Customized Performance Data & Sourcing Handbook for ZJ Drilling Rig Parts

1

Drawworks

JC10B

Medium-carbon alloy steel (40Cr)

1. Gear tooth abrasion due to insufficient lubrication and dust intrusion into the gearbox; 2. Bearing loosening and wear caused by long-term vibration during mobile drilling.

1. Use industrial gear oil of viscosity grade 150 and seal the gearbox with rubber gaskets to prevent dust entry; 2. Check bearing tightness weekly and fasten connecting bolts with torque wrench (torque: 45-50 N·m).

2

Crown Block

TC60

High-carbon steel (45#) + bearing steel (GCr15)

1. Pulley groove wear caused by friction with steel wire rope and sand dust accumulation; 2. Bearing corrosion due to exposure to humid outdoor environments.

1. Clean pulley grooves with a wire brush every 3 drilling shifts and inspect steel wire rope wear (replace when diameter reduction exceeds 3%); 2. Apply anti-rust grease to bearings monthly and install rainproof covers in rainy areas.

3

Travelling Block

YG60

High-carbon steel (45#) + bearing steel (GCr15)

1. Side wear of pulleys due to misalignment with crown block during operation; 2. Structural fatigue caused by repeated impact during drill string lowering.

1. Align crown block and travelling block before each drilling operation (coaxiality error ≤ 0.2 mm); 2. Control drill string lowering speed ≤ 0.8 m/s to reduce impact load on the block.

4

Hook

YD60

Alloy structural steel (20CrMnTi)

1. Hook opening wear due to frequent hanging of drill tools and insufficient lubrication; 2. Locking mechanism failure caused by dust and gravel jamming.

1. Lubricate the hook hinge and locking mechanism with lithium-based grease every 2 days; 2. Clean the locking mechanism with compressed air after drilling in sandy areas to remove debris.

5

Swivel

SL80

Carbon steel (Q235) + wear-resistant cast iron bushing

1. Rotating bushing wear due to insufficient lubrication and low-speed high-load operation; 2. Seal leakage caused by drilling fluid splashing and erosion.

1. Maintain lubricating oil level in the swivel cavity (not lower than 2/3 of the oil sight glass); 2. Install a splash guard around the swivel to prevent direct contact with drilling fluid.

6

Mud pump

F800*1

Gray cast iron (HT250) pump body + high-chromium cast iron (Cr26) cylinder liner

1. Cylinder liner erosion by shallow formation sand contained in drilling fluid; 2. Valve seat wear due to frequent opening and closing under low-pressure cycles.

1. Equip a 80-mesh filter at the mud pump inlet to reduce solid particle content; 2. Inspect valve seat seal surface weekly and replace if scratches exceeding 0.1 mm are found.

1

Drawworks

JC15DJ

High-strength alloy steel (42CrMo)

1. Gear surface pitting due to lubricant degradation and water intrusion; 2. Brake disc wear caused by frequent braking during drill string tripping.

1. Replace lubricating oil every 400 operating hours and test water content (keep below 0.5%); 2. Use combined braking (mechanical + auxiliary) to reduce main brake disc load during tripping.

2

Crown Block

TC90

Quenched and tempered high-carbon steel (45#) + bearing steel (GCr15SiMn)

1. Pulley bearing overheating and wear due to high-speed rotation and poor heat dissipation; 2. Structural bolt loosening caused by wind vibration in open-air drilling sites.

1. Clean bearing heat dissipation channels monthly to ensure unobstructed airflow; 2. Check and retighten crown block fixing bolts every 2 weeks (torque: 65-70 N·m).

3

Travelling Block

YG135

Quenched and tempered high-carbon steel (45#) + bearing steel (GCr15SiMn)

1. Bearing damage due to drilling fluid invasion and lubricant contamination; 2. Pulley groove deformation caused by over-tensioned steel wire rope.

1. Enhance the block’s sealing performance with double-layer oil seals; 2. Monitor steel wire rope tension daily and adjust to the rated value (avoid over-tension by more than 10%).

4

Hook

YG135

Alloy structural steel (40CrNiMoA)

1. Hook neck fatigue wear due to repeated lifting of drill strings; 2. Locking pawl wear caused by improper operation during drill tool hanging.

1. Conduct magnetic particle inspection on the hook neck every 3 months to detect fatigue cracks; 2. Ensure the locking pawl is fully engaged before lifting drill tools and avoid forced hanging.

5

Swivel

SL135

Alloy steel (40Cr) + polytetrafluoroethylene (PTFE) wear-resistant ring

1. Rotating shaft wear due to high-pressure drilling fluid scouring; 2. Seal aging caused by long-term exposure to high-temperature environment (≥ 80℃).

1. Use drilling fluid with anti-scouring additives and control inlet pressure ≤ 10 MPa; 2. Replace high-temperature resistant seals every 600 operating hours.

6

Mud pump

F800*1

Nodular cast iron (QT400-15) pump body + high-chromium cast iron (Cr28) cylinder liner

1. Piston wear due to misalignment with the cylinder liner; 2. Crankshaft bearing damage caused by unbalanced load during operation.

1. Align the piston and cylinder liner monthly (coaxiality error ≤ 0.1 mm); 2. Check crankshaft runout weekly and adjust if exceeding 0.05 mm.

1

Drawworks

JC30B

Ultra-high strength alloy steel (30CrNiMo8)

1. Gear tooth breakage due to sudden overload during drill string stuck incidents; 2. Brake system failure caused by hydraulic oil contamination.

1. Install a torque limiter to cut off power when overload exceeds 15%; 2. Filter hydraulic oil every 300 operating hours and replace the oil filter element.

2

Crown Block

TC170

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

1. Pulley groove wear caused by long-term friction with steel wire rope and sand dust abrasion; 2. Bearing damage due to insufficient lubrication under high load.

1. Replace steel wire rope when wear exceeds 5% and grind pulley grooves to maintain smoothness; 2. Inject high-pressure lubricating grease into bearings every 200 operating hours.

3

Travelling Block

YG170/YG170

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

1. Bearing seizure caused by high-temperature operation and poor heat dissipation; 2. Structural corrosion due to drilling fluid splashing.

1. Equip bearings with forced cooling systems and monitor temperature (keep below 75℃); 2. Apply anti-corrosion coating to the block surface and clean it weekly.

4

Hook

DG225/YG170

Alloy structural steel (42CrMo) with carburizing treatment

1. Hook opening deformation due to overloading and improper lifting; 2. Fatigue cracking caused by long-term alternating stress.

1. Strictly adhere to the rated load limit and avoid eccentric lifting; 2. Conduct ultrasonic flaw detection every 4 months in accordance with API Spec 8A Clause 5.3.

5

Swivel

SL170

Alloy steel (42CrMo) + wear-resistant ceramic bushing

1. Rotating joint wear due to high-speed rotation (≥ 200 rpm) and drilling fluid scouring; 2. Seal leakage caused by high-pressure drilling fluid (≥ 20 MPa).

1. Monitor rotating speed and avoid exceeding the rated value; 2. Use double-layer high-pressure seals and inspect seal integrity daily.

6

Mud pump

F1000*1

Tungsten carbide alloy cylinder liner + nodular cast iron (QT450-10) 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 120-mesh high-precision filter to remove hard particles; 2. Ensure lubricating oil flow rate to the crosshead pin ≥ 4 L/min.

1

Drawworks

JC30DJ

Ultra-high strength alloy steel (30CrNiMo8)

1. Gear wear due to alternating torque during directional drilling; 2. Brake disc thermal deformation caused by continuous braking in curve sections.

1. Use gear oil with extreme pressure resistance and conduct oil analysis every 250 operating hours; 2. Use auxiliary brakes to share the load during curve section drilling, reducing main brake usage.

2

Crown Block

TC170

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

1. Pulley side wear caused by uneven steel wire rope tension in directional drilling; 2. Structural fatigue due to lateral load.

1. Adjust steel wire rope tension evenly every week; 2. Conduct non-destructive testing (NDT) on the crown block structure every 6 months.

3

Travelling Block

YC170/YG170

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

1. Bearing damage due to lateral vibration during directional drilling; 2. Lubricant degradation caused by high-temperature operation.

1. Use shock-absorbing bearings and inspect vibration amplitude weekly; 2. Replace lubricating oil with high-temperature resistance (≥ 150℃) every 350 operating hours.

4

Hook

DG225/YG170

Alloy structural steel (42CrMo) with surface nitriding treatment

1. Hook neck wear due to combined torque and load; 2. Locking mechanism failure caused by dust and drilling fluid contamination.

1. Increase the frequency of flaw detection to every 3 months; 2. Install a dust-proof and waterproof cover for the locking mechanism and lubricate daily.

5

Swivel

SL170

Alloy steel (42CrMo) + wear-resistant ceramic bushing

1. Rotating shaft wear due to eccentric load in directional drilling; 2. Seal aging caused by chemical corrosion from drilling fluid additives.

1. Monitor the swivel’s eccentricity in real time and adjust the drill string; 2. Select seals compatible with drilling fluid additives and replace every 500 operating hours.

6

Mud pump

F1000*1

Tungsten carbide alloy cylinder liner + alloy steel (42CrNiMoA) crankshaft

1. Piston rod wear due to misalignment caused by directional drilling vibration; 2. Crankshaft fatigue damage caused by unbalanced load.

1. Align the piston rod monthly and check for bending; 2. Adjust the pump’s operation parameters to ensure load balance and reduce crankshaft stress.

1

Drawworks

JC40B

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

1. Gear surface wear due to high-temperature lubricant degradation in deep wells (≥ 120℃); 2. Brake system leakage caused by high-pressure hydraulic oil pipeline aging.

1. Use synthetic lubricating oil with high-temperature resistance (≥ 200℃); 2. Inspect hydraulic pipelines weekly for aging and replace if cracks or bulges are found.

2

Crown Block

TC225

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

1. Bearing damage due to ultra-high load (≥ 225 tons) and high-speed rotation; 2. Structural bolt fatigue caused by long-term vibration.

1. Use heavy-duty bearings with dynamic load rating ≥ 400 kN; 2. Replace structural bolts every 12 months and apply thread locking agent during installation.

3

Travelling Block

YC225

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

1. Corrosion caused by seawater or salt spray in offshore marginal oilfield drilling; 2. Pulley wear due to high-tension steel wire rope (tension ≥ 500 kN).

1. Apply anti-corrosion coating (epoxy zinc-rich paint) and conduct salt spray resistance testing quarterly; 2. Select steel wire rope with high breaking strength and inspect tension daily.

4

Hook

DG225

Alloy structural steel (42CrMo) with deep cryogenic treatment

1. Hook neck fatigue cracking due to long-term alternating load; 2. Locking device wear caused by frequent use in drill string handling.

1. Conduct ultrasonic flaw detection every 2 months in accordance with API Spec 8A Clause 7.1; 2. Lubricate the locking device weekly and replace worn locking pins immediately.

5

Swivel

SL225

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

1. Rotating joint wear due to high-pressure drilling fluid (≥ 35 MPa) scouring; 2. Seal failure 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 400 operating hours.

6

Mud pump

F1300*2

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

1. Valve seat wear due to high-frequency, high-pressure impact; 2. Crankshaft bearing damage caused by unbalanced load of dual pumps.

1. Use valve seats with PDC inserts and inspect every 50 operating hours; 2. Adjust the two pumps’ operation parameters to ensure load balance (pressure difference ≤ 2 MPa).

1

Drawworks

Matching JC Series / Matching JC Series / Matching JC Series

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

1. Gear tooth wear due to extreme torque (≥ 800 kN·m) and high-temperature operation (≥ 150℃); 2. Brake disc thermal deformation caused by continuous heavy braking.

1. Use synthetic lubricating oil with extreme pressure resistance and replace every 300 operating hours; 2. Equip brake discs with forced air cooling systems and limit continuous braking time to ≤ 8 minutes.

2

Crown Block

Matching TC Series / Matching TC Series / Matching TC Series

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

1. Bearing wear due to ultra-high load (≥ 315 tons) and high-speed rotation; 2. Structural fatigue caused by long-term operation in harsh deep well environments.

1. Use ceramic hybrid bearings with high load-bearing capacity; 2. Conduct NDT every 2 months in accordance with API Spec 4F Clause 6.2.

3

Travelling Block

Matching YG/YC Series / Matching YG/YC Series / Matching YG/YC Series

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

1. Corrosion caused by H₂S and CO₂ in sour gas 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. Replace steel wire rope every 600 operating hours and grind pulley grooves regularly.

4

Hook

Matching DG/YG Series / Matching DG/YG Series / Matching DG/YG Series

Alloy structural steel (45CrNiMoV15) with deep cryogenic treatment

1. Hook bearing seizure due to high-temperature and high-pressure in deep wells; 2. Fatigue cracking caused by repeated impact of heavy drill strings (weight ≥ 400 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

Matching SL Series / Matching SL Series / Matching SL Series

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 a multi-stage filtration system to ensure drilling fluid cleanliness; 2. Replace FFKM seals every 400 operating hours.

6

Mud pump

Matching F Series / Matching F Series / Matching F Series

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.

1. Use UHMWPE piston rings with high wear resistance; 2. Adjust the pump’s operation parameters to ensure load balance.