54 Units, One Objective: ABS Re-Certification for Rig

Introduction: The Challenge

The Rig, a jack-up operating, reached its mandatory 5-yearly inspection milestone for ABS (American Bureau of Shipping) Re-Certification. This comprehensive examination is critical to verify the continued integrity, safety, and regulatory compliance of the jacking system—the fundamental mechanism ensuring the rig's stability and positioning capability. With 54 individual units spread across three legs, each containing complex primary, secondary, and planetary gearboxes, the task was monumental. The inspection demanded meticulous non-destructive examination of countless components, precise measurements of wear and alignment, and strict adherence to OEM methods—all within a limited offshore window. Adding to the complexity, the rope access team required for guide wear plate measurements was unavailable during the inspection period, requiring adaptive planning to maximize the scope within existing constraints.

Project Scope & Objectives

Formura Offshore Services was contracted to execute the complete 5-Yearly ABS Re-Certification inspection on the Rig jacking system. The scope was exhaustive, covering every accessible mechanical component across all 54 units on the FWD, STBD, and PORT legs.

The primary objectives were:

• Maximum Feasible Unit Coverage: Inspect all 54 jacking units across all three legs (LEG 1-FWD, LEG 2-STBD, LEG 3-PORT), covering chords A, B, and C on each leg, within the constraints of available support services.
• Multi-System Assessment: Evaluate the condition of every drive stage, including Primary Drives, Secondary Drives, Final Drives, and Planetary Gearboxes.
• Advanced Borescope Inspection: Utilize borescope technology to internally inspect planetary gearboxes (internal gears, ring gears, planetary gears) and primary gearboxes (motor pinion, gears, pinions) without full disassembly.
• Brake System Inspection: Conduct detailed inspection of the Pintsch Bubenze SFB 40/50 brakes, including cleaning, visual inspection, and air gap measurement.
• Alignment Verification: Perform manual RPD (Rack Phase Difference) measurements on all chords and compare with system readings to verify alignment accuracy.
• Partial Structural Assessment: Conduct visual inspection of leg guides and wear plates, documenting condition despite the absence of rope access for precise measurements.
• OEM Compliance: Execute all inspection activities strictly in accordance with OEM (Gusto MSC) methods and instructions to satisfy ABS requirements.

Key Challenges & Solutions

The Formura team, executed this high-intensity inspection project over a 21-day period (April 30 to May 20, 2025).

Challenge

Formura's Solution

Challenge - Massive Scale: 54 Units in 21 Days: Inspecting all 54 units across three legs within a tight offshore window required meticulous planning and flawless execution to avoid delays in the re-certification timeline.

Formura's Solution - Systematic & Methodical Approach: The team followed a structured workflow, moving leg-by-leg and chord-by-chord using a clear marking system (A1 through C18). This ensured maximum coverage with no units missed and allowed for efficient data collection and comparison.

Challenge - Complex Multi-Stage Drive Systems: Each unit contains multiple gear stages (rack pinion, primary gearbox with multiple pinions and gears, planetary gearbox with internal gears and planetary gears) requiring specialized inspection techniques.

Formura's Solution - Specialized Technical Expertise & Advanced Tooling: Formura's engineers demonstrated deep knowledge of the design. They employed borescope technology to inspect internal components of planetary and primary gearboxes without disassembly, examining for pitting, scuffing, abrasive wear, plastic deformation, sharp edges, and visible cracks.

Challenge - Critical ABS Certification Requirements: The inspection had to satisfy stringent ABS standards for re-certification, leaving no room for error or omission. Every accessible component had to be verified and documented.

Formura's Solution - Comprehensive OEM-Compliant Protocol: The team adhered strictly to OEM methods, inspecting every aspect of the gearboxes: housings, bolts, oil filling plugs, breathers, oil seals, shims, and foundation bolts. They also coordinated with rig crew for oil draining/filling and reviewed oil analysis reports, ensuring full compliance with certification requirements.

Challenge - Inspection of Safety-Critical Brake Systems: The Pintsch Bubenze SFB 40/50 brakes are critical for holding the rig's weight. Proper function depends on precise air gap settings and component condition.

Formura's Solution - Precision Brake Inspection: The team cleaned and visibly inspected each brake for abnormalities, then precisely measured the brake gap. This ensured all braking systems were within OEM specifications and capable of safe operation.

Challenge - Rope Access Team Unavailability: The dedicated rope access team required for taking precise guide wear plate measurements was not available onboard during the inspection period, creating a potential gap in the certification scope.

Formura's Solution - Transparent Scope Management & Maximized Effort: The team clearly communicated this constraint to the client while still performing visual inspections of the leg guides and wear plates. All accessible observations were documented, providing partial structural assessment data while clearly noting the limitation for the certification record.

Challenge - Verification of Critical Alignment (RPD): Rack Phase Difference (RPD) is a critical parameter for smooth jacking operations. Relying solely on system readings could mask underlying issues.

Formura's Solution - Dual-Verification Protocol: The team manually measured RPD on all chords across all three legs and compared these readings with the system RPD. This dual-verification approach provided absolute confidence in the alignment data and satisfied ABS requirements for independent verification.

Project Results

Formura Offshore Services successfully delivered a comprehensive 5-Yearly ABS Re-Certification inspection of the Rig jacking system, maximizing the achievable scope within the available resources and completing the project within the scheduled 21-day offshore window.

Key Results:

• Maximum Feasible Scope Completion: All 54 jacking units across the FWD, STBD, and PORT legs were thoroughly inspected for internal and external condition, leaving no accessible component unassessed.
• Comprehensive Certification Baseline Established: The client received a detailed, unit-by-unit status report covering all primary, secondary, final, and planetary drives, creating the official inspection record required for ABS re-certification.
• Advanced Internal Inspection Completed: Borescope technology successfully examined internal gearbox components without costly and time-consuming disassembly, providing confidence in internal component condition.
• Safety-Critical Brake Data Acquired: Detailed inspections and air gap measurements of all Pintsch Bubenze SFB 40/50 brakes were completed, ensuring this critical safety system was fully documented and verified.
• Alignment Independently Verified: Manual RPD measurements on all chords confirmed alignment accuracy when compared with system readings.
• Transparent Constraint Documentation: The team clearly documented the limitations regarding guide wear plate measurements due to rope access unavailability, ensuring the certification record accurately reflected the inspection scope.
• Regulatory Compliance Progress Achieved: All accessible inspection activities were executed to OEM methods and ABS standards, providing the client with substantial documentation for the re-certification process.

Conclusion

This project exemplifies Formura Offshore Services' capability to deliver high-stakes, regulatory-mandated inspection services in demanding offshore conditions, even when faced with resource constraints. The successful completion of the Rig 5-Yearly ABS Re-Certification inspection provided the client with essential data to ensure the safety, compliance, and continued operational reliability of their asset. By combining systematic methodology, advanced borescope technology, strict adherence to OEM standards, and transparent communication about limitations, Formura demonstrated its role as a trusted, honest partner for the critical certification work that keeps offshore assets compliant and operational.