Drilling Rig Operation Manual.pdf

ZJ70DBS DRILLING RIG

March, 2010

Table of Contents

Foreword...........................................................................................................................................................1 1. Safety warning..............................................................................................................................................2 2. Introduction ..................................................................................................................................................2 2.1 Purpose and applicability .........................................................................................................................2 2.2 Standards and specifications for the design and construction ..................................................................2 2.3 Major technical specification ...................................................................................................................3 2.4 ZJ70DBS rig major corollary equipments list..........................................................................................3 3. ZJ70DBS rig structure features ..................................................................................................................6 3.1 Rig general structure ................................................................................................................................6 3.2 Rig structure features ...............................................................................................................................6 3.3 Hook speed and hoisting capacity............................................................................................................7 4. Rig installation..............................................................................................................................................8 4.1 Preparation of rig installation...................................................................................................................8 4.2 Installation sequence chart .......................................................................................................................9 4.3 Installation of each part............................................................................................................................9 4.4 Inspection after the drilling rig being installed ......................................................................................12 5. Rig commissioning .....................................................................................................................................15 5.1 Preparation before commissioning.........................................................................................................15 5.2 Commissioning of diesel generator set ..................................................................................................16 5.3 VFD system power supply commissioning............................................................................................16 5.4 Commissioning of electric transmission system ....................................................................................17 5.5 Commissioning of driller’ cabin, instruments and meters system..........................................................17 5.6 Commissioning of air-supply system equipments..................................................................................18 5.7 Commissioning of hydraulic system ......................................................................................................18 5.8 Commissioning of drawworks ...............................................................................................................18 5.9 commissioning of the rotary table..........................................................................................................19 5.10 Commissioning of Mud Pump Set .......................................................................................................19 5.11 Mast and substructure lifting, mast alignment .....................................................................................20 5.12 The parts to be installed after the mast and substructure being lifted ..................................................22 5.13 Adjustment of drilling instruments.......................................................................................................23 5.14 Adjust the winding of drawworks drum and test the crown block saver..............................................23 5.15 Test of hydraulic and pneumatic tools..................................................................................................23 5.16 Running test for solid control system...................................................................................................23 5.17 Test on high pressure manifold ............................................................................................................24 5.18 Inspection of the standard electric system on well site ........................................................................24 5.19 Drilling rig monitoring and communication system test......................................................................24 5.20 test of the top drive device ...................................................................................................................24 5.21 Test of the drilling rig final assembly...................................................................................................24 5.22 rig Moving test.....................................................................................................................................24

6 Operation and maintenance of drilling rig ...............................................................................................24 6.1 Warnings ................................................................................................................................................24 6.2 Precaution for rig operation ...................................................................................................................25 6.3 Safety rules of rig operation...................................................................................................................25 6.4 Maintenance regulations of rig...............................................................................................................27 6.5 Accident and emergency treatment ........................................................................................................30 7. Dismantling and transportation of drill rig .............................................................................................30 7.1 Lowering of mast and substructure ........................................................................................................30 7.2 Dismantling............................................................................................................................................31 7.3 Transportation ........................................................................................................................................32 8. Main components lubrication of ZJ70DBS rig ........................................................................................32 9. Bearing model list of main components....................................................................................................35 10. The drilling rig operation manuals list...................................................................................................36 11 Attached drawings of drilling rig .............................................................................................................37

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Foreword The drilling rig ZJ70DBS is designed and manufactured as per the requirements of Chinese petroleum professional standard SY/T5609-1999 "Types and basic parameters for oil drilling rigs” and related API specification. It is a kind of rig, which can satisfy the requirement for middle depth well drilling for oil and gas exploration and development. This manual has described generally the rig structure, performance feature, technical parameters, installation and commissioning, operation and maintenance, dismantlement and transportation of the drilling rig etc. Before the installation, the operators shall read the operation manual and the operation manuals of matched components carefully, and install, operate and maintain the drilling rig accordingly. Without understanding of concerned content, mistakes made when performing installation, operation or maintenance may lead to personal injury or equipment damage. The front and rear of drilling rig are determined by this: wellhead is in the front, power engine house is in the back. The left and right of drilling rig are determined by the direction from wellhead to power engine house. There is an ex-factory code for each drilling rig, please point out the ex-factory code when you order the spare parts and inquire the related things.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

1. Safety warning z

The personnel who is occupied in installation, operation and maintenance should be trained and qualified, and carry out the work with operation qualification certificate.

z

Personnel of installation, operation and maintenance must read this manual and all the operation manuals of all equipments belonging to the rig carefully before their installation, operation and maintenance; and install, operate and maintain rig according to the requirements specified in the manuals.

z

There must be a chief principal for installation, operation and maintenance; and persons who participate in the work should be assigned clearly; and detailed and reliable safety measures should be taken.

z

Personnel should strictly follow operating rules and security control regulations when operate the rig.

z

It is forbidden to maintain and repair the equipment during its operation.

z

It is forbidden to overload the equipment.

2. Introduction 2.1 Purpose and applicability This ZJ70DBS rig is designed and manufactured as per SY/T 5609-1999 “Types and basic parameters for oil drilling rigs”, API specification and related standards. It can satisfy the requirements of middle depth well drilling operation for land oil and gas exploration and development at the ambient temperature above -18℃~+55℃ and the humidity ≤98% (+20℃).

2.2 Standards and specifications for the design and construction 2.2.1 SY/T5609-1999 "Types and basic parameters for oil drilling rig". 2.2.2 Edition 3 of API Spec 4F-2008 “Specification for Drilling and Well Servicing Structures” 2.2.3 Edition 4 and Supplement 1 & 2 of API Spec 7K-2005 “Specification for Drilling and Well Servicing Equipment” 2.2.4 Edition 4 of API Spec 8C-2003 " Specification for Drilling and Production Hoisting Equipment" 2.2.5 API Spec 9A-2004 “Specification for Wire Rope” 2.2.6 AWS D 1.1-2008 “Structural Welding Code-Steel” 2.2.7 Edition 2 of API RP 500 “Classification of Locations for Electrical Installation at Petroleum Facilities Classified As Class I. Division 1 and Division 2” 2.2.8 IEC 44-81 “Electrical Apparatus for Explosive Gas Atmospheres -General Requirements”

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

2.3 Major technical specification Nominal drilling depth（4 1/2″(114mm) DP） 5″(127mm) DP

4500-7000m 4000-6000m

Max. hook load

4500kN

Weight of Max. drill string

2200kN

Drawworks Max input power

2000kW

Number of hoisting system lines

6×7 Reeve In parallel

Dia. of wireline

φ38mm (1 1/2’’)

Mud pump power ×Number

1600HP×3

Nominal opening dia. of RT

952.5mm（37 1/2″）

Mast effective height/type

45.72m/K type

Drill floor height

9m

Clear height of substructure

7 .6 m

Number of hoisting gear

one gear, stepless speed regulation

Number of RT gear

one gear, stepless speed regulation

Main diesel generator set power×Qty.

1200kW×4

Auxiliary diesel generator set power×Qty.

320kW×2

Drilling fluid manifold I.D./rated pressure

dual standpipe 4″/35MPa

Total volume of mud tanks

≈417 m3

2.4 ZJ70DBS rig major corollary equipments list No.

Name

Qty.

Ⅰ

Hoisting system equipments

1

JC70DB Drawworks（hydraulic disc brake included）

2

JJ450/45-K11 Mast（accessories included）

1set

3

DZ450/9-S1 substructure（accessories included）

1set

4

TC450 Crown block

1

5

YG450 Traveling block

1

6

DG450 Hook

1

7

Drilling wire rope6×19S+IWRC EIPS grade φ38

1 roll

8

Electrical spooler

1 set

1

Note Edition 4, API Spec7K (Parts) Edition 3, API Spec 4F Edition 3, API Spec 4F Edition 4, API Spec 8C/Edition 3, 4F Edition 4, API Spec 8C Edition 4, API Spec 8C API Spec 9A

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No.

Name

Qty.

Note

9

Deadline anchor JZG41A

1set

10

YM-16II hydraulic cathead

2sets

11

ZQ203-100 drill pipe power tong

1set

12

TQ340-35 hydraulic casing power tong

1set

13

Q250 pneumatic spinner

1set

14

5T air winch

3sets

15

0.5T air winch

1set

16

man-riding winch

1set

17

CJ7000 logging winch

1set

18

ST-80C iron roughneck

1set

19

HPU

1set

20

DZ550 BOP lifting device

1set

21

Hydraulic casing stabbing board

1set

II

Equipments for rotating system

1

RT ZP375

1pc

2

RT bushing

1set

3

RT drive device

1set

4

SL450 dual-purpose swivel

1pc

Edition 4, API Spec 8C Edition 4, API Spec 7K（parts）

III

One of them is installed on the catwalk

Edition 4, API Spec 7K

Equipments for circulating system

1

HHF-1600 drilling mud pump

3pcs

2

Mud pump set

3sets

3

Drilling fluid manifold

1set

4

Rotary hose 23m，35Mpa

2pcs

5

Solid control system

1set

6

Poor boy

1set

IV

Moving system equipments

1

Rig Moving system

1set

4

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No.

Name

Qty.

2

Rig Moving hydraulic system

1set

V

Power and air supply system

1

Diesel generator set CAT 3512B（SR4）

4sets

2

Camp generator set C15

2sets

3

Generator-air supply house

1set

4

Air supply system

1set

Electric drive and control system

1set

1

VFD house and MCC control system

1set

2

Power cable

1set

VI

VII

Driller’s cabin

1set

2

Instruments for drilling engineering parameters

1set

3

Monitoring system

1set

4

Communication system

1set

Standard electric system on well site

1set

IX

5 houses in all

Driller control system equipments

1

VIII

Note

Detection instruments and tools

1

Detection instruments

1set

2

Special tools

1set

X

Auxiliary equipments

1

Doghouse

2

Catwalk, DP rack

1set

3

RT anti-slide pad

1set

4

Racking board escaping device

1set

5

Cable trough

1set

6

Tool house

1 house

7

Material house

1 house

8

Oil tank

1set

9

Water tank

1set

10

Kill manifold

1set

1 house

Note: The items in the table can be adjusted according to user ’s requirements

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

3. ZJ70DBS rig structure features 3.1 Rig general structure The whole rig contains 5 zones of drilling floor area, power area, pump area, solid control area and oil supply area etc. After the rig is assembled, it occupies about 90m×75m area (not including tool house and living camp etc.) For the rig layout refer to attached drawing 1 Elevation and attached drawing 2 Plan. For rig transmission principle, refer to attached drawing 3 transmission system. For rig layout foundation see attached drawing 4 Foundation. In drilling floor area, there are mast, substructure, crown block, traveling block, hook, drawworks, rotary table drive device, rotary table, driller ’s cabin, dog house and various implements necessary for drilling operation etc on the drilling floor. The mast upper part includes the crown block. In power area, there are generator/air source houses and electric control house. Generator/air source houses form an integrated generating and air supply area after installation. There are three HHF-1600 mud pump sets in pump area. In solid control area, there are mud tanks, mud treating equipments and industrial water tanks etc. of solid control system. In oil and water supply area there are different kinds of oil tanks. Drilling fluid manifold includes standpipe and ground manifold, and the ground manifold is installed on the skid. Each area of rig is connected by cable tray in which there are oil, water and air lines and cable. The catwalk, drill pipe rack, electrical spooler and Moving HPU etc are placed in front of drilling floor. The substructure is placed on the 2.68-m-high Moving master skid, all equipments on the drill floor (crown block, mast, traveling and lifting system, drill floor equipments, doghouse, driller cabin, drawworks, rotary table and trip tank etc) including 150T drilling tools, can shift leftwards and rightwards together with the master skid.

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

3.3 Hook speed and hoisting capacity 3.3.1 Hoisting capacity (double motors) Motor rev rpm

Motor torque Nm

hook speed Hook load hook speed Hook load m/s m/s kN kN (12 lines) (12 lines） (10 lines) (10lines）

131.00

11876.00

0.07

4861.11

0.09

4261.36

391.00

11876.00

0.21

4861.11

0.26

4261.36

531.00

11876.00

0.29

4861.11

0.35

4261.36

710.00

11876.00

0.39

4861.11

0.46

4261.36

749.00

11876.00

0.41

4861.11

0.49

4261.36

803.00

11876.00

0.44

4861.11

0.52

4261.36

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

848.00

11262.00

0.46

4609.79

0.55

4041.05

887.00

10767.00

0.48

4407.17

0.58

3863.43

985.00

9695.00

0.54

3968.38

0.64

3478.77

1073.00

8900.00

0.58

3642.97

0.70

3193.51

1205.00

7925.00

0.66

3243.88

0.79

2843.66

1500.00

6367.00

0.82

2606.15

0.98

2284.62

1700.00

5618.00

0.93

2299.57

1.11

2015.86

2000.00

4775.00

1.09

1954.51

1.31

1713.37

2200.00

4341.00

1.20

1776.87

1.44

1557.64

Hook load KN

3.3.2 Hoisting curve（12 lines, double motors）

Hook speed m/s

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

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

4.1 Preparation of rig installation z z

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

z z z

z

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

4.2 Installation sequence chart Moving master skid, substructure

Mast

Generator& air source house and electric control house

Drilling fluid manifold standpipe

Doghouse

Drawworks

Rig commissioning

Reeve wire rope

RT and drive device

Traveling block, hook

Cable pipeline trough

Drilling fluid manifold ground part

Crown block

Mud pump set

Driller cabin

Solid control system

Lift mast and substructure

Wellhead mechanical tools

Oil tank, water tank

Wellhead alignment

Whole rig commissioning

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

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

Locate Moving master skid, use pins to connect it into a whole; then use pins to connect the Moving cylinders to the master skid and guide rails; lay the left and right base seats of the substructure lower layer onto the Moving master skid and connect them together; use connection fixing device to fix the substructure lower layer and Moving master skid into a whole; then install the middle layer columns and tie-rods. At last, install the top layer drawworks beam, RT beam, setback beam, flooring board, A-frame and other auxiliary parts. Note: The paving plates at the two sides of setback should be installed after the lifting of substructure and except the ladder of drilling floor, the ramp and the ladder leading to the solid control system are all installed after the lifting of substructure. 4.3.2 Installation of the generator/air source house and electrical control house (see the plan of the generator/air source house) Lay the VFD house according to the lofting and marked installation datum lines of rig plan. Lay each generator/air source house in sequence. The VFD house should be vertical to No.1 generator house, and their front side should be aligned. Connect the oil and air lines of each generator set and connection lines between air source equipments. Install mufflers of diesel engines. 4.3.3 Installation of drawworks The drawworks was assembled and test run before its delivering from the factory. There is a fixing buckle designed at the related substructure location. Lift the drawwoks onto its beam of the substructure and locate it according to the fixing buckle. 4.3.4 Installation of RT and drive device The RT drive device (except cardan shaft) has already been installed on skid and packed as per module for transportation. Lift the RT and lay onto the skid, connect it with pins and safety pins (adjust it with puller bolt and position it as per the mark) Install cardan shaft, be sure to keep the parallelism error of the two end flange surfaces ≤1.0mm.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.3.5 Installation of mast (refer to the operation manual of JJ450/45-K mast) Before installation the mast structural components should be inspected visually, repair or replace the distorted and damaged one if any. Turn the rope sheaves, they should rotate actively without blockage. The mast installation sequence: lower parts should be installed first, upper parts installed second, main body first and accessories second. Alternatively move stands, after main components and accessories installed, lift and support the mast with tall stand, for then installing racking board (0.5T air winch included) 4.3.6 Installation of drilling fluid manifold standpipe Install standpipe onto mast when the mast is in lower position, the union connection should be reliable. 4.3.7 Installation of crown block (see the operation manual of TC450 crown block) Connect the crown block to mast with bolts. The accessories of the crown block, such as auxiliary sheaves, lifting frame and climbing booster etc should be installed completely. 4.3.8 Install the hydraulic spooler to the substructure as per the position shown in the rig plan. 4.3.9 Install traveling block, hook and reeve the raising line and drilling line (in parallel mode) properly 4.3.10 Installation of the driller’s cabin Lift the driller’s cabin onto drill floor, and connect air line, hydraulic lines and electric lines of each system according the related numbers. 4.3.11 Installation of cable trough Install the cable troughs according to rig plan and the general drawing of cable trough; connect the pipelines of each system, and install the cables and wires according to the operation manual of electrical system. 4.3.12 Installation of the ground parts of the drilling fluid manifold They should be installed as per the operation manual of drilling fluid manifold, and connected to standpipe and mud pump discharge line.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.3.13 Installation of solid control system Install the mud tanks of the solid control system according to the lofting and marked installation datum lines of rig plan, and install the equipments inside and outside the tanks, connect the connecting lines between tanks and mud pump suction lines as per the operation manual of solid control system. 4.3.14 Installation of standard electric system on the well site (for the detail see the operation manual of the standard electric system on the well site) 4.3.15 Installation of drilling instruments Install the drilling instruments as per the requirements of the operation manual of drilling instruments. 4.3.16 Installation of monitoring and communication systems Install the monitoring and communication systems as per the operation manual of the electric drive system, the requirements of rig elevation and plan (except the parts which should be installed after lifting mast and substructure) 4.3.17 Installation of auxiliary equipments Install as per the requirements of the rig plan and elevation. 4.3.18 Installation of oil and water tanks Install the oil tanks and water tanks according to the lofting and marked installation datum lines of rig plan, connect the cable trough to oil and water tanks. 4.3.19 Installation of top drive device (for detail see the operation manual of the top drive device)

4.4 Inspection after the drilling rig being installed 4.4.1The pre-tension torques for bolts are listed below, all mainly stressed bolts should be inspected one by one with a torque wrench. Nominal dia. of bolt/mm

Grade of bolt

16

20

24

strength

27

30

36

42

Pretension torque/N.m

8.8

185-259

361-505

623-873

919-1286

1243-1740

2178-3049

3492-4889

10.9

260-364

507-710

877-1227

1292-1809

1748-2448

3063-4289

4911-6875

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.2 Inspection after the substructure installed The difference between the diagonal lengths of four bracket pin holes at rear inner sides of the left and right base seats should not be higher than 5mm. All connection parts, fixation parts should be install completely and tightened. And all pins at rotating parts should be greased. All components should be good without deformation, weld seam crack and weld opening. The substructure bottom beam must contact the foundation surface properly and main loading position should be constructed strongly. There should be no obstacle on the drilling floor in the driller ’s sight. The substructure buffer cylinders must operate normally. Raising lines should be good and reeved correctly with end fixed tightly. 4.4.3 Inspection after the mast being installed Grease all points as per the requirements. Check to ensure all connecting parts, fixing parts installed completely and reliably. All components should be good without deformation and weld seams with no crack and weld opening. Various auxiliary devices installed at the mast should be good and complete. The mast buffer cylinders must operate normally. Raising lines and drilling wirelines should be good and reeved correctly with end fixed tightly. Clear out all tools and sundries at the mast. Weight indicator should work normally. 4.4.4 Inspection after the drawworks being installed Check to ensure all guards are installed completely, pipeline connected correctly and reliably. Grease all points as per the requirements. Grease the main speed reducer according to the requirements of its manual. All piping system of hydraulic power for hydraulic disc brake, operation cabinet, control cabinet and brake caliper should be connected correctly, sealed well without leakage. For wearing condition of hydraulic brake disc and brake block, when their thickness decreases to limited value, they should be replaced. For the clearance of the hydraulic disc brake, please refer to the User Manual of Hydraulic Disc Brake and adjust it to proper position.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.5 Inspection after the crown block being installed The connection between the crown block and the upper section of the mast should be tight; positioning pins should be located reliably. 4.4.6 Inspection after the traveling block and hook being installed. All bolts and pins of traveling block and hook should be complete and tightened, and guards are good. The hook body and lock pin at fastener must work actively; the security pin of ear rings should be complete, safe and reliable. 4.4.7 Inspection after elevator links and swivel being installed. There should be no crack and deformation with the elevator links. The swivel must rotate actively and there is no leakage of oil and drilling fluid. Rotary hose should be installed with safety chains. 4.4.8 Inspection after mud pump being installed. The mud pump safety valve should be installed in a position as required; and it must work normally. The air damper on mud pump should be filled with nitrogen or air, it is forbidden to fill it with oxygen. The pressure gauge of the mud pump should be precise and its surface should be clean. 4.4.9 Inspection after the drilling fluid manifold being installed All holders and clamps should be fixed reliably; the connections of all unions are correct and sealed reliably. The hand wheels of valves are complete, operate actively without leakage. 4.4.10 Inspection after generator/air source house and air supply system being installed (exclude electric transmission) All the bolts should be installed completely and tightly. Pre-tightening torque should be in conformity with requirement. All pipeline should be clean and smooth, connected correct with clear marks, sealed reliably without leakage. Pressure gauges are complete and intact, and in calibration efficient period. The pressure of air piping should be adjusted to the required pressure. All pipelines, valves should be intact; safety valves act sensitively. The guards of transmission parts should be intact and complete, and installed reliably.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

4.4.11 Inspection after cable troughs being installed. All pipelines should be connected correctly; they are clean and smooth inside, each connection part is sealed reliably with no leakage. All cables and wiring should be connected correctly and in good order, and marked clearly. 4.4.12 Inspection after the driller’s cabin being installed The air and hydraulic lines should be clean and smooth inside, and their pipelines are connected correctly with clear marks. All connections should be sealed reliably without leakage. All instruments and meters are installed complete, sensitive and reliable. 4.4.13 Inspection after solid control system being installed All the bolts, nuts, spring washers and split pins should be installed completely and tightly. Pre-tightening torque should be in conformity with requirement. All piping, valves should be intact without water leakage 4.4.14 Inspection after the electric control system and standardized electric system on the well site being installed Check according to the related requirements in operation manual of electric control system and standardized electric system on the well site. 4.4.15 Inspection after drilling instrument system being installed Check according to the related requirements of operation manuals for drilling instruments for ensuring all instruments sensitive and reliable. 4.4.16 Inspection after monitoring system and communication system being installed Check according to the related requirements of operation manual for monitoring system and communication system. 4.4.17 Inspection after assistant parts being installed All assistant parts should be good and installed completely. All bolts for assistant parts should be installed completely and tightly. All pins and safety chains should be installed completely and reliably. The wireline for assistant equipments should be good without any damage.

5. Rig commissioning 5.1 Preparation before commissioning

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

5.3 VFD system power supply commissioning 5.3.1 Preparation Check the connections between the electrical equipment power and control cables of VFD and MCC system in VFD house, and each AC VF motor, all control switches, displaying screen, touch screen in driller ’s cabin, and lighting system and solid control system etc. Ensure all switches are in the “off “position. Power up the VFD and MCC system with generator set, test all function switches, meters, make sure display and indication are correct and parameters conform to the requirements. 5.3.2 Supply power to each zone Power up the driller ’s cabin, check the operational status of display screens, and touch screens, instruments and switches for sensitivity and reliability.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

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

5.8 Commissioning of drawworks Do the following debugging before wireline reeving. 5.8.1 Adjustment before running Open the air tank ball valve on the rear substructure to supply air for the Drawworks. Start the main reducer lubrication oil pump; check the lubrication condition of all parts. Operate the control handle of hydraulic disc brake in the driller ’s cabin and push buttons on the touch screen 5～10 times. Check the operation of the hydraulic disc brake for sensitivity and reliability. Check: The air in / out conditions of the clutch of assistant drive device The reliability and accuracy of the toggle valve. The sensitivity and reliability of the hydraulic disk brake system. 5.8.2 Commissioning at zero load A. Operating procedure Start the motor A of drawworks, check the rotation direction, and be sure the drum rotation direction is winding direction.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Start the motor B of drawworks, check the rotation direction and be sure the drum rotation direction is winding direction. Check the lubricating oil pump pressure. It should be 0.1~0.35MPa. Start motor A and B respectively, adjust the speed to 970r/min and run 20minutes respectively. Run the both motors A and B together, accelerate and decelerate them with control handle and check the operation condition. Start the assistant motor, check the rotation direction and be sure the drum rotation direction is winding direction. Accelerate and decelerate motor and check the operation condition. Process brake tests not less than 5 times at different speed for hydraulic disc brake. Note: the main motor by the side of the driller is motor A, and the one in front of driller is Motor B. B. Requirements All operations should be exact and sensitive; At all locations there is no oil leak. Lubricating oil pressure is stable and the lubricant quantity is correct. Running of drawworks shall be smooth without abnormal vibration and noise. Temperature rise of all bearings should be normal. Hydraulic disc brake is sensitive and reliable. 5.8.3 Install wirelines After the test of drawworks, lay the wireline spooler properly and reeve the drilling wireline. The active line should be threaded into the drawworks drum and fastened by clamps; the dead line should be threaded into the deadline anchor and fastened. Note: when the traveling block is located at the lowest position before mast lifting, initial wireline winding on the drum should not be less than 1 3/4 layer. As per lifting device drawing, hang the balance pulley on the hook, and then reeve lifting system wireline properly.

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

5.10 Commissioning of Mud Pump Set (May process this commissioning after lifting of mast and substructure)

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

5.11 Mast and substructure lifting, mast alignment （For details, see operation manuals of the mast and substructure） 5.11.1 Inspection before the mast lifting Before lifting the mast, check the installed parts completely according to the clause 4.4.3 to verify the installation correctness and connection reliability of each part. The raising line should be intact, and reeved correctly with end fixed reliably. Air supply and pneumatic control systems should be in normal status, the pressure of the air tanks should not be less than 0.8MPa. The drawworks should be adjusted properly and be test run normally for at lest 2hrs. Turnover the racking board and fix it properly. Move the tong counterbalance to low position. Check if the hook is locked reliably. Recheck the buffers for its normal working status. The sheave bearing of all raising lines should be greased in accordance with the requirement, and the sheave must turn freely. Check if there is any part or tool left at the mast, and if all safety facilities are ready and reliable. 5.11.2 Mast trial lifting z

Lifting operation should be carried out under the guidance of commander. The commander should stand on a position which the driller can see directly and is safe.

z

Before trial lifting, all other persons and construction implements should move away to a safe area except the worker on duty in engine house, driller, and the observers for key positions, security official and commander.

Safety distance is not less than 70m away in the front from the wellhead, and the two sides are not less than 20m away from the two sides of mast. z

The mast can be lifted by the main motor in low speed and can also be lifted by assistant motor

z

Pull the wire line tight gradually in low speeds while lifting the mast; lift the mast 100mm～ 200mm away from tall stand after the wire line being confirmed normal. At the same time observe if the lifting pull conforms with required value; and brake and observe if assistant drilling line, dead line, various pipelines, electric lines are in normal status; then put the mast

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

back to its original position, check if the raising line is reliable without loose phenomenon and lifting lug plate with no crack on weld seam. z

If every thing is OK after check, lift the mast again. When the mast lift 200mm～300mm away from the tall stand, engage the drawworks brake and hold on for 5 min.～10min. Check if the raising line end and the dead line end of drilling line are fixed properly and reliably; check if the loading parts of the substructure, main load parts of A frame etc are not deformed, if there is no crack with the weld seams; check the lifted height of the substructure to see if the counterweight is enough.

z

Lower down the mast onto the tall stand slowly and put the traveling block to a place 100mm～ 200mm away from the support surface, re-tighten the crown block connecting parts and mast bracket connecting bolts.

z

Re-lift the mast, when it leave 200mm～300mm away from the stand, engage the drawworks brake to hold on the mast in the position for 5min., then put back the mast onto the tall stand slowly, put back the traveling block to a place 100mm～200mm away from the support surface.

5.11.3 Raising the mast Operate the control valve of mast buffer cylinder to extend the piston rod completely and keep the pressure of the cylinder (3~5MPa). During lifting operation, run the drawworks slowly and control the hook speed to the range of about 0.8～1.2m/min. Note: Operate the drawworks evenly and stably. It is forbidden to brake or accelerate suddenly while it is running. When the mast lifts to 75°～80°position or leaves 2m away from the piston head of the buffer cylinder, slow down the drawworks speed to make the mast reach slowly the buffer cylinder piston head, then operate the buffer cylinder: After the mast gravity moves over the mast front support legs, cut off the power of the drawworks to make the mast locate slowly. When the mast located, pull the raising line tight gently, connect and tighten the mast to A frame and substructure timely. Lower the traveling block and hook to low position, then disconnect the connecting pins of raising line, reeve and fix the raising line according to requirements. 5.11.4 Inspection before the substructure lift Before lifting the substructure, check the installed parts again completely according to the requirements of clause 4.4.2 to confirm the various parts for proper installation and reliable connection. The raising line should be good, reeved correctly and with its end fixed reliably. Check again if the buffer cylinder works normally.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Check again if the various sheave bearings of the raising line system have been greased according to requirements, and if they are running smoothly. Check again if the connecting pins between upper layer and bottom layer have been disconnected. 5.11.5 Raising the substructure While lifting the substructure, pull the wireline tight gradually and slowly, to make the substructure lifted 100～200mm up from the installing position; at the same time watch the lifting pull exceeds regulated value or not; engage the brake and hold on at least 5min. Check if raising line is fixed at the ends properly and deadline of drilling wireline is fixed normally. Assistant drilling line, various pipelines, electric leads etc should be in normal status; then put the substructure back to its original position. Re-lift again if all is normal after checking, when the substructure is lifted 200mm～300mm up from the installed position, engage the winch brake and hold on for at least 5min.～10min. Check if the raising line is fixed at the ends properly and deadline of drilling wireline is fixed normally. Check if the loading parts and key position are in good condition without deformation and no crack on weld seam. Run the winch at low speed while lifting the substructure, control the hook speed to about 0.8～ 1.2m/min. Precaution: Run the winch evenly and stably. It is forbidden to brake or accelerate suddenly while it is running. When the substructure is lifted to 75°～80°position or the buffer cylinder piston head leaves away 0.5m from the triangle frame, slow down the hydraulic winch speed to make the buffer cylinder piston head reach the triangle frame slowly, operate the buffer cylinder then, when the piston start to retract and make the substructure locate slowly. After the substructure located, connect and tight it timely. After lowering the traveling block and hook to low position, remove the connecting pins of raising line, and remove and fix the raising line properly in the way according to the requirements. 5.11.6 Mast alignment After the mast and substructure are installed, align well head as required. Offset error of alignment between the crown block center and RT center allowed is ≤ Φ20mm. (For aligning method, see the operation manual of the mast) Be sure to make the mast in natural status while aligning it.

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

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

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

5.16 Running test for solid control system 5.16.1 Sealing performance test of the system pipeline After the whole system installed carry out the sealing performance test. Fill the circulating tank with fresh water. There should be no leakage with connecting lines between tanks, valves and bottom valves. 5.16.2 Power-on running test on the solid control system Carry out power-on test on shale shaker, vacuum degasser, desander, desilter and centrifuge respectively; they should run normally.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

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

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

5.20 test of the top drive device For detail see the operation manual of the top drive device

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

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

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

6.3 Safety rules of rig operation

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.3.1 Rig operation requirement z

Rig crew should have mechanical, electrical and instrument professional to guide or do rig routine operation and maintenance and make technical regulations for rig routine operation and maintenance.

z

Rig operators and maintenance personnel should pass on-the-job training and test qualified, work with their certificates.

z

Rig operators must comply with safe operation regulations of the drilling rig.

z

The hoisting speed and capacity must be in accord with related regulations in drawworks operation manual.

z

Mud pump flow rate and pressure must follow related rules in HHF-1600 mud pump operation manual.

z

If any part of the rig fails, stop it immediately and deal with the failure in time; restart only after failures eliminated.

z

Ensure to release all high pressure pipes or hoses completely before disconnecting them. Ensure to cut off the power supply before repair electric circuits and equipments.

6.3.2 When any following failure appears; the rig should be stopped and maintained immediately. z

Overload and overspeed operation;

z

The steel structure of mast and substructure distorted and cracked;

z

Foundation of substructure sinks or ruptures;

z

Brake or drive system fails;

z

Drilling pump’s safety valve and the charged air of air damper do not meet the requirement;

z

The bumper device fails while tripping in/out;

z

Rig instruments damaged or no metering function;

z

Air control system fails or air source pressure is lower than the allowed range;

z

Safety guards and handrails are not complete;

z

Oily thing goes into surface of brake disk, brake hub, clutch steel hub;

z

Raising line and drilling line are not checked according to the regulation.

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

6.4 Maintenance regulations of rig According to the running time and technical status of drill rig, it is divided into periodical one and staged one. Periodical maintenance is divided into shift service, weekly service and monthly service. Shift maintenance includes adjusting, lubricating, tightening, cleaning and corrosion preventing etc (conventional items), and some items specified in this chapter. Weekly maintenance includes all the items of shift maintenance. Monthly maintenance includes all the items of weekly maintenance. Staged maintenance includes the main components maintenance. If the components can not satisfy the drilling operation requirements, it should be repaired on service base. The rules for periodical maintenance followed: 6.4.1 Routine inspection and maintenance items for Mast and Substructure: Any cracks or distortion in the hoisting structure Any corrosion of the wire rings and wire loops Any damage to the hoisting wire line Lubrication of the block system All pins and safety pins are installed and complete Tightness of all bolt connection parts; Under load, periodically measure the deviation from linearity of the mast columns in total length, and any perpendicular deviation of the mast looking from the front and side of the mast. Before mast raising or lowering, check bumper devices and hydraulic system for their condition and enough oil feeding. The inclined and transversal bars and beams (brace and girder) or other parts are not allowed to be dismantled in any circumstance. It is not allowed to drill or cut holes or weld on the steel structures. Inspect the mast and substructure monthly, especially before heavy casing running. 6.4.2 Hoisting System 6.4.2.1 The shift inspection items: The braking function and anti-collision performance on the drawworks; The operation of electrical equipment in the driller ’s console; the sealing performance of air or hydraulic control connections; The fastening of the deadline and the fastline ends; The lubrication and seals of each bearing;

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

The fixation of the hook ring bolts and lock pin; check if the hook can rotate freely and the spring action is proper; The sealing performance of the swivel and drawworks, and that the quantity and temperature of lubrication oil meet requirement; The rotary table lock pin is working properly. 6.4.2.2 The weekly inspection items Check the feeding conditions of drawworks lube oil pump, lubricant cleanliness and whether it’s necessary to wash or change filter element. The bail and pins of the swivel whether or not rotate smoothly; The fixation of the traveling block shaft; The hook and sheave groove wearing at the crown block and traveling block; The sealing condition of the swivel washing pipe packing; The tightness of the universal shaft of the rotary table; 6.4.2.3 The monthly maintenance work Inspect the wearing and connection condition of each clutch, coupling and cross joint of universal shaft. Whether there are cracks on the elevator links, pins and sheaves of lifting system. 6.4.3 Mechanical drive System 6.4.3.1 Inspecting items of shift maintenance Adjust the tension of the transmission belt. Check the temperature, temperature rising and noise of gear box and rotating part. Check gear box lubricant quality, quantity, pressure and temperature; 6.4.3.2 Inspecting items of weekly maintenance Check the working condition of the lube oil pump and clean filter, Inspect the worn situation of the clutch. 6.4.3.3 Inspecting items of monthly maintenance Inspect each transmission part completely including clutch, coupling, universal shaft etc; Inspect the gear meshing of transmission box; Check or measure the oil quality of sump. 6.4.4 Circulating System 6.4.4.1 Inspecting items of shift maintenance The operation status of the mud pump power end; check the tightness of drive belt and temperature rising of each bearing.

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

The suction performance of fluid end and the working condition of piston, liner, rod etc. especially their sealing, cooling and lubrication; The tightness of the cylinder lids and valve caps of mud pumps; The working condition of charging pump and spraying pump; Whether the pressure of air damper and relief valve meet the requirements; The tightness of high pressure manifold and working condition of high pressure valve; The working conditions of solid control equipments; the temperature rise and insulation of motors; 6.4.4.2 Inspecting items of weekly maintenance Check and clean oil filters; The lubrication and abrasion of crosshead and guide plate; Whether the action of safety valve is agile or not; The insulation of the electrical circuits; The passage condition of mud gun nozzle; 6.4.4.3 Inspecting items of monthly maintenance Check the meshing condition of power end gears ， check and adjust the clearance between crossheads; Inspect the high pressure pipe by non-destructive test; Tighten connecting valve bolts of mud pumps and clean the oil trough. 6.4.5 Air Supply System 6.4.5.1 Shift inspection item Check whether the operation of the air compressor is normal. The quality, level and temperature of the oil meet requirements. Check whether the setting of auto-pressure-adjusting device and safety valve are correct or not. Check the working pressure of the air tanks and clean the tank with water; Check the air lines for their smoothness and sealing condition. 6.4.5.2 Weekly inspection item Check the condition of the air filter for clogging Check the safety valve and sequence valve. 6.4.5.3 Monthly inspection items Clean the air filters and the safety valve of air tank; Inspect the control valve of the compressor. Inspect the control valve of air dryer. 6.4.6 Driller’s Cabin (Refer to the operation manual of driller ’s cabin, please)

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

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

7. Dismantling and transportation of drill rig 7.1 Lowering of mast and substructure 7.1.1 Checking before lowering z

Grease each lubrication point and pins of rotary parts as per requirements.

z

Installation of each connection and fixation component must be complete and fastened.

z

Each part should be without serious deformation; each weld should be without crack and opening.

z

Substructure bottom beams contact properly with foundation surface, major force-bearing points must be tamped.

z

There is no barrier to block driller ’s eyesight on the drill floor.

z

Substructure buffering cylinder works normally.

z

Mast buffering cylinder works normally.

z

Lifting wireline and drilling wireline are all in good condition, while their ends fastened tightly.

z

No tools and stuffs left on the mast.

z

Weight indicator works normally.

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Dismantle all components affecting lowering of the substructure such as the ramp, slide, ladders and tool elevator etc. Control the lowering speed as slowly and evenly as possible. Prevent sudden accelerating and sudden stop. 7.1.3 Mast lowering Before mast lowering, hang the balance-blocks properly, and dismantle casing stabbing board and structural components and accessories which affect the mast lowering, then operate the bumper cylinder to push the mast away from its center of gravity, and then lower it slowly by its weight while drawworks reversely dragging. Precautions should be taken while lowering the mast: Control the lowering speed as slowly and smoothly as possible. Sudden accelerating or brake is strongly forbidden.

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

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

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

8. Main components lubrication of ZJ70DBS rig No.

Name

Location Drum shaft, coupling and grease lubrication

1

Drawworks

2

Motor

3

Mast & Substructure

4

Crown block

Specification

Lubrication maintenance cycle

Ambient temperature －20℃ above， Every NLGI 2 lithium base operation grease

Ambient temperature －20℃～ +10℃，ISO VG 150 Middle extreme gear o il Ambient temperature Gear reducer box －10℃～ +40℃，ISO or chain VG 220 transmissio Middle extreme gear n box oil oil lubrication 。 Ambient temperature +10℃～ +60℃，ISO VG 320 Middle extreme gear o il FAG-Arcanol L135V Lubrication grease Bearing

15days’

When the oil level is below the mark, add oil in time. Replace the oil completely every 6 months or the oil has been polluted.

Replace the oil completely every 3 years or the oil has been polluted Before the raising All sheave and lowering of the Temperature － above mast bearing and substructure 20℃， th e NLGI 2 lithium base Before installation and g r e a s e Pins , ear dismantling of the hole mast and substructure Ambient temperature Sheave Every 7 days of －20℃ above ， bearing NLGI 2 lithium base operation grease

Filling Qty. for the new equipment 2 kg

500 L

290 g

200 g

500g

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OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No.

Name

5

Traveling block,

6

hook

Location

Ambient Temperature －20℃ above， NLGI 2 lithium base grease lifting bail Ambient temperature pin, thrust －20℃ above ， bearing of NLGI 2 lithium base each pin grease Ambient temperature －20℃～ +50℃，ISO VG 220 Oil sump Middle extreme pressure gear oil Sheave bearing

Oil sump

7

8

9

Swivel

ZP375RT

RT drive device

Specification

Lubrication maintenance cycle Every 7 operation

days’

Filling Qty. for the new equipment 500g

Every 7 days of operation

200g

When the oil level is below the mark, add oil in time. The oil should be replaced completely after the is well drilling completed.

20L

Ambient temperature －20℃～ +50℃，ISO every 2 months of VG 220 o peration Middle extreme pressure gear oil

200g

Ambient temperature －20℃ above ， Spinner NLGI 2 lithium base grease lifting bail Ambient temperature pin, packing －20℃ above ， of wash NLGI 2 lithium base tube, grease bracket and seals of lower cover Ambient temperature －20℃～ +50℃，ISO Main oil VG 220 sump Middle extreme pressure gear oil Ambient temperature Locking －20℃above， device NLGI 2 lithium base grease Ambient temperature －20℃～ +10℃，ISO Gear box or VG 150 chain drive Middle extreme box, oil pressure gear oil; lubrication Ambient temperature －10℃～ +40℃，ISO VG 220

Every 200 hours of operation

200g

Every 72 hours of operation

200g

Every 2 months of operation

200L

Every 7 days of operation

100g

When the oil level is below the mark, add oil in time. Replace the oil completely every 6 months or the oil has been polluted.

200L

33

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No.

10

11

12

13

Name

RT drive cardan shaft

HHF-1600 drilling pump

Air winch

Deadline anchor

Location

Specification

Middle extreme pressure gear oil; Ambient temperature +10℃～ +60℃，ISO VG 320 Middle extreme pressure gear oil Ambient temperature Bearing, －20℃above， spline NLGI 2 lithium base grease Ambient temperature －20℃～ +10℃，ISO VG 150 Middle extreme pressure gear oil; Ambient temperature o il －10℃～ +40℃，ISO lubrication , VG 220 oil sump Middle extreme pressure gear oil; Ambient temperature +10℃～ +60℃，ISO VG 320 Middle extreme pressure gear oil Ambient temperature Bearing －20℃above ， with drive NLGI 2 lithium base device grease Ambient temperature －20℃～ +50℃，ISO Oil sump VG 220 Middle extreme pressure gear oil Gear and all Ambient temperature grease －20℃above ， lubrication NLGI 2 lithium base points grease Ambient temperature －30℃～ +50℃，ISO Oil fogger VG 46， ISO HM hydraulic oil Ambient temperature Sheave －20℃above ， bearing NLGI 2 lithium base grease Weight Transformer oil ，

Lubrication maintenance cycle

Filling Qty. for the new equipment

Every 72 hours of operation

100g

When the oil level is below the mark, add oil in time. Replace the oil completely every 6 months or the oil has been polluted.

350L

Every 15days operation

of

400g

Every month operation

of

2L

Every 7 days of operation

600g

When the oil level is below the mark, add oil in time.

0 .2 L

Replace all the grease completely when the well drilling is completed When calibrating the

400g Proper

34

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

No.

14

Name

All kinds of wireline

Location indicator sensor pipeline

ISO viscosity is 8.7

Wireline surface

Wireline grease

Oil cylinder 15

YM-16-Ⅱ hydraulic cathead Sheave

16

17

HPU

Moving HPU

Specification

Lubrication maintenance cycle

Filling Qty. for the new equipment

weight indicator, add o il

surface According to the operation situation

Ambient temperature －30℃～ +50℃，ISO VG 46, ISO HM hydraulic oil Ambient temperature －20℃ above ， NLGI 2 lithium base grease

Proper

Replace the oil completely every 6 months or when the oil has been polluted Every 7 days of operation

80L

100g

Replace the oil Ambient temperature completely every 6 Oil tank in －30℃～ +50℃，ISO months or the oil has HPU VG 46, ISO HM been polluted. hydraulic oil

1000L

Replace the oil Ambient temperature completely when the Oil tank in －30℃～ +50℃，ISO o il h as been HPU VG 46, ISO HM polluted. hydraulic oil

1000L

As for details, please refer to th e Compressor 18 compressor oil compressor operation manual Ambient temperature As for details, please refer to the generator －20℃ above ， Generator diesel set operation manual 19 API CH-4(CG-4) set generator SAE 15W-40 diesel engine oil Note: The listed lube oils in this table are recommended ones. According to ISO viscosity grade gas/oil separation cylinder

requirements, it is necessary to use the qualified lubricant. The period of lubrication and maintenance is the period in normal operation, and can be adjusted according to the working condition together with the quality of lubricant inspected periodically.

9. Bearing model list of main components No.

Name

Location

Spec.

1

Crown block

Crown block sheave

Φ304.8×Φ393.7×107.95

Code

Model No.

Qty.

37961K

7

35

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Sand sheave 2

Traveling block

3

hook

Traveling block Φ254×Φ347.66×101.6 sheave Hook loading Φ180×Φ360×82 bearing Φ270×Φ550×130 Loading bearing Anti-bumping

4

Swivel

bearing Upper & down alignment bearing

5 6

90*190*43

GB238-81

GB4663-19 94 GB299-64

8

1

NU2330E

1

22330C

1

23148CA

2

254941QU

3

Φ350×Φ220×98.42

4G32844H

2

Φ500×Φ300×160

3G3003760HY

2

929/660.4QU

3

Φ240×Φ400×128

9

drive device

GB/T283-9 4 GB/T288-9 4 SKF

206.375×222.25

Φ863.6×Φ 660.4×107.95

b elt

pulley drive shaft

1

32148

Drawworks Drum shaft assy.

Small

19954EQ

GB283-81

Φ150×Φ320×108

Pump

1

Φ240×Φ360×56

Horizontal shaft

Eccentric wheel bearing

87436ZW

1

Φ285.75×Φ

7

6

2007140

RT

Pinion shaft bearing Main bearing, crank shaft

37951K

GB297-84

Φ150×Φ320×108

Drilling pump

2

Φ200×Φ310×70

Horizontal shaft

Crosshead bearing

42318

GB/T2 150*270*73

assembly

83-94

or

22230C

2

FAG, SKF

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

10. The drilling rig operation manuals list Item No. 1 2 3 4 5 6 7 8 9 10 11

Name ZJ70DBS drilling rig operation manual DZ450/9-S1 substructure operation manual JJ450/45-K Mast operation manual TC-450 Crown block operation manual YC-450 Traveling block & hook operation manual DG-450 Hook operation manual SL450 swivel operation manual JC70DB Drawworks operation manual ZP375 Rotary table operation manual RT transmission device operation manual Mud pump transmission device operation manual

36

OPERATION MANUAL OF ZJ70DBS DRILLING RIG

Item No. 12 13 14 15 16 17 18 19 20

Name Solid control system operation manual Air control system operation manual Hydraulic system operation manual Rig Moving hydraulic system user manual Rig Moving device user manual Power system operation manual Electrical transmission system operation manual Driller ’s cabin operation manual Operation manual of mechanical equipments on drill floor

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

Translated

by ：

Date:

Proofread

by：

Date:

Finalized

by：

Date:

37

Attached drawing 1 Plan view of ZJ70DBS rig

Attached drawing 2 Elevation view of ZJ70DBS rig

Attached drawing 3 Drive system of ZJ70DBS rig

Attached drawing 4 Foundation of ZJ70DBS rig