Classified Technical Data & Sourcing Guide for ZJ Drilling Rig Parts

1

Drawworks

JC40DB

High-strength alloy steel (42CrMo)

1. Gear tooth abrasion due to improper lubrication and long-term high-torque operation; 2. Bearing damage caused by vibration from uneven drill string load.

1. Use API-specified high-pressure lubricating oil and replace it per 500 operating hours; 2. Monitor drill string load in real time to avoid sudden torque spikes.

2

Crown Block

TC225

Quenched and tempered high-carbon steel + bearing steel (GCr15)

1. Pulley groove wear from long-term friction with steel wire rope and sand dust contamination; 2. Structural fatigue due to repeated impact during drill string lowering.

1. Regularly clean pulley grooves and inspect steel wire rope wear (replace rope when wear exceeds 3%); 2. Conduct non-destructive testing (NDT) every 6 months to detect fatigue cracks.

3

Travelling Block

YC225

Quenched and tempered high-carbon steel + bearing steel (GCr15)

1. Bearing seizure caused by drilling fluid invasion and lubricant degradation; 2. Side wear of pulleys due to misalignment with crown block during operation.

1. Enhance sealing protection to prevent drilling fluid ingress and replace lubricants monthly; 2. Align crown block and travelling block before each drilling cycle to ensure coaxiality.

4

Hook

DG225

Alloy structural steel (40CrNiMoA)

1. Hook neck wear due to overloading and repeated lifting/lowering cycles; 2. Fatigue cracking caused by stress concentration at the hook opening.

1. Strictly adhere to the rated load limit (no overloading by more than 10% even in emergency); 2. Polish the hook opening regularly to eliminate stress concentration points and conduct magnetic particle inspection quarterly.

5

Swivel

SL225

Alloy steel + wear-resistant ceramic bushing

1. Rotating shaft wear due to insufficient lubrication and high-speed operation; 2. Seal failure caused by high-pressure drilling fluid erosion.

1. Maintain continuous lubrication pressure (0.8-1.2 MPa) during operation; 2. Replace high-pressure seals every 800 operating hours or immediately if drilling fluid leakage is detected.

6

Mud pump

F1300*2

High-chromium cast iron (HT200) cylinder liner + alloy steel crankshaft

1. Cylinder liner erosion by drilling fluid containing abrasive formation particles; 2. Valve seat wear due to frequent high-pressure opening/closing cycles.

1. Ensure drilling fluid solid content is below 5% by enhancing the filtration system; 2. Inspect valve seats weekly and replace if the seal surface has scratches exceeding 0.2 mm.

1

Drawworks

JC50DB

Ultra-high strength alloy steel (30CrNiMo8)

1. Gear pitting corrosion due to lubricant contamination by water and drilling fluid; 2. Brake disc wear caused by frequent heavy braking during deep drilling.

1. Install a lubricant water separator and test water content weekly (keep below 0.5%); 2. Avoid continuous heavy braking by using auxiliary brakes to distribute load.

2

Crown Block

TC315

High-strength structural steel (Q690) + bearing steel (GCr15SiMn)

1. Pulley bearing damage due to high-temperature operation in deep wells; 2. Structural deformation caused by uneven wind load in open-air drilling sites.

1. Equip bearings with forced cooling systems and monitor temperature (keep below 80℃); 2. Install wind deflectors in windy areas to reduce uneven load on the crown block.

3

Travelling Block

YC315

High-strength structural steel (Q690) + bearing steel (GCr15SiMn)

1. Corrosion of structural parts by hydrogen sulfide (H₂S) in sour gas wells; 2. Bearing wear due to high-load and high-speed rotation.

1. Use H₂S-resistant coating for structural parts in sour gas well scenarios; 2. Select heavy-duty bearings with dynamic load rating ≥ 500 kN and lubricate with anti-wear grease.

4

Hook

DG315

Alloy structural steel (40CrNiMoA) with carburizing treatment

1. Wear of the hook bearing due to insufficient lubrication and high-speed rotation; 2. Fatigue failure caused by repeated impact during drill string landing.

1. Inject high-temperature resistant lubricating grease into the bearing every 200 operating hours; 2. Control the drill string landing speed (≤ 0.5 m/s) to reduce impact load.

5

Swivel

SL450

Alloy steel + polytetrafluoroethylene (PTFE) wear-resistant ring

1. Wear of the rotating joint due to high-pressure drilling fluid scouring; 2. Seal aging caused by high-temperature in deep wells (≥ 120℃).

1. Use drilling fluid with low abrasiveness and add anti-scouring additives; 2. Replace high-temperature resistant seals every 600 operating hours in high-temperature wells.

6

Mud pump

F1600*2

Tungsten carbide alloy cylinder liner + nodular cast iron (QT450-10) crankshaft

1. Piston rod wear due to misalignment with the cylinder liner; 2. Crankshaft bearing damage caused by unbalanced load from dual pumps.

1. Align the piston rod and cylinder liner monthly to ensure coaxiality (error ≤ 0.1 mm); 2. Balance the load between the two pumps by adjusting the pressure regulating valve.

1

Drawworks

JC70DB

High-strength alloy steel (34CrNiMo6) with quenching and tempering

1. Gear tooth breakage due to sudden overload during drill string stuck scenarios; 2. Brake system overheating and wear caused by long-term braking in deep well tripping.

1. Install a torque limiter to cut off power when overload exceeds 15%; 2. Use combined braking (main + auxiliary) to reduce main brake load during tripping.

2

Crown Block

TC450

High-strength quenched and tempered steel (Q960) + bearing steel (GCr15SiMn)

1. Pulley groove deformation due to high-tension steel wire rope friction; 2. Bolt loosening and structural vibration caused by high wind speed in offshore or plateau drilling sites.

1. Replace steel wire rope when the diameter wear exceeds 5% and grind pulley grooves to maintain smoothness; 2. Check and fasten bolts with torque wrench monthly (torque ≥ 800 N·m).

3

Travelling Block

YC450

High-strength quenched and tempered steel (Q960) + bearing steel (GCr15SiMn)

1. Bearing damage due to high-pressure and high-temperature in deep wells; 2. Corrosion caused by seawater or salt spray in offshore drilling.

1. Use sealed bearings with pressure-resistant rating ≥ 35 MPa and high-temperature resistance; 2. Apply anti-corrosion coating (epoxy zinc-rich paint) and conduct salt spray resistance testing quarterly.

4

Hook

DG450

Alloy structural steel (42CrMo) with surface nitriding treatment

1. Hook neck fatigue cracking due to long-term alternating load; 2. Wear of the locking device due to frequent use in drill string handling.

1. Conduct ultrasonic flaw detection every 3 months in accordance with API Spec 8A Clause 5.3; 2. Lubricate the locking device weekly and replace worn locking pins immediately.

5

Swivel

SL450

Alloy steel + wear-resistant ceramic coating

1. Rotating shaft wear due to high-speed rotation (≥ 300 rpm) and drilling fluid scouring; 2. Seal failure caused by high-pressure drilling fluid (≥ 35 MPa).

1. Monitor rotating speed and avoid exceeding the rated speed; 2. Use double-layer high-pressure seals and inspect seal pressure weekly (maintain ≥ 40 MPa).

6

Mud pump

F1600*3

Tungsten carbide composite cylinder liner + alloy steel (40CrNiMoA) crankshaft

1. Valve plate wear due to high-frequency impact from drilling fluid containing hard particles; 2. Crosshead pin wear caused by insufficient lubrication.

1. Install a high-precision filter (100-mesh) to remove hard particles from drilling fluid; 2. Ensure lubricating oil flow rate to crosshead pin ≥ 5 L/min and monitor oil temperature (≤ 75℃).

1

Drawworks

JC90DB

Ultra-high strength alloy steel (38CrNiMoV5-10)

1. Gear surface wear due to high-temperature lubricant degradation in ultra-deep wells (≥ 150℃); 2. Brake disc thermal deformation caused by continuous heavy braking.

1. Use synthetic lubricating oil with high-temperature resistance (≥ 200℃) and replace every 400 operating hours; 2. Equip brake discs with forced air cooling systems and limit continuous braking time to ≤ 10 minutes.

2

Crown Block

TC675

High-strength quenched and tempered steel (Q1100) + ceramic-reinforced bearing steel

1. Bearing wear due to high-speed rotation and extreme load; 2. Structural fatigue caused by long-term operation in ultra-deep well harsh environments.

1. Use ceramic hybrid bearings with high load-bearing capacity and low friction coefficient; 2. Conduct NDT every 2 months in accordance with API Spec 4F Clause 6.2 to detect fatigue damage.

3

Travelling Block

YC675

High-strength quenched and tempered steel (Q1100) + ceramic-reinforced bearing steel

1. Corrosion caused by H₂S and CO₂ in sour gas ultra-deep wells; 2. Pulley wear due to high-tension steel wire rope (tension ≥ 600 kN).

1. Use corrosion-resistant alloy materials and apply anti-sulfide coating; 2. Select steel wire rope with high breaking strength and inspect tension daily to avoid over-tension.

4

Hook

DG675

Alloy structural steel (45CrNiMoV15) with deep cryogenic treatment

1. Hook bearing seizure due to high-temperature and high-pressure in ultra-deep wells; 2. Fatigue cracking caused by repeated impact of heavy drill strings (weight ≥ 500 tons).

1. Equip bearings with circulating cooling systems and monitor temperature in real time; 2. Use a buffer device during drill string landing to reduce impact load by 30%.

5

Swivel

SL675

Nickel-based alloy + diamond-like carbon (DLC) coating

1. Rotating joint wear due to high-pressure drilling fluid (≥ 50 MPa) scouring; 2. Seal aging caused by high-temperature and chemical corrosion.

1. Use drilling fluid with anti-corrosion additives and control pH value between 8-10; 2. Replace seals made of perfluoroelastomer (FFKM) every 500 operating hours.

6

Mud pump

F1600HL*3

Polycrystalline diamond compact (PDC) cylinder liner + alloy steel (42CrNiMoA) crankshaft

1. Piston wear due to high-pressure drilling fluid containing abrasive particles; 2. Crankshaft fatigue damage caused by unbalanced load of three pumps.

1. Use ultra-high molecular weight polyethylene (UHMWPE) piston rings with high wear resistance; 2. Adjust the three pumps’ operation parameters to ensure load balance (pressure difference ≤ 2 MPa).

1

Drawworks

JC120DB

Nickel-chromium-molybdenum alloy steel (4340)

1. Gear tooth wear due to extreme torque (≥ 1200 kN·m) and high-temperature operation; 2. Brake system failure caused by high-pressure hydraulic oil leakage.

1. Use gear oil with extreme pressure resistance and conduct oil analysis every 100 operating hours; 2. Inspect hydraulic system pipelines and seals daily to prevent high-pressure leakage.

2

Crown Block

TC900

High-strength quenched and tempered steel (Q1300) + silicon nitride ceramic bearings

1. Bearing damage due to ultra-high load (≥ 900 tons) and high-speed rotation; 2. Structural deformation caused by ultra-high pressure and temperature in ultra-deep wells.

1. Use silicon nitride ceramic bearings with ultra-high load-bearing capacity and heat resistance; 2. Conduct structural stress testing every month to monitor deformation (allowable deformation ≤ 0.2 mm).

3

Travelling Block

YC900

High-strength quenched and tempered steel (Q1300) + silicon nitride ceramic bearings

1. Corrosion caused by complex formation fluids (H₂S, CO₂, Cl⁻) in ultra-deep wells; 2. Pulley groove wear due to high-tension steel wire rope (tension ≥ 800 kN).

1. Use corrosion-resistant alloy and apply a multi-layer anti-corrosion coating (zinc-rich primer + epoxy intermediate coat + polyurethane top coat); 2. Replace steel wire rope every 800 operating hours and grind pulley grooves regularly.

4

Hook

DG900

Alloy structural steel (40CrNiMoA) with carburizing and deep cryogenic treatment

1. Hook neck wear due to ultra-high load and long-term alternating stress; 2. Locking mechanism failure caused by sand dust and drilling fluid contamination.

1. Conduct ultrasonic and magnetic particle flaw detection every 2 months in accordance with API Spec 8A Clause 7.1; 2. Install a dust-proof and waterproof cover for the locking mechanism and lubricate daily.

5

Swivel

SL675

Nickel-based alloy + DLC coating

1. Rotating shaft wear due to ultra-high pressure (≥ 70 MPa) drilling fluid scouring; 2. Seal failure caused by high-temperature (≥ 180℃) and chemical corrosion.

1. Use a multi-stage filtration system to ensure drilling fluid cleanliness; 2. Use FFKM seals with high-temperature and chemical resistance and replace every 400 operating hours.

6

Mud pump

F2200HL*3

PDC cylinder liner + alloy steel (4340) crankshaft

1. Valve seat wear due to high-frequency, high-pressure impact (≥ 70 MPa); 2. Crosshead wear caused by insufficient lubrication and high-temperature.

1. Use valve seats with PDC inserts and inspect every 50 operating hours; 2. Use forced lubrication system for crosshead with lubricating oil temperature controlled ≤ 70℃.