'0 .

NUMBER REV.

06.15.5 1 I
., OPERATING & TECHNICAL
PROCEDURE ISSUEDAT=: 03/11/96 l
INITIAL RELEASE: OEn 5/94

SUBJECT: BOOM INSPECTIONAND REPAIR PROCEDURE P;;Gf: I OF 4

1.0 PURPOSE

The purpose of this procedure is to describe the methods and procedures. by which
approval is given prior to the initiation of any repair work and to assure acceptable
straightness of repaired booms, wei~ir'lg procedures required for bo~h welder
qualifications anc welding procedure qualification, inspection procedures, and recores
thai: mcst be maintained.

2.0 SCOPE

The requirements of this procedure are appiicab!e to repairs at fie!d locations and
Weatherford Crane Service locations.

3.0 F'RQCEDURE

3.1 Authorizarion

. 3.1.' Prior to repair of the boom section (i.e.. boom base, or exter.sion) it is ....

to be surveyed by a designated Weatherford employee to °d.etermine

if repairs are necessary. If repairs are designated, methods of repair
and inspectionshall be detailed by inspectionpersonnel;
3.1.2 Personnelother than Weatherfordemployeesperforminginspection or
repairs, shall follow the guiaelines of this procedure for inspec<:ion
criteria and repairs methods. Weld procedure quaiification and operator .
qualification shall be prepared and submitted to Weatherford and/or
owner prior to commencing repairs.

3.2 Assl.:ranceof Ac;::eptable Straightness

3.2.1 The use of a jig is recommended fer repair or damaged booms having
three or more bent lacings and/or one or more bent chord(s). The
purpose of the jig is to assure proper alignment of the repaired boom.
When a boom is r~paired, an inspection for proper alignment is
mandatory. The quality control inspection may be contracted for
remote locations by the authority in 3.1.
------
3.2.2 to insurestrllCtUralintegritY of the boom section after repair, the chords
shall meet rhe overall straightness requirements of Table'. In addition,
the individual chords and lacings shall meet the requiremems of Table
2 as measured between any two adjoining panel points (see Figure A).
These dimensions can be checked with a tight-Jineor straightedge, and
shall be checked in two directions, 90 degrees apart.
{Please'see Anachment 1.)
 NUMBER REV.

06.15.5 1 I
OPERATING & TECHNICAL
PROCEDURE
ISSUE DATE: 03/11/96 l(~
INITIALRELEASE:06/15/94

SUBJECT: BOOM INSPECTION AND REPAIR PROCEDURE PAGE 2 OF 4

3.2.3 AU lacings bent more than 1/4" must be replaced. If a mildly bent
lacing cannot be straightened within the 1/16 of an inch tolerance, it
must be removed and replaced. One chord per boom section may be
spliced in one location only, or entire chord must be replaced.

3.2.4 Angular distortion (twist) shall be no"more than~:0' 6 inch for a 10 foot
section or 1/8 inch 'for longer sections as illustrated in Figure B;

3.2.5 Dents or dimples in chords or lacings shall not exceed those dimensions
shown in Figure C and Table 3- There shall be no more than 2 denrs
between panel points and defects shall be at least 6 inches apart.
Dents or dimples beyond these parameters shall require replacement
of the defective member.

3.2.6 Corrosion or abrasion damage to chords or lacings shall not exceed the
depths shown in Table 4 and illUStratedas dimension d, in Figure D.
Corrosion or abrasion which is not deeper than the values of the last
coh~m~ of Table 4 can be disregarded. -
n
3.2.7 The sum of the greatest dimensions of allcorrosion or abrasion defects
between panel points shall not exceed those values shown in Table 2.
An example of this dimension is shown as ds in Figure D.

3.3 Welding Procedures.

3.3.1 Damaged booms shall be repaired with welds complying with AWS
D 1 . 1 latest edition.

3.3.2 Both the welder making the repairs and the welding procedure
specifications used by the welder must be approved by Weatherford
or owner/owner representative. The welder Qualificationtest and the
welding procedure Qualificationtests may be one and the same for
welders who weld the proceduretest piece describedby AWS D1.1 ,
Figure5.8.1.2 test position 6GR. I
3.3.3 Shielded Metal Arc Welding (SMAW) and Flux Care Arc Welding
(FCAW)techniques may be preQualifiedby AWS D1.1. Forprequalified
procedures the welders must still be qualified. GMAW shan not be
used for boom reoair.

3.3.4 If the anglebetween the lacingand chord is lessthan 30, the joint is
not preQualified per AWS D1.1 and the fillet weld soundness test
described by AWS D1.1, must be performed. Ifthe angle between the
 NUMBER REV.

06.15.5 i
J
OPERATING & TECHNICAL r

'-- .". PROCEDURE

ISSUE DATE: 03/11/96 I
INITIAL RELEASE: 06/15/94

SUBJECT: 800M INSPECTION AND REPAIR PROCEDURE PAGE 3 OF 4

lacing and chord is less than 1!5tne joint is not permitted.

If the ratio of the diameter of a lacing to a chore on c:rcu~arsections

is greater than 1:3 or on boxsections is greater than .8, the fillet weld
joint is not pre. qualified per AWS DI.1. The necessary pr~cedure
qualificationis described by the fillet weld soundnesstest described
by AWS D1.1.

3.3.6 Welder qualification tests for welding T, y, K connections aie described

by AWS C1.1, test position 6GR. Procedure qualification is described I
by the fillet weld soundness test desc:,ibec by AWS 01.1.

3.3.7 If booms other than Weatherford's are being repairec, the base me!al
muSt first be identified to insure the proper selectiol" f fillermetal ar:d
welding procedure. (Refer to AWS D j .1 ).

3.4 Tubular 800m Lacing Repair Procedure.

3.4.1 Once a fuil and dstaiJed inspection 'of the entire boom has been
performed, and those lacing members that need to be replaced or
straightened havebeenidentified, the lacingreplacememprocedurefor
tubular chord booms is as follows:

3.4.1.1 If at all possible; replace only one lacing at a time and

complete the repair before removing another so as to
maintain the original chord alignment. If there is extensive
damage and more than one lac:ng must be replacedat one
time, extreme care must be used to hold the chord in
alignment, both vertically and horizontally, during
replacement. AU damaged lacings must be replaced with
tubing of equivalent material and properties, size and wall
thickness.

3.4.1.2 Tubular lacings to be replaced should be cut off

mechanically, preferably with a hacksaw directly above the
fillet weld anaching it to the ehcrd, leaving the original weld
on the chord member. Grind or file the remaining weld bead
flush with the chord, using extreme care not to notch the
chord or nick it in any way. See Figure 7. Lacings may be
removed from heavier booms by careful use of the arc air
:orch orcuttingtorc;h,slightlyabovethe anaching fiiletweld. I,
again using extreme care not to damage ~he chord ~ember i
in any way.
 NUMBER REV.

06.15.5 1 I
OPERATING & TeCHNICAL -l
PROCEDURE
ISSUEDATE: 03/11/96
INITIAL RELEASE: 06ii 5/94
I 0.--"

SUBJECT: 800M INSPECTIONAND REPAIR PROCEDURE PAGE 4 OF 4

3.5 Inspection Procedures

3.5.1 Inspection and acceptance of repaired booms shall be by personnel as

detailed in Section 3.1 of this procedure.

3.5.2 All NDT examinations shall be conducted by SNT-TC-' A level I! Gr Iii

techni c:ans.

4.0 RECORDS

4.1 A log of repairs shall be maintained. which inc!icates the following information:

Origir.alowner
Boemrepair serial number
Crane type
800m section
""~
800m length ;"
. ~
I
Workorder number
Re-soldto (if applicable)
Inspector's approval

4.2 These are permanem quality records and shall be maintained for the life of '(;,e
boom.

5.0 REQUIRED APFROV ALS

Revisions to this procedure shall be approved by the Chief Engineer and Quaiity
Control Manager.

ff<~n~ nager
 A':TAC~'::~7 1
Page 1 or 8

Boom Repair Procedure PANEl. ~orHi$

II

~c= CMORQS

Fiqure A. Homene~arvre

T.bi. 1. Ov.,..11ChOt'dStraignu-ss T~bl.e 2.. Tube Straightness a8:W~e!"l

Pane! P:)ints
Ma.dmum Owiation
Chord t..n Over Lanoth gf Chen! Mximum
Citviati:Jn
,0 ft. or less .12 inches f3.2 mrnl
.
i Be!'lYee:'l
(3048 mm Of'lea) t Ciameter Panel PQint:
ever 10 ft. to and .19 ind'\e: 14.Bmm,
indudln; 30 ft.
inches (mml I inehes {mlffl I
(O\<.r3C48 mm to and Len TI".an
includin; 91.u mtnl - 2 rsu .052 r1 5\
Over 30 ft.'m and .%5 in::tes (6.4 mml 2 15n .062 r1 5'
inc:fudin; 50 ft. 2.25 (571 .oea (j 7.
(Over 9 4.t mm to and 2.5 1541 . .Oi4 (1 9!.
inc:ll,ldin; 15.2.£0 mm) 2.75 (701 .cao 120)
:3 (76) .OB5 1221
3.25 (8Jl .092 {:2;;1
3.5 (891 .098 1251
3.75 (931 .10 1251
-. 4 (1021 t., 1 (2.BI

,
,- -
1
4.25

5
.s
.7S
(toel
1114J
('21 I
(1271
.12
.12
.13
.13
r:291
13 1)
rJ 21 .
13 I
I
I
I
~~ a---~~.-l
T 5.5 (1401 .14 1371
J 6 11521 .1£i !4 0\
t
6.5 (15S) .n /.: J:
7 ('781 .18 (451
I
7.5 (1911 .19 1491
t
B (2031 .20 (521
1
8S (2161 .2' 1551
I 9 (229) ..'2.3 (S 81
, 9.5 (2£11 .24 Co11
10 (254) ..2S 1641

"-'---~~""-'

.
F;;ur. B . Angular Distort.ion
 AT'!'ACm!E~'Z 1
PAGE 2 of 8

Boom.Repair Procedure
..
.~
~i,~....~
J

--.I
- ,
=
+
~a

Figure C. Dena or Dimples

o
Tube Oeft c.nt
... C. o-t
Ct Wi!nh " lAft9th
. ("""I inen. (INft -.c:."-I (nunl incM, fnwIIl
, as, 111 1%81 ..025 ICSI .11% !4 II
1 321 .us Q' 031 f081 .227 !s at
1.:. 81 167 -' '" 21 . n.o. '.4:73 ''':&1 ()
' ,.
\ 75 "'., .ISo! f&91 0404 n.1I . ..3,.
18Ti
2 11J .222 51 .oso n1 .36<4 11:01
2 %5 157. 1.2 SO If oil .056 i1 4.1 409 {101
%.! f604. .278 (7.11 ,06J n 61 "55 11%1
275 C70. .306 C781 1.069 "71 (1;J1
:J (.761 ..JJJ 185, .075 n.11 .,5.065 11"
J 25 /8:11 .361 fl21 -:.081 1.2.11' -6511 1151
3S C89t I -'89 I!!h .oea all .536 1161
3.75 CIS. 4.\7 (111 .Q506 (2'&, .512 (nl
" n021 .U4 (11) .1OJ «251 .727 nil
".:zs (1081 .472 f12J .101S (271 .773 1201
.1.5 (11.' .iCX) (131 .113 (291 JUS 1211
4.7i (12" .ill (131 .111 aOI J604 u
Ii (171 .A5i (141 .1;t5 (3-:21 J09 at
5.5 (''''01 .111 I'" .\38 CUI 1.00 121
I . ('15:21.567 (171 .150 g81 '.DS all
6o! (1651 .722 elal .163 44" 1.18 001
7 11711 .778 1201 .175 1441 1.21 ,
7.5 ""1 .8::13 a11 .J8S ".81 1.36 c:!SI
8 czo:u .u, 1231 .2a:1-ri 11 1.s- 1371
IS 1216' ."'" a.1I .213 cs ". 1.!6 13U
. 12291 1m -;751 .225 r571 1.&4 14%\
IS 12.&1I 1.06 (271 .238 fI 01 1.73 ''''1
10 1.0 (281 '"uo (641 1..12 t4i61

,,-.'
 ATTAC:iME~:1
",
PAGE 3 of 8
BoomRepair Procedure
ia~le 4. Corrosior. or Abrasion
d,
5um of

- :>
Tube
G,ut..,
C irnensionl
Sco:w..n
t!.
Mal.imum
O.th
Ci$'..':f
Un/eu
o.,:
c Oia",..., ,....., P "ift:1 AJlowo.lb/. T!..n
IN:bl:S (rnl':ll f in:n.. C"'"' I inc.'!.. 'm,,", inl:I\e$ fC'l"l1"l\1
1 f2S1 .25 ,6A' 008 f21 .CO:! roa!
j 1.:25 .31 179' 009 1.21 .
, 5
(32)
(Jet .39
"
1951 011 I:U CCS
1101
en;
1.7S !", 1111 O3 I.JI I ,005 IlJI'
2 ISH .5 CUI 015 '''' CCE IISI
225 1571 .50 "'" o, fAI 007 n71
25 164' .62 1151 019 (51 ,DOe 1191
275 (70' 69 1171 021 (51 CC! r 211
3 1761 .75 1121 02:3 10' DO! I'2Jr
325 1531 ,81 r:ztI cz: 1SI ,010 r j,
S IB91 Ie 121 I 025 t 71 O1 ' 27'
375 (95! t4 r:2'1 028 171 on r 29r
.. f1021 ' 1251 o 181 .012 1301
.25 (1081 '.05 1271 0:12 f 81 ,01:1 1:121
"5 " '4' 1.12 l291 034 (91 J 014 , 31
C.75 (12H 1.19 (301 .036 (.91 .QU, '361
5 (1271 t .%5, 1321 03! 1101 .015 I JS.
S.5 14l:1 1.:t8 (351 .04 I' OJ .017 1"21
5 {1521 1.5 {3S1 .045 (t.t) .0\8 (451
65 nE5J 1.52 (41) 049 '1 21 02\:) {SOl
i 7 (1781 1.75 ('"' 053 ",:U .021 f :31
.- 7,5 (U1J 1.S8 (481 056
060
(141 .023 f Si)
CIt 8 12C31 2 (511 11.51 C2" 1611
85 12Hit :z 12 1541 06A (1'151 02: (651
9 12291 :Z2S li7) 068 C171 cn I :I
!t5 (24n 238 (601 071 ft 81 C2!! In}
Figure D. Cort~sion Of Abrasion 10 (2541 2.5 (6-4) 07 P.!I .0:1::1 (H.

CARSON ~~c. elsc c;RINC OR SAW orF CA.MAGEC

LACING t/4 INCH (a mml .ABOVEWE~CI.CiUNC
ft£MAINIHG LACINtiAND WElD OOWNTO WSiHJH1r1l
INCH "., tnmt QF CHOAC.

Fi gure £. CueinGOHOam~gedTubul.r ucings

 A7'!R.C:!MEN! 1
PAGE 4 of 8

Boo~ Repair Procedure BOOH REPAIR AD7HOR!ZA7!ON ,

RE?A!R StRI..A~ #: REQU!RED COMPLET!ON:

IU:?AIR iw'OR-XORDER:

.
REPAIR INS T R U CT ! 0 N S

t.AC~G :

::iOIU>
S:
..,,-\ I

. D. '1". D o U.T. o X-RAY

~IN!!NG
~
INSTRUCTIONS:

S T'I M A '1' ! D REPAIR C 0 S T

IT.AI. DIR!C: LABOR BOTJP..S:

'.
-
MANACEA:
:A1.I'I'YCONTROL
 A:'TACr:ME~1' 1
?AGE 5 c: 8

--",

STE P ~

." , .
,.

/
./
..,/"
..,..-

~..\c.~~~"i ~ .Z:i"}
O~ .~ "

1.o.I~~ 0 I""... p $:.o~=:~.s

I ,,;! \...110'f C'1t. 5 K ".9J } (;0 I C)

.sr'<'\p.w,1012
 n

<10.~
c.,'10(t..,~ . ~ /, .
; ~.
r" _-:.~ /'
rx:"",.. /' /
- '". /

/.:, ;/ //
C/) .;' ,
.!.:-;. -1";'" ~
.'

,-

"

. .
VII

~I

I'~

c:~
--17
~ ~'!;; -Q 1.£"

'-'
 TO 151?14E1'?:39932 P.11/12
, . '
.' . APR 27 'ge 1:3142FR t.:EATHERFCRD-~1AJN ~,r""
...

;I . F L :~!..!!!Je:
AT'lAcmmN'! 1
PAGE 7 of S

5 TE P 4-

..t 5 - o. ~ ,... ~ 't'F; '"

101.0 I. ~ ': - F F ~ 111 . ,... ,.. - _"'!'

o '0 0 c .= ~..,.; A,.""I:,-:"

~- 21...
I..g up" ~ ., "I:' '-'c.
~~A~~~c ~~ ~; ~ZE:
rC'r. wt ~ Gt-~:............
'Fop. ~ ~'-I'.I)~i=.-
-.,.-

,/

//
.'
51,. .1)1; u "';...'''''''' -::w...c:.I:-.s
/"
/'
~~"':"U G ~.: " J~': ':'
l
UT'I'T"'" ~""LJ$. I.0oI,-...
(%,"'.. IS~ ~ .:.~ ~ u:n- .
./~ ~\...lc.."-IS'1':",,,o::: ~ ;.""
~...~ .5-' ;,:i! : ~",,-~
I ,.".'" oS' .. I 4.~ u.' ,. c,..'
S(.II.~i.JD~.~,,"""":"- D.'- I!I~;
~o. i~ ~: s ~..I '~::!

:: r::.....
c

}'~.J3)1, /JA~7'
~~~~
- -". . RFR 27 '98 13:43 FR WEATHERFO~tN TO 1~4e-?38932 P.12./12
lI
11'd', ,.,..,
t- .!'.:; a( e ... I
~ y...
ATTAcm1ENT 1
F.\G3 8 of 8

( Am D 1.1 )

... G~

1h/d(ng .II:IIiM .
nwtaltIDr=k-
CU unlin.1a!d1
ToI~

- 2..0)'-:u.4)
.&. ~..iled Aa til UI>
Pannit"_-d 1hie141n;
..!dIn;! 1'01'
IIIIU=S
SIIQIIW
SMAW
drsi
'TC-L' II. T1~ H LI
1&.011

A
OCIC\'Ii"O

- T ,12 .'''6 0 .1/10,-118

pmtiaMS fFCAWI I N~
loll C.J
Fc...1IW
SAW
Tc.L,4S:
'TC-L'.s
-
u
U
" .. D'CD118
., /1&,-0 F
Not rea. A,C,J

J,e

$in;l.Y~ ~ CZ1 TOI.,.~

Buu ioIfIt (EI)
k(.et!:I~~la:I
2.9.21 I (_13
~ in ..,
II!:!

R - .'(16.-al .1I~,,,'(1e
'a...fD'.-O't .'°'.-5'

l1l$I (I'IidI;r- . CI1

=, JDfft1. I fu . ""'ilftiUd) r AlXl1

aracw' Dt$l.ralion
Gtooorc
PeMli1':d
-ldini
lcfJ"9
10r
I

.
IorIJ TI

u
J"2
-
I
R .
cc-dn;
1.14 .-.5'
.... 3"
I. tlanl'
All
(FCA..",I
-
-
Nts
N
..
IiMAW I I f I R-3/8 .v.aH
A"112 .- F.V.OH - 1\1
ChI"'.
R. 3116 . -:110" F.V.OM Rcquil"l'l2 A.N
. .:!I:J'
RAW

SAW
..U28-GP

..
U

J"..
-

-- It -
R-:l18

R - 1/.
fl4 .-4$-
.-3Cr
",V,OM
F.V,OIc

..
Nbl c-eQ.
N01 tltC.
-
A,N
A"I\;

,.,

..... ...U2oS U " - 6IB . .. 2C"" F - N

~ A: ., prwqu8l1f~ for g.. Ift11W1II1O Mildi;.; u.il'g .P'IcI"eitCYhihgI~fllt. R.t.r fp ~ D.

.. c:: Ciouoe ~ 108OU~ tft8t81b8fDraIMIcfin;_cand aId~.
-- tl:. II 1611'"
..19 .'. u...:! it!bulldirolil.10""fttOtC' ;r~..a _10'. in c:m'Ier.M T-iCli" , 1It8 eQUilllO1/. TI Dut
~ IItJt..~ 318in. G'oo~ "'da 1ft1:OfI'I.'.,..d T;c11'lQof Dtidges-"811b. r.imcn=8d wM fidcn-'CIS ~U.11"
'1/4T, ~ rd fIIOf8CrIt"M In.
tIma N: ~ ~liOft of tft8 t...~ 1IWItJ~ In I'" Jc:IcntarhAt v",., r'lIIlI'I,:1$ ~eg to 1Ie deg prawics.ct tft811'" b._Ie ioinl
ICIOf'Ifipuralian (grDOft 8"C'14. t'DOt '.1:8, roof op8f'li>oQ),.me;" nw U~ and Nt it. dd!p" ~, 1'I'c&NIU is
...11'IWn.d..

I
** TOTFL PF.GE.12 ** I
I