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Inspeccion de Equipos Servicio y Drilling
Inspeccion de Equipos Servicio y Drilling
EQUIPMENT
INSPECTION
PROCEDURE 2020
Revision 1.0
EQUIPMENT INSPECTION PROCEDURE
EQUIPMENT INSPECTION
PROCEDURE
Equipment Inspection Procedure
A- Introduction
B- Inspection Matrix
1.0 Rotary Table
2.0 Kelly Drive Bushing
3.0 Master Bushing and Insert Bowls
4.0 Rotary Slips
5.0 Safety Clamp
6.0 Manual Tongs
7.0 Circulating Head
8.0 Drawworks
9.0 Brake Band and Linkage
10.0 Disc Brake
11.0 Rotary Hoses, Jumper Hoses
12.0 Power Tongs
13.0 Mud Pumps
14.0 Instrumentation and Gauges
15.0 Circuit Breakers
16.0 Hydraulic Catwalk
17.0 Pipe Arm
18.0 Iron Roughneck
19.0 DC Motors
21A.0 AC Motors For All Drawworks
21B.0 AC Motors For All Top Drives
22.0 Fuel and Mud Tanks
23.0 Mast and Substructure
24.0 Monkey Board and Stabbing Board
25.0 Hydraulic Raising Cylinders
26.0 Crown Block
27.0 Traveling Block and Drilling Hook
29A.0 Gooseneck for all top drives
29B.0 Field inspection For TDS 11SA And SH
29C.0 Field inspection For TDS 10SH
29D.0 Full inspection For TDS 11SA and 11SH
29E.0 Full inspection For TDS 10 SH
29F.0 Full inspection For TDS Tesco
29G.0 Full inspection For TDS Canrig 1235 and 1035
31.0 Elevator Links
32.0 Manual Elevators
33.0 Spider /Elevator
34.0 Kelly Spinner
35.0 Dead Line Anchor
36.0 Lifting Plug/Sub
37.0 Utility Winch
38.0 Man-riding Winch
40.0 Rotary Swivel
41.0 Drill Pipes
42.0 BHA and drill string accessories
43.0 Raising Lines and Spelters
44.0 Slings - Shackles - Pad Eyes
45.0 Trailers King Pin
46.0 Personal Basket
47.0 Crane Hooks
48.0 Fork Lifts Forks
49.0 Casing Running Tools
50.0 Personal Elevators
51.0 Self Propelled Manlift
52.0 Sack Handling Devices
53.0 Diverter Ball Valves
54.0 Drilling spools - Flanges
55.0 Hub Clamps
56.0 Shooting Nipple
57.0 Ram Type BOP
58.0 Bag Type Annular BOP
59.0 Choke - Kill lines
60.0 Chiksan - Swivels
61.0 High Pressure Choke Manifolds
62.0 Mud gas separator
63.0 HPP and standpipe manifold
66.0 Accumulator bottles
67.0 Mud Pump Pulsation Dampener
68.0 Mud Pump Pressure Relief Valve
69.0 Mud Flow Line
70.0 BOP Lifting Device
71.0 Air Tanks/Receivers
72.0 Air Safety Valves
74.0 Fall Arrestors and Emergency Escape Devices
75.0 Hazardous EX(e) and EX(d) Equipment
76.0 Gas Cylinders
77.0 BA Cylinders Fiber Glass
78.0 BA Cylinders Steel
79.0 Fire extinguishers
80.0 Gas Detection System
81.0 Spinning wrench
82.0 EZY Torque - Hydraulic Cathead
83.0 Thermography Inspection
1.0 PROCEDURE
The process of equipment integrity inspection is defined as comparison of equipment conformity to predetermined
standards as listed in Abraj Equipment Inspection Matrix followed by determination of action required.
In order to ensure that the integrity of Abraj equipment is maintained to render those as ‘fit for purpose’ at all times
within their given design criteria, the inspection requirements are listed on a matrix called ‘Equipment Inspection
Matrix’ (EIM), provided as Attachment 1 to this procedure. The equipment inspection matrix contents are primarily
based on the requirement of equipment manufacturer and international oilfield standards and practices.
The Maintenance and Assets Manager in Abraj are the custodian of the Equipment Inspection Matrix. Any changes
to the equipment inspection frequency or any other changes to the matrix details will be controlled by Maintenance
and Assets Manager. Any MOCs (Management of Change) or Dispensation requests related to the equipment
inspection matrix or respective procedures will be reviewed by the Maintenance and Assets Manager.
The Abraj equipment inspection matrix, provided in this procedure, defines minimum requirements as well as the
inspection frequencies for Category III /Category IV inspections of the main and critical equipment as well as other
relevant international standards and Abraj internal requirements.
The related detailed procedures contained in the Equipment Integrity Inspection manual define the scope of work
for the required inspections.
Any additional country or contract specific requirements will be incorporated into the Country/Contract Specific
Requirement section of the Inspection Matrix by rig superintendent and will be reviewed and approved by Country
operation Manager accordingly.
The inspection frequencies listed on the Inspection Matrix will apply for the equipment based on the following
criteria:
a. All the hoisting equipment falling under API RP 8B – while the equipment in use
b. All the drill stem components – while the equipment in use
c. Mast, substructure and their accessories – while the equipment in use
d. Raising lines - while the equipment in use, depending on the number of cycles
e. All lifting equipment and lifting gears – according the calendar base
f. All the drilling equipment covered under API RP 7L – If the equipment was not in use ; the age of equipment,
storage/preservation condition, loading happened on the equipment and general condition of the equipment
will be the main criteria to evaluate the inspection frequency bases. The consultancy of Dubai Technical
Operation would be required for each particular case.
g. All the well control equipment – while the equipment in use;
The age of equipment, storage/preservation condition, loading happened on the equipment and general
condition of the equipment will be the main criteria to evaluate the inspection frequency bases in case of no
operational records.
1.4 Inspection Levels
According to international standards and OEM recommendations referred in the inspection matrix, Abraj Equipment
Inspection Levels or Categories are divided as below:
1.4.1 For all equipment falling under the API RP 4G, API RP 8B, API RP 7L and API 53 STD the following
inspection categories shall apply:
a. Category I: This category involves observing the equipment during operation for indications of
inadequate performance. Any equipment found to show cracks, excessive wear etc. must be
removed from service for further examination.
b. Category II: In addition to Cat I inspection, this includes further inspection for corrosion, deformation,
loose or missing component, deterioration, proper lubrication, visible external cracks and adjustment.
Note: Cat I and Cat II inspections are integrated with scheduled preventive maintenance, therefore the
scope of this inspection procedure does not take Cat I and Cat II inspections into consideration.
c. Category III: In addition to Cat-II inspection requirements, this category should include non-
destructive testing (NDT) of exposed critical area may involve some disassembly to access specific
components, and identify wear that exceeds the manufacturer’s allowable tolerances.
d. Category IV: In addition to Cat III inspection requirements, Category IV inspection requires further
inspection for which the equipment is disassembled to the extent necessary to conduct NDT of all
primary load-carrying components as defined by the manufacturer.
a. disassembled in a suitably-equipped facility to the extent necessary to permit full inspection of all
primary-load-carrying components and other components that are critical to the equipment.
b. inspected for excessive wear, cracks, flaws and deformations.
Note:
a. Suitably–equipped facility will include Abraj rig site workshops/ yards where the necessary tools and
equipment can be made available.
b. Prior to Category III and Category IV inspections, all foreign material such as dirt, paint, grease, oil ,
scale etc. must be removed from the concerned parts by a suitable method (eg. paint-stripping,
steam-cleaning, grit-blasting).
1.4.2 For all drill pipes ,BHA and drill string accessories falling under DS–1 Vol. 3 and API RP 7G-2 inspection
standard the following inspection categories shall apply:
a. Category III: Designed for mid-range drilling conditions where a standard inspection Program is
justified. If a failure occurs, the risk of significant fishing or losing part of the hole is considered
minimal.
b. Category IV: This category may be used when drilling conditions are more difficult than category
3.Significant fishing cost or losing part of the hole are in the event of a drill stem failure.
c. Category V: This category applies to severe drilling condition. Several factors combine to make the
cost of a possible failure very high.
1.5 Qualifications for Inspector and Welder
a. Inspector Qualifications
The persons carrying out equipment integrity inspections will be suitably qualified,
In addition, the inspector conducting Category III inspection must possess ASNT Level I Technician certified
per ASNT specification SNT-TC-1A or equivalent.
The supervisor of the inspector must possess adequate knowledge and experience in this field. Typical
persons qualified to supervise the inspection could be an engineer or ASNT Level II Technician certified per
ASNT specification SNT-TC-1A, with the aid of a senior operations person (Senior mechanic, Senior
electrician, and Senior tool pusher) designated by WDI, provided they meet the above stated criteria of
experience, training and knowledge.
The Category IV inspection of the drilling structures will be conducted by or closely supervised by a
Professional Engineer, Original Equipment Manufacturer (OEM) representative or authorized representative
of other manufacturer of drilling structures. In addition that Welds visual inspection shall be conducted by AWS
certified welding inspector or equivalent.
The Category IV inspection qualifications of the other equipment covered in this standard shall have the same
CAT III requirements.
The Country management designated personnel (rig superintendent, operation manager, maintenance
manager) shall be involved in the supervision of the implemented inspection.
All inspectors and supervisors shall be certified by internationally recognized lifting equipment and lifting gear
inspection organization.
The above data will be used by the inspector to adapt respective inspection procedure.
Note: In the absence of critical area drawings, all areas of primary-load-carrying components will be
considered critical.
b. Welder Qualifications
Welders will be qualified to a recognized standard and to the level required for the application (as per ASME
IX or equivalent).
In order to have an overview of the status of the equipment inspections based on the Rig specific equipment
inspection matrix, an Inspection Tracker will be maintained by the Senior Toolpusher.
Equipment integrity inspections will be accompanied with the inspection results printed on Inspection Certificates.
The Inspection Summary / Certificate will contain the following information, as a minimum:
On receipt of the inspection certificates from the inspection company, those will be verified against the contents by
Abraj representative before acknowledging on the certificate.
The filing of the inspection certificates will be carried out in sequential manner and recorded on share point.
The Rig Superintendent will be the custodian of the original inspection certificates and will maintain the OEM
certificates and equipment inspection certificates in the sequence of the Certificates Filing already performed.
The Senior Toolpusher will maintain the copies of the OEM certificates and the copies of inspection certificates in
the same sequence of the Certificates Filing already done.
The Tool Pusher is responsible for ensuring that equipment integrity inspection in the rig is implemented in
accordance with the requirements of these procedure/guidelines. Following all the highlighted technical steps and
frequencies without any deviation.
Drilling Superintendent
To follow up status of the equipment integrity inspection and ensure that all minor and major inspections are being
planned accordingly during the suitable operational timelines, rig moves or annual maintenance plans as per the
roles and responsibilities highlighted in the procedures.
Operations manager
It is the responsibility of the Operations Manager to ensure that all the drilling superintendents are managing their
equipment integrity inspections properly and as per the company policies and procedures.
The Maintenance Manager is responsible to ensure that all the maintenance superintendents are managing their
equipment integrity inspections properly and as per the company policies and procedures; as per the roles and
responsibilities highlighted in the guidelines.
In addition of maintaining the applicable international standards and customer relevant standards compatible with
the company guidelines.
To follow up status of the equipment integrity inspection and ensure that all minor and major inspections are being
planned accordingly during the suitable operational timelines, rig moves or annual maintenance plans as per the
roles and responsibilities highlighted in the procedures.
It is the responsibility of the Preventive Maintenance Engineer to establish, closely monitor and review the
implemented technical procedures in this manual as per the roles and responsibilities and be sure that all
highlighted guidelines are properly performed. Also to highlight any opportunity of improvement for the equipment
inspection process/procedures as per the operational needs.
The chief mechanics and chief electricians are responsible for ensuring that equipment integrity inspection in the
rig is implemented in accordance with the requirements of these procedure/guidelines. Following all the highlighted
technical steps and frequencies without any deviation.
2.0 REFERENCES
2.1.1
Application, Care, and Use of Wire Rope for Oil Field Service
API RP 9B
2.1.2
CAT Category
DS 1 Drill Stem Inspection Standard
Abbreviations
IADC International Association of Drilling Contractors
ID Identification
WP Working Pressure
5. Check the rotary manual lock system (pin and holes) for any damage or cracks
6. Check the backlash and the condition of the sprocket and coupling (perform MPI).
7. Measure the rotary table opening and the master bushing for proper fit and any signs of wear or damage.
8. Check the rotary manual lock system (pin and holes) for any damage or cracks
9. After re-assembly; Check the backlash and the condition of the sprocket and coupling (perform MPI).
10. Measure the rotary table opening and the master bushing for proper fit and any signs of wear or damage.
11. Check the paint condition of the rotary table and skid.
Field Inspection – Cat IV (every 2 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Complete the full Cat III every six months inspection in addition to the following:
1. Fully disassemble the Kelly drive bushing and measure, record all main components highlighted in the CAT III inspection,
and compare measurements with wear limits.
2. Perform MPI on all main items highlighted in the CAT III as per the manufacturer’s specification.
3. Prepare and submit the inspection report.
Inspection Procedure of: Kelly Drive Bushing
Purpose: 6 Months Inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent
Field Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
4. Visually inspect the inner and outer surface areas of the bowl for any burrs and peened-over edges.
5. Clean the inside taper of the insert bowls from any abrasive materials.
6. Hold a straight edge against the tapered area to measure the tapper length (It should be as per the OEM
recommendations).
7. Measure the taper angle & throat diameter and compare with the OEM recommendations.
8. Perform MPI on the recess and load bearing areas of the Drilling Bowls.
10. After completing the inspection, Lubricate the back of the drilling Bowls before assembling in the master
bushing.
11. Observe the height of set slips in the master bushing and ensure that it is not riding low in it (master bushing
can also share the reason).
Scope of work:
1. Full Inspection – Cat IV (every ten years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Preliminary Inspection of Drum Shaft Assembly — Measure Bearing Clearances & existing
Condition of Draw-works. — Report.
32. Install /refit of all guards including new neoprene sponge rubber and gaskets.
33. Prepare and submit the inspection report.
Inspection Procedure of: DC Driven Draw-works
Purpose: 10 years inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work:
1. Full Inspection – Cat IV (every ten years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Preliminary Inspection of Drum Shaft Assembly — Measure Bearing Clearances & existing
Condition of Draw-works. — Report.
Chains
15. Inspect chains for broken links, worn side bars and rollers, missing keepers. Remove chain link if
possible and check for pin grooving. Measure one foot of the appropriate pitch and average the
wear per footage after taking the sag out of the chain or record actual chain sag below.
Recommended chain sag = 2% of the sprocket / shaft centers. Consult NOI Engineering or Service
or FMC Link Belt chain wear chart for maximum allowable chain wear / elongation.
Clutches
16. Low/High Clutch disassembled for inspection
17. Complete overhaul for the Low / High Drum Clutch assemblies including (friction shoes, springs
and diaphragms).
Input Shaft / Main Drive Shaft / Output Shaft / Jack-shaft / Line-shaft /Cat-shaft / Rotary Drive
Countershaft
18. Replace all Bearings; DS and ODS
19. MPI and dimensional check of all shafts ; check for abnormalities /wear or cracks
20. Check / Replace Transmission Shifter Clutches, actuators, Shifter clutches properly centered &
Check Shifter ring lubrication ports properly orientated
21. Visually Check / MPI Sprocket & Coupling condition; replace if required.
22. Check make-up and break out Catheads operation and condition, replace if needed.
23. Visually Check / MPI drive motor couplings; replace if required.
Lubrication System
24. Disassembly / inspections of Lube Pump Assembly
25. Check lubrication system: (Sprockets, chain, spray nozzles, hoses, piping, filters and strainers.)
34. Install /refit of all guards including new neoprene sponge rubber and gaskets
35. Prepare and submit the inspection report.
NOTE: For full disassembly and inspection all shafts, sprockets, bearing housings, clutch components,
load path components and braking system components are to be dimensionally and NDT
inspected and results recorded on component part inspection drawings & forms.
Inspection Procedure of: DW Brake Bands
Purpose: 5 years inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
2. Completely disassemble the brake system and measure and record all items and compare with wear
limits.
3. Perform NDT/MPI on all main components (dead and live end) and all connecting items such as
brackets (including pins and holes), extension rods, equalizer beam with pins and brackets, eye bolts,
bearing blocks (including the fastening bolts and nuts).
4. Visually check the brake rims for grooving defects, uneven wear or cracks as per IADC drilling
manual, Chapter F, figure F-1. Measure and record the wear, brake rim and water jacket thickness.
5. Replace all fastener bolts and nuts.
6. Replace all brake linkage bearings.
7. Replace brake lining shoes.
8. Reassemble all items and repaint as required.
9. Use the OEM procedure for burnishing the newly installed brake lining shoes.
10. Prepare and submit the inspection report.
Inspection Procedure of: DW Brake Bands
Purpose: 6 Month inspection (Field inspection)
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
3. Check the hoses for damage, cracks, rubber condition, cuts, gouges or wear.
5. Perform MPI/Liquid penetrant on all welded areas, end connections, couplings area and safety clamps.
7. Pressure test shall be performed on the hose using water and to a value equal to the 1.25 of the maximum rated working
pressure.
8. Prepare and submit the inspection report.
Inspection Procedure of: Power Tongs
Purpose: 1 Year Inspection
Reference: OEM manual
Responsibility: Rig Manager, Drilling Superintendent
Field Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Visually Check power tong for oil/air leaks and verify all hoses and connections condition.
2. Visually check air/hydraulic motor, gear case, hydraulic cylinder, air actuator and roller assembly for any damage or wear.
3. Measure and record all critical accessible components and compare them to the OEM limits.
4. Perform MPI on all critical /accessible load-bearing areas including pivot pins, die/claw assemblies, hanger and tong line
retainers/connections.
5. Check the condition and the traceability of the OEM nameplate.
6. Prepare and submit the inspection report.
Inspection Procedure of: Power Tongs
Purpose: 2 Years Inspection
Reference: OEM manual
Responsibility: Rig Manager, Drilling Superintendent
Full Inspection – Cat IV (every 2 Year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Perform the field CAT III inspection, in addition of the next steps.
2. Completely disassemble the power tong components and clean all components for detailed inspection.
3. Measure /record and MPI all critical accessible components and compare them to the OEM acceptance limits.
4. Replace all bearings, seals, hoses ,dies and rollers with new ones.
5. Overhaul the main hydraulic /air motors
6. Check the condition and the traceability of the OEM nameplate.
7. Repaint the power tong.
8. Prepare and submit the inspection report.
Inspection Procedure of: MP
Purpose: 8 years inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work:
1. Full Inspection – Cat IV (every eight years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Complete Disassembly all pump parts
• Remove belt/chain guard assemblies
• Remove pulley/sprocket drive
• Remove the taper bushing
• Remove the drive motor assembly
• Remove pinion shaft.
• Remove crankshaft from mud pump main frame.
• Remove the crossheads and connecting rods.
3. Sand blast mud pump main frame
4. MPI inspection to be carried out on crankshaft, bull gear, pinion shaft, pinion gear and connecting
rods.
5. Dimension inspection on big and small ends of connecting rods.
6. Replace pony rods and crossheads.
7. Replace the crankshaft main bearing.
8. Replace pinion shaft bearing.
9. Replace connecting rods bearings.
10. Replace crossheads bearings.
11. Replace all upper and lower crosshead guides.
12. Remove internal/external lube system and lubrication lube pipe work for inspection.
13. MPI inspections on main bolts, taper bushings, pulleys/sprockets and mud pump frame weld areas.
14. MPI inspections suction manifold, discharge manifolds, Modules, block and HP lines.
15. Clean out mud pump internally and oil contamination settling chamber and liner flush chamber
16. Reassemble adjusting shimming and alignment of Crankshaft and Pinion Shaft assemblies
17. Fluid penetration inspection for fluid ends.
18. Replace valves, seats, springs and inserts.
19. Paint as required.
20. Prepare and submit inspection reports and dimensional reports.
Inspection Procedure of: Instrumentation -Gauges
Purpose: 1-year inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Chief Electrician, Electrical PME, Electrical Superintendent.
Critical gauges and instrumentation are defined as those that could have a detrimental effect on the rig
operations or can cause unsafe situations, in the event of their failure or incorrect use. As a minimum, the
following gauges and instruments are deemed critical and will be covered in this policy.
1.5 Tools
a. All electric meters including digital/analogue multi meters, meggers , frequency meters….etc.
b. Torque wrenches
2. Technical Guidelines
Any critical instrument or gauge that is found to be out of calibration or defective will be replaced. The faulty
equipment will be returned to an approved repair facility for recalibration or replaced with new, as economically
viable. Repair/ replacement will be recorded on the Critical Instrumentation Calibration Log.
Note: Normally, this type of gauge is calibrated to display a ft-lb display taking the lever arm of the
tong into consideration.
2. Multiply the weight of the known item by the length of tong as displayed on the gauge
readout (ie: 12,000lbs X 3ft = 36,000 ft-lbs).
3. Ensure the gauge readout, after the necessary calculations are completed, is identical
to the known weight of the hoisted equipment.
2.2.1.3 Rotary Table and/or Top Drive Torque Indicator Package
i. Clamp the make-up tong to a joint of drill pipe previously fitted into the TD.
ii. Use the Top Drive or Rotary Table to apply a held torque of 20,000 ft/lbs as shown on the
TD or Rotary gauge.
iii. Verify that the rotating equipment torque display reads the same as the previously verified
tong torque display. (+/- 1%)
a. Using a hydraulic hand pump, with a certified gauge of equal or nearest scale tee’d in the outlet,
pressurize each choke control and BOP closing unit gauge in sequence.
b. Ensure the panel mounted gauge(s) match the certified gauge in the hand pump outlet port
throughout the gauges’ full range of travel.
a. Upon completion of the electrical installation of the level sensors, verify that a reading is
available at the drillers console for each unit.
b. Simulate a change in depth of reading by:
i. Float style sensor – manually raising and lowering the float
ii. Sonar style sensor – providing a manual target for the sensor to read and different levels.
c. Confirm that the readings for each sensor change relative to the simulated depth of fluid change.
a. With a calculated and known amount of fluid in the tank(s), verify that the drillers display
corresponds with the amount of fluid in the tank(s).
b. Verify that each sensor for each pit is working accurately.
Manually activate the paddle rheostat on the sensor from 0 to full and verify that the drillers display
shows a reflective reading throughout the full sweep of the paddle.
2.2.6 Tools
This standard will be applicable to all drilling rigs, new rigs and under commissioning stacked rigs and is
inclusive but not limited to SCR/VFD circuit breakers, transformers and MCC at all sites.
Field Inspection – Cat IV (every 5 Years): To be performed by accredited third party, approved by Abraj technical
authority”
1- Preparation should be made to ensure that all documentation are ready like the manufacturers literature and
recommendation, TRA, PTW and electrical isolation, lock out/tag out system.
2- Ensure that all circuit breaker receives no electrical power and that all loads are disconnected electrically and
mechanically.
a. The circuit breaker should be removed from the equipment for this test. In cases where the Circuit Breaker
can be safely isolated as installed, the test may be performed with the circuit breaker in its equipment.
b. Inspect the breakers physically and check conditions of connections.
c. Set up the test unit for insulation resistance test.
d. Set up the test unit for primary injection test.
e. Test the unit by injecting current at 150, 300 and 600 %.
f. For every setting, record the value of tripping time and then compare it to the manufacturer’s current time
characteristics.
g. If the tripping time is not within the manufacturer’s specified limits as indicated by the time current curve,
then it should be defective or latching device may be damaged.
h. If the tripping time is within the limits, then the units should be returned and ensure that all termination
was OK.
Guidelines
1- Insulation Resistance Test: Apply 500VDC line and load terminals with the circuit breaker in OFF
position and tripped position. Between phases of the breakers and phases to ground with the circuit
breaker in ON position. All reading should be one megohm or greater for each measurement. Values
below 1 megohm are considered unsafe hence breaker should be inspected for possible
contamination on its surfaces, flawed or cracked insulating material.
2- Milivolt Drop Test: It can disclose some abnormal conditions such as eroded contacts, contaminated
and or loose connections. Millivolt should be compared against manufacturer’s data. Use a 24 Volt
or less DC power supply capable of supplying rated circuit breaker current.
a. Apply a test current for not more than 1 minute across a pole equal to the breaker rating or 500
amp minimum for breaker in excess of 500 amperes. Record the mv drop and test current.
b. Repeat for a total of three readings on the pole being tested.
5- Manufacturer’s recommendation and current time characteristics curve should always be consulted for each
unit.
6- All test equipment should comply with IEC 60947-2 standard, IEEE43-2000 and IEEE 1458-2005.
7- All circuit breaker within a range of 1000Amp to 2000 Amp, should be identified and will be scheduled to have
the test done as stated in the procedure below.
8- All works will be carried out safely. Particular attention is drawn for below requirements.
Field Inspection – Cat III (every one year): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
1. Visually inspect all the unit fasteners and fittings for tightness, damage or corrosion.
2. Visually inspect all the pins/holes (bearing movement areas), pivot connections and control mechanisms for
excessive wear.
3. Visually inspect the skate, trough, trough track, trough leg, Kickers, indexers and safety pins for any damage,
deformation or excessive wear.
4. Visually inspect all drive sprockets and chains for excessive wear and stretch.
5. Extend all cylinders (including indexers and kickers cylinders) and visually inspect the chrome surface for any
pitting or excessive wear condition.
6. Conduct a thorough examination on all the lifting gears and wire ropes components.
7. Conduct a thorough examination on the trough / skate winches and check for the proper operation and
condition of the clutches, integral brakes, linings, pawls & ratchets.
8. Visually inspect all the accessible weld and critical area members in the catwalk structure & the hydraulic
system
9. Visually inspect all hydraulic hoses for damage, kinks, cuts reaching the internal wire layer of the hoses &
replace if necessary.
10. Prepare and submit the inspection report.
Inspection Procedure of: Hydraulic Catwalk
Purpose: 5 Years Inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Field Inspection – Cat III (every one year): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
1. Visually inspect all the unit fasteners and fittings for tightness, damage or corrosion.
2. Visually inspect all the pins/holes (bearing movement areas), pivot connections and control mechanisms for
excessive wear.
3. Visually inspect the tubular loading system including the pipe support, ejector mechanism, transfer arms, pipe
stoppers and tilting pistons for any damage, deformation or excessive wear.
4. Visually inspect the entire arm major components including pipe supports, clamps, jaws, funnels, top springs
and supporting beams for any damage, deformation or excessive wear.
5. Extend all cylinders (main lifting and auxiliary) and visually inspect the chrome surface for any pitting or
excessive wear condition including.
6. Visually inspect all the accessible weld and critical area members in the pipe arm and loading system structure,
frames, bracing & hydraulic system
7. Visually inspect all hydraulic hoses for damage, kinks, cuts reaching the internal wire layer of the hoses &
replace if necessary.
8. Visually check the condition electrical cables, plugs and junction boxes mounted on the unit.
9. Prepare and submit the inspection report.
Inspection Procedure of: Pipe Arm
Purpose: 5 Years Inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Full Inspection – Cat VI (every 3 years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
A thorough visual inspection of all load bearing members, welds and pickup points must be conducted to
determine the condition of the mast and substructure.
All repairs to major damage require supervision of a Professional Engineer or an OEM agent. Repairs to minor
damage may be completed by operating personnel, after consulting with the Field Support Manager, and do not
require certification. If there is any question as to whether the damage is major or minor, a Professional
Engineer or OEM agent shall be consulted.
Check the condition and content of the manufacturer’s name plate.
Prepare and submit the Inspection report.
* By possession of a recognized degree, certificate, or professional standing, or who by knowledge, training, or
experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject
matter, the work, or the subject. Inspectors should be familiar with the type of equipment to be evaluated.
* Welders - Typical persons qualified to supervise the inspection could be an engineer, NDT technician, ASNT
Level II Technician certified per ASNT specification SNT-TC-1A, or a senior operations person (Rig
Superintendent, Rig Manager, or Operations Management), designated by the owner/user company or others,
provided they meet the above criteria of experience, training and knowledge.
It is recommended that at the time of the inspection all damaged sections are marked clearly and visibly so that
needed repairs can be identified. When repairs are made, the visible markings should be removed by painting. It
is also necessary for the inspector to write "None" when no damage marks are needed, as this is his indication
that the item has passed inspection. Below is the checklist of thorough visual inspections needed to be carried
out on the mast and substructure (according to API 4G).
MAST
1. Legs
a. Front Leg DS
Symmetry Acceptable:
Symmetry Acceptable:
c. Rear Leg DS
Symmetry Acceptable:
Visible damage Acceptable:
Pin condition Acceptable:
Symmetry Acceptable:
Symmetry Acceptable:
Symmetry Acceptable:
Straightness Acceptable:
4. Feet Or Pivots
Welds Acceptable:
7. Ladders
Rungs Acceptable:
Cage Acceptable:
a) Hydraulic System
Raising ram condition Acceptable:
Hose and hose ends Acceptable:
Connections Acceptable:
Turnbuckles Acceptable:
Pins Acceptable:
Safety pins/keepers Acceptable:
Seats Acceptable:
Mechanism Acceptable:
Guides Acceptable:
Sheaves/shafts Acceptable:
Welds Acceptable:
Number of visible marks applied
11. Miscellaneous Sheaves Assemblies
Clevis/shackle Acceptable:
Sheaves Acceptable:
Bearings Acceptable:
Shafts Acceptable:
SUBSTRUCTURE
1. Shoes
Pins/bolts Acceptable:
Welds Acceptable:
2. Floor Area
Floor plates Acceptable:
Handrails & toe boards Acceptable:
Spreaders Acceptable:
Pins Acceptable:
Pad-eyes Acceptable:
Welds Acceptable:
Supports Acceptable:
Bolts Acceptable:
Flooring Acceptable:
Handrails Acceptable:
Welds Acceptable:
Pin/bolts Acceptable:
Welds Acceptable:
BOP anchor pad-eyes Acceptable:
Pad-eyes Acceptable:
6. Raising System
Pins Acceptable:
Sheaves Acceptable:
Bearings Acceptable:
Seals Acceptable:
• Any damage found during the inspection is defined as MAJOR, SECONDARY, or MINOR, on the following basis.
It is recommended that at the time of the inspection all damaged parts are marked clearly
and visibly so that needed repairs can be identified. When repairs are made, the visible
markings should be removed by painting. It is also necessary for the inspector to write
"None" when no damage marks are needed, as this is his indication that the item has
passed inspection.
Frame Straight:
Pin Hole(s):
Pins:
Safety Pins/Keepers:
Frame Welds:
Working Platform:
Landing Platform:
Handrails:
Ladder Access:
Fingers Straight:
Finger Welds:
Hoist Mounting:
2. Casing Stabbing Board:
Frame Straight:
Welds:
Handrails:
Working Platform:
Hoisting Assembly:
Hoist Mounting:
Pins or Bolts:
Safety Pins/Keepers:
Welds:
Handrails:
Pin Holes:
Pins:
Safety Pins/Keepers:
Support Cables:
Cable Connections:
Inspection Procedure of: Raising cylinders
Purpose: 5 years inspection
Reference: OEM manual / API RP 4G
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
1. Prepare and make ready the OEM Manual and drawings of the raising cylinder under inspection, it must be
used as the main guide line in all the following steps
2. Check Nameplate condition of the raising cylinder assembly and verify Specs, serial number, and record
serial number on the inspection report/certificate.
3. Inspect outside body of the cylinder for impact damage, cracks or oil leaks.
4. Extend the cylinder without carrying any load, and visually inspect the ram chroming surface for any pitting,
wear, cracks, distortion or damage.
5. Measure the OD of the different rods and check if we have any wear or over dimension in any surface
Measurement should be done all over the length of the rods “10 different points each” and to be measured
on two quadrants 90 degrees apart from each other
6. Perform NDT /liquid penetrant or MPI on the rods, cap ends, pad eyes
7. Measure the rod and cap ends eyes for any ovality or excessive wear
8. Function test the hydraulic cylinder (extend and retract) and check for any jerking motion or improper
function to be ensure that there is no internal leaks , and that counterbalance valves are working properly.
Inspection Procedure of: Crown Block
Purpose: 5 years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
(Best Performed in Rig Move or slip and cut). Drawworks must be isolated and the travelling block must be
hung off in order to check the following tasks.
1. Prepare and make ready the OEM Manual and drawings of the crown block under inspection, it must be
used as the main guide line in all the following steps
2. Check Nameplate condition of the crown block assembly and verify Specs, serial number, and record serial
number on the inspection report/certificate.
3. Visually inspect sheave cluster for even gaps between sheaves. Use a pry bar to check for side-to-side
movement of each sheave. Recommend that a maximum of 0.100” (2.4 mm) be allowed at the perimeter of
the sheave when testing the side wobble on crown block sheaves. (please refer to crown block OEM
manual for confirmed maximum limit) use no more than 10 LBS force on the sheave perimeter when
testing the bearing clearance.
4. Measure and record side movement on sheave #1, measurement records to be attached on sap.
5. Measure and record side movement on sheave #2, measurement records to be attached on sap.
6. Measure and record side movement on sheave #3, measurement records to be attached on sap
7. Measure and record side movement on sheave #4, measurement records to be attached on sap
8. Measure and record side movement on sheave #5, measurement records to be attached on sap
9. Measure and record side movement on sheave #6, measurement records to be attached on sap
10. Measure and record side movement on sheave #7, measurement records to be attached on sap
11. Measure and record side movement on sheave #8, measurement records to be attached on sap
12. Measure and record side movement on sheave #9, measurement records to be attached on sap
13. Check and record all sheave grooves and rims wall thickness, against OEM wear limits and API Spec 8C
requirements.
14. Check sheave groove and web surfaces for any cracks and deformities ;( perform MPI on the sheaves
grooves if job is performed during rig move).
15. Verify crown sheave center pin retaining bolts are tight and have secondary retention devices installed.
16. Visually check all crown cluster including fast line, frame and bumper blocks fasteners for tightness and
ensure secondary retention devices are installed.
17. Check the crown cluster /fast line pedestal, jumper bars, covers and all frame welds for any cracks or
deformation (Perform MPI/Liquid penetrant if job is planned during a rig move).
18. Check for bearing wear by running the blocks up and down at controlled high speeds. Verify there is no
wobble or unusual noise coming from the sheave bearings. Monitor the bearing noise with a stethoscope.
Make sure that the guard is in place before doing this and that the KEMS and ACS are operational
19. Prepare and submit the inspection report.
Inspection Procedure of: Travelling Block
Purpose: 5 years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
• Hook Assembly
1. Fully disassemble the hook and clean all individual items. Mark or document the position of all components.
2. MPI the hook assembly/main shaft, rod hook clevis, bail arm assemblies, swivel case, spring, spring retaining
ring, follower, bonnet and any other load bearing components. Mark any cracks, damage, deformation or
discontinuities found on the items.
3. Measure and document the wear of the hook, main shaft, swivel case, rod hook clevis, bail arms and any
pins/holes. Reject and replace any items with wear exceeding 5% of the original dimensions.
4. Reassemble the hook with new thrust bearing, case bushing, hook retaining ring and bonnet retaining ring.
5. Visually check for any missing locking pins, nuts, locking mechanisms, snap rings of hook/attachments after
reassembly.
6. Check the condition and content of the nameplate, traceability information, and serial number.
7. Prepare and submit the final /consolidated inspection report.
Inspection Procedure of: Travelling Block
Purpose: 6 Months Inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
(Best Performed in Rig Move or slip and cut). Drawworks must be isolated and the travelling block must be
hung off in order to check the following tasks.
1. Conduct API Category III inspection of the travelling block assembly. (MPI/Liquid Penetrant on exposed
critical areas – clevis /becket, adapters, latches and top cover/bonnet; if job is performed during rig move).
2. Visually inspect sheaves for even gaps between each sheave. Use a pry bar to check for side-to-side
movement of each sheave. Recommend that a maximum of 0.100” (2.4 mm) be allowed at the perimeter of
the sheave when testing the side wobble on travelling Block sheaves. Use no more than 10 LBS force on the
sheave perimeter when testing the bearing clearance.
3. Measure and record side movement on sheave #1 measurement to be recorded in separate excel file and
attached in sap for Related equipment
4. Measure and record side movement on sheave #2 measurement to be recorded in separate excel file and
attached in sap for related equipment
5. Measure and record side movement on sheave #3 measurement to be recorded in separate excel file and
attached in sap for related equipment
6. Measure and record side movement on sheave #4 measurement to be recorded in separate excel file and
attached in sap for related equipment
7. Measure and record side movement on sheave #5 measurement to be recorded in separate excel file and
attached in sap for related equipment
8. Measure and record side movement on sheave #6 measurement to be recorded in separate excel file and
attached in sap for related equipment
9. Measure and record side movement on sheave #7 measurement to be recorded in separate excel file and
attached in sap for related equipment
10. Check sheave grooves for excessive wear. Use a groove gauge. Measurement to be recorded in separate
excel file and attached in sap for related equipment
11. Check sheave groove and web surfaces for any cracks and deformities.
12. Verify travelling block sheave pin retaining bolts are tight and have secondary retention devices installed.
13. Visually check all travelling block clevis and associated pins and fastenings for tightness and ensure
secondary retention devices are installed.
14. Visually inspect the sheave guard for wire grooving, cracks and general integrity.
15. Take picture as evidence & attach to the work order.
6 Months inspection Of MCKISSICK Hook/ Block (Applicable for H001, H002 and H003)
1. Conduct API Category III inspection of the travelling block assembly. (NDT on exposed critical areas).
2. Visually inspect sheaves for even gaps between each sheave. Use a pry bar to check for side-to-side
movement of each sheave. Recommend that a maximum of 0.100” (2.4 mm) be allowed at the perimeter of
the sheave when testing the side wobble on travelling Block sheaves. Use no more than 10 LBS force on the
sheave perimeter when testing the bearing clearance.
3. Measure and record side movement on sheave #1 measurement to be recorded in separate excel file and
attached in sap for Related equipment
4. Measure and record side movement on sheave #2 measurement to be recorded in separate excel file and
attached in sap for related equipment
5. Measure and record side movement on sheave #3 measurement to be recorded in separate excel file and
attached in sap for related equipment
6. Measure and record side movement on sheave #4 measurement to be recorded in separate excel file and
attached in sap for related equipment
7. Measure and record side movement on sheave #5 measurement to be recorded in separate excel file and
attached in sap for related equipment
8. Measure and record side movement on sheave #6 measurement to be recorded in separate excel file and
attached in sap for related equipment
9. Measure and record side movement on sheave #7 measurement to be recorded in separate excel file and
attached in sap for related equipment
10. Check sheave grooves for excessive wear. Use a groove gauge. Measurement to be recorded in separate
excel file and attached in sap for related equipment
11. Check sheave groove and web surfaces for any cracks and deformities.
12. Verify travelling block sheave pin retaining bolts are tight and have secondary retention devices installed.
13. Visually check all travelling block clevis and associated pins and fastenings for tightness and ensure
secondary retention devices are installed.
14. Visually inspect the sheave guard for wire grooving, cracks and general integrity.
15. Take picture as evidence & attach to the work order.
Hook Assembly
1. Visually check the hook body and other load bearing items (bail arms, hook, rod hook clevis and all relevant
pins/bolts) for any damage or deformation.
2. If any initiation of cracks or deformation found on the load bearing areas. Further MPI is recommended.
3. Visually check for any missing locking pins, nuts, locking mechanisms, snap rings of hook/attachments and
check for any loose items.
4. Measure and document the wear of the hook, rod hook clevis, bail arms and any excessive play in
pins/holes. Reject and replace any items with wear exceeding 5% of the original dimensions.
5. Check the shank spring closing gap and the swivel rotation of the hook.
6. Check the condition and content of the nameplate, traceability information, and serial number.
7. Prepare and submit the final /consolidated inspection report.
Inspection Procedure of: Gooseneck Assembly Inspection
Purpose: 2 years inspection (Field inspection)
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
NOTE: Any indications found are a potential cause for replacing the suspect component.
Inspection Procedure of: VARCO TDS 10 SH
Purpose: 5 years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
NOTE: Any indications found are a potential cause for replacing the suspect component.
Inspection Procedure of: TESCO Top Drives (EMI 400 HP - EXI 600HP)
Purpose: 5 Years Inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Any indications found are a potential cause for replacing the suspect component. round bottom pits and
erosion are acceptable if the defect is less than 1/16 in. deep. larger defects or any crack indications are a
cause for replacing the suspect component.
Inspection Procedure of: CANRIG 1235AC-500 / CANRIG 1035AC-500
Purpose: 5 Years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
NOTE: DETAILS ON MPI INSPECTION PROCEDURES ARE IN THE FOLLOWING PUBLICATIONS: ASTM A-275, STANDARD
METHOD FOR MAGNETIC PARTICLE INSPECTION OF STEEL FORGINGS; ASTM E-709, STANDARD RECOMMENDED
PRACTICE FOR MAGNETIC PARTICLE INSPECTION; I.A.D.C., DRILLING MANUAL, 9TH EDITION
Inspection Procedure of: Links
Purpose: 6 Months inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent
A- Top Bore ID
B- Bottom Bore ID
C- Hinge Pin Hole ID Top
D- Hinge Pin Hole ID Bottom
E- Body Latch Pin Holes ID (Record the largest one)
F- Latch Pin OD (Record the smallest)
G-Hinge Pin OD (Record the smallest)
H- Taper Angle
I- Hinge Pin Hole ID
J- Door Ear Radii
K- Body Ear Radii
Full Inspection – Cat IV (every 1 Year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Complete the full Cat III every six months inspection in addition to the following:
Field Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
1. Disassemble the units as far as necessary and possible and clean all single parts.
2. Check all components visually for any cracks, damage and bends.
3. Perform MPI on hinged connections, body (inside and outside) including guide pin cases, guide halves, slip hangers, slips
and top cover halves.
4. For Spiders: Visually check for damage and wear on the yoke assembly, slip lock assembly, body (inside and outside),
door, door pins, guide plate assemblies, hinge pins, insert retainers, link blocks with link block pins, slips and dovetail slots.
MPI body (inside and outside), yoke, slips, hinge connections, door, door pins, guide plate assy. and link blocks.
5. Check condition and details of the manufacturer’s name plates.
6. Assemble the units and refurbish painting and marking as required.
7. Prepare and submit the inspection report.
Inspection Procedure of: Kelly Spinner
Purpose: 5 Years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
5. Fully disassemble the dead line anchor; and carry out a complete MPI and dimensional inspection on the
shaft, lock nut, cap, hub and drum /grooves.
6. Reassemble the deadline anchor using new bearings, seals, lock washers, snap rings, mounting bolts and
bronze inserts.
7. Ensure that all the bolts, washers, nuts and locking pins are intact, in place and in a good condition.
8. Visually check the load cell, load cell mounting and pins for any damage, leak; and use the correct clearance
gauge to check for proper installation.
9. Recharge with instrument fluid and verify the weight indicator reading Vs the actual dead load.
5. Use a pry bar to check for the drum wobbling or excessive play.
6. Ensure that all the bolts, washers, nuts and locking pins are intact, in place and in a good condition.
7. Visually check the load cell, load cell mounting and pins for any damage, leak; and use the correct clearance
gauge to check for proper installation.
8. Recharge with instrument fluid and verify the weight indicator reading Vs the actual dead load.
2. Prepare lifting plug or sub for MPI (remove paint etc.). Visually check the body, thread and lifting bail (if applicable) for any
damage wear or cracks.
3. Perform MPI on thread and bail welding area (if applicable).
4. Measure and record threads, ID of pin, lifting plate diameter, check for pin stretching.
5. Check the serial numbers.
6. Prepare and submit the inspection report.
Inspection Procedure of: Utility Winch
Purpose: 1 Year Inspection
Reference: OEM manual /ASME B30.7
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Full Inspection (every one year) By a Qualified Inspector: To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Isolate the winch by shutting off the air, unwind the winch line from the drum and inspect the line visually
for any kinks, broken lines and other damage.
2. Remove the winch from the foundation plate or mounting brackets.
3. Visually check all outside parts of the winch (including the spooling device and control valves) for proper
installation and any damage or wear.
4. Perform MPI and visual inspection on the brake band and associated components.
5. Perform MPI and visual inspection on winch connecting points to the mounting bracket or plate, bolts, clamp
area etc. as per manufacturer’s recommendation.
6. Check the condition and details of the manufacturer’s name plate.
7. Ensure the SWL is clearly marked.
8. Perform MPI on the turndown sheave attachment point in the mast.
9. Perform inspection on all line attachments (turndown sheave, shackles, swivels etc.).
10. Reinstall the winch.
11. Carry out load test (to the SWL).
12. Prepare and submit the inspection report.
Inspection Procedure of: Man Riding Winch
Purpose: 1 Year Inspection
Reference: OEM manual /ASME B30.7
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Full Inspection (every one year) By a Qualified Inspector: To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Isolate the winch by shutting off the air, unwind the winch line from the drum and inspect the line visually for
any kinks, broken wires and other damage.
2. Remove the winch from the foundation plate or mounting brackets.
3. Disassemble the complete winch including drive components.
4. Visually check all outside parts of the winch (including the spooling device and control valves) for proper
installation and any damage or wear.
5. Visually check and MPI the brake band components and mechanism for wear or damage.
6. Perform MPI and visual inspection on winch connecting points to the mounting bracket or plate, bolts, clamp
area etc. and on all main components as per manufacturer’s recommendation.
7. Check condition and details of the manufacturer’s name plate.
8. Repaint the winch (including the SWL marking) as required.
9. Reinstall the winch.
10. Carry out load test (to the SWL).
11. Prepare and submit the inspection report.
Inspection Procedure of: Swivel
Purpose: 5 Years inspection
Reference: OEM manual / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
2. Tool Joint
a. Perform a dimensional inspection on the tool joints including but not limited to
i. Box OD
ii. Pin ID
iii. Box shoulder width
iv. Tong Space
v. Box and pin thread profiles for pin stretch or box swell checks
vi. Box counterbore depth
vii. Box counterbore diameter
viii. Bevel diameter
ix. Box depth – Pin length –Pin nose diameter (for the proprietary connections)
b. Visually inspect the connections for pitting, corrosion, cracks, refacing and box hardbanding condition (No refacing
for the double shoulder connections to be done without benchmarking or in field).
c. Visually inspect the secondary shoulder area condition (for the proprietary connections).
d. Visually inspect the threads (roots, flanks) for any pitting, corrosion, galling, crack or damage.
e. Perform a black light inspection on the pin and box areas for transversal cracks and heat checking.
3. Pipe body
a. Visually inspect the pipe tube for pitting, excessive corrosion, cuts and straightness.
b. Check OD of the pipe tube and compare it with the minimum standard requirements.
c. UT the wall thickness of the pipe body (at the center of the tube and all defected area).
d. Full body EMI log (buggy) checking for cracks and discontinuities.
e. Perform MPI on the slip/upset area covering at least (48” from the pin shoulder and 48” from the box shoulder).
f. Check the condition of the internal plastic coating and classify it as per DS 1; condition 1 to 4 (Condition 4 is a cause
of rejection while condition 3 has to be closely monitored in the next inspection by full endoscope to check coating
deterioration as per DS1 Vol3 Addendum 2 guidelines).
g. Mark pipes with the required API color code.
h. Hard stamp each pipe on the pin 18deg taper, with the qualified inspector’s name and date.
i. Submit detailed inspection report.
Inspection Procedure of: Bottom Hole Assembly and Drill String Accessories
Purpose: 25/450 Hours inspection
Reference: OEM manual / DS 1 Vol3
Responsibility: Rig Manager, Drilling Superintendent
2. Connections
a. Perform a dimensional inspection on the tool joints ,including but not limited to
i. Box OD
ii. Pin ID
iii. Box shoulder width
iv. Tong Space
v. Box and pin thread profiles for pin stretch or box swell checks
vi. Box counterbore depth
vii. Box counterbore diameter
viii. Bevel diameter
ix. Pin stress relief groove
x. Boreback
xi. Shoulder flatness
xii. Box depth – Pin length – Pin nose diameter (for the proprietary connections)
b. Visually inspect the connections for pitting, corrosion, cracks, refacing and box hardbanding
condition (No refacing for the double shoulder connections done without benchmarking or in
field).
c. Visually inspect the secondary shoulder area condition (for the proprietary connections).
d. Visually inspect the threads (roots, flanks) for any pitting, corrosion, galling, crack or damage.
e. Perform a black light inspection on the pin and box areas for transversal cracks and heat
checking.
3. Body
a. Visually inspect the body for pitting, excessive corrosion, cuts and straightness.
b. Check the HWDP center upset OD (If applicable).
c. Check the drill collar elevator and slip grooves (If applicable).
d. Check the subs length (shoulder to shoulder) and compare them with the minimum standard
requirements.
e. Perform an MPI on the subs outside diameter.
f. Mark the individual items according to the given color code.
g. Grease the equipment and install thread protectors.
h. Prepare and submit the inspection report.
The IBOPs, Kelly Valves & Full Open Safety Valves (every 6 Months)
1. Identify (together with the STP or Worksite Supervisor in charge) all pad eyes, slings, lifting devices, spreaders,
sheaves and shackles that are due for inspection.
2. Make sure that all items are registered and marked with individual identification numbers as per the worksite
lifting gear register.
3. Visually check all items for damage, cracks, corrosion or wear.
4. Visually inspect all lifting slings for kinks, broken strands and wires.
5. Visually inspect all shackles for crack, twist, bending, excessive opening, pin and nut condition, holes
diameters, holes alignment.
6. To identify possible fractures if considered suspect; carry out NDT (liquid penetrant is preferable) on pad eyes
welds.
7. Check pad eye width and hole diameter for compatibility with the appropriate shackle (refer to drawing STD-
0171-00 in BMS 05.1-ES-0026)
8. Mark all slings, pad eyes and shackles according to the dedicated color code system.
9. Repaint as required.
10. Grease and lubricate as required.
11. Prepare and submit the inspection report.
Inspection Procedure of: King Pin Assembly
Purpose: 1 Year Inspection
Reference: SAE J 2228
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Field Inspection – Cat IV (every 1 Year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Visually check the king pin, fifth wheel and mounting frame and bolts for any damage, cracks, corrosion or wear.
2. Measure dimensions of king pin and compare with the specified wear tolerances from the manufacturer.
3. Perform MPI on the king pin (retention plate and skid plate welding), fifth wheel and related mounting brackets.
4. Grease the items as required.
5. Prepare and submit the inspection report.
Inspection Procedure of: Personal Basket
Purpose: 4 Years Inspection
Reference: OEM manual / BS 5655-10.2.1
Responsibility: Rig Manager, Drilling Superintendent
1. Complete the full every six months inspection in addition to the following:
3. Perform wall thickness measurement of the basket frame and floor plate and fixing points of the railing
(minimum three points per meter).
1. Visually check the basket (including railing and floor plate) for any damage, corrosion or cracks.
2. Remove the paint from the critical welded areas (main frame, floor plate and bottom part of railing etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on the lifting eye and lifting sling (if applicable).
5. Repaint as required.
6. Prepare and submit the inspection report.
Inspection Procedure of: Crane Hooks
Purpose: Yearly Inspection
Reference: OEM manual / ASME B 30.10
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Perform a complete tool teardown to inspect for any component damage and allow for re-
lubrication of all CRT components as described below two steps below.
Remove and inspect the Upper Cam Housing.
Unthread and remove the Intermediate Cam from the Upper Cam. Check the threads and
ramps for any signs of damage.
Unthread and remove the Upper Cam from the Mandrel.
Visually inspect the threads, ramps and J-hooks for any signs of damage.
Note and record the lug adjustment (number of lugs the Upper Cam is rotated back from the
shouldered position) when disassembling the tool and always follow the cam adjustment
procedure in the assembly manual when reassembling the tool.
Remove and visually inspect the Lock Sleeve and the Mandrel.
Separate the Cam Latch from the Lower Cam by removing the Lug Latches, Pin Latches, and
the alignment bolts
Carefully remove the Latch Keys, Spring-Latch and End Ring from the Cam Latch.
Remove the Spiral retaining ring using the Belleville installation tool and remove the Belleville
springs.
Fully clean the CRT, prepare for painting, and paint as per OEM specifications.
Ensure that alignment marks are visible and clear, and repaint the alignment marks as necessary.
Remove all of the tape masking and visually inspect all of the surfaces to ensure that there are no tools
or loose items left on the equipment.
Clearly mark the CRT by a system that identifies the equipment status (e.g. tagging system).
Reassemble the tool per the instructions in the CRT assembly manual.
Lubricate all areas of the tool according to the lubrication guidelines in the OEM manual.
Install and grease the bowl per the specifications in the OEM manual.
Raise the CRT and place the bowl below it.
Lower the CRT onto the bowl making sure it is centered and that the tabs on the tool line up with the slots
on the bowl.
Lower the CRT until it is resting on the bowl and spin the CRT until it is past the lock plate.
Install the lock pins into the lock plate, raise them, turn the lock pins in, and push the keeper down.
Lay the CRT back down and put it back into the transport frame.
Ensure that the tool has gone through the full maintenance, inspection, and repair (MIR) process, by
referring to the latest MIR guideline shown below.
Identify the customer requirements.
Select the appropriate size packer cups for the pipe size(s) related to the pending operation.
Apply the appropriate grease compound to the mandrel per OEM and / or Weatherford specifications.
Assemble the base tool per the instructions detailed in the Assembly and Operating Manual.
Assemble grip assembly per the instructions detailed in the Assembly and Operating Manual.
Visually inspect the condition of the integral slips / dies prior to installation. Replace if necessary.
5. Take the measurements of all the integral slips dies teeth width
Function Test
1 Latch the tool by applying vacuum to the air chamber and turning the tool to the left.
2 Verify latching by applying air pressure (40-200 psi) to the air chamber.
When doing this ensure a ring of pipe is positioned around the dies so if the tool is not
3
latched, it is not driven past the maximum extend position.
4 Verify/re-apply alignment marks.
With the tool latched, verify the alignment of yellow and white marking on the upper cam
5
housing and the bump ring which serve to identify the latched position.
Verify / re-apply paint on lower portion of upper cam housing. With the bumper removed and
6 the tool latched verify condition of the yellow paint on the lower portion of the upper cam
housing which serves to identify tool engagement.
7 Verify / re-apply paint on the keeper and the swivel which serves to identify a pinch point.
Rotate the tool clockwise to disengage latch hooks and apply air pressure to the
8 housing to extend the dies into engagement with a ring of pipe. It is best to test breakout in a
ring with the API drift diameter for the dies nominal casing weight
9 Rotate clockwise until the tool starts to climb the make-up ramps.
Rotate tool clockwise to disengage latch hooks, air pressure in the housing will extend
10
the dies into engagement with the ring of pipe.
Continue to rotate the tool to the right until the make-up ramps engage, when this happens
11
the torque to rotate the tool will increase sharply.
Bleed the air pressure from the upper cam housing and remove the Schrader valve so that
12 vacuum can be applied. Apply vacuum to the housing and rotate the tool to the left until the
tool can be rotated any further. Check to ensure that the alignment marks are aligned.
Verify that the tool is latched by applying air pressure to the housing. When doing this
13 ensure a ring of pipe is positioned around the dies so if the tool is not latched, it is not driven
past the maximum extend position.
Check drift for retracted dies, cage and CS components using a drift ring per dimension
15
specified in Appendix B. Note that the drift ring will not pass over the PkrCup.
Check condition and diameter of casing seal. Casing seal diameter should be as large as or
16 larger than the maximum anticipated casing ID. Verify that replacement seals are available
in inventory.
Check that the tool will maintain air pressure charge over time (generally overnight or for
several hours). The air seal should also be confirmed over the range of motion of the tool.
This can be done using the following steps:
● Ensure that tool is in the latched position. Install Schrader valve and apply approx. 100 psi
of air pressure (record exact air pressure) to the chamber. Leave for several hours and then
check to see that air pressure has been maintained.
● Release air pressure and remove Schrader valve. Install a pipe ring around the dies and
17
fire the tool by either unlatching and rotating to the right or by unlatching and applying light
air pressure until the pipe ring is engaged by the dies.
● Install Schrader valve and again apply approx. 100 psi of air pressure (record exact air
pressure) to the chamber. Leave for several hours and then check to see that air pressure
has been maintained.
Inspection Procedure of: Personal Elevator
Purpose: 4 Years Inspection
Reference: OEM manual / BS 5655-10.2.1
Responsibility: Rig Manager, Drilling Superintendent
1. Complete the full every six months inspection in addition to the following:
1. Visually check the basket (including railing and floor plate) for any damage, corrosion or cracks.
2. Remove the paint from the critical welded areas (main frame, floor plate and bottom part of railing etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on all elevator to sub base attachment points.
5. Perform MPI on the lifting eyes and lifting device attachment point.
6. Repaint as required.
7. Prepare and submit the Inspection report.
Inspection Procedure of: Self Propelled Manlift
Purpose: 5 Years Inspection
Reference: OEM manual / ISO 18893:2004
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
1. Complete the full every six months inspection in addition to the following:
2. Fully sandblast the self-propelled manlift basket.
3. Perform wall thickness measurement of the basket frame and floor plate and fixing points of the railing
(minimum three points per meter).
4. Repaint all of the components. Prepare and submit the inspection report.
Inspection Procedure of: Self Propelled Manlift
Purpose: 6 Month Inspection
Reference: OEM manual / ISO 18893:2004
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
1. Visually check the basket (including railing and floor plate) for any damage, corrosion or cracks.
2. Remove the paint from the critical welded areas (main frame, floor plate and bottom part of railing etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on the pad eyes and all lifting cylinders attachment points.
5. Repaint as required.
6. Prepare and submit the inspection report.
Inspection Procedure of: Sack Handling Devices
Purpose: 1 Year Inspection
Reference: OEM manual / ASME B 30.11 / BS 2853
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
2. Dismantle the standpipe manifold and HP mud manifold into individual components as best as possible.
3. Visually check all items for damage, wear, corrosion, erosion or cracks.
4. Measure the wall thickness on specific points of the standpipe and HP piping, (two points per meter) and mark position of
checkpoints in a drawing. Pay special attention to 90-degrees elbows and T-pieces.
5. Check the HP hoses (drilling hoses and vibration hoses) for damage, cracks, rubber condition and wear.
6. Visually check the safety clamps and lines.
7. Perform MPI on all welds and hammer union sealing areas (inside and outside).
8. Reassemble the standpipe, HP piping and hoses (including manifolds) and pressure test to working pressure.
9. Prepare and submit the inspection report (stamp new inspection date on stainless steel band).
Inspection Procedure of: HPP and Standpipe Manifold
Purpose: 5 Years inspection
Reference: OEM manual / API 570
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
2. Complete the full Cat III every two years inspection in addition to the following:
3. Disassemble all valves from the standpipe manifold and HP mud line manifold.
4. Visually check and dimensionally check all valve components for damage, wear, corrosion, erosion or cracks including the
inside of the valve body, bonnet , handle and stem.
5. Perform MPI/Liquid penetrant on all welds, ring joints (if applicable) and valve seat areas of the valves.
6. Reassemble the valves using new seal, O-rings, gates and seats.
7. Pressure test the manifold and relevant high-pressure piping to 1.25 of the maximum rated working pressure.
8. Repaint all components
9. Prepare and submit the inspection report.
Inspection Procedure of: Accumulator Bottles
Purpose: 5 years inspection
Reference: OEM manual / API STD 53
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
2. Check the manufacturer’s name plate and serial number of the pulsation dampener.
3. Release the nitrogen pressure and remove the pulsation dampener from the pump manifold.
4. Remove all mud and dirt from the body and the connection flange and dismantle the dampener.
5. Visually check all components (body, studs, nuts, threads and flange) for any damage, cracks and
wear.
6. Perform NDT / MPI on the ring groove and the welding between the body and the flange and wall
thickness inspection.
7. Prepare and submit the inspection report.
Note 1: Any defects found must be reported to the Technical Operations group for the correct
remedial actions.
Inspection Procedure of: MP Pulsation Dampener
Purpose: 5 years inspection
Reference: OEM manual / API RP 510
Responsibility: Rig Manager, Drilling Superintendent
2. Check the manufacturer’s name plate and serial number of the pulsation dampener.
3. Release the nitrogen pressure and remove the pulsation dampener from the pump manifold.
4. Remove all mud and dirt from the body and the connection flange and dismantle the dampener.
5. Perform NDT/MPI on the ring groove and the welding between the body and the flange.
Note 1: Any defects found must be reported to the Technical Operations group for the correct
remedial actions.
Inspection Procedure of: Mud Pump Pressure Relief Valve
Purpose: 1 Year inspection (Field inspection)
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
10. Adjust the pressure setting scale as required using manufacturer’s recommendations.
11. Repaint and stamp new inspection date in stainless steel ring.
12. Grease valve and flanges (if applicable) and reinstall relief valve on the high-pressure pump
manifold. Set the required relief pressure.
13. Prepare and submit the inspection report.
Inspection Procedure of: Flow Line
Purpose: 1-year inspection
Reference: OEM manual / API RP 13C
Responsibility: Rig Manager, Drilling Superintendent
Field Inspection – Cat III (every one year): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
Scope of work for each interval: Full Inspection – Cat IV (every four years):
Complete the CAT III every one-year inspection in addition to the following:
Field Inspection – Cat IV (every 4 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Complete the full every six months inspection in addition to the following:
1. Completely disassemble the arrestor and inspect, measure and record the wear of the critical components as per
manufacturer’s manual.
2. Compare measurements with maximum allowable tolerances.
3. Repaint all of the components.
4. Prepare and submit the inspection report.
Inspection Procedure of: Fall Arrestors and Emergency Escape Devices
Purpose: 6 Months Inspection
Reference: OEM manual / ANSI - ASSE Z359.14-2012
Responsibility: Rig Manager, Drilling Superintendent
Field Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT inspections to
be done by an accredited third party, approved by Abraj technical authority”
Field Inspection – Cat IV (every 3 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1.1 Definitions:
1.1.1 Visual inspection – A visual inspection is an inspection which identifies, without the use of access
equipment or tools, those defects, e.g. missing bolts, which are apparent to the eye.
1.1.2 Close inspection – A close inspection is an inspection which encompasses those aspects covered
by a visual inspection and, in addition, identifies those defects, e.g. loose bolts, which will become
apparent only when access equipment, e.g. steps (where necessary) and tools are used.
Close inspections do not normally require the enclosure to be opened or the equipment to be de-
energized.
1.1.3 Detailed Inspection – A detailed inspection is an inspection which encompasses those aspects
covered by a close inspection and, in addition, identifies those defects, e.g. loose terminations, which
only become apparent when the enclosure is opened up, or by the use of tools and test equipment.
1.1.4 CompEx – (meaning Competency in Ex atmospheres) is a global certification scheme for electrical
and mechanical crafts persons and designers working in potentially explosive atmospheres.
The scheme is accredited by UKAS to ISO/IEC 17024. The scheme is broken down to twelve units
covering different actions and hazardous area concepts
a. Review the rigs hazardous area layout drawings. If the drawings are inaccurate or missing, note
deficiency on the report and notify the Technical Operations.
b. Verify all electrical equipment and their connection system installed in Zone 1 or Zone 2 areas are rated
for the area they are located.
c. Inspect the equipment ensuring junction boxes, glands, cables, etc are in good condition and that all bolts
are fitted.
1.3 Update the rig Ex register and any deficiencies are reported and acted upon,
1.4 In case of any major deficiencies detected during the Close/visual inspection; a “detailed” Inspection
shall be implemented by a qualified CompEx inspector:
a. Review the rigs hazardous area layout drawings. If the drawings are inaccurate or missing
Note deficiency on the report and notify the Technical Operations.
b. Verify all electrical equipment and their connection system installed in Zone 1 or Zone 2 areas are rated
for the area they are located.
c. Inspect and verify the installation of the air ventilation systems in the drillers control, instrument panels
and the air cooling systems of the DC motors for the drawworks, top drive system and rotary table (if
applicable). Open all enclosures and ensure terminations are correct.
d. Update the rig Ex register and any deficiencies are reported and acted upon.
e. Prepare and submit the inspection report.
Inspection Procedure of: Gas Cylinders
Purpose: 5 Years Inspection
Reference: OEM / API RP 510
Responsibility: Rig Manager, Drilling Superintendent
Full Inspection – Cat IV (every 5 Years): To be performed by a competent person and to be done by an accredited
third party, approved by Abraj technical authority”
Field Inspection – Cat IV (every 3 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Note 1: The SCBA cylinder testing company / inspectors shall have their own individually licensed copies of the
relevant CGA (Compressed Gas Association) documents needed to carry out the cylinder inspections
that the testing company offers.
Inspection Procedure of: BA Cylinders Steel
Purpose: 5 Years Inspection
Reference: API RP 510 And OEM
Responsibility: Rig Manager, Drilling Superintendent
Field Inspection – Cat IV (every 5 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
Note 1: The SCBA cylinder testing company / inspectors shall have their own individually licensed copies of the
relevant CGA (Compressed Gas Association) documents needed to carry out the cylinder inspections
that the testing company offers.
Inspection Procedure of: Fire Extinguishers
Purpose: 1 Year Inspection
Reference: OEM / NFPA 10
Responsibility: Rig Manager, Drilling Superintendent
Full Inspection – Cat IV (every 1 Year): To be performed by a competent person and to be done by an accredited
third party, approved by Abraj technical authority”
Field Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Visually check the ezy torque/cathead for abnormal observation, damage or deformation.
2. Check that bolts on frame, foundation, wire lock, wire clamp, cylinder and sheaves are tightly secured.
3. Thoroughly inspect the wire rope, clamp, lock and compression spring for any damage.
4. Perform MPI on all critical /accessible load-bearing areas including frame, foundation base, sheaves grooves, lock plate
area, roll holder, pivot arm, tong post area.
5. Perform a complete function test and check for proper operation (including complete evaluation of the hydraulic cylinder-
chroming surface).
6. Check the condition and the traceability of the OEM nameplate.
7. Prepare and submit the inspection report.
Inspection Procedure of: Ezy Torque/Hydraulic Cathead
Purpose: 5 Years Inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Full Inspection – Cat IV (every 5 Years): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. The scan readings should be with live circuit under load condition. Thermography, also called
infrared inspection, is based upon the sensing of heat emitted from the surface of an object in
the form of infrared radiation
2. High resistance in circuits causes an increase in current flow. When current flow is increased,
the resulting power consumption will increase.
3. Further, high current draw can cause critical electrical circuit components, such as fuses,
circuit breakers, and transformers, to fail prematurely. These failures result in higher
maintenance and repair costs, and resultant business interruptions.
4. The Electrical Equipments should have a thermographic scan performed at least annually on
critical systems, such as circuit panels, switchgears, and transformers.
5. It is mandatory to do the Thermographic survey prior and after to the Rig Annual
Maintenance.
6. Carry out first Thermographic Survey prior to Annual Maintenance when the rig is operating at
full load to scan all the potential points and get the preliminary report.
7. Rectify the Scan observations based on first thermographic survey during annual
Maintenance.
8. Carry out second thermographic survey after the annual Maintenance when rig in operation
on load. It is a confirmation that the observations rectified.
9. Create the report with the comparison of the observation points (Before & After) to show the
observations rectified.
10. Complete the Yearly Maintenance work order (in SAP) with Thermographic report attached.