1000 KIPS Beam - Beam Manual (1400-2000)

OPERATION AND MAINTENANCE MANUAL
FOR
MAST & SUB-STRUCTURE
1000 KIPS (BEAM-BEAM)
DOC NO. 1000 KPS BB

REV 01
DATE 24.07.2017
OIL RIGS DIVISION
Bharat Heavy Electricals Limited
Hyderabad – 500 032

OPERATION & MAINTENANCE MANUAL
FOR
MAST & SUBSTRUCTURE
E1400 (BEAM-BEAM)
1
INDEX
SECTION I SPECIFICATION
SECTION 11 MAST AND ACCESSORIES, PART LIST AND

ASSEMBLY DRAWINGS
SECTION III SUBSTRUCTURE PART LIST AND ASSEMBLY DRAWINGS
SECTION IV ERECTION SEQUENCE AND ERECTION SEQUENCE
SECTION V DRAWINGS MAINTENANCE INSTRUCTIONS
2
SECTION I
Specification
3
MAST AND ACCESSORIES
DRAWING INDEX
DRAWING NUMBER TITLE
3-96545-1-0001 General arrangement of 142’0” high cantilever

‘Swing Lift’ mast and 25’0” high sub-structure.
3-96545-1-0002 Mast Assembly.
3-96545-1-0003 Mast Ladder and Safety Cage Assembly.
3-96545-1-0004 Stand Pipe Clamps Assembly.
3-96545-1-0005 Tong Counter weights Assembly.
3-96545-1-0006 Hydraulic Snubbing Unit Assembly.
3-96545-1-0007 Crown Assembly.
3-96545-1-0008 Racking Board Assembly.
3-96545-1-0009 Belly Board Assembly.
3-96545-1-0010 Slingline Equalizer Assembly.
3-96545-1-0011 24’ φ Core line Sheave Assembly.
3-96545-1-0012 Casing Stubbing Board Assembly.
3-96545-1-0013 Casing Stubbing Board Carriage Assembly.
3-96545-1-0014 16” φ Cat line Sheave Assembly.
3-96545-1-0015 14” Air Tugger Sheave Assembly.
25’ 0” HIGH SUB -STRUCTURE
3-96545-3-0020 25”-0” Sub-Structure Assembly.
3-96545-3-0021 25”-0” Sub-Structure sectional details.
3-96545-3-0022 Drill Floor and Handrails Assembly.
3-96545-1-0023 Sub-Structure Pre-Erection Layout.
3-96545-1-0024 Erection of 142’-0” Mast and Reeving diagram
4
SPECIFICATION FOR THE BHEL -BRANHAM'S UNIVERSAL CANTILEVER
"SWING LIFT" DRILLING MAST AND ACCESSORIES.
142'0" Clear Height x 30'0" Base

Static Hook Load capacity 1,000,000 on 12 Lines strung to the Travelling Block.
Maximum Wind Load Capacity with Drill pipe racked in the Mast 100 M.P.H.
Maximum Wind Loan Capacity without Drill pipe racked in Mast 115 M.P.H.
Mast built to A.P.I. 4F Specification with Monogram attached.
The mast Stem is Portal Truss designed, allowing an excellent Drillers view, and is complete with 'A' Frames,
Raising sheaves, Mast Drive Pins, Bolts and Deadline Anchor Support material to support a National Type E.B.
Anchor mounted on the Mast leg on the Drillers Side, complete with Anchor Bolts.
A Hydraulic Snubbing System has been installed in the 'A' Frames which allows the Driller to have full control
of "Break over" during the raising and lowering operations of the Mast, the use of wire line and Truch for
Snubbing is not required.
The Mast is complete with following accessories.
CROWN
The BHEL-Branham Crown Block has six 60" minimum diameter Cluster Sheaves and a minimum diameter
fastline assembly all with tapered roller bearings and grooved for 1-3/8' diameter wireline, each Sheave is
lubricated by individual grease channels with the grease nipple located at the one end of shaft.
The cluster and Fastline Assemblies are mounted on a crown Frame which is complete with Line guards, Teak
Bumper Block, Handrails and padeyes for hanging the air Hoist, cat line and Core line sheave Units.
For servicing the Crown a safety platform has been provided and is complete with checkered Plate Flooring,
3'6" high handrails and support Braces.
RACKING PLATFORM
The BHEL-Branham industries Heavy Duty platform is adjustable from 82'0" to 87'0" above Drill Floor and
has a capacity for 220 Stands of 5" diameter Drill Pipe and 10 Stands of 9 ½" Drill collars.
The platform is complete with a folding Dividing Board, 2'0" wide access Catwalk on three sides with 7'0"
Handrails with Toe plates on the outside and 3'6" Handrails on the inside, and fold up Floor Slabs on the fingers
on the Driller's Side
MAST LADDER
The Mast Ladder is a full height straight ladder and is complete with Safety Cages and carries two Ladder
Platforms.
Ladder lengths are equal to Mast Sections for ease of transportation.
MAST LEVELLING EQUIPMENT
The Mast Levelling Equipment comprises of a Hydraulic Snubbing system two sets of 2" Shim packs for each
Leg of the Mast with extra ling bolts.
5
TONG COUNTERWEIGHTS
The set of two Tong counter weights are complete with Buckets, Guides, 8" Snatch Blocks and Wire line.
BELLY BOARD
The Belly Board is an intermediate support Frame providing lateral support To Drill pipes at mid-stand and is
complete with access Cat walk and 3'6" high Handrails with the toe plates.
CASING STABBING BOARD
The BHEL -Branham Universal Casing Stubbing Board is adjustable from 23'0" above Drill Floor to 43'0"
above Drill Floor and is complete with one Half Ton Electric powered Hoist with controls and attachment
brackets. The Electric Hoist is equipped with Over speed Sensor, Load Brake and Damage Cable Sensor, two
additional Safety Locks with Speed Sensors are provided independent of the Main Load Brake.
GOOSENECK ACCESS PLATFORM
A Gooseneck Access Platform has been provided and located 47" above Drill Floor on the Off-Driller's Side of
Mast with access from the Belly Board Catwalk.
STAND PIPE CLAMPS
Four sets of Dual Standpipe Clamp for a 5” dia Stand pipe have been provided complete with Clamp Cups and
Bolts.
Located on the Off-Drillers Side of Mast.
MAST STAND
One 16'0" high Mast Stand has been provided complete with Teak Headrest for supporting the Mast during
Assembly of Racking Board to Mast.
MAST ASSEMBLY STANDS
Two 6'3" high Mast Assembly Stands have been provided complete with Teak Head rest for supporting mast
sections during Assembly.
AIR HOIST SHEAVE UNITS
The two Air Hoist Sheave Units have a 14" diameter Sheave grooved for 9/16" diameter Wire line and mounted
on Bronze bushed.
Swivel and Shackle included.
CATLINE SHEAVE UNITS
The two Cat line Sheave Units have a 16" diameter Sheave grooved for 5/8" diameter Wire line or 1½" Manila
Rope, and mounted on Bronze bushes Swivel and Shackle provided.
CORELINE SHEAVE UNIT
6
The Core line Sheave Units has a 20" diameter Sheave grooved for 9/16"diameter Wire line and mounted on
Roller Bearings. The Coreline Sheave Unit is mounted directly to the Crown padeye with the 1.1/8" diameter
pin provided.
SLINGLINE AND SLINGLINE EQUALIZER UNIT
Two 2.3/8" diameter Slinglines have been provided.
The Sling line Equalizer Unit has a 29 3/4" diameter Bronze bearing sheave grooved for 2.3/8" diameter
Wireline and is complete with padeyes for hanging Unit and Slinglines in back of Mast when not in use.
LADDER SAFTY CLIMB EQUIPMENT
A set ladder safety climb Equipment has been provided completed with carrier rail, Clamps and two safety
Belts.
DERRICKMAN ESCAPE EQUIPMENT
The Geronimo Line for emergency escape from the Racking Board is complete With wire line, Safety Slide
with Hand Brake and Ground Anchor.
7
SPECIFICATION FOR THE BHEL-BRANHAM'S SWING LIFT SELF ELEVATING SUB-

STRUCTURE.
The BHEL- Branham "Swing Lift" Self Elevating Sub-structure is 25'0" high with a 40'0" wide x 35'0" long
Drill Floor supported by 59'0" long x 8'0" wide x 4'6" high welded box sub - bases on both sides, including
cross tie members to hold sub-bases apart during assembly and erection of the structure.
The Sub-bases (bottom boxes) are complete with Mast and 'A' Frame Shoes, 2'0" x 2'0" Access window on the
Drillers Side for Air, Water and B.O.P. closing line entry and two 50 bb1 water tanks one in each sub base near
to the rear of the Rig constructed of plate ends and top with Manways and covers, a 2" diameter Vent pipe and a
4" Drain plug have been fitted. The Sub-structure has been designed to accommodate a Bharat Heavy
Electricals Ltd. E 2000 Electrical Drawworks.
Draw works and surrounding floor are raised to Drilling position by use of Draw works power and Mast raising
Line , no other rigging or wireline required. Mast raising lines need only be moved from 'A' Frame sheaves to
the sheaves on Drawworks Elevator to complete rigging for erection. Field proven Rig-Up time seven to ten
minutes After the Mast has been raised and pinned, Draw works raising time five minutes.
The Torque Tube elevating system keeps floor at consisting level during erection.
The Sub-Structure is complete with all bracing and support material while in an erect position, and has been
constructed in accordance with A.P.I. 4F Specification with Monogram attached.
The 'A' Frames are assembled to the sub-bases, and are folded into them for transportation, giving a transport
height of 10'4".
The 'A' Frames can be erected with a Gin Pole truck. No 'A' Frame Spreader is required. Front and of Sub-bases
(Bottom Box Extensions) can be removed for ease of entry of the B.O.P. Stack and during the Drilling
operation.
SETBACK SUPPORT
The Parallelogram type Set back support is designed to support 500,000 pounds of racked pipe simultaneous
with a 800,000 pounds Casing Load.
The setback area is recessed for 6" Teak flooring.
The Setback Support is pinned to the Mast while in the horizontal position and Raised with the Mast.
DRILL FLOOR
The Drill Floor consists of one set of Drill Floor panels with 8 mm thick Chequred plate for Sub-structure and
3/8" thick Checkered plate around the Rotary area and is complete with one set of Hand rails 3'6" high with toe
plates for the perimeter of the Drill Floor.
Most Drill Floor panels, Hand Rails and Floor mounted equipment can be set into position at ground level and
raised with the Draw works Elevator, and Set back Support.
COMBINATION RAMP AND STAIR
The Combination ramp and Stair is 25'0" high 6'2" wide with ½" thick plate Ramp down to the 3'6" high Cat
walk elevation with framing and stair continuing to ground level and is complete with a 3' diameter x 2'0" high
Pipe Rail on both the sides of the Ramp adjacent to the stairs.
8
The Stairs are located on the Driller's side and have removable Hand rails on one side only.
B.O.P. TROLLEY BEAMS
The set of B.O.P. Trolley Beams are designed to pin under the Sub-structure floor allowing for front entry of
the B.O.P. Stack.
Two 10 ton Trolley for handling the B.O.P. Stack are provided.
ROTARY BEAM UNIT AND ROTARY FLOOR SUPPORT UNITS
The Rotary beam and Rotary Floor Support units have been designed to accommodate a 27½” Bharat Heavy
Electricals Ltd. chain drive Rotary and are set flush with the Drill Floor.
DOG HOUSE SUPPORT
The Doghouse Supports located on the Drillers Side and pinned to the Sub-structure has been designed to
accommodate a 8'0" wide x 12'0" long Customer supplied Dog house.
SUB-STRUCTURE ACCESS STAIRWAYS
The access Stairway from ground level to the Dog house, located on the Drillers Side is a two tier stairway
comprising one 12'6" Stairway from ground level a 3'0" sq. x 12'6' high platform and one 12'6" Stairway from
Platform to dog-house and are complete with Checked plate stair treads and fixed Handrails.
The access stairway from top of Mud Tank to Drill Floor, located on the Off-Driller’s side is a two tier
stairway comprising of one 6’0” Stairway from top of Mud Tank to a 3’0” sq. x 6’0” high Platform and
one 19’0” Stairway from platform to Drill Floor level and are complete with Chequered plate stair treads and
fixed Handrails.
ACCESS LADDER
A 25’0” Aluminium Extension Ladder for under Sub-structure access is provided (Optional).
9
SECTION II
Mast and Accessories Parts List

And
Assembly DrawingS
10
MAST AND ACCESSORIES
DRAWING INDEX
DRAWING NUMBER TITLE
39654510001 General arrangement of 142' 0" high cantilever ‘Swing Lift’ mast and 25' 0" high Sub-Structure
39654510002 Mast assembly
39654510003 Mast Ladder and Safety Cage Assembly
39654510004 Standpipe Clamps and Goose Neck Access platform assembly
39654510005 Tong Counter Weight Assembly
39654510006 Hydraulic Snubbing Unit Assembly
39654510007 Crown Assembly
39654510008 Racking Board Assembly
39654510009 Belly Board Assembly
39654510010 Slingline Equalizer Assembly
39654510011 24"Φ Coreline Sheave Assembly
39654510012 Casing Stabbing Board Assembly
39654510013 Casing Stabbing Board Carriage Assembly
39654510014 16"Φ Catline Sheave Assembly
39654510015 14”Φ Snatch Block for 9”/16Φ Wire Line Assembly
11
CUSTOMER: ONGC/OIL BHEL-PART LIST DATE : _____PAGE____1___
DESCRIPTION : 142’0” HIGH SLAB MAST AND ACCESSORIES DRG.NO.: 39654510003

550 KPS STATIC HOOK LOAD INDEX
TOTAL TOTAL PAINT

QTY DESCRIPTION PAGE No. REMARKS
WT.Kgs. Sq.m.
2 MAST LOWER SECTIONS 10010 100.1
2 MAST INTERMEDIATE SECTIONS 6780 67.8
2 MAST UPPER SECTIONS 5848 58.55
2 MAST TOP SECTIONS 2954 29.7
6 MAST GIRTS 2896 9.8
1 MAST BOTTOM STUB SECTION D.S. 5146 102.9
1 MAST BOTTOM STUB SECTION O.D.S 5146 102.9
1 MAST BOTTOM SECTION D.S. 4533 90.7
1 MAST BOTTOM SECTION O.D.S 4533 90.7
8 MAST DIAGONAL BRACES 2370 30.04
1 MAST STUB SECION SPREADER C/W ROLLER 4958 59.23
1 REAR ‘A’ FRAME D.S. 7724 67.11
1 REAR ‘A’ FRAME O.D.S. 7724 67.11
1 FRONT ‘A’ FRAME D.S. 1508 23.54
1 FRONT ‘A’ FRAME O.D.S. 1508 23.54
8 LADDER SECTIONS 1886 31.54
49 CAGE HOOPS 268.3 11.38
60 CAGE STRINGERS C/W BOLTS 661.9 24.28
24 CONNECTION PLATES 34.7 1.26
2 STABBING GUIDES 93.9 2.70
2 MAST ASSEMBLY STANDS 748.4 19.32
1 GOOSE NECK ACCESS PLATFORM 35.5 0.89
2 HYDRAULIC BREAKOVER AND SNUBBING UNITS 275 -
1 CROWN 8180 78.94
12
DESCRIPTION: 142’0” HIGH SLAB MAST AND ACCESSORIES DRG.NO. 39654510003

550KPS STATIC HOOK LOAD
TOTAL TOTAL PAINT

QTY DESCRIPTION PAGE No. REMARKS
WT.Kgs. Sq.m.
1 RACKING BAORD 4200.6 110.57
1 BELLY BOARD 1647 46.56
2 TONG COUNTER WEIGHTS 690.1 14.06
4 STANDPIPE CLAMP BRACKETS 240.0 3.91
1 SLINGLINE EQUALIZER UNIT 1244.3 4.92
2 SLNGLINES 1995.5 -
1 16' 0" MAST STAND 1226.5 24.90
1 MAST BOOM KIT 327.2 6.18
1 24" Φ CORELINE SHEAVE UNIT 132.2 1.58
2 16" Φ CATLINE SHEAVE UNIT 210.4 2.70
2 14" Φ AIR TUGGER SHEAVE UNIT 202.2 2.70
1 MAST HYDRAULIC LEVELLING SYSTEM 36.3 -
40 SHIM PACKS 333.1 8.40
4 DEADLINE ANCHOR STUD BOLTS 57.9 -
1 ALUMINIUM EXTENSION LADDER 32.3 0.16
1 GERONIMO LINE 68.0 -
1 LADDER SAFETY CLIMB EQUIPMENT 68.0 -
1 CASING STABBING BOARD 1235 34.28
TOTAL 66366
TOTAL PAINT AREA OF MAST AND ACCESSORIES 1681.0
13
DESCRIPTION: MAST LOWER AND INTERMEDIATE SECTIONS DRG.NO. 39654510001 & 39654510003
PART PAINT
DESCRIPTION QTY L W H WT REMARKS
NO. COLOUR
D4A-M098 Mast Lower Section 1 9782 2676 810 5005 White
64 Φ x 178 Grip x 318 lg Field Pin C/W Safety
D 15.8
Clip
F 24.8
Clip
5046
Mast Lower Section
D4B-M098 1 9782 2676 810 5005 White
D 15.8
Clip
64 Φ 356 Grip x 496 lg Field Pin C/W Safety
F 24.8
Clip
5046
11109 2849 810 White
D8A-M088 Mast Intermediate Section 1 3390
D 15.8
Clip
F 24.8
Clip
3431
Mast Intermediate Section
D8B-M088 1 11293 2849 810 3419 White
D 15.8
Clip
F 24.8
Clip
3459.6
14
DESCRIPTION: MAST UPPER AND TOP SECTIONS DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
White
D9A-M088 Mast Upper Section 1 11282 2316 810 2924
D 15.8
Clip
F 24.8
Clip
2964.6
White
D9B-M088 Mast Upper Section 1 11282 2316 810 2927
D 15.8
Clip
F 24.8
Clip
2967.6
White
D5A-M090 Mast Top Section 1 5605 2135 810 1477
D 15.8
Clip
F 24.8
Clip
1517.6
White
D5B-M090 Mast Top Section 1 5605 2135 810 1477
D 15.8
Clip
F 24.8
Clip
1517.6
15
DESCRIPTION: MAST GIRTS DRG.NO. 39654510001 & 39654510001
PART PAINT
NO. COLOUR
White
D6A-M098 Girt Mast Lower Section 1 7083 495 191 732
J 2 35.0
Clip
767
White
D6B-M098 Girt Mast Lower Section 1 6312 495 191 551
J 2 35.0
Clip
586
16
DESCRIPTION: MAST BOTTOM STUB SECTION D.S. DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
D11R-M040 Mast Bottom Stub Section D.S. C/W 1 5702 2651 1600 5146.2 White
D12A-M040
Wireline Guard Support 2 - - - 63.5 White
D12B-M040
Wireline Guard 1 - - - 0.7
D12C-M040 Wireline Guard 1 - - - 1.2

18.1
D12D-M040 Bronze Thrust Washer 4 - - -
D12E-M040 Wireline Guard Stud 1 - - - 1.6
B6A-X007 29" Φ Sheave with Bronze Bearing, 2 260 Red

Grooved for 2.3/8" Φ Wireline
AG M 30 x 150 lg P8.8 HH. Bolt C/W 8 14.5

Field Assembly Bolt
HHN. Galv
Shop Assembly Bolt
AB M 20 x 51 lg P8.8 HH. Set Bolt C/W 8 3.6
Head Drilled 1/8" Dia Hole

L.W. Galv
Shop Assembly Bolt
AD M 24 x 229 lg P8.8 HH.Bolt C/W 1 1.2
HHN. & LW
Shop Assembly
AJ M 24 A325 Nut C/W L.W 2 0.2
3105.6
17
CUSTOMER: ONGC/OIL BHEL-PART LIST DATE : _____PAGE____7__
DESCRIPTION: MAST BOTTOM STUB SECTION O.D.S DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
D11L-M040 Mast Bottom Stub Section O.D.S. C/W 1 5702 2651 1600 5146.2 White
D12A-M040
Wireline Guard Support 2 - - - 63.5 White
D12B-M040
Wireline Guard 1 - - - 0.7
D12C-M040 Wireline Guard 1 - - - 1.2

18.1
D12D-M040 Bronze Thrust Washer 4 - - -
D12E-M040 Wireline Guard Stud 1 - - - 1.6
B6A-X007 29" Φ Sheave with Bronze Bearing, 2 544.3 Red

Grooved for 2.3/8" Φ Wireline
AG M 30x 150 lg P8.8 HH. Bolt C/W 8 14.5

Field Assembly Bolt
HHN. Galv
AB M 30 x 51 lg P8.8 HH. Set Bolt C/W 8 3.6 Shop Assembly Bolt

Head Drilled 1/8" Dia
L.W. Galv
Hole
AD M 26 x 229 lg P8.8 HH.Bolt C/W 1 1.2 Shop Assembly Bolt
HHN. & LW
Shop Assembly
AJ M 26 A325 Nut C/W L.W 2 0.2
3105.6
18
DESCRIPTION : MAST BOTTOM SECTIONS DRG.NO.39654510001&39654510002
PART PAINT
NO. COLOUR
D6R-M047
Mast Bottom Section D.S. 1 6578 3353 1905 4533 White
102 Φ x 660 Grip x 825 lg Field Pin C/W
M 1 53.4
Safety Clip
E 1 11.1
Clip
B 1 7.9
Clip
C Clip 1 10.3
4615.7
D6L-M047 Mast Bottom Section O.D.S. 1 6578 3353 1905 4533 White
102 Φ x 660 Grip x 825 lg Field Pin C/W
M 1 53.4
Safety Clip
E 1 11.1
Clip
B 1 7.9
Clip
C 1 10.3
Clip
4615.7
19
DESCRIPTION: GIRTS DRG.NO.39654510001&39654510002
PART PAINT
NO. COLOUR
D12A-M073 Girt Mast Intermediate Section 1 5451 495 152 536 White
J 2 35.0
Clip
349.3
Girt Mast Intermediate Section

D12B-M040 1 4585 444 140 445 White
H 2 30.9
Clip
243.6
White
D13A-M073 Girt Mast Upper Section 1 3718 394 127 316
G 2 29.8
Clip
209.0
Girt Mast Upper Section 1 2858 394 127 226 White

D13B-M073
G 2 29.8
Clip
175.0
20
DESCRIPTION: DIAGONAL BRACES DRG.NO:39654510001 & 39654510002
PART PAINT
NO. COLOUR
D14A-M073 Diagonal Brace Mast Lower Section 2 5082 170 165 181 White
D 4 31.6
Clip
402.2
D14B-M073 Diagonal Brace Mast Lower Section 1 8063 200 215 347 White
64 Φ x 178 Grip x 318lg Field Pin C/W Safety
D 4 31.6
Clip
365.5
White
D14C-M073 Diagonal Brace Mast Intermediate Section 1 7665 200 215 339
4 31.6
D Clip
360.1
Mast Stub Section Spreader 1 10027 2518 860 4958 White

D14-M040
Mast Stub Section Roller C/W 2 Pillar Blocks 149.6 White

TDN-A1361
63.2 Field Assembly Bolt
D Clip
M 16 x 65 lg P8.8 HH Bolt C/W HHN Galv. 0.9
AA
3275.4
21
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE___11___
DESCRIPTION : REAR ‘A’ FRAMES DRG.NO.39654510001& 39654510002
PART PAINT
NO. COLOUR
White
D15AR-M030 Rear ‘A’ Frame D.S. C/W 1 9805 1321 2134 7724
D15-M030T
Shaft Cap Plate 1 5.3
D15-M030V
8" Shaft 1 234.9
Line Guard Support 1 20.6

D15-M030W
Bronze Thrust Washer 2 13.6
D15-M030X
Line Guard Spacer 2 0.5
D15-M030Z
‘A’ Frame to Mast Bottom Section 1 102.9 White
D6A-M047
Connection Shoe
29¾"Φ Sheave grooved for 2.3/8" Φ
C41-X007 1 453.6 Red
Wireline C/W
Bearing Cup
1
Bearing Cones
2
Bearing Seats
2
L 1 34.5
76 x 279 Grip x 432 lg Double Taper.
Field Pin C/W . 2 Safety Clips
22
DESCRIPTION: FRONT AND REAR ‘A’ FRAMES DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
51 Φ x 229 x 381 lg Double Taper. Field Pin C/W.
A 1 4.1
2 Safety Clips
Shop Assembly
AC M 20 x 220 lg P8.8 Bolt C/W HHN. Galv 2 1.4
Bolt
Shop Assembly
AB M 20 x 50 lg P8.8 Set Bolt C/W. LW Galv 8 1.8
Bolt
Shop Assembly
AF M 30 x 115 lg P8.8 Bolt C/W. HHN. Galv 4 7.3
Bolt
Shop Assembly
6 M/M x 15 M/M Roofing Bolts 16 -
Bolt
6900.4
D15BR-M030 Front ‘A’ Frame D.S. 1 5639 914 483 1508.4 White
76 Φ x 203 Grip x 356 lg. Field Pin C/W. Safety
K 1 25.4
Clip
64 Ø x 178 Grip x 318 lg Field Pin C/W. Safety
D 2 15.4
Clip
114 Φ x 254 Grip x 432 lg Field Pin C/W. Safety
N 1 34.5
Clip
Shop Assembly
AE M 24 x 120 lg P8.8 Bolt C/W. HHN. Galv 4 7.3
Bolt
1591.0
23
DESCRIPTION: REAR ‘A’ FRAMES DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
White
D15AL-M030 Rear ‘A’ Frame O.D.S. C/W 1 9805 1321 2134 7724
D15-M030T
Shaft Cap Plate 1 5.3
D15-M030V
8" Shaft 1 234.9
Line Guard Support 1 20.6

D15-M030W
Bronze Thrust Washer 2 13.6
D15-M030X
Line Guard Spacer 2 0.5
D15-M030Z
‘A’ Frame to Mast Bottom Section 1 102.9
D6A-M047
Connection Shoe
29¾"Φ Sheave grooved for 2.3/8" Φ
C41-X007 1 453.6 Red
Wireline C/W
Bearing Cup
1
Bearing Cones
2
Bearing Seats
2
L 1 34.5
76 x 279 Grip x 432 lg Double Taper.
Field Pin C/W. 2 Safety Clips
24
DESCRIPTION: FRONT AND REAR ‘A’ FRAMES DRG.NO. 39654510001 & 39654510002
PART PAINT
NO. COLOUR
51 Φ x 229 x 381 lg Double Taper. Field Pin
A 1 4.1
C/W. 2 Safety Clips
Shop
AC M 20 x 220 lg P8.8 Bolt C/W HHN. Galv 2 1.4
Assembly Bolt
Shop
AB M 20 x 50 lg P8.8 Set Bolt C/W. LW Galv 8 1.8
Assembly Bolt
Shop
AF M 30 x 115 lg P8.8 Bolt C/W. HHN. Galv 4 7.3
Assembly Bolt
Shop
6 M/M x 15 M/M Roofing Bolts 16 -
Assembly Bolt
6900.4
D15BR-M030 Front ‘A’ Frame D.S. 1 5639 914 483 1508.4 White
76 Φ x 203Grip x 356 lg. Field Pin C/W.
K 1 25.4
Safety Clip
64 x 178 Grip x 318 lg Field Pin C/W. Safety
D 2 15.4
Clip
114 Φ x 254 Grip x 432 lg Field Pin C/W.
N 1 34.5
Safety Clip
Shop
AE M 24 x 120 lg P8.8 Bolt C/W. HHN. Galv 4 7.3
Assembly Bolt
1591.0
25
DESCRIPTION : DIAGONAL BRACES DRG.NO. 39654510001& 39654510002
PART PAINT
NO. COLOUR
D15A-M073 Diagonal Brace Mast Intermediate Section 1 7050 216 200 321 White
D 2 15.8
Clip
326.5
D15B-M073 Diagonal Brace Mast Upper Section 1 216 200 229 White
6372
D 2 15.8
Clip
237.2
White
D16A-M073 Diagonal Brace Mast Upper Section 1 5704 165 150 194
2 15.8
D Clip
209.9
Diagonal Brace Mast Top Section 1 5108 165 150 186 White
D16B-M073
D 64 Φ x 178 Grip x 318lg Field Pin C/W Safety 2 15.8

Clip
193.2
26
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : PAGE: 16
DESCRIPTION : LADDERS AND SAFETY CAGES DRG.NO: 39654510004
PART PAINT
NO. COLOUR
MK-D10A Ladder Section 1 5893 2387 862 205 White
White
MK-D10B Ladder Section 1 9680 862 888 411
White
MK-D10C Ladder Section 1 11109 862 888 447.76
White
MK-D10D Ladder Section 1 11059 862 888 424.6
White
MK-D10E Ladder Section 1 5605 862 888 244.7
White
MK-D10F Ladder Section 1 3500 862 888 58.05
MK-D10G Connection Plate 38 250 10 50 White
MK-D10H Connection Plate 22 135 10 50 White

Connection Plate
MK-D10I 16 50 10 50 White
Rest Platform-1
RP-1 2 0 6 90 85.5 White
AA M 16 x 50 Bolt ,NUT & WASHER 40 15
BB M 20 x 60 Bolt ,NUT & WASHER 16
Total Weight
27
CUSTOMER: ONGC/OIL BHEL-PART LIST DATE : _____PAGE: 17
DESCRIPTION: BOTTOM SECTION TO ‘A’ FRAME STABBING GUIDES, DRG.NO. 39654510001 & 39654510002
MAST ASSEMBLY STANDS AND GOOSE NECK PLATFORM
PART PAINT
NO. COLOUR
D20A-M070 Stabbing Guides 2 432 584 152 88.5 White
D20B-M070 Mounting Brackets 4

Welded to Rear ‘A’ Frames
D20C-M070 Guide Side Plate 2
Welded to Mast Bottom Section
M 24X 83 lg P8.8 Bolt C/W 8 Field Assembly Bolt
HHN Galv
93.9
D25-M040 Mast Assembly Stands 2 1626 1524 1905 746.6 Primer
M 13 x 90 lg P8.8 Bolt C/W 16 1.8 Shop Assembly Bolt
H.N & F.W
748.4
Goose Neck Access Platform 1 762 610 140 33.7 White
D29-M073
M 20 x 50 lg P8.8 Bolt C/W 4 1.8 Field Assembly Bolt
HHN Galv
35.5
28
DESCRIPTION: HYDRAULIC SNUBBING AND BREAK-OVER UNITS DRG.NO. 39654510006
PART PAINT
NO. COLOUR
Assembled to ‘A’ Frame
D30A-M040 Snubbing and Break-Over Unit D.S 1
Assembled to ‘A’ Frame
D30B-M040 Snubbing and Break-Over Unit O.D.S 1
TDN-A1051 Snubbing and Break-Over Units Nose 2 9.1

Hydraulic Cylinder Retaining Clamps
TDN-A1054 4 15.8
Trunion Mounted Hydraulic Cylinder
TDN-A1091 2 408.9
D30C-M040 ¾" Stud Coupling 8 3.6

¾" Pull Break Coupling Complete
D30D-M040 4 1.8
¾" Dowty Washer
D30A-M040 8 0.5
¾" x 45° Female Re-usable Fitting 2 0.9

D30F-M040
¾" x 90° Female Re-usable Fitting 2 0.9
D30F-M040
D30H-M040 ¾" Φ Two Wire Straight Hose with 4 1.8
Female Re-usable Union
D30J-M040 4 0.9
¾" B.S.P Stud Union Equal Male/Male
Note: Base Plates welded
D30K-M040 12 2.7
Double Pipe Clamps to Rear ‘A’ Frames
D30L-M040 4 28.2
¾" Φ x 6m lg Hydraulic Tubing
D30M-M040 4 10.4
¾" Φ x 1.5m lg Hydraulic Hose
D30N-M040 M 10 x 40 lg P8.8 Set Bolt C/W LW 8 0.5
186.9
29
DESCRIPTION: CROWN DRG.NO. 39654510007
PART PAINT
NO. COLOUR
1 Crown Frame C/W D4A-C092 Crown Flooring 1 3554 Yellow
2 Handrail 1 48.8 Yellow
3 Handrails 2 34.2 Yellow
4 Handrails 2 26.7 Yellow
5 Fastline Padeyes W/WL Retainer 2 61.6 Yellow
6 Cluster Padeyes 2 66.8 Yellow
7 Cap Plates 2 8.0 Yellow
8 Cap Plates 2 8.0 Yellow
9 Fastline Shaft 1 138.6 Yellow
10 Cluster Shaft 1 442.5 Yellow
11 Bumper Block Rod C/W Hex Nut 2 1.81 Yellow
12 F.L. Lineguard Rods C/W Hex Nut 2 1.13 Yellow
13 Bumper Blocks 2 83.8 Yellow
14 Brackets 2 10.4 Yellow
15 W.L. Retainer 2 8 Yellow
30
DESCRIPTION: CROWN DRG.NO. 39654510007
PART PAINT
NO. COLOUR
16,17 Spacers 4 18.3 Yellow
12
18,19 M24X50 Bolt C/W Soft Wire 0.52 -
20 Φ60" Sheaves 7 489.6 Yellow
21,22 Cup/Cone- Bearing Set 7/14 21.64 -
23 Grease Retainers 14 0.16 Yellow
Shop Bolts (Galv.)
24,26,27 M24X90 C/W Nut, Washer 8 0.73
25,26,27 M24X80 C/W Nut,Washer 8 0.67
28,29,30 M20X70 C/W Nut,Washer 4 0.33
Field Bolts (Galv)
31,33,34 M12X130 C/W Nut,Washer 4 0.11
32,33,34 M12X80 C/W Nut,Washer 12 0.11
Field Pins (Galv.) -
35,36 Φ 50X520 Grip W/6 Safety Pin 4 10.1
TOTAL 8180
31
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE: 21
DESCRIPTION : RACKING BOARD DRG.NO. 39654510008
PART PAINT
NO. COLOUR
7198
1 Racking Board Frame 1 3200 954 5293 White
340
2 Finger Board (D.S) 1 79 25 314 White
3 Finger Board (O.D.S) 1 2880 610 356 307 White
4 Hinged Floor Slabs 2 610 457 273 92 White

632
5 Extension Pin 1 25 273 3 White
2321
6 Hand rail 2 60 1219 58 White
1879
7 Floor slab pin 1 16 12.5 3 White
8
Diving board 1 603 191 178 32.1 White
Diving board extension 1 594 25 2 43 -

9
10 Diving board top plate 16 267 89 25 53.9 White
11 Handrail 2 2188 1188 50 43 White
12 Diving board bottom plate 1 584 20 190 22 White
13 Racking board knee brace 2 3338 100 98 186 White
14 Ladder access platform 1 627 626 291 90.2 White
15 Collar Finger Platform 2 406 305 76 24 White
32
PART PAINT
NO. COLOUR
24
Hanrail Pin 39Φ x 77-127 lg C/W Safety Clip 8 - - - 2.27 -
29 Hanrail Pin 16Φ x155-155 lg C/W Safety Clip 24 - - - 0.27 -
16 Collar finger platform pins 2 - - - 14.4 -
17 Hand rail 1 2286 2931 50 94 -
18 Hand rail 1 2286 2823 23.9 91 -
19 Hand rail 1 1905 538 368 35.5 White

20 Hand rail 1 1905 538 50 35.5 White
21 Hand rail 1 1905 538 50 57 White
22 Roller assembly 2 1600 20 20 43 -

23
Rods 2 2267 1188 50 56.4 White
25 White
Lock springs 1.5 8 0.1
26 Gal. hex M20 bolt 4 0.4 -

27,28
M20 nut & washer 24 0.54 -
30
Lock spring-1 24 0.1 -
31
Finger latch 18 0.1 -
33
PART PAINT
NO. COLOUR
51Φ x 127Grip x 279 lg Field Pin C/W Safety
32 6 4.16
Clip
33 Lock spring-2 2 4.3
Shop Assembly
38 M 20 x 90 lg Bolt P8.8 C/W Safety Clip 6 0.28
Bolt
M 20 x 130lg P8.8 Bolt C/W HHN & HFW Shop Assembly
41 14 0.38
Galv. Bolt
34 39Φ x 77Grip x 127 lg Field Pin C/W Safety
4 2.27
Clip.
35
Lock spring-1.5 4 0.1
36,39
pin. 16 Φx140gripx179lg. 13 0.1
37,40 Lock spring-1 13

0.1
4200.6
34
DESCRIPTION : BELLY BOARD DRG.NO. 39654510009
PART PAINT
NO. COLOUR
Belly Board Frame 1 7829 2538 441 1847 White
1
2 Support Brace 2 2935 127 100 116 White
Plat form 1 1433 679 267 93 White

3
Handrail Pin 39Φ x 192 Grip x 77 C/W Safety
6 - - - 4.4 -
9 Clip
Handrail Pin 51Φ x 215 Grip x 77lg C/W
10 4 - - - 1.9 -
Safety Clip
Handrail 1 3724 1263 40 28 White

4
5
6
7
8 Handrail 1 746 1263 40 33 White
11 M12x80 w/n & w 13 0.5 White
12 M12x120 W/N & W 4 - - - 0.3 -
2417
35
DESCRIPTION : TONG COUNTER WEIGHTS DRG.NO. 39654510005
PART QT PAINT
DESCRIPTION L W H WT REMARKS
NO. Y COLOUR
Tong Counter Weights Assembly 2 845
D6-M073
B5-X039 Tong Buckets 2 1991 476 273 249.6 White
Top Brackets 2 540 235 184 49.0 White

B89A-X012
Welded to Mast Lower
Bottom Brackets 2 - - - 30.4 White
B89B-X012 Section
7005/2 Pipe Tracks 4 4445 73 73 153.3 White
7005/3 Welded to Mast Upper

Hanger Connections 2 - - - 26.3 White
Section
Gusset plates 2 - - - 24.2 White
7005/5A Section
Gusset Plates 2 - - - 9.3 White
7005/5B Section
Connection Plate 1 - - - 9.9 White
7005/5C Section
Connection Plate 1 - - - 1.6 White
7005/5D Section
M 20 X 65 lg P8.8 Bolt C/W HHN & L.W
A 12 - - - 3.2 White
Galv
M 12 x 130 lf A307 HH. Bolt C/W HHN &
B 4 0.5
LW
D Snatch Block C/W Shackle 2 30.8
McKissick 419
E ½" Φ x 216' 0" lg Wireline IPS IWRC 2 90.3
36
DESCRIPTION : TONG COUNTER WEIGHTS DRG.NO. 39654510005
PART QT PAINT
NO. Y COLOUR
6 x 37 Seized Ends
F ½" Wire Rope Thimble Galv 4 0.5

G
½" Wire Rope Clips Galv Crosby G-450 12 3.6
690.1
37
DESCRIPTION : STANDPIPE CLAMPS DRG.NO. 39654510004
PART QT PAINT
NO. Y COLOUR
Standpipe Clamp 1 32.0 White
C100A-M074
C100B-M070
Clamp Fixing Bracket
C100C-M074 1 12.4 White
C100D-M074 1 9.6 White
M 20 x 70 lg P8.8Bolt C/W 32 3.77 Field Assembly Bolts

15
M 20 Hex Nut & Washer
16 ,17 48 1.86 Field Assembly Nuts, Washers
18 Clamp Cup B3A-X004 52.32

8
C100A-M074
C100B-M070

C100C-M074 1 12.4 White

C100D-M074 1 9.6 White
M 20 x 70 lg P8.8 Bolt C/W 32 3.77 Field Assembly Bolts

15
M 20 Hex Nut & Washer
16 ,17 48 1.86 Field Assembly Nuts , Washers
18 Clamp Cup B3A-X004 52.32

8
38
DESCRIPTION : SLINGLINE EQUALISER UNIT DRG.NO. 39654510011
PART PAINT
NO. COLOUR
Slingline Equalizer Unit Assembly 1 1473 838 330
1 Yoke 1 510.3 White
2 Side Plate 1 171.9 White
3 Side Plate 1 169.2 White
4 Shaft 1 95.3
5 Pins 2 23.6
756 Sheave grooved for 2.3/8"Φ
7 1 269.4 Red
Wireline C/W Bronze Bush
8 6 Grease jerk 1 0.9
9 Bronze Washer 2 0.5
C ¼" NPT Grease Nipple 1 -

M 20 x 266lg P8.8 Bolt C/W HHN &
A 1 0.9
LW Galv
M 20 x100 lg P8.8 Bolt C/W HHN &
B 4 0.5
LW Galv
2361.5
39
DESCRIPTION : 24" Φ CORELINE SHEAVE UNIT DRG.NO. 39654510012
PART PAINT
NO. COLOUR
D1-X013 24"Φ Coreline Sheave Assembly 1 835 851 165 White
24"Φ Coreline Sheave Grooved for 9/16"Φ
C4-X007 1 99.8 Red
Wireline
B3-X013 Sheave Pin 1 11.5
B4-X013 Wireline Retainer 1 0.1
B5-X013 Cap Plate 1 1.4
C2A-X013 Sheave Hanger 2 17.7 White
A M 20 x 130 lg P8.8 Bolt C/W HHN Galv. 2 0.8
B M 20 x 40 lg P8.8 Bolt C/W HHN Galv. 1 0.2
C 1/8"Φ x 2" lg Cotter Pin 2 -
E ¼"Φ NPT Grease Nipple 1 -

1.1/8"Φ x 6" Grip x 9½" Field Pin C/W
B1-X001 1 0.7
Safety Clip
132.2
40
DESCRIPTION : 16 "Φ CATLINE SHEAVE UNIT DRG.NO 39654510015
PART PAINT
NO. COLOUR
TDN-D308 16 "Φ Catline Sheave Unit Assembly 2 610 432 152 210.4 White
TDN-D301A
Sheave Hanger 2 49.9 White
TDN-D301B Sheave Pin 1 5.4
TDN-D301C Pin 1 4.1
TDN-D301D Washers 2 0.9
TDN-D301E Hub 1
TDN-C309 16 "Φ Sheave Grooved for 5/8 "Φ Wireline 1 39.5 Red
5/6 "Φ x 2½" lg ‘C’ Lock Pin
1 3/8 "Φ Hardened Washer
M 26 HHN Galv 0.9
¼" NPT Grease Nipple
M 20 x 38 lg Grub Screw
12 Ton Johnson Swivel C/W Shackle 4.5
105.2
41
DESCRIPTION : 14 "Φ AIR TUGGER SHEAVE UNIT DRG.NO. 39654510016
PART PAINT
NO. COLOUR
TDN-D813 14"Φ Air Tugger Sheave Unit Assembly 2 610 432 152 202.2 White
TDN-D815A Sheave Hanger 2 49.9 White
TDN-D815B Sheave Pin 1 5.4
TDN-D815C Pin 1 4.1
TDN-D815D Washers 2 0.9
TDN-D815E Hub 1
TDN-C814 14"Φ Sheave Grooved for 9/16"ΦWireline 1 35.4 Red
5/6 "Φ x 2½" lg ‘C’ Lock Pin
1 3/8 "Φ Hardened Washer
1" UNC HHN Galv 0.9
¼" NPT Grease Nipple
M 20 x 1½" lg Grub Screw
12 Ton Johnson Swivel C/W Shackle 4.5
101.1
42
DESCRIPTION : HYDRAULIC LEVELING SYSTEM, DEADLINE ANCHOR STUD BOLTS, DRG.NO. 39654510006
ALUMINIUM EXTENSION LADDER.
PART PAINT
NO. DESCRIPTION QTY L W H WT COLOUR REMARKS
Mast Hydraulic Levelling System
50Ton Enerpack Ram R.E.506 1 22.2
Enerpack Pump P.80 1 11.8
6' 0" Hose Assembly H.C 913 1 2.3
36.3
Deadline Anchor Stud Bolts
4 57.9
M 50 x 2'3" lg A193-B7 Stud Bolt
8 HHN & HFW A194- 2H Galv
57.9
4450 When closed
Aluminium Extension Ladder C/W 1 21.6
&
8260When open
TDN-A1369 Hooks 2 10.5
White
M 20 x 40 P8.8 Set Bolt C/W HN 6 0.2
32.3
43
DESCRIPTION: HYDRAULIC LEVELING SYSTEM, DEADLINE ANCHOR STUD BOLTS, DRG.NO .39654510006
ALUMINIUM EXTENSION LADDER & GERONIMO LINE
PART PAINT
Derrick Man Escape Equipment
Geronimo Line C/W 1 68.0
½Φ x 370' 0" lg Wireline C/W

Wireline Clips And Thimbles, Safety Slide
and Handbrake and Ground Anchor
68.0
44
DESCRIPTION : LADDER SAFETY CLIMB EQUIPMENT & SHIM PACKS DRG.NO 39654510003
PART PAINT
1050/107 Raillok Locking Device 1
Railok Aluminium Rail in 10'0" Lengths 15
Sets of Joint Plates C/W 56 off Stainless 14
Steel Bolts 8M/M x 25M/M

10M/M x 50M/M Bolt C/W HN.W and
45
Spacer
Safety Belt C/W Hook 2
68.0
SHIM Packs
TDN-A10638 1/8" Shim Pack 8 482 280 3.15 2.54 White
TDN-A1063B ¼" Shim Pack 8 482 280 6 4.85 White
TDN-A1063C ½" Shim Pack 8 482 280 12 9.70 White
TDN-A1063D 1" Shim Pack 8 482 280 25 20.2 White
298
45
DESCRIPTION : CASING STABBING BOARD TRACK FRAME DRG.NO 39654510013
PART PAINT
NO. COLOUR
1 Casing Stabbing Board Track Frame 1 10211 1245 635 372 White
2 5/8" Dee Shackle 6 - - - 0.1 -
3 Thimbles for wire ropes 6 - - - 1.1
4 Forged bull dog grip un gal. 5/16” 18 0.05
5 M 12x 50 lg P8.8 Bolt & NutGalv 4 - - - 0.59 - Shop Assembly Bolt
6 M 20 x 60lg P8.8 Bolt , Nut & washer Galv 12 - - - 0.207 - Field Bolts
7 Casing stabbing board carriage & platform 1 232 50 15 372 Field Aseembly
8 Machined wheel 4 190 63 15 16 Field Aseembly
9 Wheel shaft 4 195 60 972 3
10 M 20 x 70lg P8.8 Bolt , Nut & washer Galv 12 - - - 0.236 -
11 Forged bull dog grips 5/16” 12 - - - 0.05 -
12 Dee shackle grade 5/18” 4 0.1
13 Thimbles for wire ropes 5/16” 4 0.080
14 1/8”NPT Greese Nipple 4 0.01
15 Hook bolt assly 8 0.74
46
DESCRIPTION : CASING STABBING BOARD TRACK FRAME DRG.NO 39654510013
PART PAINT
NO. COLOUR
B16 Nut & washer 6 - - - 8
Air motor with sky locks 1 - - - 12.9
1235
47
SECTION III
Sub-structure Parts List

And
Assembly Drawings
48
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO. : 3-96545-3-0020,

1000KPS STATIC HOOK LOAD 3- 96545-3-0021, 3-96545-3-0022
LIST OF SUB ASSEBBLIES
PART PAINT
NO. COLOUR
D4A-S067 BOTTOB BOX D.S. 1 13755 BLACK
D4B-S067 BOTTOM BOX (O.D.S) 1 15454 BLACK
D7A/B-S022 BOTTOM BOX EXTENSION 1/1 8782 BLACK
D8-S067 DRAWWORKS SUPPORT 1 7655 WHITE
D10-S054 FRONT DWKS SUPPORT COLUMN 2 968 WHITE
D11A-S054 REAR DWKS SUPPORT COLUMNS 2 1147 WHITE
D11B-S054 DWKS SUPPORT COLUMN SPREADER 2 120
C12-S054 DWKS SUPPORT BRACES 2 297 WHITE
D14-S067 DWKS SUPPORT EXTENSION 1 1548 WHITE
D15-S067 SET BACK SPREADER 1 12500 WHITE
IRD-RB-7998 ROTARY BEAM UNIT 1 1885 WHITE

IRD-RS-DS-
ROTARY FLOOR SPREADER (D.S) 1 466
7944
IRD-RS-7943 ROTARY SPREADER (O.D.S) 1 581
C17B-S021 FRONT SET BACK LEGS 2 654 WHITE
D18A-S067 BOTTOM BOX REAR SPREADER 1 547 BLACK
49
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO. 3-96545-3-0020,

1000KPS STATIC HOOK LOAD 3- 96545-3-0021, 3-96545-3-0022
LIST OF SUB ASSEMBLIES
PART PAINT
NO. COLOUR
D18B-S067 BOTTOM BOX FRONT SPREADER 1 514 BLACK
D18C-S067 BOTTOM BOX SPREADER BRACES 2 153 BLACK
D40A-S054 12 TON BOP TROLLY BEAM 2 443 WHITE

COMBINATION RAMP &
1 4083 GREY
STAIR C/W HANDRAILS
STAIRWAY C/W HANDRAILS 2 461 GREY
STAIRWAY C/W HANDRAILS 1 1108 GREY
C823A REST PLATFORM 1 533 GREY
PTM-001D REST PLATFORM 1 321 GREY
D61A-S067 DOGHOUSE SUPPORT 1 2260 WHITE
EXTERIOR FLOORING C/W HANDRAILS 1 7418 GREY
TOTAL WT. 20,001
50
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE____3___
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO. : 3-96545-3-0020

SUB-STRUCTURE
PART PAINT
NO. COLOUR
D4A-S067 BOTTOM BOX D.S. C/W 1 12497 2540 1753 13755 BLACK
D45A-S021 MANWAY COVER 1 610 610 83 40.7

MANWAY COVER ATTACHED
D45B-S021 2 610 381 83 11
BY CHAIN
D4B-S067 BOTTOM BOX O.D.S. 1 12497 2540 1753 15454 BLACK
D45A-S021 MANWAY COVER 1 610 610 83 40.7

MANWAY COVER ATACHED
D45B-S021 2 610 381 83 11
BY CHAIN
51

SUB STRUCTURE
PART PAINT
NO. COLOUR
D7A-S022 BOTTOM BOX EXTENSION D.S. 1 5744 1829 1372 3960 BLACK
D7B-S022 BOTTOM BOX EXTENSION ODS 1 57441 1829 1372 4822 BLACK
DRAW WORKS SUPPORT C/W
D8-S067 1 12319 3251 1295 7655 WHITE
29 ¾”φ SHEAVE GROOVED FOR 2 3/8”φ
C43-X007 2 260 RED
WIRELINE
5”φ SHAFT 2 36 RED
DRAW WORKS SUPPORT FRONT
D10-S054 2 5969 2743 419 968 WHITE
COLOUMN
D11A-S054 DWKS SUPPORT REAR COLUMN 2 1147 WHITE
DRWWORKS SUPPORT COLUMN
D11B-S054 2 120 WHITE
SPREADER
C12-S054 DRAWWORKS SUPPORT BRACE 2 5072 279 292 297 WHITE
D14-S067 DRAWWORKS SUPPORT EXTENSION 2 12192 2311 572 1548 WHITE

SETBACK SPREADER
D15-S067 1 12319 2972 1676 12500 WHITE
IRD-RB-7998 ROTARY BEAM UNIT 1 2661 1511 1073 1885 WHITE

FRONT SET BACK LEGS
C17B-S021 2 6059 305 305 654 WHITE
BOTTOM BOX REAR SPREADER
D18A-S067 1 7264 330 321 547 BLACK
D18B-S067 BOTTOM BOX FRONT SPREADER 1 6299 381 159 514 BLACK
52

SUBSTRUCTURE
PART PAINT
NO. COLOUR
D18C-S067 BOTTOM BOX SPREADER BRACE 2 4141 254 146 153 BLACK
D40A-S054 12 TON BOP TROLLY BEAM 2 3067 521 165 443 WHITE
COMBINATION RAMP AND STAIR
1 10058 2632 737 4083 GREY
6’-2” WIDE
REST PLATFORM
C823A 1 1943 1247 927 533 GREY
TDN-D819C HANDRAIL 1 4524 635 50 46 GREY

HANDRAIL
TDN-D819B 1 6039 635 50 42.2 GREY
TDN-
STAIRWAY 2 5565 914 357 461 GREY
D819A
C823B HANDRAIL 4 2413 830 50 22 GREY
TDN-D824B HANDRAIL 4 3105 830 50 31.4 GREY
STM-S001D STAIRWAY 1 8367 914 357 1108 GREY
PTM-001D REST PLATFORM 1 3924 1047 927 321 GREY
H3 HANDRAIL 2 3810 830 50 54 GREY
H2 HANDRAIL 2 4496 830 50 54

HANDRAIL
H1 2 2708 830 50 39 GREY
53
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO. 3-96545-3-0020

STAIRWAY FROM MUD SYSTEM & STAIRWAY TO DOGHOUSE
PART PAINT
NO. COLOUR
D61A-S067 DOG HOUSE SUPPORT 1 778
D61B-S067 DOG HOUSE SUPPORT 1 782 WHITE
D61C-S067 DOG HOUSE SUPPORT GIRT 3 215.4 WHITE
54

PINS, GRIPS, BOLTS
PART PAINT
NO. COLOUR
PIN SCHEDULE C/W SAFETY CLIPS
A 51Φ X 127 GRIP-279 LG 14

B
51Φ X 386 GRIP-493 LG 2
C 64Φ X 178 GRIP-317 LG 2
D 64Φ X 406 GRIP-545 LG 2

76Φ X 203 GRIP-356 LG
E 8
F 39Φ X 127 GRIP-241 LG 6
G 89Φ X 229 GRIP-394 LG 4
H 25Φ X 51GRIP-140 LG 4
J 51Φ X 203 GRIP-355 LG 4
K 39Φ X 102 GRIP-229 LG 8
L 89Φ X 432 GRIP-597 LG 6
M 89Φ X 280 GRIP-449 LG 2
55

PART PAINT
NO. COLOUR
N 26Φ X 254 GRIP-345 LG 2
P 51Φ X 483 GRIP-622 LG 2
R 39Φ X 229 GRIP-343 LG 2
S 51Φ X 381 GRIP-520 LG 2
T 51Φ X178 GRIP-317 LG 2
U 51Φ X 254 GRIP-393 LG 4
V 51Φ X 127 GRIP-279 LG 4
W 39Φ X 127 GRIP-362 LG 2
MAST PINS
N' 115Φ X 254GRIP-432 LG 2
M' 115Φ X 660 GRIP-838 LG 2
L' 76Φ X 305 GRIP-463 LG 2
K' 76Φ X 203 GRIP-355 LG 2
56

PART PAINT
NO. COLOUR
A' 51Φ X 229 GRIP-381 LG 2
BOLT SCHEDULE
AA M12X 60 LG 4
AB M16 X 83 LG 4
AC M25 X 50 LG 8
AD M20 X 210 LG 2
AE M24 X 102 LG 20
AF M24 X 120 LG 16
57
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE___10__
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO.: 3-96545-3-0022

EXTERIOR FLOORING
PART PAINT
NO. COLOUR
FAL-8191 FLOORING PANEL 1 547 GREY
FAR-8191 FLOORING PANEL 1 532 GREY
FBR-8191 FLOORING PANEL 1 242 GREY
FBL-8191 FLOORING PANEL 1 261 GREY
FC-8191 FLOORING PANEL 1 448
FD-8191 FLOORING PANEL 1 581
FE-8191 FLOORING PANEL 1 371 GREY
FF-8191 FLOORING PANEL 1 395 GREY
FGL-8191 FLOORING PANEL 1 496
FGR-8191 FLOORING PANEL 1 496
FHL-8191 FLOORING PANEL 1 485
FHR-8191 FLOORING PANEL 1 481
FIL-8191 FLOORING PANEL 1 215
FIR-8191 FLOORING PANEL 1 215
FJ-8191 FLOORING PANEL 1 279
58
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE___11___
DESCRIPTION : 142’0” HIGH ANGLE MAST AND ACCESSORIES DRG.NO. 3-96545-3-0022

EXTERIOR FLOORING
PART PAINT
NO. COLOUR
FKR-8191 FLOORING PANEL 1 66
FKL-8191 FLOORING PANEL 1 66
HRE-8003 HANDRAIL 1 144
HRF-8003 HANDRAIL 1 151
HRAL-8003 HANDRAIL 1 83
HRS1-8003 HANDRAIL 1 77
HRI-8003 HANDRAIL 1 63
HRAR-8003 HANDRAIL 1 66
HRG-8003 HANDRAIL 2 56
HANDRAIL
HRS5-8003 4 96
HANDRAIL
HRHR-8003 1 125
59
CUSTOMER:ONGC/OIL BHEL-PART LIST DATE : _____PAGE___12_

EXTERIOR FLOORING
PART PAINT
NO. COLOUR
HANDRAIL
HRGR-8003 1 129
HRGL-8003 HANDRAIL 1 61.5
60
SECTION IV
Erection Sequence
61
OPRATION AND MAINTENANCE MANUAL
MAST AND SUB-STRUCTURE ASSEMBLY AND ERECTION SEQUENCE.
INDEX.
SECTION 1. BOTTOM BOXES, SPREADERS, BRACES AND ‘A’ PAGE 2

FRAMES.
SECTION 2. SETBACK, MAST, CROWN, LADDERS AND TONG PAGE 3 & 4

COUNTERWEIGHTS ASSEMBLY.
SECTION 3 DRAWWORKS ATTACHMENT TO BOTTOM BOXES. PAGE 5
SECTION 4 MAST REEVING AND RAISING SEQUENCE AND PAGE 6 & 7.

RACKING BOARD ATTACHMENT.
SECTION 5 DRAWWORKS REEVING AND RAISING PAGE 8
SECTION 6 ASSEMBLY AND RAISING OF DOGHOUSE SUPPORT PAGE 9

AND MAST ACCESSORIES.
SECTION 7 LOWERING PROCEDURE. PAGE 10
NOTE ;-
COMPLETE SECTIONS 1,2, and 3 before starting SECTION 4.
DATE ISSUED.
62
Section 1
BOTTOM BOXES, SPREADERS, BRACES AND ‘A’ FRAMES
Sequence one Drg. No. 3-96545-3-0020
Prepare and level Site.
1.1 Set Drillers Side (DS) and Off Drillers Side (ODS) Bottom
Boxes on Center Line using Front and rear Spreaders and
Braces to ensure that the Bottom Boxes are correctly
positioned, using Pins called up on Drg. No. 3-96545-1-0021.
1.2 Pin and Bolt Bottom Box Extensions to Bottom Boxes.
1.3 Swing out Support Arms on Bottom Box Extensions ready for
Front setback Legs.
1.4 Pin and Bottom Box Rear Extensions ready for Drawworks support.
1.5 The ‘A’ frames are normally transported folded into the
Bottom Boxes. Check that the stools are fitted to the rear
‘A’ Frames. See Sheet 18 of the Sub-structure parts List.
1.6 Pin the Wing Flooring to ‘A” Frame using lower pin connection
only. Swing into final position when the ‘A’ Frames are raised.
Flooring and pins called upon Drg. No. 3-96545-1-0022.
1.7 Sequence One 3-96545-1-0023 raise ‘A’ Frames DS and ODS with winch
Trunk of Crane by attaching slings to Padeyes near ‘A’ Frames
Sheave. Raise until Rear ‘A’ Frame is vertical with the
rollers lifting off the track.
Turn Head of Crane in opposite direction so that the roller

passes the Apex, then lower and pin at detail ‘C’ on Drg.
No. 3-96545-1-0023 using Pins called up on Drg No. 3-96545-1-0001.
1.8 The Drawworks Support Braces are normally transported pinned to

to Bottom boxes.
63
SECTION 2
SETBACK, MAST, CROWN, LADDERS & COUNTERWEIGHTS
Sequence Two Drg. No. 3-96545-1-0023
2.1 Position Front Setback Legs on Support Arms on Bottom Box

Extension and pin to Bottom Boxes DS and ODS.
2.2 Position Setback Spreader on Bottom Box Extension Stools,

and pin to Front Setback Legs.
Ensure that the top and bottom Setback Leg Pin connections
are well greased.
2.3 Pin Front B.O.P Trolly Beam to Setback Spreader DS and ODS
Step two, ensure taper on pin F drg. No. 3-96545-3-0021 points to
centreline of well.
Mast step three on Drg No.3-96545-1-0024 and 3-96545-1-0002.
2.4 Pin Mast Bottom sections to Bottom Boxes and Pin to Setback
Spreader
Ensure that the Top and Bottom Pin connections are well greased.
2.5 Bolt bottom Stub section to Bottom sections DS and ODS
2.6 Pin Stub section Spreader to Stub section after mounting

Fast-line Roller on the two pillow blocks supplied.
Check free rotation of roller.
2.7 Support Travelling Block, Hook and equalizer, with Hook

approximately 60ft. from center line of well.
2.8 Assemble Mast Lower sections DS and ODS to lower section

spreader, lift section and pin to stub section and pin in
lower section Braces.
2.9 Place Mast Assembly stands under lower sections near the top
and pack up as necessary.
2.10 Assemble Mast middle sections DS and ODS and middle section
spreader. Lift section, pin to lower section, lift slightly
to release Mast assembly stands, move stands to the top of
middle section Braces.
64
SECTION 2 cont…..
2.11 Attach lines to Tong Buckets and take lines through to the
Brackets on the middle section, reeve snatch Block and tie
line off at a convenient point on Stub Section.
2.12 Assembly Mast upper section DS and ODS, lift section and pin
to lower section, lift slightly to release mast assembly
stands move stands to top of upper section.
2.13 Normally the Mast top section is transported with the Crown
attached as shown on page of Mast parts list.
Lift Crown and top section and pin to upper section.
2.14 Assemble flooring extension, Braces and handrails to Crown

Frame. Using bolts called up on Crown assembly Drg. No.
3-96545-1-0007.
2.15 Fit Coreline Sheave, etc., to Crown Frame
2.16 Fit ladders to DS from Stub Section to Crown. See Ladder

Assembly Drg. No. 3-96545-1-0003
2.17 Fit Standpipe Clamps attached with ‘U’ Bolts to the lower
and Stub Section of Mast ODS.
Check that the Standpipe Does not interface with Setback

Spreader when raising the Mast.
If interface occurs remove Standpipe before Raising the Mast.
2.18 Lift Mast at Crown with the Crown Padeyes and place the 16’0”
high Mast Stand under top Section near the Crown Frame.
65
SECTION 3
DRAWWORKS ETC…
Sequence two continues on Drg. No. 3-96545-1-0024

Pin and Bolts called up on Drg. Nos. 3-96545-3-0020
3.1 Pin rear Drawworks Support Columns to Bottom Boxes DS and

ODS and Bolts called up on Drg. Nos. 3-96545-3-0020.
Grease pin connections.
3.2 Pin Front Drawworks Support Column to Bottom Boxes DS and

ODS and bolt together with Spreader. Step Five.
Grease pin connections.
3.3 Position Drawworks Support on Bottom Box and rear Extensions

and pin to front and rear support columns.
Grease pin connections
3.4 Pin Drawworks extension to Drawworks Support
3.5 Set Drawworks and bolt down as recommended by equipment Supplier.

Connect air and Brake water systems, fill water tanks in bottom
boxes DS and ODS.
3.6 Pin Rotary Support Beam Unit Part no. C17-S029 and Rotary Floor
Support Units.
Part no.C29-S067 and C30-S069only to Drawworks.
3.7 Fit and trim to Drawworks if necessary. Drawworks flooring

Part Nos. D32A, D32B, D33C and D33D-S093
3.8 Pin in Vertical position Bottom Section Wing Flooring to

Bottom Section, Step Eight.
Part No. D53A-S054.

Part No. D53B-S054.
66
SECTION 4
MAST REEVING, RACKING BOARD, MAST RAISING AND SNUBBING
Sequence 2A and 2B Drg. No. 3-96545-1-0023.

Place in position approximately 60ft, from the centre line of well
the Travelling Block, Hook and Equalizer before assembling the Mast
Lower Section to the Mast Stub Section.
4.1 Before Reeving, lubricate all Sheave and ensure they Rotate
freely, Using the longest Slingline, connect open Socket to
Slingline Anchor on Mast section and pass line over
‘A’ Frame Sheave, replace rear line guard roller, pass under
vertical Sheave, round horizontal Sheave on Stub section
replacing both line guards then take Slingline through
equalizer, to fit Slingline to equalizer it will be necessary
to remove Sheave and shaft from the yoke. Place Slingline
between Side Plates and then slide Sheave back into position
replacing Shaft and securing bolt.
Using shortest Slingline connect Open Socket to Slingline

Anchor on Mast Section Reeve as above connecting open
and closed socket together.
Special care must be taken when uncoiling Slingline not to

kink lines.
4.2 Bolt deadline Anchor to Mast Bottom Section Drillers side and
connect Sensor to Gauge on Drawworks.
Deadline Anchor normally transported in Bottom Section.
4.3 Place Drill line Drum in its Stand and position near Bottom
Box Extensions DS using Soft line and Snatch Blocks pull
Drill line under Setback Spreader and into Bottom Section
and up to Crown Vee Door Sheave, String Block, then take
Drill line over Fastline, replacing Line Guards, and then
back to Drawworks, spool on enough Drill Line to ensure that
the Travel Block will reach Drill Floor when Mast is in the
Vertical position.
4.4 Place equalizer on Hook.
67
SECTION 4 cont….
4.5 Before Raising the Mast :-
Check that the Bottom Section and Setback Legs pin Connections
are well greased.
Check that all bolts have been tightened.

Check that all pins have been fitted with Safety Clips.
Check that all line guards have been fitted correctly.
Check that all loose tools etc., have been removed from
Mast and Crown.
Check that all the Line and Sling line has been Reeved correctly.
4.6 Place B.O.P. Trolleys on Front B.O.P Trolley Beams and

Hook on Hoists, DS and ODS.
4.7 Assemble Racking Board Drg. No. 3-96545-1-0008 and skid under mast,
lift and pin to Mast Middle sections at selected height for
operating position.
Pin support Brace to Mast middle section, swing and tie back
Dividing Board to handrails and open gates at Drills Collar
fingers to the maximum.
4.8 Connect Hydraulic Supply to ‘Quickconnect’ Lines on ‘a’

Frames DS and ODS.
Test Cylinders to ensure that both Rams move simultaneously
in the same direction.
Fully extended Rams ready for Mast Snubbing, see Assembly Drg.
No. 3-96545-1-0006
4.9 Raise Mast slowly using Drawworks power until Mast touches
Snubbing Noses DS and ODS.
Using the Control Unit retrack Rams and Continue to Spool in
slowly with drawworks.
During this operation the Mast will ‘Break over’ its centre
of gravity. Continue retracking Rams, while taking up slack
with Hook until pin connections line up.
Pin at detail E on Drg. No. 3-96545-1-0023 using the pins called
up on Drg. No. 3-96545-1-0002
4.10 Attach Ramp to Setback support.
68
SECTION 5
DRAWWORKS RAISING
Sequence three Drg No. 3-96545-1-0024
5.1 Remove rear Line Guard on ‘A’ Frame Sheaves, partly Lower
Travel Block, Change Slingline DS and ODS from round to
over top of ‘A’ Frame Sheave, using Softline from Catheads
pull Loop in Slingline behind ‘A’ Frame while continuing
to lower Travel Block, pass Slingline over Drawworks Sheave
DS and ODS. Replace Line Guards and take up Slake with Hook.
5.2 Check that the Drawworks column pins have been well greased
Check that all Bolts have been tightened.
Check that all pins have been fitted with Safety Clips.
Check that all Drawworks and Stub Section Line Guards have been
Fitted.
The ‘A’ Frame Line Guards should not be fitted at this stage.
Check that the Slingline is Reeved correctly.
5.3 Raise Drawworks on Drawworks support slowly ensuring that the

Rotary Beam connection line up and pin Rotary Beams to Setback
Spreader.
Pin all Rotary and Floor Beams to Setback and Drawworks as

sequence four Drg. No. 3-96545-3-0020 and 3-96545-3-0021
5.4 Swing up Drawworks Lock Brace DS and ODS pin and fit Safety Clips.
5.5 Lower Travel Block and remove Slingline from Drawworks Sheaves
DS and ODS. Raise Travel Block and hang equalizer and Slingline
in the Mast, remove from Hook.
or
Lower to Drill Floor, remove and store Equalizer and Slingline.
69
SECTION 6
DOGHOUSE SUPORT AND MISC. ITEMS.
6.1 Fit remainder of Drill Floor panels, Stair platform and Stairs.
6.2 Lift Independent Rotary by Crane and position on Rotary Support

Beams and Mast Bottom Section ODS.
6.3 Pin Doghouse Support to Bottom Box DS.

Raise Doghouse Support and pin to Drill Floor.
6.4 Lift Doghouse by Crane and Bolt to Doghouse Support.
6.5 Assemble Doghouse Stair and Position.
6.6 Swing Support Arms on Bottom Extensions into Stowed position.
6.7 Remove and store Bottom Box rear Extension.
6.8 Remove Bottom Box Extension Drillers Side to facilitate

entry of B.O.P. Stack.
6.9 To assemble Casing Stabbing Board see assembly Drg. No.

3-96545-1-0013, 3-96545-1-0014. Lift with Hook and position on ODS
using Hook Bolts.
6.10 The Mast can be shimmed at drill Floor by use of the Hydraulic
Ram and pump, placed in pocket in Bottom sections.
Max. shim thickness 2”.
Retighten all bolts after levelling.
70
SECTION 7
LOWERING SEQUENCE 8
7.1 The Lowering Sequence as the reverse of the Raising Sequence,

the main sequence is noted below.
7.2 Remove any additional items added after Erection which might
interfere with the Lowering procedure.
7.3 Reverse section 6.
7.4 THIS IS VERY IMPORTANT- Remove rear B.O.P. Trolly Beams,

Hoists and Trolleys, Rotary spreader ODS.
Rehook Equalizer with Slingline, Reeve Slingline as sequence

three, making sure that the Slinglines pass over the ‘A’
Frames Sheaves DS and ODS, and round Drawworks Support Sheave
DS and ODS and sockets are correctly pinned to Lower section
Mast DS and ODS.
Replace Line Guards at Stub and Drawworks Sheaves.
Tack up slack and check Lines.
7.5 Unpin and lower Drawworks Lock Brace.

Unpin Rotary Beam Unit C17-S069 at Drawworks only.
Unpin Rotary Beam Unit C29-S067 at Setback only.
Unpin Rotary Floor Beams DS B29A-S021 at Setback only.
7.6 Connect Hydraulic Power Pack DS and ODS.
7.7 THIS IS VERY IMPORTANT:- Change Slinglines DS and ODS as shown

on Sequence two B Drg. No. 3-96545-1-0023 Make sure that the
Slinglines are round ‘A’ Frame Sheaves DS and ODS.
Replace Line Guards.

Take up slake and recheck Slinglines.
7.8 To Lower Mast remove pins and extended Rams while lowering the
Hook, maintarming very little slick as Mast ‘breaks over’
its Center of Gravity, continuous to lower Mast onto Mast Stand.
7.9 Continue section 4 in reverse and reverse section 3, 2 and 1.
71
SECTION V
Maintenance Instructions
72
-1-
MAINTENANCE INSTRUCTIONS
The following lubrication and maintenance schedule is recommended for

maximum life and safety of the mast.
LUBRICATION SCHEDULE
For tapered roller bearings and bushings, use NLGI No. 2

consistency multi purpose type grease, with E.P. (extreme pressure)
additives for excessive loads.
CROWN
SHEAVES
Fastline, deadline, cluster and crossover ; 150 hours maximum.
Catline tong counterweights ; 300 hours maximum.
Crown snatch blocks ‘A’ Frame raising sheaves (to suit usage) 600 hrs
maximum.
MAINTENANCE OF MAST
A visual inspection of the mast is necessary upon completion of each

drilling operation, periodic tightening of all bolts, and replacement
of damaged or worn bolts is required.
A visual inspect of the mast is required every sixty (60) days maximum
and after each exposure to serve environmental conditions (wind forces).
Welds are to be inspected for evidence of cracking.
MAINTENANCE OF WIRELINES
Wirelines are to be visually inspected every 600 hours maximum and to be

replaced if worn. When necessary, lubricate the rope with a good grade
of lubricant which will penetrate and adhere to the rope and which is
free from acid or alkali.
73
OPERATION OF MAST
The Mast is designed in accordance with API 4F and design criteria

as started in Section 1.
The Hook loads started in Section 1 are static loads. The closer the
user gets to the design static load, extreme caution should be used
to minimize the dynamic effect due to load motion, the driller should
restrict the velocity to a maximum, acceleration and deceleration
should be as slow as possible.
API 4F
Recommended practice for maintenance and use of drilling and well

servicing structures and recommended inspection procedure is provided
herewith for the operator’s use.
DAMAGE
If any structural members or components of the Mast and Sub-Structure
become damaged or worn, please notify ;
BHEL
OIL RIG ENGINEERING
RAMACHANDRAPURAM
HYDERABAD-32.
74
Spec 4E; Drilling and Well Servicing Structures
APPENDIX A
RECOMMENDED PRACTICE FOR MAINTENANCE AND USE OF
DRILLING AND WELL SERVICING STRUCTURES
A. 1 These general recommendation, if followed, A.9 The drilling and well servicing structure
should result in longer satisfactory service from manufacturer has used great care in design and
the Equipment. These recommendations should selection of materials for his portable mast. The
in every case be considered as supplemental to, mast should give satisfactory performance when
and not as a Substitute for, the manufactures used with in the stipulated load capacities and in
instructions. accordance with the instructions. Every operator
should be given an opportunity to study
A.2 The safe operation of the drilling and well instructions and should be given suitable
servicing structure and consequently the success instruction and training in erecting, lowering,
of the drilling operation, depends on whether the and using the mast.
foundation is adequate for the load imposed. The
design load for foundation requirements should A.10 The substructure should be restrained
be the sum of the weight of the drilling or well against up-lift, if necessary, by means of a
servicing structure, the weight of the machinery suitable dead weight or hold down anchor. The
and equipment on it, the maximum hook load of weight of the hoist and vehicle, where
the structure, and the Maximum setback load. applicable, may be considered as a part or all of
(See Par.A.17 for Portable Mast w/Guy Lines). the required anchorage.
A.3 Consult with the manufacturer for approval A.11 Each part of a bolted structure is designed
of Materials and methods before proceeding with to carry its share of the load; therefore, parts
repairs. Repair, straighten or replace any bent or omitted or improperly placed may contribute to
otherwise damaged member/ Damaged the failure of the structure. In the erection of
compression Member should be replaced rather bolted structures, so far as it can be done safely.
than repaired by straightening. Drilling and well The bolts should be tightened only slightly
servicing structures use high-strength steels tighter than finger tight until the erection of the
which require specific welding electrodes and structure is completed, after which all bolts
welding techniques. should be drawn tight. This procedure permits
correct alignment of the structures which will
A.4 Fixtures and accessories are preferably result in proper load distribution.
attached to structures by means of suitable
clamps. Do not drill or burn holes in any A.12 Sling line Inspection and Replacement.
members of perform any welding without first There are three principal factors, one or more of
obtaining approval of the manufacture. which may limit the life of a sling. They are
wear due to operation, corrosion and incidental
A.5 Wire line slings are tag lines should have damage. The first may be considered a function
suitable fittings to prevent the rope from being of the number of times the mast is raised. The
bent over sharp edges and damaged. second will be related to the time and
atmospheric conditions, and third will bear no
A.6 Loads due to impact, acceleration, and relation either, since incidental damage may
deceleration may be indicated by fluctuation of occur at the first location as well as any other.
the weight indicator and the operator should keep The following points may be useful in
the indicator readings with in the name plate determining Inspection and replacement
hook load Capacity. procedures.
A.7 In the erecting and lowering operation, the a. Charting of sling line replacement shows an
slowest practical line speed should be used. erratic pattern. Some require replacement at
a relatively early date others last several
A.8 Girts, braces, and other members should not, years longer. Early replacements generally
under any circumstances. be removed from the show incidental damage and it is possible
derrick while it is under load. that some of the longer lived once are used
75
beyond the time when they should be c. Wire rope, including operating lines, raising
replaced. lines, and guy lines should be inspected for
kinks, broken wires, or other damage. Make
b. There is no way of judging the remaining certain that guy lines are not fouled and that
strength of a rusty rope, therefore rusty sling other lines are in place in sheave grooves
lines should be replaced. Areas adjacent to before each raising or lowering operation.
end connections should be examined closely
for any evidence of corrosion. d. Checks safety latches and guides in
telescoping mast for free operation before
In the case of operations in the coastal areas, each lowering operation. Keep latches and
Sling lines left hanging in the mast may guides clean and properly lubricated.
become corroded and found unfit for further e. Check unit for level and check foundation
service. and supports for correct placement before
erecting operations.
c. It would no doubt be possible to establish a
normal sling line life expectancy in terms of f. Check lubrication of crown sheaves.
the number of locations on which it was
used, as long as a set number of was not g. Check lubrication and condition of bearings
exceeded. However this would not preclude in all sheaves, sprockets etc., which are part
the necessity for careful inspection to guard of the erection mechanism.
against incidental damage. A line with any
broken wires should be replaced. A line h. Check folding ladders for free operation
showing any material reduction of metal area before lowering operation.
from abrasion should be replaced. A line
showing kinking, crushing, or any other i. During drilling operations, it is advisable to
damage resulting in distortion of rope make scheduled inspections of all bolted
structure should be replaced. connections to insure that they are tight.
d. Replacement of lines based on normal life j. The Visual Field Inspection of Derrick or
expectancy will provide some degree of Mast and Substructure procedure is
safety but it is important that such provisions recommended for use by operating
do not cause any degree of laxity in sling line personnel (or a designated representative) to
inspection. the extent that its use satisfies conditions for
which an inspection is intended. A sample
e. Sling lines should be maintained in a well report form for this inspection procedure is
lubricated conditions. The field lubricant shown in Figure A.3. The forms are
should be compatible with the original available from International Association of
lubricant and to this end the rope Drilling Contractors (IADC). The IADC
manufacture should be consulted. The object address may be obtained from the API
of rope lubrication is to reduce internal Dallas office.
friction and to prevent corrosion.
A.14 Splicing locks should be checked
A.13 The following routine checks, as applicable, frequently for locking position or tightness,
should be made at appropriate intervals: preferably on each tour during drilling
operations. To develop its rated load capacity,
a. Inspect welds in erecting mechanism for the axis of the structure must be in alignment
cracks and other signs of deformity. throughout its length. It is important that any
splice mechanism or locks be maintained in such
b. Follow the manufacturer’s instructions in condition as to structure alignment.
checking hydraulic circuits before each
lowering operation. Make sure of adequate A.15 Guying for Portable Masts with Guy lines.
supply of hydraulic fluid. This recommendation is applicable for most
conditions encountered in the use of this type
76
mast. There will be exceptions where location

clearance, ground conditions or other unusual A.18 Supplemental Footing. Supplementing
circumstances require special considerations. footing must be provided to distribute the
Figure A.1 shows a recommended guying pattern concentrated loads from the mast mount to the
that may be used under general conditions in the ground. The manufacture’s load distribution
absence of an authorised API manufacture’s diagram indicates the magnitude and location of
recommendations. Guying should be maintained these concentrated loads. If manufacture’s load
in good condition, free from rust, corrosion, frays, distribution diagram is not available,
and kinks. Use of old sand line is not supplemental footing should be provided to carry
recommended for guy lines. the maximum hook load encountered plus the
gross weight of mast and mast mount weight
All chains, boomers, clamps and tensioning during erection. The area and type of
devices used in the guy lines shall satisfy the mast supplemental footing must be such that the safe
manufacture’s recommendations. In the absence bearing capacity of soils on location is not
of mast manufacture’s recommendations, the exceeded Table A1 indicates the safe bearing
following minimum breaking strengths should be capacity of several types of soils.
maintained; load guy lines – 18 tons; external guy
lines – 12 tons; racking board guy lines – 10 tons.
A.16 Guy line Auchors For Portable Masts With

Guy line. Guy line anchors including expanding
type anchors, concrete deadmen, or any other
approved techniques are acceptable. Soil
condition may determine most applicable type.
Recommendations for anchor design and testing
are as follows:
a. All anchors should be designed to with stand

a tension load in the direction of the well at
angle of 45° above horizontal of 7 tons
minimum.
b. Anchors should be proof tested for 7-ton

minimum load capacity annually.
c. Metal components of anchors should be

galvanized or otherwise protected against
corrosion. Sucker rods should not be used in
anchor construction. Anchor location should be
marked with stake if protections above ground
are subjected to bending or other abuse.
d. Care should be taken to avoid old pit location

or other disturbed areas for anchor location.
A.17 Mast Foundation for Portable Masts with

Guy lines. Foundations must consider ground
conditions, location preparation, and
supplemental footing as required to provide a
stable base for mast erection and to support the
mast extreme loading preparation to provide
ground conditions necessary for safe operation is
shown in Figure A.2.
77
W ET AND DRY W EIGHTS OF M AST & SUBSTRUCTURE COM PONENTS AND THEIR FIRST
M OM ENT OF AREAS ABOUT THE BASE:
Sl CG from Wet weight Dry Moment about Wet Moment

Section Dry Wt. in lb
no Base (ft) in lb base (lb-ft) about base (lb-ft)
1 Crown Block 167 19109.65 19109.65 3382408 3382408
2 Top Sec 158 10667.14 10667.14 1760078 1760078
3 Upper Sec 141 18183 18183 2454705 2454705
4 Middle Sec 95 21849.96 21849.96 2163146 2163146
5 Racking BD 88 9419.96 9419.96 1111555 1111555
6 Lower Sec 61 19078.4 19078.4 1240096 1240096
7 Belly BD 61 4730 4730 340560 340560
8 Stub Sec 35 19918.8 19918.8 816670.8 816670.8
9 Stub Sec Spd 40 12113.2 12113.2 230150.8 230150.8
10 Bottom Sec 18 27060 27060 3598980 3598980
11 TE* 125 64495.2 64495.2 4837140 4837140
12 Drill Pipes 70 321750 321750 10939500 10939500
13 DWKS 27 68500 68500 1986500 1986500
14 Floor Str 24 6809 6809 115753 115753
15 Columns 12 26195.4 26195.4 392931 392931
16 A-frame 10 40621 40621 406210 406210
17 Bottom Box 1.97 72731.28 92450.9 143280.62 182128.27
ΣM 763231.98 782951.6 46927455.62 46966303.27
* Travelling Equipment (TE) is assumed t o be locat ed at 0.7 times the clear height of the struct ure
from base per cl.8.3.2 of API-4F, Fourth edition.
UNSHIELDED WIND AREA OF M AST & SUBSTRUCTURE AND THEIR FIRST M OM ENT OF AREA ABOUT
THE BASE:
Sl
no Unshielded CG from Moment about Base
Section
Area (A) in ft² Base (ft) (ft³)
1 Crown Block 44.68 167 7461.56
2 Top Sec 37.4 158 5909.2
3 Upper Sec 75.73 141 10677.93
4 Middle Sec 77.27 95 7340.65
5 Racking BD 6.72 88 591.36
6 Lower Sec 63.9 61 3897.9
7 Belly BD 5.3 61 323.3
8 Stub Sec 68.4 35 2394
9 Stub Sec Spd 6.2 40 248
10 Bottom Sec 56.1 18 1009.8
11 TE* 60.23 125 7528.75
12 Drill Pipes 337.5 70 23625
13 DWKS 81.9 27 2211.3
14 Floor Str 91.67 24 2200.08
15 Columns 67.5 12 810
16 A-frame 97 10 970
ΣA 1177.5 77198.83
* Travelling Equipment (TE) is assumed to be located at 0.7 times the clear height of the
structure from base per cl.8.3.2 of API-4F, Fourth edition.
INSTRUCTIONS FOR PREPARATION OF SEVERE
ENVIRONMENTAL LOADS:
While there is an expect ed Wind of 115 M PH as per design, the follow ing M UST be ensured
1. Both bottom boxes on DS and ODS are filled with water
2. Front extensions of Bottom boxes are in assembled condition
DO’S AND DON’T’S FOR SAFE OPERATION OF MAST &

SUBSTRUCTURE:
DO’S
1. Foundation shall be designed for the weight of the drilling structure, the weight of
machinery and equipment on it, the maximum hook load, maximum setback load. Refer
Soil bearing diagram for magnitude and location of these concentrated load.
2. Repair, Straighten or replace any bent or otherwise damaged members in consultation with
the manufacturer for approval of Materials and methods before proceeding with repairs.
3. Loads due to impact, acceleration, and deceleration may be indicated by fluctuation of the
weight indicator and the operator should keep the indicator readings within the name plate
hook load Capacity.
4. In the erecting and lowering operation, the slowest practical line speed should be used.
5. Every operator should be given an opportunity to study instructions and should be given
suitable instruction and training in erecting, lowering, and using the mast.
6. Sling lines should be maintained in a well lubricated conditions.
7. There is no way of judging the remaining strength of a rusty rope. Therefore, check the Bull
lines every time before raising/lowering the mast for wear due to operation, corrosion and
incidental damage. As a general safety guide line, BHEL recommends usage of Bull lines
for 6 times raising and 6 times lowering or 3 years whichever is earlier. However this would
not preclude the necessity for careful inspection to guard against incidental damages.
8. Bull line with any broken wires should be replaced. A line showing any material reduction
of metal area from abrasion should be replaced. A line showing kinking, crushing, or any
other damage resulting in distortion of rope structure should be replaced.
9. The following routine checks, as applicable, should be made at appropriate intervals:
a. Inspect welds in erecting mechanism for cracks and other signs of deformity.
b. Wire rope, including operating lines, raising lines, and guy-lines should be inspected
for kinks, broken wires, or other damage. Make certain that guy-lines are not fouled
and that other lines are in place in sheave grooves before each raising or lowering
operation.
c. Check unit for level and check foundation and supports for correct placement before
erecting operations.
d. Check lubrication of crown sheaves.
e. Check for tightness of bolts.
f. Ensure safety locks in each pins.
g. Check lubrication and condition of bearings in all sheaves, sprockets etc., which are
part of the erection mechanism.
h. Check folding ladders for free operation before lowering operation.
i. During drilling operations, it is advisable to make scheduled inspections of all bolted

connections to insure that they are tight.
j. Follow erection and lowering procedures given in the manual.
k. The Visual Field Inspection of Mast and Substructure procedure is recommended for
use by operating personnel (or a designated representative) to the extent that its use
satisfies conditions for which an inspection is intended.
10. The mast & substructure shall be checked during the following period too:
i. Before heavy casing
ii. Before fishing
iii. After any fishing operation when the mast has been stressed over its rated
capacity.
iv. After free blowouts
v. When wind speed exceeds the maximum admitted value (115 MPH for bare
mast; 100 MPH for mast with full setback; 50 MPH during operation)
vi. Prior and after mast raising and lowering after earthquake.
11. Wear safety belt for working at height.
12. Wear hand gloves for line handling.
13. Mast erection and lowering shall be performed only by means of draw works.
14. Follow al safety rules and regulations.
15. Paint complete Mast and Sub-structure minimum once in a year after thorough cleaning
of the surface
DON’TS
1. Do not carry out any repair on Mast & Substructure without consulting the manufacturer.
2. Damaged compression members should be replaced rather than repair by straightening.
3. Do not drill or burn holes in any members or perform welding without obtaining the
approval of the manufacturer.
4. Girts, braces, and other members should not, under any circumstances, be removed from the
mast & substructure while it is under load.
5. Each part of a bolted structure is designed to carry its share of the load. Do not omit or place
improperly any part as it may contribute to the failure of the structure.
6. Do not use under size bolts or pins in the mast & substructure.

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OPERATION AND MAINTENANCE MANUAL

DOC NO. 1000 KPS BB

OIL RIGS DIVISION

Bharat Heavy Electricals Limited

Hyderabad – 500 032

SECTION 11 MAST AND ACCESSORIES, PART LIST AND

SECTION III SUBSTRUCTURE PART LIST AND ASSEMBLY DRAWINGS

SECTION IV ERECTION SEQUENCE AND ERECTION SEQUENCE

SECTION V DRAWINGS MAINTENANCE INSTRUCTIONS

MAST AND ACCESSORIES

DRAWING NUMBER TITLE

3-96545-1-0001 General arrangement of 142’0” high cantilever

3-96545-1-0002 Mast Assembly.

3-96545-1-0003 Mast Ladder and Safety Cage Assembly.

3-96545-1-0004 Stand Pipe Clamps Assembly.

3-96545-1-0005 Tong Counter weights Assembly.

3-96545-1-0006 Hydraulic Snubbing Unit Assembly.

3-96545-1-0007 Crown Assembly.

3-96545-1-0008 Racking Board Assembly.

3-96545-1-0009 Belly Board Assembly.

3-96545-1-0010 Slingline Equalizer Assembly.

3-96545-1-0011 24’ φ Core line Sheave Assembly.

3-96545-1-0012 Casing Stubbing Board Assembly.

3-96545-1-0013 Casing Stubbing Board Carriage Assembly.

3-96545-1-0014 16” φ Cat line Sheave Assembly.

3-96545-1-0015 14” Air Tugger Sheave Assembly.

25’ 0” HIGH SUB -STRUCTURE

3-96545-3-0020 25”-0” Sub-Structure Assembly.

3-96545-3-0021 25”-0” Sub-Structure sectional details.

3-96545-3-0022 Drill Floor and Handrails Assembly.

3-96545-1-0023 Sub-Structure Pre-Erection Layout.

3-96545-1-0024 Erection of 142’-0” Mast and Reeving diagram

SPECIFICATION FOR THE BHEL -BRANHAM'S UNIVERSAL CANTILEVER

"SWING LIFT" DRILLING MAST AND ACCESSORIES.

142'0" Clear Height x 30'0" Base

The Mast is complete with following accessories.

Ladder lengths are equal to Mast Sections for ease of transportation.

MAST LEVELLING EQUIPMENT

CASING STABBING BOARD

GOOSENECK ACCESS PLATFORM

STAND PIPE CLAMPS

Located on the Off-Drillers Side of Mast.

MAST ASSEMBLY STANDS

AIR HOIST SHEAVE UNITS

Swivel and Shackle included.

CATLINE SHEAVE UNITS

CORELINE SHEAVE UNIT

SLINGLINE AND SLINGLINE EQUALIZER UNIT

Two 2.3/8" diameter Slinglines have been provided.

LADDER SAFTY CLIMB EQUIPMENT

DERRICKMAN ESCAPE EQUIPMENT

SPECIFICATION FOR THE BHEL-BRANHAM'S SWING LIFT SELF ELEVATING SUB-

The setback area is recessed for 6" Teak flooring.

COMBINATION RAMP AND STAIR

B.O.P. TROLLEY BEAMS

ROTARY BEAM UNIT AND ROTARY FLOOR SUPPORT UNITS

DOG HOUSE SUPPORT

SUB-STRUCTURE ACCESS STAIRWAYS