54 Units, Zero Compromises: Full-Scope ABS Re-Certification

Introduction: The Challenge

The Rig, a design 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. Unlike previous sister projects, full rope access support was available, enabling complete structural assessment alongside the mechanical inspections.

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 mechanical and structural component across all 54 units on the FWD, STBD, and PORT legs.

The primary objectives were:

• 100% 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.
• 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 25/29 brakes, including cleaning, visual inspection, and air gap measurement.
• Complete Structural Assessment: Inspect leg guides and wear plates with precise measurements taken by the rope access team.
• Alignment Verification: Perform manual RPD (Rack Phase Difference) measurements on all chords and compare with system readings to verify alignment accuracy.
• Fixation System Inspection: Inspect the fixation system condition and engagement.
• OEM Compliance: Execute all inspection activities strictly in accordance with OEM methods and instructions to satisfy ABS requirements.

Key Challenges & Solutions

The Formura team, executed this high-intensity inspection project over a 20-day period (May 22 to June 10, 2025).

Challenge – Massive Scale & Tight Timeline: Inspecting 54 units across three legs within 20 days required precise planning to avoid delays in re-certification.

Formura’s Solution – Structured Execution: A systematic leg-by-leg and chord-by-chord workflow with clear markings (A1–C18) ensured complete coverage, accurate data collection, and efficient comparison.

Challenge – Complex Multi-Stage Drive Systems (CJ46 Design): Multiple gearbox stages and CJ46-specific configurations demanded specialized inspection methods.

Formura’s Solution – Advanced Expertise & Tooling: Engineers used deep design knowledge and borescope inspections to examine internal gearbox components for wear, deformation, and cracks without disassembly.

Challenge – Strict ABS Certification Requirements: All components required precise verification and documentation to meet certification standards.

Formura’s Solution – OEM-Compliant Inspection: The team followed OEM protocols, inspected all gearbox elements, coordinated oil handling, and reviewed analysis reports to ensure full compliance.

Challenge – Safety-Critical Brake System Inspection: Brake performance depended on correct air gap and component condition.

Formura’s Solution – Precision Measurement: Brakes were cleaned, visually inspected, and accurately measured to confirm safe operation within OEM limits.

Challenge – Complete Structural Assessment: Leg guide and wear plate measurements required specialized access and accuracy.

Formura’s Solution – Rope Access Coordination: Dedicated rope access support enabled precise measurement and full structural documentation.

Challenge – Critical Alignment Verification (RPD): System readings alone could not ensure accurate alignment.

Formura’s Solution – Dual Verification: Manual RPD measurements across all chords were cross-checked with system data to meet ABS verification standards.

Challenge – Fixation System Integrity: The fixation system required full inspection for safe jacking operations.

Formura’s Solution – Thorough Visual Inspection: Condition and engagement were verified as part of the certification scope.

Project Results

Formura Offshore Services successfully completed a comprehensive 5-Year ABS Re-Certification inspection of the rig jacking system, achieving 100% scope completion within the planned 20-day offshore window.

Key Results:

• Full Scope Coverage: All 54 jacking units across FWD, STBD, and PORT legs were fully inspected, assessed, and documented.
• Certification Baseline Established: A detailed unit-by-unit status report covering all drive stages created the official ABS re-certification record.
• Advanced Internal Inspection: Borescope technology enabled internal gearbox examination without costly disassembly, confirming component condition.
• Brake Safety Verification: Inspections and air-gap measurements of all Pintsch Bubenze SFB 25/29 brakes ensured full safety documentation.
• Structural Integrity Confirmed: Wear plate measurements and manual RPD verification validated alignment and compliance with ABS requirements.
• Fixation System Verified: Visual inspection confirmed correct engagement and proper condition.
• Regulatory Compliance Achieved: All work followed OEM and ABS standards, delivering complete documentation for successful re-certification.

Conclusion

Demonstrating expertise in complex offshore inspections, Formura completed the Rig 5-Yearly ABS re-certification with verified safety and compliance outcomes. Using advanced technology, structured methodology, and OEM-aligned execution, the project reinforced Formura as a reliable partner for critical offshore certification.