Workover rig system
Technical Specifications – Complete Workover Rig System
The table below lists specifications for a typical 200,000 lbs hydraulic workover rig system. Custom systems available for other hook loads and drive types.
| System Component | Specification |
|---|---|
| Mast | 3-section telescopic, extended 102 ft, retracted 46 ft, cantilever design |
| Clearance under mast | 17 ft (accommodates 10k psi BOP stack) |
| Drawworks | Hydraulic motor drive, 400 HP, 35,000 lbs line pull (bare drum) |
| Wireline | 1-1/8" diameter, 7,000 ft capacity |
| Traveling block | 200,000 lbs rating, 6 sheaves |
| Power pack | 400 HP diesel engine, 150 gal fuel tank, load-sensing pumps (90 GPM @ 2,500 psi) |
| Hydraulic oil cooler | 500,000 BTU/hr, thermostatically controlled |
| Control system | PLC-based with 12" touchscreen, data logging, emergency stop lanyards (3 locations) |
| BOP stack | 13-5/8" 10,000 psi, dual ram (blind/shear + pipe), hydraulic |
| BOP accumulator | 20 gal, 3,000 psi, 4 station (dedicated to BOP, independent of main power) |
| Pipe handling | Hydraulic catwalk (variable height, 15 ft stroke) + manual tongs (iron roughneck optional) |
| Substructure | Skid-mounted, 17 ft wide × 25 ft long, 10,000 lbs/ft² deck rating |
| System weight (total) | Approx 55,000 lbs (excludes BOP and optional equipment) |
| Footprint (working) | 40 ft × 35 ft (including outriggers and catwalk) |
| System rig-up time | 12 – 16 hours (4 crew, first setup) |
| System rig-down time | 8 – 10 hours (4 crew) |
System Applications
Our integrated workover rig system is deployed for:
| Operation | System Benefit |
|---|---|
| Full tubing changeout | Integrated pipe handling + digital depth display reduces connection errors |
| Snubbing (live well) | BOP and snubbing stack seamlessly interface with control cabin |
| Fishing | Data logging helps track overpull and jarring events |
| Casing patch & repair | Mast clearance accommodates longer tools |
| Offshore platform workover | Corrosion-resistant system modules; each fits under platform crane limits |
| Batch workover (multi-well pad) | Quick system skidding between wells – outriggers and substructure designed for pad moves |
Product Types – Workover Rig System Configurations
We offer three system platforms, each fully integrated but optimized for different environments:
| System Series | Drive | Mounting | Hook Load Range | Key System Feature |
|---|---|---|---|---|
| SJWS-H (Hydraulic) | Diesel-hydraulic | Skid or trailer | 90k – 300k lbs | Load-sensing pumps, shared cooling, PLC-controlled priority valve |
| SJWS-E (Electric) | AC-VFD (grid or gen) | Skid only (no onboard engine) | 150k – 250k lbs | Regenerative braking, silent operation, remote start/stop |
| SJWS-M (Mobile) | Diesel-hydraulic | Truck-mounted | 90k – 150k lbs | Self-contained, road-legal, system folds for transport |
All systems share the same control architecture, BOP integration, and modular module design. Spare parts are interchangeable across systems of the same hook load class.
Why Choose SJ Petro for Your Workover Rig System?
1. System-Level Warranty – One Claim, One Fix
Because we supply the entire system, you make one warranty claim. We diagnose, send parts, and fix. No back-and-forth between "drawworks supplier” and "control vendor.”
2. Reduced On-Site Integration Time
Pre-matching components at the factory cuts your rig-up time by 30–40% compared to assembling components from multiple sources. Many clients report first-well spud within 48 hours of delivery.
3. Lower Total Cost of Ownership
Integrated systems have fewer compatibility failures. Our data shows 25% fewer hydraulic leaks (because hoses are cut and fitted as a set) and 40% fewer electrical connection issues (pre-wired harnesses).
4. One Training Program for the Whole Crew
Your operators learn one control system, one set of emergency procedures, one maintenance schedule. No cross-training across different brands.
5. Free System Layout & Pad Design Support
We provide CAD drawings of the complete system footprint – including outrigger extension, catwalk position, and BOP placement. You can plan your pad or platform deck before the system arrives.
6. 15-Year System Spares Availability
We guarantee spares for every component in the system for 15 years. Critical items (PLC, hydraulic pumps, seals) are stocked regionally.
7. Sinopec Engineering Backing
As a Sinopec subsidiary, our system designs are reviewed by corporate engineering. We have access to computational fluid dynamics for hydraulic circuits and finite element analysis for mast structures.
Frequently Asked Questions (FAQ)
Q1: What is the difference between a workover rig system and a standard workover rig?
A standard rig is often a mast and drawworks sold as a unit, with power pack, controls, and BOP sourced separately. A system includes all those components, pre-integrated and tested together. It arrives as a coordinated set, not a puzzle to assemble.
Q2: Can I add my own BOP or control system to your rig system?
We prefer to supply the full system for compatibility, but we can integrate third-party BOPs if you provide full specifications. Integration adds engineering time (2–3 months) and cost ($20k–$50k). We do not integrate third-party control systems – safety risk.
Q3: How long does it take to manufacture a complete workover rig system?
For a standard hydraulic system (SJWS-H, 150k–200k lbs): 6–8 months from deposit. Electric or custom hook loads add 2–3 months. Faster delivery available for rental fleet systems – ask about quick-ship program.
Q4: Do you provide the hydraulic hoses and electrical cables pre-cut and labeled?
Yes. Every hose and cable is cut to exact length, crimped with fittings, and tagged with a number matching the system schematic. You do not need to measure or cut anything on site – just connect numbered pairs.
Q5: What documentation comes with the system?
We provide: system schematic (hydraulic + electrical), PLC program backup, component datasheets, operator manual, maintenance manual, troubleshooting guide, and a digital copy on USB. All in English.
Q6: Can the system be operated remotely (teleoperation)?
We offer an optional remote operation console that can be placed up to 300 ft away (fiber optic cable). Full remote control of all functions except BOP (kept local for safety). Used for hazardous area workovers (H2S, high pressure).
Q7: How do you handle software updates for the PLC?
We provide free software updates for 5 years. Updates are delivered on USB with instructions. Your local electrician can upload them. No proprietary lock-in – you own the PLC code.
Q8: Is the system suitable for offshore platforms?
Yes. Our SJWS-E (electric) offshore system includes: marine-grade epoxy coating, stainless steel fasteners, IP66 enclosures, and sacrificial anodes. Each module weight under 25,000 lbs to fit typical platform crane limits.
Q9: Can I get a simulation of the system before buying?
We offer a 3D interactive simulation (web-based) that shows the system raising mast, extending outriggers, and performing a tubing trip. Request access via our sales team. Not a full simulator, but shows component interactions.
Q10: What is the typical lifespan of your workover rig system?
With proper maintenance, 15–20 years. Many of our systems from 2010 are still in daily operation. We can supply refurbishment kits (new hoses, seals, control panel upgrade) at year 10 to extend life.
Q11: Do you offer a buy-back or trade-in program for old systems?
Yes. If you upgrade to a new system, we will buy back your old SJ Petro system (any age) and deduct the value from your new purchase. Trade-in value depends on condition and hours.
Q12: How do I get a system quote?
Provide: desired hook load, land or offshore, drive preference (hydraulic/electric), any special conditions (H2S, cold, desert), and whether you need BOP and pipe handling included. We will send a system proposal within 5 business days – including schematic, module list, and fixed price.
