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    Well Control Equipment

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    JoseManuelDominguezHuerta

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    © All Rights Reserved
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    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. Rig Inepection Workshep 1.0 Amoduspec 4 04 Drilling equipment nnn MAN-RIDING WINCH (Source: NOV document T366-Z-MA-001 revision 0) ‘The Hydralift Manrider Winch type HL-MR-150-110M is designed for safe and reliable personnel-handling operations on fixed or floating drilling plat- forms/vessels in a heavy-duty and critical onshore and offshore working en- vironment. The winch Is designed to meet the latest NPD and EU rules for machine directive requirements for such equipment and is type-approved by DNV/ABS. The winch unit consists of the following main components: + drum + drum foundation + mechanical driven spooling device + motor drive unit with brake + slip hub * disc brake units * valve equipment and wire rope e The winch is also equipped with hook stop (up and down) and a slack-wire detection system. In addition, a separate handheld remote control with 6- metre hoses is available. The winch is prepared for a connection to an external hydraulic power unit (ring line hydraulic system) of a constant pressure type. Pressure regulation, flow limitation valves and filters are integrated into the winch system. The winch is fitted with an accumulator for ‘emergency operation in case of hydraulic power loss from the rig's ring line system. Standard operation mode In standard operation mode for man riding the winch up/down movement is accurate and directly controlled by the winch handle. The winch handle is spring-centered to neutral position. In this mode the winch is also secured for working with moving equipment. The winch pull force is limited to 150 kg, and the winch will pay out wire if the load gets heavier than 230 kg. Emergency operation mode This mode is used when the hydraulic power supply fails during winch operation. If a person is hanging in the winch under such circumstances, it is e possible to lower or hoist the person to bring him down into a safe location. The hydraulic pressure Is in this mode maintained by an accumulator. The accumulator is automatically recharged when the winch is back in standard operation mode. AMoauspec Rig Inspection Workshop 1.0 _— 01 Drilling equipment Figure 1.276 - Remote- control console with emergency stop Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.273 - device for man rider. Figure 1.274 - Control console for man rider. Figure 1.275 - Grease points for man rider. Amoauspec a Anoduspec Rig Inspection Workshop 1.0 a 01 Drilling equipment Abbreviations: BU = Betore Use. M = Monthly. 3M = 3-monthly. ¥ = Yearly. Figure 1.272 - Recommended lubrication schematic NOV. 1a sername oe layout of man- ROBA’ Figure 1.270 Figure 1.271 - Special tools: ratchet wrench. The winch is protected from overload by a flexible coupling of the slip hub —_—_A ratchet wrench is supplied for type. tightening the drum’s flexible coupling. This wrench is to be located inside the door of the valve cabinet. AMoauspec Rig Inspection Workshop 1.0 a 01 Drilling equipment Figure 1.266 - Man-riding which specifications. a jure 1.267 and Figure 1.268 - Man-riding winch: general items and schematic. Rig Inspection Workshop 1.0 Aieaseeee saa 01 Drilling equipment 10 Air winches introduction oe Figure 1.264 - Modern man-riding winch made by NOV. Figure 1.265 - Modern man-riding winch layout (notice the accumulator bottle). Amoduspec Rig Inspection Workshop 1.0 as (01 Drilling equipment Figure 1.261 Loose equipment and poor housekeeping. Figure 1,262 Very heavy fluorescent light assembly in the derrick only hanging on its safety sling and electrical lead. Figure 1.263 Wire rope from air winch rubbing against the walkway. Rig Inspection Workshop 1.0 Asoduspec 01 Drilling equipment Figure 1.258 Winch pedestal tied off with rope at monkeyboard walkway. Figure 1.259 Unsecured and loose nuts in the derrick. If a nut falls down from this height, the impact is probably too great for even a safety helmet, thus causing a fatality. e Figure 1.260 Gas-cut pad eyes should not be used in the derrick or in any other area of the rig. Rig Inspection Workshop 1.0 Figure 1.255 Loose equipment lying in the derrick beams is scenario for a dropped- object hazard. Figure 1.256 Grating is missing, which is a clear tripping hazard. Figure 1.257 Loose nuts can cause an incident when dropping out of the derrick, Notice which nuts are adequately secured and which one lack the much-needed safety pin. Rig Inspection Workshop 1.0 Anoduspec Figure 1.252 Potential dropped object. This chair is not supported at all. Figure 1.253 Handrail missing at the end of the platform. jure 1.254 Gas-cut/home-made repairs on the derrick beams. Anoauspec nig Srenietion Workshop 3.0 = 01 Drilling equipment Figure 1.249 Monkey board layout with poor safety levels and difficult entry. There is no safety system for ladder- climbing activities. Figure 1.250 Creative but unsafe solution for monkeyboard winch brake. Poor housekeeping levels create potential dropped objects. Figure 1.251 Inertia reels to protect the derrickman; preferably two inertia reels must be installed in case the derrickman requires assistance, Rig Inspection Workshop 1.0 A loduSpec 04 Drilling equipment Figure 1.246 Self-closing doors installed at the monkeyboard level. Figure 1.247 No self-closing doors installed. Figure 1.248 Safety chains, wire rope or wire slings can be used as barriers, but it requires personnel to put them back in place after entry. Amoduspec SS ae 01 Dri quipment eo ern Figure 1.243 Rubber crash blocks which seldom splinter and do not require heavy-duty wire mesh protection. However, they can become hard in extremely cold weather areas and are vulnerable for desert conditions where excessive heat and ‘extreme sunlight ‘exposure can cause the rubber to crack as well. Figure 1.244 Cracked handrail at crown platform. It's a long way down. Figure 1.245 Derrick ladders with the rungs in a poor state. Who is doing the load test here, the heaviest man on the rig? Rig Inspection Workshop 1.0 Amoauspec Drilling equipment Figure 1.240 Fingerboard NDT- inspected: several cracks found. During one of our surveys the NDT inspector found no less than 18 cracks in the fingerboard! Figure 1.241 ‘Smashed wooden bumper blocks. No heavy-duty wire mesh installed; once again a serious dropped-object hazard. & Figure 1.242 Severely damaged wooden bumper blocks, but thanks to the heavy-duty wire mesh the wooden splinters did not fall onto the drill floor. Anoduspec Rig Inspection Workshop 1.0 sis ‘01 Drilling equipment Figure 1.237 Severely corroded beam of the derrick. Figure 1.238 Fingerboard at the monkeyboard level. None of these fingers were secured with an additional safety sling or chain. Each of these unsecured fingers represents a serious dropped-object hazard. ‘igure 1.239 Fingerboard cracked and insufficiently secured with a safety chain. Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.234 Corroded nuts and bolts at the main cross members in the derrick require replacement. Figure 1.235 Bent and deformed cross member in the derrick. Figure 1.236 Beam in the derrick filled with water caused by 2 plugged drain hole, creating excessive corrosion. Rig Inspection Workshop 1.0 Anoduspe con Works = ee Derrick Figure 1.231 Damage to any of the main members of the derrick could affect the actual load rating of the derrick. Figure 1.232 Wire sling installed over the sharp edges of the derrick beams. Figure 1.233 Note how the wire rope is becoming damaged when it is wrapped around the sharp corners of the derrick beam Rig Inspection Workshop 1.0 Anoduspec a Figure 1.229 Condition of a driller’s console found on a rig operating in Russia. Figure 1.230 The history of the @ doghouse drilling condition in Siberia Anoduspec Rig Inspection Workshop 1.0 ‘aia 01 Drilling equipn Figure 1.227 Poor location of torque gauges of the Iron Roughneck connected to the drawworks cover. Figure 1.228 Digital gauges are not always an advantage, as they are responding slower than meters with an analogue readout. Rig Inspection Workshop 1.0 wip nt Figure 1.224 Home-made temperature thermostat fitted in the driller’s house. This thing Is not really EX rated! Figure 1.225 Driller’s control house (doghouse) on a new- built rigs in Australia. This doghouse offers a good view all around. ® Figure 1.226 It is sometimes hard for the driller to see the rotary table and operate the equipment at the same time. Rig Inspection Workshop 1.0 (01 Drilling equip Figure 1.221 Star Wars-like driller’s console; the brake is now controlled with a Joystick. Be aware that the Joystick operation requires training, and make sure there are Jumper bars installed ‘over the crown block sheaves when using a Joystick. Figure 1.222 ‘Another advanced driller’s console installed on a jack-up rig. Figure 1.223 Modern driller’s consol on a new land rig. Rig Inspection Workshop 1.0 Amoduspec 01 Drilling equipment oy Figure 1.218 Poor electrical safety on top of the driller’s doghouse. Which cable is live and which one is obsolete? Which one is the EXi cable? Figure 1.219 Driller’s console with various "purge-air- protected” cabinets. Figure 1.220 Driller’s console with an EXi mud totalizing system. Rig Inspection Workshop 1.0 ©: Drilling equipment em 8 Drillers console Figure 1.213 Purge air-protected control Box with load e@ management system installed. Figure 1.214 The purge air supply is disconnected, the pressure switch is disconnected and the e alarm has “jumped out”. There shouid be an audible and a visible low-pressure purge alr alarm installed at all times. Bjoduspec Rig Inspection Workshop 1.0 as 1 Drilling equipment Figure 1.211 - NDT inspection as per API RP 8B and ISO 13534 Figure 1.212 - NDT inspection according to API RP 8B and ISO 13534, Rig Inspection Workshop 1.0 Aoduspec OL Driling equipment Figure 1.208 Excessive play for the main shaft of the travelling block. It is no longer possible to grease, as the grease @ nipple is broken off (@ so-called “Dutchman” Figure 1.209 Measuring the sheaves and bearing condition by performing a wobble test on the travelling block, which is not an easy task e Figure 1.210 What Is wrong here in the yard? Anoduspec Rig Inspection Workshop 1.0 = 01 Drilting equipment Figure 1.205 Bumper blocks protected by heavy- duty wire mesh. Figure 1.206 Distinct wear pattern on the travelling-block sheave covers a clear indication of a twisted drill line, or an excessive fleet angle of the drill line coming from the drawworks drum. Figure 1.207 Long-term storage of the travelling block in vertical position. The unauthorized welding used here to secure the block in the vertical position can actually cause severe damage on the bearings. Rig Inspection Workshop 1.0 AModuspec 1 Drilling ch a a Figure 1.202 Approximate 90% of the sheaves are condemned after five years. The sheave profile is excessively worn or too soft, or cracks are present like on this sheave (parallel to the sheave profile). Figure 1.203 Install self-closing doors at the crown. block platform entrance. Figure 1.204 Avery simple design for a self-closing gate. Amoduspec Rig Inspection Workshop 1.0 sa Drilling equipment Figure 1.199 One sheave is just hanging on the edge of the bearing. Total failure is looming. Figure 1.200 Cracked sheave on the crown cluster. Figure 1.201 No lock wire installed ‘on the bolts into the shaft of the crown block cluster. This is a potential dropped object. Rig Inspection Workshop 1.0 AModuspec 01 Drilling equipment pa Figure 1.196 This sheave shows less indication of excessive weer. Figure 1.197 New rig but no jumper bars installed over the sheaves. A sudden loss of load might cause the wires to jump off the sheaves. Figure 1.198 Very well designed Jumper bars over the sheave cluster, Amoduspec Figure 1.193 Performing a wobble test: checking for poor sheave bearings or cracked sheaves. Figure 1.194 Wear rate above the maximum allowable wear on the fastline sheave. Figure 1.195 Checking the sheaves with a sheave gauge. This “new” sheave already shows too much wear on one side A good paint job over a worn sheave, which returned like this from the workshop! aa Lice 01 Drilling equipment miss ent Inspections after jarring/top hole drilling + When the travelling block has been subject to impact loads (for instance during jarring or rough top-hole drilling), it must be inspected with re- spect to cracks, loose bolts and parts, signs of overload and deformation. + Listed below is a guideline for inspections after jarring/top-hole drilling, * Based on the actual operation carried out, those responsible for the operation must determine the required extent of inspection according to the amount of abuse and the level of impact loads to which the travelling block has been subject. * Inspect the sheave pin retainer plates (one retainer plate on each end of ‘each sheave shaft) with respect to loose bolts and parts. + Damaged parts must be removed and taken out of service. + After the equipment has been returned to service, it must be observed during its operation to verify an adequate performance. Rig Inspection Workshop 1.0 01 Drilling equipment ‘Two-weekly maintenance routine + Although only being used intermittently, the travelling block must be lubricated every other week, using the daily programme specified in the lubrication chart. Six-monthly maintenance routine + Gauge the sheaves of the travelling block. + The sheaves should be reworked or replaced if the throat bottom radius falls below the recommendation in section 3 of API RP 9B “Application, Care and Use of Wire Rope for Oll Field Service”. Yearly maintenance routine + Wash down alll the dirty parts of the equipment, and allow them to dry. * Have the (lifting-appliance) equipment inspected by a competent enterprise to verify that it is suitable for another year of operation. «Assigned copy of the inspection report must be filed in the maintenance log, and the remarks must be followed up. + The yearly inspection must include complete a dismantling, visual Inspection and MPI by means of the wet fluorescent method (see API Spec 8C) of the following load bearing components: critical areas of cheek plate, sheave shafts and critical areas of the sheaves. + Touch up all the paint damages, but wait until the inspection by the competent enterprise has been carried out. Six-monthly inspections + Visual inspection of the wire sheaves with respect to wear, deformation and cracks. + If there is any visible evidence of damage, carry out an MPI by means of the wet fluorescent method of the damaged/suspected areas. + The sheave wear measurement and acceptance criteria must be according to the recommended practice described in the API RP 9B standard. Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.192 - Grease points of the travelling block. Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.187 - Single sheave. _ Figure 1.188 - Sheave cluster. Some rigs use a single sheave for Depicted here Is a sheave cluster with 2 the fastline, as these are wearing set of automatic grease cartridges faster than all other sheaves. Also, installed, which reduces the number of changing bearings on a single visits to the crown block platform for sheave is much easier than ona —_ greasing purposes. cluster of sheaves. jure 1,190 - Grease cartridge. Figure 1.189 - Grease plug. Grease plugs need to be removed After energizing the grease cartridges, @ to energize the grease cartridges. chemical reaction inside the cartridges Is slowly pushing the grease out. Rig Inspection Workshop 1.0 Anoauspec — ng equipment 01 Dril GROOVE RADIUS Figure 1.182 and Figure 1.183 - Groove radius and sheave gauges. e The radiuses of the sheaves are measured with sheave gauges. For each type of sheave the maximum wear is already incorporated in these gauges; for instance, the 1-3/8" sheave has a "+ factor” of 1/32 inch, expressing the maximum wear. Figure 1.184 Figure 1.185 Figure 1.186 Sheave measurements using the sheave gauges. Note: Be aware that the loss of the upper layer of the hardened sheave profile can rapidly Increase the wear of the sheave profiles, so that frequent inspections are required, e Rig Inspection Workshop 1.0 04 Drilling equipment Figure 1.180 - Example of the specifications of a modern crown block cluster made by NOV. Figure 1.181 - Sheave-bearing inspection by wobble test with a crowbar. Note: There must be no tension on drill line and the travelling blocks needs to be hung off. Rig Inspection Workshop 1.0 Amoduspec cand 01 Drilling equipment etnies 6 Crown and travelling block introduction Figure 1.178 - New NOV crown block fitted with automatic grease cartridges. mm i Figure 1.179 - Modern NOV sheave cluster (most rigs have seven sheaves installed). Amoduspec Rig Inspection Workshop 1.0 a Drilling eq ipment Figure 1.177 Specifications for the commissioning test of the newly designed wash pipe assembly: + 2,000 hours at 5,000 psi/150 rpm with Nova Plus mud (including 1,000 hours with 0.006” intentional perpendicular misalignment) + -4 hours at 7,500 psi/150 rpm (test stopped after no failures) + -4 hours at 7,500 psi/225 rpm (test stopped after no failures) + -200+ hours at 5,000 psi/150 rpm with Aqua Gel mud (test stopped after no failures) Rig Inspection Workshop 1.0 Amosuspec 01 Dri as, Figure 1.174 What Is wrong here? Figure 1.175 Correct long-term storage of the swivel + in the vertical position. e Figure 1.176 New-generation wash pipe assembly. AModuspec Rig Inspection Workshop 1.0 i ot briling equipment e Figure 1.171 Main bearing of the swivel with shims to prevent excessive clearance. Figure 1.172 Home-welded plug on top of the gooseneck U-pipe. Figure 1.173 No plug available in the U-pipe means that no wire line operations are possible through this swivel. Notice also the Improper storing conditions here. es nase Figure 1.168 An alternative procedure Is to place a hydraulic jack under the shaft. e Figure 1.169 Swivel disassembled for major overhaul. Figure 1.170 ‘Schematic showing the seal arrangement in the wash pipe assembly. AModuspec Rig Inspection Workshop 1.0 ny rilling equipment CS ——— — Figure 1.165 Corroded threads of the wash pipe connection. Figure 1.166 Wash pipe assembly: at least ‘one completely dressed spare wash pipe should be available. Figure 1.167 Measuring the clearance of the main swivel bearing. By lowering the drill pipe into the slips the shaft moves up and the clearance can be taken with the dial indicator, Rig Inspection W 01 Drilling Amoduspe Figure 1.162 ‘Swivel after NDT inspection. Notice that the drill pipe connection was not carried out What other section has been forgotten? Figure 1.163 Swivel components NDT- Inspected as per API RP 8B type IV inspection standards. Figure 1.164 Swivel pins severely worn; they need to be renewed. Rig Inspection Workshop 1.0 04 Drilling equipmer Figure 1.161 Unauthorized weld repairs on the IBOPs of this top Drive. The top and bottom of the IBOP were welded together. Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.159 Home-made weld repairs applied to the lifting cylinder of the pipe handler. Figure 1.160 Hydraulic link tilt that is superseding the pneumatic design of the Varco TDS. An \duSpec Rig Inspection Workshop 1.0 04 Drilling equipment Figure 1.157 New wash pipe assembly ‘on the top drive. Notice that rust is already present on the shaft. Some rig owners chrome this shaft, thus extending the wash pipe running hours with a factor 2 to 3! Figure 1.158 Top drive: complete assembly with the dolly retract system. Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.155 Pipe handler for Varco TDS, which was removed for an NDT inspection of the load-bearing areas. Figure 1.156 The IBOPs are to be inspected regularly. AModuspec ‘ait Amoduspec ig Tispection Workahien 4:0 I 01 Drilling equipment: Figure 1.152 ‘Commutator of a high- torque DC motor. Figure 1.153 Measuring the clearance of the integrated swivel of a TDS 4. Figure 1.154 Pipe-handling and link tilt operation of a Tesco top drive, eee hae Figure 1.150 e View of the landing collar. Figure 1.154 e Commutator of a standard DC motor. Amoduspec Rig Inspection Workshop 1.0 01 Drilling equipment Figure 1.148 Crushed blower hose for the DC motor cooling feature. Figure 1.149 ‘The so-called safety pin in use here is a rusty rail. Rig Inspection Workshop 1.0 04 Drilling equipm: Figure 1.145 Dolly wheel catcher installed, plus an extra safety chain. Figure 1.146 Clear misalignment between the top drive and the centre of the rotary table. This can be adjusted on the top drive. Figure 1.147 Alignment cylinder to enable the adjustment of the top drive in relation to the well centre. Anoauspec Rig Inspection Workshop 1.0

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