Beyond ZQ203-100 User manual

Add: No. 1201, E-commerce Building, Qingzhou City,
Shandong Province, China, 262500 Tel/Fax:
[phone]
山东省青州市开发区电商大厦 1201 号
Email: [e-mail]
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ZQ203 - 100
DRILL PIPE POWER TONG
OPERATION MANUAL
ZQ203-100-SM
STANDARD:SY/T5074-2004
PATENT No.: 90102517.8
7K-0048
Company Contact
ADD.:No. 1201, E-commerce Building, Qingzhou City, Shandong,
China, 262515
TEL：[phone] FAX：[phone]
POST CODE：262515
EMAIL：[e-mail]
WEB：www.sdbeyondpetro.com

Add: No. 1201, E-commerce Building, Qingzhou City,
Shandong Province, China, 262500 Tel/Fax:
[phone]
山东省青州市开发区电商大厦 1201 号
Email: [e-mail]
Http:// www.sdbeyondpetro.com
Contents
General Description …………………………………………….. 2
Sections
1.Functions : ………………………….……………….……….. 3
2.Operation Range………………………………………............. 5
3. Structure of Main Parts……………………………. …………. 5
4. Installation and Commission ………………………………... 11
5. Adjustments of Torque and Speed of Tong Head..….……... 14
6. Operation Regulations..................…..………………..…...... 15
7. Maintenance…………………………………………….…….. 16
8. Common Troubleshooting …………………………………… 17
9. Some Explanations ………………………………...…….. 19
10. Selection of Hydraulic oil …………………..……….……… 19

Add: No. 1201, E-commerce Building, Qingzhou City,
Shandong Province, China, 262500 Tel/Fax:
[phone]
山东省青州市开发区电商大厦 1201 号
Email: [e-mail]
Http:// www.sdbeyondpetro.com

Add: No. 1201, E-commerce Building, Qingzhou City,
Shandong Province, China, 262500 Tel/Fax:
[phone]
山东省青州市开发区电商大厦 1201 号
Email: [e-mail]
Http:// www.sdbeyondpetro.com
Fig.1 General View of ZQ203-100 Drill Pipe Power Tong
1 . floating body 21 . pneumatic tyre for low speed
2. die 22. low case body
3. inserts for jaws rack 23. sleeve
4. locating handle for the upper tongs 24. brake disc
5. pin 25. relief valve
6. sleeve 26. left- hand and right- hand screw
7. rotary 27. adjusting tube
8. adjusting bolts 28 . connecting rod
9. idler 29. jaw frame
10. gear 30. plug screw
11.suspension rod 31 . jaw
12. air pressure gauge' 32. brake band
13. bi-directional air valve 33 . door
14 . shockproof pressure gauge 34 . jaw pin
15. JML12-F08H oil motor 35. jaw roller
16. hand- reversing valve 36 . cam
17. inlet pipe 37. locating handle for low tongs
18. outlet pipe 38. air cylinder for gripping
19. sun- gear 39 . spring
20. pneumatic tyre for high speed 40. locating pin
41 . locating turning pin
General Description
ZQ203- 100 Drill Pipe Power Tong is a new type of mechanized tool on drilling
floor. Lanzhou Petroleum Machinery Research Institute and JIANGSU RUSHI
MACHINERY CO., LTD. （Pre-Jiangsu Rudong Petroleum Machinery Factory ）
develop it, the tong is the combination of the upper tongs and low tongs. Open head
design allows the tongs to be on or off drilling pipe whenever necessary.
The tongs are first used in oil fields in 1981. It took 20 to 25 seconds to finish
an operation of making up or breaking out. Only one man is necessary to operate
the handle of hydraulic and pneumatic valves.
Crewmembers expressed their satisfaction that the operation is safe. Reliable,
lab our saving and preventing drilling pipes from banding. In addition, the torque is
controllable. Especially, It showed excellent performance in special operations such
as coring. Accident handling. Etc. The tongs has been used and got popularized in
ail oil fields in China and has achieve good results.
Special Features:
* The hydraulic power is only used to the hydraulic motor. all other mechanisms
are operated with pressurized air as power.

Add: No. 1201, E-commerce Building, Qingzhou City,
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*The upper tongs head can float in any direction and the low tongs are installed
in the case body.
* Shift of high and low speed with clutch without need to stop.
*The open throat of the gear can automatically restore its position
and align with the door of the tongs .
*An air cylinder is available to shift the tong onto or off the well
head without the heed of pulling or pushing the tongs by manpower.
* The suspensions hanger of the tongs is attached to one end of wire rope
recede through a pulley block that is fixed on derrick; the tongs can be adjusted to
any level by means of a hand hoist at an-other end of the wire rope.
* The deformation of the tongs head is restricted by means of the automatic
door of the tongs head at large torque (75 kN. m).
Fig. 2 ZQ203- 100 drill pipe power tong is being
Operated at well bore site

Add: No. 1201, E-commerce Building, Qingzhou City,
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1 . Functions
1.1 Hydraulic System
Rated flow 114 L/min
Max. Working pressure 16. 6 MPa
Electric motor power 30 kW
1.2 Pneumatic System 0. 5- 1 MPa
Working pressure
1.3 The speed of the tongs head at various flow see table 1 .
Table 1.Speed of the Tongs Head at Various Flow
Flow(L/min)
Speed of the Tongs Head r. p. m
High Speed
Low Speed
114
40
2.7
100
35. 1
2.4
90
31.6
2. 1
80
28
1.9
70
24. 5
1.7
60
21
1.4
1.4 The torque of the tongs head at various pressure see table 2.
Table 2.Torque of the Tongs Head at Various Pressure
Pressure of Hydraulic
System
MPa
Torque of the Tongs Head
(kN. m)
High Speed
Low Speed
16.6
10
100
15.0
9. 3
90. 5
13.O
8.5
81. 1
11.0
7. 7
68. 1
9.0
5. 7
53. 9
7.0
3. 9
41.7
5.0
3.0
29. 5
Assuming that:
1.4.1 Braking moments of brake band to the tong head is equal to 1 kN. m (the
effects of this moments have been allowed in Table 2. ) .

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1.4.2 The torque to make up (or break out) will increase due to rotational inertia
of the tongs head, but will decrease due to friction. To simplify calculation, data of
Table 2 are thought to be the result of the two kinds of torque canceling out each
other (actually, drill pipe can be tightened up with high speed torque due to
rotational inertia of the tongs head at rated speed).
1.5 Applicable Pipe O. D.
1.5.1 There are four sizes of the tongs head's laws for five sized pipe) . D.,
Jaws 8", 51/2", 5", 41/2", 31/2" for five pipe O. D. (each provided with five
sizes of rollers). They are 8", (φ203-φ183 mm) drill dollar, 51/2" (φ178-φ158 mm)
drill pipe joint, 5"(φ162-φ142mm) drill pipe joint, 41/2" (φ146-φ126 mm) drill pipe
joint, 31/2"(φ121-φ101 mm) drill pipe joint.
1.5.2 Max. Wear allowance is 20 mm for each size of drill pipe joint, eccentric
wear allowance is 5 mm.
1.5.3 The total length of drill pipe box and pin should not be less than 420 mm.
1. 6 Pneumatic cylinder for shifting the tongs
Max. stroke 1500 mm
Forward pushing force 2. 36 kN (p=O. 6 MPa)
Backward pulling force 1. 71 kN (p=0. 6 MPa)
1.7 Overall size and weight
The tongs (LxWxH) 1700 x 1000 x 1400mm (including the height of suspension
rod)
The tank (LxWxH) 1560 x 1060 x 1 190 mm
Weight of the tongs 2400 kg
Total Weight 4000 kg (including the tong and the tank)
2. Operation Range
2.1 In Tripping Operation
For drill pipe make up and break out when the torque is less than 100 kN. m
2.2 For Kelly joint make up and break out during drilling.
2.3 For 8" drill collar make up and break out.
2.4 For throwing off single.
To throw off single, adjust the suspension rod to keep inclination of the tongs
head corresponding to that of the mouse hole' s, vary the direction of the pneumatic

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shifting cylinder (use wire rope or cable attached to the derrick leg), to make the
tongs head align the mouse hole, then throw-off the single.
2.5 To keep rotation of drill string (bottom hole assembly) when rig is in trouble.
If transmission system of drilling rig is out of order. Draw works and rotary table will
not go on working, and drill string from sticking, removing the jaws from the low
tongs onto well head, an attached cable to both sides of the tongs end to prevent
the tongs from rotating. Then install the corresponding jaws into the upper tongs
according to the size of drill stem, let the laws engage with Kelly joint or drill pipe
joint, disengage the pin and clutch of rotary table and then operate the upper tongs
to drive drill stem of drill string rotating. The time to rotate drill string is well bore at
low speed (2. 7 rpm) should not be too long (usually less than half hour) .
3. Structure of Main Parts
3.1 Two-speed planet gear box
In order to achieve low torque spinning at high speed and high torque make up
or break out at low speed, the tongs is provided with a two- speed planet shift gear
and unique breaking mechanism for shifting the gear without stopping the tongs.
The efficiency of the tongs is therefore raised (Fig. 1 -3). See Fig. 3, high speed is
obtained as hydraulic motor drives planet gear(Z2) on the frame to rotate, power
comes from the sum gear (Z1) when the internal gear (Z3) is braked. For low speed,
the sequence is reversal, hydraulic motor drives the sun gear (Z6) to rotate, power
comes from the frame fitted with the planet gear (Z4) when the internal gear (Z5) is
braked.
3.2 Reducer Assembly Refer to Fig. 3, the output shaft of the two-speed planet
gear box is the input shaft of the two-speed gear reducer assembly, the notched
gear (Z11) is driven to rotate through the first step deceleration (ZI -Z8) and the
second step deceleration (Z9- Z10- Z11 ) . The function of two- idle gear (Z10) is to
keep the notched gear (Z11) rotating continuously by (Z9). This is necessary for
passing the notch.
3.3 The Tongs Head (See Fig. 1 )
3.3.1 Gripping mechanism: The notched gear(7) of transmission drives the
floating body (1) to rotate through three pins (5) . If brake band (32) continuously
prevents the brake disc from rotating with about 1 kN. m torque and the law rack
(29) with laws (31 ) is connected with the brake disc by screws , when the floating
body begins to rotate, both brake disc and the jaw rack is braked to stop because

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disc is not in touch with the tool joint. But the cam (36) with a fixed slope rotates
along with the rotation of the float body, the rollers (35) located at the back of the
jaw will go up along the spiral surface and comes close to the center along the
groove (E-E Turned), and at last grip against the drill string joint. Meanwhile the
notched gear will drive the brake disc, the jaw rack and the laws on the floating
body and drill string' to rotate for the operation of making up and braking out.
The lower tongs is to drive the jaw rack to rotate in the case body through air
gripping cylinder (38), thus gripping or loosening the joint beneath.
3.3.2 The floating body, owing to the relative position between the upper tongs
and the lower tongs is variable; it is necessary that upper tongs can float relatively
to the lower tongs.
3.3.3 The brake mechanism, in order to cause relative motion between roller
and cam (in the operation of making up and braking out), it is necessary to design a
brake mechanism of the law rack for every type of power tongs.
Refer to Fig. 1, the brake mechanism consists of the two brake bands round
the brake discs, connecting rod (28) and adjusting tube (27), the spring force of the
adjusting tube can be adjusted to change the value of braking moments by rotating
the adjusting tube. The brake mechanism can center the floating body with drill pipe
and meet the requirements of eccentric joint.
3.3.4 Restoration mechanism: There are three problems of restorations for
aligning notches to power tongs of open head, that is, the aligning of floating body
with the case body, the aligning of jaws rack of the upper tongs with the floating
body, and the aligning of laws rack of the low tongs with the case body. First, align
approximately with high speed, then align accurately with low speed, by this way,
the floating body can be aligned exactly with the case body.
The aligning of law rack of the upper tongs with the floating body is just the
same as the aligning of jaw rack of the lower tongs with the case body. Refer to B-B
turned of Fig. 1, pin (40) is fixed on the floating body, the locating turning pin (41)
connected with the locating handle (4) is fixed on the sleeve (23) of the brake disc.
Obviously, the floating body in the position as shown in Fig. 1 is capable of
relative motion to the right with respect to the brake disc, that is, to make counter
clockwise rotation (breaking out position). If the locating handle is reversely turned
180 degree, the floating body is capable of relative motion to left with respect to the
brake disc, that is, to make clockwise rotation (making up position). The brake disc
will be aligned with the floating body while the floating body is turned reversely until
the locating pin (40) is in touch with the locating turning pin (41 ) . In order to
observe conveniently, the position of the locating handle of the upper tongs should

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conform to rotational direction of make up (or break out). The position of the
locating handles for the upper tongs and the lower tongs should be the same. The
locating pin of the restoration mechanism for the lower tongs is fitted on the dial,
and fixed with bolts; other parts are fitted on the frame of the lower casing body.
3.4 Pneumatic System
As shown in Fig. 4, compressed air of drilling rig is used as the air source. In
order to prevent the harmful influence of the long distance airline on the airflow, the
tong preserves compressor air in the suspension rod, so the inner cavity of the
suspension rod is the reservoir (6) of the pneumatic system.
As shown in Fig. 4, the three reserving valves contro1 respectively the air tire
for high speed (1) and for low speed (2), air cylinder for shifting and cylinder for
gripping.
The air cylinder for shifting and the air cylinder for gripping have been shown
respectively in Fig.6 and 7.
3.5 Hydraulic System
In order to simplify hydraulic system, only the hydraulic motor uses hydraulic oil
as source power, see Fig. 5, hydraulic oil from oil tank (8) goes through oil pump (1),
filter (2) to handle-reversing valve (4), Hydraulic motor can rotate forward and
backward by controlling the hand- reversing valve. Overflow valve (7) is installed to
restrictions max. Pressure of hydraulic system. In order to keep hydraulic system in
low-pressure condition for making up, overflow valve (6) for making up is fitted. The
pressure for making up is adjusted to the valve of about 10 MPa. This is done
before leaving the factory. The working pressure can be found according to Table 2.
In order to clear away any impurities of hydraulic oil, filter (2) is fitted on the outlet of
the oil pump. Pressure oil goes through filter (2) to hydraulic motor. It is necessary
to clean or change the core of filter timely after working a period of time so as it can
be used continuously. There are two types of driving oil pump to be selected by
customers, one is driven by belts of air compressor of the rig (Fig. 8)and another is
electrically driven (Fig. 9). There are two types of hydraulic system to be selected
by customers, one is the constant displacement gear pump and another is variable
displacement plunger pump.