STABILIZER INSTALLATION

To load drill pipe onto the drill, proceed as follows:

1. If the mast is in the vertical or drilling position, lower the mast and store it in the mast rests. Refer to the appropriate topic in this manual for the exact operating procedures.

2. Obtain a crane with suitable capacity and reach to place the drill pipe into the pipe racks with the mast in the stored position. Normal placement of the crane is on the left side of the drill since this allows the shortest reach and greatest boom angle.

CAUTION: Follow all applicable safety measures when working with cranes and rigging. Failure to follow safe working procedures can cause an accident, leading to the possible death or injury of personnel.

3. Position the pipe to be installed in such a position so as to be accessible to the crane. Normal placement of the drill pipe is on the left side of the machine, laying at right angles to the machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.

CAUTION: Make sure the drill pipe is secured against unwanted or unexpected movement. Failure to secure the pipe properly may result in the pipe shifting and causing death or serious injury to personnel in the area.

4. The upper gate is open when the pipe rack is empty. This function is controlled by a limit switch in the lower pocket of the pipe rack.

5. Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it will remain horizontal while being lifted. Attach suitable tag lines to the pipe. Remove the thread protectors and clean and lubricate the threads and shoulders on each end of the pipe. Install an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over the mast.

6. Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the pipe to allow the sling to be removed from the pipe.

CAUTION: Block the pipe securely to prevent it from moving unexpectedly.

7. Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and lift the pipe sufficiently to remove the blocking.

8. Slide the pipe down the pipe rack until it rests on the bottom of the pocket. Lay the pipe in the pipe rack and remove the sling and lifting bell.

9. When the pipe rest in the bottom of the pocket it will trigger the limit switch and close the upper gate.

10. Repeat the procedure for additional lengths of pipe.

11. Unloading the pipe is the reverse of the procedure used for loading the pipe.

DRILL TOOL STRING ASSEMBLY

The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit. In assembling the tool string, the stabilizer is the first item installed, then comes a section of drill pipe and finally the bit.

To install the stabilizer proceed as follows:

1. Place the stabilizer to be installed in a position so as to be accessible to the auxiliary winch line. Clean and lubricate the threads and shoulders on each end of the stabilizer. Install a lifting bell on the pin (upper) end of the stabilizer and lift it onto the drilling deck with the auxiliary winch line. Securely block the stabilizer horizontally on blocking sufficient enough to place the stabilizer 8-10 inches above the drill deck. Remove the auxiliary winch line.

2. Remove the guide bushing from the hole in the drill deck. Place the guide bushing on the upper end of the stabilizer with the tapered end of the bushing toward the lower (box) end of the stabilizer. Reattach the auxiliary winch line to the lifting bell.

3. Install the stabilizer and drill bushing in the hole in the drill deck. Make sure the drill bushing is seated properly. Lower the stabilizer until the slots in the stabilizer are aligned with the tool wrenches. Extend the tool wrenches to hold the stabilizer in place.

4. Remove the auxiliary winch line from the stabilizer and secure it out of the way. Remove the lifting bell from the stabilizer and store it.

TOOL STRING

NOTE: The use of stabilizers that have been modified or that do not allow this procedure to be used should be avoided. The use of nonstandard stabilizers will make assembly and disassembly of the tool string difficult and dangerous.

STABILIZER INSTALLATION

To install a single section of drill pipe proceed as follows:

1. Lower the rotary/pulldown unit until the pipe coupling on the unit can be reached from the drill deck. Set the hoist brake and press the drill/propel control OFF push-button. Clean the inside threads on the coupling to remove any dirt or old lubricant. Apply a coat of drill thread compound to the threads and shoulder of the coupling.

NOTE: Use only drill pipe thread compound on the pipe threads. Drill pipe thread compound contains material that will prevent the threads from seizing and galling under the severe pressure encountered on the pipe threads.

2. Press the control ENABLE button and release the hoist brake. Raise the rotary/pulldown unit to a position mast so as to clear the pipe rack as it comes in to place. Set the hoist brake.

3. Verify that the main compressor/hydraulic pump motor is running, the hoist/pulldown speed selector switch is in PIPE RACK/JOINTS position, the operating mode selector switch is in DRILL position, and on the operator’s display terminal that the head is clear of pipe rack. Place the pipe rack selector switch in #1 position. The pipe rack joystick will now control only the #l pipe rack.

4. Lift and move the joystick forward (OVER HOLE position) to move the pipe rack over the hole. Once the rack is over the hole return the joystick to the NEUTRAL position.

5. Release the hoist brake and lower the rotary/pulldown unit until it is approximately 1 foot above the upper end of the drill pipe. Reset the hoist brake.

6. Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and carefully lower the rotary drive unit until the coupling contacts the drill pipe. Allow the rotary/pulldown unit to lower under gravity while the coupling is threading onto the pipe.

7. When the drill pipe begins to turn with the rotary coupling, stop the rotary motion and check the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the pipe is removed from the rack. If the shoulders of the pipe and coupling are contacting, the joint is made up.

CAUTION: The threads on the drill pipe are tapered to make assembly and disassembly of the pipe easier. The threads are designed to disengage after only a few revolutions of the pipe. Failure to have the pipe shoulders contacting may result in the pipe joint uncoupling and the pipe falling from the rotary/pulldown unit.

There is no provision made for holding the pipe stationary in the rack while the joint is tightened. If the joint does not tighten using the above procedure it may be necessary to apply a small amount of hoist power to the rotary/pulldown unit to lift it slightly to remove the pressure from the drill threads.

CAUTION: Do not lift the drill pipe. Lift the rotary/pulldown unit only enough to relieve the pressure on the threads. Lifting the unit enough to lift the pipe will not only put pressure on the other side of the threads, but may also allow the pipe rack upper gate to open. Should the joint uncouple at this point, the drill pipe may fall out of the rack, causing death, serious injury or serious machine damage.

If the pipe joint does not make up by relieving the weight of the drive unit from the threads it will be necessary to inspect and/or repair the threads on the rotary coupling and the drill pipe. Inspect the threads for rough surfaces and burrs and apply a liberal coat of thread compound to them. The threads should have a smooth finish and no burrs or dirt that will hinder joint make-up. The joint shoulders should also be clean and smooth and should have compound applied.

After cleaning and repairing the threads, try making the joint again. If the joint cannot be made, either the drill pipe or the coupling is defective. Replace the pipe or coupling as necessary.

8. Once the joint is made up between the coupling and the pipe, the pipe is now ready to be lifted out of the pipe rack pocket. Lift the pipe approximately a foot above the top of the pocket to allow the pipe rack to swing out of the way. Set the hoist brake.

9. Once the pipe has been lifted clear of the pipe rack, swing the pipe rack to the STORED position by lifting and pushing the joystick rearward to the STORED position.

NOTE: Verify that the upper gate on the pipe rack is open before retracting the pipe rack. Retracting the pipe rack with the gate closed will cause damage to the pipe rack.

10. Once the pipe rack has been stored the pipe should be cleaned out using the bailing air. Remove all personnel from the area and turn on the bailing air for a moment. After cleaning the pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the upper end of the stabilizer.

CAUTION: Before working around the tool string set the hoist brake. Press the control ENABLE button.

11. Release the hoist brake and lower the rotary/pulldown unit until the drill pipe is approximately 1 foot above the upper end of the stabilizer. Reset the hoist brake.

12. Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and carefully lower the rotary drive unit until the drill pipe contacts the stabilizer. Allow the rotary drive unit to continue to lower under gravity while the drill pipe is threading onto the stabilizer.

13. When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the stabilizer is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.

Installation of the drill bit is the last step in preparing the tool string.

To install the bit, proceed as follows:

1. Hoist the completed drill pipe/stabilizer assembly 2 to 3 ft (0.6 to 0.9 m) off the drill deck. Place the bit basket (furnished with machine) into the hole left by the guide bushing in thedrill deck. Remove all personnel from the drilling deck and the immediate area. Turn on the main air stream to blow any contaminants from the drill pipe and stabilizer.

2. Place the bit into the bit basket. Coat the threads and shoulders of the bit and stabilizer with drill pipe thread compound.

3. Turn the rotary rheostat clockwise until the tool string begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and slowly lower the rotary/pulldown unit and tool string onto the bit. Lower the drive unit in small increments until the threads catch and the stabilizer starts to thread itself onto the bit. As soon as the threads start to catch, set the hoist brake and let the stabilizer screw itself onto the bit.

4. When the joint is tight the rotary unit will slow down and the rotary load meter will show an increased load. At this point return the rotary rheostat to the neutral position.

5. After making the bit to stabilizer joint, hoist the rotary drive unit to allow the bit basket to be removed. Remove the bit basket and store it in a safe place.

6. Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck. Set the hoist brake and press the control ENABLE button. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

BREAKOUT WRENCH OPERATION

CAUTION: When working with the breakout wrench it is important that the hoist brake be set, the control ENABLE button is off to prevent operation of the hoist or rotary controls. Failure to follow this caution may lead to the controls being energized while personnel are in the area, leading to the death or serious injury of those personnel.

Operation of the breakout wrench is necessary anytime a pipe joint, except the joint at the rotary coupling, must be broken. This includes removing the bit or stabilizer, or separating two sections of pipe.

To break a joint with the breakout wrench, proceed as follows:

1. If a pipe joint between pipe sections or between the stabilizer and the pipe is to be broken, align the slots in the lower pipe to be broken with the tool wrench jaws. Close the tool wrench by turning the tool wrench control switch to the ENGAGE position. Make sure the lower tool is held securely by the tool wrench and that the slots or flats in the tool are aligned with the tool wrench.

CAUTION: All personnel should be removed from the drill deck when operating the breakout wrench.

2. To break the joint, turn and hold the breakout wrench switch to the EXTEND position. The jaws of the breakout wrench should grip the upper tool and turn it while the lower tool is held stationary by the tool wrench. Release the breakout wrench switch.

3. Once the joint has broken, repeat the cycle 2-3 times to loosen the joint sufficiently to allow the rotary unit to finish disassembly.

4. Turn and hold the breakout wrench switch in the RETRACT position until the breakout wrench releases the upper section of pipe and moves away from the pipe.

5. Using the rotary unit, continue disassembly of the joint. Refer to the appropriate topic for exact operating procedures.

CAUTION: The joint must uncouple freely while using the rotary unit. If the joint does not uncouple freely, repeat the procedure using the breakout wrench until it does. Constantly observe the joint between the rotary coupling and the first section of pipe when running the rotary motion in reverse. If this joint begins to uncouple, stop the rotary motion immediately and retighten the joint. If this joint uncouples the pipe will fall, possibly causing death or serious injury to personnel.

6. If the lower tool is the bit, secure the bit with the bit basket as described in the topic BIT REMOVAL. Operate the breakout wrench as described above, except that the lower tool (bit) is secured by the bit basket, not the tool wrench.

DRILL TOOL STRING DISASSEMBLY

The tool string is disassembled in reverse of assembly, that is the bit is removed first, then the drill pipe and lastly the stabilizer.

To remove the bit from the tool string, proceed as follows:

1. Raise the tool string 2 to 3 ft (0.6 to 0.9 m) above the drill deck. Install the bit basket in the hole in the drill deck.

2. Using the breakout wrench, break the joint between the stabilizer and the bit. After breaking the joint, use rotary power to disassemble the joint. Use a slight amount of hoist power to lift the tool string off of the bit to facilitate the disassembly.

3. Hoist the tool string 2 to 3 ft (0.6 to 0.9 m) off of the drill deck. Secure the rotary/pulldown unit and controls. Attach a lifting bell to the bit. Attach the auxiliary winch line to the lifting bell and lift the bit out of the bit basket.

4. After removing the bit, a new bit may be installed or the bit basket may be removed, allowing removal of the drill pipe.

To remove the drill pipe from the rotary drive unit, proceed as follows:

1. Lower the tool string until the slots or flats on the upper end of the stabilizer are aligned with the tool wrench. Clamp the stabilizer in the tool wrench. Using the breakout wrench to break the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 ft (0.6 to 0.9 m).

2. Press the control ENABLE button to the OFF position and set hoist brake. Go to the drill deck and clean the pocket of the pipe rack to be used of dirt, cuttings or any material that will interfere with the entrance of the pipe or the operation of the pipe rack gate controls. Verify that the gate controls are intact.

3. Clean and lubricate the threads and shoulder on the lower end of the pipe. This is to prevent rusting while stored in the pipe rack. After performing this function, return the controls to operating condition.

4. After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4, swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

5. Slowly lower the rotary/pulldown unit and place the lower end of the pipe into the pipe rack pocket. Make sure that the pipe is seated firmly on the bottom of the pocket.

6. Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full speed. The joint should break at the rotary coupling.

NOTE: IF THE JOINT DOES NOT BREAK IMMEDIATELY, RETURN THE ROTARY RHEOSTAT TO THE ZERO POSITION TO REDUCE THE CHANCE OF DAMAGING THE MOTOR BY STALLING IT.

7. If the joint does not break, it will be necessary to index the slots on the drill pipe so as to allow the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the drill pipe in the forward direction until the slots in the pipe are almost aligned with the pawls in the sockets. This allows the drill pipe to rotate almost one-half turn before being stopped by the pawls.

If the joint does not break in a second attempt, the drill string will need to be reassembled, a hole drilled down and then use the breakout wrench to break the joint.

8. When the joint breaks, gently raise the rotary/pulldown unit as the joint is unthreading.

9. When the joint completely unscrews, the pipe will drop to the bottom of the pipe rack pocket. The upper gate will automatically close around the drill pipe. When the joint is completely unscrewed, raise the rotary/pulldown unit until it is in a position so as not to be struck by the pipe rack when it is moved. Set the hoist brake.

10. Swing the pipe rack into the stored position.

To remove the stabilizer, proceed as follows;

1. With the stabilizer still clamped in the tool wrenches, attach a lifting bell to the upper end of the stabilizer. Attach the auxiliary winch line to the lifting bell and lift the stabilizer and guide bushing from the hole in the drill deck. Block the assembly in a horizontal position.

2. Remove the auxiliary winch line from the stabilizer. Remove the guide bushing from the stabilizer and replace the auxiliary winch line.

3. Using the auxiliary winch line, remove the stabilizer from the drill. Replace the guide bushing in the hole in the deck.