Maintenance and repairs system, made on condition includes:
Equipment performance control
- visual and instrumental condition monitoring
- technical diagnostics
- periodic (scheduled maintenance)
Repairs on condition:
- scheduled (based on current condition)
- off-schedule (emergency repairs)
The following procedures are made during equipment performance control:
-visual control, describing general condition and configuration/
- instrumental control (dimensional examination)
- technical diagnostics
Visual control is conducted to find surface defects of threads and metal parts that could arise during equipment assembly and operation. Visual control is performed with an unaided eye or using optical instruments prior to instrumental control and non-destructive testing. Visual control helps to check and determine the following:
- mechanical damage (ruptures, fractures, blisters and compression marks)
- base-metal decomposition, cracking and overlaps.
- thread defects
- defects of details and assembly units
- unfastening of screw threads
- equipment configuration
Instrumental control (dimensional examination) is used to define if details and assembly units dimensions currently used comply with regulations and specifications and to evaluate damage tolerance of defects found after visual control.
To measure shape and dimensions of equipment, assembly units, details, threads and surface defects only calibrated serviceable tools are used.
Instrumental control (dimensional examination) helps to measure the size of:
- thread damage
- base metal mechanical damage
- worn-out surface
- corrosive areas
- form deviations and misalignments of detail's surfaces
Technical diagnostics includes runtime, scheduled and off-schedule equipment checks:
- runtime diagnostic check is performed according to survey schedule fixed in diagnostic program
- scheduled check is made at least once in 3 month
- off-scheduled diagnostics is held if a client or service provider informs us that such a need arises.
Mechanical condition report is made after technical diagnostics is finished.
Maintenance and repairs are made according to service manuals worked out for each mud motor type. The manuals describe maintenance, diagnostic and repair procedures. All works done and troubles found during checkup inspection are put into mechanical condition chart (shift log).
The following works are done during scheduled maintenance:
- balancing and leveling check
- check and tensioning of all threaded connections
- full equipment units check
- oil level check and lubrication according to lube chart
- replacement of quick-wear parts
- sealing check and replacement if needed.
All works done and troubles detected are reported in maintenance, mechanical condition and repairs chart indicating:
- maintenance date
- maintenance type and works done
- detected defects and troubles
- time between maintenance
- amount of details and units replaced
- amount and costs of details and consumables involved
- out-of-service time
Repairs based on condition is made on completion of diagnostics and can be scheduled or off-schedule.
Scheduled repairs are performed according to annual and monthly roadmaps (replacements/ upgrades).They are developed on the basis of updated diagnostic forecast with account for amount of works defined during mechanical condition control. Roadmaps are made for one month with all additional works included.