DRS-01000 DRILLING RIG PARTS AND SERVICE MANUAL

INTRODUCTION AND SPECIFICATIONS

1.1 Use of this Manual

This equipment manual contains valuable operation, maintenance and troubleshooting
information. However, it cannot foresee every eventuality that will arise while working with, or
working on, the rig. While every effort is made to ensure that the information included in this
manual is accurate and complete, no guarantee is made to that effect. When a situation of
doubt, uncertainty or lacking information exists, the engineering and/or service departments at
Stewart & Stevenson should be consulted.

1.1.1 Revisions and Amendments

With complex items of equipment, manuals invariably undergo some alteration after issue. When
this becomes necessary, the relevant pages or documents shall be delivered to each manual
holder. They should be inserted into the manual and a description of the changes or additions
should be noted on the Revisions and Amendments sheet at the front of the book.

1.1.2 Third Party Information

This manual includes various datasheets, user information, drawings, service information etc.
relating to component parts of the DRS-01000, Drilling Rig that were manufactured or supplied
by other companies. This information is included in order to aid in the identification, operation
and service of the equipment. It should be noted that these documents are not controlled by
Stewart & Stevenson, and no guarantee is made regarding their accuracy or completeness. If
information is required beyond what is supplied in the provided documents, contact the
engineering and/or service departments at Stewart & Stevenson.

1.1.3 Modification or Repair of the Rig

Please consult the Stewart & Stevenson engineering and/or service departments before carrying
out any modifications, repairs or overhauls of this equipment.

1.1.4 Note, Caution, Warning and Danger Statements

Throughout this manual statements may appear which emphasize important and critical
information. These statements will be set off from the rest of the text, and will be formatted and
defined as set out below.

DANGER: indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury. This type of statement is
limited to only the most extreme situations.

WARNING: indicates a potentially hazardous situation, which, if not avoided, could

result in death or serious injury.

CAUTION: indicates a potentially hazardous situation, which, if not avoided, could result in
minor or moderate injury, or serious damage to equipment. It may also be used to
alert against unsafe practices.

NOTE: is used to notify personnel of installation, operation, or maintenance information that

is important, but not hazard related.

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INTRODUCTION AND SPECIFICATIONS

1.2 Statement of Warranty

Statement of Warranty Policy

1. Stewart & Stevenson warrants the Equipment to be free from defects in material and
workmanship for a period of TWELVE (12) months from the Date of Delivery.
2. Stewart & Stevenson reserves the right to inspect the Equipment to determine the
validity of the warranty claim and. if determined to be valid, Stewart & Stevenson will,
at its option: (1) replace the defective Equipment or parts thereof; or (2) authorize the
Equipment or part to be returned to its authorized repair facility for repair; or (3)
authorize the Equipment or part to be repaired at the Purchaser’s plant. Stewart &
Stevenson will not be responsible for any transportation costs.
3. Repair or replacement will be without charge, but removal and installation of other
parts, including additional parts furnished, will be made at the Purchaser’s expense.
No charges will be accepted for returns, repairs or alterations done by the Purchaser
unless previously authorized in writing by Stewart and Stevenson Canada Inc.
4. The Purchaser acknowledges that the Equipment is of a size, design and type
requested by the Purchaser and agrees that, except as stated herein, there are no
other warranties, express or implied, including those for merchantability or fitness for
particular use, which Stewart & Stevenson hereby disclaims.
5. The Purchaser is to pay all freight/flight charges as well as travel expenses for
warranty work performed away from the Stewart & Stevenson fabrication facility.

Not Covered Under this Warranty

1. Equipment or parts manufactured by others; however, Stewart & Stevenson will
assign the benefits of any manufacturers’ warranties if assignable.
2. Equipment or parts that are or have been in contact with corrosive chemicals or
corrosive materials.
3. Equipment or parts customarily subject to wear.
4. Failure resulting from improper use or inadequate maintenance.
5. Personal injuries or death to any person (including the Purchaser and any of their
employees, agents and/or contractors) or claims for loss or damage to property or
business, either direct, indirect or consequential, caused or contributed to by the
Equipment or any failure thereof, regardless of whether caused by Stewart &
Stevenson or any other person or by any fault or negligence of Stewart & Stevenson,
its employees, agents and contractors.
6. Mileage in excess of 200 miles from a Stewart & Stevenson Power Products LLC
facility (USA only).
7. Overtime charges are not covered under the warranty and are extra. Weekend rates
may apply.

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1.3 Photographs

Actual unit not exactly as shown.

FIGURE 1-1
DRS-01000 Drilling Rig – Driller’s Side View

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INTRODUCTION AND SPECIFICATIONS

1.4 Roading Dimensions and Weights

Actual unit not exactly as illustrated.

FIGURE 1-2
Unit Dimensions

Unit Shipping Weight:_________________________________

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INTRODUCTION AND SPECIFICATIONS

1.5 Unit Specifications

1.5.1 Trailer
The trailer is a 120,000 lb quad suspension trailer fitted with sixteen 315/80R22.5 tires. The
trailer deck is covered with safety tread plate. The front of the trailer is equipped with two
hydraulic leveling/lifting jacks and two mechanical jacks. Two belly jacks are located in the
middle of the trailer and two hydraulic leveling jacks are located at the rear of the trailer. The
trailer also includes folding diamond grip walkways, handrails, and removable stairs located on
both sides of the trailer.

Stewart and Stevenson (Crown ) is certified to manufacture Trailers and

Carriers that meet all the required Canadian and United States Federal
Motor Vehicle Safety Standards.

Stewart and Stevenson (Crown ) is registered with the National Highway

Traffic Safety Administration as a manufacturer of Motor vehicles using the
assigned WMI: 2C9/173 for trailers, and 2R9/678 for Trucks.

[Link] Running Gear

The trailer features four axles fitted to a Holland TRM-4120 mechanical suspension and sixteen
315/80R22.5 tires.

[Link] Highway Equipment

The highway lighting package comes with rear turn signal lights, clearance lights, stop/brake
lights, and reflectors. All wires are routed through cable hangers located in the trailer frame and
shielded to protect the wires from damage.

[Link] Leveling and Lifting Jacks

Four hydraulic and four mechanical jacks (with pedestals) are fitted to the trailer and are to be
used for leveling and supporting the trailer during rig operations.

[Link] Deadline Anchor

One Type "D" deadline anchor, rated at 50,000 lb, for 1-1/4 inch wireline is mounted to the trailer
deck. This is designed to accommodate a compression type hydraulic weight indicator load cell,
which is supplied by the customer.

1.5.2 Engine
These are two Detroit Diesel Series 60 diesel engines. They are 14.0 L and have an intermittent
rating of 500 BHP at 2100 RPM each.

[Link] Engine Features

The Detroit Diesel Series 60 engine is a six-cylinder, turbocharged, air to air aftercooled engine.
This fully integrated heavy-duty diesel engine with electronic controls has excellent fuel
consumption, durability, and low emissions. The engine package includes:
Alternator (24V)
Rigsaver valve
EPA Nonroad Emissions Certified
Air Filter

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Radiator (400C/1040F)
Muffler
Spark Arrestor
Direct Drive Fan
Water filter
24 V electric starter
Air compressor
Instrument Panel
Tachometer
Crown control Panel.

[Link] Engine Specifications

Rated Power Output: 500 BHP at 2100 RPM each.

1.5.3 Transmission
These are two Allison Model S5610H transmissions.

[Link] Transmission Features

The Allison Transmission Model S5610H is designed for diesel engines up to 550 net HP.
Instrumentation includes: one pressure gauge, one temperature gauge per transmission
mounted on the engine gauge panel on the operator’s side of the rig.

1.5.4 Power Take-Offs (PTOs)

Two Chelsea power take-offs are transmission mounted and pneumatically controlled.

1.5.5 Right Angle Gear Box

The Crown right angle gear box supplies power to the drawworks and is fitted to a reversing box
and Fawick (Eaton) 16VC600 clutch to drive the rotary table. A shaft drive connects to the
vertical chaincase at the rear of the trailer.

1.5.6 Compound
This is a Crown two-engine, chain driven compound with mechanical disconnects.

1.5.7 Drawworks
The Crown model CE1000SD single drum drawworks is equipped as described below:
Mounted on a heavy duty framework with sheet metal covers. Auxiliary braking is achieved with
an Eaton WCBD-236 Assist Brake.

[Link] Drawworks Specifications

Main Drum
Model: Crown CE1000SD
Drum Size: 22 inches x 37 inches
Brake Size: 44 x 11 band brakes

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Drawworks Speeds: five forward, one reverse (through engine transmission)

Drive Chain: 1-3/4 inch pitch, triple strand
Cooling: Water circulating
Auxiliary Brake: Eaton Model WCBD-236 Assist Brake

[Link] Eaton Assist Brake

One Eaton Model WCBD-236 Assist Brake, water-cooled, with piping to the edge of the trailer for
an external water source (external water source & charge pump are not supplied with the unit).

[Link] Brake Water Cooling Manifold for the Main Drum and Auxiliary Brake Cooling
One water cooling system manifold for cooling the main drum brake bands and auxiliary water
brake complete with all necessary piping to the edge of the unit and controls. A connection for an
outside water supply is also included.

1.5.8 Mast
This is a 118 ft x 440,000 lb guyed telescoping mast with a fixed base. It is constructed with
hollow structural steel framing, and is designed and built in accordance with the API 4F
Specification. The maximum mast hook load capacity is 440,000 lb on ten lines. The HSS
construction ensures minimum weight with maximum stability.

[Link] Mast Features

The mast is equipped with a ladder mounted on the off-driller’s side. A safety platform, handrails
and a fall arrest post are included with the crown frame assembly. The mast is equipped with a
block cradle, two belly lines, and two load lines.
Two 3-stage hydraulic cylinders (chrome plated) are used for raising the mast and are equipped
with safety chokes to prevent freefall in the event of a complete loss of hydraulic pressure. The
mast uses two single acting, chromed, telescoping cylinders for raising the top section.
The crown platform provides safety when servicing the crown sheaves. The crown block
assembly comes with:
Four 36 inch fleet sheaves, grooved for 1-1/4 inch drill line;
One 42 inch fastline sheave, grooved for 1-1/4 inch drill line;
One 36 inch deadline sheave, grooved for 1-1/4 inch drill line.

All crown block sheaves are steel. They are mounted on tapered roller bearing inserts, thus
bearing failure will not damage the actual sheave. Fittings are provided for individual greasing of
the bearings.

[Link] Mast Specifications

Capacity: 440,000 lb with 10 lines;
Height: 118 feet;
Line String Up: Ten;
Wind Load: As per API 4F (69 mph).

[Link] Included Mast Options

Hard pipe hydraulic lines for power Kelly spinner to the off-operator’s side of the mast;
Manual tong counterweights (Tong weight: 500 lb) mounted on the substructure base
with a line sheave fitted under the racking board with cables;

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An off-driller’s side boom pole with storage rack;

A 4 inch standpipe, 5000 psi Working Pressure, with 180 degree gooseneck at the top
and unions at the top and bottom of the standpipe (no valves or gauges are included);
Guylines for internal guying.

[Link] Racking Board

One automatic racking board for use with a 16 foot substructure.
Maximum width 11 feet, 11 inches.
Welded fingers with 5 inch spacing for 4-1/2 inch drill pipe.

[Link] Racking Board Specifications

Capacity for 13,500 feet of 4-1/2 inch drill pipe with 6-1/8 inch tool joint;
Positioned for use with Range II tubulars in doubles;
Complete with updated line guards for fingers;
Complete with a rear escape system;
A hinged walkway is included on the racking board;
There is a winch sheave support on the rear of the racking board.

[Link] Make Up and Break Out Assembly

The unit comes with two hydraulic cylinders, sheaves, rollers and cables.
The make and break cylinders are mounted on the back of the mast.
The hydraulic controls for the make up and break out functions are mounted over the
driller’s console with automatic centering at the end of the cylinder stroke.

1.5.9 Hydraulic System

The hydraulic system supplies power for the following operations:
Hydraulic winches;
Power tongs circuits;
Mast raising cylinders;
Telescoping cylinders;
Leveling cylinders;
Make and Break cylinders;
Kelly Spinner.
The equipment consists of:
One 340 gallon hydraulic tank;
Two hydraulic pumps, each mounted on one of the twin engines, each rated at a
capacity of 50 gallons per minute;
A hydraulic return filter, filler/breather, all related valves, pressure gauge, and hydraulic
control valves;
Tong pressure control.

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[Link] Winches
Two 12,000 lb hydraulic winches (Personnel handling approved, Model PD-12C-1), each
with two 8 inch sheaves and controls, and 325 feet of ½ inch winch line;
One 5000 lb hydraulic winch (boom pole, Model BG5A), and 230 feet of ½ inch wireline.

1.5.10 Pneumatic System (Air System)

The air supply for normal rig operation is provided by the following equipment:
Engine mounted air compressors, one mounted on each engine;
An air receiver system;
An air dryer;
Pneumatic plumbing (valves, drains, lubricators, filters and gauges).

1.5.11 Fuel System

One 100 gallon fuel tank is mounted on the rig trailer and is fitted with piping to the rig’s engines.
There are five ½ inch pipe connections on the top of the tank, one 1 inch pipe connection on top,
two 1 inch pipe connections on the bottom and one 1 inch pipe connection on each end at the
center of the end.

1.5.12 Control Panel

One Crown pneumatic control panel for a 16 foot substructure floor height.
Controls Gauges
Hydraulic Pump (on/off) (air) Main Air Pressure
Gear Selector, transmission (air) Hydraulic Pressure
Emergency Stop (air) Make Up tong cylinder pressure
Engine Stop (air) Break-Out tong cylinder pressure
Fast Idle (air) Slips Air Pressure
Horn (air)
Two 12,000 lb Winches (up/down)
(air/hydraulic)
One 5000 lb boom pole winch
(up/down)
Slips Air Regulator (air)
air/hydraulic)
Slips (in/out) (air)
Hoist (up/down) (air)
Assist Brake (air)
Rotary Table (air)
#1 & #2 Pump Clutch (air)
#1 & #2 Pump Throttle (air)

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1.5.13 Drill Line Spool Rack

One drill line spool rack for 3000 feet of 1-1/4 inch drill line (mechanical) is mounted on the rig
trailer gooseneck with a steel storage spool (without wireline).

1.5.14 Crown Saver

One Crown type crown saver safety shutoff device to limit block travel is installed on the
drawworks. This automatically disengages the clutch and sets the main drum brake when the
block comes too close to the crown block, or the required amount of travel has been reached.

1.5.15 Fuel System

One 100 gallon fuel tank is mounted on the rig trailer and is fitted with piping to the rig’s engines.
There are five ½ inch pipe connections on the top of the tank, one 1 inch pipe connection on top,
two 1 inch pipe connections on the bottom and one 1 inch pipe connection on each end at the
center of the end.

1.5.16 Electrical
Equipment selection and classification of areas is in accordance with current API Standard North
American Codes.

[Link] Electrical Options

Where practical, the lighting wiring is in rigid conduit with flexible terminations in liquid tight flex
or rough service cord. The connection of mast lights is with RL 80 cord connections.
A distribution panel (120/208 Volt, 60 Hz) including breakers for mast lighting, utility outlets,
engine enclosure lighting, connection to 30A 4P 4W receptacle, and a spare breaker.
Nine 4 foot explosion proof fluorescent mast lights.
One incandescent red crown light.
Additional lights – three extra light receptacles are mounted at the base of the mast (lower
section) for the customer’s installation of extra lights.

1.5.17 Substructure
A 16 foot high (floor height) substructure is supplied.

[Link] Substructure Features

The substructure is skid mounted and raised manually using the traveling block. It features: two
sets of stairs to the trailer; one layer of 4 inch timbers under the setback; a mouse hole, rat hole,
tong back up posts, a Kelly pull back post, handrails, rotary beams for the rotary table and a pipe
ramp with stairs to ground. The base of the substructure is plated on the top and seal welded on
the bottom. Plugged drains are installed for each compartment. Also included is a mast load
beam (T-sill) with pin connections to the substructure and mud boat. A 24 inch clearance is
provided for fitted the V-door.

[Link] Substructure Specifications

Floor Height: 16 feet
Width (Working Floor): 19 feet, 6 inches
Length (Working Floor): 12 feet, with a 4 foot folding porch
Width (Substructure Base): 36 feet
Clearance Under Rotary Beams: 13 feet

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Roading Height: 11 feet, 6 inches

Setback Capacity: 300,000 lb
Rotary Capacity: 450,000 lb
Rotary Table Opening: 20-1/2 inch
Rotary Table Center: 44 inches

[Link] B.O.P. Handling System

One B.O.P. handling system is included. The system is designed to handle the customer’s
B.O.P. stack. It is operated on a rail and truck system, and provides the ability to move the
B.O.P. stack to and from the well-center.
The B.O.P. is provided by the customer.

[Link] Chain Driven Rotary

Consists of one rotary chain case with adapters for a Hacker 20-1/2 inch rotary table, sprockets
and chains and a 20-1/2 inch rotary table with a 44 inch center.

[Link] Rotary Torque Indicator

One rotary torque indicator is installed in the vertical chain case and includes an idler assembly
with a rubber wheel.

[Link] Mud Boat

One crown manufactured mudboat. This unit includes steel checker plated tire guide rails and
heavy duty lugs for pinning to the load beam. The ramp comes complete with all pins,
turnbuckles and lugs to pin to the load beam.

[Link] Load Beam

The Crown manufactured load beam matches the mast load requirements. It is plated on the
bottom and comes with all pins, turnbuckles and lugs to pin to the substructure.

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1.6 Unit General Assembly Drawings

100065574.01.02. DRS-1000 Drilling Rig General Assembly.
100065574.02.02. DRS-1000 Drilling Rig General Assembly.

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