Hose Reel Unit, OMM. Discipline: TECHNIC Configuration control: X. Rev. Purpose Date Prep. Check. Appr. Changeorder No.

Transcription

1 OPERATION AND MAINTENANCE MANUAL Doc.No.: Hose Reel Unit, OMM Discipline: TECHNIC Configuration control: X Yes No Access: KOS Rev. Purpose Date Prep. Check. Appr. Changeorder No. 02 AS BUILT ID MHA OBO ECN ISSUED FOR REVIEW ID MHA OBO Summary: This document is the property of Kongsberg Offshore a.s and is not to be reproduced or disclosed to any party without the written consent of Kongsberg Offshore a.s.

2 Kongsberg Offshore as Åsgard Hose Reel Unit DOC , Rev. 2

3 Hose Reel Unit CONTENTS 1 Introduction Purpose of Equipment Location of Equipment Related KOS Documents Abbreviations Technical Data Technical Description Physical Description Functional Description Assembly of HPU/HRU Disassembly of HPU/HRU Handling and Transportation Lifting Instructions Lifting Data Transportation Instructions Preservation Standard Equipment Specific Storage Maintenance Preventive Maintenance for Equipment in Storage Preventive Maintenance for Equipment in Use Repair Repair of paint work Repair of components FIGURES 1 Intervention Control System Overview Hose Reel Unit, General Arrangement Lifting Arrangement DOC , Rev. 2

4 Hose Reel Unit 1 Introduction This manual is for the KOS supplied Hose Reel Unit (HRU). 1.1 Purpose of Equipment The purpose of a Hose Reel Unit is to accumulate and store the hose used under FCMRT operations. 1.2 Location of Equipment The equipment is located on deck of the rig or vessel, as shown in Figure Intervention Control System Overview. 1.3 Related KOS Documents Reference has been made to the following documents: OMM Hose Reel Unit, Operations OMM HPU, Deck Unit, Operation and Maintenance Manual Reference has been made to the following drawings: Hose Reel Unit, GA Hydraulic schematic, Hose Reel Unit Multi Sheave Block, GA Any other drawings related to the equipment may be found in the Intervention System Drawing File. 1.4 Abbreviations The abbreviations used are listed in KOS Abbreviation List. DOC , Rev. 2 Page 1 of 13

5 Hose Reel Unit Fig. 1 Intervention Control System Overview Page 2 of 13 DOC , Rev. 2

6 Hose Reel Unit 2 Technical Data KOS Part Number(s): Hose Reel Unit: Umbilical Clamps: (Not KOS scope of supply) Multi Sheave Block: Hose Connection Adapter Assy: Dimensions and Weights: Frame Unit Length: 2,040 mm (80.3") Width: 1,460 mm (55.1") Height w/reel Unit: 2,160 mm (85") Reel Unit Diameter: 1,850 mm (72.8") Total Weight: Total weight (Frame and Reel): 3,650 kg (8,050 lbs) Mechanical Data: Maximum normal pull: 1500 kg on first layer 405 kg on top layer with 550m umbilical Drum Capacity: 6 x 3/8" x 550 m cable (5 lengths of á 100 m) Motor: 1600 ccm (2 off) Normal Speed: Max. 20 m/min. (first layer) Connections to HPU: 1/2" ISO.B female Quick Connector (Pressure 'P') - 1 off, 4 m 3/4" ISO.B female Quick Connector (Return 'T') - 1 off, 4 m 3/8" ISO.B female Quick Connector (Drain 'D') - 1 off, 4 m DOC , Rev. 2 Page 3 of 13

7 Hose Reel Unit 3/8" ISO.B male Quick Connector (6 off) Hydraulic Data: Work pressure: 207 Bar Hydraulic Oil: Castrol Transaqua HT Cleanliness: NAS class 6 (worst operating class 8) Flow: 48 l./min. Environmental Data: Design Life: 25 years Water ingress protection: IP15 Ambient Temperature Ranges Storage: -30 to +55 C Transportation: -20 to +40 C Air temperature offshore: -18 to +40 C Sea temperature: 2 to +30 C 3 Technical Description Electronic copies of engineering drawings referenced in the following description may be retrieved from the Intervention System Drawing File. The location of documents listed below can be found by reference to the Documentation User Guide. Page 4 of 13 DOC , Rev. 2

8 Hose Reel Unit Fig. 2 Hose Reel Unit, General Arrangement DOC , Rev. 2 Page 5 of 13

9 Hose Reel Unit 3.1 Physical Description The Hose Reel Unit comprises the following subassemblies: Frame Reel Motor (2 off) Umbilical Clamps Multi Sheave Block Hose Connection Adapter Assy The Hose Reel Unit, as shown in Figure Hose Reel Unit, General Arrangement, is mounted on a steel protection Frame consisting of SQR 80x80 profiles. The Hose Reel Unit can be lifted by crane or fork lift truck. For ease of handling, the Hydraulic Power Unit (HPU) for the HRU is mounted on a separate skid (refer to OMM HPU, Deck Unit, Operation and Maintenance Manual)) and is connected by flexible hoses for the hydraulic system and cables for the control signals. The Hose Reel Unit is equipped with a Hose Connection Adapter Assy which contains: 1/2" ISO.B female Quick Connectors (Pressure 'P'), 4m (1 off) 3/4" ISO.B female Quick Connector (Return 'T'), 4m (1 off) 3/8" ISO.B female Quick Connector (Drain 'D'), 4m (1 off) 3/8" ISO.B male Quick Connector, 4m (6 off) The Hose Reel Unit is equipped with two motors attached to the centre of the Reel which also function as support and bearings. The Unit is supplied with a Multi Sheave Block of the correct size for the lift wire/umbilical. The Hose Reel Unit is designed for operation in Zone 2, Gas Group IIB areas. Page 6 of 13 DOC , Rev. 2

10 Hose Reel Unit 3.2 Functional Description The Unit is run by hydraulic cam ring motors (2 off), mounted in the centre of the drum. A multidisc brake is assembled on each of the two motors. The rotation of the motor housing is achieved by feeding pressurized oil through the motor inlet port to the oil distributor. The distributor directs the oil flow to the pistons, which are on a power stroke, driving the pistons and cam rollers outwards against the curve of the cam rings. This causes rotation of the cam ring housing assembly. When the pistons reach the end of their stroke, the distributor closes the inlet port and opens the outlet port. The next cam lobe pushes the piston back into the center of the cylinder block in preparation of the next outward power stroke. Reverse rotation is achieved by changing the direction of oil flow. The reel is operated from a directional valve which is physically secured by a manual safety lock. Flow regulated through the directional valve runs to the motors through a dual load holding valve with a shuttle valve for brake release. It is also equipped with a mechanical lock/pin for transportation. Connection is made to the HPU through Quick Connectors, type ISO.B (3 off - marked 'P', 'T' and 'D'). Connections to the Umbilical is made through Quick Connectors, type ISO.B (6 off), which are located on the Reel Assembly of HPU/HRU 1. Assemble the hoses 'P', 'T' and 'D' (4 meter bundle) from the HPU to the Quick Connectors on the Directional Valve on the HRU. 2. Shut down the Flow Valve on the HPU control panel. 3. Verify that the HPU is connected to the correct voltage and check the level of fluid in the tank, refill if low. 4. Remove the mechanical transportation pin. 5. Start the HPU by pushing the 'Green Push Button' on the Electrical Motor Starter. 6. Wheel out the needed Umbilical length using the Directional Valve and stop the Reel in a position with access to the Quick Connectors (6 off) on the Reel. 7. Lock the Handle on the Directional Valve with the Safety Lock Pin. 8. Assemble the six Umbilical Line (4 meter bundle) to the HRU Quick Connectors. The Equipment is now ready for operation of subsea Tool with the Flow- and Directional Valves on the HPU control panel. DOC , Rev. 2 Page 7 of 13

11 Hose Reel Unit Disassembly of HPU/HRU 1. Close the Flow Valve on the control panel. 2. Disconnect the six Line Umbilical (4 meter bundle) from the HRU Quick Connectors. 3. Wheel in the Umbilical using the Directional Valve. Guide the Umbilical and spool it on the Reel in accurate and compact layers. 4. Park the Reel in a position so that the Lock Pin for transportation can be positioned. 5. Stop the HPU by pushing the 'Red Push Button' on the Electrical Motor Starter. 6. Secure the Handle on the Directional Valve with the Safety Lock and place the pin to secure the reel during operation. 7. Disconnect the hoses 'P', 'T' and 'D' (4 meter bundle) from the Quick Connectors on the HRU control panel. 4 Handling and Transportation WARNING! ALWAYS ENSURE THAT ALL LIFTING EQUIPMENT IS CERTIFIED AND HAS A SWL IN EXCESS OF THE EQUIPMENT WEIGHT. CAUTION: Avoid all kind of shocks. Keep the equipment in an upright position during transport and handling. Use only certified lifting gear and certified personnel to operate lifting equipment. 4.1 Lifting Instructions 1) Securely attach the 4-legged lifting slings (KOS P/N: ) with shackles to the lifting eye pads on top of the Lifting Frame. NOTE: The mechanical lock/pin must be entered before transport. The Lifting Frame can also be handled by a forklift. Standard pockets are made in the foundation base. Page 8 of 13 DOC , Rev. 2

12 Hose Reel Unit Lifting Data Name: Weight without Umbilical: Length: Width: Height: Hose Reel Unit: 3,650 kg 2,040 mm 1,460 mm 2,160 mm DOC , Rev. 2 Page 9 of 13

13 Hose Reel Unit Fig. 3 Lifting Arrangement Page 10 of 13 DOC , Rev. 2

14 Hose Reel Unit 4.2 Transportation Instructions CAUTION: Always ensure that the equipment is secured to its transportation equipment. Prevent movement by wooden blocks, bracing and straps. Never stack the equipment. 5 Preservation 5.1 Standard The purpose of preservation and protection is to guard the equipment against all external actions normally encountered during shipment, handling, transportation and storage. Carry out a thorough, visual inspection of all pipes and connections. Check for loose or damaged components and report any defects found. If necessary, hose down the equipment with fresh water to remove all traces of salt. Remove excess water using compressed air. Protect external surfaces with plastic mesh, electrical tape or other protection to prevent damage. Non-metallic materials and corrosion resistant materials such as Xylan, Inconel, Stainless Steel, Al-Bronze, etc. are not to be coated with any preservatives unless specifically instructed. Repair any damage to the painted surfaces in accordance with KOS Specification KOS-MDS-0037 and NORSOK STD-U-CR-008, "Subsea Colour and Marking". Do not remove preservatives until just prior to use. 5.2 Equipment Specific The specific Preservation and Protection procedure is as follows: 1) Flush the system at start-up, after repair etc. 2) Remove excess water using compressed air. 3) Quick Connectors must be clean and without damage. 4) Some oil in lubrication point for the Valve Handle, when needed. 5) Repair, as necessary. Make a written report on abnormal observation, and correct all divergences from normal. 6 Storage Storage area : In an area not exposed to rain, snow, sea-spray or excessive dust. DOC , Rev. 2 Page 11 of 13

15 Hose Reel Unit Jumpers can be stored outdoor or indoor as long as they are protected from damage. All units to be stored in a warehouse for long-term storage. Storage temperature : 5 C to 20 C. Maximum air humidity : 95% The following general instructions applies for storage: Ensure that the recommended preservatives are in good condition. Re-apply as necessary, and wipe off excess preservative. For future reference and correction, make a written report on any abnormal observations made. 7 Maintenance 7.1 Preventive Maintenance for Equipment in Storage At six months intervals, visually inspect the equipment for: Loose or damaged components. Damage to paint work. Cleanliness and moisture. Corrosion, etc. Once a year, the following is to be carried through: The Lifting Gear and Baskets shall be re-certified. Make a written report on abnormal observations, and correct all divergencies from normal. 7.2 Preventive Maintenance for Equipment in Use Maintenance of the hydraulic components is very important in order to avoid any stops. Routine checks must be made based on running time or in intervals. The daily control should be done by the operator. Prior to start check the test movement, in both directions, of the directional Valve Handle. It shall be easily moved to full stroke and automatically return to neutral position when released. When doing the control/repair, it is important to have the flow diagram available. Always remember to keep the system clean. Page 12 of 13 DOC , Rev. 2

16 Hose Reel Unit It can often be an advantage to keep a log of what was wrong, and which precaution were taken. 7.3 Repair Repair, which is described in subsequent paragraphs, is limited to: Repair of paint work. Repair of components Repair of paint work Repair any damage to painted surfaces in accordance with KOS Specification KOS-MDS-0037 and NORSOK STD-U-CR-008, "Subsea Colour and Marking" Repair of components Repair components by replacing them with new or reconditioned components. Replacement is straightforward, so no procedures are necessary in addition to the general engineering rules in current use. DOC , Rev. 2 Page 13 of 13