山东科 瑞机械制造有限公司
 
    Shandong Kerui Machinery Manufacture Co.,Ltd.

PF-5.2/2.85/2.9
 
Hydraulic Station House  
 

Service Manual 
 

KR114.37.00SM

Edition: 2012-A

Dongying. China
 KR114.37.00 SM
Shandong Kerui Machinery Manufacture Co., Ltd

Preface

Thank you for choosing the products of Shandong Kerui Company.

In order that the operator and maintainer get familiar with this set of equipment and that has
regulations to maintain equipment, this manual is, thus, formulated. This manual presents the
specific requirements on the maintenance of equipment.

Correct using method and maintaining measures, not only can keep the equipment under good
state for a long time, improve the production efficiency and reduce downtime loss, but also
prolongs its service life to a maximum limit.

To ensure a safe, steady and reliable operation of the products, please read this set of
accompanying documents, especially those items of safety cautions.

Since the product involves a wide range of stuff, this manual presents only the main parts. As for
equipment not mentioned or introduced briefly, refer to their technical documents respectively for
details.

。Special information：
All the information included in this manual is based on the available newest
information when publishing. We keep the right to make amendment at any time and
not give further notice. Without obtain KERUI company written permission，written
authorization, strictly prohibit second edition, storing the accessible system, or
make any conversion in any type. Include electron, machinery, photo, tape or other
type etc. These contains should include words, figure or form.

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Important Safety Declaration

This manual may not list in details all the safety caution information, so the
product’s operation, management, handling, maintenance personnel shall be
familiar with the content of this manual, and comply with all the related standard
procedure, and pay special attention to safety cautions, notices as well as
national laws and regulations, industry requirements and the common sense of
security provisions and precautions to avoid human injury and equipment
damage. No matter what method is taken, it shall be confirmed that the method
will do no harm to personal safety, or equipment.
The correct maintenance is an important factor for safe and reliable
operation of the products. The users shall do the maintenance in the way this
manual shows.
Correct maintenance and change of the original factory’s parts are the
important factors for safe and reliable operation. The users shall do the
maintenance and change of the parts according to the warrant of the factory.

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Shandong Kerui Machinery Manufacture Co., Ltd

Please read carefully when the manual uses the following captions and signs!

Note! For providing extra operating procedure information;

Attention! Applied to the situation where equipment damage may occur if

imprecisely observe operation process, methods, etc.

Warning! Information with this symbol is very important for safety operation
and maintenance. Not complying with these warnings may bring heavy
casualties or equipment damage.

                

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Catalogue 
PREFACE ..................................................................................................................... 1
IMPORTANT SAFETY DECLARATION ............................................................... 2
CHAPTER ONE SAFETY RULES ........................................................................... 5
1.1. Qualification requirements for hydraulic station house user................. 5
1.2 SAFETY PROTECTION REQUIREMENTS FOR HYDRAULIC STATION HOUSE USER . 5
1.3 Safety requirements for operating and maintaining equipment in hydraulic
station house ........................................................................................................... 5
1.4 OTHER SAFETY ITEMS .......................................................................................... 6
1.4.1. Correct use of common tools ........................................................................ 6
1.4.2 Prevention of falling accident ........................................................................ 6
1.4.3 Safe habits ...................................................................................................... 7
CHAPTER TWO SUMMARY OF HYDRAULIC STATION HOUSE .................. 8
2.1 Overview ........................................................................................................... 8
2.2 Model Illustration ............................................................................................. 8
2.3 Main Technical Parameters ............................................................................... 8
2.4 Design Standard ................................................................................................ 9
CHAPTER THREE STRUCTURE AND WORKING PRINCIPLE ................... 10
3.1 Connection Device .......................................................................................... 11
3.2 Railing ............................................................................................................. 12
3.3 Roof ................................................................................................................ 13
3.4 Base ................................................................................................................. 13
Chapter Four Usage Care and Maintenance ......................................................... 14
4.1 INSTALLATION .................................................................................................... 14
4.2Usage Maintenance Routine Order .................................................................. 14
CHAPTER FIVE TRANSPORTATION AND STORAGE.................................... 16
5.1 The transportation of hydraulic station house ................................................. 16
5.2 Notes during hoisting and transportation ........................................................ 16
5.3 Main parts parameters for hydraulic station house ......................................... 16
5.4 Storage ............................................................................................................ 17
CHAPTER SIX TECHNICAL DOCUMENTS ALONG WITH RIG .................. 18
6.1 Product Qualification Certificate .................................................................... 18
6.2 Shipping List, Pack List and Loading List ..................................................... 18
6.3 Delivery Drawing along with Rig ................................................................... 18
  

 
 

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 KR114.37.00 SM
Shandong Kerui Machinery Manufacture Co., Ltd

Chapter One Safety Rules 

To avoid possible casualties, environment pollution, equipment damage and

property loss accident in process of installation, debugging, producing,
maintenance and overhaul, the safety rules are made according to related industry
standard specification.

1.1. Qualification requirements for hydraulic station house

user

The hydraulic station house is place to lay integrated hydraulic station and disc
brake hydraulic station, therefore, the hydraulic station house user has to be health,
without diseases affecting their jobs;

1.2 Safety protection requirements for hydraulic station

house user
For the purpose of reducing accident injury and occupational hazards, the working
environment shall reach the safety working requirements, the operator must be
equipped with protective equipment, and choose the relevant protective tools in the
workplace according to the work character and protection goal, and wear the tool
correctly.

Drilling company’s safety rules, host country’s and local labor protection law &
regulations shall specify the requirements and standards for wearing of mud labor
protection appliances, and the distribution of hydraulic station house user’s protection
appliance shall be according to SY/T 6524-2002 Oil Industry operation site laboring
safety appliance for using equip request.

1.3 Safety requirements for operating and maintaining

equipment in hydraulic station house

1) the hoisting wireline’s dia. shall no less than 22mm, and fixed fastened;
2) Sound insulation facilities shall be complete, and the noise

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figure shall be lower than clients’ requirements or those of local relevant

noise standards;
3) Each handrail has complete protection device and fixed fastened;

1.4 Other safety items

1.4.1. Correct use of common tools

Inspect carefully before using the tools. Wipe the tools clean before using or
stowing the tools and the tools shall not be put casually or even on a high place where
easy to fall. Tool storage method should make it free of damage. Put tools with cutting
edge into the toolbox, with edges covered. The tools in the toolbox shall take regular
anti-rust treatment.

To use tools better and more safely, the following are some suggestions:

1) Educate the worker to choose the right tools for each job. Help and direct the
worker to have the analysis and training about safe tool use, and then develop the
safety habit of choosing and using tools correctly;

2) Establish normal tool inspection standard and specification. Tools owned by

the workers shall also be inspected. Provide the well-site with good tools service
facilities and keep tools in good conditions;

3) Company’s tool management rules, such as rules on inspection of

hydraulic station house, should be established;

4) Provide proper depositing facilities for all kinds of tools.

1.4.2 Prevention of falling accident

To eliminate the falling accident, an overall, reasonable checking and

maintenance route shall be established and be executed strictly and seriously.

1）Check all parts of the roof and equipments of hydraulic station house,
especially various ropes and bolts, nuts which shall be often checked carefully for it
will be favorable for confirming the parts kept in solid and not dangerous condition,
and finding and dealing with the hidden troubles in time.

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Shandong Kerui Machinery Manufacture Co., Ltd

2) Special attention shall be paid to the handy tools’ management. When

climbing the ladder, do not carry handy tools but pay attention to put hands on the
ladder railings with the tools in special work bag to secure self and the personnel
below.

3）When hand tools are needed above roof by anyone at anytime, they should be
hoisted there by a strong rope and then lowered down to the ground immediately after
use. Tools can also be hoisted in tool bags but the bags shall be well carried with the
opening shall be fastened tight in case that tools or tool bags fall.

1.4.3 Safe habits

Developing good safety habits is the most effective way to preventing accidents.
Good habits mean being alert to avoid accidents and be careful of the danger. In short,
it means owning adequate safety awareness, and perfectly executing it at work.
Good safety habits is very important for correctly using hydraulic station house,
prolonging the its service life, guaranteeing operator’s health, so drilling companies in
their daily work shall train and require employees as follows:
1) Organize study classes regularly for HSE propaganda, education and training
to improve their physical quality, protection skills, and environment
sanitation condition;
2) Establish and improve various safety management system, and get HSE
protection management throughout the process of installation, using,
operation, maintenance of the drilling rig to minimize various risk;
3) Create safe healthy working environment and promote the working quality;
4) Try best to avoid or reduce the environment pollution, minimize the
environmental destruction during the drilling work.
5) Wear seat belts or other safety measures when working at a distance of 2
meters above ground;
6) Substances that are flammable, explosive, toxic and radioactive shall not be
carried by any hydraulic station house user;
7) No drinking when in or before post and no smoking in post.

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Chapter Two Summary of Hydraulic Station House

2.1 Overview

PF-5.2/2.85/2.9 hydraulic station house is placed on the upper layer of

substructure, mainly for the use of laying integrated hydraulic station and disc
brake hydraulic station, as well as providing space for cable laying.

2.2 Model Illustration

PF – 5.2 / 2.85 / 2.9

Dimension

Code

2.3 Main Technical Parameters

Dimension 5.2 m×2.85 m×2.9m（L×W×H）

Weight 3622 kg
Internal collocation integrated hydraulic power station 1set
Disc brake hydraulic power station 1set

Total weight ≤5000kg

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 KR114.37.00 SM
Shandong Kerui Machinery Manufacture Co., Ltd

Figure 1 Hydraulic station house nameplate

2.4 Design Standard

SY/T5609-1999 the Types and Basic Parameters for Oil Drilling Rigs
ANSI/AWS D1.1-2006 Structural Welding Code - Steel
SY/T5307 General Technological Specifications of Weld Assembly for Petroleum
Equipment
SY/T5957-94 Well Site Electrical Mounting Technique Requirements
AISC-USA Specification for Structural Steel Buildings

 
 
 

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Chapter Three Structure and Working Principle 

Hydraulic station house is placed on dog house support, after been fixed, the
upper surface of foundation is flush with drill floor; there has project lamp on the
roof for drill floor lighting.

Figure 2 Front view

Figure 3 Section view

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 KR114.37.00 SM
Shandong Kerui Machinery Manufacture Co., Ltd

Figure 4 Side view

3.1 Connection Device

Figure 5 Connection device

The connection device is used for fixing hydraulic station house and drill floor, after been

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fixed; the upper surface of foundation is flush with drill floor.

3.2 Railing

Figure 6 Railing 1

Figure7 Railing 2

Railing1 and 2 should be installed in accordance with drawing requirements.

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 KR114.37.00 SM
Shandong Kerui Machinery Manufacture Co., Ltd

3.3 Roof

Figure8 Roof

The roof frame is welded by rectangular tube, t3 corrugated plate forms a

pinnacle structure, so that the roof is firm and flexible, and convenient for dewatering
in time;

3.4 Base

Figure 9 Base
The base frame is welded by H beam and U bar, with t6 riffled plate on it.

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Chapter Four Usage Care and Maintenance

4.1 Installation
Hydraulic station house is installed before rising substructure.
First hoist it up to dog house support, and connect it to drill floor by connecting
device.

When transporting and moving must using crane to hoist,

Strictly prohibit dragging on any base ground using
special trapeze. Strictly prohibit other non hoisting lifting
eye or other construction body, otherwise will incur
other construction items damage and influence normal function.

4.2Usage Maintenance Routine Order

When using hydraulic station house ， besides obey the

following blow care and maintenance terms, still follow
drilling rig usage related terms. Related terms refer to
drilling rig instruction manual.

The users should examine the well site appearance of hydraulic station house at
fixed period on schedule, and report the result. The examining frequency should be
one time in one drilling month ordinary.
The user should check the base of the hydraulic station house during usage period,
stand column deformation or damage, the cracking of the welding line of main stress
area, the looseness of bolts and nuts. If there any problem, should eliminate and
repair.
When finding the damaged parts and elements, should mark clearly and obviously,
so enable carry on necessary repair. For this, suggest using bright and color distinct

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Shandong Kerui Machinery Manufacture Co., Ltd

painting mark, and clean all the painting mark after repair. Original element painting
deciduous should paint according the hydraulic station house original color.
Without permission not allow welding and drilling on the internal equipment of
hydraulic station house, for those construction items that damaged and lost during
transportation and usage can not be replaced at will, should ask for consultation from
our company. For those already damaged parts repair should negotiation with our
company so enable to make confirmation about the hydraulic station house material
and repair way. Without getting permission of our company, the operator and repair
construction technology should be approved by the machinery responsible engineer
before repairing.
During using hydraulic station house, should maintain one time per year,
ordinary conditions, the base, columns, roof, and wall of hydraulic station house
should do one time rust removal and antiseptic treatment.
Before sealing up for safe keeping should clean the surface of the room body and
dust, foul and water absorption material. All pin holes, axles are coated with greases
and wrapped well.

Note！
The environmental temperature should higher
than‐20℃。If less than such grade and using under such
working condition, should make confirmation to the cryogenic
property and taking necessary safeguard procedure and carry
on according to the cryogenic working rules API RP‐4G
chapter 16!

Warning! Without manufacturer and special administration

permission, drilling hole, cut hole and carry on welding work to the
hydraulic station house any construction element are prohibited.

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Chapter Five Transportation and Storage

5.1 The transportation of hydraulic station house

Avoid construction items collision or transformation during hydraulic station

house move and transportation; if finding any damaged or bent items, the work should
make repair and change in time because of collision.
Avoid damaging the protective layer and painting layer during loading hydraulic
station house because of collision.
When transportation during midway, every parts of hydraulic station house
should be fastened firmly, small items should be bunched in cartons to avoid lost during
transportation or other accident occurring, make sure hydraulic station house
transportation safety.

5.2 Notes during hoisting and transportation

☆ during hoisting transportation, the worker should use wire line to hang the
hydraulic station house trapeze.
☆ Using lifting appliance to hoist hydraulic station house.
☆ during transportation, the worker should adopt suitable support and suitable strap
to avoid striking and damaging hydraulic station house or overturn.

5.3 Main parts parameters for hydraulic station house

For the convenience of hoisting and transporting, herein list the house’s main
parts dimensions and weight:
Chart 1 main parts dimensions and weight
Item Drawing No. Name Qty. Dimension(L×W×H) Weight kg
1 KR114.37.00 House 1 5220×2850×2920 3662
2 KR114.37.01.00 Base 1 5220×2850×220 1880
3 KR114.37.06.00 Roof 1 5220×2850×160 900
4 KR114.36.06.00 Railing 1 2 2530×1070×48 69×2=138
5 KR114.37.08.00 Railing2 1 4900×1070×48 137

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Shandong Kerui Machinery Manufacture Co., Ltd

5.4 Storage

Before hydraulic station house sealing up for keeping should clean hydraulic
station house body and base surface, clean dust and foul and water absorbing material,
all the ear pad, pin hole, pin shaft spread on antirust oil.
Hydraulic station house should be placed on the flat, solid and good drainage dry
ground to avoid hydraulic station house deformation or water erosion.

Wire line and accessories should be painted antirust oil, using plastic wrap up and
keep in the dry place.
Suggest all the pins, bolts and nuts and some field connection small items, put in
the carton after marking and painting antirust oil.

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Chapter Six Technical Documents along with Rig 
The technical documents of hydraulic station house along with rig are
as follows:

6.1 Product Qualification Certificate

6.2 Shipping List, Pack List and Loading List

6.3 Delivery Drawing along with Rig

SUKR114.37.00 hydraulic station house

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