ZP-275 ROTARY TABLE

Operation and maintenance manual

AG27500100-SM

March, 2006
 Foreword

ZP-275 Rotary Table is an important component of drilling rig. During drilling, the
rotary table turns the Kelly; the Kelly turns the string and bit to drill the hole. The rotary
table is designed to conform to the Standard SY/T 5531 “Rotary Table for Drilling Rig”
and API 7K Spec.
In order to make operators know the rotary table well, this manual shows the
details about the rotary table. Before running the rotary table, the administrators,
technicians and operators related to this drilling job must carefully read the manual
and relative documents to master the safety-operation procedures and skills.
Meanwhile, you are also requested to abide by the rules and regulations specified in
your unit.
During application, if the parameters and information of other matched equipment
are needed, see the instruction manuals and relative documents for the matched
equipment.

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 Contents
FOREWORD............................................................................................................................................................ I

1. GENERAL............................................................................................................................................................1
1.1 FUNCTIONS AND FEATURES ..........................................................................................................................1
1.2 TECHNICAL PARAMETERS.............................................................................................................................1
2. CONSTRUCTION DESCRIPTION...................................................................................................................1

3. INSTALLATION AND ADJUSTMENT.............................................................................................................3

3.1 INSTALLATION................................................................................................................................................3
3.2 ADJUSTMENT ................................................................................................................................................3
4. OPERATION AND USE.....................................................................................................................................4
4.1. HOW TO LOCK THE MASTER BUSHING AND TURNTABLE BUSHING ..............................................................4
4.2. THE BRAKE OF THE TURNTABLE ..................................................................................................................4
4.3. THE MATCHING OF THE ROTARY TABLE AND ROLLER BUSHING ..................................................................4
5. MAINTENANCE..................................................................................................................................................5
5.1 LUBRICATION ................................................................................................................................................5
5.2. ROUTINE MAINTENANCE AND CHECK ITEMS ................................................................................................5
5.3. PERIODIC MAINTENANCE AND CHECK ITEMS ...............................................................................................6
6. PACKING, TRANSPORTATION AND STORAGE.........................................................................................6
6.1 PACKING AND TRANSPORTATION..................................................................................................................6
6.2 STORAGE ......................................................................................................................................................6
7. LIST OF BEARINGS, LISTS OF SPECIAL TOOLS AND SPARE PARTS ..............................................7
7.1 BEARINGS .....................................................................................................................................................7
7.2 SPECIAL TOOLS ............................................................................................................................................7
7.3 SPARE PARTS ...............................................................................................................................................7
8. ATTACHED DRAWINGS ...................................................................................................................................8
8.1 CONFIGURATION DRAWINGS.........................................................................................................................8
8.2 PARTS LIST OF ZP-275 ROTARY TABLE.....................................................................................................10

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

1. General

1.1 Functions and Features

During drilling, the rotary table turns the Kelly and the string hanging under the
swivel to drill the hole. On trips and running casing, the string is latched to the top
rotary table, which can receive the maximum load permitted in the drilling rig and the
long service life of the table bearings should be guaranteed in load condition. The
rotary table can transmit the enough torque and horsepower through the bevel gear
and pinion.

1.2 Technical Parameters

Model ZP-275
Table opening 698.5 mm (271/2 )
Max. Static load 4500KN
Max. Table speed 300 r/min
Gear ratio 3.67
Distance between the center of rotary table and the center of the 1st row of sprocket
1353mm (53-1/4”)
Overall dimensions (L×W×H): 2380mm×1670mm×685mm
Weight 6122 kg

2. Construction Description

The rotary table realizes reduction through a pair of spiral bevel gear and pinion,
i.e. it can obtain necessary revolutions and torques to drive the drill string for drilling
operation.
The rotary table is mainly composed of master bushing, turntable, spiral bevel
gear and pinion set, input shaft assembly, locking device, table base and top cover,
etc.
The spiral bevel gear and pinion are used to provide smooth transmission, small

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

contacting stress and high load capacity. The gear and pinion are both made of high
alloy steel through heat treatment. The meshing clearance between the gear and
pinion can be adjusted by shim (19) and shim (20.6) which is positioned on the lower
main bearing and the flange end of input shaft.
The turntable（14） is a turning part to output the speed and torque in the rotary
table. The turntable bore diameter is in conformance with the regulation of API 7 K, the
gear（12） is tightly matched with the turntable, the loading bearing and prevent jump
bearing(40) all adopt angle contact thrust bearing, the contact thrust bearing as main
bearing not only receives maximum drill string load and casing load, but also
withstands the impact load from well bottom during drilling and tripping operations. It
has a compact construction. The bottom support ring (27) is connected with the
turntable by bolts to support the main bearing, the shims (22 are used to adjust the
axial clearance of the main bearing, the turntable is positioned on the table base by
loading bearing
The input shaft assembly is cartridge type construction, a component to input the
power to the rotary table. It consists of bearing race (20.7), bearings (20.15 and
(20.16), input shaft (20.5) and pinion (20.1), etc. The input shaft is supported in the
bearing house with a radial short cylindrical roller bearing and a radial spherical roller
bearing, the shaft assembly is mounted in the table base. The input shaft end diameter
and the key sizes conform to the regulation of No.5 shaft end specified in API 7K.
The rectangular type table base (10) is made of steel casting and welded
structure; it can withstand the maximum static load. There is a lube pool in the
chamber for lubricating the bevel gears and bearings. The table base is equipped with
left and right Z-blade locking devices, which can stop the table from forward and
reverse rotation to meet the needs of down-hole drill tool and special drilling
operations. The top cover (12) welded by riffled steel plate is a rectangular face plate
and fixed to the table base with inner-hex screws.
The master bushing (18) is split type construction, 5-1/4” four-pin-drive roller
bushing or Kelly bushing is used for drilling operation, the master bushing is
connected with the turntable and Kelly bushing by brake block (15). this rotary table
also can adopt big Kelly bushing ,the Kelly bushing device is whole type substructure,
after the relevant bushing device is put into the bore, 5-1/4” four-pin-drive roller
bushing is used for drilling operation

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

The splash lubrication is applied to gear and bearing; the grease lubrication to the
pin shaft of the locking device.
The labyrinth seal is used between turntable and table base as dynamic seal; the
spring seal ring between input shaft and bearing cap; O-ring is applied to the other
static seal areas.
There are two transmission methods through the input shaft end in the rotary
table, they are sprocket which is generally integral type two-row one, and flange. The
rotary table is provided with tree sizes of sprockets which are respectively 19, 21 in
teeth and 2” in pitch, also a flange to be connected with Cardan shaft for customers’
choice(Please specify the transmission method when ordering the rotary table). We
can supply customer with other specific sprocket and transmission connection so long
as the customer put forward to the requirement.
Note: Sprocket and flange are excluded in our supply scope of the rotary table. If
needed, customers should order them additionally.

3. Installation and Adjustment

3.1 Installation

The rotary table is generally mounted on the rotary table beam in rig substructure,
the top cover of rotary table should be leveled with the drill floor, after being positioned
and aligned, the rotary table should be tightened by the setting block and bolts or other
fastening ways.
Note：Locating block and connecting bolt are excluded our supply scope of the
rotary table.

3.2 Adjustment

When being installed, the rotary table should be aligned as per following request.

Transmission method Installation and alignment position Permit

Sprocket Flatness error between the input sprocket <1.5mm
of high speed shaft and the output
sprocket of drawworks.

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

Cardan shaft Parallelism error between the input flange

of high speed shaft and the output flange <1mm
of transmission device (Progressively
measure 4 points adjacent to 90 degree).
Auxiliary error between high-speed shaft 3 mm
and the output shaft of transmission
device.
Gear coupling Auxiliary error between high-speed shaft <1.5mm
and the output shaft of transmission
device.

4. Operation and use

4.1. How to lock the master bushing and turntable bushing

Pin (32) end should arrow to the strike plate of brake block, when the pin end
arrow to the turntable and bushing, it shows that the master bushing and the turntable
bushing are locked, per contra, they are separated.

4.2. The brake of the turntable

The locking device is used to lock the turntable and bear the reaction torque
during down-hole drill tool and special operations. When the rotary table is used for
drilling operation, it should be in open position. When braking the turntable, drive the
turntable by low speed, lift control level (6) and put left and right brake shoes (1, 2) into
the turntable recess, the control handle to be in the front end (near to well bore)
means braked; to be in the back end (near to input shaft end), open.
Caution: Starting the braked rotary table may cause the table parts severe
damage.

4.3. The matching of the rotary table and roller bushing

During drilling operation or running 7” casing, install API 3# bushing in master

bushing.
While running 9-5/8” casing, install API 2# bushing in master bushing.
While running 13-3/8” casing, install API 1# bushing in master bushing.
Notice: above-mentioned 5-1/4” roller bushing, API 1# bushing, API 2# bushing

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

and API 3# bushing are excluded in our supply scope of the rotary table. If needed,
customers should order them additionally.

5. Maintenance

5.1 Lubrication

5.1.1. The bevel gears and the bearings are splash-lubricated by the oil pool. The
sulphur-phosphorus type90 # extreme-pressure oil filled with 10 % of 4# anti-rust
complex agent shall be used as lubricant. The lubricating oil shall be changed every
two months. The oil level is subject to the highness when the rotary table stops
working for 5 minutes. When the oil level lowers to the down limitation, should fill the
lubricating oil up to the upper limitation and try to avoid overfilling, otherwise, it causes
the labyrinth seal of the low turntable leakage.
5.1.2. The pin shaft of turntable locking device shall be lubricated once a week
with 2# lithium base grease by means of grease gun.
黄油润滑点（共4处）
Lubricating points

Fig. turntable locking device

5.2. Routine maintenance and check items

5.2.1. Check oil level, oil temperature and oil quality for normal once a shift.
5.2.2. Check the spring seal ring on input shaft once a shift and the labyrinth seal
of the low turntable for leakage.
5.2.3. Check the voice and vibration of running table once a shift to make sure no

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

abnormal condition will happen.

5.2.4. Check the table locking device for flexibility and reliability once a shift and
for the position requested by drilling operation.
5.2.5. Check the master bushing and turntable, bushing lock pin and brake block
for flexible and reliable rotation once a shift.

5.3. Periodic maintenance and check items

5.3.1. After completing one well, should check the lower set ring (27) and bolt (24)
for looseness, if yes, they must be tightened at 690N.m of force moment.
5.3.2. After completing one well, should check input sprocket for axial play, if
found, tighten the screws on shaft end closure.
5.3.3. After completing one well, should check input sprocket for worn-out and
deformation, if found larger, the sprocket must be repaired or replaced.
5.3.4. After completing one well, should check the bushing for worn-out and
deformation, if found larger, the bushing must be repaired or replaced.
5.3.5.When the cumulative drilling depth reaches 90000-100000 meters, should
check the bevel gear and pinion and bearing raceway for worn-out and pit corrosion, if
exceed the allowance value, they must be replaced.

6. Packing, Transportation and Storage

6.1 Packing and Transportation

During packing, the rotary table should be in brake condition; the shaft end is
coated with lubrication grease and packed as per the regulation.
The rotary table is shipped in naked packing. When moving the rotary table,
necessary crane and transportation facilities should be used, and the rotary table shall
be lifted by the four lower corners. It is not allowed to tug or pull it on the ground.

6.2 Storage

When the rotary table stops running more than 2 months, it should be stored
properly. First, unscrew the plug (21) on the table base and emptying the lubricating oil
and clean the oil pool; then, wash the gears, bearings, turntable, input shaft assembly

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

and bushing; finally, apply the rust grease to all part surfaces and fitting surfaces, and
fill in the fitting clearance of moving components with rust grease.
If a long-term storage, the rotary table should be kept in dry, ventilation and
non-corrosion warehouse and make a periodic anti-rust check.

7. List of Bearings, Lists of Special Tools and Spare Parts

7.1 Bearings

Table 2 Bearings for Rotary Table

Model Description Qty per unit Weight(kg)

91682/800 bearing 800×1060×155 1 293

1681/800 bearing 800×950×120 1 120

NU2330 Centripetal short cylinder roller
(32630) bearing 150×320×108 1 45
22330 Centripetal globe roller bearing 150×
1 43
(3630) 320×108

7.2 Special Tools

Table 3 Special tools for Rotary Table

Drawing No. Description Qty per unit Weight(kg)

AG27500134 Bushing lifting dog 2 6.8×2

7.3 Spare Parts

Table 4 Spare parts for Rotary Table

Drawing No. Description Qty per unit Weight (kg)
Spring seal ring SG180× 0.178
HG4-692 220×18 1

AG27500123 O-seal ring 800×8.6 1 0.14

AG2750012003 O-seal ring 420×8.6 2 0.07×2

AG27500129 O-seal ring 1000×8.6 1 0.16

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

8. Attached Drawings

8.1 Configuration Drawings

See following drawing 2, 3, 4, and table 5.

Fig2. 275 rotary table

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

Fig3. 275 rotary table

转盘中心线

Fig4. Input shaft assembly of 275 rotary table

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

8.2 Parts list of ZP-275 Rotary Table

Table 5 Parts List of ZP-275 Rotary Table

No. Drawing No. Name Qty.

一、ZP 275rotary table (see fig.2 and fig.3)
1 AG27500101 Left pawl 1
2 AG27500102 Right pawl 1
3 AG27500103 Control rod pin 2
4 AG27500104 Pawl pin 2
5 AG27500105 Screw plug 1/8″ 2
6 AG2750010600 Control plug 2
7 AG27500107 nameplate 1
8 AG2750010800 Oil pointer 1
9 AG27500109 Screw plug 1 1/2″ 2
10 AG2750011000 Forge welding substructure 1
11 AG27500111 Wall scraper 2
12 AG2750011200 Upper cover 1
13 AG27500113 Big rig gear 1
14 AG27500114 Turntable 1
15 AG27500115 Slipper 4
16 AG27500116 pin 4
17 AG27500117 5″master bushing 2
18 AG27500118 Break out block 2
19 AG27500119 Washer 6
20 AG2750012000 Input shaft assembly 1
21 AG27500121 screw plug 1″ 1
22 AG27500122 Lower seal set 1
23 AG27500123 O seal ring 1
24 AG27500124 Bolt M24×70 12
25 AG27500125 Washer demand
26 AG27500126 Washer demand
27 AG27500127 Lower seal set 1
28 AG27500128 stopper 1
29 AG27500129 O seal ring 1
P=50.8
30 AG27500130 Double bank chain wheel Z=19 1
P=50.8
31 AG27500131 Double bank chain wheel Z=21 1
32 AG27500132 Baffle 1
33 AG27500133 Flange 1
34 AG27500134 Main bushing lifting dog 2
35 GB1152-74 Oil cup M10×1 4
36 GB70-85 Allen screw M24×75 4
37 GB827-86 Rivet 3×10 4
38 91682/800 Bearing 800×1060×155 1

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 INSTRUCTION MANUAL FOR ZP-275 ROTARY TABLE

No. Drawing No. Name Qty.

一、ZP 275rotary table (see fig.2 and fig.3)
39 GB91-86 Cotter pin 5×35 4
40 1681/800 Bearing 800×950×120 1
41 GB93-87 Spring washer 24 12
42 GB30-76 Bolt M16×40 24
43 GB93-87 Spring bolt 16 24
二、 ZP 275rotary table input shaft (see fig4 )
20.1 AG2750012001 Small bevel gear Me=18 Z=21 1
20.2 AG275001200200 Left Bearing cover 1
20.3 AG2750012003 O-seal ring 420×8.6 2
20.4 AG2750012004 spacer 1
20.5 AG2750012005 shaft 1
20.6 AG2750012006 Washer 426×520×0.5 4
20.7 AG2750012007 Bearing sleeve 1
20.8 AG2750012008 Washer 322×400×1 1
20.9 AG2750012009 Check ring 150 1
20.10 AG2750012010 Right Bearing cover 1
20.11 AG2750012011 Shaft sleeve nut 1
20.12 AG2750012012 Key 1
20.13 AG27500121 screw plug NPT 1 1
20.14 HG4-692-67 Oil seal 180×220×18 1
20.15 GB283-64 Bearing 32630 1
20.16 GB286-64 Bearing 3630 1
20.17 GB5782-86 Bearing M20×60 16
20.18 GB93-87 Spring washer 20 16
20.19 GB32-86 Bolt M16×35 8
20.20 Iron wire φ1 demand

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