Chapter 5 Layout and Assembly
Section Contents
Scope ..
Definitions... .
Layout and Assembly Area.
Assembly Procedure
Assembly Procedure Template.
List of Figures
5.1 Bill of Materials for EXAMPLETOOL.
5.2 Assembly Drawing for EXAMPLETOOL.
2229gg99
88 DS-1° Fourth Edition, Volume 4, Drilling Specialty Tools
Chapter 5
Layout and Assembly
5.0 Scope. This chapter addresses the layout and
assembly of specialty tools and sub-tools covered by
this standard.
5.1 Definitions. Definitions of terms used in this chapter
are listed below.
5.1.1 Assembler. A person who assembles a tool
or sub-tool.
5.1.2 Assembly (noun). A common oilfield
expression to describe a series of tools or other
drill string elements that are joined together. For
example, "bottom hole assembly." Except in Chapter
8, the word "assembly" is not used as a noun in this
standard.
5.1.3 Assembly Alert Notice. A notice issued to
alert an assembler that an immediate amendment
to or modification of an assembly procedure or other
document is necessary.
5.1.4 Assembly area. An area within the vendor's
facility that is set aside for layout and assembly of
specialty tools.
5.1.5 Assembly check sheet. A check list upon
which the tool assembler records or checks off the
tool assembly steps that are required in the tool
assembly procedure.
5.1.6 Assembly drawing. A document that shows all
the components listed on a specialty tool or sub-tool
Bill of Materials in their final assembled state.
5.1.7 Assembly procedure. A written step-by-step
guide an assembler follows for assembling a specialty
tool or sub-tool
5.1.8 Assembly report. A report prepared by the
assembler as outlined in this chapter.
5.1.9 Auxiliary component (or auxiliary sub-tool).
A component or sub-tool that accompanies a tool
to the rig but is not attached to the tool or run in the
string with the tool. For example, a pump-down plug.
5.1.10 Bill of Materials (BOM). A document that
lists quantities, part numbers and descriptions of all
the components required to assemble a complete
specialty tool or sub-tool.
5.1.11 Component record. A document that confirms
to the assembler that a component is ready to be used
in the assembly of a tool.
5.1.12 Configuration. A designation that reveals how
a specialty tool is trimmed or dressed. For example,
an 8-inch EXAMPLETOOL can be configured with
either 6-5/8 Regular or NC56 end connections.
5.1.13 Significant dimension. A dimension on a
specialty tool that would normally be of interest to
rig personnel.
5.1.14 Dressing a tool. Also called “trimming.” A
process used during tool assembly that allows tools of
the same model number and part number to function
differently from one another.
5.1.15 Expendable component. A component that
is always replaced with a new component of identical
part number upon disassembly and reassembly of a
tool or sub-tool.
5.1.16 Job order (or Work order). A document that
specifies all the tools, sub-tools, and auxiliary tools,
and the desired finished configuration of the tools,
‘sub-tools, or auxiliary tools that the assembler is to
produce.
5.1.17 Layout (verb). The act of setting out all
required components, of verifying correct component
part numbers against a Bill of Materials, and of
verifying the presence of all required component
records and other required documentation for the
laid-out components, before assembling them into
a specialty tool.
5.1.18 Makeup Torque. The torque to which
threaded connections (including rotary shouldered
connections) in the tool, components and sub-
components will be screwed together during
assembly.
5.1.19 OEM approved parts supplier. A source of
replacement parts for specialty tools that is approved
by the tool manufacturer. TH)
THHill Associates, Inc.
HILL :
5.1.20 Part number. A number that identifies one type
of component from other (dissimilar) components,
Identical components will have the same part number.
5.1.21 Serial number. A unique identifier assigned
to a specific component to differentiate it from other
components of the same part number. Identical
serialized components will have the same part
number but different serial numbers.
5.1.22 Serialized component. A component that
is assigned a serial number.
5.1.23 Trimming a tool. See "dressing a tool."
5.1.24 Work order. See "Job order."
5.1.25 Temporary retaining device. A device
intended to temporarily hold a component or sub
tool in a specific position until a threshold amount
of force is applied to the temporary retaining device.
Force exceeding the threshold causes the temporary
retaining device to release the component or sub tool
from the restrained position.
5.2 Layout and assembly area. The vendor shall
provide a work space of sufficient size to allow the
assembler to comfortably and efficiently layout all
components and assemble the tool. The work space
must be free of other operations that may distract the
assembler, or that may interfere with the assembly
process. It must provide adequate space for all layout
and assembly operations. It must provide access to all
the tools and equipment required for proper assembly
Assembly of only one tool at a time is allowed in a single
assembly area.
5.3 Assembly Procedure. Prior to beginning; the
assembler shall have in his/her possession the latest
revision of the assembly procedure for the exact model
tool that is to be assembled. The assembly procedure
shall meet the following requirements:
5.3.1 Stand-alone document. The assembly
procedure must be devoted solely to assembly of the
relevant tool or sub-tool. Thatis, it should not address
other operations such as inspection, manufacture
oF quality control, except when doing so aids the
assembly process.
5,3.2 Sequential order. The procedure shall lead
the assembler through sequential assembly steps in
their proper order.
58
5.3.3 Matching nomenclature. The assembly
procedure shall use the same component part
numbers and names that are used on the Bill of
Materials and assembly drawing(s) for that tool
model.
5.3.4 Dressing. If the tool or sub-tool in question
can be dressed in more than one configuration, the
assembly procedure shall give separate instructions
for each of the possible configurations.
5.3.5 Hand tools and equipment. The assembly
procedure shall list all the hand tools and equipment
the assembler will need to properly assemble the tool
or sub tool. If any hand tools or assembly equipment
require prior calibration, the manufacturer or vendor
shall maintain suitable calibration records.
5.3.6 OEM approved parts. The assembly
procedure shall require the assembler to use only
parts approved by the tool manufacturer.
5.3.7 Makeup Torque. The procedure shall provide
or reference makeup torque values for each threaded
connection being screwed/assembled during the
assembly process. Thread compounds and makeup
torques shall be as specified by the appropriate API
specification, or the proprietary tool joint connection
manufacturer, or the end user.
5.3.8 Visual Examination of Incidental
Components. The procedure shall include guidelines
for visual examination (to check for wear, thread
galling, damage, etc.) and acceptance criteria for
incidental components.
5.3.9 Specific Requirements. If the tool belongs to
‘one of the tool families described in table 7.1, then
the assembly procedure developed by the vendor
must include the additional assembly requirements
listed in Chapter 7 of this standard.
5.4 Other Documentation. In addition to the appropriate
assembly procedure, the assembler must have the fol-
lowing documentation immediately available at the
assembly area prior to and during assembly:
5.4.1 Job Order (Work Order), The job order shail
detail part numbers (or other unique identification
system) for all tools, sub-tools, and auxiliary tools
required for a specific order. The job order must
specify any alternative “dressing” or performance
properties required for each tool, sub-tool, and DS-19 Fourth Edition, Volume 4, Drilling Specialty Tools
auxiliary tool where applicable. The job order
shall detail the exact work to be performed by the
assembler.
5.4.2 Bill of Materials (BOM). A Bill of Materials for
the tool or sub-tool to be assembled must be present
at the assembly location. The BOM shall:
2. Use the same tool model number or other uniquely
descriptive designation as the tool assembly
procedure and the tool assembly drawing(s).
b. Show part numbers and names of all the
components, including incidental components,
required to completely assemble the tool or sub-
tool.
c. Detail the componentrecords that must accompany
a component to the assembly process.
d. List the names and part numbers of all auxiliary
components that will need to accompany the tool
or sub-tool.
5.4.3 Example Bill of Materials. A BOM for
EXAMPLETOOL that meets the above requirements
is shown in figure 5.1.
5.4.4 Assembly drawing(s). Assembly drawings
shall show (directly or by reference documents that
provide this information, with identical item numbers)
the assembled tools and all components, including
incidental components, that are listed on the BOM.
The assembly drawing shall show the components
in their final positions. If any assembly procedure
steps are not clearly illustrated by the final position
view, then alternative views that clearly illustrate
those steps shall also be shown. Assembly Drawings
shall also give quantities, part numbers and names
of all components. The quantities, part numbers
BILL OF MATERIALS
TOOL MODEL: EXANPLETOOL (U8.700u size:_oncH
1 Tsnese (on Teese) | 1 TOP SUB TINSP NEW NSP CTRACEASLITY DoTHER | SEEWO FOR DRESSED PART NO.
z Eno% 7 ‘anor INSP ONEWNGP_GTRACEABLITY OTHER
z EHH 7 Tor xP INSP ONEW NSP OTRACEABLTY OTHER
fi Enos 1 House TNSP ONEW NSP OTRACEABLTY DOTHEA
5 Enos 7 008 INSP CHEW Nr OTRACEABLTY OTHER
¢ emu 7__ | RETANER SETSGREW | ORNSP_CNEWNSP OTRACEABLMY OTHER — NGIDEWTAL COMPONENTS
o EnoO 1 TETANER TDINSP GNEWINSP DTRACEARLATY DOTHER| NEW COMPONENT
. noo o TRSERT TING GNEWINSP CTRACEABLATY OTHER
[ps now 1 [RLECTRONCS ACOESS PLUG | ONSP_DNEWNER_OTRACERBLITY OTHER NODEVTAL COWPONENT
[ne eos 1 PLUG ONG [DRSP ONEWmiSP OTRACEABILTY BOTHER| NEW COMPONENT
[oa EmH08 z WALLO-ANG |OINSP GNEW NSP _OTRAGEABLITY GoTHER| NEW OOMPONENTS
[Fe [e000 2 LARGE O-RING __[DINGP CNEWiNeR OTAAGEABLTY GoTHEN| NEW couroNenTs
[Tas [erent fi ELECTRONS [BINS ONEWINSP OTRACEARUTTY OTHER
a eran 7 | BECTROWOS BATTERY —[ONSP_DNEWINSP OTRACEAARITY BOTHER| NEW COMPONENT
rn oo * ADAPTER BINGF_BNEWINSP CTRAGEABLTY GOTHER
ve [eenoss-sron asemans | 1 BOTTOM Sua [BNSP_ONEW SP TRACEABILITY BOTHER | SEE WO FOR ORESSED PART NO.
[-COMPONENT MUST ARAIVE AT ASSEMBLY ARE
IN ORIGINAL SEALED PAGKAGE WITH PART
INOMBER LABEL
INO AUXILIARY COMPONENTS ARE SHIPPED WiTH
frais Sus-TOoL
Figure 5.1 A Bill of Materials (BOM) for EXAMPLETOOL.
59 THHill Associates, Inc.
COMP QTY NAME (PARTNUMBER)
11 Tor sus rrsncss.s)
2 1 MANDREL (ETXXK-S)
I
81 TOP CAP CETUS)
41 HOUSING Enoxe sy
7 000 (EnoxXs8)
7. RETAINER SET SCREW (ETHX22)
O
RETAINER (ETXXX6)
INSERT (EDOK7-S)
4. ELECTRONICS ACCESS PLUG (ENO),
1. PLUG O-ING fenoGa)
11 2. SMALLOAING (E1008)
2 LARGE O-RING (ETO)
1
ELECTRONICS (E1115)
BATTERY (ETX12)
151 ADAPTER (ETXX145}
16 4 porromsus EW Eeoende
ASSEMBLY DRAWING
MODEL: _EXAMPLE TOOL
Oe CH a
DRESSED FOR: NC5S CONNECTIONS —
ee
Figure 5.2 An assembly drawing for EXAMPLETOOL.
and names of components shown on the assembly
drawing shall exactly match those on the Bill of
Materials. (An assembly drawing for EXAMPLETOOL
that meets the requirements of this standard is shown
in figure 5.2.)
5.4.5 Calibration certificates. Current calibration
certificates for all assembly equipment and tools that
require calibration shall be available to the assembler,
5.4.6 Copies of relevant Assembly Alert Notices.
If any alert notice is relevant to the assembly in
progress, the assembler shall obtain, review and
follow such notice
5.4.7 Copies of all applicable component records.
Component records accompany a component and
indicate to the assembler that itis fit for assembly.
60
If a component record is required, this requirement
shall be listed on the BOM. Component records shall
list the part number (and serial number if applicable)
‘of the component to which they apply, and other
pertinent information that establishes the fitness of
the component. (Not all components will need to be
‘accompanied by component records.)
5.4.8 Assembly check sheet. On this ‘sheet, the tool
assembler will record the satisfactory completion of
each tool assembly step. The steps to be checked
off on the assembly check sheet shall be listed
in the same order and with the same procedural
‘step identification as they appear on the assembly
procedure. If the assembly check list is not part of
or an attachment of the assembly procedure, then
the assembly procedure and revision level shall be
recorded on the check sheet. The assembly check
sheet shall also provide spaces for:
a. Final assembly part number, serial number,
description and (if applicable) type of trim or
dressing.
b. Job Order or Work Order under which the
assembly work was performed,
. A check block for the assembler to indicate that
he/she has obtained and reviewed applicable
Assembly Alert Notices.
d. Check blocks for the assembler to indicate that
he/she has laid out and examined all parts listed
on the Bill of Materials.
©. Check blocks for the assembler to indicate that
he/she has examined all component records that
are listed on the Bill of Materials, and that these
Tecords show that the applicable components are
ready for assembly.
1. Check blocks for the assembler to indicate when
an assembly procedure step or group of steps
have been satisfactorily completed.
g. Fields to record the serial number(s) of serialized
‘component(s) used in the tool.
h. Signature blocks for Assembler, Assembly
Supervisor and Customer's Representative.
i, Check blocks to record makeup torques for alll
threaded connections in a load path. DS-1® Fourth Edition, Volume 4, Drilling Specialty Tools
i. Check blocks to indicate that all incidental
components are free from excessive wear, galling,
thread damage, etc.
5.5 Access. The customer or its authorized representa-
tive shall have access to the assembly area unless ro-
stricted by safety requirements and to all the documents
fisted above. However, assembly procedures, bills of
materials and assembly drawings may not be copied
oF removed from the premises. Copies of applicable
calibration certificates and assembly check sheets may
be retained by the customer or its authorized represen
tative if desired
5.6 Template for Bills of Materials. Bills of Materials
for tools covered by this standard will vary according
to the vendor's practice. However, all Bills of Materials
must at a minimum meet the following requirements.
5.6.1 Completeness. The Bill of Materials must list
every component required for complete assembly of
the tool or sub-tool in question. Every component
isted on the BOM must be used in assembly of the
tool, except auxiliary components that are intended
to accompany the tool to the rig but be used after
the tool is run.
5.6.2 Component records. The Bill of Materials must
ist those component records that the assembler is
required to obtain and review.
5.6.3 Descriptive nomenclature. Components must
be listed on the BOM by part number and description.
Component part numbers and descriptions on Bills
of Materials must exactly match the corresponding
numbers and descriptions on the tool Assembly
Procedure and the tool Assembly Drawing(s).
5.7 Assembly Procedure Template. To comply with
this standard, assembly procedures must at a minimum
address the following.
5.7.1 Limited activity. Activity in the assembly area
must be limited to laying out and assembling only a
single tool or sub-tool at a time. If more than one tool
is listed on the job order, then the assembler must
complete one tool before beginning another, or the
tools must be laid out and assembled in separate
assembly areas.
5.7.2 Before assembly begins. The assembly
procedure must require that the assembler gather all
components and component records listed on the Bill
of Materials and/or Job Order. The procedure must
require the assembler to complete the steps below,
a. Layout all components in the assembly area.
b. Checkall component part numbers and descriptions,
against the Bill of Materials, Assembly Drawing(s)
and/or Job Order.
©. Verify that all Component Records listed on the
Bill of Materials and/or Job Order accompany their
components, and that these records indicate that
the components are fit for assembly.
4d. Ensure that all expendable components intended
for use in assembly are new (not reused).
e. If any components do not bear a permanently
etched or stamped part number, ensure that they
are packaged or tagged so that their part numbers
are clearly evident.
f. Verify that all shear pins, shear screws and other
temporary retaining devices used are traceable to
‘a process and corresponding report that validates
their rating. Before installing shear pins, verify
against the Bill of Materials that they are the correct
length and material type. Since a traceability and
identification number may not be present on shear
screws and pins, it is recommended that a color
code be applied on one end of the screw/pin to
help achieve some level of traceability. If a color
code is used, the color code of the shear screws
or pins used in the assembly shall be recorded on
the assembly check sheet.
5.7.3 During and after assembly. The assembly
procedure must require that the assembler perform
the following steps:
a. Makeup torques. All torqued connections that
are exposed and visible shall be marked with a
single paint scribe line across the connection after
makeup and the torque to the nearest thousand
{ft-lbs shalll be written near the line. This information
shall be part of the final assembly report (see
5.7.3.4.8).
Unless approved by the customer, making up
a connection, by torquing through another
connection of the tool not directly mating with
the connection to be made up ("torque-through"
technique) shall be prohibited.
61
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