Beruflich Dokumente
Kultur Dokumente
OF
CENTURY RIG 14
Prepared for
CENTURY DRILLING
By
Rig Inspection Services Pte Ltd
30 Toh Guan Road #08-09 ODC Districentre Singapore 608840
Inspection date: 25th 30th of March 2008
TABLE OF CONTENTS
1
INTRODUCTION
1.1
Rig Data
1.2
1.3
Applicable Standards
SUMMARY OF SURVEY
2.1
Discrepancies Categories
10
2.2
Summary of Discrepancies
10
11
3.1
Draw works
11
3.2
Rotary Table
13
3.3
Swivel
13
3.4
Kelly Spinner
14
3.5
Crown Block
14
3.6
15
3.7
Drilling Instrumentation
15
3.8
Master Bushing
16
3.9
Hawk Jaw
17
3.10
Elevators / Slips
18
3.11
Rig Tongs
18
3.12
Elevator
19
ELECTRICAL EQUIPMENT
21
4.1
Main Generators
21
4.2
Camp Generators
21
4.3
23
4.4
Transformers
24
4.5
SCR
24
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4.6
25
4.7
Lighting
26
4.8
26
4.9
AC Motors
27
4.10
DC Motors
29
4.11
Elmagco Brake
33
MECHANICAL EQUIPMENT
34
5.1
Caterpillar Engines
34
5.2
Air Compressors
35
5.3
Air Receivers
36
5.4
36
5.5
37
38
6.1
Mud Pump # 3
38
6.2
Mud Pump # 2
40
6.3
Mud Pump # 1
42
6.4
44
6.5
Vacuum Degasser
45
6.6
Mud Tanks
46
6.7
Trip Tank
46
47
7.1
Accumulator
47
7.2
48
7.3
48
7.4
Annular
49
7.5
Choke Manifold
50
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PREVENTATIVE MAINTENANCE
50
8.1
Preventative Maintenance
50
51
10
SPARE PARTS
51
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1
1.1
INTRODUCTION
Rig Data
Rig:
Owner:
Type:
Location:
Inspection Dates:
1.2
Century Rig 14
Century Resources
Land Rig
Cirebon Indonesia.
25th 30th March 2008
In accordance with the instructions received by Century Resources, two surveyors attended
Century Rig 14 in Cirebon Indonesia to complete a Rig Condition Survey.
The aim of the survey was to determine the present condition of the Drilling Package and
associated equipment ensuring the equipment was fit for the intended purpose and in a safe
operating condition.
Included in the above scope was the following:
Carryout the inspection of the equipment to the criteria of the checklist supplied by Century
Resources.
The audit was conducted in good faith and without prejudice.
1.3
Applicable Standards
The inspection criteria, which have been used as reference during this inspection, are the
owners safety and operating standards, the original equipment manufacturers maintenance and
operating specifications and accepted oilfield operating and safety practices.
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SUMMARY OF SURVEY
RIS Surveyors attended Century Rig 14 in Cirebon Indonesia to complete a Rig Condition and
Safety Survey.
An inspection work scope had been determined by correspondence with the Maintenance
Manager prior to mobilization to the rig. A subsequent meeting was held on site with the Rig
Manager and the attending surveyors to discuss and coordinate the work scope of the inspection.
The aim was to assist personnel with forward planning and to prepare documentation and the
equipment for inspection.
At the time of inspection, the rig was being packed for shipment and was not operational which
allowed very good access to most equipment for intrusive inspections. Given that a substantial
amount of the equipment was not able to be operated, it was not possible to test some of the
safety devices or carryout any functional checks on most of the equipment. Should this be
requirement by either Century or their client then a subsequent visit would be required when the
rig was in a fully operational state. This would involve the RIS surveyor to be in attendance for
the close out and acceptance of the rig.
If all recommendations and planned maintenance repair procedures are followed and a suitable
reactivation period be allowed, then it would be fair to state that the rig could be expected to
operate in a safe and continuous manner on a drilling program.
Drilling Equipment
An intrusive inspection was carried out on the National 80-UE draw works which was found to
be in an acceptable condition. Bearing lift checks were conducted on the main drive shaft, jack
shaft and drum shaft, these were all found to be within the manufacturers acceptable limits,
there was no functional testing of this unit whilst we were on site.
The rotary table was visually inspected, the gear backlash 0.043 which is acceptable. The
master and split bushings were found to be in poor condition, dimensional checks were
conducted and exceeded manufacturers specifications for wear limits.
The Ideco 500T Swivel was visually inspected; the Quill stem length was measured and was
only 10 long. It would be recommended to have a spare Quill available.
There were no NDT records available on location for neither the travelling block nor the hook
assembly. Documentation is reported to be in the Jakarta office however if not available NDT
inspection should be conducted prior to the rig commencing the new contract. On the block, one
side door was opened to access the sheaves, bearing side movement checks were conducted and
found acceptable, the sheaves were gauged with only minimal wear noticed and found to be in
good condition. The latch and lock for the hook lever were functioned and working as they
should.
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Drilling Mast
The drilling mast was visually inspected and there was no obvious damage noticed to the
structure, all main supports and diagonal braces were found to be in good condition. There were
no recent NDT reports available for the mast or substructure however a third party Inspection
Company is currently on location and in the process of conducting NDT on all critical areas of
the mast. The NDT was 80% completed during our inspection with no defects found at that
time.
The crown sheaves were rotated and side movement checks conducted on bearings, minimal
movement only was detected and found to be in good condition, the line grooves on all sheaves
were gauged and checked for wear. Only slight wear was detected however well within the API
recommendations.
A rubber type bumper block is fitted to the underside of the crown and well secured, all padeyes in the crown section were noted to be numbered and a pad-eye register was available,
currently all pad-eyes are being inspected by third party and once completed will require colour
coding with the current colour for this six monthly period.
The racking board was checked, all fingers were straight, handrails acceptable, the main frame
and pad-eyes need to be NDT inspected and is in the current work scope for the NDT.
Due to the sections of mast and substructure being stacked it was not possible to locate the mast
compliance plates to confirm load ratings.
The rig floor personnel elevator was visually inspected. Further inspection will be required once
it is rigged up on location.
All pipes handling equipment was inspected, documentation was not available on location to
show previous NDT inspections, generally the elevators and slips were found to be in good
condition.
The Iron roughneck is currently waiting on parts to repair the hydraulic motor on the pipe
spinner.
Substructure
The substructure was visually inspected and due to being packed for mobilization it was not
possible to get 100% access to all areas, NDT inspections have been conducted on all critical
areas with no defects found at the time of our visit, all accessible sections of the substructure
that were inspected were found to be in acceptable condition. The raising system appeared to be
in good condition, all sheaves were gauged and bearing checks conducted the raising lines and
bridal line were visually inspected and found to be acceptable.
No function checks were conducted on the Lantec Winches.
Electrical Equipment
Due to the mobilisation of the rig, one air compressor was the only electrical equipment that
was operational at the time. Extensive checks were performed on the electrical aspect of the
Mud pumps, Draw works and camp generators. It was agreed that the Drilling generators would
not be inspected due to the planned change out of these Engine /Generator packages.
Unfortunately the SCR house was packed and secured for shipping so further checks should be
performed on this equipment after Rig arrives on location and electrical system is energised for
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drilling operation. Checks still outstanding and should be completed prior to start up are as
follows.
Full function test of engine shut downs.
Under voltage, over and under frequency and reverse power trip tests.
Inspection of all MCC and SCR modules.
Inspection of generator power limit function (if system installed)
Drilling instrumentation checks.
Rig PA function test.
Complete lighting inspection.
Hazardous area electrical equipment inspection.
Re-inspection of electrical Generators and DC motors that had very low insulation readings
recorded as per below report.
Mechanical Equipment
As previously mentioned, it was not possible to run function tests on most of the equipments;
however we did manage to run one MCC generator 480 V to supply temporary power to the
office, no ESDs or safety systems were functioning as tested on the rig.
Both air hoists were visually inspected and have line and drum covers fitted, SWL is visible,
and line spoolers are fitted to both winches. The mechanism for disengaging the drum has been
removed and the system is locked into the engaged position to prevent free-wheeling of the
drum, and complies with safety requirements as detailed in OEM safety alerts. No function tests
have been conducted.
The Ingersoll-Rand Man Rider winch was not connected and no function test conducted this is
an approved dedicated man riding device and complies as per manufacturers spec.
The air package consists of four compressors, 2 x Sullair, 1 x Champion and 1 x Cold start.
The 2 Sullair series10 air compressors were visually inspected, only number one was
operational during the inspection. Isolation valves, instrumentation and pressure relief valves
have been checked.
The cold start with Sullair compressor was inspected and operated; the Un-loader system was
checked and functioned as it should.
Mud Systems
The mud tank system was inspected and found to have some areas with corrosion, the internal
coatings of the tanks have deteriorated in areas causing corrosion pitting and may require some
welding repairs, and work is currently in progress to descale these areas to further assess the
condition.
The low pressure lines appeared to be in good condition, it would be recommended that UT
thickness checks be conducted to assess the overall condition of the tanks and pipe work for
preventative maintenance purpose.
The standpipe and mud lines were visually inspected and appear to be in fair condition. No
documentation was available on location for previous UT inspections, the wall thickness checks
need to be conducted periodically to assess the integrity of the pipe for safe working pressure
ratings. Reports also need to be kept for any modifications of sections that have been welded
into line which should include NDT radiography proof pressure tests for the high pressure
system.
Report Title: Century Rig 14
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The three DFE shakers were inspected and were found to have been poorly transported; two of
the shakers have not been secured to the beds causing some damage to the electrics and screen
tensioners. The repairs were completed during the inspection and were found to be acceptable.
Mud pumps
The three National 9-P-100 Mud Pumps, 2 x electric and 1 x driven by Cat D399, underwent an
intrusive inspection and were found to be in acceptable condition with no major faults noted.
Bearing lift checks were conducted on all pinion, crank and eccentric bearings, the crosshead
clearances checked, all readings taken are within the manufacturers recommended tolerances.
A check of the back lash between the Bull Gear and the Drive pinion was taken and this was
found to be within the manufacturers specifications.
Well Control
The Shaffer single was opened and inspected, ram blocks rubbers and seals were found to be in
good condition. Cavity measurements were acceptable and within tolerances. No pressure test
or function tests were conducted. Ring grooves were well protected and in good condition.
On the double , the upper rams were opened and required cleaning, it appears that they were not
properly flushed on the previous job leaving a large amount of cement in the cavity and around
ram blocks, cleaning was completed and measurements taken and found to be acceptable.
The lower doors were opened and were found to be in similar condition.
No documentation for the BOP was available on location; we have been informed that this is
available in Jakarta office. Current certification should be provided and full low and high
pressure tests should be conducted to ensure that the equipment is in a safe operating condition.
The Hydril MSP 2000 20 Annular was visually inspected, the element / ring grooves appeared
to be in good condition, the 4 lifting eyes were noted to have been NDT inspected however one
of the eyes is badly damaged.
The Choke manifold was checked and all valves were free and easy to open / close, one valve
was removed for internal inspection and found to be in acceptable condition. No pressure test
charts were available for previous tests; we have been informed that the previous tests were only
conducted to 1200 psi. A full pressure test program should be undertaken which should include
both low and high pressures tests from both sides to the SWP of the respective sides of the
choke manifold.
The Accumulator was not connected during the inspection and no function test conducted, the
unit has three banks of six bottles, these banks can be isolated individually and bled back to the
reservoir, it was noted that there was a low pressure alarm fitted, the alarms was not functioned.
A full accumulator drawdown test should be conducted when the BOPs are rigged up to ensure
that the unit has sufficient residual capacity to meet both the requirement of the client and API
specification whichever of the two are greater.
We would like to thank the management of Century drilling for the opportunity to provide our
services for the inspection of Century Rig 14.
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2.1
Discrepancies Categories
Summary of Discrepancies
This section has been covered in the Action Item excel spreadsheet which supplements the main
report, these two documents encompass the report package for this survey. The equipment has
also been given a rating on the spread sheet which is based upon condition evaluation. This dual
grading has proven beneficial to other drilling contractors when prioritizing remedial work
scopes.
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The oil pump, chain and sprockets were found to be in good condition.
Both main drive couplings were inspected, the off driller side has noticeable wear on the draw
works side inner and outer splines, possibly caused from previous misalignment. We considered
the coupling acceptable for operation at this time, however, recommends conducting checks on
the alignment to prevent further deterioration.
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The brake linkage system was found to have excessive movement in the S-link and bell crank
pin bores. The main brake through shaft mounting blocks is worn and this is causing the shaft to
flex under load. There were no recent NDT records available on the rig to show bands and
linkages have been inspected.
The front left hold down bolt on Draw works motor A, appears to be bent or cross threaded.
3.1.1
Critical:
None.
Major:
Excessive wear noticed in pin bores on the S-link and the bell cranks on driller
side, the main through shaft is flexing under load, this could be due to the
amount of wear in the shaft pillow blocks. Recommend that the worn linkages be
replaces.
The main brake shaft will need to be removed to check if the wear is in the
mounting block bores or main through shaft.
No NDT records were available on rig location; if no current records are
available it would be recommended to conduct the inspection prior to
commencing work.
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Recommend to replace the hold down bolt or check that it is not bent or cross
threaded.
Minor:
The drive coupling from the DC motor to the draw works main drive shaft off
driller side was found to be worn on the inner and outer splines, we recommend
that alignment checks be conducted to ensure that further wear is not accelerated.
None.
Major:
Recommend that the gooseneck be changed out due to the modifications made
No UT reports were available on location for the gooseneck.
NDT inspection would need to be conducted on the Quill thread and lifting
points of the swivel prior to work.
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Minor:
3.4.1
Critical:
None.
Major:
Minor:
None.
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3.5.1
Critical:
Major:
Minor:
None.
None.
None.
Critical:
None.
Major:
Recommend that the hook and travelling block hang off point and critical areas
have NDT conducted prior to the rig commencing work if no NDT reports are
available in Jakarta office.
Minor:
None.
Critical:
None.
Major:
Minor:
None.
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Critical:
None.
Major:
Minor:
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3.9.1
Critical:
None.
Major:
Repair hydraulic motor for the spinner as soon as parts are available.
Conduct the services recommended by manufacturer.
Minor:
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3.10.1
Critical:
None.
Major:
Minor:
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3.11.1
Critical:
Major:
None.
Minor:
3.12 Elevator
The personnel elevator to rig floor was visually inspected and several deficiencies were noted.
The electrical installation needs remedial action, there was no inspection records available
showing MPI of critical areas, unable to locate any secondary safety locking device for the
riding basket in the event of a hoisting line failure, none of the safety devices were able to be
functioned, SWL signs need to be displayed.
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Above photos showing some electrical connections and outlets that require remedial action.
3.12.1
Elevator Discrepancies
Critical:
Major:
Minor:
None.
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ELECTRICAL EQUIPMENT
Alternator #2
Rotor
Stator
Alternator #3
Rotor
Stator
M @ 1 min
M @ 10
min
PI
4.1.1
Critical:
Major:
Major:
None.
None.
None.
Recommendations:
It is recommended that these Generator packages have complete insulation tests performed
prior to start up.
4.2 Camp Generators
Initial test of Main Gen #1 found low insulation readings. Generators were opened and cleaned
prior to any further testing. Generators could not be run so visual and PI/IR insulation tests were
performed.
No generator heaters were connected at the time.
No maintenance history was available to ascertain when the generators were last inspected and
what readings were recorded.
4.2.1
0.5
0.55
0.7
1.6
1.4
3.2
1.1
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4.2.2
Generator No 1: Deficiencies
Major:
Bad wire connection was found on exciter Diode Bridge. Rig electrician
immediately repaired this.
Major:
Recommendations:
Cleaning of generators be performed on a more regular basis.
Generator to be heated, dried and re-test prior to start up.
Control panel to be re-labelled for easy identification.
Previous insulation test records should be available on site for test reference.
4.2.3
4.2.4
0.15
0.5
0.17
1.0
1.1
Generator No 2: Deficiencies
Major:
Major:
Recommendations:
Heaters to be fitted in generator housing.
Cleaning of generators be performed on a more regular basis.
Generator to be heated, dried and re-test prior to start up.
Control panel to be re-labelled for easy identification.
Main circuit breakers located on generator power distribution panel should have under
voltage protection.
Previous insulation test records should be available on site for test reference.
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4.3.1
2.5
2.9
1.4
Minor:
Recommendations:
Rotor coils to be checked when time permits.
Cleaning of generators be performed on a more regular basis.
Previous Insulation test records should be available on site for test reference.
4.3.2
4.3.3
15
8.5
1.4
Minor:
Minor:
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Recommendations:
Rotor coils to be checked when time permits.
Cleaning of generators be performed on a more regular basis.
Power distribution circuit breakers to be labelled for easy identification.
Under voltage protection installed on camp supply breakers.
4.4 Transformers
All power and lighting transformers on Drilling package where opened, cleaned and inspected.
No defects were found. Insulation readings are as follows:
Transformer Insulation
Primary
Secondary
4.4.1
SCR 600-480V
SCR 480/220/120
MC1 480/220/120
MC2 480/220/120
180 M
2.7 M
200 M
200 M
41 M
250 M
12 M
4 M
Transformers Discrepancies
Critical:
Major:
Minor:
None.
None.
Transformers should be labelled as per their drawing reference.
4.5 SCR
At the time of inspection, the SCR house was packed and secured for transportation. We
recommend that the SCR house is thoroughly inspected once the planned Generator upgrades
are complete and Rig is in operation.
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4.5.1
SCR Discrepancies
Critical:
Major:
Minor:
None.
None.
None.
4.6.1
Critical:
None.
Major:
Major:
SCR house roof has a number of silicone repairs to prevent water leaking into
switch room.
Recommendations:
We were advised that plans are in place to change out MC1 & MC2 switch rooms. If this
upgrade is cancelled or delayed indefinite then we recommend that all motor starter modules
be removed, stripped down, cleaned, painted and rebuilt with new switch gear.
Holes in SCR house roof must be properly patched with the use of steel plate to prevent any
possibility of water leaking into switch room.
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4.7 Lighting
All lighting was packed for Transportation. Complete lighting inspection will be required once
Rig is in operation at new location.
4.7.1
Lighting Discrepancies
Critical:
None.
Major:
Standard household 220V outlets and extension cords are in use in Dog house.
These are required to be removed and replaced with appropriate hazardous area
equipment.
There is a non hazardous area electric heater situated in Dog house. This must be
removed prior to commencement of drilling.
Mud cooling tower has a non EX rated fan motor mounted in a class one zone
one area.
220V Combination plug panel located in Dog house has no certification labels
attached. All equipment located in Hazardous areas must have certification labels
attached.
Dog house wiring standard is in poor condition, improvements could be made to
improve the standard of wiring.
Mud cooling tower fan belt cover requires repairing.
4.9 AC Motors
No motors could be run due to mobilization of the rig. Overall the AC motors were in
acceptable condition with the exception of the below listed items. A number of AC motors
where megger test with no low readings recorded.
4.9.1
4.9.2
AC Motors Discrepancies
Major:
Shaker No 2 and No 3 motor supply cables between switch station and motor
have been damaged. Supply cables to be replaced. See attached photo. (Job
completed)
Major:
Mud pump 2 Blower motor connection junction box has signs of water ingress
and corrosion. See attached photo.
This was repaired.
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Minor:
A number of Agitator motor starters have cover bolts missing. See attached
photo.
Minor:
Shaker motor switch stations to be reconfigured so output motor cable has better
protection and less stress is on cable when entering cable gland. See attached
photo.
Minor:
Recommendations
New shaker motor cables installed to replace damaged cable. (Job completed)
Shaker switch stations to be reconfigured so outgoing cables create less stress on
entry glands. (Job completed)
All AC motor Junction boxes to be opened inspected for water ingress and cleaned.
Lid and J/B surfaces to be cleaned and greased with approved silicone grease to
ensure good sealing when closed.
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4.10 DC Motors
Inspections were performed at Cirebon holding yard where rig was being prepared for shipment.
All motor internals were in a satisfactory condition taking into consideration the age of the
equipment (no records available on site noting running hours or days of service).
Space heaters were present in each motor but could not be checked for correct operation due to
rig mobilization. At the time of inspection humidity levels were high and signs of moisture were
present in all the motors.
No maintenance history was available to ascertain when the motors were last inspected and
what readings were recorded.
4.10.1 DC Motors Insulation recordings
DC Motor
Draw works A
Draw works B
Rotary Table
Mud pump 1
Mud pump 2
Field (M)
500
250
4
66
70
Armature (M)
0.03
0.6
0.43
0.05
0.07
Multicore socket providing power for motor field, blower & heater supplies has
water ingress and insulation readings well below acceptable levels. EG:
Insulation readings for Field supply circuit between junction box terminal strip
and incoming connection plug has a reading of 0.02meg ohms at 500V to ground.
See attached photo.
Minor:
Motor junction box cover requires new mounting screws. At present the cover is
only held on via a small number of self tapping screws. See attached photo.
Field supply cable entry into DC motor requires correct gland entry. See attached
photo.
Minor:
Issue No: 1
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Page29
Major:
Multicore socket providing power for motor field, blower & heater supplies has
water ingress and insulation readings well below acceptable levels. EG:
Insulation readings for Field supply circuit between junction box terminal strip
and incoming connection plug has a reading of 0.02meg ohms at 500V to ground.
See attached photo.
Motor junction has open spare cable access at bottom off enclosure. Plus
Junction box lid is only held by small amount of self tapping screws. These
enclosures are supposed to be purged via blower air before motor is energised. At
present this is not possible, there for pressure switch circuitry is possibly
bypassed. See attached photo.
Issue No: 1
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Page30
Minor:
Field supply cable entering motor requires flexible conduit protection with
correct gland entry. See attached photo.
Major:
Major:
Motor junction box cover needs replacing with new. See attached photo.
Minor:
Issue No: 1
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Minor:
DC Motor recommendations:
Low Armature readings: All DC motor armatures to be cleaned, heated and megger test
prior to running. Readings to be above 1meg ohm prior to energising.
Multicore plugs to be opened and cleaned. If insulation readings cannot be improved, plugs
are to be replaced.
All mud pump and Draw works DC motor Junction Boxs to have covers repaired back to
original state with all securing bolts used plus all spare cable entries covered to ensure a
positive pressure is present during motor operations.
Rotary Table DC motor Junction Box cover to be replaced. Junction box to be checked that
a positive pressure is present during motor operations.
Draw works DC motor blower air intakes to be checked that they are in a free air zone as per
API standard 500.
Both Draw works motor Field supply cables to have correct hose and glands fitted between
Junction box and Motor entry.
All DC motor Junction box air purge pressure switches to be checked for correct operation
prior to commencement of drilling.
All DC motor heaters to be checked for correct operation when on next location and power
is available.
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F6-F8
6.5
6
Supply cable between brake J/B and supply connection plug has its inner
insulation deteriorating. See attached photo.
Major:
If a proficiency test has not been performed within the last 12 months, it is
recommended to be performed prior to commencement of drilling.
Brake Recommendations:
Cable to be changed prior to commencement of drilling.
All associated alarms and water flow rate to be checked prior to commencement of drilling.
Water PH levels must be as per manufacturers recommendations.
Brake cooling water cooling condensers to be opened inspected and cleaned prior to
commencement of drilling.
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MECHANICAL EQUIPMENT
5.1.1
Critical:
None.
Major:
Repair the loose solenoid valve on the injector pump of gen set # 2.
The cooling fan belts on gen set # 1 were found loose and worn, recommend
replacing.
The cooling fan bearing was found to have excessive movement, recommend
that the bearing be replaced.
Minor:
None.
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Critical:
None.
Major:
Minor:
None.
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5.3.1
Critical:
None.
Major:
Minor:
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Page36
5.4.1
Critical:
The static lines need to be load rated, spliced line terminations are not
acceptable, recommend that all lines have the correct end terminations and be
load rated.
The mounting points for the static lines need to be properly secured and load
rated.
Major:
Minor:
None.
None.
5.5.1
Critical:
Major:
Minor:
Issue No: 1
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6
6.1
Mud Pump # 3
National 9 P 100 Mud Pump # 3. This pump is engine driven by a Caterpillar D399 engine via a
National Torque Converter, air clutch and V-belt drive.
The power end cover of the pump was opened to perform an internal inspection, the main
bearings rollers and inner race looked bright and clean with no signs of damage. Lift clearances
were conducted using a dial indicator and hydraulic jack and were found to be minimal.
The teeth of the bull gear and pinion appeared to be in good condition, the pinion gear back lash
is within tolerance with the maximum reading noted as 0.0024. The pinion shaft bearing
clearance at drive end is 0.003 and 0.003.
The main bearing clearances were taken and found to be acceptable and RH was measured at
0.006 whilst the LH was 0.005.
The crosshead clearances were taken and found to be acceptable. It was not possible to remove
the crosshead pins to inspect the bearings, however all the crosshead pins were tight in the
crossheads around the taper fit area.
The lift, and clearances, of the connecting rod eccentric bearings and crosshead slide have been
taken and recorded on the condition sheet below.
There is no lock wires fitted to the retaining bolts for the cross head pins on all three cross heads.
These bolts may not be OEM as they are not drilled.
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Mud Pump # 3
National 9-P-100
Driven by Cat D- 399
Inspected by: Brett Slaven
Rig Inspection Services.
Good
0.003
0.022
0.004
0.004
Good
Good
0.005
0 006
Good
0.003
0.003
Good
Good
0.004
0.006
0.024
0.018
0.024
0.022
0.018
0.020
0.006
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6.1.1
Critical:
None.
Major:
The retaining bolts for all three cross head pins need to have tie wire fitted.
Minor:
None.
6.2
Mud Pump # 2
Mud Pump # 2
The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection
and was found to be in good condition with no major faults noted.
The cover for the power end was removed and surface rust was evident on the pinion shaft and
both bearings. This was cleaned and lubricated before turning, no pitting was noticed.
The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at
0.018 and within tolerance. The pinion shaft bearing clearance at drive side was 0.005 and off
side 0.003.
The main bearing clearances were taken and found to be acceptable RH was 0.004 and LH is
0.003.
It was not possible to remove the crosshead pins to inspect the bearings. All the crosshead pins
were tight in the crossheads around the taper fit area and the lock wires were in place on the pin
retainer plates.
All drive chains and sprockets were inspected and found to be in acceptable condition.
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Mud Pump # 2
National 9-P-100
DC Driven
Inspected by: Brett Slaven
Rig Inspection Services.
Good
0.006
0.018
0.004
0.005
Good
Good
0.003
0.004
Good
0.003
0.005
Good
Good
0.006
0.006
0.018
0.020
0.022
0.022
0.022
0.018
0.005
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6.2.1
Critical:
Major:
Minor:
6.3
None.
None.
None.
Mud Pump # 1
Mud Pump # 1
The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection
and was found to be in good condition with no major faults noted.
The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at
4 point and max/min findings were 0.015 and 0.024 within tolerance. The pinion shaft
bearing clearance at drive side was 0.006 and off side 0.003.
The main bearing clearances were taken and found to be acceptable RH was 0.006 and LH is
0.003.
The clearance in the connecting rod eccentric bearings and crosshead slide clearances have been
taken and found acceptable; these have been recorded on the condition evaluation sheet below.
The crosshead readings are at the tightest spot across the full area of the slides. It was not
possible to remove the crosshead pins to inspect the bearings. All the crosshead pins were tight
in the crossheads around the taper fit area and the Lock wires were in place on the pin retainer
plates.
Rod # 3 was found to have the rod seal broken and exposed out of the seal housing, when the
cover for the power end was removed surface rust was evident on the pinion shaft and both
bearings. After cleaning no pitting was noticed.
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Mud Pump # 1
National 9-P-100
DC Driven
Inspected by: Brett Slaven
Rig Inspection Services.
Good
0.006
0.024
0.004
0.006
Good
Good
0.003
0.006
Good
0.006
0.003
Good
Good
0.006
0.006
0.018
0.020
0.024
0.020
0.018
0.018
0.005
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6.3.1
Critical:
None.
Major:
Minor:
None.
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Above picture showing internal pipe welds and washing on hammer unions on the mud lines.
6.4.1
Critical:
None.
Major:
Minor:
None.
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6.5.1
Critical:
Major:
None.
None.
Minor:
Once rigged up function test, check float valve is functioning and vacuum
pressure.
Critical:
Major:
None.
None.
Minor:
Critical:
Major:
None.
None.
Minor:
Recommend to clean the corroded areas for further assessment and make repairs
as required.
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7.1 Accumulator
The fluid pressure relief valve should be set at 3,500 psi, documentation needs to be provided
showing that it releases at the set pressure as no function test was able to be conducted and no
tag was fitted to the valve.
The unit is equipped with a two bottle nitrogen backup system. The remote panel is located at
the dog house and accessible to the driller. No function tests have been conducted.
On rig up it would be recommended to conduct an accumulator drawdown test to ensure that
there is sufficient accumulator volume available with the current amount of accumulator bottles,
after confirming that the accumulator bottles have the correct pre-charge pressure.
Note: The final accumulator pressure shall be equal to or greater than 200 psi above pre-charge
pressure (API RP 53 section 17.7.1 a-g) Note: Some Chevron contracts require 500 psi above
pre-charge.
7.1.1
Accumulator Discrepancies
Critical:
None.
Major:
There was no certification available for the fluid pressure relief valve; this should
be set at 3,500 psi, during function testing check the release pressure.
Conduct a drawdown test and records should be kept for all pressures through
each step of the procedure for future reference.
Minor:
No signage was available showing that the unit auto starts. This should be placed
on the unit and visible to personnel.
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7.3.1
BOP Discrepancies
Critical:
None.
Major:
Conduct low and high pressure tests on the well bore side of the BOPS.
Minor:
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Recommendations:
7.4.1
Annular Discrepancies
Critical:
None.
Major:
The damaged eye is not suitable for lifting; recommend that if this is to be
repaired that the repair be conducted by an approved OEM facility.
Minor:
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7.5.1
Critical:
None.
Major:
Recommend that a full test of the manifold and all valves be conducted and
pressure test charts kept for review.
Minor:
None.
PREVENTATIVE MAINTENANCE
8.1
Preventative Maintenance
The general maintenance history on the mechanical side appears to be good; however the
preventative maintenance schedule should be looked at closely for the electrical prior to the rig
being prepared for its next contract. Generally the electrical maintenance has no records of any
checks being conducted.
8.1.1
Critical:
None.
Major:
Good documentation needs to be kept for services and repairs made to the
equipment for future reference.
Minor:
None.
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At the time of inspection, it was not possible to carry out a safety audit and unable to see
systems in place. We would strongly recommend that a complete safety audit is carried out on
the rig when it is rigged up prior to spud. As per the Century checklist, we were unable to
confirm if most safety equipment was available due to the rig being packed for mobilization.
9.1.1 General Safety and Training Discrepancies
Critical:
Major:
Minor:
None.
None.
None.
10 SPARE PARTS
A brief look through the warehouses found that parts were kept tidy and well organized, there
appears to be a good supply, and checked random critical spares were available, a full inventory
of parts was supplied and critical items that are usually required were listed, it would be
recommended that prior to the rig commencing its next contract that a more in depth inspection
on critical parts required be conducted.
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