Workover rig maintenance
Preventive Maintenance Programs – Choose Your Level
We offer three structured workover rig maintenance programs, tailored to your operation’s size and location.
| Program | What You Get | Price (Annual) | Best For |
|---|---|---|---|
| Basic (Self-Directed) | Maintenance manual, checklist templates, 24/7 phone support, free diagnostic software | $0 (included with rig purchase) | Experienced in-house mechanics |
| Standard (Assisted) | Basic + annual onsite inspection by SJ Petro engineer + priority spare parts shipping + remote data review (Workover iSys) | $5,000 – $12,000 (varies by rig size) | Single rig, remote location, moderate experience |
| Premium (Full Care) | Standard + quarterly onsite visits + dedicated account manager + regional spare parts stocking + 72-hour emergency parts guarantee + 10% discount on major repairs | $15,000 – $30,000 | Fleets of 3+ rigs, critical operations |
Maintenance Technical Data – Recommended Intervals
The table below shows our standard preventive maintenance schedule for a SJW-150 hydraulic workover rig. Intervals are based on operating hours or calendar time, whichever comes first.
| Component | Action | Interval (Hours) | Interval (Months) |
|---|---|---|---|
| Engine oil & filter | Change | 250 | 3 |
| Hydraulic oil | Sample & test (particulates, water) | 500 | 6 |
| Hydraulic oil | Full change | 2,000 | 24 |
| Hydraulic return filter | Replace | 500 | 6 |
| Hydraulic suction strainer | Clean | 1,000 | 12 |
| Mast pivot pins | Grease (via zerks) | 50 | — |
| Mast wire rope (hoisting lines) | Inspect for broken wires | 500 | 6 |
| Drawworks brake pads | Measure thickness | 250 | 3 |
| BOP accumulator nitrogen pressure | Check & recharge | 1,000 | 12 |
| All hydraulic hoses | Visual inspection for chafing / bulges | 250 | 3 |
| Electrical connections (control cabin) | Tighten & inspect for corrosion | 1,000 | 12 |
| Outrigger cylinder seals | Leak check | 250 | 3 |
| Engine coolant | Test freeze point / pH | 1,000 | 12 |
Genuine Spare Parts – 15-Year Availability Guarantee
We stock and manufacture spares for every workover rig we have ever built. Our guarantee: 15 years from rig delivery date, we will supply any part needed.
Spare Parts Kits (Pre-Selected)
| Kit | Contents | Price Range (USD) | Best For |
|---|---|---|---|
| First-Year Consumables | Filters (oil, hydraulic, fuel), seal kits, grease, belts, brake pads | $800 – $1,500 | All rigs – recommended at time of purchase |
| Hydraulic Component Kit | Pressure relief valves, pilot check valves, solenoid coils, hose repair fittings | $2,500 – $4,000 | Rigs in dusty/wet environments |
| Electrical/Controls Kit | Fuses, relays, limit switches, touchscreen spare (remanufactured), PLC battery | $1,200 – $2,000 | Remote sites with no nearby electronics supplier |
| Complete Annual Kit | Everything above + spare hydraulic pump cartridge, wireline sheave | $6,000 – $10,000 | Fleets, critical remote operations |
We can also customize a kit based on your operating hours and local conditions.
Regional Spare Parts Hubs
| Hub Location | Stock Focus | Typical Delivery Time (local) |
|---|---|---|
| Jingzhou, China (main) | Full inventory – all models | Same day (pickup) |
| Houston, USA | SJW-150, -200 hydraulic parts | 2–3 days |
| Dubai, UAE | SJW-150, -200, -250, plus desert package parts | 3–4 days |
| Singapore | Offshore electric models, corrosion-resistant components | 2–4 days |
Remote Diagnostics & Predictive Maintenance (Workover iSys)
Our Workover iSys telematics system turns reactive maintenance into predictive maintenance.
What It Monitors (Continuous)
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Hydraulic oil temperature and pressure
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Engine RPM, coolant temperature, fuel level
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Hook load and block position (cycling pattern)
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Mast angle and vibration (for leveling)
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BOP accumulator pressure
How It Helps You
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Alerts – Email or SMS when parameters exceed thresholds (e.g., hydraulic oil > 85°C). Catch a clogged cooler before the rig shuts down.
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Trend Analysis – See pump pressure dropping slowly over weeks – indicates wear. Change cartridges during planned downtime, not mid-job.
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Remote Support – Our engineer can log into the rig (with your permission) and see live data. Diagnose a fault without a site visit.
Pricing
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Hardware & installation (one-time): $15,000 – $25,000
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Annual subscription (cloud data, alerts, support): $3,000 – $5,000
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Local data storage (no cloud): No subscription fee – you keep data on your server.
Field Service & On-Site Repairs
When you need hands-on help, our field service engineers travel to your location.
Coverage Areas
We have full-time field service staff in:
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Americas – Houston (covers Canada, US, Latin America)
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Middle East & Africa – Dubai (covers UAE, Saudi, Nigeria, Angola)
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Asia-Pacific – Singapore (covers Australia, Indonesia, Malaysia, Thailand)
For other regions (Europe, Central Asia), we dispatch from China or partner with local certified service providers.
Typical Response Times
| Service Type | Response Time |
|---|---|
| Remote diagnostic (phone/email) | < 2 hours (24/7) |
| Remote login (via iSys) | < 1 hour (during business hours) |
| Onsite service (regional hub) | 3–5 days |
| Onsite service (from China) | 7–10 days |
Hourly Rates (Onsite Service)
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Engineer rate: $150 – $200 per hour (travel time billed at 50%)
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Travel & accommodation: at cost (no markup)
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Minimum charge: 8 hours per visit
Premium Maintenance Plan clients receive one free onsite visit per year (travel excluded).
Applications – Where Our Maintenance Solutions Are Used
Our maintenance support is deployed across:
| Client Type | Typical Maintenance Need |
|---|---|
| National oil company (Southeast Asia) | Fleet of 12 SJW-150 rigs – we provide quarterly inspections, regional spares hub, and train-the-trainer |
| Independent operator (West Africa) | Single remote rig – we provide full remote monitoring + annual onsite visit + emergency spares airfreight |
| Workover contractor (South America) | 5 rigs moving constantly – we provide consumables kits and 24/7 phone support; they handle daily maintenance |
| Offshore platform owner (Middle East) | 2 electric rigs – we provide offshore-certified service engineers who travel to platform for annual maintenance |
Why Choose SJ Petro for Workover Rig Maintenance?
1. We Know Our Rigs Best – We designed them, built them, and have serviced them for over a decade. No third-party guessing.
2. Genuine Parts Only – No Counterfeits – Our spares are manufactured to original specifications. We never source from unknown suppliers.
3. Fixed-Price Maintenance Contracts – Premium plan is a fixed annual fee (based on rig model and location). No surprise bills for routine work.
4. Free Diagnostic Software & Updates – Our Workover iSys Viewer software is free. You can install it on any Windows laptop. No license fees.
5. Maintenance Training Included – Every rig purchase includes 2 days of maintenance training (classroom + hands-on). We teach your crew how to perform daily checks, change filters, and diagnose common faults.
6. 24/7 Hotline – +86-123-4567-8900 (or local numbers in Houston, Dubai, Singapore). Always answered by a real engineer, not a call center script.
7. Maintenance History Tracking – For Premium clients, we maintain a digital logbook of every service visit, parts replaced, and hours logged. You get a quarterly report.
Frequently Asked Questions (FAQ)
Q1: Do I need a maintenance contract, or can I just call you when something breaks?
You can call anytime. We charge time and materials for unscheduled repairs. A maintenance contract gives you lower hourly rates, priority response, and free annual inspections. Most fleet operators find contracts cheaper over 3+ years.
Q2: How do I order spare parts?
Email parts@sjpetro.com or use our online parts portal (login required). Provide rig serial number (on nameplate) and part number from the manual. We will confirm price and availability within 4 business hours.
Q3: What is your parts warranty?
New genuine parts: 12 months. Remanufactured parts (e.g., hydraulic pump cartridges, control touchscreens): 6 months.
Q4: Can you train my mechanics to do their own major repairs?
Yes. We offer a 5-day "Advanced Maintenance” course at our Jingzhou facility. Topics: hydraulic pump rebuilding, mast alignment, PLC troubleshooting, BOP servicing. $3,500 per student (includes materials, lunch, certificate). Travel and accommodation extra.
Q5: How do I know if a part is counterfeit?
All genuine SJ Petro parts have a holographic label with a QR code. Scanning the QR code shows the part’s manufacturing date, batch number, and test results. If no QR code, it is not genuine.
Q6: What should I do if my rig has a hydraulic leak in the field?
Follow emergency procedure in the manual (isolate circuit, release pressure). Then call our hotline. We will help you identify the leaking component and, if you have a hose repair kit, guide you through replacement. If not, we airfreight a pre-crimped hose assembly.
Q7: How often should I replace hydraulic hoses as preventive maintenance?
We recommend every 5 years or 4,000 operating hours, whichever comes first – regardless of visible condition. Rubber ages internally. We offer a "hose refresh kit” with all hoses pre-cut, crimped, and labeled for your rig model.
Q8: Do you offer oil analysis services?
Yes. You send us a hydraulic oil sample (kit provided). We test for particle count (ISO 4406), water content (Karl Fischer), and viscosity. Report returned within 5 business days. Cost: $150 per sample. Premium plan clients get 2 free samples per year.
Q9: Can I get a loaner component while mine is being repaired?
For major components (hydraulic pumps, drawworks, control touchscreens), we offer an exchange program. You pay a deposit, we ship a remanufactured unit, you return your failed unit, and we refund the deposit minus rebuild cost. Faster than waiting for repair.
Q10: What is the most common maintenance mistake you see?
Using the wrong hydraulic oil viscosity. Many operators use standard AW68 in all conditions. For arctic or desert, you need different grades (AW32 cold, AW100 hot). We provide a viscosity selection chart with every rig.
Q11: How do I update the PLC software?
Download the latest .hex file from our website (requires login). Copy to a USB stick, plug into the control cabin’s USB port, and follow the on-screen prompts. Takes 10 minutes. Full instructions in the maintenance manual.
Q12: Do you provide maintenance for workover rigs that are not SJ Petro brand?
We can – but only for non-proprietary components (engines, hydraulic pumps, general hoses). We will not have schematics or part numbers for other brands’ masts or controls. We recommend contacting the original manufacturer for major repairs.
