RIG AUDIT REPORT

OF
CENTURY RIG 14
Prepared for
CENTURY DRILLING
By
Rig Inspection Services Pte Ltd
30 Toh Guan Road #08-09 ODC Districentre Singapore 608840
Inspection date: 25th 30th of March 2008

TABLE OF CONTENTS
1

INTRODUCTION

1.1

Rig Data

1.2

Survey Work scope

1.3

Applicable Standards

SUMMARY OF SURVEY

2.1

Discrepancies Categories

10

2.2

Summary of Discrepancies

10

DRILLING RIG EQUIPMENT

11

3.1

Draw works

11

3.2

Rotary Table

13

3.3

Swivel

13

3.4

Kelly Spinner

14

3.5

Crown Block

14

3.6

Block and Hook

15

3.7

Drilling Instrumentation

15

3.8

Master Bushing

16

3.9

Hawk Jaw

17

3.10

Elevators / Slips

18

3.11

Rig Tongs

18

3.12

Elevator

19

ELECTRICAL EQUIPMENT

21

4.1

Main Generators

21

4.2

Camp Generators

21

4.3

Mini Camp Generators

23

4.4

Transformers

24

4.5

SCR

24

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page2

4.6

Switch Gear and SCR house

25

4.7

Lighting

26

4.8

Hazardous Area Equipment

26

4.9

AC Motors

27

4.10

DC Motors

29

4.11

Elmagco Brake

33

MECHANICAL EQUIPMENT

34

5.1

Caterpillar Engines

34

5.2

Air Compressors

35

5.3

Air Receivers

36

5.4

Anti Fall Devices

36

5.5

Mechanic Work Shop

37

MUD SYSTEM AND EQUIPMENT

38

6.1

Mud Pump # 3

38

6.2

Mud Pump # 2

40

6.3

Mud Pump # 1

42

6.4

Stand Pipe Manifold and HP Lines

44

6.5

Vacuum Degasser

45

6.6

Mud Tanks

46

6.7

Trip Tank

46

WELL CONTROL EQUIPMENT

47

7.1

Accumulator

47

7.2

Single Ram BOP

48

7.3

Double Ram BOP

48

7.4

Annular

49

7.5

Choke Manifold

50

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page3

PREVENTATIVE MAINTENANCE

50

8.1

Preventative Maintenance

50

SAFETY AND OTHER MISCELLANEOUS EQUIPMENT

51

10

SPARE PARTS

51

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page4

1
1.1

INTRODUCTION
Rig Data

Rig:
Owner:
Type:
Location:
Inspection Dates:
1.2

Century Rig 14
Century Resources
Land Rig
Cirebon Indonesia.
25th 30th March 2008

Survey Work scope

In accordance with the instructions received by Century Resources, two surveyors attended
Century Rig 14 in Cirebon Indonesia to complete a Rig Condition Survey.
The aim of the survey was to determine the present condition of the Drilling Package and
associated equipment ensuring the equipment was fit for the intended purpose and in a safe
operating condition.
Included in the above scope was the following:
Carryout the inspection of the equipment to the criteria of the checklist supplied by Century
Resources.
The audit was conducted in good faith and without prejudice.
1.3

Applicable Standards

The inspection criteria, which have been used as reference during this inspection, are the
owners safety and operating standards, the original equipment manufacturers maintenance and
operating specifications and accepted oilfield operating and safety practices.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page5

SUMMARY OF SURVEY

RIS Surveyors attended Century Rig 14 in Cirebon Indonesia to complete a Rig Condition and
Safety Survey.
An inspection work scope had been determined by correspondence with the Maintenance
Manager prior to mobilization to the rig. A subsequent meeting was held on site with the Rig
Manager and the attending surveyors to discuss and coordinate the work scope of the inspection.
The aim was to assist personnel with forward planning and to prepare documentation and the
equipment for inspection.
At the time of inspection, the rig was being packed for shipment and was not operational which
allowed very good access to most equipment for intrusive inspections. Given that a substantial
amount of the equipment was not able to be operated, it was not possible to test some of the
safety devices or carryout any functional checks on most of the equipment. Should this be
requirement by either Century or their client then a subsequent visit would be required when the
rig was in a fully operational state. This would involve the RIS surveyor to be in attendance for
the close out and acceptance of the rig.
If all recommendations and planned maintenance repair procedures are followed and a suitable
reactivation period be allowed, then it would be fair to state that the rig could be expected to
operate in a safe and continuous manner on a drilling program.
Drilling Equipment
An intrusive inspection was carried out on the National 80-UE draw works which was found to
be in an acceptable condition. Bearing lift checks were conducted on the main drive shaft, jack
shaft and drum shaft, these were all found to be within the manufacturers acceptable limits,
there was no functional testing of this unit whilst we were on site.
The rotary table was visually inspected, the gear backlash 0.043 which is acceptable. The
master and split bushings were found to be in poor condition, dimensional checks were
conducted and exceeded manufacturers specifications for wear limits.
The Ideco 500T Swivel was visually inspected; the Quill stem length was measured and was
only 10 long. It would be recommended to have a spare Quill available.
There were no NDT records available on location for neither the travelling block nor the hook
assembly. Documentation is reported to be in the Jakarta office however if not available NDT
inspection should be conducted prior to the rig commencing the new contract. On the block, one
side door was opened to access the sheaves, bearing side movement checks were conducted and
found acceptable, the sheaves were gauged with only minimal wear noticed and found to be in
good condition. The latch and lock for the hook lever were functioned and working as they
should.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page6

Drilling Mast
The drilling mast was visually inspected and there was no obvious damage noticed to the
structure, all main supports and diagonal braces were found to be in good condition. There were
no recent NDT reports available for the mast or substructure however a third party Inspection
Company is currently on location and in the process of conducting NDT on all critical areas of
the mast. The NDT was 80% completed during our inspection with no defects found at that
time.
The crown sheaves were rotated and side movement checks conducted on bearings, minimal
movement only was detected and found to be in good condition, the line grooves on all sheaves
were gauged and checked for wear. Only slight wear was detected however well within the API
recommendations.
A rubber type bumper block is fitted to the underside of the crown and well secured, all padeyes in the crown section were noted to be numbered and a pad-eye register was available,
currently all pad-eyes are being inspected by third party and once completed will require colour
coding with the current colour for this six monthly period.
The racking board was checked, all fingers were straight, handrails acceptable, the main frame
and pad-eyes need to be NDT inspected and is in the current work scope for the NDT.
Due to the sections of mast and substructure being stacked it was not possible to locate the mast
compliance plates to confirm load ratings.
The rig floor personnel elevator was visually inspected. Further inspection will be required once
it is rigged up on location.
All pipes handling equipment was inspected, documentation was not available on location to
show previous NDT inspections, generally the elevators and slips were found to be in good
condition.
The Iron roughneck is currently waiting on parts to repair the hydraulic motor on the pipe
spinner.
Substructure
The substructure was visually inspected and due to being packed for mobilization it was not
possible to get 100% access to all areas, NDT inspections have been conducted on all critical
areas with no defects found at the time of our visit, all accessible sections of the substructure
that were inspected were found to be in acceptable condition. The raising system appeared to be
in good condition, all sheaves were gauged and bearing checks conducted the raising lines and
bridal line were visually inspected and found to be acceptable.
No function checks were conducted on the Lantec Winches.
Electrical Equipment
Due to the mobilisation of the rig, one air compressor was the only electrical equipment that
was operational at the time. Extensive checks were performed on the electrical aspect of the
Mud pumps, Draw works and camp generators. It was agreed that the Drilling generators would
not be inspected due to the planned change out of these Engine /Generator packages.
Unfortunately the SCR house was packed and secured for shipping so further checks should be
performed on this equipment after Rig arrives on location and electrical system is energised for

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page7

drilling operation. Checks still outstanding and should be completed prior to start up are as
follows.
Full function test of engine shut downs.
Under voltage, over and under frequency and reverse power trip tests.
Inspection of all MCC and SCR modules.
Inspection of generator power limit function (if system installed)
Drilling instrumentation checks.
Rig PA function test.
Complete lighting inspection.
Hazardous area electrical equipment inspection.
Re-inspection of electrical Generators and DC motors that had very low insulation readings
recorded as per below report.
Mechanical Equipment
As previously mentioned, it was not possible to run function tests on most of the equipments;
however we did manage to run one MCC generator 480 V to supply temporary power to the
office, no ESDs or safety systems were functioning as tested on the rig.
Both air hoists were visually inspected and have line and drum covers fitted, SWL is visible,
and line spoolers are fitted to both winches. The mechanism for disengaging the drum has been
removed and the system is locked into the engaged position to prevent free-wheeling of the
drum, and complies with safety requirements as detailed in OEM safety alerts. No function tests
have been conducted.
The Ingersoll-Rand Man Rider winch was not connected and no function test conducted this is
an approved dedicated man riding device and complies as per manufacturers spec.
The air package consists of four compressors, 2 x Sullair, 1 x Champion and 1 x Cold start.
The 2 Sullair series10 air compressors were visually inspected, only number one was
operational during the inspection. Isolation valves, instrumentation and pressure relief valves
have been checked.
The cold start with Sullair compressor was inspected and operated; the Un-loader system was
checked and functioned as it should.
Mud Systems
The mud tank system was inspected and found to have some areas with corrosion, the internal
coatings of the tanks have deteriorated in areas causing corrosion pitting and may require some
welding repairs, and work is currently in progress to descale these areas to further assess the
condition.
The low pressure lines appeared to be in good condition, it would be recommended that UT
thickness checks be conducted to assess the overall condition of the tanks and pipe work for
preventative maintenance purpose.
The standpipe and mud lines were visually inspected and appear to be in fair condition. No
documentation was available on location for previous UT inspections, the wall thickness checks
need to be conducted periodically to assess the integrity of the pipe for safe working pressure
ratings. Reports also need to be kept for any modifications of sections that have been welded
into line which should include NDT radiography proof pressure tests for the high pressure
system.
Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page8

The three DFE shakers were inspected and were found to have been poorly transported; two of
the shakers have not been secured to the beds causing some damage to the electrics and screen
tensioners. The repairs were completed during the inspection and were found to be acceptable.
Mud pumps
The three National 9-P-100 Mud Pumps, 2 x electric and 1 x driven by Cat D399, underwent an
intrusive inspection and were found to be in acceptable condition with no major faults noted.
Bearing lift checks were conducted on all pinion, crank and eccentric bearings, the crosshead
clearances checked, all readings taken are within the manufacturers recommended tolerances.
A check of the back lash between the Bull Gear and the Drive pinion was taken and this was
found to be within the manufacturers specifications.
Well Control
The Shaffer single was opened and inspected, ram blocks rubbers and seals were found to be in
good condition. Cavity measurements were acceptable and within tolerances. No pressure test
or function tests were conducted. Ring grooves were well protected and in good condition.
On the double , the upper rams were opened and required cleaning, it appears that they were not
properly flushed on the previous job leaving a large amount of cement in the cavity and around
ram blocks, cleaning was completed and measurements taken and found to be acceptable.
The lower doors were opened and were found to be in similar condition.
No documentation for the BOP was available on location; we have been informed that this is
available in Jakarta office. Current certification should be provided and full low and high
pressure tests should be conducted to ensure that the equipment is in a safe operating condition.
The Hydril MSP 2000 20 Annular was visually inspected, the element / ring grooves appeared
to be in good condition, the 4 lifting eyes were noted to have been NDT inspected however one
of the eyes is badly damaged.
The Choke manifold was checked and all valves were free and easy to open / close, one valve
was removed for internal inspection and found to be in acceptable condition. No pressure test
charts were available for previous tests; we have been informed that the previous tests were only
conducted to 1200 psi. A full pressure test program should be undertaken which should include
both low and high pressures tests from both sides to the SWP of the respective sides of the
choke manifold.
The Accumulator was not connected during the inspection and no function test conducted, the
unit has three banks of six bottles, these banks can be isolated individually and bled back to the
reservoir, it was noted that there was a low pressure alarm fitted, the alarms was not functioned.
A full accumulator drawdown test should be conducted when the BOPs are rigged up to ensure
that the unit has sufficient residual capacity to meet both the requirement of the client and API
specification whichever of the two are greater.
We would like to thank the management of Century drilling for the opportunity to provide our
services for the inspection of Century Rig 14.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page9

2.1

Discrepancies Categories

The Discrepancies in this report are categorized as follows:

Critical:
Deterioration and failure of the equipment resulting from this deficiency may lead to
environmental damage, a serious injury or loss of life.
Major:
Deterioration and failure of the equipment resulting from this deficiency may result in
significant damage to major equipment or compromise the operation.
Minor:
Deficiencies, which do not meet any of the above mentioned categories.
2.2

Summary of Discrepancies

This section has been covered in the Action Item excel spreadsheet which supplements the main
report, these two documents encompass the report package for this survey. The equipment has
also been given a rating on the spread sheet which is based upon condition evaluation. This dual
grading has proven beneficial to other drilling contractors when prioritizing remedial work
scopes.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page10

DRILLING RIG EQUIPMENT

3.1 Draw works

The National 80-UE Draw works was subjected to an intrusive inspection for condition evaluation
and was found to be in acceptable condition. The unit is DC driven.
The brake linkage system was inspected and a tolerance check of the brake shaft pillow block
clearance and found it to be excessive, new brake hubs and brake bands were fitted, the Drum
shaft bearings were checked for Lift by using a hydraulic Enerpac and a dial gauge, the readings
taken were 0.002 and 0.003 for the drillers and off drillers side respectively.
The main drive shaft bearings were checked, Drillers side = 0.012 Off Driller side = 0.010
whilst the Jack shaft bearing clearances found on the driller side = 0.006 Off Driller side =
0.012. Although these are within OEM specifications they should be monitored during future
condition checks. Chains and sprockets were checked and in acceptable condition.

The oil pump, chain and sprockets were found to be in good condition.
Both main drive couplings were inspected, the off driller side has noticeable wear on the draw
works side inner and outer splines, possibly caused from previous misalignment. We considered
the coupling acceptable for operation at this time, however, recommends conducting checks on
the alignment to prevent further deterioration.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page11

The brake linkage system was found to have excessive movement in the S-link and bell crank
pin bores. The main brake through shaft mounting blocks is worn and this is causing the shaft to
flex under load. There were no recent NDT records available on the rig to show bands and
linkages have been inspected.

The front left hold down bolt on Draw works motor A, appears to be bent or cross threaded.

3.1.1

Draw works Discrepancies

Critical:

None.

Major:

Excessive wear noticed in pin bores on the S-link and the bell cranks on driller
side, the main through shaft is flexing under load, this could be due to the
amount of wear in the shaft pillow blocks. Recommend that the worn linkages be
replaces.
The main brake shaft will need to be removed to check if the wear is in the
mounting block bores or main through shaft.
No NDT records were available on rig location; if no current records are
available it would be recommended to conduct the inspection prior to
commencing work.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page12

Recommend to replace the hold down bolt or check that it is not bent or cross
threaded.
Minor:

The drive coupling from the DC motor to the draw works main drive shaft off
driller side was found to be worn on the inner and outer splines, we recommend
that alignment checks be conducted to ensure that further wear is not accelerated.

3.2 Rotary Table

The rotary table was visually inspected. The bearing lift checks were conducted on the input
shaft bearing and found to be 0.012 the gear backlash was checked and recorded at 0.042
these readings were found to be acceptable.
3.2.1 Rotary Table Discrepancies
Critical:
None.
Major:
None.
Minor:
None.
3.3 Swivel
A visual Inspection of the Swivels was conducted; No Quill Vertical movement checks were
completed due to being packed for shipping. The length of the Quill on the Ideco was measured
and found to be 10 it would be recommended that a replacement Quill be available. No NDT
reports were available. The lift point of the bail was checked and found acceptable, there was no
movement noticed in the bail pin bores. The gooseneck extension was noticed to be threaded
and welded; the gooseneck has also had a wire line socket welded in.

3.3.1 Swivel Discrepancies

Critical:

None.

Major:

Recommend that the gooseneck be changed out due to the modifications made
No UT reports were available on location for the gooseneck.
NDT inspection would need to be conducted on the Quill thread and lifting
points of the swivel prior to work.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page13

Minor:

It would be recommended to have a replacement Quill available. If a re-cut of the

thread was required it may not leave sufficient length for the tong.

3.4 Kelly Spinner

The Kelly spinner was visually inspected; it is currently incomplete and not functioning, has
been advised that parts have been ordered.

3.4.1

Kelly Spinner Discrepancies

Critical:

None.

Major:

Recommend to rebuild once parts become available.

Minor:

None.

3.5 Crown Block

The crown was visually inspected and found to be acceptable, bearing side movement checks
were conducted, The main cluster and fast line shaft pre-load plate retaining bolts were lock
wired, sheave seals appeared to be in good condition and sheaves showed minimal wear,
generally the crown was found to be in good condition.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page14

3.5.1

Crown Block Discrepancies

Critical:
Major:
Minor:

None.
None.
None.

3.6 Block and Hook

The travelling block were packed for shipping, all sheaves were gauged and rotated with no
unusual noises detected, the sheaves show minimal wear but acceptable and appear to be well
greased, the hook lever was opened and checked for movement in the pivot pin and the latching
lock checked and found to be acceptable, no Recent NDT records were available on location.
3.6.1

Block and Hook Discrepancies

Critical:

None.

Major:

Recommend that the hook and travelling block hang off point and critical areas
have NDT conducted prior to the rig commencing work if no NDT reports are
available in Jakarta office.

Minor:

None.

3.7 Drilling Instrumentation

A visual inspection was conducted and all appear to be in acceptable condition. However,
documentation for calibration was not available for the instrumentation. It is recommended that
calibration be conducted annually, labels should be visible on the gauges showing next due date.
3.7.1

Drilling Instrumentation Discrepancies

Critical:

None.

Major:

It is recommended to have all instrumentation calibrated prior to the rig

commencing work.

Minor:

None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page15

3.8 Master Bushing

Dimensional checks of the Master bushing and split bushing were conducted and were found to
have excessive wear, the master bushing is loose in the pin bores with 3/8 movement between
the body halves.
The split #3 bushings were checked, the lower throat was measured at 11 1/8 and the upper at
14 3/8, the maximum allowable is 10 1/8 for lower throat and 14 3/8 for upper throat. Most
of the excess tolerance is caused from body spread of the master bushing. This will cause
accelerated wear of the slip bodies and possible bottle necking of the drill pipe.
Both bushing locks in the master bushing were seized and not functioning.

Wear in pin bores, 3/8 movement.

Showing gap between body and pin.

Above photos showing spread in lower tapper of the insert bowls.

3.8.1

Master Bushing Discrepancies

Critical:

None.

Major:

Recommend to replace the master bushing and slip bowls.

Minor:

Conduct slip test to check for slip die to pipe contact.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page16

3.9 Hawk Jaw

Checks were conducted on the jaws for movement and found to be in good condition, there
were no services or maintenance history available on location for this equipment; however we
were informed that it has only been in service for approximately eight months. The hydraulic
motor on the spinner has been disassembled and parts are on order. No function test was
conducted and will need to be completed once repairs have been made and rigged up on
location.

3.9.1

Hawk Jaw Discrepancies

Critical:

None.

Major:

Repair hydraulic motor for the spinner as soon as parts are available.
Conduct the services recommended by manufacturer.

Minor:

Conduct all MPI at the frequencies as recommended by the manufacturer.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page17

3.10 Elevators / Slips

All elevators have been visually inspected and found to be in good condition.
It was noted on some side door Casing Elevators that there was no provision for a secondary
safety pin on the door latching mechanism. It is recommended to fit a secondary lock to the
door latch to these older type elevators by OEM and retro fit kits are available.
The Slips and MP safety clamps were visually inspected and found to be well serviced, the die
clearances to slip bodies have been check and appear to be in good condition, and generally the
equipment was found to be in acceptable condition.
No record was available for the last Cat IV inspection of the handling equipment on location.

3.10.1

Elevators / Slips Discrepancies

Critical:

None.

Major:

If no Cat IV records are available, it is recommended to conduct full disassembly

of the handling equipment and record the pin and bore tolerances for wear
against manufacturers recommendations on the next inspection.

Minor:

Single action latch on casing elevators, it is recommended to fit a secondary lock

to the door latch to these older type elevators by the OEM and retro fit kits are
available.

3.11 Rig Tongs

The BJ type SDD.rig tongs were visually inspected, safety handles were missing from most of
the lug jaws, random pin hole dimensional checks have been conducted and found to be in
acceptable condition. NDT was being conducted during the inspection, with several cracked
jaws found, these were removed from service.
A new set of BJ HT 55 tongs were available.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page18

3.11.1

Rig Tongs Discrepancies

Critical:

Remove all reject tong jaws from the rig.

Major:

None.

Minor:

Recommend that new safety handles be fitted to the tongs jaws.

3.12 Elevator
The personnel elevator to rig floor was visually inspected and several deficiencies were noted.
The electrical installation needs remedial action, there was no inspection records available
showing MPI of critical areas, unable to locate any secondary safety locking device for the
riding basket in the event of a hoisting line failure, none of the safety devices were able to be
functioned, SWL signs need to be displayed.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page19

Above photos showing some electrical connections and outlets that require remedial action.
3.12.1

Elevator Discrepancies

Critical:

Recommend that all electrical installations be checked and repaired.

NDT of all critical areas.
Check that all safety devices are functioning correctly.
Safe working load needs to be visible at entries.
Check for secondary safety device for basket in the event of a hoisting line
failure.

Major:

Recommend a full inspection of the elevator once rigged up on location.

Minor:

None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page20

ELECTRICAL EQUIPMENT

4.1 Main Generators

The three SCR and two MCC Engine Gen packages were prepared for shipping so they were
not run. Century plan to remove and upgrade these gen sets in the near future. The decision was
made between Century senior management and RIS that these gensets would not be included in
this field inspection.
Polarisation Index and Insulation Resistance Results (Not available)
Alternator #1
Rotor
Stator

Alternator #2
Rotor
Stator

Alternator #3
Rotor
Stator

M @ 1 min
M @ 10
min
PI
4.1.1

Main Generators Discrepancies

Critical:
Major:
Major:

None.
None.
None.

Recommendations:
It is recommended that these Generator packages have complete insulation tests performed
prior to start up.
4.2 Camp Generators
Initial test of Main Gen #1 found low insulation readings. Generators were opened and cleaned
prior to any further testing. Generators could not be run so visual and PI/IR insulation tests were
performed.
No generator heaters were connected at the time.
No maintenance history was available to ascertain when the generators were last inspected and
what readings were recorded.
4.2.1

Generator No 1: Main Camp

Generator #1 PI/IR insulation test
Rotor
Stator
Exciter
M @ 1 min
M @ 10 min
PI

Report Title: Century Rig 14

0.5

0.55

0.7

1.6

1.4

3.2

1.1

Issue No: 1
Revision No: 1
Page21

4.2.2

Generator No 1: Deficiencies

Major:

Bad wire connection was found on exciter Diode Bridge. Rig electrician
immediately repaired this.

Major:

Rotor insulation reading is below acceptable level.

Recommendations:
Cleaning of generators be performed on a more regular basis.
Generator to be heated, dried and re-test prior to start up.
Control panel to be re-labelled for easy identification.
Previous insulation test records should be available on site for test reference.
4.2.3

Generator No 2: Main Camp

Generator #2 PI/IR insulation test
Rotor
Stator
Exciter
M @ 1 min
M @ 10 min
PI

4.2.4

0.15

0.5

0.17

1.0

1.1

Generator No 2: Deficiencies

Major:

Rotor insulation reading is below acceptable level.

Major:

Both Generator heaters have been removed.

Recommendations:
Heaters to be fitted in generator housing.
Cleaning of generators be performed on a more regular basis.
Generator to be heated, dried and re-test prior to start up.
Control panel to be re-labelled for easy identification.
Main circuit breakers located on generator power distribution panel should have under
voltage protection.
Previous insulation test records should be available on site for test reference.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page22

4.3 Mini Camp Generators

Inspect generators and test exciter and stator windings only. Time and labour restraints
prevented us from being able to test the rotor windings (these winding connections are hard to
get to and time consuming to disconnect). No maintenance history was available to ascertain
when the generators were last inspected and what readings were recorded. Heaters where fitted
in both generators.
Generator #1 PI/IR insulation test
Rotor
Stator
Exciter
M @ 1 min
M @ 10 min
PI

4.3.1

2.5

2.9
1.4

Generator No 1: Mini Camp Discrepancies

Minor:

Control panel requires re-labelling.

Recommendations:
Rotor coils to be checked when time permits.
Cleaning of generators be performed on a more regular basis.
Previous Insulation test records should be available on site for test reference.
4.3.2

Generator No 2: Mini Camp

Generator #2 PI/IR insulation test
Rotor
Stator
Exciter
M @ 1 min
M @ 10 min
PI

4.3.3

15

8.5
1.4

Generator No 2: Mini Camp Discrepancies

Minor:

Generator power distribution panel external wiring to be fixed up so no single

insulated wiring is present. See photo attached.

Minor:

Control panel requires re-labelling.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page23

Recommendations:
Rotor coils to be checked when time permits.
Cleaning of generators be performed on a more regular basis.
Power distribution circuit breakers to be labelled for easy identification.
Under voltage protection installed on camp supply breakers.
4.4 Transformers
All power and lighting transformers on Drilling package where opened, cleaned and inspected.
No defects were found. Insulation readings are as follows:
Transformer Insulation
Primary
Secondary
4.4.1

SCR 600-480V

SCR 480/220/120

MC1 480/220/120

MC2 480/220/120

180 M
2.7 M

200 M
200 M

41 M
250 M

12 M
4 M

Transformers Discrepancies

Critical:
Major:
Minor:

None.
None.
Transformers should be labelled as per their drawing reference.

4.5 SCR
At the time of inspection, the SCR house was packed and secured for transportation. We
recommend that the SCR house is thoroughly inspected once the planned Generator upgrades
are complete and Rig is in operation.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page24

4.5.1

SCR Discrepancies

Critical:
Major:
Minor:

None.
None.
None.

4.6 Switch Gear and SCR house

MC1 Switch room was available for partial inspection. (Some panels where secured for
transportation). Inspection of the 480V MCC modules found them in a deteriorated state and in
need of replacement / repair.
MC2 Switch room was secured for transportation and unavailable for inspection.
SCR house roof was in the process of being painted. Poor quality repairs were used to repair
water leaks in roof.

4.6.1

Switch gear and SCR house Discrepancies

Critical:

None.

Major:

MCC modules to be repaired/replaced.

Major:

SCR house roof has a number of silicone repairs to prevent water leaking into
switch room.

Recommendations:
We were advised that plans are in place to change out MC1 & MC2 switch rooms. If this
upgrade is cancelled or delayed indefinite then we recommend that all motor starter modules
be removed, stripped down, cleaned, painted and rebuilt with new switch gear.
Holes in SCR house roof must be properly patched with the use of steel plate to prevent any
possibility of water leaking into switch room.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page25

4.7 Lighting
All lighting was packed for Transportation. Complete lighting inspection will be required once
Rig is in operation at new location.
4.7.1

Lighting Discrepancies

Critical:

None.

Major:

Complete lighting inspection will be required once Rig is in operation at new

location.

4.8 Hazardous Area Equipment

Due to the rig being mobilised, this inspection was limited to what equipment we could inspect.
We recommend that a full inspection be carried out once Rig up has been completed.
Inspection of the Drill Floor Dog house revealed a number of electrical issues that should be
attended to prior to commencement of Drilling.
The mud cooling tower exhaust fan motor is not EX rated. This is located in a class one zone
one area. A question also exists over the use of pillar type bearings being used in a class one
zone one area.

Non rated outlet

Mud Cooling Tower

Report Title: Century Rig 14

Non rated plug & socket

Non rated electric heater

Id Plate fitted to mud cooling tower fan motor

Issue No: 1
Revision No: 1
Page26

Hazardous Area equipment Discrepancies

Major:
Major:
Major:
Minor:
Minor:
Minor:

Standard household 220V outlets and extension cords are in use in Dog house.
These are required to be removed and replaced with appropriate hazardous area
equipment.
There is a non hazardous area electric heater situated in Dog house. This must be
removed prior to commencement of drilling.
Mud cooling tower has a non EX rated fan motor mounted in a class one zone
one area.
220V Combination plug panel located in Dog house has no certification labels
attached. All equipment located in Hazardous areas must have certification labels
attached.
Dog house wiring standard is in poor condition, improvements could be made to
improve the standard of wiring.
Mud cooling tower fan belt cover requires repairing.

4.9 AC Motors
No motors could be run due to mobilization of the rig. Overall the AC motors were in
acceptable condition with the exception of the below listed items. A number of AC motors
where megger test with no low readings recorded.
4.9.1

Random megger test results

Motors were test at 500v
Draw works A Blower
1000M
Draw works B Blower
300M
Mud pump 1 Blower
2.5M
Mud pump 1Oiler
2.4M
MP 1 Liner washer
500 M
MP2 Blower
6 M
MP2 Oiler
14M
MP2 Liner Wash
600M

4.9.2

AC Motors Discrepancies

Major:

Shaker No 2 and No 3 motor supply cables between switch station and motor
have been damaged. Supply cables to be replaced. See attached photo. (Job
completed)

Major:

Mud pump 2 Blower motor connection junction box has signs of water ingress
and corrosion. See attached photo.
This was repaired.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page27

Minor:

A number of Agitator motor starters have cover bolts missing. See attached
photo.

Minor:

Shaker motor switch stations to be reconfigured so output motor cable has better
protection and less stress is on cable when entering cable gland. See attached
photo.

Minor:

Trip pump motor mounts to have new bolts installed.

Shaker 3 & 2 motor supply cable damage

MP2 Blower motor J/B

4.9.3

Recommendations
New shaker motor cables installed to replace damaged cable. (Job completed)
Shaker switch stations to be reconfigured so outgoing cables create less stress on
entry glands. (Job completed)
All AC motor Junction boxes to be opened inspected for water ingress and cleaned.
Lid and J/B surfaces to be cleaned and greased with approved silicone grease to
ensure good sealing when closed.

Report Title: Century Rig 14

Shaker switch station

Issue No: 1
Revision No: 1
Page28

At present nearly all centrifugal pump motors have been disconnected. We

recommend that these motors be megger checked and documented prior to
reconnection.
Once on location and earthing system has been completed. All motor frames be
checked for insulation resistance to ground. Reading must be below 1 ohm. This will
ensure all motors have been earthed via its supply cable.
All mud system centrifugal pumps to be manually rotated prior to been energised.
This is to ensure the impellers are not seized by any mud that may have been left in
the housings.

4.10 DC Motors
Inspections were performed at Cirebon holding yard where rig was being prepared for shipment.
All motor internals were in a satisfactory condition taking into consideration the age of the
equipment (no records available on site noting running hours or days of service).
Space heaters were present in each motor but could not be checked for correct operation due to
rig mobilization. At the time of inspection humidity levels were high and signs of moisture were
present in all the motors.
No maintenance history was available to ascertain when the motors were last inspected and
what readings were recorded.
4.10.1 DC Motors Insulation recordings
DC Motor
Draw works A
Draw works B
Rotary Table
Mud pump 1
Mud pump 2

Field (M)
500
250
4
66
70

Armature (M)
0.03
0.6
0.43
0.05
0.07

4.10.2 DC Motors Discrepancies

DWS A
Major:
Armature insulation reading is way below minimum acceptable levels.
Major:

Multicore socket providing power for motor field, blower & heater supplies has
water ingress and insulation readings well below acceptable levels. EG:
Insulation readings for Field supply circuit between junction box terminal strip
and incoming connection plug has a reading of 0.02meg ohms at 500V to ground.
See attached photo.

Minor:

Motor junction box cover requires new mounting screws. At present the cover is
only held on via a small number of self tapping screws. See attached photo.
Field supply cable entry into DC motor requires correct gland entry. See attached
photo.

Minor:

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page29

Water ingress in multi pin plug

J/Box cover mounting screws

Field supply cable gland

4.10.3 DC Motors Discrepancies
DWS B
Major:
Armature insulation reading is way below minimum acceptable levels.
Major:

Major:

Multicore socket providing power for motor field, blower & heater supplies has
water ingress and insulation readings well below acceptable levels. EG:
Insulation readings for Field supply circuit between junction box terminal strip
and incoming connection plug has a reading of 0.02meg ohms at 500V to ground.
See attached photo.
Motor junction has open spare cable access at bottom off enclosure. Plus
Junction box lid is only held by small amount of self tapping screws. These
enclosures are supposed to be purged via blower air before motor is energised. At
present this is not possible, there for pressure switch circuitry is possibly
bypassed. See attached photo.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page30

Minor:

Field supply cable entering motor requires flexible conduit protection with
correct gland entry. See attached photo.

Spare open cable entries

Field supply cable

4.10.4 Rotary Table Discrepancies

Major:

Armature insulation reading is way below minimum acceptable levels.

Major:

Lock out switch is seized up and in need of replacement.

Major:

Motor junction box cover needs replacing with new. See attached photo.

J/B Cover needs replacing

Lockout switch is defective

4.10.5 Mud Pump No 1 Discrepancies

Major:

Armature insulation reading is way below minimum acceptable levels.

Minor:

Junction box lid requires new mounting bolts fitted.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page31

4.10.6 Mud Pump No 2 Discrepancies

Major:

Armature insulation reading is way below minimum acceptable levels.

Minor:

Junction box lid requires new mounting bolts fitted.

DC Motor recommendations:
Low Armature readings: All DC motor armatures to be cleaned, heated and megger test
prior to running. Readings to be above 1meg ohm prior to energising.
Multicore plugs to be opened and cleaned. If insulation readings cannot be improved, plugs
are to be replaced.
All mud pump and Draw works DC motor Junction Boxs to have covers repaired back to
original state with all securing bolts used plus all spare cable entries covered to ensure a
positive pressure is present during motor operations.
Rotary Table DC motor Junction Box cover to be replaced. Junction box to be checked that
a positive pressure is present during motor operations.
Draw works DC motor blower air intakes to be checked that they are in a free air zone as per
API standard 500.
Both Draw works motor Field supply cables to have correct hose and glands fitted between
Junction box and Motor entry.
All DC motor Junction box air purge pressure switches to be checked for correct operation
prior to commencement of drilling.
All DC motor heaters to be checked for correct operation when on next location and power
is available.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page32

4.11 Elmagco Brake

Brake junction box was opened for inspection, Ohm, resistance and feeler gauge readings were
taken. All readings at acceptable level. Supply cable wiring requires replacing as soon as
possible due to its perished state. Date of last efficiency test was not available.
Brake Air Gap clearance was checked and was as per last check performed by Rig personal.
Clearances where between 0.035 and 0.049 which is well within maximum clearance range.
Insulation and OHM readings as per below:
BRAKE OHM AND INSULATION RESISTANCE.
Coils
F1-F2
F3-F4
F5-F6
Coil Resistance
6.5
6.4
6.5
Coil Insulation M
10
6
10

F6-F8
6.5
6

The supply cable

4.11.1 Elmagco Brake Discrepancies
Major:

Supply cable between brake J/B and supply connection plug has its inner
insulation deteriorating. See attached photo.

Major:

If a proficiency test has not been performed within the last 12 months, it is
recommended to be performed prior to commencement of drilling.

Brake Recommendations:
Cable to be changed prior to commencement of drilling.
All associated alarms and water flow rate to be checked prior to commencement of drilling.
Water PH levels must be as per manufacturers recommendations.
Brake cooling water cooling condensers to be opened inspected and cleaned prior to
commencement of drilling.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page33

MECHANICAL EQUIPMENT

5.1 Caterpillar Engines

The main generators were not able to be run due to mobilisation of the equipment. We were also
advised that Century plan to remove and upgrade these gen sets in the near future. However, the
service history was reviewed and they appeared to be well maintained.
The Minicamp generator engines were checked visually as they were unable to be run, the
solenoid on the injector pump on get set # 2 requires repairs, the fan belts and cooling fan
bearing has excessive movement and needs to be replaced on gen set # 1.

5.1.1

Caterpillar Engines Discrepancies

Critical:

None.

Major:

Repair the loose solenoid valve on the injector pump of gen set # 2.
The cooling fan belts on gen set # 1 were found loose and worn, recommend
replacing.
The cooling fan bearing was found to have excessive movement, recommend
that the bearing be replaced.

Minor:

None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page34

5.2 Air Compressors

There are 4 air compressors on the rig, 2 x Sullair S 10, 1 x Champion and 1 x cold start.
The PRVs on compressor 1 & 2 Sullairs were last tested on the 15/4/04, all relief valves need to
be tested annually. Only number one Sullair and the cold start were operational during the
inspection and both appeared to be operating without any problems noted.
The non return valve on # 3 compressor (Champion) discharge is not working, it is still under
pressure even when off line. It appears to be very oily in the discharge and pressure relief valve
and would recommend that the separator be checked. This unit was not able to be functioned
during the inspection and was advised they were waiting on part for repairs.
The PRV on the Champion and cold start compressors have adjustable type pressure relief
valves fitted, these should be replaced with certified pre-set type relief valves.
The cold start battery has no protection to prevent arcing across terminals.

Adjustable type PRV not certified

5.2.1

Battery for cold start

Air Compressor Discrepancies

Critical:

None.

Major:

Recommend to fit certified relief valves to the compressor units.

Replace the non return valve in the discharge line (Champion Compressor) to
prevent pressurising the unit when not on line.
Conduct full service on the Champion compressor, check oil separator and repair
oil leaks.
Fit protection for the cold start battery (battery box)

Minor:

None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page35

5.3 Air Receivers

All air receivers were visually inspected; The SWP markings were visible on all receivers.
There was no documentation available to show that the receivers have had hydrostatic testing,
UT gauging or internal inspections conducted.
The PRV certification needs to be reviewed, the PRVs in the lower substructure and compressor
room receivers have no tags fitted to show last inspection.

5.3.1

Air Receiver Discrepancies

Critical:

None.

Major:

UT thickness checks should be conducted to check for internal corrosion.

Documentation needs to be available for the PRVs set pressure and next
inspection due.

Minor:

Documentation needs to be available for the last hydrostatic tests conducted.

5.4 Anti Fall Devices

The dog house and other work shops have anti fall static lines along the roofs to attach harness
lanyards to, the lines are spliced and the mounting points are not properly secured, the fall
devices need to load rated.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page36

5.4.1

Anti Fall Device Discrepancies

Critical:

The static lines need to be load rated, spliced line terminations are not
acceptable, recommend that all lines have the correct end terminations and be
load rated.
The mounting points for the static lines need to be properly secured and load
rated.

Major:
Minor:

None.
None.

5.5 Mechanic Work Shop

The mechanics work shop / office was found to be in poor condition, major corrosion was
noticed in the walls and roof, during the inspection it was raining and water was leaking through
the roof and into the lights / computer and maintenance manuals.

5.5.1

Mechanic work Shop Discrepancies

Critical:
Major:
Minor:

Recommend that the work shop / office building be replaced.

None.
None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page37

6
6.1

MUD SYSTEM AND EQUIPMENT

Mud Pump #3

Mud Pump # 3

National 9 P 100 Mud Pump # 3. This pump is engine driven by a Caterpillar D399 engine via a
National Torque Converter, air clutch and V-belt drive.
The power end cover of the pump was opened to perform an internal inspection, the main
bearings rollers and inner race looked bright and clean with no signs of damage. Lift clearances
were conducted using a dial indicator and hydraulic jack and were found to be minimal.
The teeth of the bull gear and pinion appeared to be in good condition, the pinion gear back lash
is within tolerance with the maximum reading noted as 0.0024. The pinion shaft bearing
clearance at drive end is 0.003 and 0.003.
The main bearing clearances were taken and found to be acceptable and RH was measured at
0.006 whilst the LH was 0.005.
The crosshead clearances were taken and found to be acceptable. It was not possible to remove
the crosshead pins to inspect the bearings, however all the crosshead pins were tight in the
crossheads around the taper fit area.
The lift, and clearances, of the connecting rod eccentric bearings and crosshead slide have been
taken and recorded on the condition sheet below.
There is no lock wires fitted to the retaining bolts for the cross head pins on all three cross heads.
These bolts may not be OEM as they are not drilled.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page38

Mud Pump # 3
National 9-P-100
Driven by Cat D- 399
Inspected by: Brett Slaven
Rig Inspection Services.

Good
0.003
0.022

0.004

0.004
Good

Good

0.005

0 006

Good

0.003

0.003

Good

Good

0.004

0.006

0.024

0.018

0.024

0.022

0.018

0.020

0.006

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page39

6.1.1

Mud Pumps # 3 Discrepancies

Critical:

None.

Major:

The retaining bolts for all three cross head pins need to have tie wire fitted.

Minor:

None.

6.2

Mud Pump # 2

Mud Pump # 2

The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection
and was found to be in good condition with no major faults noted.
The cover for the power end was removed and surface rust was evident on the pinion shaft and
both bearings. This was cleaned and lubricated before turning, no pitting was noticed.
The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at
0.018 and within tolerance. The pinion shaft bearing clearance at drive side was 0.005 and off
side 0.003.
The main bearing clearances were taken and found to be acceptable RH was 0.004 and LH is
0.003.
It was not possible to remove the crosshead pins to inspect the bearings. All the crosshead pins
were tight in the crossheads around the taper fit area and the lock wires were in place on the pin
retainer plates.
All drive chains and sprockets were inspected and found to be in acceptable condition.

Sprockets and chains good condition

Report Title: Century Rig 14

Corrosion on pinion bearing

Issue No: 1
Revision No: 1
Page40

Mud Pump # 2
National 9-P-100
DC Driven
Inspected by: Brett Slaven
Rig Inspection Services.

Good
0.006
0.018

0.004

0.005
Good

Good

0.003

0.004

Good

0.003

0.005

Good

Good

0.006

0.006

0.018

0.020

0.022

0.022

0.022

0.018

0.005

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page41

6.2.1

Mud Pumps # 2 Discrepancies

Critical:
Major:
Minor:
6.3

None.
None.
None.

Mud Pump # 1

Mud Pump # 1

The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection
and was found to be in good condition with no major faults noted.
The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at
4 point and max/min findings were 0.015 and 0.024 within tolerance. The pinion shaft
bearing clearance at drive side was 0.006 and off side 0.003.
The main bearing clearances were taken and found to be acceptable RH was 0.006 and LH is
0.003.
The clearance in the connecting rod eccentric bearings and crosshead slide clearances have been
taken and found acceptable; these have been recorded on the condition evaluation sheet below.
The crosshead readings are at the tightest spot across the full area of the slides. It was not
possible to remove the crosshead pins to inspect the bearings. All the crosshead pins were tight
in the crossheads around the taper fit area and the Lock wires were in place on the pin retainer
plates.
Rod # 3 was found to have the rod seal broken and exposed out of the seal housing, when the
cover for the power end was removed surface rust was evident on the pinion shaft and both
bearings. After cleaning no pitting was noticed.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page42

Mud Pump # 1
National 9-P-100
DC Driven
Inspected by: Brett Slaven
Rig Inspection Services.

Good
0.006
0.024

0.004

0.006
Good

Good

0.003

0.006

Good

0.006

0.003

Good

Good

0.006

0.006

0.018

0.020

0.024

0.020

0.018

0.018

0.005

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page43

6.3.1

Mud Pumps # 1 Discrepancies

Critical:

None.

Major:

Replacement of seal was in progress during the inspection.

Minor:

None.

6.4 Stand Pipe Manifold and HP Lines

The mud lines were visually inspected, some end union welds were noticed to be washed in
areas. No previous UT reports were available showing wall thickness, a 5K system should be
XXS pipe to give the pressure rating, (WT = 17.05mm new).
No Radiography reports were available for previous modifications to the high pressure lines,
MPI is not an acceptable test for new pressure welds, this will only show surface breaking
defects not slag inclusions or root runs.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page44

Above picture showing internal pipe welds and washing on hammer unions on the mud lines.
6.4.1

Stand Pipe Manifold and HP Lines Discrepancies

Critical:

None.

Major:

Recommend UT inspections be conducted on all high pressure pipe work to

determine pipe integrity, and confirm that it complies with the required pressure
rating.
All pressure welding need to be conducted by a qualified welder with 6G or 3E
qualifications or current test piece certification.
All new high pressure welds need to be radiography or UT testing.

Minor:

None.

6.5 Vacuum Degasser

The Mud degasser was packed for mobilisation, a visual inspection was conducted, and the
outer shell appears in good condition. The vacuum compressor / motor V-belts were not fitted,
the compressor was rotated by hand and was found to be rotating freely, it appears that the unit
has not been in use for some time and will be required to operational to complete the inspection.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page45

6.5.1

Vacuum Degasser Discrepancies

Critical:
Major:

None.
None.

Minor:

Once rigged up function test, check float valve is functioning and vacuum
pressure.

6.6 Mud Tanks

A visual inspection was conducted on the mud system and was found to be in acceptable
condition; however there were areas of corrosion that needs to be removed to further access the
condition. The cleaning and descaling was in progress and repaired as required.
6.6.1

Mud Tank Discrepancies

Critical:
Major:

None.
None.

Minor:

Recommend to continue cleaning the corroded areas and make repairs as

required.

6.7 Trip Tank

A visual inspection was conducted on the trip tank, the general condition of the tank was poor,
and the tank and piping was badly corroded and requires descaling for further assessment and
repainting.
6.7.1

Trip Tank Discrepancies

Critical:
Major:

None.
None.

Minor:

Recommend to clean the corroded areas for further assessment and make repairs
as required.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page46

WELL CONTROL EQUIPMENT

7.1 Accumulator
The fluid pressure relief valve should be set at 3,500 psi, documentation needs to be provided
showing that it releases at the set pressure as no function test was able to be conducted and no
tag was fitted to the valve.
The unit is equipped with a two bottle nitrogen backup system. The remote panel is located at
the dog house and accessible to the driller. No function tests have been conducted.
On rig up it would be recommended to conduct an accumulator drawdown test to ensure that
there is sufficient accumulator volume available with the current amount of accumulator bottles,
after confirming that the accumulator bottles have the correct pre-charge pressure.
Note: The final accumulator pressure shall be equal to or greater than 200 psi above pre-charge
pressure (API RP 53 section 17.7.1 a-g) Note: Some Chevron contracts require 500 psi above
pre-charge.

7.1.1

Accumulator Discrepancies

Critical:

None.

Major:

There was no certification available for the fluid pressure relief valve; this should
be set at 3,500 psi, during function testing check the release pressure.
Conduct a drawdown test and records should be kept for all pressures through
each step of the procedure for future reference.

Minor:

No signage was available showing that the unit auto starts. This should be placed
on the unit and visible to personnel.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page47

7.2 Single Ram BOP

The single Shaffer LWS-SGL S# 4158 was opened for cavity dimensional inspection and was
found to be in acceptable condition. All rams and rubbers were in good condition, the upper seal
faces had slight pitting however acceptable. There was no pressure test charts or certification for
the unit available on location. It was not possible to conduct function tests during this
inspection.

7.3 Double Ram BOP

The double BOP was opened for inspection and was found to be full of cement; it appears that
they were not flushed correctly after the last operation. They were cleaned and cavity
measurements taken and found to be in acceptable condition. There was no pressure test charts
or certification for the unit available on location. It was not possible to conduct function tests
during this inspection.
All cement was removed from the rams and cavities prior to inspection.

7.3.1

BOP Discrepancies

Critical:

None.

Major:

Conduct low and high pressure tests on the well bore side of the BOPS.

Minor:

Conduct pressure tests on the hydraulic operator side of the BOPS.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page48

Recommendations:

That certification be available for review and is current.

Pressure test charts should be kept for all testing.

Cleaning procedures need to be followed

7.4 Annular
Hydril M.S.P 2000. 20
The Annular was visually inspected, the element appears to be in as new condition, and damage
was noticed on one of the four lifting eyes.

7.4.1

Annular Discrepancies

Critical:

None.

Major:

The damaged eye is not suitable for lifting; recommend that if this is to be
repaired that the repair be conducted by an approved OEM facility.

Minor:

Conduct pressure tests on the hydraulic operator side of the BOPS.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page49

7.5 Choke Manifold

No pressure charts were available showing previous tests, were have been advised that tests
have been conducted on the previous Chevron contract however only to 1,200 psi, one valve
from the manifold was disassemble for internal inspection and was found to be in good
condition.

7.5.1

Choke Manifold Discrepancies

Critical:

None.

Major:

Recommend that a full test of the manifold and all valves be conducted and
pressure test charts kept for review.

Minor:

None.

PREVENTATIVE MAINTENANCE

8.1

Preventative Maintenance

The general maintenance history on the mechanical side appears to be good; however the
preventative maintenance schedule should be looked at closely for the electrical prior to the rig
being prepared for its next contract. Generally the electrical maintenance has no records of any
checks being conducted.
8.1.1

Preventative Maintenance Discrepancies

Critical:

None.

Major:

Good documentation needs to be kept for services and repairs made to the
equipment for future reference.

Minor:

None.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page50

SAFETY AND OTHER MISCELLANEOUS EQUIPMENT

At the time of inspection, it was not possible to carry out a safety audit and unable to see
systems in place. We would strongly recommend that a complete safety audit is carried out on
the rig when it is rigged up prior to spud. As per the Century checklist, we were unable to
confirm if most safety equipment was available due to the rig being packed for mobilization.
9.1.1 General Safety and Training Discrepancies
Critical:
Major:
Minor:

None.
None.
None.

10 SPARE PARTS
A brief look through the warehouses found that parts were kept tidy and well organized, there
appears to be a good supply, and checked random critical spares were available, a full inventory
of parts was supplied and critical items that are usually required were listed, it would be
recommended that prior to the rig commencing its next contract that a more in depth inspection
on critical parts required be conducted.

Report Title: Century Rig 14

Issue No: 1
Revision No: 1
Page51