JAN EQUIPMENT INSPECTION PROCEDURE Revision 1.0 2020 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 1.1 Equipment Integrity Inspection 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. 1.2 Abraj Equipment Inspection Matrix 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. 1.3 Scope of Equipment Inspection Matrix 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 nondestructive 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. The equipment must be: 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, i. either by possession of a recognized degree, certificate or professional standing, ii. 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. Specific Category III qualifications 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. Specific Category IV qualifications 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. General Lifting gear and lifting equipment inspection All inspectors and supervisors shall be certified by internationally recognized lifting equipment and lifting gear inspection organization. Information to be provided by the inspectors the inspector will have the following information: a. Assembly drawings and drawing identifying critical areas of equipment to be inspected; b. Rejection criteria. c. History of grinding or remanufacturer, if available. 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). 1.6 Equipment Integrity Inspection Tracker 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. 1.7 Inspection Certification Control 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: a. Country Name and Rig No. b. Equipment Description – Name, Make, Serial No., Asset Number c. Date of Inspection d. Type of inspection carried out with relevant international standard reference e. Photograph/single line sketch of equipment inspected showing the area inspected f. Tools used for inspection and the calibration validity of those g. Result of Inspection with remarks h. Repair work carried out, if applicable i. Result of inspection with rework done j. Inspector and Inspection Company Details k. Name and signature of inspection company representative issuing the certificate l. Name and signature of Abraj representative accepting the certificate 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. 1.8 Roles And Responsibilities Rig Manager (Tool Pusher) 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. Maintenance Manager (MM) 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. Maintenance Superintendent (MS) 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. Preventive Maintenance Engineer (PME) 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. Chief Mechanic And Chief Electrician (CM And CE) 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 Related Standards and Specifications 2.1.1 API Specifications (always use the latest revision) API RP 4G API RP 7L Operation, Inspection, Maintenance and Repair of Drilling and Well Servicing Structures Procedures for Inspection, Maintenance, Repair, and API RP 7G-2 Remanufacture of Drilling Equipment Recommended Practice for Inspection and Classification of Used Drill Stem Elements API RP 8B Recommended Practice for Procedures for Inspections, Maintenance, Repair & Remanufacture of Hoisting Equipment API RP 9B API STD 53 API 510 API 570 Application, Care, and Use of Wire Rope for Oil Field Service Blowout Prevention Equipment Systems for Drilling Wells Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems API RP 572 Inspection Practices for Pressure Vessels API RP 576 Inspection of Pressure Relieving Devices API STD 653 Tank Inspection, Repair, Alteration, and Reconstruction 2.1.2 ASME, ASTM, ANSI Specifications (always use the latest revision) ASME B 30.7-2011 Winches ASME B 30.9 Slings ASME B 30.10 Hooks ASME B 30.11 Monorails & Underhung cranes ASME B 30.23-2005 Personnel Lifting Systems Safety Standard for Hoists ASME SE 709 Sec V Non Destructive Examination Safety Requirements for Self-Retracting Devices for ASSE Z 359.14 Personnel Fall Arrest and Rescue systems Guidebook for the Design of ASME Section VIII Pressure ASME VIII Vessels ANSI B 31.1 Power Piping 2.1.3 Other International Standards DS-1 Drill Stems Design and Inspection. IADC IADC Drilling Manual ISO 9712 Qualification and Certification of NDT Personnel ISO 2415: 2004 Forged Shackles for General Lifting Purposes Cranes - Equipment for the Lifting of Persons Part 1: Suspended Baskets Testing and Inspection of Electric and Hydraulic Lifts BS EN 14502-1 BS 5655-10 BS 3956-5 BS EN 81-1 BS EN 81-2 BS ISO 18893:2004 Fork Arm for Fork Lift Trucks – Guide for Inspection Safety Rules for the Construction and Installation of Lifts - Part 1: Electric Lifts Safety Rules for the Construction and Installation of Lifts Mobile Elevating Work Platforms – Inspections BS ISO 5057:1993 Industrial Trucks – Inspection and Repair of Fork Arms Specification for the Testing of Steel Overhead Runway Beams for Hoist Blocks Explosive Atmosphere - Part 17: Electrical Installations Inspection IEC 60079-17 and Maintenance IEC 60947-2 LV Switchgear and Control Gear IEEE STD 43-2000 RP for Testing Insulation Resistance and Electric Machinery IEEE STD 1458RP for the Selection, Field Testing and Life Expectancy of Molded 2005 Case Circuit Breakers for Industrial Application BS 2853 SAE J 2228 Kingpin Wear Limits – Commercial Trailers 2.1.4 Abbreviations NDT Non Destructive Testing UT Ultrasonic Inspection API American Petroleum Institute RP Recommended Practice ASTM American Society of Testing Materials ASME American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing MPI Magnetic Particle Inspection SWL Safe working load PMS Preventive Maintenance System CAT Category DS 1 Drill Stem Inspection Standard Abbreviations IADC International Association of Drilling Contractors ISO International Standards Organization ID Identification NDE Nondestructive Examination WP Working Pressure LEEA Lifting Equipment Engineers Association OEM Original Equipment Manufacturer Item Equipment description 1 Rota ry Ta bl e 2 Ke l l y Dri ve Bus hi ng 3 Applicable STD , OEM or Best Practice Frequency Requirements (ABRAJ) CAT III CAT IV PDO Frequency Requirements CAT III CAT IV Applicable Standards That SOW will follow 2 Ye a rs 5 Ye a rs 1 Ye a r 4 Ye a rs API RP 7L And OEM 6 Months 2 Ye a rs 6 months 1 Ye a r API RP 7L And OEM Ma s te r Bus hi ng & Bowl s 1,2 & 3 - 6 Months 6 months 1 Ye a r API RP 7L And OEM 4 DP, DC, Ca s i ng Sl i ps & Powe r Sl i ps - 6 Months - 6 Months API RP 7L And OEM 5 Sa fe ty Cl a mp - 6 Months - 6 Months API RP 8B 6 Ma nua l Rota ry Tongs for DP, DC & Ca s i ng - 6 Months - 6 Months API RP 7L And OEM 7 Ci rcul a ti ng He a ds 6 Months 1 Ye a r - - API RP 7G-2 8 Dra wworks 9 Dra wworks Bra ke Ba nds & Li nka ge s - 10 Ye a rs - - API RP 7L And OEM 6 Months 5 Ye a rs 6 months or whe n bl ocks 1 Ye a r API RP 7L And OEM 10 Dra wworks Di s c Bra ke - 1 Ye a r - 1 Ye a r API RP 7L And OEM 11 Rota ry hos e s , Vi bra tor hos e s & We l de d Conne cti ons - 1 Ye a r 1 Ye a r 3 Ye a rs API RP 7L And OEM 12 Powe r Tongs (Pne uma ti c / Hydra ul i c) 1 Ye a r 2 Ye a rs - - 13 Mud Pumps - 10 Ye a rs - - 14 Ri g I ns trume nta ti on a nd ga uge s - 1 Ye a r - - OEM 15 Ci rcui t Bre a ke rs - 5 Ye a rs - - I EEE STD 902 , NETA ,OEM 16 Hydra ul i c Ca twa l k 1 Ye a r 5 Ye a rs - - OEM 17 Pi pe Arms a nd Pi pe Loa de rs 1 Ye a r 5 Ye a rs - - OEM 18 I ron Roughne ck - 3 Ye a rs - - OEM 19 DC Motors - 5 Ye a rs - - OEM 20 Bl owe r Motors - 5 Ye a rs - - OEM 21 AC Motors - 5 Ye a rs - - OEM 22 Mud Ta nks - 10 Ye a rs - - STI SP001 23 Ma s t a nd Subs tructure 2 Ye a rs 10 Ye a rs 2 Ye a rs 10 Ye a rs API RP 4G 24 Sta bbi ng Boa rd a nd Monke y Boa rd 2 Ye a rs 5 Ye a rs 6 months 1 ye a r API RP 4G 25 Ra i s i ng Cyl i nde rs 6 Months 5 Ye a rs - - API RP 4G 26 Crown Bl ock 6 months 5 Ye a rs 6 Months 5Ye a rs API RP 8B 27 Tra ve l i ng Bl ock , hook bl ock a nd bl ock to hook a da pte rs 6 Months 5 Ye a rs 6 Months 5Ye a rs API RP 8B 28 Dri l l i ng Hook 6 Months 5 Ye a rs 6 Months 5Ye a rs API RP 8B 29 Top Dri ve Sys te m /Powe r Swi ve l 6 Months 5 Ye a rs 6 Months 5Ye a rs API RP 8B 30 Conne ctors a nd Li nk Ada pte rs 6 months 5 Ye a rs 6 Months 5Ye a rs API RP 8B 31 El e va tor Li nks - 6 Months 6 Months 1 Ye a r API RP 8B 32 DP a nd DC El e va tors , Ca s i ng & Si ngl e Joi nt El e va tors , Tubi ng El e va tors - 6 Months 6 months 1 Ye a r API RP 8B 33 Spi de r / El e va tor 6 Months 1 Ye a r 6 Months 1 Ye a r API RP 8B 34 Ke l l y Spi nne r 6 Months 5 Ye a rs 6 months 5 Ye a rs API RP 8B 35 De a dl i ne Anchor 6 Months 5 Ye a rs 6 months 5 Ye a rs API RP 8B 36 Tubul a r Li fti ng Pl ugs /ca p a nd Subs - 6 Months 6 Months - API RP 7G-2 37 Uti l i ty Wi nche s (I ncl udi ng Truck Wi nche s ) - 1 Ye a r - 1 Ye a r ASME B30.7 38 Ma n Ri di ng Wi nch 1 Ye a r - 1 Ye a r ASME B30.7 39 Rota ry Swi ve l Ba i l Ada pte rs 6 Months 1 Ye a r 6 Months 1 Ye a r API RP 8B 40 Rota ry Swi ve l s 6 Months 5 Ye a rs 6 Months 2 Ye a rs API RP 8B 41 Dri l l Pi pe - 42 Dri l l Stri ng Acce s s ori e s & BHA - 43 Ra i s i ng Li ne a nd Spe l te rs - 44 Pa d Eye s , Wi re Rope Sl i ngs & Sha ckl e s - 45 Tra i l e r Ki ng Pi ns 46 Pe rs onne l Ba s ke t 47 48 49 50 6 Months or e a ch ri g move 500 Rota ti ng Hours 8 cycl e s or 2 Ye a rs (whi che ve r - 6 Months or e a ch ri g move EVERY 250hrs for s hort we l l s or API RP 7L And OEM DS1 Vol 3 DS1 Vol 3 As pe r OEM As pe r OEM API RP 4G And API RP 9B 6 Months - 6 Months API RP 9B , ASME B30.9 , Lol e r Re gul a ti ons 3 Months 1 Ye a r 6 Months - OEM 6 Months 4 Ye a rs 6 Months 4 Ye a rs BS EN 14502-1 Cra ne Hooks 6 Months 1 Ye a r 6 Months 1 Ye a r ASME B30.10 Forkl i ft Forks & Forkl i ft Fork Support 6 Months 1 Ye a r 6 Months 1 Ye a r ANSI /I TSDF B56.6 And OEM ca s i ng runni ng tool s - 5 Ye a rs - - OEM ma nua l / DS1 Vol ume 4 Pe rs onne l El e va tors 6 Months 4 Ye a rs - - BS 5655-10 51 Se l f Prope l l e d Ma nl i fts 6 Months 5 Ye a rs - - I SO 18893 52 Sa ck Ha ndl i ng De vi ce s - 1 Ye a r - - ASME B30.16 53 Di ve rte r Ba l l Va l ve s 2 Ye a rs 5 Ye a rs - Dri l l i ng Spool s , Fl a nge s , Di ve rte r & Va l ve s - 5 Ye a rs 2 Ye a rs 55 Hub Cl a mps - 5 Ye a rs 6 months e WI MS cycl e of WI TS 1 Ye a r API STD 598 54 56 BOP Shooti ng Ni ppl e - 1 Ye a r - 1 Ye a r API STD 53 57 RAM Type BOP And Ra m Bl ocks 2 Ye a rs 5 Ye a rs 1 Ye a r 3 Ye a rs API STD 53 58 Ba g Type BOP Annul a r 2 Ye a rs 5 Ye a rs 1 Ye a r 3 Ye a rs API STD 53 59 Choke & Ki l l Li ne - 5 Ye a rs 1 Ye a r 5 Ye a rs API STD 53 60 Chi ks a ns a nd s wi ve l s - 1 Ye a r - 1 Ye a r API 570 And API RP 574 61 Hi gh Pre s s ure Choke Ma ni fol d & Va l ve s - 5 Ye a rs 1 Ye a r 5 Ye a rs API STD 53 62 Mud Ga s s e pa ra tor 5 Ye a rs - 63 Sta ndpi pe & Hi gh Pre s s ure Pi pi ng ,Ce me nt l i ne s 2 Ye a rs 5 Ye a rs 1 Ye a r 3 Ye a rs API 570 And API RP 574 64 I BOPs , Ke l l y Va l ve s a nd Ful l ope n s a fe ty va l ve s - 500 Rota ti ng Hours - EVERY 250hrs for s hort we l l s or API RP 7G-2 And OEM 65 BOP Accumul a tor Uni t - Work Orde r Onl y 1 Ye a r 5 Ye a rs API STD 53 66 Accumul a tor Bottl e s - 5 Ye a rs 1 Ye a r 5 Ye a rs API 510 67 Pul s a ti on Da mpe ne r 1 Ye a r 5 Ye a rs 1 Ye a r 5 Ye a rs API 510 And OEM 68 Mud Pump Re l i e f Va l ve s - 1 ye a r 1 Ye a r 2 Ye a rs OEM 69 Fl ow Li ne s - 1 Ye a r - 1 Ye a r API 570 And API RP 574 API STD 53 API STD 53 API STD 53 70 BOP Li fti ng De vi ce s 1 Ye a r 4 Ye a rs 1 Ye a r 3 Ye a rs ASME B30.16 /ASME B30.7 And API RP 7L 71 Ai r Pre s s ure Ve s s e l 2 Ye a rs 5 Ye a rs - 2 Ye a rs API 510 72 Ai r Pre s s ure Re l i e f Va l ve s - 5 Ye a rs 1 Ye a r - API RP 576 73 Fue l Ta nks - 10 Ye a rs - - STI SP001 74 Fa l l Arre s tor & Eme rge ncy Es ca pe De vi ce s 6 Months 4 Ye a rs - - STI SP001 75 Ex(d) & Ex(e ) Sys te ms - 3 Ye a rs - - I EC 60079-17 76 GAS Cyl i nde rs - 5 Ye a rs - 5 Ye a rs API 510 77 Bre a thi ng Ai r Cyl i nde rs Fi be r Gl a s s - 3 Ye a rs - - API 510 78 Bre a thi ng Ai r Cyl i nde rs Ste e l - 5 Ye a rs - - API 510 79 Fi re Exti ngui s he rs - 1 Ye a r - - NFPA 10 80 Ga s de te cti on s ys te m - 6 Months - - OEM 81 Spi nni ng Wre nch - 1 Ye a r - - OEM 82 Hydra ul i c Ca the a d / Ezy Torque 1 Ye a r 5 Ye a rs - - OEM - I nte rna ti ona l STD for i nfra re d i ns pe cti on 83 The rmogra phy I npe cti on - 1 Ye a r - Inspection Procedure of: Rotary Table Purpose: 2 Years inspection Reference: OEM manual / API RP 7L Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full Inspection – Cat III (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”. 1. Prepare and make ready the OEM Manual and drawings of the Rotary Table under inspection; it must be used as the main guideline in all the following steps. 2. Take the rotary table “or the complete rotary table skid” out of the substructure. 3. Check the condition of the nameplate and all serial number / traceability details. 4. Check the connections from the rotary table to the rotary beams and to the skid visually for any damage or cracks. Perform MPI on the lock pins and connections to rotary beams and skid. 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 paint condition of the rotary table and skid. 9. Prepare and submit the inspection report. Inspection Procedure of: Rotary Table Purpose: 5 Years inspection Reference: OEM manual / API RP 7L Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the Rotary Table under inspection; it must be used as the main guideline in all the following steps. 2. Take the rotary table “or the complete rotary table skid” out of the substructure. 3. Check the condition of the nameplate and all serial number / traceability details. 4. Take off the main rotary table cover along with the turntable; remove and check the condition of the main bearing. 5. Clean all the rotary table components and housing. 6. Check the condition of the gears, couplings; MPI/liquid penetrant and visual inspection to be done. 7. Check the connections from the rotary table to the rotary beams and to the skid visually for any damage or cracks. Perform MPI on the lock pins and connections to rotary beams and skid. 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. 12. Prepare and submit the inspection report. Inspection Procedure of: Kelly Drive Bushing Purpose: 2 Years Inspection Reference: OEM manual / API RP 8B Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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 Scope of work for each interval: 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. 2. 3. 4. 5. 6. 7. 8. 9. Dismantle the Kelly drive bushing. Visually check the rollers, drive pins, cover plate, bolts, and nuts for any damage or cracks. Check the wear of the roller bearings. Measure the wear of the rollers, drive pins (for pin drive). Refer to the manufacturer’s wear limits. Perform MPI on all critical welds on the housing and the drive pins and check the threads of the “hold down bolts” for damage or cracks. Check the condition and details of the manufacturer’s nameplate. Check the paint condition and repaint as required. Assemble the drive bushing and carry out one function test. Check for any loose items. Prepare and submit the inspection report. Inspection Procedure of: Insert Bowls Purpose: 6 Months inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Insert Bowls under inspection; it must be used as the main guideline in all the following steps. 2. Pull out the insert bowls from the master bushing assembly. 3. Remove both Half of the Drilling Bowls outside of master bushing using proper lifting chain Sling. 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. 9. Record the following measurements: A- Throat ID B- Insert Bowl Taper 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). 12. Prepare and submit the inspection report. Inspection Procedure of: Master Bushing Purpose: 6 Months inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Master Bushing under inspection, it must be used as the main guideline in all the following steps. 2. Pull out the master bushing from the rotary table assembly. 3. Visually check the master bushing for any damage or cracks. 4. Measure the following and compare it to the OEM wear limits: A- Master Bushing upper ID B- Master Bushing Lower ID C- Pin Drive Hole ID 5. Perform MPI on the master bushing and pin. 6. Check the availability and condition of the manufacturer Serial No. 7. Grease the bushing. 8. Prepare and submit the inspection report. Inspection Procedure of: Slips Purpose: 6 Months inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Slips under inspection, it must be used as the main guideline in all the following steps. Check the Serial No. and Manufacturer’s stamps. Thoroughly clean slip prior to inspection Verify condition of slip segments for worn backs, cracked webs and bends. Check insert slots for damage and wear. Measure clearance between the back of the insert and the insert slot. Replace slips when measurement is 3/16" (3 - 5 mm). 6. Inspect hinge pin and holder for wear and missing retaining cotter pins. 7. Inspect slip handles for crack and deformities. 8. Inspect hinge and pin eyes for abnormal wear. 2. 3. 4. 5. 9. Perform MPI on the critical areas shown below Inspection Procedure of: Safety Clamp “not used as a hoisting equipment” Purpose: 6 Months inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Safety Clamp under inspection, it must be used as the main guideline in all the following steps. Check the Serial No. and Manufacturer’s stamps. Thoroughly clean the safety clamp prior to inspection Fully disassemble the safety clamp. MPI/Liquid Penetrant the whole safety clamp components including the latch jaw, adjustment mechanism, Die carrier, links, handles and pins. 6. Measure the pins ODs and holes IDs for excessive wear “A” (Maximum clearance is 0.04”). 7. Reassemble the safety clamp and verify the clearance between the die carriers and dies assemblies “B” (0.04”). 8. Prepare and submit the inspection report. 2. 3. 4. 5. Inspection Procedure of: Tongs Purpose: 6 Months inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Tongs under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s stamps. 3. Disassemble the tongs 4. Visually check all main components (lever, long jaw, latch lug jaw, short jaw, latch, hinge law) for damage, 5. 6. bending or cracks. Perform MPI on lever, long jaw, latch lug jaw, hinge jaw, hinge pins, latch and hanger. Measure hinge pins and hinge pin holes for wear (see manufacturer’s recommendation for max. clearance). 7. Reassemble tongs, repaint and grease as required. 8. Prepare and submit the inspection report. Inspection Procedure of: Circulating heads Purpose: 6 months inspection Reference: OEM manual / API RP 7G-2 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat VI (every year): To be performed by OEM or OEM Approved Inspector: 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. Completely dismantle the circulating head. 2. Visually check all components for damage, wear or cracks. 3. Perform MPI on body and critical areas. 4. Reassemble the circulating head. 5. Repaint as required. 6. Prepare and submit the inspection report (stamp new inspection date on stainless steel band. Inspection Procedure of: Circulating heads Purpose: 6 months inspection Reference: OEM manual / API RP 7G-2 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Field Inspection – Cat III (every six month): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Visually check the circulating head for any damage, wear or corrosion. 2. Visually check the ID for erosion. 3. Measure wall thickness 2 inches from pin and box seals on circulating heads. 4. Measure wall thickness 4 inches from pin end on circulating heads. 5. Perform NDT on body and critical areas. 6. Repaint as required. 7. Prepare and submit the inspection report. Inspection Procedure of: AC 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. Completely disassemble the Draw-works 3. Remove Drum Shaft Assembly, BuIl Gear, Lube Pump Assembly and Miscellaneous items. 4. 5. 6. 7. 8. Drum Shaft Assembly Complete disassembly of Drum Shaft (NOTE: Does not include removal of Drum shaft from drum). High-pressure steam clean of Drum and painted components, MPI and dimensional check of main shaft– MPI and dimensional check of drum Grooves. Disassembly / Inspections of Encoder Assembly. Replace main bearings; DS and ODS. Inspection of Draw Works Guard assembly and miscellaneous items. Main Skid, Motor Frame & Front Porch or Driller's Platform 9. Check for corrosion, tie downs, support structure, (Especially Under Control Panel and Auxiliary Brake). 10. Blast, inspect (Visual and NDT/MPI) & paint Draw works skid. 11. 12. 13. 14. 15. 16. 17. 18. 19. Gear Box Assembly Complete disassembly of gearbox. Removal and Inspection (Visual / Dimensional / MPI) of all gears. Replace all gear box bearings. Replace oil seals. Visually Check / MPI input and output Coupling condition; replace if required. MPI for gearbox frame and dimensional check for all bearing seat areas. Check bearings clearance after assembly. Check /verify gear mesh and gears alignment. Adjust gears back lash as per OEM requirements. Input Shaft / Idler Drive Shaft / Output Shaft 20. Replace all Bearings; DS and ODS. 21. MPI and dimensional check of all shafts; check for abnormalities /wear or cracks. Lubrication System 22. Disassembly / inspections of Lube Pump Assembly. 23. Check lubrication system: (Sprockets, chain, spray nozzles, hoses, piping, filters and strainers). Associated Pipework and air and water piping 24. Check / Replace Air & water Piping & Hose. 25. Replace DS & ODS Air and water spear Water Piping & Hoses. Driller’s Control Console 26. Check Control Console Operation and Condition. 27. Check all the control Switches, throttles, joysticks and valves, replace if necessary. 28. Detailed Inspection report will be submitted after the inspections. 29. Assembly of Draw works as per OEM standards and specifications. 30. Install and align of Drum shaft and Brake System. 31. Install and align of Drive motor. 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. Completely disassemble the Draw-works 3. Remove Drum Shaft Assembly, BuIl Gear, Lube Pump Assembly and Miscellaneous items. 4. 5. 6. 7. 8. 9. 10. 11. 12. Drum Shaft Assembly Complete disassembly of Drum Shaft (NOTE: Does not include removal of Drum shaft from drum). High-pressure steam clean of Drum and painted components, MPI and dimensional check of main shaft– MPI and dimensional check of drum Grooves. Removal and Inspection (Visual / Dimensional / MPI) of Spur Gear Disassembly / Inspections of Encoder Assembly Replace main bearings ; DS and ODS Inspection of Draw Works Guard assembly and miscellaneous items Visually Check / MPI Low / High Drive Sprockets. Replace Low /High Drive Sprocket Bearings. Check / Replace High Drum Rotary Drive sprocket condition (if applicable) Main Skid, Motor Frame & Front Porch or Driller's Platform 13. Check for corrosion, tie downs, support structure, (Especially Under Control Panel and Auxiliary Brake) 14. Blast, inspect (Visual and NDT/MPI) & paint Draw works skid 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.) Associated Pipework and air and water piping 26. Check / Replace Air & water Piping & Hose 27. Replace DS & ODS Air and water spear Water Piping & Hose Driller’s Control Console 28. Check Control Console Operation and Condition 29. Check all the pneumatic valves, replace if necessary 30. Detailed Inspection report will be submitted after the inspections 31. Assembly of Draw works as per OEM standards and specifications 32. Install and align of Drum shaft and Brake System 33. Install and align of Drive motor. 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. Scope of work for each interval: 1. Full Inspection – Cat IV (every five 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. 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. Scope of work for each interval: 1. 2. 3. 4. 5. Complete required permit to work (PTW). Mechanical and electrical Lockout / Tag out. Review and complete Job Safety Analysis (JSA). Inform area authority if work is carried out on critical equipment for the ongoing operation. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan. 6. Hang off traveling block and/or top drive (if applicable) on the dedicated hang off line or clamp device. 7. Visually check the bands for any bends, twists, damage or cracks. 8. Carefully check the correct installation, alignment and adjustment of the brake linkage system according to the manufacturer’s recommendation. 9. Perform NDT/MPI on the brake bands (dead and live end) and all accessible 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). 10. Check for the correct length, position and condition of the main brake lever. 11. 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. 12. Prepare and submit the inspection report. Inspection Procedure of: DW Disc Brake Purpose: 1 year inspection Reference: OEM manual / API RP 7L Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. 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”. 2. Completely disassemble the brake system. 3. MPI all Brake structural members (calipers support arms, levers, connecting Pins, Shoe springs, shoe pins, backing Plates) for any cracks, corrosion or Weld defects. Replace any worn components as required. 4. Replace brake discs, brake blocks, calipers springs, oil seals. 5. Reassemble all items and repaint as required. 6. Carry out brake efficiency test as per OEM guidance and record. 7. Prepare and submit the inspection report. Inspection Procedure of: Rotary Hoses Purpose: 1 Years inspection Reference: OEM manual / API RP 7L Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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”. 1. Prepare and make ready the OEM Manual and drawings of the rotary hoses under inspection, it must be used as the main guideline in all the following steps. 2. Visually check all items for damage, wear, corrosion, erosion or cracks. 3. Check the hoses for damage, cracks, rubber condition, cuts, gouges or wear. 4. Visually check the safety clamps and secondary retention lines. 5. Perform MPI/Liquid penetrant on all welded areas, end connections, couplings area and safety clamps. 6. Perform endoscope /internal inspection on the hose internals. 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. Prepare and submit the inspection report. 8. Inspection Procedure of: Power Tongs Purpose: 1 Year Inspection Reference: OEM manual Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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 Scope of work for each interval: 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. Scope of work for each interval: Cat IV Every 1 year to be performed by a competent person and accredited third party, approved by Abraj technical authority”. 1- Visually check the instruments for any damage, corrosion or leaks. 2- Check condition and content of the OEM’s name plates for necessary information 3- Visually check the installation of the instruments for proper mounting of brackets, piping, hoses, fittings etc. 4- Inspect service and carry out function tests of the instruments as per OEM’s instructions. 5- Recalibrate in accordance with OEM’s requirements and apply calibration tag. 6- Mark the instruments with new/updated inspection signs/ stickers. 7- Prepare and submit the inspection report. 1. Definition of Critical Gauges and Instrumentation 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. 1.1 Drill Floor a. Hook weight load cell and gauge b. Manual tong torque load cell and gauge c. Rotary table torque indicator package d. Top drive torque indicator package 1.2 High Pressure Mud System a. Manual pressure gauge – pump discharge b. Manual pressure gauge – stand pipe manifold c. Hydrostatic / electronic stand pipe manifold pressure transducer(s) and gauge 1.3 BOP and Choke Manifold Equipment 1.3.1 Closing unit i. Annular pressure gauge ii. Manifold pressure gauge iii. Accumulator pressure gauge 1.3.2 Remote Panel (Rig Floor) i. Annular pressure gauge ii. Manifold pressure gauge iii. Accumulator pressure gauge iv. Rig air pressure gauge 1.3.3 Choke and Choke Control Panel i. Casing shut in pressure – panel display ii. Drill pipe shut in pressure – panel display iii. Hydraulic choke position indicator iv. Manual gauge at choke manifold 1.4 Mud Tank Level Sensors a. Trip tank and stripping tank (if applicable) level sensors b. Suction tank level sensors c. Intermediate tank level sensors d. Reserve tank(s) level sensor(s) e. Flow indicator sensor. (Flo-show) 1.5 Tools a. All electric meters including digital/analogue multi meters, meggers , frequency meters….etc. b. Torque wrenches 2. Technical Guidelines 2.1 Repair and Replacement 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. 2.2 Verification Procedures 2.2.1 Drill Floor 2.2.1.1 Hook Weight Indicator and Load Cell i. Option 1: Verify accuracy of the system by hanging a known value weight from the hook at a predetermined height in the mast. (IE: Top Drive, drill collars, etc.) ii. Option 2: Verify the accuracy of the system by using a hydraulic hand pump to pressurize the system from zero to the rated pressure as stated on the back of the weight indicator for a full sweep test. 2.2.1.2 Manual Tong Torque Load Cell and Gauge Verify the accuracy of the tong torque display as follows: i. Option 1: ‘Line pull’ type gauge display. 1. Using a drill collar or similar known weight item, hook the load cell in line with the floor tugger to the weight item with acceptable nubbins or lifting fixture. 2. Raise the weight item so it is fully supported by the floor winch. 3. Ensure that the gauge reading is identical to the known weight of the hoisted equipment. ii. Option 2: ‘Tong Torque’ type gauge display. 1. Follow steps 1 and 2 as above. 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%) 2.2.2 High Pressure Mud System 2.2.2.1 Manual Pressure Gauges – Pump and Stand Pipe Mounted i. Remove the Mud Pump discharge pressure gauge. ii. Using a blanking adapter on the mounting flange or hammer union, as necessary, connect the MP gauge to a hand pump with a certified gauge “tee’d” in to the output pressure line of the hand pump. iii. Pressurize the gauge using the hand pump and verify that the pressure read out is equal on both gauges. iv. Repeat the process on the remaining Mud Pump and Stand Pipe pressure gauges as required. 2.2.2.2 Electronic / Hydrostatic Standpipe Pressure Transducers i. If the transducer is installed during the test above (a), ensure that the driller’s pressure display matches the reading on the certified gauge. ii. If the transducer is not installed on the stand pipe manifold, a blanking adapter will need to be fitted and a hydraulic jack (c/w pressure gauge) will need to be installed. Pump up the transducer module and verify that the driller’s pressure display matches the pump output pressure reading. 2.2.3 BOP Closing Unit and Choke Control Gauges 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. 2.2.4 Mud Tank Level Sensors Step 1 - Empty Tank: 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. Step 2 - Known Volume in Tank: 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. 2.2.5 Flow Sensor (Flo-Show) 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 All calibration procedures should be followed as per the OEM requirements Inspection Procedure of: Low Voltage Circuit Breakers Purpose: 5 Years Inspection Reference: ANSI/NEMA AB 4 - IEC 60947 - IEEE STD 43-2000 - IEEE STD 1458-2005 Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent. Scope of work for each interval: 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. 3- Testing of circuit breakers (Primary Injection Test / Secondary Test) 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. 3- Tripping Test for Electro-Mechanical Type a. Instantaneous current trip settings – to verify protection against short circuit b. Overload current trip settings – to verify protection against overloading of the system 4- Trip Test for Solid State Type a. Long delay current trip settings b. Long delay time trip settings c. Short delay current trip settings d. Short delay time trip settings e. Instantaneous current trip settings f. Ground current trip settings g. Ground delay time trip setting 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. TRA – Task Risk Assessment: a. PTW – Permit to Work b. Electrical Isolation and lock out/tag out system. Inspection Procedure of: Hydraulic Catwalk Purpose: 1 Year Inspection Reference: OEM manual Responsibility: Management and work site supervisors. Scope of work for each interval: 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. Scope of work for each interval: 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” 1. Perform all the field/CAT III inspection procedures. 2. Perform an MPI (PT for narrow areas) for all the accessible weld and critical area members in the catwalk structure & the hydraulic system Inspection Procedure of: Pipe Arm Purpose: 1 Year Inspection Reference: OEM manual Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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. Scope of work for each interval: 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” 1. Perform all the field inspection procedures. 2. Perform an MPI (PT for narrow areas) for all the accessible weld and critical area members in the pipe arm and loading system structure, frames, bracing & hydraulic system. Inspection Procedure of: Iron Roughneck Purpose: 3 Years Inspection Reference: OEM manual Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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” 1. Fully disassemble the Iron Roughneck. 2. Check the slew and roller bearings condition. 3. Visually inspect all fasteners for damage or corrosion. 4. Visually inspect all pins/holes (bearing movement areas) for excessive wear. 5. Visually inspect all of the hanging points, lifting eyes, shackles and guide handle for excessive wear, damage or deformation. 6. Extend the lifting cylinder and visually inspect the chrome surface for any pitting or excessive wear condition. 7. Extend all of the clamping and wrenching cylinders consecutively and visually inspect the chrome surface for any pitting or excessive wear; check the attachment points and eyes for wear and excessive tolerance. 8. Visually inspect the biting edges of the jaw assemblies and their retaining bolts for any looseness or damage. 9. Check the spinning rollers diameter for excessive wear (Make the measurement from the center of the rollers away from the edges as much as possible) 10. Perform an MPI (PT for narrow areas) for all the accessible weld and critical areas including the power scope adapter assembly (if installed). 11. Visually inspect all hydraulic/pneumatic hoses for damage, kinks, cuts reaching the internal wire layer of the hoses and replace if necessary. 12. Reassemble and paint the Iron Roughneck. 13. Prepare and submit the inspection report. Inspection Procedure of: DC drive motor Purpose: 5 years inspection Reference: OEM manual Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent Scope of work for each interval: 1. Complete overhaul of the traction motor as per the minimum scope of work, the job will be carried out by external source. 2. Completely disassemble motor. 3. Steam clean armature and bake 4. Set up armature, skim commutator, undercut micas 5. MPI armature shaft & Lifting Points and feet 6. Dynamically balance armature to Quality Grade G2.5 or better 7. Clean brush gear and re-inspect 8. Clean all mechanical parts and inspect 9. Remove excitation poles and leads 10. Remove interpoles and leads 11. Grit blast frame internally and externally 12. Apply one coat primer. 13. Clean excitation coils and poles 14. Clean interpole coils and poles 15. Varnish fields and interpoles and stove. 16. Varnish armature and stove. 17. Skim and undercut commutator. 18. Reinstall excitation coils and poles on new Nomex 410 insulations and connect 19. Reinstall interpole coils and poles and connect 20. Apply anti-tracking varnish to all exposed metal surfaces. 21. Impregnate Frame in Class H varnish and bake 22. Replace cable rubbers. 23. Dynamically balance armature to Quality Grade 2.5 or better 24. Bead blast brush gear. 25. Refit leads 26. Check polarities 27. Apply one coat anti-tracking varnish to all surfaces 28. Replace carbon brushes and brush holders 29. Replace A1, A2 & S1, S2 Cable. 30. Reclaim worn DE/NDE Bearing housings 31. Replace bearings 32. Replace cut out switch 33. Replace pressure switch 34. Replace Teflon band 35. Reassemble 36. Carry out Statically test 37. Carry out no load run. 38. Re-fit hub, sprocket, etc. 39. Paint Overhauling of Blower Motors 40. Dismantle motor. 41. Grit blast complete blower motor assembly, externally and prime 42. MPI shaft, feet and lifting points 43. Measure and record flame path dimensions 44. Clean stove and re-varnish stator windings. 45. Replace bearings. 46. Dynamically balance rotor assembly. 47. Clean all parts. 48. Clean and overhaul terminal assembly 49. Assemble and test. 50. Prepare and submit the inspection report. Inspection Procedure of: AC Drive motors – All DWs Purpose: 5 Years Inspection Reference: OEM manual Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent Scope of work for each interval: 1. Complete overhaul of the traction motor as per the minimum scope of work, the job will be carried out by external source. 2. MPI bearing housings, shaft, and end shields. 3. Surge test stator windings (1720V/50HZ 1 Minute). 4. Measure turn to turn insulation of stator winding by pulse (3600V FOR 1 Minute for each winding). 5. Measure turn to turn insulation of stator winding by pulse 6. Steam clean, bake and re-varnish stator windings. 7. Clean and paint all parts. 8. Measure wear on components and record results; rectify acceptable limit if wear beyond the acceptable limits. 9. Dynamically balance motor. 10. Supply and fit 2 new bearings 11. Fit new O-rings. 12. Test run. 13. Paint with the initial color. Inspection Procedure of: Ac Drive motors – All TDS Purpose: 5 Years Inspection Reference: OEM manual / API RP 8B Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent Scope of work for each interval: 1. Complete overhaul of the traction motor as per the minimum scope of work, the job will be carried out by external source. 2. MPI bearing housings, shaft, and end shields. 3. Surge test stator windings (1720V/50HZ 1 Minute). 4. Measure turn-to-turn insulation of stator winding by pulse (3600V FOR 1 Minute for each winding). 5. Measure turn to turn insulation of stator winding by pulse 6. Steam clean, bake and re-varnish stator windings. 7. Clean and paint all parts. 8. Measure wear on components and record results; rectify acceptable limit if wear beyond the acceptable limits. 9. Dynamically balance motor. 10. Supply and fit 2 new bearings 11. Fit new O-rings. 12. Test run. 13. Paint with the initial color. Inspection Procedure of: Fuel and Mud Tanks Purpose: 10 Years inspection Reference: STI SP001 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every 10 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. Prepare and make ready the OEM Manual and drawings of the Fuel/Mud tanks under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Nameplate. 3. Empty the fuel tank completely and flush inside with water based cleaner. 4. Sand or grit blast the tank outside. 5. Visually check the tank and any associated piping for any damage, corrosion or cracks. 6. Measure and record the wall thickness of the tank (15 points per 12 Inches x 12 Inches square area) including the pedestals and skid.( minimum values are highlighted in the below guidelines Note: The following step requires compliance with all Abraj Confined Space Entry Rules! 7. Open the tank manhole and inspect the tank inside for any corrosion or cracks. 8. Perform MPI/Liquid Penetrant on all critical areas (welded seams, pedestal and skid front ends etc.) 9. Leak Test (If required) as per the below guidelines. 10. Repaint all of the components. 11. Prepare and submit the inspection report. General Inspection Guidelines Minimum Shell Thickness Inspection Procedure of: Mast /Substructure Purpose: 2 Years Inspection Reference: OEM manual / API RP 4G Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat III “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. • Visible Marking of Damage 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: Visible damage Acceptable: Pin condition Acceptable: Pin hole condition Acceptable: Safety pins/keepers Acceptable: b. Front Leg ODS Symmetry Acceptable: Visible damage Acceptable: Pin condition Acceptable: Pin hole condition Acceptable: Safety pins/keepers Acceptable: c. Rear Leg DS Symmetry Acceptable: Visible damage Acceptable: Pin condition Acceptable: Pin hole condition Acceptable: Safety pins/keepers Acceptable: d. Rear Leg ODS Symmetry Acceptable: Visible damage Acceptable: Pin condition Acceptable: Pin hole condition Acceptable: Safety pins/keepers Acceptable: Number of visible marks applied 2. A-Legs or Raising Assembly Symmetry Acceptable: Visible damage Acceptable: Legs straightness Acceptable: Pins condition Acceptable: Pins holes condition Acceptable: Safety pins/keepers Acceptable: Feet condition Acceptable: Break over sheave condition Acceptable: Bridle line anchors Acceptable: Bridle line sheave and shaft condition Acceptable: Number of visible marks applied 3. Spreaders, Girts and Strongbacks Symmetry Acceptable: Straightness Acceptable: Visible damage Acceptable: Pin condition Acceptable: Pin hole condition Acceptable: Safety pins/keepers Acceptable: Number of visible marks applied 4. Feet Or Pivots Condition of holes Acceptable: Pin condition Acceptable: Safety pins/keepers Acceptable: Visible damage Acceptable: Welds Acceptable: Number of visible marks applied 5. Crown Support Beams Beam straight Acceptable: Pins & bolts Acceptable: Safety pins/keepers Acceptable: Welds Acceptable: 6. Crown Saver Block(s) Safety mesh Acceptable: Safety cable Acceptable: Block(s) condition Acceptable: Attachment strapping Acceptable: Strapping welds Acceptable: Number of visible marks applied 7. Ladders Vertical rails straight Acceptable: Rails in alignment Acceptable: Ladder stand offs Acceptable: Stand off connections Acceptable: Rail welds Acceptable: Rungs Acceptable: Rung welds Acceptable: Rung spacing Acceptable: Access at rig floor Acceptable: Cage Acceptable: Toe clearance Acceptable: Number of visible marks applied 8. Raising, Telescoping and Guying Assemblies a) Hydraulic System Raising ram condition Acceptable: Hose and hose ends Acceptable: Connections Acceptable: b) Guy Line Anchorage Anchors and dead man Acceptable: Turnbuckles Acceptable: Cable clamps Acceptable: Guy line condition Acceptable: Number of visible marks applies 9. Locking Devices and Seats – Telescoping Masts Pin hole(s) Acceptable: Pins Acceptable: Safety pins/keepers Acceptable: Bars/dogs or pawls Acceptable: Seats Acceptable: Mechanism Acceptable: Number of visible marks applied 10. Tong Counterweights Guides Acceptable: Weight device Acceptable: Sheaves/shafts Acceptable: Wire lines Acceptable: Cable clamps Acceptable: Welds Acceptable: Number of visible marks applied 11. Miscellaneous Sheaves Assemblies Clevis/shackle Acceptable: Mast pad-eye Acceptable: Sheaves Acceptable: Bearings Acceptable: Shafts Acceptable: Sheave bolt Acceptable: Side plate bolts Acceptable: Bolt safety pins Acceptable: Grease fittings Acceptable: Safety line Acceptable: SUBSTRUCTURE 1. Shoes Pin connections Acceptable: Pin holes Acceptable: Bolt connections Acceptable: Bolt holes Acceptable: Pins/bolts Acceptable: Safety pins Acceptable: Support beams Acceptable: Welds Acceptable: Number of visible marks applied 2. Floor Area Floor plates Acceptable: Handrails & toe boards Acceptable: Handrail connections Acceptable: Setback material Acceptable: Floor bracing Acceptable: Welds Acceptable: Number of visible marks applied 3. Sub-Spreaders and Rotary Beams Rotary beams Acceptable: Spreaders Acceptable: Pin connections Acceptable: Pin holes Acceptable: Pins Acceptable: Pad-eyes Acceptable: Welds Acceptable: Number of visible marks applied 4. Dead Line Anchor Mounting Supports Acceptable: Bolts Acceptable: Flooring Acceptable: Breakover assembly Acceptable: Handrails Acceptable: Welds Acceptable: Number of visible marks applied 5. Substructure Components Beams straight Acceptable: Cross braces Acceptable: Pin/bolt holes Acceptable: Pin/bolts Acceptable: Safety pins Acceptable: Pull back posts Acceptable: Drawworks tiedowns Acceptable: Welds Acceptable: BOP anchor pad-eyes Acceptable: Pad-eyes Acceptable: Number of visible marks applied 6. Raising System Pin connections Acceptable: Pin holes Acceptable: Pins Acceptable: Wire lines Acceptable: Sheaves Acceptable: Bearings Acceptable: Seals Acceptable: Grease fittings Acceptable: Hydraulic winches Acceptable: Hydraulic cylinders Acceptable: Hydraulic hoses Acceptable: Cylinder hinge Acceptable: Number of visible marks applied Inspection Procedure of: Mast /Substructure Purpose: 10 Years Inspection Reference: OEM manual / API RP 4G Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: CAT IV: The entire mast must be inspected by a Professional Engineer or an Original Equipment Manufacturer (OEM) or his agent. This inspection shall include: Category III inspection in addition to the following: 1. The equipment is to be disassembled and cleaned to the extent necessary to conduct NDT of all defined critical areas. 2. An ultrasonic thickness test is recommended on all tubular style (or closed style) members to test for internal corrosion. 3. All welds (100 %) shall be visually examined. 4. All welds in critical areas shall be inspected using magnetic particle (MPI), liquid penetrant (PT) or ultrasonic testing (UT) in accordance with AWS D1.1. Welds on galvanized structures may require different inspection techniques and intervals. Cracks are generally identified through visual inspection on a galvanized mast/derrick. • Any damage found during the inspection is defined as MAJOR, SECONDARY, or MINOR, on the following basis. a. Major Damage – Significant geometrical distortion or structural damage to primary load carrying components including raising assembly, main legs, hinge points and crown. b. Secondary Damage – Damage or distortion to non-primary load carrying components. c. Minor Damage – Damage or distortion to ancillary equipment, i.e. ladders, monkey board, walk-around, tong hangers, etc. All damage may be repaired in the field. Major damage should be repaired in a shop-like environment and in accordance with the OEM or equivalent specifications Inspection Procedure of: Monkey Board / Stabbing Board Purpose: 2 Years Inspection Reference: OEM manual / API RP 4G Responsibility: Management and work site supervisors. Scope of work for each interval: Cat III “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 for all connections/mounting brackets and chains. 2. Visually check the main frame for bends, cracks, and deformations. 3. Visually check of the hoist (condition and wear). 4. Visually check the platform (incl. grating and handrails). 5. Visually check the welding of the monkey board fingers and the safety chain wear, cracks or deformation. 6. Visually check the stabbing board anti-fall mechanism and positive stopper installed underneath the track for any crack or deformation. 7. Perform MPI on the connections and critical weld areas of the main frame. 8. Perform a complete check on the secondary retention of all components. 9. Check the condition and content of the manufacturer’s nameplate. 10. Prepare and submit the Inspection report. Inspection Procedure of: Monkey Board / Stabbing Board Purpose: 5 Years Inspection Reference: OEM manual / API RP 4G Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: CAT IV :To Complete the full Cat III every two years inspection in addition to the following: 1. Sand blast the complete stabbing board/monkey board. 2. Perform MPI on all identified load bearing and critical areas/components of the stabbing board/monkey board as per the manufacturer’s specification. 3. Complete overhaul (including load test) of the hoist. 4. Repaint the stabbing board/monkey board. 5. Prepare and submit the inspection report. • Visible Marking of Damage 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. 1. Pipe Racking Platform: Frame Straight: Pin Hole(s): Pins: Safety Pins/Keepers: Frame Welds: Working Platform: Landing Platform: Handrails: Ladder Access: Fingers Straight: Finger Welds: Finger Safety Line(s): Hoist Mounting: 2. Casing Stabbing Board: Frame Straight: Welds: Handrails: Working Platform: Hoisting Assembly: Hoist Mounting: Lower Travel Stops: Pin or Bolt Holes: Pins or Bolts: Safety Pins/Keepers: 3. Tubing Support/Belly Board Frame Straight: 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. Scope of work for each interval: Full Inspection – Cat IV (every five 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. 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. Fully disassemble the hydraulic cylinder and clean all individual items. Mark or document the position of all components. 4. Inspect outside body of the main cylinder/barrel for impact damage, cracks or oil leaks. 5. Check, all the cylinders and rods surfaces for any pitting, wear cracks, distortion or damage; perform the required chroming or honing as required. 6. Measure the OD of the different rods and the ID of the cylinders; check if we have any wear or over dimension in any surface; Measurement should be done all over the length of the rods and cylinders “10 different points each” and to be measured on two quadrants 90 degrees apart from each other. 7. Perform NDT /liquid penetrant or MPI on the rods, cap ends, pad eyes. 8. Perform NDT/liquid penetrant or MPI on all gland nuts , retainers and stop/lock rings. 9. Measure the rod and cap ends eyes for any ovality or excessive wear. 10. Reassemble the hydraulic cylinders with the entire primary, secondary and wiper seals replaced with new ones. 11. Replace all the bleeder and counterbalance valves with new ones. 12. Perform a pressure test on the hydraulic cylinder assembly to the rated working pressure and check for any leaks or abnormalities 13. Prepare and Submit the final report ( ensure that proper air bleeding is performed on the cylinders during installation on the rig site). Inspection Procedure of: Raising Cylinders Purpose: 6 Months Inspection Reference: OEM manual / API RP 4G Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Cat III “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. 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. Scope of work for each interval: 1. Full Inspection – Cat IV (every five 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. Fully disassemble the crown block and clean all individual items. Mark or document the position of all components. 3. Perform MPI on the complete cluster frame, pad eyes, sheaves hub/web welding area, sheaves grooves, shaft ,pedestal and jumper bars/covers. Mark any crack, damage or discontinuity found on the items. 4. Measure and document the wear of the sheaves (grooves and rims) and shaft, reference the value to the OEM and API Spec 8C recommendations. 5. Reassemble the crown block using new bearings and seals. Use the sheave with the largest remaining wall thickness (shoulder thickness) as the “fastest” sheave in case that fast line sheave has same diameter as the running crown sheaves. 6. Visually check for any missing locking pins, nuts, snap rings of the block /block attachments after reassembly. 7. After reassembly; check the equal spacing between sheaves, deflection and endplay of the sheaves. 8. All pad eyes under crown platform and fall arrest device pad eye to have the SWL clearly stenciled on them. 9. Check the condition and content of the nameplate, traceability information, and serial number. 10. Prepare and submit the final /consolidated inspection report. 11. It is highly recommended to have a complete paint job on the whole crown assembly after all inspections and repairs completed, to remove any old repair marking and to avoid any future confusion. Inspection Procedure of: Crown Block Purpose: 6 Months Inspection Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Cat III “To be performed by a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority” (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. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Measure and record side movement on sheave #1, measurement records to be attached on sap. Measure and record side movement on sheave #2, measurement records to be attached on sap. Measure and record side movement on sheave #3, measurement records to be attached on sap Measure and record side movement on sheave #4, measurement records to be attached on sap Measure and record side movement on sheave #5, measurement records to be attached on sap Measure and record side movement on sheave #6, measurement records to be attached on sap Measure and record side movement on sheave #7, measurement records to be attached on sap Measure and record side movement on sheave #8, measurement records to be attached on sap Measure and record side movement on sheave #9, measurement records to be attached on sap Check and record all sheave grooves and rims wall thickness, against OEM wear limits and API Spec 8C requirements. Check sheave groove and web surfaces for any cracks and deformities ;( perform MPI on the sheaves grooves if job is performed during rig move). Verify crown sheave center pin retaining bolts are tight and have secondary retention devices installed. Visually check all crown cluster including fast line, frame and bumper blocks fasteners for tightness and ensure secondary retention devices are installed. 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). 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. Scope of work for each interval: 1. Full Inspection – Cat IV (every five 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. Fully disassemble the traveling block and clean all individual items. Mark or document the position of all components. 3. Perform MPI on the side plates, sheaves hub/web welding area, sheaves grooves, clevis/becket, shaft /top cover/bonnet and other load bearing items. Mark any crack, damage or discontinuity found on the items. 4. Measure and document the wear of the sheaves (grooves and rims), shaft and clevis/hanging attachment (including Radii, pins and pins holes) reference the value to the OEM and API Spec 8C recommendations. 5. Reassemble the traveling block using new bearings and seals. Use the sheave with the largest remaining wall thickness (shoulder thickness) as the “fastest” sheave. 6. Visually check for any missing locking pins, nuts, snap rings of the block /block attachments after reassembly. 7. After reassembly; check the equal spacing between sheaves, deflection and endplay of the sheaves. 8. Check the condition and content of the nameplate, traceability information, and serial number. 9. Prepare and submit the final /consolidated inspection report. 5 Yearly Inspection OF MCKISSICK Hook/ Block (Applicable for H001, H002 And H003) 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. 5. 6. 7. • Traveling block assembly Fully disassemble the traveling block and clean all individual items. Mark or document the position of all components. Perform MPI on the side plates, sheaves hub/web welding area, sheaves grooves, clevis, shaft and other load bearing items. Mark any crack, damage, deformation or discontinuity found on the items. Measure and document the wear of the sheaves (grooves and rims), shaft and clevis/hanging attachment (including Radii, pins and pins holes) reference the value top the OEM and API Spec 8C recommendations. Reassemble the traveling block using new bearings and seals. Use the sheave with the largest remaining wall thickness (shoulder thickness) as the “fastest” sheave. Visually check for any missing locking pins, nuts, snap rings of the block /block attachments after reassembly. After reassembly; check the equal spacing between sheaves, deflection and endplay of the sheaves. Check the condition and content of the nameplate, traceability information, and serial number. Prepare and submit the final /consolidated inspection report. • Hook Assembly Fully disassemble the hook and clean all individual items. Mark or document the position of all components. 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. 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. Reassemble the hook with new thrust bearing, case bushing, hook retaining ring and bonnet retaining ring. Visually check for any missing locking pins, nuts, locking mechanisms, snap rings of hook/attachments after reassembly. Check the condition and content of the nameplate, traceability information, and serial number. 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. Scope of work for each interval: Cat III “To be performed by a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority” (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) Traveling block assembly 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. Scope of work for each interval: 1. Complete required permit to work (PTW). 2. Mechanical and electrical Lockout / Tag out. 3. Review and complete Job Safety Analysis (JSA). 4. Inform area authority if work is carried out on critical equipment for the ongoing operation. 5. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan. 6. Completely disassemble the gooseneck assembly and remove it from the top drive bonnet. 7. Visually inspect the mud line pipe, S pipe, hammer unions, seals, and threads for any damage, pitting or excessive corrosion. 8. Perform a PT (Liquid penetrant) inspection on all the hammer unions and wireline plug threads. 9. Perform a wall thickness measurement (UT) on the mud line, extension pipe and S-pipe and compare it with the OEM and ASME B31.3 minimum requirements. 10. Check the condition of the secondary retention between the gooseneck and rotary hose and ensure that it’s matching with the drawing number STD-S-016 11. Prepare and submit the inspection report. Inspection Procedure of: VARCO TDS 11 SA/SH Purpose: 6 Month inspection (Field inspection) Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. 2. 3. 4. 5. Complete required permit to work (PTW). Mechanical and electrical Lockout / Tag out. Review and complete Job Safety Analysis (JSA). Inform area authority if work is carried out on critical equipment for the ongoing operation. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan. 6. Clean the Top drive thoroughly, wash with detergent to remove all grease, oil or mud. 7. MPI of critical exposed/external areas as per manufacturer’s recommendation: a. Bail b. Rotating link adapter c. Gearbox body d. Quill shaft upper & lower connection e. Upper and lower IBOPs f. Gripper clamp welding areas & stabbing bell g. Saver sub h. Spacer sub i. Elevator links j. Elevators k. Pipe handler links tilt catches /retainers l. Link tilt cylinders ends’ m. Link tilt clamps n. Torque Guide System including the hang – off link. (shackles, bolts, nuts etc.) 8. Visually check the welds on the top drive frame, guard, mounts and supports for cracks or damage. 9. Visually check the torque tubes for any wear, damage, proper assembly and alignment. 10. Visually check the condition of all bolted connections (including lock pins). 11. Remove the wash pipe assembly; check the upper quill shaft liner or connection for any erosion and measure the quill shaft end play (compare the measurement with OEM maximum limits) 12. Check for loose bolts and mountings for the blower, mast junction box, cable trays and hydraulic tubes. Check hydraulic cylinders, hoses, fittings and connectors and check for any oil leaks. Check the condition of blower frame welds and junction boxes mounted on top drive unit. 13. Visually check the service loop and service supports/mounts on the torque guide. 14. Visually check the Top Drive unit for loose bolts. Check lock pins of all bolts, screws, and pins. Check pins and pin holes for wear and damage. 15. Visually inspect the electrical cables on the Top Drive Unit. 16. Check all secondary retentions integrity. Inspection Procedure of: VARCO TDS 10 SH Purpose: 6 Month inspection (Field inspection) Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. 2. 3. 4. 5. Complete required permit to work (PTW). Mechanical and electrical Lockout / Tag out. Review and complete Job Safety Analysis (JSA). Inform area authority if work is carried out on critical equipment for the ongoing operation. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan. 6. Clean the Top drive thoroughly, wash with detergent to remove all grease, oil or mud. 7. MPI of critical exposed/external areas as per manufacturer’s recommendation: a. Bail b. Rotating link adapter c. Gearbox body d. Quill shaft upper & lower connection e. Upper and lower IBOPs f. Gripper clamp welding areas & stabbing bell g. Saver sub h. Spacer sub i. Elevator links j. Elevators k. Pipe handler links tilt catches /retainers l. Link tilt cylinders ends’ m. Link tilt clamps n. Dolly assembly 8. Visually check the welds on the top drive frame, guard, mounts and supports for cracks or damage. 9. Visually check the guide rails for any wear, damage, proper assembly and alignment. 10. Visually check the condition of all bolted connections (including lock pins). 11. Remove the wash pipe assembly; check the upper quill shaft liner or connection for any erosion and measure the quill shaft end play (compare the measurement with OEM maximum limits) 12. Check for loose bolts and mountings for the blower, mast junction box, cable trays and hydraulic tubes. Check hydraulic cylinders, hoses, fittings and connectors and check for any oil leaks. Check the condition of blower frame welds and junction boxes mounted on top drive unit. 13. Visually check the service loop and service supports/mounts on the torque guide. 14. Visually check the Top Drive unit for loose bolts. Check lock pins of all bolts, screws, and pins. Check pins and pin holes for wear and damage. 15. Visually inspect the electrical cables on the Top Drive Unit. 16. Check all secondary retentions integrity. Inspection Procedure of: VARCO TDS 11 SA - SH Purpose: 5 years inspection Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. Full Inspection – Cat IV (every five years): Complete the full Cat III every six months inspection in addition to the following: 2. Disassemble the Top Drive unit. 3. Inspect all the following hoisting load path components using magnetic particle techniques as specified on the Inspection Maps at the end of Section 4B of the OEM manual: a. Bail b. Rotating link adapter c. Main body casting d. Rotating link adapter shear rings e. Main shaft f. Upper and lower IBOPs g. Load stem h. Saver sub i. Spacer sub j. Main body shear rings k. Elevator links l. Elevators m. Pipe handler links tilt catches /retainers n. Link tilt cylinders ends’ o. Link tilt clamps p. Quill upper connection q. Torque Guide System including the hang – off link. (shackles, bolts, nuts etc.) r. Load collar 4. Measure and record the wear of the torque tubes and compare with maximum allowable tolerances as per OEM. 5. Check all bearings, seals, seal running surfaces, gears and splines. Refurbish as necessary. 6. Inspect the end plates and lugs in the torque tubes for any damage and ensure that the lugs are properly aligned between sections. 7. Reassemble the top drive, perform Dyno test. 8. Check all secondary retentions integrity. 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. Scope of work for each interval: 1. Full Inspection – Cat IV (every five years): Complete the full Cat III every six months inspection in addition to the following: 2. Disassemble the Top Drive unit. 3. Inspect all the following hoisting load path components using magnetic particle techniques as specified on the Inspection Maps at the end of Section 4B of the OEM manual: a. Bail b. Rotating link adapter c. Gearbox body d. Quill shaft upper & lower connection e. Upper and lower IBOPs f. Gripper clamp welding areas & stabbing bell g. Saver sub h. Spacer sub i. Elevator links j. Elevators k. Pipe handler links tilt catches /retainers l. Link tilt cylinders ends’ m. Link tilt clamps n. Dolly assembly o. Guide rails p. Load collar 4. Measure and record the wear of the guide rails and compare with maximum allowable tolerances as per OEM. 5. Check all bearings, seals, seal running surfaces, gears and splines. Refurbish as necessary. 6. Inspect all the welds in the Torque Guide System using magnetic particle techniques as specified on the inspection maps at the end of Section 4B of the OEM manual.’ 7. Reassemble the top drive, perform Dyno test. 8. Check all secondary retentions integrity. 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. Scope of work for each interval: 1. Send to TESCO authorized service center to perform complete dimensional visual, WFMPI/MPI inspection for recertification. Upon completion of inspection, schedule starts at zero operating days. 2. Disassemble the Top Drive unit. 3. Perform a magnetic particle inspection on all load bearing components over their entire surface (including internal bores) to reveal any fatigue or crack indications. the load bearing components are: • Yoke and link assembly • Split block and split block adaptor assembly (EMI 400) (Replace support bolts & liners) • Swivel gearbox housing. • Quill shaft • Load nut components (Replace all bolts) • Mud saver and actuator • Saver subs • Load collar • Elevator • Elevator links • Torque arrest system (Replace all bolts, nuts, studs & liners) • Pipe handler rotation system (Replace all bolts & nuts) • Gears train (Bull gear, Intermediate bull gear, Intermediate pinion & Input pinion) • Torque tubes (Sandblast / MPI) 4. Replace all gear box bearings, seals, O-rings, lubrication hoses and auxiliary hydraulic hoses. 5. Reassemble the top drive, perform Dyno test. 6. Check all secondary retentions integrity. 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. Scope of work for each interval: 1. Disassemble the Top Drive unit. 2. Inspect all of the following hoisting load path components using magnetic particle techniques as specified on the Inspection Maps at the end of Section 4B of the OEM manual : • Quill • Spindle • Split Ring • Upper link support • Rotary manifold outer sleeve • Housing • Upper links • Bail (if applicable) • Block Interface • Upper link pins (4) 3. Check all bearings, seals, seal running surfaces, gears and splines. Refurbish as necessary. 4. Inspect all the welds in the Torque Guide System using magnetic particle techniques as specified on the inspection maps at the end of Section 4B of the OEM manual. 5. Inspect the end plates and lugs in the torque tubes for any damage and ensure that the lugs are properly aligned between sections. 6. Reassemble the top drive, perform Dyno test. 7. Check all secondary retentions integrity. 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 Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Links under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s stamps. 3. Sand blast links as per the requirements of the Inspection Company 4. 5. 6. 7. 8. Visually check the Elevator Links for damage or cracks. MPI the whole link, measure the eye thickness for wear identification on both eyes. Measure length and check straightness of both links. Downgrade the links (according to the wear) to the new maximum load limits. Measure the following Inspection Procedure of: Elevators Purpose: 6 Months inspection Reference: OEM manual / API RP 8B Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM Manual and drawings of the Elevators under inspection, it must be used as the main guideline in all the following steps. 2. Sand blast the elevator to the inspection company’s requirements. 3. Measure the wear on the body parts, door, hinge pin, latch, latch pin, latch spring stop, latch lock bolt, door lock pin, latch cam and all other load bearing components and compare the measurements with the maximum wear tolerances. 4. MPI all of the above items as per the relevant API and manufacturer’s manuals. 5. For Y-type Elevators: check the slip visually, inserts, slip bolts, insert retainers, slip setting rings and guide plates for damage or wear. MPI the following items: slip elements, slip bolts, insert retainers and guide plates. 6. Measure clearance of hinge pin, latch pin and link ear thickness. 7. Inspect the wire line of the single joint elevators for any damage, kinks etc. 8. Measure bore taper angle, ID and height of center bore of type B and G elevators, Measure ID and thickness of top and bottom bore of R, T and S type elevators. 9. Reassemble the elevator with new springs. 10. Prepare and submit the inspection report. Chose the Appropriate Diagram Below and Enter the Measurements 1- Manual Elevator Center Latch 18 Degrees 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 2- Manual Elevator Center Latch slip type A- Body Latch Pin Holes ID (Record the largest one) B- Main Hinge Pin Hole ID Top C- Main Hinge Pin Hole ID Bottom D- Hinge Pin Hole ID E- Latch Pin OD (Record the smallest) F- Door Ear Radii G- Body Ear Radii H-Hinge Pin OD (Record the smallest) 3- Manual Elevator Center Latch Square Shoulder A- Top Bore ID B- Bottom Bore ID C- Body Latch Pin Holes ID (Record the largest one) D- Main Hinge Pin Hole ID Top E- Main Hinge Pin Hole ID Bottom F- Hinge Pin Hole ID G- Door Ear Radii H- Latch Pin OD (Record the smallest) I-Hinge Pin OD (Record the smallest) J- Body Ear Radii 4- Manual Elevator Side Door A- Hinge Pin Hole ID B- Latch Pin OD (Record the smallest) C- Latch Pin Holes ID Top D- Latch Pin Holes ID Bottom F- Body Main Hinge Pin Hole ID Top G- Body Main Hinge Pin Hole ID Bottom H- Main Hinge Pin OD (Record the smallest) I- Door Ear Radii J- Body Ear Radii 5- Manual Elevator Single Joint (Use Applicable drawing) Record All ODs and IDs shown in the drawings Inspection Procedure of: Spider Elevator Purpose: 1 Year Inspection Reference: API RP 8B / OEM manual Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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: 1. Disassemble the spider / elevator completely. 2. Measure and record all main components and compare with wear limits. 3. Perform full MPI as per manufacturer’s requirement. 4. Prepare and submit the inspection report. Inspection Procedure of: Spider Elevator Purpose: 6 Months Inspection Reference: API RP 8B / OEM manual Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the Kelly Spinner under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Name plate. 3. Break off the kelly spinner from the kelly. 4. Fully disassemble the kelly spinner and the drive components; perform MPI on the pinion, main gears, spinner body (inside and outside), bottom deck , friction plates, side plates ,brackets/gangers, sub inner threads ,bearing carriers for damage ,cracks ,wear or deformation. 5. Measure and record all above components and compare with wear limits. 6. Visually check the air or hydraulic system (piping, hoses, fittings, filters etc.); change the all flexible hoses. 7. Disassemble the air (or hydraulic) motor from the spinner housing and make a complete overhaul for the motors including new bearings seals and vanes ( if used) 8. Perform MPI on the threads, hinge eyes of turnbuckles and upsets of stem. 9. Measure the thread of the kelly drive sub for pin stretching and bore diameter. 10. Reassembly the kelly spinner with new bearings and seals. 11. After repair (if applicable) carry out function test and performance test to the maximum torque. Inspection Procedure of: Kelly Spinner Purpose: 6 Months inspection Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full 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. Prepare and make ready the OEM Manual and drawings of the Kelly Spinner under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Name plate. 3. Break off the kelly spinner from the kelly. 4. Visually check the bearing clearance and check for any damage, wear or cracks. 5. Visually check the air or hydraulic system (piping, hoses, fittings, filters etc.) 6. Disassemble the air (or hydraulic) motor from the spinner housing and visually check the condition of the motors (bearing clearance, condition of shaft, sprocket etc.) 7. Perform MPI on the threads, hinge eyes of turnbuckles and upsets of stem. 8. Measure the thread of the kelly drive sub for pin stretching and bore diameter. 9. Visually check the pinion, gears, spinner body (inside and outside), inner threads and sealing of connections for damage and wear. 10. Reassembly the kelly spinner and repaint as required. 11. Prepare and submit the inspection report. Inspection Procedure of: Dead Line Anchor Purpose: 5 Years inspection Reference: OEM manual / API RP 8B Responsibility: Management and work site supervisors. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the Deadline Anchor under inspection; it must be used as the main guideline in all the following steps. 2. Remove the dead line anchor completely from the base mounting. 3. Check the condition of the nameplate and all serial number / traceability details. 4. Visually check the anchor body, Base/mounting plate, foundation bolts, wire line guard, pigtail clamp for any damage, corrosion, deformation; MPI/liquid penetrant all the above components. 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. 10. Prepare and submit the inspection report. Inspection Procedure of: Dead Line Anchor Purpose: 6 Months inspection Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full 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. Prepare and make ready the OEM Manual and drawings of the Deadline Anchor under inspection; it must be used as the main guideline in all the following steps. 2. Hang off the top drive /traveling block, as applicable, on the dedicated hang off line or clamp; and remove the drilling line from the dead line anchor drum. 3. Check the condition of the nameplate and all serial number / traceability details. 4. Visually check the anchor body, grooves, Base/mounting plate, foundation bolts, wire line guard, pigtail clamp for any damage, corrosion, deformation; MPI/liquid penetrant all the above accessible areas. 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. 9. Prepare and submit the inspection report. Inspection Procedure of: Lifting Plugs /Subs Purpose: 6 Months inspection Reference: OEM manual / API RP 7G-2 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (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. Prepare and make ready the OEM guidelines, API Standard and drawings of the lifting plug/sub under inspection, it must be used as the main guideline in all the following steps. 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. Scope of work for each interval: 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. Scope of work for each interval: 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. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the Swivel under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Name plate. 3. Disassemble the Rotary Swivel to the extent necessary to conduct MPI/PT of all primary load carrying components as defined by manufacturer and ensure that all individual items are cleaned (Mark or document the position of each of the components). 4. Measure and document the wear of all components as necessary. 5. Visually check the body, bail, bottom connection and gooseneck for any damage, wear or cracks; MPI the critical load bearing items of the swivel like the bail, bail connection , bearing carriers /seats, bonnet ,brackets and main stem bottom connection. 6. Replace (if not already done) the 2” thread connection on top of the gooseneck with one butt welded connection. 7. Carry out wall thickness measurement and MPI of the gooseneck. 8. Reassemble the Rotary Swivel with new bearings and seals. 9. Check the swivel main bearing pre-load and add/remove shims as required. 10. Repaint as required. 11. Prepare and submit the inspection report. Inspection Procedure of: Swivel Purpose: 6 Months inspection Reference: OEM manual / API RP 8B Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full 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. Prepare and make ready the OEM Manual and drawings of the Swivel under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Name plate. 3. Visually check the body, bail, bottom connection and gooseneck for any damage, wear or cracks. 4. Replace (if not already done) the 2” thread connection on top of the gooseneck with one butt welded connection. 5. MPI the critical load bearing items of the swivel like the bail, bail connection and bottom connection. 6. Carry out wall thickness measurement of the gooseneck. 7. Check the swivel main bearing pre-load and add/remove shims as required. 8. Repaint as required. 9. Prepare and submit the inspection report. Inspection Procedure of: Drill Pipes Purpose: 6 Months inspection Reference: OEM manual / DS 1 Vol3 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every 6 Months or each rig Move): 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. Prepare and make ready the OEM Guidelines, DS 1 Standard and drawings of the Drill pipes under inspection, it must be used as the main guideline in all the following steps. 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 Scope of work for each interval: Full Inspection – Cat 3-5 (Every 250 hours for short wells or every 450 hours /after reaching 3,500 meters for long duration wells): 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. Prepare and make ready the OEM Guidelines, DS 1 Standard and drawings of the Bottom Hole Assembly and Drill String Accessories under inspection, it must be used as the main guideline in all the following steps. 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) a. Remove the valve from service. b. Fully open the valve and pump a small volume of fresh water through the valve to remove drilling mud residue from the ID bore of the valve. c. Fully close the valve and disassemble the valve completely. d. Visually Inspect threads for damage, stretching and galling. e. Visually inspect valve bore, seat bores, and stem bores for internal scratches or excessive wear. f. Perform Liquid penetrant (PT with fluorescent penetrants) on the following: i. Box / pin thread areas. ii. Area inside the operating crank window. iii. Fillet radii of internal grooves and shoulders. g. Change all the valve seat seals, Teflon rings and stem/crank O-ring. h. Reassemble the valve and fill with high-grade lithium based grease. i. With the valve in the closed position, conduct a pressure test according to OEM procedures and records the results. 1. Low Pressure test from 250 to 350 PSI for 5 minutes. 2. High-pressure test to the rated working pressure for 5 minutes. Inspection Procedure of: Raising Lines Purpose: 5 years inspection Reference: OEM manual / API RP 4G, AI RP 9B Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every 2 years or 8 Cycles): 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. Prepare and make ready the OEM Manual and drawings of the raising Line under inspection, it must be used as the main guide line in all the following steps 2. Remove the raising lines from the mast/substructure and store them carefully on a wooden palette or reel. 3. Check Nameplate or stamping condition of the raising lines assembly and verify Specs, serial number, and record serial number on the inspection report/certificate. 4. Visually check the end connections (spelters, shackles, pins, master links ….) for any damage, wear or deformation. 5. Visually check the raising lines for any damage, kinks, twist, corrosion or individual broken wires /strands and compare it to the acceptance criteria in the API RP 9B. 6. MPI /Liquid Penetrant the end connections (spelters, shackles, pins, master links ….); do not apply any eddy current inspection “only magnetic particles or liquid penetrant inspections are acceptable”. 7. Preserve with heavy oil or applicable lubricant before installation. 8. Prepare and submit the inspection report. 9. The raising lines assemblies to be completely scraped after 16 cycles of raising/lowering mast/substructure. Inspection Procedure of: Slings – Shackles – Pad Eyes Purpose: 6 Month Inspection Reference: OEM manual / API RP 9B / ASME B 30.9 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat VI “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. 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 STD0171-00 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. Scope of work for each interval: 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 Scope of work for each interval: Cat VI “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. Complete the full every six months inspection in addition to the following: 2. Fully sandblast the personnel 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. 5. Prepare and submit the inspection report. Inspection Procedure of: Personal Basket Purpose: 6 Month Inspection Reference: OEM manual / BS EN 14502-1:2005 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat III “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 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. Scope of work for each interval: Cat VI “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. Sling out the lifting block / hook. 2. Visually check the block / hook for any damage, corrosion or wear. 3. Check that hook swivel assembly is rotating freely. 4. Visually check the block sheaves depth (using a sheave groove gage) and the sheave bearing clearance using pry bar. If loose, need to identify the cause and replace the bearing, if needed. 5. Check the hook for any excessive bending, twisting, wear or throat opening and compare it with the OEM recommendations. 6. Perform MPI on the hook, hook pin, load bearing areas and outside plates of the block. 7. Repaint all of the components. 8. Prepare and submit the inspection report. Inspection Procedure of: Forklifts Forks Purpose: Yearly Inspection Reference: OEM manual / BS ISO 5057:1993 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat VI “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 support frame from the forklift as much as possible. 2. Visually check the forks and support for any damage, bends, corrosion or wear. 3. Measure the angle of the forks. The fork should be withdrawn from the service if the deviation was 3 degrees greater or less of 90o (or as per the OEM recommendations) between the blade and the shank. 4. Perform MPI on the fork arm, forks (critical areas) and attachments/brackets of the forklift support. Special attention shall be paid to the heel and the top and bottom hooks including their attachment to the shank. 5. Thoroughly measure the wear on fork arm blade and shank; if the thickness of the blade or shank is reduced to 90 % of the original thickness, or to the minimum thickness specified by OEM, the fork arm shall be withdrawn from service. A set of fork arms shall be checked for any difference in height when mounted on the fork carrier. If the difference in tip heights exceeds 3 % of the blade length or that recommended by OEM, the set of fork arms shall be withdrawn from service. 6. Check the safety chain between forks and fork support (if applicable) for damage or wear. 7. Check the bore of the shaft/pin type forks. Wear limit should not be more than 8. 10 % of the original bore or as per OEM recommendations. 9. Check for loose items (bolts, pins etc.) 10. Check the hydraulic lifting components for any damage or leakage. 11. Repaint as required. 12. Prepare and submit the inspection report. Inspection Procedure of: Casing Running Tools (CRT) Purpose: 5-years inspection Reference: OEM manual / DS1 Volume 4 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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”. Perform a complete tool teardown to inspect for any component damage and allow for relubrication 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. Remove the Bumper from the Lower Cam. Remove the Lower Cam Housing. Separate the Cage from the Upper Cam. 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. Ensure that the slip keeper is properly positioned. Assemble casing seal MPI and General Inspection Instructions 1. Perform MPI of the 100% of the mandrel surface, each jaw and die surface and spokes every 12 months. 2. Perform MPI of the 100% of the cage, intermediate cam, cam latch, upper cam, lower cam and latch keys every 12 months. 3. CAM INSPECTION - Check cam condition; ensure threads rotate freely and ramp surfaces are smooth 4. Mandrel Inspection ; perform the following dimensional check a) b) c) API Rotary Connection inspected per API RP 7G Area loss on cones acceptable Cones have uniform surface condition d) e) f) g) Flow bore appearance (free of washout or heavy corrosion) Inspect carrier thread and mandrel carrier thread Record results of UT inspection (Mandrel Neck Thickness measured in 5 locations) MANDREL INSPECTION DETAILS - SPLINE WIDTH MEASUREMENS 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. 3 When doing this 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. 4 Verify/re-apply alignment marks. 5 With the tool latched, verify the alignment of yellow and white marking on the upper cam housing and the bump ring which serve to identify the latched position. 6 Verify / re-apply paint on lower portion of upper cam housing. With the bumper removed and 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. 8 Rotate the tool clockwise to disengage latch hooks and apply air pressure to the 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. 10 Rotate tool clockwise to disengage latch hooks, air pressure in the housing will extend the dies into engagement with the ring of pipe. 11 Continue to rotate the tool to the right until the make-up ramps engage, when this happens the torque to rotate the tool will increase sharply. 12 Bleed the air pressure from the upper cam housing and remove the Schrader valve so that 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. 13 Verify that the tool is latched by applying air pressure to the housing. When doing this 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. 14 Check that die grip is appropriate for casing being run. 15 Check drift for retracted dies, cage and CS components using a drift ring per dimension specified in Appendix B. Note that the drift ring will not pass over the PkrCup. 16 Check condition and diameter of casing seal. Casing seal diameter should be as large as or larger than the maximum anticipated casing ID. Verify that replacement seals are available in inventory. 17 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 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 Scope of work for each interval: Cat VI “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. Complete the full every six months inspection in addition to the following: 2. Fully sandblast the personnel elevator 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. 5. Prepare and submit the inspection report. Inspection Procedure of: Personal Elevator Purpose: 6 Month Inspection Reference: OEM manual / BS 5655-10.2.1 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat III “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 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. Scope of work for each interval: 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” 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. Scope of work for each interval: Cat III “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 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. Scope of work for each interval: CAT IV “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. Full Inspection (every six months) By a Qualified Inspector: 2. Visually check the unit for any damage, corrosion or cracks. 3. Remove the paint from the critical welded areas (main frame, mounting plate etc.). 4. Perform MPI on all the critical welds. 5. Perform MPI on the pad eyes and lifting points (if applicable). 6. Repaint as required. 7. Prepare and submit the inspection report. Inspection Procedure of: Diverter Ball Valves Purpose: 5 years inspection Reference: OEM manual / API RP 598 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat IV Every 5 years to be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely disassemble the Diverter Ball Valve. 2. Visually check and MPI (Liquid penetrant testing) the body, Bonnets, seats, covers, bolts and nuts for damage, wear or cracks. 3. Dimensionally check all valve body and seats sealing areas. 4. Change all rubber seals, gaskets, O-rings. 5. Reassemble the ball valve. 6. Perform hydrostatic shell test, low pressure/high pressure closure test and pneumatic leak test. 7. Carry out complete overhaul and function test of valve actuator ( in case of hydraulically actuated) 8. Prepare and submit the inspection report. Inspection Procedure of: Drilling Spools / Flanges Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five 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. Visually check the equipment for any damage or cracks. 2. Measure and record the ring joint grooves, flange thickness, bolt hole size and number of holes. 3. Perform MPI on the welds between the body and flanges. 4. Pressure test to maximum working pressure and record. 5. Check the manufacturer’s name plate or stamps. 6. Check the material certificates of the equipment and if they are missing or incomplete conduct a material test. 7. Repaint the equipment as required. 8. Prepare and submit the inspection report. 9. Fully disassemble the traveling block and clean all individual items. Mark or document the position of all components. Inspection Procedure of: Hub Clamps Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Visually check the clamp and clamp with bolt and nut for any damage or cracks. 2. Measure and record the hub details, bolt and nut size. 3. Perform MPI on the hub and the clamp (including the bolt) and the weld between the hub and body (if any). 4. Check the manufacturer’s name plate or stamp. 5. Check the material certificates of the equipment and if they are missing or incomplete conduct a material test. 6. Refurbish painting of the equipment as required. 7. Prepare and submit the inspection report. Inspection Procedure of: BOP Shooting Nipple Purpose: 1-year inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Cat IV Every 1 year to be performed a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely disassemble the BOP shooting Nipple. 2. Visually check and MPI (Liquid penetrant testing) the body, end connections/flanges and side connections 3. Dimensionally check all flanges areas and ring grooves including the hold down flange. 4. Change all rubber seals, O-rings and lip seals. 5. Perform MPI and dimensional check on the hold down flange including the ACME threads. 6. Perform a wall thickness check on the shooting nipple body and compare to the minimum requirements. 7. Perform a pressure test to the rated working pressure of the annular BOP “using well head and hold down flange test plugs”. 8. Prepare and submit the inspection report. Inspection Procedure of: Ram Type BOP Purpose: 2 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Field Inspection – Cat III after 2 years from the last CAT IV inspection: To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely disassemble the BOP. 2. Visually check the body, flanges, bonnet bolts, threads and other main components for damage, wear or cracks. 3. Visually check sealing surfaces on the body, door, piston, intermediate flange, ram change piston, ram change cylinder and operating cylinder. 4. Inspect all rubber seals, gaskets, O-rings and Ram packing; replace components according to their physical condition. 5. Measure and record the wear on the ram cavities & all bonnets and check for cracks. 6. Measure and record flange ring grooves (lower, upper and side outlets). 7. Reassemble the BOP. 8. Carry out function test (with rams installed). 9. Prepare and submit the inspection report. Inspection Procedure of: Ram Type BOP Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely disassemble and sand blast the BOP. 2. Visually check the body, flanges, bolts, threads and other main components for damage, wear or cracks. 3. Measure and record the wear on the ram cavities & all bonnets and check for cracks. 4. Perform NDT on the BOP hoisting eyes and the weld between the flange and body. 5. Check sealing surfaces on the body, door, piston, intermediate flange, ram change piston, ram change cylinder and operating cylinder. Replace seals with new. 6. Measure and record flange ring grooves (lower, upper and side outlets). 7. Check hydraulic system and connections. 8. Perform MPI on all load bearing items (Ram blocks, body, flanges, pistons, operating cylinder, doors, bonnets, cavity area, bolts etc.) as per manufacturer’s recommendation. 9. Perform dimensional and hardness tests on Ram blocks. 10. Perform individual body pressure test as per manufacturer’s recommendation. 11. Reassemble the BOP. 12. Carry out function test (with rams installed) followed by one pressure test to WP. 13. Repaint the BOP (primer coat and final coat). 14. Preserve for storage and tighten on BOP transport skid. 15. Prepare and submit the inspection report Inspection Procedure of: Bag Type Annular BOP Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely disassemble and sand blast the BOP. 2. Perform MPI on all load bearing items (body, preventer head, flanges, piston, sleeve, sealing and thread areas etc.) as per manufacturer’s recommendation. 3. Perform MPI on the BOP hoisting eyes and the weld between the flange and body. 4. Measure and record the dimensions of BOP head, piston, body, lower flange, sleeve and adaptor ring (if exist), etc. Verify the measured dimensions are within the OEM tolerances/ recommendations. 5. Replace the annular packer, upper& lower piston seals, inner& outer head seals, and lower & upper adaptor ring seals (if any). 6. Check all hydraulic system and connections. 7. Individual body pressure test as per manufacturer’s recommendation. 8. Reassemble the BOP. 9. Carry out function test (with installed packing unit) followed by one pressure test to working pressure. 10. Check condition and details of the manufacturer’s name plate. 11. Repaint the BOP (primer coat and final coat). 12. Preserve for storage and tighten on BOP transport skid. 13. Prepare and submit the inspection report. Inspection Procedure of: Choke / Kill lines Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Fully disassemble the HP valves and other components. 2. Change all the valves seals and packing and check for the rising stem condition. 3. Remove the paint from the areas to be inspected. 4. Visually check all components including HP valves, hammer unions and sealing areas for any damage, deformation, wear, corrosion or cracks. 5. Measure and record all the API flanges, according to API 6A. 6. Measure and record the main components and compare with wear limits. 7. Perform MPI on all welds and sealing areas of HP valves. 8. Carry out and document wall thickness measurements on pipes (min. three measurements per meter). Compare with maximum wear limits recommended by manufacturer and API RP 574. 9. Carry out pressure tests on all components to working pressure. 10. Remove the Choke/Kill Hose from service and send it to an approved facility for the following: 11. Visually inspect the choke and kill hoses steel outer Wrap for any damage, deep notches or cuts. 12. Full internal Bore-O scope inspection 13. Full pressure test to 1.5- 2 x Working Pressure according to hose API 16C specifications. 14. MPI Inspection on all end fitting area 15. Repaint as required. 16. Grease and preserve ring joints and sealing areas. 17. Prepare and submit the inspection report. Inspection Procedure of: Chicksans – Swivels Purpose: Yearly inspection Reference: OEM manual / API 570 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full Inspection – Cat IV (every year): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Completely dismantle the swivels. 2. Visually check all pipes, swivels and hammer unions for damage, wear or cracks. 3. Visually check all seals, seats and bearing housings in the swivels. Check bearing clearance. For tolerances refer to manufacturer’s specification. 4. Measure wall thickness on specific points over the full length of the pipes (minimum three (3) points per meter) and mark the checkpoints on a sketch or drawing. 5. Measure wall thickness on complete swivels. 6. Perform MPI on the swivel and hammer union seal areas and on welds between pipe and swivel and hammer union. 7. Reassemble the swivels and joints. 8. Conduct pressure test on all components to working pressure. 9. Repaint as required. 10. Prepare and submit the inspection report (stamp new inspection date on stainless steel band). Inspection Procedure of: High Pressure Choke Manifold / Valves Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Disassemble the choke manifold and HP valves completely. 2. Visually check all items for damage, wear, corrosion, erosion or cracks. 3. Measure wall thickness on specific points of the HP piping, T-joints and buffer manifold. Mark position of checkpoints on a drawing. 4. Perform NDT on welds and hammer union sealing areas (inside and outside). 5. Measure and record all flange details and ring groove details for all valves, crosses and HP-T pieces. 6. Disassemble all valves and chokes and inspect the items for damage, corrosion, erosion, wear or cracks. 7. Perform MPI on all welds, hammer unions, ring joints and valve seat areas 8. Calibrate all pressure gauges. 9. Perform individual body test on buffer manifold to rated working pressure. 10. Carry out full inspection on the remote-control panel and gauges and stroke counter (if applicable). 11. Check the condition and details of the manufacturer’s name plate. 12. Repaint as required. 13. Prepare and submit the inspection report. Inspection Procedure of: Mud gas separator Purpose: 5 years inspection Reference: OEM manual / API STD 53 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Perform the RAMS 3 Months PM of the MGS. 2. Open the MGS Manway. 3. Verify the condition of the inner surface of the Mud Gas Separator for any signs of cracks or excessive corrosion. 4. Verify the baffles/slotted pipe condition for any damage. 5. Perform MPI on all the MGS body, inlet lines, return lines, vent lines and piping clamps/brackets welding. 6. Perform wall thickness measurement on all the MGS body and compare it with the minimum recommended thickness. 7. Prepare and submit the inspection report. Inspection Procedure of: HPP and Standpipe Manifold Purpose: 2 Years inspection Reference: OEM manual / API 570 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full Inspection – Cat III (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”. 1. Prepare and make ready the OEM Manual and drawings of the high-pressure piping and standpipe manifold under inspection, it must be used as the main guideline in all the following steps. 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. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the high-pressure piping and standpipe manifold under inspection, it must be used as the main guideline in all the following steps. 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. Scope of work for each interval: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector: a competent person and all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”. 1. Remove the accumulator bottle from service. 2. Disassemble the bladder and the poppet valve assembly. 3. Replace the bladder with a new one. 4. Check for the condition of the poppet stem, spring, spacer and stop nut and Replace any O- rings or rubber parts installed. 5. Conduct a wall thickness measurement on all the accumulator bottle shell area and compare it with minimum requirements (OEM recommendations). 6. If the thickness is thinner than the recommended OEM value, that can be a cause of rejection and removal from service and replace with new one. 7. Reassemble the accumulator, bladder and poppet valve assembly. 8. Charge accumulator bottles to the manufacturer’s requirements. 9. Repaint the accumulator bottle. 10. Prepare and submit the inspection report. Inspection Procedure of: MP Pulsation Dampener Purpose: Yearly inspection Reference: OEM manual / API RP 510 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. 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”. 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 Scope of work for each interval: 1. 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”. 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. 6. Perform MPI on the whole body and wall thickness inspection. 7. Replace all studs, nuts and fasteners with new items 8. Pressure test to working pressure (use a dummy seal). 9. Replace rubber element and stabilizer 10. Repaint all these components. 11. 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: Mud Pump Pressure Relief Valve Purpose: 1 Year inspection (Field inspection) Reference: OEM manual Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 1. Inform area authority if work is carried out on critical equipment for the ongoing operation. 2. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan. 3. Remove the relief valve from the high-pressure pump manifold. 4. Disassemble the valve, check and clean internal and external components 5. Visually check all parts for damage, cracks, corrosion and wear (especially on valve body and seat). Replace parts as required. 6. Visually check the inlet and outlet piping for signs of deposits. 7. Check the reset provision and function test of reset mechanism several times. 8. Test the relief valve to ensure that it relieves at the set pressure stated using a certified monitoring gauge. The test shall include a minimum of 3 different pressures spanning the full range of the relief valve (including zero setting) 9. The pressure relief valve manufacturer portable test kit with a proper test gauge (1/4 % full scale accuracy) and adapter flange is recommended to be used. 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 Scope of work for each interval: 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. Completely disassemble the Flow Line. 2. Clean out all solidified mud and cement using High Pressure washer cleaner. 3. Visually check and MPI all flow line assemblies, end connections and flushing line connection. 4. Visually check the flow line body for any damage, deformation, cracks or excessive corrosion. 5. Change all rubber seals, O-rings. 6. Perform a wall thickness check on the flow line piping and elbows. Compare to the minimum wall thickness required. 7. Reassemble the flow line. 8. Prepare and submit the inspection report. Inspection Procedure of: BOP Lifting Device Purpose: 1 Year Inspection Reference: OEM manual / API RP 7L Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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. Remove the BOP hoisting device from the traveling beams. 2. Dismantle the hoisting device as much as needed. 3. Visually check all items (BOP hoist body, trolley assembly, chain containers, all relevant piping) for any damage, wear/corrosion or cracks and for any missing bolts/nuts. 4. Measure and record the wall thickness of the traveling beams (in the “working area”). 5. Perform MPI on the hook, traveling beam connections and sheaves (if applicable). 6. Check the condition and content of the manufacturer’s nameplate. 7. Repaint the items as required (including the SWL sign). 8. Prepare and submit the inspection report. Inspection Procedure of: BOP Lifting Device Purpose: 4 Years Inspection Reference: OEM manual / API RP 7L Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. 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: 1. Completely disassemble of the hoisting device. 2. Visually inspect and measure the main hoist (or hydraulic cylinder) components. 3. Compare the measurements with maximum allowable tolerances from the manufacturer. 4. Reassemble the BOP lifting device using new O-rings, seals and gaskets. 5. Reinstall the unit and conduct function and performance test to maximum load. 6. Repaint all the components. 7. Prepare and submit the inspection report. Inspection Procedure of: Air Tanks Purpose: 2 Years inspection Reference: OEM manual / API 510 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: Full Inspection – Cat III (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”. 1. Prepare and make ready the OEM Manual and drawings of the Air Tanks under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Nameplate. 3. Visually check all nozzles and associated piping/fittings for any visible defects. 4. Measure and document the wall thickness of the vessel body (minimum 6 points per square meter), paying particular attention to areas where water can gather.following the below guidelines for the minimum wall thickness limits. 5. Perform MPI on critical weld joints (connections and nozzles) 6. Prepare and submit the inspection report which is to include determination of corrosion rate where previous readings are available. 7. Ensure that the SWP is clearly visible on the external of the vessel. General Inspection Guidelines and Ex for minimum thickness calculations Inspection Procedure of: Air Tanks Purpose: 5 Years inspection Reference: OEM manual / API 510 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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. Prepare and make ready the OEM Manual and drawings of the Air Tanks under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Nameplate. 3. Release the pressure from the vessel and disconnect all lines, valves and gauges etc. 4. Open the inspection hole of the vessel. 5. Visually check the vessel for any damage, corrosion or wear. 6. Visually check all nozzles and associated piping/fittings for any visible defects. 7. Measure and document the wall thickness of the vessel body (minimum 6 points per square meter), paying particular attention to areas where water can gather.following the below guidelines for the minimum wall thickness limits. 8. Perform MPI on critical weld joints (connections and nozzles) 9. Prepare and submit the inspection report which is to include determination of corrosion rate where previous readings are available. 10. Where deemed necessary by the inspector, a hydrostatic pressure test may be required to 1.5 the rated working pressure. 11. The test medium should be water and special consideration should be given to the supporting structure and foundation design. 12. Ensure that the SWP is clearly visible on the external of the vessel. General Inspection Guidelines and Ex for minimum thickness calculations Inspection Procedure of: Air Safety Valves Purpose: 1 Years inspection Reference: OEM manual / API RP 576 Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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”. 1. Prepare and make ready the OEM Manual and drawings of the Safety Valve under inspection, it must be used as the main guideline in all the following steps. 2. Release the pressure from the vessel. 3. Remove the air pressure Safety valve. 4. Visually check the safety valve for any damage, corrosion or wear. 5. Visually check the inlet and outlet piping for signs of deposits. 6. Test the safety valve to ensure that it relieves at the set pressure stated using a certified monitoring gauge. 7. Repaint and stamp new inspection date in stainless steel ring. 8. Check the condition and content of the manufacturer’s nameplate. 9. Prepare and submit a certification certificate. Inspection Procedure of: Fall Arrestors and Emergency Escape Devices Purpose: 4 Years Inspection Reference: OEM manual / ANSI - ASSE Z359.14-2012 Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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 Scope of work for each interval: 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. Remove the arrestor or escape device from the working position. 2. Visually check the device for any damage, corrosion, wear or cracks. 3. Visually check the wire line for any cuts, kinks, corrosion or broken wire. 4. Check that the “Pull line “can be pulled out and retracts fully. 5. Perform MPI on the welds, the mounting brackets and any shackle or swivel. 6. Check the condition and content of the manufacturer’s nameplate. 7. Repaint the items as required. 8. Prepare and submit the inspection report. Inspection Procedure of: EX (e) and EX (d) systems Purpose: 3 Years Inspection Reference: IEC 60079-17 – Explosive Atmosphere – Part 17: Electrical Installations Inspection and Maintenance Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent Scope of work for each interval: 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 deenergized. 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 1.2 “Close/Visual” Inspection (3 years) 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 Scope of work for each interval: 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” 1. 2. 3. 4. 5. 6. Remove the cylinders from service. Verify all valves, caps and regulators condition. Change all gauges and hoses with new ones Perform complete hydro-test as per manufacturer’s specifications and API RP 510 requirements. Stamp new expiry date on the cylinders. Prepare and submit the inspection report Inspection Procedure of: BA Cylinders FG Purpose: 3 Years Inspection Reference: API RP 510 And OEM Responsibility: Rig Manager, Drilling Superintendent Scope of work for each interval: 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. 2. 3. 4. Remove the cylinders from service. Perform complete hydro-test as per manufacturer’s specifications. Stamp new expiry date on the cylinders. Prepare and submit the inspection report 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 Scope of work for each interval: 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” 1. 2. 3. 4. Remove the cylinders from service. Perform complete hydro-test as per manufacturer’s specifications. Stamp new expiry date on the cylinders. Prepare and submit the inspection report 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 Scope of work for each interval: 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” 1. Verify extinguishers properly mounted and accessible 2. Verify charge pressure and handle lock and seal installed properly. 3. Verify powder level correct, dry and not compacted 4. Verify discharge hose and nozzle in good condition and not plugged with powder. 5. Verify the external condition of the extinguisher body for dents, punches, cracks or damage. 6. Perform hydrostatic pressure test to the factory testing pressure and as per the procedures of the NFPA 10 requirements. Inspection Procedure of: Gas Detection System Purpose: 3 Months Calibration Reference: OEM manual Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent Scope of work for each interval: Cat IV Every 3 Months to be performed by a competent person and accredited third party, approved by Abraj technical authority”. 1. Control Unit and sensors need to be verified Vs the relevant output of 4-20 mAmps, reading on the control unit and Scale Bar. 2. If values are not matching the input of the sensors calibration cylinders; a full calibration need to be done. 3. The calibration to be done is for zero settings and full-scale setting. 4. Re-verify the final readings after doing the full calibration adjustment on the control unit. 5. Prepare and submit the calibration report. Inspection Procedure of: Spinning Wrench Purpose: 1 Year inspection Reference: OEM manual Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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”. 1. Prepare and make ready the OEM Manual and drawings of the Spinning wrench under inspection, it must be used as the main guideline in all the following steps. 2. Check the Serial No. and Manufacturer’s Name plate. 3. Visually inspect all the unit fasteners for tightness, damage or corrosion. 4. Visually inspect all the pins/holes (bearing movement areas) for excessive wear. 5. Visually inspect all the hanging points, lifting eyes, shackles and adjustment bolts for excessive wear, damage or deformation. 6. Extend lifting cylinder and visually inspect the chrome surface for any pitting or excessive wear condition. 7. Visually inspect the snub line attachments, brackets, shackles and pins for excessive wear, damage or deformation. 8. Extend the clamping cylinder and visually inspect the chrome surface for any pitting or excessive wear; check the attachment points and eyes for wear and excessive tolerance. 9. Remove the drive motor (If applicable); clean muffler and check the drive and gear case pinion gears condition. 10. Check the spinning rollers diameter for excessive wear (Make the measurement from the center of the rollers away from the edges as much as possible) 11. Perform an MPI (PT for narrow areas) for all the accessible weld and critical areas including the power scope adapter assembly (if installed). 12. Visually inspect all hydraulic/pneumatic hoses for damage, kinks, cuts reaching the internal wire layer of the hoses and replace if necessary. 13. Prepare and submit the inspection report. Inspection Procedure of: Ezy Torque/Hydraulic Cathead Purpose: 1 Year Inspection Reference: OEM manual Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Scope of work for each interval: 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 cylinderchroming 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. Scope of work for each interval: 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. Completely disassemble the ezy torque/hydraulic cathead. 2. Perform Complete CAT III inspection beside the following steps. 3. Change all the hydraulic cylinder seals with new ones. 4. Visually check the hydraulic cylinder for any damage, wear or deformation. 5. Replace all the sheaves bearings /bushings and seals with new ones. 6. Replace all hydraulic hoses with new ones. 7. Perform MPI on all critical load-bearing areas including frame, foundation base, lock plate area, axle, roll holder, sheaves/ sheaves grooves and pivot arm. 8. Reassemble the ezy torque/hydraulic cathead; repaint as required. 9. Perform a complete function and pulling test to the rated working load. 10. Check the condition and the traceability of the OEM nameplate. 11. Prepare and submit the inspection report. Inspection Procedure of: Thermography Inspection Purpose: 1 Years Inspection Reference: NFPA 70B Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent. Scope of work: 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. Benefits of Thermographic Inspection a) Equipment life can be extended b) Plant downtime may be reduced c) Plant reliability may be increased d) Plant repairs scheduled for the most convenient time e) Quality of repair work may be inspected
