Technical Manual for Drilling Works for Technical Support Plan for the Drillers in DDCA (2013)

Annex 12 Feedback Form from Client

Client Feedback Form on Hiring Service of Drilling Equipment

Thank you for taking the time to fill out this form. Your feedback is important and will

help us deliver quality service to you. When completed please either:

Email to: _____________________ or Fax to: _________________________

No. of Order Form

Business Entity Name

Question

Answer

Hiring of Equipment

How was timeliness of

 Equipment was available right on time when we needed.

availability of the equipment

 We had to wait for equipment to be available.

you hired this time?

Was the equipment handed over

 Yes

to you as per agreed time and

 No

date?

How would you rate condition

 Very good

of the equipment you hired this

 Good

time?

 Fair

 Poor

 Very poor

How would you evaluate

 It helped us aquire new skills/ knowledge on the drilling works.

usefulness of technical advice/

 It helped us recognize the importance of certain skills/ knowledge

guidance from our technical

anew.

instructor?

 We could not receive any useful advice/guidance we expected.

How would you evaluate cost

 Very expensive compared with value of the service.

you paid for the hiring service?

 Expensive, but the service has corresponding value.

 Fair

 Very cheap compared with value of the service.

Purchase of Consumables

Did you receive consumables

 Yes

you ordered to purchase by the

 No

time

you

required

for

 We did not buy consumables from DDCA.

construction works?

Overall Satisfaction and Comments/ Suggestions

What factor(s) made you to

 Availability of equipment in the period we needed

choose our hiring service?

 Availability of equipment which others do not hire out

 Price of the rental fee

 Reliability of condition of equipment

 Specifications and capacity of equipment

 Availability of technical instructor who provides advice/ guidance

on site

 Other (Please specify:

)

How would you rate level of

 Very high

your overall satisfaction on our

 High

hiring service against your

 Fair

expectation?

 Low

 Very low

Could you tell us about areas

which you would like to receive

futher technical advice/guidance

from our technical instructor, if

any?

Any

other

comments/

suggestions

A-28

3. Operation Days and Sales by Items for Hiring

(1) Drilling Rig

Operation

Average Contract

Equipment No.

Sales (Tsh)

No. of Contracts

No. of BH Drilled

Days

Value (Tsh)

No.1

No.2

No.3

No.4

No.5

No.6

Total

Cumulative

Average

(2) Air Compressor

Operation

Average Contract

Equipment No.

Sales (Tsh)

No. of Contracts

No. of BH Drilled

Days

Value (Tsh)

No.1

No.2

No.3

No.4

No.5

Total

Cumulative

Average

(3) Mud Pump

Operation

Average Contract

Equipment No.

Sales (Tsh)

No. of Contracts

No. of BH Drilled

Days

Value (Tsh)

No.1

No.2

No.3

No.4

No.5

Total

Cumulative

Average

(4) Pumping Test Unit

Operation

Average Contract

Equipment No.

Sales (Tsh)

No. of Contracts

No. of BH Drilled

Days

Value (Tsh)

No.1

No.2

No.3

No.4

No.5

Total

Cumulative

Average

A-30

Manual on Hiring of Drilling Equipment

Appraisal of Applications for Use of Hiring Service

(1) No. of Applications Received

(2) No. of Applications which Satisfy Requirements

(3) Distribution of Applications Rejected

a. No water well drilling permit

b. No CRB registration as a specialist contractor

c. No availability of permanent employee in the drilling team

Rental Contracts Signed in the Month

Client of

No. of BH to be

Contract

Location of

Name of

Hiring

Hired

Hirer for

Drilled with

Amount

Drilling

Use of BH

Hirer

Period

Equipment

Drilling

Hired

(Tsh)

Site

Works

Equipment

Troubles/ Accidents on Equipment for Hiring

Complaints/ Comments/ Suggestions Received from Clients

Other Issues (if any)

Preapred by ___________________ on ___________________

A-31

Maintenance Guideline, Maintenance System for Hiring Equipment

1 BACKGROUND

Aiming at alleviating poverty through improvements in the governance of water resources

management and the sustaiblable delivery for water supply and sanitation services, the Government

of United Republic of Tanzania (hereinafter referred to as “the Government of Tanzania”) has been

implementing the Water Sector Development Programme (WSDP) since 2007 to address shortfalls

in urban and rural water supply infrastructure, to improve water resources management, and to

strengthen the sector institutions and their capacities (MoW 2006). The target of the Programme

is to achieve increase of proportions of the rural population with access to clean and safe water to

90% by 2025. It also calls for increased access to clean and safe water to the urban population to

100% by 2025.

WSDP estimates that approximately 79,000 water points need to be constructed in the Rural Water

Supply and Sanitation (RWSS) component in order to meet the target mentioned above.

91% of

these water facilities are expected to be sourced with the groundwater, which requires drilling of

1,200 wells annually. The Urban Water Supply and Sanitation (UWSS) component also has high

demand of borehole construction in specific regional and district centres where surface water

sources are scarce. Although private drilling companies are the main actor for groundwater

development in WSDP, their current capacity in drilling wells is approximately 600 per annum. In

other words, their capacities such as technical abilities and resources have a great gap compared

with the demand in the water sector.

Taking this situation into consideration, MoW procures new drilling equipment in WSDP in order

to support Drilling and Dam Construction Agency (DDCA) for strengthening of its capacity in

borehole construction and providing technical support services to private drilling companies with

utilizing the procured equipment.

“The Strategy for Strengthening Water Well Drilling Industry in

Tanzania” formulated by MoW in 2006 in parallel with designing of WSDP states necessity to

establish the plant and the equipment hiring unit within DDCA to manage the equipment procured

for the hiring service (MoW 2006). This is supported by the Executive Agencies (Drilling and

Dam Construction Agency) (Establishment) Order, 1999, which describes that hiring of the drilling

equipment to other organisations, is a part of the secondary functions of DDCA.

A maintenance system was established by the Project in order to maintain the equipment for the

hiring services properly. DDCA is responsible for preventive maintenance and repair works of the

equipment before and after the equipment is hired. On the other hand, the hirer will conduct

routine maintenance of the hired equipment on site under supervision and instruction of the

technical instructor from DDCA.

This is the first version of maintenance guideline for the hiring equipment to operate maintenance

system for hiring equipment. The maintenance of the equipment for hiring service should be

implemented in accordance with the guideline, plan and manual on the maintenance system of the

hired equipment. The guideline indicates the principles of the maintenance system for the hiring

equipment.

The equipment hiring service by DDCA starts April 2013 and continues the service during the

entire project period. Accordingly, the maintenance guideline will be updated and/or modified by

reflecting the results of the activities.

2 DOCUMENTS FOR MAINTENANCE SYSTEM

The documents, namely maintenance guideline (this document), maintenance plan and maintenance

manual for the hiring equipment were prepared by the DDCAP project, in order to manage the

maintenance system for the hiring equipment. The roles and the contents of each document are

summarized as follows.

Maintenance Guideline, Maintenance System for Hiring Equipment

Document 1: Maintenance Guideline

The guideline stipulates the operation principles of the maintenance system as well as the roles and

responsibility of both the owner (DDCA) and the hirer (private companies). Under the system to

hire drilling equipment and machineries, the guideline aims at keeping good working conditions of

the hiring equipment and machinery in order to accommodate the demand of the private drilling

companies.

Document 2: Maintenance Plan

The maintenance plan demonstrates the plans for the periodic service, spare parts, consumable

parts, tools, procurement, staff assignment, training and budget. The maintenance works for the

hiring equipment should be carried out according to the maintenance plan.

Document 3: Maintenance Manual

The separate maintenance manuals for the owner and the hirer were provided. The manuals

indicate the method and procedures of the maintenance works by each party.

3 PRECONDITION OF MAINTENANCE WORKS FOR HIRING

EQUIPMENT

3.1 SPECIFICATION OF WELLS TO BE DRILLED BY USING HIRING EQUIPMENT

The hiring equipment are primarily used for the drilling works for WSDP in order to contribute for

its programme goal. According to the results of the drilling works of phase

1 of RWSS

component of WSDP, the specifications of wells are summarized as the following:

 Average depth: 95.9 m

 Casing and screen pipes: mainly 150 mm (6”) of nominal diameter (95 % of all contracts),

pvc made

Both DTH and mud drilling methods are employed. From the above results, standard

specifications of wells for these two methods are as shown in Figure 1. The DTH drilling

methods are estimated to occupy 70 % of the cases of drilling, according to the past experiences of

DDCA. This percentage shall be annually reviewed and modified from the results of the annual

results of the drilling by the hiring equipment.

12" PVC

14" -1/2"

12" PVC

14-1/2"

Casing

Roller Bit

Casing

Roller Bit

4 m

10" Steel Casing

12"DTH or

Roller Bit

10-50 m

6"PVC Casing

6"PVC Screen

8-1/4" DTH

10-1/2" Roller

Bits

Average Depth: 100 m

Maximum Depth: 150 m

Maximum Detph: 150 m

DTH Drilling Wells

Mud Drilling Wells

Figure 1 Standard Specification of Wells Drilled under WSDP

Maintenance Guideline, Maintenance System for Hiring Equipment

3.2 DRILLING EQUIPMENT TO BE HIRED

MoW is now procuring the drilling equipment with the fund of WSDP. It consists of two of 300

m drilling rigs and six of 150 m drilling rigs, necessary rig accessories, supporting equipment such

as air compressors and pumping test units etc., and supporting vehicles. Two 300 m rigs are

planned to be used for DDCA’s own drilling works and 150 m rigs are for both DDCA’s works and

hiring to the private companies. A set of 150 m drilling rig with accessories were designed so as

to be capable of drilling wells of which specifications are described in 3.1. A combination of the

components of drilling equipment varies depending on the drilling method to be employed and

design of a well. Therefore, a suitable combination will be selected by a hirer according to their

needs with the consultation by DDCA. Table 1 shows the major drilling equipment to be hired.

The machineries such as drilling rigs, air compressors, mud pumps, pumping test units are the

principal target of the maintenance activities.

Table 1 Drilling Equipment for Hiring

Item

Specification

Qty

I. New Equipment to be Procured in WSDP

1. Truck mounted drilling rig

Rotary cum DTH, max. depth 150m

6 units

2. Trailer mounted air compressor

650CFM, 246 psi

5 units

3. Rig accessories

Drill pipes, DTH bit, work casing, etc.

1 set for each rig

4. Fishing tools

Tap, jack, etc.

1 set for each rig

5. Trailer mounted mud pump

20kg/cm², 600 l/min.

5 units

6. Trailer mounted pumping test unit

Generator, riser pipe, submersible pump

5 units

Table 2 shows the detailed contents of “3 Rig accessores” of Table 1. Necessary items will be

selected for hiring according to the hirer’s needs. Items with the check of the column

“Maintenance” are materials capable to be worn and/or small machineries to be maintained. The

reduction of the materials and conditions of the machineries shall be inspected by the maintenance

section before and after the hiring. Other items with the check in “Consumable” consist of DTH

bits, roller bits, stabilizers etc. They are consumed after the use in drilling of several wells.

However, it is difficult to predict their lives since they depend on the specific coditions of each

wells such as geology, drilling diameter, depth etc. Therefore, if a hirer want to DDCA to procure

these consumables, DDCA will sell them to the hirer. In other way, calculated lumpsum price will

be charged in the hiring tariff for DDCA to supplement the consumed materials.

Inspection of such miscellaneous items before and after hiring, maintenance of small machineries

and supplementation of the consumed materials are one of important activities of the equipment

maintenance, too.

Table 2 List of Rig Accessories, Casing Tools, Fishing Tools, Steel Casing and Direct

Mud Circulation Drilling Tools

No.

Description

Unit

Qty

Maintnance

Consumable

Rig Accessories

Drill pipes 41/2'' O.D flush type with API 31

1/2''IF BOX and pin joints furnished with wrech

Pcs

squares and steel made protectors,6m long/pc

Drilling collars 5''0.D,2''IF BOX and pin

joints,furnished with wretch squares and steel

Pcs

protectors,6m long/pc

Hoisting swivel API 1/2'' IF Pin joint

Pcs

Hoisting plug API 1/2'' IF Pin joint

Pcs

Drill pipes collar hanger

Pcs

Cross over sub API 3 1/2 IF BOX and pin

Pcs

DTH Hammer assembly for 6 1/4''(150mm) hole

drilling API 3 1/2 Regular pin and 8'' to 10'' hole

Assy

drillling

DTH Hammer assembly for 12''(300mm) hole

Assy

drilling API 3 1/2 Regular pin

Maintenance Guideline, Maintenance System for Hiring Equipment

No.

Description

Unit

Qty

Maintnance

Consumable

DTH Button Bit for 12''(300mm) hole drilling

Pcs

Bit sub for drill pipes/collar to 6 1/4'' DTH

Hammer API 3 1/2'' Regular box and API 3 1/2'' IF

Pcs

Box joint

Bit sub for drill pipes/collar to 6 1/4'' DTH

Hammer API 3 1/2'' Regular box and API 3 1/2'' IF

Pcs

Box joint

DTH Button bit for 6 1/4''(159mm) hole drilling

Pcs

DTH Button bit for 8 1/4''(216mm) hole drilling

Pcs

DTH Button bit for 10''(254mm) hole drilling

Pcs

Bit grindeer for button bit and body

dressing,furnished with 15 m long high pressure

Pcs

air hose

Tricone roller bits 6 1/2'' dia

Pcs

Tricone roller bits 8 1/2'' dia

Pcs

Tricone roller bits 10 1/2'' dia

Pcs

Tricone roller bits 12 1/2'' dia

Pcs

Roller bits 8 1/2'' dia

Pcs

Roller bits 10 1/2'' dia

Pcs

Roller bits 12 1/2'' dia

Pcs

Roller bits 14 1/2'' dia

Pcs

Drag bits three winged 8 1/2'' dia

Pcs

Drag bits three winged 10 1/2'' dia

Pcs

Drag bits three winged 12 1/2'' dia

Pcs

Drag bits three winged 16 1/2'' dia

Pcs

Roller bit 16'' dia for soft formation

Pcs

Stabilizer for

6 1/4'' hole body dia,1.5m long API

3 1/2 IF BOX and pin joints furnished with wretch

Pcs

squares and steel made thread protectors on both

ends

Stabilizer for

8 1/2'' hole 5'' body dia,1.5m long

API 3 1/2 IF BOX and pin joints furnished with

Pcs

wretch squares and steel made thread protectors on

both ends

Stabilizer for

10'' hole 5'' body dia,1.5 long API

3 1/2 IF BOX and pin joints furnished with wretch

Pcs

squares and steel made thread protectors on both

ends

Stabilizer for

12'' hole 5'' body dia,1.5m long

API 3 1/2 IF BOX and pin joints furnished with

Pcs

wretch squares and steel made thread protectors on

both ends

Casing Tools

a)Casing lamp with bolts,nuts,wrench and sling

Pcs

wire for 4'' PVC casing ,3 pairs/sets

b)Casing lamp with bolts,nuts,wrench and sling

Pcs

wire for 6'' PVC casing ,3 pairs/sets

c)Casing lamp with bolts,nuts,wrench and sling

Pcs

wire for 8'' PVC casing ,3 pairs/sets

d)Casing lamp with bolts,nuts,wrench and sling

Pcs

wire for 10'' PVC casing ,3 pairs/sets

e)Casing lamp with bolts,nuts,wrench and sling

Pcs

wire for 12'' PVC casing ,3 pairs/sets

f)Casing head for 8'' casing

Pcs

g)Casing head for 10'' casing

Pcs

h)Casing head for 12'' casing

Pcs

i)Casing shoe for 8'' casing

Pcs

j)Casing shoe for 10'' casing

Pcs

k)Casing shoe for 12'' casing

Pcs

l)Casing sub , API 3 1/2 IF BOX to 8 '' casing

Pcs

m)Casing sub , API 3 1/2 IF BOX to 10 '' casing

Pcs

n)Casing sub , API 3 1/2 IF BOX to 12 '' casing

Pcs

o)Casing hoist plug with sling wire for 8'' casing

Pcs

p)Casing hoist plug with sling wire for 10'' casing

Pcs

Maintenance Guideline, Maintenance System for Hiring Equipment

No.

Description

Unit

Qty

Maintnance

Consumable

q)Casing hoist plug with sling wire for 12'' casing

Pcs

Fishing Tools

a)Fishing taper tap,API 3.5'' IF BOX JOINT

Pcs

b)Fishing die overshoot API 3 1/2 IF BOX JOINT

Pcs

c) Drill pipe clamp with bolt nut wretch and sling

Pcs

wire 2 pairs/seat

d) Hydraulic jack with hand operated pump hose

Pcs

and pressure gauge,50 ton capacity,2 jacks/seats

e)Fishing magnet

Pcs

Steel Work Casing

a) Steel work casing ,threaded flush joint type

Pcs

8''(216.3 mm O.D /190.9 MM I.D) 3m long /pc

b) Steel work casing ,threaded flush joint type

Pcs

10''(267mm O.D /242MM I.D) 3m long /pc

c) Steel work casing ,threaded flush joint type

Pcs

14''(356mm O.D /344MM I.D) 3m long /pc

Direct Mud Circulatin Drilling Tools

Mud testing kit including mud balance ,marsh

funnel,viscocity meter with measuring cup sand

Pcs

content kit,stop watch and thermometer

Collapsible water tank with housing bag 3000

Set

Litre capacity

Portable water level indicator,dry battery operated

Set

type,measuring capacity of 200m

4 MAINTENANCE ACTIVITIES IN THE PROCESS OF HIRING

Various activities of the maintenance

shall be conducted according to each

phase of equipment hiring as shown in

Figure 2. Condition check of the hiring

equipment is conducted by following

“hiring equipment service check

sheet”prior to hiring. Before delivery

of the equipment to the hirer, photos of

the equipment shall be taken to verify

the condition.

During hiring, the

owner is responsible for daily

maintenance with using “daily service

check sheet” under the supervision of

the technical instructor dispatched from

the owner. In case of the breakdown

of the equipment on site, the mechanic

from the owner will be dispatched to

the site.

When the equipment is

returned by the hirer, the condition

check will be conducted by the owner

in presence of the hirer by following the

“hiring equipment service check sheet”.

Photos of the equipment shall be taken

Figure 2 Maintenance Activities to be

to verify the condition if it is as same as

Implemented During Hiring

before hiring.

Besides these

maintenance activities which shall follow the timing of the hiring, the periodic service maintenance

shall be conducted according to the kilometrage or operating hours of each equipment.

Maintenance Guideline, Maintenance System for Hiring Equipment

5 CONTENTS OF MAINTENANCE

5.1 SCOPE OF MAINTENANCE

The baseline survey which was conducted in the project revealed that the maintenance of DDCA’s

existing drilling equipment was implemented on the basis of the “breakdown maintenance”, instead

of the “preventive maintenance”. The periodic service are conducted only for vehicles by the

manufacturer’s agent in Tanzania. However, the quality of their services is not satisfactory and

the prices are expensive. The maintenance of the other equipment such as drilling, air compressor

mud pumps etc. are only the repairing for the breakdown or the replacement of parts after the

wearing. Such “break down maintenance” system causes the delay of repairing due to the lack of

the stock of the spare parts and the shortening of the machine lives because leaving certain

breakdown will leads further breakdown of the other parts of mechanical and/or hydraulic system.

Therefore, in order to keep the good conditions of machine without the distinct interruption of the

hirer’s drilling work, the

“preventive maintenance” system is adopted to formulate this

maintenance system for the hiring equipment, which includes the maintenance activities based on

the operating hours or kilometrages bases maintenance plan, spare parts stockage according to the

hiring plan and condition check system before and after hiring. In this context, the following

maintenance activities are defined to be components of the maintenance actvitiies.

Condition check

In order to assure the good conditions of the equipment, the condition check will be conducted

before and after hiring by using “condition check sheet”. It will be done in the workshop of

DDCA by the owner in presence of the hirer.

Periodic service maintenance

Once the timing of kilometrage or operation hours which needs replacement or repairing are

confirmed from the records, the periodic service mainantenance will be done by the owner. The

condition of the exhaustion and damage of the parts are also confirmed so that the necessary

measures such as replacement of the spareparts are taken before they are worn out completely.

The record of the periodic service maintenance will be filled into the form of “periodic service

maintenance check sheet”.

Daily service maintenance

The daily service maintenance will be done by the hirer in order to avoid the troubles or

breakdowns during equipment operation. The hirer will conduct it by using the “daily service

check sheet” under the supervision of technical instructor dispatched from the owner.

Repairing

The repairing works

consist

the

replacement

spareparts and fixing

of parts. In principle,

the necessary repairing

works are to be done

under

the

Figure 3

Flow of Mainteance in a Year

responsibility of

the

owner. If a breakdown happens on site, the owner will mobilize the mechanics to the site for the

repairing. In case that repairing works are caused due to the faults or negligence of the hirer

during the operation of the hiring equipment, the owner will charge the cost for the repairing to the

hirer.

The flow of the maintenance works in a year is shown in Figure 3. Condition check, periodic

service maintenance and daily service maintenance are done in constantly either before, during or

Maintenance Guideline, Maintenance System for Hiring Equipment

after hiring. On the other hand, the repairing work will be done in case the breakdowns or

malfunctionality is occurred unexpectedly.

5.2 RESPONSIBILITY OF OWNER AND HIRER

The assignement of the resiponsibility of the owner and the hirer related to the maintenance

activivies shall be clearly defined in the agreement of the hiring between the owner and the hirer.

Not only the maintenance works but also the case of loss or damage of equipment and safety

measures shoud be stipulated. The responsibility of each aspect between the owner and the hirer

is as described below.

Condition check

Owner:

 For the commencement of the contract in delivery of the hiring equipment, in case that any

defects are detected, the owner should repair the equipment or replace it to a substituted one.

 Upon the receiving the equipment after finishing of the operation of the hiring equipment,

the condition will be inspected by the owner to confirm in presence of the hirer if the

equipment is as it were before hiring.

Hirer:

 Before receiving the equipment, the hirer shall inspect the condition of hiring equipment in

the presense of the owner in order to confirm that there is no defect for the operation. The

standard, specification, efficiency, function and number of the equipment shall be confirmed,

too.

 When any defect is detected, the hirer shall immediately inform of it to the owner so that the

owner takes necessary measures such as the repairing of the equipment or replacement of the

parts.

 The condition check shall be done by the owner in presence of the hirer when the hiring

equipment is returned to the owner. Without the hirer’s presence there, the hirer has no

right to reject the result of inspection from the owner.

 The equipment shall be returned with the same condition as it was before hiring. When

damages or defects are detected upon returning, the hirer shall recover it as the same

condition of the original one or compensate for the cost of repairing to the owner.

Periodic service maintenance

Owner:

 When the equipment reaches the operation hours or kilometres which requires replacement

of the spare parts or reparing from the record, periodic maintenance shall be conducted.

The cost of the service is borne by the owner.

 The periodic service maintenance shall be planned so that it is conducted on time during the

spare time of the hiring.

 The intensive use of the particular equipment shall be avoided. It shall be confirmed and

adjusted from the past record of the periodic service check sheet in order for balanced

operation of the hiring equipment.

Daily service maintenance

Owner:

 The technical instructor dispatched from the owner shall supervise the daily service

maintenance to be conducted by the hirer on site.

Hirer:

 The hirer shall conduct the daily service maintenance on site during hiring including the days

when the equipment is not operated.

Maintenance Guideline, Maintenance System for Hiring Equipment

 In case that any troubles and breakdowns are detected as the result of the daily service

maintenance, the hirer shall inform the owner of it immediately.

Repairing

Owner:

 The owner shall keep necessary spare parts for the periodical replacement, the parts easy to

be worn out and any other general parts based on the spare parts procurement plan.

 According to the maitenance plan, the spare parts shall be kept in the stock for the periodic

service maintenance and/or repairing so as not to cause the interruption of the drilling works

by the hirer.

 The repairing and maintenance shall be conducted when the equipment is not hired out.

The reservation status of the hiring equipment shall be confirmed in advance.

 When certain parts are found to be old, the owner shall repair or replace the parts

immediately before it is worn out completely.

Hirer:

 The repairing cost will be compensated when the breakdown is ocurred as a result of

operation mistake or intentional damage by the hirer.

 When the hirer causes damages to a third party during the installation, storage and operation

of the equipment, the hirer settles the situation on its own responsibility.

Case of loss or damage of equipment

Hirer:

 When the equipment suffers damages or theft during the hiring period, the hirer shall be

responsible for the items stipulated in the contract, irrespective of the reason, whether it is

natural disasters such as earthquakes, tsunamis, eruptions, typhoons, or any other.

 When the equipment cannot be returned to the owner due to the loss of equipment or

considerable damages at the time of the acceptance inspection upon the return of the

equipment, the hirer shall make a compensation which worth the replacement of the

equipment.

 When the repairing or replacement caused by the fault of the hirer requires some time, the

hirer shall compensate for the damages and losses such as the suspension of operation to be

shouldered by the owner.

Safety measures

Owner:

 When the maintenance on site is impossible, substitute drilling equipment shall be arranged

with the agreement of the hirer so that the suspension of the operation of hiring equipment is

limited to minimum.

Hirer:

 The hirer shall follow the principles of i) persons involved in drilling operations must pay

high attention to safety in order to avoid dangers for themselves and others. ii) the operation

shall be safely conducted by proper daily inspections, equipment handling and consideration

of environment on site as well, during the operation of hiring equipment

 In cases that major equipment troubles or damages happen during operation, the owner’s

mechanic will be dispatched to the site to conduct the inspection and repairing.

 When any accident or trouble happens, the hirer shall inform the owner of it. In cases of

accidents during operation or transportation, the situation must firstly be confirmed. If the

accident is resulted in injury or death, the injured person must be transferred to the place for

shelter or hospital first, followed by the inspection of the drilling equipment.

Maintenance Guideline, Maintenance System for Hiring Equipment

 The response should be taken emergently by following the procedure as shown in Figure 4

when the accidents are happened.

Maintenance on the spot

Possible

Urgently arriving at the

Arranging alternative

Troubles of equipments

site to check the

Maintenance

Impossible

drilling equipment

equipment

Urgently arriving at the

Possible

Damage of equipments

site to check the

Maintenance

during operation

Impossible

equipment

Occurrence of an

accident

Urgently arriving at the

Inspecting the drilling

Personnel injuries

site to confirm the

Transporting the injured

equipment

situation of an accident

Urgently arriving at the

Accidents during

site to confirm the

Report to the police

Handling of the accident

transportation

situation of an accident

Figure 4 General Response to Mechanical Problems and Accidents

6 MAINTENACE ORGANIZATION

Figure 5 shows the organization structure of DDCA. The hiring business will be operated by the

hiring business unit to be installed under the business support department in order to commence the

hiring business. With the intimate relationship between the hiring business unit, the maintenance

section under the technical support department will be in charge of the maintenance for the hiring

equipment in addition the one for DDCA’s existing equipment.

Figure 5 Organization Structure in DDCA

Maintenance Guideline, Maintenance System for Hiring Equipment

Currently, the technical support department has 62 staffs. Among them, 23 staffs are allocated in

the maintenance section and it is further divided into four sections of “Garage”, “Panel Beating and

Spray Paint”, “Auto Electric” and “Earth Work Moving Plant”, each section of which corresponds

to the different field of the maintenance, as shown in Figure 6. The maintenance section is

headed by three engineers, the head of maintenance section, the assistant head and the mechanical

engineer.

Technical Support Dept.

Manager 1 prs.

Zonal Offices

Arusha : Technician 1 prs.

Mwanza : Technician 1 prs.

Sunbawanga : Technician 1 prs.

Maintenance Sec.

Dodoma : Technician 1 prs.

Head 1 prs.

Ass.Head 1 prs.

Mac. Eng. 1 prs.

Garage Sec.

Panel Beating and Spray

Auto Electric Section

Earth Work Moving

- Mechanics 2 prs.

Paint Sec.

- Head 1 prs.

Plant Sec.

- Technician 1 prs.

- Head 1 prs.

- Electrician

1 prs.

- Head 1 prs.

- Others 3 prs.

- Panel Beater 1 prs.

- Operator 2 prs.

- Welder 1prs.

- Plant Mechanics

1 prs.

Figure 6 Organization of Maintenance Section

The headquarters of DDCA are located in Dar es Salaam and 5 zonal and 6 DPO offces are locted

in the country as shown in Figure 7. These offices can be considered to be “future local base” for

the maintenance as to be depots for equipment and the workshop for maintenance. However, in

the beginning of the operation of the hiring business, it is preferable to directly manage all the

equipment by the headquarters in Dar es Salaam. According to the progress of the business and

the quantitative trend of the hiring by each area, the maintenance organization including local

offices shall be reorganized with the consideration of the use of local resources such as the existing

workshop facilities of DDCA’s offices and the basin water offices.

Figure 7 Locations of DDCA Zonal and DPO Offices in the Country

Maintenance Guideline, Maintenance System for Hiring Equipment

7 FORMULATION OF MAINTENANCE PLAN

7.1 PLANNING

The maintenance plan shall be formulated by the maintenance section by following the annual

operation plan of hiring service to be formulated by the hiring business unit. According to the

annual operation plan of hiring service, the timing of periodic service maintenance shall be

estimated. Then the quantity of the spare parts to be kept shall be calculated based on the

operation plan of each equipment. The procurement of mechanical tools and the allocation of

maintenance staff shall be also considered to conduct the maintenance activities. The utilization

of the resources in branch offices such as zonal and DPO offices of DDCA shall be considered in

formulation of the plans as well.

7.2 CONTENTS OF MAINTENANCE PLAN

The maintenance plan consists of 10 components. Table 3 shows the contents of each component.

Each plan shall be formulated by the maintenance section in due conformity with the annual

operation plan of operation of hiring service to be formulated by the hiring business unit. The

maintenance plan compiled with these components will be incorporated into the final version of

annual plan of operation of hiring service. At the end of the fiscal year, the next maintenance

plans shall be prepared according to the result of the annual review of the maintenance activities.

Table 3 Maintenance Plans

Plan

Contents

1. Annual Action Plan

Outline of annual maintenance activities

2. Periodic Service Maintenance

Plan of periodic service maintenance, replacement of spare parts and

Plan

consumable parts of each equipment

3. Daily Service Plan

Plan of daily service

4. Repairing Plan

Plan of repairing of breakdown

5. Spare parts and Consumable

Inventory of store parts and consumable parts

Parts Control and Procurement

Plan for the procurement of spare parts and consumable parts for

Plan

periodic service maintenance and repairing

6. Maintenance Tools Control and

Inventory of maintenance tools

Procurement Plan

Listing-up of necessary tools and procurement plan

7. Maintenance Equipment

Condition check of maintenance equipment

Control and Procurement Plan

Listing-up of necessary equipment and procurement plan

8. Personnel Assignment Plan

Personnel assignment to each maintenance activity

9 Technicl Enhancement Plan

Action plan for the enhancement of maintenance techniques and

skills

10 Budget Plan

Budget plan for the maintenance activities and the procurement

8 REVISION OF MAINTENANCE SYSTEM

8.1 MONITORING AND EVALUATION OF SYSTEM

The maintenance work will be operated in a Plan-Do-Check-Action (PDCA) cycle as shown in

Figure 8. It starts from preparation of annual action plan and budget plan which is to be

incorporated into the annual plan of operation of hiring business. The implementation stage

involves various maitnenance activities in accordance with the process of maintenance described in

detail in Figure 8. The performance of the maintenance will be monitored from time to time to

check;

 If there is any gaps between what has been planned and implemented, and

 If the expected output and outcomes are realized.

Maintenance Guideline, Maintenance System for Hiring Equipment

Action should be taken to solve problems and improve the process management based on findings

from the monitoring. These improved solutions shall also be reflected in the planning stage in the

subsequent cycle.

Figure 8 Cycle of Maintenance Operation

Maintenance section shall prepare monthly and annual reports to be submitted to the hiring

business unit so that the unit can prepare the following reports to be submitted to the management

team of DDCA and MAB;

 Monthly report to be submitted not later than 10 days after the end of the month

 Annual report to be submitted not later than 14 days after the end of the year.

The above reporting procedures notwithstanding, DDCA shall report promptly to MoW on any

major even likely to affect efficient and effective utilization of the equipment.

8.2 PROCEDURE FOR REVISION OF SYSTEM

At this moment, the first version of the maintenance guideline, plan and manuals are prepared.

They shall be reviewed and revised until the commencement of the trial operation. Once the

contents of the business model for the equipment hiring system are determined, these documents

shall be also finalized accordingly. After the start of the trial operation of the maintenance system,

continuous revision shall be carried out in order to improve the maintenance system of hiring

equipment.

Contents

1 Background

2 Documents for Maintenance System

3 CONTENTS OF Plan

4 Annual action plan

4.1 Action Plan Intended for Preventive Maintenance

4.2 Details of Annual Action Plan

5 Periodic service maintenance plan

5.1 Management of Periodic Service Maintenance

5.2 Utilization of Periodic Service Manual and Periodic Service Check Sheet

6 Daily service plan

6.1 Daily Service Maintenance Management

6.2 Utilization of Daily Service Manual and Daily Service Check Sheet

7. Repairing plan

7.1 Repairing Work

7.2 Case Necessary for Repairing

8 Spare parts and consumable parts control and procurement plan

8.1 Procurement of spare parts

8.1.1 Specification of spare parts

8.1.2 Spare Parts Procurement Plan

8.1.3 Drilling Consumable Plan

9 Maintenance equipment control and procurement plan

10 personnel assignment plan

10.1 Allocation of Hiring Equipment

10.2 Staff allocation

11 Technical enhancement plan

12 Budget plan

Tables

Table 1 Maintenance Plans

Table 2 General Maintenance Plan

Table 3 Annual Operation Plan of Drilling Rig

Table 4 Replacement Timing of Spare Parts for Rig Truck and Rig Plant

Table 5 Inventory of Spare Parts for Rig Truck and Rig Plant

Table 6

3 Year’s Spare Parts Procurement Budget Plan for a Drilling Rig

Table 7 Annual Drilling Plan for the 1^st Year of the Hiring Business

Table 8 Necessary Drilling Consumables for a DTH Borehole and Mud Drilling Borehole12

Table 9 Annual Procurement Plan and Budget for Drilling Consumable

Table 10 List of Required Equipment in each Section

Table 11 Cost of Necessary Maintenance Equipment

Table 12 Plan for Training

Table 13 Maintenance Budget for the 1^st Year’s Use of Hiring Equipment

Figures

Figure 1 Annual Action Plan for Maintenance of Hiring Equipment

Figure 2 Periodical Service Check Sheet

Figure 3 Daily Service Check Sheet

Figure 4 Procedure of Spare Parts Procurement Plan

Figure 5 Procedure of Drilling Consumable Procurement Plan

Figure 6 Allocation and Management Area of the Hiring Equipment

Maintenance Plan, Maintenance System for Hiring Equipment

1 BACKGROUND

Ministry of Water (MoW) formulated a “Strategy for Strengthening Water Well Drilling Industry in

Tanzania” in 2006, and mandated the capacity development of private drilling companies to DDCA

(Drilling and Dam Construction Agency) by launch their new services such as a hiring of drilling

equipment and technical instructions. The reason behind is the capacity of private drilling

companies such as technical abilities and resources have a great gap compared with the demand of

groundwater development under the Water Sector Development Programme (WSDP).

Accordingly, the Groundwater Development and Management Capacity Development Project

(DDCAP) was launched on March 2012, under the technical assistance of Japan International

Cooperation Agency (JICA). A purpose of the project is to “enhance the DDCA’s capacity to

support the water well drilling industry” by strengthening of DDCA’s techniques for groundwater

development and their capacity of technology transfer toward private drilling companies, and by

establishment of an equipment hiring system in DDCA.

A maintenance system was established by the Project in order to maintain the equipment for the

hiring service properly. DDCA is responsible for preventive maintenance and repair works of the

equipment before and after the equipment is hired. On the other hand, the hirer will conduct

routine maintenance of the hired equipment on site under supervision and instruction of the

technical instructor from DDCA.

This is first version of maintenance plan for the hiring equipment to operate maintenance system

for hiring equipment. The maintenance of the equipment for hiring service should be

implemented in accordance with the guideline, plan, and manual on the maintenance system of the

hired equipment. The maintenance plan indicates the plans for the periodical service maintenance,

spare parts, consumable parts, tools, procurement, staff assignment, training and budget. After the

commencement of the equipment hiring service by DDCA, the maintenance plan will be updated

and/or modified by reflecting the results of the activities as well as the maintenance guideline.

2 DOCUMENTS FOR MAINTENANCE SYSTEM

The documents, namely maintenance guideline, maintenance plan (this document) and maintenance

manual for the hiring equipment were prepared by the DDCAP project, in order to manage the

maintenance system for the hiring equipment. The roles and the contents of each document are

summarized as follows.

Document 1: Maintenance Guideline

The guideline stipulates the operation principles of the maintenance system as well as the roles and

responsibility of both the owner (DDCA) and the hirer (private companies). Under the system to

hire drilling equipment and machineries, the guideline aims at keeping good working conditions of

the hiring equipment and machinery in order to accommodate the demand of the private drilling

companies.

Document 2: Maintenance Plan

The maintenance plan demonstrates the plans for the periodic service, spare parts, consumable

parts, tools, procurement, staff assignment, training and budget. The maintenance works for the

hiring equipment should be carried out according to the maintenance plan.

Document 3: Maintenance Manual

The separate maintenance manuals for the owner and the hirer were provided. The manuals

indicate the method and procedures of the maintenance works by each party.

Maintenance Plan, Maintenance System for Hiring Equipment

3 CONTENTS OF PLAN

Table 1 shows the contents of the maintenance plan. These sub-plans are prepared according to

the principle of the maintenance guideline. The activities described in the plans will be conducted

by referring to the maintenance manual.

Table 1 Maintenance Plans

Sub-Plan

Contents

1. Annual Action Plan

Outline of annual maintenance activities

2. Periodic Service Maintenance

Plan of periodic service maintenance, replacement of spare parts and

Plan

consumable parts of each equipment

3. Daily Service Plan

Plan of daily service

4. Repairing Plan

Plan of repairing of breakdown

5. Spare parts and Consumable

Inventory of store parts and consumable parts

Parts Control and Procurement

Plan for the procurement of spare parts and consumable parts for

Plan

periodic service maintenance and repairing

6. Maintenance Tools Control and

Inventory of maintenance tools

Procurement Plan

Listing-up of necessary tools and procurement plan

7. Maintenance Equipment

Condition check of maintenance equipment

Control and Procurement Plan

Listing-up of necessary equipment and procurement plan

8. Personnel Assignment Plan

Personnel assignment to each maintenance activity

9 Technical Enhancement Plan

Action plan for the enhancement of maintenance techniques and

skills

10 Budget Plan

Budget plan for the maintenance activities and the procurement

4 ANNUAL ACTION PLAN

4.1 ACTION PLAN INTENDED FOR PREVENTIVE MAINTENANCE

Concerning the maintenance of drilling equipment of DDCA and the private drilling companies, the

inspection works as “preventive maintenance” are not always conducted, because the maintenance

tends to be conducted as repair services in response to problems. This may cause serious

accidents because problems are not detected beforehand, and important parts of the vehicle may

become completely damaged. In order to smoothly utilize the drilling equipment and efficiently

continue drilling operations,

“preventive maintenance” placing emphasis on inspection works

following appropriate maintenance and management plan of equipment is necessary. In order to

efficiently operate hiring services to the private companies, plan for equipment maintenance based

on “preventive maintenance” will be necessary.

4.2 DETAILS OF ANNUAL ACTION PLAN

The maintenance plans for the hiring equipment will be prepared, implemented and reviewed

according to the schedule shown in Figure 1. As for the budget plan, since the fiscal year of

Tanzania starts in July, the amount of spare parts for the following fiscal year should be calculated

in November (6 months in advance) after examining the condition of the equipment. It is

preferable that the spare parts are purchased at 2 separate times, one at the beginning and the other

one at the middle of the fiscal year.

The latter purchase will be made depending on the stock so

that the excess stock or out of stock shall be avoided.

Maintenance Plan, Maintenance System for Hiring Equipment

Year

Present financial year

Next financial year

Month

Spare parts and Consumable Parts

Control and Procurement Plan

Maintenance Equipment Control and

Procurement Plan

Maintenance Tools Control and

Procurement Plan

Budget Plan

Daily Service Plan

Periodic Service Maintenance Plan

Repairing Plan

Personnel Assignment Plan

Technical Enhancement Plan

Evaluation

Planning

Action

Figure 1 Annual Action Plan for Maintenance of Hiring Equipment

5 PERIODIC SERVICE MAINTENANCE PLAN

5.1 MANAGEMENT OF PERIODIC SERVICE MAINTENANCE

Three officers of the head, the assistant head, the mechanical engineer of the DDCA maintenance

section are responsible to manage the periodic service. The implementation of the periodic

services is supervised by these officers. The periodic service schedule for the following year shall

be determined by them based on the mileage of vehicles and operation hours of the hiring

equipment which were confirmed through the implementation of the periodic services. The TCO

(Transport Control Officer) of DDCA who are in charge of the management of the vehicle

operation will be informed of the next schedule.

5.2 UTILIZATION OF PERIODIC SERVICE MANUAL AND PERIODIC SERVICE CHECK SHEET

The periodic service shall be conducted by mechanics of DDCA at the workshop in the

headquarters according to the record of mileage and operation period. The basic principles of the

periodic maintenance are as follows.

 Periodic service shall be conducted in accordance with the inspection items shown in the

“periodic service check sheet (Figure 2)”.

 The spare parts and oils shall be replaced in every periodic service. These spare parts and

oils should be prepared prior to the service period.

 The operator of the equipment, who checks the daily mileage and operation hours of the

equipment, will decide the timing of the periodic service. The DDCA maintenance section

will arrange for the periodic service accordingly.

 In case troubles and malfunction are detected in the periodic service, they shall be reported

to the management of the maintenance section.

Maintenance Plan, Maintenance System for Hiring Equipment

Periodic service check sheet

Date

Type

Model

Reg. No.

Mileage

Checked by

✔

Change

Adjust

Clean up

Tighten

Lubricant

Service truck

Outside

Oil, Filter and water

Qty.

Brake air tank, piping (leakage, condition)

Engine oil (amount, leakage)

Brake air tank Drain (leakage, condition)

Engine oil filter (leakage)

Front Brake hose, pipe (leakage, damage)

Fuel filter (leakage)

Brake lining front (leakage, damage, wear-out)

Air cleaner (blocking )

Rear Brake hose, pipe (leakage, damage)

Hydraulic oil (amount, leakage )

Brake lining rear (leakage, damage, wear-out)

Hydraulic oil filter (leakage)

Parking brake (condition, damage, wear-out)

Power steering (amount, leakage)

Hydraulic pump, cylinder(leakage, condition)

Brake oil (amount, leakage)

Tire (depth of ditch, damage )

Clutch oil (amount, leakage)

Wheel nut bolt (damage, loosening )

Transmission (amount, leakage)

Frame, body (tightening, damage)

Differential (amount, leakage)

Lights / Miller

(tightening, damage)

Radiator, coolant (amount, leakage)

Attachment (Crane, Water tank)

Battery (amount, loosening )

Driving

Engine room

Engine general (start, running sound, smoking )

Fan belt (damage, loosening )

Foot brake

Fan (damage, loosening )

Hand brake

Injector pump, Nozzle (leakage)

Clutch / Transmission

Generator (damage, condition )

Steering

Starter (damage, condition )

Noise

Comments:

Figure 2 Periodical Service Check Sheet

6 DAILY SERVICE PLAN

6.1 DAILY SERVICE MAINTENANCE MANAGEMENT

The daily service maintenance will be conducted during hiring period by the hirer under the

supervision of the technical instructor dispatched from DDCA with using “daily service check

sheet”. Eventually, the “daily service check sheet” will be submitted to the DDCA maintenance

section.

6.2 UTILIZATION OF DAILY SERVICE MANUAL AND DAILY SERVICE CHECK SHEET

The daily service maintenance shall be conducted before and after the operation of equipment

according to the items shown in “daily service check sheet” (Figure 3). The basic principles of

the daily service maintenance are as follows.

 The operator of the hiring equipment from the hirer conducts the daily service.

 The operator will pay attention to the condition of the equipment in entire operation. In

case that strange noise, smell, vibration, liquid leakage are detected, he will swiftly suspend

the operation and report to the technical instructor dispatched from DDCA.

Maintenance Plan, Maintenance System for Hiring Equipment

Daily service check sheet

✔：

Good

X：

Not good

ー：

Nothing

Type: Truck mounted rig

Date

Model:

Start

End

Start

End

Start

End

Start

End

Reg. No.:

Hours

Checked by:

Time

：

Place

Contents

Check

Engine oil (amount, leakage)

Fuel (amount, leakage)

Engine

Air filter (blocking)

Radiator (coolant water leakage)

Fan belt (condition)

Hydraulic pump (condition)

Hydraulic hose and pipe

Hydraulic

pump

Hydraulic oil (leakage)

Hydraulic oil (level)

Hydraulic oil (leakage)

Hydraulic

oil cooler

Fan (condition)

Mud pump (condition)

Hydraulic hose and pipe (leakage)

Mud

Cylinder (condition)

pump

Gear oil (level)

Greasing

Hydraulic oil (leakage)

Control

Control switch (condition)

panel

Control meter (condition)

Gear oil (level)

Rotation

gear box

Hydraulic oil (leakage)

Wire rope (condition)

Mast

Hydraulic motor (condition)

Hydraulic hose and pipe (leakage)

Remarks

Figure 3 Daily Service Check Sheet

7. REPAIRING PLAN

7.1 REPAIRING WORK

The repairing work consists of replacement of the spare parts and fixing. In principle, the

repairing shall be done in case of i) the breakdown is occurred while operation on site, ii) the

timing of the periodic maintenance comes. The repairing will be done by the owner.

7.2 CASE NECESSARY FOR REPAIRING

Table 2 summarizes the case necessary for repairing the drilling equipment and vehicles. Each

component will have the specific problems and the several experts will respond to them.

Necessary spare parts for general repairing will be procured according to the repairing plan. If

another case is happened while operation of the equipment hiring, it will be added into the plan.

Table 2 General Maintenance Plan

Part of the

General problem

Person in charge of repair

Location of repairing

vehicle

works

Engine of the

Oil or water leakage

Person in charge of

Drilling site

vehicle

drilling

Maintenance Plan, Maintenance System for Hiring Equipment

Part of the

General problem

Person in charge of repair

Location of repairing

vehicle

works

Engine trouble

Mechanic of the Dar es

Drilling site or the Dar es

Salaam garage

Engine start-up failure

Mechanic of the Dar es

Dar es Salaam garage

Salaam garage

Problems with the fuel

Mechanic of the Dar es

Outsourcing

system

Salaam garage

Vehicle

Problems with the tyres

Person in charge of

Drilling site

chassis

and wheels

drilling

Problems with the

Mechanic of the Dar es

Drilling site or the Dar es

suspension

Salaam garage

Problems with the brake

Mechanic of the Dar es

Drilling site or the Dar es

Salaam garage

Problems with the steering

Mechanic of the Dar es

Dar es Salaam garage

Salaam garage

Problems with the

Mechanic of the Dar es

Dar es Salaam garage

transmission and

Salaam garage

differential systems

Drilling

Oil leakage of the oil

Person in charge of

Drilling site

equipment

pressure system

drilling

Problems with the oil

Mechanic of the Dar es

Drilling site or the Dar es

pressure system

Salaam garage

Welding repair

Person in charge of

Drilling site or the Dar es

drilling

Salaam garage

Welder of Dar es Salaam

garage

8 SPARE PARTS AND CONSUMABLE PARTS CONTROL AND

PROCUREMENT PLAN

8.1 PROCUREMENT OF SPARE PARTS

8.1.1 SPECIFICATION OF SPARE PARTS

The spare parts are classified into the following three categories.

(1) Spare parts used for periodic service (periodic service spare parts)

 Spare parts used at periodic service

 Filters (air filter, engine oil, fuel, hydraulic oil)

 Oils (engine oil, gear oil, power steering oil, hydraulic oil, radiator coolant)

The quantity of spare parts required annually for periodic service can be calculated according to the

mileage and operated hours of the equipment for each case supposed in the repairing plan. The

spare parts shall be purchased after calculating the required quantity with using the “calculating

sheet for required spare parts”.

(2) General spare parts necessary during while operation

The spare parts necessary for general operation of the equipment hiring will be mainly the

following items.

 Tires

 Batteries

 Brake, Clutch (brake lining, crutch disc, brake cup seal)

 Engine spare parts (fan belt, radiator hose)

Maintenance Plan, Maintenance System for Hiring Equipment

 Oil seals, bushes, hoses (hub seal, hydraulic seal, bush, high pressure hose)

The quantity of spare parts required for periodic service maintenance can be estimated from the

mileage and operation hours of the equipment. However, even before the required timing of the

replacement has not yet come, the necessity of the replacement could be happened by any chance.

The quantity of the spare parts including additional ones will be calculated with using the

“calculating sheet for required spare parts”.

(3) Spare parts for emergency due to accidents and collision

The spare parts needed emergently due to the unexpected accidents or corrosion will be

estimated as the following items.

 Window glass, lights(windshield, light bulbs, lens)

 Engine(alternator, starter, radiator)

 Chassis(shock absorber, leaf spring)

It is preferable that at least one set of these items for each equipment are prepared for the case of

emergency.

8.1.2 SPARE PARTS PROCUREMENT PLAN

Following procedures are necessary, in order to

Annual Equipment Operation Plan

estimate the necessary quantities of spare parts and

(1) Annual Kilometrage and Operation Hours of

their budget for the annual use of the hiring

Equipment

equipment:

(1) Set the annual operation mileage and operation

Inventory of Necessary Parts

hours of each equipment according to the annual

operation plan of the hiring business,

(2) replacement timing

(3) Unit price of

(kilometrage or operation

each part

(2) List up the necessary parts to be replaced and

hours)

their replacement timing

(mileage or operation

Cost Estimation

hours) of each equipment,

(3) Investigate the unit prices of the parts,

(4) Annual necessary

(4) Calculate the annual necessary quantities of each

Quantity = (1) / (2)

parts from (1) and (2),

(5) Procurement Cost =

(3) x (4)

(5) Calculate the cost for procurement from (3) and

(4).

Figure 4 Procedure of Spare Parts

Procurement Plan

The above procedures are summarized in Figure 4.

Currently, DDCA has not received the operation manuals of each equipment from the supplier,

which provide the list of necessary spare parts and the replacement timing. In this reason, the

maintenance section estimated the quantities and the budget of spare parts procurement for a

drilling rig from their experience. According to this estimation for a drilling rig, the budget of

spare parts procurement for other hiring equipment was estimated. The actual estimation for a rig

using the above procedures is described below:

(1) Operation Plan of a Drilling Rig

A drilling rig consists of two components of a rig truck and a rig plant. Table 3 shows the annual

operation plan for each component for three years.

Table 3 Annual Operation Plan of Drilling Rig

Replacement

Annual

Mileage / Operation Hours

Equipment

Nos.

Timing

Mileage

1^st Year

2^nd Year

3^rd Year

Rig Truck

Mileage

20,000

40,000

60,000

Rig Plant

Operation Hours

1,500

3,000

4,500

Maintenance Plan, Maintenance System for Hiring Equipment

(2) Replacement Timing of Parts for a Drilling Rig

Table 4 Shows the list of spare parts and their replacement timing. Principally, replacement

timing of spare parts for rig truck is based on the mileage and the one for rig plant is based on

operation hours.

Table 4 Replacement Timing of Spare Parts for Rig Truck and Rig Plant

Rig Truck

Rig Plant

Replacement

Category

Parts name

(operation

(mileage/ year)

hours / year)

Engine oil filter

10,000km

Engine oil filter

250h

Fuel filter

30,000km

Fuel filter

1,000h

Filters

Water separator

30,000km

Filters

Water separator

1,000h

Air filter

60,000km

Air filter

2,000h

Hydraulic filter

2 year

Hydraulic filter

3,000h

Engine oil

10,000km

Engine oil

250h

Transmission oil

30,000km

Gear oil

1,500h

Oil

Differential oil

30,000km

Hydraulic oil

3,000h

Oil

Hydraulic oil

2 year

Grease

250h

Power steering oil

100,000km

Battery

1 year

Grease

10,000km

Consumable

Fan belt

1 year

Tire

90,000km

Hydraulic hose

2 years

Battery

1 year

Consumable

Brake lining

60,000km

Brake oil seal

60,000km

Fan belt

50,000km

(3) List of Spare Parts and Unit prices for a Drilling Rig

Table 5 shows the inventory of spare parts for a rig truck and a rig plan. This contains necessary

quantities for each replacement and unit prices of each spare parts, in addition to the information of

the annual mileage and operation hours of each equipment and replacement timing of each spare

parts described in above (1) and (2).

Table 5 Inventory of Spare Parts for Rig Truck and Rig Plant

Replacement

mileage / Operation

Unit Price

Parts

Qty

Unit

Criteria

Hours

(Tsh)

1 Parts for Rig Truck

1-1 Filter for Truck

1-1-1

Engine oil filter

Mileage

10,000

pc.

300,000

1-1-2

Fuel filter

Mileage

30,000

pc.

200,000

1-1-3

Water separator

Mileage

30,000

pc.

200,000

1-1-4

Air cleaner

Mileage

60,000

pc.

300,000

1-2 Oil for Truck

1-2-1

Engine oil

Mileage

10,000

litter

10,000

1-2-2

Transmission oil

Mileage

30,000

litter

5,000

1-2-3

Differential oil

Mileage

30,000

litter

5,000

1-2-4

Hydraulic oil

Years

100

litter

5,000

1-2-5

Power steering oil

Mileage

100,000

litter

8,000

1-2-6

Grease

Mileage

10,000

0.5

5,000

1-3 Consumption parts for Truck

1-3-1

Tire

Mileage

90,000

pc.

1,500,000

1-3-2

Battery

Years

pc.

500,000

1-3-3

Brake lining

Mileage

60,000

set

600,000

1-3-4

Brake oil seal

Mileage

60,000

set

400,000

Maintenance Plan, Maintenance System for Hiring Equipment

Replacement

mileage / Operation

Unit Price

Parts

Qty

Unit

Criteria

Hours

(Tsh)

1-3-5

Fan belt

Mileage

50,000

set

100,000

1-3-6

Rubber bush

Mileage

50,000

set

600,000

1-4 Other parts for Truck

1-4-1

Grass

Mileage

35,000

set

500,000

1-4-2

Lights

Mileage

35,000

set

1,000,000

1-4-3

Electric

Mileage

35,000

set

500,000

1-4-4

Others

Mileage

35,000

lot

200,000

2 Parts for Rig Plant

2-1 Filter for Drilling Rig

2-1-1

Engine oil filter

Hours

250

pc.

300,000

2-1-2

Fuel filter

Hours

1,000

pc.

200,000

2-1-3

Water separator

Hours

1,000

pc.

200,000

2-1-4

Air cleaner

Hours

2,000

pc.

300,000

2-1-5

Hydraulic oil filter

Hours

3,000

pc.

200,000

2-2 Oil for Drilling Rig

2-2-1

Engine oil

Hours

250

litter

10,000

2-2-2

Gear oil

Hours

1,500

litter

5,000

2-2-3

Hydraulic oil

Hours

3,000

400

litter

5,000

2-2-4

Grease

Hours

250

kｇ

5,000

2-3 Consumption parts for Drilling Rig

2-3-1

Battery

Years

pc.

1,000,000

2-3-2

Fun belt

Years

set

100,000

2-3-3

Hydraulic hose

Years

set

1,500,000

2-3-4

Others

Years

set

200,000

(4)

Budget of Spare Parts Procurement for a Drilling Rig

Table 6 Shows the budget plan of spare parts procurement for a drilling rig for 3 years.

The

necessary spare parts to be replaced are differently estimated by each year. Accordingly, the

maintenance section estimated the quantities of spare parts and their budget for each year of 3 years’

use. The average of 3 years’ budget was reported to the account section of DDCA as a first year’s

budget.

The calculated annual budget for maintenance of a drilling rig is Tsh 14,625,667 (sum of Tsh

6,295,667 and Tsh 8,330,000). The CIP price of a drilling rig is US$260,894 (x 1,600 Tsh/US$ =

Tsh 417,430,400). According to these calculations, an annual budget for maintenance of a drilling

rig is equivalent to 3.5 % of the price of a drilling rig. Since DDCA has not received the operation

manuals of each equipment which shall give the necessary information of spare parts inventory,

this 3.5 % is adapted to estimate the annual spare parts procurement budget for other equipment.

After the final delivery of the equipment and manuals and the 1^st year’s operation of the hiring

business, the spare parts procurement plan and budget shall be adjusted based on the manuals’

instructions and the results of the operation of the hiring business.

Maintenance Plan, Maintenance System for Hiring Equipment

Table 6

3 Year’s Spare Parts Procurement Budget Plan for a Drilling Rig

1st Year

2nd Year

3rd Year

Total

Replacement

Mileage /

Unit Price

No.

Parts

Qty

Unit

Amount

Criteria

Years

(Tsh)

Qty

(Tsh)

One Rig Truck

1-1-1

Engine oil filter

Mileage

10,000

pc.

300,000

600,000

1,800,000

1-1-2

Fuel filter

Mileage

30,000

pc.

200,000

400,000

1-1-3

Water separator

Mileage

30,000

pc.

200,000

400,000

1-1-4

Air cleaner

Mileage

60,000

pc.

300,000

1-2-1

Engine oil

Mileage

10,000

litter

10,000

500,000

150

1,500,000

1-2-2

Transmission oil

Mileage

30,000

litter

5,000

50,000

150,000

1-2-3

Differential oil

Mileage

30,000

litter

5,000

50,000

150,000

1-2-4

Hydraulic oil

Years

100

litter

5,000

100

500,000

100

500,000

1-2-5

Power steering oil

Mileage

100,000

litter

8,000

24,000

72,000

1-2-6

Grease

Mileage

10,000

0.5

5,000

15,000

1-3-1

Tire

Mileage

90,000

pc.

1,500,000

4,500,000

1-3-2

Battery

Years

pc.

500,000

1,000,000

3,000,000

1-3-3

Brake lining

Mileage

60,000

set

600,000

1-3-4

Brake oil seal

Mileage

60,000

set

400,000

1-3-5

Fun belt

Mileage

50,000

set

100,000

1-3-6

Rubber bush

Mileage

50,000

set

600,000

1-4-1

Grass

Mileage

35,000

set

500,000

1,000,000

1-4-2

Lights

Mileage

35,000

set

1,000,000

2,000,000

1-4-3

Electric

Mileage

35,000

set

500,000

1,000,000

1-4-4

Others

Mileage

35,000

lot

200,000

400,000

Total

6,329,000

6,229,000

6,329,000

18,887,000

Annual Average

6,295,667

One Rig Plant

2-1-1

Engine oil filter

Hours

250

pc.

300,000

1,800,000

5,400,000

2-1-2

Fuel filter

Hours

1,000

pc.

200,000

400,000

200,000

400,000

1,000,000

2-1-3

Water separator

Hours

1,000

pc.

200,000

400,000

200,000

400,000

1,000,000

2-1-4

Air cleaner

Hours

2,000

pc.

300,000

600,000

2-1-5

Hydraulic oil filter

Hours

3,000

pc.

200,000

400,000

2-2-1

Engine oil

Hours

250

litter

10,000

150

1,500,000

150

1,500,000

150

1,500,000

450

4,500,000

2-2-2

Gear oil

Hours

1,500

litter

5,000

200,000

120

600,000

2-2-3

Hydraulic oil

Hours

3,000

400

litter

5,000

200

1,000,000

200

1,000,000

200

1,000,000

600

3,000,000

2-2-4

Grease

Hours

250

kｇ

5,000

30,000

90,000

2-3-1

Battery

Years

pc.

1,000,000

2,000,000

6,000,000

2-3-2

Fan belt

Years

set

100,000

300,000

2-3-3

Hydraulic hose

Years

set

1,500,000

2-3-4

Others

Years

set

200,000

600,000

Total

8,130,000

9,030,000

7,830,000

24,990,000

Annual Average

8,330,000

Maintenance Plan, Maintenance System for Hiring Equipment

8.1.3 DRILLING CONSUMABLE PLAN

Rig accessories of which detailed contents are

Annual Drilling Plan

shown in the maintenance guideline include

(1) Annual number of DTH boreholes and mud

drilling consumables such as DTH hammers, DTH

drilling boreholes

bits, roller bits, steel casings etc.

These

consumables are consumed in drilling of several

(2) Driling depth of borehole

boreholes. It is difficult to charge the fixed tariff

for the drilling consumables as their lives varies

Inventory of Drilling Consumables

depending on the specifications of each boreholes

and drilling conditions. Therefore, the drilling

(3) Average life (metrage

(5) Unit price of each

consumables will not be hired. The hirers shall

or hours) of each

consumable

procure for themselves necessary quantities of

consumable

drilling consumables or they will purchase them

from DDCA. In order to respond to the hirers’

(4) Average consumed

quantity perborehole

demand of the purchase of the drilling

consumables, DDCA shall keep necessary

Cost Estimation

quantities as stocks. DDCA shall estimate the

necessary quantities of the drilling consumables

(6) Necessary quantity

and their budget from the past experiences and the

per borehole = (4) x (1)

(7) Cost per

results of the operation of the hiring business.

borehole = (6) x (5)

Following procedures are necessary, in order to

(8) Procurement Cost =

estimate the necessary quantities of drilling

(7) x (1)

consumables and their budget for the annual

drilling works under the hiring business:

Figure 5 Procedure of Drilling

Consumable Procurement Plan

(1) Set the annual number of DTH boreholes and

mud drilling boreholes based on the annual operation plan of the hiring business,

(2) Set the average depth of borehole,

(3) List-up the necessary drilling consumables and their lives for DTH drilling borehole and mud

drilling borehole,

(4) Estimate the necessary quantities of drilling consumables per borehole for DTH drilling

borehole and mud drilling borehole,

(5) Investigate the unit prices of drilling consumables,

(6) Calculate the quantities of drilling consumables per borehole for DTH drilling borehole and

mud drilling borehole,

(7) Calculate the procurement cost of drilling consumables per borehole for DTH drilling borehole

and mud drilling borehole,

(8) Annual procurement cost of drilling consumables.

The above procedures are summarized in Figure 5.

Number of DTH boreholes and mud drilling boreholes under the annual drilling plan for the hiring

business, average drilling depth, inventory of drilling consumables shall be annually reviewed for

the formulation of the procurement plan of the drilling consumables. The estimation for the 1^st

year using the above procedures is described below:

(1) Annual Drilling Plan under Annual Operation Plan of Hiring Business

The following annual drilling plan was prepared under the annual operation plan of the hiring

business and described in Chapter

4 of the guidelines on hiring of drilling equipment and

machinery. The total number of boreholes to be drilled is 33, of which 23 is DTH for boreholes

(70 %) and 10 is for mud drilling boreholes (30 %). These percentages were estimated from the

Maintenance Plan, Maintenance System for Hiring Equipment

past experience of DDCA. Average drilling depth is 100 m. This is from the results of the

drilling works in the rural water supply component of WSDP.

Table 7 Annual Drilling Plan for the 1^st Year of the Hiring Business

Item

Plan

Number of DTH boreholes to be drilled

Number of mud drilling boreholes to be drilled

Total number of boreholes to be drilled

Average Drilling Depth

100 m

(2) Inventory of Drilling Consumables

Table 8 Summarizes the necessary drilling consumables respectively for a DTH borehole and a

mud drilling borehole, with the information of their lives, average consumed quantities per

borehole, unit prices, amount per borehole etc.

Table 8 Necessary Drilling Consumables for a DTH Borehole and Mud Drilling Borehole

DTH Drilling Borehole (Drilling Depth : 100 m)

12-1/2"

Roller Bit

0.200

227

0.00440

2823.09

12.42

19,872

Tricone

12-1/2"

3.5

0.286

263

0.00380

5515.69

20.96

33,536

Surfac

0 to 5

Roller Bit

e Hole

12-1/2"

Drag Bit

120

0.500

238

0.00420

996.38

4.18

6,688

10"

Steel Casing

0.03000

564.62

16.94

27,104

10"

Casing Shoe

0.10000

308.4

30.84

49,344

10-1/2"

DTH

1000

1.429

714

0.00140

10675.53

14.95

23,920

10-1/2"

DTH Bit

1.429

0.02860

972.66

27.82

44,512

10-1/2"

Roller Bit

4.5

1.111

0.03170

1636.91

51.89

83,024

Condu

5 to 30

Tricone

ctor

10-1/2"

1.000

0.01430

3582.23

51.23

81,968

Roller Bit

Hole

10-1/2"

Drag Bit

5.5

100

1.273

0.01270

822.02

10.44

16,704

Steel Casing

0.03000

453.12

13.59

21,744

Casing Shoe

0.10000

260.96

26.10

41,760

Produc

8-1/4"

DTH

1000

10.000

100

0.01000

10675.53

106.76

170,816

30 to

tion

8-1/4"

100 m

DTH Bit

10.000

0.22220

806.6

179.23

286,768

Hole

Pilot

6-1/4"

30 to

DTH

1000

5.000

200

0.00500

10675.53

53.38

85,408

Hole

6-1/4"

100 m

DTH Bit

5.000

0.12500

498.19

62.27

99,632

Drill Pipe

0.03000

533.78

16.01

25,616

Replac

8-1/4"

100

Stabilizer

0.04000

880.73

35.23

56,368

ement

6-1/4"

Stabilizer

0.04000

789.99

31.60

50,560

Total Amount (Tsh)

765.84

1,225,344

Mud Drilling Borehole (Drilling Depth: 100 m)

12-1/4"

Roller Bit

0.200

227

0.00440

2823.09

12.42

19,872

Tricone

12-1/4"

3.5

0.286

263

0.00380

5515.69

20.96

33,536

Surfac

0 to 5

Roller Bit

e Hole

12-1/4"

Drag Bit

120

0.500

238

0.00420

996.38

4.18

6,688

10"

Steel Casing

0.03000

564.62

16.94

27,104

10"

Casing Shoe

0.10000

308.4

30.84

49,344

10-1/2"

Roller Bit

4.5

10.000

0.28570

1636.91

467.67

748,272

Produc

5 to

Tricone

tion

10-1/2"

10.000

0.14290

3582.23

511.90

819,040

100 m

Roller Bit

Hole

10-1/2"

Drag Bit

5.5

100

3.636

0.03640

822.02

29.92

47,872

8-1/2"

Roller Bit

6.250

0.20830

1708.09

355.80

569,280

Pilot

5 to

Tricone

Hole

8-1/2"

100 m

2.5

10.000

0.15380

3250.11

499.87

799,792

Roller Bit

Drill Pipe

0.03000

533.78

16.01

25,616

Replac

8-1/4"

100

Stabilizer

0.04000

880.73

35.23

56,368

ement

6-1/4"

Stabilizer

0.04000

789.99

31.60

50,560

Total Amount (Tsh)

2033.34

3,253,344

Maintenance Plan, Maintenance System for Hiring Equipment

(3) Drilling Consumable Procurement Plan and Budget

Based on the annual drilling plan and the inventory of the drilling consumables for DTH boreholes

and mud drilling boreholes, described in above (1) and (2), the quantities and budget for the drilling

consumables for the 1^st year of the hiring business were estimated as shown in Table 9. In the

condition that the annual number of boreholes to be drilled is 33, the cost for drilling consumables

is Tsh 60,715,888. However, DDCA needs not to purchase all the quantity in the beginning of the

operation year, since the actual contents of the consumables will be changed according to the

results of the drilling works and the selection of the hirers on whether they purchase the drilling

consumables for themselves or from DDCA. Accordingly, DDCA’s engagement to ensure the

smooth implementation of the hiring business is to keep certain part of the annual quantities of

drilling consumables and make prompt supplementation after selling the drilling consumables to

the hirers.

Table 9 Annual Procurement Plan and Budget for Drilling Consumable

Consumed Number for 33

Consumed Numbers / BH

boreholes / rig

Item

8" casing shoe

0.1

0.07

261

18.27

29,232

2.3

600.21

960,336

10" casing shoe

0.1

308.4

30.84

49,344

3.3

1017.72

1,628,352

8" steel casing

0.03

0.021

453.1

9.52

15,232

0.69

312.65

500,240

10" steel casing

0.03

564.6

16.94

27,104

0.99

558.97

894,352

4-1/2" drill pipe

0.03

533.8

16.01

25,616

0.99

528.44

845,504

DTH Hammer for 12" hole

0.0164

0.0115

10676

122.77

196,432

0.3772

4026.81

6,442,896

6-1/4" DTH bit

0.125

0.0875

498.2

43.59

69,744

2.875

1432.30

2,291,680

8-1/4" DTH bit

0.2222

0.1555

806.6

125.43

200,688

5.1106

4122.21

6,595,536

10" DTH bit

0.0286

0.02

972.7

19.45

31,120

0.6578

639.82

1,023,712

8-1/2" tricone roller bit

0.1538

0.0461

3250

149.83

239,728

1.538

4998.67

7,997,872

10-1/2" tricone roller bit

0.0143

0.1429

0.0529

3582

189.50

303,200

1.7579

6297.20

10,075,520

12-1/4" tricone roller bit

0.0038

5516

20.96

33,536

0.1254

691.67

1,106,672

8-1/2" roller bit

0.2083

0.0625

1708

106.76

170,816

2.083

3557.95

5,692,720

10-1/2" roller bit

0.0317

0.2857

0.1079

1637

176.62

282,592

3.5861

5870.12

9,392,192

12-1/2" roller bit

0.0044

2823

12.42

19,872

0.1452

409.91

655,856

10-1/2" drag bit

0.0127

0.0364

0.0198

822

16.28

26,048

0.6561

539.33

862,928

12-1/2" drag bit

0.0042

996.4

4.18

6,688

0.1386

138.10

220,960

6-1/4" stabilizer

0.04

790

31.60

50,560

1.32

1042.79

1,668,464

8-1/2" stabilizer

0.04

880.7

35.23

56,368

1.32

1162.56

1,860,096

Total Amount

1,146

1,833,920

37,947

60,715,888

9 MAINTENANCE EQUIPMENT CONTROL AND

PROCUREMENT PLAN

The work environment of the maintenance section including maintenance tools and equipment is an

important factor for the smooth implementation of the maintenance activities. The baseline

survey in the Project revealed that DDCA’s maintenance tools were not sufficient and the

equipment got aged. Conditions of the maintenance tools were improved by the procurement of

new tools by the Project. The maintenance section conducted the survey of the existing

maintenance facilities and listed up the list of necessary maintenance equipment to be procured

with the 1^st and 2^nd priorities as shown in Table 10.

Table 10 List of Required Equipment in each Section

No.

Equipment

Specification

Qty.

Price (Tsh)

1^stPriorirty

2^nd Priority

Maintenance Section

air compressor

20bar

1,800,000

Maintenance Plan, Maintenance System for Hiring Equipment

No.

Equipment

Specification

Qty.

Price (Tsh)

1st Priorirty

2nd Priority

washing machine

3,000,000

hydraulic press

1,000,000

injection nozzle tester

800,000

valve sharpener

650,000

high lift jack

600,000

pipe bending machine

600,000

torque wrench

0-100/100-400

560,000

puller

250,000

compression gauge

1,000,000

Micrometre screw gauge

200,000

cooling system tester

200,000

tire press

200,000

valve seat grinding set

150,000

RPM meter

110,000

bench vice

200,000

injector tool

100,000

valve spring compressor

180,000

telescopic gauge

75,000

air hose

70,000

die UNC

70,000

die MM

70,000

hole punch

140,000

wheel spanners

198,000

hydraulic jack

10ton

60,000

armatures tester

55,000

pressure gauge

50,000

filter strap

100,000

piston ring squeezer

45,000

die gauge

45,000

hydraulic jack

5ton

40,000

thread gauge

80,000

honing tool

40,000

Venire calliper

35,000

tire lever

128,000

die handle

60,000

battery terminal cleaner

30,000

chain spanner

50,000

air gun

25,000

grease pump HD

200,000

foot pump

20,000

die UNF

10,000

hacksaw blade

100,000

hand pump

8,000

hacksaw frame

3,500

Oil filter pump

200,000

Hexagon wrench set

300,000

Sub-total

8,479,500

5,428,000

Panel beating and spray paint section

Welding machine

Generator 3phase 5kw

2,000,000

Air compressor

300L with accessories

2,000,000

Spray gun

500,000

Spray mask

Heavy duty

400,000

Bench drill

1,000,000

Power hacksaw

500,000

Rivet machine

200,000

Panel beating tools

1,500,000

Body jack

5ton

1,000,000

Chain block

500,000

Maintenance Plan, Maintenance System for Hiring Equipment

No.

Equipment

Specification

Qty.

Price (Tsh)

1^stPriorirty

2^nd Priority

hammer

1set

500,000

Body file

100,000

Sub-total

6,200,000

4,000,000

Auto electric section

Battery tester

500,000

Battery charger

2,000,000

Hydrometer

200,000

Boosting cable

300,000

Sub-total

2,200,000

800,000

Table 11 shows the cost of the necessary maintenance equipment for each section under the

maintenance section. Total cost is Tsh 27,107,500 for which 1^st priority is Tsh 16,879,500 and 2^nd

priority is Tsh 10,228,000. DDCA shall proceed the procurement of the maintenance equipment

as well as the annual control of the conditions of the maintenance tools and equipment, in order for

the smooth implementation of the maintenance activities.

Table 11 Cost of Necessary Maintenance Equipment

1st priority

2nd priority

Section

Total (Tsh)

(Tsh)

Garage section

8,479,500

5,428,000

13,907,500

Panel beating and spray paint section

6,200,000

4,000,000

10,200,000

Auto electric section

2,200,000

800,000

3,000,000

Total (Tsh)

16,879,500

10,228,000

27,107,500

10 PERSONNEL ASSIGNMENT PLAN

10.1 ALLOCATION OF HIRING EQUIPMENT

It is preferable that the rig-mounted trucks are kept at each district office for hiring service in order

to curtail the costs of relocation. Since it is possible that there will be no drilling operations in a

certain district for a long period of time, it is necessary to draw up an allocation plan that reflects

the current drilling situations so that the equipment can be effectively utilized. It is also proposed

that the equipment be allocated at the DPO (Drilling project officer) office of the Mtwara and

Tabora districts, as it will be difficult to cover the whole of Tanzania with the current 4 district

offices.

10.2 STAFF ALLOCATION

(1) Increasing the number of staff

Considering the current number of hiring equipment (8 drilling equipment, 5 support trucks and

1water tank), periodic services must be conducted 26 times annually. In addition, the vehicles for

DDCA works (7 drilling equipment and 5 support trucks) require 26 periodic services per year,

making the number 50 times a year. Moreover, considering the repairs of vehicles damaged by

accidents (36 times a year should it occur 3 times a month), it is feared that the 3 mechanics posted

at the DDCA Dar es Salaam garage will not be enough to appropriately conduct the maintenance of

hiring equipment.

(2) Reviewing the current staff allocation

At the moment, the mechanics of Dar es Salaam garage are dispatched in order to conduct serious

repairs of drilling equipment. The mechanics are allocated in Arusha, Mwanza, Dodomca and

Mbeya. Figure 6 shows the headquarters and branch offices of DDCA where the mechanics are.

However since minor repairs and inspection of the DDCA’s drilling equipment are conducted by

the drillers, the mechanics allocated at these 4 locations are rarely engaged in maintenance works.

When hiring the equipment to the private companies however, the DDCA will be responsible for

the repairs of the equipment, and it will be obliged to mobilize these mechanics in order to swiftly

and appropriately conduct repairs. Prior to the start of the hiring system, it will be necessary to

Maintenance Plan, Maintenance System for Hiring Equipment

revise the allocation of the mechanics and decide the person in charge of the repairs according to

the location to which the equipment will be hired to.

Figure 6 Allocation and Management Area of the Hiring Equipment

11 TECHNICAL ENHANCEMENT PLAN

The technical maintenance training for the mechanics of the maintenance section were held 9 times,

on every Wednesday afternoon from 14:00 to 15:30. The knowledge and ability of the mechanics

became evident through the trainings, and the expert will implement the following plan in order to

further improve the technical ability of the mechanics during the next dispatch (8 weeks, 12 hours

of seminar).

Table 12 Plan for Training

Area

Item

Contents

Schedule

Speed, torque, engine revolution

1hour

Basic knowledge

Calculation

Pressure

Fuel consumption

2 stroke engine basics

0.5hour

4 stroke engine basics

1hours

Valve timing diagram

Valve clearance

Engine

Turbo charger

Diesel engine

1hours

Fuel system

Vehicle

Water system

Oil system

Transmission basics

0.5hour

Chassis

Differential basic

Brake system basic

1hours

Electrical basics

3hours

Electric

Battery, Alternator, Starter, Lights

Maintenance Plan, Maintenance System for Hiring Equipment

Area

Item

Contents

Schedule

Trouble shooting

Engine, chassis

1hours

Hydraulic pump

3hours

Hydraulic system

Structure

Hydraulic motor

Hydraulic cylinder

12 BUDGET PLAN

The annual budget of the equipment maintenance shall be calculated based on the necessary spare

parts and consumables for each equipment. As described in Chapter 8, the maintenance cost for a

drilling rig was calculated to be 3.5 % of the CIP price of a drilling rig. The maintenance cost for

the other hiring equipment was calculated using this ratio of 3.5 %, as shown in Table 13. Total

cost is Tsh 155,323,200. The annual maintenance cost calculated by the maintenance section shall

be reported to the hiring business unit for them to include it in the hiring tariff with other items

such as management cost, risk for exchange rate, SGA (selling, general & administrative expenses),

profit etc. The maintenance budget shall be annually reviewed and modified according to the

results of the operation of the hiring business.

Table 13 Maintenance Budget for the 1^st Year’s Use of Hiring Equipment

Unit

Maintenance Cost

Amount

Price

(3.5% per annum)

Equipment

Unit

Qty

CIP

Remarks

CIP

(US$)

US$

Tsh

(US$)

Truck Mounted Drilling rig 150

Service &

units

260,894

1,565,364

54,788

87,660,800

Maintenance

Trailer Mounted Air

Service &

units

39,081

195,405

6,839

10,942,400

Compressor

Maintenance

Service &

Trailer Mounted Mud pump

units

30,740

153,700

5,380

8,608,000

Maintenance

Trailer Mounted Pumping Test

Service &

units

94,247

471,235

16,493

26,388,800

Unit

Maintenance

3.5 % of only

Rig Accessories

sets

216,428

1,298,569

8,308

13,292,800

necessary items

3.5 % of only

Casing tools

sets

12,573

75,440

2,220

3,552,000

necessary items

3.5 % of only

Fishing Tools

sets

2,538

15,230

209

334,400

necessary items

Direct Mud Circulation Drilling

3.5 % of only

sets

16,488

98,927

2,840

4,544,000

Tools & Accessories

necessary items

Total

3,965,467

97,077

155,323,200

Contents

1 PURPOSE OF MAINTENANCE MANUAL OF HIRING EQUIPMENT

CONDITION CHECK OF HIRING EQUIPMENT BEFORE AND AFTER HIRING

2.1

Hiring Equipment Condition Check Sheet

2.2

Contents of the Hiring EquipmentCondition Check Sheet

3 PERIODIC SERVICE

3.1

Periodic Service Check Sheet

3.2

Contents of the Periodic Service Check Sheet

Appendices

[Form A-1] Hiring Equipment Condition Check Sheet for Truck-mounted Drilling Rig

[Form A-2] Hiring Equipment Condition Check Sheet for Support Truck

[Form A-3] Hiring Equipment Condition Check Sheet

for Trailer-mounted Air Compressor / Mud Pump / Pumping Test Unit

[Form B-1] Periodic Service Check Sheet for Truck-mounted Drilling Rig

[Form B-2] Periodic Service Check Sheet for Support Truck

[Form B-3] Periodic Service Check Sheet

for Trailer-mounted Air Compressor / Mud Pump / Pumping Test Unit

Maintenance Guideline for OWNER, Maintenance System for Hiring Equipment

1 DOCUMENTS FOR THE MAINTENANCE SYSTEM

The documents, namely maintenance guideline, maintenance plan and maintenance manual for the

hiring equipment were prepared by the Groundwater Development and Management Capacity

Development (DDCAP) Project, in order to manage the maintenance system for the hiring

equipment. The roles and the contents of each document are summarized as follows.

This is Document 3: Maintenance Manual for the Owner for the maintenance works for hiring

equipment.

Document 1: Maintenance Guidlene

The guidline stipulates the roles and responsibility of both lessee (DDCA) and lesser (private

drilling company). The gidline is a principle for the operation of the maintenance system. The

guidline is derected to a system to hire drilling equipment and machinery. The guideline aims to

maintain the equipment and machinery for hiaring as good working condition in order to

accommodate demand of the private drilling companies.

Document 2: Maintenance Plan

The maintenance plan demonstrates the plans for the periodical service, sparparts, consumable

parts, tools, procurement, staff assignment, training and budjet. The maintenance works for the

hiring equipment should be carried out according to the maintenance plan.

Document 3: Maintenance Manual

The separate maintenance manuals for Owner (DDCA) and Hirer (private drilling company) were

provided. The manuals indicate the method and procedures of the maintenance works.

2 PURPOSE OF MAINTENANCE MANUAL OF HIRING

EQUIPMENT

The maintenance manual of hiring equipment indicates the methods and procedures of actually

conducting the maintenance and management of hiring equipment, as stipulated in the guideline for

hiring management. This manual will be revised according to the conditions of the hiring

equipment, and the revision will be conducted by the the maintenance section of DDCA.

3 CONDITION CHECK OF HIRING EQUIPMENT BEFORE AND

AFTER HIRING

When inspecting hiring equipment, the condition of the equipment is checked following the daily

service manual and by filling in the items on the “hiring equipment condition check sheet”

concerning the condition of the equipment before and after use.

3.1 HIRING EQUIPMENT CONDITION CHECK SHEET

The hiring equipment condition check sheet will be used for the following equipment:



[Form A-1] Truck Mounted Drilling Rig



[Form A-2] Support trucks (Cargo trucks, Cargo truck with crane and Water tank truck)



[Form A-3] Trailer Mounted Air Compressor



[Form A-3] Trailer Mounted Mud Pump



[Form A-3] Trailer Mounted Pumping Test Unit

3.2 CONTENTS OF THE HIRING EQUIPMENTCONDITION CHECK SHEET

The following contents will be filled in the daily service check sheet before and after the operation

of the hired equipment:

Maintenance Manual of Hiring Equipment for OWNER (DDCA)

 Date

 Type and model of equipment

 Mileage (operated hours) before operation, mileage (operated hours) after operation

 Name of the person who conducted the condition check

 The condition will be judged in two categories: good and bad

 Any comments on the condition of the equipment will be filled in the “Comments” column.

 After confirming the condition of the equipment, the HMWS of the DDCA and the person in

charge of the hirer who hired the equipment sign the paper.

 Photograph of the equipment taken before and after operation is attached to the check sheet

Table 1 shows an example of how to fill in the check sheet is presented below, using the following

case of a vehicle problem as an example.

 The fuel tank was not full when the equipment was returned

 Oil leakage was detected from the oil pressure pipe

 No other problems were found

Table 1 Example of the Hiring Equipment Condition Check Sheet

Hiring equipment condition check sheet

Truck Rig

Photo

Model :IVECO

Type:䇭Ri䌧

Reg. No.:䇭STK XXXX

Front

Mileage:

15,500km

Checked by:䇭䇭Uzawa

Date (Before)

1/6/2012

Date(After)

10/9/2012

Place

No.

Check

Condition

Before

After

Engine

Fuel

full tank

䅝

㬍

Engine general

start, running sound, smoke

䅝

Right

Engine oil

amount, condition

䅝

Out side

Body, Cabin

tightening, damage

䅝

wiper and side mirror

tightening, damage

䅝

Tire

damage

䅝

Electric

lighting device

tightening, damage

䅝

Left

Switch, meter, wiring

working, damage

䅝

Running

Clutch

working sound, smoking

䅝

Brake

working sound, smoking

䅝

Parking brake

working sound, smoking

䅝

Chassis

working, damage

䅝

Back

Rig

Engine condition

start, running sound, smoke

䅝

Fuel

full tank

䅝

Hydraulic oil

amount, leakage

䅝

Hydraulic hose, pipe

damage

䅝

㬍

Rotation gear box

Oil level

䅝

Coments:

Fuel is䇭NOT full.

Mud pump

Mud pump condition

damage

䅝

Hydraulic pipe leakage

Condition

damage

䅝

DDCA HMWS :

Mr. George B

Private company:

Mr. XXXXXX

4 PERIODIC SERVICE

When conducting periodic service according to the mileage of the vehicle or the operation hours of

the equipment, “periodic service check sheet” shall be used. By following this check sheet, the

service can be kept in the same quality, regardless of the ability or the experience of the persons in

charge. Detecting any machine problems at early stage by periodic services is important so that

the suitable conditions of the equipment for the hiring will be kept.

Maintenance Guideline for OWNER, Maintenance System for Hiring Equipment

4.1 PERIODIC SERVICE CHECK SHEET

The periodic service check sheet will be used for the following hiring equipment:



[Form B-1] Truck Mounted Drilling Rig



[Form B-2] Support trucks (Cargo trucks, Cargo truck with crane and Water tank truck)



[Form B-3] Trailer Mounted Air Compressor



[Form B-4] Trailer Mounted Mud Pump



[Form B-5] Trailer Mounted Pumping Test Unit

4.2 CONTENTS OF THE PERIODIC SERVICE CHECK SHEET

The following contents will be filled in the periodic service check sheet before and after the

operation of the hired equipment:

 Date

 Type and model of the equipment

 Mileage (operated hours) before operation, mileage (operated hours) after operation

 Name of the person who conducted the periodic inspection

 The condition will be judged in these six categories: ok, change, adjust, clean up, tighten and

lubricant

 Any comments on the condition of the equipment will be filled in the “remarks” column.

Table 2 shows an example of how to fill in the check sheet is presented below, using the following

case of a vehicle problem as an example.



20L of engine oil and engine oil filter is replaced



10L of hydraulic oil refilled



2L of differential oil refilled

 Adjustment of the fan belt

 Adjustment of the front, back and parking brake

 Tightening of the clip nut

 Comment in the remarks column: the consumption of the brake lining

Maintenance Manual of Hiring Equipment for OWNER (DDCA)

Table 2 Example of how to fill in the periodic service check sheet

Periodic service check sheet

Date

Type

Model

Reg. No.

Mileage

Checked by

11/9/2012

Survice truck

IVECO

STK XXXXX

19,892km

Mr. UZAWA

䅝

䅞

Change

Adjust

Clean up

Tighten

Lubricant

Service truck

Outside

Oil, Filter and water

Qty.

䅝

Brake air tank, piping (leakage, condition)

䅞

Engine oil (amount, leakage)

20 L

䅝

Brake air tank Drain (leakage, condition)

䅞

Engine oil filter (leakage)

䅝

Front Brake hose, pipe (leakage, damage)

䅝

Fuel filter (leakage)

Brake lining front (leakage, damage, wear-out)

Air cleaner (blocking )

䅝

Rear Brake hose, pipe (leakage, damage)

Hydraulic oil (amount, leakage )

10 L

Brake lining rear (leakage, damage, wear-out)

䅝

Hydraulic oil filter (leakage)

Parking brake (condition, damage, wear-out)

䅝

Power steering (amount, leakage)

䅝

Hydraulic pump, cylinder(leakage, condition)

䅝

Brake oil (amount, leakage)

䅝

Tire (depth of ditch, damage )

䅝

Clutch oil (amount, leakage)

Wheel nut bolt (damage, loosening )

䅝

Transmission (amount, leakage)

䅝

Frame, body (tightening, damage)

Differential (amount, leakage)

2 L

䅝

Lights / Miller

(tightening, damage)

䅝

Radiator, coolant (amount, leakage)

㪄

Attachment (Crane, Water tank)

䅝

Battery (amount, loosening )

Driving

Engine room

䅝

Engine general (start, running sound, smoking )

Fan belt (damage, loosening )

䅝

Foot brake

䅝

Fan (damage, loosening )

䅝

Hand brake

䅝

Injector pump, Nozzle (leakage)

䅝

Clutch / Transmission

䅝

Generator (damage, condition )

䅝

Steering

䅝

Starter (damage, condition )

䅝

Noise

Comments:

Good condition

Brake lining ya mbele Zimeanza kulika

Maintenance Manual of Hiring Equipment for OWNER (DDCA)

Periodic service check sheet

Truck-mounted Rig

[Form B-1]

Date

Type

Model

Reg. No.

Mileage

Checked by

䅝

䅞

Change

Adjust

Clean up

Tighten

Lubricant

Truck

Outside

Oil, Filter and water

Qty.

Brake air tank, piping (leakage, condition)

Engine oil (amount, leakage)

Brake air tank Drain (leakage, condition)

Engine oil filter (leakage)

Front Brake hose, pipe (leakage, damage)

Fuel filter (leakage)

Brake lining front (leakage, damage, wear-out)

Air cleaner (blocking )

Rear Brake hose, pipe (leakage, damage)

Hydraulic oil (amount, leakage )

Brake lining rear (leakage, damage, wear-out)

Hydraulic oil filter (leakage)

Parking brake (condition, damage, wear-out)

Power steering (amount, leakage)

Hydraulic pump, cylinder(leakage, condition)

Brake oil (amount, leakage)

Tire (depth of ditch, damage )

Clutch oil (amount, leakage)

Wheel nut bolt (damage, loosening )

Transmission (amount, leakage)

Frame, body (tightening, damage)

Differential (amount, leakage)

Lights / Miller

(tightening, damage)

Radiator, coolant (amount, leakage)

Attachment (Crane, Water tank)

Battery (amount, loosening )

Driving

Engine room

Engine general (start, running sound, smoking )

Fan belt (damage, loosening )

Foot brake

Fan (damage, loosening )

Hand brake

Injector pump, Nozzle (leakage)

Clutch / Transmission

Generator (damage, condition )

Steering

Starter (damage, condition )

Noise

Rig

Hydraulic pump

Oil, Filter and water

Qty.

Hydraulic pump (condition)

Engine oil (amount, leakage)

Hydraulic hose and pipe

Engine oil filter (leakage)

Hydraulic oil (leakage)

Fuel filter (leakage)

Hydraulic oil (level)

Air cleaner (blocking )

Mud pump

Hydraulic oil (amount, leakage )

Mud pump (condition)

Hydraulic oil filter (leakage)

Hydraulic hose and pipe (leakage)

Radiator, coolant (amount, leakage)

Cylinder (condition)

Fan belt (damage, loosening )

Gear oil (level)

Battery (amount, loosening )

Greasing

Fan (damage, loosening )

㪤㪸㫊㫋

Injector pump, Nozzle (leakage)

Wire rope (condition)

Generator (damage, condition )

Hydraulic motor (condition)

Starter (damage, condition )

Hydraulic hose and pipe (leakage)

Control panel

Rotation gear

Hydraulic oil (leakage)

Gear oil (level)

Control switch (condition)

Hydraulic oil (leakage)

Control meter (condition)

comments:

A - 4

Technical Manual for Drilling Works for Technical Support Plan for the Drillers in DDCA (2013) - page 7