User'S Manual: Zj40Dbst Drilling Rig

ZJ40DBST DRILLING RIG
USER'S MANUAL
ZJ325-SC
Sichuan Honghua Petroleum Equipment Co., Ltd.
August, 2011
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Foreword
USER’S MANUAL OF ZJ40DBST DRILLING RIG
ZJ40DBST drilling rig is oil drilling rig which is designed and manufactured as per SY/T
5609-1999 The types and basic parameters for oil drilling rigs and related API newest
specifications. It can satisfy the requirements on middle depth well drilling for oil and gas
exploration and development.
This manual generally describes the overall structure, performance characteristics,
technical parameters, installation and commissioning, operation and maintenance,
dismantlement and transportation etc of the drilling rig.
Before installation and operation, the personnel engaged in installation, operation and
maintenance shall read this manual and user's manuals of supporting components carefully,
and install, operate and maintain the drilling rig as required. Improper installation, operation or
repair may cause personal injury or equipment damage if operators do not know related
contents.
The front and the back of the drilling rig are determined as follows: the wellhead is in the
front, the power engine house is at the back.
The left and the right of the drilling rig are determined by viewing from the wellhead to
the power engine house.
Every drilling rig has an ex-factory serial number; please provide its ex-factory serial
number when ordering spare parts or inquiring related things.
Table of contents
1. Safety warnings......................................................................................................................1
2. Drilling rig description..........................................................................................................1
2.1 Purposes and applicability.....................................................................................................1
2.2 Standards and specification for design and manufacture.......................................................1
2.3 Main technical parameters.....................................................................................................2
2.4 Major corollary equipment list of drilling rig ZJ40DBST.....................................................2
3. Structural features of ZJ40DBST drilling rig.....................................................................5
3.1 Overall structure of drilling rig..............................................................................................5
3.2 Structural features of drilling rig...........................................................................................6
3.3 Speed and lifting capacity of hook........................................................................................7
4. Installation of drilling rig......................................................................................................8
4.1 Preparation work before drilling rig installation....................................................................8
4.2 Installation sequence diagram of drilling rig.........................................................................9
4.3 Installation of parts of drilling rig..........................................................................................9
4.4 Check after drilling rig installation......................................................................................12
5. Commissioning of drilling rig.............................................................................................16
5.1 Preparation work before commissioning.............................................................................16
5.2 Commissioning of diesel generator set................................................................................16
5.3 Power supply commissioning of VFD system.....................................................................17
5.4 Commissioning of electric drive system..............................................................................18
5.5 Commissioning of driller's control cabin, instrument and meter system.............................18
5.6 Commissioning of air source system equipment.................................................................18
5.7 Commissioning of hydraulic system....................................................................................19
5.8 Running commissioning of DW..........................................................................................19
5.9 RT running commissioning..................................................................................................20
5.10 Commissioning of mud pump set......................................................................................20
5.11 Commissioning of generating air supply and VFD house trailing device.........................20
5.12 Commissioning of pump set trailing device......................................................................21
5.13 Commissioning of drawworks trailing device...................................................................21
5.14 Commissioning of mast trailing device and wireline spooler trailing device....................21
5.15 Mast and substructure lifting and mast alignment.............................................................21

5.15.1 Check before mast lifting................................................................................................21
5.15.2 Lifting of mast................................................................................................................22
5.15.3 Check before substructure lifting....................................................................................22
5.15.4 Lifting of substructure....................................................................................................23
5.15.5 Mast alignment...............................................................................................................23
5.16 Parts installed after mast and substructure lifting..............................................................23
5.17 Commissioning of drilling instruments.............................................................................23
5.18 Adjustment of wireline on DW drum and test of crown block saver.................................24
5.19 Test of hydraulic and pneumatic tools...............................................................................24
5.20 Run test of solids control system.......................................................................................24
5.21 Test of high pressure manifold...........................................................................................24
5.22 Check of standard electric system on well site..................................................................24
5.23 Test of monitoring and communication system.................................................................25
5.24 Test of whole drilling rig....................................................................................................25
6. Operation and maintenance of drilling rig........................................................................25
6.1 Warnings..............................................................................................................................25
6.2 Precautions for drilling rig operation...................................................................................25
6.3 Safety practice for drilling rig operation..............................................................................26
6.4 Maintenance regulations of drilling rig...............................................................................27
6.5 Operation and maintenance during algid stage....................................................................31
6.6 Accident and emergency treatment......................................................................................32
7. Disassembly and transportation of drilling rig.................................................................32
7.1 Lowering of mast and substructure of drilling rig...............................................................32
7.2 Disassembly of drilling rig..................................................................................................33
7.3 Transportation of drilling rig................................................................................................34
8. Lubrication table for main components............................................................................35
9. Main part bearing model summary list.............................................................................37
10. User's manuals list.............................................................................................................39
11. Attached drawings of drilling rig......................................................................................39
User's Manual of ZJ40DBST Drilling Rig
1. Safety warnings
 Only well-trained, qualified and licensed persons can install, operate and
maintain the equipment.
 Before the installation, operation and maintenance of the drilling rig, operators
shall read this manual and user's manuals of all equipment belonging to the
drilling rig carefully, install, operate and maintain the drilling rig as per the
requirements in the manuals.
 There shall be a chief principal designated for installation, operation and
maintenance, the persons participating in work shall be assigned with clear
work, and detailed and reliable safety measures shall be available.
 In the operation process, strictly execute the operation specifications and
technical safety rules.
 It is forbidden to maintain and repair equipment during its operation.
 Never try to overload equipment.
2. Drilling rig description
2.1 Purposes and applicability

ZJ40DBST drilling rig is an oil drilling rig which is designed and manufactured as per
SY/T 5609-1999 The types and basic parameters for oil drilling rigs, and API related
standards. Its performances can meet middle depth well drilling application for land oil and
gas exploration and development in areas at an ambient temperature from -18℃ to +55℃ and
an air humility not more than 90% (+20℃).
2.2 Standards and specification for design and manufacture
2.2.1. SY/T5609-1999 The types and basic parameters of oil drilling rig
2.2.2. API Spec 4F-2008 3rd edition Specification for Drilling and Well Servicing
Structures
2.2.3. API Spec 7K-2001 5th edition Specification for Drilling and Well Servicing
Equipment
2.2.4. API Spec 8C-2003 4theditionSpecification for drilling and production hoisting
equipment.
1
2.2.5. API Spec 9A-2004 25th edition Specification for wire rope
2.2.6. AWS D1.1-2008 Structural welding code-steel
2.2.7 APT RP 500 2nd edition Recommended practice for classification of locations for
power equipment installations at petroleum facilities classified as class I, division 1 and
division 2
2.2.8. IEC 44-81 Electrical apparatus for explosive gas atmospheres-general
requirements
2.3 Main technical parameters
Nominal drilling depth (4 1/2’’ (114 mmm) DP) 4000m;13120
Max. hook load 2250kN; 505.000 lb
Max. drill string weight 1440kN; 323.724 lb
Input power of DW 1000kW; 1341hp
Line of hoisting system 5×6, in parallel
Diameter of wirelineφ32mm: 1 ¼”
Mud pump power ×number 1600HP×2
Nominal opening diameter of RT 698.5mm (27 1/2'')
Effective height/type of mast 43m/K type141`
Height of drill floor 6.7m 22`.
Clear height of substructure 5.5m 18`.
Hoisting gear number one gear, stepless speed regulating
RT number one gear, stepless speed regulating
Power ×number of main diesel generator set 1101kW×3
Diameter/rated pressure of drilling fluid manifold ,single standpipe 4''/35MPa; 5000psi
Total volume of mud tanks 291m3 1778 bls
2.4 Major corollary equipment list of drilling rig ZJ40DBST
No. Name Qty. Remarks
⑴ Equipment of lifting system
API Spec 7K (parts and
1 JC40DB DW (including hydraulic disc brake) 1 set
components), the 5th edition
2 JJ225/44-K4 mast (including accessories) 1 set API Spec 4F, the 3rd edition
DZ225/6.7-S6 substructure
3 1 set API Spec 4F, the 3rd edition
(including accessories)
4 TC225 Crown Block 1 set API Spec 8C 4th edition/4F
2
3rd edition　
5 YC225 traveling block 1 set API Spec 8C, the 4th edition
API Spec 8C, the 4th edition
6 DG225 Hook 1 set
7 SL225 Swivel 1 set API Spec 8C, the 4th edition

8 Air spinner FMS-20 1 set
Drilling wireline
9 1 coil
6×19S+IWRC EIPS grade φ32
10 Deadline stabilizer JZG24 1 set
⑵ Equipment of rotating system
1 RT ZP275 1 set API Spec 7K 5th edition　
2 RT bushing 1 set
3 RT drive device 1 set
4 6027C top drive device 1 set
⑶ Equipment of circulating system
API Spec 7K (parts and
1 HHF-1600 drilling mud pump 2 sets
components), the 5th edition
2 Mud pump set 2 sets
3 Drilling fluid manifold 1 set
4 Rotary hose 4”, fig1002, 35Mpa 1 pc
5 Solids control system 1 set
⑷ Equipment of power and air supply system
1 Diesel generator set CAT 3512B (SR4B) 3 sets
2 Auxiliary generator (CAT C15) 1 set
3 Generator and air supply house 1 set 3 in total
4 Auxiliary generator house 1 set
5 Air supply system 1 set
⑸ HPU 1 set
⑹ Movable HPU 1 set
⑺ Electric drive and control system 1 set
1 VFD house and MCC control system 1 set
2 Power cable 1 set
⑻ Equipment of driller's control system
3
1 Driller's control cabin 1 set

Drilling engineering parameter
2 1 set
instrument system
3 Monitoring system 1 set
4 Communication system 1 set
⑼ Standard electric system on well site 1 set
⑽ Detection instruments and tools
1 Gas detection system 1 set
2 Special tools 1 set
⑾ Trailing system
1 Trailing device for generator house 4 sets
2 Trailer for VFD house 1 set
2 Mast trailing device 1 set
3 Pump set trailing device 2 sets
4 Mud tank trailing device 1 set in solids control system
5 Wire line spooler trailing device 1 set
6 DW trailing device 1 set
⑿ Auxiliary equipment
1 Doghouse 1
2 Cable tray 1 set
3 Casing stabbing board 1 set
4 Hydraulic cathead 1 set
5 Escaping device on monkey board 1 set
6 Electric wireline spooler 1 set
7 Diesel tank 1 set
8 Water tank 1 set
⒀ Drill floor implement
1 YM-10 Hydraulic cathead 2 sets
2 5T air winch 2 sets
3 0.5T air winch 1 set For monkey board
4 DZ400 BOP lifting device 1 set
5 TM-80 iron roughneck 1 set
⒁ Well control device
4
1 FKQ960-8 BOP accumulator 1 set

2 35-35 BOP 1 set
3 Choke and kill manifold 1 set
4 QSY70DTY BOP pressure test device 1 set
Note: Configuration Items can be increased or decreased as per the user's requirements.
3. Structural features of ZJ40DBST drilling rig
3.1 Overall structure of drilling rig

The drilling rig is divided into six parts of drill floor area, power area, pump house area,
solids control area, oil and water supply area and barrack area. After the drilling rig is
assembled, its floor space is about 120m×55m (not including tool house and accommodation
etc).
The rig layout please sees: fig. 1 plan drawing, fig.2 elevation drawing; the rig
transmission principle sees: fig. 3 drive system diagram; and the rig foundation arrangement
sees fig. 4 foundation drawing.
The drill floor area comprises mast, substructure, crown block, travelling block and hook,
and DW, RT driving device, RT, driller's control cabin, dog house and all tools etc on drill
floor for drilling operation.
The power area includes generating air source house and electric control house, they are
placed on the trailing device of generator house and VFD house to realize the whole hauling.
After the generating air supply house installation, it forms a generating and air supply area
through walkway connection and electric control house is arranged on one side of the
generator house near pumps house.
There are 2 sets of HHF-1600 mud pump sets in the pump area, they are placed on the
trailing device of pump set respectively to realize the whole hauling for single pump.
The solids control area is provided with mud tanks, mud processing equipment of solids
control system, and each tank can realize the whole hauling.
All oil tanks and water tanks are installed in the oil and water supply area, the oil tanks
can be hauled integrally and independently.
The drilling fluid manifold comprises standpipes and ground manifolds.
The areas of the drilling rig are connected by cable trays, and all oil, water and air main
pipelines and cables are arranged in the cable trays.
There are hydraulic cat walk, drill pipe rack and logging drawworks arranged at the front
5
of drill floor.
3.2 Structural features of drilling rig
ZJ40DBST drilling rig is designed by integrating mechanical, electrical and digital
control techniques, mainly achieves digital control function and has automation,
intelligentization and informationization functions. All parts of the drilling rig adopt mature
and advance techniques at home and abroad for structural design, work reliable, are moved
and transported conveniently, run economically and meet HSE requirements.
DW, RT and mud pump all adopt independent alternating-current variable frequency
electric driving systems without mutual interference and can better meet drilling application.
Mast is a K type structure and meets the requirements of supporting Canrig6027AC top
driving devices, and lifted by hydraulic cylinder, the substructure also adopts hydraulic
cylinder lifting with swing-up structure. Main equipment and driller's control cabin etc on drill
floor are all installed at low positions.
DW is a single-shaft DW with simple structure and drives drum through one reducing
gear box by using a variable frequency motors, and main brake is a hydraulic disc brake, safe
and reliable. All running parameters of DW comprise tripping speeds and hook position, and
all safety devices can be controlled digitally.
RT is independently driven by an alternating-current variable frequency motor through
gear reduction box and cardan shaft and provided with inertia brake. Control system has
complete monitoring and over-torsion protection functions.
Two 1600HP mud pumps are arranged, and every pump is driven by two alternating-
current variable frequency motors with high reliability and convenient displacement
regulation.
Power system is provided with three 1101kW diesel generator sets and one 455kW
auxiliary generator set and has enough standby power, and the drilling rig has strong self-
maintaining capacity.
Electric drive system adopts a vector variable frequency driving system, and main electric
equipment is arranged in VFD house.
An integrated driller's control cabin is provided, driller completes main operations of the
drilling rig in the driller's control cabin, and the real-time display, storage, print and
management of parameters (signals) are achieved.
3.3 Speed and lifting capacity of hook

3.3.1 Lifting capacity
6
Motor speed Hook load kN Hook speed m/s Hook load kN Hook speed
r/min (10 lines)lbs (10 lines)ft/min (8 lines) m/s (8 lines)
0 1952438.827 0 1621 0
158.6 2250505.820 0.0917.71 1869 0.11
318.6 2250 0.18 1869 0.23
478.7 2250 0.27 1869 0.34
638.7 2250 0.36 1869 0.45
800.7 2250 0.45 1869 0.56
926.5 2197493.905 0.52102.33 1825 0.65
1005 2010 0.56 1670 0.7
1044.2 1925 0.58 1599 0.73
1083.4 1844 0.61 1532 0.76
1122.6 1768 0.63 1469 0.79
1161.6 1696 0.65 1409 0.81
1200.7 1505338.337 0.67131.85 1250 0.84
1340.7 1214 0.75 1008 0.94
1620.7 837 0.91 695 1.14
1760.7 711 0.98 591 1.23
1900.7 612 1.06 508 1.33
2040.7 536 1.14 445 1.43
2200 470105.660 1.23242.00 390 1.54
3.3.2 Lifting curve (10 lines)
Hook load kN
Hook speed m/s
3.3.3 Lifting capacity of auxiliary driving device (12 lines)

Max. lifting capacity: 1489kN (10lines), hook speed: 1.37m/min.
7
4. Installation of drilling rig
The installation of the drilling rig shall conform to the requirements of final assembly
process with the requirements in this manual.
4.1 Preparation work before drilling rig installation
 Only trained and qualified persons can install the drilling rig with qualification
certificates.
 The personnel engaged in drilling rig installation, particularly the person in charge of
the installation shall first read this manual and user's manuals of all parts to make
themselves know the structural features and the installation and commissioning
requirements of the drilling rig and its parts.
 All tools and equipment for installing the drilling rig shall be complete and have
good service performance. Metering devices and instruments used shall be qualified.
 Well site and foundation for installing the drilling rig shall accord with requirements
of drawing samples and technical files approved as per specified procedures.
 As the drilling rig is heavy equipment, ensure personal safety and equipment safety
in the installation process, ensure enough capacity of lifting equipment and lifting
belt for heavy and large modules, and ensure their completeness in the use process.
 Check equipment, parts and components for completeness, qualification and damage
before the installation of the drilling rig, clean and remove dirt from the parts and
components.
4.2 Installation sequence diagram of drilling rig
8
Substructure DW trailer Mast
Generating air source house, VFD trailer Generating air source house, electric control houseDrawworks
Crown block Standpipe of drilling fluid Traveling block, hook
Main pipeline trough of overhead cable, substructure

RT and drive device Driller’s control cabin
Doghouse
Mud pump set trailer Mud pump set Ground part of drilling fluid manifold
Solids control system (inc.mud tank trailer)Oil tank, water tank Lift mast and substructure
Reeve wire line
Top drive Align well Wellhead Rig whole commissioning

installation head mechanization tools
Note: other auxiliary facilities can be crossways installed while ensuring safety and
available field.
4.3 Installation of parts of drilling rig
As per the plan of the drilling rig, take the wellhead center as a reference, loft on the
plane of the well site foundation and draw installation datum line for each area.
4.3.1 Installation of substructure (please see User's Manual of DZ225/6.7-S Substructure
for details)
Use wellhead centerline and the drawn lines of drill floor area as references, place the left
and right base seats of the substructure bottom layer, connect the left and right base seats into a
whole, install all columns, tie rods and lifting cylinder of the middle layer, and finally install
left and right upper seats, intermediate seat (setback beam, RT beam, motor beam and floors)
and other auxiliary parts of the top layer.
Note: except the ladders to drill floor, the ramp and the ladders to solids control etc shall
be installed after the substructure is lifted.
4.3.2 Trailing installation of generating air supply house and VFD house (please see the
plan drawings of generating air supply house and trailing device for details)
Install VFD house on the trailer and generating air supply house on its trailing device, and
then place and set the generating air supply house trailer and VFD house trailer as per the plan
9
of the drilling rig and the lofting and marking positions. Install all devices in generating air
supply house.
Connect the oil supply pipelines and the air pipelines of all machines and the connecting
pipelines among devices of the air supply system.
Install mufflers for diesel engines.
4.3.3 Installation of DW
The DW had been assembled and commissioned before delivery from factory. There are
positioning blocks at corresponding positions of substructure and drawworks trailer. Lift the
DW onto the trailer or DW beam of the substructure and install it in place as per the positions
of the positioning blocks. Fasten the bolts connected with the DW beam.
4.3.4 Installation of RT and driving device
The RT driving device (except the cardan shaft) had been installed on the motor beam of
the substructure integrally and is packed and installed as per transported modules. The RT
driving device will be installed together with the motor beam during field installation.
Lift and place the RT onto the RT beam, connect it with pins and install safety pins
properly (or adjust by using puller bolts and position it as per marks).
Install the cardan shaft, and ensure that the parallelism tolerance of flange faces at two
ends of the cardan shaft is not more than 1.0 mm.
4.3.5 Installation of mast (please see User's Manual of JJ225/43-K Mast for details)
Before installation, check the appearances of mast components, repair or replace the
positions deformed or damaged, and rotate every rope guide sheave which shall be flexible
without blockage.
The installation of the mast conforms to the sequence of lower parts, upper parts, main
body and accessories. Alternately move bracket, install mast main body and accessories, and
then support the mast by high stand to install monkey board (including 0.5t air winch).
4.3.6 Installation of standpipe of drilling fluid manifold
When the mast is at low position, install the standpipe of the drilling fluid manifold on
the mast, and then connect and seal it by unions reliably.
4.3.7 Installation of crown block (please see User's Manual of TC225 Crown Block for
details)
The crown block is connected with the mast by bolts. The accessories of the crown block
such as auxiliary sheave, lifting frame and climb assistantoretc shall be installed completely.
4.3.8 Place the wireline spooler as per the positions shown by the plan.
4.3.9 Install traveling block and hook, reeve hoisting wireline and drilling wireline (along
10
the line).
4.3.10 Installation of driller's control cabin
Lift the driller's control cabin onto the drill floor, and connect the lines of the pneumatic,
hydraulic and electric systems as per serial numbers.
4.3.11 Installation of cable tray
Install substructure main cable tray and cable tray in solids control area of pump set as
per the plan of the drilling rig and the cable tray general drawing. Connect the pipelines of all
systems, and install the cables and wires as per the User's Manual of Electric System.
4.312 Installation of mud pump set trailing device (please its user’s manual for details)
Install trailing device of mud pump set including mud pump set as per the plan of the
drilling rig and the lofting and marking positions. Pressure relief line of safety valve for mud
pump must return back to mud tank.
4.3.13 Installation of ground part of drilling fluid manifold
Install it as per the User's Manual of Drilling Fluid Manifold, and connect it with the
standpipe part and the mud pump discharge pipeline.
4.3.14 Installation of solids control system
Install the mud tanks (inc. mud tank trailer) of the solids control system as per the lofting
and drawing positions of the plan of the drilling rig, install the equipment in and on the tanks
as per the User's Manual of Solids Control System, and connect the communicating pipes
among the tanks and the mud pump suction pipelines.
4.3.15 Installation of standard electric system on well site (please see User's Manual of
Standard Electric System on Well Site for details.)
4.3.16 Installation of drilling instruments
Install the drilling instruments as per requirements of User's Manual of Drilling
Instruments.
4.3.17 Installation of monitoring system and communication system
Install the monitoring system and the communication system as per User's Manual of
Electric Drive and the elevation and the plan of the drilling rig (except the parts installed after
the mast and the substructure are lifted.)
4.3.18 Installation of auxiliary equipment
Install the auxiliary equipment as per the elevation and the plan of the drilling rig.
4.3.19 Installation of oil tanks and water tanks
Install the oil tanks and the water tanks as per lofting and drawing position of the plan of
the drilling rig, and connect the pipelines among the cable trays, the oil tanks and the water
11
tanks.
4.4 Check after drilling rig installation
4.4.1 The pretension torques for bolt connection are shown in the following table, and
check every main stressed bolt by force moment spanner one by one.
Bolt nominal diameter/mm
Bolt
16 20 24 27 30 36 42
strength
5/8” ¾” 15/16” 1 1/16” 1 3/16” 1 3/8” 1 5/8”
grade
Pretension torque/N.mlb-ft (factor:0,735)
185-259
8.8 361-505 623-873 919-1286 1243-1740 2178-3049 3492-4889
136-191
4911-6875
10.9 260-364 507-710 877-1227 1292-1809 1748-2448 3063-4289
3622-5070
4.4.2 Check after substructure installation
 Installation of every connection and fixation component must be complete and
fastened. Grease pins at rotating parts.
 Every part shall not have serious deformation, and every weld shall not have crack
and opening.
 Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
 There is no barrier to block driller's eyesight on the drill floor.
 Lifting cylinders of substructure work normally.
4.4.3 Check after mast installation
 Grease every lubrication point as required.
fastened
and opening.
 All auxiliary facilities assembled on the mast are complete and good.
 Lifting cylinders of mast work normally.
 The drilling wireline is complete and reeved correctly, and its ends are fixed firmly.
 No tools and stuffs left on the mast.
 Weight indicator works normally.
4.4.4 Check after mast trailer installation
 Check tires for surface wear and state and tire pressure for conformity with
12
requirements.
 Check surface of rigid suspension for deformation or cracks, the rotating parts for
favorable lubrication, flexible rotation and firm and reliable installation, the brake
clearance of hubs for conformity with requirements (please see the operating
instruction manuals of axles and rigid suspension for the adjustment of brake
clearance).
 Check the welded parts such as the trailer connector and supporting seats etc for
damage, the pins at joints for locking with safety pins, and the bolts, nuts, spring
washers and split pins for completeness.
 Check the hydraulic control system for flexible operation and the pipes and quick
release joints for correct and reliable connection.
 Check whether trailing module is detached from other fixed module completely.
 Towing hook of tractor saddle should be open completely after trailing device
connected with tractor.
 After the trailing device connected with tractor, the lamps should be in good
condition, the air passage is smoothly without any leakage.
4.4.5 Check after DW installation
 Check and ensure all guards are installed completely, pipelines are connected
correctly and reliably and hasps are connected firmly.
 Grease all lubricating points as required.
 Grease main speed reducer as per requirements in its user's manual.
 The pipelines of hydraulic source, operating cabinet and control cabinet of hydraulic
disc brake and brake caliper system are connected correctly and sealed reliably
without leakage.
 Check the wearing conditions of brake disc and brake block of hydraulic disc brake,
when the abrasion thicknesses reach ultimate value, replace them.
 Adjust the brake clearance of hydraulic disc brake to proper position as per the User's
Manual of Hydraulic Disc Brake.
4.4.6 Check after crown block installation
Crown block is fixedly connected to the upper section of the mast and positioned by
positioning pins reliably.
4.4.7 Check after traveling block and hook installation
 The bolts and pins are complete and firm, and guards are good.
 The hook body and the hook opening locking pin shall be operated flexibly, and the
13
safety locking pins of the hook bail are complete, safe and reliable.
4.4.8 Check after swivel installation
 Swivel rotates flexibly, no oil and drilling fluid leakage during rotation.
 Rotary hose shall be provided with safety chain additionally.
4.4.9 Check after mud pump installation
 Install safety valve of mud pump as per required position, and ensure it works
normally.
 The pulsation dampener of mud pump is filled with nitrogen or air, and it is
forbidden to fill oxygen.
 The surface of mud pump pressure gauge is clean and accurate.
4.4.10 Check after mud pump set trailer installation
fastened
and opening.
 The tyre surface should be in good condition without any obvious abrasion, and the
tyre pressure accords with the specification and requirements.
 Rotating parts of axle and rigid suspension should be lubricated well, rotated flexibly,
and installed firmly and reliably.
 Brake clearance of hub is in line with specification and requirements.(the adjustment
for brake clearance please see the operation manual of axle and rigid suspension)
4.4.11 Check after drilling fluid manifold installation
 All supports and pipe clamps are fixedly reliably. All unions are connected correctly
and sealed reliably.
 Valve hand wheels are complete, closed and opened flexibly without leakage.
4.4.12 Check after installation of generating air supply house trailer and VFD house
trailer
14

fastened
and opening.
 The tyre surface should be in good condition without any obvious abrasion, and the
tyre pressure accords with the specification and requirements.
 Brake clearance of hub is in line with specification and requirements.(the adjustment
for brake clearance please see the operation manual of axle and rigid suspension)
4.4.13 Check after generating air supply house installation (except electric drive part)
 All connecting bolts are installed completely and fixedly. The pretension torque
meets requirements.
 All pipelines are clean, smooth, connected correctly, marked clearly and sealed
reliably without leakage.
 All pressure gauges are complete and good in effective period. Air line pressure is
adjusted to specified pressure.
 All pipelines and valves are good. Safety valves are sensitive and reliable.
 The guards of all drive parts are complete and good, and fixed firmly.
4.4.14 Check after cable trays installation
 All pipelines are connected correctly, clean and smooth inside. All joints are sealed
reliably without leakage.
 All cables and wires are arranged tidily, connected correctly and marked clearly.
4.4.15 Check after driller's control cabin installation
 The air and hydraulic pipelines are clean and smooth inside. The lines of the air,
hydraulic and electric systems are connected correctly and marked clearly. All joints
are sealed reliably without leakage.
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 All instruments and meters are installed completely, sensitive and reliable.
4.4.16 Check after solids control system installation
 All connecting bolts, nuts, spring washers and split pins are complete and fixed. And
the per-torque of bolts are in line with requirements.
 All pipelines and valves are good without water leakage.
 The tyre surface of solids control tank trailing device should be in good condition
without any obvious abrasion, and the tyre pressure accords with the specification
and requirements.
4.4.17 Check after electric control system and well site standard electric system
installation
Check as per requirements in the User's Manual of Electric Control System and Well Site
Standard Electric System.
4.4.18 Check after drilling instrument system installation
Check as per the related requirements in the User's Manuals of Drilling Instruments to
make sure all instruments are sensitive and reliable.
4.4.19 Check after monitoring system and communication system installation
Check as per the related requirements in user's manuals of monitoring system and
communication system.
4.4.20 Check after auxiliary part installation
 Auxiliary parts are installed completely and are good.
 The bolts of the auxiliary parts are installed completely and firmly. All connecting
pins and safety chains are complete and good.
 The wireline for the auxiliary equipment shall be good without damage.
5. Commissioning of drilling rig
5.1 Preparation work before commissioning

5.1.1 Fill equipment with lubricating oil, grease, fuel oil, hydraulic oil and cooling water
as per the specification in corresponding user's manuals.
5.1.2 Clean sundries near equipment, check cables and pipelines for correct and reliable
connection and seal.
5.1.3 Check the equipment before its running as per user's manuals.
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5.2 Commissioning of diesel generator set

5.2.1 Check the air supply pipelines of the diesel engine, the power and control cables of
the generator set and the VFD house for correct connection, start the generator set to supply
power to the air source purifier, start screw air compressor (directly start cold start air
compressor) and make the pressure of air tank reach to 1.0MPa. 145 psi
5.2.2 Start the main generator sets respectively, check the running conditions and
commission them to working states.
5.2.3 The functions of the main generator sets are commissioned to meet designed
parameter values and the following requirements.
 The diesel engine is started smoothly and runs stably at rated speed.
 The generator sets generate and output power stably.
 Synchronous operation loop control is normal.
 Short circuit, overcurrent, overfrequency, underfrequency and reverse power
protection functions are normal.
 All meters and indicator lamps have normal display.
Please see the User's Manual of Diesel Generator Sets for details.
5.3 Power supply commissioning of VFD system
5.3.1 Preparation
 Check VFD, MCC systems and all AC VF motors in VFD house, the power and
control cables of electric appliances of control switches, display screens, touch
screens, illumination systems and solids control systems etc in driller's control cabin
for connection, and all switches shall be at off position.
 Diesel generator set supplies power to the VFD and MCC system, commission all
functional switches and instruments, ensure correct indication and display, and
ensure that parameters accord with requirements.
5.3.2 Supply power to areas
 Supply power to driller's control cabin, all display screens are clear, touch screens are
sensitive and instruments are normal, and all switches work flexibility and reliability.
 Power up the AC VF motors on DW, start main motors of drawworks, check their
rotation and running conditions and the running condition of blower.
 Power up RT driving motor, check its rotation and running condition as well as the
running condition of blower.
 Power up the AC VF motors on mud pumps, and check their rotation direction of
running condition.
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 Supply power to every lighting point and check its working condition.
 Power up HPU, start up motor, and check rotating direction and running condition.
 Supply power to solids control system, check rotation and running condition of the
motor of the solids control equipment.
 Power up oil pumps and water pump of oil tank and water tank, and check rotation
and running condition.
 Supply power to other electric appliances and check their working condition.
(Please see User's Manual of Electric Drive System for specific requirements.)
5.4 Commissioning of electric drive system
5.4.1 The switch of the driller's control cabinet and PLC are logically true. Assignment
relationship of by-pass of PLC is correct.
5.4.2 The functions of wind loss and locking protection for every main motor are normal.
5.4.3 Air inflation and undervoltage alarm function of drill floor is normal.
5.4.4 The automatic function, feedback function and locking function are normal.
5.4.5 Loading equilibrium test of mud pump is normal.
5.4.6 Function of emergency brake button is normal.
5.4.7 DW dynamic braking system function is normal. (Test with DW together.)
(Please see User's Manual of Electric Drive System for specific requirements.)
5.5 Commissioning of driller's control cabin, instrument and meter system
Please see user’s manual of driller’s control cabin and operation manuals of all
instruments and meters for details. (It can be performed after the mast and the substructure are
lifted.)
5.5.1 Power-on commissioning of computer part.
5.5.2 On-line commissioning of drill floor monitor and computer.
5.5.3 Passageway test of analog quantity sensor.
5.5.4 Input of initialized data of system
5.5.5 The pressure and liquid level sensors shall be installed properly. All cable and
pipeline shall be connected correctly. Functions are normal.
5.5.6 All cameras of monitoring system shall be installed properly, and image
transmission and display are normal.
5.5.7 Communication system works normally.
5.5.8 Calibrate the flow meters, sensors and indicators as per the requirements of the
operation manuals.
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5.6 Commissioning of air source system equipment

Start up No.1 and No.2 electric screw compressor sets respectively and commission them
to operative mode. Check working condition of air source purification device and equipment,
and air leakage and oil leakage are forbidden.
5.7 Commissioning of hydraulic system
Please see the User's Manual of Hydraulic System and the User's Manual of Hydraulic
Disc Brake Device.
5.7.1 Test the combined HPU to working condition.
5.7.2 Test the movable HPU to working condition.
5.7.3 Test the hydraulic disc brake to working condition.
5.7.4 Function commissioning for lifting cylinders of mast and substructure
5.7.5 Function commissioning for jacking cylinders of generating air supply house trailer
and VFD house trailer.
5.7.6 Function commissioning for jacking cylinder of pump set trailer
5.7.7 Function commissioning for jacking cylinder of solids control tank trailer
5.7.8 Function commissioning for jacking cylinder of drawworks trailer
5.7.9 The commissioning of all hydraulic implement (It can be performed after the mast
and the substructure are lifted.)
5.8 Running commissioning of DW
Perform the following commissioning before wireline is reeved:
5.8.1 Commissioning before running
 Open the ball valve on the air tank of the substructure to supply air to DW.
 Start up lubrication pump of main reducing gear box to check whether all parts are
lubricated well.
 Operate control handle of hydraulic disc brake in the driller's control cabin and push
buttons on the touch screen for 5 ～10 times. Check the accuracy of hydraulic disc
brake system action.
Check: The air intake and exhaust conditions of auxiliary drive device
The reliability and correctness of the action of anti-collision toggle valve
The flexibility and reliability of hydraulic disc brake
5.8.2 Idle running commissioning
5.8.2.1 Running procedure:
 Start drawworks motor to check its rotation direction and make sure the rotation
direction of drum is the direction of winding.
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 Check the pressure of lubrication pump and make it within 0.1 ～0.35Mpa. 15 a 51
psi
 Start drawworks motor and make it running for 20 minutes at the rotating speed of
803r/min.
 Adjust the speed of drawworks main motor by control handle to check its running
condition.
 Start auxiliary drive motor to check its rotation direction and make sure the rotation
direction of drum is the direction of winding. And adjust the motor by increasing and
decreasing speed to check its running condition.
 Braking test of hydraulic disc brake shall not be less than 5 times at different speeds.
5.8.2.2 Commissioning requirements:
 All operations are accurate and flexible.
 All parts are sealed well without seepage and oil leakage.
 Lubricating oil pressure is stable, and the lubricant quantity is proper.
 Stable running, no abnormal vibration and sound.
 The bearings at all positions are normal in temperature rise.
 Hydraulic disc brake is flexible and reliable.
5.8.3 Reeving of wireline
 After DW is commissioned and qualified, put wireline spooler in right location and
reeve wireline. The fixed end is reeved into deadline stabilizer and fastened and the
movable end is reeved into DW drum and fixed with wireline clamp seat.
5.9 RT running commissioning
(It can be performed after the mast and the substructure are lifted.)
5.9.1 Start RT drive motor to check its rotation direction and make sure the RT has a
positive rotation. And adjust the motor by increasing and decreasing speed to check its running
condition.
5.9.2 Engage the RT inertia brake, and check the brake function and the interlocking
condition of the motor.
5.10 Commissioning of mud pump set
(It can be performed after the mast and the substructure are lifted.)
Test to working state as per the requirements in the User's Manual of HHF-1600 Mud
Pump Set.
5.11 Commissioning of generating air supply and VFD house trailing device
5.11.1 With the cooperation of jacking cylinder, the trailer could go back and engage the
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generating air supply house and VFD house trailing devices for 1-2 times, and do the
connection test.
5.11.2 Test of the air brake for axle (shaft). Check the reliability of air brake.
5.11.3 Electrical test.Make sure directive lighting of trailer outline etc electric function is
in good condition.
5.12 Commissioning of pump set trailing device
pump set trailing devices for 1-2 times, and do the connection test.
in good condition.
5.13 Commissioning of drawworks trailing device
drawworks trailing devices for 1-2 times, and does the connection test.
in good condition.
5.14 Commissioning of mast trailing device and wireline spooler trailing device
5.14.1 Lower down the mast by mast lifting cylinder and crane to position, and then
install the connecting device of trailer below crown block by pins, and connect wireline
spooler trailer to the rear of mast trailer.
in good condition.
5.15 Mast and substructure lifting and mast alignment
(Please see the user's manuals of mast and substructure for details.)
5.15.1 Check before mast lifting
 Before mast lifting, check the parts which have been already installed as per clause
4.4.3 to ensure all parts are installed correctly and connected reliably.
 The lifting cylinder is in good condition and ends are fixed firmly.
 The hydraulic system and hydraulic control system are normal and the working
pressure is not less than 25MPa. 3625 psi
 Overturn and fix the operation platform of the monkey board.
 Place the tong counterweight to low position.
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 Check again the status of the hydraulic lifting cylinders and their pipelines and
controlling valves, and then connect them with the hydraulic power unit to check
whether their pistons are acting synchronously according to requirements specified in
operation manual.
 Check the mast for left work pieces or tools and the safety facilities for completeness
and reliability.
5.15.2 Lifting of mast
 The lifting work must be commanded by a commander. The position where the
commander is must be seen by driller and must be safe.
 Before mast lifting, all persons and construction machinery must be in safety zone
except rear personnel in cabin, driller, and personnel observing key parts, safety
officer and the commander.
Safety distance: the distance between position dead ahead and bore shall not be less
than 70m, and distance among two sides to two sides of mast shall not be less than 20m.
 Before formally lifted, the mast must be carefully checked again; check all
connections’ status and be sure no sundries on the mast. Lift the mast slowly by the
lifting cylinder. When mast is about 200mm off the high-stand, stop lifting. Leave it
in that position for at least 10 minutes, during this time visually inspect the critical
welding seams and stress areas for any broken parts, deformation, cracks of welding
seam; check for any leakages or other abnormalities on the lifting cylinders etc and
then keep inspection records.
 When finishing inspections, lower the mast to the high-stand slowly, repeat this
operation for another two times, and make sure there are no abnormalities then lift
the mast formally.
 Lift the mast slowly and evenly. When the mast nearly reaches the upright position
(about 80°), slow down again to make the mast reach the upright position smoothly,
and then connect the front legs of the mast with the upper seats of substructure by
pins to complete the whole lifting operation. During lifting, attentions shall be paid to
observation of working pressure of the lifting cylinders, if it exceeds the rated
working pressure, stop lifting immediately and lower the mast down on the high-
stand, and find out the reasons and eliminate the failures, and then start lifting again.
 After the mast is placed in place, retract the lifting cylinder and fix it on the mast
upright column.
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5.15.3 Check before substructure lifting

 Before substructure lifting, check the parts which have been already installed as per
clause 4.4.2 to ensure all parts are installed correctly and connected reliably.
 The lifting cylinder is in good condition and ends are fixed firmly.
 Check again whether the lifting cylinder works normally.
 Check again whether the connecting pins between the upper layer and the bottom
layer basement have been removed.
5.15.4 Lifting of substructure
 Lift the substructure about 100～200mm off the substructure installation position, at
the same time, observe whether the pressure values of lifting cylinder exceeding the
rated value, and then place the substructure to the original position for 3 times
repeatedly.
 Lift the substructure slowly and evenly after confirming there is nothing wrong, and
observe if there is any abnormal condition occurred during substructure components
lifting, stop lifting if any, and lower down the substructure to check and do the
troubleshooting, and then lift it again.
 After lifting in place, fix the inclined stay bars between top layer and base by 8
pieces of Φ70 pins.
 With the cooperation of crane, install all parts left on the floor, so far the substructure
installation has already completed.
Notice: the lifting cylinder shall run stably at a uniform speed.
5.15.5 Mast alignment
 After the mast and the substructure are lifted, align wellhead as required. It is
required that the offset between the crown block center and the RT center is not more
than Φ20mm. (For aligning method, please see the User's Manual of Mast.)
 Make sure to make the mast in natural status while aligning it.
5.16 Parts installed after mast and substructure lifting
5.16.1 Wellhead mechanical tools.
5.16.2 Well control device.
5.16.3 Ladders from drill floor to solid control system.
5.16.4 Other parts of the substructure, such as safety slide, V door ramp, catwalk and drill
pipe racks etc.
5.16.5 Swivel, connect it with rotary hose
5.16.6 Other auxiliary parts.
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5.17 Commissioning of drilling instruments

5.17.1 Check whether the sensors are installed properly and cables and pipelines are
connected correctly or not.
5.17.2 Calibrate the display and indicating instruments as per the requirements and
specifications of manuals.
5.18 Adjustment of wireline on DW drum and test of crown block saver
5.18.1 Adjust the wireline on the DW drum, and ensure at least 9 cycles of wireline on
the drum always.
5.18.2 Commissioning of anti-collision toggle valve device
Adjust the position of the toggle valve, so that it works when 28 m 92 pies stand is lifted
and the lower end surface of the stand is 2m 6,5´ away from the drill floor, make the hydraulic
disc brake braked urgently for stopping the DW drum, now check its reliability.
5.19 Test of hydraulic and pneumatic tools
Test them as per individual operation manuals.
5.19.1 Run test of hydraulic cathead.
5.19.2 Test of running, lifting capacity and braking of pneumatic DW.
5.20 Run test of solids control system
5.20.1 Sealing performance test of system pipeline
After the whole system is installed, carry out sealing performance test. Fill the circulating
tank with fresh water. There shall be no leakage for connecting lines between tanks, valves and
bottom valves.
5.20.2 Power-on running test of solids control equipment
 Carry out power-on trial test on shale shaker, desilting and desanding cleaners and
vacuum degasser respectively; they shall run normally.
 Carry out power-on running test on agitator, charging pump and mixing pump
respectively, they shall run normally.
5.20.3 Performance test for solids control trailer
The single mud tank can realize the whole hauling as per the design requirements.
5.21 Test of high pressure manifold
5.21.1 Carry out static hydraulic test with fresh water on ground manifold, standpipe,
valve sets of high pressure manifold, and test pressure is 35MPa, 5000 psi stable pressure
time is 10min, pressure drop is not more than 2MPa. 290 psi
5.22 Check of standard electric system on well site
5.22.1 Check various sockets and plugs for reliable connection, check whether they
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consist with explosion-proof requirements, and conform to technical standard requirements of

API.
5.22.2 Power on every area to check whether the motors of equipment, lighting lamps,
every explosion-proof distribution box and control box work normally.
5.23 Test of monitoring and communication system
Test the desk phones and mobile communication equipment, and they shall meet design
requirements. Check the installation position of the cameras of the monitoring system for
correctness and the picture transfer and display for normalness.
5.24 Test of whole drilling rig
Start DW, mud pump, RT and solid control system to carry out test on the whole drilling
rig for linkage performances.
6. Operation and maintenance of drilling rig
6.1 Warnings
6.1.1 Operate the drilling rig following its user's manual and the related safety rules
strictly.
6.1.2 It is forbidden to check and repair equipment without cutting of power source and
control source.
6.1.3 When inspecting and repairing a VF motor, make sure the auxiliary switch beside
junction box has been closed and locked by copper lock, insert locking pin, and ensure the
main circuit is power off.
6.1.4 Before the drilling rig works, check and adjust the wireline on DW drum. Make
sure the initial wireline on the drum is not less than 9 circles at any time to prevent the
wireline from slipping due to excessive strain of wireline clamp. Then retighten the bolts and
nuts of wireline clamp seat.
6.1.5 When the drilling rig works, personnel are not allowed to stay in the area of the mud
pump relief valve, high pressure manifolds and rotary hose.
6.1.6 In the operation of the drilling rig, the speed regulation of every running part shall
be slow and smooth, avoid the impact to mechanical and electric systems due to violent
changes in speed.
6.1.7 When the rig needs to transport fast, adopt corresponding saddle load and
movement speed as per the design recommendation. Never try to overload and over speed.
6.2 Precautions for drilling rig operation
6.2.1 Select the generator sets with proper power to match the power requirements as per
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drilling conditions.
6.2.2 During drilling operation, adjust the hoisting speed of the DW upon its load, drilling
technical requirement and DW hoisting curve; adjust discharge pressure and strokes of the
mud pumps as per the drilling technical requirements; and adjust the RT speed as per drilling
technical requirements.
6.2.3 Before operation, check whether both ends of drilling wireline is fixed in
conformity with requirements, all savers are reliable and agile, the DW brake system and
clutch are reliable, and all electrical appliances and instruments are connected correctly and
work smoothly or not.
6.2.4 During operation, make sure the pressures of air supply system and hydraulic
pressure system meet the regulated working pressure.
6.2.5 During working, make sure the gears and bearings etc of transmission system are
lubricated sufficiently and reliably. Check whether the quality and quantity of the lube
oil/grease for each part meet the requirements, and supplement or replace the lube oil as per
the regulated operation period.
6.2.6 Check the rotation condition of mud pump direct drive motor periodically.
6.2.7 Check inflation pressure of mud pump discharge air bag periodically.
6.2.8 All ladders, handrails and guards shall be firm and reliable without looseness.
6.2.9 It is forbidden to operate the drilling rig over speed and over load and violate any
operation regulations while using any part of the drilling rig.
6.2.10 Check the hydraulic cylinders of mast and substructure, and jacking cylinder of all
trailers for reliability.
6.3 Safety practice for drilling rig operation
6.3.1 Requirements on drilling rig operation
 There shall be mechanical, electrical and instrument professionals in drilling crew
and technical regulations for drilling rig routine operation and maintenance shall be
made. The routine operation and maintenance of drilling rig are guided and treated.
 Only trained and qualified persons can operate and maintain the drilling rig with
qualification certificates.
 The operators must follow the safety operation regulations.
 The lifting speed and lifting capacity of drilling rig must be in conformity with
related regulation in the User's Manual of DW.
 The displacement and pressure of mud pump must be in conformity with the related
regulation in the User's Manual of HHF-1600 Drilling Pump.
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 When any part of the drilling rig goes wrong, stop using the part and treat faults, and
use it again after troubleshooting.
 Make sure to release pressure inside pipelines to zero in the disconnection of any
high pressure pipelines or hoses. Ensure the power has been cut off before repair the
electric circuit and equipment.
 When the trailing modules need to be transported fast, adopt corresponding saddle
load and movement speed as per the design recommendation.
6.3.2 It is forbidden to operate the drilling rig, and repair it in time when it is in one of
following conditions:
 The drilling rig is used over load and over speed.
 The steel structures of the mast and the substructure deform or crack.
 The foundation of the substructure sinks or ruptures.
 Brake and drive systems are out of control.
 The safety valve and the charged air of air dampener of mud pump are not in
conformity with requirements.
 The crown block savers fail during tripping.
 The instruments of the drilling rig are damaged or have no metering function.
 The pneumatic control system fails or air supply pressure is lower than the allowed
range.
 Guards and handrails are incomplete.
 Oily substances enter the surfaces of brake disc, brake huh and clutch steel hub.
 The lifting cylinder and the drilling wireline are not checked as required.
 The jacking cylinder of all trailing system has oil leakage.
 The tyre of trailing system worn seriously with leakage, and the hub is out of shape.
6.3.3 All operators are forbidden to perform the following operation
 All parts (including whole trailing device) runs with overload, overtemperature and
overpressure.
 Check and repair equipment without cutting off the power source and the control
source of the drilling rig.
 Make up threads with RT
 Adjust the brake when the hook is loaded.
 Water brake disc, brake hub and friction hub.
6.4 Maintenance regulations of drilling rig
The maintenance is divided into periodic maintenance and staged maintenance as per the
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technical condition and the running time of the drilling rig.

The periodic maintenance is divided into shift maintenance, weekly maintenance and
monthly maintenance.
The shift maintenance items comprise the routine contents of adjustment, lubrication,
fixing, cleaning and corrosion prevention and the shit maintenance items regulated in this
section.
The weekly maintenance items comprise the shit maintenance items.
The monthly maintenance items comprise the weekly maintenance items.
The staged maintenance mainly includes the maintenance of main components. When the
maintained components are judged to be not able to satisfy the drilling operation requirements
through technical detection, they shall be repaired on service base.
The periodical maintenance regulations of the drilling rig are as follows:
6.4.1 The routine maintenance items of mast and substructure:
 Lifting components shall not crack and deform.
 The lifting cylinder has no oil leakage.
 Lubrication of all sheaves is favorable.
 All pins shall be installed in place and safety pins are complete.
 The joints of all bolts must be firm and reliable.
 Under load, periodically measure the straightness error of the stand posts of mast and
the error of perpendicularity among the front and lateral surfaces of the mast and the
level.
 Before lifting and lowering, check the buffer device and the hydraulic system for
completeness and sufficient oil supply.
 In any condition, it is not allowed to remove the cross and inclined tension beams
and other components on mast.
 It is not allowed to drill holes and cut holes or weld all components of the steel
structures.
 Check mast and substructure per month or before the bearing of special load such as
casing.
6.4.2 Lifting system
6.4.2.1 Shift maintenance and check items
 The test of the braking function and anti-collision performance of the DW shall be
safe and reliable.
 The reliability of the electric appliances on the driller's control console and the
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sealing performances of all pneumatic control and hydraulic pipelines.

 The ends of the deadline and the fastline are fixed reliably.
 The lubrication and sealing performances of all bearings are favorable.
 The fixation of bolt of bail retainer bar of hook and stop pin, the flexible rotation of
hook body and the free expansion of springs.
 The favorable seal of all sealed positions of swivel, RT and DW and the conformity
of the oil amount and oil temperature with requirements.
 The flexibility and reliability of the stop pin of RT.
6.4.2.2 Weekly maintenance and check items
 The oil supply of the lubrication pump of DW, the cleanness of lubrication oil, and
the cleaning and the replacement of filter elements of filters.
 The flexible rotation of the bail and pin of swivel.
 The fixation of traveling block shaft.
 The wear of the sheave grooves of crown block and traveling block.
 The seal of the washing pipe packing of swivel.
 The fixation of the cardan shaft of RT.
6.4.2.3 Monthly maintenance and check items
 The connection and wear of clutch, coupling and cross sub of cardan shaft.
 Cracks of bail, pin and sheaves of lifting system.
6.4.3 Mechanical drive system
6.4.3.1 Shift maintenance and check items:
 Check the temperature, temperature rise and abnormal noise of all drive boxes and
rotating parts.
 Check the lubrication oil of the gearbox for quality, amount, pressure and
temperature.
6.4.3.2 Weekly maintenance and check items:
 Running condition of oil pump and cleaning of filter.
 Check the wear of clutch.
6.4.3.3 Monthly maintenance and check items:
 Check all driving parts completely. Including clutch, coupling and universal shaft etc.
 Check the gear meshing of gearbox.
 Measure the quality of the oil in oil bath.
6.4.4 Circulating system
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 The operation status of the power end of mud pump, the temperature rise and
insulating property of direct drive motor.
 The suction performance of fluid end of mud pump, the sealing, cooling and
lubrication of piston, liner, tie rod etc.
 The pressing reliability of the cylinder lids and valve caps of mud pumps.
 The working condition of charging pump and spraying pump.
 Conformity of charging pressure of pulsation dampener and safety valve with
requirements.
 The fixation of high pressure manifold, and the flexibility of high pressure valve etc.
 The working condition of solid control equipment, and the temperature rise and the
insulating property of motor.
 Check and clean lubrication oil filters
 Lubrication and wear of crosshead and guide plate.
 The flexibility of action of safety valve.
 The insulation condition of circuits.
 The smoothness of spray nozzle of mud gun.
6.4.4.3 Monthly maintenance and check items:
 The meshing condition of gears at power ends of mud pump, and check and adjust
the gap of the crosshead.
 Check the high pressure pipe through non-destructive test.
 Fasten connecting valve bolts of mud pump and clean oil sump.
6.4.5 Air supply system
 No abnormality during the startup and the stop of air compressor, and conformity of
oil quality, oil amount and oil temperature with requirements.
 Check the automatic pressure regulating device and the safety valve for conformity
with requirements.
 Check the working pressure of air tank and discharge water for pollution discharge.
 Check the smoothness and the favorable seal of pipelines.
 Check the working condition of air filter without blockage.
 Check safety valve and sequence valve.
6.4.5.3 Monthly maintenance and check items
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 Clean filter and safety valve of air tank.

 Check control valves of compressor.
 Check control valves of dryer.
6.4.6 The routine maintenance items of trailing system
(Refer to all user’s manual of trailing device)
A person shall be specially assigned to maintain the trailer, and partial troubles shall be
handled by professional vehicle repair departments.
 Fill the grease at lubrication points.
 Carry out rain-proof, moisture-proof and rust-proof treatment to cylinder and tyre
including hub of trailing device.
 Check the paint quality on the surfaces of the trailing device and repair in time if the
paint is damaged.
 Check the welding structure members of trailing device for crack and deformation.
 Check installation bolts and tyre bolts of axle and rigid suspension, and dose not to
replace them with common ones.
 Check whether the air piping system and electrical system on the carriage are loose.
 Release the water in air reservoir to avoid condensate water accumulated.
6.4.6.3 Monthly maintenance and check items (before using)
 Check the tyre pressure and abrasion.
 Check the seal of pipe connection, and does the leakage test.
 Check hydraulic oil cylinders, pipelines and hydraulic control valves, remove
troubles and leakage or replace them in time.
 Check the nut on kingpin, tyre bolt and installation bolts of axle and rigid suspension
for looseness.
 Check whether the internal surface of brake hub for axle and rigid suspension and
outer surface of brake shoe are stained with grease.
Note: For the maintenance of hydraulic cylinders, axles and rigid suspension please refer
to their operation instruction manuals.
6.4.7 Driller's control cabin
(Please refer to the User's Manual of Driller's Control Cabin.)
6.4.8 Electric Drive system
(Please refer to the User's Manual of Electric Drive System)
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6.5 Operation and maintenance during algid stage

6.5.1 High pressure mud system
 Check valve chamber, circulating manifolds and valves for no icing before the
startup of mud pump.
 Check mud tanks, connecting lines and valves for no icing before the startup of mud
circulating system.
 Check water tanks, connecting lines and valves for no icing before the startup of
water supply system.
 When the mud pump stops working, discharge the drilling fluid at the hydraulic end
of mud pump, rotary hose and high and low pressure manifolds.
 After mud circulating system stops, drilling fluid in mud tank and connecting lines
shall be discharged completely.
 After water supply system stops, water in water tanks and connecting lines shall be
discharged completely.
6.5.2 Lubrication system
 Low temperature lube oil and grease shall be selected as required.
 For lube system with heating device, preheating is necessary before drive device
starts.
6.5.3 Lifting system
Prevent the drainage hole at the lower part of the bail of swivel from icing.
6.5.4 Other systems
When the temperature is lower than -20℃ (average of monthly lowest temperature)，do
not use the drilling rig under the maximal load. Take measures on the factors which may cause
damage to the main structural components of mast and substructure. All oil, air and water
delivery pipelines shall be prevented from being frozen.
6.6 Accident and emergency treatment
6.6.1 If any mechanical accident such as DP sticking and the like happens in drilling
process, it shall be treated as per mechanical accident treatment regulations.
6.6.2 If fire alarm happens in the well site, it shall be treated as per fire alarm accident
treatment regulations.
6.6.3 When emergency happens in the well site and staff must retreat urgently, personnel
on duty have to follow unified command and retreat as soon as possible after finishing
emergency operation. Mast men on racking board can use escaping device to get out quickly;
staff on drill floor can adopt escaping slide to make a speedy fleeing.
32
7. Disassembly and transportation of drilling rig
7.1 Lowering of mast and substructure of drilling rig

7.1.1 Check before the lowering of mast and substructure of drilling rig
 Grease every lubrication point as required. Grease pins at rotating parts.
fastened
and opening.
 Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
 There is no barrier to block driller's eyesight on the drill floor.
 Lifting cylinders of substructure work normally.
 Check whether the pins connecting with inclined tie rods of top layer and bottom
layer of substructure are dismantled.
 Lifting cylinders of mast work normally.
 The drilling wireline is complete and its ends are fixed firmly.
 No tools and stuffs left on the mast.
 Weight indicator works normally.
7.1.2 Lowering of substructure
Lower down the substructure by lifting cylinder slowly, and observe the abnormal
phenomena, if any, lower down it again after lifting the substructure to working position and
troubleshooting.
After the substructure lowered down completely, install the 4 Φ70 pins between left and
right & rear seats and left and right & upper seats and 4 Φ90 pins connecting between left and
right & front seats and left and right & upper seats, and then lower down the mast as per its
user's manual.
7.1.3 Lowering of mast:
Remove the casing stabbing board and all components or accessories which may affect
the mast lowering. And then lower down the mast by lifting cylinder slowly.Control lowering
speed, lower down the mast slowly at a uniform speed during lowering down.
7.2 Disassembly of drilling rig
7.2.1 The principle for disassembling the drilling rig is: disassemble firstly those installed
last and disassemble last those installed first.
33
7.2.2 Disassemble the drilling rig into components, then pack or bundle up every
component separately. Larger components such as mast and substructure shall be disassembled
into smaller units in terms of the size of carrying vehicles, and DW, diesel engine set, VFD
house and trailing device etc can be transported as a module.
7.2.3 Pack fasteners separately as per components, and use labels to identify them. High-
strength bolts and nuts for mast, crown block, deadline stabilizer and universal shaft shall be
packed separately after disassembly to avoid confusing with others. All pins and safety pins
shall be subjected to anti-rusting treatment, bundled up and boxed as per component sorts, so
as to prevent rusting, impact, damage and confusion.
7.2.4 Disassemble air, fluid and water pipelines only after pressure is released. Discharge
fluid and water in pipelines and use compressed air to dry them.
7.2.5 The interfaces of the disassembled air, fluid and water pipelines shall be sealed or
bundled up, so as to keep clean inside pipelines and at interfaces and avoid impurities from
going inside. Notice: two ends of every interface shall be marked by the same No.
7.2.6 The pins, bolts and nuts for mast and substructure should be coated with antirust oil
and boxed, and they cannot be piled randomly. The high-strength bolts and nuts for cardan
shaft should be with the connecting flange, and packed with cardan shaft together.
7.2.7 The hoses of air system shall be prevented from oil, and the outer threads of every
pipeline shall be bundled up, so as to keep the threads from impact and damage and keep the
pipeline clean.
7.2.8 If long-distance transportation or long-term storage is required, perform rain
proofing, moisture proofing and rust removal treatment.
7.3 Transportation of drilling rig
When the drilling rig is transported, make a transportation plan according to the overall
dimensions and weights of its components and the road conditions, and make a transportation
vehicle number table according to the vehicle conditions. The transportation units of mast and
substructure shall be transported intensively and other parts shall be transported intensively as
per components.
34
8. Lubrication table for main components
Filing
Maintenance
No Part name Position Oil spec. amount for
period
. new device
Drum shaft,
Ambient temperature above -20℃ 2 kg
coupling, grease Every 15 days
NLGI 2 lithium base grease
lubrication
Ambient temperature
-20℃～+10℃, ISO VG 150
Medium and extreme pressure
When the oil level is
gear oil
1 DW Gear reducer box below the mark, add
Ambient temperature
or chain oil in time.
-10℃～+40℃, ISO VG 220 500L
transmission oil Replace the oil
tank, oil completely every 6
gear oil
lubrication months or when the
Ambient temperature
oil has been polluted.
+10℃～+60℃, ISO VG 320
gear oil
Replace the grease
completely every 3
2 Motor Bearing FAG-Arcanol L135V years or when the 290 g
lubrication grease grease has been
polluted.
Before lifting and
All sheave lowering mast and
bearings substructure every
Mast
3 Ambient temperature above -20℃ time 200 g
Substructure NLGI 2 lithium base grease Before installing and
disassembling mast
Pins and padeyes
and substructure
every time
4 Crown block Ambient temperature above -20℃ 500g
Sheave bearings Every 7 days
Travelling Ambient temperature above -20℃
5 Sheave bearings NLGI 2 lithium base grease Every 7 days 500g
block
Bail pin, pins Ambient temperature above -20℃ 200g
Every 7 days
Thrust bearing NLGI 2 lithium base grease
Ambient temperature When the oil level is
6 Hook -20℃～+50℃, ISO VG 220 below the mark, add
Medium and extreme pressure oil in time. Replace 20L
Oil pool
gear oil all lubrication oil
after every well is
drilled.
gear oil
Main oil pool Every two months 200g
Ambient temperature
-20℃～+50℃, ISO VG 220
7 Swivel
Bail pin, washing
pipe packing, Ambient temperature above -20℃
Every 72h 200g
bracket and lower NLGI 2 lithium base grease
cover oil seal
35
Spinner and centre Ambient temperature above -20℃
8 Kelly spinner Every 200h 200g
pipe bearing NLGI 2 lithium base grease
Ambient temperature
-20℃～+50℃, ISO VG 220 200L
Main oil pool Every two months
9 RT ZP275 Medium and extreme pressure
gear oil
Ambient temperature above -20℃ 100g
Locking device Every 7 days
gear oil When the oil level is
Gear reducer box Ambient temperature below the mark, add
or chain oil in time.
10 RT drive -20℃～+10℃, ISO VG 150
transmission oil Replace the oil 200L
device Ambient temperature
tank, oil completely every 6
-10℃～+40℃, ISO VG 220
lubrication months or when the
Ambient temperature
+10℃～+60℃, ISO VG 320
RT Ambient temperature above -20℃
11 transmission Bearing, spline NLGI 2 lithium base grease Every 72h 100g
cardan shaft
Ambient temperature
-20℃～+10℃, ISO VG 150
gear oil
When the oil level is
Ambient temperature
below the mark, add
-10℃～+40℃, ISO VG 220 oil in time.
Machine oil pool, 350L
Replace the oil
HHF-1600 oil lubrication Medium and extreme pressure
12 completely every 6
mud pump gear oil months or when the
Ambient temperature
+10℃～+60℃, ISO VG 320
gear oil
Belt transmission Ambient temperature above -20℃
device Every 15 days 400g
Bearing
Ambient temperature
-20℃～+50℃, ISO VG 220
Oil pool Replace once a month 2L
gear oil
13 Air winch Gears and all Ambient temperature above -20℃
grease lubrication Every 7 days 600g
points
Ambient temperature When the oil level is
-30℃～+50℃, ISO VG 46 below the mark, add 0.2 L
Oil sprayer
oil in time.
ISO HM hydraulic oil
14 Deadline Sheave bearings Ambient temperature above -20℃ Replace all 400g
lubrication grease
36
NLGI 2 lithium base grease after every well is
drilled.
stabilizer Transformer oil with
Weight indicator Fill while correcting Proper
sensor pipe ISO viscosity of 8.7 weight indicator
15 All wirelines Wireline surface Wireline surface grease As per use condition Proper
Ambient temperature Replace the hydraulic

oil completely every
YM-10 Oil cylinder -30℃～+50℃, ISO VG 46 80L
6 months or when the
16 Hydraulic ISO HM hydraulic oil oil has been polluted.
cathead Ambient temperature above -20℃ Every 7 days
Sheave 100g
17 HPU -30℃～+50℃, ISO VG 46 1000L
Oil tank of HPU 6 months or when the
ISO HM hydraulic oil oil has been polluted.

18 Movable HPU -30℃～+50℃, ISO VG 46 1500L
Oil tank of HPU 6 months or when the
ISO HM hydraulic oil oil has been polluted.
Please see User's

19 Compressor Oil/gas separation Compressor oil Manual of
cylinder
Compressor
Ambient temperature above -20℃ Please see Operation
Manual of generator
20 Generator set Diesel engine API CH-4(CG-4) set.
SAE 15W-40 diesel engine oil
Explanation: the listed lube oils in this table are recommended ones. According to ISO
viscosity grade requirements, it is necessary to use the qualified lubrication oil. The lubrication
and maintenance period is suitable for the normal condition, and user can properly adjust the
period of replacing oil as per the actual working condition and the periodic oil quality check.
9. Main part bearing model summary list
No. Part name Position Spec. Code Model Qty.
Crown block
Φ203.2×Φ276.22×95.25 37941K 7
Crown sheave
1
block Auxiliary
80×170×39 GB283-81 42316 2
sheave
Traveling Traveling block
2 Φ203.2×Φ276.22×95.25 37941K 5
block sheave
37
Hook load
3 Hook Φ160×Φ350×120 GB4663-1994 3-939 1
bearing
Load bearing GB299-64 9019456Q 1
Anti-jump
Φ200×Φ310×70 GB297-84 2007140 1
bearing
4 Swivel Upper and
lower
GB283-81 32240 1
alignment
bearings
Load bearing Φ800×Φ1060×155 91682/800 1
Bearing Φ800×Φ950×120 GB/T283-94 1681/800 1

5 RT
Bearing Φ150×Φ320×108 GB/T288-94 32630 1
Bearing Φ150×Φ320×108 GB/T288-94 3630 1

Drum shaft
6 DW Φ240×Φ360×128 SKF 24048CC 2
assembly.
Crosshead
Φ285.75×Φ206.375×222.25 254941QU 3
bearing
Pinion shaft
Φ350×Φ220×98.42 4G32844H 2
Drilling bearing
7
mud pump Main bearing
Φ500×Φ300×160 3G3003760HY 2
of crankshaft
Eccentric
Φ863.6×Φ660.4×107.95 929/660.4QU 3
wheel bearing
8 Please see all bearings for rest components in user's manuals.
10. User's manuals list
No. Name
1 User's Manual of ZJ40DBSTDrilling Rig
38
2 User's Manual of DZ225/6.7-S Substructure

3 User's Manual of JJ225/43-K Mast
4 User's Manual of TC-225 Crown Block
5 User's Manual of YC-225 Traveling Block
6 User's Manual of DG-225 Hook
7 User's Manual of SL225 Swivel
8 User's Manual of JC40B
9 User's Manual of ZP275 RT
10 User's Manual of RT Drive Device
11 User's Manual of HHF-1600 Mud Pump
12 User's Manual of Mud Pump Drive Device
13 User's Manual of Solids Control System
14 User's Manual of Pneumatic Control System
15 User's Manual of Hydraulic System
16 User's Manual of Trailing System
17 User's Manual of Power System
18 User's Manual of Electric Drive System
19 User's Manual of Driller's Control Cabin
20 User's Manual of Mechanical Equipment on Drill Floor
11. Attached drawings of drilling rig
Attached drawing 1 Plan of ZJ40DBST Drilling Rig

Attached drawing 2 Elevation of ZJ40DBST Drilling Rig
Attached drawing 3 Drive System Drawing of ZJ40DBST Drilling Rig
Attached drawing 4 Foundation Drawing of ZJ40DBST Drilling Rig
39
Attached drawing 1 Elevation of ZJ40DBST Drilling Rig
40
Attached drawing 2 Plan of ZJ40DBST Drilling Rig
41
Attached drawing 3 Drive System Drawing of ZJ40DBST Drilling Rig
42
Attached drawing 4 Foundation Drawing of ZJ40DBST Drilling Rig
43

User'S Manual: Zj40Dbst Drilling Rig

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ZJ40DBST DRILLING RIG

Sichuan Honghua Petroleum Equipment Co., Ltd.

5.15 Mast and substructure lifting and mast alignment.............................................................21

User's Manual of ZJ40DBST Drilling Rig

2. Drilling rig description

2.1 Purposes and applicability

7 SL225 Swivel 1 set API Spec 8C, the 4th edition

1 Driller's control cabin 1 set

1 FKQ960-8 BOP accumulator 1 set

3. Structural features of ZJ40DBST drilling rig

3.1 Overall structure of drilling rig

3.3 Speed and lifting capacity of hook

3.3.2 Lifting curve (10 lines)

Hook speed m/s

3.3.3 Lifting capacity of auxiliary driving device (12 lines)

4. Installation of drilling rig

4.2 Installation sequence diagram of drilling rig

Substructure DW trailer Mast

Crown block Standpipe of drilling fluid Traveling block, hook

Main pipeline trough of overhead cable, substructure

Top drive Align well Wellhead Rig whole commissioning

 Installation of every connection and fixation component must be complete and

5. Commissioning of drilling rig

5.1 Preparation work before commissioning

5.2 Commissioning of diesel generator set

5.6 Commissioning of air source system equipment

5.15.3 Check before substructure lifting

5.17 Commissioning of drilling instruments

consist with explosion-proof requirements, and conform to technical standard requirements of

6. Operation and maintenance of drilling rig

technical condition and the running time of the drilling rig.

sealing performances of all pneumatic control and hydraulic pipelines.

 Clean filter and safety valve of air tank.

6.5 Operation and maintenance during algid stage

7. Disassembly and transportation of drilling rig

7.1 Lowering of mast and substructure of drilling rig

8. Lubrication table for main components

Ambient temperature Replace the hydraulic

Ambient temperature Replace the hydraulic

Please see User's

9. Main part bearing model summary list

No. Part name Position Spec. Code Model Qty.

Load bearing GB299-64 9019456Q 1

Bearing Φ800×Φ950×120 GB/T283-94 1681/800 1

Bearing Φ150×Φ320×108 GB/T288-94 3630 1

10. User's manuals list

2 User's Manual of DZ225/6.7-S Substructure

11. Attached drawings of drilling rig

Attached drawing 1 Plan of ZJ40DBST Drilling Rig

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