mast trailing device

15 Attached drawing 2 Chassis frame

16 Attached drawing 3 Support frame

17 Attached drawing 4 Top frame

18 Attached drawing 5 Side beam

19 Attached drawing 6 Tow device