ZJ50/3150D Drilling Rig

Operation Manual
 Contents
Introduction ....................................................................................................................... 1
Safety Rules ....................................................................................................................... 2
1. General description of drilling rig ............................................................................... 5
1.1 General ......................................................................................................................... 5
1.2 Main technical parameter .......................................................................................... 6
1.3 Overall layout and drive introduction ...................................................................... 8
2. Main components of the rig ......................................................................................... 9
2.1 JC-50D Drawworks .................................................................................................... 9
2.2 Mast .............................................................................................................................11
2.3 Substructure ...............................................................................................................11
2.4 Hoisting system & table drive device ...................................................................... 12
2.5 F-1600 Mud Pump unit ............................................................................................ 12
2.6 HP manifold ............................................................................................................... 13
2.7 Accessory tools........................................................................................................... 13
2.8 Power system ............................................................................................................. 14
2.9 Air system .................................................................................................................. 15
2.10 Instrument system ................................................................................................... 16
2.11 Electric-driving control system .............................................................................. 16
2.12 Electric circuit on site ............................................................................................. 16
2.13 Solid control system ................................................................................................ 16
2.14 Fast line guide.......................................................................................................... 16
3. Rig Assembly ............................................................................................................... 16
3.1 Assembling preparation............................................................................................ 16
3.2 Installation procedures ............................................................................................. 17
3.3 The procedure and requirements of assembly ....................................................... 17
3.4 Inspection after assembling ...................................................................................... 20
4．Rig testing .................................................................................................................. 20
4.1 Testing preparation .................................................................................................. 20
4. 2 Testing procedure and requirements ...................................................................... 22
5．Drilling rig operation ................................................................................................ 29
5.1 Warnings .................................................................................................................... 29
5.2 Notices ........................................................................................................................ 29
5.3 Well drilling operation............................................................................................. 31
5.4 Tripping operation .................................................................................................... 32
5.5 Crown saver adjustment .......................................................................................... 32
6. The disassembling and transportation of drilling rig ........................................... 33
6.1 Rig down .................................................................................................................... 33
6.2 Rig disassemble ......................................................................................................... 34
6. 3 Rig transporting ....................................................................................................... 34
7．Attachments ............................................................................................................... 35
 Introduction
ZJ50/3150D drilling rig is designed and manufactured in accordance with China Petroleum &
Natural Gas Standard SY/T 5609 “Type and Basic parameters of Oil Drilling Rig” and the API
relevant Specifications and requirements. This kind of drilling rig can meet the requirements
of oil & gas exploration and developments in depth rating of 5000m (1,6404ft) when using
Ф114.3mm (4 1/2″) drilling pipe.
In order to make relevant operators familiarize and master using the drilling equipment, the
operation manual has a comprehensive and general introduction to drilling equipments’
installation, calibration and operation. Before operating the drilling rig, managerial personnel,
technical personnel and operators should carefully study not only the operation manual, but
also all relevant technical data of drilling equipments in operation manual and maintenance
manual, knowledge and familiarize all details, moreover need to have the corresponding
safety operation knowledge and skills.
The personnel safety is the most important when using and operating the equipment.
Entire technical documents attached to the drilling rig should be offered to buyers and
consumers as guiding documents of management and operation.
It is not permitted whoever will copy the documents in any way. Any parties or persons shall in
no way to reproduce or provide to the third parties these documents, otherwise to bear the
consequence of liability. Although the operation manual has been carefully examined and
proof-read, there maybe still some improprieties. Please make a comment.

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 Safety Rules
General safety precautions that are closely associated with ZJ50/3150 drilling rig equipments
are listed as follows. These precautions will not appear in the subsequent chapters, and also
the above said precautions have no relationship with some particular processes. The users
have to master and utilize the recommended precautionary measures while use and maintain
the drilling equipment. Specific preventive measures are included in the warning statement of
the manual.
1. Qualifier
Only the authorized qualifiers are allowed to operate and maintain the drilling equipment.
2. Protective equipment
Operators and facility maintainers must wear protective clothing, crash helmet, protective
shoes and other safeguards while using and maintaining. If there is poisonous or harmful gas
escaping in drilling operation, operators must wear poison preventers in addition.
3. Safety habits
When installing, operating, disassembling and maintaining the equipment, good safety habits
must be fully ready to comply. Owners’/operators’ responsibility is to establish good safety
habit, staff training and mandatory compliance with safety practices
4. Operation
Operators shouldn’t proceed operating the equipment until carefully study the operation
manual and completely familiarize with all parts’ operation controlling and function. Operators
who only read the operation manual can’t pass the designated examination of the equipment
operating.
5. Unauthorized persons
When operating, maintaining and running the equipment, the unauthorized persons should be
far away from it.
6. High voltage
To ensure that the pressure of HV return circuit released and decreased to zero before trying
to disassemble the HV return circuit parts. There should be a man appointed to look after the
high voltage power source and keep it in shutting condition all the time when operating.
7. Equipments maintenance
Break rules are not permitted in parts’ disassembling and maintenance. If some parts
(accumulator) store some fluid under pressure, it is necessary to release the pressure and
decrease it to zero when disassembling and maintenance.

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8. The maintenance of electric controlling
To ensure the electric controlling system and circuit that are need to be repaired and
maintained are kept in shutting condition before trying to maintain and repair them. There
should be a man appointed to look after the electric switches and keep them in shutting
condition all the time. There should be more than two men to do the maintaining and repairing
work of electric controlling system and circuit.
9. Hoisting
The weight ratio of the hoisting equipment capability and the moved objects should be taken
into account, when hoisting and moving objects.
Persons should be kept far away from the hoisted objects; people are not permitted to under
the hoisted objects in any circumstance.
10. Solvent/dye using
Users should comply with the manufacturer’s warnings and safety instructions when using. In
addition, the above said solvent and dye can be only used in ventilating places and the
permitted area. The abandoned dishcloth which was polluted by solvent and dye must be put
into specific processors.
11. using of compressed air
The effective cutting protector and personal protector must be worn when using the
compressed air, because even if the compressed air pressure declined to less than 30psi
when using compressed air, there will be also a mixed particulars environment. The
compressed air mouth will never be allowed to toward to the users themselves and the
others.
12. Moveable objects
Hands, hair, clothes, jewelries, dishcloths, and tools should be kept far away when operating
moveable objects.
13. Visibility
It is forbidden to operate the equipment when visibility is not high enough, as well as after
sunset and before sunrise unless a suitable and effective light source.
14. Before startup
To make sure all the controlling elements are in suitable locations (such as ON, OFF, middle
etc.) before start the equipment, the wind speed required to ≤8.3m/s (16knots).
When up/down the derrick equipment.
15. Working area
To keep the working area clean and clear when operating the equipment, and make sure

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there is no obstacle, hand tools and other objects.
16. Electric welding, gas welding etc. operation
The electric welding, gas welding etc. operation is allowable when installing and
disassembling the equipment. And when flaring up, it should be far away from dangerous
region when operating and need to obtain the approval of related person.

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1. General description of drilling rig
1.1 General
ZJ50D drilling rig is a kind of Land DC electrical driving landing rig which max. drilling depth
capacity is 5,000m（16，404ft）. It is suitable for exploration and development of oil and gas
in depth rating of 3,200～5,000m（10,499～16,404ft）. It is designed in accordance with China
Petroleum and Natural Gas Standard SY/T 5609 “Type and Basic parameters of Oil Drilling
Rig” and API relevant Specifications and requirements of API Company in USA.
The drilling rig adopts AC-DC electric drive digital control. Whose drums are driven by two DC
electric motors through chain. Rotary table is driven by DC electric motor through one grade
reducing gear box. Mud pump is geared by two DC motors passing narrow V-joint groups.
ZJ50D Rig technical and structural characteristics
1) It is adopted advanced complete digitization AC frequency conversion control technique,
by means of integration design of electric actuating system PLC and touch screen and
gas, electric, fluid, drilling instrument parameter to realize intellectualization driller control
drilling rig.
2) It is adopted modular design, multiple combinations to enhance the drilling rig
commonality and interoperability. It has the following advantages: neat and coordinating
overall layout, less equipment modules and easy to be disassembled and assembled
when moved to another place. Equipments on derrick floor, mast and low location of
substructure are entirely hoisted by drawworks’ dynamic, so it is more convenient to
install, and also it saves slings.
3) Drawworks is single shaft gear drive, one-shift stepless speed, so that mechanical drive is
easy and reliable. Main brake is hydraulic disc brake, the auxiliary brake is motor energy
consumption braking, which can control the brake torque by computer ration controlling.
Operation and controlling shall be easy, convenient and labour saving so that drilling
operation is more safe and reliable.
Drawworks is equipped with independent automatic driller so as to realize automatically bit
feed and to proceed actual time monitoring condition the operational mode of tripping and
drilling.
4) Rotary table is adopted independent drive, and it is driven by the motor through cardan
than passing the 1-step gear box. Gear box is sunk under the derrick floor. Derrick floor is
level, smooth and wide, easy operation. As Rotary table is adopted independent drive and
connected motor and gear box by cardan, so the cardan don’t need to be strictly lined in
when installing.
5) It is adopted dual-hoisting type for entire hoisting substructure. Mast and all floor

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 equipments is low-level installing. The mast is hoisted to the right position by drawworks
power firstly, and then the derrick and the entire equipment are hoisted to the right
position by drawworks power.
6) The rig is equipped with independent driller’s cabin. It gathers electricity, gas, fluid control
as well as television, communication together, it can realize logical controlling, monitoring
and protection of the whole drilling process by PLC, and realize data storage, print,
remote transmit etc.. All controlling handles, brakes, weight indicators etc, drilling
instruments of the rig is concentrated and located in driller’s cabin, so that driller could
operate and observe very easy and convenient.
7) It is adopted advanced crown block saver system which is composed by electronic
crown-saver, over-wind valve and spring saver valve etc., so it can effectively prevent the
traveling block from bumping crown block upward and tamping down the rotary table.
8) It is adopted high efficiency solid control system and the purification equipments that are
concentrated installation, the tank surface is comfortable, clean, and tidy.
9) The ZJ50D drilling rig meets the requirements of new well drilling technology and the
market, it can be operated normally in temperature of -20℃～+50℃ (-4℉～122℉) ,
relative humidity ≤90% [+20℃ (+68℉)] environment and extreme bad climatic condition in
the field.

1.2 Main technical parameter

1) Nominal drilling depth: Ф127mm (5″)DP 2,800～4,500m（9,186～14,764ft）
Ф114.3mm(4 ½″)DP 3,500～5,000m（11,483～16,404ft）
Maximal hook load 3,150kN (708,150 lbs)
Maximal drill stem weight 1,600kN (359,690lbs)
2) Power rating of drawworks 1,100kW (1,500HP)
Drawworks shift 1+1R DC drive, stepless speed regulation
Main brake hydraulic disc brake
Auxiliary brake Electromagnetic eddy current brake
3) Maximal line series of hoisting system 6×7
Drill line diameter Ф35mm (1-3/8″)
Sheave OD of hoisting system Ф1,270mm（50″）
4) Swivel stem bore size Ф75mm（3″）
5) Drilling pump type F-1600
Drilling pump rated power 1,193 kW (1,600HP)
6) Nominal diameter of rotary table opening Ф952.5mm（37 ½″）
Table shift 1+1R stepless speed regulation

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7) Mast type and effective height open front type,
45m（147.6ft）
Height of racking platform 24.5m（80.4ft）,25.5m（83.7ft）,26.5m(86.9ft)
8) Substructure style dual-hoisting style
(Body structure is parallelogram)
Drilling floor height 9m (29.5ft)
Drilling floor area 10.31m×12m (33.8ft×39.4ft)
Basal face height of table beam (clear distance height) 7.62m (25ft)
9) Dynamic type of drive AC-DC DC drive
10) Diesel generator set CAT3512
Diesel number×master power 4×1070kW (1,455HP)
Rotate speed of diesel engine 1,200r/min
Generator type SR4
Generator capacity 1500HP
Power factor 0.7 Brushless excitation
Assisting generator set CAT3406C
Rated power 265kW (355HP)
Rated rotation speed 1,800r/min
Rated frequency 60Hz
Rated voltage 480V
11) DC motor
Qty. ×Rated power 7×800kW（1073HP）
12) Electric actuating system
SCR control unit one-for-two control 4 sets cabinets
Input voltage 600VAC
Output voltage 0-750VDC adjustable
Output current 1800A, DC (long-term)
MCC system 480V/208V/120V 60Hz
13) Drilling fluid manifold Ф103mm×35Mpa（4″×5，076psi）
Standpipe Ф103mm×35MPa（4″×5，076psi），
Dual-standpipe
14) Air source pressure 0.7～0.9Mpa（101.5～130.5psi）
Gas tank （1.75×2+4）m3(3×384.9+1,057)US gal
15) Accommodation environment
Ambient temperature： -20～+50℃（-4℉～130℉）

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 Relative humidity： ≤90% ；[+20℃ (68℉)]
Wind speed： Below 110km/h

1.3 Overall layout and drive introduction

1. The drilling rig adopts 4 sets of CAT3512 1120KW diesel generator as main power. The
DC motor of drawworks, rotary table and two mud pumps are driven separately by 0-750
DC that is changed from 600V 60Hz AC by SCR cabinet commutation via SCR unit.
Drawworks is driven independently by two 800kW DC motors, main brake of drawworks
adopts hydraulic disc brake (double disc) and the auxiliary brake adopts electromagnetic
eddy current brake. Rotary table is driven independently by a 800kW DC motor. The
F-1600 mud pumps are driven respectively by two 800kW DC motors.
2. Open front mast and dual-hoisting substructure are hoisted by drawworks power. Mast
and all equipments of derrick floor are installed in low-level.
3. Drawworks is arranged on the derrick floor. Main brake is hydraulic disc brake and the
auxiliary brake is electromagnetic eddy current brake with independent automatic driller.
4. The layout of drilling rig meets the requirements of explosion proof, safety, drilling
engineering and convenient installation, disassembling and maintenance of equipment.
5. The drilling rig is divided into five areas: drilling floor area, pump house area,
dynamic/electric control area, mud circulation and water tank area and oil tank area.
Drilling floor area including: mast, substructure, drawworks, rotary table, traveling and hoisting
system, mechanization equipments and tools of well head, driller’s cabin, doghouse, drill pipe
slide (ramp, catwalk) and pipe rack, elevator, drilling line spooler, air winch etc. Drilling floor is
equipped with two air winches with hoisting capacity of 50kN (11,023 lbs).
Racking board is equipped with one 5KN (1, 102 lbs) and one 50KN air winch, escaping
equipment and anti-falling equipment etc. There is a doghouse at the left side of drill floor, and
the house body size is 9,000×2,400×2,800 mm. There is a dog house at the right side of drill
floor, and the house body size is 9,000×2,400×2,800 mm.
Drilling floor is equipped with mechanization tools of well head:
a. Screw on hydraulic cathead YM-16ⅡF Maximal pulling power160kN (35,969 lbs.) ;
b. Screw off hydraulic cathead YM-16ⅡF Maximal pulling power160kN (35,969 lbs.);
c. Combined hydraulic station: Rated pressure 16Mpa (2320 psi) (located at the front end of
doghouse).

The height of catwalk and pipe rack is 1, 070mm (42.1in) ,and the width of catwalk is
1,800mm (70.9in) . There is absorber in the catwalk. Cementing manifold is drawn by derrick
floor ramp and catwalk.

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Drilling line spooler is arranged on the right side earth surface of substructure, and BOP
handling device with hoisting capacity of 60,000 lbs is equipped on the guide rail under drill
floor.

¾ Pump house area: located with 2 F-1600 mud pump sets, drill fluid manifold etc.

¾ Dynamic/electric area: 4 main diesel generator sets are parallel arrangement, and an
auxiliary generator set house and a SCR/MCC house are vertical and clean placing.

¾ Mud circulation and water tank including: mud circulation tank, mud purification
equipment and water tank etc.

¾ Oil tank area including: all kinds of oil tanks, pump and pipelines.

¾ Connecting pipes/hose of oil, gas, water, electric etc. Among each area shall be laid in
the piping groove. It adopts folding pipe groove from earth surface to drilling floor.

2. Main components of the rig

2.1 JC-50D Drawworks
¾ Rated input power 1,100kW(1,500HP)
¾ Max. pull of fast line 340kN(76,435lbs)
¾ Diameter of wire line Φ35mm(1-3/8 in)
¾ Shift 4 shift (stepless speed regulation)
¾ Sizes of groove drum（Diameter×Length） Φ685×1138mm (30×44.8 in)
¾ Size of brake disc（OD×Thickness） Ф1,600×76mm(60×3in)
¾ Overall size of drawworks 6800×3995×2815mm(267.7×157.2×110.8 in)
¾ Auxiliary brake DS-50S Electromagnetic eddy current brake
¾ Max. torque of electromagnetic eddy current brake 75kN.m
¾ Weight of drawworks 40200kg(88,625 lbs)

JC50D drawworks is divided to the front/back sections which is convenience for

assembling/disassembling and transportation and connecting with locating device and
connecting seat separately. The flange connecting places of chain hood has seal groove and
perform seal by filling sponge plate.
The front section of JC50D drawworks includes: front frame, drum shaft, air-water pipeline,

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high/low speed hood shield etc. The back section includes: back frame, input shaft,
intermediate shaft, shifting mechanism, gas line, lubricating system etc.
JC50D drawworks is three-shaft drawworks of inner variable speed, wall plate type and entire
closeness. The inner variable speed can make drawworks attain four shifts; input gear has
two types: one is pneumatic machine shift; the other one is air clutch shift. Pneumatic
machine shift need be stopped to change gear.
Driving chain of drawworks adopts forced lubrication, there are brake disc circulating water
cooling and water-cooling electromagnetic eddy current brake.
For the function, JC50D02 drawworks drive mainly consists of:
(1) Drive section: draw, distribute and transmit power, mainly includes: input shaft,
intermediate shaft, drum shaft assy. and driving chain etc.
(2) Lifting section: Main responsibility is for raising & lowering mast, drill floor, running and
pulling drilling tools, casing and lifting heavy objects etc., main includes: drum shaft assy.
(3) Control section: Controlling drawworks run and vary speed. Mainly includes: air clutch,
tooth clutch and electric/gas circuit valve, pipeline etc.
(4) Lubricating section: Bearing and chain etc. lubrication on each run places, organic oil
lubrication and lubricating grease lubrication, includes: oil cup, injection nozzle, oilway and
pipeline etc.
(5) Brake mechanism: Controlling RTH speed and brake, which includes: main brake
(hydraulic disc brake) and auxiliary brake (electromagnetic eddy current brake).
(6) Supporting section: Assembling and fastening each parts of drawworks, includes:
front/back frame, each chain hood and hood shield etc.
Divided from components, main consists of: drawworks frame, drum shaft, intermediate shaft,
input shaft, hydraulic disc brake, electromagnetic eddy current brake, crown block saver,
cooling water pipeline, air control system, lubricating system etc.
JC500D drawworks is a new AC frequency conversion controlled single-shaft gear drawworks,
it is composed of AC frequency conversion electrical motor, reducer casing, hydraulic
pressure disc brake, drum shaft, cradle, automatic driller, air system, lubrication system etc.
units. The main brake of drawworks is hydraulic pressure disc brake, auxiliary brake function
is realized by main electric motor energy consumption brake, and also deployed independent
automatic driller.
Drawworks electric motors, reducer casing, drum shaft and brake system are all assembled
on a substructure, so this can form an independent transport unit. All control of drawworks
(electricity, gas, fluid) is concentrated in driller control room, whose operation could be
convenient and flexible. (Details please refer to service manual)

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2.2 Mast
¾ Max. hook load (6×7 rope system, static load, no leaning and tribbles on monkey board)
3,150kN (708,150lbs)
¾ Effective height 45m(147.6ft)
¾ Top span (front/side) 2.1/2.05m（6.9ft×6.7ft）
¾ Bottom span 8m（26.2ft）
¾ The height of monkey board 24.5m,25.5m,26.5m(80ft, 83.7ft, 86.9ft)
¾ The capacity of tribbles［114.3 mm (4½")DP, 28m（91.9ft）tribbles］ 5000m(16,404ft)
241.3 mm (9½") DC, 8 post
¾ The capability of resisting wind
- Wait the weather (no hook load, lean full tribbles on monkey board) 36m/s(70knots)
- Safety devices (no hook load, no leaning tribbles on monkey board) 47.8m/s(93knots)
- Raising & lowering mast ≤8.3m/s(16knots)
¾ Self weight 65000 kg (145,600 lbs)

The mast is open front type, which is composed of mast body, monkey board, A-frame and
hoisting equipment; which is matched with pneumatic casing board, drill-line stabilizer,
hanger climbing-bar, tongs balance weight, pulleys and one monkey board air winch 5KN
and another 50KN air winch as well as the ladders , Geronimo lines from monkey board
/crown platform and auxiliary mounting agency , anti-falling devices.
2.3 Substructure
¾ The height of drilling floor 9m(29.5ft)
¾ The area of drilling floor 10.31m×12m(33.8ft×39.4ft)
¾ Basal surface height of table beam 7.62m(25ft)
¾ The distance from wellhead center to drum center 3.42m(11.2ft)
¾ Max. load of table beam 3,150kN(708,150 lbs)
¾ Setback capacity 114.3 mm (4 1/2")DP, 28m（91.9ft）tribble 5000m(16404ft)
241.3 mm (9-1/2")DC 8 post
¾ Max. load of rotary table and the largest assemblage of rated tribble load：
Max. load of rotary table 3,150kN(708,150 lbs)
Rated tribble load 1,600kN (359,690 lbs)
Theory weight 160000 kg (358,400lbs)

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2.4 Hoisting system & table drive device
¾ Maximal hook load 3,150kN(7,081,50 lbs)
¾ Drilling line diameter Φ35mm(1-3/8 in)
¾ Line series hoisting system 6×7
Drilling line of hoisting system is putting on in order. Deadline anchor shall be located in the
right side of mast (facing to mast). All components material, rope groove of sheave, joint size,
contact radius and safety factor of intensity design of hoisting equipment are all in accordance
with API 8A and 4F criteria.
ZP-375 Rotary table drive device
¾ The type of rotary table ZP375
Through hole diameter of rotary table 952.5mm（37¼in）
Max. dead load of rotary table 5,850kN(1,315,132 lbs)
Max. working torque of rotary table 32,362 Nm(23,869 lbf ft)
The highest speed of rotary table 300r/min
Table gear drive ratio i=3.56
¾ The type and power of electrical motors YJ13X7 800kW(1,073HP)
¾ Reduction ratio of reducing gear box 1.3125
¾ Output speed of rotary table 0～300r/min
¾ Overall size (excluding electric motors, cardan shaft)
3,900×2,872×1,388（153.5×113.1×54.6）
¾ Weight 15,500 kg (34,172 lbs)
Rotary drive device are mainly composed of the following parts: AC frequency conversion
electrical motors, cardan shafts, reducing gear box of rotary table, ZP375 rotary table
assembly, table beam, platform, lubrication system and control section etc. wherein ZP375
rotary table comply with API 7K.
Rotary drive device except electrical motors and cardan shafts, the whole device form an
independent assembling and transporting unit, which shall be called body.
2.5 F-1600 Mud Pump unit
¾ Narrow Ｖ-type leather belt type： 4×5ZV25J
Length： 8,000 mm (26.2 ft)
¾ The diameter of belt pulley： Ø630/ Ø 1,250mm(Ø 24.8/49.2in)
¾ The type of mud pump： F-1600 horizon triplex single action pump
Rated power 1,193kW (1600HP)

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 Max. diameter of cylinder liner Ø 180mm(Ø 7 in)
The maximum pressure 35Mpa (5,000psi)
Rated dash 120s/min
The length of stroke 304.8mm (12 in)
The diameter of induction port I.D 12"
The diameter of discharge port 5 1/8"-API 5,000 flange
¾ Overall size of pump set 9,250×4,026×3,050mm(364.2×158.5×120 in)
¾ Weight 39,737kg(87,605 lbs)
The whole F-1600 pump set drive device is on a driving substructure. It can adjust the
tensions of leather belt through adjust leading screw, which is driven by an AC frequency
conversion electrical motors through cardan shaft & drive shaft and geared by narrow V join
groups belt. And it is composed of the substructure with pumps, the substructure of electric
motor, the leather belt tension adjustment devices, belt pulley, narrow V belt, belt cover etc.
The center distance between the two pumps is 3660mm (144 in).
2.6 HP manifold
¾ Nominal bore size 102mm(4″)
¾ Max. working pressure 35Mpa(5,000psi)
¾ Strength test pressure 70MPa(10,000psi)
¾ Applied temperature -29℃～＋121℃(-20℉～250℉)
¾ Applied medium fresh water, mud, crude oil, fracturing fluid etc.
¾ The type of connection union
¾ The type of lock gate drive hand operate
The high pressure manifold is one of the main devices of high pressure jet drilling. To control
the mud from mud pump through high pressure valve, and input high pressure mud fluid to
the cavity of drilling pipe, blow out from drill bit, produce the high pressure mud wild water, to
realize the high pressure jet drilling. Meanwhile, it can also realize travel empty, fill up mud etc.
drilling operation. It shall improve the drilling speed and decrease drilling cost obviously by
using the product.
2.7 Accessory tools
¾ Hydraulic pressure power station
¾ The capacity of oil tank 1000L
Circulating rate of each pump

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 Max. circulating rate of wellhead tools 120L/min(oil-in pumps)
Max. circulating rate of disc brake pump 15L/min(oil-in pumps)
The circulating rate of oil-in pumps 36L/min
Rated pressure of each pump
Oil feed pump of wellhead tools 16Mpa
Oil feed pump of disc brake 7.5Mpa
Oil feed pumps 0.5Mpa
Electrical motors power
Machinery pump electrical motors 37kW
Disc brake pump electrical motors 2×3kW
Oil-in pump electrical motors 0.75kW
Cooling unit electrical motors 0.75kW
Heat exchanger power 3×2＝6kW
Max. Power of heating radiator 18.6kW
Overall size (L×W×H) 1800×1860×1680mm
Weight 1650kg
¾ Hydraulic cathead YM-16ⅡF
Rated working pressure 16 MPa(2,321psi)
Rated hauling capacity 160kN (35,969 lbs)
Rated rate of flow 120L/min (31.7 US gal/min)
Nominal dragging course 1,500mm (59 in)
Wellhead mechanized tools are mainly used in assemble /withdraw thread of pipe connection,
tripping, casing job in drilling. It can reduce the intensity of driller’s hand operating, save
drilling time and improve drilling efficiency by using hydraulic control.
Drilling rig shall be provided with iron roughneck, screw on/off hydraulic cathead and
hydraulic power station supplied for these devices etc.
2.8 Power system
¾ The quantity of main diesel generator set 4
The type of diesel engine CAT3512
The power and rotary speed of diesel engine 1,102kW(2,447HP)，1,200r/min
The type of diesel engine SR4
The capacity of generator set 1500KVA
The voltage, frequency and power factor of generator set 600V, 60Hz, 0.7

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 ¾ The quantity of auxiliary generator set 1
Type CAT3406C
Rated power 265kW (355HP)
Rated speed 1,800r/min
Rated frequency 60Hz
Rated voltage 480V
¾ Main motor

Function Drawworks motor Table motor Drill pump motor

Type YZ08/YZ08A YZ08 YZ08/08A

Rated power kW（HP） 800(1,073) 800(1,073) 800(1,073)

Rated voltage V 750 750 750

Rated current A 1150 1150 1150

Rated speed r/min 970 970 970

The highest rotary speed r/min 1500 1500 1500
Rated frequency Hz 60 60 60

The maximum frequency Hz 60 60 60

Rated torque Nm（lbf-ft） 8034（5925） 8034（5925） 8034（5925）
Number of poles 6 6 6

2.9 Air system

¾ Electric screw compressor set
Type LS12-50HP Sullair screw compressor
Volume flux 5.5m3/min(1，452 US gal/min)
The pressure of air out 1Mpa（145 psi）
Type of cooling ABC
Electric motor 37kW (50HP) 460V 60Hz
Overall size 2,000×1,200×1,680mm (78.7×47.3×66 in)
- The working pressure of system 0.9MPa（131 psi）
- The type of dryer Cooling-type dryer

15
 - Adapt to environment temperature -20℃～＋55℃（-4℉～130℉）
- Oil content of finished gas ≤5 ppm
- Dust content of finished gas ≤5 ppm[granule diameter≤5μm(200 Micro-inch)]
¾ - The type of cold boot air compressor W-0.8/12 type
2.10 Instrument system
Refer to the operation manual
2.11 Electric-driving control system
Reference to the operation manual
2.12 Electric circuit on site
Reference to the operation manual
2.13 Solid control system
Reference to the operation manual

2.14 Fast line guide

The fast line guide is composed of guide pulley set, fixed substructure, wire line and other
accessories, which is suitable for guiding the tide arrangement of fast line in drums, and
suitable forΦ35m（Φ1 3/8”） wire lines.
3. Rig Assembly
3.1 Assembling preparation
The equipment installation should be level, steady, positional, whole. Before assembling, the
assembling and operating person should study the operation manuals for each part, prepare
works well.
The following survey instruments need to be prepared when assembling drilling rig, steel tape,
balance level, dial gauge, tailor ’ s chalk line, pump etc.
The following tools are offered together with the rig which are used in assembling and
adjusting, such as: crowbar, spanner, pipe tongs, forehammer, hand hammer, hoisting jack,
dry oil station and rope for hoisting etc..
There are two 25 T and two 40T cranes need to be prepared when assembling.
The overweight, ultralong great parts, for example: drawworks, drill pump set, electric control
room, generator room, oil/water tank, mast and substructure etc. When entrucking, unloading
from a vehicle and assembling , the specialized hoisting rope shall be used, these parts even
have specialized hanger. The hoist cable shall be hanged on ear when hoisting, the hoist
cable shall be suitable, or it will compress the devices and parts when the hoist cable is too
short, and damage the devices and parts.

16
The whole well site shall be level and steady, no obstacle. Build ferroconcrete base according
to rig underlying graph. The foundation pit of the drilling rig main devices shall set on the earth
excavation. Embankment is not allowed. The compression strength of foundation pit shall no
less than 0.38MPa (55psi), the basic plane error shall be no more than 3 mm (0.12 in ) . The
fabrication cement bar can be lay on the mud pump sets, solid control system, power plant
and electric control system base, but it must be level and steady.
Mark out vertical and horizontal centre lines and all position lines of ground equipment,
according to wellhead center.

3.2 Installation procedures

Substructure, table drive drawworks

Driller console, doghouse, fuel/water/electricity fluid

Mast, crown block, traveling
pipelines, cable tray, generator room, electric control room,
block, hook, string the block
drill pump set

Fast-line guide, ladders, emergency escaping slide, Solid

Mast & substructure hoisting control system, fuel system, catwalk ,rack pipe, inclined
ramp, casing board devices etc.

adjust the wellhead

3.3 The procedure and requirements of assembly

Study carefully the operation manuals of each part
before assembling drilling rig parts.

3.3.1 Substructure assembling

The left/right front base shall be assembled in position according to the scribe on the base,
make the wellhead indicator of the left/right front base alignment with wellhead centre line.
Assemble the other components of substructure according to substructure specifications.
3.3.2 Table drive device assembling
Rotary table drive device have been lined in before leaving factory, when being assembled on
well site, it is only need to inspect table beam pad eye hole (6 parts 12 holes), and the surface
cleanness of the relevant connecting holes of substructure and joint pin shaft etc.. When
confirmed there are no dangerous factors, the whole rotary table drive device can be hanged
into the assembly position. Insert 6 joint pin shafts, and notice that perform from the outside of

17
wellhead to the center of wellhead when inserting pin shafts, and lock pin shafts with clips
separately.
The electric motors mating assembly have been lined in before leaving factory, which is
transferred together with the right upper base of substructure, so it is only need to inspect
whether the connection of electric motors anchor bolts is firm or not.
Make the end face of the two cardan flanges are parallel, when connecting and assembling
the cardan, the error: ≤1 mm (0.04 in), angle oblique degree of cardan: ≤30~50.
3. 3.3 Drawworks installation
The drawworks have been lined in before leaving factory, and located and weld position
blocks on the relevant position of the drilling rig substructure. So only the following steps need
to be taken, when installed on site:
1) Hang the drawworks to the drawworks beam of substructure, after locating according to
locating block; fix the drawworks and drilling rig structure well with anchor bolt.
2) Connect the lubricate pipelines of drawworks, clean and wash the pipeline joints with
clean kerosene or gasoline before connection, make sure no sewage come into the
conduit.
3.3.4 Installation of guide and BOP shifter
Detailed procedures see the specifications of rig substructure and BOP manual.

3.3.5 Mast installation

1) Put the mast assembly lower support well, connect the lower segment of mast well and
assemble on the substructure.
2) Assemble A-frame: A-frame can adopt the ground assembly method, whole hoisting in
position or put the horizontal A-frame on the finished assembly lower segment of mast,
and then reverse the whole body in position.
3) The mast installation order is lower section first upper section later, main body first
accessories later.
4) Alternately move the small bench (mast support), after the main body and the accessories
being finished assembling, than use the big bench to support the monkey board (including
two air winches).
5) It must put on the clips after inserting each joint pins, and it must assemble grower washers
to the connection part of bolt, because it is single nut.
Notice: Assemble casing board and drill line stabilizer after erecting mast.
3.3.6 Crown block installation
First, hang the crown block to the top of the mast, make sure the locating pin that is on the top
of the mast be inserted into the locating pinhole on crown block shelf, and then connect with
M30bolt. The crown block accessories shall be assembled completely, such as auxiliary

18
pulleys, girder-type50 KN (11,023 lbs) gin pole,
Notice: The cantilever of girder-type gin pole shall toward the rear of the mast (toward
the upper site before hoisting the mast).

3.3.7 Assemble the traveling block, hook , string the raise line, the drilling line of crown
block and traveling block well (the type is clockwise), and hang balance pulleys well.
3.3.8 Assemble the driller console.
3.3.9 Assemble left/right doghouse.
3.3.10 Assemble the wellhead mechanized tools
1) Hang and assemble the hydraulic station on the rear of left driller doghouse and fix them
well;
2) Connect the on/off screw of hydraulic cathead and substructure well;
3.3.11 Assemble the air/hydraulic pressure/water pipeline and cable
Plug and connect the air/hydraulic/ pressure/water circuit sand cable etc. among drawworks,
table drive device, doghouse, wellhead mechanized tools and driller console. Clean and wash
each joint with clean kerosene or washing gasoline when connecting different pipeline joints,
make sure no sewage comes into the conduit.
3.3.12 Assemble the oil/water/electricity system
Assemble the oil/water/electricity system according to the rig floorplan drawings and relevant
specifications.
3.3.13 Assemble the drilling pump set, solid control system, generator room, SCR
room, mud material room, oil tank and water tank etc
Assemble the drilling pump set, solid control system, generator room, SCR room, mud
material room, oil tank, water tank etc. devices according to the rig floorplan drawings and
relevant part specifications.
3.3.14 Connect high/low pressure mud pipelines, air lines, fuel lines, water lines, power
cables and lighting cables on site, and put various cables into cable tank.
3.3.15 Assemble the platform and handrail assembly on substructure etc

Notice: Assemble inclined ramp, ladder etc. after hoisting the substructure.
3.3.16 Requirements of assemble and line in see the following table

Assembly and line in requirements table

Installation
No. Parts of assemble and line in Design requirements
procedures
1 The rotary table open centre make column ≤2mm（0.08 in） 1.3.2
alignment with wellhead centre, the allowed
tolerance in any direction

19
 The two flanges end face’s parallel allowance of ≤1mm（0.04 in）
the cardan (measure at 4 points phase contrast
90 degree in order.)
The beveling angle allowance of the cardan ≤3°～5°

2 The horizontal distance between drawworks drum ±2 mm（0.08 in） 1.3.3

to right/left base cross hole axis is 3,420 mm
(134.6 in), the centre mark of drawworks drum
located at the left side 53 mm (2.09 in) of the
centre mark of drawworks substructure beam
vertical wellhead.
3.4 Inspection after assembling
3.4.1 Put the devices according to the required position size of the floor plan on site
3.4.2 After five diesel generator rooms being in position make sure that they are formed as an
entire object, the bonding among the generator rooms shall be tight and neat. The
arrangement of connecting pipe shall be neat and fixed strong.
3.4.3 After SCR, MCC room in position, the cable into the pipeline groove and the cable
connecting generator set shall be orderly, beautiful, and fixed strong.
3.4.4 All pipelines shall be lay orderly and connected correctly.
3.4.5 After all electric systems are assembled in position, make full inspection of wirings
which shall be safe, beautiful and orderly. The wire-lines, switches and lamps shall be
fixed firmly.
3.4.6 The layout of oil/water/gas supply pipelines shall be orderly and fixed strong.
3.4.7 The studs and clips of the mast and substructure shall be all in readiness, the assemble
of handrail and receptacle shall be strong.
3.4.8 Make sure the coupling bolts of all parts are connected strongly, no looseness.

4 Rig testing
4.1 Testing preparation
4.1.1 Lubricant oil, lubricant grease, fuel, hydraulic oil and recirculated cooling oil should be
filled in the different parts of rig, mono-device and system (including diesel engine, air
compressor, generator set, rig actuating system and other machines) according to the
respective operation manual, make them be prepared for startup and action.
4.1.2 All the control and operation handles should be put in the initial position.
4.1.3 Check if each revolving parts can rotate smoothly, and if any interference exists

20
 between revolving parts and fixing parts such as guard and case. Check whether all
the rotary motions are flexible or not, do them.
4.1.4 Check if all connections are reliable and good secured, such as pipe joints and pipe
clamp, bolts and pins of all metal components, the bolts and teeterboard between drive
machine / working machine and bases.
4.1.5 Check the pressure of the air compressor, lubricant oil and water cooling system, if the
pressure is not in the working range please adjust it to be. The working pressure of air
compressor, lubricant oil and water cooling system is as the following table.

Table 4 Air compressor working pressure

Pressure MPa (psi)
Location
Maximum Normal Minimum
Console main line 0.9 (130.5) 0.8 (116) 0.7 (102)
Rotary table
0.9 (130.5) 0.8 (116) 0.7 (102)
inertial brake

Table 5 Water pressure

Pressure MPa (psi)
Location
Maximum Normal Minimum
Main drum brake 0.3 (43.5) 0.2 (29) 0.1 (14.5)

Table 6 Engine oil lubricant system

Pressure MPa (psi)
Location
Maximum Normal Minimum
Drawworks lubricant points 0.5 (72.5) 0.4 (58) 0.2 (29)
R-table lubricant points 0.5 (72.5) 0.3 (43.5) 0.2 (29)

Table 7 Hydraulic oil system

Pressure MPa (psi)
Location
Maximum Normal Minimum
Disc brake lubricant points 7 (1,015) 6.5 (942.5) 6 (870)

4.1.6 Fill lubrication oil in lubricating point of valves and gear box according to maintenance
manual and attached drawing II.

21
4. 2 Testing procedure and requirements
4.2.1 Fuel system testing
1) Check if all the connections of fuel pipelines are correct; confirm there is no any oil
seepage, than can supply oil to the diesel generator.
2) Test the fuel system according to its operation manual; make sure it is in the working
condition.
4.2.2 Power system testing
1) Startup the diesel air compressor, check if it is in the working condition, if not adjust it to be.
2) Start up the No.1 diesel generator set when the air system pressure raising up to 0.7～0.9
MPa (102～130.5psi), check if it is in the working condition (60HZ,600V), if not adjust it to
be.
3) Startup No.1, No.2 electro screw compressors set, and adjust them to the working
condition according to its operation manual.
4) Startup No.2, No.3, No IV diesel generator set, and adjust it to the working condition
according to its operation manual.
5) Make every generator engine incorporate in power network and test.
6) Closed the switch after the electric network running well, and supply the electricity to the
well site. Check if the well site electro system installation is correct before closing the
switch, if all electro equipment switch blades are in the cutting of position, do not close the
switch until confirm everything is OK.
Notice: The adjustment of diesel air compressor set, electro screw compressor set,
diesel generator set and electric network should be done strictly according each
operation manual.
4.2.3 Electrical control system adjustment
1) Check if all the dynamic/control cable joint switches are in the cutting off position, such as
the VFD/SCR (MCC) room, VFD motor, driller electrical control cabinet, lightening system and
solid control system etc.
2) Test all the function switches and indicator gauges, make sure their indication & showing
exactitude, the parameter meets the requirements. The diesel generator set supply power to
VFD/SCR (MCC) room.
3) Supply power in division：
¾ Supply power to driller electrical console drawworks VFD motor. Check the status of all
the indictor lamps and switches, and startup the check the & A/C generator, than check
their condition of steering and running.
Notice: Study the drawworks operation manual carefully before the drawworks

22
 generator running.
¾ Supply power to drill pump DC motor, check step by step according to the above said
requirements,
¾ Supply power to VFD motor of R-table, check step by step according to the above said
requirement,
¾ Supply power to purification plant electrical screw compressor set, check the status of all
dictator lamps and switches,
¾ Supply power to lightening area; check the working condition of the set light.
¾ Supply power to wellhead mechanization tools and hydraulic station and startup electro
motor; check their condition of steering and running.
¾ Supply power to disc brake hydraulic station, check steering and running condition of
electricity equipment.
¾ Supply power to solid control system, check steering and running condition of electricity
equipment.
¾ Supply power to oil/water tanks, check steering and running condition of electricity
equipment.
¾ Supply power to the other electricity equipments, check their working condition.
4) Do not supply power until confirming all the equipments are in working condition
4.2.4 Air system testing
1) Startup the air compressor, check if the air pressure control is in normal range. The control
range of the pressure should be 0.7～0.9Mpa (102～130.5psi). When the pressure lower than
0.7Mpa (102 psi), the air compressor should be turned on automatically, while the pressure
raise up to 0.9Mpa (130.5 psi), the air compressor should be turned off automatically. Check if
the air processing unit is normal.
2) Check the air system seal condition of the well site.
3) Operate all the gas operating valves, check all effectors are in working condition.
4) Do not supply power to the air system until confirming all the equipments are in working
condition.
4.2.5 Cooling water system testing

1) Check and make sure all the pipelines’ connections in water tank, structure and drawworks
are correct, reliable and secured
2) Fill enough cooling water to the water cooling tank, the cooling water should be pre-treated
demineralized water.
3) Startup the water pump electrical motor in water tank, supply water to brake flange, check if
all the water pressure and discharge meets the requirements.

23
4) Do not supply water to the systems until confirming all the equipments are in working
condition.
4.2.6 HPU of floor power tools testing
1) Check and make sure all the pipelines’ connections between hydraulic cathead/wireline
spooler/derrick snubber assembly and HPU of floor power tools are correct, reliable and
secured, which are water tank, structure and drawworks
2) Startup well head mechanization pump electric motor of HPU of floor power, check if there
is any seepage in hydraulic station and all the return circulates oil pressure is among the
normal range.
3) After all the parts are normally running; adjust them to the working condition according to
the related requirements.
4) Do not supply hydraulic oil to the systems until confirming all the equipments are in working
condition.
4.2.7 Hydraulic disc brake testing
1) Check and make sure all the hydraulic lines’ connections between disc brake hydraulic
station and disc brake are correct, and the level of hydraulic oil should be normal.
2) Start up disc brake bump electric motor, check if there is any seepage in hydraulic station
and all the return circulate oil pressure is among the normal range.
3) Check and make sure all the water and oil supply in normal condition, fill enough lubricant
grease in all the lubricant points according to the related requirements.
4) Adjust the interspace between the service caliper & safety caliper and the brake block &
brake flange, operate all the operating hand valves of working brake, parking brake and
emergency brake, the brake caliper action should be accurate, sensitive and reliable. (If
the brake caliper action is not sensitive, need to clear out the air from the pipelines and
check if the nitrogen pressure of storage generator meets the requirements).
5) Adjust them to the working condition
4.2.8 Drawworks testing
1) Check and make sure that the safety guard assembly complete, all the connections of
pipelines and cables are correct, reliable and good secured. Fill enough lubricant grease in
all the lubricant points according to the related requirements, and fill in enough lubricant oil
to the oil tank.
2) Startup lubricant oil pump, cooling water pump and disc brake oil pump etc.

24
3) Observe all the instruments’ parameters are in the designated range, such as the motor oil
pressure, water pressure, air pressure, the pressure of disc brake hydraulic system and the
sensor parameter.
4) Operate the control valves on driller floor 5～10 times separately, examine if the logical
relationship among the valves are right, all the actions are accurate and the brake is
sensitive and reliable.
Focus inspection：
¾ The air input/output condition of auto driller clutch
¾ The sensibility and reliability of brake
5) Dry run testing
¾ Startup the A electrical motor air-blower, then startup the A electrical motor after
confirming the air-blower rolling direction is right, and examine its running direction.
¾ Turn out the A electrical motor then start B electrical motor air-blower, and then startup
the Electrical motor after confirming the air-blower rolling direction is right, and examine
its running direction.
¾ After confirming rolling direction both of a motor and B motor is right and the lubricant oil
pressure is normal, then startup the A & motor at the same time lower the electric motor
speed to check the oil supply & running condition by hand wheel.
6) Startup one motor, reduce the motor rotary speed to1200 rpm slowly, for 30 min running,
make the following examination.
¾ On running of the Drawworks, it should be with no interference status, such as polish,
bump and rubbing.
¾ The lubricant oil pressure should be stable, the lubrication should be good.
¾ Check the working condition of drum and brake.
7) Reduce the rotary speed to1200 rpm slowly, for 5 min running, make the examination
according to above said.
8) Drawworks testing requirements
¾ All the operating parts are accurate and sensitive;
¾ All the parts are well sealed, without any oil seepage;
¾ The lubricant oil pressure is stable, the oil amount of the lubricant points are suitable;
¾ Run smoothly and steadily, without any abnormal shock and noise;
¾ The temperature increment of all the bearings is normal.

25
4.2.9 Wire line winded on the drum
Fix one end of wire line in the socket of drawworks drum by rope clamp, commonly the wrap
capacity of wire line is one and a half layer for 6X7 system. After the mast finishing the raising,
when the traveling block is lowered down to the surface of drill floor, the wrap capacity of wire
line on the drum should keep 10 rounds on the first layer.
4.2.10 Mast and structure hoisting
Notice: The maximum wind speed should be less than 8.3m/s (16.12UK knot) when hoist the
mast and structure
1) Check if there is any unnecessary fixed spare parts and sundries on the mast; check if
there is any barrier which affect the mast & structure hoisting and check if the buffer
solution cylinder is running well; check if all the revolving parts are in good lubricant
condition.
2) Pull-up the A-frame and fix it well
3) Assemble the mast raising line
4) Raise up the mast, stop raising when the mast depart from the tall support about 200mm
(8in) , observe if there is any abnormality of mast tall support , raising line and block line,
when everything is OK, then raise up the mast formally.
5) Startup the snubber assembly, when the included angle between mast and the ground is
60° ,operate gentlely and steadily in the whole mast raising process, do not operate
violently, in case of causing vibration and accidents.
6) when finish raising, use U screw & press plate to connect the A-frame and mast, use the
double nut to tight the U screw.
7) Dismantle mast raising line, assemble the structure raising line
8) Raise up the structure, when the distance between the upper base and the lower shoe
is100mm (4in) , stop raising and make checking, when there is no any abnormality then can
raise the structure.
9) The speed should be smooth and steady during the whole mast raising up period, when the
included angle between structure and the ground is 60°, startup the snubber assembly,
extend the piston rod of buffer hydro cylinder 600mm (23 5/8 in) , position the structure
smoothly and steadily.
10) When the Substructure is raised up to the working position, push the pin rolls and fix them
by safety pins.

26
Notice:
Pay close attention to the reading changes of the weight indicator during the process
of mast and Substructure raising, if the weight indicator reading increases abruptly
or there is any interference of the mast equipments, stopping raising immediately. Lay
down the mast of Substructure, and do not raise it up until all the troubles and errors
are eliminated
4.2.11 Well-head centre calibration
Use the theodolite to inspect the alignment of crown block centre and rotary table center, or
hanging the heavy objects (such as drill pipe etc.) to the traveling system to inspect the
alignment of mast centre and the well head centre. The crown block centre should be aligned
with rotary table centre; the dimensional deviation should be less than 20mm (0.8in).
4.2.12 Line-spooler adjustment
Before installation, fill up fully grease for all positions that need grease, then turn every
movable part by hand. If no smoothly, solve the problem then begin to mount. View the
running status of reel at both high speed and low speed after finishing installation. If running is
no good, short the length of wire line to achieve the best situation.
4.2.13 Adjustment of over-wind valve of crown block saver
First lean the level of valve against closely on the wire lines wrapped on the drum whose
position is ahead of the wrapped wire lines, then fix the valve. Raise the traveling block slowly
and stop the hook when it reach to the set saver height and observe if the over-wind valve
take action or not, and action accuracy and feed-back of disc brake.
4.2.14 Adjustment of Electrical saver device
Mount the encoder on the drum shaft, and set height value of upper and lower limit on the
saver device. Raise or lower the traveling block and hook to the height of over upper limit or
below the lower limit, observe if electrical control system cut off the power of drawworks
motors and the response of disk brake.
4.2.15 R-table drive device testing

1) Check and make sure it is fully equipped and the pipelines’ connections are reliable and
good secured, all the lubricant points should be filled in enough lubricant grease according
to the requirements, the oil tank should be filled in enough lubricant oil.
2) Startup the lubricant oil pump, adjust the lubricant oil pressure to 0.2～0.5MPa (29～
72.5psi), check the lubricant points condition, adjust the chock valves of all the lubricant

27
 points, make sure there is enough and suitable lubricant oil.
3) Operate the internal brake valves on the driller floor 5～10 times, check if the air charge
and discharge speed of the brake valve’s clutch is fast.
4) Startup the air-blower electrical motor after confirming the air-blower rolling direction is
right, then startup the rotary table electrical motor, and checks its running direction.
5) Lower the speed to 500rpm slowly, and make the following examination:
¾ On running of the independent table drive, it should be no interference status, such as
polish, bump and rubbing;
¾ The lubricant oil pressure should be stable, the lubrication should be good.
6) Cut off the electricity of electrical motor, check the effect of inertial brake.
4.2.16 The drill bump set testing
1) Charge the 4.5Mpa (653psi) N2 or air to bleed-off air chamber of F-1600 mud pump, and
charge 0.07～0.1Mpa (10.2～14.5psi) air to suck air chamber.
2) Startup the electrical motor air-blower after confirming the air-blower rolling direction is
right, then startup the electrical motor in low speed, and checks its running direction, the
working condition of all the drive parts, lubrication condition and the pipelines sealed
condition to see if all of them are OK.
3) When all the things are OK, and then adjust them to the working condition according to the
requirements.
4.2.17 Well-head mechanization tools testing
1) Check and make sure all the pipelines’ connections are right and reliable;
2) Operate the control switches of the hydraulic cathead; check the cathead hydraulic cylinder
working condition, its action should be accurate and sensitive.
4.2.18 Peripheral control devices testing
1) Check if the camera equipping of TV monitoring system is suitable, the picture transmitting
and displaying is normal;
2) Check if the lighting system arrangement is right, if it is in working condition.
4.2.19 Solid control system testing
Test it according to its operation manual
4.2.20 BOP control testing
Test it according to its operation manual
4.2.21 The other well-site testing which are not incorporated in this manual should be

28
done accordingly to the equipments operation instructions.
4.2.22 Do not proceed the drilling operation until all the equipments are finished
testing and tested OK.
5 Drilling rig operation

The detailed operations please refer to the following operation manual such as driller
control cabinet, Drawworks, table drive device, electrical control system and drilling
pump set etc..

5.1 Warnings
5.1.1 When the traveling block is lowered down to the rotary table level, the first layer of
wireline on the drum of drawworks should keep 16 to 24 circles to avoid wireline
clamp surging by over large strength.
5.1.2 Forbidden to check and maintain the equipment without cutting off the power.
5.1.3 Forbidden any people entrancing and staying in the area around the drilling pump
safety valve & manifold, when rig is working.
5.1.4 The adjustment of rig speed should be slowly, smoothly and steadily, avoid excessive
speed changes causing excessive shock to the electrical system and mechanical
system.
5.1.5 On checking and repairing motors, make auxiliary switch on the side of junction box
on the “OFF” position and latch it pin and lock to ensure main circuit is cut off.
5.1.6 The requirements of drilling pump air chamber in charging/discharging and the air
charging of disc brake hydraulic pressure storage generator: only the N2 or air can be
charged, forbid O2, H2 and other flammable & explosive gas.
5.1.7 When maintain the pressure equipment, do not make the operation until the system
pressure release to zero.
5.1.8 When maintain the electrical control system and the well site electric circuit, powered
off the electricity of the maintenance parts, forbid single-man operating.
5.1.9 Two sets crown savers should work normally.

5.2 Notices
5.2.1 In general drilling working condition, can use 1 main motor, but in deeper well tripping
operation, should use 2 main motors running simultaneously. When one generator is
broken, the other one motor can be used to lift drill string weight at Max. drilling depth

29
 at slow speed.
5.2.2 Before tripping in, firstly supply cooling water to the brake disc, notice the cooling
water should be pre-treated demineralized water.
5.2.3 Feed the lubricant oil to drawworks, table drive and the drilling pump equipment etc,
fill the oil by closed and filtering method, and ensure the oil is clean and clear.
5.2.4 Every shift should check the over wind valve of crown block and electrical digital
crown saver, make sure all the crown savers are sensitive and reliable.
5.2.5 At common situation, the mud pump can suck mud freely below 100rpm stroke. But
suction status is affection by length of suction pipes, effective pressure head, mud
proportion, viscosity, air content etc. So it is recommended to use charging pump to
better suction conditions.
5.2.6 The cardan bolts should be the specially made hi-strength bolts, forbid to replace
them by ordinary one.
5.2.7 The weight bearing parts of hoisting equipment, the mast and the structure should not
be cut and welded without permission.
The allowable hook load and hook speed for every shift of Drawworks are listed in the
following table:

Hook load and hook speed data table

Low speed clutch High speed clutch

Drawworks shift
Low gear High gear Low gear High gear

V
Rope 0.2498～0.3681 0.7481～1.1014 0.4215～0.6207 1.2608～1.8565
m/s
series
Q
Equal 5×6 2799～1901 998～678 1792～1271 639～434
hoisting KN
speed
and load V
of hook Rope 0.2081～0.3067 0.6234～0.9178 0.3512～0.5173 1.0507～1.5471
m/s
series
Q
6×7 3150～2169 1138～773 2044～1388 728～495
KN

30
5.3 Well drilling operation
5.3.1 The drilling operation in this manual is only the operating procedure and taboos which
is for the users’ reference only.
5.3.2 Do not proceed the drilling operating until all the rig equipments are tested OK and the
drilling fluid is already well prepared.
5.3.3 According to the drilling technology requirements, connect the bit to the cross over
sub and Kelly by using the bit breaker.
5.3.4 Lay down the bit to the ground, put bushing into the rotary table hole, startup the
rotary table, turn on the mud pump, feed bit to drill.
5.3.5 The maximum working torque of the ZP375 rotary table is 32362N.m (23869lbf.ft), the
maximum rotate speed is 300rpm. The rotary table is driven independently, the rotate
speed can be adjust steplessly among 0～293 rpm. The overspeed and overload of
rotary table is forbidden when drilling.
5.3.6 The rig is equipped with F-1600 Mud Pumps which rated stroke is 120rpm and
completed with six sizes liners from 5" to 7". When drilling, Select the suitable
diametrical cylinder liner according to the necessary pressure and discharge capacity
of drilling technology. Usually, it is better to select larger diameter cylinder and keep
pump running at the lower stroke under the condition of meeting the drilling
technology, the overspeed and overload of pump is forbidden.
5.3.7 Bit Bouncing Operation
During the drilling operation, if confronted the complex stratum may occur Bit
Bouncing. When Bit Bouncing happens, brake the Drawworks as soon as possible,
and turn the switch of rotary table inertial brake to the “Manual” position for about 1
second (depends on the time that inertial brake clutch holds friction hub completely),
then shut off rotary table motor slowly (turn control hand wheel of rotary table motor to
zero position slowly). Turn the switch inertial brake to the “Release” position and turn
back to “Manual” position rapidly. Repeat the above operation for several time to
make drill pipe rebound orderly until the energy of Bit Bouncing has been fully
released. Then operate the drawworks to trip out drill string and begin drilling
operation again per Clause 4 (Tripping Operation).
Warning:
On Bit Bouncing, it is forbidden to shut off motor firstly or operate the inertial brake of rotary

31
table in the meantime of shutting off motor. Otherwise it may lead to accident of Back-off of
drill string.
5.4 Tripping operation
5.4.1 Tripping out operation
1) Put the Kelly and swivel into the rat hole, and hang the big ring of single elevator ring onto
the auxiliary hook of hook.
2) Hang the elevator to the elevator ring.
3) Startup the drawwoks motor A & B, select the motor rotated speed according to the load of
hook. 4) Loosen the brake, and then pull out the drill stem till all stems are out. Stop the
drawworks, control the brake then lay down the drill stem elevator, use the well-head
mechanization tools to loosen the screw and disassemble screw, put the disassembled
thribles to the setback (monkey board).
5) Lay down the empty traveling block to the well-head; operate as above (the 4th step) said.
6) During the tripping out operation, select the reasonable drawwoks shift group according to
the hook load, make fully use of the drawworks, enhance the work efficient. Refer to the
“Hook load and hook speed data table” and “rig hoisting curve drawing”
The tripping in is the reverse operation of the tripping out, the differences are as follows:
1) Need to startup the drawworks brake disc cooling system;
2) During the tripping in process, need to use the main generator power brake, the process is:
turn the main generator power brake handle to “brake” direction, loosen the main brake, feed
the bit, control the brake torque by controlling the rotation angle of the main generator power
( the bigger the angle is, the larger the torque is), so as to control the lay down speed, when
the elevator approaches to the derrick floor, use the main brake and the main generator
power brake together to lay down the elevator to the rotary table smoothly and steadily.
5.5 Crown saver adjustment
To avoid the traveling block bump the crown block and ensure the drilling operation safety,
two inter-redundantly saver devices are equipped with the ZJ50D series drilling rig.
When crown savers begin to work, firstly need to check if the traveling block and hoisting
system had been damaged or not, after confirming everything is OK, then adjust the crown
savers to the initial position.
5.5.1 Adjustment of Crown Block Saver
The adjustment of crown block saver is mainly to adjust over-wind saver valve. First confirm

32
the position of wire line on the Drum of Drawworks according to the set value (7~6.5m to
23~21.3ft below the of Crown Block Beam), then fix the save valve on the position ahead the
wrapped direction of wire line and the valve level lean against the wire line. When the
traveling block goes on raising up to exceed the set height limit, the wrapped wire line on the
drum touch the level and make level slant to turn on saver valve. It leads to air supply for
air-control brake valve of disk brake system and perform emergency brake. So the traveling
block is avoided to bump the crown block.
Reset saver valve if it takes action
Pressure the button of “Saver Release” Valve, lower down the traveling system slowly to
safety height and brake the Drawworks completely. Press the button of “Saver Release”
Valve, in the meantime turn the level to straight position and then loose the button of “Saver
Release” Valve to reset it.
5.5.2 Traveling block electrical crown block saver
This device can calculate the position of traveling block by SCP (single chip processor)
system by means of output signal from the sensor on the drum shaft of drawworks. It can
display height and running speed of traveling block on LED. The device has the function of
preventing “Upper Bump, Lower Tamp”.

6. The disassembling and transportation of drilling rig

6.1 Rig down
The rig down procedure is lay down the substructure firstly then lay down the mast which is
contrary to the rig raising.

6.1.1 Substructure down

Firstly pull the structure away from the center of gravity position by using the buffer hydro
cylinder, then lay down it slowly by gravity.
Attention:
1) All the parts which affect the rig down should be disassembled, such as catwalk, ladders
and the emergency escaping ladder etc. Refer to the structure operation manual.
2) Lay down slowly and steadily and try to keep in the same speed, forbid to lay down and
stop abruptly.
3) Take off the slanting ladder in the rear floor before lay down to avoid creating larger
resistance.

33
6.1.2 Mast down
Hang the balance wheel well before laying down the mast, after that pull the mast away from
the center of gravity position by using the buffer hydro cylinder, and then lay it down slowly by
gravity.
Attention:
1) Disassemble the casing board and all the parts which affect the rig down.
2) Control the speed, lay down slowly and steadily and try to keep in the same speed.

6.2 Rig disassemble

The principle of rig disassembling is：earlier disassemble the parts that are assembled later,
and later disassemble the parts that are assembled earlier.

Attention:
1) All the disassembled connections of gas, oil and water pipelines should be sealed, keep
the pipelines inside and outside tidy and clean, avoid the dirty things.
2) Packing the fastening pieces independently when disassembled, mark it with label or put
into the appointed packing box.
3) All the drawworks joints should be well protected by the sealed board.
4) The bolts and nuts which are used to connect the cardan are made by high strength
materials, keep them away from the other bolts and nuts, take special way to pack & keep
them, such as attached them to be cardan flange transported together with cardan.
5) The air system hose should avoid oil, all the external thread should be bound up by clean
plastics to avoid the external thread being damaged and keep the inside pipelines clean.
6) Forbid to swing and bump when disassembling & hoisting to avoid equipments being
damaged.
7) If need long distance transportation or long time storage, should take the anti-rain,
moisture-proof and corrosion resistant, and make packing case and packing list.

6. 3 Rig transporting
Make a plan for the vehicles transporting operating according to the size, volume & weight
when transporting.
The users also could make the transporting program according to its requirements.

34
7 Attachments
Table I Operation manual List of the rig components
According to purchase contract, only supply purchase product instruction manual

No. Name of Instruction Manual

1 TC-315 Crown Block Operation Manual

2 YC-315 Traveling Block Operation Manual

3 DG315 Hook Operation Manual

4 SL-450 Swivel Operation Manual

5 JJ315/45-K Mast Operation Manual

6 Floor man Anti-dropping Device Operation Manual

7 Escaping Device Operation Manual

8 DZ315/9-S Structure Operation Manual

9 Deadline Anchor Operation Manual

10 Hydraulic BOP Handling Device Operation Manual

11 JC50D Drawworks Gearing Device Operation Manual

12 Hydraulic Disc Brake Operation Manual

13 Table Drive Device Operation Manual

14 ZP-375 Rotary Table Operation Manual

15 Bushing Operation Manual

16 Doghouse Operation Manual

17 Driller Control Cabinet Operation Manual

18 Air Supply Operation Manual

19 5t Air Winch Operation Manual

20 0.5t Winch Operation Manual

21 Hydraulic Pressure Station Operation Manual

22 Hydraulic cathead Operation Manual

23 Hydraulic line-spooler Machine Operation Manual

24 String Device Operation Manual

35
25 Line Cutter Device Operation Manual

26 DC Motor Operation Manual

27 Diesel Generator room Operation Manual

36
ZJ50/3150D Drilling Rig
Maintenance Manual
 Contents
1. Operation and maintenance regulation ................................................................. 3
2. Periodic Maintenance .............................................................................................. 4
2.1 Mast and substructure ........................................................................................... 4
2.2 Hoisting and rotary system ................................................................................... 4
2.3 Air supply system ................................................................................................... 5
2.4 Hydraulic system .................................................................................................... 6
2.5 High pressure mud system .................................................................................... 6
3. Operation and Maintenance during cold season................................................... 7
3.1 High pressure mud system .................................................................................... 7
3.2 Hoisting system....................................................................................................... 7
3.3 Other system ........................................................................................................... 7
4. Oil List of Rig Component ...................................................................................... 9
5. Main rig specified tool list ....................................................................................... 1
5.1 As-built tools list ..................................................................................................... 1
5.2 Slings list ................................................................................................................. 2
 Introduction
ZJ50/3150D drilling rig is designed and manufactured as customer’s requirements,

according to China Petroleum & Natural Gas Standard SY/T 5609“Type and Basic

parameters of Oil Drilling Rig” and the API relevant Specifications and requirements of API.

This kind of drilling rig can meet drilling requirements of oil and gas industry up to depth of

5000m（16,404ft）, using Ф114.3mm(4 1/2″)drilling pipe.

This manual offers us a over-all general introduction of matched equipment、installing、

debugging and operating.. Any related person, before running this rig, shall not only read

this manual carefully, but also independent manuals and data sheets for any matched

equipments, to be familiar with all the details, and also to have corresponding safety

knowledge and techniques.

Safety for persons is the most important either in operating or servicing the rig. Activities

shall comply with HSE requirements and related Company regulations.

This manual is offered to the clients and users as a guide literature to lubricating,

transportation, installation, testing, maintain and repair etc. All rights reserved, no men or

any parties shall be allowed to reproduce or provide to the third party, otherwise to bear

the consequence of liability.

Although this manual has been carefully examined and proofreaded, there maybe still

some improprieties. Please make comments.

1
 Safety

Safety first ! !!

Avoid the personal injury: Power source shall be cut off while
maintaining the rigs. Locking device should be assembled in order to
avoid mishandling and warning signs shall be obvious.

Safety first ! ! !

Supply power after ensure all the maintenance and routine inspection
has been finished.

Safety first ! ! !

All safety device should be in good condition when operate mechanical

and electric apparatus, including the follows: crown saver, safety
valves, relief valves of gas, hydraulic, oil system, alarm and safety
equipment of power machine, inspect these safety unit every shift to
ensure normal operation.

2
1. Operation and maintenance regulation
In order to make the rig operate normally and sustained as well as prolong service life of

all components, except operate the rig properly according to the regulation, the

maintenance also have to be performed.

1.1 There should be equipped or appointed mechanical, electro and instrument

professional person in the drilling team to be in charge of the normal operation and

maintenance work.

1.2 Stop operation and resolve the problem in time when the rig takes malfunction.

1.3 It is forbidden to rotate over speed, excess temperature, excess pressure and

operated against the rules.

1.4 During the rig running period, the periodic maintenance work should be done,

including: shift maintenance, weekly maintenance, monthly maintenance, half year

maintenance and yearly maintenance. The problems which are found during maintenance

can be solved by operators or related professionals according to the requirements. The

complicated repairs, such as change the bearings should be finished in repair factory or

maintenance station.

1.4.1 Shift maintenance operation working includes: routine checking, testing, lubricating,

fastening, cleaning, anti-corrosion operating and the following specified shift maintenance

working.

1.4.2 Weekly maintenance job includes the shift maintenance jobs. Routine inspection for

weekly maintenance jobs should be done by operator independently, some complicated

jobs (or high difficulty work, such as change filter cartridge or check insulating property)

should be done together with related persons.

1.4.3 Monthly maintenance job includes weekly maintenance jobs, during the monthly

maintenance inspection, if there is any heavy workload or high difficult jobs (such as

adjust friction plate of clutch, clean and maintain the air drive components, etc.) should

be operated accompany with related persons and technical engineers.

1.4.4 After running half a year or a year, some of the moving parts may be worn out, other

non-moving parts performance may also been changed, should be adjusted, maintained

3
and replaced, these work should be done according to the technical engineers’

suggestions or in the related repair factory, professional maintenance station.

2. Periodic Maintenance

2.1 Mast and substructure

2.1.1 General maintenance and checking

- Check whether there is any crack or deformation in lift components parts;

- Check whether there is any corrosion and rust in string ring, rope slings;

- Check whether the wire-line is damaged and it has stubble and corrosion etc.;

- Check the lubricating condition of pulley system;

- Check whether all the pins and safety pins are all in readiness;

- Check whether all the connections of bolts are firm;

- Measure the full length straightness errors of mast standing pipe and the vertical errors

between front side and the horizontal surface of mast periodically, under the load

condition ;

2.1.2 It is forbidden to dismantle the cross beam, diagonal beam and other elements of

the mast under any condition.

2.1.3 It is forbidden to drill or cut any as well as any welding on the steel structures.

2.1.4 Check the mast and substructure every month or before trip in heavy casing or

bearing such special load.

2.2 Hoisting and rotary system

2.2.1 Every shift maintenance

- The connections, operating performance and brake performance of crown save;

- Reliability of electric elements in driller’s control cabin and the seal condition of air

control & hydraulic pipelines;

- The tighten condition for ends of deadline and fast line;

- Check whether the fast line guide work normally and make the adjustment;

- The lubricating and seal condition of all the bearings;

- The fix condition of hook bearing bolts and stop pins, the hook should revolve flexibly, the

springs expand freely;

4
- The seal parts of swivel, rotary table drive, and the drawwoks should be in good seal

condition, the oil quantity and the oil temperature should meet the requirements, the rotary

table stop pin should sensitive and reliable;

- Check whether all the bolts are fastened and reliable;

- Check the tautness of the chain and the temperature of the gear parts;

- If any of the following problems occurred please deal with immediately such as the

noise is too loud, or the tooth gear, chain or chain sprocket are seriously worn out.

2.2.2 Weekly maintenance

- Check the oil supply condition for lubricant oil pumps of drawworks & rotary table drive

device, whether oil is clean, whether it needs to replace the filter element.

- Whether the water swivel lifting bail and pin shaft rotate flexibly;

- The fix condition of traveling block;

- The worn condition of crown block and traveling block pulley groove;

- The seal condition of water swivel wash pipe packing;

- The fasten condition of rotary table cardan flange;

- The worn condition of fast line guide, and repair it if required;

2.2.3 Monthly Maintenance

- Check the connecting and worn condition of all clutches and cardan cross joints;

- Whether there is any crack in the lift bails, pins and pulleys of lifting system;

- Check the worn condition of drilling wire line, replace or cut it if required;

2.3 Air supply system

2.3.1 Every shift maintenance

- Check whether there is any abnormal condition when start-up and stop the air

compressor, whether the oil quality, quantity and the temperature meet the requirements.

- Check the automatic pressure adjustment device and relief valve;

- Check the operating pressure of air storage tank, and release water as well as bleed;

- Check whether the pipelines unblocked, the seal condition is good.

2.3.2 Weekly maintenance

- Check the working condition of the air cleaner, whether there is any blocked

5
- Check all the clutches and fast air bleeder is reliable.

2.3.3 Monthly Maintenance

- Clean the relief valves of filter and air storage tank;

- Check the control valves of air compressor;

- Check the control valves of the air drier;

2.4 Hydraulic system

2.4.1 Every shift maintenance

- Check whether all hydraulic pumps of combined hydraulic unit are in good working

condition, the oil level of oil tank is qualified, any oil filter blocked, any oil leakage and the

disc brake of energy accumulator works normally, the oil temperature is in a normal

working range;

- Check whether all pipelines of mechanical wellhead tools and hydraulic disc brake any

oil leakage, pipelines unblocked, all pressure gauges display normally;

2.4.2 Weekly maintenance

- Check whether Nitrogen-fill pressure of combine hydraulic unit accumulator is qualified;

- Check whether oil level of oil tank is qualified, check oil quality and core of oil filter is

cleaning;

2.4.3 Monthly Maintenance

- Clean oil filter core;

- Fill Nitrogen of disc brake accumulator to meet the requirements of Nitrogen-filled

pressure;

- Check all valves and pipelines.

2.5 High pressure mud system

2.5.1 Every shift maintenance

- Check the power end working condition of mud pump;

- Check the suction capability of mud pump fluid end and the seal, cooling & lubricating

condition of piston, cylinder liner, drag link;

- Check the charge pump and spray pump working condition;

- Check whether the charge pressure of air case and relief valve meet the requirements;

6
- Check the high pressure manifold fix condition and high pressure valves switches are

flexible;

- Check the tighten reliable for the cylinder head and valve pot cover of mud pump;

- Adjust the rate of tension of transmission belt.

2.5.2 Weekly maintenance

- Check and clean the lubricant filter;

- Check the lubricant condition crosshead and guide plate;

- Check the whether relief valves rotate flexibly.

2.5.3 Monthly Maintenance

- The clearance of power end and crosshead for mud pump;

- The high-pressure manifolds should be NDT tested as per stipulations;

- Tighten the bolts for mud pump and clean the oil groove.

3. Operation and Maintenance during cold season

3.1 High pressure mud system

3.1.1 Check the valve cavity and circulation manifold, there should be non-freeze.

3.1.2 When the mud pump stopped, should release the drilling fluid from the fluid end,

swivel, high and low pressure manifold of mud pump. Release liquid from water tank of

spay pump

3.2 Hoisting system

3.2.1 Release the cooling water of disc and electromagnetic after finish tripping in

operation.

3.2.2 Prevent relief hole in the lower side of swivel bail from freezing.

3.3 Other system

3.3.1 When the temperature is lower than -20℃ (-4℉), take the precautions for, main

structures of mast and substructure to avoid damage.

For the detailed information, please see API “Recommended Practice for Maintenance

and Use of Drilling and Well Servicing Structures”, “API Recommended Practice 4G” with

chapter 9 “ Precaution and Procedures for Low Temperature Operation”.

7
3.3.2 Should take freeze-proof measures to oil, gas and water pipelines and control

valves.

8
4. Oil List of Rig Component

Table 1 Oil List of Rig Components

Item Part name Position Ambient
Oil Specification Recommended oil Utilized Periodic Fill-up Amount
Temperature
TC-315 Bearing for crown 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon Once a week. It should be
Crown block block and grease EP 2 EP 2 clear old lubricating grease
YC-315 travelling block -30℃~+5℃ NIGI 0 Extreme pressure Mobilux Beacon of bearing before fill up new 500g (1.1 lb)
1
Travelling block lithium grease EP 0 EP 0 lubricating grease.

-40℃~+50℃ NLGI 2 Extreme pressure Mobilith

composite lithium grease SHC 220
Ball pin, center pin 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon
DG-315 and thrust bearing grease EP 2 EP 2
2 hook NIGI 0 Extreme pressure Mobilux Beacon 72 hours working time 200g (0.44 lb)
-30℃~+5℃
lithium grease EP 0 EP 0

-40℃~+50℃ NLGI 2 Extreme pressure Mobilith

composite lithium grease SHC 220
Main tank (add +10℃~+68℃ AGMA Mild EP#7 L-CKD Mobilgear Spatan
rust-proof, 460 gear oil API GL-5 634 EP 460 Every shift
3 SL-450 Swivel anti-bubble, 85W-140 gear oil 200g (0.44 lb)
anti-sulfur&phosph -7℃~+38℃ AGMA Mild EP#6 L-CKD Mobilgear Spatan
orus,extreme 460 gear oil API GL-5 632 EP 320
wear-resist etc.) 85W-90 gear oil

-29℃~+16℃ AGMA Mild EP#2 Mobilgear Spatan

API GL-5 85W-90 gear oil 626 EP 68

9
 -40℃~+27℃ API GL-5 75W-90 gear oil Mobilgear
SHC220
Bearings and 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon 72 hours working time 200g (0.44lb)
gears for wash grease EP 2 EP 2
pipe packing, oil -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon
seal, bail pin and grease EP 0 EP 0
pneumatic spinner NLGI 2 Extreme pressure Mobillith
-40℃~+50℃
composite lithium grease SHC 220
Main oil tank (add +10℃~+68℃ AGMA Mid EP #7 L-CKD Mobilgear Spatan
rust-proof,anti-bub 460 gear oil, API GL-5, 634 EP 460
ble, anti-sulfur & 85w-140 gear oil Replace every month 120L (32Us gal)

4 ZP-375 phosphorus, -7℃~+38℃ AGMA Mid EP #6 L-CKD Mobilgear Spatan

extreme 460 gear oil, API GL-5, 632 EP 320
rotary table wear-resist etc.) 85w-90 gear oil

-29℃~+16℃ AGMA Mid EP #2 Mobilgear Spatan

API GL-5,80w-90 gear oil 626 EP 68

-40℃~+27℃ API GL-5,75w-90 gear oil Mobilgear

SHC220
Bearing cover for 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon Once a week 800g (1.76 lb)
input shaft, bearing lithium grease EP 2 EP 2
of which lubricated -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon
by lubricating lithium grease EP 0 EP 0
grease, oil seal
-40℃~+50℃ NLGI 2 Extreme pressure Mobillith
and lock shift
composite lithium grease SHC 220
mechanism for
rotary table

10
 0℃~+50℃ NIGI 2 Molybdenum Mobliux
bisulfide extreme XHP 222
pressure lithium Extra level Every time when raise and
JJ315/45-K-1 mast Bearings used for grease(SH/T0587-1994) lowering mast and 200g (0.44 lb)

5 DZ315-9S raising of must and -30℃~+5℃ NIGI 0 Molybdenum substructure

Substructure substructure bisulfide extreme
pressure lithium
grease(SH/T0587-1994)

-40℃~+50℃ NIGI 2 Extreme pressure Mobillith

composite lithium SHC 220
grease(SH/T0535-1993)
For grease 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon
JC50D drawworks lubricating: lithium grease EP 2 EP 2 Every 24 hours working
drive unit bearing, coupling, -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon time

6 coupling, brake shifter, brake tong lithium grease EP 0 EP 0

caliper and air guide cock NLGI 2 Extreme pressure Mobillith
-40℃~+50℃
composite lithium grease SHC 220
For oil lubricating: -18℃~+60℃ AGMA 5 EP Mobilgear Beacon Fill up when lubricating oil 1000L (264 US gal)
oil tank(rust-proof, L-CKD 220 gear oil API 630 EP 220 level is under the
anti-bubble, GL-5, SAE 80W-90 gear calibration tails of oil lever.
anti-sulfur& oil Change all lubricating oil
phosphorus, -34℃~+43℃ AGMA 4 EP Mobilgear Beacon after finish drilling operation
extreme L-CKD 220 gear oil API SHC629 EP 150 for one well
wear-resist etc. GL-5, SAE 80W-90 gear
oil

11
 For lubricating 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon
grease: bearing lithium grease EP 2 EP 2 Every 24 hours working 20~50g
Rotary table and cardan shaft -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon time (264 US gal)

7 drive unit lithium grease EP 0 EP 0

-40℃~+50℃ NLGI 2 Extreme pressure Mobilgear

composite lithium grease SHC 220
For oil lubricating: 0℃~+40℃ L-AN 100 SAE 30 Mobilgear Spartan Fill up when lubricating oil
oil tank and Machine oil 627 EP 100 level is under the 350L
transmission gear L-AN 68 SAE 20 Mobilgear Spartan calibration tails of oil lever. (95.5 US gal)
-10℃~0℃
Machine oil 626 EP 68 Change all lubricating oil
API SD or above, SAE Mobilgear after finish drilling operation
-34℃~+68℃
5w/30 Machine oil SHC 626 for one well
Gear box for mud +10℃~+68℃ AGMA 4 EP #7 L-CKD Mobilgear Spartan Check oil lever every eight
pump(add 460 gear oil API GL-5, 634 EP 460 hoses and fill up properly,
rust-proof,anti-bub SAE 85W-140 gear oil change lubricating oil in oil

F-1600 ble,anti-sulfur&pho AGMA 4 EP #6 L-CKD Mobilgear Spartan basin every six months as
-7℃~+38℃
sphorus, extreme 320 gear oil API GL-5, 632 EP 320 well as clear dirty oil of
8 mud pump wear-resist etc.) SAE 85W-90 gear oil which deposit in the grease
AGMA 4 EP L-CKD 220 Mobilgear Spartan groove by crosshead
-29℃~+16℃
gear oil API GL-5, SAE 626 EP 68
80W-90 gear oil

-40℃~+27℃ API GL-5, SAE 80W-90 Mobilgear

gear oil SHC 220
Bearings of which 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon Check every four hours and
lubricated by lithium grease EP 2 EP 2 coat lubricating grease

12
 lubricating -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon
grease(for spray lithium grease EP 0 EP 0
pump, drive shaft
and cardan shaft),
-40℃~+50℃ NLGI 2 Extreme pressure Mobilgear
valve pot cover
composite lithium grease SHC 220
screw of fluid end,
cylinder head
screw, discharge
strainer screw, etc.

+10℃~+68℃ AGMA Mild EP #7 L-CKD Mobilgear Spartan

460 gear oil API GL-5, 634 EP 460
Oil basin 85W-140 gear oil Change one time every one

9 5t air winch -7℃~+38℃ AGMA Mild EP #6 L-CKD Mobilgear Spartan week 2L (0.5 US gal)
320 gear oil API GL-5, 632 EP 320
SAE 85W-90 gear oil

-29℃~+16℃ AGMA Mild EP #2 Mobilgear Spartan

API GL-5, SAE 80W-90 626 EP 68
gear oil
Gear transmission 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon
position and lithium grease EP 2 EP 2 Fill one time every 500 0.7L (0.2 US gal)
grease fill position -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon hours working time
lithium grease EP 0 EP 0

-40℃~+50℃ NLGI 2 Extreme pressure Mobilgear

composite lithium grease SHC 220

0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon

lithium grease EP 2 EP 2 400g(0.88 lb)

13
10 Dead line anchor Bearing -30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon Fill one time for each well
lithium grease EP 0 EP 0

-40℃~+50℃ NLGI 2 Extreme pressure Mobilgear

composite lithium grease SHC 220

Oil cylinder Same as HPU

11 Hydraulic cathead Sheave 0℃~+50℃ NLGI 2 Extreme pressure Mobilux Beacon

lithium grease EP 2 EP 2 Every shift 100g (0.22 lb)

-30℃~+5℃ NLGI 0 Extreme pressure Mobilux Beacon

lithium grease EP 0 EP 0

-40℃~+50℃ NLGI 2 Extreme pressure Mobilgear

composite lithium grease SHC 220

-10℃~+50℃ L-HM68 hydraulic oil Mobil Nuto

DET26 H 68 Change lubricating oil

L-HM46 hydraulic oil Mobil Nuto every six months working

-15℃~+40℃
12 Hydraulic power DET 25 H 46 time, clean oil tank and
Mobil Univis insuction pipe at mean time
-20℃~+50℃ L-HV46 hydraulic oil
unit
DET 15M N 46

-30℃~+25℃ L-HV32 hydraulic oil Mobil Univis

DET 13M N 32

-40℃~+50℃ L-HS46 hydraulic oil Mobil

SHC 525

13 Wire line Wire line Anti-rust grease for wire Mobilarm a According to the reality Proper
798 condition
line

14
5. Main rig specified tool list
5.1 As-built tools list
S/N P/N Name Qty.
1 Grease tool 2
2 Crowbar= 1000 2
3 Crowbar L=1500 2
4 Lengthen move pipeφ21× 1000 2
5 Lengthen move pipeφ21× 1500 2
6 Lengthen move pipeφ34× 1000 2
7 Lengthen move pipeφ34× 1500 2
8 GB1164-89 Grease gun 400( with one AB bean for each ) 2
9 GB1108-91 Steel saw bow ( adjustable )300mm 1
10 SG10-80 Hand hacksaw blade (1.0 1.8)300mm 50
11 GB1063-89 Straight screwdriver 100， 150,200,300mm 1
12 GB1064-89 Phillips screwdriver 100,150， 200mm 1 for each
13 GB6295.1-86 Wire cutter 160,200mm 1 for each
14 GB8406-87 Pipe tongs 300,450,900mm 2 for each
15 GB4953-85 Crocodile clipper 160,200mm 2 for each
16 GB44440-84 Monkey spanner 200,300,450mm 2 for each
17 Heavy-duty box wrench (26 pieces ) 1set
18 GB4388-84 Double solid wrench (10 pieces ) 1set
19 GB4388-84 Box spanner (10pieces ) 1set
20 GB5356-85 Inner hexagon spanner (13 pieces) 1set
21 GB255-82 Octagon hammer (3,6， 5.4kg) 2 for each
22 Bench worker hammer (with wood handle )(0.5， 1kg) 2 for each
23 GB5180-56 Blunt flat file (1#， 4#)300mm 1 for each
24 GB5180-56 Sharp head flat file (with wood handle) 300mm 1 for each
25 GB5180-56 Square file (2#， 3# with wood handle)300mm 1 for each
26 GB5180-56 Triangle file (2#， 4# with wood handle)300mm 1 for each
27 GB5180-56 Semicircle file (1#， 3# with wood handle)300mm 1 for each
28 GB5180-56 Round file (1#， 3# with wood handle)300mm 1 for each
29 GB5180-56 Hand drive dispensing pump 1set
30 SJB-D60 Oil filter truck 1set
5.2 Slings list

S/N P/N Name Qty.

1 W13×3 m 2 circular trench assembly lifting rope 4
2 W20×5 m 2 circular trench assembly lifting rope 4
3 W16×4 m 4 circular trench assembly lifting rope 4
4 W29×6 m Annular hoist rope assembly 4
5 W13×6 m Annular hoist rope assembly 4
6 W16×8 m Annular hoist rope assembly 4
7 W26×10 m Annular hoist rope assembly 4
8 W29×12 m Annular hoist rope assembly 4
9 W35×12 m Annular hoist rope assembly 4
10 W38×12m Annular hoist rope assembly 4