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RECOMMENDED PRACTICE 3.

0A
FOR SERVICE RIGS
INSPECTION & CERTIFICATION OF
SUBSTRUCTURES, DRAWWORKS & CARRIERS

November 2003
Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

CANADIAN ASSOCIATION OF OILWELL DRILLING CONTRACTORS


RECOMMENDED PRACTICE 3.0A
INSPECTION AND CERTIFICATION OF SUBSTRUCTURES,
DRAWWORKS & CARRIERS (SR)

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................. 2

HISTORY ........................................................................................................................ 2

REVIEW PROCESS........................................................................................................ 3
1. SCOPE – CRITICAL COMPONENTS .................................................................. 4
1.1 SUBSTRUCTURE........................................................................................ 4
1.2 DRAWWORKS – Braking Components .................................................... 4
1.3 CARRIER ..................................................................................................... 4
2. INSPECTION LEVELS ......................................................................................... 4
3. TYPES OF SUBSTUCTURES ............................................................................. 6
3.1 CLASS 1 – HYDRAULIC RAISING VARIABLE FLOOR HEIGHT .............. 6
3.2 CLASS 2 – STANDARD FIXED FLOOR ..................................................... 7
4. CERTIFICATION & INSPECTION OF SUBSTRUCTURES ................................ 8
4.1 1000 OPERATING DAYS MAJOR CERTIFICATION.................................. 8
4.2 DAMAGE REPAIR RECERTIFICATION ..................................................... 9
4.3 ONE YEAR LEVEL III INSPECTION REQUIREMENTS ............................. 9
5. DRAWWORKS – BRAKING COMPONENTS ................................................... 11
5.1 CLASS 1 – SINGLE DRUM – INCLUDE ONLY HOISTING DRUM .......... 11
5.2 CLASS 2 – DOUBLE DRUM – INCLUDES HOISTING DRUM AND
SANDLINE DRUM ..................................................................................... 11
5.3 INSPECTION OF DRAWWORKS BRAKING COMPONENTS ................. 12
6. CARRIERS ......................................................................................................... 15
6.1 INSPECTION OF CARRIERS .................................................................... 15
7. PERSONNEL QUALIFICATION AND DOCUMENTATION ............................... 19
8. TRAINING .......................................................................................................... 19
9. INSPECTION FREQUENCY .............................................................................. 20
10. IMPLEMENTATION ........................................................................................... 20

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

INTRODUCTION
The Canadian Association of Oilwell Drilling Contractors (CAODC) Engineering &
Technical (E&T) Committee has developed a Recommended Practice (RP) for
substructures, drawworks, and carriers. This document dated November 2003
supersedes all prior editions of this Recommended Practice.

The information contained herein is a recommendation only of certification schedules for


substructures, drawworks, and carriers currently utilized in the Canadian well servicing
industry. An attempt has been made to establish some practical recommended
operating practices for substructures, drawworks, and carriers in the Canadian well
servicing industry.

The recommendations contained in this document should be considered in conjunction


with the requirements of the original equipment manufacturers (OEM). Companies
should operate and maintain the equipment within the operating limitations, such as
load ratings, as designed by the OEM.

If the OEM stipulates increased levels of inspection or accelerated


inspection/certification cycles, the contractors must follow the OEM guidelines unless
granted approval to follow this CAODC Recommended Practice by a Professional
Engineer (P. Eng).

CAODC has produced this Recommended Practice based on industry


experience. However, this document should be considered in conjunction with all
relevant legislation and the requirements of provincial regulatory authorities. This
document should not be construed as a legal opinion, and users are advised to seek
legal counsel to address their specific facts and circumstances.

CAODC does not accept any liability to any person for any loss, damage, or costs,
arising directly or indirectly, whether in contract, tort, or otherwise, from any action or
inaction taken as a result of any person relying on or otherwise using this
document. Any use of this document is at the user’s own risk on the basis that that any
use of this document by the user constitutes agreement to the terms of this disclaimer
and the user is obliged to inform any subsequent user of such terms.

HISTORY
The Service Rig Safety & Technical Committee set out to draft guidelines for improving
the overall safety of service rig critical components with an emphasis on those
operations where the critical components are handled or repaired. During drilling and
well servicing operations, it is evident that few problems occur and those that do are
often related to a previous difficulty when handling the critical components.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

The Service Rig Safety & Technical Committee has drawn upon a number of resources
in the formation of these guidelines. Input was received from independent
manufacturers, Professional Engineers, welders and operations personnel.

The Service Rig Safety & Technical Committee wishes to thank all who were involved.

REVIEW PROCESS
CAODC Recommended Practices are reviewed and revised, reaffirmed, or withdrawn at
least every five years. A one-time extension of up to two years may be added to this
review cycle. Email any comments or items of concern to rpfeedback@caodc.ca.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

1. SCOPE – CRITICAL COMPONENTS

1.1 SUBSTRUCTURE
Factors which affect the condition of a substructure include loads imposed on
the substructure, frequency of raising/lowering floor, substructure design,
method of transporting and handling, materials utilized, age of substructure
and types of wells serviced.

1.2 DRAWWORKS – Braking Components


Factors which affect the condition of a drawworks braking include hook loads
of drawworks, frequency of high hook load/stuck situations, drawworks
design, maintenance of linkage parts, materials utilized in components, age
of drawworks, and types of wells serviced.

1.3 CARRIER
Factors which affect the condition of a carrier/trailer include frequency of
moves, carrier / trailer design, inspection of frame / load points, materials
utilized in frame, age of carrier, terrain of move, condition of suspension, and
types of wells serviced.

2. INSPECTION LEVELS
Four levels of inspection are recommended in this manual, to ensure that
equipment is properly maintained and serviceable. Levels I and II will be visual
inspection. Levels III and IV will require documentation in the rig’s CAODC Mast
and Overhead Equipment Log Book and require outside technical assistance.

Level I: Visual observation of the equipment by the rig crew prior to and/or
during operation and/or during routine service.

Level II: Level I inspection plus a more thorough inspection of load areas by
the operator or rig manager to check for proper lubrication, obvious
external cracks, premature wear or deterioration, missing parts or
guards.

Level III: Level III inspection requires that the equipment on the rig be
thoroughly checked in the field to determine the serviceability. This
may, at the inspector’s discretion, include Non Destructive Testing
(NDT) techniques on load areas and may require some minor
disassembly of guards. This inspection must be documented in the
CAODC Mast and Overhead Equipment Log Book. Technical
assistance provided for the inspection could be an NDT technician, a
senior well servicing individual, designated by the company, or

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

engineer as per Section 7 - Personnel Qualification And


Documentation. This person would be required to supervise or assist
in the inspection and sign off in the CAODC Mast and Overhead
Equipment Log Book that the inspection was completed.

Level IV: A Level IV inspection would require the equipment to be


disassembled as required to do a complete inspection, including Non
Destructive Testing of all critical areas. NDT inspectors for a Level IV
inspection would be required, as a minimum, to have certification of
“Level II, Canadian General Standards Board (CGSB) Non
Destructive Testing”. Repairs will be completed as per Section 4 -
Certification & Inspection of Substructures, Section 5.3 - Inspection
of Drawworks Braking Components, Section 6.1 – Inspection of
Carriers.

The entire substructure must be inspected by a Professional


Engineer or an Original Equipment Manufacturer (OEM) or his agent.
This inspection should, at the inspector’s discretion, include Non
Destructive Testing (NDT) of all critical load-bearing areas. All
deficiencies and repairs will be corrected, as indicated in Section 4 -
Certification & Inspection of Substructures of this Recommended
Practice.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

3. TYPES OF SUBSTUCTURES

3.1 CLASS 1 – HYDRAULIC RAISING VARIABLE FLOOR HEIGHT


Handling is a lesser concern than Class 2 Substructures. Class 1
substructures are usually vertically sling loaded onto the deck of a trailer.
When the substructures are manually loaded utilizing a winch tractor the
stress on the substructure is low as length of the substructure is small
creating a low center of gravity.

Figure 1 – Type 1 Substructure

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

3.2 CLASS 2 – STANDARD FIXED FLOOR


Class 2 substructures are usually bed loaded utilizing a winch tractor to load
the substructure onto the deck of a trailer. When the substructures are
manually loaded utilizing a winch tractor the stress on the substructure is
high as there is an extended length hanging over the roll of the trailer while
loading.

Figure 2 – Type 2 Substructure

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

4. CERTIFICATION & INSPECTION OF SUBSTRUCTURES

4.1 1000 OPERATING DAYS MAJOR CERTIFICATION


After reaching the required number of operating days, the following
procedure is recommended for completing a mast certification. One operating
day is comprised of 24 accumulated operating hours.

a) Clean Substructure, if required, to prepare for inspection;

b) Inspect the Substructure using a qualified Engineer or an authorized


Original Equipment Manufacturer (OEM) agent. Actual inspection
requirements, which should include Non Destructive Testing, will be to
the certifying Engineer or agent’s discretion. Documentation is as
deemed necessary by the certifying person but should address items
outlined in Section 4 (f) - Certification & Inspection of Substructures;

c) All repairs to major damage must be certified by a Professional


Engineer or OEM’s agent. Repairs may be completed in a field
environment, provided they can be done to the certifying person’s
satisfaction;

d) Lifting Point Design: For both classes of substructures, the certifying


Engineer or OEM shall designate lifting points;

e) Certification would stay in effect for wells spudded prior to the 1000-
day period;

f) Final certification of Substructures should include:

i. Clear height;

ii. Rotary table capacity rating (daN);

iii. Rotary table capacity rating;

iv. Setback capacity (if applicable);

v. Clear height;

vi. Author of repairs, date and location of repairs;

vii. Name and date of manufacturer;

viii. Substructure serial number;

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

ix. Complete documented results of the Level IV inspection, as


described in Section 4 - Certification & Inspection of
Substructures;

x. Date and period of certification.

Any damage found during the Level IV inspection is defined as MAJOR or


MINOR on the following basis:

A. MAJOR DAMAGE: geometrical distortion or structural damage to table


beams, hydraulic raising assembly, or any other load bearing member;

B. MINOR DAMAGE: damage or distortion to secondary equipment, i.e.:


ladders, floor plating, walkarounds, stairs or cosmetic damage to
diagonal girts and minor beam distortions.

4.2 DAMAGE REPAIR RECERTIFICATION


Occasionally between major recertification or following a visual inspection,
repairs may be required to retain the operating integrity of the substructure.
Any damage that requires repairs is classified as major or minor, as outlined
in Section 4.1 - 1000 Operating Days Major Certification. The repair process
would proceed as follows:

a) All repairs to major damage require the supervision of a Professional


Engineer or an OEM agent. The repairs must be documented in the
CAODC Mast and Overhead Equipment Log Book and signed by the
certifying party;

b) Repairs to minor damage may be completed by operating personnel,


at the discretion of the rig manager or higher authority, 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 should be
consulted;

c) The above recertification is for the repair of actual damage to maintain


certification during the 1,000 operating day interval. This repair
certification does not extend the 1,000 operating day period, unless a
major certification utilizing a Level IV inspection is undertaken for the
entire substructure.

4.3 ONE YEAR LEVEL III INSPECTION REQUIREMENTS


Every calendar year from the date of Level IV inspection the substructure
should be Level III inspected as per the criteria outlined in Section 2 –

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

Inspection Levels. As a minimum a thorough visual inspection of all load-


bearing members is required. The following procedure is recommended for
completing a substructure Level III Inspection:

a) Clean load beams, if required, to prepare for inspection;

b) A thorough visual inspection should be performed by personnel


outlined in Section 7 - Personnel Qualification And Documentation;

c) Any repairs that need to be performed to the equipment should follow


the guidelines outlined in Section 4.2 - Damage Repair Recertification;

d) The person inspecting the Substructure is required to sign off in the


CAODC Mast and Overhead Equipment Log Book that the inspection
was completed.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

5. DRAWWORKS – BRAKING COMPONENTS

5.1 CLASS 1 – SINGLE DRUM – INCLUDE ONLY HOISTING DRUM


Service rigs with only single drum drawworks only have one set of braking
components. Larger drawworks utilize a secondary brake assist (hydromatic
or disc brake). Maintenance of the equipment is necessary for safe operation
and follows the guidelines of inspection for service rig overhead equipment.

Single Drum Drawworks Setup

5.2 CLASS 2 – DOUBLE DRUM – INCLUDES HOISTING DRUM AND


SANDLINE DRUM
Service rigs utilizing a sandline drum contain two sets of essential braking
components. Additional chains, clutches, and jackshafts are utilized in this
setup. Larger drawworks utilize a secondary brake assist (hydromatic or disc
brake) on the hoisting drum. Maintenance of the equipment is necessary for
safe operation and follows the guidelines of inspection for service rig
overhead equipment.

Double Drum Drawworks Setup

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

5.3 INSPECTION OF DRAWWORKS BRAKING COMPONENTS

5.3.1 1000-Day BRAKING COMPONENT INSPECTION


After reaching the required number of operating days, the following
procedure is recommended for completing a drawworks braking
component inspection. One operating day is comprised of 24
accumulated operating hours.

a) Clean drawworks, if required, to prepare for inspection;

b) Disassemble components in brake linkage, clean if require, to


prepare for inspection;

c) Inspect the drawworks bands and linkages using a qualified


Non Destructive Testing technician. Pay particular attention to
threaded connections and any welded material.

Any damage found during the Level IV inspection is defined as


MAJOR or MINOR on the following basis:

A. MAJOR DAMAGE: Damage requiring welding, worn threads,

B. MINOR DAMAGE: Oblong pinholes, minor scarring of


components.

All major damage must be repaired and secondary NDT Inspection


performed. Repairs may be completed in a field environment, provided
they can be done and accessible for NDT Inspection.

Final Inspection Documentation of Drawworks should include:

a) Author of repairs, date and location of repairs;

b) Name and date of manufacturer;

c) Drawworks serial number;

d) Complete documented results of the Level IV inspection, as


described in Section 5.3.1 - 1000-day Braking Component
Inspection;

e) Date and period of certification.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

5.3.2 DAMAGE REPAIR INSPECTION


Occasionally between major inspections following a visual inspection,
repairs may be required to retain the operating integrity of the
drawworks. Any damage that requires repairs is classified as major or
minor, as outlined in Section 5.3.1 - 1000-day Braking Component
Inspection. The repair process would proceed as follows:

a) All repairs to major damage require supervision of senior well


servicing personnel. Inspection reports should be documented
after all repairs. The repairs must be documented in the
CAODC Mast and Overhead Equipment Log Book and signed
by the inspection personnel;

b) Repairs to minor damage may be completed by operating


personnel, at the discretion of the rig manager or higher
authority, and do not require re-inspection;

c) The above inspection is for the repair of actual damage to


maintain operating limits during the 1000-day inspection cycle.
This repair inspection does not extend the 1000-day inspection
requirement unless a major component breakdown inspection
utilizing a Level IV inspection is undertaken for all the
drawworks components.

5.3.3 ONE YEAR LEVEL III INSPECTION REQUIREMENTS


Every calendar year from the date of Level IV inspection the
drawworks should be Level III inspected as per the criteria outlined in
Section 2 – Inspection Levels. As a minimum a thorough visual
inspection of all brake linkage and brake assembly is required. After
reaching the required number of calendar days, the following
procedure is recommended for completing a Drawworks Level III
Inspection:

a) Clean drawworks, if required, to prepare for inspection;

b) Disassemble components in brake linkage, clean if require, to


prepare for inspection.

Note: threaded connections should be closely checked as worn


threads could lead to catastrophic drawworks failure causing
harm to personnel and equipment. Replacement braking
components should be OEM specified or as specified by a
Professional Engineer;

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

c) A thorough visual inspection should be performed by personnel


outlined in Section 7 - Personnel Qualification And
Documentation;

d) Any repairs that need to be performed to the equipment should


follow the guidelines outlined in Section 5.3.2 – Damage Repair
Inspection;

e) The person inspecting the Drawworks is required to sign off in


the CAODC Mast and Overhead Equipment Log Book that the
inspection was completed.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

6. CARRIERS
Both Class 1 and 2 Carriers have the same inherent problems with operating
hazards. The following are just some cause/effect problems with Carriers:

a) Raising Rams attached to the frame of the Carrier raise and lower the
derrick causing stress at the attachment point;

b) Drawworks are attached rigidly to the frame causing stresses in high hook
load situations;

c) Masts are attached and utilize the carrier frame as a load-bearing item
causing a load distribution through the frame;

d) Carriers are mobile creating vibrations and impacts on joints when moving.

Class 1 - Self-Propelled Mobile Carrier

Class 2 - Rig Trailer

6.1 INSPECTION OF CARRIERS

6.1.1 1000-Day MAJOR COMPONENT BREAKDOWN INSPECTION


After reaching the required number of operating days, the following
procedure is recommended for completing a carrier major component
inspection:

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

a) Clean carrier, if required, to prepare for inspection;

b) Disassemble components on carrier (mast, wheels, raising ram,


etc.) clean if required, to prepare for inspection;

c) Inspect the carrier frame using qualified personnel outline in


Section 7 - Personnel Qualification And Documentation. Pay
particular attention to torque tube and carrier frame between
rear axles.

Note: one operating day is comprised of 24 accumulated


operating hours.

Any damage found during the Level IV inspection is defined as


MAJOR or MINOR on the following basis:

A. MAJOR DAMAGE: Damage requiring welding to carrier


structural frame, Torque Tube, damage to axle attachment
points.

All major damage must be repaired and NDT Inspection


performed. Repairs may be completed in a field environment,
provided they can be done and accessible for NDT Inspection;

B. MINOR DAMAGE: Oblong pinholes, minor scarring of


components, rust pits, cosmetic welding,

Final Inspection Documentation of Carrier should include:

a) Author of repairs, date and location of repairs;

b) Name and date of manufacturer;

c) Carrier serial number;

d) Complete documented results of the Level IV inspection, as


described in Section 2 – Inspection Levels;

e) Note in CAODC Overhead Equipment Log Book signed by


senior operating personnel.

6.1.2 DAMAGE REPAIR CERTIFICATION


Occasionally between major inspections following a visual inspection,
repairs may be required to retain the operating integrity of the carrier.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

Any damage that requires repairs is classified as major or minor, as


outlined in Section 6.1.1 - 1000-day Major Component Breakdown
Inspection. The repair process would proceed as follows:

a) Repairs to minor damage may be completed by operating


personnel, at the discretion of the rig manager or higher
authority, and do not require re-inspection;

b) All repairs to major damage require the supervision of a


Professional Engineer or an OEM agent. The repairs must be
documented in the CAODC Mast and Overhead Equipment Log
Book and signed by the certifying party;

c) The above certification is for the repair of actual damage to


maintain operating limits during the 1000-day inspection cycle.
This repair inspection does not extend the 1000-day inspection
requirement unless a major component breakdown inspection
utilizing a Level IV inspection procedure is undertaken for all the
carrier components.

6.1.3 ONE YEAR LEVEL III INSPECTION REQUIREMENTS


Every calendar year from the date of Level IV inspection the carrier
should be Level III inspected as per the criteria outlined in Section 2 –
Inspection Levels. After reaching the required number of calendar
days, the following procedure is recommended for completing a carrier
Level III Inspection:

a) Clean carrier, if required, to prepare for inspection;

b) Visually inspect all critical load areas on the carrier frame


including the torque tube (raising ram connection), turnbuckle
connections, rear axle connection points, and drawworks frame
connections.

Note: torque tube (raising ram connection) is shock loaded


when mast is raised and lowered. Cracks usually exist in this
area and can lead to a catastrophic failure.
c) A thorough visual inspection should be performed by personnel
outlined in Section 7 - Personnel Qualification And
Documentation;

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

d) Any repairs that need to be performed to the equipment should


follow the guidelines outlined in Section 6.1.2 – Damage Repair
Certification;

e) The person inspecting the carrier is required to sign off in the


CAODC Mast and Overhead Equipment Log Book that the
inspection was completed.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

7. PERSONNEL QUALIFICATION AND DOCUMENTATION

a) The certifying Engineer must have previous experience and training in


structural analysis and have a practical working knowledge of service rigs;

b) Welders must hold a valid journeyman welding ticket and should have
experience in service rig maintenance;

c) NDT inspectors for a Level IV inspection would be required, as a minimum,


to have certification of “Level II, Canadian General Standards Board
(CGSB) Non Destructive Testing”. They should also have prior experience
in the inspection of service rigs;

d) Service rig company personnel undertaking Level III inspections will be


individuals designated by the company who have adequate experience and
knowledge in service rig maintenance. These individuals will typically be
experienced field superintendents, engineers, rig up superintendents or
operations managers;

e) It is recommended that all member companies provide training courses for


specific CAODC Recommended practice requirements. These training
courses should discuss, in depth, the critical components in service rig
recommended practices;

f) It is recommended that all member companies keep relevant documentation


in regard to inspections outlined in the CAODC Recommended Practices to
ensure a proper maintenance history for equipment is established.

8. TRAINING
Proper training of personnel continues to be one of the most critical considerations
in the care of critical components. This not only includes the rig personnel but also
the truckers that are handling these masts and the welders repairing them. Most
damage occurs during moving and handling, thus trained and alert personnel are
our best method of eliminating handling damage to critical components.

Personnel must also be trained to conduct regular visual inspections. This is not
only to satisfy regulatory demands or identify existing flaws, but to ensure that all
equipment involved will operate in the manner for which it was designed, thus
preventing new damage.

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Recommended Practice 3.0A — Inspection and Certification of Substructures,
Drawworks & Carriers (SR)

9. INSPECTION FREQUENCY

Equipment Daily Weekly Annual 24000 HRS


Derrick Log Derrick Log
Documentation N/A Tour Sheet
Book Book
Substructure I II III IV
Drawworks I II III IV
Carrier II III IV

10. IMPLEMENTATION
It is expected that contractors utilizing this Recommended Practice will comply with
Level III inspections by December 31, 2003 and that Level IV inspections will be
complied with at the next regularly scheduled Level IV period.

All equipment requiring a Level IV inspection upon issuance of this Recommended

Practice should consider following the guidelines herein when repairing masts.

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