GUIDANCE NOTES FOR

SURVEY AND INSPECTION OF JACKING

SYSTEMS

JULY 2016

American Bureau of Shipping

Incorporated by Act of Legislature of
The State of New York 1862

Copyright  2016
American Bureau of Shipping
ABS Plaza
16855 Northchase Drive
Houston, TX 77060 USA
This Page Intentionally Left Blank
GUIDANCE NOTES FOR
SURVEY AND INSPECTION OF JACKING SYSTEMS

CONTENTS

1 Purpose ............................................................................................................... 1
2 Definitions........................................................................................................... 1
3 General Survey Requirements.......................................................................... 1
4 Frequency of Surveys......................................................................................... 1
5 Design Specific Survey Requirements.............................................................. 2
Purpose

The purpose of these Guidance Notes is to establish a guideline for minimum

requirements for inspection of Rack and Pinion jacking gear at Special Periodical
Survey of Hull for Self-Elevating Drilling Units so that the application of the below
noted Rule requirement will be uniform throughout ABS.

Part 7, Chapter 2, Section 5, paragraph 13.15 is the current requirement for inspection
of jacking gear, see excerpt below from the ABS Rules for Building and Classing Mobile
Offshore Drilling Units.

13.15 Self-Elevating Drilling Units – Leg Jacking Systems (2011)

On self-elevating type drilling units, leg jacking 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
Surveyor’s satisfaction, by an effective crack detection method.
At Special Periodical Survey No. 2 and subsequent Special Periodical 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 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 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:

 Baker Marine
 Friede & Goldman
 Keppel FELS
 LeTourneau
 NOV/BLM
Definitions

Closed Systems – Jacking systems that cannot carry out a visual examination of the
gears in place by removal of inspection covers, as not all Closed Designs are fitted with
inspection covers. These types of systems, without inspection covers, have to 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. Typical designs of
this type are the Friede & Goldman, Keppel FELS, and BLM.

Open Systems – Jacking systems that are fitted with removable inspection covers that
enable in-place visual examination of the gears. Typical designs of this type are
LeTourneau/Cameron, Baker Marine and National Oilwell Varco.

Jacking Gear Function Test – Operational testing of the jacking gear while jacking
under normal load, distance to be jacked is one complete revolution of the climbing
pinion.
General Survey Requirements
It is recommended that the following requirements be applied to all Units and jacking
System designs:
1. Record Keeping – Number of hours and loading while jacking should be kept for
review and used as a reference for the required examinations. These records
should include hours jacking under preload, normal loading, pulling stuck legs
and jacking in heavy weather. Verification of these records should be done at
each Annual Classification Survey.
2. Lube Oil Analysis – Lube oil from the gear boxes of systems that are designed as
“closed systems”, e.g. planetary drive type, should be taken and analyzed twice
each year, as a minimum. When excessive metal content or other conditions that
would indicate possible failure of the gearbox are found, the gearbox is to be
examined. Examination may consist of removal of the gearbox and opening in a
controlled environment, or the Owner may opt for a thorough internal boroscope
survey, along with changing or filtration of oil, along with another oil sample
after operation. Any issues raised from oil sample results are to be resolved prior
to completion of the Special Survey.
3. Climbing pinions should be closely examined at each Special Survey, tooth
profile checked and non-destructively tested as considered necessary.
4. Rack tooth profiles are to be examined and compared to the tolerances set by the
Unit’s designer. Any out of tolerance must be corrected. Areas of the 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.
a. Rack tooth profiles should be generally examined at each attendance
during Special Survey
b. Vessel records shall be examined for areas of the legs where jacking under
preload and where legs are highly loaded during leg penetration
c. Vessel records shall be consulted for areas of known leg damage
Commented [RG1]: Suggest following verbiage be incorporated
somehow to this item…”given due consideration to installation of
new parts and subsequent re-filtering and analysis. Examination via
boroscope is also acceptable provided sufficient ports are provided
to allow for thorough internal examination.
Commented [DR2]: I do not believe it is reasonable to
determine the rack to be examined by reviewing operational records
nor is it reasonable to try to identify areas most “highly loaded”
during jacking operations while going on location. Reason being:
1. Operational records will not readily provide information to
determine “highly loaded” areas. It would be an arduous task to
research operational records for this purpose.
2. Typical Jackups have leg lengths ranging from 360 ft to 500 ft.
The rigs operate in water depths ranging from 20 ft to 300 ft. Leg
penetration typically ranges from 5 ft to 100 ft. “Typical”
difference between initial penetration and final penetration during
preload operations ranges from 0 ft to 40 ft. (same applies to
jetting operations).
Each location is unique which leads to the loads being distributed
over an extensive length of rack.
It is not reasonable to expect a surveyor to target inspections on the
“highly loaded” area of the rack as he simply cannot determine
where to look. It is also not reasonable to inspect the entire leg as
there will be 3 legs consisting of 3 or 4 racks per leg (6 or 8 for
opposing pinion configurations).
I recommend changing guidance to be:
1.Examine rack tooth profile accessible to surveyor during each
attendance during the SPS (as the SPS typically requires multiple
visits at which time the rig is both elevated and floating which
gives access to multiple rack elevations).
2.a general visual inspection
3. interview the crew for known damage
Commented [RG3]: I agree with Darrel on this, but I think this
is where ABS is going with this wording:
1)They know the leg rack experiences highest loading during
preloading operations
2) Today’s newer more capable rigs can jack with preload either
partial (establishing location) and with full preload after
establishing location.
3)Due to above, I don’t see them changing this but I do agree
adding the additional guidance Darrel shows above. It makes
more sense from a general standpoint. Anything giving us and the
surveyor more options or ways to satisfy a requirement is good.
Commented [DF4R3]:
 5. Shock pads, were fitted, are to be examined, dimensions confirmed to be in
accordance with the OEM specifications and found or placed in satisfactory
condition.

6. Leg guide wear plates are to be examined and found or placed in satisfactory
condition.
a. Liners are to be confirmed to be in place.
b. Liners are to be examined for cracking or missing retaining welds.
c. Liner wear is to be within OEM tolerances.
Note: Lower liners are to be examined while the vessel is elevated.
Commented [DR5]: Recommend additional guidance be
provided to the surveyor:
1.Lower leg guides must be examined during elevated position as
they are not accessible while rig is in floating condition.
2.Advise the surveyor that review of drilling contractor’s
maintenance records on leg guide wear plates in lieu of
examination is acceptable.

7. General conditions of the jacking installation including all auxiliary equipment

to be inspected for damage, wear, or corrosion. This to include items such as
the gearbox and motor, foundations, mounting arrangements, bolting, and
connection couplings. Other ancillary equipment such as operating and control,
piping and wiring installations along with their supporting structures should also Commented [CA6]: It is assumed that this is supposed to be
checked by the surveyors, but I still see dangerous conditions that
be included. could result from corrosion or piping and wiring issues and would
like to see it specially noted to remind surveyors. .

Commented [RG7]: Due to lack of close-up access to lower

guides at different times of operation, and as an alternative way to
satisfy the requirement, I agree.

Frequency of Surveys

1. 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 Surveyor’s
satisfaction, and if considered necessary by an effective crack detection method.

2. Commencing at Special Periodical Survey No. 2 the Jacking Gear is to be

examined in accordance with the ABS Rules every five years at Special Periodical
Survey by the Original Equipment Manufacturer (OEM) or a third part mutually
agreeable to the Owner and ABS. Drilling Contractor shall submit a plan to ABS
addressing any findings from the Jacking Gear examination and a timeline for
any required component renewals.
Commented [RG8]: Agreed! We did this on E86 and E87 last
year and ABS NOLA and ABS Houma had no issues with their
acceptance to this approach.
Commented [DR9]: Advise surveyor that drilling contractor is
required to submit a plan to the surveyor addressing findings from
the 3rd party inspection. Surveyor will then review/reject/accept
contractor’s plan.

In recent years, the surveyors have used the inspection reports to

create class recommendations requiring repair/renewal of jacking
system components. Most surveyors do not have the expertise or
experience to interpret the inspection reports and determine
appropriate repair/renewal of jacking system components.
3. Consideration may be given to allowing the Jacking Gear to be examined under
continuous survey, i.e. a percentage of the Jacking Gear to be examined 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 Unit’s records, VIM Database,
where it will be available to the attending surveyor.

4. Jacking Gear could be put on the ABS Preventive Maintenance Program where
the gear is examined in accordance with an ABS Approved maintenance plan that
is based on the OEM recommendations and the maintenance records are reviewed
at each Annual Survey. The requirements for the Preventive Maintenance
Program are found in Part 7, Appendix 14 of the ABS Rules for Building and
Classing Steel Vessels, section 3. In addition to the requirements in Appendix
14, the Preventative Maintenance Plan for Jacking Gear will be required to be
submitted to the Corporate Offshore Survey Department for review. This is due
to the specialized nature of this equipment. This plan will then be placed in the
Unit’s records, VIM Database, where it will be available to the attending
surveyor.

Preventative Maintenance Programs for Jacking gears may contain the following:
a. History of each gearbox or gear, including:
i. Time in service
ii. Hours used
iii. Loads
iv. Oil sampling frequency
v. Oil sampling method
vi. Trending of oil samples
vii. Record of extreme events affecting jacking system
b. List of items to be examined
c. Acceptance criteria for each item
d. Provisions for oiling or preventing corrosion while in static condition
e. Ordering of worn components prior to end of life, so replacements will be
available even though components have long lead times
f. Consideration of the historical performance of the jacking system when
evaluating components
g. Maintenance of training records for personnel conducting examinations
Design Specific Survey Requirements

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 – This category includes Baker Marine, LeTourneau and
National Oilwell designs. All gears are to be visually examined as needed
based on the jacking hours, either through removal of gears, inspection ports,
or by removal of covers. Boroscope examination may be acceptable provided
that there are sufficient ports to give a thorough examination. Bearing
clearances should be evaluated measured and results evaluated 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 gear mesh patterns give an indication of bearing wear.

2. Closed Type Systems – This category includes Friede & Goldman, BLM, and
KeppelFELs designs. As these gears can only be opened and examined in a
workshop, unless fitted with inspection covers, it is recommended that for the
second Special Survey (10 years) and subsequent Special Surveys, that one
gear box be examined, this may be modified 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 a there are sufficient ports to give a thorough examination of all
gears. It is recommended that the gearbox with the most hours of service, or
highest loads 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 testing would be
required 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 recommended tolerances. Upon completion of
inspection, a function test is to be carried out including an examination while
in operation.