GRC Transactions, Vol.

37, 2013

Non-Destructive Testing Applied to Rig Inspection

(A Case Study of Menengai Geothermal Project)
Desmond Mulama and Anthony Ng’ang’a
Geothermal Development Company (K) Ltd. Nairobi, Kenya
[email protected]

Keywords Best Industry practice according to International standards

Non-destructive testing, Menengai Geothermal Project, rig i.e. API, DSI and statutory regulations require that drilling rigs
inspection, magnetic particle inspection, visual inspection, and their components be subjected to inspection and monitoring
electromagnetic inspection and drill string of their components to ensure their integrity of service, safety of
working personnel and reliability of information.

ABSTRACT 2.0 Logistics and Operations

This paper describes the various Non-destructive-testing Non-destructive Testing (NDT) in GDC commenced in 2012
(NDT) techniques that have been applied and used in ensuring following the need to investigate the integrity of equipment and as-
the integrity of geothermal drilling components at the Menengai sets and to monitor and improve the reliability of these equipment,
Geothermal Project in Kenya. tools and processes after being in use for approximately two years.
NDT is an analysis technique that finds wide application in The need to fast track the procurement of the inspection ser-
the Oil, Gas and Geothermal Industry to determine the state or vices was also necessitated by the rising cases of washouts and
function of equipment without requiring invasive approaches such failure of drill string components and resulting costs and extensive
as disassembly or failure testing. It mainly involves the statutory down time from tripping and fishing, or even loss of entire wells.
testing of the lifting equipment, derrick , the drill string and as- The inspection service entailed Magnetic particle/Visual/
sociated components. Dimensional inspection on BHA Tools such as; Drill Collar, Sta-
Other applications include maintenance/ repair aid testing of bilizers, Heavy weight drill pipes, Kelly, Roller Reamers, Fishing
miscellaneous equipment and quality and safety assurance testing Tools, Pup Joints, Various crossover subs, Penetrant Testing on
of new equipment parts and fabrications. Non-magnetic drill collars, Electromagnetic inspection on Drill
Aspects concerning the inception of the inspection service at Pipes, API Drifting/VTI for Casings/ Tubing and Visual/ MPI on
Menengai, the techniques/ methods and equipment applied, the Lifting equipment.
business significance of the project and areas of improvement are In addition, straightening of bent pipes, re-facing and hard
discussed and analyzed in this paper. banding of tool joints was part of the inspection services.
The tender was awarded to a local inspecting company, Qual-
1.0 Introduction ity Inspectors Limited, who followed guidelines provided by; API
(API RP 7G-2: Recommended practice for Drill Stem Design and
In the year 2009, the government of Kenya created the Geo- Operating Limits) and TH Hill (DS-1 Fourth Edition: Drill Stem
thermal Development Company to fast track the development of Inspection Standards). The inspectors also mobilized the services
geothermal resources in the country. The company was given the of an OCTG inspections supervisor as team leader to ensure the
mandate to drill up to 1400 steam wells to provide steam for the quality of inspection and to implement the effectiveness of inter-
generation of 5000MW of geothermal power by the year 2030. national practice.
For this reason, the company has so far acquired through pur-
chase 4 (2000Hp) drilling rigs complete with all the accessories, 3.0 Methods/Techniques and Equipment Employed
drill string tubular, cementing equipment, air drilling package,
fishing tools, directional drilling and lifting equipment to support The following is a summary of the NDT methods, equipment
its drilling operations. and required standards, which were applied.

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a) Visual Inspection d) Ultrasonic Testing (UT)

This is a Trained Naked-eye examination that was This method was used mainly to check the wall thick-
used to detect mechanical damages like gross fatigue ness of the tubular.
cracks, dents, corrosion, seal damages, hard facing, bevel
damages, box swell, tong space and thread damage on the e) Electromagnetic Inspection (EMI)
components. Pipe outside diameters were also inspected This method was used to locate three dimensional flaws.
using an OD gauge. It was used to evaluate the full length of drill pipes tubes for
However visual evaluation does not detect disconti- locating internal and external pitting, cuts, gouges, localized
nuities. Therefore inspections were not limited to visual wall loss and fatigue cracks.
examination.
There was an inspection protocol covering the delivery of
b) Magnetic Particle Testing (MPI) components and access to the rig and color coding of accepted and
MPI is consisted of the wet continuous magnetic par-
ticle inspection and the dry continuous magnetic particle
inspection.
The wet fluorescent MPI method was applied to the
BHA, HWDP tool joints & drill pipe tool joints. It was
used to detect transverse surface flaws in the tool-joints.
The Dry Magnetic Particle Inspection involves the ex-
amination of the external surface of drill pipe and HWDP
upsets and slip areas.
The pipes are magnetized with a DC magnetizing coil with
longitudinal magnetization for detection of transverse cracks.

c) Penetrant Testing
This is a very sensitive nondestructive testing method
that was used to detect very small surface discontinuities
that could not be inspected with MPI. (Picture 1. Showing an inspector conducting Magnetic Particle Inspection
on a drill pipe).

(Table 1. Different methods of NDT as applied to various equipment and the tools used).
Equipment Methods Defects Tools
Drill pipe tube bodies Electromagnetic Inspection Fatigue cracks, corrosion pits, mechanical EMI kit, Black light,
(API RP 7G) damage 220V, 100W.
Ultrasonic wall thickness measurement Wall reduction Inspection mirror,
Blanket,
OD (outside diameter) gauging OD wear, crushing, necking, swell
Spray can, lead
Visual inspection Mechanical damage gauge, profile gauge,
Dry magnetic particle inspection (MPI) Fatigue cracks in end areas vernier caliper, OD &
of end areas ID caliper, steel rule,
Electronic end area inspection Fatigue cracks, corrosion pits, mechanical tally meter, depth
damage in end areas gauge.
Optical inspection of internal upsets
Drill pipe tool-joints Visual Mechanical damage, weight/ grade identifi-
cation. (including thread damages)
Dimensional Mechanical damage, wear
Wet magnetic particle inspection / Fatigue cracks.
liquid suspension inspection
Rotary shouldered connections on drill Visual Mechanical damage Black light, 220V,
collars and BHA components Dimensional Mechanical damage, wear, inadequate BSR 100W.
(DCs, stabilizers, reamers and subs etc.) Inspection mirror,
Wet magnetic particle inspection (MPI) Fatigue cracks in threads.
Blanket, Spray can,
Ultrasonic inspection Fatigue cracks in threads lead gauge, profile
Tool bodies OD (outside diameter) gauging over the OD wear, crushing, necking, swell gauge, vernier cali-
full length per, OD & ID caliper,
Wet magnetic particle inspection (MPI) Fatigue cracks. steel rule, tally meter,
depth gauge.
Handling Equipment (Slips, tongs, eleva- Magnetic particle inspection of stressed AC yoke, Inspection
tors, Kelly drive bushings, rotary table areas mirror, penetrant, OD
bushings etc.) (API RP 7G) & ID caliper, Steel
Lifting equipment; (slings, chains, Air rule, Tally meter,
Visual Mechanical damage
receivers, cranes, forklifts, air winch lift- depth gauge
ing tackles.(API RP 7G) MPI of stressed areas Fatigue cracks

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(Table 2. Sample inspection report from GDC showing summary of tubular During fishing operations, for instance, a lot of effort is applied
defects). in attempts to free the string which most times, result to over pulls,
No. S/N
Condition
Remarks
tensional and bending stresses, increasing the need for periodic
Box Pin Body drill string inspection.
8” DRILL COLLARS(6 5/8R B X P)
1 R1-01DC C OK OK For Recut Box Connection Time Analysis for Different Activities
2 R1-02DC C OK OK Junk During a Drilling Operation
61/2” DRILL COLLAR(NC50 B X P)
1 FL1001837H C OK OK For Recut Box Connection Wait on
2 FL1002545 TD OK OK For Recut Box Connection Drilling Wait on Sticking Drilling Well
3 FL1001831H SD SD OK For Recut Box & Pin Connection Time Ops Repairs & fishing materials Logging Total
4 FL1001803 SD SD OK For Recut Box & Pin Connection Hours 1377.5 155.25 805.5 42 19 2399.25
5” HEAVY WEIGHT DRILL PIPE(NC50 B X P) Days 57 6 34 2 1 100
1 FL1003214H OK SD OK For Recut Pin Connection
% 57 6 34 2 1 100
2 FL100645H OK SD OK For Recut Pin Connection
3 FL1003160H SD OK OK For Recut Box Connection
4 FL1003125H SD OK OK For Recut Box Connection
5 FL1003189H OK SD OK For Recut Pin Connection
6 FL1003181H C OK OK For Recut Box Connection
SW/
7 FL10032244 OK OK For Recut Box Connection
BB
8 FL1003123H SD OK OK For Recut Box Connection
9 FL1000693H SD OK OK For Recut Box Connection
S/N – Serial number C – Crack TD – Thread damage
SD – Seal Damage SW – Swelled HB – Hard banding

rejected items. Every inspected item was given its own inspec-
tion report countersigned by both parties. (Client and contractor)
Where necessary a technical opinion was given covering integ-
rity of the item, test method and frequency of testing to enhance
components reliability. (Graph 1. Graphical representation of the time analysis above).

4.0 Significance/Benefits Arising From

Adopting NDT Being a pilot inspection project, there were a lot of challenges
faced in the execution of the project namely;
NDT was applied by GDC typically for the following reasons:
• The contract was limited to the quantities submitted
• Cost reduction for inspection by the drilling operations department. A
This includes costs incurred in purchase of replacement permanently based inspection system could address all
tools and spares, fishing, labor and other logistical costs that inspection needs where quantities to be inspected are not
results from equipment failure. Preventive maintenance limited.
costs a lot less than equipment failures.
• No site space was allocated for the exercise. This was dif-
• Improve equipment reliability and maximize produc- ficult since the inspectors were forced to use the drilling
tivity site and sometimes even operating from the catwalks. (As
Through reduced down times and increased perfor- shown in picture 2 below). A specific site should be set
mance expectancy of tools. aside for the inspection exercise, and not the storage yard
• Accident prevention or the rig sites.
Ensuring that employees and assets remain safe. • The inspection program was adversely interrupted by
Slings and other lifting tackles are inspected to ensure no weather (during heavy rains).
failure occurs during operation that could cause accidents.
Lifting equipment like cranes and forklifts are inspected on • There were considerable delays in the project resulting from
regular basis to ensure they are safe for use. the unavailability of handling equipment e.g. fork lifts and
their operators.
• Improve company’s competitive levels in the industry
Quality assurance in all operations, conservation of • Complex reporting structures that involved both the client
capital as well as being at par with the company’s overall and the service provider resulting in slow critical decision
time based targets. (i.e. 5000Mwe by 2030) making.
• Lack of consistency in the inspection service. The time lapse
A typical time analysis for a well drilled at Menengai shows between the first and the second inspection service contract
that, approximately 40% of total time is taken during wait on was overly extended, hence, some concerns/ problems that
repairs, sticking and fishing operations. could have been avoided occurred.

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Therefore, if a proper inspection system is imple-

mented, the above cost plus varying fishing costs would
be substantially reduced.
GDC should also implement a highly effective tubular
management system to increase efficiency and performance
of drilling operations. A tubular management system, with
a full inspection yard and machining shop, will streamline
the coordination between drilling operations and the inspec-
tion service, and improve the quality level and reliability of
components. The conventional method of bundling tubular
as currently followed by GDC, results in excessive damage
and subsequent costs. Use of a cradle system in packaging,
storage, transportation and handling of tubular will ensure
minimal damage and increased safety.

(Picture 2. NDT inspectors at work at the Menengai Geothermal site).

6.0 Conclusion
• Knowledge barrier between the expert and the supporting Non-destructive testing (NDT) inception was a timely and
staff also contributed to a slowed process since time was critical step taken by GDC towards improved operation standards
divided between teaching/ instructing and inspecting. and increased level of competitiveness in the geothermal industry
• Lack of critical inspecting equipment and spare parts, as a whole.
among many other challenges. This was a major driving force for the company towards
achieving its milestone goals of producing 5000Mwe worth of
steam by the year 2030 as mandated by the government of Kenya.
5.0 Areas of Improvement The company has a lot to achieve and will take even more bold
Following the inception of the inspection service by a third steps to ensure that the inspection service delivery is improved
party company to GDC, the project does not seem to have benefited and use the outcomes as key performance indicators to outline and
from additional investments, leading to stagnation in equipment measure its progress towards achieving strategic goals.
capitalization and human resource training and development. NDT An effective NDT culture will, consequently lead to the im-
at present fully depends on expatriate and third party labor, this provement of other key operations for the company. A separate
is proving to cost just as much as the failure costs we are trying inspection yard along with a proper tubular management system
to evade, since the company does not have trained and certified in place will provide the best improvement by operating as an
personnel and equipment to facilitate this need. independent system. Safety standards would also improve as an
Considering data collected from a sample of GDC’s completed outcome of the NDT inspection service.
wells at Menengai, the average drilling day rate is approximated
at USD. 30,000 and an average of 20 days are lost as down time 7.0 References
due to drill string and BHA failure. Thus the approximate cost GDC well completion reports
for the down times is;
Provision of Drill pipe Inspection Services at Menengai Geothermal Project;
30,000 X 20 = 600,000 USD (for every well) Final Inspection Report. GDC/HQS/029/2011.12

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