February

Inspection
Manual 2022
Revision 6
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Intentionally Omitted

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Document History

Issu Rev Date Issued Prepared / Reviewed By Brief on Revision

e No Revised By
. No / Revised
1 1 11/04/2018 George Craig Zahran Al Kindi  Initial Issue

1 2 Sep, 2020 Cristian O. Mostafa I.  Document name changed from

“Equipment Inspection Procedure” to
Akhilesh M.
“Inspection Manual”.
 Procedures been updated addressing
API Q2 1st Edition Requirements
 The following clauses been modified:
Clause 5 – Procedure
Clause 5.2 – Abraj Equipment
Inspection Matrix.
 Two new clauses been added in the
procedure:
Clause 5.7 – Calibration of
Equipment.
Clause 5.9 – Record Keeping &
Equipment History.
 Revised the inspection table/inspection
intervals as per last agreement with
PDO.
 Revised Clause 4 Definition
1 3 Dec, 2020 Cristian O. Mostafa I.  Revised the inspection table/inspection
intervals.
Akhilesh M.
 Revised on equipment inspection steps
for several equipment’s (From
Gooseneck Assembly- page 120 to Flo
Line – page 146)
1 4 Feb, 2020 A.A.Elaziz Mostafa I.  Rearrange inspection matrix table item
no.
M.Hussein
 Add new equipment that was add by
Akhilesh in the inspection matrix table.
 Sort the pages to match Inspection
Matrix table
 Revised the inspection table/inspection
intervals. Line 68, 69 and 71
 Add 2 pages and Revised on
equipment inspection steps for Mud
pump relief valve ( page 151 – page
152)
 Revised on equipment inspection steps
for BOP lifting device ( page 156)

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 Add standard references in table 6.1.1,

6.1.2 and 6.1.3 (page 13 and 14)

1 5 July 2021 A.A.Elaziz Mostafa I.  Complete Revise of the inspection

manual and categorize the equipment
Azan Al Adawi
Akhilesh
Cristian O.
Ahmed Salah
1 6 February 2022 A.A.Elaziz Mostafa I.  1.4 Changed raising cylinder CAT III to
1 Year & CAT IV for PDO NOV rigs
Azan Al Adawi
only to 3 years
Akhilesh  1.7 Changed PDO structure pad eye
CAT IV interval to 10 years and add
Cristian O.
new work instructions
Ahmed Salah  2.5 Changed TDS CAT III to 1 Year
and add new Work Instruction
 2.5.7 Add instruction for end play
 3.1 Add new instructions to Mud Pump
power end CAT III and CAT IV
 3.3 Changed Rotary table CAT IV to 5
years for PDO rigs
 3.15 Changed the load phrase of BOP
hoisting
 7.2 Changed pulsation dampener CAT
IV to 2 Years for PDO rigs
 9.10 Changed the man riding load test
to 1.25 SWL
 14.1 Changed responsibility of King
Pin CAT III from Chief Mechanic to Rig
Manager

Document Authorization

Revision 6 Document Owner Document Custodian

Salah Al Harthy Saif Al Hussaini

Acting Managing Director Acting Director Drilling & Workover

Feb, 2022

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User Notes:

This document is the property of Abraj Energy Services S.A.O.C. Neither the whole nor any part of this
document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form
by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent
of the owner.

The requirements of this document are mandatory. Non-compliance shall only be authorized by Quality
Department through STEP-OUT approval.

A controlled copy of the current version of this document is on available in Abraj document management
system. Before making reference to this document, it is the user's responsibility to ensure that any hard
copy, or electronic copy, is current. For assistance, contact the Document Custodian.

Users are encouraged to participate in the ongoing improvement of this document by providing
constructive feedback to the Document Custodian. Uncontrolled copies of this document may be issued
to interested parties or customers, subject to the consent of the Document Custodian.

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Table of Contents

1.0 OBJECTIVE .................................................................................................................................... 11

2.0 SCOPE ............................................................................................................................................ 11
3.0 RESPONSIBILITY .......................................................................................................................... 11
4.0 DEFINITION .................................................................................................................................... 11
5.0 PROCEDURE ................................................................................................................................. 11
5.1 Equipment Integrity Inspection ..................................................................................................... 11
5.2 Abraj Equipment Inspection Matrix ......................................................................................... 12
5.3 Scope of Equipment Inspection Matrix ........................................................................................ 12
5.4 Inspection Levels ............................................................................................................................ 13
5.5 Qualifications for Inspector and Welder ...................................................................................... 14
5.6 Equipment Integrity Inspection Tracker ....................................................................................... 15
5.7 Calibration of Equipment ............................................................................................................... 15
5.8 Inspection Certification Control .................................................................................................... 16
5.9 Record Keeping & Equipment History ......................................................................................... 16
5.10 Roles and Responsibilities .......................................................................................................... 17
6.0 REFERENCES ...................................................................................................................................... 19
6.1 Related Standards and Specifications ......................................................................................... 19
7.0 Equipment inspection Matrix.............................................................................................................. 23
1.1.1 Mast and Substructure CAT III ................................................................................................ 25
1.1.2 Mast and Substructure CAT IV ................................................................................................ 34
1.2.1 Mast & Substructure Moving System CAT III ......................................................................... 35
1.2.2 Mast & Substructure Moving System CAT IV ......................................................................... 36
1.3.1 Stabbing Board and Monkey Board CAT III ............................................................................ 37
1.3.2 Stabbing Board and Monkey Board CAT IV ........................................................................... 38
1.4.1 Raising cylinders CAT III .......................................................................................................... 40
1.4.2 Raising cylinders CAT IV ......................................................................................................... 41
1.5 Raising Line and Spelters ........................................................................................................... 42
1.6.1 Raising / Scoping Winch
es CAT III ............................................................................................................................................. 43
1.6.2 Raising /Scoping Winches CAT IV ........................................................................................... 44
1.7.1 Mast and substructure Pad Eyes CAT III ................................................................................ 45
1.7.2 Mast and substructure Pad EyesCAT IV ................................................................................ 46
1.8 Wire Rope Slings & Shackles ..................................................................................................... 47
1.9.1 Pad eyes welded to runway beam CAT III............................................................................... 48
1.9.2 Pad eyes welded to runway beam CAT IV .............................................................................. 49
2.1.1 Crown Block CAT III .................................................................................................................. 50
2.1.2 Crown Block CAT IV ................................................................................................................. 51

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2.2.1 Travelling Block CAT III ............................................................................................................ 52

2.2.2 Traveling Block CAT IV ............................................................................................................ 54
2.3.1 Drilling Hook CAT III ................................................................................................................. 56
2.3.2 Drilling Hook CAT IV ................................................................................................................. 57
2.4.1 Deadline Anchor CAT III ........................................................................................................... 58
2.4.2 Deadline Anchor CAT IV ........................................................................................................... 59
2.5.1 Top Drive System/ VARCO TDS 11 SA/SH CAT III ................................................................. 60
2.5.2 Top Drive System/ VARCO TDS 11 SA/SH CAT IV ................................................................. 62
2.5.3 Top Drive System/ VARCO TDS 10 SH CAT III ....................................................................... 63
2.5.4 Top Drive System/ VARCO TDS 10 SH CAT IV ....................................................................... 65
2.5.5 Top Drive System/ CANRIG 1235AC-500 / CANRIG 1035AC-500 CAT III ............................. 66
2.5.6 Top Drive System/ CANRIG 1235AC-500 / CANRIG 1035AC-500 CAT IV ............................. 67
2.5.7 Top Drive System/ TESCO Top Drives (EMI 400 HP - EXI 600HP) CAT III ............................ 68
2.5.8 Top Drive System/ TESCO Top Drives (EMI 400 HP - EXI 600HP) CAT IV ........................... 70
2.6.1 Power (BX) Elevator CAT III .................................................................................................... 71
2.6.2 Power (BX) Elevator CAT IV ..................................................................................................... 72
2.7 Elevator Links .............................................................................................................................. 75
2.8 Rotary Swivel Bail Adapters ....................................................................................................... 77
2.9.1 Rotary Swivels CAT III .............................................................................................................. 78
2.9.2 Rotary Swivels CAT IV .............................................................................................................. 79
2.10 DP and DC Elevators, Casing & Single Joint Elevators, Tubing Elevators ......................... 80
2.11.1 Spider Elevator CAT III ........................................................................................................... 87
2.11.2 Spider Elevator CAT IV ........................................................................................................... 88
2.12.1 Casing running tool/ Volant CAT III ....................................................................................... 89
2.12.2 Casing running tool Volant CAT IV ....................................................................................... 90
2.13.1 casing running tool / Canrig CCDS CAT III .......................................................................... 91
2.13.2 Casing running tool / Canrig CCDS CAT IV .......................................................................... 93
2.14.1 Kelly Spinner CAT III ............................................................................................................... 94
2.14.2 Kelly Spinner CAT IV .............................................................................................................. 95
2.15 Electronic Load Cell ................................................................................................................... 96
3.1.1 Mud Pumps Power End CAT III ............................................................................................... 97
3.1.2 Mud Pump Power End CAT IV ................................................................................................. 98
3.2.1 Mud Pumps Fluid End CAT III .................................................................................................. 99
3.2.2 Mud Pumps Fluid End CAT IV ................................................................................................ 100
3.3.1 Rotary table CAT III ................................................................................................................. 101
3.3.2 Rotary table CAT IV ................................................................................................................ 102
3.4 Kelly Drive Bushing ................................................................................................................... 103
3.5 Master Bushing .......................................................................................................................... 104
3.6 Bowls 1,2 & 3 ( Insert bushing) ................................................................................................. 105

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3.7 Manual Slips ............................................................................................................................... 106

3.8.1 Power Slips (Hydraulically operated & pneumatically operated) CAT III ........................... 108
3.8.2 Power Slips (Hydraulically operated & pneumatically operated) CAT IV .......................... 109
3.9 Rotary hoses, Vibrator hoses & Welded Connections ........................................................... 110
3.10.1 DC Driven Drawworks CAT III ............................................................................................. 111
3.10.2 DC Driven Drawworks CAT IV .............................................................................................. 112
3.10.3 AC Driven Drawworks CAT III .............................................................................................. 114
3.10.4 AC Driven Drawworks CAT IV .............................................................................................. 115
3.11.1 Draw works Brake Bands & Linkages CAT III .................................................................... 117
3.11.2 Draw works Brake Bands & Linkages CAT IV .................................................................... 118
3.12 Drawworks Disc Brake ............................................................................................................ 119
3.13 Manual Rotary Tongs for DP, DC & Casing ........................................................................... 120
3.14 Safety Clamp ............................................................................................................................ 121
3.15.1 BOP Handling System CAT III .............................................................................................. 123
3.15.2 BOP Handling System CAT IV ............................................................................................. 124
4.1.1 Pipe Arms and Pipe Loaders (Lower Guide Arm) CAT III .................................................... 125
4.1.2 Pipe Arms and Pipe Loaders (Lower Guide Arm) CAT IV ................................................... 126
4.2.1 Hydraulic Catwalk CAT III ....................................................................................................... 127
4.2.2 Hydraulic Catwalk CAT IV ...................................................................................................... 128
4.3.1 Catwalk and V-door CAT III .................................................................................................... 130
4.3.2 Catwalk and V-door CAT IV .................................................................................................... 131
4.4.1 Iron Roughneck CAT III .......................................................................................................... 132
4.4.2 Iron Roughneck CAT IV ......................................................................................................... 133
4.5.1 Power Tongs CAT III ............................................................................................................... 134
4.5.2 Power Tongs CAT IV ............................................................................................................... 135
4.6 Spinning Wrench........................................................................................................................ 136
4.7.1 Hydraulic Cathead Ezy Torque CAT III ................................................................................. 137
4.7.2 Hydraulic Cathead Ezy Torque CAT IV ................................................................................ 138
4.8 Utility Winches ........................................................................................................................... 139
4.9.1 Mechanized Pipe Bins CAT III................................................................................................ 140
4.9.2 Mechanized Pipe Bins CAT IV ............................................................................................... 141
5.1 Drill Pipe...................................................................................................................................... 142
5.2 Tubular Lifting Plugs cap and Subs ......................................................................................... 143
5.3.1 Circulating Heads CAT III ....................................................................................................... 144
5.3.2 Circulating Heads CAT IV ....................................................................................................... 145
5.4 Drill String Accessories & BHA ................................................................................................ 146
5.5.1 Kelly Valves and Full open safety valves CAT III ................................................................ 147
5.5.2 Kelly Valves and Full open safety valves CAT IV................................................................. 148
5.6.1 Top Drive IBOPs CAT III ......................................................................................................... 149

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5.6.2 Top Drive IBOPs CAT IV ......................................................................................................... 150

6.1.1 Mud Tanks CAT III ................................................................................................................... 151
6.1.2 Mud Tanks CAT IV .................................................................................................................. 152
6.2 Shale shakers Basket ................................................................................................................ 153
6.3 Low pressure pipe Lines Flow line ........................................................................................... 154
6.4.1 Sack Handling Devices CAT III .............................................................................................. 155
6.4.2 Sack Handling Devices CAT IV.............................................................................................. 156
7.1.1 Mud Pump Reset Relief Valves CAT III ................................................................................. 157
7.1.2 Mud Pump Reset Relief Valves CAT IV ................................................................................. 158
7.2.1 Pulsation Dampener CAT III ................................................................................................... 159
7.2.2 Pulsation Dampener CAT IV .................................................................................................. 160
7.3 Standpipe & High Pressure Piping, Cement lines .................................................................. 161
7.4.1 High Pressure Manifold & Valves CAT III.............................................................................. 162
7.4.2 High Pressure Manifold & Valves CAT IV ............................................................................. 163
7.5 Chicksans and swivels .............................................................................................................. 164
7.6.1 S-pipe/ Gooseneck Assembly CAT III ................................................................................... 165
7.6.2 S-Pipe/ Gooseneck Assembly CAT IV ................................................................................... 166
8.1.1 RAM Type BOP And Ram Blocks CAT III .............................................................................. 167
8.1.2 RAM Type BOP And Ram Blocks CAT IV ............................................................................. 168
8.2.1 Bag Type BOP Annular CAT III .............................................................................................. 169
8.2.2 Bag Type BOP Annular CAT IV .............................................................................................. 170
8.3.1 Drilling Spools, Flanges, Mud cross, Test Stumps & DSA CAT III ..................................... 171
8.3.2 Drilling Spools, Flanges, Mud cross, Test Stumps & DSA CAT IV ..................................... 172
8.4.1 Hub Clamps CAT III ................................................................................................................. 173
8.4.2 Hub Clamps CAT IV ................................................................................................................ 174
8.5.1 BOP Control Unit CAT III ........................................................................................................ 175
8.5.2 BOP Control Unit CAT IV ....................................................................................................... 176
8.6.1 Choke & Kill Line CAT III ........................................................................................................ 177
8.6.2 Choke & Kill Line CAT IV ........................................................................................................ 178
8.7.1 Choke manifold and kill system CAT III ................................................................................ 179
8.7.2 Choke manifold and kill system CAT IV................................................................................ 180
8.8.1 Mud Gas separator CAT III ..................................................................................................... 181
8.8.2 Mud Gas separator CAT IV ..................................................................................................... 182
8.9.1 Manual gate valve & HCR gate valve & NRV CAT III ............................................................ 183
8.9.2 Manual gate valve & HCR gate valve & NRV CAT IV............................................................ 184
8.10.1 Hydraulic adjustable chock & Manual adjust chock CAT III ............................................. 185
8.10.2 Hydraulic adjustable chock & Manual adjust chock CAT IV ............................................. 186
8.11.1 RCD Rotating Circulating Device CAT III ............................................................................ 187
8.11.2 RCD Rotating Circulating Device CAT IV ........................................................................... 188

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9.1.1 Fall Arrestor & Emergency Escape Devices CAT III ............................................................ 189
9.1.2 Fall Arrestor & Emergency Escape Devices CAT IV ............................................................ 190
9.2.1 Self-Propelled Man lifts CAT III .............................................................................................. 191
9.2.2 Self-Propelled Man lifts CAT IV.............................................................................................. 192
9.3.1 Personnel Basket CAT III ....................................................................................................... 193
9.3.2 Personnel Basket CAT IV ....................................................................................................... 194
9.4 Gas detection system ................................................................................................................ 195
9.5 BA Compressor .......................................................................................................................... 196
9.6.1 Breathing Air Cylinders Steel CAT III .................................................................................... 197
9.6.2 Breathing Air Cylinders Steel CAT IV .................................................................................... 198
9.7.1 Breathing Air Cylinders Fiber Glass CAT III ......................................................................... 199
9.7.2 Breathing Air Cylinders Fiber Glass CAT IV ......................................................................... 200
9.8.1 Fire Extinguishers CAT III ...................................................................................................... 201
9.8.2 Fire Extinguishers CAT IV ...................................................................................................... 202
9.9 Diesel / Electric Fire Pump ........................................................................................................ 203
9.10.1 Man Riding Winch CAT III .................................................................................................... 204
9.10.2 Man Riding Winch CAT IV .................................................................................................... 205
10.1.1 AC Generator CAT III ............................................................................................................ 206
10.1.2 AC Generator CAT IV ............................................................................................................ 207
10.2 Circuit Breakers ....................................................................................................................... 208
10.3 Fuel Tanks ................................................................................................................................ 210
11.1.1 Eddy current brake CAT III ................................................................................................... 213
11.1.2 Eddy current brake CAT IV................................................................................................... 214
11.2.1 AC Traction Motors (MP-DW) CAT III .................................................................................. 215
11.2.2 AC Traction Motors (MP-DW) CAT IV ................................................................................. 216
11.3.1 DC Traction Motors (MP-DW) CAT III .................................................................................. 217
11.3.2 DC Traction Motors (MP-DW) CAT IV ................................................................................. 218
11.4.1 TDS AC Traction Motor CAT III ............................................................................................ 219
11.4.2 TDS AC Traction Motor CAT IV ........................................................................................... 220
11.5 Ex (d) & Ex(e) Systems ............................................................................................................ 221
11.6 Thermography Inspection ....................................................................................................... 223
12.1.1 Air Pressure Vessel CAT III .................................................................................................. 223
12.1.2 Air Pressure Vessel CAT IV ................................................................................................. 226
12.2 Air Pressure Relief Valves....................................................................................................... 228
13.1 Forklift Forks & Forklift Fork Support .................................................................................... 229
14.1 Trailer King Pins....................................................................................................................... 230
14.2 Rig Instrumentation and gauges ............................................................................................ 231
14.3 GAS Cylinders .......................................................................................................................... 235

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1.0 OBJECTIVE
This procedure describes the control system that defines the process for the Inspection and Test
Program of critical service-related products and the control of testing, measuring, monitoring, detecting
equipment that are utilized in execution of service of the Quality Management System of Abraj.
2.0 SCOPE
This procedure applies to all personnel with authority to control service-related product, tools and
equipment established under the Quality Management System of Abraj
3.0 RESPONSIBILITY
Maintenance Manager: Owner of the annual maintenance budget.
Operations Manager: Owner of the annual operations budget.
Drilling Superintendent: Responsible for overall management of the major scopes.
Rig Manager: Responsible for site management of annual maintenance and rig-based overhauls.
Maintenance Superintendent: Responsible for development of the Inspection plan.
4.0 DEFINITION

OEM – Original Equipment Manufacturer;

Standard - something established by authority, custom, or general consent as a model, example, or

point of reference;

Intelex – Online platform used be Abraj Energy Services SAOC for controlled document storage;

SAP – Online system used by Abraj Energy Services SAOC for computerized maintenance system;

5.0 PROCEDURE

5.1 Equipment Integrity Inspection

The process of equipment integrity inspection is defined as comparison of equipment conformity to
predetermined standards as listed in Abraj Equipment Inspection Matrix followed by determination of
action required.
Identification of Equipment

All the equipment used for execution of service shall be identified by tags or stickers as shown below;
 Unique serial number
 Calibration/ Inspection status and due Date
 Custodian

The details of all the equipment shall be identified in the Intelex/SAP system. This shall include;
1. Equipment name
2. Equipment unique serial number
3. Custodian of the equipment
4. Location/ area for use

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5. Calibration/ Inspection Frequency

6. Calibration/ Inspection Method
7. Acceptance Criteria
8. Reference to Calibration/ Inspection Certificate
9. Due date

5.2 Abraj Equipment Inspection Matrix

In order to ensure that the integrity of Abraj equipment is maintained to render those as ‘fit for purpose’
at all times within their given design criteria, the inspection requirements are listed on a matrix called
‘Equipment Inspection Matrix’ (EIM), provided as Attachment 1 to this procedure. The equipment
inspection matrix contents are primarily based on the requirement of equipment manufacturer and
international oilfield standards and practices.

The Maintenance and Assets Manager in Abraj are the custodian of the Equipment Inspection Matrix.

Step Out:

Any changes to the equipment inspection frequency or any other changes to the matrix details will be
controlled by Maintenance. Any Step out, dispensation requests related to the equipment inspection
matrix, or respective procedures will be reviewed by the Maintenance Manager.

A formal step out shall then be raised and submitted to the relevant preventive Maintenance
Engineer/Maintenance superintendent by the site Maintenance Supervisor/ Rig manager for approval
and authorization.

As part of the review of the any change, it is important to consider whether there is an impact on the
security of the work site or the safety of persons there in. A formal risk assessment shall be undertaken
in consultation with the risk assessment team prior to approval of step out.

5.3 Scope of Equipment Inspection Matrix

The Abraj equipment inspection matrix, provided in this procedure, defines minimum requirements as
well as the inspection frequencies for Category III /Category IV inspections of the main and critical
equipment as well as other relevant international standards and Abraj internal requirements.

The related detailed procedures contained in the Equipment Integrity Inspection manual define the
scope of work for the required inspections.

Any additional country or contract specific requirements will be incorporated into the Country/Contract
Specific Requirement section of the Inspection Matrix by rig superintendent and will be reviewed and
approved by Country operation Manager accordingly.

The inspection frequencies listed on the Inspection Matrix will apply for the equipment based on the
following criteria:
a. All the hoisting equipment falling under API RP 8B – while the equipment in use
b. All the drill stem components – while the equipment in use
c. Mast, substructure and their accessories – while the equipment in use
d. Raising lines - while the equipment in use, depending on the number of cycles

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e. All lifting equipment and lifting gears – according the calendar base
f. All the drilling equipment covered under API RP 7L – If the equipment was not in use ;
the age of equipment, storage/preservation condition, loading happened on the equipment and
general condition of the equipment will be the main criteria to evaluate the inspection
frequency bases. All the well control equipment – while the equipment in use;
The age of equipment, storage/preservation condition, loading happened on the equipment and
general condition of the equipment will be the main criteria to evaluate the inspection frequency
bases in case of no operational records.

5.4 Inspection Levels

According to international standards and OEM recommendations referred in the inspection matrix,
Abraj Equipment Inspection Levels or Categories are divided as below:

5.4.1 For all equipment falling under the API RP 4G, API RP 8B, API RP 7L and API 53 STD the
following inspection categories shall apply:

a. Category I: This category involves observing the equipment during operation for
indications of inadequate performance. Any equipment found to show cracks, excessive wear
etc. must be removed from service for further examination.

b. Category II: In addition to Cat I inspection, this includes further inspection for corrosion,
deformation, loose or missing component, deterioration, proper lubrication, visible external
cracks and adjustment.

Note: Cat I and Cat II inspections are integrated with scheduled preventive maintenance,
therefore the scope of this inspection procedure does not take Cat I and Cat II inspections into
consideration.

c. Category III: In addition to Cat-II inspection requirements, this category should include
nondestructive testing (NDT) of exposed critical area may involve some disassembly to access
specific components, and identify wear that exceeds the manufacturer’s allowable tolerances.

d. Category IV: In addition to Cat III inspection requirements, Category IV inspection requires
further inspection for which the equipment is disassembled to the extent necessary to conduct
NDT of all primary load-carrying components as defined by the manufacturer.

The equipment must be:

a. Disassembled in a suitably equipped facility to the extent necessary to permit full inspection
of all primary-load-carrying components and other components that are critical to the equipment.

b. Inspected for excessive wear, cracks, flaws, and deformations.

Note:

a. Suitably equipped facility will include Abraj rig site workshops/ yards where the necessary
tools and equipment can be made available.

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b. Prior to Category III and Category IV inspections, all foreign material such as dirt, paint,
grease, oil, scale etc. must be removed from the concerned parts by a suitable method (eg. paint-
stripping, steam-cleaning, grit-blasting).

5.4.2 For all drill pipes ,BHA and drill string accessories falling under DS–1 Vol. 3 and API RP
7G-2 inspection standard the following inspection categories shall apply:

a. Category III: Designed for mid-range drilling conditions where a standard inspection
Program is justified. If a failure occurs, the risk of significant fishing or losing part of the hole is
considered minimal.

b. Category IV: This category may be used when drilling conditions are more difficult than
category

3. Significant fishing cost or losing part of the hole are in the event of a drill stem failure.

c. Category V: This category applies to severe drilling condition. Several factors combine to
make the cost of a possible failure very high.

5.5 Qualifications for Inspector and Welder

a. Inspector Qualifications

The persons carrying out equipment integrity inspections will be suitably qualified,
i. Either by possession of a recognized degree, certificate, or professional standing,
ii. Or who by knowledge, training or experience has successfully demonstrated the
ability to solve or resolve problems relating to the subject matter, the work or the subject.

Specific Category III qualifications

In addition, the inspector conducting Category III inspection must possess ASNT Level I Technician certified
per ASNT specification SNT-TC-1A or equivalent.

The supervisor of the inspector must possess adequate knowledge and experience in this field. Typical
persons qualified to supervise the inspection could be an engineer or ASNT Level II Technician certified
per ASNT specification SNT-TC-1A, with the aid of a senior operations person (senior mechanic, senior
electrician, and senior tool pusher) designated by Abraj, provided they meet the above stated criteria of
experience, training and knowledge.

Specific Category IV qualifications

The Category IV inspection of the drilling structures will be conducted by or closely supervised by a
Professional Engineer, Original Equipment Manufacturer (OEM) representative or authorized
representative of other manufacturer of drilling structures. In addition that Welds visual inspection shall be
conducted by AWS certified welding inspector or equivalent.

The Category IV inspection qualifications of the other equipment covered in this standard shall have the
same CAT III requirements.

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The Country management designated personnel (rig superintendent, operation manager, and maintenance
manager) shall be involved in the supervision of the implemented inspection.

General Lifting gear and lifting equipment inspection

All inspectors and supervisors shall be certified by internationally recognized lifting equipment and lifting
gear inspection organization.

Information to be provided by the inspectors

The inspector will have the following information:

a. Assembly drawings and drawing identifying critical areas of equipment to be inspected; b.
Rejection criteria.
c. History of grinding or remanufacturer, if available.

The above data will be used by the inspector to adapt respective inspection procedure.

Note: In the absence of critical area drawings, all areas of primary-load-carrying components will be considered
critical.

b. Welder Qualifications

Welders will be qualified to a recognized standard and to the level required for the application (as per ASME
IX or equivalent).

5.6 Equipment Integrity Inspection Tracker

In order to have an overview of the status of the equipment inspections based on the Rig specific
equipment inspection matrix, an Inspection Tracker will be maintained by the Senior Tool pusher.

5.7 Calibration of Equipment

Prior to use of any TMMDE, the operator/ inspector shall verify its calibration status and conform the
equipment satisfy the calibration requirements.

The equipment shall be calibrated against measurement standards traceable to international or

national measurement standards, when no such standards are available, it shall be calibrated
against manufacturer’s specification based on the intended use.

When equipment is outsourced for calibration, Maintenance department shall raise the purchase
request which shall include appropriate purchasing information related to calibration and that
shall include as a minimum;
 Calibrating Standards
 Acceptance criteria
 Accuracy and tolerance

The calibrate equipment shall be verified by the Maintenance department as per the procedure for
verification of SRP.

The computer software used in the testing, measuring, monitoring and detection of specified

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requirements, the ability of the software to satisfy the intended application shall be confirmed
prior to initial use and reconfirmed, as necessary.

The Certificate of calibration and other relevant records of calibration shall be kept under the custody
of Maintenance Manager.

5.8 Inspection Certification Control

Equipment integrity inspections will be accompanied with the inspection results printed on
Inspection Certificates.

The Inspection Summary / Certificate will contain the following information, as a minimum:
a. Country Name and Rig No.
b. Equipment Description – Name, Make, Serial No., Asset Number
c. Date of Inspection
d. Type of inspection carried out with relevant international standard reference
e. Photograph/single line sketch of equipment inspected showing the area inspected
f. Tools used for inspection and the calibration validity of those
g. Result of Inspection with remarks
h. Repair work carried out, if applicable
i. Result of inspection with rework done
j. Inspector and Inspection Company Details
k. Name and signature of inspection company representative issuing the certificate
l. Name and signature of Abraj representative accepting the certificate

On receipt of the inspection certificates from the inspection company, those will be verified against
the contents by Abraj representative before acknowledging on the certificate.

The filing of the inspection certificates will be carried out in sequential manner and recorded on
share point.

The Rig Superintendent will be the custodian of the original inspection certificates and will maintain
the OEM certificates and equipment inspection certificates in the sequence of the Certificates
Filing already performed.

The Senior Tool pusher will maintain the copies of the OEM certificates and the copies of
inspection certificates in the same sequence of the Certificates Filing already done.

5.9 Record Keeping & Equipment History

All work orders must record accurately and completely

 The work performed including the repairs, observations or measurements made
 The detail of all parts, internal and external labor and services used on the job
 Any service reports or other support documentation should be attached to the work order where
possible.

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Equipment that requires certification or calibration must be managed in the SAP system to ensure it does
not expire and the calibration shall be performed prior to the calibration dates identified in the SAP.

Copies of certification and calibration records must be maintained, easily accessible and should ideally be
attached to the work order under the custody of Maintenance Manager.

5.10 Roles and Responsibilities

Rig Manager (Tool Pusher)

The Tool Pusher is responsible for ensuring that equipment integrity inspection in the rig is
implemented in accordance with the requirements of these procedure/guidelines. Following all the
highlighted technical steps and frequencies without any deviation.

Drilling Superintendent

To follow up status of the equipment integrity inspection and ensure that all minor and major
inspections are being planned accordingly during the suitable operational timelines, rig moves or
annual maintenance plans as per the roles and responsibilities highlighted in the procedures.

Operations manager

It is the responsibility of the Operations Manager to ensure that all the drilling superintendents are
managing their equipment integrity inspections properly and as per the company policies and
procedures.

Maintenance Manager (MM)

The Maintenance Manager is responsible to ensure that all the maintenance superintendents are
managing their equipment integrity inspections properly and as per the company policies and
procedures; as per the roles and responsibilities highlighted in the guidelines.

In addition of maintaining the applicable international standards and customer relevant standards
compatible with the company guidelines.

Maintenance Superintendent (MS)

To follow up status of the equipment integrity inspection and ensure that all minor and major
inspections are being planned accordingly during the suitable operational timelines, rig moves or
annual maintenance plans as per the roles and responsibilities highlighted in the procedures.

Preventive Maintenance Engineer (PME)

It is the responsibility of the Preventive Maintenance Engineer to establish, closely monitor and
review the implemented technical procedures in this manual as per the roles and responsibilities
and be sure that all highlighted guidelines are properly performed. Also to highlight any opportunity
of improvement for the equipment inspection process/procedures as per the operational needs.

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Chief Mechanic and Chief Electrician (CM And CE)

The chief mechanics and chief electricians are responsible for ensuring that equipment integrity
inspection in the rig is implemented in accordance with the requirements of these
procedure/guidelines. Following all the highlighted technical steps and frequencies without any
deviation.

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6.0 REFERENCES

6.1 Related Standards and Specifications

6.1.1

API Specifications (always use the latest revision)

Operation, Inspection, Maintenance and Repair of Drilling and

API RP 4G Well Servicing Structures

Procedures for Inspection, Maintenance, Repair, and

API RP 7L Remanufacture of Drilling Equipment

Recommended Practice for Inspection and Classification of

API RP 7G-2 Used Drill Stem Elements

Recommended Practice for Procedures for Inspections,

API RP 8B Maintenance, Repair & Remanufacture of Hoisting Equipment

Application, Care, and Use of Wire Rope for Oil Field Service
API RP 9B
API STD 53 Blowout Prevention Equipment Systems for Drilling Wells

Pressure Vessel Inspection Code: In-Service Inspection,

API 510
Rating, Repair, and Alteration
Piping Inspection Code: In-service Inspection, Rating, Repair,
API 570
and Alteration of Piping Systems
API RP 572 Inspection Practices for Pressure Vessels

API RP 576 Inspection of Pressure Relieving Devices

API STD 653 Tank Inspection, Repair, Alteration, and Reconstruction

API 520 Sizing and Selection

API 521 Guideline for Pressure Relieving and Depressing Systems

API 54

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6.1.2

ASME, ASTM, ANSI Specifications (always use the latest revision)

ASME B 30.7-2011 Winches
ASME B 30.9 Slings
ASME B 30.10 Hooks
ASME B 30.11 Monorails & Underhung cranes
ASME B 30.23-2005 Personnel Lifting Systems Safety Standard for Hoists
ASME SE 709 Sec V Non Destructive Examination
Safety Requirements for Self-Retracting Devices for
ASSE Z 359.14
Personnel Fall Arrest and Rescue systems
pressure relief devices which majorly is used for
ASME PTC 25 assessment of testing facility and apparatus for safety
valves
Guidebook for the Design of ASME Section VIII
ASME VIII
Pressure Vessels
Quality Assurance Requirements for Nuclear Facility
ASME NQA-1 Applications
General Requirements for Calibrations Laboratories
ANSI/NCSL Z540-1 and Measuring and Testing Equipment
defines the accuracy grades of dial-type gauges
ASME B40.1
Defines the accuracy grades of digital gauges.
ASME B40.7
ANSI B 31.1 Power Piping

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6.1.3

Other International Standards

DS-1 Drill Stems Design and Inspection.
IADC IADC Drilling Manual
ISO 9712 Qualification and Certification of NDT Personnel
ISO 2415: 2004 Forged Shackles for General Lifting Purposes
Cranes - Equipment for the Lifting of Persons Part 1:
BS EN 14502-1
Suspended Baskets
BS 5655-10 Testing and Inspection of Electric and Hydraulic Lifts
BS 3956-5 Fork Arm for Fork Lift Trucks – Guide for Inspection
Safety Rules for the Construction and Installation of Lifts -
BS EN 81-1
Part 1: Electric Lifts
BS EN 81-2 Safety Rules for the Construction and Installation of Lifts
General Requirements for the Competence of Testing and
ISO/IEC 17025
Calibrations Laboratories
ISO 9001 Requirements for Quality Management Systems
Quality Assurance Criteria for Nuclear Power Plants and
10 CFR 50 Appendix B
Fuel Reprocessing Plants
10 CFR Part 21 Reporting of Defects and Noncompliance
IS: 3624-1987 Specifications for Pressure and Vacuum gauges”
(Reaffirmed 2004)
Indicating and recording pressure gauges, vacuum gauges
OIML R 101 :1991 and pressure- Vacuum gauges with elastic sensing
elements (ordinary instruments)
EURAMETCg-17, Guidelines on the calibration of Electromechanical
Version2.0(03/2011) Manometers”
DKD R-6-1 Guidelines on Calibration of Pressure Gauge
Guidelines on Calibration of measuring devices for
DKD R-6-2
Vacuum
Vacuum Gauges- Calibration by direct comparison with a
ISO 3567:2011
reference gauge
2011Vacuum Technology-Vacuum gauges-Evaluation of
ISO 27893:2011 results of calibrations by direct comparison with reference
gauge
BS EN ISO4126-1, 2,3 Which is construction standard similar to API STD 526.
OIML R-97:1990 1990 Barometers (International Recommendation)
BS ISO18893:2004
Mobile Elevating Work Platforms – Inspections

BS ISO 5057:1993 Industrial Trucks – Inspection and Repair of Fork Arms

Specification for the Testing of Steel Overhead Runway
BS 2853
Beams for Hoist Blocks
Explosive Atmosphere - Part 17: Electrical Installations
IEC 60079-17
Inspection and Maintenance
IEC 60947-2 LV Switchgear and Control Gear

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IEEE STD 43-2000 RP for Testing Insulation Resistance and Electric

Machinery
IEEE STD 14582005 RP for the Selection, Field Testing and Life Expectancy of
Molded Case Circuit Breakers for Industrial Application
SAE J 2228 Kingpin Wear Limits – Commercial Trailers

6.1.4

Abbreviations
NDT Non Destructive Testing

UT Ultrasonic Inspection
API American Petroleum Institute

RP Recommended Practice
ASTM American Society of Testing Materials

ASME American Society of Mechanical Engineers

ASNT American Society for Nondestructive Testing

MPI Magnetic Particle Inspection

SWL Safe working load

PMS Preventive Maintenance System

CAT Category

DS 1 Drill Stem Inspection Standard

Abbreviations
IADC International Association of Drilling Contractors

ISO International Standards Organization

ID Identification

NDE Nondestructive Examination

WP Working Pressure

LEEA Lifting Equipment Engineers Association

OEM Original Equipment Manufacturer

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 7.0 Equipment inspection Matrix
Applicable STD , OEM or Best Practice Frequency
PDO Frequency Requirements
Requirements (ABRAJ)
Item Equipment description Applicable Standard That SOW will follow
CAT III CAT IV CAT III CAT IV
1 Drilling structures
1.1 Mast and Substructure 2 Years 10 Years 2 Years 10 Years API RP 4G
1.2 Mast Moving System 2 Years 5 Years 2 Years 5 Years API RP 4G
1.3 Stabbing Board and Monkey Board 2 Years 5 Years 6 months 1 year API RP 4G
1.4 Raising Cylinders 1 Year 5 Years 1 Year 5 Years / 3 Years for NOV rigs only API RP 4G
1.5 Raising Line and Spelters 1 Cycle - 1 Cycle - OEM, API RP 4G And API RP 9B
1.6 Raising/Scoping Winches 1 Year 5 Year 1 Year 5 Year ASME B30.7, OEM
1.7 Mast and substructure Pad Eyes 2 Years 10 Years 6 Months 10 Years API RP 4G
1.8 Wire Rope Slings,& Shackles - 6 Months - 6 Months API RP 9B , ASME B30.9
1.9 Pad eyes welded to runway beam 2 Years 10 Years 1 Year 4 Years PDO SP 2275, API 4G
2 Hoisting equipment
2.1 Crown Block 6 months 5 Years 6 Months 5Years API 8C, API RP 8B and API RP 9B
2.2 Travelling Block 6 Months 5 Years 6 Months 5Years API 8C, API RP 8B and API RP 9B
2.3 Drilling Hook 6 Months 5 Years 6 Months 5Years API 8C, API RP 8B
2.4 Deadline Anchor 6 Months 5 Years 6 months 5 Years API 8C, API RP 8B
2.5 Top Drive System /Power Swivel 1 Year 5 Years 1 Year 5 Years OEM, API 8C, API RP 8B
2.6 Power Elevator 6 Months 1 Year 6 Months 1 Year OEM
2.7 Elevator Links - 6 Months 6 Months 1 Year API 8C, API RP 8B
2.8 Rotary Swivel Bail Adapters - 6 Months 6 Months 1 Year API 8C, API RP 8B
2.9 Rotary Swivels 6 Months 5 Years 6 Months 2 Years API 8C, API RP 8B
DP and DC Elevators, Casing & Single Joint Elevators,
2.10 - 6 Months 6 months 1 Year API 8C, API RP 8B
Tubing Elevators
2.11 Spider Elevator 6 Months 1 Year 6 Months 1 Year API 8C, API RP 8B
2.12 Casing running tool VOLANT 3 Months 1 Year 3 Months 1 Year API 8C, API RP 8B & OEM manual / DS1 Volume 4
2.13 Casing running tool Canrig (CCDS) 6 months 1 Year 6 months 1 Year API 8C, API RP 8B & OEM manual / DS1 Volume 4
2.14 Kelly Spinner 6 Months 5 Years 6 months 5 Years API 8C, API RP 8B
2.15 Electronic Load Cell - 1 Year - 1 Year OEM
3 Drilling Equipment
3.1 Mud Pumps Power End 6 Months 8 Years 6 Months 8 Years API RP 7L ,API 7K And OEM
3.2 Mud Pumps Fluid End 1 Year 5 Years 1 Year 5 Year API RP 7L ,API 7K And OEM
3.3 Rotary Table 1 Year 5 Years 1 Year 5 Years API RP 7L And OEM
3.4 Kelly Drive Bushing - 6 Months 6 months 1 Year API RP 7L And OEM
3.5 Master Bushing - 6 months 6 months 1 Year
3.6 Bowls 1,2 & 3 ( Insert bushing) - 6 months 6 months 1 Year API RP 7L And OEM
3.7 Manual Slips - 6 months - 6 months API RP 7L And OEM
3.8 Power Slips 6 months 1 Year - 6 Months API RP 7L And OEM
3.9 Rotary hoses, Vibrator hoses & Welded Connections 1 Year - 1 Year - API RP 7L And OEM
3.10 Draw works 6 Months 10 Years 6 Months 10 Years API RP 7L And OEM
3.11 Draw works Brake Bands & Linkages 6 Months 5 Years 6 months or when blocks changed 1 Year API RP 7L And OEM
3.12 Draw works Disc Brake - 1 year - 1 Year API RP 7L And OEM/Abraj Best practice
3.13 Manual Rotary Tongs for DP, DC & Casing - 6 Months - 6 Months API RP 7L And OEM
3.14 Safety Clamp - 6 Months - 6 Months API RP 8B, API RP 7L
OEM/ASME B30.16 /ASME B30.7 And
3.15 BOP Handling System 1 Year 5 Years 1 Year 3 Years
API RP 7L and API 7K/ Abraj Best Practice
4 Tubular handling equipment
4.1 Pipe Arms and Pipe Loaders (Lower Guide Arm) 1 Year 5 Years 1 Year 5 Years OEM
4.2 Hydraulic Catwalk 1 Year 5 Years 1 Year 5 Years OEM
4.3 Catwalk and V-door 2 Years 10 years 2 Years 10 years API RP 4G
4.4 Iron Roughneck 1 Year 5 Years 1 Year 5 Years OEM/ Abraj Best Practice
4.5 Power Tongs (Pneumatic / Hydraulic) 1 Year 2 Years 1 Year 2 Years OEM
4.6 Spinning Wrench - 1 Year - 1 Year Abraj Best Practice ,OEM
4.7 Hydraulic Cathead / Ezy Torque 1 Year 5 Years 1 Year 5 Years OEM, Abraj Best Practice
4.8 Utility Winches - 1 Year - 1 Year ASME B30.7, OEM manual, API RP 7G-2
4.9 Mechanized Pipe Bins 1 Year 5 Years 1 Year 5 Years OEM
5 Drilling Stem elements
5.1 Drill Pipe - 6 Months or each rig move 6 Months or each rig move As per PDO request API 5DP, DS1 Vol3, DS1 Vol4
5.2 Tubular Lifting Plugs/cap and Subs - 6 Months - 6 Months API RP 7G-2, API RP 7A1
5.3 Circulating Heads - 6 Months 6 Months 1 Year API RP 7G-2, API 7-1, API 7-2
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Every 250hrs for short wells

Every 250hrs for short wells/every 450
Drill String Accessories & BHA (HWDP, Drill Collar and /every 450 hours / after reaching
5.4 - - hours /after reaching 3,500 meters for long API RP 7G-2, DS1 Vol3 Cat 3-5, DS1 Vol4 Cat 3-5
subs) 3,500 meters for long duration
duration wells
wells
5.5 Kelly Valves and Full open safety valves 1 Years 5 Years 1 Years 5 Years API RP 7G-2 &API STD 53
5.6 Top Drive IBOPs 500 Rotating Hours 5 Years 500 Rotating Hours 5 Years Abraj best practice ,OEM
6 Low pressure Mud system
6.1 Mud Tanks 2 Years 10 Years - 10 Years STI SP001, API RP 653
6.2 Shale shakers Basket 1 Year - 1 Year - Abraj Best Practice
6.3 Low pressure pipe Lines/Flow line - 2 Years - 1 Year API 570 And API RP 574
6.4 Sack Handling Devices 1 Year 5 Years 1 Year 5 Years ASME B30.16, BS 2853
7 High Pressure Circulating System
7.1 Mud Pump Reset Relief Valves 1 Year 2 Years 1 Year 2 Years OEM, API 510/RP572/RP576/ASME VIII
7.2 Pulsation Dampener 1 Year 5 Years 1 Year 2 Years API 510 And OEM
7.3 Standpipe & High Pressure Piping ,Cement lines 1 Years - 1 Year - API 570 And API RP 574
7.4 High Pressure Manifold & Valves 1 Year 5 Years 1 Year 5 Year Abraj Best Practice, API STD 53
7.5 Chicksans and swivels - 1 Year - 1 Year API 570 And API RP574, API RP14E
7.6 S-pipe/ Gooseneck Assembly 1 Years 5 Years 1 Years 5 Years
8 Well control system
8.1 RAM Type BOP And Ram Blocks 1 Years 5 Years 1 Year 5 Years API STD 53, API 16A, API 16AR
8.2 Bag Type BOP Annular 1 Years 5 Years 1 Year 5 Years API STD 53, API 16A, API 16AR
8.3 Drilling Spools, Flanges,Mud cross, Test Stumps & DSA 1 Year 5 years 1 Year 5 Years API STD 53, API 16A
8.4 Hub Clamps 1 Year 5 Years 6 months 3 Years API STD 53, API 16A
8.5 BOP Control Unit 1 Year 5 Years 1 Year 5 Years API STD 53, API 16D
8.6 Choke & Kill Line 1 Year 5 Years 1 Year 5 Years API STD 53, API 16C
8.7 Choke manifold and kill system 1 Year 5 Years 1 Year 5 Years API STD 53, API 16C & API 6A
8.8 Mud Gas separator 1 Year 5 Years 1 Year 5 Years API STD 53, API 510/RP572/RP576/ASME VIII
8.9 Manual gate valve & HCR gate valve & NRV 1 Year 5 Years 1 Year 5 Years API 6A, API STD 53
8.10 Hydraulic adjustable chock & Manual adjust chock 1 Year 5 Years 1 Year 5 Years API 6A, API 16C, API STD 53
8.11 RCD Rotating Circulating Device 1 Year 5 years 1 Year 5 Years OEM
9 Safety Equipment
9.1 Fall Arrestor & Emergency Escape Devices 6 Months 1 Year 6 Months 1 Year API RP 54, ANSI/ASSE Z359.4, OEM, BS EN365,AS/NZS 1891.4
9.2 Self-Propelled Man lifts 6 Months 5 Years 6 Months 5 Years OEM, ISO 18893
9.3 Personnel Basket 6 Months 4 Years 6 Months 4 Years BS EN 14502-1, ASTM E165 ,ASTM E709 PR-1708
9.4 Gas detection system 6 Months - 6 Months - OEM
9.5 BA Compressor 1 Year - 1 Year - OEM, API RP 49
9.6 Breathing Air Cylinders Steel 1 Year 5 Years 1 Year 5 Years NFPA 1852 & DOT
9.7 Breathing Air Cylinders Fiber Glass 1 Year 3 Years 1 Year 3 Years NFPA 1852 & DOT
9.8 Fire Extinguishers 6 Month 5 Year 6 Month 5 Year NFPA 10, MD 286
9.9 Diesel / Electric Fire Pump 6 Months - 6 Months - NFPA 25
9.10 Man Riding Winch 1 Year 3 Year - 1 Year OEM, ASME B30.07, ASME B30.23, API RP 54
10 Power Generation system
10.1 AC generator 1 Year 40000 Hours 1 Year 40000 Hours Best practices. Abraj Internal standard
10.2 Circuit Breakers - 5 years - 5 years IEC 60947-2, IEEE STD 902 , NETA ,OEM
10.3 Fuel Tanks - 10 Years - 10 Years STI SP001, API RP 653
11 Electric system
11.1 Eddy current brake 1 Year 5 Years 1 Year 5 Years Best practices. Abraj Internal standard
11.2 AC Traction Motors (MP-DW) 1 Year 7 Years 1 Year 7 Years Best practices. Abraj Internal standard
11.3 DC Traction Motors (MP-DW) 1 Year 7 Years 1 Year 7 Years Best practices. Abraj Internal standard
11.4 TDS AC Traction motor 1 Year 5 Years 1 Year 5 Years Best practices. Abraj Internal standard
11.5 Ex(d) & Ex(e) Systems - 3 Years - 3 Years IEC 60079-17
11.6 Thermography Inspection - 1 Year - 1 Year ASTM E1934 - 99a, NFPA 70B, ISO 18251-1
12 Air system
Air Pressure Vessel (Air receiver, compressor separator
12.1 2 Years 5 Years 2 Years 2 Years API 510 / RP 572 / RP 576 ASME VIII
and Desiccant Air Dryer)
12.2 Air Pressure Relief Valves 1 Year - 1 Year - OEM, API 510/RP572/RP576/ASME VIII
13 Mobile equipment
13.1 Forklift Forks & Forklift Fork Support 6 Months - 6 Months - ANSI /ITSDF B56.6 And OEM
14 Others
OEM/SAE J2228
14.1 Trailer King Pins 6 Months - 6 Months -
ASTM E165 ASTM E709
14.2 Rig Instrumentation and gauges - 1 Year - 1 Year OEM
14.3 GAS Cylinders - 5 Years - 5 years ASME VIII ASTM E165 ASTM E709

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Equipment: 1.1.1 Mast and Substructure
Frequency: 2 Years , CAT III inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling Superintendent, Operation Manager

Scope of work for each interval:

1. A thorough visual inspection of all load bearing members, welds and pickup points must be
conducted to determine the condition of the mast and substructure.
2. All repairs to major damage require supervision of a Professional Engineer or an OEM agent.
Repairs to minor damage may be completed by operating personnel, after consulting with the
Field Support Manager, and do not require certification. If there is any question as to whether
the damage is major or minor, a Professional Engineer or OEM agent shall be consulted.
3. Check the condition and content of the manufacturer’s name plate.
4. Prepare and submit the Inspection report.

* By possession of a recognized degree, certificate, or professional standing, or who by knowledge,

training, or experience, has successfully demonstrated the ability to solve or resolve problems
relating to the subject matter, the work, or the subject. Inspectors should be familiar with the type of
equipment to be evaluated. * Welders - Typical persons qualified to supervise the inspection could
be an engineer, NDT technician, ASNT

Level II Technician certified per ASNT specification SNT-TC-1A, or a senior operations person (Rig

Superintendent, Rig Manager, or Operations Management), designated by the owner/user company or

others, provided they meet the above criteria of experience, training and knowledge.

• Visible Marking of Damage

It is recommended that at the time of the inspection all damaged sections are marked clearly and
visibly so that needed repairs can be identified. When repairs are made, the visible markings should be
removed by painting. It is also necessary for the inspector to write "None" when no damage marks are
needed, as this is his indication that the item has passed inspection. Below is the checklist of thorough
visual inspections needed to be carried out on the mast and substructure (according to API 4G).
Items that do not need attention should be checked to indicate that the item was inspected.
Item that are not applicable should be marked in the box as "NA"(not applicable).Items that are
warped, worn, damaged, cracked welds , rusted , bent , in need of repair or replacement, or
otherwise in need of further attention, mark an "X" in the box and provide comments on the
inspected items.
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 Drilling Mast Visual Inspection Form:

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Equipment: 1.1.2 Mast and Substructure

Frequency: 10 Years , CAT IV inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling Superintendent, Operation Manager

Scope of work for each interval:

CAT IV: The entire mast to be inspected by a Professional Engineer or an Original Equipment
Manufacturer (OEM) or his agent. This inspection shall include: Category III inspection in addition to
the following:
1. The equipment is to be disassembled and cleaned to the extent necessary to conduct NDT of all
defined critical areas.
2. An ultrasonic thickness test is recommended on all tubular style (or closed style) members to test
for internal corrosion.
3. All welds (100 %) shall be visually examined.
4. All welds in critical areas shall be inspected using magnetic particle (MPI), liquid penetrant (PT) or
ultrasonic testing (UT) in accordance with AWS D1.1. Welds on galvanized structures may require
different inspection techniques and intervals. Cracks are generally identified through visual
inspection on a galvanized mast/derrick.
• Any damage found during the inspection is defined as MAJOR, SECONDARY, or MINOR, on the
following basis.
a. Major Damage – Significant geometrical distortion or structural damage to primary load carrying
components including raising assembly, main legs, hinge points and crown.
b. Secondary Damage – Damage or distortion to non-primary load carrying components.
c. Minor Damage – Damage or distortion to ancillary equipment, i.e. ladders, monkey board, walk-
around, tong hangers, etc.
All damage may be repaired in the field. Major damage should be repaired in a shop-like environment
and in accordance with the OEM or equivalent specifications

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Equipment: 1.2.1 Mast & Substructure Moving System

Frequency: 2 Years, CAT III inspection
Reference: API 4G
Responsibility: Rig Manager, Drilling Superintendent, Chief Mechanic, Mechanical PME

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority

1. Perform MPI of all load bearing components and members as per API 4G, should be
conducted to determine the condition of the mast dolly and documented.
2. Check all structure and fifth wheel bolts for tightness and condition, any damaged
bolt must be replaced by same grade
3. Check Towing frame bad eye for wear, verify towing bad eye bolts condition and
tightness, replace if required
4. Check axles bearings condition, grease
5. Major inspection of HPU & cylinders for leaks and defects, send to town for repair if
required
6. MPI all cylinder clevis and mounting bad eye
7. MPI kingpin and ensure related dimensions are within accepted tolerance. Refer to
King pin inspection manual 14.1
8. Send HPU pump for inspection and adjustment.
9. Evaluate Tire condition, Verify tread depth, Tire pressure, condition and
age(cuts, scrapes, punctures, bulges, bumps or cracks)
10. Verify tires bolts torque, check torque indicator for lose or missing ones. Tight the bolts as
per OEM specification

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Equipment: 1.2.2 Mast & Substructure Moving System
Frequency: 5 Years, CAT IV inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling Superintendent, Chief Mechanic, Mechanical PME

Scope of work for each interval:

Cat IV “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority

1. Perform CAT III Inspection

2. Send mast moving system to certified API 4G workshop for full dismantle
3. Fully sand blast
4. Carry out MPI inspection, ultrasonic inspection of load bearing areas & other related
pins. Sand blast the load bearing areas and repainted to determine the condition of
the mast dolly and document the result.
5. Send the cylinders for major overhaul, testing & recertification.
6. Replace the tire very 10 years
7. Replace axle bearings, seals and bushing.
8. Replace towing frame bolts
9. Send Engine for major overhaul whenever 10000 operating hrs. reached

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Equipment: 1.3.1 Stabbing Board and Monkey Board
Frequency: 2 Years (PDO 6 months) , CAT III inspection
Reference: API RP 4G
Responsibility: Rig manager, Drilling Superintendent, Operation Manager

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
1. Visually check for all connections/mounting brackets and chains.
2. Visually check the main frame for bends, cracks, and deformations.
3. Visually check of the hoist (condition and wear).
4. Visually check the platform (incl. grating and handrails).
5. Visually check the welding of the monkey board fingers and the safety chain wear,
cracks or deformation.
6. Visually check the stabbing board anti-fall mechanism and positive stopper installed
underneath the track for any crack or deformation.
7. Perform MPI on the connections and critical weld areas of the main frame.
8. Perform a complete check on the secondary retention of all components.
9. Check the condition and content of the manufacturer’s nameplate.
10. Prepare and submit the Inspection report.

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Equipment: 1.3.2 Stabbing Board and Monkey Board

Frequency: 5 Years (PDO 1 Year) , CAT IV inspection
Reference: API RP 4G
Responsibility: Rig manager, Drilling Superintendent, Operation Manager

Scope of work for each interval: Cat IV “To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”

Complete the full Cat III every two years inspection in addition to the following:
1. Sand blast the complete stabbing board/monkey board.
2. Perform MPI on all identified load bearing and critical areas/components of the stabbing
board/monkey board as per the manufacturer’s specification.
3. Complete overhaul (including load test) of the hoist.
4. Repaint the stabbing board/monkey board.
5. Prepare and submit the inspection report.

Visible Marking of Damage

It is recommended that at the time of the inspection all damaged parts are marked clearly and visibly so
that needed repairs can be identified. When repairs are made, the visible markings should be removed
by painting. It is also necessary for the inspector to write "None" when no damage marks are needed, as
this is his indication that the item has passed inspection.
1. Pipe Racking Platform:
Frame Straight:
Pin Hole(s):
Pins:
Safety Pins/Keepers:
Frame Welds:
Working Platform:
Landing Platform:
Handrails:
Ladder Access:
Fingers Straight:
Finger Welds:
Finger Safety Line(s):
Hoist Mounting:
2. Casing Stabbing Board:
Frame Straight:
Welds:
Handrails:
Working Platform:
Hoisting Assembly:
Hoist Mounting:
Lower Travel Stops:
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Pin or Bolt Holes:
Pins or Bolts:
Safety Pins/Keepers:
3. Tubing Support/Belly Board
Frame Straight:
Welds:
Handrails:
Pin Holes:
Pins:
Safety Pins/Keepers:
Support Cables:
Cable Connections:

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Equipment: 1.4.1 Raising cylinders
Frequency: 1 Years, CAT III inspection
Reference: API RP 4G
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling Superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
1. Prepare and make ready the OEM Manual and drawings of the raising cylinder under
inspection, it must be used as the main guide line in all the following steps
2. Perform full cleaning and servicing on cylinders
3. Check Nameplate condition of the raising cylinder assembly and verify Specs, serial number,
and record serial number on the inspection report/certificate.
4. Inspect outside body of the cylinder for impact damage, cracks or oil leaks.
5. Extend the cylinder without carrying any load, and visually inspect the ram chroming
surface for any pitting, wear, cracks, distortion or damage.

6. Perform NDT /liquid penetrant or MPI on both cylinder end pad eyes ( rod end & barrel end)
7. Ensure gland nut or bolts are tightened
8. Check all easy connections for defect, ensure quick coupling are fully engaged
9. Function test the hydraulic cylinder (extend and retract) and check for any jerking motion or
mis- staging to ensure that there is no internal/External leaks, and that counterbalance
valves are working properly.

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Equipment: 1.4.2 Raising cylinders
Frequency: 5 Years (PDO 3 years for NOV rigs only) , CAT IV inspection
Reference: API RP 4G
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager,
Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the raising cylinder under
inspection, it must be used as the main guide line in all the following steps
2. Check Nameplate condition of the raising cylinder assembly and verify Specs, serial
number, and record serial number on the inspection report/certificate.
3. Fully disassemble the hydraulic cylinder and clean all individual items. Mark or
document the position of all components.
4. Strip down cylinder
5. Trueness check of the sleeves and plunger
6. Provide inspection report, including all findings
7. Rebuild cylinder with new seal kit from OEM or approved equivalent by Abraj.
8. New Counter Balance Valve and new relief Valve to be fitted as per old one typically
9. For Hyco cylinders to be pressure tested before Dismantle and measure the sleeve
expansion or deflection and results to be send to Abraj for approval of dismantle.
10. Pre-grinding of the Cylinders sleeves and rods to clear surface faults.
11. Chroming of the piston section/s
12. Honing of the cylinder
13. Replacing the Pin sleeves/Bearings on cylinder end and Rod end
14. UT test for the connecting hydraulic pipe
15. Repair/replace the connecting pipes as required.
16. MPI for the clevis on Rod end and Cylinder end
17. Blasting, chipping and painting with original coating
18. Pressure testing the cylinders as API 8C 5th Edition. Pressure drop should not Exceed
2.5% of the test pressure.
19. Final report with Certificate of conformance.

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Equipment: 1.5 Raising Line and Spelters

Frequency: Every Cycle , CAT III inspection
Reference: API RP 4G, AI RP 9B, OEM Manual
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection–Cat III (Every Cycle): To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
1. Prepare and make ready the OEM Manual of the raising Line under inspection, it must be
used as the main guide line in all the following steps
2. Remove the raising lines from the mast/substructure and store them carefully on a wooden
palette or reel.
3. Check Nameplate or stamping condition of the raising lines assembly and verify Specs,
serial number, and record serial number on the inspection report/certificate.
4. Visually check the end connections (spelters, shackles, pins, master links etc.) for any
damage, wear or deformation.
5. Visually check the raising lines for any damage, kinks, twist, corrosion or individual broken
wires
/strands and compare it to the acceptance criteria in the API RP 9B.
6. MPI /Liquid Penetrant the end connections (spelters, shackles, pins, master links etc.); do not
apply any eddy current inspection “only magnetic particles or liquid penetrant inspections are
acceptable”.
7. Preserve with heavy oil or applicable lubricant before installation.
8. Prepare and submit the inspection report.
9. The raising lines assemblies to be completely scraped after 10 cycles of
raising/lowering mast/substructure.
10. Replace the raising line if:
 There is any sign of corrosion at end connection and wires near end connections.
 There is a serious twist, pressed flatness, cuts, impacted damage or bird cage like
 If broken wire within steel rope
 Achieve expected standard life and lifting times

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Equipment: 1.6.1 Raising / Scoping Winches
Frequency: 1 Years, CAT III Inspection
Reference: OEM/ ASME B30.7
Responsibility: Chief Mechanic, Mechanical PME, Mechanical superintendent, Rig Manager,
Drilling Superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”

1. Check presence of name plate

2. Check frames, cases and brackets for deformed, cracked or corroded main components.
Replace damaged parts.
3. Check retainer rings, split pins, caps crews, nuts, and other fasteners on winch
4. MPI foundation brackets
5. Conduct performance test at rated SWL

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Equipment: 1.6.2 Raising /Scoping Winches
Frequency: 5 Years, CAT IV inspection
Reference: OEM/ ASME B30.7
Responsibility: Chief Mechanic, Mechanical PME, Mechanical superintendent, Rig
Manager, Drilling Superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT and load test inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Full dismantle of winch, Refer to OEM manual for dismantling steps
2. Change seals, Bushing and bearings if necessary. Required range 0.020”‐0.030” bearing
end play
3. Load test (not less than 110% of the rated load nor more than 125%)
4. Load test to be followed by MPI

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Equipment: 1.7.1 Mast and substructure Pad Eyes
Frequency: 2 Years (PDO 6 months), CAT III inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling Superintendent, Operation Manager

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority

1. Inspect overall condition of pad eye, check integrity for distortion and cuts
2. Inspect pad eye shape for ovality or hole elongation
3. Check the welding for cracks
4. Perform visual and NDT examination

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Equipment: 1.7.2 Mast and substructure Pad Eyes
Frequency: 10 Years , CAT IV inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling Superintendent, Operation Manager

Scope of work for each interval:

1. Inspect overall condition of pad eye, check integrity for distortion and cuts
2. Inspect pad eye shape for ovality or hole elongation
3. Check the welding for cracks
4. In event of pad eye replacement, hole required to be machined not flame cut
5. Preform initial proof load test for lifting pad eyes shall be tested to 1.5t X SWL and non-lifting
pad eyes shall be tested to 1.3 X SWL
6. Visual and NDT to follow the Load test.

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Equipment: 1.8 Wire Rope Slings & Shackles
Frequency: 6 Month, CAT IV inspection
Reference: API RP 9B / ASME B 30.9
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Identify (together with the TP or Worksite Supervisor in charge) all, slings, lifting
devices, spreaders, sheaves and shackles that are due for inspection.
2. Make sure that all items are registered and marked with individual identification numbers as per
the worksite lifting gear register.
3. Visually check all items for damage, cracks, corrosion or wear.
4. Visually inspect all lifting slings for kinks, broken strands and wires.
5. Visually inspect all shackles for crack, twist, bending, excessive opening, pin and nut
condition, holes diameters, holes alignment.
6. Mark all slings, pad eyes and shackles according to the dedicated color code system.
7. Repaint as required.
8. Lubricate as recommended.
9. Prepare and submit the inspection report.

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Equipment: 1.9.1 Pad eyes welded to runway beam
Frequency: 2 Year (PDO 1 Year), CAT III inspection
Reference: PDO SP 2275
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Inspect overall condition of pad eye, check integrity for distortion and cuts
2. Inspect pad eye shape for ovality or hole elongation
3. Check the welding for cracks
4. Apply Performance test at SWL
5. Visual and NDT to follow the Load test.

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Equipment: 1.9.2 Pad eyes welded to runway beam
Frequency: 10 Year (PDO 4 Years), CAT IV inspection
Reference: PDO SP 2275
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Inspect overall condition of pad eye, check integrity for distortion and cuts
2. Inspect pad eye shape for ovality or hole elongation
3. Check the welding for crack
4. Perform Proof load test at 1.25 SWL. Proof load tests can be carried out to various
standards, results must be recorded on a Test Certificate.
5. Visual and NDT to follow the Load test.

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Equipment: 2.1.1 Crown Block
Frequency: 6 Months, CAT III inspection
Reference: OEM manual / API RP 8B/ API 8C/ API RP 9B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent, Operation Manager

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
Drawworks must be isolated and the travelling block must be hung off in order to check the
following tasks. (Best Performed in Rig Move or slip and cut).
1. Prepare and make ready the OEM Manual and drawings of the crown block under
inspection, it must be used as the main guide line in all the following steps
2. Check Nameplate condition of the crown block assembly and verify Specs, serial
number, and record serial number on the inspection report/certificate.
3. Visually inspect sheave cluster have even gap between sheaves.
4. Check and record all sheaves side movement (including fast line and dead line sheaves),
measurement records to be attached on SAP. Use a pry bar to check for side-to-side
movement of each sheave. Recommend that a maximum of 0.100” (2.4 mm) be allowed at
the perimeter of the sheave when testing the side wobble on crown block sheaves. (Please
refer to crown block OEM manual for confirmed maximum limit)
Use no more than 10 LBS force on the sheave perimeter when testing the bearing clearance.
5. Check and record all sheave grooves (including fast line and dead line sheave) using a
groove gauge for excessive wear against OEM wear limits and API Spec 8C
requirements.
6. Check sheave groove and web surfaces for any cracks and deformities ;( perform MPI
on the sheaves grooves if job is performed during rig move).
7. Verify crown sheave center pin retaining bolts are tight and have secondary retention
devices installed.
8. Visually check all crown cluster including fast line, frame and fasteners for tightness and
ensure secondary retention devices are installed.
9. Check the crown cluster /fast line pedestal, jumper bars, covers and all frame welds for any
cracks or deformation (Perform MPI/Liquid penetrant if job is planned during a rig move).
10. Check for bearing wear by running the blocks up and down at controlled high speeds. Verify
there is no wobble or unusual noise coming from the sheave bearings. Monitor the bearing
noise with a stethoscope.
11. Ensure that the guard is in place before doing this and that the Crown Saver System is
operational
12. Prepare and submit the inspection report.

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Equipment: 2.1.2 Crown Block
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API RP 8B /API 8C/ API RP 9B
Responsibility: Rig Manager, Drilling superintendent, Operation Manager, Mechanical
PME, Mechanical Superintendent,

Scope of work for each interval: Cat IV “To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Fully disassemble the crown block and clean all individual items. Mark or document the
position of all components.
2. Perform MPI on the complete cluster frame, pad eyes, sheaves hub/web welding area,
sheaves grooves, shaft, pedestal and jumper bars/covers. Mark any crack, damage or
discontinuity found on the items.
3. Measure and document the wear of the sheaves (grooves and rims) and shaft, reference
the value to the OEM and API Spec 8C recommendations.
4. Reassemble the crown block using new bearings and seals. Use the sheave with the largest
remaining wall thickness (shoulder thickness) as the “fast line” sheave in case that fast line
sheave has same diameter as the running crown sheaves.
5. Visually check for any missing locking pins, nuts, snap rings of the block /block
attachments after reassembly.
6. After reassembly; check the equal spacing between sheaves, deflection and endplay
of the sheaves.
7. All pad eyes under crown platform and fall arrest device pad eye to have the SWL clearly
stenciled on them.
8. Check the condition and content of the nameplate, traceability information, and serial
number.
9. Prepare and submit the final /consolidated inspection report.
10. It is highly recommended to have a complete paint job on the whole crown assembly
after all inspections and repairs completed, to remove any old repair marking and to
avoid any future confusion.

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Equipment: 2.2.1 Travelling Block
Frequency: 6 Months, CAT III inspection
Reference: OEM manual / API RP 8B/ API 8C/ API RP 9B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent, Operation Manager

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
Drawworks must be isolated and the travelling block must be hang off in order to check the
following tasks. (Best Performed in Rig Move or slip and cut).
1. Conduct API Category III inspection of the travelling block assembly. (MPI/Liquid
Penetrant on exposed critical areas – clevis /becket, adapters, latches and top
cover/bonnet; if job is performed during rig move).
2. Visually inspect sheave cluster have even gap between sheaves.
3. Check and record all sheaves side movement, measurement records to be attached on
SAP. Use a pry bar to check for side‐to‐side movement of each sheave. Recommend that
a maximum of 0.100” (2.4 mm) be allowed at the perimeter of the sheave when testing the
side wobble on travelling Block sheaves. Use no more than 10 LBS force on the sheave
perimeter when testing the bearing clearance.
4. Check and record all sheave grooves using a groove gauge for excessive wear
against OEM wear limits and API Spec 8C requirements.
5. Check sheave groove and web surfaces for any cracks and deformities.
6. Verify travelling block sheave pin retaining bolts are tight and have secondary
retention devices installed.
7. Visually check all travelling block clevis and associated pins and fastenings for tightness
and ensure secondary retention devices are installed.
8. Visually inspect the sheave guard for wire grooving, cracks and general integrity.

 MCKISSICK Hook/ Block (Applicable for H001, H002 and H003)Traveling block assembly :

1. Conduct API Category III inspection of the travelling block assembly. (NDT on
exposed critical areas).
2. Visually inspect sheave cluster for even gaps between each sheave.
3. Check and record all sheaves side movement, measurement records to be attached on
SAP. Use a pry bar to check for side-to-side movement of each sheave. Recommend that a
maximum of 0.100” (2.4 mm) be allowed at the perimeter of the sheave when testing the side
wobble on crown block sheaves.

4. Check and record all sheave grooves using a groove gauge for excessive wear against
OEM wear limits and API Spec 8C requirements
5. Check sheave groove and web surfaces for any cracks and deformities.

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6. Verify travelling block sheave pin retaining bolts are tight and have secondary retention
devices installed.
7. Visually check all travelling block clevis and associated pins and fastenings for
tightness and ensure secondary retention devices are installed.
8. Visually inspect the sheave guard for wire grooving, cracks and general integrity.
9. Inspect hook lock parts for deformation
10. Measure dimensions and compare with OEM, max allowable wear is 5%:
a) Hook
b) Shank pin & index ring pin

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Equipment: 2.2.2 Traveling Block
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API RP 8B/ API 8C/ API RP 9B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent, Operation Manager

Scope of work for each interval:

Full inspection – Cat IV (every five years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Fully disassemble the traveling block and clean all individual items. Mark or document the
position of all components.
2. Perform MPI on the side plates, sheaves hub/web welding area, sheaves grooves,
clevis/becket, shaft /top cover/bonnet and other load bearing items. Mark any crack, damage
or discontinuity found on the Items.
3. Measure and document the wear of the sheaves (grooves and rims), shaft and
clevis/hanging attachment (including Radii, pins and pins holes) reference the value to
the OEM and API Spec 8C recommendations.
4. Reassemble the traveling block using new bearings and seals. Use the sheave with
the largest remaining wall thickness (shoulder thickness) as the “fastest” sheave.
5. Visually check for any missing locking pins, nuts, snap rings of the block /block
attachments after reassembly.
6. After reassembly; check the equal spacing between sheaves, deflection and endplay of the
sheaves.
7. Check the condition and content of the nameplate, traceability information, and serial number.
8. Prepare and submit the final /consolidated inspection report.

 MCKISSICK Hook/ Block (Applicable for H001, H002 And H003)Traveling block assembly:
1. Fully disassemble the traveling block and clean all individual items. Mark or document the
position of all components.
2. Perform MPI on the side plates, sheaves hub/web welding area, sheaves grooves, clevis,
shaft and other load bearing items. Mark any crack, damage, deformation or discontinuity
found on the items.
3. Measure and document the wear of the sheaves (grooves and rims), shaft and
clevis/hanging attachment (including Radii, pins and pins holes) reference the value to
the OEM and API Spec 8C recommendations.
4. Reassemble the traveling block using new bearings and seals. Use the sheave with
the largest remaining wall thickness (shoulder thickness) as the “fastest” sheave.
5. Visually check for any missing locking pins, nuts, snap rings of the block /block
attachments after reassembly.
6. Check spring condition, MPI & inspect coil for broken coils. Change as required
7. After reassembly; check the equal spacing between sheaves, deflection and endplay of the
sheaves.
8. Check the condition and content of the nameplate, traceability information, and serial number.

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9. Measure dimensions and compare with OEM, maximum allowable wear is 5%:
a. Hook
b. Shank pin & index ring pin
c. Latch assembly
d. Latch pin
e. Follower
f. Centre pin
g. Load center plate
h. Bolt assembly load
i. Bonnet
j. spreader

10. Prepare and submit the final /consolidated inspection report.

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Equipment: 2.3.1 Drilling Hook
Frequency: 6 Months, CAT IV inspection
Reference: OEM manual / API 8C/ API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”

1. Visually check the hook body and other load bearing items (bail arms, hook, rod hook clevis
and all relevant pins/bolts) for any damage or deformation.
2. If any initiation of cracks or deformation found on the load bearing areas. Further
MPI is recommended.
3. Visually check for any missing locking pins, nuts, locking mechanisms, snap
rings of hook/attachments and check for any loose items.
4. Measure and document the wear of the hook, rod hook clevis, bail arms and any excessive
play in pins/holes. Reject and replace any items with wear exceeding 5% of the original
dimensions.
5. Check the shank spring closing gap and the swivel rotation of the hook.
6. Check the condition and content of the nameplate, traceability information, and serial number.
7. Prepare and submit the final /consolidated inspection report.

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Equipment: 2.3.2 Drilling Hook

Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API 8C/ API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Cat IV “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
1. Fully disassemble the hook and clean all individual items. Mark or document the position
of all components.
2. MPI the hook assembly/main shaft, rod hook clevis, bail arm assemblies, swivel case,
spring, spring retaining ring, follower, bonnet and any other load bearing components. Mark
any cracks, damage, deformation or discontinuities found on the items.
3. Measure and document the wear of the hook, main shaft, swivel case, rod hook clevis, bail
arms and any pins/holes. Reject and replace any items with wear exceeding 5% of the
original dimensions.
4. Reassemble the hook with new thrust bearing, case bushing, hook retaining ring and
bonnet retaining ring.
5. Visually check for any missing locking pins, nuts, locking mechanisms, snap
rings of hook/attachments after reassembly.
6. Check the condition and content of the nameplate, traceability information, and serial number.
7. Prepare and submit the final /consolidated inspection report.

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Equipment: 2.4.1 Deadline Anchor
Frequency: 6 Months, CAT III inspection
Reference: OEM manual / API 8C, API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Chief
Electican,
Electrical PME , Electrical Superintendent, Rig Manager, Drilling
superintendent,

Scope of work for each interval:

Full Inspection–Cat III (every 6 Months): To be performed by a competent person and all
NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Prepare and make ready the OEM Manual and drawings of the Deadline Anchor under
inspection; it must be used as the main guideline in all the following steps.
2. Hang off the top drive /traveling block, as applicable, on the dedicated hang off line or clamp;
and remove the drilling line from the dead line anchor drum.
3. Check the condition of the nameplate and all serial number / traceability details.
4. Visually check the anchor body, grooves, Base/mounting plate, foundation bolts, wire line
guard, pigtail clamp for any damage, corrosion, deformation; MPI/liquid penetrant all the above
accessible areas.
5. Use a pry bar to check for the drum wobbling or excessive play.
6. Ensure that all the bolts, washers, nuts and locking pins are intact, in place and in a
good condition.
7. Visually check the load cell, load cell mounting and pins for any damage, leak; and use the
correct clearance gauge to check for proper installation.
 Check dead line anchor Electronic Load cell (If applicable), Operator should verify the
accuracy of the load cell read outs after the load has been tested at the system rating.

8. Recharge with instrument fluid and verify the weight indicator reading Vs the actual dead load.
9. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 2.4.2 Deadline Anchor
Frequency: 5 Year, CAT IV inspection
Reference: OEM manual / API 8C, API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent , Chief
Electican, Electrical PME , Electrical Superintendent, Rig Manager, Drilling
superintendent,

Scope of work for each interval:

Full Inspection–Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Deadline Anchor under
inspection; it must be used as the main guideline in all the following steps.
2. Remove the dead line anchor completely from the base mounting.
3. Check the condition of the nameplate and all serial number / traceability details.
4. Visually check the anchor body, Base/mounting plate, foundation bolts, wire line guard,
pigtail clamp for any damage, corrosion, deformation; MPI/liquid penetrant all the above
components.
5. Fully disassemble the dead line anchor; and carry out a complete MPI and dimensional
inspection on the shaft, lock nut, cap, hub and drum /grooves.
6. Reassemble the deadline anchor using new bearings, seals, lock washers, snap rings,
mounting bolts and bronze inserts.
7. Ensure that all the bolts, washers, nuts and locking pins are intact, in place and in a
good condition.
8. Visually check the load cell, load cell mounting and pins for any damage, leak; and use the
correct clearance gauge to check for proper installation.
 Check dead line anchor Electronic Load cell (If applicable), Operators should verify the
accuracy of the load cell read outs after the load has been tested at the system rating.
Calibrate electronic load cell by Abraj approved vendors.

9. Recharge with instrument fluid and verify the weight indicator reading Vs the actual dead load.
10. Prepare and submit the inspection report.

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 Abraj Inspection Manual

Equipment: 2.5.1 Top Drive System/ VARCO TDS 11 SA/SH

Frequency: 1 Year , CAT III inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

Full Inspection: To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority
1. main Shaft :
1. VISUAL INSPECT FOR DAMAGES AND WEAR
2. Radial Groove ,0.650 Max and 0.620 Min
3. Split landing collar
4. Lower Portion MPI & Block light & Stress Release Grooves (SRG) on Thread
5. Retainer Landing Collar
6. End Play Main shaft 0.001 to 0.003”
7. Bonnet seal Replace
8. Linear & Seal Replace
9. Check upper bearing retainer O-ring, isolator and oil seal for wear.
2. Check Gear Box:
1. Internal Gear Box Inspection
2. Primary gear mesh backlash (pinion gear to compound gear) - 0.006" to 0.030"
3. Secondary gear mesh backlash (compound gear to bull gear)-0.006" to 0.040"
4. Check gear box lubrication pump assy for wear and damage
5. insure that breather is clean out
3. Bail:
1. Bail pin Inspection/ MPI(OD less than 4.125”)
2. Bail bush (ID More Than 4.450”)
3. Bail MPI
4. Rotating link Adapter
1. VISUAL INSPECTION FOR DAMAGES AND OIL LEAK
2. EARS MPI
3. Replace Glyd ring, O-ring and bushing on RLA.
4. Perform dye penetrant test on RLA stem
5. Motor Brake:
1. Pads wear limit 0.09”Minimum
6. Carriage Assembly

1. Skid out top drive and check all the rollers, replace if needed
7. Shot pin assy.
1. Rebuild shot pin assy
8. Pipe handler:
1. Pipe handler support pin diameter-1.940" to 2.000"
2. Check Stabilizer Spring

1. MEASURE GATE BORE OD For allowable tolerance and Repair if required

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 Abraj Inspection Manual
9. CLAMP CYLNDER:
3. MEASURE GATE PIN OD For allowable tolerance and replace if required
4. MEASURE GATE BORE OD For allowable tolerance and Repair if required
5. STABBING GUIDE bolt hole rethread if required
10. Link Tilt:
1. Check PINS AND BUSHINGS FOR WEAR AND REPLACE AS REQUIRED
2. CHECK COLLAPSIBLE LINK WEAR
11. ELEVATORS links:
1. MPI BOTH EYES
12. HYDRAULIC TANK
1. REPLACE BLADDER
2. REPLACE HYDRUALIC OIL WITH ISO VG 46
13. S-PIPE:
1. MPI AND UT
2. Check the gooseneck pilot alignment with the main shaft record measurement
14. ACCUMULATORS
1. CHECK FOR NITROGEN, SYSTEM 800 PSI, COUNTERBALANCE 900 PSI, TIME DELAY 800
PSI
15. TIE BACK:
1. FULL SAND BLAST AND MPI
2. CHECK ALL SECONDARY RETENTION ARE IN PLACE
16. GUIDE BEAM:
1. GUIDE BEAM BORE AND PIN MPI AND INSPECTION
2. CHECK THE SECONDARY RETENTION
17. INTERMEDIATE TORQUE ARRESTOR:
1. FULL SAND BLAST AND MPI
2. CHECK PIN AND PAD EYES AND THREAD ROAD FOR ANY DAMAGE
3. ADJUST THE TIE BACK AS PER OEM
18. MPI Performed on TDS main component
1. Main shaft Lower portion.
2. Bail
3. Landing collar
4. Upper IBOP
5. Rotating Link adapter ear.
6. Elevator links
7. Saver sub
8. Guide beam pad eye.
9. Guide beam stopper plate
10. Tie back link.

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 Abraj Inspection Manual
Equipment: 2.5.2 Top Drive System/ VARCO TDS 11 SA/SH
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent, Operation Manager

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”

1. Disassemble the Top Drive unit.

2. Inspect all the following hoisting load path components using magnetic particle
techniques as specified on the Inspection Maps at the end of Section 4B of the OEM
manual:
 Bail
 Rotating link adapter
 Main body casting
 Rotating link adapter shear rings
 Main shaft
 Upper and lower IBOPs
 Load stem
 Saver sub
 Spacer sub
 Main body shear rings
 Elevator links
 Elevators
 Pipe handler links tilt catches/retainers
 Link tilt cylinders ends’
 Link tilt clamps
 Quill upper connection
 Torque Guide System including the hang – off link. (Shackles, bolts, nuts etc.)
 Load collar
 Connector and link adapter

3. Perform dye penetrant test on RLA stem

4. Measure and record the wear of the guide rails and compare with maximum allowable
tolerances asper OEM.
5. Check all bearings, seals, and seal running surfaces, gears and splines. Refurbish as
necessary.
6. Inspect all the welds in the Torque Guide System using magnetic particle
techniques as specified on the inspection map sat the end of Section 4B of the
OEM manual.
7. Reassemble the top drive
8. Check all secondary retentions integrity.

NOTE: Any indications found are a potential cause for replacing the suspect component.

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 Abraj Inspection Manual
Equipment: 2.5.3 Top Drive System/ VARCO TDS 10 SH
Frequency: 1 year, CAT III inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

Full Inspection: To be performed by a competent person and all NDT inspections to be done
by an accredited third party, approved by Abraj technical authority”

 main Shaft :
1. VISUAL INSPECT FOR DAMAGES AND WEAR
2. Radial Groove ,0.650 Max and 0.620 Min
3. Split landing collar
4. Lower Portion MPI & Block light & Stress Release Grooves (SRG) on Thread
5. Retainer Landing Collar
6. End Play Main shaft 0.001 to 0.003”
7. Bonnet seal Replace
8. Linear & Seal Replace
9. Check upper bearing retainer O-ring, isolator and oil seal for wear.
 Check Gear Box:
1. Gear Box Inspection
2. Primary gear mesh backlash (pinion gear to compound gear) - 0.006" to 0.030"
3. Secondary gear mesh backlash (compound gear to bull gear)-0.006" to 0.040"
4. Check gear box lubrication pump assy for wear and damage
 Bail:
1. Bail pin Inspection/ MPI(OD less than 4.125”)
2. Bail bush (ID More Than 4.450”)
3. Bail MPI
 Rotating link Adapter
1. VISUAL INSPECTION FOR DAMAGES AND OIL LEAK
2. EARS MPI
3. Replace Glyd ring, O-ring and bushing on RLA.
4. Perform dye penetrant test on RLA stem

 Motor Brake:
1. Pads wear limit 0.09”Minimum
 Carriage Assembly

1. Skid out top drive and check all the rollers.

 Shot pin assy.
1. Check wear on Pin/Sleeve/ Bushing
 Pipe handler:
1. Pipe handler support pin diameter-1.940" to 2.000"
2. Check Stabilizer Spring

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 CLAMP CYLNDER:
1. MEASURE GATE PIN OD For allowable tolerance and replace if required
2. MEASURE GATE BORE OD For allowable tolerance and Repair if required
3. STABBING GUIDE bolt hole rethread if required
 Link Tilt:
1. Check PINS AND BUSHINGS FOR WEAR AND REPLACE AS REQUIRED
2. CHECK COLLAPSIBLE LINK WEAR
 ELEVATORS links:
1. MPI BOTH EYES
 HYDRAULIC TANK
1. REPLACE BLADDER
2. REPLACE HYDRUALIC OIL WITH ISO VG 46
 S-PIPE:
1. MPI AND UT
2. Check the gooseneck pilot alignment with the main shaft record measurement
 ACCUMULATORS
1. CHECK FOR NITROGEN, SYSTEM 1400 PSI, COUNTERBALANCE 900 PSI, TIME
DELAY IBOP 500 PSI
 TIE BACK:
1. FULL SAND BLAST AND MPI
2. CHECK ALL SECONDARY RETENTION IN PLACE
 GUIDE BEAM:
1. GUIDE BEAM BORE AND PIN MPI AND INSPECTION
2. CHECK THE SECONDARY RETENTION
 INTERMEDIATE TORQUE ARRESTOR:
1. FULL SAND BLAST AND MPI
2. CHECK PIN AND PAD EYES AND THREAD ROAD FOR ANY DAMAGE
3. ADJUST THE TIE BACK AS PER OEM
 MPI Performed on TDS main component
1. Main shaft Lower portion.
2. Bail
3. Landing collar
4. Upper IBOP
5. Rotating Link adapter ear.
6. Elevator links
7. Saver sub
8. Guide beam pad eye.
9. Guide beam stopper plate
10. Tie back link.

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 Abraj Inspection Manual
Equipment: 2.5.4 Top Drive System/ VARCO TDS 10 SH
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent, Operation Manager

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
Disassemble the Top Drive unit:
1. Inspect all the following hoisting load path components using magnetic particle
techniques as specified on the Inspection Maps at the end of Section 4B of the OEM
manual:
A. Rotating link adapter
B. Gear box body
C. Quill shaft upper & lower connection
D. Upper and lower IBOPs
E. Gripper clamp welding areas & stabbing bell
F. Saver sub
G. Spacer sub
H. Elevator links
I. Elevators
J. Pipe handler links tilt catches/retainers
K. Link tilt cylinder sends’
L. Link tilt clamps
M. Dolly assembly
N. Guide rails
O. Load collar
P. Connector and link adapter
2. Perform dye penetrant test on RLA stem
3. Measure and record the wear of the guide rails and compare with maximum allowable
tolerances as per OEM.
4. Check all bearings, seals, and seal running surfaces, gears and splines. Refurbish as
necessary.
5. Inspect all the welds in the Torque Guide System using magnetic particle techniques as
specified on the inspection map sat the end of Section 4B of the OEM manual.’
6. Reassemble the top drive, perform Dyno test.
7. Check all secondary retentions integrity.

NOTE: Any indications found are a potential cause for replacing the suspect component.

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 Abraj Inspection Manual

Equipment: 2.5.5 Top Drive System/ CANRIG 1235AC-500 / CANRIG 1035AC-500

Frequency: 1 Year, CAT III inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat III: To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Make the necessary arrangements for Abraj approved third party MPI inspector to visit the rig and
inspect the below listed equipment.
2. Once a year, or every 3,000 operating hours perform:
 Magnetic particle inspection of the exposed surfaces of all load bearing components and load
collar grooves to reveal any fatigue or crack indications. The load bearing components are:
1. drive stem/main shaft (lower portion),
2. Load collar (split rings)
3. Upper and lower IBOP (LWCV)
4. Link adapter saver and spacer subs
5. Upper links support
6. Upper links and pins
7. Pipe handler welding area
8. Spindle Lower end
9. Rotary manifold outer sleeve
10. Main housing upper link area
11. Male half coupling
12. Goose neck.
 Any indications found are a potential cause for replacing the suspect component.
 Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. Deep.
3. Perform an ultrasonic inspection (UT) on goose neck
4. Inspect pump adapter plate components for wear.
5. Check that tool joint lock is re-installed properly. The torque on all locking screws should be 362 ± 5
ft lb
6. Measure main bearing end play-0.002" - 0.004"
7. Inspect all torque tube Cylinders for leaks
8. torque tube pin diameter-1.745" - 1.750"
9. Top drive-HPU:
 Clean hydraulic tank and replace Hydraulic oil
 Replace high pressure filter and return filter
 Replace breather
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 Abraj Inspection Manual
Equipment: 2.5.6 Top Drive System/ CANRIG 1235AC-500 / CANRIG 1035AC-500
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent, Operation Manager

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Disassemble the Top Drive unit.
2. Inspect all of the following hoisting load path components using magnetic particle
techniques as specified on the Inspection Maps:
•Quill
•Spindle
•Split Ring
•Upper link support
•Rotary manifold outer sleeve
•Housing
•Upper links
•Bail (if applicable)
•Block Interface
•Upper link pins(4)
3. Check all bearings, seals, and seal running surfaces, gears and splines. Refurbish as
necessary.
4. Inspect all the welds in the Torque Guide System using magnetic particle techniques as
specified on the inspection maps at the end of Section 4B of the OEM manual.
5. Inspect the end plates and lugs in the torque tubes for any damage and ensure that the lugs
are properly aligned between sections.
6. Reassemble the top drive,
7. Check all secondary retentions integrity.

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 Abraj Inspection Manual
Equipment: 2.5.7 Top Drive System/ TESCO Top Drives (EMI 400 HP - EXI 600HP)
Frequency: 1 Year, CAT III inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent,

Scope of work for each interval:

1. Check and Adjust counter balance Cushion Height as per SOP/OEM manual
2. Measure Dolly Pin hole are not more than 31mm
3. Measure the Dolly Pins not less than 30mm
4. Make sure the retainer lock plate of the dolly pin is secured and wire locked
5. Replace the damage Dolly Teflon plate and adjust the shims to make gap 2-4 mm between the
Teflon pads and the torque tube as per SOP/ OEM guide lines
6. Check the quill shaft end play and record.it must be no End Play at all gauge should read Zero
and if any then adjust preload between 0.005” to 0.007”, refer to SOP/Manual
7. Check the pinion shaft end play and record.it must be no End Play at all gauge should read Zero
and if any then adjust preload between 0.002” to 0.004”, refer to SOP/Manual
8. Replace Top bearing seals
9. Replace top sleeve and pinion shaft top seal
10. perform local paint strip and MPI on below:
a. Swivel Yoke
b. Swivel Links
c. Hook Contact Points
d. Swivel lock pins and Holes
e. Swivel Link yoke Pin Bores
f. Swivel Gear Box Holes
g. Swivel gear Box Pins
h. Load Nut Groove.
i. Load Nut split Collar
j. Upper load retainer
k. Load Nut sleeve
l. Load collar ears
m. Load nut, load shoulder
n. Quill Pin end (Thread)
o. Torque Busing(Dolly)
p. Tilt cylinder Mounted Stem Breakaway Mount.

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11. Visual Inspection for below
a. Slewing gear teeth
b. Pipe handler spool
c. Upper grabber leg
d. Grabber
e. Load collar spring if any missing broke /Cracked
f. Pipe handler lock segment
g. Pipe handler lock body & shim plates

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 Abraj Inspection Manual
Equipment: 2.5.8 Top Drive System/ TESCO Top Drives (EMI 400 HP - EXI 600HP)
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API 8C / API RP 8B
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent, Operation Manager

Scope of work for each interval:

Full Inspection – Cat IV (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Send to authorized service center to perform complete dimensional visual, WFMPI/ MP
inspection for recertification. Upon completion of inspection, schedule starts at zero
operating days.
2. Disassemble the Top Drive unit.
3. Perform a magnetic particle inspection on all load bearing components over their entire
surface (Including internal bores) to reveal any fatigue or crack indications. the load
bearing components are:
•Yoke and link assembly
•Split block and split block adaptor assembly (EMI400)(Replace support bolts & liners)
•Swivel gearbox housing.
•Quill shaft
•Load nut components(Replace all bolts)
•Mud saver and actuator
•Saver subs
•Load collar
•Elevator
•Elevator links
•Torque arrest system (Replace all bolts, nuts, studs & liners)
•Pipe handler rotation system(Replace all bolts & nuts)
•Gear strain (Bull gear, Intermediate bull gear, Intermediate pinion & Input pinion)
•Torque tubes (Sandblast / MPI)
4. Replace all gearbox bearings, seals, O-rings, lubrication hoses and auxiliary hydraulic
hoses
5. Reassemble the top drive
6. Check all secondary retentions integrity.

Any indications found are a potential cause for replacing the suspect component. Round
bottom pits and erosion are acceptable if the defect is less than 1/16 in. deep. Larger defects
or any crack indications are a cause for replacing the suspect component.

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 Abraj Inspection Manual
Equipment: 2.6.1 Power (BX) Elevator
Frequency: 6 MONTHLY, CAT III inspection
Reference: OEM
Responsibility: Rig Manager/ Drilling Superintendent, Chief Mechanic/Mechanical PME

Scope of work for each interval:

Full Inspection–Cat III (every 6 Months): To be performed by a competent person and all
NDT Inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Function test elevator and check functionality of feedback signal

2. Checks for cracks and loose fittings/hoses.
3. Checks for signs of deformations and leakages.
4. Check for signs of wear and corrosion.
5. Check for no loose components and presence of all warning signs.
6. Check for state of lubrication.
7. Check all possible settings (eg. Valves) on the elevator.
8. Checking the condition of the overall structure (elevator links, hydraulic system) and
the interaction of all components and possible attachments with the elevator.
9. NDT tests of critical components (elevator is largely assembled) such as link ears
and latch lug
10. Dimensional inspection for following
A. Hinge pins
B. Latch pins
C. Hinge & latch pin holes
D. Link ear height
11. Check orientation of elevator door and latch
12. Visually check springs for wear and material weakening.
13. Lubricate all parts.

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 Abraj Inspection Manual
Equipment: 2.6.2 Power (BX) Elevator
Frequency: 1 YEARLY, CAT IV inspection
Reference: OEM
Responsibility: Rig Manager/ Drilling Superintendent, Chief Mechanic/Mechanical PME

Scope of work for each interval:

Full Inspection – Cat IV (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”

1. Function test elevator and check functionality of feedback signal.

2. Checks for cracks and loose fittings/hoses.
3. Checks for signs of deformations and leakages.
4. Check for signs of wear and corrosion.
5. Check for no loose components and presence of all warning signs.
6. Check for state of lubrication and conservation.
7. Check all possible settings (eg. Valves) on the elevator.
8. Checking the condition of the overall structure (elevator links, hydraulic system) and
the interaction of all components and possible attachments with the elevator.
9. Visually check springs for wear and material weakening.
10. Lubricate all parts.
11. Checking wear limits (link ears, hinge pins, latch pins and socket holes), refer to OEM
manual for minimum tolerance.
12. Checking wear limits at the tool joint of a drill pipe. The elevator wear is measured
Directly at the pipe inlet of the elevator. Refer to OEM manual for minimum
tolerance.
13. Complete NDT test of all critical areas (elevator is completely disassembled).
A. Hinge pin
B. Latch pin
C. Elevator door
D. Elevator latch
E. Bushing
14. Check the condition of cylinder seal and replace selected hydraulic components.
15. Replace wear‐intensive components.

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CRITICAL AREAS BODY BX ELEVATOR

CRITICAL AREAS DOOR BX ELEVATOR

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CRITICAL AREAS LATCH BX

ELEVATOR

CRITICAL AREA BUSHING BX ELEVATOR

FRAME

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 Abraj Inspection Manual
Equipment: 2.7 Elevator Links
Frequency: 6 Month, CAT III inspection
Reference: OEM manual / API RP 8B/ASTM E709/ASTM A275
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection–Cat IV (every 6 Months): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Check and record identification no.

2. Sand blast links (Full body)
3. Visually check the Elevator Links for damage or cracks.
4. MPI the whole link, measure the eye thickness for wear identification on both eyes.
5. Measure length and OD of straight section and check straightness of both links.
6. If dimensional checks are not in line with recommended values as per original, it can be downgraded
to less rated capacity subjected to wear to the new maximum load limits.
7. Measure the following

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Equipment: 2.8 Rotary Swivel Bail Adapters

Frequency: CAT IV inspection (Prior Use)
Reference: API RP 8B/ANST E709
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection–Cat IV (Prior Using): To be performed by a competent person and all NDT
inspections to be done by an accredited third part.
1. Check and record identification traceability no and ensure valid COC is in place.
2. Visually check the body and bail for any damage, wear or cracks.
3. MPI the critical load bearing items of the hook and bail adapter.
4. Repaint as required.
5. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 2.9.1 Rotary Swivels
Frequency: 6 Months, CAT III inspection
Reference: API 8C / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent, Chief Mechanic, Mechanical PME,
Mechanical Superintendent.

Scope of work for each interval:

Full Inspection–CAT III (every 6 Months): To be performed by a competent person and all
NDT Inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Prepare and make ready the OEM Manual and drawings of the Swivel under inspection,
it must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Name plate.
3. Visually check the body, bail, bottom connection and gooseneck for any damage, wear
or cracks.
4. Replace (if not already done) the 2” thread connection on top of the gooseneck with
one butt welded connection.
5. MPI the critical load bearing items of the swivel like the bail, bail connection and bottom
connection.
6. Carry out wall thickness measurement of the gooseneck.
7. Check the swivel main bearing pre‐load and add/remove shims as required.
8. Repaint as required.

9. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 2.9.2 Rotary Swivels
Frequency: 5 Year (PDO 2 Years), CAT IV inspection
Reference: API 8C / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent, Chief Mechanic, Mechanical
PME, Mechanical Superintendent.

Scope of work for each interval:

Full Inspection–Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Swivel under inspection, it
must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Name plate.
3. Disassemble the Rotary Swivel to the extent necessary to conduct MPI/PT of all primary
load carrying components as defined by manufacturer and ensure that all individual items are
cleaned (Mark or document the position of each of the components).
4. Measure and document the wear of all components as necessary.
5. Visually check the body, bail, bottom connection and gooseneck for any damage, wear or
cracks; MPI the critical load bearing items of the swivel like the bail, bail connection ,
bearing carriers seats, bonnet brackets and main stem bottom connection.
6. Replace (if not already done) the 2” thread connection on top of the gooseneck with one
butt welded connection.
7. Carry out wall thickness measurement and MPI of the gooseneck.
8. Reassemble the Rotary Swivel with new bearings and seals.
9. Check the swivel main bearing pre‐load and add/remove shims as required.
10. Repaint as required.
11. Prepare and submit the inspection report.

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Equipment: 2.10 DP and DC Elevators, Casing & Single Joint Elevators, Tubing Elevators
Frequency: 6 Monthly, CAT IV inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

To be performed by a competent person and all NDT inspections to be done by an accredited third
party.
1. Degrease, Clean and remove all foreign particles.
2. Disassemble the complete elevator and make ready for sand blasting.
3. Full Sand blasting of the elevator.
4. Full body MPI, as a minimum all critical areas to be included.
5. Measure the wear on the body parts, door, hinge pin, latch, latch pin, latch spring stop, latch lock
bolt, door lock pin, latch cam and all other load bearing components and compare the
measurements against OEM tolerance.
6. For Slip type Elevators, Inspect all areas visually followed by MPI including but not limited to
inserts, slip bolts, insert retainers, slip setting rings and guide plates for damage or wear.
7. Conduct dimension inspection on all areas shown in image below.
8. Measure bore taper angle, ID and height of center bore of type B and G elevators, Measure ID and
thickness of top and bottom bore of R, T and S type elevators.
9. Reassemble the elevator after lubricating the back face of slip assembly; replace the worn parts as
required. Ensure all safety pins and stopper pins are in place.
10. Repaint the elevator to original color. Mark the handles and safe area with green color.
11. Prepare and submit the inspection report.

Chose the Appropriate Diagram Below and Enter the Measurements

Manual Elevator Center Latch 18 Degrees

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A- Top Bore ID
B- Bottom Bore ID
C- Hinge Pin Hole ID Top
D- Hinge Pin Hole ID Bottom
E- Body Latch Pin Holes ID (Record the largest one)
F- Latch Pin OD (Record the smallest)
G- Hinge Pin OD (Record the smallest)
H- Taper Angle
I- Hinge Pin Hole ID
J- Door Ear Radii
K- Body Ear Radii

Manual Elevator Center Latch slip type

A- Body Latch Pin Holes ID (Record the largest one)

B- Main Hinge Pin Hole ID Top
C- Main Hinge Pin Hole ID Bottom
D- Hinge Pin Hole ID
E- Latch Pin OD (Record the smallest)
F- Door Ear Radii
G- Body Ear Radii
H- Hinge Pin OD (Record the smallest)

Manual Elevator Center Latch Square Shoulder

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Top Bore ID
A. Bottom Bore ID
B. Body Latch Pin Holes ID (Record
the largest one) D- Main Hinge Pin
Hole ID Top
C. Main Hinge Pin Hole ID Bottom
D. Hinge Pin Hole ID
E. Door Ear Radii
F. Latch Pin OD (Record the smallest)
G. I-Hinge Pin OD
(Record the smallest)
H. Body Ear Radii

Manual Elevator Side Door

A- Hinge Pin Hole ID

B- Latch Pin OD (Record the smallest)
C- Latch Pin Holes ID Top
D- Latch Pin Holes ID Bottom
F- Body Main Hinge Pin Hole ID Top
G- Body Main Hinge Pin Hole ID Bottom
H- Main Hinge Pin OD (Record the smallest)
I- Door Ear Radii
J- Body Ear Radii

Manual Elevator Single Joint (Use Applicable drawing)

Record All ODs and IDs shown in the drawings

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A. Body Latch Pin Holes ID (Record the largest one)
B. Latch Pin OD (Record the smallest) G-Hinge Pin OD (Record the smallest) H‐ Taper Angle
C. H i n g e Pin Hole ID
D. Door Ear Radii
E. Body Ear Radii

Manual Elevator Center Latch slip type

A‐ Body Latch Pin Holes ID (Record the

largest one)
B‐ Main Hinge Pin Hole ID Top
C‐ Main Hinge Pin Hole ID Bottom
D‐ Hinge Pin Hole ID
E‐ Latch Pin OD (Record the smallest)
F‐ Door Ear Radii
G‐ Body Ear Radii
H-Hinge Pin OD (Record the smallest)

Manual Elevator Center Latch Square Shoulder

Top Bore ID
A‐ Bottom Bore ID
B‐ Body Latch Pin Holes ID (Record the largest one) D- Main Hinge Pin Hole ID Top

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E‐ Main Hinge Pin Hole ID Bottom
F‐ Hinge Pin Hole ID
G‐ Door Ear Radii
H‐ Latch Pin OD (Record the smallest) I- Hinge Pin OD (Record the Smallest) J- Body Ear Radii

Manual Elevator Side Door

A‐ Hinge Pin Hole ID

B‐ Latch Pin OD (Record the smallest)
C‐ Latch Pin Holes ID Top
D‐ Latch Pin Holes ID Bottom
F‐ Body Main Hinge Pin Hole ID Top
G‐ Body Main Hinge Pin Hole ID Bottom
H‐ Main Hinge Pin OD (Record the smallest)
I‐ Door Ear Radii
J‐ Body Ear Radii

Manual Elevator Single Joint (Use Applicable drawing)

Record All ODs and IDs shown in the drawings

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Critical Areas for Center Latch Elevators

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Critical Areas for Side Door Elevator

Critical Areas for Single Joint Elevator

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Equipment: 2.11.1 Spider Elevator
Frequency: 6 Months, CAT III inspection
Reference: OEM manual / API RP 8B/ API 8C
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Field Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Disassemble the units as far as necessary and possible and clean all single parts.
2. Check all components visually for any cracks, damage and bends.
3. Perform MPI on hinged connections, body (inside and outside) including guide pin cases,
guide halves, slip hangers, slips and top cover halves.
4. For Spiders: Visually check for damage and wear on the yoke assembly, slip lock assembly,
body (inside and outside), door, door pins, guide plate assemblies, hinge pins, insert
retainers, link blocks with link block pins, slips and dovetail slots.
MPI body (inside and outside), yoke, slips, hinge connections, door, door pins, guide plate
assy. and link blocks.
5. Check condition and details of the manufacturer’s name plates.
6. Assemble the units and refurbish painting and marking as required.
7. Prepare and submit the inspection report.

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Equipment: 2.11.2 Spider Elevator
Frequency: 1 Year, CAT IV inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
Complete the full Cat III every six months inspection in addition to the following:
1. Disassemble the spider / elevator completely.
2. Measure and record all main components and compare with wear limits.
3. Perform full MPI as per manufacturer’s requirement.
4. Prepare and submit the inspection report.

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Equipment: 2.12.1 Casing running tool/ Volant
Frequency: 3 months , CAT III inspection
Reference: OEM manual / API 8C / API RP 8B / DS1 Volume 4
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent.

Scope of work for each interval:

1. Perform a complete tool teardown to inspect for any component damage and allow
for re- lubrication of all CRT components
2. Remove and inspect the upper cam housing.
3. Remove the upper housing lock ring.
4. Rotate the upper cam housing relative to the upper cam until the splines misalign.
Remove and inspect the upper cam housing.
5. Unthread and remove the intermediate cam from the upper cam.
6. Check the threads and ramps for any signs of damage.
7. Unthread and remove the upper cam from the mandrel. Check the threads, ramps and j-
hooks for any signs of damage.
 Note and record the lug adjustment (number of lugs the upper cam is rotated back
from the shouldered position) when disassembling the tool and always follow the
cam adjustment procedure in the assembly manual when reassembling the tool.
8. Remove and inspect the lock sleeve and the mandrel.
9. Remove the bumper from the lower cam.
10. Remove the lower cam housing.
11. Separate the cage from the upper & lower cam, by removing the lug latches, pin latches,
and the alignment bolts
12. Carefully remove the latch keys, spring-latch and end ring from the cam latch.

13. After the complete tool teardown ensure all the parts are free of any contaminants and
lubrication before inspection and reassembly.

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Equipment: 2.12.2 Casing running tool Volant
Frequency: 1 years, CAT IV inspection
Reference: OEM manual / API 8C / API RP 8B / DS1 Volume 4
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent.
Scope of work for each interval:
Full Inspection–Cat IV (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. All inspections are to be related to API RP 8B
2. Complete disassembly for the Tool for performing NDT, MPI, LPI & UT
3. Inspect critical areas in the CRT to assess specific components and to identify any damage
4. Conduct MPI per section 8.4.7 of API Specification 8C, of all primary load carrying components,
include the Mandrel, jaws, spokes, and dies.
5. Mandrel Bore Erosion / Neck Thickness Check
6. Conduct an ultrasonic inspection at 5 or more equally spaced locations to check the average
thickness of the Mandrels top neck.
7. Use the thickness data to calculate the cross sectional area as explained in Appendix B. Area
reduction must not exceed 5%.
8. The end of the Mandrel can be used as a gauge block and verified using a calibrated Vernier caliper.
9. Upper Cam Housing, clean and visually inspect the cam surfaces and all thread flanks to ensure they
are smooth and show no signs of galling or deformation.
10. Inspect all the cams for any pitting, raised or lowered edges along the surface and the threads.
11. Conduct an MPI inspection on all primary cam assembly components, including: Upper Cam,
Intermediate Cam, Lower Cam and Latch Cam.
12. Check backlash in make-up threads by engaging the threads and measuring relative axial movement
between the Upper and Intermediate Cams.
13. Verify that the Belleville spring condition is acceptable and that the Belleville stack is applying load
to the spiral retaining ring.
14. Inspect all Mandrel threads including the tool joint threads, Carrier threads and Cam threads to
ensure that they are smooth and show no signs corrosion or galling. .
15. Inspect the rest of the Mandrel surface for any pitting, galling, rust, raised or lowered edges.
16. Inspect the splines for any damage, pitting or corrosion.
17. Measure Mandrel top neck outer diameter.
Base Tool
Mandrel Spline Min. Width (in) Mandrel Top Neck Min. diameter (in)

CRTi4-7.0 0.985 4.125

18. The Mandrel Neck Area Reduction limit is 5%. Running the CRT Mandrel at or beyond the 5% limit
does not comply with API 8C ratings requirements and needs to be replaced.
19. The dies must be sufficiently sharp to be able to penetrate the surface of the casing in order to grip
in either hoist or torque
20. Remove the Cage seals and thoroughly clean the Cage. Inspect for any visual wear or deformation. It
is recommended to subject the cage through an MPI. This will give us any indications of potential
cage failure.
21. Look for any Cage twists, or bending along the window grooves as well as any signs of surface
irregularities.
22. Inspect Bumper surfaces and thread condition for wear, pitting or signs of deformation. Check for
debris buildup in the Bumper holes where bolts are installed to rotationally lock the Bumper to the
Lower Cam.

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Equipment: 2.13.1 Casing running tool / Canrig CCDS

Frequency: 6 month , CAT III inspection
Reference: OEM manual / API 8C
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent.
Scope of work for each interval:
Full Inspection Cat III (every 6 Months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Disassemble the die lock clamp from the CCDS crossover sub connection
2. Break out the cross over sub, visually inspect the top and bottom connection thread and the bore for
wear and corrosion (allowable wear in the thread is 0.125’’ or scrap the crossover )
3. conduct NDT on all the carrying load components for the cross over sub and inspected excessive
wear , flaws and deformation
4. Conduct NDT on all the lifting nubbins and inspected excessive wear , flaws and deformation
5. Visually inspect the dies and body for the die lock clamp for damage , corrosion , distortion
6. Place the CCDS on the quill stand , disassemble the drive sleeve bolts, grapples
7. Dismantle link tilt assembly from the drive assembly (tilt arms, tilt guards , inner and outer alignment
rings, retaining rings , link tilt carrier , cylinder hoses , hydraulic cylinders , o rings , bumper from the
actuator top support)
8. Evaluate condition for the alignment rings , o rings for the actuator top support , replace if needed
9. Replace two diagonally opposing top collar bolts with two 5/8’’ x 6’’ lifting eyes , use a crane to lift till
the weight of the actuator assembly is supported then dismantle the remaining top collar 10 bolts then
dismantle the 2 halves of the split rings
10.- lift the actuator off the mandrel , dismantle the stop collar bolts then slide the collar out of the
mandrel
11. Conduct NDT on below:
A. Split rings , and replace all cap head bolts body
B. Split collars and replace all cap screws
C. grapples
D. All mandrel surface ( visually inspect and measure the mandrel bore for wear and corrosion,
scrap the mandrel if the diameter of the mandrel bore exceeds the following 2.12’’ for the 7’’ , 9
5/8’’ and 3.06’’ for the 13’’ , 17 7/8’’
E. Steel stop collar and replace all the damaged cap screws
F. link tilt hanger carrier , link assembly , cylinder rod ends and welds on the rod ends
G. Anti-rotation bracket

12. Remove spearhead from the mandrel and change all the O rings , apply white lithium grease to the
new o rings and the spearhead threads , then reinstall the spearhead to the mandrel and torque it to
600 lbs.ft
13. Inspect the outside for the actuator for damage
14. Conduct actuator test pre assembly
15. energize the actuator to the release (open ) position to protect the seal area at the top of the stroke
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16. Visually and dimensionally inspect the hanger carrier trunions
17. Ensure the link hanger carrier rotates freely
18. Full assemble for the link tilt assembly and the CCDS drive assembly & conduct drive assembly
spin test

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Equipment: 2.13.2 Casing running tool / Canrig CCDS
Frequency: 1 Year , CAT IV inspection
Reference: OEM manual, API 8C
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent.
Scope of work for each interval:
Full Inspection–Cat IV (every 1 Year): To be performed by a competent person and all
NDT Inspections to be done by an accredited third party, approved by Abraj technical
authority”.

Complete full Cat III every six months inspection in addition to the following:

1. Equipment shall be disassembled in a suitably‐equipped facility to the extent necessary

to permit full inspection of all primary‐load‐carrying components and other components
that are critical to the equipment.
2. Disassembly and clean elevator.
3. NDT Load bearing components:
 Elevator body
 Lifting ears
 Latch
 Latch seat
 Elevator hinge pin

4. The grapple dies must be sufficiently sharp to be able to penetrate the surface of the casing in
order to grip in either hoist or torque Use the following to determine the serviceability of a
grapple.
 Drive size: 4‐1/2 and 5‐1/2 in:
A. Accept Minimum 0.025‐0.030 inch
B. Reject Minimum ≤ 0.024 inch
 Drive size: 7 to 20 in:
A. Accept Minimum 8 out of 9 0.049‐0.060 inch
B. Reject Minimum 2 out of 9 ≤ 0.048 inch

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Equipment: 2.14.1 Kelly Spinner

Frequency: 6 Months, CAT III inspection
Reference: OEM manual / API RP 8B/ API 8C
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent

Scope of work for each interval:

Full Inspection–CAT III( every 6 Months): To be performed by a competent person and all
NDT Inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Prepare and make ready the OEM Manual and drawings of the Kelly Spinner under
inspection, it must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Name plate.
3. Break off the Kelly spinner from the Kelly.
4. Visually check the bearing clearance and check for any damage, wear or cracks.
5. Visually check the air or hydraulic system (piping, hoses, fittings, filters etc.)
6. Disassemble the air (or hydraulic) motor from the spinner housing and visually check the
condition of the motors (bearing clearance, condition of shaft, sprocket etc.)
7. Perform MPI on the threads, hinge eyes of turnbuckles and upsets of stem.
8. Measure the thread of the Kelly drive sub for pin stretching and bore diameter.
9. Visually check the pinion, gears, spinner body (inside and outside), inner threads and
sealing of connections for damage and wear.
10. Reassemble the Kelly spinner and repaint as required.
11. Prepare and submit the inspection report.

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Equipment: 2.14.2 Kelly Spinner
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API RP 8B/ API 8C
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling superintendent

Scope of work for each interval:

Full Inspection–CAT IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

Complete the full Cat III every six months inspection in addition to the following:

1. Prepare and make ready the OEM Manual and drawings of the Kelly Spinner under inspection, it
must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Name plate.
3. Break off the kelly spinner from the kelly.
4. Fully disassemble the kelly spinner and the drive components; perform MPI on the pinion,
main gears, spinner body (inside and outside), bottom deck , friction plates, side plates
,brackets/gangers, sub inner threads ,bearing carriers for damage ,cracks ,wear or deformation.
5. Measure and record all above components and compare with wear limits.
6. Visually check the air or hydraulic system (piping, hoses, fittings, filters etc.); change the all
flexible hoses.
7. Disassemble the air (or hydraulic) motor from the spinner housing and make a complete overhaul
for the motors including new bearings seals and vanes ( if used)
8. Perform MPI on the threads, hinge eyes of turnbuckles and upsets of stem.
9. Measure the thread of the kelly drive sub for pin stretching and bore diameter.
10. Reassembly the kelly spinner with new bearings and seals.
11. After repair (if applicable) carry out function test and performance test to the maximum torque.

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Equipment: 2.15 Electronic Load Cell
Frequency: 1 Year, CAT IV inspection
Reference: OEM manual
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work for each interval:

1. Dismantle the electronic load cell, and send to OEM or third party workshop for calibration.
2. Perform Visual inspection and service on load cell and ensure it is in good condition.
3. Inspect the electrical cord for any damage and ensure proper continuity.
4. Perform calibration with supply voltage 8 – 28 VDC.
5. Apply load on the cell and record the milliamps signal output from the sensor (4-20
mA), do calibration on multiple steps (5000 Lbs. each), from Zero to Max to Zero again,
as per OEM procedures.
6. Compare the signals to standard values and calculate the calibration error percentage, that
should not exceed 0.25% of full load capacity
7. Receive & install back the load cell and do the electrical connections, ensure proper function.
8. Receive calibration certificate and upload on SAP.

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Equipment: 3.1.1 Mud Pumps

Frequency: 6 Months , CAT III inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work:
1. Drain and clean the power end oil sump and the settling tank under the crossheads. Refill with
ISO-VG grade 320 in the mud pump when the operating temperature is +50°f To +155°f.
2. Inspect the power end for badly leaking gaskets or loose cap screws.
3. Check the filter in the discharge pipe. Clean it if it is plugged.
4. Check cross head clearances.
5. Remove the covers disconnect the splined hub use dial gauge to check the coupling Alignment
ensure that
a. Max tolerance for face alignment is no more than 0.007" and bore alignment is no More
than 0.007".
b. Readings to be reported into sap
6. Remove power end covers and check power end bearing clearances (main shaft Bearings,
connecting rod bearings;
a. Cross head bearings; main crankshaft bearing; eccentric bearing clearances and
Record into sap.
7. Take gears backlash and record into sap.
8. All readings to be evaluated by HO PME and take action accordingly
9. Verify condition of gears. (galling, flaking, cracking, etc.)
10. Verify main bearing housing. (cracks).
11. Verify main bearing retainers.
12. Change all pony rod seals. Verify pony rod's and crosshead's (cracks)
13. Verify drive chain master link cotter keys/ verify condition of belts.
14. Verify alignment and tightness of chains/belts.
15. Verify teeth, all sprockets/pulleys.
16. Verify bolts in top and bottom sprockets/ taper bushings for pulleys.

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Equipment: 3.1.2 Mud Pump Power End
Frequency: 8 Years , CAT IV inspection
Reference: OEM manual / API RP 7L/ API 7K
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling Superintendent

Scope of work:
1. Full Inspection – Cat IV (every 8 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Complete Disassembly all pump parts
a. Remove belt/chain guard assemblies
b. Remove pulley/sprocket drive
c. Remove the taper bushing • Remove the drive motor assembly
d. Remove pinion shaft.
e. Remove crankshaft from mud pump main frame.
f. Remove the crossheads and connecting rods.
3. Sand blast mud pump main frame
4. MPI inspection to be carried out on crankshaft, bull gear, pinion shaft, pinion gear and
connecting rods.
5. Dimension inspection on big and small ends of connecting rods.
6. Replace pony rods and crossheads.
7. Replace the crankshaft main bearing.
8. Replace pinion shaft bearing.
9. Replace connecting rods bearings.
10. Replace crossheads bearings.
11. Replace all upper and lower crosshead guides.
12. Remove internal/external lube system and lubrication lube pipe work for inspection.
13. MPI inspections on main bolts, taper bushings, pulleys/sprockets and mud pump frame weld
areas.
14. MPI inspections suction manifold, discharge manifolds, Modules, block and HP lines.
15. Clean out mud pump internally and oil contamination settling chamber and liner flush chamber
16. Reassemble adjusting shimming and alignment of Crankshaft and Pinion Shaft assemblies
17. Fluid penetration inspection for fluid ends.
18. Replace valves, seats, springs and inserts.
19. Paint as required.
20. Prepare and submit inspection reports and dimensional reports.

 Note: Based on bearing condition MOH can be re-planned as necessary

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Equipment: 3.2.1 Mud Pumps Fluid End
Frequency: 1 Years , CAT III inspection
Reference: API RP 7L ,API 7K And OEM
Responsibility: Rig Manager, Drilling Superintendent

Scope of work:
Full Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Visually inspect fluid end of pump (remove piston, liner, valve & valve seats, and suction &
Delivery modules.
2. Visual inspect all areas for wear, cracks, damage & deformation.
3. All sealing areas, ring grooves to be checked for any damage/ corrosion.
5. Inspect swollen or torn piston rubbers or any burning marks in the piston rubbers.
6. Ensure threads on retainer in good condition
7. Perform MPI on suction & delivery modules, and piston rod.
8. Inspect any unequal or eccentric wear pattern, which confirms misalignment of parts.
9. Perform NDT testing of all welds and critical areas.
10. Perform MPI on discharge line.
11. Ensure weep holes in fluid cylinder and valve pots are open and not plugged
11. After assembling pump, pressure test fluid end to the rated pressure

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Equipment: 3.2.2 Mud Pumps Fluid End
Frequency: 5 Years , CAT IV inspection
Reference: API RP 7L ,API 7K And OEM
Responsibility: Rig Manager, Drilling Superintendent

Scope of work:
Full Inspection – Cat IV (every 5 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

Complete the full Cat III every six months inspection in addition to the following:

1. Fully disassemble the fluid end,

2. Perform MPI on all welds, threads and sealing areas
3. Repair as required( repair to be performed in authorized workshop)
4. Reassemble all fluid end components
5. Pressure test to RWP of mud pump or liner (whichever is less)
6. Prepare and submit inspection report

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Equipment: 3.3.1 Rotary table
Frequency: 1 Year , CAT III inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling Superintendent

Scope of work for each interval:

Full Inspection – CAT III (every 1 Years): To be performed by a competent person and all
NDT Inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Prepare and make ready the OEM Manual and drawings of the Rotary Table under
inspection; it must be used as the main guideline in all the following steps.
2. Take the rotary table “or the complete rotary table skid” out of the substructure.
3. Check the condition of the nameplate and all serial number / traceability details.
4. Check the connections from the rotary table to the rotary beams and to the skid visually
for any damage or cracks. Perform MPI on the lock pins and connections to rotary beams
and skid.
5. Check the rotary manual lock system (pin and holes) for any damage or cracks
6. Check the backlash and the condition of the sprocket and coupling (perform MPI).
7. Measure the rotary table opening and the master bushing for proper fit and any signs of
wear or damage.
8. Check the paint condition of the rotary table and skid.
9. Prepare and submit the inspection report.

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Equipment: 3.3.2 Rotary table
Frequency: 5 Years (PDO 4 Years), CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling Superintendent

Scope of work for each

interval:
Full Inspection – CAT IV (every 5 Years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Rotary Table under
inspection; it must be used as the main guideline in all the following steps.
2. Take the rotary table “or the complete rotary table skid” out of the substructure.
3. Check the condition of the nameplate and all serial number / traceability details.
4. Take off the main rotary table cover along with the turntable; remove and check the
condition of the main bearing.
5. Clean all the rotary table components and housing.
6. Check the condition of the gears, couplings; MPI/liquid penetrant and visual inspection
to be done.
7. Check the connections from the rotary table to the rotary beams and to the skid visually for
any damage or cracks. Perform MPI on the lock pins and connections to rotary beams and
skid.
8. Check the rotary manual lock system (pin and holes) for any damage or cracks
9. After re-assembly; Check the backlash and the condition of the sprocket and coupling
(perform MPI).
10. Change all bearings
11. Check and record input shaft and table bearing axial end play
12. Measure the rotary table opening and the master bushing for proper fit and any signs of
wear or damage.
13. Check the paint condition of the rotary table and skid.
14. Prepare and submit the inspection report.

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Equipment: 3.4 Kelly Drive Bushing
Frequency: CAT IV inspection (Prior Use & Every 6 month)
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Field Inspection – Cat IV (Prior use & every 6 Months): To be performed by a competent person and
all NDT Inspections to be done by an accredited third party.
1. Dismantle the Kelly drive bushing.
2. Visually check the rollers, drive pins, cover plate, bolts, and nuts for any damage or cracks
3. Check the wear of the roller bearings.
4. Measure the wear of the rollers, drive pins (for pin drive). Refer to the manufacturer’s wear
limits.
5. Perform MPI on all critical welds on the housing and the drive pins and check the threads
of the “hold down bolts” for damage or cracks.
6. Check the condition and details of the manufacturer’s nameplate.
7. Check the paint condition and repaint as required.
8. Assemble the drive bushing and carry out one function test. Check for any loose items.
9. Prepare and submit the inspection report

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Equipment: 3.5 Master Bushing

Frequency: 6 Month , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection– Cat IV: To be performed by a competent person and all NDT inspections to be
done by an accredited third party.
1. Pull out the master bushing from the rotary table assembly.
2. Visually check the master bushing for any damage or cracks.
3. Measure the following and compare it to the OEM wear limits:
A‐ Master Bushing upper ID
B‐ Master Bushing Lower ID
C‐ Pin Drive Hole ID

4. Perform MPI on the master bushing and pin.

5. Check the record identification no.

6. Grease the bushing.

7. Prepare and submit the inspection report.

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Equipment: 3.6 Bowls 1,2 & 3 ( Insert bushing)
Frequency: 6 Month , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection CAT (Every 6 Months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
1. Remove both Half of the Drilling Bowls outside of master bushing using proper lifting chain
Sling and prepare for inspection.
2. Visually inspect the inner and outer surface areas of the bowl for any burrs and peened-
over edges.
3. Clean the inside taper of the insert bowls from any abrasive materials.
4. Hold a straight edge against the tapered area to measure the tapper length (It should be
as per the OEM recommendations).
5. Measure the taper angle & throat diameter and compare with the OEM recommendations.
6. Perform MPI on the recess and load bearing areas of the Drilling Bowls.
7. Record the following measurements:
A‐ Throat ID
B‐ Insert Bowl Taper

8. After completing the inspection, Lubricate the back & front face of the drilling Bowls
before assembling in the master bushing.
9. Prepare and submit the inspection report.

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Equipment: 3.7 Manual Slips
Frequency: 6 Month , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Check and record identification no.

2. Thoroughly clean slip prior to inspection
3. Verify condition of slip segments for worn backs, cracked webs and bends.
4. Check insert slots for damage and wear.
5. Inspect hinge pin and holder for wear and missing retaining cotter pins.
6. Inspect slip handles for crack and deformities.
7. Inspect hinge and pin eyes for abnormal wear.

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Perform MPI on the critical areas shown below

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Equipment: 3.8.1 Power Slips (Hydraulically operated & pneumatically operated)
Frequency: 6 Monthly, CAT III inspection
Reference: OEM Manual, API RP 7L
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Inspection for Carrier/Actuator (Hydraulically Operated)

1. Check and record identification no
2. Clean tool thoroughly
3. Check all grease restrictors are open
4. Check whether all grease nipples are present and functioning
5. Check condition of inline filters in hook-up manifold
6. Check the condition of the main hydraulic/Air filter according to the procedure
7. Grease tool according to daily + weekly greasing procedure
8. Check Power Slip body & slip assembly.
9. Carry out a hydraulic function test.

Inspection for Carrier/Actuator (Pneumatically Operated)

1. Check and record identification no
2. Clean tool thoroughly
3. Grease all greasing point
4. Check whether all grease nipples are present and functioning
5. Inspect the lifting arm connecting points for any damage, deformity or cracks
6. Inspect the lifting point.
7. Check Power Slip body & slip assembly.
8. Carry out a hydraulic function test.

Inspection for Slip Segments

1. Check and record identification no.
2. Thoroughly clean slip prior to inspection
3. Verify condition of slip segments for worn backs, cracked webs and bends.
4. Check insert slots for damage and wear.
5. Inspect hinge pin and holder for wear and missing retaining cotter pins.
6. Inspect slip handles for crack and deformities.
7. Inspect hinge and pin eyes for abnormal wear.

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Equipment: 3.8.2 Power Slips (Hydraulically operated & pneumatically operated)
Frequency: 1 Yearly (PDO 6 Months), CAT IV inspection
Reference: OEM Manual, API RP 8B
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection CAT IV (Every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
Inspection for Carrier/Actuator (Hydraulically Operated)
1. Check and record identification no
2. Clean the Power Slip thoroughly
3. Carryout Cat III inspection in addition to following
4. Check all bolts and nuts for the proper make up torque and lock wire
5. Check the Power slip visually for extreme wear, abnormalities.
6. Lubricate the Power slip, refer to OEM manual for lubrication points
7. Inspect the guide cover hinge boss screws and replace if any damage found.
8. Carry out functional testing.

Inspection for Carrier/Actuator (Pneumatically Operated)

1. Check and record identification no
2. Clean tool thoroughly
3. Carryout Cat III inspection in addition to following
4. Grease all greasing point
5. Check whether all grease nipples are present and functioning
6. Inspect the lifting arm connecting points for any damage, deformity or cracks
7. Inspect the base plate assembly for any damage, deformity and cracks.
8. Check Power Slip body & slip assembly.
9. Carry out a hydraulic function test.

Inspection for Slip Segments

1. Check and record identification no.
2. Thoroughly clean slip prior to inspection
3. Verify condition of slip segments for worn backs, cracked webs and bends.
4. Check insert slots for damage and wear.
5. Inspect hinge pin and holder for wear and missing retaining cotter pins.
6. Inspect slip handles for crack and deformities.
7. Inspect hinge and pin eyes for abnormal wear.

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Equipment: 3.9 Rotary hoses, Vibrator hoses & Welded Connections

Frequency: 1 Year , CAT III inspection
Reference: OEM manual / API 7K
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection CAT III (Every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
1. Remove the Rotary / Vibratory Hose / Circulating Hose from service & clean
2. Visually inspect the Rotary / Vibratory Hose / Circulating Hose outer Wrap for any damage,
deep notches or cuts.
3. NDT inspection of hammer union/end connections.
4. Full internal Bore-O scope inspection.
5. Full pressure test to Rated Working Pressure.
6. Prepare and submit the inspection report.

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Equipment: 3.10.1 DC Driven Drawworks

Frequency: 6 Months , CAT III inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling superintendent, Chief Mechanic, PME, Mechanical
Superintendent,
Scope of work for each interval:

Full Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Oil and filters to be changed
2. All bearings clearance must be measured
3. Inspect sprocket and chain for wear
4. Measure the elongation and adjust/replace as required.
5. Verify drive line & coupling for loose bolt
6. Adjust pressures of the braking system as per OEM setting
7. Inspect for any cracks, defects in hydraulic cylinders, fasteners and deformity in
caliper support arm, pins and levers.
8. Inspect the spray nozzles, lubrication pump. Ensure a
Proper oil pressure
9. Visually inspect brake disc for cracks/thermal ageing.
10. Using groove gauge inspect the LeBus grove for wear and make sure that shoulder
between groove are not sharp
11. Check condition of inertia brake & function test
12. Unspool the drill line and check and measure the depth of LeBus grooves
Note: LeBus groove maximum depth 1/3 rope diameter.
13. Check the clamp condition, replace if required condition
14. MPI of bolts on draw works main skid.

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Equipment: 3.10.2 DC Driven Drawworks

Frequency: 10 Years , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical Superintendent
Scope of work for each interval:

1. Full Inspection – Cat IV (every 10 years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Preliminary Inspection of Drum Shaft Assembly — Measure Bearing Clearances & existing
Condition of Draw-works. — Report.
3. Remove Drum Shaft Assembly, BuIl Gear, Lube Pump Assembly and Miscellaneous items.

Drum Shaft Assembly

4. Complete disassembly of Drum Shaft (NOTE: Does not include removal of Drum shaft from
drum).
5. High-pressure steam clean of Drum and painted components, MPI and dimensional check of
main shaft– MPI and dimensional check of drum Grooves.
6. Removal and Inspection (Visual / Dimensional / MPI) of Spur Gear
7. Disassembly / Inspections of Encoder Assembly
8. Replace main bearings ; DS and ODS
9. Inspection of Draw Works Guard assembly and miscellaneous items
10. Visually Check / MPI Low / High Drive Sprockets.
11. Replace Low /High Drive Sprocket Bearings.
12. Check / Replace High Drum Rotary Drive sprocket condition (if applicable)

Main Skid, Motor Frame & Front Porch or Driller's Platform

13. Check for corrosion, tie downs, support structure, (Especially Under Control Panel and
Auxiliary Brake)
14. Blast, inspect (Visual and NDT/MPI) & paint Draw works skid

Chains
15. Inspect chains for broken links, worn side bars and rollers, missing keepers. Remove chain
link if possible and check for pin grooving. Measure one foot of the appropriate pitch and
average the wear per footage after taking the sag out of the chain or record actual chain sag
below.
Recommended chain sag = 2% of the sprocket / shaft centers. Consult OEM for Link Belt
chain wear chart for maximum allowable chain wear / elongation.

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Clutches
16. Low/High Clutch disassembled for inspection
17. Complete overhaul for the Low / High Drum Clutch assemblies including (friction shoes,
springs and diaphragms).

Input Shaft / Main Drive Shaft / Output Shaft / Jack-shaft / Line-shaft /Cat-shaft / Rotary Drive
Countershaft
18. Replace all Bearings; DS and ODS
19. MPI and dimensional check of all shafts; check for abnormalities /wear or cracks
20. Check / Replace Transmission Shifter Clutches, actuators, Shifter clutches properly
centered & Check Shifter ring lubrication ports properly orientated
21. Visually Check / MPI Sprocket & Coupling condition; replace if required.
22. Check make-up and break out Catheads operation and condition, replace if needed.
23. Visually Check / MPI drive motor couplings; replace if required.

Lubrication System
24. Disassembly / inspections of Lube Pump Assembly
25. Check lubrication system: (Sprockets, chain, spray nozzles, hoses, piping, filters and
strainers.)

Associated Pipework and air and water piping

26. Check / Replace Air & water Piping & Hose
27. Replace DS & ODS Air and water spear Water Piping & Hose

Driller’s Control Console

28. Check Control Console Operation and Condition
29. Check all the pneumatic valves, replace if necessary
30. Detailed Inspection report will be submitted after the inspections
31. Assembly of Draw works as per OEM standards and specifications
32. Install and align of Drum shaft and Brake System
33. Install and align of Drive motor.
34. Install /refit of all guards including new neoprene sponge rubber and gaskets
35. Prepare and submit the inspection report.

NOTE: For full disassembly and inspection all shafts, sprockets, bearing housings, clutch
components, load path components and braking system components are to be
dimensionally and NDT inspected and results recorded on component part
inspection drawings & forms.

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Equipment: 3.10.3 AC Driven Drawworks

Frequency: 6 Months , CAT III inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical Superintendent
Scope of work for each interval:

Full Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Change oil filters, clean breather
2. Inspect gear box for gear teeth worn out
3. Measure all bearings reading of the transmission gear box & add all measurements
in sap along with pictures as evidences
4. Measure drum shaft bearings
5. Check aux. Motor clutch, measure and record thickness of the friction lining.
(thickness when replacement is necessary 7.0mm)
6. Check thickness of brake pad. Replace if necessary.
7. check drive coupling for loose bolt, if found loose, perform alignment
8. Grease all couplings
9. MPI of bolts on draw works main skid.
10. Adjust pressures of the braking system
11. Inspect for any cracks, defects in hydraulic cylinders, fasteners.
12. Check for deformity in caliper support arm, pins and levers, replace if necessary
13. Check lubrication system; check the spray nozzles, lubrication pump. Ensure
a proper oil pressure
14. Visually inspect brake disc for cracks/thermal ageing.
15. Using groove gauge inspect the LeBus grove for wear and make sure that
shoulder between groove are not sharp
16. Unspool the drill line and check and measure the depth of LeBus grooves
Note: LeBus groove maximum depth 1/3 rope diameter.
17. Check the clamp condition, replace if required condition

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 Abraj Inspection Manual
Equipment: 3.10.4 AC Driven Drawworks
Frequency: 10 Years , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every 10 years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Preliminary Inspection of Drum Shaft Assembly — Measure Bearing Clearances & existing
Condition of Draw-works. — Report.
2. Remove Drum Shaft Assembly, BuIl Gear, Lube Pump Assembly and Miscellaneous items.

Drum Shaft Assembly

4. Complete disassembly of Drum Shaft (NOTE: Does not include removal of Drum shaft from
drum).
5. High-pressure steam clean of Drum and painted components, MPI and dimensional check of
main shaft– MPI and dimensional check of drum Grooves.
6. Disassembly / Inspections of Encoder Assembly.
7. Replace main bearings; DS and ODS.
8. Inspection of Draw Works Guard assembly and miscellaneous items.

Main Skid, Motor Frame & Front Porch or Driller's Platform

9. Check for corrosion, tie downs, support structure, (Especially Under Control Panel and
Auxiliary
Brake).
10. Blast, inspect (Visual and NDT/MPI) & paint Draw works skid.

Gear Box Assembly

11. Complete disassembly of gearbox.
12. Removal and Inspection (Visual / Dimensional / MPI) of all gears.
13. Replace all gear box bearings.
14. Replace oil seals.
15. Visually Check / MPI input and output Coupling condition; replace if required.
16. MPI for gearbox frame and dimensional check for all bearing seat areas.
17. Check bearings clearance after assembly.
18. Check /verify gear mesh and gears alignment.
19. Adjust gears backlash as per OEM requirements.

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Input Shaft / Idler Drive Shaft / Output Shaft

20. Replace all Bearings; DS and ODS.
21. MPI and dimensional check of all shafts; check for abnormalities /wear or cracks.

Lubrication System
22. Disassembly / inspections of Lube Pump Assembly.
23. Check lubrication system: (Sprockets, chain, spray nozzles, hoses, piping, filters and
strainers).

Associated Pipework and air and water piping

24. Check / Replace Air & water Piping & Hose.
25. Replace DS & ODS Air and water spear Water Piping & Hoses.

Driller’s Control Console

26. Check Control Console Operation and Condition.
27. Check all the control Switches, throttles, joysticks and valves, replace if necessary.
28. Detailed Inspection report will be submitted after the inspections.
29. Assembly of Draw works as per OEM standards and specifications.
30. Install and align of Drum shaft and Brake System.
31. Install and align of Drive motor.
32. Install /refit of all guards including new neoprene sponge rubber and gaskets.
33. Prepare and submit the inspection report.

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Equipment: 3.11.1 Draw works Brake Bands & Linkages
Frequency: 6 Month, CAT III inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical Superintendent.

Scope of work for each interval:

Full Inspection – Cat III (6 Month): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Hang off traveling block and/or top drive (if applicable) on the dedicated hang off line or
clamp device.
2. Visually check the bands for any bends, twists, damage or cracks.
3. Carefully check the correct installation, alignment and adjustment of the brake linkage
system according to the manufacturer’s recommendation.
4. Perform NDT/MPI on the brake bands (dead and live end) and all accessible connecting
items such as brackets (including pins and holes), extension rods, equalizer beam with
pins and brackets, eye bolts, bearing blocks (including the fastening bolts and nuts).
5. Check for the correct length, position and condition of the main brake lever.
6. Visually check the brake rims for grooving defects, uneven wear or cracks. Measure
and record the wear, brake rim and water jacket thickness.
7. Prepare and submit the inspection report.

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Equipment: 3.11.2 Draw works Brake Bands & Linkages

Frequency: 5 Years (PDO 1 Year) , CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical Superintendent.

Scope of work for each interval:

1. Full Inspection – Cat IV (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
2. Completely disassemble the brake system and measure and record all items and compare with
wear limits.
3. Perform NDT/MPI on all main components (dead and live end) and all connecting items such
as brackets (including pins and holes), extension rods, equalizer beam with pins and brackets, eye
bolts, bearing blocks (including the fastening bolts and nuts).
4. Visually check the brake rims for grooving defects, uneven wear or cracks. Measure and
record the wear, brake rim and water jacket thickness.
5. NDT/MPI the equalizer beam
6. Replace all fastener bolts and nuts.
7. Replace all brake linkage bearings.
8. Replace brake lining shoes.
9. Reassemble all items and repaint as required.
10. Use the OEM procedure for burnishing the newly installed brake lining shoes.
11. Prepare and submit the inspection report.

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Equipment: 3.12 Drawworks Disc Brake

Frequency: 1 Year , CAT IV inspection
Reference: OEM manual / API RP 7L/ Abraj Best Practice
Responsibility: Rig Manager, Chief Mechanic, Mechanical PME, Mechanical Superintendent
Chief Electrician, Electrical PME

Scope of work for each interval:

Full Inspection – Cat IV (1 year): To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”.
1. Completely disassemble the brake system.
2. MPI all Brake structural members (calipers support arms, levers, connecting Pins, Shoe springs, shoe
pins, backing Plates) for any cracks, corrosion or Weld defects. Replace any worn components as
required.
3. Replace brake blocks, calipers springs, oil seals.
4. Reassemble all items and repaint as required.
5. Carry out brake efficiency test as per OEM guidance and record.
6. Prepare and submit the inspection report.

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Equipment: 3.13 Manual Rotary Tongs for DP, DC & Casing
Frequency: 6 Month, CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
To be performed by a competent person and all NDT inspections to be done by an accredited third
party.
1. Check and record identification no
2. Disassemble and clean the tongs completely
3. Visually check all main components (lever, long jaw, latch lug jaw, short jaw, latch,
hinge law) for damage, bending or cracks. Also inspect the hanging arm
4. Perform MPI on all critical area including lever, long jaw, latch lug jaw, hinge jaw, hinge
pins, latch and hanger.
5. Measure hinge pins and hinge pin holes for wear (see manufacturer’s
recommendation for max. clearance).

6. Reassemble tongs, repaint and grease as required. Ensure all stopper pins for dies and
safety pins for shackles are in place.
7. Prepare and submit the inspection report.

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Equipment: 3.14 Safety Clamp

Frequency: 6 Month, CAT IV inspection
Reference: OEM manual / API RP 7L
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
To be performed by a competent person and all NDT inspections to be done by an accredited third
party.
1. Check and record the identification.
2. Thoroughly clean the safety clamp prior to inspection
3. Checks for cracks and loose fittings, signs of deformations, signs of wear and corrosion.
4. Checking the condition of the overall structure and the interaction of all components and
possible attachments with the Safety Clamp.
5. Fully disassemble the safety clamp.
6. MPI/Liquid Penetrant the whole safety clamp components including the latch jaw, adjustment
mechanism, Die carrier, links, handles and pins (Safety Clamp is completely disassembled)
7. Measure the pins ODs and holes IDs for excessive wear “A”, refer to OEM manual for tolerance.
8. Replace any worn out components
9. Reassemble the safety clamp and verify the clearance between the die carriers and dies
assemblies “B” Maximum Clearance “B” = 0.094” [2.387 mm].
10. Ensure all stopper pins and die keepers are in place.
11. Prepare and submit the inspection report

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Critical Areas to be inspected

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Equipment: 3.15.1 BOP Handling System

Frequency: 1 Year , CAT III inspection
Reference: OEM manual / ASME B30.16 /ASME B30.7 / API RP 7L/API 7K/ Abraj Best
Practice
Responsibility: Rig Manager, Chief Mechanic, PME, Mechanical superintendent

Scope of work for each interval:

Field Inspection – Cat III (every one year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Remove the BOP hoisting device from the traveling beams.
2. Dismantle the hoisting device as much as needed.
3. Visually check all items (BOP hoist body, trolley assembly, chain containers, all relevant
piping) for any damage, wear/corrosion or cracks and for any missing bolts/nuts.
4. Measure and record the wall thickness of the traveling beams (in the “working area”).
5. Perform MPI on the hook, traveling beam connections and sheaves (if applicable).
6. Check the condition and content of the manufacturer’s nameplate.
7. Repaint the items as required (including the SWL sign).
8. Prepare and submit the inspection report.

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Equipment: 3.15.2 BOP Handling System

Frequency: 5 Years (PDO 3 Years), CAT IV inspection
Reference: OEM manual / ASME B30.16 / ASME B30.7 /API RP 7L/API 7K/ Abraj Best
Practice
Responsibility: Rig Manager, Chief Mechanic, Mechanical PME, Mechanical superintendent
Scope of work for each interval:

Full Inspection – Cat IV (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”

Complete the CAT III every one-year inspection in addition to the following:

1. Completely disassemble of the hoisting device.

2. Visually inspect and measure the main hoist (or hydraulic cylinder) components.
3. Compare the measurements with maximum allowable tolerances from the manufacturer.
4. Reassemble the BOP lifting device using new O-rings, seals and gaskets.
5.Any Load bearings Parts (bearings, chain, Cylinder rod, brake, Motor gear box ) Must be from
OEM ONLY or manufacture under OEM approval
6.Replace all Hoses, Hydraulic hoses shall meet the requirements of SAE J 517
7.No load testing of purpose-built systems shall be required, based on the following:
a. If the user replaces primary load carrying components prior to or when the limits specified
in are reached, and they have either been independently load tested or warranted by the
system manufacturer to be fit for purpose prior to installation.
b. When damaged or deteriorated components are replaced with new components, re-qualified
Components (used components Determined to be in serviceable condition by the
system manufacturer), or remanufactured components that have been warranted by
the system manufacturer to be fit for service.
8.load testing is required include but are not limited to the following:
a. When primary load carrying components have been remanufactured and such components
or their Attachments to the load path have not been warranted by the system manufacturer to
be fit for service, and cannot be independently Load tested prior to installation.
b. When measurable wear and / or corrosion limits to all primary load carrying components are
not provided by the system manufacturer, and such components have been found to be visibly
worn or corroded, and cannot otherwise be independently load Tested, and it is desired by the
user to
Continue operation of the system with such components installed.
c. When a means to measure the fatigue life-cycle limit of all primary load carrying
components or the system itself are not provided by the system manufacturer, the user
should implement load testing at certain load values and intervals, based on system
Manufacturer’s recommendations. d. When the limits specified in b) and c) above are
specified by the system manufacturer, and the user does not replace, remanufacture, or
repair such components in a manner such that the
systems or components are warranted by the system manufacturer that they are fit for
service when such limits are reached or exceeded
9. If load test is Required it shall be done at maximum system rated capacity and at least to SWL of
the BOP stack and all of its attachments.
10. Repaint all the components.
11. Prepare and submit the inspection report.

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Equipment: 4.1.1 Pipe Arms and Pipe Loaders (Lower Guide Arm)
Frequency: 1 Year, CAT III inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent,
Chief Electrician, Electrical PME, Electrical Superintendent.
Scope of work for each interval:
Field Inspection – Cat III (every 1 year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Visually inspect all the unit fasteners and fittings for tightness, damage or corrosion.
2. Visually inspect all the pins/holes (bearing movement areas), pivot connections and
control mechanisms for excessive wear.
3. Visually inspect the tubular loading system including the pipe support, ejector mechanism,
transfer arms, pipe stoppers and tilting pistons for any damage, deformation or excessive
wear.
4. Visually inspect the entire arm major components including pipe supports, clamps,
jaws, funnels, top springs and supporting beams for any damage, deformation or
excessive wear
5. Extend all cylinders (main lifting and auxiliary) and visually inspect the chrome surface for
any pitting or excessive wear condition including.
6. Check the cylinders for any leakage, or corrosion
7. Inspect all the accessible weld and critical area members in the pipe arm and loading
system structure, frames, bracing & hydraulic system MPI the below items:
a) Pin rear main pivot
b) Tool head pin for grabber
c) Cylinders pins
d) Arm assembly roller pins
8. Visually inspect all hydraulic hoses for damage, kinks, cuts reaching the internal
wire layer of the hoses & replace if necessary.
9. Check the angular alignment of with the mast (adjust if required)
10. Check Pneumatic system for any leaks from hoses, air bag, quick release valve
and fitting or excessive bending and/or twisting.
11. Inspect movement dampeners functionality
12. Ensure all cylinders actuate smooth and at the same rate
13. Inspect the telescoping tubes gap wear pads, using shims adjust the gap as necessary
14. Visually check the condition electrical cables, sensors, plugs and junction boxes
mounted on the unit boxes for dryness, tightness, and proper fit of all glands and seals.

15. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 4.1.2 Pipe Arms and Pipe Loaders (Lower Guide Arm)
Frequency: 5 Year, CAT VI inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent,
Chief Electrician, Electrical PME, Electrical Superintendent.
Scope of work for each interval:
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Perform CAT III
2. Perform an MPI (PT for narrow areas) for all the accessible weld and critical area
members in the pipe arm and loading system structure, frames, bracing & hydraulic
system.
3. Replace any defected components

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 Abraj Inspection Manual
Equipment: 4.2.1 Hydraulic Catwalk
Frequency: 1 Year, CAT III inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
1. Visually inspect all the unit fasteners and fittings for tightness, damage or corrosion.
2. Visually inspect all the pins/holes (bearing movement areas), pivot connections and
control mechanisms for excessive wear.
3. Visually inspect the skate, trough, trough track, trough leg, Kickers, indexers and safety
pins for any damage, deformation or excessive wear.
4. Visually inspect all drive sprockets and chains for excessive wear and stretch.
5. Extend all cylinders (including indexers and kickers cylinders) and visually inspect the
chrome surface for any pitting or excessive wear condition.
6. Conduct a thorough examination on all the lifting gears and wire ropes components.
7. Conduct a thorough examination on the trough / skate winches and check for the
proper operation and condition of the clutches, integral brakes, linings, pawls &
ratchets.
8. Visually inspect all the accessible weld and critical area members in the catwalk structure
& the hydraulic system
9. Visually inspect all hydraulic hoses for damage, kinks, cuts reaching the internal wire
layer of the hoses & replace if necessary.
10. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 4.2.2 Hydraulic Catwalk
Frequency: 5 Year, CAT VI inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Perform all the field/CAT III inspection procedures.
2. Carry out initial inspection on the machine
3. Issue initial inspection report & recommendations for repair/certification
4. Copy of the parts list manual will be provided by Abraj to high light the required material
5. OEM parts will be supplied by Abraj if not else advised by Abraj during the job
6. Abraj approval for any welding WPS is required for any crack findings
7. Al bolts and nuts to sorted locally with exact same Grade and material.
8. Final Test Package to be Submitted after Job completion include all hydraulic repair and
pressure test , MPI reports and welding procedure used
9. Complete painting for the equipment as per OEM specifications
10. No modifications are allowed unless approved by Abraj maintenance head office
11. Follow all provided product information bulletin for testing and adjustment procedure that will
be part of the Scope
12. Complete dismantle for all hydraulic components
13. Submit initial report for all findings
14. Send all Hydraulic cylinders to 3rd party to replace the seal kit and inspect the piston and Rod
and repair as required. Pressure test is a mast after repair complete
15. Send all hydraulic motors to 3rd party for inspection,
16. Send both Main Hydraulic Pumps to 3rd party for inspection, confirm internal parts and setting
up the pump out put pressure
17. All hoses to be changed mandatory
18. All Control Valves/Solenoids stations to be send to 3rd party for inspection/pressure testing &
re sealing with new seal kit
19. Hydraulic tank to be dumbed, cleaned, flushed & send for inspection to 3rd party
20. All filters to be replaced
21. All hydraulic valves to be inspected/replaced
22. Pressure test for all hydraulic SS pipes, replace if failed
23. Servicing oil cooler heat exchanger by sending to dedicated 3rd party
24. Carry out NDT for load bearing area for Main Arm, back arm and Trough
25. Check straightness and Correct any Findings of the Main Arm, back arm and Trough
26. Inspect/Repair the roller Channel

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27. Gull wings to be sandblast all critical welding areas & MPI
28. All indexer pins to be Sandblasted, MPI
29. V-Door Ramp, all critical areas to be sandblasted, MPI
30. sandblasted, MPI the Main cylinder mounting Area
31. Check all landing shoe & perform MPI on its welding areas and Mounting Foundation
32. Replace all Grease Zerks
33. Trough to be dismantled from the Pipe cat frame
34. All pins to be inspected, MPI and dimensional check
35. Replace all the Bushing as required
36. All Kicker Plate to be inspected/replaced
37. Skate drive to be inspected/replaced
38. Skate hydraulic motor to be send 3rd party for inspection
39. Skate chain & its tensioner assembly including all parts to be inspected/replaced
40. Wire tensioner assembly including all parts to be inspected/replaced
41. Winch wire rope to be change
42. Pipe cat skate to be inspected, replace chain & sprockets
43. Safety pins to be inspected/replaced
44. Check/replace skate Rubber bumper
45. Replace all The Rollers if Necessary
46. Trough chain guard to be inspected/repaired/replaced if necessary
47. Replace all Grease Zerks
48. Send Electrical Motors for overhaul, open, inspected, changing bearing, varnish the winding
49. (As the motors working good and no ground fault I recommend to send it to Abraj Workshop as
no rewinding required)
50. Clean cable trays inspected it and repaired any broken sections
51. Clean and inspect all Pipe cat cables for any external damaged.
52. Megger all cables.
53. Clean and check all plug and receptacles.
54. Check emergency light.
55. Checked all joysticks on remote.
56. Clean, Inspect and test all solenoid valves.
57. Inspected control Box and tightened all terminals.

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 Abraj Inspection Manual
Equipment: 4.3.1 Catwalk and V-door
Frequency: 2 Years, CAT III inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”

1. Check the condition and content of the manufacturer’s name plate

2. Perform MPI of all load bearing components and members as per API 4G, should be
conducted to determine the condition of the V Door/catwalk and documented.
3. Check all structure bolts/pins for tightness and condition, any damaged bolt/pins
must be replaced by same material grade
4. Inspect overall structure condition, check for bend, damage or any broken parts
Inspect v‐groove for damage and bends that may obstruct the tubulars movement

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 Abraj Inspection Manual

Equipment: 4.3.2 Catwalk and V-door

Frequency: 10 Years, CAT IV inspection
Reference: API RP 4G
Responsibility: Rig Manager, Drilling superintendent

Scope of work for each interval:

Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”

1. The equipment is to be disassembled and cleaned to the extent necessary to conduct NDT
of all defined critical areas.
2. Perform MPI of all load bearing components and members as per API 4G, should be
conducted to determine the condition of the V Door/catwalk and documented.
3. Check all structure bolts/pins/hinges for tightness and condition, any damaged
bolt/pins must be replaced by same material grade
4. Inspect overall structure condition, check for bend, damage or any broken parts
5. Inspect v‐groove for damage and bends that may obstruct the tubulars movement.
Repair if any
6. Submit report of inspection/repair

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 Abraj Inspection Manual

Equipment: 4.4.1 Iron Roughneck

Frequency: 1 Year, CAT III inspection
Reference: OEM manual/ Abraj Best Practice
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat VI (every 1 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Fully disassemble the Iron Roughneck.
2. Check the slew and roller bearings condition.
3. Visually inspect all fasteners for damage or corrosion.
4. Visually inspect all pins/holes (bearing movement areas) for excessive wear.
5. Visually inspect all of the hanging points, lifting eyes, shackles and guide handle for
excessive wear, damage or deformation.
6. Extend the lifting cylinder and visually inspect the chrome surface for any pitting or
excessive wear condition.
7. Extend all of the clamping and wrenching cylinders consecutively and visually inspect
the chrome surface for any pitting or excessive wear; check the attachment points and
eyes for wear and excessive tolerance.
8. Visually inspect the biting edges of the jaw assemblies and their retaining bolts for
any looseness or damage.
9. Check the spinning rollers diameter for excessive wear (Make the measurement from the
center of the rollers away from the edges as much as possible)
10. Perform an MPI (PT for narrow areas) for all the accessible weld and critical areas
including the power scope adapter assembly (if installed).
11. Visually inspect all hydraulic/pneumatic hoses for damage, kinks, cuts reaching the
internal wire layer of the hoses and replace if necessary.
12. Reassemble and paint the Iron Roughneck.
13. Prepare and submit the inspection report.

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Equipment: 4.4.2 Iron Roughneck

Frequency: 5 Year, CAT VI inspection
Reference: OEM manual / Abraj Best Practice
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. REMOVE AND SEND IT TO BASE FOR MAJOR OVERHAULING
2. Perform all the field/CAT III inspection procedures.
3. Perform an MPI (PT for narrow areas) for all the accessible weld and critical area
members in the Iron Roughneck structure & the hydraulic system

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Equipment: 4.5.1 Power Tongs
Frequency: 1 Year, CAT III inspection
Reference: OEM manual
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Field Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Visually Check power tong for oil/air leaks and verify all hoses and connections condition.
2. Visually check air/hydraulic motor, gear case, hydraulic cylinder, air actuator and
roller assembly for any damage or wear.
3. Measure and record all critical accessible components and compare them to the OEM limits.
4. Perform MPI on all critical /accessible load-bearing areas including pivot pins,
die/claw assemblies, hanger and tong line retainers/connections.
5. Check the condition and the traceability of the OEM nameplate.
6. Prepare and submit the inspection report

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Equipment: 4.5.2 Power Tongs
Frequency: 2 Year, CAT IV inspection
Reference: OEM manual
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection – Cat IV (every 2 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Perform the field CAT III inspection, in addition of the next steps.
2. Completely disassemble the power tong components and clean all components for
detailed inspection.
3. Measure /record and MPI all critical accessible components and compare them to the OEM
Acceptance limits.
4. Replace all bearings, seals, hoses, dies and rollers with new ones.
5. Overhaul the main hydraulic /air motors
6. Check the condition and the traceability of the OEM nameplate.
7. Repaint the power tong.
8. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 4.6 Spinning Wrench
Frequency: 1 Year, CAT IV inspection
Reference: Abraj Best Practice/ OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent
Scope of work for each interval:
Full Inspection–CAT IV (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Spinning wrench
under inspection, it must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Name plate.
3. Visually inspect all the unit fasteners for tightness, damage or corrosion.
4. Visually inspect all the pins/holes (bearing movement areas) for excessive wear.
5. Visually inspect all the hanging points, lifting eyes, shackles and adjustment bolts for
excessive wear, damage or deformation.
6. Extend lifting cylinder and visually inspect the chrome surface for any pitting or excessive
wear condition.
7. Visually inspect the snub line attachments, brackets, shackles and pins for excessive
wear, damage or deformation.
8. Extend the clamping cylinder and visually inspect the chrome surface for any pitting
or excessive wear; check the attachment points and eyes for wear and excessive
tolerance.
9. Remove the drive motor (If applicable); clean muffler and check the drive and gear case
pinion gears condition.
10. Check the spinning rollers diameter for excessive wear (Make the measurement from the
center of the rollers away from the edges as much as possible)
11. Perform an MPI (PT for narrow areas) for all the accessible weld and critical areas
including the power scope adapter assembly (if installed).
12. Visually inspect all hydraulic/pneumatic hoses for damage, kinks, cuts reaching the
internal wire layer of the hoses and replace if necessary.
13. Prepare and submit the inspection report.

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Equipment: 4.7.1 Hydraulic Cathead Ezy Torque
Frequency: 1 Year, CAT III inspection
Reference: OEM manual/ Abraj Best Practice
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent.
Scope of work for each interval:
Field Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Visually check the ezy torque/cathead for abnormal observation, damage or deformation.
2. Check that bolts on frame, foundation, wire lock, wire clamp, cylinder and sheaves are
tightly secured.
3. Thoroughly inspect the wire rope, clamp, lock and compression spring for any damage.
4. Perform MPI on all critical /accessible load-bearing areas including frame, foundation
base, sheaves grooves, lock plate area, roll holder, pivot arm, tong post area.
5. Perform a complete function test and check for proper operation (including complete
evaluation of the hydraulic cylinder chroming surface).
6. Check the condition and the traceability of the OEM nameplate.
7. Prepare and submit the inspection report.

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Equipment: 4.7.2 Hydraulic Cathead Ezy Torque

Frequency: 5 Year, CAT IV inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Completely disassemble the ezy torque/hydraulic cathead.
2. Perform Complete CAT III inspection beside the following steps.
3. Change all the hydraulic cylinder seals with new ones.
4. Visually check the hydraulic cylinder for any damage, wear or deformation.
5. Replace all the sheaves bearings /bushings and seals with new ones.
6. Replace all hydraulic hoses with new ones.
7. Perform MPI on all critical load-bearing areas including frame, foundation base, lock plate
area, axle, roll holder, sheaves/ sheaves grooves and pivot arm.
8. Reassemble the ezy torque/hydraulic cathead; repaint as required.
9. Perform a complete function and pulling test to the rated working load.
10. Check the condition and the traceability of the OEM nameplate.
11. Prepare and submit the inspection report.

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Equipment: 4.8 Utility Winches
Frequency: 1 Year, CAT IV inspection
Reference: OEM manual/ API RP 7G-2, ASME B30.7
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection (every 1 year) By a Qualified Inspector: To be performed by a competent person and
all NDT inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Isolate the winch by shutting off the air, unwind the winch line from the drum and inspect the
line visually for any kinks, broken lines and other damage.
2. Remove the winch from the foundation plate or mounting brackets.
3. Visually check all outside parts of the winch (including the spooling device and control
valves) for proper installation and any damage or wear.
4. Perform MPI and visual inspection on the brake band and associated components.
5. Perform MPI and visual inspection on winch connecting points to the mounting bracket or
plate, bolts, clamp area etc. as per manufacturer’s recommendation.
6. Check the condition and details of the manufacturer’s name plate.
7. Ensure the SWL is clearly marked.
8. Perform MPI on the turndown sheave attachment point in the mast.
9. Perform inspection on all line attachments (turndown sheave, shackles, swivels etc.).
10. Reinstall the winch.

11. Carry out load test to the SWL

12. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 4.9.1 Mechanized Pipe Bins
Frequency: 1 Year, CAT III inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:

1. Visually inspect all the unit fasteners and fittings for tightness, damage or corrosion.
2. Visually inspect all the pins/holes (bearing movement areas), pivot connections and control
mechanisms for excessive wear.
3. Visually inspect the bridges, sheaves, support beams, bed, wire rope, conveyor beam, and
safety pins for any damage, deformation or excessive wear.
4. Visually inspect all drive sprockets and chains for excessive wear and stretch.
5. Extend all cylinders and visually inspect the chrome surface for any pitting or excessive wear
condition.
6. Conduct a thorough examination on all the lifting gears and wire ropes components.
7. Conduct a thorough examination on the hydraulic motors and gearbox
8. Visually inspect all the accessible weld and critical area members in the structure & the
hydraulic system
9. Visually inspect all hydraulic hoses for damage, kinks, cuts reaching the internal wire layer of
the hoses & replace if necessary.
10. Prepare and submit the inspection report.

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Equipment: 4.9.2 Mechanized Pipe Bins

Frequency: 5 Year, CAT VI inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling superintendent
Scope of work for each interval:
Full Inspection – Cat VI (every 5 years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Perform all the field/CAT III inspection procedures.
2. Perform an MPI (PT for narrow areas) for all the accessible weld and critical area members in
the catwalk structure & the hydraulic system

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Equipment: 5.1 Drill Pipe

Frequency: 6 Month , CAT IV inspection
Reference: API 5DP, DS1 Vol3, DS1 Vol4
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Field Inspection – Cat III (every 6 months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Prepare the tubular for inspection. Clean with wash gun soon after laydown, remove all debris and
clean all thread protectors.
2. Read and record the identification no.
3. Inspect the tool Joints
a. Perform a dimensional inspection on the tool joints including but not limited to
a. Box OD
b. Pin ID
c. Box shoulder width
d. Tong Space
e. Box and pin thread profiles for pin stretch or box swell checks
f. Box counter bore depth
g. Box counter bore diameter
h. Bevel diameter
i. Box depth – Pin length –Pin nose diameter (for the proprietary connections)
b. Visually inspect the connections for pitting, corrosion, cracks, re-facing and box hard banding
condition (No re-facing for the double shoulder connections to be done without benchmarking or
in field).
c. Visually inspect the secondary shoulder area condition (for the proprietary connections).
d. Visually inspect the threads (roots, flanks) for any pitting, corrosion, galling, crack or damage.
e. Perform a black light inspection on the pin and box areas for transversal cracks and heat
checking.
4. Inspect Pipe body
a. Visually inspect the pipe tube for pitting, excessive corrosion, cuts and straightness.
b. Check OD of the pipe tube and compare it with the minimum standard requirements.
c. UT the wall thickness of the pipe body (at the center of the tube and all defected area).
d. Full body EMI log (buggy) checking for cracks and discontinuities.
e. Perform MPI on the slip/upset area covering at least (48” from the pin shoulder and 48” from the
box shoulder).
f. Check the condition of the internal plastic coating and classify it as per DS 1; condition 1 to 4
(Condition 4 is a cause of rejection while condition 3 has to be closely monitored in the next
inspection by full endoscope to check coating deterioration as per DS1 Vol3 Addendum 2
guidelines).
g. Mark pipes with the required API color code.
5. Submit detailed inspection report.

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 Abraj Inspection Manual
Equipment: 5.2 Tubular Lifting Plugs cap and Subs
Frequency: 6 Month , CAT IV inspection
Reference: API RP 7G-2, API RP 7A1
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Field Inspection – Cat IV (every 6 months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1 Check and record identification no.
2 Prepare lifting plug or sub for MPI (remove paint etc.). Visually check the body, thread and
lifting bail (if applicable) for any damage wear or cracks.
3 Perform MPI on thread and bail welding area (if applicable).
4 Measure and record threads, ID of pin, lifting plate diameter, check for pin stretching.
5 Repaint to Original color.
6 Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 5.3.1 Circulating Heads
Frequency: 6 Month , CAT III inspection
Reference: API RP 7G-2, API 7-1, API 7-2
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Field Inspection – Cat III (every 6 months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Visually check the circulating head for any damage, wear or corrosion.
2. Visually check the ID for erosion.
3. Perform Pin & Box connection inspection
4. Perform NDT on body and critical areas.
5. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 5.3.2 Circulating Heads
Frequency: 1 Years, CAT IV inspection
Reference: API RP 7G-2, API 7-1, API 7-2
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every year): To be performed by Approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.
Complete the full Cat III every six months inspection in addition to the following:
1. Completely dismantle the circulating head.
2. Visually check all components for damage, wear or cracks.
3. Perform MPI on body and critical areas.
4. Reassemble the circulating head.
5. Repaint as required.
6. Prepare and submit the inspection report (stamp new inspection date on stainless
steel band.

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 Abraj Inspection Manual
Equipment: 5.4 Drill String Accessories & BHA
Frequency: 500 Rotating Hours, CAT IV inspection
Reference: API RP 7G-2, DS1 Vol3 Cat 3-5, DS1 Vol4 Cat 3-5
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection–Cat3-5 (Every 250 hours for short wells or every 450 hours/after reaching
3,500meters for long duration wells): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare the tubular for inspection. Clean with wash gun soon after laydown, remove all
debris and clean all thread protectors.
2. Read and record the identification no.
3. Inspect the tool Joints
a. Perform a dimensional inspection on the tool joints including but not limited to
i. Box OD
ii. Pin ID
iii. Box shoulder width
iv. Tong Space
v. Box and pin thread profiles for pin stretch or box swell checks
vi. Box counter bore depth
vii. Box counter bore diameter
viii. Bevel diameter
ix. Box depth – Pin length –Pin nose diameter (for the proprietary connections)
b. Visually inspect the connections for pitting, corrosion, cracks, re facing and box hard
banding condition (No re facing for the double shoulder connections done without
benchmarking or in field).
c. Visually inspect the secondary shoulder area condition (for the proprietary connections).
d. Visually inspect the threads (roots, flanks) for any pitting, corrosion, galling, crack or
damage.
e. Perform a black light inspection on the pin and box areas for transversal cracks and
heat checking.
4. Inspect Body
a. Visually inspect the body for pitting, excessive corrosion, cuts and straightness.
b. Check the HWDP center upset OD (If applicable).
c. Check the drill collar elevator and slip grooves (If applicable).
d. Check the subs length (shoulder to shoulder) and compare them with the minimum
standard requirements.
e. Perform an MPI on the subs outside diameter.
f. Mark the individual items according to the given color code.
g. Grease the equipment and install thread protectors.
h. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 5.5.1 Kelly Valves and Full open safety valves
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API RP 7G
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat III (every 1 year): To be performed by approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Remove the valve from service.

2. Fully open the valve and pump a small volume of fresh water through the valve to remove
drilling mud residue from the ID bore of the valve.
3. If resources are available, pressurize valve up to 300 Psi using water and function valve to
dislodge any mud from seat spring and prevent any likelihood of being difficult to operate.
4. Visually Inspect threads for damage, stretching and galling.
5. Visually inspect valve bore, seat bores, and stem bores for internal scratches, excessive wear
or corrosion
6. Perform Liquid penetrant on pin & Box threads area according to API RP 7G on 180 operating
days or 1 yearly whichever is less.
7. Function test valves without excessive force
8. Pressure test Kelly cock, Gray valve and drop in sub to the rated working pressure in the
direction of flow
9. Prepare and Submit inspection report

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 Abraj Inspection Manual
Equipment: 5.5.2 Kelly Valves and Full open safety valves
Frequency: 5 Yearly, CAT IV inspection
Reference: API RP 7G-2 &API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every 5 year): To be performed by approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Remove the valve from service.

2. Fully open the valve and pump a small volume of fresh water through the valve to remove
drilling mud residue from the ID bore of the valve.
3. If resources are available, pressurize valve up to 300 Psi using water and function valve to
dislodge any mud from seat spring and prevent any likelihood of being difficult to operate.
4. Fully close the valve and disassemble the valve completely.
5. Visually Inspect threads for damage, stretching and galling.
6. Visually inspect valve bore, seat bores, and stem bores for internal scratches or excessive
wear.
7. Perform Liquid penetrant (PT with fluorescent penetrants) on the following:
 Box / pin thread areas.
 Area inside the operating crank window.
 Fillet radii of internal grooves and shoulders.
8. Change all the valve seat seals, Teflon rings and stem/crank O-ring.
9. Reassemble the valve and fill with high-grade lithium based grease.
10. Function test valves without excessive force
11. Pressure test Kelly cock, Gray valve and drop in sub to the rated working pressure in the
direction of flow
12. Prepare and Submit inspection report.

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 Abraj Inspection Manual
Equipment: 5.6.1 Top Drive IBOPs
Frequency: 1 Yearly, CAT III inspection
Reference: Abraj best practice ,OEM
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat III (every 1 year): To be performed by approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Remove the valve from service.

2. Fully open the valve and pump a small volume of fresh water through the valve to remove
drilling mud residue from the ID bore of the valve.
3. If resources are available, pressurize valve up to 300 Psi using water and function valve to
dislodge any mud from seat spring and prevent any likelihood of being difficult to operate.
4. Visually Inspect threads for damage, stretching and galling.
5. Visually inspect valve bore, seat bores, and stem bores for internal scratches, excessive
wear or corrosion
6. Perform Liquid penetrant on pin & Box threads area according to API RP 7G on 180 operating
days or 1 yearly whichever is less.
7. Function test valves without excessive force
8. Pressure test Kelly cock, Gray valve and drop in sub to the rated working pressure in the
direction of flow
9. Prepare and Submit inspection report

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 Abraj Inspection Manual
Equipment: 5.6.2 Top Drive IBOPs
Frequency: 5 Yearly, CAT IV inspection
Reference: Abraj best practice ,OEM
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every 5 year): To be performed by approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Remove the valve from service.

2. Fully open the valve and pump a small volume of fresh water through the valve to remove
drilling mud residue from the ID bore of the valve.
3. If resources are available, pressurize valve up to 300 Psi using water and function valve to
dislodge any mud from seat spring and prevent any likelihood of being difficult to operate.
4. Fully close the valve and disassemble the valve completely.
5. Visually Inspect threads for damage, stretching and galling.
6. Visually inspect valve bore, seat bores, and stem bores for internal scratches or excessive
wear.
7. Perform Liquid penetrant (PT with fluorescent penetrants) on the following:
 Box / pin thread areas.
 Area inside the operating crank window.
 Fillet radii of internal grooves and shoulders.
8. Change all the valve seat seals, Teflon rings and stem/crank O-ring.
9. Reassemble the valve and fill with high-grade lithium based grease.
10. Function test valves without excessive force
11. Pressure test Kelly cock, Gray valve and drop in sub to the rated working pressure in the
direction of flow
12. Prepare and Submit inspection report.

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 Abraj Inspection Manual
Equipment: 6.1.1 Mud Tanks
Frequency: 2 Year , CAT III inspection
Reference: STI SP001, API RP 653
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:

Full Inspection – Cat III (every 2 year): To be performed by approved Inspector: a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Check and record the traceability list.

2. Empty the tank completely and flush inside with water based cleaner.
3. Visually inspect the interior of tanks for any pilled off coating or localized corrosion.
4. Apply re-coat wherever required.
5. MPI all the lifting pad eyes, connecting links of stairs etc.
6. Visually check the tank and, associated piping, gratings, handrails, light post and all other
post for any damage, corrosion or cracks.
7. Perform UT wall thickness

8. Conduct 3rd Party DROP inspection

9. Fill the tank with fresh water and perform function test
10. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 6.1.2 Mud Tanks
Frequency: 10 Year , CAT IV inspection
Reference: STI SP001, API RP 653
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Full Inspection – Cat IV (every 10 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
11. Check and record the traceability list.
12. Empty the tank completely and flush inside with water based cleaner.
13. Sand or grit blast the tank inside and outside.
14. Visually check the tank and any associated piping for any damage, corrosion or cracks.
15. Perform MPI/Liquid Penetrant on all critical areas (welded seams, pedestal and skid front ends
etc.)
16. Measure and record the wall thickness of the tank (15 points per 12 Inches x 12 Inches square
area)
including the pedestals and skid.( minimum values are highlighted in the below guidelines
Note: The following step requires compliance with all Abraj Confined Space Entry Rules!
17. Repair as required
18. Apply base coat and top coat with Abraj approved paint
19. Fill the tank with fresh water and perform leak test.
20. Repaint all of the components and exterior.
21. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 6.2 Shale shakers Basket
Frequency: 1 Year, CAT III inspection
Reference: Abraj Best Practice
Responsibility: Rig Manager, Drilling superintendent, Chief Mechanic, Mechanical PME,
Mechanical superintendent

Scope of work for each interval:

1. Clean out any solids buildup in the skid compartment that may cause the vibrating
basket to bottom out or interfere with screening
2. Dis-connect basket assembly from the frame, full sand blasting of basket by third party
3. Re-painting the basket assembly with its original color (antirust paint) as per Abraj
painting procedure.
4. Re-assemble to its frame, replacing the four (4) main basket support springs if one
spring appears more compressed than the others. Replace springs, bolts & fasteners
if required.
5. Upon completion of assembling run machine and perform audible & physical check.
6. Check basket angle adjustment

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 Abraj Inspection Manual
Equipment: 6.3 Low pressure pipe Lines Flow line
Frequency: 2 Year (PDO 1 Year), CAT IV inspection
Reference: API 570 And API RP 574
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Completely disassemble the Flow Line.

2. Clean out all solidified mud and cement using High Pressure washer cleaner.
3. Visually check and MPI all flow line assemblies, end connections and flushing line connection.
4. Visually check the flow line body for any damage, deformation, cracks or excessive corrosion.
5. Change all rubber seals, O-rings.
6. Perform a wall thickness check on the flow line piping and elbows. Compare to the minimum
wall thickness required.
7. Reassemble the flow line.
8. Prepare and submit the inspection report

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 Abraj Inspection Manual
Equipment: 6.4.1 Sack Handling Devices
Frequency: 1 Year, CAT III inspection
Reference: OEM manual / ASME B 30.11 / BS 2853
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

CAT III “To be performed by a competent person and all NDT inspections to be done by an accredited
third party.
 Inspection for Beam
1. Visually check the unit for any damage, corrosion or cracks.
2. Remove the paint from the critical welded areas (mainframe, mounting plate etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on the pad eyes and lifting points (if applicable).
5. Repaint as required.
6. Prepare and submit the inspection report.
7. Refer to inspection manual 1.9 for detailed criteria

 Inspection for Big Bag Hoist

8. Remove the Big Bag hoisting device from the traveling beams.
9. Dismantle the hoisting device as much as needed.
10. Visually check all items (hoist body, trolley assembly, chain containers, all relevant piping) for any
damage, wear/corrosion or cracks and for any missing bolts/nuts.
11. Perform MPI on the hook
12. Verify Brake functionality
13. Verify hook axial movement
14. Check pendant function, ensure release mechanism of buttons
15. Check the condition and content of the manufacturer’s nameplate.
16. Repaint the items as required (including the SWL sign).
17. Prepare and submit the inspection report.

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 Abraj Inspection Manual

Equipment: 6.4.2 Sack Handling Devices

Frequency: 5 Year, CAT IV inspection
Reference: OEM manual / ASME B 30.11 / BS 2853
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

CAT IV “To be performed by a competent person and all NDT inspections to be done by an accredited
third party.
 Inspection for Beam
1. Visually check the unit for any damage, corrosion or cracks.
2. Full sand blasting of the beams
3. Perform MPI on all weld and critical area.
4. Perform MPI on the pad eyes and lifting points (if applicable).
5. Repaint as required.
6. Prepare and submit the inspection report.
7. Refer to inspection manual 1.9 for detailed criteria

 Inspection for Big Bag Hoist

8. Remove the Big Bag hoisting device from the traveling beams.
9. Dismantle the hoisting device as much as needed to conduct inspection as per OEM
recommendation.
10. Visually check all items (hoist body, trolley assembly, chain containers, all relevant piping) for any
damage, wear/corrosion or cracks and for any missing bolts/nuts.
11. Perform MPI on the hook
12. Replace the seal kit, hoses, air filter etc.
13. Check brake and motor vane for wear, change as required
14. Check chain sprocket and bearing, change as required
15. Check gearbox, perform oil change
16. Load test to 1.25 times the SWL
17. Check the condition and content of the manufacturer’s nameplate.
18. Repaint the items as required (including the SWL sign).
19. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 7.1.1 Mud Pump Reset Relief Valves
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API 7K / API 510/ RP 572/ RP 576/ ASME III
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

1. Inform area authority if work is carried out on critical equipment for the ongoing operation.
2. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs plan.
3. Insure that all pressures are bleed off
4. Remove the relief valve from the high-pressure pump bleed off line.
5. Flushing out the valve body cleaning any debris.
6. visual inspection for bonnet assy. mechanism and rectify if required
7. Inspect outer stem bushing seal for damage.
8. inspect the valve body for washout
9. inspect valve seat for washout
10. Replace all soft seals.
11. Assemble the valve and bonnet assy. and pack it with EP2 grease
12. Valve calibration for the full range of working pressure
13. Test the relief valve to ensure that it relieves at the set pressure stated using a certified
monitoring gauge. The test shall include a minimum of 3 different pressures spanning the full
range of the relief valve (including zero setting)
14. If valve is out of tolerance calibration step to be repeated
15. Paint Valve Body
16. pack the valve and seal and make ready to be shipped back to the rig

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 Abraj Inspection Manual

Equipment: 7.1.2 Mud Pump Reset Relief Valves

Frequency: 2 Yearly, CAT IV inspection
Reference: OEM manual / API 7K / API 510/ RP 572/ RP 576/ ASME III
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work:
Full Inspection – CAT IV (every 2 year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Inform area authority if work is carried out on critical equipment for the ongoing operation.
2. Ensure the use of Certified / Calibrated appropriate tools/test equipment for required jobs
plan.
3. Insure that all pressures are bleed off
4. Remove the relief valve from the high-pressure pump bleed off line.
5. Flushing out the valve body cleaning any debris.
6. inspection for bonnet assy. mechanism for any worn our parts that must be replace
7. Redress the valve with Major repair kit
8. MPI and UT the valve body
9. Honing valve body throat if required.
10. Pressure test the valve body 1.5 times of the max working pressure.
11. Replace valve body seat if inspection rejected
12. Assemble the valve and bonnet assy and pack it with EP2 grease
13. Inspect Springs Condition
14. valve calibration for the full range of working pressure
15. Test the relief valve to ensure that it relieves at the set pressure stated using a certified
monitoring gauge. The test shall include a minimum of 3 different pressures spanning the
full range of the relief valve (including zero setting)
16. If valve is out of tolerance calibration step to be repeated
17. Paint Valve Body
18. pack the valve and seal and make ready to be shipped back to the rig

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 Abraj Inspection Manual
Equipment: 7.2.1 Pulsation Dampener
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API 7K / ASME VIII Div. 1 / API RP 510
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – Cat III (every one year): To be performed by a competent
person and all NDT inspections to be done by an accredited third party, approved by Abraj
technical authority”.
1. Check the manufacturer’s name plate and serial number of the pulsation dampener.
2. Release the nitrogen pressure and remove the pulsation dampener from the pump manifold.
3. Remove all mud and dirt from the body and the connection flange.
4. Visually check all components (body, studs, nuts, threads and flange) for any damage,
cracks and wear. Ensure studs are fully inside and equal standoff between flanges.
5. Perform NDT / MPI on the ring groove and the welding between the body and the flange and
wall thickness inspection and compare against OEM minimum wall thickness requirement.
Note 1: Any defects found must be reported to the Technical Operations group for the correct
remedial actions
6. Charge pulsation dampener as per to the manufacturer’s recommendations.
7. Repaint the pulsation dampener if required.
8. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 7.2.2 Pulsation Dampener
Frequency: 5 Yearly (PDO 2 Years), CAT IV inspection
Reference: OEM manual / API 7K / ASME VIII Div. 1 / API RP 510

Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – CAT IV (every 5 years): To be performed by a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Check the manufacturer’s name plate and serial number of the pulsation dampener.
2. Release the nitrogen pressure and remove the pulsation dampener from the pump manifold.
3. Remove all mud and dirt from the body and the connection flange and dismantle the dampener.
4. Perform NDT/MPI on the ring groove and the welding between the body and the flange.
5. Perform MPI on the whole body and wall thickness inspection.
6. Replace all studs, nuts and fasteners with new items
7. Hydro test the dampener to 1.5 time of RWP. In case wall thickness is below OEM
recommendation, it can be downgraded to lower pressure rating.
8. Install new rubber element and stabilizer.
9. Pressure test to RWP after assembly.
10. Repaint all these components.
11. Prepare and submit the inspection report.
Note 1: Any defects found must be reported to the Technical Operations group for the
correct remedial actions.

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 Abraj Inspection Manual
Equipment: 7.3 Standpipe & High Pressure Piping, Cement lines
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API 7K / RP 510
Responsibility: Rig Manager, Drilling Superintendent

Scope of work : In Field Inspection – Cat III: To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Clean the High Pressure Lines / Cement Line / Kill Line.
2. Visually inspect externally and also ensure no cuttings are accumulated in piping’s. If required
utilize various methods for cleaning interior of piping’s.
3. NDT inspection of all weld and hammer union/end connections.
4. Perform a wall thickness measurement (UT) and compare it with the OEM minimum wall thickness.
Value in last column of table (Min Wall thickness with additional 15% SF) to be utilized as reference,
if value is between last column and 2nd last column, management approval is required and re-
ordering need to be done.
5. Measuring point shall be circled on body to ensure that UT thickness measurement is done at same
point every year

Point Measured Wall Thickness Min Reqd.

12’ O Clock 3’ O Clock 6’ O Clock 9’ O Clock Thickness

6. Dimension inspection & gauging of hammer union.

7. Pressure test to Rated Working Pressure.
8. Install stainless steel tag with information such as date of testing, RWP, Serial No etc.
9. Prepare and submit the inspection report.

Note:
1. Any Repair to be carried out by licensed 3rd party workshop
2. All repair to be followed by Heat Treatment and stress relieving
3. All repair to be followed by Hydro testing to 1.5 time RWP

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 Abraj Inspection Manual

Equipment: 7.4.1 High Pressure Manifold & Valves

Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / API 7K / API RP 570
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – Cat III: To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Thoroughly flush through all lines & valves, Degrease and clean the standpipe and
ground manifold.
2. Carry out MPI on all weld areas and hammer union sealing areas (inside and outside)
3. Measure the wall thickness on specific points of the standpipe and HP piping, (two points
per meter) and mark position of checkpoints in a drawing. Pay special attention to 90-
degrees elbows and T-pieces
4. Operate and ensure all mud gate valves & choke Open / Close freely.
5. Strip down 1-2 valves on manifold or all those valves which are not moving freely to
inspect the cavity and extent of corrosion & pitting. If excessive corrosion & pitting
observed, strip down all Valves.
6. Reassemble the stripped down valve with new bonnet gasket and soft seals. Fill the cavity
with HP Recommended grease.
7. Grease the valve stem using HP grease.
8. Pressure test the manifold and all valves to RWP. Choke to remain open while pressure
testing
9. Prepare and submit the inspection report (preferably install stainless steel tag with
information such as date of testing, RWP, Serial No etc.)

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 Abraj Inspection Manual
Equipment: 7.4.2 High Pressure Manifold & Valves
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – CAT IV (every 5 Years): To be performed by a competent person
and all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.
1. Thoroughly flush through all lines & valves, Degrease, clean the standpipe, and ground
manifold.
2. Disassemble the valves on manifold completely.
3. Visually check all valve components for damage, wear, corrosion, erosion or cracks
including the inside of the valve body, bonnet, handle and stem, gate & Seat. Replace as
required.
4. Perform MPI/Liquid penetrant on all welds, hammer union and valve seat areas of the valves
5. Measure wall thickness on specific points of the HP piping. Mark position of checkpoints
on a drawing.
6. Reassemble the valves using new seal & O-rings. Replace gates and seats as required.
Utilize company approved HP grease for filling cavity and stem.
7. Pressure seat test of the individual to RWP. Follow Abraj Pressure testing procedure.
8. In case of any body repair, manifold to be shell tested to 1.5 times of rated working
pressure followed by Heat treatment.
9. Repaint the manifold as valve to original paint.
10. Check the condition and details of the manufacturer’s name plate, if serial no is fading away,
place the steel tag with Serial no and RWP clearly marked on it.
11. Prepare detailed inspection report with images & MPI of cavity of each individual valves and
12. Submit The inspection report.

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 Abraj Inspection Manual
Equipment: 7.5 Chicksans and swivels
Frequency: 1 Yearly, CAT IV inspection
Reference: OEM manual / API 570 /API RP 574/ API RP 14E
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent

Scope of work: Full Inspection – Cat IV To be performed by a competent person and all NDT
Inspections to be done by an accredited third party”.
1. Degrease and clean for inspection
2. Visual inspection of the pipe bore for erosion and corrosion.
3. Visual inspection and inspection by the use of thread and form gauges of threads and load
shoulders and inspection of sealing surface conditions, bolts and lock rings, for:
 male sub inspection,
 female union thread half inspection,
 wing nuts,
 hub inspection (including clamps and bolts),
 segment and retaining clip (circlip) inspection,
 Swivel joint ball race inspection.
4. Check threads for minor damage may be removed from the thread using a light file. Male
and female thread should both be inspected with GO and NO GO caliper.
5. Hammer union wing nuts shall be replaced where the lug is too small to strike accurately,
delivering a tangential blow.
6. Magnetic Particle Inspection (MPI) of hammer union segments.
7. Check the wall thickness at the points indicated by manufacturer. Any component with a
wall thickness at or below the dimensions shown should be taken out of service and
quarantined.
8. Pressure testing of assembly to low pressure 250-350 Psi and high pressure to RWP for
rigid pipework, unless repairs/modifications have been carried to the item of equipment in
which case it shall be subject to a maximum test pressure of 1.5 time RWP.
9. Repaint as required
10. Prepare and submit the inspection report.
11. Install new banded tags on steel hose assembly once it passed through all test. Band
should contain following information as minimum
 Serial No
 Max allowable working pressure
 Date of Test
 Type of service; Standard or H2S
 MPI segments on the most used connections

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 Abraj Inspection Manual
Equipment: 7.6.1 S-pipe/ Gooseneck Assembly
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – To be performed by a competent person and all NDT inspections
to be done by an accredited third party, approved by Abraj technical authority”.
1. Completely disassemble the gooseneck assembly and remove it from the top drive.
2. Visually inspect the mud line pipe, S pipe, hammer unions, seals, and threads for any damage,
pitting or excessive corrosion.
3. Perform a PT (Liquid penetrant) inspection on all the hammer unions and wireline plug threads.
4. Perform a wall thickness measurement (UT) on the mud line, extension pipe and S-pipe and
compare it with the OEM minimum wall thickness. In case of OEM reference not available, ASME
B31.3 can be utilized for calculating minimum wall thickness.
Point Measured Wall Thickness
Min Reqd.
12’ O Clock 3’ O Clock 6’ O Clock 9’ O Thickness
Clock

5. Check the condition of the secondary retention between the gooseneck and rotary hose and
ensure that it is suitable.
6. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 7.6.2 S-Pipe/ Gooseneck Assembly
Frequency: 5 Yearly, CAT VI inspection
Reference: OEM manual / API RP 8B
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Scope of work: In Field Inspection – To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Completely disassemble the gooseneck assembly and remove it from the top drive
2. Visually inspect the mud line pipe, S pipe, hammer unions, seals, and threads for any
damage, pitting or excessive corrosion.
3. Full Body Sand blasting
4. Full body MPI
5. Perform a PT (Liquid penetrant) inspection on all the hammer unions and wireline plug
threads.
6. Perform a wall thickness measurement (UT) on the mud line, extension pipe and S-pipe
and compare it with the OEM and ASME B31.3 minimum requirements.
7. Pressure testing to 1.5 times RWP
8. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.1.1 RAM Type BOP And Ram Blocks
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

In Field Inspection – Cat III every years from the last CAT IV/CAT III inspection: To be performed by
a competent person and all NDT inspections to be done by an accredited third party.
1. Inspect lifting pad eyes/frame/plate (MPI)
2. Inspect all ring grooves for pitting or damage (Visual/MPI)
3. Inspect the conditions of threads used for the hydraulic control hose connectors (Visual)
4. Inspect condition of bonnet seal groove (Visual/MPI)
5. Inspect bonnets bolts for thread galling and carry out NDT on thread and plain shaft area
(Visual/MPI)
6. Inspect condition of bonnet seal (cuts, hardness, form, age, etc.) and replace as required
7. Inspect BOP body at the bonnet seal area for pits and damage (Visual)
8. Inspect ram bores for scouring and pitting (Visual)
9. Inspect ram body for wear and damage (Visual)
10. Confirm spare rams and casing rams are also inspected (MPI)
11. Inspect vertical bore for drill pipe and drill bit damage max allowable wear 3/16” and 1/32”
in the area of ring-grooves
12. Inspect ram change piston rods for wear or pitting (Visual)
13. NDT Inspect piston rod groove, connecting rod button, ram operating piston rods for wear or
pitting and cracks
14. MPI of the weld on body, end connections/flanges and side connection (MPI)
15. Inspect operating piston tail rod for wear or pitting, ensure mesh protection in good condition
(Visual)
16. Inspect manual locking screws; hand wheels, clean, greased & operational
17. Inspect ram packers for cracking and cut or damages (Visual)
18. Inspect shear blades & shear blade bolts (Visual)
19. Conduct function test of BOP
20. Carry out BOP Chamber Test, refer Chamber testing procedure.
21. Carry out Pressure testing to RWP, refer BOP testing procedure.

Note:
1. No heating, welding, or cutting is allowed on any part of this equipment.
2. All repair work to be executed and certified by 3rd party.
3. 3rd party is required for NDT, UT.
4. Scour marks must be polished
5. Carry out pressure test in accordance with Abraj Procedure

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 Abraj Inspection Manual
Equipment: 8.1.2 RAM Type BOP And Ram Blocks
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53/ API 16A / API 16A
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by OEM or OEM Approved Inspector:
a competent person and all NDT inspections to be done by an accredited third party, approved
by Abraj technical authority”.
1. Completely disassemble and sand blast the BOP.
2. Visually check the body, flanges, bolts, threads and other main components for damage,
wear or cracks.
3. Measure and record the wear on the ram cavities & all bonnets and check for cracks.
4. Perform NDT on the BOP hoisting eyes and the weld between the flange and body.
5. Check sealing surfaces on the body, door, piston, intermediate flange, ram change
piston, ram change cylinder and operating cylinder. Replace seals with new.
6. Measure and record flange ring grooves (lower, upper and side outlets).
7. Check hydraulic system and connections.
8. Perform MPI on all load bearing items (Ram blocks, body, flanges, pistons, operating
cylinder, doors, bonnets, cavity area, bolts etc.) as per manufacturer’s
recommendation.
9. Perform dimensional and hardness tests on Ram blocks.
10. Perform individual body pressure test as per manufacturer’s recommendation.
11. Reassemble the BOP.
12. Carry out function test (with rams installed) followed by one pressure test to WP.
13. Repaint the BOP (primer coat and final coat).
14. Preserve for storage and tighten on BOP transport skid.
15. Prepare and submit the inspection report

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 Abraj Inspection Manual
Equipment: 8.2.1 Bag Type BOP Annular
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work In Field Inspection – Cat III every years to be performed by a competent person and
all NDT inspections to be done by an accredited third party.
1. Inspect lifting pad eyes/frame/plate (MPI)
2. Inspect all ring grooves for pitting or damage (Visual/MPI)
3. Inspect the conditions of threads used for the hydraulic control hose connectors (Visual)
4. Remove the top cap.
5. Remove the packing unit, adapter ring, and piston and inspect the packing unit and
seals for damage or wear. Refer the OEM manual for Disassembly & Assembly
procedure
6. Inspect the interior sealing surfaces of the preventer for wear or damage. If damaged,
send the preventer to a shop for repair.
7. Check the inner body sleeve for wear, damage and looseness.
8. Inspect the conditions of threads used for the hydraulic control hose connectors
9. Check the wear plate in the inner bottom face of the head for wear.
10. Inspect the packing unit for wear, cracking, damages and correct elastomer composition
11. Check the seal ring for nicks, cuts etc.
12. Replace any rubber goods that are damaged or cracked
13. Inspect the stud and nuts on top and bottom of the preventer. Replace any stud or nut that
has damaged threads or is missing. Confirm that studs are securely attached to the
preventer’s body.
Replace any stud that is not the recommended
length
14. Reassemble the preventer. Grease or oil all component parts before reassembling preventer
15. Conduct function test of BOP
16. Carry out BOP Chamber Test, refer Chamber testing procedure.
17. Carry out Pressure testing to RWP (if new element installed) or 70% of RWP in all other case,
refer
BOP testing procedure

Note:
1. No heating, welding, or cutting is allowed on any part of this equipment.
2. All repair work to be executed and certified by 3rd party.
3. 3rd party is required for NDT, UT.
4. Scour marks must be polished
5. Carry out pressure test in accordance with Abraj Procedure

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 Abraj Inspection Manual
Equipment: 8.2.2 Bag Type BOP Annular
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53/ API 16A / API 16AR
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat IV (every five years): To be performed by OEM or OEM
Approved Inspector: a competent person and all NDT inspections to be done by an accredited third
party.
1. Completely disassemble and sand blast the BOP.
2. Perform MPI on all load bearing items (body, preventer head, flanges, piston, sleeve, sealing
and thread areas etc.) as per manufacturer’s recommendation.
3. Perform MPI on the BOP hoisting eyes and the weld between the flange and body.
4. Measure and record the dimensions of BOP head, piston, body, lower flange, sleeve and
adaptor ring (if exist), etc. Verify the measured dimensions are within the OEM tolerances/
recommendations.
5. Replace the annular packer, upper& lower piston seals, inner& outer head seals, and lower &
upper adaptor ring seals (if any).
6. Check all hydraulic system and connections.
7. Individual body pressure test as per manufacturer’s recommendation.
8. Reassemble the BOP.
9. Carry out function test (with installed packing unit) followed by one pressure test to
working pressure.
10. Check condition and details of the manufacturer’s name plate.
11. Repaint the BOP (primer coat and final coat).
12. Preserve for storage and tighten on BOP transport skid.
13. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.3.1 Drilling Spools, Flanges, Mud cross, Test Stumps & DSA
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

In Field Inspection – Cat III years from the last CAT IV/CAT III inspection. To be performed by a
competent person and all NDT inspections to be done by an accredited third party, approved by
Abraj technical authority”.
1. Remove studs/bolts and check corrosion and mechanical damage, replace if required
2. Inspect all ring grooves for pitting or damage (Visual/MPI)
3. Inspect for abnormal wear & corrosion (Pitting)
4. Inspect vertical bore for drill pipe and drill bit damage max allowable wear 3/16” and 1/32”
in the area of ring-grooves
5. MPI of the weld on body, end connections/flanges and side connection (MPI)
6. Check the manufacturer’s name plate or stamps and attach a tag if original number is
missing or fading away.
7. Carry out Pressure testing to RWP, refer BOP testing procedure.

Note:
1. No heating, welding, or cutting is allowed on any part of this equipment.
2. All repair work to be executed and certified by 3rd party.
3. 3rd party is required for NDT, UT.
4. Scour marks must be polished
5. Carry out pressure test in accordance with Abraj Procedure

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 Abraj Inspection Manual
Equipment: 8.3.2 Drilling Spools, Adapter Flanges, Mud cross, Test Stumps & DSA
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API STD 53 / API 16A / API 6A
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection – Cat IV (every five years): To be performed by a competent person and all NDT
Inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Remove studs/bolts and check corrosion and mechanical damage, Replace as required
2. Inspect all ring grooves for pitting or damage
3. Inspect for abnormal wear & corrosion (Pitting)
4. Inspect vertical bore for drill pipe and drill bit damage, carry weld repair as needed. All weld
repair to be followed by heat treatment.
5. MPI of the weld on body, end connections/flanges and side connection (MPI)
6. Conduct Hardness testing.
7. Check the manufacturer’s name plate or stamps. If original number missing and faded,
place the marking as per API Spec 6A/16A.
8. Carry out shell testing to 1.5 times to RWP.
9. Repaint the equipment
10. Prepare and submit the inspection report.

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 Abraj Inspection Manual

Equipment: 8.4.1 Hub Clamps

Frequency: 1 Year (PDO 6 Month) , CAT III inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Field Inspection–Cat III (every 1 years): To be performed by OEM or OEM Approved Inspector: a
competent person and all NDT inspections to be done by an accredited third party, approved by
Abraj technical authority”.

1. Visually check the clamp and clamp with bolt and nut for any damage or cracks.
2. Measure and record the hub details, bolt and nut size.
3. Perform MPI on the hub and the clamp (including the bolt) and the weld between the hub and
body (if any).
4. Check the manufacturer’s name plate or stamp.
5. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.4.2 Hub Clamps
Frequency: 5 Yearly (PDO 3 Year), CAT IV inspection
Reference: OEM manual / API STD 53
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

Full Inspection–Cat IV (every 5 years): To be performed by OEM or OEM Approved Inspector: a
competent person and all NDT inspections to be done by an accredited third party, approved by
Abraj technical authority”.
1. Visually check the clamp and clamp with bolt and nut for any damage or cracks.
2. Measure and record the hub details, bolt and nut size.
3. Perform MPI on the hub and the clamp (including the bolt) and the weld between the hub and
Body (if any).
4. Check the manufacturer’s name plate or stamp.
5. Check the material certificates of the equipment and if they are missing or incomplete
conduct a material test.
6. Refurbish painting of the equipment as required.
7. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.5.1 BOP Control Unit
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / API 16D / ASME VIII Div.1
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Verify the BSR protected from accidental closure

2. Inspect the condition of both pneumatic and triplex pump system and ensure free of leak and fully
operational.
3. Ensure hydroelectric switch and pneumatic switch correctly set
4. Ensure pressure relief system calibrated
5. Ensure all connection, piping’s and reservoir are intact and free from leak.
6. Ensure fluid level gauge is clean and easily readable.
7. Ensure both control panels are connected and air pressure is same on unit
8. Ensure all functions can be operated from both the panels.
9. Check and ensure all light are working and alarms are operational
10. Check and record accumulator bottle pre-charge pressure and ensure it is as per OEM
recommendations.
11. Record the time required for charging unit from pre-charge to 3000 psi, it shouldn’t exceed 15
minutes with both pump system and 30 minutes with one pump system. Check for unusual noise
and vibrations while operating pumps.
12. Check and record pressure at which Pneumatic and Electric pump system stops. Air pump shall
stop between 95% (2850 Psi) to 100% (3000 Psi) and Triplex pump shall stop between 97% (2900
psi) to 100% (3000 Psi)
13. Bleed of pressure from control system and record at what pressure pumps system automatically
kick in. Triplex pump shall kick in when pressure is reduce to 90% (2700 Psi) and Air pump shall
kick in when pressure is reduced to 85% (2550 Psi).
14. Once unit is fully charged, operate bypass valve to high pressure and check for leaks from any of 4
way valve by looking into reservoir through inspection cover.
15. Inspect condition of all the hydraulic hose supplying pressure to BOP and ensure their outer covers
are intact and entire system is leak proof.
16. Conduct function testing once control system is rigged up with BOP
17. Conduct drawdown test as per Abraj procedure
18. Conduct chamber test cum hydraulic circuit integrity test as per Abraj procedure.
19. Prepare and submit inspection report

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 Abraj Inspection Manual
Equipment: 8.5.2 BOP Control Unit
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53 / API 16D / ASME VIII Div.1
Responsibility: Rig Manager, Drilling Superintendent
Scope of work: To be performed by OEM, OEM authorized workshop, API 16D licensed workshop or
API 16D certified company (CEM) authorized workshop in absence of OEM or their agent in region.
1. Remove the BOP control unit from service, de-pressurize, clean from outside and prepare for
sending it to contracted workshop for Cat IV inspection. Ensure all hoses and cables are sent
along with unit and panels.

Detailed SOW of inspection in workshop as follow:

2. Carry out Initial inspection and submit inspection reports highlighting any non-compliance.
3. Submit complete list of repair kits needed for unit recertification. Only OEM parts to be used for
recertification.
4. Dismantle & strip down the complete unit.
5. Complete inspection and testing of accumulator unit with 2 remote control panels including but
not limited to service of Air pumps, Triplex Pump & Electric Motors, inspection and repair of
selector valves, calibration of pressure relief valves, pneumatic-electric switches, pressure
gauges & pressure transducer etc.
6. Conduct MPI and UT wall thickness measurement of Accumulator Bottles, HP piping’s,
Accumulator manifold etc.
7. Conduct hydro testing of each accumulator bottle and piping.
8. Strip down triplex pump, Pneumatic pumps, selector valves and pressure regulators for
inspection.
9. Upon inspection, dress the components with new OEM repair kits.
10. Pressure testing of each selector valves.
11. Assemble all the components together on unit.
12. Carry out calibration or all pressure gauges and pressure relief valves.
13. Carry out integrity of all hydraulic system
14. Carry out post inspection function testing including but not limited to
a. Triplex Pump test – Shall charge unit to 3000 Psi in less than 30 minutes
b. Pneumatic Pump test – Shall charge unit to 3000 Psi in less than 30 minutes
c. Function testing and pressurization of each 4 way valves
d. Function testing of both Annular Regulator and Manifold regulator; Annular regulator to
be function tested from both panel and main unit
e. Bypass test and leak detection for all 4 way valve except for annular on open and close
side
f. Annular 4 way valve integrity test up to 1500 Psi/3000 psi based on maximum rating of
PTR
g. Gauge reading comparison and verification of calibration tags etc.
h. Check mechanical integrity of complete hydraulic system e.g. leak from triplex pump
piston rod, pneumatic pumps, Hydro-pneumatic switch, abnormal vibration, alignment
issue etc.
i. Verify setting of Hydroelectric switch; to be set at 2700 Psi; pump jump in at 2700 Psi
and cut off at 3000 Psi +/50 Psi
j. Verify setting of Hydro-pneumatic switch; to be set at 2550 Psi, Air pump jump in at 2550
Psi and cut off @ 2850 Psi +/-50 Psi
15. Recertification of complete unit to meet API 16D (Manufacturing year edition) requirement.
Note: All Pressure testing shall be done and recorded in accordance with API 53
16. Re - painting of the unit as per original color
17. COC will be required after job Completion. To issue full report along with photos during & after
the jobs. Report must contain COC for complete unit with Material traceability record listing all
component with S/N.

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 Abraj Inspection Manual
Equipment: 8.6.1 Choke & Kill Line Hose
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / API 16C
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – Cat III: To be performed by a competent person and all NDT
Inspections to be done by an accredited third party.
1. Remove the Choke/Kill Hose from service & clean
2. Visually inspect the choke and kill hoses steel outer Wrap for any damage, deep notches or
cuts.
3. NDT inspection of flanges and ring groove.
4. Full internal Bore-O scope inspection.
5. MPI Inspection on all end fitting area
6. Full pressure test to Rated Working Pressure.
7. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.6.2 Choke & Kill Line
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53 / API 16C/ API Q1/ISO – QMS licensed
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection: To be performed by a certified workshop preferably having API 16C
License or API Q1/ISO certification for Quality management system.
1. Remove the Choke/Kill Hose from service and send it to an approved facility for the following:
2. Visually inspect the choke and kill hoses steel outer Wrap for any damage, deep notches or
cuts.
3. NDT inspection of flanges and ring groove, repair as required.
4. Full internal Bore-O scope inspection.
5. MPI Inspection on all end fitting area
6. Full pressure test to 1.25 – 1.5 times Rated Working Pressure according to hose API 16C
Specifications.
7. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.7.1 Choke manifold and kill system
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / API 16C
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – Cat III: To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Thoroughly flush through all lines & chokes, Degrease and clean the choke / Kill manifold.
2. Carry out MPI on all weld areas
3. Record UT thickness on all spacer spools, buffer chambers etc. Mark position of checkpoints
on a drawing

Manual Valves
1. Operate and ensure all manual valves Open / Close freely.
2. Strip down 1-2 valves on manifold and all those valves, which are not moving freely to
inspect the cavity and extent of corrosion & pitting. If excessive corrosion & pitting
observed, strip down all valves.
3. Reassemble the stripped down valve with new bonnet gasket and soft seals. Fill the cavity with
HP recommended grease.
4. Grease the valve body cavity by removing the grease fitting cap located on the bonnet flange
OD and also stem bearing with HP grease

Manual Adjustable Choke

1. Retract the choke needle fully
2. Loosen the bleed off plug and check threads
3. Loosen bonnet nut, clean threads and remove bonnet assembly.
4. Clean internal area and ensure sealing area is free from erosion and wear.
5. Fill the cavity with HP grease and reassemble the choke
6. Move the choke to ensure that it is free to operate

Hydraulically Operated choke

1. Open and check actuating mechanism.
2. Grease the remote choke with HP grease

Remote choke control panel

1. Check both manual and pneumatic pump assembly
2. Clean filter & lubricator, change as required
3. Check Hydraulic fluid level and fill with clean oil
4. Check and ensure all hoses are physically intact and properly connected
5. Inspect position indication and ensure it is calibrated
6. Remove and clean gauge protector. Fill oil to hose before reconnecting.
7. Ensure all gauges are calibrated and calibration stickers are available
8. Function test operation of hydraulic choke with remote panel and ensure position indicator is
responding to operation as well speed control valves are also working.
9. Check pre-charge pressure in accumulator bottle if available and ensure it is as per OEM
recommendations.

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 Abraj Inspection Manual
Equipment: 8.7.2 Choke manifold and kill system
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53 / API 16C/ API Q1/ISO – QMS licensed
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection: To be performed by OEM or OEM Approved workshop or

API certified workshop.
1. Disassemble the choke manifold and all valves completely.
2. Visually check and dimensionally check all valve components for damage, wear,
corrosion, erosion or cracks including the inside of the valve body, bonnet, handle and
stem
3. Conduct dimensional check for all pressure sealing components such as Gate & Seat.
4. Perform MPI/Liquid penetrant on all welds, ring groove, hammer union and valve seat areas of
the valves
5. Measure wall thickness on specific points of the HP piping, all blocks and buffer manifold.
Mark position of checkpoints on a drawing.
6. Measure and record all the API flanges, according to API 6A.
7. Reassemble the valves using new seal, O-rings, gates and seats as required. Utilize company
approved HP grease for filling cavity and stem.
8. Pressure test the individual valve & entire manifold; Shell test @ 1.5 times RWP & Seat Test @
RWP.
9. Repaint as valve to original paint.
10. Calibrate all pressure gauges.
11. Carry out full inspection on the remote-control panel and gauges and stroke counter (if
applicable).
12. Check the condition and details of the manufacturer’s nameplate.
13. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.8.1 Mud Gas separator
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / ASME VIII Div. 1
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat III to be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Flush the MGS with clean water, drain, clean and Dry.
2. Open the MGS Manway.
3. Verify the condition of the inner surface of the Mud Gas Separator for any signs of
cracks or excessive corrosion.
4. Verify the baffles/slotted pipe condition for any damage.
5. Perform MPI on all the MGS body, inlet lines, return lines, vent lines and piping
clamps/brackets welding.
6. Perform wall thickness measurement on all the MGS body and compare it with the minimum
recommended thickness.
7. Rig up fully and function test the MGS to ensure all connections are free from leak and
verify unobstructed flow and proper operation.
Note: The MGS requires a one-time hydrostatic test during manufacturing or upon installation.
Any subsequent welding on the MGS vessel shall require an additional hydrostatic test to be
performed.
8. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.8.2 Mud Gas separator
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53 / ASME VIII Div. 1
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat IV to be performed by ASME licensed workshop.

1. Flush the MGS with clean water, drain, clean and Dry.
2. Clean the MGS external body and prepare for transferring the MGS to workshop.
Detailed SOW for MGS inspection in workshop
3. Open all the cover for MGS
4. Sand blast inside and outside of MGS
5. Verify the condition of the inner surface of the Mud Gas Separator for any signs of
cracks or excessive corrosion.
6. Verify the baffles/slotted pipe condition for any damage.
7. Perform MPI on full MGS body, inlet lines, return lines, vent lines and piping
clamps/brackets welding.
8. Perform wall thickness measurement on full MGS body and compare it with the minimum
recommended thickness
9. Repair as required
10. Conduct hydro-testing of MGS to 1.25-1.5 time of RWP
11. Paint the MGS to original color
12. Install recertification nameplate
13. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.9.1 Manual gate valve & HCR gate valve & NRV
Frequency: 1 Yearly, CAT III inspection
Reference: OEM manual / API STD 53 / API 6A
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: In Field Inspection – To be performed by a competent person and all NDT
inspections to be done by an accredited third party.
1. Degrease and pressure clean valves and remove the paints from area to be inspected.
2. Fully disassemble the HP valves and other components.
3. Change all soft seals and bonnet gasket.
4. Visually check all valve components for damage, wear, corrosion, erosion or cracks
including the inside of the valve body, bonnet, handle and stem.
5. Perform MPI/Liquid penetrant on all welds, ring joints (if applicable) and valve seat areas of
the valves.
6. Reassemble the valves using new soft seals and bonnet gasket.
7. Pressure test the valve to RWP.
8. Repaint as valve to original paint.
9. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.9.2 Manual gate valve & HCR gate valve & NRV
Frequency: 5 Yearly, CAT IV inspection
Reference: OEM manual / API STD 53 / API 6A & API Q1/ISO – QMS licensed
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat IV to be performed by a certified API 6A Workshop and all
NDT inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Degrease and pressure clean valves and sand blast the valve.
2. Fully disassemble the HP valves and other components.
3. Change all the valves seals and packing and check for the rising stem condition.
4. Visually check and dimensionally check all valve components for damage, wear,
corrosion, erosion or cracks including the inside of the valve body, bonnet, handle and
stem.
5. Perform MPI/Liquid penetrant on all welds, ring joints (if applicable) and valve seat areas of the
valves.
6. Measure and record all the API flanges, according to API 6A.
7. Reassemble the valves using new seal, O-rings, gates and seats as required.
8. Pressure test the valve; Shell test @ 1.5 times RWP & Seat Test @ RWP.
Note: For Hydraulically operated valves, pressure test the hydraulic circuit to 1.5
times the RWP
9. Repaint as valve to original paint.
10. Grease and preserve ring joints and sealing areas.
11. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.10.1 Hydraulic adjustable chock & Manual adjust chock
Frequency: 1 Years, CAT III inspection
Reference: OEM manual / API STD 53 / API 16C
Responsibility: Rig Manager, Drilling Superintendent

Scope of work of each interval:

Manual Adjustable Choke

1. Retract the choke needle fully
2. Loosen the bleed off plug and check threads
3. Loosen bonnet nut, clean threads and remove bonnet assembly.
4. Clean internal area and ensure sealing area is free from erosion and wear.
5. Fill the cavity with HP grease and reassemble the choke
6. Move the choke to ensure that it is free to operate

Hydraulically Operated choke

1. Open and check actuating mechanism.
2. Grease the remote choke with HP grease

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 Abraj Inspection Manual
Equipment: 8.10.2 Hydraulic adjustable chock & Manual adjust chock
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / API STD 53 / API 16C
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat IV to be performed by a certified API 16C Workshop and all
NDT inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Remove the valve from service

2. Degrease and clean the valve and prepare for sending to workshop
3. Fully disassemble the valves.
4. Visually check and dimensionally check all valve components for damage, wear,
corrosion, erosion or cracks including the inside of the valve body, bonnet, handle and
stem.
5. Perform MPI/Liquid penetrant on all welds, ring joints (if applicable) and valve seat areas of
the valves.
6. Measure and record all the API flanges, according to API 6A.
7. Change all the valves seals and packing.
8. Reassemble the valves using new seal, O‐rings and other seals as recommended.
9. Pressure test the valve; Shell test @ 1.5 times RWP.
Note: For Hydraulically operated valves, pressure test the hydraulic circuit to 1.5 times the
RWP
10. Repaint as valve to original paint.
11. Grease and preserve ring joints and sealing areas.
12. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 8.11.1 RCD Rotating Circulating Device
Frequency: 1 Years, CAT III inspection
Reference: OEM Manual, API 16 RCD
Responsibility: Rig Manager, Drilling Superintendent

Scope of work In Field Inspection – Cat III every years to be performed by a competent person and
all NDT inspections to be done by an accredited third party.

1. Inspect lifting pad eyes/frame/plate (MPI)

2. Inspect all ring grooves for pitting or damage (Visual/MPI)
3. Remove the sleeve and inspect the packing unit and seals for damage or wear. Refer the OEM
manual for Disassembly & Assembly procedure
4. Check the inner body for wear, damage and corrosion.
5. Replace any rubber goods that are damaged or cracked.
6. Check the condition of latching/locking assembly
7. MPI the connecting link of latch/locking assembly.
8. Reassemble the rotating head. Grease or oil all component parts before reassembling preventer

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 Abraj Inspection Manual

Equipment: 8.11.2 RCD Rotating Circulating Device

Frequency: 5 Years, CAT IV inspection
Reference: OEM Manual, API 16 RCD
Responsibility: Rig Manager, Drilling Superintendent

Scope of work: Full Inspection – Cat IV to be performed by a certified API 16 RCD Workshop and
all NDT inspections to be done by an accredited third party, approved by Abraj technical
authority”.

1. Degrease and clean.

2. Full body sand blasting
3. Inspect lifting pad eyes/frame/plate (MPI)
4. Inspect all ring grooves for pitting or damage (Visual/MPI)
5. Inspect connecting link of latch/locking assembly
6. Conduct dimensional inspection of sleeve bore and body bore and other major components
7. Check the inner body for wear, damage and corrosion.
8. Replace all rubber goods with new.
9. Reassemble the rotating head. Grease or oil all component parts before reassembling preventer

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 Abraj Inspection Manual
Equipment: 9.1.1 Fall Arrestor & Emergency Escape Devices
Frequency: 6 Month, CAT III inspection
Reference: API RP 54, ANSI/ASSE Z359.4/ OEM/ BS EN365/AS/NZS 1891.4
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Field Inspection – Cat III (every 6 Months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Remove the arrestor or escape device from the working position.
2. Visually check the device for any damage, corrosion, wear or cracks.
3. Visually check the wire line for any cuts, kinks, corrosion or broken wire.
4. Check that the “Pull line “can be pulled out and retracts fully.
5. Perform MPI on the welds, the mounting brackets and any shackle or swivel.
6. Check the condition and content of the manufacturer’s nameplate.
7. Repaint the items as required.
8. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.1.2 Fall Arrestor & Emergency Escape Devices
Frequency: 1 Years, CAT IV inspection
Reference: API RP 54, ANSI/ASSE Z359.4/ OEM/ BS EN365/AS/NZS 1891.4
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Field Inspection – Cat IV (every 1 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
Complete the six months inspection in addition to the following:
1. Completely disassemble the arrestor and inspect, measure and record the wear of the
critical components as per manufacturer’s manual.
2. Compare measurements with maximum allowable tolerances.
3. Repaint all of the components.
4. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.2.1 Self-Propelled Man lifts
Frequency: 6 Month, CAT III inspection
Reference: OEM manual / ISO 18893:2004
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Cat III (Every 6 Months)“To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Visually check the basket (including railing and floor plate) for any damage, corrosion or
cracks.
2. Remove the paint from the critical welded areas (main frame, floor plate and bottom part of
railing etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on the lifting eye and lifting sling (if applicable).
5. Repaint as required.
6. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.2.2 Self-Propelled Man lifts
Frequency: 5 Years, CAT IV inspection
Reference: OEM manual / ISO 18893:2004
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
CAT IV (Every 5 Years)“To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Complete the full every six months inspection in addition to the following:
2. Fully sandblast the self-propelled man lift basket.
3. Perform wall thickness measurement of the basket frame and floor plate and fixing points
of the railing (minimum three points per meter).
4. Repaint all of the components. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.3.1 Personnel Basket
Frequency: 6 Month, CAT III inspection
Reference: BS EN 14502-1/ ASTM E165 /ASTM E709 PR-1708
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Cat III “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
1. Visually check the basket (including railing and floor plate) for any damage, corrosion or
cracks.
2. Remove the paint from the critical welded areas (main frame, floor plate and bottom part of
railing etc.).
3. Perform MPI on all the critical welds.
4. Perform MPI on the lifting eye and lifting sling (if applicable).
5. Repaint as required.
6. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.3.2 Personnel Basket
Frequency: 4 Years, CAT IV inspection
Reference: BS EN 14502-1/ ASTM E165 /ASTM E709 PR-1708
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Cat VI “To be performed by a competent person and all NDT inspections to be done by an
accredited third party, approved by Abraj technical authority”
1. Complete the full every six months inspection in addition to the following:
2. Fully sandblast the personnel basket.
3. Perform wall thickness measurement of the basket frame and floor plate and fixing points
of the railing (minimum three points per meter).
4. Repaint all of the components.
5. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.4 Gas detection system
Frequency: 6 Month, CAT IV inspection
Reference: OEM manual
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent

Scope of work for each interval:

1. Verify power to monitor is correct

2. Verify power and alarm indicator lights are functioning
3. Verify digital readout is correct.
4. Verify Low & High alarms set points are functioning, with correct values.
5. Check calibration gas expiry date and the span of gas.
6. Check sensors calibration by applying test gas and wait till the reading become stable.
7. Check sensor reading is equal to span of test gas with ±10% tolerance; for example: (for
LEL% we are using 50% , so we should read from 45 to 55%, for H2S we are using 25 PPM, so
we should read from 23 to 27 PPM.
8. Verify that sensors are clean and not contaminated
9. Verify correct operation of unit by applying span gas to each sensor
10. Verify alarm sirens and strobe lights are functioning
11. Perform all calibration and inspection procedure by certified third party technician
12. Prepare and submit calibration certificate

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 Abraj Inspection Manual
Equipment: 9.5 BA Compressor
Frequency: 1 Year, CAT III inspection
Reference: OEM, API RP 49
Responsibility: Chief Mechanic, Mechanical PME

Scope of work for each interval:

Field Inspection – Cat III (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Change Air purification filter cartridge
2. Change Air intake filter element
3. Change Compressor oil
4. Service/inspection water & oil separator
5. Service/inspection automatic condensate drain system
6. Inspect 0ressure maintaining valve
7. Inspect non return valve
8. Inspect drive belts
9. Inspect pressure gauges for filling device
10. Check all electric solenoid valves plugs
11. Check all safety valves, intermediate pressure 2nd,3rd stages
12. Check final pressure safety relief valve for compressor
13. Inspect Inter and after coolers are not obstructed
14. Check all external nuts and bolts for correct tightness
15. Inspect 3rd stage temperature sensor
16. Visually inspect the complete system
17. Check operation of Auto condensate drain valves
18. Test run compressor
19. Check for any oil and air leaks
20. Cary out air purity test and issue certificate

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 Abraj Inspection Manual

Equipment: 9.6.1 Breathing Air Cylinders Steel

Frequency: 1 Years, CAT III inspection
Reference: NFPA 1852 & DOT
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:

1. Verify date stamped on all the bottles: it is mandatory that hydraulic pressure testing of
each bottle including main overhaul of its reducing valve have to be performed by
certified workshop before expiry
2. Inspect the external condition of the bottles, if dents or other kind of damage is found,
the bottle(s) must be removed from service and pressure released, bottle(s) are to be sent
to a certified workshop for repair/inspection
3. Inspect the bottle valves for condition and leaks

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 Abraj Inspection Manual

Equipment: 9.6.2 Breathing Air Cylinders Steel

Frequency: 5 Years, CAT IV inspection
Reference: NFPA 1852 & DOT
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Remove the cylinders from service.
2. Perform complete hydro-test as per manufacturer’s specifications.
3. Stamp new expiry date on the cylinders.
4. The service life of metal cylinder is determined at time of requalification
5. Prepare and submit the inspection report
Note 1: the SCBA cylinder testing company / inspectors shall have their own individually
licensed copies of the relevant CGA (compressed gas association) documents
needed to carry out the cylinder inspections that the testing company offers.

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 Abraj Inspection Manual
Equipment: 9.7.1 Breathing Air Cylinders Fiber Glass
Frequency: 1 Years, CAT III inspection
Reference: NFPA 1852 & DOT
Responsibility: Rig Manager, Drilling Superintendent,

Scope of work for each interval:

1. Verify date stamped on all the bottles: it is mandatory that hydraulic pressure testing of
each bottle including main overhaul of its reducing valve have to be performed by
certified workshop before expiry
2. Inspect the external condition of the bottles, if dents or other kind of damage is found,
the bottle(s) must be removed from service and pressure released, bottle(s) are to be sent
to a certified workshop for repair/inspection
3. Inspect the bottle valves for condition and leaks

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 Abraj Inspection Manual
Equipment: 9.7.2 Breathing Air Cylinders Fiber Glass
Frequency: 3 Years, CAT IV inspection
Reference: NFPA 1852 & DOT
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Remove the cylinders from service.

2. Perform complete hydro-test as per manufacturer’s specifications.
3. Stamp new expiry date on the cylinders.
4. Maximum life service of fiberglass cylinders is 15 years
5. Prepare and submit the inspection report
Note 1: The SCBA cylinder testing company / inspectors shall have their own
individually licensed copies of the relevant CGA (Compressed Gas Association)
documents needed to carry out the cylinder inspections that the testing company
offers.

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 Abraj Inspection Manual
Equipment: 9.8.1 Fire Extinguishers
Frequency: 6 Month, CAT III inspection
Reference: NFPA 10, MD 286
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:

1. Replace temper seal on all fire extinguishers

2. Replace metal tag after inspection of all fire extinguishers at rig & camp.
3. Replace Discharge hose assembly if required during inspection of fire extinguishers
4. Vendor responsible for Painting of fire extinguishers at rig & camp.
5. Technician attaining calibration job at rig should have valid & approved H2S card.
6. Maintain the record of inspection of fire extinguishers in rigs and submit the original
calibration certificate & updated log book

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 Abraj Inspection Manual
Equipment: 9.8.2 Fire Extinguishers
Frequency: 5 Years, CAT IV inspection
Reference: NFPA 10, MD 286
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

1. Verify extinguishers properly mounted and accessible

2. Verify charge pressure and handle lock and seal installed properly.
3. Verify powder level correct, dry and not compacted
4. Verify discharge hose and nozzle in good condition and not plugged with powder.
5. Verify the external condition of the extinguisher body for dents, punches, cracks or damage.
6. Perform hydrostatic pressure test to the factory testing pressure and as per the
procedures of the NFPA 10 requirements.
7. Where this may not be feasible for reasons of logistics or costs, replace the fire
extinguishers with new ones. For below list, do not send for hydro test, discard and place
a new purchase instead:

1 DCP 2KG
2 4.5 KG DCP
3 6 KG DCP
4 9 KG DCP
5 12 kg DCP
6 6 LITER FOAM
7 9 LITR FOAM
8 6 LITER WATER
9 9 LITER WATER

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 Abraj Inspection Manual

Equipment: 9.9 Diesel / Electric Fire Pump

Frequency: 6 Months, CAT III inspection
Reference: OEM manual/ NFPA 25
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

1. Monitor for abnormal noise.

2. Check fuel tank/ level ( make sure fuel tank is ¾ full)
3. Check all hoses, fuel lines, and cooling line connections for any leakage and to ensure they are
in a good condition.
4. Change the coolant
5. Check crankcase vent system
6. Change engine oil
7. Change fuel & oil filters
8. Check all foundation bolts.
9. Clean air cleaner
10. Clean fuel tank.
11. Perform no flow test, diesel engine driven pump at least for 10 minutes.

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 Abraj Inspection Manual
Equipment: 9.10.1 Man Riding Winch
Frequency: 1 Year, CAT III inspection
Reference: OEM manual/ ASME B30.07, ASME B30.23, API RP 54
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Field Inspection CAT III (every 1 year) By a Qualified Inspector: To be performed by a competent
person and all NDT inspections to be done by an accredited third party, approved by Abraj
technical authority”
1. Isolate the winch by shutting off the air, unwind the winch line from the drum and inspect
the line visually for any kinks, broken wires and other damage.
2. Remove the winch from the foundation plate or mounting brackets.
3. Disassemble the complete winch including drive components.
4. Visually check all outside parts of the winch (including the spooling device and control
valves) for proper installation and any damage or wear.
5. Visually check and MPI the brake band components and mechanism for wear or damage.
6. Perform MPI and visual inspection on winch connecting points to the mounting bracket or
plate, bolts, clamp area etc. and on all main components as per manufacturer’s
recommendation.
7. Check condition and details of the manufacturer’s name plate.
8. Repaint the winch (including the SWL marking) as required.
9. Reinstall the winch.
10. Carry out load test, Load testing to be performed annually at a proof load of 1.25x SWL.
11. Prepare and submit the inspection report.

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 Abraj Inspection Manual
Equipment: 9.10.2 Man Riding Winch
Frequency: 3 Year, CAT IV inspection
Reference: OEM manual/ ASME B30.07, ASME B30.23, API RP 54
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work for each interval:

1. Examine the gears for worn, cracked, or broken teeth. Replace if necessary.
2. Examine the bushings for wear, scoring or galling. Replace if necessary.
3. Examine the shafts for ridges caused by wear. If you can see ridges on the shafts, replace the
shaft. Do an inspection for scoring or galling.
4. Examine all threaded parts and replace the parts with damaged threads.
5. Examine drum band brake lining for oil, grease and glazing.
a. If band brake lining is oil soaked greasy or glazed, replace the brake band.
b. Remove small glazed areas of band brake lining by sanding lightly with a fine grit
emery cloth.
c. Measure the thickness of drum band brake lining. If drum brake band lining is less than
0.062 inch (2 mm) thick anywhere along edges, replace the brake band assembly.
6. Do an inspection of the motor housing gear bores for wear or scoring. Replace the motor
housing if you see scratches or the wear pattern is not equal.
7. Examine the motor gears for:
a. Ridges or more grooving on outside diameter of gears.
b. Contact between gears and gear housing.
8. Examine slack wire device for:
a. Wear, grooves or scoring of rollers. Replace if necessary.
b. Free turn. Rollers must operate without binding and without more side-to-side play.
9. Examine bearings for:
a. Loss of grease, and grit, dirt or other contaminants. All motor bearings are factory
lubricated and sealed. If dry or contaminated, replace the bearing.
b. Damage. Do an inspection of the roller bearings (needle). If the bearings are damaged
or you see any contamination, replace the bearings.
10. Examine the disc brake for:
a. Wear, Replace the brake discs if you do not see the grooving pattern or if discs are
cracked or chipped.
b. Thickness of disc. If it is less than 0.047 in (1.2 mm), replace.
11. Load testing to be performed at a proof load of 1.25x SWL.

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 Abraj Inspection Manual
Equipment: 10.1.1 AC Generator
Frequency: 1 Year , CAT III inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work:

1. Visually inspect the generator for any damage or abnormalities.

2. Clean generator filters and all windings by dry compressed air
3. Inspect all windings thoroughly for any signs of damage or overheat.
4. Inspect rotating rectifier bridge for any abnormalities
5. Inspect power and control cables for any signs of damage or overheat.
6. Grease the drive end and the non-drive end bearing as per manufacturer specification (Refer
to the OEM manual for amount and frequency).
7. Inspect engine control panel & sensors wiring and connectors.
8. Inspect the space heaters and verify their functionality.
9. Inspect & tighten all power and control cables
10. Measure and record all windings resistance and insulation resistance
11. Measure rotating bridge rectifiers and confirm readings are within range.
12. Measure exciter air gap and ensure it is in range, as per OEM recommendations.
13. When Generator completes 5 Years in operation and still not reached 40,000 Hrs to be
major overhauled, the below evaluation is required:
a. Do Run out test on DE & NDE shafts and ensure it is not exceeding 5 Thou
b. Measure the temperature of DE & NDE bearings and bearing housings, and
ensure it is not exceeding 90C
14. IF all readings are in range, continue using the generator till major overhaul due hours
15. Evaluation to be done on yearly basis (after 5 years) till major overhaul due hours
16. IF any reading are out of range, inform H.O. to plan for major overhaul.

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 Abraj Inspection Manual
Equipment: 10.1.2 AC Generator
Frequency: 40,000 Hrs , CAT IV inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.
Scope of work:
Full Inspection–Cat IV (every 40,000 Hrs): To be performed by a competent person accredited third
party, approved by Abraj technical authority”.
1. Complete overhaul of the generator as per the minimum scope of work, the job will be
carried out by external source.
2. Inspect all generator components for damage and abnormalities.
3. Conduct MPI on Generator foundation, lifting pads, rotor shaft and bearing housing.
4. Record all coils windings resistance and insulation resistance.
5. Perform Surge test on stator windings (1720V/50HZ 1 Minute).
6. Measure turn-to-turn insulation of main stator winding by pulse (3600V FOR 1 Minute for
each winding).
7. Rewind the windings if any of above test failed, as per OEM standards
8. Inspect, steam clean, bake & varnish all windings to insulation class H.
9. Dynamically balance main rotor to Quality Grade 2.5 or better
10. Inspect bearing housings for crack or wear, Repair & machine if required
11. Replace all bearings and seals
12. Inspect & service Diode assembly, lead cables, terminal box and space heater, replace any
if required.
13. Carry out Static test on all windings & no load run test.
14. Assemble and paint with the initial color.

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 Abraj Inspection Manual
Equipment: 10.2 Circuit Breakers
Frequency: 5 Year , CAT IV inspection
Reference: IEC 60947-2, IEEE STD 902 , NETA ,OEM
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.
Scope of work for each interval:
This standard will be applicable to all drilling rigs, new rigs and under commissioning stacked rigs and
is inclusive but not limited to SCR/VFD circuit breakers, transformers and MCC feeders at all sites.

1- Preparation should be made to ensure that all documentation are ready like the manufacturers
literature and recommendation, TRA, PTW and electrical isolation, lock out/tag out system.
2- Ensure that all circuit breaker receives no electrical power and that all loads are disconnected
electrically and mechanically.
3- Testing of circuit breakers (Primary Injection Test / Secondary Test)
a. The circuit breaker should be removed from the equipment for this test. In cases where the
Circuit Breaker can be safely isolated as installed, the test may be performed with the circuit
breaker in its equipment.
b. Inspect the breakers physically and check conditions of connections.
c. Set up the test unit for insulation resistance test.
d. Set up the test unit for primary injection test.
e. Test the unit by injecting current at 150, 300 and 600 %.
f. For every setting, record the value of tripping time and then compare it to the manufacturer’s
current time characteristics.
g. If the tripping time is not within the manufacturer’s specified limits as indicated by the time
current curve, then it should be defective or latching device may be damaged.
h. If the tripping time is within the limits, then the units should be returned and ensure that all
termination was OK.
Guidelines
1- Insulation Resistance Test: Apply 500VDC line and load terminals with the circuit breaker in OFF
position and tripped position. Between phases of the breakers and phases to ground with the
circuit breaker in ON position. All reading should be one megohm or greater for each
measurement. Values below 1 megohm are considered unsafe hence breaker should be
inspected for possible contamination on its surfaces, flawed or cracked insulating material.

2- Millivolt Drop Test: It can disclose some abnormal conditions such as eroded contacts,
contaminated and or loose connections. Millivolt should be compared against manufacturer’s
data. Use a 24 Volt or less DC power supply capable of supplying rated circuit breaker current.
a. Apply a test current for not more than 1 minute across a pole equal to the breaker rating or
500 amp minimum for breaker in excess of 500 amperes. Record the mv drop and test
current.
b. Repeat for a total of three readings on the pole being tested.

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3- Tripping Test for Electro-Mechanical Type

a. Instantaneous current trip settings – to verify protection against short circuit

b. Overload current trip settings – to verify protection against overloading of the system

4- Trip Test for Solid State Type

a. Long delay current trip settings

b. Long delay time trip settings
c. Short delay current trip settings
d. Short delay time trip settings
e. Instantaneous current trip settings
f. Ground current trip settings
g. Ground delay time trip setting

5- Manufacturer’s recommendation and current time characteristics curve should always be

consulted for each unit.
6- All test equipment should comply with IEC 60947-2 standard, IEEE43-2000 and IEEE 1458-2005.
7- All circuit breaker within a range of 1000Amp to 2000 Amp, should be identified and will be
scheduled to have the test done as stated in the procedure below.
8- All works will be carried out safely. Particular attention is drawn for below requirements.
TRA – Task Risk Assessment:
a. PTW – Permit to Work.
b. Electrical Isolation and lock out/tag out system.

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Equipment: 10.3 Fuel Tanks
Frequency: 10 Year , CAT IV inspection
Reference: STI SP001, API RP 653
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.
Scope of work for each interval:
Full Inspection – Cat IV (every 10 Years): To be performed by a competent person and all NDT inspections
to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Fuel/Mud tanks under inspection, it
must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Nameplate.
3. Empty the fuel tank completely and flush inside with water based cleaner.
4. Sand or grit blast the tank outside.
5. Visually check the tank and any associated piping for any damage, corrosion or cracks.
6. Measure and record the wall thickness of the tank (15 points per 12 Inches x 12 Inches square area)
including the pedestals and skid.( minimum values are highlighted in the below guidelines
Note: The following step requires compliance with all Abraj Confined Space Entry Rules!
7. Open the tank manhole and inspect the tank inside for any corrosion or cracks.
8. Perform MPI/Liquid Penetrant on all critical areas (welded seams, pedestal and skid front ends etc.)
9. Leak Test (If required) as per the below guidelines.
10. Repaint all of the components.
11. Prepare and submit the inspection report.

General Inspection Guidelines

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Minimum Shell Thickness

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Equipment: 11.1.1 Eddy current brake

Frequency: 1 Year , CAT III inspection
Reference: OEM manual
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent, Rig Manager, Drilling
Superintendent

Scope of work:
1. Visually inspect the bake for any damage or abnormality.
2. Measure and record all coils winding resistance & insulation resistance.
3. Inspect the termination junction box and ensure the ex-integrity.
4. Inspect the brake power & control cables.
5. Open and service all power and control plugs and sockets.
6. Inspect & clean brake magnet breathers (two on each side).
7. Inspect cooling water overflow vent and ensure it is clear of any obstruction.
8. Measure the brake air gap between magnet and drum.
9. The final air gap reading should be average of four readings with 90 degree difference.
10. Inspect the brake alarm system components (flow switches, temperature switch, control & alarm
panel) and ensure that all are in good condition.
11. Perform brake efficiency test as per OEM efficiency calculation sheet.
12. Check alignment of the brake with drawworks to be within TIR 0.010”, if it exceeds, perform
alignment to achieve acceptable range.

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Equipment: 11.1.2 Eddy current brake
Frequency: 5 Year , CAT IV inspection
Reference: OEM manual
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent, Rig Manager,
Drilling Superintendent

Scope of work
Full Inspection –Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Complete overhaul of the brake as per the minimum scope of work, the job will be
carried out by external source.
2. Inspect all brake components for damage, cracks or any abnormalities.
3. Grit Blast and prime all brake components.
4. Conduct MPI on foundations
5. Record brake coils winding resistance & insulation resistance, and repair / replace coils
if required.
6. Record Drum and magnets Dimensions before and after grit blast, Weld & machine
them to size as per OEM standards if required.
7. Replace all Bearings & seals.
8. Inspect bearing housings for crack or wear, Repair & machine if required.
9. Supply and fit new coil breathers.
10. Re-assemble & paint the brake.
11. Ensure to maintain air gap in range as per OEM standards after assembling.

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Equipment: 11.2.1 AC Traction Motors (MP-DW)

Frequency: 1 Year , CAT III inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work of each interval:

1. Visually inspect motor for any damage or abnormalities.

2. Inspect all motor connectors, cables & terminals with infrared thermometer
3. Inspect motor while running for unusual noise or vibration.
4. Check motor bearings temperature and ensure it is not exceeding 55C
5. Check stator and rotor temperature with thermometer and compare reading with ABB HMI.
Maximum stator temperature 155C, maximum rotor temperature 195C
6. Check motor mounting bolts for tightness.
7. Inspect motor junction box , Check & retighten all electrical connection
8. Inspect motor RTD resistance & the interlock system.
9. Inspect ESD switch and ensure proper condition & function
10. Inspect motor pressure switch and ensure proper condition & function
11. Inspect and Clean the encoder and its connections
12. Using oscilloscope check the encoder signal to VFD house
13. Measure and record the motor winding resistance and insulation resistance.
14. The minimum reading should be 2 Mega ohms.
15. Inspect space heater and ensure proper condition & function
16. Check motor shaft alignment with the driving unit (MP/DW)

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Equipment: 11.2.2 AC Traction Motors (MP-DW)

Frequency: 7 Year , CAT IV inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work of each interval:

Full Inspection –Cat IV (every 7 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Complete overhaul of the traction motor as per the minimum scope of work, the job will be
carried out by external source.
2. Inspect all motor components for damage or any abnormalities
3. Conduct MPI on Motor foundations, lifting pads, rotor shaft, bearing housing and end
shields.
4. Record motor stator winding resistance & insulation resistance.
5. Perform Surge test on stator windings (1720V/50HZ 1 Minute).
6. Measure turn-to-turn insulation of stator winding by pulse (3600V FOR 1 Minute for each
winding).
7. Rewind stator windings if any of above test failed, as per motor OEM standards.
8. Steam clean, bake and re-varnish stator windings.
9. Inspect bearing housings for crack or wear, Repair & machine if required
10. Dynamically balance motor to quality grade 2.5 or better.
11. Replace all bearings & seals.
12. Carry out Static & no load run tests.
13. Assemble and paint with the initial color.

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Equipment: 11.3.1 DC Traction Motors (MP-DW)

Frequency: 1 Year , CAT III inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work of each interval:

1. Visually inspect the motor for any damage or abnormality.

2. Inspect carbon brushes, Replace if length below (28 mm) and ensure free movement inside
holder
3. Check condition of brush holder and spring tension.
4. Measure brush holder clearance to commutator (range 1/16” to 3/32”)
5. Inspect commutator thoroughly and ensure in good condition.
6. Check commutator bars for any damage, flashover or arcs.
7. Check commutator mica depth and record it (should be about 0.047”)
8. Inspect motor space heater and ensure proper condition & function.
9. Blow motor interior by clean dry compressed air (max. press. 70 psi)
10. Inspect motor junction box , Check & retighten all electrical connection
11. Measure and record the motor winding resistance and insulation resistance.
12. Check lockout switch and pressure switch are operational.
13. Clean spark arrestors screen and ensure proper airflow.
14. Check tightness of foundation bolts.
15. Check condition of covers seals and gaskets.
16. Check condition of power cables, ground cables, plugs and receptacles.
17. While motor is in operation, check for any noise, vibration or overheat.

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Equipment: 11.3.2 DC Traction Motors (MP-DW)

Frequency: 7 Year , CAT IV inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work of each interval:

Full Inspection –Cat IV (every 7 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.

1. Inspect all motor components for damage or any abnormalities.

2. Conduct MPI on Motor foundations, lifting pads, rotor shaft, bearing housing and end shields.
3. Grit blast frame internally and externally
4. Record motor stator, interpoles & rotor windings resistance & insulation resistance.
5. Perform Surge test on stator windings (1720V/50HZ 1 Minute)
6. Inspect, steam clean, bake & varnish all windings to insulation class H.
7. Skim and undercut commutator.
8. Replace all Nomex 410 insulations
9. Apply anti-tracking varnish to all exposed metal surfaces.
10. Dynamically balance armature to Quality Grade 2.5 or better
11. Replace all carbon brushes and brush holders
12. Replace A1, A2 & S1, S2 Cable.
13. Inspect bearing housings for crack or wear, Repair & machine if required
14. Replace all bearings and seals
15. Inspect & service cut out switch, pressure switch and space heater, replace if required.
16. Carry out Static & no load run tests.
17. Assemble and paint with the initial color.

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Equipment: 11.4.1 TDS AC Traction Motor

Frequency: 1 Year , CAT III inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work of each interval:

1. Visually inspect motor for any damage or abnormalities.

2. Grease the motor bearings as per OEM manual instructions, and never over lubricate the
motors.
3. Measure and record the motor winding resistance and insulation resistance
4. Inspect motor junction box, check & retighten all electrical connection.
5. Inspect space heater and ensure proper condition & function.
6. Inspect all motor connectors, cables & terminals with infrared thermometer
7. Tighten terminals for instrument j-box and aux motor j-box
8. Perform function test with the driller for all robotic functions and report any deficiencies.
9. Inspect power and control service loops, ensure it is free from damage and moving part is
away from mast beams or any other obstacles.
10. Ensure service loop jackets are installed and covering the loop properly to protect from
scratches and outer damages.

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Equipment: 11.4.2 TDS AC Traction Motor
Frequency: 5 Year , CAT IV inspection
Reference: Best practices. Abraj Internal standard
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.
Scope of work:
Full Inspection –Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
11. Complete overhaul of the traction motor as per the minimum scope of work, the job will be
carried out by external source.
12. Inspect all motor components for damage or any abnormalities
13. Conduct MPI on Motor foundations, lifting pads, rotor shaft, bearing housing and end shields.
14. Record motor stator winding resistance & insulation resistance.
15. Perform Surge test on stator windings (1720V/50HZ 1 Minute).
16. Measure turn-to-turn insulation of stator winding by pulse (3600V FOR 1 Minute for each
winding).
17. Rewind stator windings if any of above test failed, as per motor OEM standards.
18. Steam clean, bake and re-varnish stator windings.
19. Inspect bearing housings for crack or wear, Repair & machine if required
20. Dynamically balance motor to quality grade 2.5 or better.
21. Replace all bearings & seals.
22. Carry out Static & no load run tests.
23. Assemble and paint with the initial color.

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Equipment: 11.5 Ex (d) & Ex(e) Systems
Frequency: 3 Years, CAT IV inspection
Reference: IEC 60079-17
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work for each interval:

1.1 Definitions:
1.1.1 Visual inspection – A visual inspection is an inspection which identifies, without the use of
access equipment or tools, those defects, e.g. missing bolts, which are apparent to the eye.

1.1.2 Close inspection – A close inspection is an inspection which encompasses those aspects covered
by a visual inspection and, in addition, identifies those defects, e.g. loose bolts, which will
become apparent only when access equipment, e.g. steps (where necessary) and tools are used.
Close inspections do not normally require the enclosure to be opened or the equipment to be de
energized.

1.1.3 Detailed Inspection – A detailed inspection is an inspection which encompasses those aspects
covered by a close inspection and, in addition, identifies those defects, e.g. loose terminations,
which only become apparent when the enclosure is opened up, or by the use of tools and test
equipment.

1.1.4 CompEx – (meaning Competency in Ex atmospheres) is a global certification scheme for electrical
and mechanical crafts persons and designers working in potentially explosive atmospheres.
The scheme is accredited by UKAS to ISO/IEC 17024. The scheme is broken down to twelve units
covering different actions and hazardous area concepts

1.2 “Close/Visual” Inspection (3 years)

a. Review the rigs hazardous area layout drawings. If the drawings are inaccurate or missing,
note deficiency on the report and notify the Technical Operations.
b. Verify all electrical equipment and their connection system installed in Zone 1 or Zone 2 areas
are rated for the area they are located.
c. Inspect the equipment ensuring junction boxes, glands, cables, etc are in good condition and
that all bolts are fitted.
1.3 Update the rig Ex register and any deficiencies are reported and acted upon,
1.4 In case of any major deficiencies detected during the Close/visual inspection; a “detailed”
Inspection shall be implemented by a qualified CompEx inspector:
a. Review the rigs hazardous area layout drawings. If the drawings are inaccurate or missing
Note deficiency on the report and notify the Technical Operations.
b. Verify all electrical equipment and their connection system installed in Zone 1 or Zone 2 areas
are rated for the area they are located.
c. Inspect and verify the installation of the air ventilation systems in the drillers control,
instrument panels and the air cooling systems of the DC motors for the drawworks, top drive

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system and rotary table (if applicable). Open all enclosures and ensure terminations are
correct.
d. Update the rig Ex register and any deficiencies are reported and acted upon.
e. Prepare and submit the inspection report.

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Equipment: 11.6 Thermography Inspection
Frequency: 1 Years, CAT IV inspection
Reference: ASTM E1934 - 99a, NFPA 70B, ISO 18251-1
Responsibility: Chief Electrician, Electrical PME, Electrical Superintendent.

Scope of work for each interval:

1. The scan readings should be with live circuit under load condition. Thermography, also called
infrared inspection, is based upon the sensing of heat emitted from the surface of an object in
the form of infrared radiation
2. High resistance in circuits causes an increase in current flow. When current flow is increased,
the resulting power consumption will increase.
3. Further, high current draw can cause critical electrical circuit components, such as fuses,
circuit breakers, and transformers, to fail prematurely. These failures result in higher
maintenance and repair costs, and resultant business interruptions.
4. The Electrical Equipment’s should have a thermographic scan performed at least annually on
critical systems, such as circuit panels, switchgears, and transformers.
5. It is mandatory to do the Thermographic survey prior and after to the Rig Annual Maintenance.
6. Carry out first Thermographic Survey prior to Annual Maintenance when the rig is operating at
full load to scan all the potential points and get the preliminary report.
7. Rectify the Scan observations based on first thermographic survey during annual Maintenance.
8. Carry out second thermographic survey after the annual Maintenance when rig in operation on
load. It is a confirmation that the observations rectified.
9. Create the report with the comparison of the observation points (Before & After) to show the
observations rectified.
10. Complete the Yearly Maintenance work order (in SAP) with Thermographic report attached.
 Benefits of Thermographic Inspection
a) Equipment life can be extended
b) Plant downtime may be reduced
c) Plant reliability may be increased
d) Plant repairs scheduled for the most convenient time
e) Quality of repair work may be inspected

Equipment: 12.1.1 Air Pressure Vessel

Frequency: 2 Yearly, CAT III inspection

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Reference: API 510 / RP 572 / RP 576 ASME VIII
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig Manager,
Drilling Superintendent

Scope of work of each interval:

Full Inspection–Cat III (every 2 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Air Tanks under inspection, it
must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Nameplate.
3. Visually check all nozzles and associated piping/fittings for any visible defects.
4. Measure and document the wall thickness of the vessel body (minimum 6 points per square
meter), paying particular attention to areas where water can gather. Following the below
guidelines for the minimum wall thickness limits.
5. Perform MPI on critical weld joints (connections and nozzles)
6. Prepare and submit the inspection report which is to include determination of corrosion rate
where previous readings are available.
7. Ensure that the SWP is clearly visible on the external of the vessel.

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General Inspection Guidelines and Ex for minimum thickness calculations

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Equipment: 12.1.2 Air Pressure Vessel

Frequency: 5 Yearly, CAT IV inspection
Reference: API 510 / RP 572 / RP 576 ASME VIII
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent, Rig
Manager, Drilling Superintendent

Scope of work:
Full Inspection–Cat IV (every 5 Years): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Air Tanks under inspection, it
must be used as the main guideline in all the following steps.
2. Check the Serial No. and Manufacturer’s Nameplate.
3. Release the pressure from the vessel and disconnect all lines, valves and gauges etc.
4. Open the inspection hole of the vessel.
5. Visually check the vessel for any damage, corrosion or wear.
6. Visually check all nozzles and associated piping/fittings for any visible defects.
7. Measure and document the wall thickness of the vessel body (minimum 6 points per square
meter), paying particular attention to areas where water can gather following the below
guidelines for the minimum wall thickness limits.
8. Perform MPI on critical weld joints (connections and nozzles)
9. Prepare and submit the inspection report which is to include determination of corrosion rate
where previous readings are available.
10. Where deemed necessary by the inspector, a hydrostatic pressure test may be required to
1.5 the rated working pressure.
11. The test medium should be water and special consideration should be given to the
supporting structure and foundation design.
12. Ensure that the SWP is clearly visible on the external of the vessel.

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General Inspection Guidelines and Ex for minimum thickness calculations

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Equipment: 12.2 Air Pressure Relief Valves
Frequency: 1 Yearly, CAT III inspection
Reference: OEM, API 510/RP572/RP576/ASME VIII
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent.

Scope of work of each interval:

Full Inspection–Cat III (every 1 Year): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”.
1. Prepare and make ready the OEM Manual and drawings of the Safety Valve under
inspection, it must be used as the main guideline in all the following steps.
2. Release the pressure from the vessel.
3. Remove the air pressure Safety valve.
4. Visually check the safety valve for any damage, corrosion or wear.
5. Visually check the inlet and outlet piping for signs of deposits.
6. Test the safety valve to ensure that it relieves at the set pressure stated using a certified
monitoring gauge.
7. Repaint and stamp new inspection date in stainless steel ring.
8. Check the condition and content of the manufacturer’s nameplate.
9. Prepare and submit a certification certificate.

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Equipment: 13.1 Forklift Forks & Forklift Fork Support

Frequency: 6 months , CAT III inspection
Reference: OEM manual / ANSI /ITSDF B56.6 / OEM
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Rig Manager,
Drilling Superintendent
Scope of work for each interval:
CAT III (Every 6 months) “To be performed by a competent person and all NDT inspections to be
done by an accredited third party, approved by Abraj technical authority”
1. Disassemble the support frame from the forklift as much as possible.
2. Visually check the forks and support for any damage, bends, corrosion or wear.
3. Measure the angle of the forks. The fork should be withdrawn from the service if the deviation
was 3 degrees greater or less of 90o (or as per the OEM recommendations) between the blade
and the shank.
4. Perform MPI on the fork arm, forks (critical areas) and attachments/brackets of the forklift
support.
Special attention shall be paid to the heel and the top and bottom hooks including their
attachment to the shank.
5. Thoroughly measure the wear on fork arm blade and shank; if the thickness of the blade or
shank is reduced to 90 % of the original thickness, or to the minimum thickness specified by
OEM, the fork arm shall be withdrawn from service. A set of fork arms shall be checked for any
difference in height when mounted on the fork carrier. If the difference in tip heights exceeds 3
% of the blade length or that recommended by OEM, the set of fork arms shall be withdrawn from
service.
6. Check the safety chain between forks and fork support (if applicable) for damage or wear.
7. Check the bore of the shaft/pin type forks. Wear limit should not be more than 10 % of the
original bore or as per OEM recommendations.
8. Check for loose items (bolts, pins etc.)
9. Check the hydraulic lifting components for any damage or leakage.
10. Repaint as required.
11. Prepare and submit the inspection report.

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Equipment: 14.1 Trailer King Pins
Frequency: 6 months , CAT III inspection
Reference: OEM/ SAE J2228/ ASTM E165 /ASTM E709
Responsibility: Rig Manager, Drilling Superintendent
Scope of work for each interval:
Field Inspection – Cat III (every 6 months): To be performed by a competent person and all NDT
inspections to be done by an accredited third party, approved by Abraj technical authority”
1. Visually check the king pin, fifth wheel and mounting frame and bolts for any damage,
cracks, corrosion or wear.
2. Measure dimensions of king pin and compare with the specified wear tolerances
from the manufacturer. King pin gauge maybe used to evaluate wear
3. For Bolted kingpins, check all bolts for wear and tightness
4. Perform MPI on the king pin (retention plate and skid plate welding), fifth wheel and
related mounting brackets.
5. Verify the flatness of skid plate in all direction
6. Check Skid plate for cracks, Signs of pitting, deep grooves, or unusual wear
7. Grease the items as required.
8. Prepare and submit the inspection report.

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Equipment: 14.2 Rig Instrumentation and gauges

Frequency: 1 Year , CAT IV inspection
Reference: OEM manual
Responsibility: Chief Mechanic, Mechanical PME, Mechanical Superintendent. Chief Electrician,
Electrical PME, Electrical Superintendent.
Scope of work for each interval:
Cat IV Every 1 year to be performed by a competent person and accredited third party, approved by
Abraj technical authority”.
1- Visually check the instruments for any damage, corrosion or leaks.
2- Check condition and content of the OEM’s name plates for necessary information
3- Visually check the installation of the instruments for proper mounting of brackets, piping, hoses,
fittings etc.
4- Inspect service and carry out function tests of the instruments as per OEM’s instructions.
5- Recalibrate in accordance with OEM’s requirements and apply calibration tag.
6- Mark the instruments with new/updated inspection signs/ stickers.
7- Prepare and submit the inspection report.

1. Definition of Critical Gauges and Instrumentation

Critical gauges and instrumentation are defined as those that could have a detrimental effect on the rig
operations or can cause unsafe situations, in the event of their failure or incorrect use. As a minimum,
the following gauges and instruments are deemed critical and will be covered in this policy.
1.1 Drill Floor
a. Hook weight load cell and gauge
b. Manual tong torque load cell and gauge
c. Rotary table torque indicator package
d. Top drive torque indicator package

1.2 High Pressure Mud System

e. Manual pressure gauge – pump discharge
f. Manual pressure gauge – stand pipe manifold
g. Hydrostatic / electronic stand pipe manifold pressure transducer(s) and gauge

1.3 BOP and Choke Manifold Equipment

1.3.1 Closing unit

i. Annular pressure gauge
ii. Manifold pressure gauge

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iii. Accumulator pressure gauge
1.3.2 Remote Panel (Rig Floor)
i. Annular pressure gauge
ii. Manifold pressure gauge
iii. Accumulator pressure gauge
iv. Rig air pressure gauge
1.3.3 Choke and Choke Control Panel
i. Casing shut in pressure – panel display
ii. Drill pipe shut in pressure – panel display
iii. Hydraulic choke position indicator
iv. Manual gauge at choke manifold

1.4 Mud Tank Level Sensors

a. Trip tank and stripping tank (if applicable) level sensors
b. Suction tank level sensors
c. Intermediate tank level sensors
d. Reserve tank(s) level sensor(s)
e. Flow indicator sensor. (Flo-show)
1.5 Tools
a. All electric meters including digital/analogue multi meters, meggers, frequency
meters, etc.
b. Torque wrenches

2. Technical Guidelines:
2.1 Repair and Replacement :
Any critical instrument or gauge that is found to be out of calibration or defective will be replaced.
The faulty equipment will be returned to an approved repair facility for recalibration or replaced
with new, as economically viable. Repair/ replacement will be recorded on the Critical
Instrumentation Calibration Log.
2.2 Verification Procedures
2.2.1 Drill Floor
2.2.1.1 Hook Weight Indicator and Load Cell:
Option 1: Verify accuracy of the system by hanging a known value weight from the hook at
a predetermined height in the mast. (IE: Top Drive, drill collars, etc.)
Option 2: Verify the accuracy of the system by using a hydraulic hand pump to pressurize
the system from zero to the rated pressure as stated on the back of the weight indicator for
a full sweep test.
2.2.1.2 Manual Tong Torque Load Cell and Gauge Verify the accuracy of the tong torque display as
follows:
Option 1: ‘Line pull’ type gauge display.

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1. Using a drill collar or similar known weight item, hook the load cell in line with the floor tugger to
the weight item with acceptable nubbins or lifting fixture.
2. Raise the weight item so it is fully supported by the floor winch.
3. Ensure that the gauge reading is identical to the known weight of the hoisted equipment.
Option 2: ‘Tong Torque’ type gauge display.
1. Follow steps 1 and 2 as above.
Note: Normally, this type of gauge is calibrated to display a ft-lb display taking the lever arm of
the tong into consideration.
2. Multiply the weight of the known item by the length of tong as displayed on the gauge readout (ie:
12,000lbs X 3ft = 36,000 ft-lbs).
3. Ensure the gauge readout, after the necessary calculations are completed, is identical to the
known weight of the hoisted equipment.
2.2.1.3 Rotary Table and/or Top Drive Torque Indicator Package
i Clamp the make-up tong to a joint of drill pipe previously fitted into the TD.
ii Use the Top Drive or Rotary Table to apply a held torque of 20,000 ft/lbs as shown on the
TD or Rotary gauge.
iii Verify that the rotating equipment torque display reads the same as the previously verified
tong torque display. (+/- 1%)
2.2.2 Mud Tank Level Sensors Step 1 empty Tank: High Pressure Mud System
2.2.2.1 Manual Pressure Gauges – Pump and Stand Pipe Mounted Remove the Mud Pump discharge
pressure gauge.
I. Using a blanking adapter on the mounting flange or hammer union, as necessary, connect the MP
gauge to a hand pump with a certified gauge “tee’d” in to the output pressure line of the hand
pump. iii. Pressurize the gauge using the hand pump and verify that the pressure read out is equal
on both gauges.
II. Repeat the process on the remaining Mud Pump and Stand Pipe pressure gauges as required.
2.2.2.2 Electronic / Hydrostatic Standpipe Pressure Transducers
I. If the transducer is installed during the test above (a), ensure that the driller’s pressure display
matches the reading on the certified gauge.
II. If the transducer is not installed on the stand pipe manifold, a blanking adapter will need to be
fitted and a hydraulic jack (c/w pressure gauge) will need to be installed. Pump up the transducer
module and verify that the driller’s pressure display matches the pump output pressure reading.
2.2.3 BOP Closing Unit and Choke Control Gauges
a. Using a hydraulic hand pump, with a certified gauge of equal or nearest scale tee’d in the outlet,
pressurize each choke control and BOP closing unit gauge in sequence.
b. Ensure the panel mounted gauge(s) match the certified gauge in the hand pump outlet port
throughout the gauges’ full range of travel.
2.2.4 Mud Tank level sensor: Step 1 empty
tank
a. Upon completion of the electrical installation of the level sensors, verify that a reading is available
at the drillers console for each unit.

b. Simulate a change in depth of reading by:

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i. Float style sensor – manually raising and lowering the float

ii. Sonar style sensor – providing a manual target for the sensor to read and different levels.

a. Confirm that the readings for each sensor change relative to the simulated depth of fluid change.
Step 2 - Known Volume in Tank:

a. With a calculated and known amount of fluid in the tank(s), verify that the drillers display
corresponds with the amount of fluid in the tank(s).

b. Verify that each sensor for each pit is working accurately.

2.2.5 Flow Sensor (Flo-Show)

Manually activate the paddle rheostat on the sensor from 0 to full and verify that the drillers display
shows a reflective reading throughout the full sweep of the paddle.
2.2.6 Tools
All calibration procedures should be followed as per the OEM requirements

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Equipment: 14.3 GAS Cylinders

Frequency: 5 Year , CAT IV inspection
Reference: ASME VIII ASTM E165 ASTM E709
Responsibility: Rig Manager, Drilling Superintendent

Scope of work for each interval:

1. Remove the cylinders from service.

2. Verify all valves, caps and regulators condition.
3. Change all gauges and hoses with new ones
4. Perform complete hydro-test
5. Stamp new expiry date on the cylinders.
6. Prepare and submit the inspection report

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