Valve annular

Regulator manifold
Bybass

Regulator annular Transmiter annular

Transmiter manifold

Transmitter acumlator

Air pump#1 Air pump#2 Air pump#3 Triplex pump

 External supply
Surge bottle
1-Contain blader
2-Install on oil line ( Annular)
3-it use for once

Backup unit
1-Install at inlet of air line
2-Contain air or nitrogen without blader(like use with welder)
3-Use it just for pressure to run air pump

Air liquid switch

1-Install on main air line (like a regulator)
2-It off at 2700 PSI this is the purpose of it
3-Before valve of air pump(before inlet air of air pump)
4-It have oil line above of it before inlet of transmeter of accumlator
(press on it till 2700PSI then stop)
5-It have bybass under it
(If it stack (go down) I can cancel it and open bybass)
(If there is oil come from it while it open I can blocked it)
(I can use it if there is a problem at triplex pump so
I open it to reach 3000PSI from air pump only)

Gage
There are two type of Gage
1- At Remote (Air)
2-At Com unit (Oil) like (Anular&Acumlator&Manifold) Except air supply

Transmitter&Regulator
It have 3 transmitter and 2 Regulator
Transmitter
1- Accumlator (3000 PSI)
2-Manifold(1500 PSI)
3-Annular (700-800)PSI
Change Oil signal to air to read it at gage of remote
(Its like a piston press on oil and it have inlet for air so
from pressure of piston press on air to get the pressure at gage of remote
Regulator
1-Manifold
2-Anuular
It control the preessure of oil

Triplex pump
It have solonid at triplex to stop at 3000PSI
If any problem at it so I can run it manual from switch at panel
There are two switch at panel (Automatic&Manual)
 Valve
Inlet close

Action Action

Retun to tank

Transmiter

Air inlet(120PSI) Out to remote

to gage at com unit

Pipe
 Pump
Model HHF-1600 triplex-cylinder single action piston type
Rated power 1600HP/1176kw
Rated stroke number120 stroke/min when motor speed is at 970r/m
Max displacement 720GPM
Max working pressure5000 psi
Rated power 1200kw
Transmation ratio 1.981/1
 Pinion Bearing

Pinion Bearing
Pinion Gear
Pinion Shaft

Main Bearing

Main Bearing
Pull Gear
Crank shaft

Exntric Bearing Exntric Bearing Exntric Bearing

Rocker arm
PL PL PL

Cross head Cross head Bearing Cross head Bearing Cross head Bearing

Pony rod Pony rod Pony rod

1- Measure Pinion bearing&Main bearing by filer

2- Measure Exntric bearing&Cross head bearing by dial indicator

Bomco-internal lubrication-gear-depend on pump speed-DC- bad

HH-External lubrication-Control circuit-not less 25PSI-AC- good
 How many Bearings exist on the traditional triplex mud pump?
2 pcs are Main bearings for the crankshaft
2 pcs are Main bearing for the jack shaft (pinion shaft)
3 pcs are the Eccentric bearings (Con Rods/Crankshaft) ‫ و اﺛﺒﺖ اﻟﻤﻐﻨﺎطﯿﺲ ﻋﻠﻰ اﻟﻜﺮاﻧﻚ ﻋﻠﺸﺎن ﻟﻮ ﺣﺼﻞ و اﺗﺤﺮك‬connecting rod ‫اﺣﻂ اﻻﺑﺮه ﻋﻠﻰ‬
don’t measure
3 pcs are the Cross-head wrest pin bearings ‫اﻛﺴﺘﻦ اﻟﺒﺎﻣﺐ ﺑﻌﺘﻠﮫ ﻣﺜﻼ ﺑﯿﻦ اﻟﺘﺮوس و اﺳﺘﺨﺪم ﻋﺘﻠﮫ ﺑﯿﻦ ﺟﺴﻢ اﻟﺒﺎﻣﺐ و اﻟﺒﻠﯿﮫ‬
the middle one,
So total are 10 bearings
The 4 main bearings for crank and jack shafts you have to measure them using a feeler gauge from the top portion between the rolling elements and outer race.
The rest 6 bearings for the Con Rods you have to use the dial gauge and hydraulic jack ( I don’t like it , I prefer a 5 ton chain block is better)
About the bearings Clearance’s:
1. If measurements are Min 0.008" Max 0.010"
Then it's OK till next 3 monthly inspections.
2. If measurements are Min 0.011 Max 0.013"
Then it's OK to run but start planning for future replacement.
3. If measurements are Min 0.014 Max 0.016"
Then it should be replaced at first break in the drilling (Logging, or well completion).
4. If measurements are above 17" then it should be replaced immediately.
Back lash 30~40 thaw (measue eat fom teath and plus not

Crosshead guide left 0.015`` minimum 0.025`` maximum

Crosshead guide center 0.015`` minimum 0.025`` maximum
Crosshead guide right 0.015`` minimum 0.025`` maximum
Run out test (dial indicator) at pony rod and rotate pump
1- Which pumps types you know?
H-H $ Bomco
2- For which refer the national type 14P220 ?
Refer to 14’’ stroke length and 2200 hp.
3-What is the 6 months service maintenance for 12T1600?
Check the following clearances
Crosshead guide left 0.015`` minimum 0.025`` maximum
Crosshead guide center 0.015`` minimum 0.025`` maximum
Crosshead guide right 0.015`` minimum 0.025`` maximum
Crosshead bearing left MAX wear limit 0.015 inch order new when reach 0.012 inch
Crosshead bearing center MAX wear limit 0.015 inch order new when reach 0.012 inch
Crosshead bearing right MAX wear limit 0.015 inch order new when reach 0.012 inch
Main bearing left MAX wear limit 0.012 inch order new when reach 0.008 inch
Main bearing right MAX wear limit 0.012 inch order new when reach 0.008 inch
Pinion shaft bearing left MAX wear limit 0.018 inch order new when reach 0.012 inch
Pinion shaft bearing right MAX wear limit 0.018 inch order new when reach 0.012 inch
Eccentric bearing left MAX wear limit 0.018 inch order new when reach 0.012 inch
Eccentric bearing center MAX wear limit 0.018 inch order new when reach 0.012 inch
Eccentric bearing right MAX wear limit 0.018 inch order new when reach 0.012 inch
Check bull gear backlash 0.040 inch
Check foundation and / or hold-down bolts
Check suction flange bolting
Check pump coupling
Remove power end rear cover drain oil clean sump and flush lubrication system Change oil and
change filter every 6 month/1000-hrs which ever come first. Start oil lube pump check all oil lines
are in good condition and are feeding oil to bearings.
Refit power end rear cover. Change wiper seals

Visually inspect discharge module wear plate

Make MPIeck drive belts for wear condition and tension.
4- What is the function of pulsation dampener ?
To remove the fluctuating in pump delivery in the time period
between pumping strokes
5- Did we can use dry air as replacement of nitrogeen ?
No we can’t becouse air (oxgen) not idle gas and can aid in raising the fire
especially with mud chemical if diaghram faluired
6- How can you describe the mud pump as a pump ?
- Positive displacement – reciprocating – triblex
- Convert rotation movement to angular then to linear movement

7- Why we can’t use gear pump instead of centrifugal as super charge pump?
 Becouse we need flow rate as main no pressure , only we need pressure from 50-70 psi
to open the suction valve and also in the time period of mud pump pressure build up we have
to avoid pressure build up between super charge delivery and closed suction valve s ( centrifugal
pump will make flow internal leak).

8- Can you mention the bearing types in national-oilwell?

Main (crank shaft)(2) tappered double row
Pinion shaft (2) spherical ,double row self aligninig
Connecting rod(3) straight roller (cylinderical)
Crosshead pin (3) needle,double row
MP can operate with any stroke / min in the range from 1 to full load stroke / min. ( × )
Just in VFD
MP has no suction pulsation dumper ( × )
MP pulsation dumper use less if MP pressure is less than the charge of pulsating dumper.
(× )

The clearance between cross head and cross head lower guide should be 0.015: 0.025.
(×)
 Identify Models of Engines you have worked with? #........
1- What are procedures of valve lash & fuel timing adjustment for 3500 CAT engines?
# piston no.1 TDC compression stroke , insert the timing bolt then follow the table
in testing & adjusting manual to identify and mark valves and injectors to be adjusted in this stroke.
After adjustment done, remove the timing bolt , turn the engine by turning tool in
the same standard rotation to get piston # 1 exhaust stroke and adjust all remaining valves and injectors.
Adjustment to be done by using CAT special tools.
Make valve lash every 4000 hours
torqu for bolt in,ex is 70N & inj is 120N
2- How do you identify piston no.1 in compression stroke?
both intake & exhaust valves are closed.
3- What is the standard rotation direction for the engine?
counterclockwise as viewed from flywheel end.
4-What are the setting values for valve lash?
0.020 in for intake valves 0.040 in for exhaust valves
5- Identify the safety protection shutdown cases of 3500 Engine.
1. High coolant temperature.
2. low oil pressure.
3. Over speed.
4. High crankcase pressure.
6-What is the function of vibration damper?
It limits the torsional vibration of the crankshaft.
7- What is the function of aftercooler?
It increases the volumetric efficiency of the engine.
How?
By increasing the air density so that the air mass increases for the same volume. Ɣ
8-Why diesel engine have two valve intake and two exhaust ?
can reduce wear on each cam lobe
allow more power from higher RPM
provide additional cooling to the cylinder head
improving the mixing of air and fuel at low engine speeds
9--What is the cold cylinder cutout ?
The engine uses a strategy cold cylinder cutout to reduce white exhaust smoke after
start up and during Extended idiling in cold wether During cold start the ECM turns off one unit injector at
a time in order to determine if each cylinder Is firing

The cold cylinder cutout provides the following benefits:-

Reduction of white smoke
Reduction in the use of ether injection
Reduction of warm up time
Improved engine starting
10-What is the vibration dumper?
A vibration damper resembles a miniature flywheel that is either pressed on or bolted to
the front of the cranksha .
Why it is used?
The force from combustion in the cylinders will cause the crankshaft to twist. This is
called torsional (twisting) vibration. If the vibration is too great, the crankshaft will be damaged. The
vibration damper limits the torsional vibrations to an acceptable amount to prevent damage to the
cranksha
What it is. consist of ?
Vibration dampers are available in two basic designs -a rubber damper and a viscous Damper
A- Rubber Vibration Damper
The rubber vibration damper is installed on the front of the crankshaft.
The hub and ring are isolated by a rubber ring. The rubber vibration
damper has alignment marks on the hub and the ring. The marks give an
indication of the condition of the rubber vibration damper

B- Viscous Vibration Damper

The viscous vibration damper is also installed on the front of the
crankshaft. The viscous damper is simply a weight inside a metal
housing or case. The space between the weight and the housing is filled
with a viscous (very thick or sticky) fluid. As the weight moves through
the fluid, it dampens and absorbs the shock and torsional vibration of the
cranksha .
How can you check it is damage?
Replace the rubber vibration damper if:
• it is bent or damaged
• the rubber is deteriorated, cracked, or has moved from its original location
• the bolt holes are oversized and bolts fit loosely
Replace the viscous vibration damper if:
• it shows signs of leaking
• it is bent or damaged
• the bolt holes are oversized and the bolts fit loosely
• there is cranksha failure due to torsional forces

11-What is the ECM?

The electronic control module is the computer which controls the engine is used to perform computing
functions to execute this fonctions:-
- Governing – injec on – ming control – system diagnos c and data link communica on

12-What is the different between the hydraulic coupling and the torque converter?
They are similar design but the fluid coupling simply transmits torque (with some friction loss) while a
torque converter amplifies torque similar reduction gear.

13-- When starting engine the oil pressure increases as engine worm up proportionally. (×)
14- Piston ring can be detected with out disassembly. (√)
15- Timing for engine with turbo charger different from engine with out turbo charger .( ×
16- Combustion for 3500 B series start around 3 degree before top dead center (√)

17- Engine 3406 series, if engine is filled with water only no additives necessary changes
must be done for engine sitting. ( × )
18- Warming up engine at ideal speed is better than warming up at rated speed with
partially loaded. (× )
19- Standby engine (emergency engine) power is lower than continuous generator power.
(√
20-)Emergency generator in rig site can used in camp if camp engine are down. ( × )
21- Inlet air to transmitter from 0 : 120 psi . ( × )
22- Outlet air from transmitter form 0 : 120 psi . ( × )
11-Choose the correct answer .
23- AL ( Piston – Journal Bearing – Liner – Piston Rings – Crank Shaft)
24- CU (Piston – Journal Bearing – Liner – Piston Rings – Crank Shaft)
25- Cadmium (Piston – Journal Bearing – Liner – Piston Rings – Crank Shaft)
26- Chromium (Piston – Journal Bearing – Liner – Piston Rings – Crank Shaft)
27- Fe (Piston – Journal Bearing – Liner – Piston Rings – Crank Shaft )
28- White
a-Boor injector b- Leaking cylinder head and gasket
d- Worn piston rings c- Worm liner seals
e- (c and d)
29- Blue
a-Boor injector b- Leaking cylinder head and gasket
d- Worn piston rings c- Worm liner seals
e- (c and d)

30- Black
a-Boor injector b- Leaking cylinder head and gasket
d- Worn piston rings c- Worm liner seals
e- (c and d)
31- Why oil in fuel ?
Seal injector
32- water in oil :
Failure of the oil cooler core
Failure of cylinder head gasket
Crack in cylinder head
Cracked cylinder liner
Cylinder liner seals
Water pump
33- Oil in water
engine oilcooler core
Cylinder head gasket
Water pump
34- Fuel in oil
Leaking seals on the case of the unit injector or on the barrel of the unit injector
Leaking seals on the fuel line adapter for the cylinder head
Excessive leakage from the unit injector tip or breakage of the unit injector tip
Cracked fuel supply manifold
Leaking seal on the fuel transfer pump
35- Fuel in water
Injector sleeve or injector sleeve seal
36- Coolant temprature too high?
Radiator
Coolant leak
Faulty radiator cooling fan (if applicable)
Faulty pressure relief valve
Faulty temperature regulator
Faulty jacket water coolant pump
Load on the system
37- Coolant temprature too low?
Faulty water temperature regulator
Long idle periods
Very light loads
38-Crank case pressure high?
Worn engine components
Plugged crankcase breather

39-Engine Cranks but Will Not Start?

Diagnostic codes
Event codes
Fuel supply
Electrical power supply to the Electronic Control Module (ECM)
Starting aids (if applicable)
Engine shutdown switches (if applicable)
Engine speed/timing
Unit injectors
Combustion
40-Engine Has Early Wear?
Engine Oil
Incorrect maintenance intervals
Contaminated engine oil
Low oil pressure
Contaminated Air
Leaks in air intake system
Contaminated Fuel
Inspect the fuel filters for contamination.
41-Engine Misfires, Runs Rough or Is Unstable?
Diagnostic codes
Electrical connectors
Fuel supply
Cold mode operation and cold cylinder cutout
Throttle signal
Unit injectors
Air inlet and exhaust system
42-Engine Overspeed
Intake air is combustible.
Sudden drop of load
43-Engine Stalls at Low RPM
Unit injectors
Fuel supply
Air shutoff valves (if applicable) or blocked air supply
Low engine idle
Accessory equipment

44-Engine Will Not Crank

Batteries
Battery cables
Starting circuit
Starting motor solenoid
Starting motor
Shutdown switch
Flywheel ring gear
Engine accessories
Hydraulic cylinder lock
Internal engine problem
45-Excessive Engine Oil Consumption
Oil leaks
Oil level
Engine oil cooler
Turbocharger
Valve guides
Piston rings
Incorrect installation of the compression ring and/or the intermediate ring
46-Excessive Black Smoke?
Air shutoff (if applicable)
Air inlet and exhaust system
Fuel injector
Turbocharger
Atmospheric pressure sensor
Fuel quality
Valve adjustment

47-Excessive White Smoke

Coolant temperature sensor
Water temperature regulators
Engine speed/timing sensor
Unit injectors
Flash file
Fuel supply
Component wear
Cooling system
Exhaust Temperature Is Too High
Air inlet and exhaust system
Fuel injectors
Aftercooler (if applicable)
48-Low Engine Oil Pressure
Low engine oil level
Dirty engine oil filters
Restriction at engine oil pump
Restriction in engine oil cooler(s)
Fuel dilution of engine oil
Camshaft and/or camshaft bearings
Crankshaft bearings

49-Low Power/Poor or No Response to Throttle

Fuel supply
Derate mode
Cold mode operation and cold cylinder cutout
Throttle signal
Electrical connectors
Injector
Fuel Ratio Control Limit (FRC)
Air inlet restriction
Exhaust restrictions
Electronic Control Module (ECM)
Air shutoff valve (if applicable)
Fuel position multiplier (if applicable)
50-Mechanical Noise (Knock) in Engine
Faulty accessory
Damage to valve train components
Failure of connecting rod bearing
Crankshaft bearings
51-Noise Coming from Cylinder
Low quality fuel
Engine speed/timing sensor
Electrical connectors
Injector
Not enough lubrication
Too much valve lash
Damage to valve train components
Failure of connecting rod bearing

52-Poor Fuel Consumption

Engine speed/timing sensor(s)
Electrical connectors
Injector
Fuel supply
Air inlet restrictions
Exhaust restrictions
53-Too Much Valve Lash
Rocker arm
Not enough lubrication
Worn rocker arm
Worn bridges for valves
Worn pushrods
Worn valve lifters
Worn camshaft
Worn valve stem
Incorrect valve lash
Loose retaining bolt(s) for rocker shaft
Worn valve springs
Valve seats
54-Too Much Vibration
Vibration damper
Loose engine supports
Fan blade
Misfiring cylinder
Alignment and balance
55-Valve Rotocoil or Spring Lock Is Free
Cracked inlet valve rotocoil
Broken spring locks
Broken valve spring(s)
56-Can Not Reach Top Engine RPM
Fuel supply
Derated engine
Cold mode
Throttle signal
Air inlet restriction
Exhaust restriction
Leaks in air system
Valve adjustment
Injectors
Faulty accessory equipment
57-Types of engines?
Standby
Continus
Emegency
58- how adjust injector?
By cat tool
adjust it on its base at 64.34 mm
put it on injector and adjust the stipnes of sping till achieve it with available ( + or - 8 )
59-How to check engine shut down because coolant temprature?
remove sensor plug its location and use lighter on it it warning at 102C and shutdown at 107C
60- How to check engine shut down because oil pressure?
remove sensor plug its and keep it at atmospheric pressure 14.5
61- How to check engine shut down because crankcase?
remove sensor plug its and keep it at atmospheric then ‫ اﻧﻔﺦ ﻓ ﻪ‬shutdown at 3.5kpa and warning at 2kpa
62- How to check engine shut down because overspeed?
you cant but in some kind of engine like 3516 you can do it from panel about 1.18 from rated speed 1700
63- what the function of tubo charger?
increase specific power
64-What it mean blue smoke?
mean that oil in combustion
65- How you change Rear seal?
Disassemply generator
Disassemply spider coupling
Disassemply flywheel
cut old seal and take it out by hammer jack
clean its place and make sure its ok
install new one dry by special tool
It have arrow to show the direction reear is counter clockwise
Assemply flywheel
Assemply spider coupling
Install generator
Make allignment
66- How you change Rear seal?
Disassemply radiator
Disassemply fan and pulley
Disassemply vibration damper
cut old seal and take it out by hammer jack
clean its place and make sure its ok
install new one dry by special tool
It have arrow to show the direction font seal is clockwise because I am looking fom front
two seal are different
67- How you change cam?
you can take it from front or back
If back have to Disassemply generator and if from front disassemply radiator
but you can make it without disassemply them BY
Devide it to two part from back
make engine at TDC compession stroke (1,2 are closed)
Disassemply cover at back
Disassemply bolt of cam gear
take cam gear out
open side door for cam
put special tool and pull it while I am rotating
break toque of bolt that connect two part of cam trough cam side door
when it go back disassemply screw
both part are different
68- At how many hours you change turbo?
20,000 hours
‫ﻋﻴﻨﺔ اﻟ ﺖ ‪65-‬‬ ‫اﻟﻤﻌﺎدن‬
‫ﻋﻴﻨﺔ اﻟ ﺖ ‪ :‬ﻋﻨﺪ ﺗﺰو ﺪ اﻟ ﺖ او ﺗﻐﻴ اﻟ ﺖ ﻗﺪ ﻜﻮن ﻳﻮﺟﺪ رﻣﻞ ﻓﻴ ل ﻣﻊ اﻟ ﺖ " اذن اﻟﺴ ﺐ وﺟﻮد رﻣﻞ ‪1-‬‬ ‫ﺳ ﺐ ﻇﻬﻮر اﻟﺴﻠ ﻜﻮن‬
‫" ﻣﻊ اﻟ ﺖ‬
‫‪ liner – crank shaft‬ﺳ ﺐ ﻇﻬﻮر ﺣﺪ ﺪ ﻋﻴﻨﺔ اﻟ ﺖ ‪ :‬ﺗﺎ ﻞ ‪2-‬‬
‫‪ : bearing‬ﺳ ﺐ ﻇﻬﻮر ﻧﺤﺎس ﻋﻴﻨﺔ اﻟ ﺖ ‪3-‬‬

‫)‪ pump " mechincal clutch " (workover‬اﻟـﻰ ‪ engine‬ﻧﻘﻞ اﻟﺤﺮﻛﺔ ﻣﻦ ‪66-‬‬
‫" ‪ rig " transmission‬ا ‪ engine‬ﻧﻘﻞ اﻟﺤﺮﻛﺔ ﻣﻦ ‪67-‬‬
 Elbow
Oil cycle Adaptor
↓
Turbo left ↓
← ← ← ← ← ← ← ← ↓
Left cam ↓
← ← ← ← ← ← ← ← ↓
Gallery piston cooling jet [Link] ↓
← ← ← ← ← ← ← ←
Adaptor
↓
Main oil gallery( crank&[Link])
← ← ← ← ← ← ← ←
↓
↓ [Link] Gallery piston cooling jet
↓ → → → → → → →
↓
↓ Right cam
↓ → → → → → → →
↓
↓ Turbo right
→ → → → → → →
Don’t let the oil pass to cooling jet to don’t lose the pressure so build up the
[Link] pressure till 19 PSI to make sure the oil go to all engine and cylinder head
and rise crank shaft
Note
# Normal engine oil pressure at rated rpm 50 to 65 psi
# Maximum engine oil pressure 87
# Minimum engine oil pressure 20 psi
 IN Supply
Rocker arm shaft → ↓
↑ ↑ ↑ ↓
Lifter
↑ ↑ ↑
Turbo
Cylinder head
↑ ↑ ↑
Cam shaft ↓ OUT
↑ ↓

↑ → → → →
↑ Rocker arm shaft
↑
↑
↑ ← ← ←
E EJ IN ↑
↑
↑

↑ Oil pins
 Air motor

Air source → → Signal fom bottom → to Solonid

Stop at relay
↓
to air motor ← Air source pass ← then Signal to relay ← Pendix out

Diesel cycle ‫ﺎرﻛﻪ‬

Filter
← ← ← ← ← ← ↓ ↑ ↑
↓ ↓ ↑ ↑
→ → → → → → ↓ Manifold ↑ ↑
↑ ↓ ↑ ↓ ↑ ↑
↑ ↓ ↑ ↓ ↑ ↑
↑ ↓ ↑ ↓ ↑ ↑
↓ ↑ ↑
Cylinder head Cylinder head Cylinder head ↑ ↑
Regulator
Return 2 1
Pump
 Water cycle → →
To radiator

Thermostat
→ →
To pump suction ↓
→ →
↑ ↑ ↑ ↓
Cylinder head Cylinder head
↑ ↑ ↑
Liner Liner Liner

Block
←
Oil cooler ←
↑
Pump
1- What types you know ?
NOV ( tds 9/11 sa, tds11 sh , ps-500 ), can rig , tesco).
2- What is the RLA function and how many ports in it then mention them?
# Achieve swivel hose function between fixed (td. Body manifold) and rotating part (drive shaft).A8
# 10 ports ( 8 active , 2 spare) .

# IBOP closed, BOP opened, link tilt float, link tilt (M/H) “MOUSE HOLE’’, link tilt (D/D) DERRICK DICK,
clamp (piston), clamp (rod), and lifting port.
3- What’s lifting port function?
It is oil path to hang the RLA and keep it off the load collar and avoid friction and damage.
4- Mention the yearly inspection? 14 JOB.
A- Major overhaul for RLA
B- - MPI for RLA housing, STEM shaft, positioner gear.
C- Disassembly for the AC motors Blowers and inspect hydraulic brake calipers on 1500 psi and friction
pads
condition and thickness at 0 .09’’
D- Hydrostatic test on heat exchanger on 3000 psi, oil cooler (hydraulic oil ) 300 psi ( few types).
E- Visual check for encoder belt and adjust if required
F- Change hydraulic and gear oil and filters and oil samples analysis
G- MPI for AC – drilling motors hubs.
H- Inspect hydraulic reservoir bladder (change /2 years).
I- Inspect bail, bushings and pins.
J- MPI on S-pipe and main shaft.
K- Over haul for wash pipe (seal kit or complete kit) “/500 hrs water base mud “ and
/300 hrs oil base mud “ …..Every 6 months…..

L- Gears back lash (positioner and shot pin gear) 0.03’’-0.04’’

M- Detect main shaft endplay to be from .001’’ -.002’’ if more reshimming order.
5- What about 5 years inspection?
A- Yearly jobs
B- MPI for (upper,lower IBOP , Main body,main body cover,split load collar,radial grooves and stem)
6- What do you know about the accumulators?
A- Counter balance system (CB) 900 PSI discharge ,728’’3 (vertical)
B- System accumulator (SA) 800 PSI , 125’’3 (vertical )
C- IBOP time delay accumulator (CV) 800 PSI , 30’’3 (horizontal)
7- Oil tanks capacities?
25 gallon (hydraulic)
15 gallon (gear)
8- Variable, fixed pumps AC- motors power?
10 HP, 1800 RPM
9- Top drive weight?
25,250 Ibs.
10- What is the different between counter balance and stand jump?
Counter balance (CB) make reverse equilibrium by hanging the T.D weight off the bail and hook.
(JUST active only when bail start leave the hook) (DEFAULT ACTIVE)1600 psi
Stand jump (SJ) active mainly during pipes breakout to carry top drive over to protect thread damage.
SJR(190 PSI) active = 1600+190=1790 psi

11- What is meaning of PH-50 pipe handler?

50,000 [Link] torque.A43
12- Gear reduction ratio, what is meaning?
0.5 (main shaft (1) rpm when AC- motor (10.5) rpm )
Ac-motors rpm 1200, drilling speed 228 rpm = 2*1200/228=10.
13-Hydraulic tank bladder pressure?
Atmospheric pressure by breather to prevent air bubbles in oil and keep oil suction
priming with oil (atmospheric equalizing).
14- how to Inspect wash pipe alignment with top drive.
A-Remove the wash pipe assembly and replace the grease fitting.
B-Check the main shaft axial movement by applying an upward force to the main shaft and
measuring the amount of axial movement with a dial indicator.

C-If axial shaft movement is not .001 in. to .003 in., remove the bearing retainer and adjust the number of
shims
under the bearing retainer as required allowing .001 in. to .003 in. of axial shaft movement (end play)
with
the bearing retainer caps crews tightened to the required Torque depending on the size of the cap screw.
15- How to Check for primary and secondary gear set backlash?
Drain the gearbox oil Remove the access cover and the pump adapter plate to check primary and
secondary gear
set backlash
Run a piece of solid wire solder through the primary and secondary gear meshes and measure the
thickness of the two flat spots made by the gear teeth surfaces with a micrometer
If the primary gear mesh backlash exceeds .030 in. or the secondary gear mesh backlash exceeds .040 in
excessive gear wear or bearing failure may be indicated
16-Note: Hydraulic circuit’s components functions should be aware?
1- Normally –open logic cartridge metering (in counter balance circuit)
Sjr : stand jump relief
PCC : pressure reducing valve
UV: UNLOADER valve
SV 1,2 : SINGLE AND DOUBLE Solenoid valve
PF,PV : FIXED pump port, variable pump port .
RV 1,2 : variable ,fixed pump relieve valve.
17-What are the main jobs you do can mention?
Change bottom seal
Change upper seal
Change RLA on rig floor or in rig move
Change upper,lower IBOP and saver sub
Check load collar
Overhaul RLA
Detect main shaft end play and order shims
Change shot pin block
Setting tilt link system (synchronized, mouse hole position, drill side position)
Setting counter balance and stand jump
Change hydraulic tank bladder
Change disc brake pads
Hydrostatic test on the heat exchanger
18-how you make test for RLA?
Remove one side and give pressure in another side till 1000 psi
19- how many o-ring and seal while you overhauling RLA?
at body
1 oring
1 teflon
10 seal
1 teflon
at stem
1 thermal
1 o-ring outside
1- whiperseal inside
at gear
1 seal
20- Steps of RLA?
Disassembly guard
Disassembly link
Disassembly pipe handler (graper)
Disassembly tool joint
Disassembly pipe for shotpin
Disassembly shotpin
Disassembly pipe
21-distance at adjust allignment of top drive?
30 inch
22- how many roller at topdrive?
16 roller 4 inch
4 roller 6 inch
2 roller 2 inch
23-Adjust fixed & variable and unloading valve?
Setting fixed displacement pump
1. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when
looking into pump shaft/ electric motor fan). Correct as required.

2. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that
would indicate cavitation; check for leaks.
3. Locate the tube connecting manifold port PF to the lubrication motor.
Disconnect the tube at the manifold end, cap the tube and plug the PF port using steel fittings.
4. Set the relief valve RV1 for the variable displacement pump to a minimum setting,
fully counterclockwise, which allows the hydraulic system to operate without building up pressure
5. Set the relief valve RV2 to minimum pressure, fully counterclockwise.
6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the
pressure increases to 400 psi at test point PF. Set the jam nut on RV2.
7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor.

8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate.
9. Restart the hydraulic system electric motor.
Setting the Variable Displacement Pump
1. Connect an ammeter to the electric motor. Note the full-load
amps on the motor nameplate.
2. Restart the hydraulic system electric motor.
3. Set the counterbalance mode valve to the RUN position.
4. Adjust UV1, fully clockwise, to maximum pressure.
5. Connect a gauge to test point PV. Note the ammeter reading
while RV1 is at minimum setting.
6. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a
steady rate. During the pressure rise, observe the ammeter. The motor current should rise to a maximum
value at 800 psi, then drop off and begin to rise again. The point where the current drops is the pump
pressure compensator setpoint.
7. Adjust relief valve RV1 to its minimum setting. If maximum motor
current does not occur at 800 psi, adjust the pump pressure
compensator as required
8. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.
9. Connect a gauge to test point SA, and leave the gauge on PV.
10. Adjust relief valve RV1 to 2,200 psi and secure the jam nut
11. Install steel cap over the adjustment screw to discourage
unauthorized adjustment
12. Adjust unloading valve UV1 counterclockwise until the pressure
at PV drops off, then an additional two turns counterclockwise.
The pressure cycles like a sawtooth wave.
24-Mention load coller gap?
0.65 &0.62 inch
 Draw work
JC50DB
Input powet 1200kw (600W x 2 )
Main drive ratio of reducer 6.51
Auxiliary drive ratio of reducer 4.5
Auxiliary Brake Dynamic brake
1- Which types draw works types you know?
National 110 UE,1320 UE
DRILLMEC MAS7000,7500
WIRTH
T.T.S
2- MENTION the main jobs you faced?
Measure hi-LO CLUTCHES, main BNG’S
Change friction pads for cathead
Complete overhaul for LOW ,HIGH clutches
6-mobths inspections (maintenance)
Install overhauled or new auxiliary brake (wichita,elmagco) and set an aligning job
Change friction pad sets for caliper disc brake
Overhaul cathead makeup, break out
Change brake band assembly for conventional brake system
Change prime motor (D-C-A) and set aligning for the float shaft in NOV models
Change kicker plates by welding
3- What is the braking methods common use in D.W’S?
AS general classification A21
1-friction:
1.a. mechanical – brake band (NOV,DRILLMEC MAS7000
1.b. pneumatic - WICHITA (v236,v336,v436)
1.c. hydraulic - caliper disc brake (wirth,TTS,HH and drillmec MAS7500)
2- MAGNETIC
ECB : Eddy Current Brake (Baylor’s brake – ELMAGCO-
3-HYDROMATIC
Hydro-retarder technology
4- dynamic brake --- regenerative power
Opposing force coming from main electric motors (Can’t use as parking brake)
4- Mention the parameters should be considered to achieve efficient lubrication?
Right lubricant (oil, grease) ( designer instructions)
Right place
Right time period (as manual instruction time intervals
5- Cooling procedure in the brakes various types?
For friction types brake band (water flow from rotor seal to brake rim )
wichita (water jacket plates- grooved –copper)
caliper disc ( by air convection)
For hydromatic ( water fluid flow )
For magnetic ( by water reservoir in elmagco and flow rate)
For dynamic ( by motors cooling fan and fins ( blower acts)
6- What is the different between the heat exchanger and radiator?
Heat exchanger cooling the flow outlet from the pump
Radiator cooling the flow which return from the system
7- What is the different between the service brake, parking brake?
Service brake that using permanently during the drilling and most operation (it just
engaged when take the signal to engaged)
Parking brake that always engaged but used only when we need to stopping
permanently and saving the load ( take signal to disengaged and release for restart
continuing the oprtation (NORMALLY ENGAGMENT)

8- MENTION THE TYPES OF CLUTCHS?

Axial movement twin discs
Radial movement—air flex ( cb,vc)
9- What is the different between air transmitting clutch and brake clutch?
Air clutch brake driven stopped
Transmitting clutch driven run(rotate) with the drive
10- For twin disc clutch inspections? way?
Check the sprocket BNG clearance
Drain nipple movement indicate friction discs wear WAY
FIX extension nipple for on the drain nipple
Release the low clutch air (not engaged)
Fix dial indicator on D.W body and dial knob to touch the extension nipple (zero reading adjust)
Mesh the low clutch and read the dial reading value For new clutch discs dissplacement 3/16 ‘’
For max. Wear reading 9/16’’
Note: when reading is 7/16’’ request overhaul for clutch
11- What the brake band brake adjusting steps?
Three points
A-1- Equalizer beam (bar) gaps to be equal on both sides that is to guarantee equal grip
on both rims at the same time when brake is applied (1/4’’)
B-2- Driller’s lever to be at appropriate angle (35) /level (32’’) that is to attain adequate
manual control over brake mechanism
C-3- Clearance between rollers rests and brake bands
-set the travel of brake bands (on/off) the rim
-prevent excessive releasing movement and band deformation
12- What is different between EDC and ADS?
EDS : ELCTRONIC DRILLING SYSTEM
Using wichita brake as service brake for drilling feeding by using input drilling parameters during PLC
control unit
• In modern D.W’S using Wichita service brake

ADS : AUTOMATIC DRILLER SYSTEM

USE MECHANICAL CONTROL ON THE DRILLER brake band lever (for drilling feeding)
and take input parameters by drum rotational movement and weight indicator.

13-How many cluthes at drawwork?and where them?

Two
A-High Clutch on magco brake side (off the driller side)
B-Low Clutch on the driller side

14-What type of oil is used in the drawwork?

Gear 100&150&220&320&460&680
15-What type of pump used in the drawwork?
Oil pump gear pump
16-How much the clearance in the disk brake?
40 thaw
17-How many type of hydraulic cylinder are used in disk brake?
Single acting cylinder
18-What is used for the drawwork and el magco brake cooling?
Water with pressure 40-50 psi
19-What is the required PH value of elmagco cooling water?
PH-9
20-What is inertia brake?
Inertia brake is air flux clutch installed after the DC motor
21-What is Quick release valve?
Its valve use in the clutches air inlet to release the pressure in case of the pressure drop
22-How many gear in the drawwork?
Depend of the speed
(Low Low&Low High&High Low&High High)
23-How the gear shift works?
By pneumatic cylinder
24-You can use Low and High clutch together?
No,only one clutch a time
25-If there is no air can you use clutch?
Yes,by the manual engaggement
26-Can you Increase or decrease the clutch air?
Yes,by control valve on the panel
27-How many stuffing boxes at drawwork?
Two stuffing box
28-What is the use of stuffing box?

Set of seals and two bearing keep the drawwork main shaft rotation & save the air and water hoses
29- How to measure the clearance of EATON brake?

1- Drawwork lube pump in reverse operation should be more than 10 psi . ( × )

- In DW the oil pump is a type of gear oil pump (CB-100) √
- Oil pump is one-way pump √
- Oil pump pressure you must adjust between 0.2 : 0.4 Mpa ×
- If we want to reversal rotation we must rotate positively enough before reversal
rotation (5 min )
2- Service clipper with rim must be clearance (0.5: 1 mm). ( × )
- Adjust clearance between safety caliper and friction disc (0.5 : 1 mm ) √
- N2 in bottle must be 4 mpa (accumulator) √
- Max pressure in circuit (6 :7 mpa ) √
- Min thickness of brake pad 12 mm √
3- The DW rim cooling required 0.1 gal/min to every horse power consumed. ( × )
- 35 psi cooling pump outlet
4- The DW rim cooling required 0.1 gal/min to every horse power consumed. ( × )
from 40-80GAL/MIN
5- Hydraulic disc brake circuit does not have unloading valve. ( √
6- The DW in can work in emergency cases without clutches. ( √ )
7- Any of DW four speed can be selected the while DC motor is rotating. ( × )
1-Mention protection at drawwork?
Block contro l its electronic device to protect block control at up and down by setting parameter
Crown-o matic (tougle valve) have to line of air one have pressure and second one will
pass the air pressue
when it activate (moved)
Crown saver it’s a wire when travelling block touch it move the valve at mast to cut air
Clearance for bad at discbrake?
0.5-1 mm for safety and 0.3-0.7 fo service
Minimum thickness of bad?
12 mm
 Rotary
Inertia brake clutch LT500/250T ventilated type air tube clutch
Rated power 600kw/600v
Model ZP375
Drive ratio 3.56
Rotation speed of rotary table 0-220r/min
Max working torque 45000N.m
Max short time torue of rotary table 58500N.m
Weight of rotary table drive device 12500kg
1-In air compressor the pressure and oil pressure is the same till exit point? Yes
2- The two motor in BOP crane connected ( Parallel or Series )
Mention types of compressor?
1- is on/off
this less than 25hp on till achieve pressure then stop
2-load/unload
this open the gate when pressue reach low minimum at setting
then when reach the maximum pressure at setting close the gate
3-Modulation ( mechanical/electrical )
this one close the gate gradually before reach maximum pressure at setting
then close it completely when achieve maximum pressure at setting
4- variable frequency
this one decrease motor speed when achieve maximum pessure at setting