EQUIPMENT MAINTENANCE STRATEGY

INSPECTION, MAINTENANCE AND CALIBRATION

OF GAS / SMOKE / FIRE DETECTION & FIRE
FIGHTING SYSTEMS
Equipment code 2213
KCAD Class 384

CONTENTS

1. PURPOSE...................................................................................................................................2

2. SCOPE........................................................................................................................................2

3. EQUIPMENT CRITICALITY........................................................................................................2

4. RESPONSIBILITIES...................................................................................................................2

5. REFERENCES............................................................................................................................2
5.1 Reference documents........................................................................................................2
5.2 Associated forms................................................................................................................2

6. DOCUMENTATION....................................................................................................................3

7. ABBREVIATIONS.......................................................................................................................3

8. SAFETY CONSIDERATIONS.....................................................................................................3

9. GENERAL CONSIDERATIONS.................................................................................................3
9.1 Maintenance & Inspection..................................................................................................3
9.2 Calibration..........................................................................................................................4
9.3 Record Keeping.................................................................................................................4

10. MAINTENANCE STRATEGY.....................................................................................................4

10.1 Gas Detection Systems (Fixed).........................................................................................5
10.1.1 Monthly...................................................................................................................5
10.1.2 Yearly.....................................................................................................................5
10.1.3 3-Yearly..................................................................................................................5
10.1.4 On demand job (after rigmove)..............................................................................6
10.2 Smoke & Fire Detection Systems......................................................................................6
10.2.1 Monthly...................................................................................................................6
10.2.2 Yearly.....................................................................................................................6
10.3 Fire Extinguishers..............................................................................................................6
10.3.1 Monthly...................................................................................................................6
10.3.2 2-Yearly..................................................................................................................6
10.4 Fire Pumps & Ancillary Equipment.....................................................................................7
10.4.1 Weekly....................................................................................................................7
10.4.2 Monthly...................................................................................................................7
10.4.3 Yearly.....................................................................................................................7

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

11. REVISIONS.................................................................................................................................7

12. ATTACHMENTS.........................................................................................................................7

1. PURPOSE

The purpose of this maintenance strategy is to define the KCA DEUTAG minimum
maintenance & inspection requirements for gas / smoke / fire detection & firefighting
equipment.

2. SCOPE

This equipment maintenance strategy will apply to all KCA DEUTAG Land drilling rig
operations. This maintenance strategy contains the minimum requirements to avoid and
minimize a resulting potential risk

Different client requirements must be risk assessed and any deviation needs mutual written
approval.

3. EQUIPMENT CRITICALITY

Firefighting equipment and fire, gas and smoke detection equipment are classified as category
A that means its maintenance priority is high.

4. RESPONSIBILITIES

The Rig Manager / Drilling Superintendent is responsible for the implementation of this
maintenance strategy.

The Toolpusher is responsible for the safety and effectiveness of the operation.

The Maintenance Supervisor is responsible for the effective implementation and management
of maintenance & inspection, including record keeping.

The assigned maintenance person (e.g. mechanic/ electrician, driller etc.) is responsible for
the actual maintenance of the equipment.

5. REFERENCES

5.1 Reference documents

K-LD-EM-GU-003 – Guidance for Fire & Smoke Detection Systems on Land Drilling Rigs

5.2 Associated forms

N/A

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

6. DOCUMENTATION

The manufacturer’s manuals, certificates and other records must always be kept up to date
and be available for general reference/ review.
In addition key documents such as certificate of conformance are to be available from the
computerized maintenance system.

7. ABBREVIATIONS

KCAD KCA DEUTAG

HSE Health Safety and Environment
SET Safe, Efficient, Trouble-free
TRIC Task Risk Identification Card
WW World-wide
CMMS Computerized Maintenance Management System
ITM Inspection, Testing and Maintenance
PMR Preventative Maintenance Routine
GDS Gas Detection System

8. SAFETY CONSIDERATIONS

Maintenance and Inspection must only be performed by competent authorized personnel in

accordance with KCA DEUTAG and local / contract specific HSE regulations.

1. Carry out pre-job planning and risk assessment in accordance with local laws, KCA
Deutag and client policies, (TRIC, SET, WW-Standard, HSE-Manual, Work instruction)
etc. To support this, manuals must be available to clarify any queries.
2. Ensure work permits are obtained and, if required, isolate all energy sources before
working on equipment.
3. Personnel performing this job should be competent, be familiar with the equipment and
have received adequate instructions to perform the job safely.

9. GENERAL CONSIDERATIONS

Fire, Gas and Smoke Detection Systems comprises of various instruments, sensors, control
units and cabling. This equipment shall be fit for purpose, inspected, tested and maintained in
compliance with the manufacturer’s recommendations.

Firefighting Systems comprises of portable & fixed fire extinguishers, fire hoses and
components, fire blankets and flame retardant PPE. This equipment shall be fit for purpose,
inspected, tested and maintained in compliance with the manufacturer’s recommendations.

9.1 Maintenance & Inspection

Maintenance includes the visual inspection, adjustments, cleaning, lubrication, function-test,

and replacement of expendable parts, as necessary to maintain the serviceability of the
equipment.

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

It any repair work or replacement of components is required, on any detection / firefighting

system. The system must be recalibrated and function tested to ensure the system is fully
operational & system integrity is established.

9.2 Calibration

To correlate the readings of (an instrument) with those of a standard in order to check the
instruments accuracy. Reference gauge/ instruments must have valid calibration certification.
Tolerance or reference gauge shall be within ± 0.5 % of full scale, minimum tolerance. All
calibrations must be carried out in accordance with manufacturers’ recommendations.

9.3 Record Keeping

Two types of records are essential for the long term care of fire detection & firefighting
systems and equipment.

Original Documentation: Original documentation of existing fire detection & firefighting

systems (where available), and for all new systems shall be retained for the lifespan of the
system. A copy of these documents must be available at rig site for general reference /
review, and also uploaded to the relevant CMMS system. Original documents consist of
the following:

a) Date of installation;
b) As-built drawings;
c) Operation and maintenance manuals;
d) Installer information;
e) Designation of equipment types and inventory of devices;
f) Equipment and system settings
g) Equipment data sheets.

ITM Records: Inspection, testing and maintenance records shall be maintained for the
lifespan of the system. A copy of these records must be available at rig site for general
reference / review, and also uploaded to the relevant CMMS system. ITM records consist
of the following:

a) Date;
b) Procedure performed;
c) Name and signature of the servicing personnel and the organisation’s company
name;
d) Test results;
e) Equipment and system deficiencies;
f) Corrective actions, including parts replaced and settings or programming changes.

10. MAINTENANCE STRATEGY

Inspections, tests and maintenance of fire detection & firefighting systems shall be performed in
accordance with the manufacturer’s instructions. The following frequencies highlight the minimum
requirements for the essential care of fire detection & firefighting equipment however is not meant to
replace manufacturer’s instructions.

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

10.1 Gas Detection Systems (Fixed)

10.1.1 Monthly

Visual check of the fixed gas detection system:

1. Visual check the gas detection sensors for any cracks or damage.
2. Visual check the sensors dust/splash guards for cleanliness.
3. Visual check alarm sounder and flashlight for any cracks or damage.
4. Visual inspection of the accompanying cables, junction boxes and connectors
for cracks or damage.
5. Visual check gas detection control unit for power indicator and status indication
(for example: power indicator is "on", Malfunction and alarm indications are
"Off")
Function check of the fixed gas detection system:
6. Carry out the function test of gas detection system according to manufacturer
procedure. As minimum zero value test and function test with test gas need to
be done for each sensor. If required carry out re-calibration for each gas sensor.
Record the calibration data on the calibration sheet. The record must be kept by
KCAD for minimum next 3 years. If no local specific sheets are available, please
use KOMS template K-CW-EM-FO-005.
7. Initiate device-specific test functions verifying functionality and indicators during
operation, but if possible without activating rig shutdown (if applicable).

10.1.2 Yearly

System check of the fixed gas detection system:

1. Carry out complete system check of the Gas Detection System. Carry out re-
calibration according to manufacturer calibration procedure.
2. Record the calibration data on the calibration sheet. The record must be kept
for minimum next 3 years. If no local specific sheets are available, please use
KOMS template K-CW-EM-FO-005.
3. Initiate the tripping of device-specific test functions verifying functionality, with
activation of all applicable output switching functions.
4. Check function and condition of alarm horn, flash light and other activated by
alarm devices or equipment.

10.1.3 3-Yearly

1. Check condition of the Gas Detection System and accessories.

2. Check the calibration records from last 3 years for completeness.
3. Check that calibration was carried out in defined time intervals.
4. Check completeness of Gas Detection System documentation inclusive
drawings, calibration procedure and certificates.

Remark:
Additionally to the above mentioned checks, country specific regulations (ATEX,
GOST, etc.) and regional climatic requirements (Arctic, desert, seawater) need to
be taken into consideration.

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

10.1.4 On demand job (after rigmove)

After each Rig Move carry out following task items:

Visual checks:
1. Visual check the gas detection sensors for any cracks or damage.
2. Visual check the sensors dust/splash guards for cleanliness.
3. Visual check alarm sounder and flashlight for any cracks or damage.
4. Visual inspection of the accompanying cables, junction boxes and connectors
for cracks or damage.
5. Visual check gas detection control unit for power indicator and status indication
(for example: power indicator is "on", Malfunction and alarm indications are
"Off")

Function check:
6. Carry out the function test of gas detection system according to manufacturer
procedure. As minimum zero value test and function test with test gas need to
be done for each sensor. If required carry out re-calibration for each gas
sensor. Record the calibration data on the calibration sheet. The record must
be kept by KCAD for minimum next 3 years. If no local specific sheets are
available, please use KOMS template K-CW-EM-FO-005.

Note: Problems found should be corrected straight away and the toolpusher and
an electrical Supervisor should also be informed about these problems
immediately.

*- A competent person is someone who, through training and experience, has

sufficient knowledge to assess the safe and proper condition of the equipment to
be examined and re-calibrate.

10.2 Smoke & Fire Detection Systems

10.2.1 Monthly

1. Visual and function check smoke &fire detection system including sensors, call
points, alarm indicators.

10.2.2 Yearly

1. Change out batteries in the smoke detectors (if applicable)

10.3 Fire Extinguishers

10.3.1 Monthly

1. Visually check all fire extinguishers for any mechanical damage.

2. Visually check all fire extinguishers are correctly charged. Any fire extinguisher
that is not correctly charged must be taken out of service & a replacement fitted.

10.3.2 2-Yearly

1. All fire extinguishers to be returned to manufacturer for a factory service &

replacement

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 EQUIPMENT MAINTENANCE STRATEGY - LAND
INSPECTION, MAINTENANCE AND CALIBRATION OF
GAS / SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS

2. Record the change out date and fire extinguisher serial number in the PMR
history.

10.4 Fire Pumps & Ancillary Equipment

10.4.1 Weekly

1. Visually check the fire pump and ancillary equipment for any mechanical
damage.
2. Weekly run checks to be carried out in accordance with manufacturer’s
instructions.

10.4.2 Monthly

1. Check level and specific gravity of diesel engine battery electrolyte

10.4.3 Yearly

1. Close visual inspection of the equipment and all maintenance to be carried out
according to OEM requirements.

11. REVISIONS

SUBJECT: Strategy - INSPECTION, MAINTENANCE AND CALIBRATION OF GAS /

SMOKE / FIRE DETECTION & FIRE FIGHTING SYSTEMS
DOCUMENT NUMBER: K-LD-EM-GU-004
DATE: 15/03/2012 VERSION: 3
COUNTRY / LOCATION Corporate Wide : CW
APPROVER: Dieter Diroll
CUSTODIAN Ralf Liedtke

REVISION DETAILS New document for implementation.

.

12. ATTACHMENTS

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