Top Drive Drilling Equipment

HSE Manual
Model： DQ70BSC

Serial No： 06032

 Contents

1. Overview .............................................................................................. 1
2. Regulation for safe operation on well site ........................................... 2
3. Regulation for safe installation of Top Drive........................................ 4
4. Regulation for safe electric operation .................................................. 7
5. Regulation for safe hydraulic operation............................................. 10
6. Regulation for safe operation of Top Drive........................................ 14
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.

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BPM Top Drive HSE Manual

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

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BPM Top Drive HSE Manual

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 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.

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BPM Top Drive HSE Manual

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.

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BPM Top Drive HSE Manual

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.
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.

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BPM Top Drive HSE Manual

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.
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.
² Slippage of connector is found on the hose.
² Damage, cut or abrasion of outer covering.
² Hardened hose, heat cracking or carbonization.
² Cracked, damaged or seriously corroded connector.
² Connector or hose leakage.
² Hose bent, bruised or twisted.
² 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
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BPM Top Drive HSE Manual

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.
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

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BPM Top Drive HSE Manual

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.
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.

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BPM Top Drive HSE Manual

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
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BPM Top Drive HSE Manual

(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.
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 【Pump Running】 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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