Preventive Maintenance in Action: A 36-Unit Jacking System Health Assessment

Introduction: The Challenge

Maintaining the mechanical integrity of a jacking system is critical for the safety and operational capability of any offshore rig. A Hull 56 Electric Baker Marine jacking system operating, a detailed understanding of its current condition was required. The rig needed a thorough, expert assessment of its jacking system to identify potential failures before they occurred, ensure compliance with OEM standards, and plan future maintenance effectively. Without a baseline "health check," the risk of unexpected breakdowns, costly emergency repairs, and compromised operational safety remained unacceptably high.

Project Scope & Objectives

Formura Offshore Services was contracted to carry out a comprehensive Health Check of the entire jacking system. The scope was exhaustive, covering the mechanical components of all drive systems and the critical braking assemblies.

The primary objectives were:

• 100% Unit Coverage: Inspect all 36 jacking units across the Forward, Starboard, and Port legs (Chords A, B, and C on each leg).
• Multi-System Assessment: Evaluate the condition of every drive stage, including Primary Drives, Secondary Drives, and Final Drives on each unit.
• Brake System Inspection: Conduct a detailed inspection of the Stearns Self Adjusting Disc Brakes (82000 series) on all units, including solenoid air gap measurements.
• OEM Compliance: Execute all inspection activities strictly in accordance with OEM (Baker Marine) methods and instructions.
• Establish a Baseline: Provide the client with a comprehensive, unit-by-unit status report to inform maintenance planning and ensure operational readiness.

Key Challenges & Solutions

The Formura team, executed this high-intensity inspection project over a 10-day period (July 29 to August 7, 2023) in an offshore environment.

Challenge - Scale & Time Constraints: Inspecting all 36 units across three legs in just 10 days required meticulous planning and efficient execution to avoid disrupting rig operations.

Formura's Solution - Systematic & Methodical Approach: The team followed a structured workflow, moving leg-by-leg and chord-by-chord. They utilized a clear marking system (e.g., B.A1, S.C4) consistent with previous reports to ensure no unit was missed and data could be easily compared historically.

Challenge - Complexity of Multi-Stage Drives: Each unit contains multiple gear stages (Motor Pinion, 1st/2nd Reduction, Final Gear) with varying tooth sizes and pitch (e.g., 7T ¾” P, 12T - 3 P, 64T - 1-1/2” P), each requiring specific inspection criteria.

Formura's Solution - Specialized Technical Expertise: Formura's engineers demonstrated deep knowledge of the Baker Marine system. They meticulously inspected each component for specific failure modes, including pitting, plastic deformation, uneven surfaces, sharp edges, and visible cracks, tailoring their assessment to each gear type.

Challenge - Critical Brake System Assessment: The Stearns self-adjusting disc brakes are safety-critical components. Simply looking for visible damage is insufficient; internal wear can lead to failure.

Formura's Solution - Precision Measurement & Inspection: The team didn't just visually inspect the brakes. They measured critical parameters like the brake solenoid air gap and inspected the motor coupling for seal leaks, grease leaks, and wear, ensuring the entire braking mechanism was assessed for functionality, not just external damage.

Challenge - Offshore Logistics & Access: Working on an active rig field presents access and logistical challenges, requiring the team to be self-sufficient and adaptable.

Formura's Solution - Experienced Offshore Personnel: The team's prior experience in offshore environments allowed them to navigate the logistical constraints effectively, bringing the necessary tools and expertise to complete the inspection scope without relying on extensive rig resources.

Project Results

Formura Offshore Services successfully delivered a complete and detailed health check of jacking system, completing the project within the scheduled 10-day offshore window.

Key Results:

• 100% Scope Completion: All 36 jacking units across the FWD, STBD, and PORT legs were thoroughly inspected, leaving no component unassessed.
• Comprehensive Baseline Established: The client received a detailed, unit-by-unit status report on all primary, secondary, and final drives, creating a vital baseline for future condition-based maintenance.
• Safety-Critical Brake Data Acquired: Detailed inspections and air gap measurements of the Stearns disc brakes on all units were completed, ensuring this critical safety system was fully understood.
• Informed Maintenance Planning: By identifying components with pitting, deformation, or wear, the health check enabled to move from reactive repairs to proactive, planned maintenance, significantly reducing the risk of future operational downtime.

Conclusion

This project exemplifies Formura Offshore Services' capability to deliver high-quality, technical inspection services in demanding offshore conditions. The successful completion of the jacking system health check provided the client with essential data to ensure the safety, reliability, and longevity of their asset. It underscores Formura's role as a trusted partner not just for repair, but for the critical diagnostic work that prevents failures before they start.