Umbilical Reel System Preservation, Storage and Maintenance
Umbilical Reel System Preservation, Storage and Maintenance Document type
Doc.no :
PSM-0000020384
Final Documentation
Page :
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Status
Change no.
As Built
500000005409
Date
Version
Revision
00
-
22.06.2001
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. ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy
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TABLE OF CONTENTS Section 1.
Page
INTRODUCTION ....................................................................................................... 8 1.1
PURPOSE OF MANUAL .................................................................................. 8
1.2
SYMBOLS AND CONVENTIONS .................................................................. 8
1.3
SAFETY NOTES ............................................................................................... 8 1.3.1 Mechanical ............................................................................................. 9 1.3.2 Electrical ................................................................................................. 9 1.3.3 Hydraulic ................................................................................................ 9
2.
3.
1.4
ABBREVIATIONS ............................................................................................ 10
1.5
REFERENCE DOCUMENTS ........................................................................... 10
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS ................................................. 10
1.7
CONSUMABLES .............................................................................................. 10
PRESERVATION AND STORAGE .......................................................................... 11 2.1
PRESERVATION .............................................................................................. 11
2.2
STORAGE.......................................................................................................... 11
2.3
REPLACEMENT/REPAIR................................................................................ 11
TESTING ..................................................................................................................... 11 3.1
4.
TEST DETAILS ................................................................................................. 11
EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL REEL SYSTEM ...... 12 4.1
MAINTENANCE CHECKLIST - UMBILICAL REEL ................................... 13 4.1.1 Basic Tasks ............................................................................................. 14 4.1.2 Mobilisation ............................................................................................ 16 4.1.3 De-Mobilisation ...................................................................................... 17 4.1.4 Periodic Maintenance ............................................................................. 18 4.1.5 Mandatory Maintenance ......................................................................... 19 4.1.6 In Storage Maintenance .......................................................................... 20 4.1.7 Incoming Goods Inspection .................................................................... 21
4.2
MAINTENANCE CHECKLIST - UMBILICAL SHEAVE ............................. 22 4.2.1 Basic Tasks ............................................................................................. 23 4.2.2 Mobilisation ............................................................................................ 24
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4.2.3 De-Mobilisation ...................................................................................... 25 4.2.4 Periodic Maintenance ............................................................................. 26 4.2.5 Mandatory Maintenance ......................................................................... 27 4.2.6 In Storage Maintenance .......................................................................... 28 4.2.7 Incoming Goods Inspection .................................................................... 29 4.3
MAINTENANCE CHECKLIST - BASKET FOR WOCS EQUIPMENT ....... 30 4.3.1 Basic Tasks ............................................................................................. 31 4.3.2 Mobilisation ............................................................................................ 32 4.3.3 De-Mobilisation ...................................................................................... 33 4.3.4 Periodic Maintenance ............................................................................. 34 4.3.5 Mandatory Maintenance ......................................................................... 35 4.3.6 In Storage Maintenance .......................................................................... 36 4.3.7 Incoming Goods Inspection .................................................................... 37
4.4
MAINTENANCE CHECKLIST – TOPSIDE JUMPERS (WOCS) ................. 38 4.4.1 Basic Tasks ............................................................................................. 39 4.4.2 Mobilisation ............................................................................................ 41 4.4.3 De-Mobilisation ...................................................................................... 42 4.4.4 Periodic Maintenance ............................................................................. 43 4.4.5 Mandatory Maintenance ......................................................................... 43 4.4.6 In Storage Maintenance .......................................................................... 44 4.4.7 Incoming Goods Inspection .................................................................... 45
5.
ATTACHMENTS ........................................................................................................ 46
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FIGURES Page Figure 1 Umbilical Reel, Main Components ......................................................................... 5 Figure 2 Umbilical Sheave, Main Components ................................................................... 6 Figure 3 Basket for WOCS Equipment, Main Components .................................................. 7
TABLES Page Table 1 Storage Conditions ................................................................................................ 11
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Figure 1 Umbilical Reel, Main Components
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Figure 2 Umbilical Sheave, Main Components
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Figure 3 Basket for WOCS Equipment, Main Components
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INTRODUCTION
This manual is for the following equipment supplied by FMC Kongsberg Subsea (FMC):
Umbilical Reel
Umbilical Sheave
Basket for WOCS Equipment
Topside Jumpers (WOCS)
There may be project specific variations to these standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File, which this PSM normally is part of. 1.1 PURPOSE OF MANUAL This manual provides the user with the necessary information to perform routine preventive maintenance. A guide to fault finding is included together with instructions for the repair or replacement of individual components where relevant. The manual is intended to be used by competent, trained personnel. 1.2 SYMBOLS AND CONVENTIONS The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS. The text set off in this manner provides warning notice that failure to follow these directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment. The text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. The text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
1.3 SAFETY NOTES FMC’s and the Customer’s Health and Safety System must be adhered to at all times.
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Mechanical
Stay away from rotating parts under operation.
1.3.2
Electrical
Isolate the power supply at source before working on electrical equipment. Allow sufficient time for the internal components to cool before opening Junction Boxes. Do not switch on power supplies until all electrical isolation permits have been withdrawn. Never attempt to bypass or override control functions using temporary leads.
1.3.3
Hydraulic
Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while it is pressurised. Never attempt to bypass or override control functions using temporary jumpers. Always wear suitable protective clothing and safety glasses when there is a possibility of contact with hydraulic fluid.
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1.4 ABBREVIATIONS Abbreviation
Description
Dunf.
Dunfermline
FMC
FMC Kongsberg Subsea
MF
Maintenance File
Kbg.
Kongsberg
QS
Quality System
1.5 REFERENCE DOCUMENTS All the relevant reference documents will be compiled in the Maintenance File together with this manual. 1.6 TEST EQUIPMENT AND SPECIFIC TOOLS N/A 1.7 CONSUMABLES Equipment Hydraulic Oil Lubricants
FMC P/N
Quantity
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2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation is to guard the equipment against all external actions normally encountered during handling, transportation and storage. Preservation is to be in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The Umbilical Reel System must be preserved to protect it from rain, snow, ice dust, solar radiation or sand in accordance with Section 4 of this document. Table 1 Storage Conditions Item
Condition
Storage area:
Indoor/Outdoor in a controlled environment.
Storage temperature:
- 30°C to + 50°C
Maximum air humidity:
98% RH
If stored outdoors cover the Umbilical Reel System with a tarpaulin.
If storage temperature is below 0°C, all hydraulic fluids that are not low temperature resistant must be changed to a suitable fluid.
2.3 REPLACEMENT/REPAIR Generally repair is limited to replacement of damaged or broken components, with new or reconditioned components. Damaged components must be returned to FMC, for inspection or possible rework. If considered necessary test the Umbilical Reel System after repair.
3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FMC Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS N/A
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4. EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL REEL SYSTEM The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the service system.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance scenario (Mobilisation, De-mobilisation, etc.).
4)
Once filled out and signed out scan the Checklists and create a PDF file using the REP number as filename.
Tasks in the individual checklists that are not relevant are to be marked as not applicable (N/A).
The following Checklists are available: Title Maintenance Checklist
When the Checklist is used. All scenarios.
Basic Tasks
All scenarios.
Mobilisation
When preparing for Transit and/or shipping Offshore.
De-Mobilisation
When returning into Storage after Transit and/or shipment from Offshore.
Periodic Maintenance
Light preventive maintenance at fixed intervals.
Mandatory Maintenance
Extensive preventive maintenance incl. strip-down and re-certification at fixed intervals. When the equipment is in Storage
In Storage Maintenance Incoming Goods Inspection
When the equipment is received
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MAINTENANCE CHECKLIST - UMBILICAL REEL
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REP No:
Product Name: Umbilical Reel Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: 1 month
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Description Equipment to be checked in accordance with section 4.1.1 below. Equipment to be checked in accordance with section 4.1.2 below. Equipment to be checked in accordance with section 4.1.3 below. Equipment to be checked in accordance with section 4.1.4 below.
Date/sign
Remarks
Equipment to be checked in accordance with section 4.1.5 below. Every 6 months: Equipment to be checked in accordance with section 4.1.6 below. Every 12 months: Equipment to be checked in accordance with section 4.1.6 below.
Incoming Inspection
Equipment to be inspected in accordance with section 4.1.7 below.
Sign Out of responsible personnel:
Date:
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Basic Tasks
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Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Check Lifting Equipment/component certificates and marking.
1.6
Check Yrkeshygienisk (YH) datablad, (Safety Data Sheet). Return waste must be marked according to regulations.
1.7
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.8
Check for damages and corrosion. Check that protection caps are installed.
1.9
Check/tighten bolt connections (spot check).
1.10
Check movable parts. "Move up" and lubricate/grease if needed.
1.11
Inspect hydr. Fittings/couplings. Check for damages, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
1.12
Inspect that hydr. Valves, regulators, etc., are easy to operate. "Move up" and lubricate/grease if needed.
1.13
Check pressure gauges in accordance with relevant guidelines and standards.
1.14
Check measuring equipment in accordance with relevant guidelines and standards.
1.15
Inspect filters (Pop up indicator). Change filter if required.
REP No: Date/Sign.
Remarks
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Description Inspect that the hydraulic oil is according to specifications regarding water content, particles and bacteria. Perform a sample test and check that cleanliness level is equal or better than NAS Class 6. Perform flushing of hydraulic lines and components if needed.
1.17
Inspect el. Components (control panel/junction boxes), cables and contacts. Inspect for damages or unfixed items. Verify that protection caps are installed.
1.18
Perform control of EX-equipment in accordance with relevant guidelines and standards.
1.19
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.20
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1
2.2
2.3 2.4 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1 6.2 6.3 6.4 6.5 6.6
PROD. SPECIFIC CHECKS Check spooling device. If required adjust the spooling device according to vendor procedures. Check brakes. If required adjust brakes according to vendor procedures. Inspect the cogwheels and chain. Inspect air motor. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Inspect oil level in gear and air motor. If necessary refill with recommended oil type. Grease all lubrication points with recommended grease. Grease the winch cogwheels and chains with recommended grease. Check that the umbilical subsea end is safely terminated to the termination bracket. If possible, lock the winch drum from unintentional rotation during storage by means of the lock pin. Protect external surfaces with plastic mesh, electrical tape or similar to prevent damage.
Date/Sign.
15 of 46 Remarks
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Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING Test Umbilical Reel in accordance with the relevant HFT/OMM. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
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De-Mobilisation
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5.0 5.1 6.0 6.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. If extended testing is necessary due to repair of the equipment, contact FMC QS/Project for detailed instructions. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
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Periodic Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0
REP No: Date/Sign.
Remarks
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Mandatory Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. Check last calibration date on Gauges and Check Valves. Yearly calibration is required on Gauges and Check Valves. Re-calibrate if necessary.
2.3
Check last certification date on Ex-equipment. Yearly certification is required on Ex-equipment. Re-certify if necessary.
2.4 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
Re-place air filter. Replace o-ring if damaged. ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
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In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.1.1. Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. Pay out some meters of Umbilical to have the air motor cycled and thus circulate the lubricants. Preferably lock the drum in an other position than before running to vary the static load point on the bearing.
2 3
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REP No:
Interval (months) 12 12 6
Date/Sign
Remarks
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Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
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MAINTENANCE CHECKLIST - UMBILICAL SHEAVE
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REP No:
Product Name: Umbilical Sheave Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: 1 month
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Incoming Inspection
Description Equipment to be checked in accordance with section 4.2.1 below. Equipment to be checked in accordance with section 4.2.2 below. Equipment to be checked in accordance with section 4.2.3 below. Equipment to be checked in accordance with section 4.2.4 below.
Date/sign
Remarks
Equipment to be checked in accordance with section 4.2.5 below. Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.2.6 below. Equipment to be inspected in accordance with section 4.2.7 below.
Sign Out of responsible personnel:
Date:
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Basic Tasks
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Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.6
Check for damages and corrosion.
1.7
Check/tighten bolt connections (spot check).
1.8
Check movable parts. "Move up" and lubricate/grease if needed.
1.9
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.10
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1 2.2 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1 6.2
PROD. SPECIFIC CHECKS Inspect the rolls for damages and tear. Inspect and verify proper condition of suspension device. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Lubricate / Grease up all moveable parts. Store the Umbilical sheave into the dedicated sheave compartment in the basket.
REP No: Date/Sign.
Remarks
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Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
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De-Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
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Periodic Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0
REP No: Date/Sign.
Remarks
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Mandatory Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
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In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.1.1/1.0 Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0
2
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REP No:
Interval (months) 12 12
Date/Sign
Remarks
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Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
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4.3
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MAINTENANCE CHECKLIST - BASKET FOR WOCS EQUIPMENT
Scan to PDF format after sign-out, file doc. on address
REP No:
Product Name: Basket for WOCS Equipment Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: N/A
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Description Equipment to be checked in accordance with section 4.3.1 below. Equipment to be checked in accordance with section 4.3.2 below. Equipment to be checked in accordance with section 4.3.3 below. N/A
Date/sign
Remarks
Equipment to be checked in accordance with section 4.3.5 below. Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.3.6 below.
Incoming Inspection
Equipment to be inspected in accordance with section 4.3.7 below.
Sign Out of responsible personnel:
Date:
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Basic Tasks
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Check Lifting Equipment/component certificates and marking.
1.6
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.7
Check for damages and corrosion. Check that protection caps are installed.
1.8
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.9
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION N/A
REP No: Date/Sign.
Remarks
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Mobilisation
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.2 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
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De-Mobilisation
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
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Mandatory Maintenance
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 2.0 2.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS Check last certification date on lifting slings. Yearly certification is required on lifting slings. Re-certify if necessary.
3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
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In Storage Maintenance
Scan to PDF format after sign-out, file doc. on address
Item
Description
1
Perform general checks in accordance with the information provided in Section 4.3.1./1.0
REP No:
Interval (months) 12
Date/Sign
Remarks
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Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
FMC Kongsberg Subsea Version :
4.4
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MAINTENANCE CHECKLIST – TOPSIDE JUMPERS (WOCS)
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REP No:
Product Name: Topside Jumpers (WOCS) Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: N/A
Log No.
Mandatory Maintenance: N/A
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Incoming Inspection
Description Equipment to be checked in accordance with section 4.3.1 below. Equipment to be checked in accordance with section 4.4.2 below. Equipment to be checked in accordance with section 4.4.3 below. N/A
Date/sign
Remarks
N/A
Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.4.6 below. Equipment to be inspected in accordance with section 4.4.7 below.
Sign Out of responsible personnel:
Date:
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Basic Tasks
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check Yrkeshygienisk (YH) datablad, (Safety Data Sheet). Return waste must be marked according to regulations.
1.5
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.6
Remove possible non-painted surface protection. Check and lubricate all seals available.
1.7
Check for damages and corrosion. Check that protection caps are installed.
1.8
Check/tighten bolt connections (spot check).
1.9
Check movable parts. "Move up" and lubricate/grease if needed.
1.10
Inspect hydr. Fittings/couplings. Check for damages, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
1.11
Inspect that the hydraulic oil is according to specifications regarding water content, particles and bacteria. Perform a sample test and check that cleanliness level is equal or better than NAS Class 6. Perform flushing of hydraulic lines and components if needed.
1.12
Perform control of EX-equipment in accordance with relevant guidelines and standards.
1.13
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.14
Check painted surfaces and markings for damages. Repair accordingly.
REP No: Date/Sign.
Remarks
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Description PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Cover each jumper end with plastic mesh, secured with adhesive tape to protect the stabs/end interface. During storage / transport, the topside jumpers must be protected from damage caused by the following: Sharp edges and corners Falling and moving objects Welding and grinding operations Prolonged exposure to direct sunlight.
6.3 Always store hydraulic jumpers filled with control fluid.
Date/Sign.
40 of 46
Remarks
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Mobilisation
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.3 6.0 6.3
Description GENERAL Perform general checks in accordance with the information provided in Section 4.4.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.4.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.4.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.4.1/6.0.
REP No: Date/Sign.
Remarks
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De-Mobilisation
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.2 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.4.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.4.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.4.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.4.1/6.0.
REP No: Date/Sign.
Remarks
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4.4.5
Mandatory Maintenance N/A
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In Storage Maintenance
Scan to PDF format after sign-out, file doc. on address
Item
Description
1
Perform general checks in accordance with the information provided in Section 4.4.1./1.0
REP No:
Interval (months) 12
Date/Sign
Remarks
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Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
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CORRECTIVE MAINTENANCE REPORT Scan to PDF format after sign-out, file doc. on address
REP No:
Equipment Name: FMC Part Number: Fault Reference Document: Reference Drawing Number: Task Description
Date
Comments
Parts Used
Date
Comments
Discipline:
Man hours:
Name:
Signature:
Doc.no :
PSM-0000020384
Final Documentation
Page :
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Status
Change no.
As Built
500000005409
Date
Version
Revision
00
-
22.06.2001
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. ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy
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TABLE OF CONTENTS Section 1.
Page
INTRODUCTION ....................................................................................................... 8 1.1
PURPOSE OF MANUAL .................................................................................. 8
1.2
SYMBOLS AND CONVENTIONS .................................................................. 8
1.3
SAFETY NOTES ............................................................................................... 8 1.3.1 Mechanical ............................................................................................. 9 1.3.2 Electrical ................................................................................................. 9 1.3.3 Hydraulic ................................................................................................ 9
2.
3.
1.4
ABBREVIATIONS ............................................................................................ 10
1.5
REFERENCE DOCUMENTS ........................................................................... 10
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS ................................................. 10
1.7
CONSUMABLES .............................................................................................. 10
PRESERVATION AND STORAGE .......................................................................... 11 2.1
PRESERVATION .............................................................................................. 11
2.2
STORAGE.......................................................................................................... 11
2.3
REPLACEMENT/REPAIR................................................................................ 11
TESTING ..................................................................................................................... 11 3.1
4.
TEST DETAILS ................................................................................................. 11
EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL REEL SYSTEM ...... 12 4.1
MAINTENANCE CHECKLIST - UMBILICAL REEL ................................... 13 4.1.1 Basic Tasks ............................................................................................. 14 4.1.2 Mobilisation ............................................................................................ 16 4.1.3 De-Mobilisation ...................................................................................... 17 4.1.4 Periodic Maintenance ............................................................................. 18 4.1.5 Mandatory Maintenance ......................................................................... 19 4.1.6 In Storage Maintenance .......................................................................... 20 4.1.7 Incoming Goods Inspection .................................................................... 21
4.2
MAINTENANCE CHECKLIST - UMBILICAL SHEAVE ............................. 22 4.2.1 Basic Tasks ............................................................................................. 23 4.2.2 Mobilisation ............................................................................................ 24
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4.2.3 De-Mobilisation ...................................................................................... 25 4.2.4 Periodic Maintenance ............................................................................. 26 4.2.5 Mandatory Maintenance ......................................................................... 27 4.2.6 In Storage Maintenance .......................................................................... 28 4.2.7 Incoming Goods Inspection .................................................................... 29 4.3
MAINTENANCE CHECKLIST - BASKET FOR WOCS EQUIPMENT ....... 30 4.3.1 Basic Tasks ............................................................................................. 31 4.3.2 Mobilisation ............................................................................................ 32 4.3.3 De-Mobilisation ...................................................................................... 33 4.3.4 Periodic Maintenance ............................................................................. 34 4.3.5 Mandatory Maintenance ......................................................................... 35 4.3.6 In Storage Maintenance .......................................................................... 36 4.3.7 Incoming Goods Inspection .................................................................... 37
4.4
MAINTENANCE CHECKLIST – TOPSIDE JUMPERS (WOCS) ................. 38 4.4.1 Basic Tasks ............................................................................................. 39 4.4.2 Mobilisation ............................................................................................ 41 4.4.3 De-Mobilisation ...................................................................................... 42 4.4.4 Periodic Maintenance ............................................................................. 43 4.4.5 Mandatory Maintenance ......................................................................... 43 4.4.6 In Storage Maintenance .......................................................................... 44 4.4.7 Incoming Goods Inspection .................................................................... 45
5.
ATTACHMENTS ........................................................................................................ 46
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FIGURES Page Figure 1 Umbilical Reel, Main Components ......................................................................... 5 Figure 2 Umbilical Sheave, Main Components ................................................................... 6 Figure 3 Basket for WOCS Equipment, Main Components .................................................. 7
TABLES Page Table 1 Storage Conditions ................................................................................................ 11
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Figure 1 Umbilical Reel, Main Components
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Figure 2 Umbilical Sheave, Main Components
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Figure 3 Basket for WOCS Equipment, Main Components
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INTRODUCTION
This manual is for the following equipment supplied by FMC Kongsberg Subsea (FMC):
Umbilical Reel
Umbilical Sheave
Basket for WOCS Equipment
Topside Jumpers (WOCS)
There may be project specific variations to these standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File, which this PSM normally is part of. 1.1 PURPOSE OF MANUAL This manual provides the user with the necessary information to perform routine preventive maintenance. A guide to fault finding is included together with instructions for the repair or replacement of individual components where relevant. The manual is intended to be used by competent, trained personnel. 1.2 SYMBOLS AND CONVENTIONS The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS. The text set off in this manner provides warning notice that failure to follow these directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment. The text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. The text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
1.3 SAFETY NOTES FMC’s and the Customer’s Health and Safety System must be adhered to at all times.
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Mechanical
Stay away from rotating parts under operation.
1.3.2
Electrical
Isolate the power supply at source before working on electrical equipment. Allow sufficient time for the internal components to cool before opening Junction Boxes. Do not switch on power supplies until all electrical isolation permits have been withdrawn. Never attempt to bypass or override control functions using temporary leads.
1.3.3
Hydraulic
Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while it is pressurised. Never attempt to bypass or override control functions using temporary jumpers. Always wear suitable protective clothing and safety glasses when there is a possibility of contact with hydraulic fluid.
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1.4 ABBREVIATIONS Abbreviation
Description
Dunf.
Dunfermline
FMC
FMC Kongsberg Subsea
MF
Maintenance File
Kbg.
Kongsberg
QS
Quality System
1.5 REFERENCE DOCUMENTS All the relevant reference documents will be compiled in the Maintenance File together with this manual. 1.6 TEST EQUIPMENT AND SPECIFIC TOOLS N/A 1.7 CONSUMABLES Equipment Hydraulic Oil Lubricants
FMC P/N
Quantity
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2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation is to guard the equipment against all external actions normally encountered during handling, transportation and storage. Preservation is to be in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The Umbilical Reel System must be preserved to protect it from rain, snow, ice dust, solar radiation or sand in accordance with Section 4 of this document. Table 1 Storage Conditions Item
Condition
Storage area:
Indoor/Outdoor in a controlled environment.
Storage temperature:
- 30°C to + 50°C
Maximum air humidity:
98% RH
If stored outdoors cover the Umbilical Reel System with a tarpaulin.
If storage temperature is below 0°C, all hydraulic fluids that are not low temperature resistant must be changed to a suitable fluid.
2.3 REPLACEMENT/REPAIR Generally repair is limited to replacement of damaged or broken components, with new or reconditioned components. Damaged components must be returned to FMC, for inspection or possible rework. If considered necessary test the Umbilical Reel System after repair.
3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FMC Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS N/A
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4. EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL REEL SYSTEM The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the service system.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance scenario (Mobilisation, De-mobilisation, etc.).
4)
Once filled out and signed out scan the Checklists and create a PDF file using the REP number as filename.
Tasks in the individual checklists that are not relevant are to be marked as not applicable (N/A).
The following Checklists are available: Title Maintenance Checklist
When the Checklist is used. All scenarios.
Basic Tasks
All scenarios.
Mobilisation
When preparing for Transit and/or shipping Offshore.
De-Mobilisation
When returning into Storage after Transit and/or shipment from Offshore.
Periodic Maintenance
Light preventive maintenance at fixed intervals.
Mandatory Maintenance
Extensive preventive maintenance incl. strip-down and re-certification at fixed intervals. When the equipment is in Storage
In Storage Maintenance Incoming Goods Inspection
When the equipment is received
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MAINTENANCE CHECKLIST - UMBILICAL REEL
Scan to PDF format after sign-out, file doc. On address
REP No:
Product Name: Umbilical Reel Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: 1 month
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Description Equipment to be checked in accordance with section 4.1.1 below. Equipment to be checked in accordance with section 4.1.2 below. Equipment to be checked in accordance with section 4.1.3 below. Equipment to be checked in accordance with section 4.1.4 below.
Date/sign
Remarks
Equipment to be checked in accordance with section 4.1.5 below. Every 6 months: Equipment to be checked in accordance with section 4.1.6 below. Every 12 months: Equipment to be checked in accordance with section 4.1.6 below.
Incoming Inspection
Equipment to be inspected in accordance with section 4.1.7 below.
Sign Out of responsible personnel:
Date:
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Basic Tasks
Scan to PDF format after sign-out, file doc. on address Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Check Lifting Equipment/component certificates and marking.
1.6
Check Yrkeshygienisk (YH) datablad, (Safety Data Sheet). Return waste must be marked according to regulations.
1.7
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.8
Check for damages and corrosion. Check that protection caps are installed.
1.9
Check/tighten bolt connections (spot check).
1.10
Check movable parts. "Move up" and lubricate/grease if needed.
1.11
Inspect hydr. Fittings/couplings. Check for damages, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
1.12
Inspect that hydr. Valves, regulators, etc., are easy to operate. "Move up" and lubricate/grease if needed.
1.13
Check pressure gauges in accordance with relevant guidelines and standards.
1.14
Check measuring equipment in accordance with relevant guidelines and standards.
1.15
Inspect filters (Pop up indicator). Change filter if required.
REP No: Date/Sign.
Remarks
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Description Inspect that the hydraulic oil is according to specifications regarding water content, particles and bacteria. Perform a sample test and check that cleanliness level is equal or better than NAS Class 6. Perform flushing of hydraulic lines and components if needed.
1.17
Inspect el. Components (control panel/junction boxes), cables and contacts. Inspect for damages or unfixed items. Verify that protection caps are installed.
1.18
Perform control of EX-equipment in accordance with relevant guidelines and standards.
1.19
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.20
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1
2.2
2.3 2.4 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1 6.2 6.3 6.4 6.5 6.6
PROD. SPECIFIC CHECKS Check spooling device. If required adjust the spooling device according to vendor procedures. Check brakes. If required adjust brakes according to vendor procedures. Inspect the cogwheels and chain. Inspect air motor. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Inspect oil level in gear and air motor. If necessary refill with recommended oil type. Grease all lubrication points with recommended grease. Grease the winch cogwheels and chains with recommended grease. Check that the umbilical subsea end is safely terminated to the termination bracket. If possible, lock the winch drum from unintentional rotation during storage by means of the lock pin. Protect external surfaces with plastic mesh, electrical tape or similar to prevent damage.
Date/Sign.
15 of 46 Remarks
FMC Kongsberg Subsea Version :
4.1.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
16 of 46
Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING Test Umbilical Reel in accordance with the relevant HFT/OMM. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.1.3
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
17 of 46
De-Mobilisation
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5.0 5.1 6.0 6.1
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. If extended testing is necessary due to repair of the equipment, contact FMC QS/Project for detailed instructions. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.1.4
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
18 of 46
Periodic Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.1.5
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
19 of 46
Mandatory Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. Check last calibration date on Gauges and Check Valves. Yearly calibration is required on Gauges and Check Valves. Re-calibrate if necessary.
2.3
Check last certification date on Ex-equipment. Yearly certification is required on Ex-equipment. Re-certify if necessary.
2.4 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
Re-place air filter. Replace o-ring if damaged. ASSEMBLE/DISASSEMBLE N/A TESTING Perform testing in accordance with the information provided in Section 4.1.2/4.0. QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.1.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.1.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.1.6
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.1.1. Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0. Pay out some meters of Umbilical to have the air motor cycled and thus circulate the lubricants. Preferably lock the drum in an other position than before running to vary the static load point on the bearing.
2 3
20 of 46
REP No:
Interval (months) 12 12 6
Date/Sign
Remarks
FMC Kongsberg Subsea Version : 4.1.7
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
21 of 46
Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
FMC Kongsberg Subsea Version :
4.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
22 of 46
MAINTENANCE CHECKLIST - UMBILICAL SHEAVE
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REP No:
Product Name: Umbilical Sheave Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: 1 month
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Incoming Inspection
Description Equipment to be checked in accordance with section 4.2.1 below. Equipment to be checked in accordance with section 4.2.2 below. Equipment to be checked in accordance with section 4.2.3 below. Equipment to be checked in accordance with section 4.2.4 below.
Date/sign
Remarks
Equipment to be checked in accordance with section 4.2.5 below. Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.2.6 below. Equipment to be inspected in accordance with section 4.2.7 below.
Sign Out of responsible personnel:
Date:
FMC Kongsberg Subsea Version : 4.2.1
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
23 of 46
Basic Tasks
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Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.6
Check for damages and corrosion.
1.7
Check/tighten bolt connections (spot check).
1.8
Check movable parts. "Move up" and lubricate/grease if needed.
1.9
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.10
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1 2.2 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1 6.2
PROD. SPECIFIC CHECKS Inspect the rolls for damages and tear. Inspect and verify proper condition of suspension device. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Lubricate / Grease up all moveable parts. Store the Umbilical sheave into the dedicated sheave compartment in the basket.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.2.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
24 of 46
Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.2.3
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
25 of 46
De-Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.2.4
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
26 of 46
Periodic Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.2.5
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
27 of 46
Mandatory Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.2.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.2.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.2.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.2.6
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.1.1/1.0 Perform product specific checks in accordance with the information provided in Section 4.2.1/2.0
2
28 of 46
REP No:
Interval (months) 12 12
Date/Sign
Remarks
FMC Kongsberg Subsea Version : 4.2.7
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
29 of 46
Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
FMC Kongsberg Subsea Version :
4.3
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
30 of 46
MAINTENANCE CHECKLIST - BASKET FOR WOCS EQUIPMENT
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REP No:
Product Name: Basket for WOCS Equipment Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: N/A
Log No.
Mandatory Maintenance: 12 Months
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Description Equipment to be checked in accordance with section 4.3.1 below. Equipment to be checked in accordance with section 4.3.2 below. Equipment to be checked in accordance with section 4.3.3 below. N/A
Date/sign
Remarks
Equipment to be checked in accordance with section 4.3.5 below. Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.3.6 below.
Incoming Inspection
Equipment to be inspected in accordance with section 4.3.7 below.
Sign Out of responsible personnel:
Date:
FMC Kongsberg Subsea Version : 4.3.1
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
31 of 46
Basic Tasks
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Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
1.5
Check Lifting Equipment/component certificates and marking.
1.6
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.7
Check for damages and corrosion. Check that protection caps are installed.
1.8
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.9
Check painted surfaces and markings for damages. Repair accordingly.
2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION N/A
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.3.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
32 of 46
Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.3.3
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
33 of 46
De-Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.3.4
00
Doc.no.: PSM-0000020384 Revision :
Periodic Maintenance N/A
-
Page no. :
34 of 46
FMC Kongsberg Subsea Version : 4.3.5
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
35 of 46
Mandatory Maintenance
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.3.1/1.0. PROD. SPECIFIC CHECKS Check last certification date on lifting slings. Yearly certification is required on lifting slings. Re-certify if necessary.
3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1
ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.3.1/5.0. PRESERVATION N/A
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.3.6
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
36 of 46
In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.3.1./1.0
REP No:
Interval (months) 12
Date/Sign
Remarks
FMC Kongsberg Subsea Version : 4.3.7
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
37 of 46
Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
FMC Kongsberg Subsea Version :
4.4
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
38 of 46
MAINTENANCE CHECKLIST – TOPSIDE JUMPERS (WOCS)
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REP No:
Product Name: Topside Jumpers (WOCS) Maintenance Type: Mobilisation:
De-mobilisation:
Storage:
Periodic Maintenance:
Mandatory Maintenance:
Incoming Inspection:
FMC (Dunf./Kbg.) Part No.:
Serial No.:
Supplier Part No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Non Critical
Periodic Maintenance: N/A
Log No.
Mandatory Maintenance: N/A
REFERENCED DOCUMENTS Assembly drawing no.: Maintenance Spares Bill of Material (BOM)/Spares List:
MAINTENANCE PROGRAM Interval After Use, Transit Mobilisation De-mobilisation Periodic Maintenance Mandatory Maintenance / Complete Overhauling In Storage Maintenance
Incoming Inspection
Description Equipment to be checked in accordance with section 4.3.1 below. Equipment to be checked in accordance with section 4.4.2 below. Equipment to be checked in accordance with section 4.4.3 below. N/A
Date/sign
Remarks
N/A
Every 6 months: N/A Every 12 months: Equipment to be checked in accordance with section 4.4.6 below. Equipment to be inspected in accordance with section 4.4.7 below.
Sign Out of responsible personnel:
Date:
FMC Kongsberg Subsea Version : 4.4.1
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
39 of 46
Basic Tasks
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Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check Yrkeshygienisk (YH) datablad, (Safety Data Sheet). Return waste must be marked according to regulations.
1.5
Wash down the equipment. If necessary wash-down with fresh water to remove all traces of salt. Remove excess water using compressed air.
1.6
Remove possible non-painted surface protection. Check and lubricate all seals available.
1.7
Check for damages and corrosion. Check that protection caps are installed.
1.8
Check/tighten bolt connections (spot check).
1.9
Check movable parts. "Move up" and lubricate/grease if needed.
1.10
Inspect hydr. Fittings/couplings. Check for damages, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
1.11
Inspect that the hydraulic oil is according to specifications regarding water content, particles and bacteria. Perform a sample test and check that cleanliness level is equal or better than NAS Class 6. Perform flushing of hydraulic lines and components if needed.
1.12
Perform control of EX-equipment in accordance with relevant guidelines and standards.
1.13
Inspect that the marking on the equipment and all sub components are intact. Update if needed.
1.14
Check painted surfaces and markings for damages. Repair accordingly.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
Step 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1 6.0 6.1 6.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
Description PROD. SPECIFIC CHECKS N/A ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Punch out by QS. Produce relevant report and file. PRESERVATION Cover each jumper end with plastic mesh, secured with adhesive tape to protect the stabs/end interface. During storage / transport, the topside jumpers must be protected from damage caused by the following: Sharp edges and corners Falling and moving objects Welding and grinding operations Prolonged exposure to direct sunlight.
6.3 Always store hydraulic jumpers filled with control fluid.
Date/Sign.
40 of 46
Remarks
FMC Kongsberg Subsea Version : 4.4.2
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
41 of 46
Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.4.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.4.1/2.0. ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.4.1/5.0. PRESERVATION Perform preservation in accordance with the information provided in Section 4.4.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version :
4.4.3
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
42 of 46
De-Mobilisation
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Description GENERAL Perform general checks in accordance with the information provided in Section 4.4.1/1.0. PROD. SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.4.1/2.0 ASSEMBLE/DISASSEMBLE N/A TESTING N/A QS CHECK-OUT Perform QS checkout in accordance with the information provided in Section 4.4.1/5.0. PRESERVATION, SHORT TERM/TRANSP. Perform preservation in accordance with the information provided in Section 4.4.1/6.0.
REP No: Date/Sign.
Remarks
FMC Kongsberg Subsea Version : 4.4.4
00
Doc.no.: PSM-0000020384 Revision :
Periodic Maintenance N/A
4.4.5
Mandatory Maintenance N/A
-
Page no. :
43 of 46
FMC Kongsberg Subsea Version :
4.4.6
00
Doc.no.: PSM-0000020384 Revision :
-
Page no. :
44 of 46
In Storage Maintenance
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Item
Description
1
Perform general checks in accordance with the information provided in Section 4.4.1./1.0
REP No:
Interval (months) 12
Date/Sign
Remarks
FMC Kongsberg Subsea Version : 4.4.7
00
Doc.no.: PSM-0000020384 Revision :
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Page no. :
45 of 46
Incoming Goods Inspection
Scan to PDF format after sign-out, file doc. on address EQUIPMENT NAME: PART NO.:
REP No:
QTY/ SERIAL NO.:
MMT NO./ DELIVERY NOTE: SUPPLIER:
INSPECTION ACTIVITIES Item:
Checked
1.0 1.1
TRANSPORTATION Transportation Damage
1.2
Consignment Note signed
1.3
Correct Quantity of received materials
2.1
VISUAL INSPECTION Equipment Marking
2.2
Lifting Gear Identification
3.1
DOCUMENTATION Dispatch Dossier
2.0
3.0 3.2
Lifting Certificates
3.3
MSDS Material Safety Data Sheet
3.4
Punch List
OUTSTANDING ITEMS TRANSPORT DAMAGE
N/A:
DESCRIPTION:
INSPECTION SITE: SIGNATURE:
NCR Ref.
DATE:
FMC Kongsberg Subsea Version :
00
Doc.no.: PSM-0000020384 Revision :
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5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT
46 of 46
CORRECTIVE MAINTENANCE REPORT Scan to PDF format after sign-out, file doc. on address
REP No:
Equipment Name: FMC Part Number: Fault Reference Document: Reference Drawing Number: Task Description
Date
Comments
Parts Used
Date
Comments
Discipline:
Man hours:
Name:
Signature:
