Audit Report Century 14 Rev 1

RIG AUDIT REPORT

OF CENTURY RIG 14

Prepared for

CENTURY DRILLING

By

Rig Inspection Services Pte Ltd

30 Toh Guan Road #08-09 ODC Districentre Singapore 608840

Inspection date: 25th 30th of March 2008

Report Title: Century Rig 14 Issue No: 1 Revision No: 1 Page2

TABLE OF CONTENTS

1 INTRODUCTION 5

1.1 Rig Data 5

1.2 Survey Work scope 5

1.3 Applicable Standards 5

2 SUMMARY OF SURVEY 6

2.1 Discrepancies Categories 10

2.2 Summary of Discrepancies 10

3 DRILLING RIG EQUIPMENT 11

3.1 Draw works 11

3.2 Rotary Table 13

3.3 Swivel 13

3.4 Kelly Spinner 14

3.5 Crown Block 14

3.6 Block and Hook 15

3.7 Drilling Instrumentation 15

3.8 Master Bushing 16

3.9 Hawk Jaw 17

3.10 Elevators / Slips 18

3.11 Rig Tongs 18

3.12 Elevator 19

4 ELECTRICAL EQUIPMENT 21

4.1 Main Generators 21

4.2 Camp Generators 21

4.3 Mini Camp Generators 23

4.4 Transformers 24

4.5 SCR 24


4.6 Switch Gear and SCR house 25

4.7 Lighting 26

4.8 Hazardous Area Equipment 26

4.9 AC Motors 27

4.10 DC Motors 29

4.11 Elmagco Brake 33

5 MECHANICAL EQUIPMENT 34

5.1 Caterpillar Engines 34

5.2 Air Compressors 35

5.3 Air Receivers 36

5.4 Anti Fall Devices 36

5.5 Mechanic Work Shop 37

6 MUD SYSTEM AND EQUIPMENT 38

6.1 Mud Pump # 3 38

6.2 Mud Pump # 2 40

6.3 Mud Pump # 1 42

6.4 Stand Pipe Manifold and HP Lines 44

6.5 Vacuum Degasser 45

6.6 Mud Tanks 46

6.7 Trip Tank 46

7 WELL CONTROL EQUIPMENT 47

7.1 Accumulator 47

7.2 Single Ram BOP 48

7.3 Double Ram BOP 48

7.4 Annular 49

7.5 Choke Manifold 50


8 PREVENTATIVE MAINTENANCE 50

8.1 Preventative Maintenance 50

9 SAFETY AND OTHER MISCELLANEOUS EQUIPMENT 51

10 SPARE PARTS 51


1 INTRODUCTION 1.1 Rig Data Rig: Century Rig 14 Owner: Century Resources Type: Land Rig Location: Cirebon Indonesia. Inspection Dates: 25th 30th March 2008 1.2 Survey Work scope In accordance with the instructions received by Century Resources, two surveyors attended Century Rig 14 in Cirebon Indonesia to complete a Rig Condition Survey.

The aim of the survey was to determine the present condition of the Drilling Package and associated equipment ensuring the equipment was fit for the intended purpose and in a safe operating condition.

Included in the above scope was the following: Carryout the inspection of the equipment to the criteria of the checklist supplied by Century Resources. The audit was conducted in good faith and without prejudice. 1.3 Applicable Standards The inspection criteria, which have been used as reference during this inspection, are the owners safety and operating standards, the original equipment manufacturers maintenance and operating specifications and accepted oilfield operating and safety practices.


2 SUMMARY OF SURVEY RIS Surveyors attended Century Rig 14 in Cirebon Indonesia to complete a Rig Condition and Safety Survey.

An inspection work scope had been determined by correspondence with the Maintenance Manager prior to mobilization to the rig. A subsequent meeting was held on site with the Rig Manager and the attending surveyors to discuss and coordinate the work scope of the inspection. The aim was to assist personnel with forward planning and to prepare documentation and the equipment for inspection.

At the time of inspection, the rig was being packed for shipment and was not operational which allowed very good access to most equipment for intrusive inspections. Given that a substantial amount of the equipment was not able to be operated, it was not possible to test some of the safety devices or carryout any functional checks on most of the equipment. Should this be requirement by either Century or their client then a subsequent visit would be required when the rig was in a fully operational state. This would involve the RIS surveyor to be in attendance for the close out and acceptance of the rig.

If all recommendations and planned maintenance repair procedures are followed and a suitable reactivation period be allowed, then it would be fair to state that the rig could be expected to operate in a safe and continuous manner on a drilling program.

Drilling Equipment An intrusive inspection was carried out on the National 80-UE draw works which was found to be in an acceptable condition. Bearing lift checks were conducted on the main drive shaft, jack shaft and drum shaft, these were all found to be within the manufacturers acceptable limits, there was no functional testing of this unit whilst we were on site.

The rotary table was visually inspected, the gear backlash 0.043 which is acceptable. The master and split bushings were found to be in poor condition, dimensional checks were conducted and exceeded manufacturers specifications for wear limits.

The Ideco 500T Swivel was visually inspected; the Quill stem length was measured and was only 10 long. It would be recommended to have a spare Quill available.

There were no NDT records available on location for neither the travelling block nor the hook assembly. Documentation is reported to be in the Jakarta office however if not available NDT inspection should be conducted prior to the rig commencing the new contract. On the block, one side door was opened to access the sheaves, bearing side movement checks were conducted and found acceptable, the sheaves were gauged with only minimal wear noticed and found to be in good condition. The latch and lock for the hook lever were functioned and working as they should.


Drilling Mast

The drilling mast was visually inspected and there was no obvious damage noticed to the structure, all main supports and diagonal braces were found to be in good condition. There were no recent NDT reports available for the mast or substructure however a third party Inspection Company is currently on location and in the process of conducting NDT on all critical areas of the mast. The NDT was 80% completed during our inspection with no defects found at that time.

The crown sheaves were rotated and side movement checks conducted on bearings, minimal movement only was detected and found to be in good condition, the line grooves on all sheaves were gauged and checked for wear. Only slight wear was detected however well within the API recommendations.

A rubber type bumper block is fitted to the underside of the crown and well secured, all pad-eyes in the crown section were noted to be numbered and a pad-eye register was available, currently all pad-eyes are being inspected by third party and once completed will require colour coding with the current colour for this six monthly period.

The racking board was checked, all fingers were straight, handrails acceptable, the main frame and pad-eyes need to be NDT inspected and is in the current work scope for the NDT.

Due to the sections of mast and substructure being stacked it was not possible to locate the mast compliance plates to confirm load ratings.

The rig floor personnel elevator was visually inspected. Further inspection will be required once it is rigged up on location.

All pipes handling equipment was inspected, documentation was not available on location to show previous NDT inspections, generally the elevators and slips were found to be in good condition.

The Iron roughneck is currently waiting on parts to repair the hydraulic motor on the pipe spinner.

Substructure The substructure was visually inspected and due to being packed for mobilization it was not possible to get 100% access to all areas, NDT inspections have been conducted on all critical areas with no defects found at the time of our visit, all accessible sections of the substructure that were inspected were found to be in acceptable condition. The raising system appeared to be in good condition, all sheaves were gauged and bearing checks conducted the raising lines and bridal line were visually inspected and found to be acceptable.

No function checks were conducted on the Lantec Winches.

Electrical Equipment Due to the mobilisation of the rig, one air compressor was the only electrical equipment that was operational at the time. Extensive checks were performed on the electrical aspect of the Mud pumps, Draw works and camp generators. It was agreed that the Drilling generators would not be inspected due to the planned change out of these Engine /Generator packages. Unfortunately the SCR house was packed and secured for shipping so further checks should be performed on this equipment after Rig arrives on location and electrical system is energised for


drilling operation. Checks still outstanding and should be completed prior to start up are as follows. Full function test of engine shut downs. Under voltage, over and under frequency and reverse power trip tests. Inspection of all MCC and SCR modules. Inspection of generator power limit function (if system installed) Drilling instrumentation checks. Rig PA function test. Complete lighting inspection. Hazardous area electrical equipment inspection. Re-inspection of electrical Generators and DC motors that had very low insulation readings

recorded as per below report.

Mechanical Equipment As previously mentioned, it was not possible to run function tests on most of the equipments; however we did manage to run one MCC generator 480 V to supply temporary power to the office, no ESDs or safety systems were functioning as tested on the rig.

Both air hoists were visually inspected and have line and drum covers fitted, SWL is visible, and line spoolers are fitted to both winches. The mechanism for disengaging the drum has been removed and the system is locked into the engaged position to prevent free-wheeling of the drum, and complies with safety requirements as detailed in OEM safety alerts. No function tests have been conducted.

The Ingersoll-Rand Man Rider winch was not connected and no function test conducted this is an approved dedicated man riding device and complies as per manufacturers spec.

The air package consists of four compressors, 2 x Sullair, 1 x Champion and 1 x Cold start. The 2 Sullair series10 air compressors were visually inspected, only number one was operational during the inspection. Isolation valves, instrumentation and pressure relief valves have been checked.

The cold start with Sullair compressor was inspected and operated; the Un-loader system was checked and functioned as it should. Mud Systems The mud tank system was inspected and found to have some areas with corrosion, the internal coatings of the tanks have deteriorated in areas causing corrosion pitting and may require some welding repairs, and work is currently in progress to descale these areas to further assess the condition.

The low pressure lines appeared to be in good condition, it would be recommended that UT thickness checks be conducted to assess the overall condition of the tanks and pipe work for preventative maintenance purpose.

The standpipe and mud lines were visually inspected and appear to be in fair condition. No documentation was available on location for previous UT inspections, the wall thickness checks need to be conducted periodically to assess the integrity of the pipe for safe working pressure ratings. Reports also need to be kept for any modifications of sections that have been welded into line which should include NDT radiography proof pressure tests for the high pressure system.


The three DFE shakers were inspected and were found to have been poorly transported; two of the shakers have not been secured to the beds causing some damage to the electrics and screen tensioners. The repairs were completed during the inspection and were found to be acceptable.

Mud pumps The three National 9-P-100 Mud Pumps, 2 x electric and 1 x driven by Cat D399, underwent an intrusive inspection and were found to be in acceptable condition with no major faults noted. Bearing lift checks were conducted on all pinion, crank and eccentric bearings, the crosshead clearances checked, all readings taken are within the manufacturers recommended tolerances.

A check of the back lash between the Bull Gear and the Drive pinion was taken and this was found to be within the manufacturers specifications.

Well Control The Shaffer single was opened and inspected, ram blocks rubbers and seals were found to be in good condition. Cavity measurements were acceptable and within tolerances. No pressure test or function tests were conducted. Ring grooves were well protected and in good condition.

On the double , the upper rams were opened and required cleaning, it appears that they were not properly flushed on the previous job leaving a large amount of cement in the cavity and around ram blocks, cleaning was completed and measurements taken and found to be acceptable. The lower doors were opened and were found to be in similar condition.

No documentation for the BOP was available on location; we have been informed that this is available in Jakarta office. Current certification should be provided and full low and high pressure tests should be conducted to ensure that the equipment is in a safe operating condition.

The Hydril MSP 2000 20 Annular was visually inspected, the element / ring grooves appeared to be in good condition, the 4 lifting eyes were noted to have been NDT inspected however one of the eyes is badly damaged.

The Choke manifold was checked and all valves were free and easy to open / close, one valve was removed for internal inspection and found to be in acceptable condition. No pressure test charts were available for previous tests; we have been informed that the previous tests were only conducted to 1200 psi. A full pressure test program should be undertaken which should include both low and high pressures tests from both sides to the SWP of the respective sides of the choke manifold.

The Accumulator was not connected during the inspection and no function test conducted, the unit has three banks of six bottles, these banks can be isolated individually and bled back to the reservoir, it was noted that there was a low pressure alarm fitted, the alarms was not functioned. A full accumulator drawdown test should be conducted when the BOPs are rigged up to ensure that the unit has sufficient residual capacity to meet both the requirement of the client and API specification whichever of the two are greater.

We would like to thank the management of Century drilling for the opportunity to provide our services for the inspection of Century Rig 14.


2.1 Discrepancies Categories The Discrepancies in this report are categorized as follows: Critical: Deterioration and failure of the equipment resulting from this deficiency may lead to environmental damage, a serious injury or loss of life. Major: Deterioration and failure of the equipment resulting from this deficiency may result in significant damage to major equipment or compromise the operation. Minor: Deficiencies, which do not meet any of the above mentioned categories. 2.2 Summary of Discrepancies This section has been covered in the Action Item excel spreadsheet which supplements the main report, these two documents encompass the report package for this survey. The equipment has also been given a rating on the spread sheet which is based upon condition evaluation. This dual grading has proven beneficial to other drilling contractors when prioritizing remedial work scopes.


3 DRILLING RIG EQUIPMENT 3.1 Draw works The National 80-UE Draw works was subjected to an intrusive inspection for condition evaluation and was found to be in acceptable condition. The unit is DC driven.

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

The oil pump, chain and sprockets were found to be in good condition.

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


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

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

3.1.1 Draw works Discrepancies Critical: None. Major: Excessive wear noticed in pin bores on the S-link and the bell cranks on driller

side, the main through shaft is flexing under load, this could be due to the amount of wear in the shaft pillow blocks. Recommend that the worn linkages be replaces.

The main brake shaft will need to be removed to check if the wear is in the

mounting block bores or main through shaft.

No NDT records were available on rig location; if no current records are available it would be recommended to conduct the inspection prior to commencing work.


Recommend to replace the hold down bolt or check that it is not bent or cross

threaded. Minor: The drive coupling from the DC motor to the draw works main drive shaft off

driller side was found to be worn on the inner and outer splines, we recommend that alignment checks be conducted to ensure that further wear is not accelerated.

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

3.3.1 Swivel Discrepancies Critical: None. Major: Recommend that the gooseneck be changed out due to the modifications made No UT reports were available on location for the gooseneck. NDT inspection would need to be conducted on the Quill thread and lifting

points of the swivel prior to work.


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

thread was required it may not leave sufficient length for the tong. 3.4 Kelly Spinner The Kelly spinner was visually inspected; it is currently incomplete and not functioning, has been advised that parts have been ordered.

3.4.1 Kelly Spinner Discrepancies Critical: None. Major: Recommend to rebuild once parts become available. Minor: None. 3.5 Crown Block The crown was visually inspected and found to be acceptable, bearing side movement checks were conducted, The main cluster and fast line shaft pre-load plate retaining bolts were lock wired, sheave seals appeared to be in good condition and sheaves showed minimal wear, generally the crown was found to be in good condition.


3.5.1 Crown Block Discrepancies Critical: None. Major: None. Minor: None. 3.6 Block and Hook The travelling block were packed for shipping, all sheaves were gauged and rotated with no unusual noises detected, the sheaves show minimal wear but acceptable and appear to be well greased, the hook lever was opened and checked for movement in the pivot pin and the latching lock checked and found to be acceptable, no Recent NDT records were available on location. 3.6.1 Block and Hook Discrepancies Critical: None. Major: Recommend that the hook and travelling block hang off point and critical areas

have NDT conducted prior to the rig commencing work if no NDT reports are available in Jakarta office.

Minor: None. 3.7 Drilling Instrumentation A visual inspection was conducted and all appear to be in acceptable condition. However, documentation for calibration was not available for the instrumentation. It is recommended that calibration be conducted annually, labels should be visible on the gauges showing next due date.

3.7.1 Drilling Instrumentation Discrepancies Critical: None. Major: It is recommended to have all instrumentation calibrated prior to the rig

commencing work. Minor: None.


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

Wear in pin bores, 3/8 movement. Showing gap between body and pin.

Above photos showing spread in lower tapper of the insert bowls. 3.8.1 Master Bushing Discrepancies Critical: None. Major: Recommend to replace the master bushing and slip bowls. Minor: Conduct slip test to check for slip die to pipe contact.


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

3.9.1 Hawk Jaw Discrepancies Critical: None. Major: Repair hydraulic motor for the spinner as soon as parts are available. Conduct the services recommended by manufacturer. Minor: Conduct all MPI at the frequencies as recommended by the manufacturer.


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

3.10.1 Elevators / Slips Discrepancies Critical: None. Major: If no Cat IV records are available, it is recommended to conduct full disassembly

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

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

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

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


3.11.1 Rig Tongs Discrepancies Critical: Remove all reject tong jaws from the rig. Major: None. Minor: Recommend that new safety handles be fitted to the tongs jaws. 3.12 Elevator The personnel elevator to rig floor was visually inspected and several deficiencies were noted. The electrical installation needs remedial action, there was no inspection records available showing MPI of critical areas, unable to locate any secondary safety locking device for the riding basket in the event of a hoisting line failure, none of the safety devices were able to be functioned, SWL signs need to be displayed.


Above photos showing some electrical connections and outlets that require remedial action. 3.12.1 Elevator Discrepancies Critical: Recommend that all electrical installations be checked and repaired. NDT of all critical areas. Check that all safety devices are functioning correctly. Safe working load needs to be visible at entries.

Check for secondary safety device for basket in the event of a hoisting line failure.

Major: Recommend a full inspection of the elevator once rigged up on location. Minor: None.


4 ELECTRICAL EQUIPMENT 4.1 Main Generators The three SCR and two MCC Engine Gen packages were prepared for shipping so they were not run. Century plan to remove and upgrade these gen sets in the near future. The decision was made between Century senior management and RIS that these gensets would not be included in this field inspection. Polarisation Index and Insulation Resistance Results (Not available)

Alternator #1 Alternator #2 Alternator #3 Rotor Stator Rotor Stator Rotor Stator M @ 1 min

M @ 10 min PI

4.1.1 Main Generators Discrepancies Critical: None. Major: None. Major: None. Recommendations: It is recommended that these Generator packages have complete insulation tests performed

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

Generator #1 PI/IR insulation test Rotor Stator Exciter M @ 1 min 0.5 0.55 1.1

M @ 10 min 0.7 1.6 PI 1.4 3.2


4.2.2 Generator No 1: Deficiencies Major: Bad wire connection was found on exciter Diode Bridge. Rig electrician

immediately repaired this. Major: Rotor insulation reading is below acceptable level. Recommendations: Cleaning of generators be performed on a more regular basis. Generator to be heated, dried and re-test prior to start up. Control panel to be re-labelled for easy identification. Previous insulation test records should be available on site for test reference.

4.2.3 Generator No 2: Main Camp

Generator #2 PI/IR insulation test Rotor Stator Exciter M @ 1 min 0.15 0.5 4

M @ 10 min 0.17 1.0 PI 1.1 2

4.2.4 Generator No 2: Deficiencies Major: Rotor insulation reading is below acceptable level. Major: Both Generator heaters have been removed. Recommendations: Heaters to be fitted in generator housing. Cleaning of generators be performed on a more regular basis. Generator to be heated, dried and re-test prior to start up. Control panel to be re-labelled for easy identification. Main circuit breakers located on generator power distribution panel should have under

voltage protection. Previous insulation test records should be available on site for test reference.


4.3 Mini Camp Generators Inspect generators and test exciter and stator windings only. Time and labour restraints prevented us from being able to test the rotor windings (these winding connections are hard to get to and time consuming to disconnect). No maintenance history was available to ascertain when the generators were last inspected and what readings were recorded. Heaters where fitted in both generators.

Generator #1 PI/IR insulation test Rotor Stator Exciter M @ 1 min 2.5 8

M @ 10 min 2.9 PI 1.4

4.3.1 Generator No 1: Mini Camp Discrepancies Minor: Control panel requires re-labelling. Recommendations: Rotor coils to be checked when time permits. Cleaning of generators be performed on a more regular basis. Previous Insulation test records should be available on site for test reference.

4.3.2 Generator No 2: Mini Camp

Generator #2 PI/IR insulation test Rotor Stator Exciter M @ 1 min 4 15

M @ 10 min 8.5 PI 1.4

4.3.3 Generator No 2: Mini Camp Discrepancies Minor: Generator power distribution panel external wiring to be fixed up so no single

insulated wiring is present. See photo attached. Minor: Control panel requires re-labelling.


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

Transformer Insulation SCR 600-480V SCR 480/220/120 MC1 480/220/120 MC2 480/220/120

Primary 180 M 200 M 41 M 12 M Secondary 2.7 M 200 M 250 M 4 M

4.4.1 Transformers Discrepancies Critical: None. Major: None. Minor: Transformers should be labelled as per their drawing reference. 4.5 SCR At the time of inspection, the SCR house was packed and secured for transportation. We recommend that the SCR house is thoroughly inspected once the planned Generator upgrades are complete and Rig is in operation.


4.5.1 SCR Discrepancies Critical: None. Major: None. Minor: None. 4.6 Switch Gear and SCR house MC1 Switch room was available for partial inspection. (Some panels where secured for transportation). Inspection of the 480V MCC modules found them in a deteriorated state and in need of replacement / repair.

MC2 Switch room was secured for transportation and unavailable for inspection.

SCR house roof was in the process of being painted. Poor quality repairs were used to repair water leaks in roof.

4.6.1 Switch gear and SCR house Discrepancies Critical: None. Major: MCC modules to be repaired/replaced. Major: SCR house roof has a number of silicone repairs to prevent water leaking into

switch room. Recommendations: We were advised that plans are in place to change out MC1 & MC2 switch rooms. If this

upgrade is cancelled or delayed indefinite then we recommend that all motor starter modules be removed, stripped down, cleaned, painted and rebuilt with new switch gear.

Holes in SCR house roof must be properly patched with the use of steel plate to prevent any possibility of water leaking into switch room.


4.7 Lighting All lighting was packed for Transportation. Complete lighting inspection will be required once Rig is in operation at new location. 4.7.1 Lighting Discrepancies Critical: None. Major: Complete lighting inspection will be required once Rig is in operation at new

location. 4.8 Hazardous Area Equipment Due to the rig being mobilised, this inspection was limited to what equipment we could inspect. We recommend that a full inspection be carried out once Rig up has been completed.

Inspection of the Drill Floor Dog house revealed a number of electrical issues that should be attended to prior to commencement of Drilling.

The mud cooling tower exhaust fan motor is not EX rated. This is located in a class one zone one area. A question also exists over the use of pillar type bearings being used in a class one zone one area.

Non rated outlet Non rated plug & socket Non rated electric heater

Mud Cooling Tower Id Plate fitted to mud cooling tower fan motor


Hazardous Area equipment Discrepancies Major: Standard household 220V outlets and extension cords are in use in Dog house.

These are required to be removed and replaced with appropriate hazardous area equipment.

Major: There is a non hazardous area electric heater situated in Dog house. This must be removed prior to commencement of drilling.

Major: Mud cooling tower has a non EX rated fan motor mounted in a class one zone one area.

Minor: 220V Combination plug panel located in Dog house has no certification labels

attached. All equipment located in Hazardous areas must have certification labels attached.

Minor: Dog house wiring standard is in poor condition, improvements could be made to improve the standard of wiring.

Minor: Mud cooling tower fan belt cover requires repairing. 4.9 AC Motors No motors could be run due to mobilization of the rig. Overall the AC motors were in acceptable condition with the exception of the below listed items. A number of AC motors where megger test with no low readings recorded.

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

4.9.2 AC Motors Discrepancies Major: Shaker No 2 and No 3 motor supply cables between switch station and motor

have been damaged. Supply cables to be replaced. See attached photo. (Job completed)

Major: Mud pump 2 Blower motor connection junction box has signs of water ingress

and corrosion. See attached photo. This was repaired.


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

Minor: Shaker motor switch stations to be reconfigured so output motor cable has better

protection and less stress is on cable when entering cable gland. See attached photo.

Minor: Trip pump motor mounts to have new bolts installed.

Shaker 3 & 2 motor supply cable damage

MP2 Blower motor J/B Shaker switch station 4.9.3 Recommendations

New shaker motor cables installed to replace damaged cable. (Job completed) Shaker switch stations to be reconfigured so outgoing cables create less stress on

entry glands. (Job completed) All AC motor Junction boxes to be opened inspected for water ingress and cleaned.

Lid and J/B surfaces to be cleaned and greased with approved silicone grease to ensure good sealing when closed.


At present nearly all centrifugal pump motors have been disconnected. We recommend that these motors be megger checked and documented prior to reconnection.

Once on location and earthing system has been completed. All motor frames be checked for insulation resistance to ground. Reading must be below 1 ohm. This will ensure all motors have been earthed via its supply cable.

All mud system centrifugal pumps to be manually rotated prior to been energised. This is to ensure the impellers are not seized by any mud that may have been left in the housings.

4.10 DC Motors Inspections were performed at Cirebon holding yard where rig was being prepared for shipment. All motor internals were in a satisfactory condition taking into consideration the age of the equipment (no records available on site noting running hours or days of service). Space heaters were present in each motor but could not be checked for correct operation due to rig mobilization. At the time of inspection humidity levels were high and signs of moisture were present in all the motors.

No maintenance history was available to ascertain when the motors were last inspected and what readings were recorded.

4.10.1 DC Motors Insulation recordings

DC Motor Field (M) Armature (M) Draw works A 500 0.03 Draw works B 250 0.6 Rotary Table 4 0.43 Mud pump 1 66 0.05 Mud pump 2 70 0.07

4.10.2 DC Motors Discrepancies DWS A Major: Armature insulation reading is way below minimum acceptable levels. Major: Multicore socket providing power for motor field, blower & heater supplies has

water ingress and insulation readings well below acceptable levels. EG: Insulation readings for Field supply circuit between junction box terminal strip and incoming connection plug has a reading of 0.02meg ohms at 500V to ground. See attached photo.

Minor: Motor junction box cover requires new mounting screws. At present the cover is only held on via a small number of self tapping screws. See attached photo.

Minor: Field supply cable entry into DC motor requires correct gland entry. See attached photo.


Water ingress in multi pin plug J/Box cover mounting screws

Field supply cable gland 4.10.3 DC Motors Discrepancies DWS B Major: Armature insulation reading is way below minimum acceptable levels. Major: Multicore socket providing power for motor field, blower & heater supplies has

water ingress and insulation readings well below acceptable levels. EG: Insulation readings for Field supply circuit between junction box terminal strip and incoming connection plug has a reading of 0.02meg ohms at 500V to ground. See attached photo.

Major: Motor junction has open spare cable access at bottom off enclosure. Plus Junction box lid is only held by small amount of self tapping screws. These enclosures are supposed to be purged via blower air before motor is energised. At present this is not possible, there for pressure switch circuitry is possibly bypassed. See attached photo.


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

Spare open cable entries Field supply cable 4.10.4 Rotary Table Discrepancies Major: Armature insulation reading is way below minimum acceptable levels. Major: Lock out switch is seized up and in need of replacement. Major: Motor junction box cover needs replacing with new. See attached photo.

J/B Cover needs replacing Lockout switch is defective 4.10.5 Mud Pump No 1 Discrepancies Major: Armature insulation reading is way below minimum acceptable levels. Minor: Junction box lid requires new mounting bolts fitted.


4.10.6 Mud Pump No 2 Discrepancies Major: Armature insulation reading is way below minimum acceptable levels. Minor: Junction box lid requires new mounting bolts fitted. DC Motor recommendations: Low Armature readings: All DC motor armatures to be cleaned, heated and megger test

prior to running. Readings to be above 1meg ohm prior to energising. Multicore plugs to be opened and cleaned. If insulation readings cannot be improved, plugs

are to be replaced. All mud pump and Draw works DC motor Junction Boxs to have covers repaired back to

original state with all securing bolts used plus all spare cable entries covered to ensure a positive pressure is present during motor operations.

Rotary Table DC motor Junction Box cover to be replaced. Junction box to be checked that a positive pressure is present during motor operations.

Draw works DC motor blower air intakes to be checked that they are in a free air zone as per API standard 500.

Both Draw works motor Field supply cables to have correct hose and glands fitted between Junction box and Motor entry.

All DC motor Junction box air purge pressure switches to be checked for correct operation prior to commencement of drilling.

All DC motor heaters to be checked for correct operation when on next location and power is available.


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

Coils F1-F2 F3-F4 F5-F6 F6-F8 Coil Resistance 6.5 6.4 6.5 6.5 Coil Insulation M 10 6 10 6

The supply cable

4.11.1 Elmagco Brake Discrepancies Major: Supply cable between brake J/B and supply connection plug has its inner

insulation deteriorating. See attached photo. Major: If a proficiency test has not been performed within the last 12 months, it is

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

commencement of drilling.


5 MECHANICAL EQUIPMENT 5.1 Caterpillar Engines The main generators were not able to be run due to mobilisation of the equipment. We were also advised that Century plan to remove and upgrade these gen sets in the near future. However, the service history was reviewed and they appeared to be well maintained.

The Minicamp generator engines were checked visually as they were unable to be run, the solenoid on the injector pump on get set # 2 requires repairs, the fan belts and cooling fan bearing has excessive movement and needs to be replaced on gen set # 1.

5.1.1 Caterpillar Engines Discrepancies Critical: None. Major: Repair the loose solenoid valve on the injector pump of gen set # 2.

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

Minor: None.


5.2 Air Compressors There are 4 air compressors on the rig, 2 x Sullair S 10, 1 x Champion and 1 x cold start.

The PRVs on compressor 1 & 2 Sullairs were last tested on the 15/4/04, all relief valves need to be tested annually. Only number one Sullair and the cold start were operational during the inspection and both appeared to be operating without any problems noted.

The non return valve on # 3 compressor (Champion) discharge is not working, it is still under pressure even when off line. It appears to be very oily in the discharge and pressure relief valve and would recommend that the separator be checked. This unit was not able to be functioned during the inspection and was advised they were waiting on part for repairs. The PRV on the Champion and cold start compressors have adjustable type pressure relief valves fitted, these should be replaced with certified pre-set type relief valves. The cold start battery has no protection to prevent arcing across terminals.

Adjustable type PRV not certified Battery for cold start 5.2.1 Air Compressor Discrepancies Critical: None. Major: Recommend to fit certified relief valves to the compressor units. Replace the non return valve in the discharge line (Champion Compressor) to

prevent pressurising the unit when not on line. Conduct full service on the Champion compressor, check oil separator and repair

oil leaks. Fit protection for the cold start battery (battery box) Minor: None.


5.3 Air Receivers All air receivers were visually inspected; The SWP markings were visible on all receivers.

There was no documentation available to show that the receivers have had hydrostatic testing, UT gauging or internal inspections conducted.

The PRV certification needs to be reviewed, the PRVs in the lower substructure and compressor room receivers have no tags fitted to show last inspection.

5.3.1 Air Receiver Discrepancies Critical: None. Major: UT thickness checks should be conducted to check for internal corrosion.

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

Minor: Documentation needs to be available for the last hydrostatic tests conducted. 5.4 Anti Fall Devices The dog house and other work shops have anti fall static lines along the roofs to attach harness lanyards to, the lines are spliced and the mounting points are not properly secured, the fall devices need to load rated.


5.4.1 Anti Fall Device Discrepancies Critical: The static lines need to be load rated, spliced line terminations are not

acceptable, recommend that all lines have the correct end terminations and be load rated.

The mounting points for the static lines need to be properly secured and load

rated.

Major: None. Minor: None. 5.5 Mechanic Work Shop The mechanics work shop / office was found to be in poor condition, major corrosion was noticed in the walls and roof, during the inspection it was raining and water was leaking through the roof and into the lights / computer and maintenance manuals.

5.5.1 Mechanic work Shop Discrepancies Critical: Recommend that the work shop / office building be replaced. Major: None. Minor: None.


6 MUD SYSTEM AND EQUIPMENT 6.1 Mud Pump #3 Mud Pump # 3 National 9 P 100 Mud Pump # 3. This pump is engine driven by a Caterpillar D399 engine via a National Torque Converter, air clutch and V-belt drive.

The power end cover of the pump was opened to perform an internal inspection, the main bearings rollers and inner race looked bright and clean with no signs of damage. Lift clearances were conducted using a dial indicator and hydraulic jack and were found to be minimal.

The teeth of the bull gear and pinion appeared to be in good condition, the pinion gear back lash is within tolerance with the maximum reading noted as 0.0024. The pinion shaft bearing clearance at drive end is 0.003 and 0.003.

The main bearing clearances were taken and found to be acceptable and RH was measured at 0.006 whilst the LH was 0.005.

The crosshead clearances were taken and found to be acceptable. It was not possible to remove the crosshead pins to inspect the bearings, however all the crosshead pins were tight in the crossheads around the taper fit area.

The lift, and clearances, of the connecting rod eccentric bearings and crosshead slide have been taken and recorded on the condition sheet below.

There is no lock wires fitted to the retaining bolts for the cross head pins on all three cross heads. These bolts may not be OEM as they are not drilled.


0 006

0.004

0.0030.003

0.004

0.003

Good

0.005

Good

Good

Good

0.022

Good

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

0.024 0.018 0.024

0.022 0.018 0.020

0.0060.0040.006

Good


6.1.1 Mud Pumps # 3 Discrepancies Critical: None. Major: The retaining bolts for all three cross head pins need to have tie wire fitted. Minor: None. 6.2 Mud Pump # 2 Mud Pump # 2 The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection and was found to be in good condition with no major faults noted.

The cover for the power end was removed and surface rust was evident on the pinion shaft and both bearings. This was cleaned and lubricated before turning, no pitting was noticed. The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at 0.018 and within tolerance. The pinion shaft bearing clearance at drive side was 0.005 and off side 0.003. The main bearing clearances were taken and found to be acceptable RH was 0.004 and LH is 0.003.

It was not possible to remove the crosshead pins to inspect the bearings. All the crosshead pins were tight in the crossheads around the taper fit area and the lock wires were in place on the pin retainer plates.

All drive chains and sprockets were inspected and found to be in acceptable condition.

Sprockets and chains good condition Corrosion on pinion bearing


0.004

0.005

0.0030.005

0.004

0.006

Good

0.003

Good

Good

Good

0.018

Good

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

0.018 0.020 0.022

0.022 0.022 0.018

0.0060.0060.005

Good


6.2.1 Mud Pumps # 2 Discrepancies Critical: None. Major: None. Minor: None. 6.3 Mud Pump # 1 Mud Pump # 1 The National 9-P-100 Mud Pump is driven by DC motors. This pump underwent an inspection and was found to be in good condition with no major faults noted. The bull gear and pinion gear teeth are in good condition, the pinion gear backlash was taken at 4 point and max/min findings were 0.015 and 0.024 within tolerance. The pinion shaft bearing clearance at drive side was 0.006 and off side 0.003. The main bearing clearances were taken and found to be acceptable RH was 0.006 and LH is 0.003.

The clearance in the connecting rod eccentric bearings and crosshead slide clearances have been taken and found acceptable; these have been recorded on the condition evaluation sheet below. The crosshead readings are at the tightest spot across the full area of the slides. It was not possible to remove the crosshead pins to inspect the bearings. All the crosshead pins were tight in the crossheads around the taper fit area and the Lock wires were in place on the pin retainer plates. Rod # 3 was found to have the rod seal broken and exposed out of the seal housing, when the cover for the power end was removed surface rust was evident on the pinion shaft and both bearings. After cleaning no pitting was noticed.


0.006

0.004

0.0060.003

0.006

0.006

Good

0.003

Good

Good

Good

0.024

Good

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

0.018 0.020 0.024

0.020 0.018 0.018

0.0060.0060.005

Good


6.3.1 Mud Pumps # 1 Discrepancies Critical: None.

Major: Replacement of seal was in progress during the inspection.

Minor: None.

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


Above picture showing internal pipe welds and washing on hammer unions on the mud lines. 6.4.1 Stand Pipe Manifold and HP Lines Discrepancies Critical: None. Major: Recommend UT inspections be conducted on all high pressure pipe work to

determine pipe integrity, and confirm that it complies with the required pressure rating.

All pressure welding need to be conducted by a qualified welder with 6G or 3E

qualifications or current test piece certification. All new high pressure welds need to be radiography or UT testing. Minor: None. 6.5 Vacuum Degasser The Mud degasser was packed for mobilisation, a visual inspection was conducted, and the outer shell appears in good condition. The vacuum compressor / motor V-belts were not fitted, the compressor was rotated by hand and was found to be rotating freely, it appears that the unit has not been in use for some time and will be required to operational to complete the inspection.


6.5.1 Vacuum Degasser Discrepancies Critical: None. Major: None. Minor: Once rigged up function test, check float valve is functioning and vacuum

pressure. 6.6 Mud Tanks A visual inspection was conducted on the mud system and was found to be in acceptable condition; however there were areas of corrosion that needs to be removed to further access the condition. The cleaning and descaling was in progress and repaired as required. 6.6.1 Mud Tank Discrepancies Critical: None. Major: None. Minor: Recommend to continue cleaning the corroded areas and make repairs as

required. 6.7 Trip Tank A visual inspection was conducted on the trip tank, the general condition of the tank was poor, and the tank and piping was badly corroded and requires descaling for further assessment and repainting. 6.7.1 Trip Tank Discrepancies Critical: None. Major: None. Minor: Recommend to clean the corroded areas for further assessment and make repairs

as required.


7 WELL CONTROL EQUIPMENT 7.1 Accumulator The fluid pressure relief valve should be set at 3,500 psi, documentation needs to be provided showing that it releases at the set pressure as no function test was able to be conducted and no tag was fitted to the valve.

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

7.1.1 Accumulator Discrepancies Critical: None. Major: There was no certification available for the fluid pressure relief valve; this should

be set at 3,500 psi, during function testing check the release pressure. Conduct a drawdown test and records should be kept for all pressures through

each step of the procedure for future reference. Minor: No signage was available showing that the unit auto starts. This should be placed

on the unit and visible to personnel.


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

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

7.3.1 BOP Discrepancies Critical: None. Major: Conduct low and high pressure tests on the well bore side of the BOPS. Minor: Conduct pressure tests on the hydraulic operator side of the BOPS.


Recommendations: That certification be available for review and is current. Pressure test charts should be kept for all testing. Cleaning procedures need to be followed

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

7.4.1 Annular Discrepancies Critical: None. Major: The damaged eye is not suitable for lifting; recommend that if this is to be

repaired that the repair be conducted by an approved OEM facility. Minor: Conduct pressure tests on the hydraulic operator side of the BOPS.


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

7.5.1 Choke Manifold Discrepancies Critical: None. Major: Recommend that a full test of the manifold and all valves be conducted and

pressure test charts kept for review. Minor: None. 8 PREVENTATIVE MAINTENANCE 8.1 Preventative Maintenance The general maintenance history on the mechanical side appears to be good; however the preventative maintenance schedule should be looked at closely for the electrical prior to the rig being prepared for its next contract. Generally the electrical maintenance has no records of any checks being conducted. 8.1.1 Preventative Maintenance Discrepancies Critical: None. Major: Good documentation needs to be kept for services and repairs made to the

equipment for future reference. Minor: None.


9 SAFETY AND OTHER MISCELLANEOUS EQUIPMENT At the time of inspection, it was not possible to carry out a safety audit and unable to see systems in place. We would strongly recommend that a complete safety audit is carried out on the rig when it is rigged up prior to spud. As per the Century checklist, we were unable to confirm if most safety equipment was available due to the rig being packed for mobilization. 9.1.1 General Safety and Training Discrepancies Critical: None. Major: None. Minor: None. 10 SPARE PARTS A brief look through the warehouses found that parts were kept tidy and well organized, there appears to be a good supply, and checked random critical spares were available, a full inventory of parts was supplied and critical items that are usually required were listed, it would be recommended that prior to the rig commencing its next contract that a more in depth inspection on critical parts required be conducted.

Audit Report Century 14 Rev 1

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Transcript of Audit Report Century 14 Rev 1