ZJ40 Truck-mounted Drilling Rig-SJ Petro-2

1

Column I (Z05010300013AA)

Q690 high-strength alloy steel; cast steel (ZG270-500) connecting flanges; galvanized steel bolts

1. Fatigue cracking due to long-term bearing of platform load and operational vibration; 2. Corrosion of flanges and bolts from rain, humidity, and drilling fluid splashing

1. Conduct non-destructive testing (NDT) for welds every 6 months; 2. Apply anti-corrosion coating annually and use waterproof covers for idle periods

2

Column II (Z05010300014AA)

Q690 high-strength alloy steel; 304 stainless steel fasteners; EPDM rubber sealing gaskets

1. Deformation due to uneven load distribution during platform operation; 2. Seal failure leading to moisture intrusion and internal corrosion

1. Ensure uniform load placement on the platform; 2. Inspect seals monthly and replace damaged ones with OEM-compatible parts

3

Stairs (Z05010400285AA)

Q355B carbon steel steps; anti-slip rubber mats; aluminum alloy handrails

1. Wear of anti-slip mats due to frequent personnel walking; 2. Corrosion of steps from rain and mud accumulation in outdoor operations

1. Replace anti-slip mats when anti-slip coefficient <0.6; 2. Clean steps regularly to remove mud and touch up anti-corrosion paint annually

4

Stairs assembly (Z05010400288AA)

Q355B carbon steel frame; anti-slip steel plates; stainless steel (304) connecting pins

1. Frame weld cracking due to vibration during rig transportation; 2. Connecting pin wear from frequent assembly and disassembly

1. Secure the stairs assembly with binding straps during transportation; 2. Apply molybdenum disulfide lubricant to pins monthly and inspect welds quarterly

5

Guardrail assembly (Z05010601268AA)

Q235B carbon steel railings; plastic anti-collision sleeves; galvanized steel brackets

1. Anti-collision sleeve aging and cracking due to long-term sun exposure and temperature fluctuations; 2. Bracket loosening caused by operational vibration

1. Replace anti-collision sleeves every 6 months; 2. Use locking bolts and retighten brackets every 150 operating hours

6

Dolly (Z05010800001AA)

Q235B carbon steel frame; polyurethane wheels; stainless steel (304) axles

1. Wheel wear and deformation due to friction with uneven drilling site ground; 2. Axle corrosion from mud and moisture intrusion

1. Avoid moving the dolly on excessively rough ground; 2. Clean wheels and axles after use and apply anti-corrosion grease

7

Bottom assembly (Z05011200133AA)

Q355B carbon steel base; reinforced concrete prefabricated blocks; 2205 duplex stainless steel connecting rods

1. Base deformation due to uneven ground stress during rig setup; 2. Connecting rod corrosion caused by long-term contact with soil and water

1. Level and compact the ground before installation, use backing plates for soft soil; 2. Paint connecting rods annually and inspect for corrosion monthly

8

Bottom assembly (Z05011200134AA)

Q355B carbon steel base; rubber damping pads; galvanized steel fasteners

1. Damping pad wear due to long-term load bearing and vibration; 2. Fastener loosening caused by rig transportation vibration

1. Replace damping pads when compression deformation exceeds 20%; 2. Retighten fasteners after transportation and use lock washers

1

Rotary table beam (Z05011400069AA)

Q690 high-strength alloy steel; 42CrMo alloy steel reinforcing plates; welded structure with flaw detection

1. Weld cracking due to high torque and vibration during rotary table operation; 2. Surface wear from friction with drilling tools

1. Conduct NDT on welds every 500 drilling hours; 2. Install wear-resistant plates on contact surfaces and replace when worn

2

Top assembly (left) (Z05011401131AA)

Q355B carbon steel frame; aluminum alloy lightening panels; silicone rubber seals

1. Seal failure leading to moisture intrusion and internal corrosion; 2. Frame deformation due to lateral force from pipe handling

1. Inspect seals monthly and replace if damaged; 2. Ensure pipe handling operations are smooth to avoid excessive lateral force

3

Top assembly (right) (Z05011401141AA)

Q355B carbon steel frame; 304 stainless steel fasteners; rubber damping pads

1. Damping pad aging due to long-term vibration; 2. Fastener corrosion caused by drilling fluid splashing

1. Replace damping pads every 6 months; 2. Apply anti-corrosion grease to fasteners and install splash guards

4

Rotary table area (Z05012100001AA)

NM400 wear-resistant steel plate; Q355B carbon steel frame; anti-slip paint coating

1. Wear of steel plate due to friction with drilling tools and pipe rotation; 2. Anti-slip paint peeling due to frequent cleaning and foot traffic

1. Inspect plate wear every 300 operating hours, replace when thickness decreases by 10%; 2. Touch up anti-slip paint quarterly

5

Setback area (Z05012200052AA)

Q355B carbon steel frame; polyurethane anti-collision blocks; stainless steel (304) pins

1. Anti-collision block wear due to frequent drilling rod placement and collision; 2. Frame corrosion from rain and drilling fluid accumulation

1. Replace anti-collision blocks when wear exceeds 50%; 2. Drain accumulated fluid timely and clean the area regularly

6

Pipe ramp (Z05020100112AA)

Q355B carbon steel ramp; polyurethane wear-resistant lining; steel reinforcement

1. Lining wear due to high-frequency pipe sliding; 2. Ramp deformation due to uneven pipe load

1. Replace lining every 400 pipe-handling cycles; 2. Distribute pipes evenly on the ramp and avoid overloading

7

Catwalk and pipe rack (Z05020200121AA)

Q355B carbon steel structure; anti-slip steel plates; galvanized steel railings

1. Anti-slip plate wear due to pipe sliding and personnel walking; 2. Railing corrosion from outdoor exposure

1. Replace anti-slip plates when anti-slip pattern is worn flat; 2. Paint railings annually and inspect for loose connections monthly

8

Pipe rack (Z05020300044AA)

Q355B carbon steel frame; rubber pipe supports; stainless steel (304) fasteners

1. Rubber support aging and cracking due to sun exposure and temperature changes; 2. Frame weld cracking due to pipe impact during loading

1. Replace rubber supports every 6 months; 2. Load pipes smoothly and avoid impact, inspect welds quarterly

9

BOP handling guiderails (Z05090900001AA)

Q690 high-strength alloy steel; 304 stainless steel guide rollers; lubricated bearings

1. Guide roller wear due to BOP sliding and friction; 2. Bearing damage caused by dust and moisture intrusion

1. Lubricate bearings every 100 BOP handling operations; 2. Install dust covers on rollers and clean regularly

1

Main drum (Z03010000164AA)

45# carbon steel drum body; 20CrMnTi alloy steel gear ring; chrome-plated surface

1. Drum surface wear due to long-term friction with steel wire rope; 2. Gear ring tooth wear and breakage due to high torque transmission

1. Check wire rope alignment regularly to avoid uneven wear; 2. Replace gear oil according to maintenance schedule and inspect gear teeth every 500 operating hours

2

Sand drum (Z03030000028AA)

45# carbon steel drum; polyurethane wear-resistant lining; GCr15 bearing steel

1. Lining wear due to abrasive sand and debris during drilling; 2. Bearing damage caused by insufficient lubrication and vibration

1. Clean the drum surface after each use in sandy environments; 2. Inject lithium-based grease into bearings every 100 operating hours

3

Drawworks frame and guard (Z03050000136AA)

Q355B carbon steel frame; steel guard plate; anti-corrosion paint coating

1. Frame weld cracking due to high vibration during hoisting; 2. Guard plate corrosion from rain and drilling fluid splashing

1. Conduct NDT on welds every 6 months; 2. Clean the guard plate regularly and touch up paint when damaged

4

Right angle gear box (Z03070000007AA)

40Cr alloy steel case; 20CrNiMo gear set; GCr15 bearing steel

1. Gear wear due to contaminated gear oil; 2. Bearing overheating and damage caused by poor heat dissipation

1. Replace gear oil and filters regularly, test oil cleanliness; 2. Ensure the gear box cooling system is functional and clean air vents weekly

5

Installation of upper drive box and lower drive box and tong counterbalance unit (Z03180000001AA)

42CrMo alloy steel connecting shafts; rubber damping sleeves; stainless steel (304) fasteners

1. Damping sleeve aging due to long-term vibration; 2. Shaft wear caused by misalignment during installation

1. Replace damping sleeves every 800 operating hours; 2. Ensure precise alignment during installation and recheck every 3 months

6

Auxiliary brake system (Z03280000003AA)

Cast iron (HT250) brake drum; copper alloy brake pads; 304 stainless steel hydraulic pipes

1. Brake pad wear due to frequent braking during hoisting; 2. Hydraulic pipe corrosion and leakage caused by moisture

1. Check brake pad thickness monthly, replace when <5mm; 2. Inspect hydraulic pipes for leakage weekly and apply anti-corrosion grease

7

Lower chain case (Z06020000004AA)

45# carbon steel case; 20CrMnTi chain; copper alloy bushings

1. Chain wear and elongation due to high-load transmission; 2. Bushing wear caused by insufficient lubrication

1. Tension the chain regularly and replace when elongation exceeds 3%; 2. Add chain lubricant every 200 operating hours

8

Rotary table drive lower box (Z06110000001AA)

40Cr alloy steel case; 20CrNiMo gear set; GCr15 bearings

1. Gear wear due to improper meshing caused by vibration; 2. Bearing damage from contaminated lubricating oil

1. Check gear meshing condition quarterly; 2. Replace lubricating oil and filters according to schedule

9

Rotary table drive upper box (Z06110000002AA)

40Cr alloy steel case; 20CrMnTi gears; silicone rubber seals

1. Seal failure leading to oil leakage and contamination; 2. Gear tooth breakage due to sudden load changes during drilling

1. Inspect seals monthly for oil leakage; 2. Avoid sudden load changes and operate the rotary table smoothly

1

Schematic diagram of hydraulic system (Z07260000042AA) [Auxiliary Part]

Oil-resistant rubber hoses; brass fittings; stainless steel (316) clips; PVC protective sleeves

1. Hose aging and cracking due to high-temperature engine radiation; 2. Fitting corrosion caused by hydraulic oil leakage and moisture

1. Install heat shields between hoses and engine; 2. Inspect for leakage weekly and replace aging hoses/fittings immediately

2

Cathead cylinder (Z07150000016AA)

27SiMn alloy steel cylinder barrel; chrome-plated piston rod; nitrile rubber seals

1. Piston rod scratches from collision with drilling tools; 2. Seal failure caused by contaminated hydraulic oil

1. Install a protective sleeve on the piston rod; 2. Replace hydraulic oil and filters regularly, test oil cleanliness

3

Cathead cylinder lines (Z07050000002AA)

High-pressure hydraulic rubber hose; 304 stainless steel pipe; brass fittings

1. Hose wear due to friction with rig components during cylinder movement; 2. Fitting loosening caused by operational vibration

1. Use cable protectors at friction points; 2. Retighten fittings quarterly and use locking nuts

4

Two bank valve lines (Z07060200001AA)

PTFE-lined hydraulic hose; stainless steel (316) fittings; aluminum alloy pipe clamps

1. Hose lining damage due to high-pressure hydraulic oil impact; 2. Pipe clamp corrosion from outdoor moisture

1. Ensure hydraulic pressure does not exceed the hose’s rated limit; 2. Paint pipe clamps annually and inspect for tightness monthly

5

Seven bank valve lines (Z07060000012AA)

High-pressure steel wire braided hose; brass fittings; rubber damping sleeves

1. Hose fatigue and cracking due to frequent bending during valve operation; 2. Damping sleeve aging from temperature fluctuations

1. Ensure the hose bending radius ≥10× hose diameter; 2. Replace damping sleeves every 6 months

6

Raising lines (Z07030000002AA)

High-pressure hydraulic rubber hose; 304 stainless steel fittings; steel wire reinforcement

1. Hose wear due to high load during mast raising; 2. Fitting corrosion caused by rain and drilling fluid

1. Inspect the hose before each mast raising operation; 2. Cover fittings with waterproof caps when idle

7

Raising cylinder (Z07120000001AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; Viton rubber seals

1. Piston rod corrosion from outdoor exposure; 2. Seal failure due to high-temperature environment

1. Apply anti-corrosion grease to the piston rod after use; 2. Use high-temperature resistant seals and monitor cylinder temperature

8

Three bank valve lines (Z07060300002AA)

PTFE hydraulic hose; brass fittings; aluminum alloy pipe clamps

1. Hose leakage due to fitting misalignment during installation; 2. Pipe clamp wear from vibration

1. Ensure precise fitting alignment during installation; 2. Replace pipe clamps when they show signs of wear

9

Telescoping cylinder (Z07130000033AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; EPDM rubber seals

1. Piston rod wear due to collision during telescoping; 2. Seal failure leading to hydraulic oil leakage

1. Clear obstacles around the cylinder before telescoping; 2. Inspect seals monthly for leakage

10

Hydraulic winch lines (Z07040000002AA)

High-pressure steel wire braided hose; 304 stainless steel fittings; rubber protective sleeves

1. Hose wear due to friction with the winch drum; 2. Fitting loosening caused by winch vibration

1. Install protective sleeves at friction points; 2. Retighten fittings after every 50 winch operations

11

Oil pump lines (Z07010000003AA)

High-pressure hydraulic rubber hose; brass fittings; steel pipe clamps

1. Hose damage due to high-pressure oil impact during pump startup; 2. Pipe clamp corrosion from moisture

1. Start the oil pump smoothly to avoid pressure surges; 2. Paint pipe clamps annually and inspect tightness weekly

12

Jack lines (Z07020000002AA)

High-pressure hydraulic rubber hose; 304 stainless steel fittings; rubber damping pads

1. Hose wear due to friction with the jack during lifting; 2. Fitting corrosion caused by contact with soil and water

1. Use cable protectors between the hose and jack; 2. Clean fittings after use and apply anti-corrosion grease

13

Jack cylinder (Z07140000002AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; nitrile rubber seals

1. Piston rod wear due to uneven ground during lifting; 2. Seal failure caused by contaminated hydraulic oil

1. Use backing plates on soft ground to ensure stable lifting; 2. Replace hydraulic oil and filters according to maintenance schedule

14

Jack cylinder (Z07140000009AA)

27SiMn alloy steel cylinder; chrome-plated piston rod; nitrile rubber seals

1. Cylinder body corrosion from outdoor rain and humidity; 2. Piston rod scratches from foreign object collision

1. Cover the cylinder with a waterproof tarpaulin when idle; 2. Install a protective cover on the piston rod