1、 Guide for Survey and Inspection of Jacking Systems GUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS NOVEMBER 2016 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 2016 American Bureau of Shipping. All rights reserved. ABS Plaza 16855 Northchase Drive Ho
2、uston, TX 77060 USA ii ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 Foreword Foreword This Guide has been prepared by ABS to provide Owners guidelines to establish minimum requirements for inspection of Rack and Pinion jacking gear at Special Periodical Survey of Hull for Self-Elevati
3、ng Drilling Units. This Guide provides more details regarding the examination of open and closed type jacking systems of a Self-Elevating Drilling Units. The maintenance crew will benefit from understanding the general and design specific survey requirements for a Rack and Pinion jacking gear. This
4、will enable better planning, execution and consistent application of the scope of surveys and inspection during Special Surveys for jacking systems. This Guide becomes effective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to
5、verify that this version of this Guide is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to 0Hrsdeagle.org. Table of Contents GUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS CONTENTS SECTION 1 Purpose . 1 SECTION 2 Definitions . 2 1 Closed
6、Systems 2 3 Open Systems 2 5 Jacking Gear Function Test 2 SECTION 3 General Survey Requirements 3 SECTION 4 Scope of Surveys . 4 SECTION 5 Design Specific Survey Requirements . 5 1 Open Type Systems . 5 3 Closed Type Systems . 5 ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 iii This Pa
7、ge Intentionally Left Blank Section 1: Purpose SECTION 1 Purpose The purpose of these Guide is to establish minimum requirements for inspection of Rack and Pinion jacking gear at Special Periodical Survey of Hull for Self-Elevating Drilling Units for consistent application of the below noted Rule re
8、quirement. 7-2-5/13.15 of the ABS Rules for Building and Classing Mobile Offshore Drilling Units (MODU Rules) is the current requirement for inspection of jacking gear, see excerpt below: 13.15 Self-Elevating Drilling Units Leg Jacking Systems (2011) On self-elevating type drilling units, leg jackin
9、g systems are to be examined and reported on. Pinions and gears of the climbing pinion gear train of rack and pinion systems are to be examined as far as practicable, to the Surveyors satisfaction, by an effective crack detection method. At Special Periodical Survey No. 2 and subsequent Special Peri
10、odical Surveys, the leg jacking system is to be examined in the presence of the Surveyor by the original equipment manufacturer or other third party inspector mutually agreeable to the owner and the Surveyor. The above Rule gives a requirement for in-depth inspection commencing at Special Periodical
11、 Survey No.2, which is at 10 years from delivery of the Unit, by the Original Equipment Manufacturer or a third party inspector agreeable to both ABS and the Owner; however, the extent of the inspection is not clearly defined as there are multiple manufacturers and designs of Jacking Systems and the
12、 inspection requirements for each vary. The following designs of Jacking Systems are predominantly used on Self-Elevating Drilling Units and are considered in these instructions: Open Type Systems Closed Type Systems ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 1 Section 2: Definition
13、s SECTION 2 Definitions 1 Closed Systems Closed jacking systems are systems where a visual examination of the gears in place by removal of inspection covers cannot be carried out, as not all Closed Designs are fitted with inspection covers. These types of systems, without inspection covers, have to
14、be removed from the unit and disassembled in a shop to carry out visual examination of the gear units. Most commonly they are planetary drive type units. 3 Open Systems Open Jacking systems are systems that are fitted with removable inspection covers that enable in-place visual examination of the ge
15、ars. 5 Jacking Gear Function Test A jacking Gear Function test refers to operational testing of the jacking gear while jacking under normal load. In the function test, distance to be jacked is one complete revolution of the climbing pinion. 2 ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .20
16、16 Section 3: General Survey Requirements SECTION 3 General Survey Requirements The following requirements are to be applied to all units and jacking system designs: i) Record Keeping. Number of hours and loading while jacking should be kept for review and used as a reference for the required examin
17、ations. These records should include hours jacking under preload, normal loading, pulling stuck legs and jacking in heavy weather. Verification of these records should be performed at each Annual Classification Survey. ii) Lube Oil Analysis. Lube oil from the gear boxes of systems that are designed
18、as “closed systems” (i.e., planetary drive type) should be retrieved, and analyzed twice each year, as a minimum. When excessive metal content or other conditions that would indicate failure of the gearbox are found the gearbox is to be opened and examined prior to completion of the Special Survey.
19、iii) Climbing pinions should be closely examined at each Special Survey, tooth profile checked and non-destructively tested as considered necessary. iv) Rack teeth profiles are to be examined, compared to the tolerances set by the Units designer. Any out of tolerance must be corrected. Areas of the
20、Rack to be examined should be determined from operational records but should include the areas of the leg most highly loaded during jacking operations while going on location. v) Shock pads, were fitted, are to be examined, dimensions confirmed to be in accordance with the OEM specifications and fou
21、nd or placed in satisfactory condition. vi) Leg guide wear plates are to be examined and found or placed in satisfactory condition. a) Liners are to be confirmed in place b) Liners are to be examined for cracking or missing retaining welds c) Liner wear is to be within the OEMs tolerances Note: Lowe
22、r liners are to be examined while the Unit is elevated. vii) The jacking systems including all auxiliary equipment are to be inspected for damage, wear, or corrosion. This is to include items such as the gearbox and motors, foundations, mounting arrangements, bolting, and connection couplings. Other
23、 ancillary equipment such as operating and control, piping and wiring installations along with their supporting structure should also be included. viii) During any inspection lock-out, tag-out or similar isolation of the jacking system is to be carried out. This included pressure systems, electrical
24、 systems, and structural components. ix) Provision of Safe Access. Due to increased likelihood of survey work being carried out at height or over water, reference is made to the entire text of 1-1-5/7 of the ABS Rules for Conditions of Classification Offshore Units and Structures (Part 1) and ABS Su
25、rveyors Safety. In short, ABS Surveyors will conduct surveys, provided the clients established safety procedures are not less effective than those contained in the ABS Safety Manual and associated procedures. x) Any replacement parts are to be manufactured in accordance with the ABS Rule requirement
26、s. ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 3 Section 4: Scope of Surveys SECTION 4 Scope of Surveys i) At Special Survey No. 1 Pinions and gears of the climbing pinion gear train of rack and pinion systems are to be examined as far as practicable, to the Surveyors satisfaction, a
27、nd if considered necessary by an effective crack detection method. ii) Commencing at Special Periodical Survey No. 2 and beyond, the Jacking Gear is to be examined in accordance with the ABS Rules by the Original Equipment Manufacturer (OEM) or a third part mutually agreeable to the Owner and ABS. T
28、he Drilling Contractor shall submit a plan to ABS addressing any findings from the Jacking Gear examination and a timeline for any required component renewals. iii) Consideration may be given to examining the Jacking Gear under continuous survey (i.e., a percentage of the Jacking Gear to be examined
29、 annually, minimum of 20% of the gear per year). The plan for continuous survey is to be submitted to the Corporate Offshore Survey Department for review and acceptance. This plan will then be placed in the Units records, where it will be available to the attending Surveyor. iv) Self-elevating units
30、 may be placed on Preventative Maintenance Program (PMP), as specified in Appendix 7-2-A4 of the MODU Rules. However, the following typical items of a jacking system cannot be enrolled in PMP and will be examined to the Surveyors satisfaction. a) For Planned Maintenance (PM) Visual examination and/o
31、r testing of jacking system machinery Operational testing of jacking systems b) For Condition Monitoring (CM) Operational testing of jacking systems 4 ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 Section 5 : Design Specific Survey Requirements SECTION 5 Design Specific Survey Requirem
32、ents The following requirements are noted as design specific and take into consideration the unique aspects of each design; these are to be done in addition to the General Inspection requirements noted above. 1 Open Type Systems All gears are to be visually examined as needed based on the jacking ho
33、urs, either through removal of gears, inspection ports, or by removal of covers. Boroscope examination may be acceptable provided that a there are sufficient ports to give a thorough examination. Brakes are to be examined for excessive wear and the proper clearances, bearing clearances should be eva
34、luated and brakes are to be examined for excessive wear and the proper clearances. Inspection of the high speed gear box, where fitted, may be limited to lube oil analysis and satisfactory function testing. Upon completion of inspection a function test is to be carried out. Note: Gear profiles and g
35、ear mesh patterns give an indication of bearing wear. 3 Closed Type Systems As these gears can only be opened and examined in a workshop, unless fitted with inspection covers, for the second Special Survey (10 years) and subsequent Special Surveys, that one gear box be examined. This may be modified
36、 by the number of hours of use, provided that corrosion while in static position is accounted for. When choosing which gearbox to examine, the actual age load and usage history of the gearbox should be considered. Boroscope examination may be acceptable provided that there are sufficient ports to gi
37、ve a thorough examination of all gears. The gearbox with the most hours of service or highest loads is to be examined at this time. A record of which gearbox was examined is to be kept for future reference. If the condition of this gearbox is acceptable, then only lube oil analysis and operational t
38、esting would be recommended for the remaining gear boxes. Based on the number of jacking hours, this requirement may be increased. Brakes are to be examined for excessive wear and the proper clearances, bearing clearances as accessible should also be taken and compared to the tolerances. Upon comple
39、tion of inspection, a function test is to be carried out including an examination while in operation. ABSGUIDE FOR SURVEY AND INSPECTION OF JACKING SYSTEMS .2016 5 Part 1: Rules for Classification of Offshore Units and Structure RULES FOR CONDITIONS OF CLASSIFICATION OFFSHORE UNITS AND STRUCTURES 20
40、16 PART 1 (Updated August 2016 see next page) American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 2015 American Bureau of Shipping. All rights reserved. ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Updates August 2016 consolidation includes: July 20
41、16 version plus Notice No. 2 July 2016 consolidation includes: February 2016 version plus Notice No. 1 and Corrigenda/Editorials February 2016 consolidation includes: January 2016 version plus Corrigenda/Editorials ABSRULES FOR CONDITIONS OF CLASSIFICATION OFFSHORE UNITS AND STRUCTURES .2016 iii Rul
42、e Change Notice (2016) Rule Change Notice (2016) The effective date of each technical change since 1993 is shown in parenthesis at the end of the subsection/paragraph titles within the text of each Part. Unless a particular date and month are shown, the years in parentheses refer to the following ef
43、fective dates: (2000) and after 1 January 2000 (and subsequent years) (1996) 9 May 1996 (1999) 12 May 1999 (1995) 15 May 1995 (1998) 13 May 1998 (1994) 9 May 1994 (1997) 19 May 1997 (1993) 11 May 1993 Listing by Effective Dates of Changes from the 2015 Rules EFFECTIVE DATE 1 October 2015 shown as (1
44、 October 2015) (based on the contract date for new construction between builder and Owner) Part/Para. No. Title/Subject Status/Remarks 1-1-3/5 Service Limitations To specify classification notations for restricted service. (Incorporates Notice No. 1) Listing by Effective Dates of Changes from the 20
45、16 Rules Notice No. 1 (effective on 1 July 2016) to the 2016 Rules, is summarized below. EFFECTIVE DATE 1 July 2016 shown as (1 July 2016) Part/Para. No. Title/Subject Status/Remarks 1-1-A2/5.5 Product Quality Assurance Certification (PQA) Tier 4 (IACS UR Z26 Alternative Certification Scheme) To inc
46、orporate IACS UR Z26, which replaces UR M5 construction procedures, safety procedures and construction supervision remain the responsibility of the shipyard, the offshore unit or structures repairer, manufacturer, Owner or other client. For classification, the offshore units or structures are to com
47、ply with the requirements of the applicable Rules and/or Guides. 3 Certificates and Reports (1 January 1996) 3.1 Plan review and surveys during and after construction are conducted by ABS to verify to itself and its committees that an offshore unit, structure, item of material, equipment or machiner
48、y is in compliance with the Rules, Guides, standards, or other criteria of ABS and to the satisfaction of the attending Surveyor. All reports and certificates are issued solely for the use of ABS, its committees, its clients and other authorized entities. 3.3 ABS will release information from report
49、s and certificates to the cognizant authorities, e.g., Coastal State or Port State to assist in rectification of deficiencies during port state control intervention. Such information includes text of conditions of classification, survey due dates and certificate expiration dates. The Owner will be advised of any request and/or release of information. 3.5 ABS will release certain information to the offshore unit or structures underwriters and P for reasonable handling and loading; as well as for avoidance of distributions of weight which are like
