Dando DUKE STAGE IV Operating instructions

OPERATING AND MAINTENANCE MANUAL
DANDO DUKE STAGE IV
CABLE PERCUSSION RIG
TRAILER MOUNTED
SOCOTEC UK LTD.
DANDO DRILLING INTERNATIONAL LTD. REF.: SO/1950010
(PLEASE QUITE THIS NUMBER WHEN ORDERING SPARE PARTS)
DANDO DRILLING INTERNATIONAL LTD.
UNIT G, FORD AIRFIELD INDUSTRIAL ESTATE,
FORD, Nr ARUNDEL, WEST SUSSEX,
BN18 0HY, ENGLAND
E-MAIL: [email protected]
WEB SITE: http://www.dando.co.uk
TEL: [phone] FAX: [phone]

CONTENTS
SECTION 1 - GENERAL ..............................................................................................................................1
1.1 GENERAL SAFETY......................................................................................................................3
1.2 OPERATING AND MAINTENANCE MANUAL.............................................................................3
1.3 CODE OF SAFE DRILLING PRACTICE......................................................................................3
1.4 SAFETY PRECAUTIONS.............................................................................................................4
1.4.1 STARTING RIG ENGINE.........................................................................................................4
1.4.2 LEVELLING THE RIG..............................................................................................................4
1.4.3 MAST RAISING........................................................................................................................4
1.4.4 DRILLING OPERATIONS........................................................................................................4
1.4.5 WARNINGS..............................................................................................................................4
1.4.6 BATTERIES .............................................................................................................................5
1.4.7 TRAILER MOUNTED RIGS.....................................................................................................5
1.5 GUIDANCE NOTES ON SAFETY................................................................................................6
1.5.1 PERSONNEL...........................................................................................................................6
1.5.2 TRAVELLING TO, ON AND FROM DRILLING SITES............................................................6
1.5.3 DRILLING SITE PREPARATORY AND RESTORATION WORKS.........................................8
1.5.4 SETTING UP............................................................................................................................9
1.5.5 DRILLING OPERATIONS - GENERAL ...................................................................................9
1.5.6 DRILLING OPERATIONS –CABLE PERCUSSION.............................................................10
1.5.7 PLANT MAINTENANCE ........................................................................................................11
1.5.8 SITE ABANDONMENT ..........................................................................................................12
1.5.9 TRAINING..............................................................................................................................13
1.5.10 WELFARE AND PERSONAL PROTECTION........................................................................14
1.5.11 WIRE ROPES - GENERAL SAFETY AND MAINTENANCE.................................................16
1.6 RECOMMENDATIONS ..............................................................................................................20
1.7 WARNINGS................................................................................................................................21
SECTION 2 –TECHNICAL DATA..............................................................................................................23
2.1 RIG SERIAL NUMBER –............................................................................................................25
2.2 GENERAL DATA........................................................................................................................25
2.2.1 RIG DIMENSIONS –TRAILER VERSION ............................................................................25
2.2.2 RIG DIMENSIONS –TRACKED VERSION ..........................................................................25
2.2.3 DRILLING DEPTHS AND DIAMETERS .................................................................................25
2.2.4 POWER UNIT ........................................................................................................................26
2.2.5 COMPRESSOR .....................................................................................................................26
2.2.6 HYDRAULIC SYSTEM...........................................................................................................26
2.2.7 MAST .....................................................................................................................................26
2.2.8 STABILISING OR LEVELLING JACKS .................................................................................26
2.2.9 MAIN FREE FALL WINCH.....................................................................................................26
2.2.10 TOOLING WINCH.................................................................................................................26
2.2.11 TYRES ...................................................................................................................................26
2.2.12 TOWING WEIGHTS –TRAILER VERSION..........................................................................27

2.2.13 FINE FEED BRAKE CONTROL.............................................................................................27
2.2.14 SPT HAMMER ASSEMBLY (OPTIONAL EXTRA)................................................................27
SECTION 3 –OPERATING INSTRUCTIONS ...........................................................................................29
3.1 ACCEPTANCE OF RIG..............................................................................................................31
3.2 TRANSPORT..............................................................................................................................31
3.3 CONTROLS................................................................................................................................31
3.3.1 FREE SPOOL WINCH BRAKE..............................................................................................34
3.3.2 FREE SPOOL WINCH CLUTCH ...........................................................................................35
3.3.3 ENGINE..................................................................................................................................35
3.4 ASSEMBLY OF RIG...................................................................................................................35
3.4.1 SITE PREPARATION ............................................................................................................35
3.4.2 ERECTING PROCEDURE.....................................................................................................35
3.4.3 TAKE-DOWN PROCEDURE.................................................................................................42
3.5 SPT AUTO HAMMER DEPLOYMENT.......................................................................................46
3.5.1 DEPLOYMENT PROCEDURE ..............................................................................................46
3.5.2 STOWING PROCEDURE......................................................................................................48
3.6 SPT HAMMER OPERATION......................................................................................................49
3.7 CABLE PERCUSSION OPERATION.........................................................................................49
SECTION 4 –RIG MAINTENANCE AND SERVICE .................................................................................51
4.1 ENGINE FUEL............................................................................................................................53
4.2 ENGINE OIL ...............................................................................................................................53
4.3 ENGINE COOLANT....................................................................................................................53
4.4 COMPRESSOR OIL...................................................................................................................53
4.5 BRAKE FLUID ............................................................................................................................53
4.6 TOOLING WINCH ......................................................................................................................53
4.7 BATTERY ..................................................................................................................................53
4.8 GREASING POINTS ..................................................................................................................53
4.9 HYDRAULIC SYSTEM...............................................................................................................54
4.9.1 HYDRAULIC HEADER TANK................................................................................................54
4.9.2 HYDRAULIC CHASSIS TANK...............................................................................................55
4.9.3 HYDRAULIC TANK BREATHER ASSEMBLY.......................................................................56
4.10 CONTROL CIRCUITS ................................................................................................................56
4.11 TO FIT NEW LEVELLING JACK CYLINDER.............................................................................56
SECTION 5 –SPARE PARTS ILLUSTRATIONS AND LISTINGS............................................................61
200105418 - TRAILER MODULE
200105417 - DRAW BAR ASSEMBLY
200105453 - TANDEM BRAKED SUSPENSION UNIT ASSEMBLY
200105420 - WHEEL MODULE
200105320 - MUD GUARD ASSEMBLY
200100922 - OFFSIDE REAR TRAILER CANOPY & LIGHT ASSEMBLY
200100923 - NEARSIDE REAR TRAILER CANOPY & LIGHT ASSEMBLY
200105610 - BRAKE ASSEMBLY
200105573 - BELLY PLATE ASSEMBLY [TRAILER]
200105153 - CORE RIG
200105282 - A-FRAME ASSEMBLY
700200256 - 0.375IN HOSE BURST VALVE ASSEMBLY [VUBA380 & VUBA61100088]
200105965 - MAST ASSEMBLY

200105253 - MAST SUB-ASSEMBLY
200101191 - CROWN WIRELINE RETAINER ASSEMBLY
200105526 - MAST HYD GUARD ASSEMBLY
200105403 - INNER MAST WEAR STRIP ASSEMBLY
200105404 - MAST RAISE BRACKET ASSEMBLY
200105999 - OVERRUN DEVICE ASSEMBLY
200105258 - WHIP CHECK ASSEMBLY
200105238 - OUTER LEG SUB-ASSEMBLY [RIGHT]
200105798 - OUTER LEG SUB-ASSEMBLY [LEFT]
200105959 - MAST FOOT ASSEMBLY
200105513 - MAIN MAST LIGHTING ASSEMBLY
200105715 - 0.44 TONNE WINCH ASSEMBLY [NP05 - DANDO DUKE]
200105963 - TIE BAR SUPPORT ASSEMBLY
200105110 - HOISTING REEL ASSEMBLY
200105131 - HOISTING DRUM ASSEMBLY
200105132 - CLUTCH ASSEMBLY
200105133 - BRAKE ASSEMBLY
200105204 - BRAKE BEARING ASSEMBLY
200105555 - DRUM SAFETY GUARD ASSEMBLY
200105795 - MOTOR ASSEMBLY
200108466 - GREASER EXTENSION ASSEMBLY
200105191 - HEADACHE POST ASSEMBLY
200105348 - HEADACHE POST SEAT ASSEMBLY
200105520 - HEADACHE POST CANOPY NS ASSEMBLY
200105171 - LEVELLING JACK ASSEMBLY
200105357 - FUEL TANK ASSEMBLY (44L)
200105358 - FUEL TANK LID ASSEMBLY
200105365 - FILLER ASSEMBLY (44L FUEL TANK)
200105783 - HYDRAULIC TANKS ASSEMBLY
200105375 - HYDRAULIC HEADER TANK ASSEMBLY
200105770 - HYDRAULIC CHASSIS TANK ASSEMBLY
200109147 - HYDRAULIC TANK BREATHER ASSEMBLY
200800297 - DANDO DUKE RETURN MANIFOLD ASSEMBLY
200800305 - HYDRAULIC PUMP ASSEMBLY
200105501 - ELECTRICAL CONTROL ASSEMBLY
200800237 - COMPRESSOR MODULE
200105510 - BATTERY ASSEMBLY
200105355 - GUARD ASSEMBLY [HYD OIL TANK]
200105152 - ENGINE ASSEMBLY
200100925 - DUKE EXHAUST MK2 ASSEMBLY
200800504 - ENGINE OIL DRAIN EXTENSION ASSEMBLY
200105457 - CANOPY ASSEMBLY
200105411 - FRONT CANOPY ASSEMBLY [OS]
200105408 - FRONT CANOPY SUB-ASSEMBLY [OS]
200105449 - 1/2" BSP HYD QUICK CONNECT ASSEMBLY
200105663 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [OS]
200105412 - FRONT CANOPY ASSEMBLY [NS]
200105907 - FRONT CANOPY SUB-ASSEMBLY [NS]
200105914 - FRONT CANOPY [NS] DOOR AND PANEL ASSEMBLY
200105917 - FRONT CANOPY [NS] DOOR ASSEMBLY
200105919 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [NS]
200105415 - REAR CANOPY ASSEMBLY
200105414 - REAR CANOPY SUB-ASSEMBLY
200105416 - REAR CANOPY DOOR & PANEL ASSEMBLY
200105194 - REAR CANOPY DOOR ASSEMBLY [NS]
200102246 - UMBILICAL DOOR ASSEMBLY
200105428 - REAR CANOPY DOOR ASSEMBLY [OS]
200105483 - CONTROL CONSOLE ASSEMBLY
200105473 - RECEIVER TANK ASSEMBLY
200106329 - SAFETY LATCH ASSEMBLY
200105452 - LIFTING EYE ASSEMBLY
200105460 - AIR HOSE REEL ASSEMBLY

200109131 - FINE CONTROL BRAKE ASSEMBLY
200109130 - LEVER ASSEMBLY
200109136 - FINE CONTROL CLEVIS ASSEMBLY
200115119 - BRAKE RESERVOIR HOSE ASSEMBLY
200115120 - BRAKE CALIPER HOSE ASSEMBLY
200108353 - STOWAGE ASSEMBLY - SPREADER BAR
200108355 - CLAMP BRACKET ASSEMBLY - SPREADER BAR
200109000 - CASING JACK ASSEMBLY [MEDIUM]
200109101 - CONSOLE & RAM ASSEMBLY [CASING JACK]
200109102 - CASING JACK KIT [MEDIUM]
200108315 - CORE EXTRACTOR ASSEMBLY
200105970 - STOWAGE ASSEMBLY (MULTI-HEIGHT SPT HAMMER)
200106333 - SPT STOWING WINCH ASSEMBLY
200105329 - STRAP GUIDE ASSEMBLY (SPT)
200106815 - MULTI-HEIGHT SPT HAMMER ASSEMBLY
200106304 - SPT HAMMER ASSEMBLY
200106201 - DRIVE CHAIN ASSEMBLY
200106816 - MULTI-HEIGHT SPT KIT
SECTION 6 –HYDRAULIC CIRCUIT ......................................................................................................261
SECTION 7 –ELECTRICAL CIRCUITS ..................................................................................................265
APPENDIX A –ENGINE PERKINS 403D-15...........................................................................................285
APPENDIX B –COMPRESSOR DYNASET HK450/8-14........................................................................397
APPENDIX C –TOOLING WINCH DINAMIC OIL NP05 .........................................................................463
APPENDIX D –PNEUMATIC CLUTCH WPT POWER TRANSMISSION CORP. W14-OC-202............501
APPENDIX E –PNEUMATIC BRAKE WPT POWER TRANSMISSION CORP. W14-OE-218...............539
APPENDIX F –REFERENCES................................................................................................................551
APPENDIX G –TEST REPORTS............................................................................................................555

SECTION 1
GENERAL
1

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SECTION 1 - GENERAL
1.1 GENERAL SAFETY
As Designers, Manufacturers and Suppliers of Specialised Equipment, Dando
Drilling International Ltd ensure so far as it is reasonable that our products are
safe and without risk to health when properly used.
You are requested to take the necessary steps to ensure that the appropriate
information is made available to all those involved with the proper use of our
products, or to anyone who may work on, purchase, or otherwise acquire such
products for their own use.
1.2 OPERATING AND MAINTENANCE MANUAL
Dando Drilling International Ltd support all new products being supplied to
their customers with a comprehensive Operator Manual which clearly defines
mandatory instructions for the operation, safe use and maintenance of the
products. Further, where proprietary items are incorporated into products of
Dando Drilling International Ltd, comprehensive Operators Manuals on these
items are also supplied, together with the Operating Manuals etc. on any
vehicle or other carrier supplied as part of a contract.
It is the responsibility of the owners or hirers of such products to ensure that
operators are provided with these Manuals and are suitably instructed
regarding the purpose of these Manuals and safety instructions. In addition,
operators should be suitably and adequately trained in the use of the product.
1.3 CODE OF SAFE DRILLING PRACTICE
It is the responsibility of the owners and hirers of this equipment to ensure
that the operators of the equipment are aware that drilling sites can be
potential hazardous environments, and that safe drilling practice should
always be adhered to.
Dando Drilling International draw your attention to the Code of Safe Drilling
Practice as published by the British Drilling Association [Ref 1], and would
recommend that all operators are fully conversant with all aspects covered by
this publication and take the necessary steps to become B.D.A. Accredited
Drillers. For operators outside the United Kingdom, we would recommend
that their national equivalent to the B.D.A. publication is adhered to.
The Guidance Notes on safety that follow are extracted from the British
Drilling Association’s publication “Code of Safe Drilling Practice”, and Dando
Drilling International would like to acknowledge with thanks their permission
to reproduce this section. Further guidance on percussion drilling can be
found in Guidance for the Operation of Cable Percussion Rigs and
Equipment also published by the British Drilling Association [Ref 2].
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1.4 SAFETY PRECAUTIONS
WARNING. BREATHING DUST IS DANGEROUS TO HEALTH
1) Operate in a well-ventilated place and use appropriate extraction
equipment or a damp cloth to remove dust.
2) Dampen all dust.
3) Dispose of waste in heavy gauge plastic sacks in accordance with
legislative requirements.
GENERAL INSTRUCTIONS AND WARNINGS
1.4.1 STARTING RIG ENGINE
Check that all controls are in a neutral/disengaged/minimum position.
1.4.2 LEVELLING THE RIG
Before attempting to raise the mast, ensure that the rig is set up on a firm level
base, and all jacks are in contact with the ground.
1.4.3 MAST RAISING
CAUTION: Before attempting to raise the mast, ensure that the mast
framework is clear of any obstructions.
1.4.4 DRILLING OPERATIONS
Before commencing any drilling operations, ensure that the spreader bar and
stay bars are fitted and secured.
1.4.5 WARNINGS
THIS RIG IS FITTED WITH AN ALTERNATOR
DO NOT disconnect batteries when engine is running.
DO NOT turn ignition key to '0' position on switch while the engine is running.
IF ANY ARC WELDING takes place on the rig DISCONNECT BOTH
BATTERY AND ALTERNATOR. When brazing, soldering or welding, it is
essential that any excessive heat source is kept away from the vicinity of the
alternator and any nylon piping or rubber hose.
FAILURE TO COMPLY WITH THESE WARNING WILL LEAD TO
COMPONENT DAMAGE AND MAY CAUSE INJURY.
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