ZJ70-4500 DBS Drilling Rig User Manual

User Manual of ZJ70DBS Drilling Rig
前言
ZJ70DBS 钻机是按 SY/T 5609-1999《石油钻机型式与基本参数》及有
关 API 规范设计制造的石油钻机。可满足中深井石油、天然气勘探和开发
钻井的需要。
本手册从总体上描述了钻机的总体结构、性能特点、技术参数以及钻机
的安装调试、操作维护、拆卸运输等内容。
负责钻机安装、操作、维修的人员在安装使用钻机之前，请详细阅读本
钻机用户手册及本钻机所配套各部分的用户手册，并按各手册的要求安装、
使用、维修钻机。若不了解相关内容，错误的安装、操作或维修可能会到导
致人身伤害或设备损坏。
钻机的前、后是这样确定的：井口位于前面，动力机房位于后面。
ZJ70/4500DBS Drilling Rig
钻机的左边和右边是从井口向动力机房看来确定的。
ZJ480-SC
March, 2014
第 I 页，共 37 页
Foreword
ZJ70DBS drilling rig is a petroleum drilling rig which is designed and manufactured as
per GB/T 23505-2009 Petroleum drilling and workover rigs and related API specification. It
can satisfy the requirements on middle and deep well drilling for petroleum and gas
exploration and development.
This manual generally describes the overall structure, performance characteristics,
technical parameters, installation and commissioning, operation and maintenance,
dismantlement and transportation etc of the drilling rig.
Before installation and operation, the personnel engaged in installation, operation and
maintenance shall read this manual and user manuals of supporting components carefully, and
then install, operate and maintain the drilling rig as required. Improper installation, operation
or repair may cause personal injury or equipment damage if operators do not know relevant
contents.
The front and the back of the drilling rig are determined as follows: the wellhead is in the
front, and the DW is at the back.
The left and the right of the drilling rig are determined by viewing from the wellhead to
the DW.
Contents
1. Safety warnings ....................................................................................................................... 1

2. Description of drilling rig ........................................................................................................ 1
2.1. Purposes and application range .................................................................................... 1
2.2. Standards and specifications for design and manufacture............................................ 1
2.3. Main technical parameters ........................................................................................... 2
2.4. Major corollary equipment list of ZJ70DBS drilling rig.............................................. 2
3. Structural features of ZJ70DBS drilling rig ............................................................................ 4
3.1. Overall structure of drilling rig .................................................................................... 4
3.2. Structural features of drilling rig .................................................................................. 5
3.3. Speed and lifting capacity of hook ............................................................................... 6
4. Installation of drilling rig ........................................................................................................ 7
4.1. Preparation work before installation ............................................................................ 7
4.2. Installation sequence diagram of drilling rig................................................................ 8
4.3. Installation of all parts of drilling rig ........................................................................... 8
4.4. Check after installation............................................................................................... 11
5. Commissioning of drilling rig ............................................................................................... 14
5.1. Preparation work before commissioning.................................................................... 14
5.2. Commissioning of diesel generator set ...................................................................... 14
5.3. Power supply commissioning of VFD system ........................................................... 14
5.4. Commissioning of electric drive system .................................................................... 15
5.5. Commissioning of driller's control cabin, instrument and meter system ................... 15
5.6. Commissioning of air supply system equipment ....................................................... 16
5.7. Commissioning of hydraulic system .......................................................................... 16
5.8. Commissioning of hydraulic disc brake ..................................................................... 16
5.9. Running commissioning of DW ................................................................................. 16
5.10. Running commissioning of RT ................................................................................ 18
5.11. Commissioning of utilized mud pump ..................................................................... 18
6. Mast and substructure lifting and mast alignment ................................................................ 18
6.1. Check before mast lifting ........................................................................................... 18
6.2. Trial lifting of mast ..................................................................................................... 18
I
6.3. Lifting of mast ............................................................................................................ 19

6.4. Check before substructure lifting ............................................................................... 20
6.5. Lifting of substructure ................................................................................................ 20
6.6. Mast alignment ........................................................................................................... 21
6.7. Parts installed after mast and substructure lifting ...................................................... 21
6.8. Commissioning of drilling instruments ...................................................................... 21
6.9. Adjustment of wireline on DW drum and test of crown block saver ......................... 21
6.10. Test of hydraulic and pneumatic implements ........................................................... 21
6.11. Running test of solids control system....................................................................... 21
6.12. Test of high pressure manifold and cementing manifold ......................................... 22
6.13. Check of standard electric system on well site ........................................................ 22
6.14. Test of monitoring and communication systems ...................................................... 22
6.15. Linkage test of whole drilling rig ............................................................................. 22
7. Operation and maintenance of drilling rig ............................................................................ 22
7.1. Warnings ..................................................................................................................... 22
7.2. Precautions for drilling rig operation ......................................................................... 23
7.3. Safety techniques for drilling rig operation................................................................ 24
7.4. Maintenance regulations of drilling rig ...................................................................... 25
7.5. Operation and maintenance during algid stage .......................................................... 28
7.6. Accident and emergency treatment ............................................................................ 28
8. Disassembly and transportation of drilling rig ...................................................................... 29
8.1. Lowering of mast and substructure of drilling rig...................................................... 29
8.2. Disassembly of drilling rig ......................................................................................... 30
8.3. Transportation of drilling rig ...................................................................................... 30
9. Lubrication table for main components ................................................................................ 31
10. Main part bearing model summary list ............................................................................... 35
11. User manuals list ................................................................................................................. 36
12. Attached drawings of drilling rig ........................................................................................ 37
II
1. Safety warnings
Only trained and qualified operators can install, operate and repair equipment with
qualification certificates.
Before the installation, operation and maintenance of the drilling rig, operators shall
read this manual and user manuals of all equipment belonging to the drilling rig
carefully, and then install, operate and maintain the drilling rig as per the
requirements in the manuals.
There shall be a chief principal designated for installation, operation and
maintenance, the persons participating in work shall be assigned with clear work,
and detailed and reliable safety measures shall be available.
In operation process, strictly execute operation specifications and technical safety
rules.
It is forbidden to maintain and repair equipment during its operation.
Do not overload equipment.
2. Description of drilling rig

2.1. Purposes and application range
ZJ70DBS drilling rig is a petroleum drilling rig which is designed and manufactured as
per SY/T 23505-2009 Petroleum drilling and workover rigs and related API standards. Its
performances can meet middle depth well drilling application for land oil and gas exploration
and development in areas at an ambient temperature from -18℃ to +50℃ and an air humility
not more than 90% (+20℃).
2.2. Standards and specifications for design and manufacture
2.2.1. GB/T23505-2009 Petroleum Drilling and Workover Rigs
2.2.2. API Spec 4F Specification for Drilling and Well Servicing Structures, the 4th edition
2.2.3. API Spec 7K Specification for drilling and well servicing equipment, the 5th edition
2.2.4. API Spec 8C Specification for drilling and production hoisting equipment, the 5th
edition
2.2.5. API Spec 9A, Specification for wire rope, the 26h edition
2.2.6. AWS D1.1 Structural welding code-steel
2.2.7. API RP 505 Recommended practice for classification of locations for electrical
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installations at petroleum facilities

2.2.8. IEC 60079-2004 Electrical apparatus for explosive gas atmospheres-general
requirements
2.3. Main technical parameters
Nominal drilling depth (4 1/2'' (114mm) DP) 4500-7000m
5'' (127mm) DP 4000-6000m
Maximum hook load 4,500kN
Input power of DW 2000kW
Lines of hoisting system 6×7, along the line
Diameter of wireline φ38mm
Power ×number of mud pumps 1600hP×3
Nominal opening diameter of RT 952.5mm (37 1/2'')
Effective height/type of mast 45.5m/K type
Height of drill floor 10.5m
Clear height of substructure 9.1m
Hoisting gear number one gear, stepless speed regulating
Gear number of RT one gear, stepless speed regulating
Power× number of main diesel generator set 1200kW×4
Power× number of auxiliary diesel generator set 364kW×1
Drift diameter/rated pressure of drilling fluid manifold double standpipe 4''/35MPa
Total volume of mud tanks ≈452m3
2.4. Major corollary equipment list of ZJ70DBS drilling rig
No. Description Qty. Remarks
I Equipment of lifting system
JC70DB DW (including hydraulic disc API Spec 7K (components and
1 1 set
brake) parts), the 5th edition
2 JJ450/45-K mast (including accessories) 1 set API Spec 4F-2013, the 4th edition
DZ450/10.5-G substructure (including
3 1 set API Spec 4F-2013, the 4th edition
accessories)
API Spec 8C-2012, the 5th edition
4 TC450 crown block 1 set
API Spec 4F-2013, the 4th edition
5 YC450 travelling block 1 set API Spec 8C-2012, the 5th edition
6 DG450 hook 1 set API Spec 8C-2012, the 5th edition
2
Drilling wireline 6×19S+IWRC EIPS

7 1 coil API Spec 9A, the 26th edition
level φ38
8 Electric wireline spooler 1 set
9 Deadline anchor JZG41 1 set
10 YM-16-II hydraulic cathead 2 sets
Two is on drill floor and one is at
11 5T air winch 3 sets
catwalk.
12 0.5T air winch 2 sets
13 Composite HPU 1 set
II Equipment of rotating system
1 RT ZP375 1 set API Spec 7K-2010, the 5th edition
2 RT bushing 1 set
3 RT drive device 1 set
III Equipment of circulating system
API Spec 7K (parts and
1 HHF-1600 drilling mud pump 3 sets
components), the 5th edition
2 Utilized mud pump 3 sets
3 Drilling fluid manifold 1 set
4 Rotary hose 23m/19m, 35Mpa 1 for each
5 Solids control system 1 set
Equipment of power and air supply
IV
system
1 Diesel generator set CAT 3512B 4 sets
2 Auxiliary generator set CAT C15 1 set
3 Generator and air supply house 1 set 5 buildings
4 Air supply system 1 set
V Electric drive and control system 1 set
1 VFD house and MCC control system 1 set
2 Power cable 1 set
VI Equipment of driller's control system
1 Driller's control cabin 1 set
Drilling engineering parameter
2 1 set
instrument system
3
3 Monitoring system 1 set

4 Communication system 1 set
VII Standard electric system on well site 1 set
VIII Detection instrument and tool
1 Detection instrument 1 set
2 Special tool 1 set
IX Auxiliary equipment
1 Driller's control cabin 1 building
2 Catwalk, DP rack 1 set
4 Escape device on monkey board 1 set
5 Cable tray 1 set
6 Fuel tank 60m3×2 1 set
7 Camp oil storage tank 40m3 1 set
8 Overhead oil tank 30m+5m 1 set
9 Water tank 80m×2 1 set
3. Structural features of ZJ70DBS drilling rig

3.1. Overall structure of drilling rig
3.1.1 The layout of drilling rig refers to plan in attached drawing 1 and elevation in attached
drawing 2.
3.1.2 The drive principle of drilling rig refers to drive system drawing in attached drawing 3.
3.1.3 The placement positions of all components for drilling rig refer to foundation drawing in
attached drawing 4.
The drilling rig is divided into five parts of drill floor area, power area, pump house area,
solid control area and oil and water supply area. After the drilling rig is assembled, its floor
space is about 100m×50m (excluding tool house and accommodation etc).
The drill floor area comprises mast, substructure, crown block, traveling block, hook and
swivel, and DW, RT drive device, RT, driller's control cabin and doghouse which are installed
on drill floor, and all drill floor implements etc necessary for drilling operation.
The power area comprises generator and air supply houses and electric control house. The
generator and air supply houses are installed and communicated with one another to form a
whole electricity generation and air supply area, and the electric control house is arranged on
one side of the generator house near mud pumps.
The pump house area comprises three HHF-1600 utilized mud pumps.
4
The solid control area is provided with mud tanks, mud processing equipment and
industrial water tanks of solid control system.
The oil and water supply area is provided with all oil tanks and water tanks etc.
The drilling fluid manifold comprises standpipes and ground manifolds.
The areas of the drilling rig are connected by cable trays, and all oil, water and air main
pipelines and cables are arranged in the cable trays.
Catwalk, DP rack and wireline spooler are arranged in the front of the drilling floor.
3.2. Structural features of drilling rig
ZJ70DBS drilling rig is designed by integrating mechanical, electrical and digital control
techniques, mainly achieves digital control function and primarily has automation,
intelligentization and informationization functions. All parts of the drilling rig adopt mature
and advanced techniques at home and abroad for structural design, work reliably, are moved
and transported conveniently, run economically and meet HSE requirements.
DW, RT and mud pump all adopt independent alternating-current variable frequency
electric driving systems without mutual interference and can better meet drilling application.
Mast has a K type structure and meets the requirement of supporting Varco TDS11SA top
drive device, and substructure has a slingshot type structure. Mast and substructure are both
raised by the power from DW. Main equipment and driller's control cabin etc on drill floor are
all installed at low positions.
DW is a single-shaft DW with simple structure and drives drum through two reducing
gear boxes by using two 1000Kw variable frequency motors, and main brake is a hydraulic
disc brake, safe and reliable. All running parameters of DW comprise tripping speeds and hook
position, and all safety devices can be controlled digitally.
RT is independently driven by an alternating-current variable frequency motor through
angle gear box and cardan shaft and provided with inertia brake. Control system has complete
monitoring and over-torsion protection functions.
Three 1600HP mud pumps are arranged, and each pump is directly driven by one
alternating-current variable frequency motor with high reliability and convenient displacement
regulation.
Power system is provided with four 1200kW diesel generator sets and one 292kW
auxiliary generator set and has enough standby power, and the drilling rig has strong
self-maintaining capacity.
Electric drive system adopts a vector variable-frequency driving system, and main
electric equipment is arranged in VFD house.
5
An integrated driller's control cabin is provided, driller completes main operations of the
drilling rig in the driller's control cabin, and the real-time display, storage, print and
management of parameters (signals) are achieved.
3.3. Speed and lifting capacity of hook
3.3.1 Lifting capability (12 lines)
Motor Hook Lifting capacity kN

speed speed Continuous Continuous
Short-time condition
condition (single condition (double
n(r/min) m/s motor) motor)
(double motor)
0 0 1723.8 3447.6 4550.8
158.6 0.09 1723.7 3447.4 4550.6
318.6 0.17 1723.7 3447.4 4550.6
478.7 0.26 1723.7 3447.3 4550.5
638.7 0.35 1723.7 3447.4 4550.6
800.7 0.43 1731 3461.9 4569.8
838 0.45 1653.5 3307 4365.3
877.4 0.47 1579.7 3159.4 4170.3
926.5 0.5 1496.3 2992.5 3950.1
965.8 0.52 1434.8 2869.6 3787.9
1005 0.54 1379.2 2758.3 3641
1044.2 0.56 1327.2 2654.5 3503.9
1083.4 0.59 1279.4 2558.8
1122.6 0.61 1234.6 2469.3
1161.6 0.63 1192.8 2385.7
1200.7 0.65 1154.3 2308.6
1340.7 0.72 931.1 1862.1
1480.7 0.8 766.7 1533.5
1620.7 0.88 642.4 1284.8
1760.7 0.95 545.9 1091.7
1900.7 1.03 469.5 939
2040.7 1.1 408 816
2180.7 1.18 357.8 715.6
2320.7 1.25 316.3 632.6
3.3.2 Lifting curve (12 lines)
6
3.3.3 The max. lifting capacity of the auxiliary driving device is 3280kN (12 lines), and the
max. hook speed is 36.3m/h (12 lines).
4. Installation of drilling rig

The installation of the drilling rig shall conform to the requirements of SY/T 6586-2012
site installation and inspection for drilling rigs and also accord with the requirements in this
manual.
4.1. Preparation work before installation
Only trained and qualified persons can install the drilling rig with qualification
certificates.
The personnel engaged in installation of drilling rig, particularly the person in charge of
the installation shall first read this manual and user manuals of all parts to make them know
the structural features and the installation and commissioning requirements of the drilling rig
and its parts.
All tools and equipment for installing the drilling rig shall be complete and have good
service performance. Metering devices and instruments used shall be qualified.
Well site and foundation for installing the drilling rig shall accord with requirements of
drawing samples and technical files approved as per specified procedures.
As the drilling rig is heavy equipment, ensure personal safety and equipment safety in the
installation process, ensure enough capacity of lifting equipment and lifting belt for heavy and
large modules, and ensure their completeness in the use process.
Check equipment, parts and components for completeness, qualification and damage
7
before the installation of the drilling rig, clean and remove dirt from the parts and components.
4.2. Installation sequence diagram of drilling rig
Substructure Mast Crown block
Generator and air supply DW RT and drive device

house and electric control
house
Drilling fluid manifold standpipe Traveling block and hook

Utilized mud pump
Doghouse Cable tray Driller's control cabin
Ground part of drilling fluid manifold Solids control system Oil tank and water tank
Commission rig Reeve wireline Raise mast and substructure Correct wellhead
Wellhead mechanical tool Commission whole rig
Note: other auxiliary facilities can be crossways installed while ensuring safety and
available field.
4.3. Installation of all parts of drilling rig
As per the plan of the drilling rig, take the wellhead center as a reference, loft on the
plane of the well site foundation, draw installation datum line for each area, and pave
steel-wood foundation as per the foundation drawing of drilling rig.
4.3.1 Installation of substructure (please refer to the User Manual of DZ450/10.5-G
Substructure for details)
Use wellhead centerline and the drawn lines of drill floor area as references, place the left
and right base seats of the bottom layer basement of the substructure, connect the left and right
base seats into a whole, install all columns and tie rods of the middle layer, and finally install
DW beam, RT beam, setback beam, floors, A-frame and other auxiliary parts of the top layer.
Notice: the floors on two sides of the setback shall be installed after the substructure is
lifted; except the ladders to drill floor, the ramp, the safety slide and the ladders to solid
control etc shall be installed after the substructure is lifted.
4.3.2 Installation of generator and air supply house and electric control house (referring to the
8
plan of generator and air supply house in detail)

Place VFD house as per the plan of the drilling rig and the lofting and marking positions,
and place all generator and air supply houses in sequence. It is required that the VFD house
and the 1# generator houses are placed vertically with front edges aligned.
Connect the oil supply pipelines and the air pipelines of all machines and the connecting
pipelines among devices of the air supply system.
Install mufflers for diesel engines.
4.3.3 Installation of DW
The DW had been assembled and commissioned before delivery from factory. There are
positioning blocks at corresponding positions of substructure. Lift the DW onto the DW beam
of the substructure and install it in place as per the positions of the positioning blocks. Fasten
the bolts connected with the DW beam.
4.3.4 Installation of RT and drive device
The RT driving device (except the cardan shaft) had been installed on the motor beam of
eth substructure integrally and is installed together with the motor beam.
Lift and place RT on RT beam, connect by using pin and install safety pin.
Install the cardan shaft, and ensure that the parallelism tolerance of flange faces at two
ends of the cardan shaft is not more than 1.0mm.
4.3.5 Installation of mast (referring to the User Manual of JJ450/45-K Mast in detail)
Before installation, check the appearances of mast components, repair or replace the
positions deformed or damaged, and rotate every rope guide sheave which shall be flexible
without blockage.
The installation of the mast conforms to the sequence of lower parts, upper parts, main
body and accessories. Alternately move bracket, install mast main body and accessories, and
then support the mast by high stand to install monkey board (including 0.5t air winch).
4.3.6 Installation of standpipe of drilling fluid manifold
When the mast is at low position, install the standpipe of the drilling fluid manifold on
the mast, and then connect and seal it by unions reliably.
4.3.7 Installation of crown block (referring to the User Manual of TC450 Crown Block in
detail)
The crown block is connected with the mast by bolts. The accessories of the crown block
such as auxiliary sheave, lifting frame and climbing assistantor etc shall be installed
completely.
4.3.8 Place the wireline spooler as per the positions shown in the plan.
9
4.3.9 Install traveling block and hook, reeve hoisting wireline and drilling wireline (along the
line).
4.3.10 Installation of driller's control cabin
Lift the driller's control cabin onto the drill floor, and connect the lines of the pneumatic,
hydraulic and electric systems as per serial numbers.
4.3.11 Installation of cable tray
Install it as per the plan of the drilling rig and the cable tray general drawing. Connect the
pipelines of all systems, and install the cables and wires as per the User Manual of Electric
System.
4.3.12 Installation of utilized mud pump
Install the utilized mud pump as per the lofting and drawing positions of the plan of the
drilling rig.
4.3.13 Installation of ground part of drilling fluid manifold
Install it as per the User Manual of Drilling Fluid Manifold, and connect it with the
standpipe part and the mud pump discharge pipeline.
4.3.14 Installation of solids control system
Install the mud tanks of the solid control system as per the lofting and drawing positions
of the plan of the drilling rig, install the equipment in and on the tanks as per the User Manual
of Solid Control System, and connect the communicating pipes among the tanks and the mud
pump suction pipelines.
4.3.15 Installation of standard electric system on well site (referring to the User Manual of
Standard Electric System on Well Site in detail)
4.3.16 Installation of drilling instruments
Install the drilling instruments as per the requirements in the User Manual of Drilling
Instruments.
4.3.17 Installation of monitoring system and communication system
Install the monitoring system and the communication system as per the User Manual of
Electric Drive and the elevation and the plan of the drilling rig (except the parts installed after
mast and substructure are lifted).
4.3.18 Installation of auxiliary equipment
Install the auxiliary equipment as per the elevation and the plan of the drilling rig.
4.3.19 Installation of oil tanks and water tanks
Install the oil tanks and the water tanks as per lofting and drawing position of the plan of
the drilling rig, and connect the pipelines among the cable trays, the oil tanks and the water
10
tanks.
4.4. Check after installation
4.4.1 The pretension torques for bolt connection are shown in the following table, and check
every main stressed bolt by force moment spanner one by one.
Bolt Bolt nominal diameter/mm
strength 16 20 24 27 30 36 42
grade Pretension torque/N.m
8.8 185-259 361-505 623-873 919-1286 1243-1740 2178-3049 3492-4889
10.9 260-364 507-710 877-1227 1292-1809 1748-2448 3063-4289 4911-6875
4.4.2 Check after substructure installation

The difference among the diagonal sizes of four support pin shaft holes at the inner
side of the rear tops between the left and the right lower seat cannot be more than 5mm.
Installation of every connector and fastener must be complete and fastened. Grease
pins at rotating parts.
Each part shall not have serious deformation, and each weld shall not have crack and
opening.
Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
There is no barrier to block driller's eyesight on the drill floor.
Buffering cylinders of substructure work normally.
The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
4.4.3 Check after mast installation
Grease every lubrication point as required.
Installation of every connector and fastener must be complete and fastened.
opening.
All auxiliary facilities assembled on the mast are complete and good.
Buffering cylinders of mast work normally.
Hoisting wireline and drilling wireline are complete and reeved correctly, and their
ends are fastened tightly.
No tools and stuffs are left on the mast.
Weight indicator works normally.
4.4.4 Check after installation of DW
11
Check and ensure all guards are installed completely and pipelines are connected
correctly and reliably.
Grease all lubricating points as required.
Grease main speed reducer as per requirements in its user manual.
The pipelines of hydraulic source, operating cabinet and control cabinet of hydraulic
disc brake and brake caliper system are connected correctly and sealed reliably without
leakage.
Check the wearing conditions of brake disc and brake block of hydraulic disc brake,
when their thicknesses reach ultimate value, replace them.
Adjust the brake clearance of hydraulic disc brake to proper position as per the User
Manual of Hydraulic Disc Brake.
4.4.5 Check after crown block installation
Crown block is fixedly connected to the upper section of the mast and positioned by
positioning pins reliably.
4.4.6 Check after travelling block and hook installation
The bolts and pins of the traveling block are complete and firm, and guards are good.
The hook body and the hook mouth locking pin of the hook shall be operated flexibly,
and the safety locking pins of the hook bail are complete, safe and reliable.
4.4.7 Check after elevator link and swivel installation
Elevator links have no crack and deformation.
Swivel rotates flexibly, no oil and drilling fluid leakage during rotation.
Rotary hose shall be provided with safety chain additionally.
4.4.8 Check after installation of mud pump
Safety valves of mud pump are selected as required and installed at specified
positions. It is forbidden to block or disconnect the safety valve, and relief valve lids are
complete and good.
The pulsation dampener of mud pump is filled with nitrogen or air, and it is
forbidden to fill oxygen.
The surface of mud pump pressure gauge is clean and accurate.
4.4.9 Check after drilling fluid manifold installation
All supports and pipe clamps are fixed reliably. All unions are connected correctly
and sealed reliably.
Valve hand wheels are complete, closed and opened flexibly without leakage.
4.4.10 Check after generator and air supply house installation (except electric drive part)
12
All connecting bolts are installed completely and fixedly. The pretension torque
meets requirements.
All pipelines are clean, smooth, connected correctly, marked clearly and sealed
reliably without leakage.
All valve hand wheels (or handles) are complete, closed and opened flexibly.
The guards of all drive parts are complete and good, and fixed firmly.
4.4.11 Check after cable tray installation
All pipelines are connected correctly, clean and smooth inside. All joints are sealed
All cables and wires are arranged tidily, connected correctly and marked clearly.
4.4.12 Check after driller's control cabin installation
The air and hydraulic pipelines are clean and smooth inside. The lines of the air,
hydraulic and electric systems are connected correctly and marked clearly. All joints are sealed
All instruments and meters are installed completely, sensitive and reliable.
4.4.13 Check after air supply system installation
All connecting bolts are installed completely and fixedly. The pretension torque
meets requirements.
All pressure gauges are complete and good in effective period. Air line pressure is
adjusted to specified pressure.
All pipelines and valves are good without air leakage. Safety valves are sensitive and
reliable.
4.4.14 Check after electric control system and well site standard electric system installation
Check as per requirements in the User Manual of Electric Control System and Well Site
Standard Electric System.
4.4.15 Check after installation of drilling instrument system
Check as per the related requirements in the User Manuals of Drilling Instruments.
Ensure all instruments to be sensitive and reliable.
4.4.16 Check after installation of drilling rig monitoring system and communication system
Check as per the related requirements in user manuals of monitoring system and
communication system.
4.4.17 Check after installation of auxiliary part
Auxiliary parts are installed completely and are good.
The bolts of the auxiliary parts are installed completely and firmly. All connecting
13
pins and safety chains are complete and good.

The wireline for the auxiliary equipment shall be good without damage.
5. Commissioning of drilling rig

5.1. Preparation work before commissioning
Fill equipment with lubricating oil, grease, fuel oil, hydraulic oil and cooling water as per
the specification in corresponding user manuals.
Clean sundries near equipment, check cables and pipelines for correct and reliable
connection and seal.
Check the equipment before its running as per user manuals.
5.2. Commissioning of diesel generator set
Check the air supply pipelines of the diesel engine, the power and control cables of the
generator set and the VFD house for correct connection, start the auxiliary generator set to
supply power to the air supply purifier, start screw air compressor or directly start cold start air
compressor so that pressure of air tank is up to 1.0MPa.
Start the main generator sets respectively, check the running conditions and commission
them to working states.
The functions of the main generator sets and the auxiliary generator set are commissioned
to meet designed parameter values and the following requirements.
The diesel engine is started smoothly and runs stably at rated speed.
The generator sets generate and output power stably.
Synchronous operation loop control is normal.
Short circuit, overcurrent, overfrequency, underfrequency and reverse power
protection functions are normal.
All meters and indicator lamps have normal display.
(Detailed requirements refer to the User Manual of Diesel Generator Set.)
5.3. Power supply commissioning of VFD system
5.3.1 Preparation:
Check VFD house and power and control cables of electric appliances such as AC
VF motor, and control switches, display screens, touch screens, illumination systems and
solids control systems etc in the driller's control cabin for connection, and all switches
should be at off positions.
Diesel generator set supplies power to the VFD house, commission all functional
switches and instruments, ensure correct indication and display, and ensure that
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parameters accord with requirements.

5.3.2 Supplying power to areas
Supply power to driller's control cabin, check display screens for clearness, touch
screens for sensitivity and instruments for normalness, and check working conditions of all
switches.
Power up the AC VF motors on DW, start two main motors separately, check their
rotation directions and running conditions and the running condition of blower.
Power up RT driving motor, check its rotation and running condition as well as the
running condition of blower.
Power up the AC VF motors on mud pumps, and check their rotation direction of
running condition.
Supply power to every lighting point and check its working condition.
Power up HPU, start up motor, and check rotating direction and running condition.
Supply power to solid control system, check rotation and running condition of the
motor of the solid control equipment.
Power up oil pumps and water pump of oil tank and water tank, and check rotation
and running condition.
Supply power to other electric appliances and check their working condition.
(Detailed requirements refer to the User Manual of Electric Drive System.)
5.4. Commissioning of electric drive system
5.4.1 The switch of the driller's control cabin and PLC are logically correct. Bypass
assignment relationship of PLC is correct.
5.4.2 The functions of wind loss and locking protection for each main motor are normal.
5.4.3 Air inflation and underpressure alarming functions of drill floor are normal.
5.4.4 The automatic function, feedback function and locking function are normal.
5.4.5 Loading equilibrium test of mud pump is normal.
5.4.6 Function of emergency parking button is normal.
5.4.7 Dynamic braking system of DW functions normally. (Commission with DW
simultaneously)
(Detailed requirements refer to the User Manual of Electric Drive System.)
5.5. Commissioning of driller's control cabin, instrument and meter system
5.5.1 For the commissioning of the driller's control cabin, please refer to the User manual of
driller's control cabin.
5.5.2 Commissioning of instrument and meter system (it can be performed after lifting of mast
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and substructure)
Power-on commissioning of computer part
On-line commissioning of drill floor monitor and computer.
Channel test of analog quantity sensor.
Input of initialized data of system.
The pressure and liquid level sensors shall be installed properly. All cable and
pipeline shall be connected correctly. Functions are normal.
All cameras of monitoring system shall be installed properly, and image transmission
and display are normal.
Communication system works normally.
Calibrate the flow meters, sensors and indicators as per the requirements of the
operation manuals.
5.6. Commissioning of air supply system equipment
Start up No.1 and No.2 electric screw compressor sets respectively and commission them
to operative mode as per requirements in manual.
Check working condition of air supply purification device and equipment, and air leakage
and oil leakage are forbidden.
5.7. Commissioning of hydraulic system
Refer to the User Manual of Hydraulic System and the User Manual of Hydraulic Disc
Brake Device in detail.
The commissioning of the hydraulic system comprises the commissioning of HPU,
hydraulic disc brake device, mast lifting buffer cylinder, hydraulic tools and etc. Mainly check
every operation control mechanism for correct installation and connection and commission to
corresponding working state.
Test mast and substructure lifting and lowering hydraulic system to ensure hydraulic
components function normally. System shall be under the pressure of 3-4MPa without oil
leakage and pressure relief.
5.8. Commissioning of hydraulic disc brake
Check and affirm pipes and cables for correct and reliable connection again.
Commission the hydraulic disc brake to working state as per the User Manual of
Hydraulic Brake Device.
5.9. Running commissioning of DW
Perform the following commissioning before wireline is reeved:
5.9.1 Commissioning before running
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Open the ball valve on the air tank at the back of the substructure to supply air to DW.
Start up lubrication pump of main reducing gear box, operate control handle of hydraulic
disc brake in the driller's control cabin and push buttons on the touch screen for 5-10 times
respectively. Check the electromagnetic valves of the hydraulic disc brake system can act
correctly or not, and also check whether brakes are sensitive and reliable or not.
Check:
The air intake and exhaust conditions of automatic bit feed clutch.
The reliability and correctness of the action of anti-collision toggle valve
The flexibility and reliability of hydraulic disc brake
5.9.2 Idle running commissioning
Running procedure:
Start the motor A of DW, and check its rotation direction.
Start the motor B of DW, and check its rotation direction.
Start the motor A of DW, regulate speed to 970r/min, and check pressure of lubrication oil
pump, which shall be 0.1-0.3Mpa.
Run the motors A and B of DW simultaneously, accelerate and decelerate the motors by
control handle, and check running condition.
Braking test of hydraulic disc brake shall not be less than 5 times at different speeds.
Commissioning requirements:
All operations are accurate and flexible.
All parts are sealed well without seepage and oil leakage.
Lubricating oil pressure is stable, and the lubricant quantity is proper.
Stable running, no abnormal vibration and sound.
The bearings at all positions are normal in temperature rise.
Hydraulic disc brake is flexible and reliable.
Note: the main motor on the side of driller is motor A, and main motor on the other side
is motor B.
5.9.3 Reeving of wireline
After DW is commissioned and qualified, put wireline spooler in right location and reeve
wireline. The movable end is reeved into DW drum and fastened with wireline clamp seat, and
the fixed end is reeved into deadline stabilizer and fixed.
Notice: when the traveling block is lifted to the lowest position where the mast is lifted, the initial
wound wireline on the drum shall not be less than 13/4 layers.
Hang the balance sheave on the hook as per the lifting device drawing, and then reeve the
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wireline of the lifting system.

5.10. Running commissioning of RT
(It can be performed after the mast and the substructure are lifted.)
Start the RT driving motor at low speed, set a rotation speed, and check the rotation
direction.
Engage the RT inertia brake, and check the brake function and the interlocking condition
of the motor.
5.11. Commissioning of utilized mud pump
(It can be performed after the mast and the substructure are lifted.)
Commission it to working state as per the requirements in the User Manual of HHF-1600
Utilized Mud Pump.
6. Mast and substructure lifting and mast alignment

(Refer to the user manuals of mast and substructure in detail.)
6.1. Check before mast lifting
6.1.1 Before mast lifting, completely check the parts which have been already installed as per
clause 4.4.3 to ensure all parts are installed correctly and connected reliably.
6.1.2 The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
6.1.3 The air supply system and the pneumatic control system are normal, and the pressure of
the air tank is not less than 0.8MPa.
6.1.4 The DW is commissioned and qualified, and runs for at least two hours normally.
6.1.5 Overturn and fix the operation platform of the monkey board.
6.1.6 Place the tong counterweight to low position.
6.1.7 Check the hook for complete locking.
6.1.8 Check again the buffer device for normal working.
6.1.9 The sheave bearing of all raising lines shall be greased in accordance with the
requirement. The sheave must rotate freely.
6.1.10 Check the mast for left work pieces or tools and the safety facilities for completeness
and reliability.
6.2. Trial lifting of mast
6.2.1 The lifting work must be commanded by a commander. The position where the
commander is must be seen by driller and must be safe.
6.2.2 Before mast trial lifting, all persons and construction machinery must be in safety zone
except rear personnel in cabin, driller, personnel observing key parts, safety officer and the
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commander. Safety distance: the distance between position dead ahead and wellhead shall not
be less than 70m, and distance from two sides to two sides of mast shall not be less than 20m.
6.2.3 Tension wireline gradually at a low speed during mast lifting. After making sure there is
no sticking for wireline, lift mast to leave 100mm-200mm away from high stand and observe
whether lifting tensile force is more than specified value or not. Brake to ensure there are no
sticking and winding for auxiliary drilling wireline, deadline of drilling wireline, pipes and
wires etc, put mast back to its position, and check whether hoisting wireline is complete, firm
and reliable or not. Welding joints of lifting padeye shall not have cracks.
6.2.4 After checking without errors, lift the mast again. When the mast is 200mm-300mm
higher than the tall stand, brake DW, stay for 5min-10min. Check the fixed end of hoisting
wireline and deadline of drilling wireline, they shall be fixed completely and tightly; check the
bearing components of the key part of the substructure such as rod piece and A-frame for
deformation, the welding joints shall not have cracks; and check height of substructure lifted
to judge whether the counterweight t is enough or not.
6.2.5 Lower the mast to the tall stand slowly, put travelling block to the location which is
100mm-200mm higher than a supporting surface, and fasten the fixing and connecting
components of crown block and connecting bolts of mast support again.
6.2.6 Lift the mast again, when the mast is 200mm-300mm higher than the tall stand, brake
DW. After staying for 5min, lower the mast slowly to the tall stand, and put travelling block to
the location which is 100mm-200mm higher than the supporting surface.
6.3. Lifting of mast
6.3.1 Operate the control valve of the mast buffer device, completely stretch out its piston rod,
and maintain oil cylinder pressure (3-5MPa).
6.3.2 During the lifting, run the DW at a low speed, and control the hook speed at about
(0.8-1.2)m/min.
Notice: the DW shall run stably at a uniform speed. It is forbidden to brake or
accelerate in the process.
6.3.3 When the mast is lifted to 75-80 degrees or the mast is about 2m away from the piston
head of the buffer device, decelerate the DW, slowly make the mast slowly approach the piston
head of the buffer device, and operate the buffer device, remove the DW power when the
center of gravity of the DW is over the front leg of the mast, and slowly place the mast in
place.
6.3.4 After the mast is placed in place, slightly tension the hoisting wireline and connect mast
with A-frame and substructure tightly.
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6.3.5 After the traveling block and the hook at low positions, remove the connecting pins of
hoisting wireline, hang, place and fix the hoisting wireline of the mast at positions as required.
6.4. Check before substructure lifting
6.4.1 Before mast substructure, check the parts which have been already installed as per clause
4.4.2 to ensure all parts are installed correctly and connected reliably.
6.4.2 The hoisting wireline is complete and reeved correctly, and its ends are fixed firmly.
6.4.3 Check again the buffer device for normal working.
6.4.4 The sheave bearings of all raising lines shall be greased in accordance with the
requirement. The sheave must rotate freely.
6.4.5 Check again whether the connecting pins between the upper layer and the bottom layer
basement have been removed.
6.5. Lifting of substructure
6.5.1 While lifting the substructure, tension the wireline gradually at a low speed, lift the
substructure (100-200)mm away from the installation position, simultaneously observe
whether the lifting pull exceeds a specified value, brake and stay for at least 5min. Check
whether the ends of the hoisting wireline and the dead line of drilling wireline are fixed
normally. The auxiliary drilling wireline, all pipelines and electric leads etc shall be hung and
wound, and then put the substructure back to its original position.
6.5.2 After check, lift the substructure again. When the substructure is 200mm-300mm higher
than the installation position, brake DW, stay for 5min-10min. Check the ends of the hoisting
wireline and the deadline of the drilling wireline, which shall be fixed completely, firmly, and
reliably without looseness, and check the stress rods and the bearing components at the key
parts of the substructure, which shall not deform, and the weld joints shall not crack.
6.5.3 During the lifting, run the DW at a low speed, and control the hook speed at about
(0.8-1.2)m/min.
Notice: the DW shall run stably at a uniform speed. It is forbidden to brake or
accelerate in the process.
6.5.4 When the substructure is lifted to 75-80 degrees or the piston head of the buffer is about
0.5m away from the A-frame, decelerate the DW, make the piston head of the buffer device of
the substructure approach the A-frame, and then operate the buffer device, and make the
substructure placed in place slowly when the piston begins shrinking.
6.5.5 After the substructure is located in place, connect and tight it in time.
6.5.6 After the traveling block and the hook is placed at low positions, remove the connecting
pins of hoisting wireline, hang, place and fix the hoisting wireline of the substructure at
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positions as required.
6.6. Mast alignment
6.6.1 After the mast and the substructure are lifted, align wellhead as required. It is required
that the offset between the crown block center and the RT center is not more than Φ20mm.
(Correction method refers to the User Manual of Mast.)
6.6.2 Make sure to make the mast in natural status while aligning it.
6.7. Parts installed after mast and substructure lifting
6.7.1 Wellhead mechanical tools
6.7.2 Well control device
6.7.3 Ladders from drill floor to solids control and ladders from drill floor to back field
6.7.4 Other parts of the substructure, such as safety slide, V door ramp, catwalk and drill pipe
racks etc
6.7.5 Swivel, connect it with rotary hose
6.7.6 Other auxiliary parts
6.8. Commissioning of drilling instruments
6.8.1 Check whether the sensors are installed properly and cables and pipelines are connected
correctly or not.
6.8.2 Calibrate the display and indicating instruments as per the requirements and
specifications of manuals.
6.9. Adjustment of wireline on DW drum and test of crown block saver
6.9.1 Adjust the wireline on the DW drum, and ensure at least 9 cycles of wireline on the drum
always.
6.9.2 Commissioning of anti-collision toggle valve device
Adjust the position of the toggle valve, so that it acts when 28m stand is lifted and the
lower end surface of the stand is 2m away from the drill floor, make the hydraulic disc brake
braked urgently for stopping the DW drum, now check its reliability.
6.10. Test of hydraulic and pneumatic implements
Test as per respective operation manuals.
6.10.1 Run test of DP power tong and casing tong.
6.10.2 Running test of hydraulic cathead.
6.10.3 Run test of pneumatic spinner.
6.10.4 Test of running, lifting capacity and brake of air winch.
6.11. Running test of solids control system
6.11.1 Sealing performance test of system pipeline
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After the whole system is installed, carry out sealing performance test. Fill the circulating
tank with fresh water. There shall be no leakage for connecting lines between tanks, valves and
bottom valves.
6.11.2 Power-on running test of solid control equipment
Carry out power-on trial test on shale shaker and vacuum degasser respectively; they
shall run normally.
Carry out power-on running test on agitator, charging pump and mixing pump
respectively, they shall run normally.
6.12. Test of high pressure manifold and cementing manifold
6.12.1 Carry out static hydraulic test with fresh water on ground manifold, standpipe, valve
sets of high pressure manifold, and test pressure is 35MPa, stable pressure time is 10min,
pressure drop is not more than 2MPa.
6.12.2 Static pressure test of cementing manifold, test pressure is 70MPa, pressure stabilizing
time is 15 minutes, and pressure drop is not more than 3MPa.
6.13. Check of standard electric system on well site
6.13.1 Check various sockets and plugs for reliable connection, check whether they consist
with explosion-proof requirements, and conform to technical standard requirements of API.
6.13.2 Power on every area to check whether the motors of equipment, lighting lamps, all
explosion-proof distribution boxes and control boxes work normally.
6.14. Test of monitoring and communication systems
Test the telephones and mobile communication equipment installed at the positions of the
drilling rig, and they should meet design requirements. Check the installation position of the
cameras of the monitoring system for correctness and the picture transfer and display for
normalness.
6.15. Linkage test of whole drilling rig
Start DW, mud pump, RT and solid control system to carry out test on the whole drilling
rig for linkage performances.
7. Operation and maintenance of drilling rig

7.1. Warnings
7.1.1 Operate the drilling rig as per its user manual and the related safety rules strictly.
7.1.2 It is forbidden to examine and repair equipment without cutting of power source and
control source.
7.1.3 When inspecting and repairing a VF motor, make sure the auxiliary switch beside
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junction box is closed and locked by copper lock, insert locking pin, and ensure the main
circuit is power off.
7.1.4 Before the drilling rig works, check and adjust the wireline wound on DW drum. Make
sure the initial wireline wound on the drum is not less than 9 turns in any conditions to prevent
the wireline clamp from slipping due to excessive strain. Then retighten the bolts and nuts of
wireline clamp seat.
7.1.5 When the drilling rig works, personnel are not allowed to stay near the mud pump relief
valve, high pressure manifolds and rotary hose.
7.1.6 In the operation of the drilling rig, the speed regulation of each running part shall be
slow and smooth, avoid the impact to mechanical and electric systems due to violent changes
in speed.
7.1.7 The hoist on the drill floor is used for loading objects only.
7.2. Precautions for drilling rig operation
7.2.1 Select proper generator set to match the power as per drilling conditions.
7.2.2 During drilling operation, adjust the hoisting speed of the DW as per its load, drilling
technical requirement and DW hoisting curve, adjust discharge pressure and strokes of the
mud pumps as per the drilling technical requirements; and adjust the RT speed as per drilling
technical requirements.
7.2.3 Before operation, check whether dead end and live end of drilling wireline is fixed in
conformity with requirements, all savers are reliable and agile in action, the DW brake system
and clutch are reliable, and all electrical appliances and instruments are connected correctly
and work reliably or not.
7.2.4 During operation, make sure the pressures of air supply system and hydraulic pressure
system meet the regulated working pressure.
7.2.5 In the operation, under the bigger the drilling string weight (exceeding 1300kN), the DW
is driven by two main motors better. When one of the two main motors goes wrong and cannot
be used, the other one can hoist max. weight of drilling string at a low speed.
7.2.6 During working, make sure the gears and bearings etc of drive system are lubricated
sufficiently and reliably. Check whether the quality and quantity of the lubricating oil/grease
for each part meet the requirements, and supplement or replace the lubricating oil as per the
regulated operation period.
7.2.7 Periodically check and adjust the tightness of drilling pump's drive belt, and check
whether the charging pressure of the pulsation dampener meets the requirement or not.
7.2.8 All ladders, handrails and guards shall be firm and reliable without looseness.
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7.2.9 It is forbidden to run the drilling rig at overspeed and overload and violate any operation
regulations while using any part of the drilling rig.
7.3. Safety techniques for drilling rig operation
7.3.1 Requirements on drilling rig operation
There shall be mechanical, electrical and instrument professionals in drilling crew,
and technical regulations for drilling rig routine operation and maintenance shall be made.
The routine operation and maintenance of drilling rig are guided and treated.
Only trained and qualified persons can operate and maintain the drilling rig with
qualification certificates.
The operators must follow the safety operation regulations.
The lifting speed and lifting capacity of drilling rig must be in conformity with
related regulation in the User Manual of DW.
The displacement and pressure of mud pump must be in conformity with the related
regulation in the User Manual of HHF-1600 Drilling Pump.
When any part of the drilling rig goes wrong, stop using the part and treat faults, and
use it again after troubleshooting.
7.3.2 It is forbidden to operate the drilling rig, and repair it in time when the drilling rig is in
one of following conditions:
The drilling rig is used at overload and overspeed.
The steel structures of the mast and the substructure deform or crack.
The foundation of the substructure sinks or ruptures.
Brake and drive systems are out of control.
The safety valve and the air charging of pulsation dampener of mud pump are not in
conformity with requirements.
The crown block savers fail during tripping.
The instruments of the drilling rig are damaged or have no metering function.
The pneumatic control system fails or air supply pressure is lower than the allowed
range.
Guards and handrails are incomplete.
Oily substances enter the surfaces of brake disc, brake huh and clutch steel hub.
The hoisting wireline and the drilling wireline are not checked as required.
7.3.3 All operators are forbidden to perform the following operation
Run the components of drilling rig over load, over speed, over temperature and over
pressure.
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Check and repair equipment without cutting off the power source and the control
source of the drilling rig.
Make up threads with RT.
Adjust the brake when the hook is loaded.
Water brake disc, brake hub and friction hub.
7.4. Maintenance regulations of drilling rig
The maintenance is divided into periodic maintenance and staged maintenance as per the
technical condition and the running time of the drilling rig.
The periodic maintenance is divided into shift maintenance, weekly maintenance and
monthly maintenance.
The shift maintenance items comprise the routine contents of adjustment, lubrication,
fixing, cleaning and corrosion prevention and the shit maintenance items regulated in this
section.
The weekly maintenance items comprise the shit maintenance items.
The monthly maintenance items comprise the weekly maintenance items.
The staged maintenance mainly includes the maintenance of main components. When the
maintained components are judged to be unavailable to satisfy the drilling operation
requirements through technical detection, they shall be repaired on service base.
The periodical maintenance regulations of the drilling rig are as follows:
7.4.1 The routine maintenance items of mast and substructure:
Lifting components shall not crack and deform.
No corrosion for wire rings and slings and no corrosion traces near the near ends.
The lifting wireline shall be good without damage.
Lubrication of sheave system is favorable.
All pins shall be installed in place and safety pins are complete.
The joints of all bolts must be firm and reliable.
Under load, periodically measure the straightness error of the stand posts of mast and
the error of perpendicularity among the front and lateral surfaces of the mast and the level.
Before lifting and lowering, check the buffer device and the hydraulic system for
completeness and sufficient oil supply.
In any condition, it is not allowed to remove the cross and inclined tension beams
and other components on mast.
It is not allowed to drill holes and cut holes or weld all components of the steel
structures.
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Check mast and substructure per month or before the bearing of special load such as
casing.
7.4.2 Lifting system
7.4.2.1 Shift maintenance and check items
The test of the braking function and anti-collision performance of the DW shall be
safe and reliable.
The reliability of the electric appliances on the driller's control console and the
sealing performances of all pneumatic control and hydraulic pipelines.
The ends of the deadline and the fastline are fixed reliably.
The lubrication and sealing performances of all bearings are favorable.
The fixation of bolt of bail retainer bar of hook and stop pin, the flexible rotation of
hook body and the free expansion of springs.
The favorable seal of all sealed positions of swivel, RT and DW and the conformity
of the oil amount and oil temperature with requirements.
The flexibility and reliability of the stop pin of RT.
7.4.2.2 Weekly maintenance and check items
The oil supply of the lubrication pump of DW, the cleanness of lubrication oil, and
the cleaning and the replacement of filter elements of filters.
The flexible rotation of the bail and pin of swivel.
The fixation of traveling block shaft.
The wear of the sheave grooves of crown block and traveling block.
The seal of the washing pipe packing of swivel.
The fixation of the cardan shaft of RT.
7.4.2.3 Monthly maintenance and check items
The connection and wear of clutch, coupling and cross sub of cardan shaft.
Cracks of bail, pin and sheaves of lifting system.
7.4.3 Mechanical drive system
7.4.3.1 Shift maintenance and check items:
Adjust the tension of the drive belt, check the temperature, temperature rising and
noise of gear box and rotating part.
Check the lubrication oil of the gearbox for quality, amount, pressure and
temperature.
7.4.3.2 Weekly maintenance and check items:
Running condition of oil pump and cleaning of filter.
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Check the wear of clutch.

7.4.3.3 Monthly maintenance and check items:
Check all drive parts completely, including clutch, coupling and cardan shaft etc.
Check the gear meshing of gearbox.
Measure the quality of the oil in oil bath.
7.4.4 Circulating system
The operation status of the power end of mud pump, check the tightness of drive belt
of pump and the temperature rise of each bearing.
The suction performance of fluid end of mud pump, the sealing, cooling and
lubrication of piston, liner, tie rod etc.
The pressing reliability of the cylinder lids and valve caps of mud pumps.
The working condition of charging pump and spraying pump.
Conformity of charging pressure of pulsation dampener and safety valve with
requirements.
The fixation of high pressure manifold and the flexibility of high pressure valve etc.
The working condition of solid control equipment, and the temperature rise and the
insulating property of motor.
Check and clean lubrication oil filters.
Lubrication and wear of crosshead and guide plate.
The flexibility of action of safety valve.
The insulation condition of circuits.
The smoothness of spray nozzle of mud gun.
7.4.4.3 Monthly maintenance and check items:
The meshing condition of gears at power end of mud mump, and check and adjust
the gap of the crosshead.
Check the high pressure pipe through non-destructive test.
Fasten connecting valve bolts of mud pump and clean oil sump.
7.4.5 Air supply system
No abnormality during the startup and the stop of screw air compressor, and
conformity of oil quality, oil amount and oil temperature with requirements.
Check the automatic pressure regulating device and the safety valve for conformity
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with requirements.
Check the working pressure of air tank and discharge water for pollution discharge.
Check the smoothness and the favorable seal of pipelines.
Check the working condition of air filter without blockage.
Check safety valve and sequence valve.
7.4.5.3 Monthly maintenance and check items
Clean filter and safety valve of air tank.
Check control valves of compressor.
Check control valves of dryer.
7.4.6 Driller's control cabin
(Refer to the User Manual of Driller's Control Cabin.)
7.4.7 Electric drive system
(Refer to the User Manual of Electric Drive System)
7.5. Operation and maintenance during algid stage
7.5.1 High-pressure mud system
Check valve chamber, circulating manifolds for no icing before the startup of mud
pump.
When the mud pump stops working, discharge the drilling fluid at the hydraulic end
of mud pump, rotary hose and high and low pressure manifolds.
7.5.2 Lifting system
Prevent the drainage hole at the lower part of the bail of swivel from icing.
7.5.3 Other systems
When the air temperature is lower than -20℃ (average value of monthly lowest
temperatures), do not use the drilling rig under the maximal load. Take measures on the factors
which may cause damage to the main structural components of mast and substructure. All oil,
air and water delivery pipelines shall be prevented from being frozen.
7.6. Accident and emergency treatment
7.6.1 If any mechanical accidents such as DP sticking etc happen in drilling process, they shall
be treated as per mechanical accident treatment regulations.
7.6.2 If fire alarm happens in the well site, it shall be treated as per fire alarm accident
treatment regulations.
7.6.3 When emergency happens in the well site and staff must retreat urgently, personnel on
duty have to follow unified command and can retreat after finishing emergency operation.
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Mast men on racking board can use escaping device to get out quickly; staff on drill floor can
adopt escaping slide to make a speedy fleeing.
8. Disassembly and transportation of drilling rig

8.1. Lowering of mast and substructure of drilling rig
8.1.1 Check before the lowering of mast and substructure of drilling rig
Grease every lubrication point as required. Grease pins at rotating parts.
Installation of every connector and fastener must be complete and fastened.
opening.
Bottom beams of substructure contact properly with foundation surface, and major
bearing points must be tamped.
There is no barrier to block driller's eyesight on the drill floor.
Buffering cylinders of substructure work normally.
Buffering cylinders of mast work normally.
Hoisting wireline and drilling wireline are both in good condition, and their ends are
fastened tightly.
No tools and stuffs left on the mast.
Weight indicator works normally.
8.1.2 Lowering of substructure:
When lowering the substructure, firstly move the substructure to diverge from the center
of gravity by the buffer cylinders, the DW reversely drag the substructure and the substructure
is lowered by its dead weight. Pay attention to the following items when lowering the mast:
Dismantle all components affecting the lowering of the substructure such as the ramp,
ladders, sliding board and hoist etc.
Control lowering speed, lower the substructure slowly at a uniform speed, and it is
forbidden to speed up or brake suddenly.
8.1.3 Lowering of mast:
Before the mast lowering, hang the balance sheaves properly, then operate the buffer
cylinders to push the mast away from its center of gravity, and then lower it by its dead weight
while DW reversely drags it. Pay attention to the following items when lowering the mast:
Remove the casing stabbing board and all components or accessories which may affect
the mast lowering.
Control lowering speed, lower the mast slowly at a uniform speed, and it is forbidden to
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speed up or brake suddenly.

8.2. Disassembly of drilling rig
The principle for disassembling the drilling rig is: disassemble firstly those installed last
and disassemble last those installed first. Pay attention to the following items in the
disassembly:
Disassemble the drilling rig into components, then pack or bundle up every component
separately. Larger components such as mast and substructure shall be disassembled into
smaller units as per requirements of transporting vehicles, and DW, diesel engine set, VFD
house and MCC house etc can be transported as a module.
Pack fasteners separately as per components, and use labels to identify them.
High-strength bolts and nuts for mast, crown block, deadline stabilizer and universal shaft
shall be packed separately after disassembly to avoid confusing with others. All pins and
safety pins shall be subjected to anti-rusting treatment, bundled up and boxed as per
component sorts, so as to prevent rusting, impact, damage and confusion.
Disassemble air, fluid and water pipelines only after pressure is released. Discharge fluid
and water in pipelines and use compressed air to dry them.
The interfaces of the disassembled air, fluid and water pipelines shall be sealed or
bundled up, so as to keep clean inside pipelines and at interfaces and avoid impurities from
going inside. Notice: two ends of every interface shall be marked by the same No.
The pins, bolts and nuts for mast and substructure and the high-strength bolts and nuts for
cardan shall be coated with antirust oil and boxed, and they cannot be piled randomly.
The hoses of air system shall be prevented from oil, and the outer threads of every
pipeline shall be bundled up, so as to keep the threads from impact and damage and keep the
pipeline clean.
If long-distance transportation or long-term storage is required, perform rain proofing,
moisture proofing and rust removal treatment.
8.3. Transportation of drilling rig
When the drilling rig is transported, make a transportation plan according to the overall
dimensions and weights of its components and the road conditions, and make a transportation
vehicle number table according to the vehicle conditions. The transportation units of mast and
substructure shall be transported intensively and other parts shall be transported intensively as
per components.
30
9. Lubrication table for main components

No. Filing
amount
Part name Position Oil spec. Maintenance period
for new
equipment
Drum shaft, Ambient temperature
coupling above -20℃, NLGI 2,
Each 15 running days 2 kg
grease lithium base grease.
lubrication
Ambient temperature
-20℃ to +10℃, ISO
VG 150 medium and
extreme pressure gear
oil. When the oil level is
1 DW Ambient temperature: below the mark, add
Gear reducer
-10℃ to +40℃, ISO oil in time.
box or chain
VG 220 medium and Replace the lubricating 500 L
drive oil tank
extreme pressure gear oil completely each 6
oil lubrication
oil. months or when the oil
Ambient temperature: is polluted.
+10℃ to +60℃, ISO
VG 320 medium and
oil.
FAG-Arcanol L135V Replace the grease
lubrication grease completely every 3
2 Motor Bearing 290 g
years or when the
grease is polluted.
Before lifting and
All sheave lowering mast and
bearings substructure every
Ambient temperature
Mast time
3 above -20℃, NLGI 2, 200 g
Substructure Before installing and
lithium base grease.
Pins and padeye disassembling mast
holes and substructure each
time
Ambient temperature
4 Crown block Sheave bearings above -20℃, NLGI 2, Each 7 running days 500g
31
Ambient temperature
5 Traveling block Sheave bearings above -20℃, NLGI 2, Each 7 running days 500g
Ambient temperature
Bail pin, pins
above -20℃, NLGI 2, Each 7 running days 200g
Thrust bearing
Ambient temperature: When the oil level is
6 Hook
-20℃ to +50℃, ISO below the mark, add
Oil pool VG 220 medium and oil in time. Replace all 20L
extreme pressure gear lubrication oil after
oil. every well is drilled.
Ambient temperature:
-20℃ to +50℃, ISO
Each two running
Main oil pool VG 220 medium and 200g
months
oil.
Ambient temperature
Each 200 running
Spinner above -20℃, NLGI 2, 200g
7 Swivel hours
Bail pin,
washing pipe
Ambient temperature
packing,
above -20℃, NLGI 2, Each 72 running hours 200g
bracket and
lower cover oil
seal
-20℃ to +50℃, ISO
Each two running
Main oil pool VG 220 medium and 200L
months
8 ZP375 RT
oil.
Ambient temperature
Locking device above -20℃, NLGI 2, Each 7 running days 100g
Ambient temperature When the oil level is
Gear reducer -20℃ to +10℃, ISO below the mark, add
box or chain VG 150 medium and oil in time.
9 RT Drive Device 200 L
drive oil tank, extreme pressure gear Replace the lubricating
oil lubrication oil. oil completely each 6
Ambient temperature: months or when the oil
32
-10℃ to +40℃, ISO is polluted.

VG 220 medium and
oil.
+10℃ to +60℃, ISO
VG 320 medium and
oil.
Ambient temperature
RT drive cardan
10 Bearing, spline above -20℃, NLGI 2, Each 72 running hours 100g
shaft
Ambient temperature
-20℃ to +10℃, ISO
VG 150 medium and
oil. When the oil level is
Ambient temperature: below the mark, add
-10℃ to +40℃, ISO oil in time.
Engine oil pool,
VG 220 medium and Replace the oil 350L
oil lubrication
HHF-1600 mud extreme pressure gear completely every 6
11
pump oil. months or when the oil
Ambient temperature: has been polluted.
+10℃ to +60℃, ISO
VG 320 medium and
oil.
Belt drive Ambient temperature
device above -20℃, NLGI 2, Each 15 running days 400g
Bearing lithium base grease.
-20℃ to +50℃, ISO
Oil pool VG 220 medium and Replace once a month 2L
12 Air winch
oil.
Gears and all Ambient temperature
grease above -20℃, NLGI 2, Each 7 running days 600g
lubrication lithium base grease.
33
points
Ambient temperature When the oil level is
-30℃ to +50℃, ISO below the mark, add
Oil sprayer 0.2 L
VG 46, ISO HM oil in time.
hydraulic oil
Ambient temperature Replace all lubrication
Sheave bearings above -20℃, NLGI 2, grease after every well 400g
lithium base grease. is drilled.
13 Deadline anchor
Weight Transformer oil with
Fill while correcting
indicator sensor ISO viscosity of 8.7 Proper
weight indicator
pipe
Wireline
14 All wirelines Wireline surface grease As per use condition Proper
surface
Ambient temperature: Replace the hydraulic
-30℃ to +50℃, ISO oil completely every 6
Oil cylinder 80L
VG 46, ISO HM months or when the oil
YM-16-II
15 hydraulic oil is polluted.
Hydraulic cathead
Ambient temperature Each 7 days
Sheave above -20℃, NLGI 2, 100g
Ambient temperature: Replace the hydraulic
Oil tank of -30℃ to +50℃, ISO oil completely every 6
16 Composite HPU 1000L
HPU VG 46, ISO HM months or when the oil
hydraulic oil is polluted.
Oil and gas Refer to the User
17 Compressor separating Compressor oil Manual of Compressor
cylinder in detail
Ambient temperature refer to the Operation
above -20℃, API Manual of Generator
18 Generator set Diesel engine CH-4(CG-4)SAE Set in detail.
15W-40 diesel engine
oil
Explanation: the listed lubrication oil in this table is recommended. According to ISO
viscosity grade requirements, it is necessary to use the specified lubrication oil. The
lubrication and maintenance period is suitable for the normal condition, and user can properly
adjust the period of replacing oil as per the actual working condition and the periodic oil
quality check.
34
10. Main part bearing model summary list

No. Part name Position Spec. Code Model Qty.
Sheave, crown
304.8×393.7×107.95 37961K 7
Crown block
1
block
Sand sheave 90×190×43 GB283-81 42318 2
Traveling Traveling block

2 254×347.66×101.6 37951K 6
block sheave
Hook load
3 Hook 180×360×82 GB4663-1994 87436ZW 1
bearing
Load bearing 270×550×130 19954EQ 1
4 Swivel
Upthrust bearing 200×310×70 GB297-84 2007140 1

Upper and lower
alignment 240×360×56 GB283-81 32148 1
bearings
Horizontal shaft 150×320×108 GB/T283-94 NU2330E 1

5 RT
Horizontal shaft 150×320×108 GB/T288-94 22330C 1
Drum shaft
6 DW 240×400×128 SKF 23148CA 2
assembly
Crosshead bearing 285.75×206.375×222.25 254941QU 3
Pinion shaft
350×220×98.42 4G32844H 2
bearing
Drilling
7 Crankshaft main
mud pump 500×300×160 3G3003760HY 2
bearing
Eccentric wheel
863.6×660.4×107.95 929/660.4QU 3
bearing
8 Bearings for other components refer to respective user manuals.
35
11. User manuals list

No. Description
1 User Manual of ZJ70DBS Drilling Rig
2 User Manual of DZ450/10.5-G Substructure
3 User Manual of JJ450/45-K Mast
4 User Manual of TC-450 Crown Block
5 User Manual of YC-450 Traveling Block
6 User Manual of DG-450 Hook
7 User Manual of JC70DB DW
8 User Manual of ZP375 RT
9 User Manual of RT Drive Device
10 User Manual of HHF-1600 Mud Pump
11 User Manual of Utilized Mud Pump
12 User Manual of Solids Control System
13 User Manual of High-Pressure Manifold
14 User Manual of Pneumatic Control System
15 User Manual of Hydraulic System
16 User Manual of Power System
17 User Manual of Electric Drive System
18 User Manual of Driller's Control Cabin
19 User Manual of 60m3×2 Fuel Oil Tank
20 User Manual of 40m3 Camp Oil Tank
21 User Manual of 30+5m3 Overhead Oil Tank
22 User Manual of 80m3×2 Water Tank
23 User Manual of TSJ-1500 Series Hydraulic Hoist
24 User Manual of Electric Wireline Spooler
25 User Manual of SL450 Swivel
26 User Manual of Cable Tray
27 User Manual of Generator House
28 User Manual of 75m3 Oil Tank
29 User Manual of 25m3 Water Tank
30 User Manual of Agitator
31 User Manual of Liquid-Gas Separator
36
12. Attached drawings of drilling rig

Attached drawing 1 Elevation of ZJ70DBS drilling rig
Attached drawing 2 Plan of ZJ70DBS drilling rig
Attached drawing 3 Drive system drawing of ZJ70DBS drilling rig
Attached drawing 4 Foundation drawing of ZJ70DBS drilling rig
12.1. Details of numbers in elevation and plan
No. Drawing No. (code) Description Spec. Qty.
1 MD248.00 Catwalk 1
2 ZGJ008.00 DP rack 1
3 Air winch FA150KGiMR12A1-CE 1
4 TSJ002.00 Hydraulic hoist 10.5-1500 1
5 ZB054.00 RT drive device 1
6 ZGF064.00 Doghouse 1
7 Driller's control cabin SAKSONZJ70DBS 1
8 YZ133.00 Composite HPU 1000 1
9 Submersible hydraulic cathead YM-16-Ⅱ 2
10 DLC276.00 Cable tray 1
11 FDF149.00 Generator house 1
12 VFD house 2 SAKSONZJ70DBS 1
13 VFD house 1 SAKSONZJ70DBS 1
14 YG104.00 Oil tank 30+5 1
19 YG048.00 Oil tank 60×2 1
20 SHG110.00 Living water tank 25 2
21 YG061.00 Oil tank 75×1 1
22 FDF192.00 Generator house 1
23 GCF010.00 Machine repair room 2
24 YG105.00 Oil tank 40 1
25 SHG108.00 Water tank 80×2/G 1
26 BZ178.00 Utilized drilling pump 3NB1600M-DBZ 3
27 GH290.00 Drilling fluid manifold 102/35 1
28 GK220.00Ⅰ Solids control system 1
29 ZGF085.00 Drill floor tool house 1
30 Air winch XJFH-5/35KS 3
31 DS004.00 Wireline spooler 35/2300-D 1
32 TC087.00 Crown block 450 1
33 JJ102.00 Mast 450/45-K 1
34 6×19S+IWRC+EIPS Drilling wireline φ38×2200M; left-hand
35 DG003.00 Hook DG450 1
36 SL001.00 Dual-purpose swivel SL450 1
37 Hydraulic casing stabbing board YFZ200-6.5 ZJ407-06XY 1
37
Attached drawing 1 Elevation of ZJ70DBS drilling rig
38
Attached drawing 2 Plan of ZJ70DBS drilling rig
39
Attached drawing 3 Drive system drawing of ZJ70DBS drilling rig
40
Fig. 4 Foundation drawing of ZJ70DBS drilling rig
41
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User Manual of ZJ70DBS Drilling Rig

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

6.3. Lifting of mast ............................................................................................................ 19

User Manual of ZJ70DBS Drilling Rig

2. Description of drilling rig

installations at petroleum facilities

Drilling wireline 6×19S+IWRC EIPS

3 Monitoring system 1 set

3. Structural features of ZJ70DBS drilling rig

Motor Hook Lifting capacity kN

3.3.2 Lifting curve (12 lines)

4. Installation of drilling rig

Substructure Mast Crown block

Generator and air supply DW RT and drive device

Drilling fluid manifold standpipe Traveling block and hook

Doghouse Cable tray Driller's control cabin

Wellhead mechanical tool Commission whole rig

plan of generator and air supply house in detail)

4.4.2 Check after substructure installation

pins and safety chains are complete and good.

5. Commissioning of drilling rig

parameters accord with requirements.

wireline of the lifting system.

6. Mast and substructure lifting and mast alignment

7. Operation and maintenance of drilling rig

Check the wear of clutch.

8. Disassembly and transportation of drilling rig

speed up or brake suddenly.

9. Lubrication table for main components

-10℃ to +40℃, ISO is polluted.

10. Main part bearing model summary list

Traveling Traveling block

Load bearing 270×550×130 19954EQ 1

Upthrust bearing 200×310×70 GB297-84 2007140 1

Horizontal shaft 150×320×108 GB/T283-94 NU2330E 1

11. User manuals list

12. Attached drawings of drilling rig

Attached drawing 1 Elevation of ZJ70DBS drilling rig

Attached drawing 2 Plan of ZJ70DBS drilling rig

Attached drawing 3 Drive system drawing of ZJ70DBS drilling rig

Fig. 4 Foundation drawing of ZJ70DBS drilling rig

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