Work Class ROV Operations. Syllabus Summary

Transcription

1 Work Class ROV Operations Syllabus Summary

2 Information contained within this document was accurate at time of publication, and the document will be amended periodically to satisfy course changes as required. Rev 1.7, 12 August The Underwater Centre (Fort William) Limited No reproduction of this publication or any part thereof is permitted in any form, including reprographic or electronic, without permission of The Underwater Centre (Fort William) Limited. The Underwater Centre (Fort William) Limited Marine Walk, Carmichael Way, Fort William Inverness-shire, Scotland. PH33 6FF T. +44 (0) F. +44 (0)

3 Contents 1 Course Overview Summary Target audience description Pre-requisite experience Course size Duration of the Course and Time Definition Course Objectives... 2 ROV Industry Familiarisation... 2 Electrical and Electronic Systems... 3 High Voltage Awareness... 5 Introduction to Hydraulics... 6 Working at Height... 9 ROV Operations... 9 Introduction to ROV Maintenance Course Profile Week Week Week Week Week Assessment and Certification Assessment Formative Assessment Summative Assessment Certification Resources Location Staffing Learning Resources i

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5 1 Course Overview 1.1 Summary In conjunction with IMCA and representatives of major employers in the UK ROV industry, this training syllabus was developed to raise the standard of ROV training to include specific work class equipment. The course addresses the following units of Competence: ROV Industry Familiarisation Electrical and Electronic Systems Introduction to Hydraulics Working at Height ROV Operations High Voltage Awareness (IMCA Stage 1) Introduction to ROV System Maintenance 1.2 Target audience description The course is aimed at personnel meeting the minimum trade requirements of IMCA R 002 (relevant trade in electrical, electronic or hydraulic trades). It is not suitable for non-trades personnel with the exception that industry may nominate personnel who have demonstrated to them that they have skills and knowledge that would make them suitable for the course. CVs will be assessed in advance of attending the course. 1.3 Pre-requisite experience Required: IMCA R 002 Valid Offshore Medical Certificate Valid BOSIET (OPITO Approved) Entitlement to study in the UK. Recommended: International English Language Testing System (IELTS) score 4.5 or greater. 1.4 Course size Maximum: 8 candidates. 1.5 Duration of the Course and Time Definition Training will be delivered over a 5 week period. The training day is of 8 hours, defined as hrs, with one hour lunch break. The timetable may be altered to suit prevailing circumstances. Candidates are expected to complete study assignments and additional simulator sessions during some evenings or weekends. Page 1 of 19

6 2 Course Objectives Work Class ROV Operations, Syllabus Summary At the end of the course, the successful candidate will have achieved objectives as follows. Course Section Objective No Description of Objective ROV Industry Familiarisation 1.1 Demonstrate and display understanding of safety and environmental issues Describe hazards encountered in an offshore environment Define the requirements for safe working practices, with particular reference to ROV systems, high voltage and hydraulic systems Demonstrate safe workshop work practices with regard to own and others safety Follow standard accident reporting procedures Identify the relevant legislation and interpret its relevance to the workplace Identify, wear, store and maintain personal protective equipment (PPE) appropriately Demonstrate an understanding of the potential environmental impacts of ROV operations and maintenance. 1.2 Appreciate typical industry arrangements for work cycles, crew changes and personal responsibilities Identify the variety of work cycles in various workplaces Apply appropriate Quality Assurance/Quality Control procedures to workplace standards. 1.3 Understand the working environment List and Identify offshore installations and vessels from which ROVs might operate Identify hazards relevant to particular installation/vessel types Outline the roles of key offshore personnel. 1.4 Recognise the development of ROVs over time and their functions relative to scope of work Explain the development of ROVs over time Describe a range of ROV operations Explain the use of a variety of ROV tools and survey equipment. 1.5 Recognise the importance of lifting equipment systems and their operation and maintenance Identify the main lifting mechanisms used in ROV operations Identify the safety aspects of the various types of lifting equipment Demonstrate an understanding of recertification procedures Carry out visual inspection and outline potential defects. Page 2 of 19

7 1.6 Outline the duties of the members of an ROV crew and understand the competence scheme Describe the IMCA ROV Certificate of Competence Scheme and its requirements Describe the roles and responsibilities of each team member in an ROV crew. Electrical and Electronic Systems 2.1 Demonstrate knowledge of safety and safe working practices with ROV electrical systems in accordance with current industry practices Define the requirements for safe working practices, with particular reference to ROV electrical system hazards Explain and, where appropriate, demonstrate the use of tag out/lock out procedure Demonstrate safe working practices with regard to safety of self and others while working on the ROV electrical system Participate in the development of a Job Safety Analysis or use an existing JSA to carry out a task safely. 2.2 Demonstrate knowledge of ROV power supplies Identify the high and low voltage power supplies in an ROV electrical system Locate the power distribution circuits in a system wiring diagram Identify the high voltage components supplied in an ROV system Identify the circuits supplied with low voltage in an ROV system. 2.3 Outline the wiring layout of an ROV and use wiring diagrams to trace specific circuits Draw a block diagram of a typical work class ROV showing the locations of control and sensor electronics Trace a sensor or control circuit from surface to subsea (or viceversa), listing connector and contact numbers whenever possible Explain the signal path of a nominated sensor or control circuit as directed by supervisor Locate the telemetry path and indicate where it consists of electrical or optical signals. 2.4 Identify and explain the connections between analogue and digital signals from surface to subsea and vice-versa Locate a source of digital information from control console or subsea and explain how it is conveyed from source to target Locate a source of analogue information from control console or subsea and explain how it is conveyed from source to target Explain the operation of thruster control electronic signals from joystick to subsea thruster control unit Identify a range of sensors that may be found on a typical ROV system Outline a range of information that may be available via diagnostic and feedback systems from a work class ROV. Page 3 of 19

8 2.5 Demonstrate a clear understanding of the use, routing, maintenance and testing of electrical cabling in an ROV Use correct cleaning procedure when cleaning subsea connectors Use correct fitting procedures for installation of electrical cables to an ROV Demonstrate correct electrical testing procedure for electrical cables using a range of test equipment Demonstrate correct procedure for splicing electrical cable using appropriate materials. 2.6 Operate video switching and recording system Demonstrate the correct procedure to connect video inputs and outputs on a video switcher Demonstrate correct operation of video switcher to record and display required signals. 2.7 Outline the theory and use of fibre optic (FO) communication systems and demonstrate the termination of an optic fibre Clearly explain the safety precautions and hazards associated with working with fibre optics Explain the theory of fibre optic data transmission Differentiate between single and multimode fibre data transmission Outline the various signals that may be transmitted via fibre optic cable in a typical work class ROV Explain the use of FO transmitter, receiver and wave division multiplexer Explain the use of basic fibre optic test equipment Explain the method of determining fault locations using an Optical Time Domain Reflectometer Demonstrate the correct procedure for termination of an optic fibre. 2.8 Demonstrate a clear understanding of the safe use of electricity underwater as outlined in the current industry guidance literature (currently IMCA) Identify the advantages of using isolated power supplies in ROVs Differentiate between AC and DC Ground Fault Detection systems Identify the methods used to detect ground faults in AC and DC circuits Differentiate between Ground Fault Detection and Ground Fault Interrupt principles. 2.9 Use and maintain electrical test equipment Select test equipment appropriate to the task Demonstrate safe use of test equipment for a variety of electrical tests according to manufacturer s specifications Return test equipment to store in appropriate condition. Page 4 of 19

9 High Voltage Awareness 3.1 Demonstrate knowledge of safety and safe working practices with ROV electrical systems in accordance with industry guidance notes, Codes of Practice and relevant local legislation Define the requirements for safe working practices, with particular reference to ROV HV electrical systems hazards Explain and, where appropriate, demonstrate the use of tag out/lock out procedure Demonstrate safe working practices with regard to safety of self and others while working on the ROV HV electrical system List potential hazards relating to electrical equipment in addition to electric shock Identify industry guidance notes, Codes of Practice and legislation relevant to high voltage safety in ROV systems. 3.2 Demonstrate knowledge of earthing and bonding systems Explain safety aspects of earthing equipment Differentiate between earthing and bonding. 3.3 Demonstrate knowledge of HV protection systems Identify the purpose of a Line Insulation Monitor (LIM) Explain the operating principle of a Ground Fault Interrupt circuit (GFI) Explain the use of isolating transformers. 3.4 Classify hazardous areas and describe the limitations on the use of electricity in them Recall the classification requirements of hazardous areas in offshore installations Describe the certification and labelling of electrical appliances Describe the risks involved with using electricity in the vicinity of flammable gases and vapours Describe the characteristics of intrinsically safe apparatus List the requirements of portable electrical equipment used on offshore vessels and structures. 3.5 Describe components used in hazardous areas Differentiate between methods of Ex & EExe protection Describe characteristics of Ex equipment and A60 rated containers Describe maintenance of Ex equipment and A60 containers Outline requirements of cable glanding in hazardous areas List characteristics of flameproof enclosures Describe inspection and maintenance of flameproof enclosures. Page 5 of 19

10 3.6 Describe inspection and maintenance of flameproof enclosures Prepare JSA for work on system Identify sources of power in subsystem Complete Permit to Work application Tag equipment prior to commencing work on system Effectively lock out all appropriate power supplies Complete requirements of permit before re-energising equipment Identify procedures for live testing but only test live circuits when no other options exist. 3.7 Use and maintain electrical test equipment Select test equipment appropriate to the task Demonstrate safe use of test equipment for a variety of electrical tests according to manufacturer s specifications Return test equipment to store in appropriate condition. Introduction to Hydraulics 4.1 Demonstrate knowledge of safe working practices when working with hydraulic circuits and components Define the requirements for safe working practices, with particular reference to ROV electrical system hazards Demonstrate appropriate care when energising circuits and components, taking into account personal safety, the safety of others and care of equipment Identify the appropriate first aid in the event of a hydraulic injury. 4.2 Demonstrate knowledge of the fundamentals of fluid power Describe the terms force, pressure, work and power in relation to hydraulic circuits and their relationships to each other Explain Pascal s Law Explain the Law of Conservation of Energy Calculate pressure, force and area when given two of the variables Describe the advantages of using hydraulics over electrical power in ROVs Describe the relationship between pressure and load Identify methods of reducing energy waste and heat generation in basic hydraulic circuits Identify the factors responsible for speed of actuators. 4.3 Demonstrate knowledge of hydraulic circuit symbols Use the correct symbols for a range of components as listed in the range statement. Page 6 of 19

11 4.4 Demonstrate knowledge of the principles and operation of hydraulic pumps Describe the operation of fixed and variable displacement pumps Identify a fixed displacement pump Explain the need for pressure relief in fixed displacement pump circuits Explain the general procedure for setting relief valves Explain the operation of a pressure compensated variable displacement piston pump Explain the operation of gear pumps (external and internal) Identify a vane pump Identify appropriate safety devices to protect pumps and other components from excessive pressure Explain the purpose of the case drain in a pump and potential problems with case drain circuits Identify possible pump problems by their symptoms. 4.5 Demonstrate knowledge of pressure and directional components Identify and describe a range of pressure and directional control components as detailed in the Range Statement Describe the function of solenoid valves Describe the potential causes of failure of solenoid valves Identify possible DCV and pressure control problems by their symptoms. 4.6 Demonstrate knowledge of the function and operation of flow control List the factors that control flow through a flow control valve Describe the use of bypass check valve when used with needle valve as a throttle control Describe the use of pilot-operated check valves with particular reference to ROV circuits Differentiate between meter in and meter out flow control Identify possible flow control component problems by their symptoms. 4.7 Demonstrate knowledge of the function and operation of hydraulic motors Describe the operation of piston motors and gear motors (including gerotors) Explain the forces a motor is subject to when starting and stopping and the circuit protection required to prevent damage as listed in the Range Statement Identify possible motor problems by their symptoms. 4.8 Demonstrate knowledge of the function and operation of servo and proportional valves Describe the operation of a servo valve Describe the operation of a proportional control valve Identify possible servo and proportional control valve problems by their symptoms. Page 7 of 19

12 4.9 Demonstrate knowledge of accumulators Identify the symbol for an accumulator Differentiate between pre-charge for shock absorption and pressure retention Differentiate between bladder and piston accumulators Recall safety procedures for working with accumulators Demonstrate knowledge of fluid management and contamination control Demonstrate an understanding of the effects of fluid contamination and the procedures required to optimise fluid cleanliness Recognise the importance of correct filtration List the advantages of clean oil Differentiate between the requirements of pressure and return filters Identify the purpose and use of water-removing filters Check hydraulic system components Identify system components correctly Explain the characteristics and operational function of each system component Inspect and test the operational function of each component Where appropriate, complete service reports using standard operating procedures. Range Statement Symbol recognition should include, but not be limited to: motors and pumps directional controls, their actuators and return mechanisms pressure and flow control valves lines and connectors filters and heat exchangers Directional and Control valves should include: solenoid valves 2-way, 3-way and 4-way valves 2 and 3 position valves a range of actuation methods including solenoid, detent, piloted open centre, closed centre, float centre and tandem centre return mechanisms to include: spring and load Pressure controls should include: pressure reducing valve pressure relief valves, including direct-acting, vented and piloted counterbalance valve brake valve sequence valve air bleed valve Page 8 of 19

13 Flow controls should include: fixed orifice variable orifice (needle valve) flow control locations (meter-in and meter-out) pressure compensated flow controls check valves, including standard, spring-loaded, pilot-to-open and pilot-to-close Motor protection components should include: cross port relief valves cross-port make-up check valves. Working at Height 5.1 Describe the HSE legislation to which an individual is required to comply with when working at height. 5.2 Demonstrate the correct methods by which an individual must utilise working at height equipment when performing ROV tasks in Workshop and Vessel environments Demonstrate the ability to inspect Working at Height safety equipment prior to its use. 5.3 Demonstrate the ability to recover a casualty from a suspended location. ROV Operations 6.1 Identify a variety of environmental conditions affecting ROV operations List the major environmental factors affecting ROV operations and state their effect on limiting vehicle operation Relate the Beaufort scale to sea conditions and ROV operations. 6.2 Carry out Pre & Post Dive Checks Carry out Pre and Post Dive Checks in accordance with enterprise and industry standards Report discrepancies found to supervisor Propose solutions to rectify problems. 6.3 Carry out Launch & Recovery operations Apply safe working practices during launch and recovery activities Maintain adequate communication with control room or deck officer Assess environmental conditions and vessel movement (where applicable) and evaluate limitations to launch and recovery operations in accordance with enterprise and industry standards. Page 9 of 19

14 6.4 Pilot the ROV Undock the vehicle (where appropriate) correctly in accordance with enterprise procedures Use camera(s) appropriately to maintain visual reference and facilitate operations Use lights in most appropriate manner to provide the best possible video for observation and recording Use thruster controls appropriately to move the vehicle to the job site in accordance with enterprise and industry standards Operate the manipulator (where appropriate) in accordance with enterprise procedures Dock the vehicle (where appropriate) correctly in accordance with enterprise procedures. 6.5 Use sonar & acoustic transponders to aid navigation (only appropriate when these aids are available in training situation) Interpret a sonar display to navigate to job site Relate the position of the vehicle to the job site using acoustic transponder/responder navigation aids. 6.6 Maintain appropriate Dive, Video and Maintenance Logs Record relevant information in dive/video log in accordance with enterprise and industry standards Record maintenance carried out in maintenance/technical log in accordance with enterprise procedures. 6.7 Record audio & video data Check video recording equipment to ensure correct data is being recorded in accordance with industry and enterprise standards Ensure that annotation equipment does not degrade video quality Use appropriate terminology to add commentary to operational video in accordance with enterprise and industry standards Apply correct procedure to protect recorded data from accidental loss Label data media correctly in accordance with enterprise procedures. 6.8 Apply the enterprise s scheduled maintenance program Carry out scheduled maintenance in accordance with enterprise procedures Record scheduled maintenance in accordance with enterprise procedures. 6.9 Use appropriate fault finding techniques to identify equipment faults Carry out basic mechanical, electrical/electronic or hydraulic fault finding techniques as required Observe all safety requirements appropriate to the task as determined in the JSA or as directed by the supervisor. Page 10 of 19

15 Introduction to ROV Maintenance 7.1 Carry out mechanical retermination of armoured umbilical Ensure system isolated and appropriate permits in place Gather tooling required for task Prepare clevis for retermination, remove old umbilical using industry acceptable practices Fit clevis to umbilical in correct orientation Prepare umbilical for retermination, strip armour from umbilical Clean and broom armour to enterprise standard Mix and set wire lock compound, ensuring product is in date. 7.2 Carry out electrical retermination of armoured umbilical or tether Ensure system isolated and appropriate permits in place Prepare tether/umbilical and lay through correct path through TMS/Vehicle Terminate copper conductors to enterprise standard Terminate optical fibres to enterprise standard Carry out appropriate electrical and optical tests Carry out functional checks as per enterprise standards. 7.3 Carry out maintenance to TMS to enterprise standards in accordance with enterprise planned maintenance schedule Fill compensated oil-filled housings and cables ensuring air bled correctly Clean and lubricate mechanical components as required Inspect and maintain components as required, e.g. latches, pan & tilt units, cameras, hydraulic components Replace components as required Follow correct Working at Height practices. 7.4 Carry out maintenance to ROV to enterprise standards in accordance with enterprise planned maintenance schedule Fill compensated oil-filled housings and cables ensuring air bled correctly Clean and lubricate mechanical components as required Inspect and maintain components as required, e.g. pan & tilt units, cameras, hydraulic components, manipulators, etc Replace components as required Check manipulator bolt torques (particularly mounting bolts) in accordance with manufacturer s specifications Record maintenance to enterprise standards Inform supervisor of anomalies. Page 11 of 19

16 7.5 Use standard workshop practices Maintain a clean workplace Practice good tool control. 7.6 Follow enterprise health, safety and environmental policies and procedures Follow permit requirements. 3 Course Profile The course is delivered utilising instructor-led contextualised training, spanning a 5 week period. The approach includes a blend of theoretical and practical training and assessment facilitated by operational equipment, simulation systems, procedural guides and computeraided instruction. Candidates are required to undertake some pre-learning work, in preparation for the start of the course. Included in this pre-course material is: HSE, Legislation; Work Cycles, Life Offshore, Industry Conditions, Vessel Types, Offshore Structures; History and Current Use of ROVs, ROV Application and Tooling; and Roles and Responsibilities of ROV Crew, Roles of Other Offshore Personnel, ROV Systems. The following timetable may be altered to suit prevailing circumstances. Page 12 of 19

17 Week 1 Page 13 of 19

18 Week 2 Page 14 of 19

19 Week 3 Page 15 of 19

20 Week 4 Page 16 of 19

21 Week 5 Page 17 of 19

22 4 Assessment and Certification 4.1 Assessment All training and assessment is carried out using a competency-based approach, the competences being determined by the guidelines for competence in IMCA R 002, IMCA R 010 and IMCA C005 (Pilot Technician Grade II) and general industry expectations as determined by consultation. The course is designed in a modular fashion, requiring individuals to prove competency either by written examination or practical demonstration of the skills taught. The candidate will be required to maintain a ROV Pilot/Technician Logbook. The Logbook is both a legal document and accepted by industry as an accurate reflection of the individual s accumulated experience and qualification. 4.2 Formative Assessment Candidates will be informally assessed by: verbal questions during lessons and practical tasks Confirmation of Understanding verbal question and answer sessions at key points of Lesson Plans observation during practical sessions. In addition, candidates will be formally assessed throughout the course by: written assignments group presentations assessed group discussions simulator exercises practical assessments written exams competence logbook. 4.3 Summative Assessment Candidates will be formally assessed by: final written theory exam final practical assessment. 4.4 Certification Successful candidates will receive a certification card from The Underwater Centre which will indicate the key components covered. Verification of competency can be obtained from The Underwater Centre. Page 18 of 19

23 5 Resources 5.1 Location 5.2 Staffing Work Class ROV Operations, Syllabus Summary All training will take place at The Underwater Centre in a contextual learning environment, including: purpose equipped classroom WCROV Mechanical Workshop WCROV Electrical Workshop WCROV Control Cabin WCROV Simulator Cabin onshore tank complex WCROV vessel Loch Sunart Pier WCROV Cabin. ROV Pilot Technician (PT1) ROV Pilot Technician (PT2) ROV Supervisor ROV Support Technician All staff are proven competent as per IMCA standards and TUC competencies. Staffing levels are complemented by accredited providers for specific elements, notably Working at Height. 5.3 Learning Resources Dedicated training resources include: WCROV spread Obs Class ROV Spread TXL Maintenance Platforms T3 or T4 manipulator Fibre Optic Electronic Maintenance Systems Hydraulic Maintenance Systems High Voltage Training System TXL Simulator Working at Height Training system Camera Training system. Training documentation for each candidate includes: Reference Manual for each element of the course. Page 19 of 19