JJ22543-K3 Mast User Manual

JJ225/43-K3 井架
用户手册
JJ217-SC
JJ225/43-K3 Mast
User Manual
JJ217-SC
September,, 2011
September
四川宏华石油设备有限公司
20 11 年 9 月
2011
编制：
审核：
批准：
USER'S MANUAL FOR JJ225/43-K3MAST
Foreword
The JJ225/43-K3 mast is one of the major equipment of ZJ40DBST Drilling rig. It
is designed and manufactured according to the client’s requirement and its design
conforms to the 3rd edition specifications of API Spec 4F.
In order to ensure our user to operate the mast properly, we have prepared this
User's Manual of JJ225/43-K3 Mast. This manual introduces the technical parameters,
structural features, installation, lifting and lowering, adjustment, lubrication,
maintenance, mothballing, carrying and the transportation etc of the mast in details, and
the operators must read this manual carefully before their installation and operation.
There is a recommended one year spare parts list attached to this manual as a
reference for users ordering spare parts. If the spare parts needed by the users are not
included in the spare parts list, please order the spare parts as per the parts list of the
mast.
Every mast has a serial number. Please point out the model, serial number and
manufacturing date of the mast when users order spare parts or enquire related things.
Contact information:
Sichuan Honghua Petroleum Equipment Co., Ltd.
Address: South section II, Zhongshan Road, Guanghan, Sichuan
Postal code: 618300
Office telephone: 86-838-5151724
Fax: 86-838-5151100
Website: www.hhcp.com.cn
Telephone of after service department: 86-838-5152112
Telephone of home marketing department: 86-838-5101571
Telephone of foreign marketing department: 86-28-86013524

USER'S MANUAL FOR JJ225/43-K3 MAST
Table of contents
1 Safety warnings.......................................................................................... 1
2 Product description.....................................................................................1
2.1 Purposes and applicability.......................................................................1
2.2 Standards and specifications for design and manufacture.......................2
2.3 Technical parameters............................................................................... 2
3 Structural features and main components...................................................3
3.1 Main structure......................................................................................... 3
3.2 Main components.................................................................................... 6
4 Installation and test run.............................................................................. 6
4.1 Pre-installation preparation..................................................................... 6
4.2 Installation of mast.................................................................................. 6
5 Lifting and lowering of mast...................................................................... 8
5.1 Pre-lifting preparation............................................................................. 8
5.2 Lifting of mast......................................................................................... 9
5.3 Adjustment of mast................................................................................10
5.4 Lowering of mast...................................................................................10
6 Lubrication............................................................................................... 10
7 Maintenance............................................................................................. 11
8 Storage and transportation........................................................................12
9 Spare parts list.......................................................................................... 12
9.1 Recommended one year spare parts list................................................ 12
9.2 Spare parts lift....................................................................................... 14
10 Attached tables........................................................................................14
11 Other description.................................................................................... 16
12 Parts list (please see attachment)............................................................ 17
13 Attached drawings.................................................................................. 17
I
1 Safety warnings
� Only trained and qualified persons can install, operate and maintain the mud
pump set with qualification certificates.
� Operators must read related operation manuals before operation and can
operate or maintain equipment after the familiarity with its functions and
operation.
� There shall be a chief principal designated for installation and maintenance,
the persons participating in the work shall be assigned with clear work, and
detailed and reliable safety measures shall be available.
� In the operation process, strictly execute its operation specifications and follow
technical safety rules.
� Do not run equipment in the dark except that there are proper lighting
facilities.
� Persons on duty shall wear labor protection articles as required.
� The used lifter and handling equipment must adapt to related weight to be
operated.
� Make sure to release pressure to zero in disconnection of any high pressure
pipelines or hoses. Follow similar procedures in wiring of electric appliances
and make sure to cut off power supply before trying repair.
� It is forbidden to maintain and repair equipment during its operation.
� Do not overload equipment.
2 Product description
2.1 Purposes and applicability
2.1.1 Purposes
JJ225/43-K3 mast is one of the important components of ZJ40DBST drilling rig, it
is used for emplacing crown block, hanging traveling system, racking drill pipes and
stands, performing normal drilling operations, tripping in and out, dealing with down-
hole accidents etc, and it is a main bearing structural component of a drilling rig.
2.1.2 Applicability:
1
Nominal drilling capacity 5'' drill pipe 4000m/13123ft

Max. rated static hook load 2250kN/500000lbs
Ambient temperature -18℃~+55℃
Humidity ≤98%(+20℃)
2.2 Standards and specifications for design and manufacture
2.2.1 Basic parameters accord with SY/T5609-1999 “The types and basic parameters for
oil drilling rig”.
2.2.2 Design accords with the third edition of API Spec 4F-2008 “Specification for
Drilling and Well Servicing Mast and Substructure”.
2.2.4 Design accords with AISC 335-1989 “Specification for Steel Structure Building”.
2.2.4 Design accords with AWS D1.1/D1.1M:-2002 “Structural Welding Code-Steel”.
2.2.5 Design accords with the 25th edition of API Spec 9A-2004 “Specifications for Wire
Rope”.
2.2.6 Design accords with the twelfth edition of API RP 9B-2005 “Recommended
Practice on Application, Care, and Use of Wire Rope for Oilfield Service”.
2.2.7 Design accords with the fourth edition of API Spec 8C-2003 “Specification for
drilling and production hoisting equipment”.
2.3 Technical parameters
Max. rated static hook load 2250 KN(5×6 wireline, no wind load, no setback)
Note: acceleration, impact, setback and wind will reduce the max imum hook load.
maximum
Effective height of mast 43.05m
Top span front 2100mm side 2550mm
Bottom span front 3,650mm side 3,800mm
Allowable wind load
Expected working condition (No hook load and no racking load) 47.8m/s (93knots)
Unexpected working condition (No hook load and full racking load) 36m/s (70knots)
Lifting and lowering ≤16.5m/s（32knots）
Monkey board capacity (5"－3-section stand) 160stands, 8 1/2" DC 10 stands
Operational height of monkey board 26.5m、26m、25.5m
Theoretical weight of mast 40920kg
2
Height of drill floor 6.7m

Rig to be matched ZJ40DBST
Crown block matched TC225-8 Crown block
Substructure matched DZ225/6.7-S Substructure
Substructure security level E2/U2
Process specification language PSL 1
Ambient temperature -18℃—+55℃, humidity: ≤90% (+20℃).
3 Structural features and main components
3.1 Main structure
3.1.1 This mast is a front open mast without guylines and mainly comprises a mast
main body, monkey board, ladders, standpipe operation board, lifting cylinder and mast
accessories etc. The main structure and overall dimension of the mast are shown in
Figure 1.
3.1.2 The mast body consists of 3 sections. The length of lower section I is 15m, the
length of intermediate section is 15.175m, the length of upper section is 12.125mEach
section can be transported as an integrated unit by trailer, also can be transported
separately (the upper section can be transported with crown block together). The most
advantages of the mast are of modularized structure, easy to be moved and transported to
save a lot of time
3.1.3 The mast front legs locate on the left and right upper seats of the substructure,
the back leg on the intermediate seat. To adjust the position of the mast and align the
hook with the borehole, the adjusting shims could be added in between the mast and
substructure seats.
3.1.4 The mast is assembled horizontally in the lower location and raised and
lowered as an integrated unit by the hydraulic lifting cylinder.
3.1.5 The capacity of monkey board is designed according to the user’s requirement
and set three different installation heights, i.e. 26.5m, 26m and 25.5m away from drill
floor surface.
3.1.6 For conveniences of installation and maintenance of high-pressure manifold, a
standpipe board is available.
3.1.7 The mast is designed in full considerations of driller’s eyeshot and
3
conveniences of operation.
3.1.8 The deadline anchor is fixed on the right back side of mast and with a height
of 3.39m above the drill floor. For convenience of mast transportation, the deadline
anchor and its devices can be rotated to the inner side of mast.
4
Fig.1 Main structure and overall dimensions of mast
5
3.2 Main components
Please see the weights and the transportation dimensions of the main parts of this
mast in attached list 1.
4 Installation and test run
4.1 Pre-installation preparation
4.1.1 The persons engaged in installation must be qualified, read the User's Manual of
Mast carefully before installation, master the technical requirements of mast installation,
observe safety rules and install the mast as per operation rules and procedures, and blind
operation is forbidden.
4.1.2 All preparation work shall be completed before mast installation, including
installation tools and lifters etc. Count and check the parts and components as per the
models and quantities listed in the mast delivery list, repair and replace the parts
impacted to deform during the transportation process, and supplement the missing ones.
4.1.3 Requirements on installation foundation: the area, 50m/164ft long and 15m/49.2ft
wide, along the mast lying position, shall be tamped, leveled and drained for parts
stockpiling and lifting operation. Particularly, the area under the high stand shall be
leveled and have enough bearing capacity (the compressive stress shall not be less than
0.6Mpa), to ensure the base of high stand is horizontal, allowance in flatness is no more
than 50mm, the front (the side of crown block) is high and the back is low.
Notice: coat pin holes and the surfaces of pins with lubricating grease while
installing pins, and install corresponding shear pins and safety pins when all pins
are installed in place.
4.1.4 Install the substructure as per the user's manual of substructure and check the
axiality of two pin holes of mast supports at both left and right side.
4.2 Installation of mast
When installing the mast, please refer to the installation and lifting drawing of
mast& substructure and the following items.
4.2.1 After checking and ascertaining all parts and components, place the upper section
of mast by crane, and then drive in the φ130 leg-pins, shear pins, and safety pins.
6
Warning: Connection pins between sections of mast should be installed as per

mast,, notice
the following drawing except lower section and upper section of mast
the installation direction of pins; otherwise they will be interfered with the
guide rail seat of top drive.
Warning: Connection pins between sections of mast should be installed as per the
mast,, notice the
following drawing except lower section and middle section of mast
installation direction of pins; otherwise they will be interfered with the guide rail
seat of top drive.
Fig 2 Installation drawing for connection pins between sections

4.2.2 Place the intermediate and upper sections (together with crown block) sequentially
and install all connection pins between sections such as φ100 and φ80 bi-taper
pins, shear pins and safety pins etc; and then set the upper section on the stands,
7
connect the monkey board and its accessories with upper section, intermediate
section and lower section, finally install the standpipe board and tong counter
weight etc.
4.2.3 Install other equipment as per the general requirements for rig.
4.2.4 Connect the lifting cylinders with the mast and substructure at the jack-up positions,
and then drive all pins and safety pins in; get ready for raising the mast. Below is
the Lifting schematic diagram.
Fig 3 Schematic diagram for mast lifting
5 Lifting and lowering of mast
5.1 Pre-lifting preparation
5.1.1 The installation, lifting and lowering of mast should be conducted under a unified
command by a skilled staff; all operators must carefully read the operation manuals for
mast and drilling rig, be familiar with operation methods and performances of the rig;
and follow the operational safety regulations, to ensure safety.
5.1.2 When the mast is lifted, the max. wind speed cannot be more than 16.5m/s, the
ambient temperature shall be more than 4 ℃, and please refer to the recommended
practice for low-temperature operation in API Spec 4E specification if the ambient
temperature is lower than 4 ℃.
5.1.3 To ensure the good performances and reliability, the hydraulic lifting system shall
be idle-tested before lifting.
5.1.4 Safety inspection
5.1.4.1 Before the mast is lifted formally, carefully check the mast. Check whether the
8
pins and safety pins are installed properly. Be sure no tools or other sundries left on the
mast
5.1.4.2 Check all bolts and nuts for tightness and the split pins or spring washers for
missing.
5.1.4.3 Check whether the dive board of monkey board is turned over and the tong
balance weight is at low position.
5.1.4.4 Check the status of the hydraulic lifting cylinders and their pipelines and
controlling valves, and then connect them with the hydraulic power unit to check whether
their pistons are acting synchronously according to requirements specified in operation
manual.
※ Notice
1. When mast is being raised, traveling block and hook is only allowed to be
placed in mast lower section or drill floor and be fixed firmly. If this rig is
equipped with a top drive, it should be lifted together with mast and the
top drive only can be fixed on the mast lower section.
2. The inspections as mentioned above are very important and absolutely
necessary for safely lifting the mast to its working position, which should
lifting
be strictly carried out by a skilled person assigned
5.2 Lifting of mast
To ensure safety of operator and equipment, the mast lifting shall be carefully
carried out and under a unified command by a skilled staff after all inspections being
passed and without any faults.
5.2.1Once the mast being supported by stand, it must be lifted within 24 hours to prevent
distortion and deformations of the mast.
5.2.2 Before formally lifted, the mast must be carefully checked again; check all
connections’ status and be sure no sundries on the mast. Lift the mast slowly by the
lifting cylinder. When mast is about 200mm off the high-stand, stop lifting. Leave it in
that position for at least 10 minutes, during this time visually inspect the critical welding
seams and stress areas for any broken parts, deformation, cracks of welding seam; check
for any leakages or other abnormalities on the hydraulic lifting cylinders etc and then
keep inspection records.
9
When finishing inspections, lower the mast to the high-stand slowly, repeat this
operation for another two times, and make sure there are no abnormalities then lift the
mast formally.
5.2.3 Lift the mast slowly and evenly. When the mast nearly reaches the upright position
(about 80°), slow down again to make the mast reach the upright position smoothly, and
then connect the front legs of the mast with the upper seats of substructure by pins to
complete the whole lifting operation. During lifting, attentions shall be paid to
observation of working pressure of the lifting cylinders, if it exceeds the rated working
pressure, stop lifting immediately and lower the mast down on the high-stand, and find
out the reasons and eliminate the failures, and then start lifting again.
5.3 Adjustment of mast
Having completed the mast lifting, jack up the mast (supporting) legs with the
equipped jack and add or reduce the adjusting shims below the legs to adjust the position
of the mast. Correcting the front and side of the mast by transit survey, to ensure the
alignment of centerlines of the crown block, rotary table and borehole; the deviation
between centerlines of them should be less than 12mm. Also it can be checked by
hanging a Kelly on the traveling block hook and making its centerline align with the
rotary table’s centerline, the deviation between both centerlines should also be less than
12mm (mast must be in vertical position).
5.4 Lowering of mast
In principle, the operation procedures for lowering the mast is just the other way to
those for raising the mast, which shall be referred to.
6 Lubrication
The rotating parts of the mast shall be filled with oil once before the mast is lifted
and lowered each time, see the Fig 4.
10
Fig.4 Lubrication points for lifting of lowering of mast
7 Maintenance
7.1 After the mast is lifted, carefully overturn the operation console of the monkey board
to the working position without impact.
7.2 After the mast is lifted, install the casing stabbing board.
7.3 Prevent the moving components of traveling block, hook and elevator etc from
colliding the operation console.
7.4 In the use process, periodically check the mast for the bending, deformation or
damage of the mast legs and inclined and cross tie rods, the extrusion deformation of the
padeyes, the cranking of the welding joints of the main stressed parts, the completeness
of pins and safety pins, and the looseness of the bolts. Take measures for treating
abnormal conditions to prevent heavy loss.
7.5 Before lifting the mast each time, previously coat pins, padeyes and padeye holes
with lubricating grease, and install the shear pins and safety pins after the pins are
installed.
7.6 During installation and maintenance, do not cut and weld on the main stress
components to prevent the reduction of the mast intensity.
7.7 In winter operation, please refer to recommended practice in API Spec 4G, inspect
mast completely and repair it if necessary.
7.8 In the installation and storage processes of the lifting wirelines, prevent extrusion,
11
twist, excessive bend and contact with corrosive substances of acids alkalis, salts or mud
etc, and lubricate the wirelines periodically.
7.9 Before the mast is installed each time, check the lifting wirelines, replace with new
ones if there is broken wire, damage and excessive rusting etc.
7.10 Before the mast is installed each time, check all sheaves for rotation, the sheaves
shall be rotated with a hand flexibly without blockage, compact and friction, and repair if
there are abnormal phenomena.
8 Storage and transportation
8.1 Before the mothballing, remove dust, dirt and Absorbent materials and coat all
padeye pin holes and pins with anti-rust grease.
8.2 The mast shall be placed in the dry place with good water drainage and supported
away from the ground to prevent wetted corrosion. While placing the mast, there shall be
enough supporting points and supporting beams below the mast to prevent the mast from
deformation.
8.3 The wirelines (the galvanized wirelines excepted) and the accessories shall be coated
with anti-rust grease, packed with plastic cloth and then stored in the dry place. It is
suggested that all pins, bolts, nuts and small parts for field assembly are marked, coated
with anti-rust oil and then stored in boxes.
8.4 When the mast is stored outdoors, cover it with tarp.
8.5 Prevent the mast from collision, bending, damage to components, damage to fitting
surfaces and damage to protecting layers or paint layers in transportation.
9 Spare parts list
9.1 Recommended one year spare parts
1 Pin Φ100×465 JJ217.13 1 pc HH

2list Pin Φ80×360 JJ217.22 1 pc HH
3 Pin φ20×125 JJ217.04.22 2 pc HH
4 Pin φ60×195 HHXD060.195 2 pc HH
5 Pin φ40×145 HHXD040.145 2 pc HH
6 Pin φ30×105 HHXD030.105 2 pc HH
12
7 Shear pin φ15×95 HHXZ015.095 10 pc HH

8 Pin 30×105 HHXD030.105 2 pc HH
9 Pin φ20×85 HHXD020.085 12 pc HH
10 Pin φ50×175 HHXD050.175 3 pc HH
11 Shear pin Φ25×180 HHXZ025.180 10 pc HH
12 Safety pin Φ6×120 HHBZ6.120 20 pc HH
15 D-shackle (S6)D×3.25t-5/8 8 pc outsource
16 Washer 24 GB/T97.1 4 pc Standard
20 Oil cup M10×1 JB/T7940.1 2 pc Standard
21 Bolt M30×240 GB/T31.1 4 pc Standard
25 Nut M20 GB/T6178 26 pc Standard
Wire line pc Standard
12KT GB/T5976 8
30 clamp
6KT GB5976 9
31 clamp
16KT GB5976 6
32 clamp
33 Pin 5×45 GB/T91 4 pc Standard
34 Pin 4×40 GB/T91 4 pc Standard
35 Pin φ10×35 GB/T882 1 pc Standard
13
36 Pin φ12×50 GB/T882 3 pc Standard
9.2 Spare parts lift
1 Pin Φ100×465 JJ217.13 2 pc HH

2 Pin Φ80×360 JJ217.22 2 pc HH
3 Pin φ20×125 JJ217.04.22 8 pc HH
4 Pin φ60×195 HHXD060.195 6 pc HH
5 Pin φ40×145 HHXD040.145 10 pc HH
6 Pin φ30×105 HHXD030.105 4 pc HH
7 Shear pin φ15×95 HHXZ015.095 14 pc HH
8 Pin 30×105 HHXD030.105 3 pc HH
9 Pin φ20×85 HHXD020.085 6 pc HH
10 Pin φ50×175 HHXD050.175 9 pc HH
11 Shear pin Φ25×180 HHXZ025.180 14 pc HH
15 D-shackle (S6)D×3.25t-5/8 4 pc Outsource
18 Oil cup M10×1 JB/T7940.1 2 pc Standard
10 Attached tables
Attached table 1 Weights and transportation sizes of main components of mast

Parts name L（m）×W（m）×H（m） Piece weight（kg）
Upper section 12.225×3.81×2.89 7000
Intermediate section 15.405×3.886×2.81 8000
14
Lower section 15.3×3.958×3.345 13800

Monkey board 5.85×3.4×0.6 4000
Attached table 2 Summary list of mast connection pins
Qty of
Dia. Of
Specification shear Drawing code
Connection Drawing code shear
SN Diameter× Sum Qty pin of shear
position of pin pin(Safety
total length (Safety pin(Safety pin)
pin)
pin)
Lifting
1 φ120×535 4 4 JJ217.14 φ25 8 HHXZ025.180
cylinder
Mast leg and
2 φ130×520 2 2 JJ217.18 φ25 2 HHXZ025.180
substructure
Front leg of
3 φ100×475 2 2 JJ217.20 φ25 2 HHXZ025.180
mastand mast
Front leg of
4 φ100×355 2 mast and 2 HHXD100.355 φ25 2 HHXZ025.180
substructure
Upper
section and
5 φ80×360 4 intermediate 4 JJ217.22 φ15 8 HHKX.15.02
section of
mast
Monkey
Safety
6 φ60×195 6 board and 6 HHXD060.195 6 HHBZ6.120
pin6×120
mast
Safety
7 φ50×240 2 High stand 2 JJ217.09.01.01 2 HHBZ6.120
pin6×120
Cross stay
Safety
8 φ50×175 4 bar of front 4 HHXD050.175 4 HHBZ6.120
pin6×120
leg
Suspension Safety
9 φ40×170 1 1 JJ217.03.03 1 HHBZ4.065
sheave pin4×65
Monkey Safety
10 φ40×145 10 10 HHXD040.145 10 HHBZ4.065
board pin4×65
Drag device Safety
11 φ35×190 1 1 JJ217.04.21.04 1 HHBZ4.065
on monkey pin4×65
15
board
Climb assist
Safety
12 φ30×130 1 device and 1 HHZL01.04 1 HHBZ3.050
pin3×50
mast
Monkey
7
board
Working
board of 16
ladders Safety
13 φ30×105 33 HHXD030.105 33 HHBZ4.065
Standpipe pin4×65
6
board
Casing
stabbing 4
board
Monkey Safety
14 φ20×125 8 8 JJ217.04.22 8 HHBZ3.050
board pin3×50
Safety
15 φ20×85 46 Ladder assy 46 HHXD020.085 46 HHBZ3.050
pin3×50
Lower
section and
16 φ100×465 4 4 JJ217.13 φ25 8 HHXZ025.180
intermediate
section
11 Other description
For the wind area, the static moment to the base, dry weight and wet weight of mast,,
please refer to “operation manual of substructure”, the weight of any liquid and top drive
are excluded when lifting this mast.
16
12 Parts list (please see attachment)
13 Attached drawings
Attached drawing 1: Nameplate
中华人民共和国
四川宏华石油设备有限公司
17
Attached drawing 2：Mast

Mast load distribution
18
19

JJ22543-K3 Mast User Manual

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JJ225/43-K3 井架

Address: South section II, Zhongshan Road, Guanghan, Sichuan

Postal code: 618300

Office telephone: 86-838-5151724

Telephone of after service department: 86-838-5152112

Telephone of home marketing department: 86-838-5101571

Telephone of foreign marketing department: 86-28-86013524

2.1 Purposes and applicability

Nominal drilling capacity 5'' drill pipe 4000m/13123ft

2.2 Standards and specifications for design and manufacture

2.3 Technical parameters

Height of drill floor 6.7m

3 Structural features and main components

3.1 Main structure

Fig.1 Main structure and overall dimensions of mast

3.2 Main components

4 Installation and test run

4.1 Pre-installation preparation

4.2 Installation of mast

Warning: Connection pins between sections of mast should be installed as per

Fig 2 Installation drawing for connection pins between sections

Fig 3 Schematic diagram for mast lifting

5 Lifting and lowering of mast

5.1 Pre-lifting preparation

5.2 Lifting of mast

5.3 Adjustment of mast

5.4 Lowering of mast

Fig.4 Lubrication points for lifting of lowering of mast

8 Storage and transportation

9 Spare parts list

9.1 Recommended one year spare parts

1 Pin Φ100×465 JJ217.13 1 pc HH

7 Shear pin φ15×95 HHXZ015.095 10 pc HH

36 Pin φ12×50 GB/T882 3 pc Standard

9.2 Spare parts lift

1 Pin Φ100×465 JJ217.13 2 pc HH

Attached table 1 Weights and transportation sizes of main components of mast

Lower section 15.3×3.958×3.345 13800

12 Parts list (please see attachment)

Attached drawing 1: Nameplate

Attached drawing 2：Mast

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