Maintaining Rig Masts

Author:C.
Nielsen Ref: EMS - 307 - 01

EQUIPMENT AND MAINTENANCE
Checked By: K. Roberts STANDARD Page 1 of 14
Approved By: F. RAT Issued: June 93
Masts Revision: 1.0
SUBJECT: Table of Contents Family - 307
Masts
Table of Contents
1. Purpose......................................................................................................................................... 2
2. Scope............................................................................................................................................ 2
3. References:................................................................................................................................... 2
4. Responsibility: Rig Superintendent............................................................................................... 3
5. Equipment Class: Major............................................................................................................... 3
6. Maintenance Considerations......................................................................................................... 3
6.1. Mast Stresses............................................................................................................... 3
6.1.1. Mast Tilt..................................................................................................... 3
6.1.2. Effects of wind and motion......................................................................... 3
6.2. Mast Rating................................................................................................................. 4
6.2.1. Conditions of the metal structure................................................................ 5
6.2.1.1. Geometric defects...................................................................... 5
6.2.1.2. Straightness of Structural Members:......................................... 6
6.2.1.3. Corrosion................................................................................... 6
6.2.1.4. Non Destructive Testing............................................................ 7
6.3. STRUCTURAL REPAIR AND MODIFICATION....................................................... 8
6.4. PRECAUTIONS TO BE TAKEN WHEN RAISING MASTS...................................... 8
6.4.1. POSITION OF THE MAST........................................................................ 9
6.4.2. VARIOUS PRECAUTIONS....................................................................... 9
6.4.3. PRECAUTION CONCERNING THE RAISING LINES............................. 10
7. Safety Considerations.................................................................................................................... 11
8. Resources...................................................................................................................................... 11
9. Maintenance Summary................................................................................................................. 12
Author:C. Nielsen Ref: EMS - 307 - 01
Masts Revision: 1.0
SUBJECT: General Considerations Family - 307
1. Purpose
To insure that all Masts owned and operated by Sedco Forex is maintained in a safe and efficient manner; to
define those responsible for the maintenance and to detail a system of preventative maintenance procedures.
2. Scope
This Maintenance Standard applies to all rigs owned or operated by Sedco Forex. Responsible personnel shall
ensure that all the operation and maintenance requirements detailed in this document are properly carried out.
3. References:
Document Edition Date Description
API SPEC 4E Third Edition June 1, 1988 Specification for Drilling and Well
Servicing Structures
API SPEC 4F First Edition May 1, 1985 Specification for Drilling and Well
Servicing Structures
API SPEC RP4G First Edition January 1, 1992 Recommended Practice for
Maintenance and Use of Drilling and
Well Servicing Structures
Drilling Manual Eleventh Edition 1992 International Association of Drilling

Contractors Drilling Manual
Masts Revision: 1.0
4. Responsibility: Rig Superintendent
5. Equipment Class: Major
6. Maintenance Considerations
6.1. Mast Stresses
A mast, is subjected to various stresses: mechanical (compression, buckling, torsion), atmospheric (effects of the
wind) or chemical (corrosion) which necessitates regular maintenance be performed so as to minimize and
correct deterioration due to these stresses.
6.1.1. Mast Tilt
Mast tilt gives rise to a horizontal stress. This tilt is such that greater stress is placed on one leg of the mast than
the others and causes fatigue phenomena resulting in premature aging of the structure.
The solution is a preventive one:
• make sure the site is level
• ensure there is adequate bearing capacity of the soil by providing supplemental footing if necessary.
• adjust verticality of the mast when there are provisions for shimming.
6.1.2. Effects of wind and motion
Masts are sensitive to the effects of wind and motion. The static hook load capacity decreases when the
wind speed increases. Similarly, the static hook load decreases when dynamic motion increases, as in the
case of floating rigs. These effects are especially critical when all the string is setback in the mast (when
lowering a casing for example). Therefore, the following information must be available:
Standard Mast:
• Maximum rated static hook loadcapacity
• Maximum wind (knots) load capacity without setback
• Maximum wind (knots) load capacity with stipulated setback
• Dynamic capabilities, if designed for such conditions
• Maximum number of stands and size of pipe infull setback.
Floating Unit Mast:
Masts Revision: 1.0
• Maximum rated static hook load capacity.

• Maximum number of stands and size of pipe in full setback
• Maximum simultaneous for operating:
• Maximum working hook load
• Wind load (knots)
• Roll and period
• Pitch and period
• Heave and period
• Stipulated pipe setback
Maximum simultaneous for waiting on weather:
• Wind load (knots)
• Roll and period
• Stipulated pipe setback
Maximum simultaneous for survival:
• Wind load
• Roll and period
Similarly the substructure ratings for rotary load and setback load must be available. Normally,
substructures on floating rigs are matched with the mast dynamic conditions.
Masts Revision: 1.0
6.2. Mast Rating
The rig superintendent and the drillers shall be aware of the rating of the mast. This is normally identified by
a nameplate bearing the following information:
• Manufacurer's name
• Manufacturer's address
• Spec 4F
• Serial Number
• Height in feet
• Maximum rated static hook load, in pounds, with guy lines if applicable, stated for number of lines to
traveling block.
• Maximum rated wind velocity in knots, with guy lines if applicable, with rated capacity of pipe racked.
• The API specification and edition of the API specification under which the structure was designed and
manufactured.
• Manufacturer's guying diagram - For structures as applicable.
• Graph plotting maximum allowable static hook load versus wind velocity varying from zero to maximum
rated wind velocity with full rated setback and with maximum number of lines to the traveling block.
• CAUTION: ACCELERATION OR IMPACT, ALSO SETBACK AND WIND LOADS WILL REDUCE
THE MAXIMUM RATED STATIC HOOK LOAD CAPACITY.
6.2.1. Conditions of the metal structure
Working with a mast in poor condition is dangerous. The following section describes the major defects
that weaken a mast, together with the preventive measures to be taken.
6.2.1.1. Geometric defects
The term "geometric defect" is used to mean all straightness defects concerning the steel sections in
general.
Masts Revision: 1.0
A steel beam may be deformed either due to mechanical damage or misalignment. In the case of
misalignment of the mast, or due to damaged bracing, the defect may consist of an even curve over the
entire length of a section.
In this case, if the defect is done away with (in the above examples, by giving the mast good verticality by
jacking it or replacing the defective bracing), the angle will normally straighten out due to its elasticity. If
such is not the case, it must be replaced or at least straightened out, since its mechanical properties are
considerably decreased in this condition.
In the case of mechanical damage (due to improper slinging or impact), the defect may consist of a sharp
angle bend over a portion of the length of the steel section, or it may simply be an indentation in the
flange.
In this case the steel section may require replacement, or if the damage is minor it can be straightened.
Mechanical damage is the more frequently encountered. It may be the result of one of the following
causes:
• Improper slinging
• Careless handling during rig moves.
• Mechanical impact during drilling operations (e.g. blows from the traveling block) or heavy
tools/equipment.
• Work under heavy loads.
The possible preventive measures are as follows:
• Marking the "slinging" points with paint on the various sections .
• Adequate preparation and organization so as to work without undue haste.
• Use caution when performing tripping to prevent swin ging of the traveling block as much as
possible.
• Knowledge of the static and dynamic hook load capacities.
Despite these preventive measures, an accident or technical difficulty sometimes occurs. The problem is
then knowing what the permissible tolerances for straightness of the angles are.
6.2.1.2. Straightness of Structural Members:
Structural members shall be straight within the following guidelines:
• Compression members shall not d eviate from straightness by more than 1/1000 of the axial length
between points which are laterally supported. However, main angles must not vary by more than
3mm (1/8") over the entire length, and secondary angles must not vary by more than 6mm (1/4")
over the length of the angle..
• All members shall be free from twists, bends, and open joints. Sharp kinks or bends shall be cause
for repair.
Masts Revision: 1.0
Note: Sub-structures.
Substructures must also be maintained free of geometric defects, to avoid catastrophic failure
due to the cumulative effects of these.
6.2.1.3. Corrosion
Masts being made from steel, are subject to corrosion.
The masts, and especially those which have not been provided with special protection such a galvanizing,
must therefore be regularly checked.
Substructures are particularly susceptible to corrosion owing to splashing water from the floor. Therefore,
special attention shall be paid to maintaining substructures clean, and painted.
Galvanized masts are not completely protected from corrosion. Components damaged by impact or other
mechanical contact may start corroding at the point of damage, unless the coating is spot repaired
immediately. The same holds true for repaired surfaces. Therefore, even galvanized masts shall be
inspected.
Corrosion may have disastrous consequences but can be avoided by performing regular preventive
inspections.
6.2.1.4. Non Destructive Testing
MPI of mast welds is not normally done on a routine basis. However, it shall be done under the
following circumstances:
• Following damage to any element
• Following repairs
• Following a visual inspection, if suspect welds are found.
When mast damage occurs as the result of any impact whatsoever, the primary effect is damage to an
element, i.e. the damage caused to the angle or beam.
Secondary effects can also occur, i.e. the damage caused to the connections of this angle (welds or bolts).
But most of the time the connections are damaged.
There may be breaking off of the weld, beginning of a crack or a definite crack, damage to the connecting
bolts, ovalization of drilled holes.
These defects must be repaired immediately.
The nuts and bolts are to be changed systematically. over a 10-year frequency, and all doubtful bolts are
to be replaced during the regular inspections (every 12 months).
Masts Revision: 1.0
Bolts in poor condition shall be replaced by bolts having the same dimensions and grade of steel.
The mast elements might have play at their connections. They are joined by combinations of bored
gussets plates plus connecting pins. These steels have the following approximate properties:
• an elastic limit greater than 70 kg/mm²
• a Brinell hardness greater than 300.
Since these pins are quite hard, they have a tendency to enlarge the bore of the gusset plates.
If the pin holes become enlarged or oval by more than 1/8", repairs will be necessary. R&E should be
consulted for the correct repair procedure.
In order to minimize damage to masts, the following general guidelines should be followed:
• Repair, straighten or replace any bent or otherwise damaged members
• Use welding procedures approved by the manufacturer
• Use suitable clamps to attach fixtures and accessories. Do not drill or burn holes in any members
or perform welding without first obtaining approval from R&E.
• Girts, braces and other members should always be in place when the structure is under load.
6.3. STRUCTURAL REPAIR AND MODIFICATION
Repairs and modifications to the mast shall be performed only with the approval of R&E with respect to
materials and methods used.
6.4. PRECAUTIONS TO BE TAKEN WHEN RAISING MASTS
One of the most critical operations, is raising or lowering of the mast.
If an accident occurs during this operation the implications can be enormous in terms of human and financial loss. At
minimum, it could mean a long standby.
Therefore, special attention shall be paid to carrying out raising operations, and to maintaining the raising mechanism.
Masts Revision: 1.0
6.4.1. POSITION OF THE MAST
• The mast will be ideally raised if it is perfectly horizontal or slightly above horizontal.
• The mast should be in the horizontal position before raising it, by adapting the height of the stands.
• The recommendations of the manufacturer must be adhered to.
6.4.2. VARIOUS PRECAUTIONS
• Follow the manufacturers instruction manual concerning raising and lowering the mast.
• Special attention shall be paid to tightening of the bolts, the condition of the assembly pins and the
retaining pins for these pins. Indeed, all these factors are essential conditions for the rigidity of the
mast, but they also keep any parts from falling during raising.
• Special attention shall be paid so that no tool is "forgotten" on an angle.
• The moving part of the racking platform is to be folded and attached to the railing so that it does
not suddenly fall during raising.
• -A check shall be made to be sure no slings or cables whatsoever hinder free raising of the mast.
• The traveling block is to be carefully checked (to make sure the wraps are in the grooves and do
not pass over one another).
• The Rig Superintendent is to make sure there is enough cable wound around the drum when the
mast is ready to be raised.
• During raising, the traveling block rises and cable is wound around the drum. But, when the
raising lines are to be removed, the traveling block must be lowered almost to table level. If, at
this time, there is not enough cable on the drum, the traveling block might fall on the table.
In order to ensure there is enough cable on the drum, the following precautions are to be taken:
• Know how many wraps around the drum corresponds to movement of the traveling block over a
given height.
• Count the number of wraps wound around the drum when the mast is ready to be raising off the
ground.
• Measure the number of meters between the traveling block position when the mast is ready to be
raised off the ground and the lowest traveling block position with the mast raised.
• Calculate the minimum number of wraps there will be on the drawworks in this last position.
The minimum number of wraps on is to be in accordance with the manufacturer's recommendations. In
the absence of any manufacturer's recommendation the following shall apply:
Grooved drums: 9 wraps
Plain drums: one full layer of line plus 6 wraps on plain drums
Masts Revision: 1.0
6.4.3. PRECAUTION CONCERNING THE RAISING LINES
Due to the critical nature of raising lines, they must be very carefully inspected at regular intervals.
At each move, the raising lines are to be visually checked over their entire length to look for any
defects. Particular attention is to be paid to the areas near the sockets and around the sheaves.
Raising lines should be replace every 15 rig moves or 3 years, whichever comes first. Furthermore
any one of the following reasons is cause for raising line replacement:
• Rust between the strands. (Light surface rust on the outer strands only, can be ignored)
• 2 broken wires
• Reduction in diameter or increase due to core deterioration
• Any reduction of metal area due to abrasion
• Kinking, crushing ,doglegs, birdcaging, mashed wires, welding damage, heat admage, or any
other damage resulting in rope distortion
• Damaged sockets
Inspection of the pulleys is also important. Pulleys in poor condition (worn grooves, pulleys not freely
turning about their pins) may be the source of rapid deterioration of the raising lines.
Additionally, the raising lines must be coated with grease. The raising lines are in a "stacked
condition" most of the time. In aggressive atmospheres and when the wells are deep, very close
attention must be paid to this problem.
Grease, or stacking type protective compounds having the following properties will be used:
• good adherence,
• good resistance to washing with water,
• a good rust inhibitor.
A stacking type protective compound is preferred to ordinary grease.
Where a well is programmed for more than 6 months, it is recommended to protect physically the
most exposed parts with old lenghts of fire hose or rubber hose.
Checked By:K. Roberts STANDARD Page 11 of 14
Masts Revision: 1.0
SUBJECT: Safety Considerations Family - 307
7. Safety Considerations
**Various level of maintenance have been applied to each safety precaution item in order to clearly identify the
skill requirements necessary for an individual(s) to execute an operation safely.
Item Level Description
1 D3 Insure proper work permits are obtained before performing maintenance on this equipment
2 D3 Insure individuals performing the maintenance are familiar with the manufacturer's
operation and maintenance manuals before beginning the maintenance.
3 D2 Ensure Safety harness is used when work in mast.
4 D2 Secure handtools with a safety line to prevent dropping them.
5. D3 Keep personnel away from drill floor when working in the derrick.
8. Resources
Safety Harness
Handtools
Yellow paint (to mark damaged areas)
Tautline (to measure straightness of elements)
Masts Revision: 1.0
SUBJECT: Maintenance Summary Family - 307
9. Maintenance Summary
Frequency Department Maintenance Summary

1. Weekly Drilling • Visual inspection for loose nuts, bolts, pins, light
fixtures, and for foreign objects.
• Check that all pipe racking fingers are straight
and provided with a safety restraint.
• Check that all sheaves hanging in mast are
provided with safety lines.
• Check that the drilling line is not rubbing on mast
legs, girders or other objects that may cause
damage to the line.
3. Every 6 Months Drilling • Check for damage to paint work and repair as
necessary.
4. Every 6 Months 3rd Party • MPI of raising lines spelter sockets
(Lifting Gear
• Visual inspection of raising lines
Certified)
Masts Revision: 1.0
5. Annually Drilling • Check Crown Safety platform for damage.

• Check Crown Assembly handrails for cracked
welds or damage.
• Check Crown Frame for bent Beam Flanges and
Beam Webs.
• Check Legs for bowing, cracked welds, pin
connection condition and that Safety Pins are
installed.
• Check Spreaders on the back panel Trusses for
damage and cracked welds
• Ensure Spreader Bolts and Pins are of proper
length and that Bolt Holes are not oval.
• Check Girts and bracing for bending, damage
and cracked welds.
• Check feet Pivots for damage, cracked Welds,
worn holes, worn Pins and corrosion.
• Check Racking Platform Fingers for damage and
cracked welds.
• Check handrails and handrail connections for
damage
• Check Ladders for bad rungs, bad connections
and cracked welds.
• Check all bolts on the entire mast for tightness
with a wrench. Ensure all nut locking pins are in
place.
• Check watertable transverse beam welds for
cracks (NDT)
• Telescoping Masts - inspect telescoping
mechanicsm locking devices.
6. Every 15 Rig Moves Drilling • The raising lines are to be replaced. The old lines
or every 3 years are to be NDT'd, thoroughly inspected and load
tested by a competent company. Those raising
lines which pass this inspection, can be returned
to the rig and reused for 15 more rig moves,
whereapon they will need to be recertified again.
Masts Revision: 1.0
7. Every 5 Years Drilling • Third party NDT inspection of welded connections.

The 5 yearly inspection can be organized so that
parts of the mast are inspected every rig move or
every 6 months, for example.
8. Prior to Raising Mast Drilling • Ensure bolts, assembly pins and the retaining pins
for are correctly fitted to ensure rigidity of the mast.
• Ensure there are no loose parts or tools left lying
on the mast.
• Ensure the moving part of the racking platform is
folded and attached to the railing so that it does not
suddenly fall during raising.
• Check to be sure no slings or cables whatsoever
hinder free raising of the mast.
• Check the travelling block wire wraps are in the
grooves and do not pass over one another.
• Check lubrication and condition of sheaves,

sprockets, pins etc., which are part of the raising
mechanism.
• Inspect wire rope, including operating lines, raising

lines, for kinks, broken wires, corrosion or other
damage.
• Ensure there is enough cable wound around the

drum to allow blocks to be lowered sufficiently to
remove raising lines.
• Portable masts with hydraulic raising mechanisms -

check the hydraulic system for correct operation
and integrity.

Maintaining Rig Masts

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Maintaining Rig Masts

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Author:C.

Nielsen Ref: EMS - 307 - 01

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: Table of Contents Family - 307

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

Drilling Manual Eleventh Edition 1992 International Association of Drilling

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

4. Responsibility: Rig Superintendent

5. Equipment Class: Major

6.1. Mast Stresses

The solution is a preventive one:

• make sure the site is level

6.1.2. Effects of wind and motion

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

• Maximum rated static hook load capacity.

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

6.2. Mast Rating

• Manufacturer's guying diagram - For structures as applicable.

6.2.1. Conditions of the metal structure

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

6.2.1.2. Straightness of Structural Members:

Structural members shall be straight within the following guidelines:

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

Masts being made from steel, are subject to corrosion.

6.2.1.4. Non Destructive Testing

These defects must be repaired immediately.

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

6.3. STRUCTURAL REPAIR AND MODIFICATION

6.4. PRECAUTIONS TO BE TAKEN WHEN RAISING MASTS

One of the most critical operations, is raising or lowering of the mast.

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

6.4.1. POSITION OF THE MAST

6.4.2. VARIOUS PRECAUTIONS

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: General Considerations Family - 307

6.4.3. PRECAUTION CONCERNING THE RAISING LINES

• Reduction in diameter or increase due to core deterioration

• Any reduction of metal area due to abrasion

• good resistance to washing with water,

• a good rust inhibitor.

A stacking type protective compound is preferred to ordinary grease.

Approved By: F. RAT Issued: June 93

Masts Revision: 1.0

SUBJECT: Safety Considerations Family - 307

Item Level Description