Rig Inspection Workshop Coursebook Land rigs - Jack-up rigs — Platform rigs 2009 1.0 Author: Jaap Peetsold ReouSosc wi For further information regarding ModuSpec Training please contact the author. Gapingseweg 1a 4353 JA Serooskerke Tel: +31 118 563050 Fax: +31 118 563055 a Email: moduspec@moduspec.com Website: www.moduspec.com AUSTRALIA | CANADA | THE NETHERLANDS | SINGAPORE | USA | UNITED KINGDOMAvoduspec at Rig Inspection Workshop 1.0 Coursebook Table of contents Table of contents Table of contents.. Chapter 01 - Drilling equipment Chapter 02 - Mud processing equipment... Chapter 03 - Engine room and power plant Chapter 04 ~ Electrical equipment Chapter 05 - Safety equipment. Chapter 06 - Marine equipment .. Chapter 07 - Well control equipment .. Chapter 08 - Appendices Moduspece All nights reserves. All rights of ownership, to all materials prepared for this training manual by ModuSpec whether written or not, shall remain the property of ModuSpec; copyright and distribution rights are reserved by ModuSpec at its sole discretion. No part of this publication may be reproduced, stored In a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, oF otherwise ‘without prior permission in writing, from the ModuSpec Head of Training. Care has been taken to compose this training manual, however, possible (printing) faults or ‘incompleteness of subject material may appear. ModuSpec accepts no responsibilty for use or misuse of information contained herein.Rig Inspection Workshop 1.0 4 Drilling equipment Chapter 01 Drilling equipment weyansune Introduction drawworks Rotary table... Top drive introduction Top drive Swivel. ‘Crown and travelling block introduction . Crown and travelling block... Drillers console... DERICK sssersssse 10 Air winches introduction, 11. Air Winches sssscsesssseeee 12. Lifting and handling equipmentpec Anodus pny Rig Inspection 01 Drilling equipr 1 Introduction drawworks oY ee Ba AY == _amiwiwiey, Figure 1.1 - Overall picture of the layout of the drill floor, derrick, tr ravelling block and crown block.Rig Inspection Workshop 1.0 Amoduspec 01 Driling equipment sa a FIG. 44 LINK ADAPTER INSPECTION: pt ty fuze see mete Sete women ieee, e Bier wean acres wees oz Figure 1.334 - NDT inspection of link adapter as per API RP 8B and ISO 13534.Rig Inspection Workshop 1.0 ling equipment FIG, 42 — GLOCK-TO.HOOK ADAPTER INSPECTION: Figure 1.333 - NDT inspection of block-to-hook adapter as per to API RP 8B and ISO 13534.Serene mr es et FIG. 44 LINK ADAPTER INSPECTION: Figure 1.332 - NDT inspection of link adapter as per API RP 8B and 180 13534.Amoduspec Rig Inspection Workshop 1.0 e veorecrion Figure 1.331 - NDT inspection of hook as per API RP 8B and ISO 13534,Rig Inspection Workshop 1.0 Amoduspec 01 Drilling equipment ee INSPECTION, e mesoom oF Pivor MOVEMENT ano e ‘BEARING WEAR LOOSE FasTENcas! emhcxs, meoD Figure 1.329 - NDT inspection of deadline anchor as per API RP 8B and ISO 13534. Figure 1.330 - NDT inspection of rotary slips as per API RP 8B and ISO 13534.Rig Inspection Workshop 1.0 01 Drilling equipment INSPECTION, Figure 1.328 - Swivel NDT inspection as per to API RP 8B and ISO 13534,Rig Inspection Workshop 1.0 Amoduspec O1 Driling equipment = PIG. 483 CASING, TUBING, AND DRILL PIPE ELEVATORS SLIP TYPE ELEVATOR INSPECTION: Figure 1.327 - NDT inspection of slip-type elevator as per API RP 8B and ISO 13534.AModuspec Se eee ¥1G, 482 CASE . USING AND DRILL PIPE ELEVATORS CENTER LATCH ELEVATORS INSPECTION: WEAR OF PINS anoLts + Figure 1.326 - NDT inspection of centre latch elevator as per API RP 8B and ISO 13534Rig Inspection Workshop 1.0 AModuspec 01 Drilling equipment FUG, $3 ELEVATOR LINK INSPECTION: fg Settn semunce, ieene e Sane rt eaten om ieee ee pion Steer” Ewe arn cu ens tC wan rom an eenow = Figure 1.325 - Elevator link inspection as per API RP 8B and ISO 13534.Anoduspec Rig Inspection Workshop 1.0 ee 01 Drilling equipment PIG. 4N CASING. TUBING AND DRILL PEPE 1 HYATONS SIDE HOOK ELEVATUR INSPECTION Figure 1.324 - NDT inspection of side door elevator as per API RP 8B and ISO 13534.Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.322 This is what happens when the top drive collides with the crown block sheave cluster and the drill line breaks. Figure 1.323 One of the crown block sheaves ending up inside driller's doghouse.ey Rig Inspection Worksh 01 Dr Figure 1.319 Pipe spinner should have a safety sling attached from hanging line to the lifting point on spinner. If the lifting cylinder or its component fails, the spinner cannot fall down onto the operating crew. Figure 1.320 Bent and overstressed bracket for the back-up tong. Figure 1.324 Severely corroded and damaged back-up sling. A certified sling with a moulded eye must be installed here,Rig Inspection Workshop 1.0 Amoduspec 01 Drilling equipment Figure 1.316 Drill pipe slips cracked, most likely due to worn master bushings or the Use of the wrong angle drill pipe inserts. Figure 1.317 Unauthorized welding on the safety clamps. Figure 1.318 Rig-made handling equipment must not be used,AModuspec Rig Inspection Workshop 1.0 aa 01 Drilling equipment Figure 1.313 Elevator NDT inspection. Figure 1.314 Unauthorized welding of the rig number onto the elevators. This elevator must be scrapped immediately. Figure 1.315 Drill pipe slips in a very poor state.Rig Inspection Workshop 1.0 Rewce 01 Drilling equipment rrr) Figure 1.310 Wear on eye of the elevator link, Downrating by means of the OEM instructions fs required. Figure 1.311 Table for downrating the elevator links from measuring the eyes. Figure 1.312 Replace the non-OEM hinge pin.Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.307 Unauthorized welding to connect the tong dies on the casing tong. This element can shatter to a thousand pieces under load! Figure 1.308 Home-made arm and non- ‘OEM stud in the new tong ‘on a brand new rig. Figure 1.309 Dramatic failure of the elevator links, which shows the importance of NDT inspection.Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.304 Unauthorized welding of an extension to the tong arm. Figure 1.305 Using a tong die as a spacer is not recommended. Figure 1.306 Completely destroyed tong section. AmoduspecAModuspec Rig Inspection Workshop 1.0 a 1 Dring eaupment e 12 Lifting and handling equipment Figure 1.301 No pins to back up the tong inserts. If the tong die would fall inside the well, it could cause prolonged downtime. Figure 1.302 Inspection of rig tongs is very important to the safety of personnel. Figure 1.303 NDT inspection on tongs, but what about inspecting the hanging arm as well?Rig Inspection Workshop 1.0 AModuspec 01 Drilling equipment a ns mmm eT; Figure 1.299 Automatic line-spooling device and line- tensioning system installed. The drum ‘guard was removed for this inspection, Figure 1.300 No guard over the drum, no line spooling device, no silencer, no hold-down bolts, no WL sign and no isolation valve installed. Nice colour, though.Rig Inspection Workshop 1.0 01 Drilling equipment e - Figure 1.296 Schematic showing how to secure the snatch- blocks and wires with a safety sling. Ensure that the safety sling's safe working load (SWL) rating is at least two times the SWL rating of the tugger wire. The distance between — the snatch-block bottom and the safety wire loop must be as short as reasonably possible in order to reduce the dynamic impact, should the tugger line fail. Figure 1.297 Also a small hydraulic winch requires to have a drum guard installed. Figure 1.298 This winch was used as the designated man- riding winch on this rig.Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.295 Snatch-locks underneath the crown block platform secured with safety slings. The preferred shackles in the derrick are of the four-item type (like the ones painted orange). ‘The upper shackles need to be replaced, as these are the two-item shackles. Amoduspec ‘iatAnoduspec Rig Inspection Workshop 1.0 — OL Dr Figure 1.292 Simple-designed spooling device from the manufacturer. igure 1.293 Home-made spooling device that operates satisfactorily. Figure 1.294 No spooling device fitted, so that the wire ends up tangled on drum.Rig Inspection Workshop 1.0 Anoduspec 01 Drilling equipment Figure 1.289 Rig worker using his e own hand as a spooling device. Figure 1.290 Home-made spooling device, although perfectly suitable, Notice the silencer on the air exhaust. Figure 1.291 This air winch is Installed the wrong way round, The spooling device is located on the wrong side, so that the operator has to stand in front of winch to spool! the wire rope.Amoduspec Rig Inspection Workchop.2.0 meee pet e Figure 1.286 Overstressed foundation bolt with a very low-quality safety pin. Figure 1.287 Poor maintenance of this tugger; the wire requires replacement as soon as possible. Can you mention five obvious deficiencies here? Figure 1.288 Sharp spikes sticking |, out of the damaged 4 tugger wire.Rig Inspection Workshop 1.0 1. Drilling equipment Figure 1.283 Free-fall handles must either be secured on or altogether removed from all the winches. Figure 1.284 Locking system to isolate and prevent the use of the free-fall mechanism. Figure 1.285 Foundation bolt missing from and bent stud on the brake assembly,Anoduspec Rig Inspection Workshop 1.0 01 Dri ais Pe Me = Figure 1.280 ‘ ow Oil-contaminated brake: the brake lining should be replaced first. Figure 1.281 Plastic bag put inside the brake assembly Is not a professional way to clean or adjust the brake. Figure 1.282 1 Brake adjusted with a Wil heavy 1502 coupling.Rig Inspection Workshop 1.0 Anoduspec 04 Drilling equipment isi meme 11 Air Winches Figure 1.277 Drill floor with utility e and man-riding tugger. Figure 1.278 New man-riding winch being installed. Figure 1.279 Man-riding winch: adjustment block with adjustment screws to adjust the speed and load-limiting device. @Rig Inspection Workshop 1.0 04 Drilling equipment es ----orrree ‘SAFETY FUNCTIONS In order to achieve a safe operation of the winch and a commitment to the regulation requirements from both proving authority and client, extra hydraulic/mechanical systems (J.e. in addition to the ordinary winch system) have been incorporated to the winch. Moving equipment This system eliminates the risk of overload to personnel from an external force caused by moving equipment by using a slip/hub adjusted to circa 230 kg. If any external force is applied to a person hanging in the winch, the winch will pay out wire and avoid any overload to the person. The payout function will always be active, except when the manual or hydraulic disc brakes are active. Slack-wire stop system This system Is applied to the winch to avoid slack wire during lowering. The system consists of a wire sheave connected to a rotating bracket. When load e is applied to the wire, the wire sheave and bracket are rotated upwards until a valve handle is moved to its on position. This sequence gives a pressure permit to the winch-down operation. If for some reason the person becomes attached to an object during a lowering sequence and Is not able to continue to descend, the wire sheave on the rotating bracket will rotate down and moves the valve handle to the off position. This will cut off the oil pressure to the winch-down side of the motor and stop the descent, therefore preventing slack wire. Pressure roller on the drum The roller consists of a spring-applied roller pressed against the wire on the drum, to keep it from unwinding if slack wire should occur. Wire end stop system The wire end stop system Is installed to avold winch-holsting/lowering movements after the person has reached its maximum/minimum destina- tion. Always leave a minimum of 5 turns of wire on the drum. Emergency system e This system Is installed to the winch to achieve safe lowering or hoisting of 2 person to a safe location, due to the absence of pressure from the ring line system. After choosing the emergency operation on the three-way ball valve, the accumulator pressure is selected and it is ready for selecting the winch direction on the control desk. It is important to reset the emergency valves to their normal position after a return of pressure. Emergency stop/brake ‘An emergency stop button is installed on the winch control panel. An emer- gency brake button is also installed on the hydraulic remote-control panel.Rig Inspection Workshop 1.0 Anoduspec 01 Drilling equipment a mee Brake 3 The manual disc brake is manually operated on the winch. The disc brake operates directly on the drum flange. Brake 4 This brake is connected to a load control valve, When the operating handle is in hoisting position, pressure will release the mechanical brake on the motor and open the load control valve and the hoisting will proceed. If the operating handle is in neutral position, the winch will hold It position by means of the load control vaive and the motor brake will be activated. Valve cabinet The valve cabinet houses all the main valves and critical components for the winch. The valve cabinet is totally enclosed for long-term operation in a corrosive environment. Hydraulic valves All the valves for the winch are installed inside the motor side cabinet to protect them from any external mechanical and/or chemical damage. @ Control panel The winch can be operated locally from the winch control panel or from the pendant hydraulic remote control. Both contro! panels have the following control functions: + emergency stop + brake for stop of winch + winch up/down control lever for stepless speed/direction control of the winch The control panel is located on the winch. A local main control valve is fitted into the control panel for the winch system. The valve is equipped with a winch-hoisting/ pressure-limiting valve and flow-limiting valve for easy connection to the rig’s ring-line system with overcapacity. The control panel is also equipped with clear operation instructions. To achieve a better view and communication between operator and the man rider, an extra pendant hydraulic remote-control device Is installed. The pendant remote is fitted with a control valve and an emergency brake valve and Is hydraulically connected to the main panel by means of a 6-metre-long eS multi-hose. Upon request, a cordless radio-operated control system is also available. Wire The winch is equipped with 110 metres of 10-mm rotation-resistant wire The wire is fastened to the drum by three bolted clamps. The outer end of the wire Is equipped with a closed spelter socket of an offshore type.AModuspec Rig Inspection Workshop 1.0 as (01 Drilling equipment «re e MAIN DESIGN Drum and drum foundation steel structure The drum is made of stainless-steel plates bolted together. The winch structure is built of plate elements. All welding Is performed in accordance with the approved procedures. One of the drum flanges is equipped with a split opening to allow wire end termination on the outside of the flange. Three bolted clamps secure the wire end. The winch is equipped with the mechanical spooling system to ensure an op- timal build-up of wire rope on the drum. The system ensures excellent spool- ing and a long wire lifetime. The winch drum is well protected from personnel contact by a stainless-steel metal cover fitted to the winch foundation by bolts. The cover is equipped with a hinged hatch for simple inspection of the drum/wire. The cover also protects the drum from oil spillage, mud and wa- ter. Mechanical spooling device The spooling device consist of a wire guide, a double-grooved driveshaft, a e sprocket wheel on the drive shaft and drum shaft, and a chain between the driveshaft and the drum shaft. When the drum rotates the drum shaft drives the double-grooved drive shaft on the spooling device, which moves the wire guide that guides the wire on to the drum. The winch drum is driven by an OMT motor connected to one side of the winch drums, transferring the output torque to the drum. The motor has high total efficiency and runs smoothly, even at an extremely low speed. Drum brake units In addition to the hydraulic brake integrated in the motor, there are two extra brakes of a disc type working directly on the drum. One is hydraulic- operated and the other is manual-operated. There is also a counterbalance valve mounted on the motor. Brake 1 ‘The hydraulic brake in the motor Is designed for fail-safe operation, which means that the brake actuates when pressure supply is lost, for instance due @ to a ruptured hose or pipe. The hydraulic brake is a dual-load control valve. The motor brake consists basically of a set of plate springs. When pressure is. lost, the piston is forced to move backwards by the plate springs and at the same time the piston moves the brake disk together until the required brake torque is achieved, Brake 2 The hydraulic disc brake needs hydraulic pressure from the emergency stop valve on the remote control. The disc brake operates directly on the drum. flange.