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ZJ70DBS DRILLING RIG

March, 2010
Table of Contents

Foreword...........................................................................................................................................................1
1. Safety warning..............................................................................................................................................2
2. Introduction ..................................................................................................................................................2
2.1 Purpose and applicability .........................................................................................................................2
2.2 Standards and specifications for the design and construction ..................................................................2
2.3 Major technical specification ...................................................................................................................3
2.4 ZJ70DBS rig major corollary equipments list..........................................................................................3
3. ZJ70DBS rig structure features ..................................................................................................................6
3.1 Rig general structure ................................................................................................................................6
3.2 Rig structure features ...............................................................................................................................6
3.3 Hook speed and hoisting capacity............................................................................................................7
4. Rig installation..............................................................................................................................................8
4.1 Preparation of rig installation...................................................................................................................8
4.2 Installation sequence chart .......................................................................................................................9
4.3 Installation of each part............................................................................................................................9
4.4 Inspection after the drilling rig being installed ......................................................................................12
5. Rig commissioning .....................................................................................................................................15
5.1 Preparation before commissioning.........................................................................................................15
5.2 Commissioning of diesel generator set ..................................................................................................16
5.3 VFD system power supply commissioning............................................................................................16
5.4 Commissioning of electric transmission system ....................................................................................17
5.5 Commissioning of driller cabin, instruments and meters system..........................................................17
5.6 Commissioning of air-supply system equipments..................................................................................18
5.7 Commissioning of hydraulic system ......................................................................................................18
5.8 Commissioning of drawworks ...............................................................................................................18
5.9 commissioning of the rotary table..........................................................................................................19
5.10 Commissioning of Mud Pump Set .......................................................................................................19
5.11 Mast and substructure lifting, mast alignment .....................................................................................20
5.12 The parts to be installed after the mast and substructure being lifted ..................................................22
5.13 Adjustment of drilling instruments.......................................................................................................23
5.14 Adjust the winding of drawworks drum and test the crown block saver..............................................23
5.15 Test of hydraulic and pneumatic tools..................................................................................................23
5.16 Running test for solid control system...................................................................................................23
5.17 Test on high pressure manifold ............................................................................................................24
5.18 Inspection of the standard electric system on well site ........................................................................24
5.19 Drilling rig monitoring and communication system test......................................................................24
5.20 test of the top drive device ...................................................................................................................24
5.21 Test of the drilling rig final assembly...................................................................................................24
5.22 rig Moving test.....................................................................................................................................24
6 Operation and maintenance of drilling rig ...............................................................................................24
6.1 Warnings ................................................................................................................................................24
6.2 Precaution for rig operation ...................................................................................................................25
6.3 Safety rules of rig operation...................................................................................................................25
6.4 Maintenance regulations of rig...............................................................................................................27
6.5 Accident and emergency treatment ........................................................................................................30
7. Dismantling and transportation of drill rig .............................................................................................30
7.1 Lowering of mast and substructure ........................................................................................................30
7.2 Dismantling............................................................................................................................................31
7.3 Transportation ........................................................................................................................................32
8. Main components lubrication of ZJ70DBS rig ........................................................................................32
9. Bearing model list of main components....................................................................................................35
10. The drilling rig operation manuals list...................................................................................................36
11 Attached drawings of drilling rig .............................................................................................................37
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Foreword
The drilling rig ZJ70DBS is designed and manufactured as per the requirements of Chinese

petroleum professional standard SY/T5609-1999 "Types and basic parameters for oil drilling rigs and

related API specification. It is a kind of rig, which can satisfy the requirement for middle depth well

drilling for oil and gas exploration and development.

This manual has described generally the rig structure, performance feature, technical parameters,

installation and commissioning, operation and maintenance, dismantlement and transportation of the

drilling rig etc.

Before the installation, the operators shall read the operation manual and the operation manuals of

matched components carefully, and install, operate and maintain the drilling rig accordingly. Without

understanding of concerned content, mistakes made when performing installation, operation or

maintenance may lead to personal injury or equipment damage.

The front and rear of drilling rig are determined by this: wellhead is in the front, power engine

house is in the back.

The left and right of drilling rig are determined by the direction from wellhead to power engine

house.

There is an ex-factory code for each drilling rig, please point out the ex-factory code when you

order the spare parts and inquire the related things.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

1. Safety warning
z The personnel who is occupied in installation, operation and maintenance should be trained and
qualified, and carry out the work with operation qualification certificate.
z Personnel of installation, operation and maintenance must read this manual and all the operation
manuals of all equipments belonging to the rig carefully before their installation, operation and
maintenance; and install, operate and maintain rig according to the requirements specified in the
manuals.
z There must be a chief principal for installation, operation and maintenance; and persons who
participate in the work should be assigned clearly; and detailed and reliable safety measures should
be taken.
z Personnel should strictly follow operating rules and security control regulations when operate the
rig.
z It is forbidden to maintain and repair the equipment during its operation.
z It is forbidden to overload the equipment.

2. Introduction

2.1 Purpose and applicability


This ZJ70DBS rig is designed and manufactured as per SY/T 5609-1999 Types and basic
parameters for oil drilling rigs, API specification and related standards. It can satisfy the requirements of
middle depth well drilling operation for land oil and gas exploration and development at the ambient
temperature above -18~+55 and the humidity 98% (+20).

2.2 Standards and specifications for the design and construction


2.2.1 SY/T5609-1999 "Types and basic parameters for oil drilling rig".
2.2.2 Edition 3 of API Spec 4F-2008 Specification for Drilling and Well Servicing Structures
2.2.3 Edition 4 and Supplement 1 & 2 of API Spec 7K-2005 Specification for Drilling and Well
Servicing Equipment
2.2.4 Edition 4 of API Spec 8C-2003 " Specification for Drilling and Production Hoisting
Equipment"
2.2.5 API Spec 9A-2004 Specification for Wire Rope
2.2.6 AWS D 1.1-2008 Structural Welding Code-Steel
2.2.7 Edition 2 of API RP 500 Classification of Locations for Electrical Installation 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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

2.3 Major technical specification


Nominal drilling depth4 1/2(114mm) DP 4500-7000m
5(127mm) DP 4000-6000m
Max. hook load 4500kN
Weight of Max. drill string 2200kN
Drawworks Max input power 2000kW
Number of hoisting system lines 67 Reeve In parallel
Dia. of wireline 38mm (1 1/2)
Mud pump power Number 1600HP3
Nominal opening dia. of RT 952.5mm37 1/2
Mast effective height/type 45.72m/K type
Drill floor height 9m
Clear height of substructure 7 .6 m
Number of hoisting gear one gear, stepless speed regulation
Number of RT gear one gear, stepless speed regulation
Main diesel generator set powerQty. 1200kW4
Auxiliary diesel generator set powerQty. 320kW2
Drilling fluid manifold I.D./rated pressure dual standpipe 4/35MPa
Total volume of mud tanks 417 m3

2.4 ZJ70DBS rig major corollary equipments list


No. Name Qty. Note
Hoisting system equipments
Edition 4, API
1 JC70DB Drawworkshydraulic disc brake included 1
Spec7K (Parts)
Edition 3, API
2 JJ450/45-K11 Mastaccessories included 1set
Spec 4F
Edition 3, API
3 DZ450/9-S1 substructureaccessories included 1set
Spec 4F
Edition 4, API
4 TC450 Crown block 1 Spec 8C/Edition
3, 4F
Edition 4, API
5 YG450 Traveling block 1
Spec 8C
Edition 4, API
6 DG450 Hook 1
Spec 8C
7 Drilling wire rope619S+IWRC EIPS grade 38 1 roll API Spec 9A
8 Electrical spooler 1 set

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No. Name Qty. Note


9 Deadline anchor JZG41A 1set
10 YM-16II hydraulic cathead 2sets
11 ZQ203-100 drill pipe power tong 1set
12 TQ340-35 hydraulic casing power tong 1set
13 Q250 pneumatic spinner 1set
One of them is
14 5T air winch 3sets installed on the
catwalk
15 0.5T air winch 1set
16 man-riding winch 1set
17 CJ7000 logging winch 1set
18 ST-80C iron roughneck 1set
19 HPU 1set
20 DZ550 BOP lifting device 1set
21 Hydraulic casing stabbing board 1set
II Equipments for rotating system
Edition 4, API
1 RT ZP375 1pc
Spec 7K
2 RT bushing 1set
3 RT drive device 1set
Edition 4, API
4 SL450 dual-purpose swivel 1pc
Spec 8C
III Equipments for circulating system
Edition 4, API
1 HHF-1600 drilling mud pump 3pcs
Spec 7Kparts
2 Mud pump set 3sets
3 Drilling fluid manifold 1set
4 Rotary hose 23m35Mpa 2pcs
5 Solid control system 1set
6 Poor boy 1set
IV Moving system equipments
1 Rig Moving system 1set

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No. Name Qty. Note


2 Rig Moving hydraulic system 1set
V Power and air supply system
1 Diesel generator set CAT 3512BSR4 4sets
2 Camp generator set C15 2sets
3 Generator-air supply house 1set 5 houses in all
4 Air supply system 1set
VI Electric drive and control system 1set
1 VFD house and MCC control system 1set
2 Power cable 1set
VII Driller control system equipments
1 Drillers cabin 1set
2 Instruments for drilling engineering parameters 1set
3 Monitoring system 1set
4 Communication system 1set
VIII Standard electric system on well site 1set
IX Detection instruments and tools
1 Detection instruments 1set
2 Special tools 1set
X Auxiliary equipments
1 Doghouse 1 house
2 Catwalk, DP rack 1set
3 RT anti-slide pad 1set
4 Racking board escaping device 1set
5 Cable trough 1set
6 Tool house 1 house
7 Material house 1 house
8 Oil tank 1set
9 Water tank 1set
10 Kill manifold 1set
Note: The items in the table can be adjusted according to user s requirements

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

3. ZJ70DBS rig structure features

3.1 Rig general structure


The whole rig contains 5 zones of drilling floor area, power area, pump area, solid control area and
oil supply area etc. After the rig is assembled, it occupies about 90m75m area (not including tool house
and living camp etc.)
For the rig layout refer to attached drawing 1 Elevation and attached drawing 2 Plan. For rig
transmission principle, refer to attached drawing 3 transmission system. For rig layout foundation see
attached drawing 4 Foundation.
In drilling floor area, there are mast, substructure, crown block, traveling block, hook, drawworks,
rotary table drive device, rotary table, driller s cabin, dog house and various implements necessary for
drilling operation etc on the drilling floor. The mast upper part includes the crown block.
In power area, there are generator/air source houses and electric control house. Generator/air source
houses form an integrated generating and air supply area after installation.
There are three HHF-1600 mud pump sets in pump area.
In solid control area, there are mud tanks, mud treating equipments and industrial water tanks etc. of
solid control system.
In oil and water supply area there are different kinds of oil tanks.
Drilling fluid manifold includes standpipe and ground manifold, and the ground manifold is
installed on the skid.
Each area of rig is connected by cable tray in which there are oil, water and air lines and cable.
The catwalk, drill pipe rack, electrical spooler and Moving HPU etc are placed in front of drilling
floor.
The substructure is placed on the 2.68-m-high Moving master skid, all equipments on the drill floor
(crown block, mast, traveling and lifting system, drill floor equipments, doghouse, driller cabin,
drawworks, rotary table and trip tank etc) including 150T drilling tools, can shift leftwards and rightwards
together with the master skid.

3.2 Rig structure features


ZJ70DBS rig is designed by integrating mechanical, electrical and digital control technologies with
advanced and proven technology from China and Overseas, possesses elementary functions for
automation, intelligence and information gathering. Its design meets HSE requirements. Hence, its
operation is reliable with easy transportation and economic running.
Along left and right sides of the rig, two sets of main and auxiliary guide rails are placed on the
well site. The master skid is placed on the main and auxiliary guide rails, it can achieve step-by-step
Moving being pushed or pulled by the four cylinders on its front and back.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

When the major part of the rig are Moving, equipments of solid control area, pump house area,
power area and oil& water feeding area stand still. The connection between drill floor area and other areas
is achieved by movable cable trough and guide trough.
The DW, RT and drilling pump adopt independent AC VF electrical drive system without
interference with each other, which should satisfy the requirement of drilling technique.
The mast of this rig is a K type satisfies the installation requirements of Varco TDS-11SA top drive;
while substructure is a slingshot structure. Mast and substructure use power of drawworks to rise. Major
equipments on drill floor and driller s cabin etc. all adopt low-position installation.
The drawworks is a single shaft drawworks, which adopts two 1000KW VF motors via a gear box to
drive the drum respectively with simple structure; the main brake is a hydraulic disc brake, which is safe
and reliable. All the operating parameters of the drawworks including tripping speed, hook position,
safety settings etc. are digitally controlled.
The rotary table is driven by an AC VF motor via angle driving box and cardan shaft separately, the
Rotary Table is equipped with inertia brake, its control system has a monitoring function and over-torque
protecting function.
This drilling rig is equipped with three 1600hp mud pumps; each one is driven by one AC VF motor,
which is reliable and easy to adjust the flow rate.
The power system consists of four 1200KW diesel generator sets and two 320kW auxiliary
generator sets. The power is equipped with enough reservation and the drilling rig holds a strong
self-maintaining capability.
The electrical drive adopts vector VF drive system. Its major electrical equipments are all located in
the VFD house.
This rig is equipped with an integral driller s cabin, in which a driller can finish major operations,
and it achieves real time display, memory, print and management of parameters (signal).

3.3 Hook speed and hoisting capacity

3.3.1 Hoisting capacity (double motors)


hook speed Hook load hook speed Hook load
Motor rev Motor torque
m/s kN m/s kN
rpm Nm
(12 lines) (12 lines (10 lines) (10lines
131.00 11876.00 0.07 4861.11 0.09 4261.36
391.00 11876.00 0.21 4861.11 0.26 4261.36
531.00 11876.00 0.29 4861.11 0.35 4261.36
710.00 11876.00 0.39 4861.11 0.46 4261.36
749.00 11876.00 0.41 4861.11 0.49 4261.36
803.00 11876.00 0.44 4861.11 0.52 4261.36

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

848.00 11262.00 0.46 4609.79 0.55 4041.05


887.00 10767.00 0.48 4407.17 0.58 3863.43
985.00 9695.00 0.54 3968.38 0.64 3478.77
1073.00 8900.00 0.58 3642.97 0.70 3193.51
1205.00 7925.00 0.66 3243.88 0.79 2843.66
1500.00 6367.00 0.82 2606.15 0.98 2284.62
1700.00 5618.00 0.93 2299.57 1.11 2015.86
2000.00 4775.00 1.09 1954.51 1.31 1713.37
2200.00 4341.00 1.20 1776.87 1.44 1557.64

3.3.2 Hoisting curve12 lines, double motors


Hook load KN

Hook speed m/s

3.3.3 Auxiliary drive lifting capacity


Max. lifting capacity of auxiliary drive is 2800kN (12 lines), max. hook speed is 60m/h (10 lines).

4. Rig installation
Rig installation should follow requirements of rig final assembly technology and this manual too.

4.1 Preparation of rig installation


z Rig installation personnel should pass on-the-job training and test qualified, work with their
certificates.
z Before installation, concerned personnel should read the instructions and operation manuals for
each component of the rig and understand the rigs technical and structural features and
installation requirements.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

z The rig installation requires many kinds of tools and equipments with good performance. The
gauges and meters on hand should be qualified.
z The well site and foundation should satisfy the related standards of technique documents and
approved drawings in accordance with regular procedures.
z The drilling rig is heavy-duty equipment, pay attention to the safety of the personnel and the
equipment. Because some modules are bigger in dimension and weight, be sure to use proper
lifting equipments and riggings which should be in normal status.
z Before installation, equipments and parts of each module must be checked whether they are
complete, qualified and undamaged; and clean them (the component and parts).

4.2 Installation sequence chart

Moving master skid,


substructure Mast Crown
block
Generator& air source
Drawworks RT and drive device
house and electric control
house

Drilling fluid manifold Traveling


standpipe block, hook
Mud pump
set
Doghouse Cable pipeline Driller cabin
trough

Drilling fluid manifold Solid control Oil tank,


ground part system water tank

Rig
commissioning
Reeve wire Lift mast and substructure Wellhead
rope alignment

Wellhead mechanical Whole rig commissioning


tools

Notes: Under condition of safety and having enough space, the other auxiliary equipments can be
installed at the same time.

4.3 Installation of each part


Set wellhead center as benchmark in the light of rig plan; perform lofting on well site foundation
and mark installation datum lines for each zone

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.3.1 Installation of substructure (for details see DZ450/9-S1 substructure operation manual)
Take the wellhead centerline and lineation of drilling floor as benchmark,

Locate Moving master skid, use pins to connect it into a whole; then use pins to connect the
Moving cylinders to the master skid and guide rails; lay the left and right base seats of the substructure
lower layer onto the Moving master skid and connect them together; use connection fixing device to fix
the substructure lower layer and Moving master skid into a whole; then install the middle layer columns
and tie-rods. At last, install the top layer drawworks beam, RT beam, setback beam, flooring board,
A-frame and other auxiliary parts.
Note: The paving plates at the two sides of setback should be installed after the lifting of
substructure and except the ladder of drilling floor, the ramp and the ladder leading to the solid control
system are all installed after the lifting of substructure.

4.3.2 Installation of the generator/air source house and electrical control house (see the plan of the
generator/air source house)
Lay the VFD house according to the lofting and marked installation datum lines of rig plan. Lay
each generator/air source house in sequence. The VFD house should be vertical to No.1 generator house,
and their front side should be aligned.
Connect the oil and air lines of each generator set and connection lines between air source
equipments.
Install mufflers of diesel engines.

4.3.3 Installation of drawworks


The drawworks was assembled and test run before its delivering from the factory. There is a fixing
buckle designed at the related substructure location. Lift the drawwoks onto its beam of the substructure
and locate it according to the fixing buckle.

4.3.4 Installation of RT and drive device


The RT drive device (except cardan shaft) has already been installed on skid and packed as per
module for transportation.
Lift the RT and lay onto the skid, connect it with pins and safety pins (adjust it with puller bolt and
position it as per the mark)
Install cardan shaft, be sure to keep the parallelism error of the two end flange surfaces 1.0mm.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.3.5 Installation of mast (refer to the operation manual of JJ450/45-K mast)


Before installation the mast structural components should be inspected visually, repair or replace
the distorted and damaged one if any. Turn the rope sheaves, they should rotate actively without
blockage.
The mast installation sequence: lower parts should be installed first, upper parts installed second,
main body first and accessories second. Alternatively move stands, after main components and
accessories installed, lift and support the mast with tall stand, for then installing racking board (0.5T
air winch included)

4.3.6 Installation of drilling fluid manifold standpipe


Install standpipe onto mast when the mast is in lower position, the union connection should be
reliable.

4.3.7 Installation of crown block (see the operation manual of TC450 crown block)
Connect the crown block to mast with bolts. The accessories of the crown block, such as auxiliary
sheaves, lifting frame and climbing booster etc should be installed completely.

4.3.8 Install the hydraulic spooler to the substructure as per the position shown in the rig plan.

4.3.9 Install traveling block, hook and reeve the raising line and drilling line (in parallel mode)
properly

4.3.10 Installation of the drillers cabin


Lift the drillers cabin onto drill floor, and connect air line, hydraulic lines and electric lines of
each system according the related numbers.

4.3.11 Installation of cable trough


Install the cable troughs according to rig plan and the general drawing of cable trough; connect the
pipelines of each system, and install the cables and wires according to the operation manual of electrical
system.

4.3.12 Installation of the ground parts of the drilling fluid manifold


They should be installed as per the operation manual of drilling fluid manifold, and connected to
standpipe and mud pump discharge line.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.3.13 Installation of solid control system


Install the mud tanks of the solid control system according to the lofting and marked installation
datum lines of rig plan, and install the equipments inside and outside the tanks, connect the connecting
lines between tanks and mud pump suction lines as per the operation manual of solid control system.

4.3.14 Installation of standard electric system on the well site (for the detail see the operation
manual of the standard electric system on the well site)

4.3.15 Installation of drilling instruments


Install the drilling instruments as per the requirements of the operation manual of drilling
instruments.

4.3.16 Installation of monitoring and communication systems


Install the monitoring and communication systems as per the operation manual of the electric drive
system, the requirements of rig elevation and plan (except the parts which should be installed after
lifting mast and substructure)

4.3.17 Installation of auxiliary equipments


Install as per the requirements of the rig plan and elevation.

4.3.18 Installation of oil and water tanks


Install the oil tanks and water tanks according to the lofting and marked installation datum lines of
rig plan, connect the cable trough to oil and water tanks.

4.3.19 Installation of top drive device (for detail see the operation manual of the top drive device)

4.4 Inspection after the drilling rig being installed

4.4.1The pre-tension torques for bolts are listed below, all mainly stressed bolts should be
inspected one by one with a torque wrench.
Grade Nominal dia. of bolt/mm
of bolt 16 20 24 27 30 36 42
strength 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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.2 Inspection after the substructure installed


The difference between the diagonal lengths of four bracket pin holes at rear inner sides of the left
and right base seats should not be higher than 5mm.
All connection parts, fixation parts should be install completely and tightened. And all pins at
rotating parts should be greased.
All components should be good without deformation, weld seam crack and weld opening.
The substructure bottom beam must contact the foundation surface properly and main loading
position should be constructed strongly.
There should be no obstacle on the drilling floor in the driller s sight.
The substructure buffer cylinders must operate normally.
Raising lines should be good and reeved correctly with end fixed tightly.

4.4.3 Inspection after the mast being installed


Grease all points as per the requirements.
Check to ensure all connecting parts, fixing parts installed completely and reliably.
All components should be good without deformation and weld seams with no crack and weld
opening.
Various auxiliary devices installed at the mast should be good and complete.
The mast buffer cylinders must operate normally.
Raising lines and drilling wirelines should be good and reeved correctly with end fixed tightly.
Clear out all tools and sundries at the mast.
Weight indicator should work normally.

4.4.4 Inspection after the drawworks being installed


Check to ensure all guards are installed completely, pipeline connected correctly and reliably.
Grease all points as per the requirements.
Grease the main speed reducer according to the requirements of its manual.
All piping system of hydraulic power for hydraulic disc brake, operation cabinet, control cabinet and
brake caliper should be connected correctly, sealed well without leakage.
For wearing condition of hydraulic brake disc and brake block, when their thickness decreases to
limited value, they should be replaced.
For the clearance of the hydraulic disc brake, please refer to the User Manual of Hydraulic Disc
Brake and adjust it to proper position.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.5 Inspection after the crown block being installed


The connection between the crown block and the upper section of the mast should be tight;
positioning pins should be located reliably.

4.4.6 Inspection after the traveling block and hook being installed.
All bolts and pins of traveling block and hook should be complete and tightened, and guards are
good.
The hook body and lock pin at fastener must work actively; the security pin of ear rings should be
complete, safe and reliable.

4.4.7 Inspection after elevator links and swivel being installed.


There should be no crack and deformation with the elevator links.
The swivel must rotate actively and there is no leakage of oil and drilling fluid.
Rotary hose should be installed with safety chains.

4.4.8 Inspection after mud pump being installed.


The mud pump safety valve should be installed in a position as required; and it must work
normally.
The air damper on mud pump should be filled with nitrogen or air, it is forbidden to fill it with
oxygen.
The pressure gauge of the mud pump should be precise and its surface should be clean.

4.4.9 Inspection after the drilling fluid manifold being installed


All holders and clamps should be fixed reliably; the connections of all unions are correct and sealed
reliably.
The hand wheels of valves are complete, operate actively without leakage.

4.4.10 Inspection after generator/air source house and air supply system being installed (exclude
electric transmission)
All the bolts should be installed completely and tightly. Pre-tightening torque should be in
conformity with requirement.
All pipeline should be clean and smooth, connected correct with clear marks, sealed reliably without
leakage.
Pressure gauges are complete and intact, and in calibration efficient period. The pressure of air
piping should be adjusted to the required pressure.
All pipelines, valves should be intact; safety valves act sensitively.
The guards of transmission parts should be intact and complete, and installed reliably.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.11 Inspection after cable troughs being installed.


All pipelines should be connected correctly; they are clean and smooth inside, each connection part
is sealed reliably with no leakage.
All cables and wiring should be connected correctly and in good order, and marked clearly.

4.4.12 Inspection after the drillers cabin being installed


The air and hydraulic lines should be clean and smooth inside, and their pipelines are connected
correctly with clear marks. All connections should be sealed reliably without leakage.
All instruments and meters are installed complete, sensitive and reliable.

4.4.13 Inspection after solid control system being installed


All the bolts, nuts, spring washers and split pins should be installed completely and tightly.
Pre-tightening torque should be in conformity with requirement.
All piping, valves should be intact without water leakage

4.4.14 Inspection after the electric control system and standardized electric system on the well site
being installed
Check according to the related requirements in operation manual of electric control system and
standardized electric system on the well site.

4.4.15 Inspection after drilling instrument system being installed


Check according to the related requirements of operation manuals for drilling instruments for
ensuring all instruments sensitive and reliable.

4.4.16 Inspection after monitoring system and communication system being installed
Check according to the related requirements of operation manual for monitoring system and
communication system.

4.4.17 Inspection after assistant parts being installed


All assistant parts should be good and installed completely.
All bolts for assistant parts should be installed completely and tightly. All pins and safety chains
should be installed completely and reliably.
The wireline for assistant equipments should be good without any damage.

5. Rig commissioning

5.1 Preparation before commissioning

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Before rig commissioning, make sure the equipments are filled with lube oil, grease, fuel, hydraulic
oil and cooling water.
Clear out all the sundries near the equipments and check the connection and seal of cable and lines.
Check the equipments before their operation according to the instructions of their operation
manuals.

5.2 Commissioning of diesel generator set


5.2.1 Check the connection between diesel air-feeding pipelines and generator sets, and VFD
power & controlling cable, after that start auxiliary generator set to supply power for air purification
equipments and then start the screw air compressor, or start cold-start air compressor directly, in order to
make the air tank pressure up to 1.0Mpa.
5.2.2 Start each main generator sets respectively, check the running condition and debug to normal
working condition.
5.2.3 Process functional commissioning of main generator sets to designed parameter value and
fulfill following requirements.
The diesel is well started and running successfully at rated speed.
Power output of generator sets is smooth.
Synchronous operating loop is normally controlled.
Protections for short circuit, overcurrent, overfrequency, underfrequency and counter power run
normally.
Meters and indicator lights display normally.
(Check diesel generator set operation manual for detailed information.)

5.3 VFD system power supply commissioning

5.3.1 Preparation
Check the connections between the electrical equipment power and control cables of VFD and
MCC system in VFD house, and each AC VF motor, all control switches, displaying screen, touch
screen in driller s cabin, and lighting system and solid control system etc. Ensure all switches are in the
off position.
Power up the VFD and MCC system with generator set, test all function switches, meters, make
sure display and indication are correct and parameters conform to the requirements.

5.3.2 Supply power to each zone


Power up the driller s cabin, check the operational status of display screens, and touch screens,
instruments and switches for sensitivity and reliability.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Power up the AC VF motors on the drawworks, start the 2 main motors respectively, check the
rotation direction and synchronous condition, also check the operation of the blower.
Power up the motor on the rotary table, check the rotation direction and running condition, also
check running condition of blower.
Power up the AC VF motors on the mud pumps, check the rotation direction and running condition.
Supply power to each lightening device and check the operation.
Power up HPU, substructure lifting HPU and outsourcing implements HPU and start motor, check
its rotating direction and running condition.
Power up the solid control system and check motors of each solid control equipment and their
running condition.
Power up the pumps of oil tank and water tank, check the operation of the pumps.
Supply power to the other electric equipments and check their operation.
(Refer to electrical drive system operation manual for detailed information)

5.4 Commissioning of electric transmission system


5.4.1 Logic of switches in driller cabin and PLC are correct. Bypass assignment is correct.
5.4.2 Air-feed-failure protection and lock protection function of each main motor run well.
5.4.3 Low air pressure alarm in driller s cabin runs well.
5.4.4 Each auto function, feedback function, lock function are correct.
5.4.5 Balance test for mud pump with load runs well.
5.4.6 Function of emergency stop button is correct.
5.4.7 Dynamic brake (consumption) system of drawworks runs well. (Test simultaneously with
drawworks commissioning)
(Refer to electrical drive system operation manual for detailed information)

5.5 Commissioning of driller cabin, instruments and meters system


Refer to driller s cabin operation manual for commissioning of driller s cabin. Commissioning of
instruments and meters system (May run this commissioning after lifting of mast and substructure)
Supply power to computer and test it.
Run online test for drill floor monitor and computer.
Simulation quantity sensor channel commissioning
Input initialization data to system.
Each pressure sensor, fluid level sensor are properly installed, cables and pipelines are correctly
connected, and functions are well fulfilled.
Each camera of monitoring system is well installed, and transmission and displaying of image run
normally.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Communication system runs well.


Calibrate each flow meter, sensor, indicator as per requirements and regulations instrument of their
operation manuals.

5.6 Commissioning of air-supply system equipments


Start No.1, 2 electrical screw compressor sets respectively, and adjust them to working condition as
per its operation manual. Check the working condition of air source purification devices and equipments,
air or oil leaking must be got rid of.

5.7 Commissioning of hydraulic system


Refer to hydraulic system user manual and hydraulic disc brake device user manual for detailed
information.
Commissioning of hydraulic system consists of HPU, hydraulic disc brake device, mast lifting
buffering cylinder and hydraulic implements etc. Major inspections include correct installation and
connection of each operation and control device, and adjust them to working condition.
Test mast and substructure lifting and lowering hydraulic system, ensure the functions of hydraulic
components are correct, system keeps its pressure as 3-4MPa and without oil leakage or pressure relief.

5.8 Commissioning of drawworks


Do the following debugging before wireline reeving.

5.8.1 Adjustment before running


Open the air tank ball valve on the rear substructure to supply air for the Drawworks.
Start the main reducer lubrication oil pump; check the lubrication condition of all parts.
Operate the control handle of hydraulic disc brake in the driller s cabin and push buttons on the
touch screen 510 times. Check the operation of the hydraulic disc brake for sensitivity and reliability.
Check:
The air in / out conditions of the clutch of assistant drive device
The reliability and accuracy of the toggle valve.
The sensitivity and reliability of the hydraulic disk brake system.

5.8.2 Commissioning at zero load


A. Operating procedure
Start the motor A of drawworks, check the rotation direction, and be sure the drum rotation
direction is winding direction.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Start the motor B of drawworks, check the rotation direction and be sure the drum rotation
direction is winding direction.
Check the lubricating oil pump pressure. It should be 0.1~0.35MPa.
Start motor A and B respectively, adjust the speed to 970r/min and run 20minutes respectively.
Run the both motors A and B together, accelerate and decelerate them with control handle and
check the operation condition.
Start the assistant motor, check the rotation direction and be sure the drum rotation direction is
winding direction. Accelerate and decelerate motor and check the operation condition.
Process brake tests not less than 5 times at different speed for hydraulic disc brake.
Note: the main motor by the side of the driller is motor A, and the one in front of driller is Motor B.
B. Requirements
All operations should be exact and sensitive;
At all locations there is no oil leak.
Lubricating oil pressure is stable and the lubricant quantity is correct.
Running of drawworks shall be smooth without abnormal vibration and noise.
Temperature rise of all bearings should be normal.
Hydraulic disc brake is sensitive and reliable.

5.8.3 Install wirelines


After the test of drawworks, lay the wireline spooler properly and reeve the drilling wireline. The
active line should be threaded into the drawworks drum and fastened by clamps; the dead line should be
threaded into the deadline anchor and fastened.
Note: when the traveling block is located at the lowest position before mast lifting, initial wireline
winding on the drum should not be less than 1 3/4 layer.
As per lifting device drawing, hang the balance pulley on the hook, and then reeve lifting system
wireline properly.

5.9 commissioning of the rotary table


(May process this commissioning after lifting of mast and substructure)
Start the RT drive motor, check the rotation direction of the rotary table, and make sure it rotates
positively. Accelerate and decelerate motor and check the operation condition.
Engage the RT inertia brake; check the brake function and the interlock control of the motor.

5.10 Commissioning of Mud Pump Set


(May process this commissioning after lifting of mast and substructure)

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Test and adjust the mud pump set to working condition according to the Operation Manual of
HHF-1600 Mud Pump set.

5.11 Mast and substructure lifting, mast alignment


For details, see operation manuals of the mast and substructure

5.11.1 Inspection before the mast lifting


Before lifting the mast, check the installed parts completely according to the clause 4.4.3 to verify
the installation correctness and connection reliability of each part.
The raising line should be intact, and reeved correctly with end fixed reliably.
Air supply and pneumatic control systems should be in normal status, the pressure of the air tanks
should not be less than 0.8MPa.
The drawworks should be adjusted properly and be test run normally for at lest 2hrs.
Turnover the racking board and fix it properly.
Move the tong counterbalance to low position.
Check if the hook is locked reliably.
Recheck the buffers for its normal working status.
The sheave bearing of all raising lines should be greased in accordance with the requirement, and
the sheave must turn freely.
Check if there is any part or tool left at the mast, and if all safety facilities are ready and reliable.

5.11.2 Mast trial lifting


z Lifting operation should be carried out under the guidance of commander. The commander
should stand on a position which the driller can see directly and is safe.
z Before trial lifting, all other persons and construction implements should move away to a safe
area except the worker on duty in engine house, driller, and the observers for key positions,
security official and commander.
Safety distance is not less than 70m away in the front from the wellhead, and the two sides are not
less than 20m away from the two sides of mast.
z The mast can be lifted by the main motor in low speed and can also be lifted by assistant
motor
z Pull the wire line tight gradually in low speeds while lifting the mast; lift the mast 100mm
200mm away from tall stand after the wire line being confirmed normal. At the same time
observe if the lifting pull conforms with required value; and brake and observe if assistant
drilling line, dead line, various pipelines, electric lines are in normal status; then put the mast

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

back to its original position, check if the raising line is reliable without loose phenomenon and
lifting lug plate with no crack on weld seam.
z If every thing is OK after check, lift the mast again. When the mast lift 200mm300mm away
from the tall stand, engage the drawworks brake and hold on for 5 min.10min. Check if the
raising line end and the dead line end of drilling line are fixed properly and reliably; check if the
loading parts of the substructure, main load parts of A frame etc are not deformed, if there is no
crack with the weld seams; check the lifted height of the substructure to see if the counterweight
is enough.
z Lower down the mast onto the tall stand slowly and put the traveling block to a place 100mm
200mm away from the support surface, re-tighten the crown block connecting parts and mast
bracket connecting bolts.
z Re-lift the mast, when it leave 200mm300mm away from the stand, engage the drawworks
brake to hold on the mast in the position for 5min., then put back the mast onto the tall stand
slowly, put back the traveling block to a place 100mm200mm away from the support surface.

5.11.3 Raising the mast


Operate the control valve of mast buffer cylinder to extend the piston rod completely and keep the
pressure of the cylinder (3~5MPa).
During lifting operation, run the drawworks slowly and control the hook speed to the range of about
0.81.2m/min.
Note: Operate the drawworks evenly and stably. It is forbidden to brake or accelerate suddenly while
it is running.
When the mast lifts to 7580position or leaves 2m away from the piston head of the buffer
cylinder, slow down the drawworks speed to make the mast reach slowly the buffer cylinder piston head,
then operate the buffer cylinder: After the mast gravity moves over the mast front support legs, cut off
the power of the drawworks to make the mast locate slowly.
When the mast located, pull the raising line tight gently, connect and tighten the mast to A frame and
substructure timely.
Lower the traveling block and hook to low position, then disconnect the connecting pins of raising
line, reeve and fix the raising line according to requirements.

5.11.4 Inspection before the substructure lift


Before lifting the substructure, check the installed parts again completely according to the
requirements of clause 4.4.2 to confirm the various parts for proper installation and reliable connection.
The raising line should be good, reeved correctly and with its end fixed reliably.
Check again if the buffer cylinder works normally.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Check again if the various sheave bearings of the raising line system have been greased according to
requirements, and if they are running smoothly.
Check again if the connecting pins between upper layer and bottom layer have been disconnected.

5.11.5 Raising the substructure


While lifting the substructure, pull the wireline tight gradually and slowly, to make the substructure
lifted 100200mm up from the installing position; at the same time watch the lifting pull exceeds
regulated value or not; engage the brake and hold on at least 5min. Check if raising line is fixed at the
ends properly and deadline of drilling wireline is fixed normally. Assistant drilling line, various pipelines,
electric leads etc should be in normal status; then put the substructure back to its original position.
Re-lift again if all is normal after checking, when the substructure is lifted 200mm300mm up from
the installed position, engage the winch brake and hold on for at least 5min.10min. Check if the raising
line is fixed at the ends properly and deadline of drilling wireline is fixed normally. Check if the loading
parts and key position are in good condition without deformation and no crack on weld seam.
Run the winch at low speed while lifting the substructure, control the hook speed to about 0.8
1.2m/min.
Precaution: Run the winch evenly and stably. It is forbidden to brake or accelerate suddenly
while it is running.
When the substructure is lifted to 7580position or the buffer cylinder piston head leaves away
0.5m from the triangle frame, slow down the hydraulic winch speed to make the buffer cylinder piston
head reach the triangle frame slowly, operate the buffer cylinder then, when the piston start to retract and
make the substructure locate slowly.
After the substructure located, connect and tight it timely.
After lowering the traveling block and hook to low position, remove the connecting pins of raising
line, and remove and fix the raising line properly in the way according to the requirements.

5.11.6 Mast alignment


After the mast and substructure are installed, align well head as required. Offset error of alignment
between the crown block center and RT center allowed is 20mm. (For aligning method, see the
operation manual of the mast)
Be sure to make the mast in natural status while aligning it.

5.12 The parts to be installed after the mast and substructure being lifted
Well head mechanical tools
Well control device

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

The ladders from drill floor to front, back of the site and right side.
The other parts of the substructure, such as safety slideway, V door ramp, catwalk and drill pipe racks
etc.
Swivel, and connect to rotary hose
Other assistant parts

5.13 Adjustment of drilling instruments


Check if the sensors are installed properly, and cables and pipelines are connected correctly.
Calibrate the monitor and indicating instruments according to the requirements of their involving
manual.

5.14 Adjust the winding of drawworks drum and test the crown block saver
Adjust the winding of the drawworks drum for ensuring at least 9 cycles of initial winding on the
drum always.
Adjust toggle valve
Adjust the position of the toggle valve to make it act when 28m stand is lifted and the lower end
surface of the stand is 2m away from the drill floor, and make the hydraulic disc brake engaged urgently
for stopping the drawworks drum, now check its reliability.

5.15 Test of hydraulic and pneumatic tools


Test according to the requirements of their involving manuals:
DP power tong and casing tong running test
Running test for hydraulic cathead
Pneumatic spinner running test
Running, lifting capacity and brake tests of air winch
Running test for iron roughneck

5.16 Running test for solid control system

5.16.1 Sealing performance test of the system pipeline


After the whole system installed carry out the sealing performance test. Fill the circulating tank with
fresh water. There should be no leakage with connecting lines between tanks, valves and bottom valves.

5.16.2 Power-on running test on the solid control system


Carry out power-on test on shale shaker, vacuum degasser, desander, desilter and centrifuge
respectively; they should run normally.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Carry out power-on test on agitator, charging pump & mixing pump respectively, they should run
normally.

5.17 Test on high pressure manifold


Carry out static hydraulic test with fresh water on ground manifold, standpipe, valve sets, and test
pressure is 35MPa, stable pressure time is 10min, pressure drop 2MPa.

5.18 Inspection of the standard electric system on well site


5.18.1 Check various sockets and plugs for reliable connection, check if they conform to the
explosion-proof requirements, and conform to technical standard requirements such as API etc.
5.18.2 Power on each area to check if the motors of all equipments, lighting lamps, each
explosion-proof distribution box and control box work normally.

5.19 Drilling rig monitoring and communication system test


Test the desk phones and mobile communication equipments; they should meet the design
requirements. Test the position of each camera lens of the monitory system for correctness and normal
picture transfer and display.

5.20 test of the top drive device


For detail see the operation manual of the top drive device

5.21 Test of the drilling rig final assembly


At the same time start drawworks, mud pump, RT and solid control system to carry out running test
of the drilling rig final assembly for linkage performance.

5.22 rig Moving test


Do Moving test to mast and substructure on their working condition (lifted condition), prepare
Moving hydraulic source as per rig Moving hydraulic system user manual, operate Moving operation
box as per requirements, ensure the synchronous acting of the eight cylinders, and test the Moving
performance of the rig.

6 Operation and maintenance of drilling rig

6.1 Warnings
6.1.1 Operate the rig following the operation manual of the rig and the related safety rules seriously.
6.1.2 It is forbidden to repair equipments before shut-down of the power and control source.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.1.3 When inspecting and repair a VF motor, make sure the auxiliary switch beside junction box has
been closed and locked. Ensure the main circuit is power off.
6.1.4 Before the operation of rig, check and adjust the rope winding on drawworks drum. Make sure
the wire line on the drum is not less than 9 circles anytime to prevent the line from slipping because of the
excessive strain in wire line clamp. Then retighten the bolts and nuts of clamps.
6.1.5 When the rig is operating, personnel are not allowed to stay in the area of the mud pump relief
valve and high pressure manifolds and rotary hose.
6.1.6 In the operation of rig, the speed regulation should be slow and smooth, avoid the impact to
mechanical and electric systems because of violent changes in speed.

6.2 Precaution for rig operation


6.2.1 Select the generator sets with proper power to match the power requirements according to the
drilling operation conditions.
6.2.2 During drilling operation, adjust the hoisting speed of the drawworks upon its load, drilling
technical requirement and hoisting curve; and adjust discharge pressure and stroke of the mud pumps as
per the technical requirements; adjust the RT speed according to drilling technical requirements.
6.2.3 Before operation, check if both ends of drilling lines have been fixed firmly; if all the bumper
devices are reliable and agile; if DW brake system and clutch are reliable; all electrical equipments and
instruments are connected correctly and working smoothly.
6.2.4 During operation, make sure the pressures of air source system and hydraulic pressure system
meet the regulated working pressure.
6.2.5 When operating the rig, if the drilling string is heavier than 1600KN, the drawworks had
better adopt dual motor driving. When one of the two main motors fails, the other one may hoist max.
weight of drill string 2200kN at low speed in short time.
6.2.6 During drilling, make sure the gears and bearings etc of transmission system are lubricated
properly. Check if the quality and quantity of the lube oil/grease for each part meet the requirements,
and supplement or change the lube oil according to the regulated operation period.
6.2.7 Periodically check and adjust the tightness of drilling pumps drive belt;
6.2.8 Check if charging air pressure of the air damper meets the requirement periodically.
6.2.9 All the ladders, handrails and safety guards should be firm enough.
6.2.10 It is forbidden to operate the rig at overspeed, overload and violate any operation regulation.
6.2.11 Periodically check the cylinders of mast and substructure for reliable operation.

6.3 Safety rules of rig operation

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.3.1 Rig operation requirement


z Rig crew should have mechanical, electrical and instrument professional to guide or do rig
routine operation and maintenance and make technical regulations for rig routine operation
and maintenance.
z Rig operators and maintenance personnel should pass on-the-job training and test qualified,
work with their certificates.
z Rig operators must comply with safe operation regulations of the drilling rig.
z The hoisting speed and capacity must be in accord with related regulations in drawworks
operation manual.
z Mud pump flow rate and pressure must follow related rules in HHF-1600 mud pump
operation manual.
z If any part of the rig fails, stop it immediately and deal with the failure in time; restart only
after failures eliminated.
z Ensure to release all high pressure pipes or hoses completely before disconnecting them.
Ensure to cut off the power supply before repair electric circuits and equipments.

6.3.2 When any following failure appears; the rig should be stopped and maintained immediately.
z Overload and overspeed operation;
z The steel structure of mast and substructure distorted and cracked;
z Foundation of substructure sinks or ruptures;
z Brake or drive system fails;
z Drilling pumps safety valve and the charged air of air damper do not meet the requirement;
z The bumper device fails while tripping in/out;
z Rig instruments damaged or no metering function;
z Air control system fails or air source pressure is lower than the allowed range;
z Safety guards and handrails are not complete;
z Oily thing goes into surface of brake disk, brake hub, clutch steel hub;
z Raising line and drilling line are not checked according to the regulation.

6.3.3 All rig operators are forbidden to do the following operations


Run rig components at overload, over speed, over temperature, over pressure;
Inspect and repair the equipment without shutting down the power and control source;
Make up thread with rotary table;
Adjust the brake when hook is loaded;
Pour water on brake disk, brake hub, friction hub.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.4 Maintenance regulations of rig


According to the running time and technical status of drill rig, it is divided into periodical one and
staged one.
Periodical maintenance is divided into shift service, weekly service and monthly service.
Shift maintenance includes adjusting, lubricating, tightening, cleaning and corrosion preventing etc
(conventional items), and some items specified in this chapter.
Weekly maintenance includes all the items of shift maintenance.
Monthly maintenance includes all the items of weekly maintenance.
Staged maintenance includes the main components maintenance. If the components can not satisfy
the drilling operation requirements, it should be repaired on service base.
The rules for periodical maintenance followed:

6.4.1 Routine inspection and maintenance items for Mast and Substructure:
Any cracks or distortion in the hoisting structure
Any corrosion of the wire rings and wire loops
Any damage to the hoisting wire line
Lubrication of the block system
All pins and safety pins are installed and complete
Tightness of all bolt connection parts;
Under load, periodically measure the deviation from linearity of the mast columns in total length,
and any perpendicular deviation of the mast looking from the front and side of the mast.
Before mast raising or lowering, check bumper devices and hydraulic system for their condition and
enough oil feeding.
The inclined and transversal bars and beams (brace and girder) or other parts are not allowed to be
dismantled in any circumstance.
It is not allowed to drill or cut holes or weld on the steel structures.
Inspect the mast and substructure monthly, especially before heavy casing running.

6.4.2 Hoisting System


6.4.2.1 The shift inspection items:
The braking function and anti-collision performance on the drawworks;
The operation of electrical equipment in the driller s console; the sealing performance of air or
hydraulic control connections;
The fastening of the deadline and the fastline ends;
The lubrication and seals of each bearing;

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

The fixation of the hook ring bolts and lock pin; check if the hook can rotate freely and the spring
action is proper;
The sealing performance of the swivel and drawworks, and that the quantity and temperature of
lubrication oil meet requirement;
The rotary table lock pin is working properly.
6.4.2.2 The weekly inspection items
Check the feeding conditions of drawworks lube oil pump, lubricant cleanliness and whether its
necessary to wash or change filter element.
The bail and pins of the swivel whether or not rotate smoothly;
The fixation of the traveling block shaft;
The hook and sheave groove wearing at the crown block and traveling block;
The sealing condition of the swivel washing pipe packing;
The tightness of the universal shaft of the rotary table;
6.4.2.3 The monthly maintenance work
Inspect the wearing and connection condition of each clutch, coupling and cross joint of universal
shaft.
Whether there are cracks on the elevator links, pins and sheaves of lifting system.

6.4.3 Mechanical drive System


6.4.3.1 Inspecting items of shift maintenance
Adjust the tension of the transmission belt. Check the temperature, temperature rising and noise of
gear box and rotating part.
Check gear box lubricant quality, quantity, pressure and temperature;
6.4.3.2 Inspecting items of weekly maintenance
Check the working condition of the lube oil pump and clean filter,
Inspect the worn situation of the clutch.
6.4.3.3 Inspecting items of monthly maintenance
Inspect each transmission part completely including clutch, coupling, universal shaft etc;
Inspect the gear meshing of transmission box;
Check or measure the oil quality of sump.

6.4.4 Circulating System


6.4.4.1 Inspecting items of shift maintenance
The operation status of the mud pump power end; check the tightness of drive belt and temperature
rising of each bearing.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

The suction performance of fluid end and the working condition of piston, liner, rod etc. especially
their sealing, cooling and lubrication;
The tightness of the cylinder lids and valve caps of mud pumps;
The working condition of charging pump and spraying pump;
Whether the pressure of air damper and relief valve meet the requirements;
The tightness of high pressure manifold and working condition of high pressure valve;
The working conditions of solid control equipments; the temperature rise and insulation of motors;
6.4.4.2 Inspecting items of weekly maintenance
Check and clean oil filters;
The lubrication and abrasion of crosshead and guide plate;
Whether the action of safety valve is agile or not;
The insulation of the electrical circuits;
The passage condition of mud gun nozzle;
6.4.4.3 Inspecting items of monthly maintenance
Check the meshing condition of power end gears check and adjust the clearance between
crossheads;
Inspect the high pressure pipe by non-destructive test;
Tighten connecting valve bolts of mud pumps and clean the oil trough.

6.4.5 Air Supply System


6.4.5.1 Shift inspection item
Check whether the operation of the air compressor is normal. The quality, level and temperature of
the oil meet requirements.
Check whether the setting of auto-pressure-adjusting device and safety valve are correct or not.
Check the working pressure of the air tanks and clean the tank with water;
Check the air lines for their smoothness and sealing condition.
6.4.5.2 Weekly inspection item
Check the condition of the air filter for clogging
Check the safety valve and sequence valve.
6.4.5.3 Monthly inspection items
Clean the air filters and the safety valve of air tank;
Inspect the control valve of the compressor.
Inspect the control valve of air dryer.

6.4.6 Drillers Cabin


(Refer to the operation manual of driller s cabin, please)

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.4.7 Electric drive system


(Refer to the operation manual of electrical drive system, please)

6.5 Accident and emergency treatment


6.5.1 If any mechanical accident like DP sticking happens in drilling process, it should be dealt with
as per mechanical accident treatment regulations.
6.5.2 If fire alarm happens in the wellsite, it should be dealt with as per fire alarm treatment
regulations.
6.5.3 When emergency happens in the wellsite, staff must retreat urgently, personnel of each position
have to follow unified command and retreat as soon as possible after finishing emergency operation.
Derrickmen on racking board can use escaping device to get out quickly; staff on drill floor can use
escaping slideway to make a speedy fleeing.

7. Dismantling and transportation of drill rig

7.1 Lowering of mast and substructure

7.1.1 Checking before lowering


z Grease each lubrication point and pins of rotary parts as per requirements.
z Installation of each connection and fixation component must be complete and fastened.
z Each part should be without serious deformation; each weld should be without crack and
opening.
z Substructure bottom beams contact properly with foundation surface, major force-bearing
points must be tamped.
z There is no barrier to block driller s eyesight on the drill floor.
z Substructure buffering cylinder works normally.
z Mast buffering cylinder works normally.
z Lifting wireline and drilling wireline are all in good condition, while their ends fastened
tightly.
z No tools and stuffs left on the mast.
z Weight indicator works normally.

7.1.2 Substructure Lowering


When lowering the substructure, firstly move the substructure to diverge from the center gravity
position by the buffer cylinder. Drawworks should reversely drag and the substructure should be
lowered by its self-weight. Precautions should be taken while lowering the substructure:

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Dismantle all components affecting lowering of the substructure such as the ramp, slide, ladders and
tool elevator etc.
Control the lowering speed as slowly and evenly as possible. Prevent sudden accelerating and
sudden stop.

7.1.3 Mast lowering


Before mast lowering, hang the balance-blocks properly, and dismantle casing stabbing board and
structural components and accessories which affect the mast lowering, then operate the bumper cylinder
to push the mast away from its center of gravity, and then lower it slowly by its weight while drawworks
reversely dragging. Precautions should be taken while lowering the mast:
Control the lowering speed as slowly and smoothly as possible. Sudden accelerating or brake is
strongly forbidden.

7.2 Dismantling
7.2.1 The principle for dismantling is: dismantle firstly those installed last, dismantle last those
installed first.
7.2.2 Dismantle the rig into components then pack them in unit. Larger components like mast and
substructure should be disassembled into smaller units in terms of the size of carrying vehicles,
drawworks, diesel generator set and VFD house etc. can be transported as a module.
7.2.3 Pack fasteners separately in units of components, and use labels to identify them. High
strength bolts and nuts for mast, crown block, deadline stabilizer and universal shaft should be packed
separately after disassembly to avoid confusing with others. Anti-rust treatment and packing should be
processed to pins and safety pins, also must be packed separately as per components they belong to; rust,
break and confusion must be avoided.
7.2.4 Dismantle air, fluid, water pipelines only after pressure released. Discharge fluid and water in
pipelines and use compressed air to dry them.
7.2.5 The connector of air, oil and water pipelines should be sealed to avoid impurities going inside
and marked at the two ends with the same number.
7.2.6 The pins, bolts and nuts for mast and substructure (including the high strength bolts and nuts
for universal shaft) should be greased and packed, put into a proper position. The high strength bolts,
nuts for universal shaft should be located at connection flanges and packed together with the universal
shaft.
7.2.7 The hose for air system should be prevented from oil and the outside screw(male) thread should
be bound up to avoid damage and you shall keep inner pipe clean.
7.2.8 For long distance transportation or long time storage, anti-rain, anti-damp and anti-rust
treatments are necessary.

31
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

7.3 Transportation
When rig is transported, make a transportation schedule according to the components dimensions
and weights Scheme a transporting load table according to the list of main components together with the
vehicles capacity. The transporting units of mast and substructure shall be put together in groups; the
other parts shall be transported together with their components

8. Main components lubrication of ZJ70DBS rig


Filling Qty.
Lubrication
No. Name Location Specification for the new
maintenance cycle
equipment
Drum shaft, Ambient temperature
coupling 20 above
Every 15days
and grease NLGI 2 lithium base 2 kg
operation
lubrication grease

Ambient temperature
20 +10ISO
VG 150
Middle extreme gear
o il
1 Drawworks Ambient temperature When the oil level is
Gear
below the mark, add
reducer box 10 +40ISO
oil in time. Replace
or chain VG 220
the oil completely 500 L
transmissio Middle extreme gear
every 6 months or
n box oil oil
the oil has been
lubrication
polluted.
Ambient temperature
+10
+60ISO VG 320
Middle extreme gear
o il
FAG-Arcanol L135V Replace the oil
Lubrication greasecompletely every 3
2 Motor Bearing 290 g
years or the oil has
been polluted
Before the raising
All sheave and lowering of the
bearing Temperature above mast and
Mast 20 substructure
3 & NLGI 2 lithium base Before th e 200 g
Substructure g re a se installation and
Pins , ear
dismantling of the
hole
mast and
substructure
Ambient temperature
Crown Sheave 20 above Every 7 days of
4 500g
block bearing NLGI 2 lithium base operation
grease

32
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Filling Qty.
Lubrication
No. Name Location Specification for the new
maintenance cycle
equipment
Ambient Temperature
Traveling
Sheave 20 above Every 7 days
5 block, 500g
bearing NLGI 2 lithium base operation
grease
lifting bail Ambient temperature
pin, thrust 20 above Every 7 days of
200g
bearing of NLGI 2 lithium base operation
each pin grease
Ambient temperature When the oil level is
6 hook 20 +50ISO below the mark, add
VG 220 oil in time. The oil
Oil sump Middle extreme should be replaced 20L
pressure gear oil completely after the
well drilling is
completed.
Ambient temperature
20 +50ISO
VG 220 every 2 months of
Oil sump 200g
Middle extreme o peration
pressure gear oil
Ambient temperature
20 above Every 200 hours of
Spinner 200g
7 Swivel NLGI 2 lithium base operation
grease
lifting bail Ambient temperature
pin, packing 20 above
of wash NLGI 2 lithium base
Every 72 hours of
tube, grease 200g
operation
bracket and
seals of
lower cover
Ambient temperature
20 +50ISO
Main oil Every 2 months of
VG 220 200L
sump operation
Middle extreme
8 ZP375RT pressure gear oil
Ambient temperature
Locking 20above Every 7 days of
100g
device NLGI 2 lithium base operation
grease
Ambient temperature
When the oil level is
20 +10ISO
below the mark, add
Gear box or VG 150
oil in time. Replace
RT drive chain drive Middle extreme
9 the oil completely 200L
device box, oil pressure gear oil;
every 6 months or
lubrication Ambient temperature
the oil has been
10 +40ISO polluted.
VG 220

33
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Filling Qty.
Lubrication
No. Name Location Specification for the new
maintenance cycle
equipment
Middle extreme
pressure gear oil;
Ambient temperature
+10 +60ISO
VG 320
Middle extreme
pressure gear oil
Ambient temperature
RT drive Bearing, 20above Every 72 hours of
10 100g
cardan shaft spline NLGI 2 lithium base operation
grease
Ambient temperature
20 +10ISO
VG 150
Middle extreme
pressure gear oil; When the oil level is
Ambient temperature below the mark, add
o il 10 +40ISO oil in time. Replace
lubrication , VG 220 the oil completely 350L
HHF-1600 oil sump Middle extreme every 6 months or
11 drilling pressure gear oil; the oil has been
pump Ambient temperature polluted.
+10 +60ISO
VG 320
Middle extreme
pressure gear oil
Ambient temperature
Bearing
20above Every 15days of
with drive 400g
NLGI 2 lithium base operation
device
grease
Ambient temperature
20 +50ISO
Every month of
Oil sump VG 220 2L
operation
Middle extreme
pressure gear oil
Gear and all Ambient temperature
12 Air winch grease 20above Every 7 days of
600g
lubrication NLGI 2 lithium base operation
points grease
Ambient temperature
When the oil level is
30 +50ISO
Oil fogger below the mark, add 0 .2 L
VG 46 oil in time.
ISO HM hydraulic oil
Ambient temperature Replace all the
Sheave 20above grease completely
400g
13 Deadline bearing NLGI 2 lithium base when the well
anchor grease drilling is completed
Weight Transformer oil When calibrating the Proper

34
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Filling Qty.
Lubrication
No. Name Location Specification for the new
maintenance cycle
equipment
indicator ISO viscosity is 8.7 weight indicator, add
sensor o il
pipeline
All kinds of Wireline Wireline surface According to the
14 Proper
wireline surface grease operation situation
Ambient temperature Replace the oil
30 +50ISO completely every 6
Oil cylinder 80L
VG 46, months or when the
YM-16- oil has been polluted
ISO HM hydraulic oil
15 hydraulic
Ambient temperature Every 7 days of
cathead
20 above operation
Sheave 100g
NLGI 2 lithium base
grease
Replace the oil 1000L
Ambient temperature
completely every 6
Oil tank in 30 +50ISO
16 HPU months or the oil has
HPU VG 46, ISO HM been polluted.
hydraulic oil
Replace the oil 1000L
Ambient temperature
completely when the
Moving Oil tank in 30 +50ISO
17 o il h as been
HPU HPU VG 46, ISO HM polluted.
hydraulic oil
As for details, please
gas/oil
refer to th e
18 Compressor separation compressor oil
compressor
cylinder
operation manual
Ambient temperature As for details, please
20 above refer to the generator
Generator diesel
19 API CH-4(CG-4) set operation manual
set generator
SAE 15W-40 diesel
engine oil
Note: The listed lube oils in this table are recommended ones. According to ISO viscosity grade
requirements, it is necessary to use the qualified lubricant. The period of lubrication and maintenance is
the period in normal operation, and can be adjusted according to the working condition together with the
quality of lubricant inspected periodically.

9. Bearing model list of main components


No. Name Location Spec. Code Model No. Qty.

Crown Crown block


1 304.8393.7107.95 37961K 7
block sheave

35
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Sand sheave 90*190*43 GB238-81 42318 2


Traveling Traveling block
2 254347.66101.6 37951K 6
block sheave
Hook loading GB4663-19
3 hook 18036082 87436ZW 1
bearing 94
Loading bearing 270550130 GB299-64 19954EQ 1
Anti-bumping
20031070 GB297-84 2007140 1
4 Swivel bearing
Upper & down
24036056 GB283-81 32148 1
alignment bearing
GB/T283-9
Horizontal shaft 150320108 NU2330E 1
4
5 RT
GB/T288-9
Horizontal shaft 150320108 22330C 1
4
6 Drawworks Drum shaft assy. 240400128 SKF 23148CA 2
285.75
Crosshead bearing 254941QU 3
206.375222.25
Pinion shaft 35022098.42 4G32844H 2
Drilling bearing
7
pump Main bearing, 500300160 3G3003760HY 2
crank shaft
863.6
Eccentric wheel 929/660.4QU 3
bearing 660.4107.95
Small b elt GB/T2
Pump
8 pulley drive shaft 150*270*73 83-94 or 22230C 2
drive device
assembly FAG, SKF

9 For bearings of other components, please see Operation manuals of the components.

10. The drilling rig operation manuals list


Item No. Name
1 ZJ70DBS drilling rig operation manual
2 DZ450/9-S1 substructure operation manual
3 JJ450/45-K Mast operation manual
4 TC-450 Crown block operation manual
5 YC-450 Traveling block & hook operation manual
6 DG-450 Hook operation manual
7 SL450 swivel operation manual
8 JC70DB Drawworks operation manual
9 ZP375 Rotary table operation manual
10 RT transmission device operation manual
11 Mud pump transmission device operation manual

36
OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Item No. Name


12 Solid control system operation manual
13 Air control system operation manual
14 Hydraulic system operation manual
15 Rig Moving hydraulic system user manual
16 Rig Moving device user manual
17 Power system operation manual
18 Electrical transmission system operation manual
19 Driller s cabin operation manual
20 Operation manual of mechanical equipments on drill floor

11 Attached drawings of drilling rig


Attached drawing 1 Plan view of ZJ70DBS rig
Attached drawing 2 Elevation view of ZJ70DBS rig
Attached drawing 3 Drive system of ZJ70DBS rig
Attached drawing 4 Foundation of ZJ70DBS rig

Translated by Date:

Proofread by Date:

Finalized by Date:

37
Attached drawing 1 Plan view of ZJ70DBS rig
Attached drawing 2 Elevation view of ZJ70DBS rig
Attached drawing 3 Drive system of ZJ70DBS rig
Attached drawing 4 Foundation of ZJ70DBS rig