WOCS UmbilicalJumpers and Test Equipment Preservation, Storage ...
WOCS UmbilicalJumpers and Test Equipment Preservation, Storage and Maintenance Document type
Doc.no :
PSM-0000020965
Final Documentation
Page
1 of 25
:
Status
Change no.
Date
Version
Revision
Released Version
500000016718
01.11.2002
02
A
This document is the property of FMC Kongsberg Subsea AS and is not to be reproduced or disclosed to any party without the written consent of FMC Kongsberg Subsea AS. 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 ....................................................................................................... 4 1.1
PURPOSE OF MANUAL.................................................................................. 4
1.2
SYMBOLS AND CONVENTIONS .................................................................. 4
1.3
SAFETY NOTES ............................................................................................... 5 1.3.1 Mechanical.............................................................................................. 5 1.3.2 Electrical................................................................................................. 5 1.3.3 Hydraulic ................................................................................................ 6
2.
3.
1.4
ABBREVIATIONS............................................................................................ 6
1.5
REFERENCE DOCUMENTS ........................................................................... 7
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS................................................. 8
1.7
CONSUMABLES .............................................................................................. 8
1.8
DEFINITIONS ................................................................................................... 9
PRESERVATION AND STORAGE .......................................................................... 10 2.1
PRESERVATION .............................................................................................. 10
2.2
STORAGE.......................................................................................................... 10
2.3
REPLACEMENT / REPAIR.............................................................................. 11
2.4
FAULTFINDING............................................................................................... 11
TESTING..................................................................................................................... 12 3.1
4.
TEST DETAILS................................................................................................. 12
EQUIPMENT MAINTENANCE CHECKLIST ......................................................... 13 4.1
MAINTENANCE CHECKLIST........................................................................ 14 4.1.1 Basic Tasks ............................................................................................. 15 4.1.2 Mobilisation............................................................................................ 18 4.1.3 De-mobilisation ...................................................................................... 19 4.1.4 Periodic Maintenance ............................................................................. 20 4.1.5 Mandatory Maintenance ......................................................................... 21 4.1.6 In Storage Maintenance .......................................................................... 22 4.1.7 Incoming Goods Inspection and Test ..................................................... 23
5.
ATTACHMENTS........................................................................................................ 24
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TABLES Page Table 1 Electrical Jumpers ...................................................................................................8 Table 2 Hydraulic Jumpers ..................................................................................................8 Table 3 Electrical Jumpers / Umbilicals Storage Conditions.............................................10 Table 4 Hydraulic Jumpers / Umbilcals Storage Conditions .............................................10
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1. INTRODUCTION This manual is for the following equipment supplied by FMC Kongsberg Subsea AS (FKS) for the Work Over Control System (WOCS) Topside System: ·
Electrical Jumpers.
·
Hydraulic Jumpers.
·
Pneumatic Jumpers / Hoses.
·
Electrical / Hydraulic Jumpers.
There may be project specific variations to the standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File (MF), which this PSM normally is part of.
1.1 PURPOSE OF MANUAL This manual provides the service personnel with the necessary information to perform routine preventive maintenance. Where relevant, a guide to fault finding is included together with instructions for repair. The manual is intended 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. 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. Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
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1.3 SAFETY NOTES FKS’s and the Customer’s Health and Safety System must be adhered to at all times.
1.3.1
Mechanical
Keep clear of rotating parts and avoid sharp edges / corners.
Do not twist a jumper hose more than 360° over a 3 metre length (measured at termination). Do not apply snags to a jumper hose. Avoid sharp edges and contact with chemicals. Avoid locating the jumper hoses near ozone producing equipment, e.g. electric motors, batteries, welding equipment, etc. Do not apply tension to a jumper hose using more than 500 N for more than 10 minutes. Do not exceed 150 mm bending radius of a jumper hose. Avoid dropping the connectors, use dust caps for protection.
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. Use dust caps on the connectors' interfaces when not in use.
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Electrical jumpers are pressurised with silicone oil and are not to be opened without using special tools.
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. Avoid any contact with chemicals.
1.4 ABBREVIATIONS The following abbreviations are used in this manual: Abbreviation
Description
BOP
Blow Out Preventer
DH
Down Hole
DnV
Det norske Veritas
Dunf.
Dunfermline
ESD
Emergency ShutDown
ETU
Electronic Test Unit
FKS
FMC Kongsberg Subsea AS
HPU
Hydraulic Power Unit
Kbg.
Kongsberg
LCP
Local Control Panel
LS
Landing String
LV
Lubricator Valve
MCP
Motor Control Panel
MF
Maintenance File
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Abbreviation
Description
MMT
Material Movement Ticket
MSDS
Material Safety Data Sheet
N/A
Not Applicable
N/A
Not Applicable
NDT
Non Destructive Testing
P/N
Part Number (Previous denotation of Material Number)
QN
Quality Notification
QS
Quality System
R/R
Running / Retrieval
RH
Relative Humidity
SD
ShutDown
WO
Work Order
WOCS
Work Over Control System
XT
Xmas Tree
1.5 REFERENCE DOCUMENTS This manual is supplied as a part of a WOCS Maintenance File (MF). All relevant reference documents will be compiled in this MF. Always use the latest revision of any documents.
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1.6 TEST EQUIPMENT AND SPECIFIC TOOLS Table 1 Electrical Jumpers Equipment
FKS P/N
Quantity
Electrical Test Connector
N/A
2
Multimeter
N/A
1
Megger
N/A
1
Table 2 Hydraulic Jumpers Equipment
FKS P/N
Quantity
MQC Flushing Plate
N/A
2
1.7 CONSUMABLES Equipment
FKS Material No
Quantity
Anti Freeze
N/A
As Required
Black plastic sheet
N/A
As required
Clycerol
N/A
As Required
CRC Electra Shield
N/A
As Required
Dielectric Silicon Oil
N/A
As required
Filters
N/A
Specified per system.
Glycerin
N/A
As Required
Hydraulic Fluid
N/A
As Required
Hydraulic Oil
N/A
As Required
Lubricant
N/A
As Required
Nitrogen Gas
N/A
As Required
Plastic Bubble Sheet
N/A
As required
Silica Gel
N/A
As Required
Tarpaulin
N/A
As Required
WD-40
N/A
As Required
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1.8 DEFINITIONS Basic Tasks
All scenarios, including after use / before transport / shipping, etc.
Mobilisation
When preparing for use offshore.
De-mobilisation
When preparing for storage after use offshore.
Periodic Maintenance
When performing light preventive maintenance at fixed intervals or number of runs / runtime.
Mandatory Maintenance
When performing extensive preventive maintenance included strip-down and recertification at fixed intervals or numbers of runs / runtime.
In Storage Maintenance
When the equipment is in storage
Incoming Goods Inspection
When the equipment is received (First Time Received).
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2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation process is to protect the equipment against accidents normally encountered during handling, transportation and storage. Preservation is to be carried out in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The equipment must be preserved in order to provide protection from rain, snow, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document. Table 3 Electrical Jumpers Storage Conditions Item
Condition
Storage area
Indoor/Outdoor in a controlled environment.
Maximum air humidity
100% RH
Short Term (< 2 months ) storage Temperature
- 20o C to + 50oC
Medium Term (< 6 months ) storage Temperature
- 20o C to + 30oC
Long Term (> 6 months ) storage Temperature
- 20o C to + 25oC
·
If there is sunlight present in the storage area, cover the assemblies with black plastic or similar protection.
·
It is recommend during long term storage that the assemblies are stored in the original packing crate. If re-use of original packing crates is not feasible, the assemblies should be coiled and stored in a horizontal position.
·
If stored outdoors cover the assemblies with a tarpaulin or similar. Table 4 Hydraulic Jumpers Storage Conditions
Item
Condition
Storage area:
Indoor
Storage temperature:
-
14°C* to + 60°C
* Note check the hydraulic fluid actually installed. Maximum air humidity:
95% RH
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Always store hydraulic jumpers filled with the recommended control fluid. Unless for inspection purposes or preparation for offshore use, the Hydraulic Jumpers must remain in their preserved condition.
2.3 REPLACEMENT / REPAIR In general, any repair is limited to direct replacement of damaged or broken components with new or reconditioned parts. Damaged components must be returned to FKS for inspection or possible rework. If considered necessary, test the equipment after repair.
2.4 FAULTFINDING N/A.
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3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Maintenance Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FKS Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS The equipment (WOCS) in question will be tested as one system. Refer to the relevant Hook-up and Function Test (see the MF for each project specific referance) for details. For the hydraulic jumpers, Pressure Test and Flushing to be carried out before use, in accordance with the relevant procedure referenced in section 4 of the MF.
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4. EQUIPMENT MAINTENANCE CHECKLIST The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the company's Service System.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.
4)
Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.
Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A). In a service system where a task is given a specified number (individual Service Order Number), the .PDF file name must include the identity (number) of this Service Order.
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MAINTENANCE CHECKLIST
Scan to PDF format after signing, file document on address REP No: Product Name: Maintenance Type: Mobilisation: Periodic Maintenance:
De-mobilisation:
In Storage Maintenance:
Mandatory Maintenance:
Incoming Goods Inspection:
FMC's (Dunf./Kbg.) Material No.:
Serial No.:
Supplier Material No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Critical
Periodic Maintenance: Every 6 months
Mandatory Maintenance: N/A
Log No.
In Storage Maintenance: Every 6 months and every 12 months.
REFERENCED DOCUMENTS Assembly Drawing No.:
MAINTENANCE PROGRAM Activity
Description
Mobilisation
Equipment to be checked in accordance with Section 4.1.2.
De-mobilisation
Equipment to be checked in accordance with Section 4.1.3.
Periodic Maintenance
Equipment to be checked in accordance with Section 4.1.4.
Mandatory Maintenance / Complete Overhauling
N/A
In Storage Maintenance
Equipment to be checked in accordance with Section 4.1.6.
Incoming Goods Inspection
Equipment to be inspected in accordance with Section 4.1.7
Signature of personnel responsible:
Date/sign
Remarks
Date:
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Basic Tasks
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO).
Date/Sign.
Remarks
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 the relevant local Health, Environment and Safety Data Sheet / Requirements. Return waste must be marked in accordance with local 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. Refer to FKS Document PRD-0000021584 or valid procedure for washing instructions.
1.6
Remove possible non-painted surface protection. Check and lubricate all seals available.
1.7
Check for proper fastening of mounted components. Check for damage and corrosion. Check that securing clamps/pins are installed.
1.8
Inspect hydraulic fittings/couplings. Check for damage, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while the system is pressurised. 1.9
Inspect that the hydraulic oil is according to specifications regarding water contents, particles and bacteria level. Perform flushing of hydraulic lines and components if necessary.
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Description Inspect electrical components (control panels / junction boxes), cables and contacts / connection points. Change silica gel where required. Inspect for damage or unfixed (loose) items. Verify that protection caps are installed where required.
1.11
Check the most recent certification date on all Exequipment. A yearly certification is required on Ex-equipment. Perform a visual inspection of EX-equipment. If necessary (apparent damage or fault), call for a third party examination and repair.
1.12
Check surface treatment and markings. Repair if necessary.
2.0 2.1
3.0
PRODUCT SPECIFIC CHECKS Inspect and check all interface connection to rig or installation supplies - i.e. electrical, hydraulic, air and water supplies.
3.1
ASSEMBLE/DISASSEMBLE N/A.
4.1
TESTING N/A
5.1
QS CHECKOUT Punch out by QS.
4.0 5.0 6.0 6.1
PRESERVATION Fill the hydraulic system using the recommended fluid.
6.2
Cover QCs, filling nipples and couplers using plastic bags.
6.3
Coil hoses with QC neatly, store inside the HPU Container or in the associated shipping basket.
6.4
Apply dielectric silicone oil to connector mating surfaces. Fit dust and protection caps.
6.5 6.6
6.7
6.8
Wrap connectors in bubble plastic secured with adhesive tape. During medium and long term storage, cover assemblies if exposed to sunlight Protect external surfaces using plastic mesh, electrical tape or other protective measures in order to prevent damage. Non-metallic materials and corrosion resistant materials (e.g. Xylan, Inconel, Stainless Steel, AlBronze, etc.) are NOT to be coated using preservatives unless specifically instructed.
Date/Sign.
Remarks
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Description Arrange the different parts in order to prevent direct metal-to-metal contact.
6.10
Arrange for protection against moisture and condensation.
6.11
Ensure all Quick Connectors are protected by caps in order to prevent ingress of contamination.
6.12
For storage areas with varying temperatures, ensure that there is sufficient ventilation to keep the equipment condensation free.
6.13
Cover each jumper end with plastic mesh, secured with adhesive tape to protect the stabs/end interface. During storage / transport, the jumpers must be protected from damage caused by the following: - Sharp edges and corners
6.14
Date/Sign.
- Falling and moving objects - Welding and grinding operations - Prolonged exposure to direct sunlight. Always store the hydraulic jumpers filled with control fluid.
Remarks
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Mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A. TESTING
Ubilical and Jumpers 4.1
5.0
Test the equipment in accordance with the relevant test procedure (associated document referenced in the MF, chapter 4 ).
5.1
QS CHECKOUT Perform the QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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De-mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 2.2
3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. For a storage period of more than two weeks, fill the hydraulic system with the recommended hydraulic fluid. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test the equipment in accordance with the relevant procedure (associated document referenced in the MF, chapter 4).
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
6.2
Place in original Packing case if the equipment is to be stored long term
Date/Sign.
Remarks
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Periodic Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 2.0 2.3 2.4
3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. For a storage period of more than two weeks, fill the hydraulic system with the recommended hydraulic fluid. ASSEMBLE / DISASSEMBLE N/A TESTING
4.3
Test the equipment in accordance with the relevant procedure (associated document referenced in the MF, chapter 4).
4.4
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.2
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.3
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
6.4
Place in original Packing case if the equipment is to be stored long term
Date/Sign.
Remarks
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In Storage Maintenance
Scan to PDF format after signing, file document on address REP No: Item
Description
Every 12 months: 1)
Perform basic tasks in accordance with information provided in Section 4.1.1 / 1.0.
2)
Operate MQC plate mechanism and verify correct function.
3)
Preserve in accordance with Section 4.1.1/ 6.0.
Every 6 months 4)
Perform basic tasks in accordance with information provided in Section 4.1.1/1.0.
5)
Re-fill the hydraulic system with the recommended hydraulic fluid, if neccary.
6)
Preserve in accordance with Section 4.1.1/ 6.0.
Date/Sign.
Remarks
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Incoming Goods Inspection and Test
Scan to PDF format after signing, file document on address REP No: EQUIPMENT NAME: MATERIAL NO.
QTY / SERIAL NO.
MMT NO./ DELIVERY NOTE SUPPLIER: INSPECTION ACTIVITIES Item
Description
1.0
TRANSPORTATION
Checked
1.1
Unpacking of Equipment.
1.2
Transportation Damage.
1.3
Consignment Note Signed.
1.4
Correct Quantity of Received Materials.
2.0
N/A
QN Ref
VISUAL INSPECTION 2.1
Equipment Marking.
2.2
Lifting Gear Identification.
3.0
DOCUMENTATION 3.1
Dispatch Dossier.
3.2
Lifting Certificates.
3.3
Material Safety Data Sheet (MSDS).
3.4
Punch List.
OUTSTANDING ITEMS TRANSPORT DAMAGE
DESCRIPTION:
INSPECTION SITE:
SIGNATURE:
DATE:
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5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT Fill in the following data if applicable: ·
Equipment Name.
·
FKS Material Number.
·
Reference Document (this is the number of the current PSM manual).
·
Reference Drawing Number(s).
CORRECTIVE MAINTENANCE REPORT Scan to PDF format after signing, file document on address REP No: Equipment Name: FKS Material Number: Fault Reference Document: Reference Drawing Number(s): Task Description
Date
Comments
Parts Used
Date
Comments
Discipline
Man-hours:
Name:
Signature:
Doc.no :
PSM-0000020965
Final Documentation
Page
1 of 25
:
Status
Change no.
Date
Version
Revision
Released Version
500000016718
01.11.2002
02
A
This document is the property of FMC Kongsberg Subsea AS and is not to be reproduced or disclosed to any party without the written consent of FMC Kongsberg Subsea AS. ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy
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02
Revision :
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Doc.no.:
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TABLE OF CONTENTS Section 1.
Page
INTRODUCTION ....................................................................................................... 4 1.1
PURPOSE OF MANUAL.................................................................................. 4
1.2
SYMBOLS AND CONVENTIONS .................................................................. 4
1.3
SAFETY NOTES ............................................................................................... 5 1.3.1 Mechanical.............................................................................................. 5 1.3.2 Electrical................................................................................................. 5 1.3.3 Hydraulic ................................................................................................ 6
2.
3.
1.4
ABBREVIATIONS............................................................................................ 6
1.5
REFERENCE DOCUMENTS ........................................................................... 7
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS................................................. 8
1.7
CONSUMABLES .............................................................................................. 8
1.8
DEFINITIONS ................................................................................................... 9
PRESERVATION AND STORAGE .......................................................................... 10 2.1
PRESERVATION .............................................................................................. 10
2.2
STORAGE.......................................................................................................... 10
2.3
REPLACEMENT / REPAIR.............................................................................. 11
2.4
FAULTFINDING............................................................................................... 11
TESTING..................................................................................................................... 12 3.1
4.
TEST DETAILS................................................................................................. 12
EQUIPMENT MAINTENANCE CHECKLIST ......................................................... 13 4.1
MAINTENANCE CHECKLIST........................................................................ 14 4.1.1 Basic Tasks ............................................................................................. 15 4.1.2 Mobilisation............................................................................................ 18 4.1.3 De-mobilisation ...................................................................................... 19 4.1.4 Periodic Maintenance ............................................................................. 20 4.1.5 Mandatory Maintenance ......................................................................... 21 4.1.6 In Storage Maintenance .......................................................................... 22 4.1.7 Incoming Goods Inspection and Test ..................................................... 23
5.
ATTACHMENTS........................................................................................................ 24
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TABLES Page Table 1 Electrical Jumpers ...................................................................................................8 Table 2 Hydraulic Jumpers ..................................................................................................8 Table 3 Electrical Jumpers / Umbilicals Storage Conditions.............................................10 Table 4 Hydraulic Jumpers / Umbilcals Storage Conditions .............................................10
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1. INTRODUCTION This manual is for the following equipment supplied by FMC Kongsberg Subsea AS (FKS) for the Work Over Control System (WOCS) Topside System: ·
Electrical Jumpers.
·
Hydraulic Jumpers.
·
Pneumatic Jumpers / Hoses.
·
Electrical / Hydraulic Jumpers.
There may be project specific variations to the standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File (MF), which this PSM normally is part of.
1.1 PURPOSE OF MANUAL This manual provides the service personnel with the necessary information to perform routine preventive maintenance. Where relevant, a guide to fault finding is included together with instructions for repair. The manual is intended 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. 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. Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
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02
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1.3 SAFETY NOTES FKS’s and the Customer’s Health and Safety System must be adhered to at all times.
1.3.1
Mechanical
Keep clear of rotating parts and avoid sharp edges / corners.
Do not twist a jumper hose more than 360° over a 3 metre length (measured at termination). Do not apply snags to a jumper hose. Avoid sharp edges and contact with chemicals. Avoid locating the jumper hoses near ozone producing equipment, e.g. electric motors, batteries, welding equipment, etc. Do not apply tension to a jumper hose using more than 500 N for more than 10 minutes. Do not exceed 150 mm bending radius of a jumper hose. Avoid dropping the connectors, use dust caps for protection.
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. Use dust caps on the connectors' interfaces when not in use.
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Electrical jumpers are pressurised with silicone oil and are not to be opened without using special tools.
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. Avoid any contact with chemicals.
1.4 ABBREVIATIONS The following abbreviations are used in this manual: Abbreviation
Description
BOP
Blow Out Preventer
DH
Down Hole
DnV
Det norske Veritas
Dunf.
Dunfermline
ESD
Emergency ShutDown
ETU
Electronic Test Unit
FKS
FMC Kongsberg Subsea AS
HPU
Hydraulic Power Unit
Kbg.
Kongsberg
LCP
Local Control Panel
LS
Landing String
LV
Lubricator Valve
MCP
Motor Control Panel
MF
Maintenance File
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Abbreviation
Description
MMT
Material Movement Ticket
MSDS
Material Safety Data Sheet
N/A
Not Applicable
N/A
Not Applicable
NDT
Non Destructive Testing
P/N
Part Number (Previous denotation of Material Number)
QN
Quality Notification
QS
Quality System
R/R
Running / Retrieval
RH
Relative Humidity
SD
ShutDown
WO
Work Order
WOCS
Work Over Control System
XT
Xmas Tree
1.5 REFERENCE DOCUMENTS This manual is supplied as a part of a WOCS Maintenance File (MF). All relevant reference documents will be compiled in this MF. Always use the latest revision of any documents.
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1.6 TEST EQUIPMENT AND SPECIFIC TOOLS Table 1 Electrical Jumpers Equipment
FKS P/N
Quantity
Electrical Test Connector
N/A
2
Multimeter
N/A
1
Megger
N/A
1
Table 2 Hydraulic Jumpers Equipment
FKS P/N
Quantity
MQC Flushing Plate
N/A
2
1.7 CONSUMABLES Equipment
FKS Material No
Quantity
Anti Freeze
N/A
As Required
Black plastic sheet
N/A
As required
Clycerol
N/A
As Required
CRC Electra Shield
N/A
As Required
Dielectric Silicon Oil
N/A
As required
Filters
N/A
Specified per system.
Glycerin
N/A
As Required
Hydraulic Fluid
N/A
As Required
Hydraulic Oil
N/A
As Required
Lubricant
N/A
As Required
Nitrogen Gas
N/A
As Required
Plastic Bubble Sheet
N/A
As required
Silica Gel
N/A
As Required
Tarpaulin
N/A
As Required
WD-40
N/A
As Required
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1.8 DEFINITIONS Basic Tasks
All scenarios, including after use / before transport / shipping, etc.
Mobilisation
When preparing for use offshore.
De-mobilisation
When preparing for storage after use offshore.
Periodic Maintenance
When performing light preventive maintenance at fixed intervals or number of runs / runtime.
Mandatory Maintenance
When performing extensive preventive maintenance included strip-down and recertification at fixed intervals or numbers of runs / runtime.
In Storage Maintenance
When the equipment is in storage
Incoming Goods Inspection
When the equipment is received (First Time Received).
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2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation process is to protect the equipment against accidents normally encountered during handling, transportation and storage. Preservation is to be carried out in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The equipment must be preserved in order to provide protection from rain, snow, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document. Table 3 Electrical Jumpers Storage Conditions Item
Condition
Storage area
Indoor/Outdoor in a controlled environment.
Maximum air humidity
100% RH
Short Term (< 2 months ) storage Temperature
- 20o C to + 50oC
Medium Term (< 6 months ) storage Temperature
- 20o C to + 30oC
Long Term (> 6 months ) storage Temperature
- 20o C to + 25oC
·
If there is sunlight present in the storage area, cover the assemblies with black plastic or similar protection.
·
It is recommend during long term storage that the assemblies are stored in the original packing crate. If re-use of original packing crates is not feasible, the assemblies should be coiled and stored in a horizontal position.
·
If stored outdoors cover the assemblies with a tarpaulin or similar. Table 4 Hydraulic Jumpers Storage Conditions
Item
Condition
Storage area:
Indoor
Storage temperature:
-
14°C* to + 60°C
* Note check the hydraulic fluid actually installed. Maximum air humidity:
95% RH
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Always store hydraulic jumpers filled with the recommended control fluid. Unless for inspection purposes or preparation for offshore use, the Hydraulic Jumpers must remain in their preserved condition.
2.3 REPLACEMENT / REPAIR In general, any repair is limited to direct replacement of damaged or broken components with new or reconditioned parts. Damaged components must be returned to FKS for inspection or possible rework. If considered necessary, test the equipment after repair.
2.4 FAULTFINDING N/A.
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3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Maintenance Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FKS Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS The equipment (WOCS) in question will be tested as one system. Refer to the relevant Hook-up and Function Test (see the MF for each project specific referance) for details. For the hydraulic jumpers, Pressure Test and Flushing to be carried out before use, in accordance with the relevant procedure referenced in section 4 of the MF.
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4. EQUIPMENT MAINTENANCE CHECKLIST The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the company's Service System.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.
4)
Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.
Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A). In a service system where a task is given a specified number (individual Service Order Number), the .PDF file name must include the identity (number) of this Service Order.
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MAINTENANCE CHECKLIST
Scan to PDF format after signing, file document on address REP No: Product Name: Maintenance Type: Mobilisation: Periodic Maintenance:
De-mobilisation:
In Storage Maintenance:
Mandatory Maintenance:
Incoming Goods Inspection:
FMC's (Dunf./Kbg.) Material No.:
Serial No.:
Supplier Material No.:
Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Category: Critical
Periodic Maintenance: Every 6 months
Mandatory Maintenance: N/A
Log No.
In Storage Maintenance: Every 6 months and every 12 months.
REFERENCED DOCUMENTS Assembly Drawing No.:
MAINTENANCE PROGRAM Activity
Description
Mobilisation
Equipment to be checked in accordance with Section 4.1.2.
De-mobilisation
Equipment to be checked in accordance with Section 4.1.3.
Periodic Maintenance
Equipment to be checked in accordance with Section 4.1.4.
Mandatory Maintenance / Complete Overhauling
N/A
In Storage Maintenance
Equipment to be checked in accordance with Section 4.1.6.
Incoming Goods Inspection
Equipment to be inspected in accordance with Section 4.1.7
Signature of personnel responsible:
Date/sign
Remarks
Date:
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Basic Tasks
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO).
Date/Sign.
Remarks
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 the relevant local Health, Environment and Safety Data Sheet / Requirements. Return waste must be marked in accordance with local 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. Refer to FKS Document PRD-0000021584 or valid procedure for washing instructions.
1.6
Remove possible non-painted surface protection. Check and lubricate all seals available.
1.7
Check for proper fastening of mounted components. Check for damage and corrosion. Check that securing clamps/pins are installed.
1.8
Inspect hydraulic fittings/couplings. Check for damage, unfixed items, leakage, etc. Check that blind plugs/protection caps are installed.
Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while the system is pressurised. 1.9
Inspect that the hydraulic oil is according to specifications regarding water contents, particles and bacteria level. Perform flushing of hydraulic lines and components if necessary.
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Description Inspect electrical components (control panels / junction boxes), cables and contacts / connection points. Change silica gel where required. Inspect for damage or unfixed (loose) items. Verify that protection caps are installed where required.
1.11
Check the most recent certification date on all Exequipment. A yearly certification is required on Ex-equipment. Perform a visual inspection of EX-equipment. If necessary (apparent damage or fault), call for a third party examination and repair.
1.12
Check surface treatment and markings. Repair if necessary.
2.0 2.1
3.0
PRODUCT SPECIFIC CHECKS Inspect and check all interface connection to rig or installation supplies - i.e. electrical, hydraulic, air and water supplies.
3.1
ASSEMBLE/DISASSEMBLE N/A.
4.1
TESTING N/A
5.1
QS CHECKOUT Punch out by QS.
4.0 5.0 6.0 6.1
PRESERVATION Fill the hydraulic system using the recommended fluid.
6.2
Cover QCs, filling nipples and couplers using plastic bags.
6.3
Coil hoses with QC neatly, store inside the HPU Container or in the associated shipping basket.
6.4
Apply dielectric silicone oil to connector mating surfaces. Fit dust and protection caps.
6.5 6.6
6.7
6.8
Wrap connectors in bubble plastic secured with adhesive tape. During medium and long term storage, cover assemblies if exposed to sunlight Protect external surfaces using plastic mesh, electrical tape or other protective measures in order to prevent damage. Non-metallic materials and corrosion resistant materials (e.g. Xylan, Inconel, Stainless Steel, AlBronze, etc.) are NOT to be coated using preservatives unless specifically instructed.
Date/Sign.
Remarks
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Description Arrange the different parts in order to prevent direct metal-to-metal contact.
6.10
Arrange for protection against moisture and condensation.
6.11
Ensure all Quick Connectors are protected by caps in order to prevent ingress of contamination.
6.12
For storage areas with varying temperatures, ensure that there is sufficient ventilation to keep the equipment condensation free.
6.13
Cover each jumper end with plastic mesh, secured with adhesive tape to protect the stabs/end interface. During storage / transport, the jumpers must be protected from damage caused by the following: - Sharp edges and corners
6.14
Date/Sign.
- Falling and moving objects - Welding and grinding operations - Prolonged exposure to direct sunlight. Always store the hydraulic jumpers filled with control fluid.
Remarks
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Mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A. TESTING
Ubilical and Jumpers 4.1
5.0
Test the equipment in accordance with the relevant test procedure (associated document referenced in the MF, chapter 4 ).
5.1
QS CHECKOUT Perform the QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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De-mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 2.2
3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. For a storage period of more than two weeks, fill the hydraulic system with the recommended hydraulic fluid. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test the equipment in accordance with the relevant procedure (associated document referenced in the MF, chapter 4).
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
6.2
Place in original Packing case if the equipment is to be stored long term
Date/Sign.
Remarks
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Periodic Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 2.0 2.3 2.4
3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. For a storage period of more than two weeks, fill the hydraulic system with the recommended hydraulic fluid. ASSEMBLE / DISASSEMBLE N/A TESTING
4.3
Test the equipment in accordance with the relevant procedure (associated document referenced in the MF, chapter 4).
4.4
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.2
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.3
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
6.4
Place in original Packing case if the equipment is to be stored long term
Date/Sign.
Remarks
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In Storage Maintenance
Scan to PDF format after signing, file document on address REP No: Item
Description
Every 12 months: 1)
Perform basic tasks in accordance with information provided in Section 4.1.1 / 1.0.
2)
Operate MQC plate mechanism and verify correct function.
3)
Preserve in accordance with Section 4.1.1/ 6.0.
Every 6 months 4)
Perform basic tasks in accordance with information provided in Section 4.1.1/1.0.
5)
Re-fill the hydraulic system with the recommended hydraulic fluid, if neccary.
6)
Preserve in accordance with Section 4.1.1/ 6.0.
Date/Sign.
Remarks
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Incoming Goods Inspection and Test
Scan to PDF format after signing, file document on address REP No: EQUIPMENT NAME: MATERIAL NO.
QTY / SERIAL NO.
MMT NO./ DELIVERY NOTE SUPPLIER: INSPECTION ACTIVITIES Item
Description
1.0
TRANSPORTATION
Checked
1.1
Unpacking of Equipment.
1.2
Transportation Damage.
1.3
Consignment Note Signed.
1.4
Correct Quantity of Received Materials.
2.0
N/A
QN Ref
VISUAL INSPECTION 2.1
Equipment Marking.
2.2
Lifting Gear Identification.
3.0
DOCUMENTATION 3.1
Dispatch Dossier.
3.2
Lifting Certificates.
3.3
Material Safety Data Sheet (MSDS).
3.4
Punch List.
OUTSTANDING ITEMS TRANSPORT DAMAGE
DESCRIPTION:
INSPECTION SITE:
SIGNATURE:
DATE:
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5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT Fill in the following data if applicable: ·
Equipment Name.
·
FKS Material Number.
·
Reference Document (this is the number of the current PSM manual).
·
Reference Drawing Number(s).
CORRECTIVE MAINTENANCE REPORT Scan to PDF format after signing, file document on address REP No: Equipment Name: FKS Material Number: Fault Reference Document: Reference Drawing Number(s): Task Description
Date
Comments
Parts Used
Date
Comments
Discipline
Man-hours:
Name:
Signature:
