RECOMMENDED PRACTICE FOR WELL SERVICING RIGS INSPECTION AND REPAIR OF MASTS AESC AESC ‘anuary 23, 2002 Page 1 of 7AESC RECOMMENDED PRACTICE INSPECTION AND REPAIR OF MASTS Introduction The Association of Energy Service Contractors (AESC) Technical Committee has developed the following Recommended Practice for the Inspection and Repair of Masts. The AESC recognizes that most member companies currently have in-house mast inspection policies in place. ‘The intent of this document is to compile and publish industry standards for inspection and repair intervals, define the qualifications of relevant personnel and provide checklists to assist member companies in the process. ‘The recommendations contained in this document should be considered in conjunction with API RP 4G (American Petroleum Institute Recommended Practice 4G). ‘The AESC does not accept any liability based on the recommendations contained herein. This document standardizes the methodology involved in the inspection, repair and refinbishment of masts currently in service. The AESC Technical Committee believes that applying these practices to members’ maintenance programs will greatly benefit the goal of increased safety in the workplace. Factors which affect the condition of a mast include loads imposed on the mast, frequency of raising/lowering, mast design, method of transporting and handling, materials utilized, age of mast, metal corrosion, and types of wells serviced. The AESC Technical Committee has drawn upon a number of resources in the formation of these guidelines. Input was received from mast manufacturers, refurbishment companies, professional engineers, and operations personnel. The AESC and the Technical Committee wish to thank all that were involved. Training Proper training of personnel continues to be one of the most critical considerations in the care of a mast. This includes the rig personnel, mechanics, and welders, as well as the individuals providing inspection. Field personnel should be trained to conduct regular visual inspections. Many costly incidents and repairs can be avoided by adhering to a stringent visual inspection procedure that identifies potential problems well in advance of equipment failure. Active training programs will assist field personnel to identify existing problems and ensure that all equipment involved will operate in the manner for which it was designed. AESC January 23, 2002 Page 20f7Inspection Types and Frequency Category I I tr IV Category I: Category II: Category Ill: Category IV: Daily RigUp 2Year 10 Year Documentation x Optional x Optional x Rig File x Rig File ‘Visual observation of the mast by the rig crew during operation for indications of inadequate performance. This inspection should also be carried out by the operator or rig manager and be included as part of the daily rig walk around. Category I inspection plus a more thorough inspection of, but not limited to, load bearing areas and sheaves for cracks, damage, corrosion, loose or missing components and premature wear. ‘This more detailed inspection should be performed during rig up operations, A thorough visual inspection of all load bearing components and members must be conducted to determine the condition of the mast. This inspection would be completed a minimum of once every two years and be documented on the checklist in Figure 1. The completed (and signed) Mast Inspection Form, as well as documentation of any major repairs completed, are to be documented in the permanent rig file. This inspection could be completed by qualified personnel in the field or in a shop environment and must include a rig up / rig down operation. A Category IV inspection requires the mast be removed from the carrier and disassembled as necessary to conduct a complete inspection, including Non Destructive Testing (NDT) of all major load-bearing components. In addition, a UVT test (Ultrasound) is recommended on all tubular style (or closed style) derricks to test for internal corrosion. This test provides a baseline for metal thickness to assist in determining if corrosion is occurring inside the tubular structure. It is recommended that Category IV inspections be completed by qualified personnel in a shop environment. ‘This inspection should be completed a minimum of once every ten years. In particularly corrosive environments (humidity, salt, etc), member companies may wish to expedite this process. ‘Companies may also want to consider checking for internal corrosion on closed faced derricks on a more expedited schedule. Further explanation of the requirements of a Category IV inspection are defined below: AESC ‘January 23, 2002 Page 3 of 7Category IV Inspections ‘The following procedure is recommended for completing a mast Category IV Inspection & Repair, @ ) (©) @ © oO @ ) Remove mast from carrier and sandblast. Place mast on derrick bed, pipe racks or other suitable supports. Clean mast, ifrequired, to prepare for inspection. Inspect the mast using a certified ASNT Level II Technician, Mast Inspection Checklist (Figure 1) should be completed fully and signed by the Inspector. Any damage found during the Category IV inspection is defined as MAJOR or MINOR on the following basis: (1) Major Damage: Geometrical distortion or structural damage to raising assembly, main legs, hinge points, crown or any other load bearing member. (2) Minor Damage: Damage or distortion to secondary equipment, i.e., ladders, monkeyboard, walkarounds, tong hangers or cosmetic damage to diagonal braces. Alll repairs to must be completed by a certified welder in accordance with AWS D1L.1. Itis recommended that these repairs be completed in a shop environment, in accordance with the Original Equipment Manufacturers (OEM) specifications. Repairs to minor damage may be completed in the field or in a shop environment, On alll closed face derrick styles, a U/T (ultrasound) test or equivalent should be completed to check for internal corrosion. Intemal cameras, usually run on a cable, may also be used to visually inspect for internal corrosion. Documentation of all major repairs should be captured in the permanent rig file, and include the following: mast serial number name and date of manufacturer clear height static hook load rating with maximum lines strung author of repairs, date and location of repairs complete documented results of the Category IV inspection, as described herein. Copy of NDT inspection and inspectors qualifications date and documentation of all repairs performed AESC ‘January 23, 2002 Page 4 0f7Personnel Qualification and Documentation Welders on desrick repairs must be certified in accordance with AWS D1.1 and should have experience in mast maintenance. All welding completed should be in accordance with the requirements of AWS D1.1. Service rig company personnel undertaking Category II inspections will be individuals designated by the company who have adequate experience and knowledge in masts. These individuals will typically be experienced field superintendents, engineers, rig supervisors, rig operators, or operations managers. The individual supervising the Category III inspection must possess adequate knowledge and experience. Typical persons qualified would be an engineer, an NDT technician, 2 ASNT Level II Technician, or a senior service operations person, designated by the company or others, provided they meet the above criteria of experience, training and knowledge. NDT inspectors for a Category IV inspection would be required, as a minimum, to have certification as an ASNT Level II Technician. In addition, Category IV inspectors must have previous experience and practical working knowledge of masts and other structures. The Category IV inspection should be conducted by or closely supervised by a Certified Welding Inspector (CWI) or an Original Equipment Manufacturer (OEM) representative. ‘The company providing the Category IV inspection would provide a “Certificate of Derrick Inspection & Reetification”, signed by the inspector to be added to the rig file after completion of the Category IV inspection and repair process. Implementation Itis expected that contractors utilizing this Recommended Practice will comply with Category IN inspections by December 31, 2003. It is expected that contractors utilizing this Recommended Practice will comply with Category IV inspections by December 31, 2008. Each contractor attempting to utilize this Recommended Practice would need to complete Category IV inspections on approximately 15% of their working fleet each year in order to successfully meet this seven year conversion period. Derricks which have been refurbished and documented in the past ten years in general accordance with the guidelines for a Category IV inspection contained herein would be considered in compliance with this Recommended Practice. Alll equipment requiring a Category IV inspection upon issuance of this Recommended Practice should consider following the guidelines herein when repairing masts. AESC ‘Tanuary 23, 2002 Page 5 0f7