ZJ70DBS Drilling Rig

ZJ368-SC
April, 2012
 Foreword
ZJ70DBS drilling rig is an oil drilling rig which is designed and
manufactured as per GB/T 23503-2009 Petroleum drilling and workover rigs
and related API specification. It can satisfy the requirements on middle and deep
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 manuals of supporting
components carefully, and then install, operate and maintain the drilling rig as
required. If related contents are not known, improper installation, operation or
maintenance may cause human injury or equipment damage.
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.
 User Manual of ZJ70DBS Drilling Rig

Contents
1. Safety warnings ....................................................................................................................... 1

2. Description of drilling rig ........................................................................................................ 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 ZJ70DBS drilling rig .................................................. 2

3. Structural features of ZJ70DBS drilling rig ............................................................................ 5

3.1. Overall structure of drilling rig ......................................................................................... 5

3.2. Structural features of drilling rig ...................................................................................... 5
3.3. Speed and lifting capacity of hook ................................................................................... 6

4. Rig installation ........................................................................................................................ 7

4.1. Preparation work before installation ................................................................................. 7

4.2. Installation sequence diagram of drilling rig .................................................................... 8
4.3. Installation of all parts of drilling rig ................................................................................ 8
4.4. Check after installation ................................................................................................... 11

5. Commissioning of drilling rig ............................................................................................... 14

5.1. Preparation work before commissioning ........................................................................ 14

5.2. Commissioning of diesel generator set ........................................................................... 14
5.3. Power supply commissioning of VFD system ................................................................ 14
5.4. Commissioning of electric drive system......................................................................... 15
5.5. Commissioning of driller's control cabin, instrument and meter system........................ 16
5.6. Commissioning of air supply system equipment ............................................................ 16
5.7. Commissioning of hydraulic system .............................................................................. 16
5.8. Running commissioning of DW ..................................................................................... 17
5.9. RT running commissioning ............................................................................................. 18
5.10. Commissioning of utilized mud pump ......................................................................... 18
5.11. Mast and substructure lifting and mast alignment ........................................................ 18
5.12. Parts installed after mast and substructure lifting ......................................................... 22
5.13. Commissioning of drilling instruments ........................................................................ 22
5.14. Adjustment of wireline on DW drum and test of crown block saver ........................... 22
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 User Manual of ZJ70DBS Drilling Rig
5.15. Test of hydraulic and pneumatic tools .......................................................................... 22
5.16. Run test of solids control system .................................................................................. 23
5.17. Test of high-pressure manifold ..................................................................................... 23
5.18. Check of standard electric system on well site ............................................................. 23
5.19. Test of monitoring and communication systems .......................................................... 23
5.20. Online test of drilling rig .............................................................................................. 23

6. Operation and maintenance of drilling rig ............................................................................ 24

6.1. Warnings ......................................................................................................................... 24

6.2. Precautions for drilling rig operation .............................................................................. 24
6.3. Safety techniques for drilling rig operation .................................................................... 25
6.4. Maintenance regulations of drilling rig .......................................................................... 26
6.5. Operation and maintenance during algid stage ............................................................... 29
6.6. Accident and emergency treatment ................................................................................. 30

7. Disassembly and transportation of drilling rig ...................................................................... 31

7.1. Lowering of mast and substructure of drilling rig .......................................................... 31

7.2. Disassembly of drilling rig ............................................................................................. 32
7.3. Transportation of drilling rig .......................................................................................... 32

8. Lubrication table for main components ................................................................................ 33

9. Main part bearing model summary list ................................................................................. 36

10. User manuals list ................................................................................................................. 37

11. Attached drawings of drilling rig......................................................................................... 37 

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 User Manual of ZJ70DBS Drilling Rig
User Manual of ZJ70DBS Drilling Rig
1. Safety warnings
z Only trained and qualified operators can install, operate and repair equipment with
qualification certificates.
z Before the installation, operation and maintenance of the drilling rig, operators shall
read this manual and user manuals of all equipment belonging to the drilling rig
carefully, and then install, operate and maintain the drilling rig as per the
requirements in the manuals.
z 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.
z In operation process, strictly execute operation specifications and technical safety
rules.
z It is forbidden to maintain and repair equipment during its operation.
z Do not overload equipment.
2. Description of drilling rig

2.1. Purposes and applicability

ZJ70DBS drilling rig is an oil drilling rig which is designed and manufactured as per
GB/T 23503-2009 Petroleum drilling and workover rigs and related API specification. Its
performances can meet middle and deep well drilling application for land oil and gas
exploration and development in areas at a desert ambient temperature from -18℃ to +50℃
and an air humility not more than 90% (+20℃).

2.2. Standards and specification for design and manufacture

2.2.1. GB/T 23503-2009 Petroleum drilling and workover rigs

2.2.2. API Spec 4F, the 3rd edition Specification for Drilling and Well Servicing Structures
2.2.3. API Spec 7K, the 5th edition Specification for Drilling and Well Servicing Equipment
2.2.4. API Spec 8C, the 4th edition Specification for drilling and production hoisting
equipment
2.2.5. API Spec 9A, Specification for wire rope, the 25th edition
2.2.6. AWS D1.1-2008 Structural welding code-steel
2.2.7. API RP 500 Recommended practice for classification of locations for power equipment
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installations at petroleum facilities classified as class I, division 1 and division 2, the 2nd
edition
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 mm) DP) 7000m

(5'' (127mm) DP) 6000m
Max. hook load 4500kN
Max. drill string weight 2520kN
Input power of DW 2000kW
Lines of hoisting system 6×7, along the line
Diameter of wireline φ38mm
Mud pump power ×number 1600HP×3
Nominal opening diameter of RT 952.5mm (37 1/2'')
Effective height/type of mast 45.5m/K type
Height of drill floor 10.5m
Clear height of substructure 9.1m
Hoisting gear number one gear, stepless speed regulating
Gear number of RT one gear, stepless speed regulating
Power× number of main diesel generator set 1200kW×4
Drift diameter/rated pressure of drilling fluid manifold double standpipe 4''/35MPa
Total volume of mud tanks ≈417.3 m3

2.4. Major corollary equipment list of ZJ70DBS drilling rig

No. Description Qty Remarks

I Equipment of lifting system
JC70DB DW (including hydraulic disc API Spec 7K (parts and
1 1 set th
brake) components), the 5 edition
2 JJ450/45-K mast (including accessories) 1 set API Spec 4F, the 3rd edition
DZ450/10.5-G substructure (including
3 1 set API Spec 4F, the 3rd edition
accessories)
API Spec 8C, the 4th edition/4F,
4 TC450 crown block 1 set
the 3rd edition

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5 YC450 travelling block 1 set API Spec 8C, the 4th edition
6 DG450 hook 1 set API Spec 8C, the 4th edition
7 SL450 swivel 1 set API Spec 8C, the 4th edition
8 FMS-20 Pneumatic spanner 1 set
Drilling wireline 6×19S+IWRC EIPS
9 1 coil Right-handed
grade φ38
10 DQ450DBZ direct drive top drive 1 set
11 DH500 elevator link: L=144'' 1 pair
12 DH500 elevator link: L=190'' 1 pair
13 Deadline anchor JZG41 1 set
II Equipment of rotating system
1 RT ZP375 1 set API Spec 7K, the 5th edition
2 RT bushing 1 set
3 RT drive device 1 set
III Equipment of circulating system
API Spec 7K (parts and
1 HHF-1600 drilling mud pump 3 sets th
components), the 5 edition
2 Utilized mud pump 3 sets
3 Drilling fluid manifold 1 set
4 Cementing manifold 1 set
1 for
5 Rotary hose 35Mpa, 19m, 23m
each
6 Solids control system 1 set
Equipment of power and air supply
IV
system
1 Diesel generator set CAT 3512B(SR4) 4 sets
2 Auxiliary generator CAT 15 1 set
3 Camp generator CAT 15 2 sets
4 Generator and air supply house 1 set 5 buildings in total
5 Camp generator house 1 set 1 building in all
6 Air supply system 1 set
V Composite HPU 1 set
VI Electric drive and control system 1 set

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1 VFD house and MCC control system 1 set
2 Power cable 1 set
VII Equipment of driller's control system
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
VIII Standard electric system on well site 1 set
IX Detection instrument and tool
1 Detection instruments 1 set
2 Special tool 1 set
X Auxiliary equipment
1
1 Left and right doghouse building
for each
2 Cable Tray 1 set
3 Pneumatic casing stabbing board 1 set
4 Catwalk 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
XI Drill floor implement
1 YM-16-II hydraulic cathead 2 sets
One at catwalk and two at drill
2 5T air winch 3 sets
floor
3 0.5T air winch 1 set For monkey board
4 Logging winch CJ7000 1 set
5 BOP lifting device DZ550 1 set
6 Man-riding winch LS2-150RLP-L 1 set
7 DP power tong ZQ203-100 1 set
8 Casing tong TQ340-35 1 set

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3. Structural features of ZJ70DBS drilling rig

3.1. Overall structure of drilling rig

The drilling rig is divided into five parts: a drill floor area, a power area, a pump house
area, a solids control area and an oil and water supply area etc. After the drilling rig is
assembled, the floor area is about 88m×36m.
For the rig layout, please refer to attached drawing 1 rig plan and attached drawing 2 rig
elevation; for the rig drive principle, please refer to attached drawing 3 drive system diagram;
and for the rig foundation arrangement, please refer to attached drawing 4 rig 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, doghouse and all tools etc on drill floor
for drilling operation.
The power area comprises generator and air supply houses and electric control house. The
generator and air supply houses are installed and communicated with one another to form a
whole electricity generation and air supply area, and the electric control house and the
generator and air supply house are arranged on one side of the generator house near back field.
The pump house area comprises three HHF-1600 utilized mud pumps.
The solids control area is provided with mud tanks and mud processing equipment etc of
solids control system.
The oil and water supply area is provided with oil tanks and water tanks etc.
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.
Catwalk and DP rack are arranged in front of drill floor.

3.2. Structural features of drilling rig

ZJ70DBS drilling rig is designed by integrating mechanical, electrical and digital control
techniques, mainly achieves digital control function and primarily has automation,
intelligentization and informationization functions. All parts of the drilling rig adopt mature
and advanced techniques at home and abroad for structural design, work reliably, are moved
and transported conveniently, run economically and meet HSE requirements.
DW, RT and mud pump all adopt independent alternating-current variable frequency

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electric driving systems without mutual interference and can better meet drilling application.
Mast is a K type structure and meets the requirement of DQ450DBZ top driving devices,
and substructure is a slingshot type structure and is lifted by using the power of DW. 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 two reduction
boxes by using two 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
angle gear box and cardan shaft and provided with inertia brake. Control system has complete
monitoring and over-torsion protection functions.
Three 1600HP mud pumps are arranged, and each pump is driven by one
alternating-current variable frequency motor with high reliability and convenient displacement
regulation.
Power system is provided with four 1200kW diesel generator sets 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 and MCC 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

Motor speed Hook speed m/s Hook load kN Hook speed m/s Hook load kN
r/min (12 lines) (12 lines) (10 lines) (10 lines)
147 0.08 3495.56 0.10 3064.29
227 0.12 3495.56 0.15 3064.29
267 0.15 3495.56 0.17 3064.29
307 0.17 3495.56 0.20 3064.29
347 0.19 3495.56 0.23 3064.29
387 0.21 3495.56 0.25 3064.29
427 0.23 3495.56 0.28 3064.29
467 0.25 3495.56 0.31 3064.29
507 0.28 3495.56 0.33 3064.29
547 0.30 3495.56 0.36 3064.29
587 0.32 3495.56 0.38 3064.29
627 0.34 3495.56 0.41 3064.29
667 0.36 3495.56 0.44 3064.29
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707 0.38 3495.56 0.46 3064.29
747 0.41 3495.56 0.49 3064.29
799 0.43 3495.69 0.52 3064.40
838 0.46 3332.07 0.55 2920.97
916 0.50 3047.50 0.60 2671.51
1072 0.58 2602.37 0.70 2281.30
1150 0.63 2431.27 0.75 2131.31
1266 0.69 2129.74 0.83 1866.98
1424 0.78 1743.10 0.93 1528.04
1623 0.88 1362.89 1.06 1194.74
1865 1.02 1013.98 1.22 888.88
2109 1.15 744.03 1.38 652.24
2231 1.21 630.85 1.46 553.02

3.3.2 Lifting curve (12 lines)

3.3.3 Lifting capacity of auxiliary driving device (12 lines)

Max. lifting capacity: 2,474 kN (10lines), hook speed: 0.69m/min.
4. Rig installation
The installation of the drilling rig shall conform to the requirements of final assembly
process as well as the requirements in this manual.

4.1. Preparation work before installation

z Only trained and qualified persons can install the drilling rig with qualification
certificates.
z The personnel engaged in drilling rig installation, particularly the person in charge of
the installation shall first read this manual and user manuals of all parts to make
themselves know the structural features and the installation and commissioning
requirements of the drilling rig and its parts.
z 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.
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z Well site and foundation for installing the drilling rig shall accord with requirements
of drawing samples and technical files approved as per specified procedures.
z 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.
z 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

Mast
Generator and air supply house and
Substructure VFD house
DW

Crown block Standpipe of drilling fluid manifold Traveling block, hook

Overhead main
Driller's
cable tray of
RT and drive device Doghouse control cabin
substructure

Utilized Ground part of drilling Solids control Oil tank,

mud pump fluid manifold system water tank

Rig Lift mast and

commissioning Reeve wireline substructure Install top drive

Correct Wellhead mechanical

On-line commissioning
wellhead tool

Note: other auxiliary facilities can be crossways installed while ensuring safety and
available field.

4.3. Installation of all 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 refer to the User Manual of DZ450/10.5-G
Substructure for details)
Use wellhead centerline and the drawn lines of drill floor area as references, place the left
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and right base seats of the bottom layer basement of the substructure, connect the left and right
base seats into a whole, install all columns and tie rods of the middle layer, and finally install
DW beam, RT beam, setback beam, floors, A-frame and other auxiliary parts of the top layer.
Notice: the floors on two sides of the setback shall be installed after the substructure is
lifted; except the ladders to drill floor, the ramp and the ladders to solid control etc shall be
installed after the substructure is lifted.
4.3.2 Installation of generator and air supply house and VFD house (please refer to the plan of
generator and air supply house for details)
Place generator and air supply house and VFD house as per the plan of the drilling rig
and the lofting and marking positions. Place VFD house, generator and air supply house and
air supply equipment in sequence. Connect all generator and air supply houses into a whole.
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. Lift the DW onto the 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 transported as per transportation modules. The
RT driving device is 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 1.0mm.
4.3.5 Installation of mast (please refer to the User Manual of JJ450/45-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).

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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 refer to the User Manual of TC450 Crown Block for
details)
The mast is connected with the mast by bolts. The accessories of the crown block such as
auxiliary sheave, lifting frame and climbing assistantor etc shall be installed completely.
4.3.8 Place the wireline spooler as per the positions shown in the plan.
4.3.9 Install traveling block and hook, reeve hoisting wireline and drilling wireline (along 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 Mounting of cable tray
Install cable tray on drill floor and ground cable tray respectively 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 Manual of Electric System.
4.3.12 Installation of ground part of drilling fluid manifold
Install it as per the User Manual of Drilling Fluid Manifold, and connect it with the
standpipe part and the mud pump discharge pipeline.
4.3.13 Installation of solids control system
Install the mud tanks of the solid 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 Manual
of Solid Control System, and connect the communicating pipes among the tanks and the mud
pump suction pipelines.
4.3.14 Installation of standard electric system on well site (please refer to User Manual of
Standard Electric System on Well Site)
4.3.15 Installation of drilling instruments
Install the drilling instruments as per the requirements in the User Manual of Drilling
Instruments.
4.3.16 Installation of monitoring system and communication system
Install the monitoring system and the communication system as per the User Manual of
Electric Drive System and the elevation and the plan of the drilling rig (except the parts
installed after the mast and the substructure are lifted).

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4.3.17 Installation of auxiliary equipment
Install the auxiliary equipment as per the elevation and the plan of the drilling rig.
4.3.18 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 oil tanks and the water tanks.

4.4. Check after 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 Bolt nominal diameter/mm
strength 16 20 24 27 30 36 42
grade Pretension torque/N.m
8.8 185-259 361-505 623-873 919-1286 1243-1740 2178-3049 3492-4889
10.9 260-364 507-710 877-1227 1292-1809 1748-2448 3063-4289 4911-6875
4.4.2 Check after substructure installation
z The difference among the diagonal sizes of four support pin shaft holes at the inner
sides of the rear parts between the left and the right lower seat cannot be more than 5mm.
z Installation of every connector and fastener must be complete and fastened. Grease
pins at rotating parts.
z Every part shall not have serious deformation, and every weld shall not have crack
and opening.
z Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
z There is no barrier to block driller's eyesight on the drill floor.
z Buffering cylinders of substructure work normally.
z The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
4.4.3 Check after mast installation
z Grease every lubrication point as required.
z Installation of every connector and fastener must be complete and fastened.
z Every part shall not have serious deformation, and every weld shall not have crack
and opening.
z All auxiliary facilities assembled on the mast are complete and good.
z Buffering cylinders of mast work normally.
z Hoisting wireline and drilling wireline are complete and reeved correctly, and their
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ends are fastened tightly.
z No tools and stuffs are left on the mast.
z Weight indicator works normally.
4.4.4 Check after DW installation
z Check and ensure all guards are installed completely and pipelines are connected
correctly and reliably.
z Grease all lubricating points as required.
z Grease main speed reducer as per requirements in its user manual.
z 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.
z Check the wearing conditions of brake disc and brake block of hydraulic disc brake,
when the abrasion thicknesses reach ultimate value, replace them.
z Adjust the brake clearance of hydraulic disc brake to proper position as per the User
Manual of Hydraulic Disc Brake.
4.4.5 Check after crown block installation
Crown block is fixedly connected to the upper section of the mast and positioned by
positioning pins reliably.
4.4.6 Check after travelling block and hook installation
z The bolts and pins of the travelling block are complete and firm, and guards are
good.
z The hook body and the hook opening locking pin of the hook shall be operated
flexibly, and the safety locking pins of the hook bail are complete, safe and reliable.
4.4.7 Check after elevator link and swivel installation
z Elevator links have no crack and deformation.
z Swivel rotates flexibly, no oil and drilling fluid leakage during rotation.
z Rotary hose shall be provided with safety chain additionally.
4.4.8 Check after mud pump installation
z Install safety valve of mud pump as per required position, and ensure it works
normally.
z The pulsation dampener of mud pump is filled with nitrogen or air, and it is
forbidden to fill oxygen.
z The surface of mud pump pressure gauge is clean and accurate.
4.4.9 Check after drilling fluid manifold installation

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z All supports and pipe clamps are fixedly reliably. All unions are connected correctly
and sealed reliably.
z Valve hand wheels are complete, closed and opened flexibly without leakage.
4.4.10 Check after generating air supply house installation (except electric drive part)
z All connecting bolts are installed completely and fixedly. The pretension torque
meets requirements.
z All pipelines are clean, smooth, connected correctly, marked clearly and sealed
reliably without leakage.
z All pressure gauges are complete and good in effective period. Air line pressure is
adjusted to specified pressure.
z All pipelines and valves are good. Safety valves are sensitive and reliable.
z The guards of all drive parts are complete and good, and fixed firmly.
4.4.11 Check after cable tray installation
z All pipelines are connected correctly, clean and smooth inside. All joints are sealed
reliably without leakage.
z All cables and wires are arranged tidily, connected correctly and marked clearly.
4.4.12 Check after driller's control cabin installation
z 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.
z All instruments and meters are installed completely, sensitive and reliable.
4.4.13 Check after solids control system installation
z All connecting bolts, nuts, spring washers and split pins are complete and fixed. The
pretension torque of bolts meets requirements.
z All pipelines and valves are good without water leakage.
4.4.14 Check after electric control system and well site standard electric system installation
Check as per requirements in the User Manual of Electric Control System and Well Site
Standard Electric System.
4.4.15 Check after drilling instrument system installation
Check as per the related requirements in the User Manuals of Drilling Instruments.
Ensure all instruments to be sensitive and reliable.
4.4.16 Check after monitoring system and communication system installation
Check as per the related requirements in user manuals of monitoring system and
communication system.

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4.4.17 Check after auxiliary part installation
z Auxiliary parts are installed completely and are good.
z The bolts of the auxiliary parts are installed completely and firmly. All connecting
pins and safety chains are complete and good.
z 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 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 manuals.

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.
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.
z The diesel engine is started smoothly and runs stably at rated speed.
z The generator sets generate and output power stably.
z Synchronous operation loop control is normal.
z Short circuit, overcurrent, overfrequency, underfrequency and reverse power
protection functions are normal.
z All meters and indicator lamps have normal display.
Please refer to the User Manual of Diesel Generator Set for details.)

5.3. Power supply commissioning of VFD system

5.3.1 Preparation:

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z Check VFD and MCC systems and all AC VF motors in VFD house, the power and
control cables of electric appliances such as 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.
z 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 Supplying power to areas
z Supply power to driller's control cabin, all display screens are clear, touch screens are
sensitive, instruments are normal, and all switches work flexibly and reliably.
z Power up the AC VF motors on DW, start two main motors separately, check their
rotation direction and running conditions and the running condition of blower.
z Power up RT driving motor, check its rotation and running condition as well as the
running condition of blower.
z Power up the AC VF motors on mud pumps, and check their rotation direction of
running condition.
z Supply power to every lighting point and check its working condition.
z Power up composite HPU, start up motor, and check rotating direction and running
condition.
z Supply power to solid control system, check rotation and running condition of the
motor of the solid control equipment.
z Power up oil pumps and water pump of oil tank and water tank, and check rotation
and running condition.
z Supply power to other electric appliances and check their working condition.
(Please refer to User 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 cabin and PLC are logically correct. Bypass
assignment relationship of PLC is correct.
5.4.2 The functions of wind loss and locking protection for each 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 parking button is normal.
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5.4.7 Dynamic braking system of DW functions normally. (Commission with DW together)
(Please refer to User Manual of Electric Drive System for specific requirements.)

5.5. Commissioning of driller's control cabin, instrument and meter system

Please refer to User Manual of Driller’s Control Cabin and operation manuals of all
instruments and meters for detailed requirements. (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 commissioning 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.

5.6. Commissioning of air supply system equipment

Start up No.1 and No.2 electric screw compressor sets respectively and commission them
to operative mode as per requirements in manual. Check working condition of air supply
purification device and equipment, and air leakage and oil leakage are forbidden.

5.7. Commissioning of hydraulic system

Please refer to the User Manual of Hydraulic System and the User Manual of Hydraulic
Disc Brake Device.
5.7.1 Commission the composite HPU to working condition.
5.7.2 Commission the hydraulic disc brake to working condition.
5.7.3 Function commissioning for lifting cylinders of mast and substructure
5.7.4 Commission all hydraulic implements. (It can be performed after the mast and the
substructure are lifted.)

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5.8. Running commissioning of DW

Perform the following commissioning before wireline is reeved:

5.8.1 Commissioning before running
z Open the ball valve on the air tank at the back of the substructure to supply air to
DW.
z Start up lubrication pump of main reducing gear box to check whether all parts are
lubricated well.
z 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 action accuracy of hydraulic
disc brake system.
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:
z Start motor A of DW to check its rotation direction and make sure the rotation
direction of drum is the wire winding direction.
z Start motor B of DW to check its rotation direction and make sure the rotation direction of
drum is the wire winding direction.
z Check the pressure of lubrication pump and make it within 0.1-0.35Mpa.
z Start and run motors A and B of DW at a speed of 970r/min for 20min
respectively.
z Run the motors A and B of DW simultaneously, accelerate and decelerate the
motors by control handle, and check running condition.
z Start auxiliary drive motor to check its rotation direction and make sure the
rotation direction of drum is the wire winding direction. Adjust the motor by
increasing and decreasing speed to check its running condition.
z Braking test of hydraulic disc brake shall not be less than 5 times at different
speeds.
Note: the main motor on the side of driller is motor A, and main motor on the other
side is motor B.
5.8.2.2 Commissioning requirements:
z All operations are accurate and flexible.
z All parts are sealed well without seepage and oil leakage.
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z Lubricating oil pressure is stable, and the lubricant quantity is proper.
z Stable running, no abnormal vibration and sound.
z The bearings at all positions are normal in temperature rise.
z Hydraulic disc brake is flexible and reliable.
5.8.3 Reeving of wireline
z 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.
Notice: when the traveling block is put at the lowest position where the mast is lifted, the
initial wound wireline on the drum shall not be less than 13/4 layers.
z Hang the balance sheave on the hook as per the lifting device drawing, and then
reeve the wireline of the lifting system.

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 is in positive
rotation. 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 condition and the interlocking
condition of the motor.

5.10. Commissioning of utilized mud pump

(It can be performed after the mast and the substructure are lifted.)
Commission it to working state as per the requirements in the User Manual of HHF-1600
Utilized Mud Pump.

5.11. Mast and substructure lifting and mast alignment

(Please refer to the user manuals of mast and substructure for details.)

5.11.1 Check before mast lifting

z Before mast lifting, check the parts which have been already installed as per clause
4.4.4 to ensure all parts are installed correctly and connected reliably.
z The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
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z The air supply system and the pneumatic control system are normal, and the pressure
of the air tank is not less than 0.8MPa.
z The DW is commissioned and qualified, and runs for at least two hours normally.
z Overturn and fix the operation platform of the monkey board.
z Place the tong counterweight to low position.
z Check the hook for complete locking.
z Check again the buffer device for normal working.
z The sheave bearing of all raising lines shall be greased in accordance with the
requirement. The sheave must rotate freely.
z Check the mast for left workpieces or tools and the safety facilities for completeness
and reliability.

5.11.2 Trial lifting of mast

z The lifting work must be commanded by a commander. The position where the
commander is must be seen by driller and must be safe.
z Before mast lifting, all persons and construction machinery must be in safe zone except
rear personnel in cabin, driller, personnel observing key parts, safety officer and the
commander.
Safety distance: the distance between position dead ahead and wellhead shall not
be less than 70m, and distance from two sides to two sides of mast shall not be less than
20m.
z Mast can be lifted at a low speed by main motor or mast can be lifted by auxiliary
motor.
z 6.2.3 Tension wire line gradually at a low speed during mast lifting. After make sure
there is no sticking for wire line, lift mast to leave high stand 100mm-200mm and
observe whether lifting tensile force is more than rated value (178t) or not. Brake to
ensure there are no sticking and winding for auxiliary drilling wireline, deadline of
drilling wireline, pipes and wires, put mast back to its position, and check whether
hoisting wireline is complete or not. Welding joints of lifting padeye shall not have
cracks.
z After checking, lift the mast again. When the mast is 200mm-300mm away from the
tall stand, brake DW, and stay for 5min-10min. Check the fixed end of hoisting
wireline and deadline of drilling wireline, they shall be fixed completely and tightly;
check the bearing components of the key part of the substructure such as rod piece and
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A-frame for deformation, the welding joints shall not have cracks; and check height of
substructure lifted to judge whether the counterweight t is enough or not.
z Lower the mast to the tall stand slowly, put travelling block to the location which is
100mm-200mm away from a supporting surface, and fasten the fixing and connecting
components of crown block and connecting bolts of mast support again.
z Lift the mast again, when the mast is 200mm-300mm away from the tall stand, brake
DW. After staying for 5min, lower the mast slowly to the tall stand, and put travelling
block to the location which is 100mm-200mm away from the supporting surface.

5.11.3 Lifting of mast

z Operate the control valve of the mast buffer device, completely stretch out its piston
rod, and maintain oil cylinder pressure (3-5MPa).
z During the lifting, run the DW at a low speed, and control the hook speed at about
(0.8-1.2)m/min.
Notice: the DW shall run stably at a uniform speed. It is forbidden to brake or accelerate
in the process.
z When the mast is lifted to 75-80 degrees or the mast is about 2m away from the piston
head of the buffer device, decelerate the DW, slowly make the mast slowly approach
the piston head of the buffer device, and operate the buffer device, remove the DW
power when the center of gravity of the DW is over the front leg of the mast, and
slowly place the mast in place.
z After the mast is placed in position, slightly tense the hoisting wireline and connect
mast with A-frame and substructure tightly.
z After the traveling block and the hook are lowered at low positions, remove the
connecting pins of hoisting wireline, hang, place and fix the hoisting wireline of the
mast at positions as required.

5.11.4 Check before substructure lifting

z 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.
z The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
z Check again the buffer device for normal working.
z The sheave bearings of all raising lines shall be greased in accordance with the

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requirement. The sheave must rotate freely.
z Check again whether the connecting pins between the upper layer and the bottom layer
basement have been removed.

5.11.5 Lifting of substructure

z While lifting the substructure, tension the wireline gradually at a low speed, lift the
substructure 100-200mm away from the installation position, simultaneously observe
whether the lifting pull exceeds a specified value (175t), brake and stay for at least
5min. Check whether the ends of the hoisting wireline and the dead line of drilling
wireline are fixed normally. The auxiliary drilling wireline, all pipelines and electric
leads etc shall be hung and wound, and then put the substructure back to its original
position.
z After check, lift the substructure again. When the substructure is 200mm-300mm
higher than the installation position, brake DW, stay for 5min-10min. Check the ends
of the hoisting wireline and the deadline of the drilling wireline, which shall be fixed
completely, firmly, and reliably without looseness, and check the stress rods and the
bearing components at the key parts of the substructure, which shall not deform, and
the weld joints shall not crack.
z During the lifting, run the DW at a low speed, and control the hook speed at about
(0.8-1.2)m/min.

Notice: the DW shall run stably at a uniform speed. It is forbidden to brake or

accelerate in the process.

z When the substructure is lifted to 75-80 degrees or the piston head of the buffer is
about 0.5m away from the A-frame, decelerate the DW, make the piston head of the
buffer device of the substructure approach the A-frame, and then operate the buffer
device, and make the substructure placed in place slowly when the piston begins
shrinking.
z After the substructure is located in place, connect and tight it in time.
z After the traveling block and the hook is placed at low positions, remove the
connecting pins of hoisting wireline, hang, place and fix the hoisting wireline of the
substructure at positions as required.

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5.11.6 Mast alignment

z 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 refer to the User Manual of Mast.)
z Make sure to make the mast in natural status while aligning it.

5.12. Parts installed after mast and substructure lifting

5.12.1 Wellhead mechanical tools

5.12.2 Well control device
5.12.3 Ladders from drill floor to solid control system
5.12.4 Other parts of the substructure, such as safety slide, V door ramp, catwalk and drill pipe
racks etc.
5.12.5 Swivel, connect it with rotary hose
5.12.6 Other auxiliary parts

5.13. Commissioning of drilling instruments

5.13.1 Check whether the sensors are installed properly and cables and pipelines are connected
correctly or not.
5.13.2 Calibrate the display and indicating instruments as per the requirements and
specifications of manuals.

5.14. Adjustment of wireline on DW drum and test of crown block saver

5.14.1 Adjust the wireline on the DW drum, and ensure there are at least 9 cycles of initial
wound wireline on the drum always.
5.14.2 Commissioning of anti-collision toggle valve device
Adjust the position of the toggle valve, so that it acts when 28m stand is lifted and the
lower end surface of the stand is 2m away from the drill floor, make the hydraulic disc brake
braked urgently for stopping the DW drum, now check its reliability.

5.15. Test of hydraulic and pneumatic tools

Test them as per respective operation manuals.

5.15.1Run test of hydraulic cathead

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5.15.2 Test of running, lifting capacity and braking of pneumatic DW

5.16. Run test of solids control system

5.16.1 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.
5.16.2 Power-on running test of solids control equipment
z Carry out power-on trial test on shale shaker, desilting and desanding cleaners and
vacuum degasser respectively; they shall run normally.
z Carry out power-on running test on agitator, charging pump and mixing pump
respectively, they shall run normally.

5.17. Test of high-pressure manifold

Please see User Manual of High Pressure Manifold for details.

5.18. Check of standard electric system on well site

5.18.1 Check various sockets and plugs for reliable connection, check whether they meet
explosion-proof requirements and conform to technical standard requirements of API or not.
5.18.2 Power on every area to check whether the motors of equipment, lighting lamps, every
explosion-proof distribution box and control box work normally or not.

5.19. Test of monitoring and communication systems

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.

5.20. Online test of drilling rig

Start DW, mud pump, RT and solid control system to carry out test on the whole drilling
rig for linkage performances.

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6. Operation and maintenance of drilling rig

6.1. Warnings

6.1.1 Operate the drilling rig following its user manual and 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.

6.2. Precautions for drilling rig operation

6.2.1 Select the generator sets with proper power to match the power requirements as per
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 In the operation, when the drilling string is heavier than 1300KN, the DW is driven by

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two main motors better. When one main motor of the DW goes wrong and cannot be used, a
single main motor can be used for hoisting the max. weight 2,520kN of drilling string at a low
speed.
6.2.6 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 lubricating
oil/grease for each part meet the requirements, and supplement or replace the lubricating oil as
per the regulated operation period.
6.2.7 Periodically check the drive belt of mud pump for looseness and adjust in time.
6.2.8 Check inflation pressure of mud pump discharge pulsation dampener periodically.
6.2.9 All ladders, handrails and guards shall be firm and reliable without looseness.
6.2.10 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.
6.2.11 Check the hydraulic cylinders of mast and substructure for working reliability.

6.3. Safety techniques for drilling rig operation

6.3.1 Requirements on drilling rig operation

z 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.
z Only trained and qualified persons can operate and maintain the drilling rig with
qualification certificates.
z The operators must follow the safety operation regulations.
z The lifting speed and lifting capacity of drilling rig must be in conformity with
related regulation in the User Manual of DW.
z The displacement and pressure of mud pump must be in conformity with the related
regulation in the User Manual of HHF-1600 Drilling Pump.
z When any part of the drilling rig goes wrong, stop using the part and treat faults, and
use it again after troubleshooting.
z 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.
6.3.2 It is forbidden to operate the drilling rig, and repair it in time when it is in one of
following conditions:
z The drilling rig is used at overload and overspeed.
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z The steel structures of the mast and the substructure deform or crack.
z The foundation of the substructure sinks or ruptures.
z Brake and drive systems are out of control.
z The safety valve and the air charging of pulsation dampener of mud pump are not in
conformity with requirements.
z The crown block savers fail during tripping.
z The instruments of the drilling rig are damaged or have no metering function.
z The pneumatic control system fails or air supply pressure is lower than the allowed
range.
z Guards and handrails are incomplete.
z Oily substances enter the surfaces of brake disc, brake huh and clutch steel hub.
z The hoisting wireline and the drilling wireline are not checked as required.
6.3.3 All operators are forbidden to perform the following operation
z Run the components of drilling rig over load, over speed, over temperature and over
pressure.
z Check and repair equipment without cutting off the power source and the control
source of the drilling rig.
z Make up threads with RT
z Adjust the brake when the hook is loaded.
z 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
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 unavailable to satisfy the drilling operation
requirements through technical detection, they shall be repaired on service base.
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The periodical maintenance regulations of the drilling rig are as follows:
6.4.1 The routine maintenance items of mast and substructure:
z Lifting components shall not crack and deform.
z No corrosion for wire rings and slings and no corrosion traces near the near ends.
z The lifting wireline shall be good without damage.
z Lubrication of sheave system is favorable.
z All pins shall be installed in place and safety pins are complete.
z The joints of all bolts must be firm and reliable.
z 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.
z Before lifting and lowering, check the buffer device and the hydraulic system for
completeness and sufficient oil supply.
z In any condition, it is not allowed to remove the cross and inclined tension beams
and other components on mast.
z It is not allowed to drill holes and cut holes or weld all components of the steel
structures.
z 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
z The test of the braking function and anti-collision performance of the DW shall be
safe and reliable.
z The reliability of the electric appliances on the driller's control console and the
sealing performances of all pneumatic control and hydraulic pipelines.
z The ends of the deadline and the fastline are fixed reliably.
z The lubrication and sealing performances of all bearings are favorable.
z 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.
z The favorable seal of all sealed positions of swivel, RT and DW and the conformity
of the oil amount and oil temperature with requirements.
z The flexibility and reliability of the stop pin of RT.
6.4.2.2 Weekly maintenance and check items
z The oil supply of the lubrication pump of DW, the cleanness of lubrication oil, and

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the cleaning and the replacement of filter elements of filters.
z The flexible rotation of the bail and pin of swivel.
z The fixation of traveling block shaft.
z The wear of the sheave grooves of crown block and traveling block.
z The seal of the washing pipe packing of swivel.
z The fixation of the cardan shaft of RT.
6.4.2.3 Monthly maintenance and check items
z The connection and wear of clutch, coupling and cross sub of cardan shaft.
z Cracks of bail, pin and sheaves of lifting system.
6.4.3 Mechanical drive system
6.4.3.1 Shift maintenance and check items:
z Adjust the tension of the drive belt, check the temperature, temperature rising and
noise of gear box and rotating part.
z Check the lubrication oil of the gearbox for quality, amount, pressure and
temperature.
6.4.3.2 Weekly maintenance and check items:
z Running condition of oil pump and cleaning of filter.
z Check the wear of clutch.
6.4.3.3 Monthly maintenance and check items:
z Check all driving parts completely. Including clutch, coupling and universal shaft etc.
z Check the gear meshing of gearbox.
z Measure the quality of the oil in oil bath.
6.4.4 Circulating system
6.4.4.1 Shift maintenance and check items:
z The operation status of the power end of mud pump, check the tightness of drive belt
of pump and the temperature rise of each bearing.
z The suction performance of fluid end of mud pump, the sealing, cooling and
lubrication of piston, liner, tie rod etc.
z The pressing reliability of the cylinder lids and valve caps of mud pumps.
z The working condition of charging pump and spraying pump.
z Conformity of charging pressure of pulsation dampener and safety valve with
requirements.
z The fixation of high pressure manifold and the flexibility of high pressure valve etc.
z The working condition of solid control equipment, and the temperature rise and the

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insulating property of motor.
6.4.4.2 Weekly maintenance and check items:
z Check and clean lubrication oil filters.
z Lubrication and wear of crosshead and guide plate.
z The flexibility of action of safety valve.
z The insulation condition of circuits.
z The smoothness of spray nozzle of mud gun.
6.4.4.3 Monthly maintenance and check items:
z The meshing condition of gears at power end of mud mump, and check and adjust
the gap of the crosshead.
z Check the high pressure pipe through non-destructive test.
z Fasten connecting valve bolts of mud pump and clean oil sump.
6.4.5 Air supply system
6.4.5.1 Shift maintenance and check items:
z No abnormality during the startup and the stop of air compressor, and conformity of
oil quality, oil amount and oil temperature with requirements.
z Check the automatic pressure regulating device and the safety valve for conformity
with requirements.
z Check the working pressure of air tank and discharge water for pollution discharge.
z Check the smoothness and the favorable seal of pipelines.
6.4.5.2 Weekly maintenance and check items:
z Check the working condition of air filter without blockage.
z Check safety valve and sequence valve.
6.4.5.3 Monthly maintenance and check items
z Clean filter and safety valve of air tank.
z Check control valves of compressor.
z Check control valves of dryer.
6.4.6 Driller's control cabin
(Please refer to the User Manual of Driller's Control Cabin.)
6.4.7 Electric Drive system
(Please refer to the User Manual of Electric Drive System)

6.5. Operation and maintenance during algid stage

6.5.1 High pressure mud system

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z Check valve chamber, circulating manifolds and valves for no icing before the
startup of mud pump.
z Check mud tanks, connecting lines and valves for no icing before the startup of mud
circulating system.
z Check water tanks, connecting lines and valves for no icing before the startup of
water supply system.
z 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.
z After mud circulating system stops, drilling fluid in mud tank and connecting lines
shall be discharged completely.
z After water supply system stops, water in water tanks and connecting lines shall be
discharged completely.
6.5.2 Lubrication system
z Lube oil and grease shall be selected as required.
z 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 air temperature is lower than -20℃ (average value of monthly lowest
temperatures), 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.

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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
z Grease every lubrication point as required. Grease pins at rotating parts.
z Installation of every connector and fastener must be complete and fastened.
z Every part shall not have serious deformation, and every weld shall not have crack
and opening.
z Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
z There is no barrier to block driller's eyesight on the drill floor.
z Buffering cylinders of substructure work normally.
z Buffering cylinders of mast work normally.
z Hoisting wireline and drilling wireline are both in good condition, and their ends are
fastened tightly.
z No tools and stuffs left on the mast.
z Weight indicator works normally.
7.1.2 Lowering of substructure
When lowering the substructure, firstly move the substructure to diverge from the center
of gravity by the buffer cylinders, the DW reversely drag the substructure and the substructure
is lowered by its dead weight. Pay attention to the following items when lowering the mast:
Dismantle all components affecting the lowering of the substructure such as the ramp,
ladders and sliding board etc.
Control lowering speed, lower the substructure slowly at a uniform speed, and it is
forbidden to speed up or brake suddenly.
7.1.3 Lowering of mast:
Before mast lowering, hang balancing shave, remove casing platform and components or
accessories obstructing the lowering of mast. Push mast to deviate from gravity center by
buffer oil cylinder, and DW reversely drags the mast so that mast is lowered by dead weight.
Pay attention to the following items when lowering the mast:
Control lowering speed, lower the mast slowly at a uniform speed, and it is forbidden to
speed up or brake suddenly.

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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.
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 MCC house 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.

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8. Lubrication table for main components
No. Filing
amount
Part name Position Oil spec. Maintenance period
for new
equipment
Drum shaft, Ambient temperature
coupling above -20℃, NLGI 2 Each 15 running days 2 kg
grease lubrication lithium base grease
Ambient temperature
-20℃ to +50℃, ISO
VG 150 medium and
extreme pressure gear
oil. When the oil level is
1 DW Ambient temperature: below the mark, add
Gear reducer box
-10℃ to +40℃, ISO oil in time.
or chain drive oil 500 L
VG 220 medium and Replace the lubricating
tank
extreme pressure gear oil completely each 6
oil lubrication
oil. months or when the oil
Ambient temperature: is polluted.
+10℃ to +60℃, ISO
VG 320 medium and
extreme pressure gear
oil.
FAG-Arcanol L135V Replace the grease
2 Motor lubrication grease completely every 3 290 g
Bearing
years or when the
grease is polluted.
Before lifting and
All sheave lowering mast and
bearings substructure every
Mast Ambient temperature
3 time 200 g
above -20℃, NLGI 2
Substructure Before installing and
lithium base grease
Pins and padeye disassembling mast
holes and substructure each
time
Ambient temperature
4 Crown block Sheave bearings above -20℃, NLGI 2 Each 7 running days 500g
lithium base grease
Ambient temperature
5 Travelling block Sheave bearings above -20℃, NLGI 2 Each 7 running days 500g
lithium base grease
Ambient temperature
Bail pin, pins 200g
above -20℃, NLGI 2 Each 7 running days
Thrust bearing
lithium base grease
6 Hook Ambient temperature: When the oil level is
-20℃ to +50℃, ISO below the mark, add
Oil pool VG 220 medium and oil in time. Replace all 20L
extreme pressure gear lubrication oil after
oil. every well is drilled.
medium and extreme
pressure gear oil.
Each two running
Main oil pool Ambient temperature 200g
7 Swivel months
-20℃ to +50℃, ISO
VG 220
Bail pin, washing Ambient temperature Each 72 running hours 200g
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 User Manual of ZJ70DBS Drilling Rig
pipe packing, above -20℃, NLGI 2
bracket and lithium base grease
lower cover oil
seal
Ambient temperature:
-20℃ to +50℃, ISO
Each two running 200L
Main oil pool VG 220 medium and
months
8 ZP375 RT extreme pressure gear
oil.
Ambient temperature
Locking device above -20℃, NLGI 2 Each 7 running days 100g
lithium base grease
medium and extreme
pressure gear oil.
Ambient temperature When the oil level is
-20℃to +10℃, ISO below the mark, add
Gear reducer box VG 150 oil in time.
9 or chain drive oil
RT drive device Ambient temperature Replace the lubricating 200 L
tank, oil
-10℃ to +40℃, ISO oil completely each 6
lubrication
VG 220 months or when the oil
Ambient temperature is polluted.
+10℃ to +60℃, ISO
VG 320
Ambient temperature
RT drive cardan
10 Bearing, spline above -20℃, NLGI 2 Each 72 running hours 100g
shaft
lithium base grease
Ambient temperature
-20℃ to +10℃, ISO
VG 150
medium and extreme
pressure gear oil.
Ambient temperature: When the oil level is
-10℃ to +40℃, ISO below the mark, add
oil in time.
Machine oil pool, VG 220 medium and 350L
Replace the oil
oil lubrication
HHF-1600 mud extreme pressure gear completely every 6
11 months or when the oil
pump oil. has been polluted.
Ambient temperature
+10℃ to +60℃, ISO
VG 320
medium and extreme
pressure gear oil.
Ambient temperature
Transmission above -20℃, NLGI 2 400g
Each 15 running days
device bearing
lithium base grease
Ambient temperature
12 Air winch Oil pool Replace once a month 2L
-20℃ to +50℃, ISO

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 User Manual of ZJ70DBS Drilling Rig
VG 220
medium and extreme
pressure gear oil.
Ambient temperature
Gears and all
grease lubrication above -20℃, NLGI 2 Each 7 running days 600g
points lithium base grease
Ambient temperature
When the oil level is
-30℃ to +50℃, ISO
below the mark, add 0.2 L
Oil sprayer
VG 46, ISO HM oil in time.
hydraulic oil
Ambient temperature
above -20℃, Replace all lubrication
Sheave bearings grease after every well 400g
NLGI 2 lithium base
13 Deadline anchor is drilled.
grease
Transformer oil with
Weight indicator Fill while correcting Proper
sensor pipe ISO viscosity of 8.7 weight indicator

14 All wirelines Wireline surface Wireline surface grease As per use condition Proper

Ambient temperature: Replace the hydraulic

-30℃ to +50℃, ISO oil completely every 6 80L
Oil cylinder
YM-16-II VG 46, ISO HM months or when the oil
15 hydraulic oil is polluted.
Hydraulic cathead
Ambient temperature Each 7 days
Sheave above -20℃, NLGI 2 100g
lithium base grease
Ambient temperature: Replace the hydraulic
-30℃ to +50℃, ISO oil completely every 6
16 Composite HPU Oil tank of HPU VG 46, ISO HM months or when the oil 1000L
hydraulic oil is polluted.

Oil and gas Please refer to the

17 Compressor separating Compressor oil User Manual of
cylinder Compressor
Ambient temperature Please refer to
above -20℃, API Operation Manual of
18 Generator set Diesel engine CH-4(CG-4)SAE Generator Set.
15W-40 diesel engine
oil

Explanation: the listed lubrication oil in this table is recommended. According to ISO viscosity
grade requirements, it is necessary to use the specified 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.

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 User Manual of ZJ70DBS Drilling Rig

9. Main part bearing model summary list

Part
No. Position Spec. Code Model Qty
name
Crown block
Φ304.8×Φ393.7×107.95 37961K 7
Crown sheave
1
block
Auxiliary sheave 80×170×39 GB283-81 42316 2

Travelli
Travelling block
2 ng Φ254×Φ347.66×101.6 37951K 6
sheave
block
Hook load
3 Hook Φ180×Φ360×82 GB4663-1994 87436ZW 1
bearing

Load bearing Φ270×Φ550×130 GB299-64 91754Q4 1

Anti-jump bearing Φ200×Φ310×70 GB297-94 32040 1

4 Swivel
Upper and lower
alignment Φ240×Φ360×56 GB283-94 NU1048 1
bearings

Load bearing Φ1050×Φ1270×220 2687/1049 1

5 RT Horizontal shaft Φ150×Φ320×108 GB/T283-94 NU2330E 1

Horizontal shaft Φ150×Φ320×108 GB/T288-94 22330C 1

Drum shaft
6 DW Φ240×Φ400×128 SKF 23148CA 2
assembly
Crosshead bearing Φ285.75×Φ206.375×222.25 254941QU 3
Pinion shaft
Φ350×Φ220×98.42 4G32844H 2
Drillin bearing
7 g mud Main bearing of
Φ500×Φ300×160 3G3003760HY 2
pump crankshaft
Eccentric wheel
Φ863.6×Φ660.4×107.95 929/660.4QU 3
bearing
Pump Small belt pulley
8 drive Drive shaft 150×270×73 SKF 22230C 2
device assembly
9 Please refer to all bearings for rest components in respective user manuals.

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 User Manual of ZJ70DBS Drilling Rig
10. User manuals list
No. Description
1 User Manual of ZJ70DBS Drilling Rig
2 User Manual of DZ450/10.5-G Substructure
3 User Manual of JJ450/45-K Mast
4 User Manual of TC-450 Crown Block
5 User Manual of YC-450 Traveling Block
6 User Manual of DG-450 Hook
7 User Manual of JC70DB DW
8 User Manual of ZP375 RT
9 User Manual of RT Drive Device
10 User Manual of HHF-1600 Mud Pump
11 User Manual of Mud Pump Drive Device
12 User Manual of Solids Control System
13 User Manual of Pneumatic Control System
14 User Manual of Hydraulic System
15 User Manual of Electric Drive System
16 User Manual of Driller's Control Cabin
11. Attached drawings of drilling rig
Attached drawing 1 Plan of ZJ70DBS Drilling Rig
Attached drawing 2 Elevation of ZJ70DBS Drilling Rig
Attached drawing 3 Drive System Drawing of ZJ70DBS Drilling Rig
Attached drawing 4 Foundation Drawing of ZJ70DBS Drilling Rig

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 User Manual of ZJ70DBS Drilling Rig
Attached drawing 1 Plan of ZJ70DBS Drilling Rig

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 User Manual of ZJ70DBS Drilling Rig
Attached drawing 2 Elevation of ZJ70DBS Drilling Rig

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 User Manual of ZJ70DBS Drilling Rig
Detail list
No. Drawing No. (code) Description Spec. Qty
1 TC087.00 Crown block TC450 1
2 JJ102.00 Mast JJ450/45-K 1
Wireline
3 6×19S+IWRC EIPS %%C38, L2200m 1
(right-handed)
4 DQ004.00 Top drive DQ450DBZ 1
5 Escaping device RG10D 1
6 0.5t air winch JQH-5×48 1
7 Falling arrester HW5-12/AH5 3
8 JC059.00 DW JC70DB 1
9 DZ190.00 Substructure DZ450/10.5-G 1
10 YC003.00 Travelling block YC450 1
11 DG003.00 Hook DG450 1
12 SL001.00 Swivel SL450 1
13 JDH001-01 500t Elevator link DH500, L=144'' 1
14 JDH001-08 500t Elevator link DH500, L=190'' 1
15 Deadline anchor JZG41 1
16 BOP lifting device DZ550 1
17 Man-riding winch LS2-150RLP-L 1
18 ZB054.00 RT drive device 1
19 DP power tong ZQ203-100 1
20 Driller's control cabin 1
21 ZY063.00 Composite HPU 1
22 Hydraulic cathead YM-16Ⅱ 2
23 ZGF064.00 Doghouse 1
24 DLC202.00 Cable tray 1
Generator and air
25 FDF149.00 1
supply house
Pneumatic control
26 ZJ103.51.00 1
system

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 User Manual of ZJ70DBS Drilling Rig
VFD/MCC house and
27 1
electric drive system
28 YG013.00 Oil tank 75m3 1
29 MD248.00 Catwalk 1
30 ZGJ003.00 DP rack 8
Electric wireline
31 DS005.00 1
spooler
Air winch (low
32 XJFH-5/35L 3
support)
33 RT non-slip mat 1
Hydraulic casing
34 TQ340-35Y 1
power tong
35 Logging winch CJ7000 1
36 ZGF085.00 Tool house 1
37 GK158.00 Solids control system 1
Drilling fluid
38 GH269.00 1
manifold
Electric system on
39 1
well site
General assembly
40 ZJ368.50.00 1
fittings
41 BZ021.00 Utilized mud pump 3
42 SHG019.00 Industrial water tank 80m3×2 2
Camp generator
43 FDF150.00 1
house

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 User Manual of ZJ70DBS Drilling Rig

Attached drawing 3 Drive System Drawing of ZJ70DBS Drilling Rig

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 User Manual of ZJ70DBS Drilling Rig

Attached drawing 4 Foundation Drawing of ZJ70DBS Drilling Rig

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 ZJ70DBS 钻机用户手册

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