Drilling Rig Maintenance Manual

Drilling Rig
Maintenance Manual
Contents
FOREWORD ......................................................................................................................................................... II
SAFETY ................................................................................................................................................................ III
1 REGULATIONS ON OPERATION AND MAINTENANCE ...........................................................................1
SHIFT MAINTENANCE ............................................................................................................................................1

WEEKLY MAINTENANCE ........................................................................................................................................1
MONTHLY MAINTENANCE .....................................................................................................................................2
SIX-MONTH MAINTENANCE AND ONE-YEAR MAINTENANCE .................................................................................2
2 REGULATIONS ON PERIODIC MAINTENANCE .........................................................................................3
2.1 MAST AND SUBSTRUCTURE..............................................................................................................................3

2.2 HOISTING AND ROTARY SYSTEM ......................................................................................................................4
2.3 AIR SUPPLY SYSTEM ........................................................................................................................................5
2.4 HYDRAULIC SYSTEM .......................................................................................................................................6
2.5 HIGH PRESSURE MUD SYSTEM ........................................................................................................................9
2.6 USAGE AND MAINTENANCE FOR DRILLING LINE .................................................................................... 11
3 OPERATION AND MAINTENANCE IN COLD SEASON...........................................................................14
3.1 HIGH PRESSURE MUD SYSTEM ......................................................................................................................14

3.2 LIFTING SYSTEM ............................................................................................................................................14
3.3 AIR CONTROL SYSTEM...................................................................................................................................14
3.4 OTHER SYSTEMS ............................................................................................................................................14
4 OVERHAUL FOR DRILLING RIG .................................................................................................................16
5 LIST OF SPECIAL TOOLS FOR MAIN MACHINE .....................................................................................17
5.1 LIST OF ATTACHED TOOLS .............................................................................................................................. 17

5.2 SLING LIST .....................................................................................................................................................19
6 LIST OF RECOMMENDED LUBRICATING OIL .........................................................................................20
I
Foreword
ZJ40/2250DB13 drilling rig is a low-temperature variable frequency drive cluster

fast moving rig for drilling in Russia developed for ZPEC (Zhongman Petrolum and
Natural Gas Group) in, with a drilling capactiy of 4000 m (5" drill pipe).
In order to ensure the relevant operators can be familiar with and know well the
operation of the drilling rig, this manual introduces the general description of
maintenance of the drilling rig. Before operating the drilling rig, the management staff,
technicians and the operators using the drilling rig must carefully read the manual and
the relevant technical data of this drilling rig, know well and be familiar with all the
details. Besides, they should possess the corresponding safe operation knowledge
and skills.
When the drilling rig is in operation, the personnel safety is absolutely important!
The manual may not fully list all conditions affecting the performance and failure of
the rig.
In case the equipment is in failure, the capability of the operators and the
understanding and practice of the maintenance are very important.
The complete technical document attached to this drilling rig is provided for the
buyer and user of this drilling rig as the guiding material in maintenance. Nobody can
copy it by any means or supply to the third party, otherwise, the legal responsibility will
be undertaken for the consequence produced.
Notwithstanding detailed examination and proofreading, improper may still exist in
this Manual. Making a comment or criticism is welcomed.
II
Safety
The following safety precautions which are closely related to the
ZJ40/2250DB13 rig are listed in below. Such precautions will not be introduced
in the sequent chapters and sections of this Manual. During operation and
maintenance, working personnel must master and exercise such
recommended measures. Details about special measures are contained in the
WARNINGS of this Manual.
1. Qualified personnel
Only the qualified personnel with authorization are allowed to operate and
maintain the said equipment.
2. Protection devices
The operators must wear protective suit, crash helmet, protective footwear and
other protection devices. During drilling operations, they must also be provided with
antitoxic equipment if noxious and harmful gas leaks.
3. Safety practice
Favorable, overall and safe practices must be observed at any time upon
installation, operation, removal and maintenance of equipment. It is the responsibility
of the owner/operator to establish favorable and safe practices, personnel training and
enforce them to comply with.
4. Operation of components
The operator shall not work before he/she has thoroughly read the operation
manuals of this equipment and fully acquaint him/her with all operation controls and
functions.
5. Unauthorized personnel
Unauthorized personnel shall be kept off the equipment upon its operation,
maintenance or running.
III
6. High Pressure
Before trying to remove any of the high-pressure loop components, make sure
that the pressure in the loop is released to zero. And while operating, make sure that
the power source of high pressure is always at closed status.
7. Maintenance against rules
Removing and maintaining components against rules shall be prohibited. For
some components (such as accumulator) that keep liquid under pressure, its pressure
must be fully released prior to removal and maintenance.
8. Maintenance of electric control
Before attempt to maintain and repair the electric control system and electric
circuit, make sure the electric control system and electric circuit to be repaired and
maintained have been cut off the power supply. During operation, electrical switches
(electric brakes) shall be kept under surveillance by specially-assigned persons to
make them always under power-off state. Maintenance and repair of electric control
system and electric circuit shall be carried out by more than two persons.
9. Lift
When lifting and moving an object, make sure the weight of equipment to lift or
move is within the allowable range of load indicated on the lifting devices and slings.
Meanwhile, pay attention to surrounding safety. Any person shall not be under the
object to be lifted under any circumstance.
10. Application of solvents or dyes
The application of the solvent or the dye should be used for particular
environment and under safe conditions. Therefore make sure the manufacturers’
warning and safety cautions are followed and such solvents or dyes are only used
under good ventilation and in permissible areas. Any waste mops polluted by the
solvent or dye should be put in specific treatment containers.
11. Use of compressed air
The equipment using compressed air may produce an environment mixed with
IV
fine particles even if the pressure of compressed air is reduced to less than 30psi.
Therefore, effective chip guards and individual protection devices must be provided
when using compressed air. Additionally, it shall never be allowed to make the
compressed air vent towards to yourself and others.
12. Moving parts
Hands, hair, cloths, ornaments, wiping cloths and tools shall be kept off upon
maintenance of moving parts.
13. Visibility
When visibility is low, maintenance of equipment is not allowed, including such
period before sunrise and after sunset unless appropriate and effective light source is
provided.
14. Before lifting and lowering
Make sure all control elements are in place (ON, OFF, Middle) before starting the
device. Lift and lower the mast as much as possible when the temperature is higher in
a day and take the effect of wind speed into account.
15. Working area
When operating the equipment, working area should be kept clean and free from
obstruction, hand tools and other substances.
16. Requirements on hot work
During installation and removal of the equipment, it is allowed to perform hot work
(electric welding, gas welding and etc.); however, you should keep away from
dangerous areas during hot work and acquire necessary approval from the person
concerned.
V
Safety First!
To prevent bodily injury, power source shall be under cut-off state
upon equipment maintenance, and locking measures to avoid
misoperation and obvious warning signs shall be provided.
Safety First!
It is necessary to confirm that all maintenance and routine inspection
work is finished before power is supplied!
Safety First!
When mechanical and electrical equipment are running, all safety
devices shall be kept under good condition, including crown-block saver,
safety valves, overflow valves, auto-alarm and breaking devices in air,
hydraulic and oil systems. All of such safety devices must be checked
each shift and confirmed that they works normally.
VI
1 Regulations on Operation and Maintenance
In order that the drilling rig can be kept normal and continuous working, and
service life of its all parts and components can become as long as possible, not only
correct operation but also maintenance for it must be carried out.
In order to enable continuous normal operation of the rig and extend the service
life of spare parts, in addition to the correct operation according to the regulations, the
maintenance must be carried out.
1.1 The construction team shall provide or designate mechanical, electrical,
instrument personnel for the normal use and maintenance of the rig.
1.2 In case of any failure or abnormity, the rig should be stopped and troubleshoot.
1.3 It is strictly forbidden to drill over-speed, over temperature, over-pressure
operation or to violate the regulations.
1.4 During the whole service period, the rig shall be periodically maintained at
shift, weekly, monthly, semi-annually and yearly. The problems found during
maintenance can be solved by operators or professionals as the case may be, and the
heavy workload (such as replacement of bearings) shall be solved by repair station or
repair shop.
Operation manuals or maintenance manuals for the equipment or its matching
components can be referred to for the maintenance of the related equipment or the
matching components not mentioned in the manual.
Shift Maintenance
Shift maintenance operation includes conventional operation such as routine
inspection, debugging, lubrication, fastening, cleaning, and anticorrosion as well as
shift maintenance items stated in the following provisions.
Shift maintenance operation is fully completed by operators independently and
belongs to their routine inspection work.
Weekly Maintenance
Weekly maintenance operation includes shift maintenance operation.
The routine inspection of weekly maintenance operation shall be fully completed
1
by operators independently. Some items with much workload (or difficulty) (such as
replacement of filter cores and inspection of insulation performance) may be
completed by operators together with association by the relevant staff.
Monthly Maintenance
Monthly maintenance operation includes weekly maintenance operation.
Maintenance items with much workload or difficulties found in monthly maintenance
inspection (such as adjusting the friction block of the clutch and cleaning & maintaining
of pneumatic components etc.) need completing by the related personnel and
technical personnel.
Six-month Maintenance and One-year Maintenance

After six months’ or a year’s use, components in all moving parts will bear some
necessary abrasion, and performance of the other non-moving parts will also have
some change. So they must be adjusted, maintained, and replaced. All such work
needs examining & repairing and maintaining completely in a professional machine
repair station or shop by professional machine repair personnel according to the
recommendations of technical personnel for equipment management.
2
2 Regulations on Periodic Maintenance
2.1 Mast and Substructure
Prior to repairing or modifying mast, consult the manufacturer to obtain the

confirmation of the mast raw materials and modification methods. Without the consent
of the manufacturer, the operator and construction technology must be approved by
the mechanical engineer to repair or modify.
The mast shall be repaired or modified by the rig mast manufacturer in
accordance with relevant regulations and standards.
The mast shall be maintained semiannually during normal use. Generally, the
de-rusting and anti-corrosion treatment shall be carried out at least every six months.
In case of serious corrosion caused by drilling, workover fluid, oil, natural gas,
saturated salt water and hydrogen sulfide, the rust removal and anti-corrosion
treatment shall be conducted after well is finished and before moving.
2.1.1 Routine inspection and maintenance

➢ Check the lifting components for any crack and deformation.
➢ Check the rope loop and the sling for rust, and ensure there is no corrosion
mark near the end.
➢ Ensure the mast expansion drilling line is intact.
➢ Check the lubrication of sheave system.
➢ Whether the pins are in place and whether the safety pins are complete.
➢ Whether all bolted connections are secure.
➢ In case of load, periodically measure the straightness error of the mast
column in the full length range, and observe whether the welding seams of
the main bearing force components in the mast and substructure are listed.
2.1.2 The mast is one of the main stressed components of the rig. Without
permission, welding and drilling are not allowed on the mast. The components
damaged or missing during transport and use shall not be substituted at will, and
technical consultation shall be made to the manufacturer.
2.1.3 The components on the steel structure do not allow drilling and tapping, or
any welding.
2.1.4 The maximum load capacity of mast is the maximum load that can be
3
experienced at normal ambient temperatures.
Refer to its Maintenance Manual.
2.2 Hoisting and Rotary System
2.2.1 Items to be Checked by Each Shift

➢ Check the connection, working performance and the brake performance of
the crown saver.
➢ Check the reliability of the electrical elements located inside the driller’
cabin and check the sealing of the air pipeline and the hydraulic pipeline.
➢ Check the fixing condition between the deadline and the fastline’s end.
➢ Check the lubrication and the sealing performance of all bearings.
➢ Check the fixing conditions of the bolts for the hook’s bail and ensure the
hook body can be freely rotated and the spring can be flexibly extended and
retracted.
➢ Check and ensure the sealing positions of the swivel, rotary table drive
device and the drawworks are with good sealing and the oil level and oil
temperature of the oil tanks can meet the requirements.
➢ Check whether the rotary table’s locking pins are flexible and reliable or not.
➢ Check whether the bolts for different components have been properly
tightened and are reliable or not.
➢ Check the rate of tension of the chain and check the temperature of the
drive positions.
➢ In case of much noise or seriously abraded gear, chain or chain sprocket
etc., it should be resolved in time.
2.2.2 Weekly Maintenance and Inspection Items
➢ Check the oil supply condition of each lubricating oil pump of drawworks
and rotary table drive device, whether the lubricating oil is clean, and whether
the filter element shall be replaced.
➢ Check whether the bail and the pins of swivel (if equiped) can be freely
rotated or not.
➢ Check the fixing condition of the traveling block’s shaft.
➢ Check the abrasion conditions of the sheave grooves of the crown block
and the traveling block.
➢ Check the sealing condition of the packing of the swivel (if equiped)’s
4
washpipe.
2.2.3 Monthly Maintenance and Inspection Items
➢ Check the connections and the abrasion conditions of different
components, clutches and different couplings.
➢ Check the fixing conditions of the pins between the rotary table and the
rotary beam.
➢ Check whether the bails, pins and sheaves of the hoisting system have any
crack or not.
➢ Check the abrasion condition of the drilling line and check whether it needs
to be changed or cut or not.
Refer to its Maintenance Manual.
2.3 Air Supply System

➢ Check whether the start and stop of the air compressors are in good
condition or not and check whether the oil quality, oil level and the oil
temperature can conform to the specification or not.
➢ Check the automatic pressure regulating device and the relief valve.
➢ Check the working pressure of the air receiver and drain the water in time.
➢ Check whether the pipeline is smooth or not and check whether the sealing
is in good condition or not.
➢ Check the working condition of the air filters and check whether there is
any block or not.
➢ Check whether the clutches and the quick release air valves are reliable or
not.
➢ Clean the filters and the air receivers’ relief valves.
➢ Check the control valves of the air compressors.
➢ Check the control valve of the air dryer.
Pipeline pollution may cause pipe blockage, valve parts malfunction or even
damage, and safety accident may occur. Always clean the pipelines and replace them
if necessary.
5
⚫ When the rig is moved, the disconnected pipe joint must be protected, the
exposure of the withhold hose must be covered with clean cloth and the like,
and the exposure of the metal pipeline shall be blocked by soft wooden cork.
⚫ Before the installation of pipeline, compressed air shall be used to clean the
pipeline. And the pipeline cannot be connected until all dirty things are cleared.
Processing of pneumatic component failure
When the pneumatic control component is found to be in fault or malfunction, the
valve shall not be disassembled casually. The reason for the failure is not always the
valve element itself, which may be due to the blockage of the air pipeline or the low
pressure. In case of this problem, do not disassemble the pneumatic control
component. The processing method is to determine the position of the fault with
reference to the pneumatic control principle diagram first, and then to separately check
(check the control air circuit, open the air joint in section, and check the ventilation). If
the control air circuit is clear, check the working air circuit again. Disengage the
hydraulic pipeline of the valve to check the ventilation condition, if blocked, check the
intake pipeline of the valve, and if the air pipeline is clean, it is proved that there is a
problem in the valve part before opening the valve part for maintenance. In general,
the spare valve shall be used to replace the defective valve, and then check the
defected valve, so as to ensure normal drilling operation.
Maintain entire air system after the driller has completed on a well or after a
certain period (no more than 3 months) and check the damageable members. Make
sure you replace or clean them in time to avoid operation under improper state.
Refer to its Maintenance Manual
2.4 Hydraulic System

➢ Ensure the quick connector is clean and connected accurately
➢ Check whether each hydraulic pump of hydraulic power unit and disc brake
power unit works normally, the oil level of the oil tank is satisfactory, the oil
filter is blocked, the oil leakage is free, or the accumulator operation is
normal. Oil temperature and pressure shall be within normal operating range.
➢ Check whether all hydraulic pipelines of the wellhead mechanical tools
6
and the hydraulic disc brake has any oil leakage or not, check whether the
pipelines are smooth or not and check whether the displays of all pressure
gauges are in good condition or not.
➢ Check whether the nitrogen charging pressure of the disc brake HPU’s
accumulator can meet the requirement or not.
➢ Check whether the oil level of the oil tank is satisfactory, the oil quality is
clean, or the filter element of the oil filter is clean. If the screen is damaged
and the dirt accumulates, replace it in time and replace the hydraulic oil if
necessary.
➢ Clean the element of the oil filter.
➢ Supplement the nitrogen for the disc brake HPU’s accumulator so that it can
meet the requirement of the nitrogen charging pressure.
➢ Check all valves and the pipelines.
Select the appropriate hydraulic oil

Hydraulic oil plays a role of pressure transmission, lubrication, cooling and sealing
in the hydraulic oil system. The improper selection of hydraulic oil is the main reason
for the early failure and declining durability of hydraulic system. The hydraulic oil shall
be selected according to the brands specified in the Operation Manual. In case of the
necessity to use alternative oil, the performance of which shall be the same as that of
original brand. Hydraulic oil different grades can not be mixed in order to avoid
chemical reaction and changes in performance. If the oil is dark brown, milky white
with strange smell, it is deteriorated and cannot be used.
Prevent hydraulic system from solid impurities
Clean hydraulic oil is the life of hydraulic system. There are many precise fittings in
the hydraulic system, some of which are provided with damping holes or slots. Solid
impurities could give rise to pulling of the precision matching part, unsmoothness of
the valve, blockage of the oil passage, and endanger the safe operation of the
hydraulic system. In general, the way of solid material invasion is: dirty hydraulic oil;
dirty oil filling tool; careless oil filling and maintenance, desquamation of hydraulic
7
element. The system can be prevented from solid impurities by the following
measures:
a. During filling, the hydraulic oil must be filtered and the filling tool shall be
reliably cleaned. The filter at the oil filling port of the hydraulic oil tank shall not be
removed just to increase the oil filling speed. When the hydraulic station is equipped
with oil pump, priority shall be given to it. When the hydraulic station has no oil pump,
the hydraulic oil shall be filled by the oil trolley with filter. The fuel personnel shall wear
clean gloves and work clothes.
b. Remove the filler cap, filter cover, detection hole, hydraulic oil pipe of the
hydraulic oil tank during maintenance. Avoid the dust when the oil passage of the
hydraulic system is exposed. The removal part shall be cleaned thoroughly before
opening. When to remove the oil tank filler cap, remove the soil around the tank cover
first, loosen the oil tank cover and remove the debris remaining at the joint position
(not to flush with water to prevent water from penetrating into the tank), and open the
tank cap after cleaning. If it is necessary to use wiping materials and iron hammer,
choose the wiping materials without fiber impurities and the special hammer with
rubber on its striking face. Hydraulic components and hydraulic hose shall be carefully
cleaned and assembled when dried by high-pressure wind. Select the properly
packaged genuine filter element (if the package is damaged, the filter element may not
be clean even the filter core is intact). When changing oil, clean the filter at the same
time and clean the inside of the filter housing carefully before installing the filter
element.
c. The cleaning oil of the hydraulic system must use the same brand of hydraulic
oil as that used for the system, the oil temperature is between 45 ~ 80℃, and the
impurities in the system shall be taken away as much as possible by the large flow.
The hydraulic system shall be cleaned more than three times, and the system shall be
discharged completely when the oil is still hot after each cleaning. After cleaning, clean
the filter, replace the new filter element and add new oil.
d. Each joint and pipeline shall be bound after disassembled, and the quick joint
shall be provided with appropriate protection cover and cap to prevent dust from
8
entering the system.
Prevent hydraulic system from air:
Hydraulic oil contains air with volume ratio of about 6% to 8% under normal
pressure and temperature, the air will be free from the oil when the pressure is
reduced, and the burst of air bubble could cause cavitation to hydraulic element and
generate noise. If a large amount of air entered the oil fluid, the cavitation could be
intensified, and the compaction index of hydraulic oil could be increased, which could
bring up some negative effects, such as reduced working efficiency and crawl of the
executing element. In addition, the air could oxidize the hydraulic oil and accelerate its
deterioration. Emphasis shall be laid on the following points to prevent air:
a. Exhaust the air in the system after repairing and oil-changing.
b. The suction pipe port of the hydraulic oil pump shall not exceed the oil level, and
must be sealed well.
c. The oil pump drive shaft shall be sealed well and the original oil seal shall be
used for replacing the oil seal.
Prevent hydraulic system from water
Too much water in hydraulic system could rust hydraulic element, deteriorate and
emulsify oil fluid, reduce lubrication oil intensify, and accelerate machine wear. In
addition to preventing water intrusion during maintenance, attention shall be paid to
tightening the cover when the oil storage tank is not used, and put it upside down
appropriately; the hydraulic oil with much water shall be filtered multiple times, and the
dried filter paper shall be replaced once every filtering. When no special instrument is
used to detect, the hydraulic oil can be dripped onto the hot iron plate, only if there is
no steam and the oil starts to fire immediately can the system be filled.
2.5 High Pressure Mud System

➢ Check the working conditions of the mud pumps’ power ends.
➢ Check the suction performance of the mud pumps’ fluid ends and the
sealing, cooling and lubrication conditions of the pistons, liners and the
9
extension rods and so on.
➢ Check the working conditions of the charging pumps and the spraying
pumps.
➢ Check whether the pulsation dampeners’ nitrogen charging pressure and
the relief valves can meet the requirements or not.
➢ Check the conditions of the high pressure manifold’s fixing and the high
pressure valves’ open and close and so on.
➢ Check the pressing reliability of the mud pumps’ cylinder bonnets and
valve bonnets.
➢ Adjust the rate of tension of the transmission belts.
➢ Check and clean the lubricating oil filters.
➢ Check the lubrication for the crossheads and the guide plates.
➢ Check the flexibility of the relief valves’ action.
➢ Check the clearance of gears and crossheads of the mud pumps’ power
ends.
➢ Tighten the bolts of the mud pumps and clean the oil sump.
Operation and lubrication of the equipment
Proper Operation and maintenance of the equipment is important to ensure the
normal operation and improve the service life. Users shall carefully read the
maintenance manual and the attached data before using the pump set.
Regularly check the tightness of the belt, adjust the lead screw on the
substructure to tension the belt; the belt if cannot be tensioned shall be replaced with a
new one; regularly check whether the motor, filling pump, spraying pump work properly
and the line and pipe are properly connected; regularly check the inflation volume of
the pneumatic tire union, and regularly and quantitatively inflate it according to its
maintenance manual; regularly check whether the union and pump connecting bolts of
the outlet elbow assembly are connected firmly, ensure all connections are properly
made and pump set works normally.
Before and after start-up, check whether the oil supply of each lubricating point is
normal, if the lubrication is insufficient or the oil is deteriorated, fill and replace it in time.
Refer to the drilling data plate for detailed oil products.
10
2.6 Usage and Maintenance for Drilling Line
2.6.1 Matters to Be Noted while Moving the Drilling Line

➢ When the drilling line reeled on the drum is to be moved with tension or hoisting
chain, the wood block must be placed between the hoisting and the drilling line to
prevent the drilling line from being damaged or to avoid the deformation of the drilling
line’s strand.
➢ The bar for moving the drum should be pushed on the flange of the drum instead
of on the drilling line.
➢ The drum should not pass or be placed on any hard or sharp object.
➢ Do not push down the drum from the truck or the high platform.
➢ The drum should not pass or be left on any medium which is harmful to the steel
such as the sludge or the mud residue and so on.
➢ While the drilling line is reeled off from the drum, the method of limiting the
drum’s movement can be adopted to ensure the drilling line is at the tension state.
➢ While the drilling line is reeled on the drum, adequate pull should be kept on the
drilling line to ensure the drilling line can be properly reeled.
2.6.2 Matters to Be Noted during Usage of Drilling Line
➢ If it is possible, the new drilling line, after being installed, should be operated with
controlled load and speed for short time, thus it is helpful for the drilling line to reach
the working state.
➢ The drilling line should not be twisted.
➢ The drilling line should not be knocked with any tool such as the hammer, axe or
bar etc. which may result in unnecessary crack or damage. Therefore, when it is
required to connect the drilling line, special attention should be paid during the
operation and the wood block should be placed between the drilling line and the
hammer.
➢ If the drilling line is covered with dirt or grit, it should be cleaned with brush. Using
solvent may damage the drilling line.
➢ When the drilling line is reeled on the drum, the tight and uniform state should be
kept.
➢ The quick change of load and the height of working speed are much related to
the service life of the drilling line.
11
➢ In the process of using the drilling line, it should be periodically lubricated. When
it is necessary, the high quality lubricating oil should be adopted to lubricate the drilling
line, and it should percolate through and adhere to the drilling line and should not
contain any acid and alkali.
➢ During the operation, pay attention to the abrasion conditions of the sheaves and
the drum grooves because the abraded sheaves and the drum grooves may result in
the excessive abrasion of the drilling line.
➢ From the point view of the service life of the drilling line, the condition and shape
of the sheave groove is very important and they should be periodically checked. The
sheave groove’s radius should not be lower than the value specified in Table 1,
otherwise it may reduce the service life of the drilling line. The repaired sheave groove
should meet the requirement of the recommended radius for the new sheave as
specified in Table 1.
Table 1 Radius of Sheave Groove
Nominal Min. Radius of Min. Radius of

Max. Radius of
Diameter of Abraded Sheave New Sheave
Sheave Groove
Drilling Line Groove Groove
in mm in mm in mm in mm
1 3/8 35 0.705 17.91 0.729 18.52 0.756 19.20
2.6.3 Site Faults and Causes

➢ The following site faults and the related reasons have provided some site
conditions and common practices that may result in the premature change of the
drilling line. Keep in mind that the key reason for removing the drilling line in any case
may be that it is caused by one or some conditions and practices as listed in the
following table.
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Table 2 Site Faults and Causes
Site Fault Causes
There is fierce shock, twist, damage, local abrasion, weakening of
one or some strands, rusting one cohesion condition or overload

All strands of drilling line are
caused by elastic extenuation.
broken
The metal area is worn due to the broken steel wires which are
caused by excessive bend.
There is overload, twist, local abrasion or rusting one cohesion
condition.
One strand or some strands
Fatigue, over-speed, slippage, loose operation, concentrated
are separated
vibration at the positions of the fixed sheaves and the deadline
anchor.
Insufficient lubrication
Insufficient protection during the operation

Excessive corrosion
Exposed to the sprayed salt, corrosive gas, water containing soda,
acid water, mud or dirt
Lay length becomes longer, Some kinds of overload frequently happened
but diameter becomes
smaller
Premature abrasion of steel It is caused by the pressure and the friction heat due to sliding and
wire it is unrelated to the drill depth.
There is excessive vibration due to the imperfect drilling conditions
Fatigue fracture of steel wire such as high speed, drilling line’s slipping or adequate dimension of
sheave groove and sheave.
Much overload
Excessive squeeze or
The drilling line on the drum is too loose or it is irregularly reeled on
pressing
the drum.
Rupture or core’s protruding Sudden unloading of the drilling line
after the drilling line is Wrong drilling actions or vibration
squashed Sheave with too small diameter is used.
13
Drilling line falls down The drilling line is too loose
The drilling line is not tightly reeled on the drum.
Irregular reeling on drum The drum groove is wrong.
The rotary plate of drilling line is improper.
3 Operation and Maintenance in Cold Season
3.1 High Pressure Mud System
3.1.1 Before starting the mud pump, check whether the valve pots and the
circulation manifold is smooth not and ensure there is any block condition such as the
freezing or other foreign matter.
3.1.2 When the drilling pump stops working, the drilling fluid in hydraulic end,
swivel, and high & low pressure manifold of the drilling pump should be drained out.
Liquid in the tank of the spray pump should be drained out.
3.2 Lifting System
3.2.1 Drain the coolant out of the brake disc after drilling is completed.
3.2.12 Drain hole under the lifting bail of the swivel (if equiped) shall avoid
freezing.
3.3 Air Control System
3.3.1 Each shift should check the level of the coolant inside the anti-freezing
device.
3.3.2 The hose should not have any indentation.
3.3.3 The water should not enter into the air pipeline and the air filters.
3.3.4 Before starting the air compressor, the lubricating oil should be preheated.
3.4 Other Systems
3.4.1 When temperature is below -20 ℃ (-4℉), measures for preventing main
components of the mast and substructure from destroying shall be taken. Details are
referred to API Recommended Practice for Maintenance and Use of Drilling and Well
Servicing Structures: API Recommended Practice 4G, Chapter 9 Precaution and
14
Procedures for Low Temperature Operation.
3.4.2 Anti-freezing measures for oil, gas and water transmission pipelines and
control valve of the rig shall be taken.
15
4 Overhaul for Drilling Rig
After the equipment has normally run for a period of time, its main driving
elements reached their wear limit and the basic parts are deformed or damaged, which
deprived it of basic service performance, such a period of running time is specified as
overhaul period and expressed by hour. For details about the principle of overhaul and
the technical requirements for each component, please refer to relevant maintenance
manuals.
16
5 List of Special Tools for Main Machine
5.1 List of attached tools
Drawing No. / Standard Remarks

No. Name Qty.
No.
1 T106-010.00 Dry oil station assembly 2
2 T106-001 Hexagonal crowbar L=1000 2
3 T106-002 Hexagonal crowbar L=1500 2
4 T106-003 3 4 "extension socket L=1000 2
5 T106-004 3 4 "extension socket L=1500 2
6 T106-005 1 1/4″ thicken socket L=1000 2
7 T106-006 1 1/4″ thicken socket L=1500 2
Grease gun 400 (with each one
8 061302021164400010 Type A grease nipple and Type B 2
grease nipple)
Aluminium alloy square tube saw
9 400306140630001000 1
bow 12〃
10 400306157300240000 Manual steel hacksaw blade (12”) 50 24 teeth
11 400306157300320000 Manual steel hacksaw blade (12”) 50 32 teeth
12 400104010158010000 Flat screwdriver with wooden 1 158mm
Cross screwdriver with wooden
16 400104020148010000 1
handle 148mm
17 400104020208010000
handle 1 208mm
18 400104020258010000
handle 1 258mm
Wire cutting plier (with plastic
19 400102012000100000
tube) 1 6"
20 400102011500100000 Wire cutting plier 1 8"
21 400309010300010000 Pipe wrench 2 300mm
22 400309010450010000 Pipe wrench 2 450MM
23 400309010900010000 Pipe wrench 2 900mm
24 400102081600100000 Slip-joint pliers 2 160mm
25 400102082000100000 Slip-joint pliers 2 200mm
26 400101112000300000 Adjustable wrench 2 8"
17
Metric 12.5 mm series sleeve
29 400101012271070000
assemblies (27) 1box
Metric full-polished
30 400101330090100000
double-opening wrenches (13) 1set
Applied to
31 400101341001301000 Metric spherical hex wrenches (9) 1set
1.5～10mm
32 400101091200100000 Metric hex wrench 12mm 1
39 400103020400100000 Hammer 2 4kg
Length: 300mm,
40 400306013002003000
Flat file DIN7261A 1 middle
Length: 300mm,
41 400306013003003000
Flat file DIN7261A 1 thin
Length: 300mm,
42 400306023002003000
Square file DIN7261D 1 middle
Length: 300mm,
43 400306023003003000
Square file DIN7261D 1 thin
Length: 300mm,
44 400306053002003000
Triangle file DIN7261C 1 middle
Length: 300mm,
45 400306053003003000
Triangle file DIN7261C 1 thin
Length: 250mm,
46 400306042502003000
Semi-round file DIN7261E 1 middle
Length: 250mm,
47 400306042503003000 1
Semi-round file DIN7261E thin
Length: 250mm,
48 400306032501003000 1
Round file 7261F thick
Length: 250mm,
49 400306032502003000 1
Round file DIN7261E thick
Metric double offset ring spanner SW6X7-30X32
50 400101060900001000 1set
sets (12)
51 400103100500100000 Fitter's hammer 0.5kg 2
52 400103101000100000 Fitter's hammer 1kg 2
18
Drilling line threading device
53 WG05000003 YS-Ⅱ(applicable for 4
Φ20-Φ37mm)
54 260302010602731500 1-0.27/150A inflator（50HZ） 1
Hydraulic drilling line cutter YB48
55 390199090110380000 1
(applicable for10-38mm)
56 400319040101600000 Mechanical jack 16t 1
57 400319030500010000 50t hydraulic jack 1
58 069901010900000000 9m telescoping aluminum ladder 1
59 512605040000300000 Manual oil filling pump SJB-D60 1
60 T501-5003 Striking wrench S=65 1
High pressure charging hose II
61 T106-0800 1
L=20070
5.2 Sling List
No. Code Name Qty.

1 400319120103801200 Ring sling ф38x12 4
2 400319120103501200 Ring sling ф35x12 4
3 400319120102901200 Ring sling ф29x12 4
4 400319120102900600 Ring sling ф29x6 4
5 400319120102601000 Ring sling ф26x10 4
6 400319120101600800 Ring sling ф16x8 4
7 400319120101300600 Ring sling ф13x6 4
8 Four-hook sling for assembly
400319120211600400 ф16x4 4
9 Two-hook sling for assembly
400319120202000500 ф20x5 4
10 Two-hook sling for assembly
400319120201300300 ф13x3 4
11 400319120111300800 Sling for assembly ф13x8 4
12 400319120111300400 Sling for assembly ф13x4 4
13 061403031506014000 Bow shackle S-BW6.5-7/8 4
14 061403031517011000 Bow shackle S-BW17-1 1/2 4
19
6 List of Recommended Lubricating Oil
No. Ambient
Compon Recommended Recommended Amou
Position Temperatur Oil Brand & Spec. Cycle
ent Name Oil I Oil II nt
e
TC225 NLGI 2 Extreme Kunlun Oil
Fill once a
1 Crown Sheave of crown block -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220 200g
week
block Lithium Based Grease Grease
NLGI 2 Extreme Kunlun Oil
Sheave shaft end, brake, Fill once a
-40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220 200g
support pin end, etc. week
Lithium Based Grease Grease
YG-225
2 traveling Replace
hook Kunlun Oil lubricating oil Appropr
Main bearing and spring KG/S220Heavy Duty Mobilgear SHC
-45℃～+50℃ KG/S220Heavy according to its iate
of hook barrel Gear Oil XMP220
Duty Gear Oil quality during amount
use.
Check the oil
Main oil tank
level every shift
(Note: The oil contains
and replace all
rust prevention, Kunlun Oil
KG/S220Heavy Duty Mobilgear SHC lubricating oil
corrosion resistance, -45℃～+50℃ KG/S220Heavy 30L
Gear Oil XMP220 every year (or
anti-foam and parathion Duty Gear Oil based on the oil
type extreme pressure
quality during
anti-wear additives.)
SL225 use).
3
swivel NLGI 2Extreme
Kunlun Oil
Pressure Complex Every 8 work
Wash pipe packing -40℃～+50℃ LME Bearing Mobilith SHC 220 50g
Lithium Based hours
Grease Grease
NLGI 2Extreme
Kunlun Oil
Pressure Complex Fill once a
Oil seal, bail pin -40℃～+50℃ LME Bearing Mobilith SHC 220 100g
Lithium Based week
Grease Grease
20
No. Ambient
e
Kunlun Oil
AGMA Mild EP # 7 KG460 Heavy Check the oil
Main oil tank +10℃～+68℃ Mobilgear 634
L-CKD 460Gear Oil Duty Gear Oil level every shift
CKD460 Gear Oil and replace all
rust prevention,
Kunlun Oil lubricating oil
corrosion resistance, KG/S220Heavy Duty 30L
-40℃～+27℃ KG/S220Heavy Mobilgear SHC 220 every year (or
anti-foam and parathion Gear Oil
ZP-375ZD Duty Gear Oil based on the oil
4 type extreme pressure
rotary table Kunlun Oil quality during
anti-wear additives.) KG/S150Heavy Duty Mobilgear SHC
-50℃～+17℃ KG/S150Heavy use).
Gear Oil 150
Duty Gear Oil
Bearing bush of input
shaft, bearing lubricated
-40℃～+55℃ Pressure Complex LME Bearing Mobilith SHC 220 Once a week 100g
by grease, oil seal, rotary
table lock device
NLGI 2 Extreme
Traction pin, supporting Kunlun Oil
Semi-trailer Pressure Complex Once every
5 device, steel plate spring -40℃～+50℃ LME Bearing Mobilith SHC 220 400g
assembly Lithium Based 5000km
suspension Grease
Grease
Grease location: bearing, NLGI 2 Extreme Kunlun Oil

JC40DB Fill once a 20～
6 coupling, brake caliper, -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220
drawworks week 50g
air guide Lithium Based Grease Grease
21
No. Ambient
e
Position lubricated by oil: Check the oil
oil tank level every shift
(Note: The oil contains and replace all
Kunlun Oil
rust prevention, KG/S220Heavy Duty lubricating oil
-45℃～+50℃ KG/S220Heavy Mobilgear SHC 220 600L
corrosion resistance, Gear Oil every year (or
anti-foam and parathion Duty Gear Oil based on the oil
type extreme pressure quality during
anti-wear additives.) use).
Location of grease: NLGI 2 Extreme Kunlun Oil

Fill once a 20～
bearing, drum gear -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220
week 50g
coupling Lithium Based Grease Grease
Rotary
7 table drive Check the oil
device level every shift
and replace all
Kunlun Oil
Oil lubrication position: KG/S220Heavy Duty lubricating oil
-45℃～+50℃ KG/S220Heavy Mobilgear SHC 220 27L
gear oil tank Gear Oil every year (or
Duty Gear Oil based on the oil
quality during
use).
Kunlun Oil Check the oil
AGMA Mild EP # 7 KG460 Heavy level every shift
Drilling pump gearbox +10℃～+68℃ Mobilgear 634
L-CKD 460Gear Oil Duty Gear Oil and
CKD460 Gear Oil supplement it
F-1300L rust prevention,
properly.
8 Drilling corrosion resistance, AGMA Mild EP # KG320 Heavy Duty 378L×2
Change the
pump anti-foam and parathion 6/L-CKD KG320 Heavy
-7℃～＋38℃ Gear Oil lubricating oil in
type extreme pressure 320Industrial Duty Gear Oil
Enclosed Gear Oil Mobilgear 632 the oil bath
anti-wear additives.) CKD320 Gear Oil every year and
-29℃～＋ AGMA Mild EP KG68 Heavy Duty clean the dirty
22
No. Ambient
e
16℃ #2/L-CKD KG68 Heavy Duty Gear Oil oil in the
68Industrial Enclosed Gear Oil Mobilgear 626 cross-head
Gear Oil precipitation
L-CKT 220 Synthetic tank.
KG/S220 Heavy
-40℃～+27℃ Extreme Pressure KG/S220 Heavy Duty Gear Oil
Industrial Gear Oil Duty Gear Oil Mobilgear SHC 220
L-CKT 150 Synthetic KG/S150 Heavy
NLGI 2 Extreme 2#Extreme Pressure
Kunlun Oil
Pressure Lithium 2#Extreme Lithium Based
0℃以上
Based Grease Pressure Lithium Grease
Based Grease Mobilux EP 2
（GB7323）
NLGI 1 Extreme 1#Extreme Pressure
Kunlun Oil
Grease lubricated Pressure Lithium Lithium Based
0℃以下 1#Extreme
bearing (for spray pump, Grease
Based Grease Pressure Lithium
drive shaft, cardan shaft) Mobilux EP 1 Fill once a
（GB7323） Based Grease 100g
bonnet threads, cylinder week
head threads, discharge NLGI 2 Extreme Kunlun Oil
screen cap threads, etc. -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220
NLGI 1 Extreme
TSA-L Low
Pressure Complex Temperature
-50℃～0℃
Lithium Based Long-term Bearing
Grease
Grease（合成型）
5t hydraulic Each grease injection Fill once a
9 -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220 0.7L
winch site week
23
No. Ambient
e
Deadline
10 Bearing -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220 Once every well 50g
anchor
Hydraulic Fill once a
11 Sheave -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220 50g
cathead week
Replace
Machine hydraulic oil
Kunlun Oil
and tool L-HS46 Hydraulic every year, and
12 Oil tank -40℃～+50℃ L-HS46 Mobil SHC 525 1800 L
hydraulic Oil clean oil tank
power unit Hydraulic Oil and suction
pipe.
Replace
hydraulic oil
Hydraulic Kunlun Oil
L-HS46 Hydraulic every year, and
13 power unit Oil tank -40℃～+50℃ L-HS46 Mobil SHC 525 250 L
Oil clean oil tank
for moving Hydraulic Oil and suction
pipe.
Mast lifting
sheave, Fill once a About
14 Sheave -40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220
tongs week 500g
sheave
L-CKT 220 Synthetic KG/S220 Heavy Check the oil
Pump gearbox level before
(Note: The oil contains each use and
rust prevention, fill
15 Drilling line
corrosion resistance, 20L
spooler L-CKT 150 Synthetic KG/S150 Heavy appropriately,
anti-foam and parathion
-50℃～+16℃ Extreme Pressure KG/S150 Heavy Duty Gear Oil replace the oil
type extreme pressure
anti-wear additives.) in oil bath every
year.
24
No. Ambient
e
-40℃～+50℃ Pressure Complex LME Bearing Mobilith SHC 220
Bearing lubricated by Lithium Based Grease Grease Fill it before
NLGI 1 Extreme TSA-L Low 100g
grease each use
Pressure Complex Temperature
-50℃～0℃
Lithium Based Grease Long-term Bearing
(synthetic) Grease
Note:
1.When the ambient temperature is lower than -40 ℃, the NL GI-1 Extreme Pressure Complex Lithium Based Grease
(synthetic) shall be used for the outdoor grease equipment (-50 ℃ ~ 0 ℃).
2. Refer to Selection Guide for Lubricating Oils for BOMCO Products (2016 Edition) for details.
25

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Drilling Rig

SAFETY ................................................................................................................................................................ III

1 REGULATIONS ON OPERATION AND MAINTENANCE ...........................................................................1

SHIFT MAINTENANCE ............................................................................................................................................1

2 REGULATIONS ON PERIODIC MAINTENANCE .........................................................................................3

2.1 MAST AND SUBSTRUCTURE..............................................................................................................................3

3 OPERATION AND MAINTENANCE IN COLD SEASON...........................................................................14

3.1 HIGH PRESSURE MUD SYSTEM ......................................................................................................................14

4 OVERHAUL FOR DRILLING RIG .................................................................................................................16

5 LIST OF SPECIAL TOOLS FOR MAIN MACHINE .....................................................................................17

5.1 LIST OF ATTACHED TOOLS .............................................................................................................................. 17

6 LIST OF RECOMMENDED LUBRICATING OIL .........................................................................................20

ZJ40/2250DB13 drilling rig is a low-temperature variable frequency drive cluster

The following safety precautions which are closely related to the

maintenance, working personnel must master and exercise such

recommended measures. Details about special measures are contained in the

WARNINGS of this Manual.

maintain the said equipment.

antitoxic equipment if noxious and harmful gas leaks.

installation, operation, removal and maintenance of equipment. It is the responsibility

enforce them to comply with.

the power source of high pressure is always at closed status.

7. Maintenance against rules

Removing and maintaining components against rules shall be prohibited. For

must be fully released prior to removal and maintenance.

8. Maintenance of electric control

(electric brakes) shall be kept under surveillance by specially-assigned persons to

object to be lifted under any circumstance.

10. Application of solvents or dyes

solvent or dye should be put in specific treatment containers.

11. Use of compressed air

compressed air vent towards to yourself and others.

12. Moving parts

maintenance of moving parts.

When visibility is low, maintenance of equipment is not allowed, including such

14. Before lifting and lowering

a day and take the effect of wind speed into account.

15. Working area

obstruction, hand tools and other substances.

16. Requirements on hot work

To prevent bodily injury, power source shall be under cut-off state

upon equipment maintenance, and locking measures to avoid

misoperation and obvious warning signs shall be provided.

It is necessary to confirm that all maintenance and routine inspection

work is finished before power is supplied!

When mechanical and electrical equipment are running, all safety

devices shall be kept under good condition, including crown-block saver,

safety valves, overflow valves, auto-alarm and breaking devices in air,

each shift and confirmed that they works normally.

inspection, debugging, lubrication, fastening, cleaning, and anticorrosion as well as

shift maintenance items stated in the following provisions.

Shift maintenance operation is fully completed by operators independently and

belongs to their routine inspection work.

The routine inspection of weekly maintenance operation shall be fully completed

replacement of filter cores and inspection of insulation performance) may be

completed by operators together with association by the relevant staff.