SJ Petro Workover Rig XJ250(SXJ250) Replacement Parts Guide

1

Drawworks

250 HP, Double Main Drum, Sand Drum (9/16” Grove, 7000 ft)

High-strength alloy steel (Q460) frame, carbon steel (16Mn) drums, heat-treated gears

1. Drum grove wear from rope friction; 2. Gear fatigue from high-torque operation; 3. Bearing damage from insufficient lubrication.

1. Inspect drum grooves monthly for wear per API 4F; 2. Use OEM-specified lubricants for gears/bearings; 3. Avoid overloading beyond rated hook load.

2

Travelling Block

YG70, 3×24, 70 Tons

Alloy steel (40Cr) sheaves, stainless steel (304) pins, anti-corrosion coated frame

1. Sheave groove wear from drilling line friction; 2. Pin corrosion in harsh oilfield environments; 3. Bearing failure from vibration.

1. Align with crown block to reduce rope/sheave wear; 2. Lubricate bearings every 50 operating hours; 3. Inspect sheave grooves for uneven wear quarterly.

3

Crown Block

6 – 1 lines

Alloy steel (Q355B) frame, hardened alloy steel sheaves, galvanized fasteners

1. Sheave wear from continuous rope contact; 2. Frame corrosion from outdoor oilfield exposure; 3. Fastener loosening from vibration.

1. Check sheave alignment per API 4F standards; 2. Apply anti-corrosion coating annually; 3. Retorque fasteners weekly to OEM specs.

4

Drilling Line

Blue Strand 7/8”, 6 x 19 IPS, IWRC

High-carbon steel wires, galvanized coating, independent wire rope core (IWRC)

1. Fatigue from repeated bending over sheaves; 2. Abrasion from contact with rig components; 3. Corrosion from moisture/oilfield chemicals.

1. Rotate rope regularly to distribute wear; 2. Clean and lubricate weekly with wire rope grease; 3. Replace if broken wires exceed API 9B limits.

5

Sand Line

Blue Strand 9/16”, 6 x 7 IPS, FC

High-carbon steel wires, galvanized coating, fiber core (FC)

1. Tensile fatigue from sand lifting; 2. Abrasion from wellbore debris; 3. Core degradation from moisture.

1. Avoid overloading beyond rope capacity; 2. Inspect for fraying before each use; 3. Store in dry conditions when not in service.

6

Hydraulic Winch

½” & 5/8” wire rope, cap. 3 ton & 5 ton

Alloy steel (16Mn) drum, hydraulic cylinder (45# steel), nitrile rubber seals

1. Seal leakage from hydraulic fluid contamination; 2. Drum wear from rope friction; 3. Hydraulic component failure from pressure spikes.

1. Filter hydraulic fluid to prevent contamination; 2. Inspect wire rope for wear monthly; 3. Maintain hydraulic pressure within rated limits (≤3000 psi).

7

Hoist Steel Base

Suitable to the rig carrier

High-strength carbon steel (Q355B), welded construction, anti-corrosion painted

1. Weld joint fatigue from rig vibration; 2. Corrosion from oilfield chemicals/moisture; 3. Deformation from uneven load distribution.

1. Inspect welds annually with NDT per API 1104; 2. Touch up anti-corrosion paint as needed; 3. Ensure level installation to distribute load evenly.

1

Mast

SJ Petro, Height 95 ft

High-strength alloy steel (Q460) sections, bolted/welded construction, anti-corrosion coated

1. Structural fatigue from wind loads; 2. Corrosion from outdoor exposure; 3. Bolt loosening from rig vibration.

1. Inspect for structural cracks per API 4F every 6 months; 2. Retorque bolts weekly; 3. Lower mast during severe weather to reduce wind load.

2

Rig Carrier

SJ Petro, 4 axels, 8 x 8

High-strength steel frame, reinforced axles (alloy steel), rubber tires (oil-resistant)

1. Frame corrosion from oilfield debris/chemicals; 2. Axle wear from off-road operation; 3. Tire damage from sharp rocks.

1. Clean frame regularly to remove debris; 2. Inspect axles and bearings monthly; 3. Use tire protectors in rocky terrain.

3

Working Platform

Class II & III BOP

Carbon steel (Q235B) platform, anti-slip surface, aluminum alloy railings

1. Surface corrosion from moisture/oil; 2. Rail wear from operator contact; 3. Structural fatigue from repeated loading.

1. Keep platform clean and dry; 2. Inspect railings for stability weekly; 3. Avoid overloading beyond Class II/III rated capacity.

1

Prime Mover Engine

CAT C-9 ACERT

Cast iron (HT250) engine block, aluminum alloy cylinder heads, steel crankshaft

1. Piston ring wear from poor fuel quality; 2. Coolant system failure leading to overheating; 3. Oil degradation from extended service intervals.

1. Use CAT-specified fuel and oil; 2. Inspect coolant levels daily; 3. Service per CAT maintenance schedule (every 500 hours).

2

Transmission

Allison 4700 OFS

Alloy steel gears, aluminum alloy housing, friction clutches (ceramic-faced)

1. Clutch wear from harsh shifting; 2. Gear damage from torque spikes; 3. Fluid contamination causing valve sticking.

1. Shift smoothly to reduce clutch wear; 2. Replace transmission fluid every 1000 hours; 3. Use Allison-approved filters.

3

Engine

Cummins K19

Cast iron (HT300) engine block, forged steel crankshaft, aluminum alloy pistons

1. Turbocharger failure from oil contamination; 2. Injector wear from poor fuel filtration; 3. Bearing damage from insufficient lubrication.

1. Install high-quality fuel filters; 2. Inspect turbocharger weekly; 3. Use Cummins-specified engine oil and change every 250 hours.

1

Annular BOP

Hydrill, 11” x 3000 Psi

Alloy steel (4140) body, nitrile rubber (NBR) packing element, stainless steel (316) internals

1. Packing element wear from tubular movement; 2. Body corrosion from well fluids; 3. Seal leakage from pressure cycles.

1. Inspect packing element monthly per API 16A; 2. Flush with clean fluid after use; 3. Avoid overpressuring beyond 3000 Psi.

2

RAM BOP

Shaffer, 11” x 3000 Psi

Forged alloy steel (4340) body, hardened steel rams, fluororubber (FKM) seals

1. Ram wear from wellbore debris; 2. Seal degradation from harsh well fluids; 3. Hydraulic component failure from contamination.

1. Clean rams after each use; 2. Replace seals annually; 3. Filter hydraulic fluid to prevent contamination of ram actuators.

3

Fluid End

OPI 350

High-strength alloy steel (4140), heat-treated, chrome-plated plungers

1. Plunger wear from abrasive well fluids; 2. Valve seat damage from debris; 3. Corrosion from acidic fluids.

1. Install suction filters to remove debris; 2. Use corrosion inhibitors for acidic fluids; 3. Inspect plungers for wear weekly.

4

Accumulator

Shengkai

Carbon steel (Q355B) shell, rubber bladder, stainless steel (304) valves

1. Bladder degradation from pressure cycles; 2. Shell corrosion from moisture; 3. Valve leakage from debris.

1. Inspect bladder annually per API 16D; 2. Maintain precharge pressure as specified; 3. Keep accumulator clean and dry.

What lubricant is recommended for the Allison 4700 OFS transmission?

Use Allison TES 295-approved automatic transmission fluid (ATF). Replace every 1000 operating hours, and use only Allison-certified filters to prevent valve sticking and gear damage, complying with Allison’s maintenance guidelines.

How often should the annular BOP packing element be replaced?

Replace the packing element every 6 months or immediately if leakage is detected. For harsh well conditions (abrasive debris, acidic fluids), shorten intervals to 3–4 months, per API 16A inspection requirements.

What is the maximum safe working load for the travelling block (YG70, 70 Tons)?

The maximum safe working load is 70 Tons, aligned with the rig’s nominal hook load of 112,000 lbs. Never exceed this limit, and inspect the block weekly for sheave wear or bearing issues to prevent catastrophic failure.