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Multiplex (MUX) PodCare and Maintenance

Course

Basic Training Manual

copyright 2010 Hydril USA Distribution LLCHouston, Texas

GNRC-NA-MPM100524

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Published by GE Oil & Gas

Multiplex (MUX) Pod Care and Maintenance Course

Basic Training Manual

GNRC-NA-MPM100524

GE Oil & Gas makes no warranties of any kind, expressed or implied, including any warranty of

mechanical fitness for any particular purpose that the work performed pursuant to this manual

will be free from defects in workmanship or material. GE Oil & Gas retains for itself all propriety

rights in and to all designs, engineering details, data, and procedures set forth herein. This man-

ual is intended for the sole use of GE Oil & Gas customers, and they shall strictly control copyingand distribution of same, as this manual and all paper and electronic copies thereof may be

recalled by GE Oil & Gas at any time.

This manual makes recommendations only. The customer is at all times responsible for actual

disassembly, inspection, reassembly, and testing of the equipment. The customer also is solely

responsible for providing competent and qualified persons; equipment and facilities to perform

such operations; and for workmanship and safety. If at any time the customer is unable to

understand recommendations made in this manual or is unable to follow those recommenda-

tions, they should consult the nearest GE Oil & Gas location. GE Oil & Gas reserves the right to

make additions, changes or deletions on the equipment described, at any time, without obliga-

tion.

No portion of this work may be reproduced by any means, electronic, mechanical, photocopy-

ing, recording, or otherwise, without prior written permission from GE Oil & Gas.

Copyright 2010 Hydril USA Distribution LLC

All rights reserved. Printed in the United States of America.

To contact GE Oil & Gas:

Pressure Control Systems

ATTN: Customer Service and Training

3300 North Sam Houston Parkway East

Houston, TX 77032-3411 USA

Phone (281) 449-2000 (USA)

(800) 231-0023 (USA and Canada)

Fax (281) 985-2828 (USA)

Web www.geoilandgas.com/hydril

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MUX Pod Care and Maintenance Course i - 1


Introduction

Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1

Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1

Ancillary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-2

Chapter 1Pod Lifting Techniques

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Using the Pod Lift Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 2Pod Section Assembly and Disassembly

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1


Separating the EH and LVCU Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Joining the EH and LVCU Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Chapter 3SEM Housing Dome and Chassis

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Required Tools and Accessories for Dome . . . . . . . . . . . . . . . . . . . . . . . 3-1

Required Tools and Accessories for SEM Chassis . . . . . . . . . . . . . . . . . 3-2

Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Removing the Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Removing the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Dome Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Installing the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Installing the Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Chapter 4Removal and Installation of the Pod Transformer

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


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Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing the Transformer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing the Heat Shields and Transformer . . . . . . . . . . . . . . . . . . . . 4-3

Transformer Housing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Reassembling the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Chapter 5Pod Wedge Packer Seals

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Lowering the Pod Wedge by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Removing the Packer Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Chapter 6Solenoid Housing Pressure Compensator

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1


Solenoid Housing Cover/Compensator Removal . . . . . . . . . . . . . . . . . 6-2

Preparing the Solenoid Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Placing a New Bladder in Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Reattach Cover to Solenoid Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Chapter 7Shear Seal Valves

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


Removing the Solenoid Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Removing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Disassembling the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Inspecting the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Reassembling the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Installing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Installing the Solenoid/Shear Seal Housing Cover . . . . . . . . . . . . . . . 7-15

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Chapter 8Solenoids

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


Draining the Solenoid Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Removing the Solenoid/Shear Seal Housing Cover . . . . . . . . . . . . . . . 8-2

Removing the Shear Seal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Removing the Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Solenoid Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Installing the Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Chapter 9Filling the Solenoid Housing

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1


Preparation for Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . 9-2

Solenoid Housing Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

An Alternativeto the Above Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Preparation for Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . . . . . 9-7

Solenoid Housing Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Chapter 10Solenoid/Shear Seal Valve Assembly Testing

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Solenoid Test Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Solenoid Pull-in/Drop-out Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Preparation of EH Function Solenoid Testing . . . . . . . . . . . . . . . . . . . 10-4

EH Function Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Auto Shear Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Solenoid Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Solenoid Fire Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Solenoid Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

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Chapter 11Pressure Transducer

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1


Remove Pod Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Transducer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Installation of Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Chapter 12Pressure Transducer Calibration

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1


Calibrating Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Chapter 13One Atmosphere Housing Hydrostatic Test

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1


Test Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Test Procedure for Test Port O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

Test Procedure For External Cable Connector Ports . . . . . . . . . . . . . 13-4

Test Procedure For The MUX Cable VCC29 Connector . . . . . . . . . . . . 13-4Test Completion and Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

Chapter 14Subsea Regulator

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1


Regulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Regulator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

Reinstall the Subsea Regulator on the Pod . . . . . . . . . . . . . . . . . . . . . 14-9

Chapter 15SPM Valve

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

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Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Chapter 162.5 Liter Regulator Accumulators

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1


Removing the Regulator Accumulators . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Installing the Regulator Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . 16-4

Chapter 17

Regulator Accumulators Precharge

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Test Equipment, Supplies, Facility Requirements . . . . . . . . . . . . . . . . 17-1

Preparation for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2

Accumulator Precharge Circuit Pressure Test . . . . . . . . . . . . . . . . . . . 17-2

Accumulator Precharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4

Chapter 18Flowmeter Removal and Installation

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

Flowmeter Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5

Chapter 19Flowmeter Calibration

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

Required Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

Preparation For Determination of Pod K-Factor . . . . . . . . . . . . . . . . . 19-1

Function Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2

K-Factor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3

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MUX Pod Care and Maintenance Course ii - 1


Introduction

Course Description

The Hydril Multiplex (MUX) Pod Care and Maintenance course is for subsea technicians and supervisors,hydraulic engineers and technicians, and anyone interested in understanding the maintenanceprocedures for the MUX control pod. The Basic MUX Control System course is a recommendedprerequisite for this course.

Each course model is intended to give a student 1) an understanding of what equipment makes up aMUX control pod, 2) how each piece of equipment operates and interrelates with the pod, 3) how toinstall and remove each component, and 4) basic maintenance and troubleshooting of the equipment.

Course ObjectivesThis course is designed with several objectives in mind. As the student reads this manual andparticipates in the classroom these goals should be achieved.

An understanding of the purpose and function of the MUX control pod.

The ability to identify the major components that make up the pod.

An introduction to these components and their operation and interaction.

The ability to remove and to install the components on the MUX control pod.

The ability to maintain and troubleshoot the customer-serviceable parts of the pod.

This manual is developed to act as a guide during the classroom and serve as a reference guide to thesystem. As always, for exact system information, students should refer to the Hydril Operations &Maintenance Manual Set for the MUX control system installed on their rig.

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INTRODUCTIONIntroductionAncillary Materials

ii - 2 MUX Pod Care and Maintenance Course

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Ancillary MaterialsThere are no ancillary materials for this class.

How to Use This Manual

Scope

The scope description provides a quick overview of the chapter contents, and allows you toquickly familiarize yourself with the subject matter.

Conventions

This manual uses the following conventions.

Note...Notes provides additional useful information.

Caution...Cautions indicates procedures which can potentially damageequipment if not performed properly.

Warning...

Warnings indicate potentially hazardous situations or procedures orwhich can potentially injure or kill personnel if not performedproperly.

Things to Remember...Things to Remember contains important facts about individualcomponents in the MUX system, bullet points, special instructions, orinstallation tips.

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NotesChapter 1

Pod Lifting Techniques

ScopeThe purpose of this procedure is to demonstrate the proper techniquefor using the pod lift frame to lift the MUX pods.

Figure 1-1 Subsea Pod

Required Tools and Accessories Pod lift frame

5

/16" open ended wrench 11/16" open ended wrench

(2) Lifting straps rated to lift 26,420 lbs.

(2) 11/2" - 21 ton shackles (entire assembly)

(2) 11/4" - 9.5 ton shackles (EH section)

Overhead crane/hoist

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CHAPTER1Pod Lifting Techniques

Notes Using the Pod Lift Frame

1. Attach a shackle to each of the lifting eyes on top of the pod liftframe.

Figure 1-2 Pod Lift Frame

2. Insert a lifting strap through each shackle.

3. Center the crane hoist over the lift frame, and lower the hoist toa height suitable for attaching the straps.

4. Install both loops of the lifting straps onto the hoist hook.

5. Ensure that the hoist safety latch closes to prevent the loopsfrom coming off the hook.

6. Raise the hoist until the straps are tight. Ensure the weight ofthe pod lift frame is evenly distributed.

Remember... Before using the overhead crane and the

pod lift frame to move any part of the pod,

survey the path of travel to ensure that it isand will be clear.

Remove all trip hazards, and identify anyoverhead obstacles which may present aproblem throughout the operation.

Be Careful...The entire pod assembly weighs 22,700 lbs. TheEH section weighs 10,100 lbs. empty, and the

LVCU section weighs 12,600 lbs. empty. Toprevent damage to equipment and/or bodilyinjury, ensure the shackles and lifting straps areappropriately rated for this lifting procedure.

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7. Adjust the straps until the weight is evenly distributed.

8. Locate the four bolts (one bolt per corner) installed in the upperfour corners of the pod assembly.

9. Using the 11/16" and the 5/16" wrenches, loosen the nuts from thebolts, and remove both the nuts and the bolts from the podassembly.

Figure 1-3 Removing the Bolts and Nuts

10. Continue raising the hoist until the bottom end of the lift framelegs are higher than the assembly to be lifted.

11. Center the lift frame over the assembly.

12. Align the frame legs with the holes at each corner of theassembly.

13. Lower the lift frame into the holes.

14. Install a retaining bolt in each of the four holes.

15. Install a nut on each of the bolts.

16. Tighten each retaining bolt assembly.

17. Raise the hoist until the straps are tight.

Dont Forget...If the lift frame does not appear level, lower thehoist until the straps slacken.

Be Careful...To prevent damage to the pod electronics,ensure the legs of the frame do not come incontact with the electronics dome or thetransformer housing when centering the frameover the EH section.

Notes

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Notes

18. Continue raising the assembly.

Figure 1-4 Lifting the Pod EH Assembly

19. Move the assembly to the desired location.

Remember... If the lift frame does not appear level, lower

the hoist until the straps slacken.

Adjust the straps until the weight is evenlydistributed.

Make Sure...When lift the entire pod or the LVCU, ensure thatthe assembly is clear of the pod test stand orother supporting framework before moving.

Watch Out...To prevent bodily injury, keep a safe distancefrom the pod assembly when it is suspended.Watch the path of travel to ensure no onewalks in front of or under the pod assemblywhile it is in motion.

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20. Lower the assembly into its destination location until the strapsare slack.

21. Loosen the nuts from the retaining bolts.

22. Remove the nuts and bolts.

23. Use the hoist to raise the pod lift frame until the bottom of thelegs are above the EH section electronics dome.

24. Move the pod lift frame to a safe location.

25. Lower the hoist until the straps are slack.

26. Remove the straps from the hoist hook.

27. Install the four retaining bolts in the four corners of the EHsection. Install the nuts on the bolts and hand tighten.

This student ____________________________________________ hassuccessfully completed the procedures described in this chapter.

InstructorSignature ________________________________ Date ___________

Remember... When separating the EH section from the

LVCU, ensure the EH section legs clear theLVCU before moving.

When lifting the EH section from its stand,ensure the legs clear the stand beforemoving.

Notes

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NotesChapter 2

Pod Section Assembly

and Disassembly

ScopeThis purpose of this procedure is to show how to separate and to jointhe electro-hydraulic (EH) and the lower valve control unit (LVCU)sections of the MUX control pod.

Figure 2-1 Subsea Pod

Required Tools and Accessories Pod lift frame

Ratchet

Extension

5/16" Allen socket

15/16" open ended wrench


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CHAPTER2Pod Section Assembly and Disassembly

Notes (2) Lifting straps rated to lift 26,420 lbs.

(2) 21 ton shackles (entire assembly)

(2) 9.5 ton shackles (EH section)


A-frame ladder Nickel-plated Never Seez

Separating the EH and LVCU Sections

1. Remove all of the cap screws that hold the solenoind/shear sealhousing covers.

2. Remove the covers from both sides of the E/H section and setthem aside.

3. Using the 15/16" wrench, loosen the retaining bolts that arelocated on the junction plates. (They will not totally removefrom the EH junction plate)

4. Locate the four bolts installed in the upper four corners of thepod assembly.

Be Careful...The entire pod assembly weighs 22,700 lbs. TheEH section weighs 10,100 lbs., and the LVCUsection weighs 12,600 lbs. To prevent damageto equipment and/or bodily injury, ensure the

shackles and lifting straps are appropriatelyrated for the lifting procedure.

Remember... Before using the overhead crane and the

pod lift frame to move any part of the pod,survey the path of travel to ensure that it isand will be clear.

Remove all trip hazards, and identify anyoverhead obstacles which may present a

problem throughout the operation.

Check to See...Ensure the LVCU is fastened securely to a stableplatform or a pod test stand.

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5. Using the 11/16" and the 15/16" wrenches, loosen the nut and boltassembly.

6. Attach a shackle to each of the lifting eyes on top of the pod liftframe.

Figure 2-3 Pod Lift Frame

7. Insert the lifting strap through each shackle on the pod lift frame.

8. Center the crane hoist over the lift frame, and lower the hoist toinstall the straps.

9. Hook both sides of the strap to the hoist.

10. Raise the hoist until the straps are tight. Ensure the weight ofthe pod lift frame is evenly distributed.




Notes

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Notes

11. Center the lift frame over the EH section.

12. Align the frame legs with the holes at each corner of the EHhousing.

13. Lower the lift frame until the retaining bolt holes in the EHsection line up with the holes in the frame legs.

14. Install a retaining bolt in each of the four holes. Tighten eachretaining bolt.

15. Locate the retaining bolts installed in the upper four corners of

the LVCU.

16. Using the 15/16" wrench, loosen the nuts from the bolts. Removethe nuts and bolts from the LVCU.


18. Continue raising the pod lift frame until the bottom ends of the

EH section legs are above the LVCU.19. Carefully move the EH section to its stand.

20. Align the EH section legs with the stand.

21. Lower the EH section onto the stand until the straps are slack.

22. Using the 15/16" and the 11/16" wrenches, loosen the nuts fromthe retaining bolts.


Be Careful...When centering the frame over the EH section,ensure the legs of the frame do not come incontact with the electronics dome or the

transformer housing.




Be Careful...Separating the EH section from the LVCUinvolves the hydraulic junction plates at bothends of the pod. To prevent damage to the

junction plate O-rings and seal subs, ensure thecrane is centered over the pod prior to lifting.

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Figure 2-4 Lifting the Pod EH Assembly

24. Use the hoist to raise the pod lift frame until the bottom of thelegs are above the EH section electronics dome.



27. Remove the straps from the hoist.

28. Install the retaining bolts in the four corners of the EH section.

29. Install the nuts on the bolts hand tight.

30. Install the retaining bolts in the four corners of the LVCU.

31. Install the nuts on the bolts hand tight.

Joining the EH and LVCU Sections1. Use the 5/16" Allen socket to remove the cap screws that hold

the Solenoid/shear seal housing cover in place.

2. Set the screws in a cup or bag so that they will not bemisplaced.

3. Set the covers off to the side so that they will not become anobstacle or safety hazard.

4. Locate the four bolts (one bolt per corner) installed in the upperfour corners of the EH section.

5. Loosen the nuts from the bolts. Remove the nuts and bolts fromthe EH section.

Notes

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Notes


6. Attach an appropriately rated shackle to each of the lifting eyeson top of the pod lift frame.

7. Insert a 26,420 lb. rated lifting strap through each shackle.

8. Center the crane hoist over the lift frame, and lower it to aheight suitable for installing the straps.

9. Install both loops of the lifting straps onto the hoist hook andensure that the hoist safety latch closes.


11. Adjust the straps until the weight is evenly distributed.

12. Continue raising the hoist until the bottom end of the lift framelegs are above the EH section dome.

13. Center the lift frame over the EH section.

14. Align the frame legs with the holes at each corner of the EHhousing.

15. Lower the lift frame until the retaining bolt holes in the pod lineup with the holes in the frame legs.

16. Install a retaining bolt in each of the four holes. Install a nut oneach of the bolts.

Verify...Ensure that the weight of the pod liftlift frame isevenly distributed.

Be Careful...When centering the frame over the EH section,ensure the legs of the frame do not come incontact with the electronics dome or thetransformer housing.

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17. Tighten each retaining bolt assembly using the 15/16" wrench inconjunction with the 11/16" wrench.

18. Locate the retaining bolts installed in the upper four corners ofthe LVCU.

19. Loosen the nuts from the bolts.

20. Remove the nuts and bolts from the LVCU.

21. Raise the hoist until the straps are tight. (Ensure that the weightof the pod lift frame is evenly distributed)

22. Continue raising the EH section until the legs are above theLVCU.

23. Move the EH section until it is centered over the LVCU.

24. To ensure the EH section is oriented properly with the LVCU,locate the pod select valve on the LVCU.

25. Orient the EH section over the LVCU so the electronics dome ison the same side of the assembly as the pod select valve.

26. Slowly lower the EH section until the junction plates mate.

27. Before contact, verify that both junction plates are properlyaligned.

Figure 2-6 Aligning the Junction Plates




Be Careful...

Joining the EH section with the LVCU involvesthe hydraulic junction plates at both ends of thepod. To prevent damage to the junction plate O-rings and seal subs, employ the assistance of aco-worker to guide the EH section into positionas it is lowered.

Notes

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Notes

28. Slowly lower the EH section onto the LVCU.

29. Install the retaining bolts in the four corners of the LVCU.

30. Install a nut on each bolt and tighten hand tight.

31. Place an A-frame ladder next to the pod assembly.

32. Locate the retainer bolts that are on the junction plates.

33. There are four bolts per side; tighten each bolt down until itbottoms out.

34. Move the ladder to the side of the pod where the HPHT andFlowmeter connections are located.

35. Remove the cover plate located on the side of the LVCU.

36. Take the cable that is coming from the top of the pod wedgeand attach to the J5 connection point..

37. Take the cable that is coming from the inner body of the LVCUand connect to the J6 connection.

.

Figure 2-7 Junctions for the HPHT and the Flowmeter

38. Replace the panel.

39. Standing on the ladder, loosen the nuts attaching the pod liftframe to the EH section.


41. Raise the pod lift frame until the bottom of the legs are abovethe EH section electronics dome.



44. Remove the straps from the hoist hook.

45. Install the retaining bolts in the four corners of the EH section.Install the nuts on the bolts and hand tighten.

Be Careful...Proceed slowly when lowering the EH section toprevent cutting the O-rings.

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This student ____________________________________________ hassuccessfully completed the procedures described in this chapter.

InstructorSignature ____________________________ Date ___________

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NotesChapter 3

SEM Housing Dome and Chassis

ScopeThe purpose of this procedure is to describe the removal andinstallation of the MUX control pods SEM chassis and housing dome.

Figure 3-1 SEM Housing Dome

Required Tools and Accessories for Dome 5/8" Allen socket

Ratchet


(2) 1/4" shackles

Clevis/lift frame (GE Oil & Gas # AC534)

1" shackle

Full circle lifting strap, 4 feet in length

Petroleum jelly

Nickel-plated Never Seez

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CHAPTER3SEM Housing Dome and Chassis

Notes Required Tools and Accessories for SEM Chassis Phillips head screwdriver

3/8" Allen socket

Ratchet

(2) lifting straps, 10 feet in length


Small flat head screwdriver

Remove Pod Power

1. Turn the subsea power breaker located at the PDP to the OFFposition and place a lockout tag on the PDP.

2. Place the CCU logic drawer subsea SEM power switch to the A-ON/B-ON position.

3. Remove the Pyle National connector at the umbilical J-box, orremove the VCC-29 connector at the pod.

Removing the DomeBefore removing the dome, ensure a level area for it to be placed.

1. Attach the clevis frame to the dome.

2. Attach a 1" shackle to the clevis.

3. Run the strap through the shackle and hook the ends of thestrap on to the hoist.

4. Remove all of the cap screws attaching the SEM housing dometo the one atmosphere housing.

5. Set the cap screws aside in a secure and clean location.

6. Remove Test Port 4 (TP4).

7. Lift the hoist until the strap becomes taut.

Watch Out...The pod is powered by 720 VAC and 120 VACsignals. To prevent electric shock, ensure thatall power sources are locked out before

proceeding.

Watch Out...The SEM dome weighs 1,100 pounds. Toprevent bodily injury, DO NOT walk under thedome when it is suspended.

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8. Slowly lift the dome off the one atmosphere housing.

9. Once the housing clears the chassis, move it to a safe location.

10. Lower the hoist and remove the strap.

Removing the ChassisBefore removing the chassis, designate a work area where the chassiswill be placed once it is removed. Ensure that the area is clean andlevel.

1. Take the lifting strap and connect the two1

/4

" shackles to eye-bolts.

2. Attach the strap to the hook on the hoist.

3. Raise the hoist until the straps are hanging loosely above thechassis.

4. Remove both cowlings from the chassis.

5. Remove the two top mounting screws for the navigationcomputer.

6. Pull out the navigation computer and place it in a clean area.

7. Disconnect the transducer connector (hypertronic connectorA/BP1).

8. Desconnect Solenoid Connector #1 (hypertronic connectorA/BP3).

9. Disconnect Solenoid Connector #2 (hypertronic connectorA/BP4).

10. Disconnect the 90 VAC & 48 VAC input connector (hypertronicconnector JPWR1).

11. Disconnect the X/Y riser angle connector (DB9 JSENS).

12. Disconnect the solenoid #15 (hyper 4-pin connector).

13. Disconnect the SEM communication connector (4-pin, ML-Modem).

14. Disconnect the navigation communication connector (4-pin,ML-RS485).

Remember...Ensure the path of travel for the dome is free oftrip hazards and overhead obstacles.

Remember...Be sure that all cables and connectors arelabeled before disconnecting.

Notes

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Notes 15. Disconnect the ROV.NAV. connector (Hyper, 4-pin).

16. Disconnect the flowmeter connector (DB9, JF1).

17. Disconnect the gyro connector (DB15).

18. Place all of the cables in the one atmosphere housing beforeremoving the chassis from the housing.

19. Using the small screwdriver, remove all of the screws that holdthe chassis to the housing.

20. Set the screws aside in a place that will be secure.

21. Slowly lift the hoist and remove the chassis.

22. Set the chassis in the designated area and remove the strap.

Dome Maintenance1. Remove the O-rings and backup rings from the base of the

dome.

2. Check the O-ring grooves and sealing surfaces for cuts andabrasions.

3. Replace the O-rings. Lightly lubricate the new O-rings withpetroleum jelly.

4. Install the new O-rings on the base of the dome.

Installing the Chassis1. Connect the two 1/4" shackles to the eye bolts.

2. Lift the chassis and set in on the one atmosphere housing.

3. Route the cables located in the one atmosphere housing upthrough the center of the chassis.

4. Rotate the chassis until it is oriented with the PC boards facingout.

5. Connect the JPWR1 connector to the PPWR1 connector of thechassis.

6. Connect the JSENSF 9-pin female connector of the pod to theJSENSM 9-pin male connector of the chassis.

7. Connect the chassis, 4-pin MIL-M connector of the surfacecommunication harness to the 4-pin MIL-F connector of thepod surface communication harness.

8. Connect the DB15 connector of the gyro harness of the chassisto the DB15 connector.

9. Connect the DB9 connector of the flowmeter harness of theSEM2003 to the DB9 connector PF1 of the hypertronic plugA/BP1 in the pod.

10. Secure the chassis to the one atmosphere housing, using thebase mounting screws.

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(If converting from SEM 1999 to SEM 2003, add the steps below to thesteps that are shown above)

1. Change the pin out of the 4-pin female connector of the podwhich was originally for NAV communication as follows:

2. Move the wire from Pin 3 to Pin 2.

Move the wire from Pin 4 to Pin 1.

3. Connect the modified 4-pin female connector of the pod to the4-pin male connector of the NAV communication harness of thechassis.

4. Modify the pin out of the hypertronic plug A/BP1 in the pod asfollows:

Remove FLM1 from Pin E18.

5. Perform the three steps below:

Remove the 4-pin HYPER-M connector (w/cable) from theoriginal SEM.

Connect Pin 1 to Pin J3 of the hypertronic plug A/BP3 in thepod.

Connect Pin 3 to Pin K3 of the hypertronic plug A/BP3 in thepod.

Remove FLM2 from Pin F18 to Pin E18.

Installing the Dome1. Attach the clevis frame to the top of the dome.

2. Attach the shackle to the eye bolt and lifting device.

3. Lower the hoist above the dome.

4. Run the strap through the shackle and hook the ends of thestrap on to the hoist.

5. Lift the hoist until the strap becomes taut.

6. Slowly lift the dome off the ground.

7. Center the dome over the chassis.

8. Slowly lower the dome over the chassis.

9. Align the bolt holes with the holes in the dome.

10. Lower the dome onto the one atmosphere housing.

11. Lubricate the dome cap screws with nickel-plated Never Seezand install them in the bolt holes.

Be Careful...Two people should perform the next step. Clearcommunication is vital to prevent damage tothe chassis.

Notes

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Notes 12. Tighten the cap screws in a star pattern.

13. Torque the bolts to 80 ft-lbs (108 Nm).

This student _______________________________________ hassuccessfully completed the procedures described in this chapter.


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NotesChapter 4

Removal and Installation of the

Pod Transformer

ScopeThis purpose of this procedure is to demonstrate the process forremoving the transformer housing that is located on the MUX pod,and removing the transformer that is located under the housing. Thischapter will also cover the installation of the transformer and housing.

Figure 4-1 Pod Transformer

Required Tools and Accessories Lifting eye

Clevis frame lift (GE Oil & Gas # AC534)

1" shackle

(2) 1/4" shackle

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CHAPTER4Removal and Installation of the Pod Transformer

Notes 3/8" drive ratchet

3/8" drive extension, 4 feet in length

1/2" socket with a 3/8" drive


9

/16" open ended wrench 3/8" Allen socket with a 3/8" drive

1/8" Allen wrench


Open ended wrench

Full circle lifting strap, 4 feet in length

Nylon strap, 6 feet in length

Transformer housing shackle

O-ring pick

Petroleum jelly


Heat sink compound

Clean cloths

Remove Pod Power1. To lock out the 720 VAC, turn the subsea power breaker located

at the PDP to the OFF position and place a lockout tag on thePDP.

2. To lock out the 120 VAC, place the CCU logic drawer subseaSEM power switch to the A-ON/B-ON position.

3. To ensure that the pod is completely de-energized, remove thePyle National connector at the umbilical J-box, or remove theVCC-29 connector at the pod when possible.

Removing the Transformer Housing

Before removing the transformer housing, indentify the location thatthe housing will be placed once it has been removed. Ensure the areais clean and level.

1. Locate the cap screws that mount the transformer housing tothe pod (see Figure 4-2).

Watch Out...The pod is powered by 720 VAC and 120 VAC

signals. To prevent electric shock, ensure thatall power sources are locked out beforeproceeding.

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2. Use the ratchet, the four-foot extension, and the 5/8" Allensocket to remove the cap screws.

Figure 4-2 Transformer Housing Cap Screws

3. Attach the eye bolt to the top of the transformer housing.

Figure 4-3 Clevis Lift Frame and Eye Bolt

4. Thread the lifting strap through the eye bolt and attach bothends of the strap to the hoist.

5. Slowly raise the hoist.

6. Set the housing in a safe location.

Removing the Heat Shields and Transformer1. Remove the heat shields from the transformer with the 1/8"

Allen wrench. Place the screws in a cup or a container.

Dont Forget...Stabilize the housing as it rises so it does notbump into the transformer and damage it.

Notes

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Notes

Figure 4-4 Transformer Heat Shields

2. Set the heat shields in a safe location.

3. Using the 9/16" open ended wrench, remove the two boltsholding the transformer to the one atmosphere housing.

4. Place the bolts in a cup or a container.

5. Using the 11/16" open ended wrench, remove the cap located onthe top of the transformer.

6. Using the 1/2" socket, remove the cable connections. Cut all ofthe zip ties that hold the wires to the transformer body.

7. Place the wires on top of the one atmosphere housing.

8. Using the 11/16" open ended wrench, reinstall the cap to the topof the transformer.

9. Grasp the handle on top of the transformer (see Figure 4-5) andcarefully lift it off the one atmosphere housing.

10. Place the transformer on a work bench.

Figure 4-5 Transformer Handle

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Transformer Housing Maintenance1. Remove the two O-rings and three backup rings from the

transformer housing.

2. Inspect the O-ring grooves for galling, cuts, and abrasions.

3. Using a clean, wet cloth, wipe out the O-ring grooves on thetransformer. Remove any grit and residue.

4. Using a clean, wet cloth, wipe the one atmosphere housingclean.

Figure 4-6 Housing O-Rings

5. Lubricate two new O-rings with petroleum jelly. Install the newO-rings on the transformer housing (see Figure 4-6).

6. Install the backup rings.

Reassembling the Transformer1. Lift the transformer by the handle and carry it to the one

atmosphere housing.

2. Install it on the housing.

3. Route the wires up the side of the transformer and zip tie themin place.

4. Reattach the connections to their appropriate location:

Each wire is identified by a tag. The number on the tag thatis preceded by a dash is the position identifier.

Match the wire number to its appropriate location on thetop of the transformer (see Figure 4-7).

Remember...

The transformer housing upper O-ring has abackup ring on both sides.

The lower O-ring has a backup ring abovethe O-ring.

Notes

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Notes Center each wire lug over its designated connection, andusing the 1/2" socket, fasten in place with a lock nut.

Figure 4-7 Top of the MUX Transformer

5. Lubricate the two transformer cap screws with nickel-platedNever Seez and install them in the one atmosphere housing.

6. Brush heat sink compound on the transformer frame work.

7. Install the heat shields on the transformer.

8. Brush heat sink compound on the heat shields.

9. Route the lifting strap through the shackle on top of thetransformer housing.

10. Using the hoist, lift the housing and center it over the

transformer.

11. Align the holes in the transformer housing with the bolt holes inthe one atmosphere housing.

12. Slowly seat the housing on the one atmosphere housing.

13. Brush nickel-plated Never Seez on the cap screws.

14. Using the cap screws, tighten in a star pattern till the housingthe rest of the way down until it seats properly.

15. Install the cap screws into the housing and torque to 24 ft-lbs(33 Nm).

16. Remove the lifting strap and shackle from the top of thetransformer housing.

Remember...Have an assistant guide the housing over thetransformer to reduce the risk of damage to thetransformers.

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NotesChapter 5

Pod Wedge Packer Seals

ScopeThis purpose of this procedure is to demonstrate the removal andinstallation of the MUX pod rubber packer seals and packer sealretainers.

Figure 5-1 Pod Wedge Packer Seals

Required Tools and Accessories 2" open ended wrench

1" open ended wrench

1/2" packer seal tool (GE Oil & Gas # 3135320)

1" packer seal tool (GE Oil & Gas # 3135321)

11/2" packer seal tool (GE Oil & Gas # 3135322)

WD-40

Petroleum jelly


Clean cloths

DisassemblyTo remove the packer seals, the pod wedge must first be exposed.Follow the steps below to expose the wedge from the body of theLVCU by using a stand.

Lowering the Pod Wedge by Hand

1. Using the principles described in Chapter 1, Pod LiftingTechniques, raise the pod.

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CHAPTER5Pod Wedge Packer Seals

Notes 2. As shown in Figure 5-2, place a stand or similar stableobject under the pods wedge.

Figure 5-2 Stand for Pod Wedge

3. Lower the pod unit until the wedge rests on the stand.4. Continue lowering the pod until the weight is off the

shoulder bolt.

Figure 5-3 Stand Penetrating Body of LVCU to Support Pod Wedge

5. Remove the shoulder bolt that is located in the side ofthe wedge.

Figure 5-4 Remove Shoulder Bolt

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6. Lift the pod. The wedge will fully extend (See Figure 5-5).

Figure 5-5 Pod Wedge Fully Extended

7. Support the pod on a stand or blocks. Figure 5-6 shows astand that GE Oil & Gas built specifically for this process.

Figure 5-6 LVCU Stand for Replacing Packer Seals

Removing the Packer Seals

1. Place the appropriate size tool in the packer seal andloosen the packer seal.

Figure 5-7 Packer Seal Tools

Notes

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Notes

Figure 5-8 Remove Packer Retainer with Packer Seal Tool

2. Pull the packer seal retainer from the cavity and set itaside.

Figure 5-9 Packer Retainer

3. Remove the packer seal from the pod wedge and setaside or discard.

4. Set the wave spring(s) aside.

Figure 5-10 Packer Seal and Wave Spring

Did You Know...Only the 1/2" packer has two wave springs. Thetwo larger packer seals only have one wavespring.

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Inspection1. Inspect the seal ports for thread damage, galling, cuts,

abrasions or other signs of wear.

Reassembly1. Clean the wedge using WD-40 spray and a clean cloth. Remove

all dirt and foreign particles, paying attention to the seal portthreads and the port passages in the wedge.

Figure 5-11 Parts for Reassembly

2. Lubricate the wave spring(s) with a liberal amount of petroleumjelly.

3. Install the wave spring into the seal port cavity. The petroleum

jelly should hold the wave spring in place.

4. Lubricate the the packer seal with petroleum jelly and install itin the wedge.

5. Lubricate the packer seal retainer threads with nickel-platedNever Seez.

6. Install the packer seal retainer into the cavity.

7. Select the appropriate sized packer seal tool and open endedwrench.

8. Tighten the packer seal till it bottoms out.

Remember... The wave springs are not a complete circle.

They have breaks in them.

Rotate the springs so that the breaks are onopposite sides of each other.

Notes

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Notes

9. Continue this process for all of the seals that need to bereplaced.



Be Aware...There is not a torque value for the packer seals.

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NotesChapter 6

Solenoid Housing Pressure

Compensator

ScopeThe purpose of this procedure is to demonstrate the process toremove the solenoid cover and extract the bladder that is locatedinside the cover. The process also demonstrates replacing the coverwith a new bladder and reinstalling the cover on the solenoid housing.

Figure 6-1 Solenoid Housing Pressure Compensator

Required Tools and Accessories (2) 1/4" shackles

Ratchet

Extension

5/16" Allen socket

Overhead hoist


O-ring pick

Petroleum jelly


Clean cloths

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CHAPTER6Solenoid Housing Pressure Compensator

Notes Solenoid Housing Cover/Compensator RemovalFor this process, you will need the hoist, the strap, the two shackles,and the ratchet set.

1. Maneuver the hoist over the solenoid housing.

2. Attach the two shackles to the strap.3. Attach the two shackles to the picking eyes located on either

end of the housing cover.

4. Using the ratchet, the extension, and the 5/16" Allen socket,remove the cap screws that hold the solenoid cover to thehousing.

5. Remove the screws and place them in a cup or a container.

6. Attach the strap to the hoist.

7. Begin lifting the hoist until the strap is tight.

8. Slowly lift the cover off of the housing.

9. Remove the cover from the housing and place it on a worktable.

10. Remove the four cap screws holding the protector cap downand place them in a container.

Figure 6-2 Cover Plate

11. Remove the next set of four cap screws. Place them in a safeplace so they will become lost.

Be Careful...When lifting the cover off of the housing, therewill probably be dielectric fluid coming from outof the cover and housing. Be careful to not slipon this overflow.

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Figure 6-3 Cap Screws

12. As shown in Figure 6-4, flip the cover over and remove the capscrews that are holding the stainless steel plate to the bottomof the cover.

Figure 6-4 Removing Stainless Steel Plate

13. Remove the old bladder from the cover.

14. Unscrew the stainless steel compensation port from the top ofthe bladder and set it aside. See Figure 6-5.

Figure 6-5 Compensation Port

Notes

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Notes Preparing the Solenoid Housing Cover1. Remove the old O-rings and set aside.

2. Take a clean cloth and wipe off any buildup and debris on thetop of the housing.

3. Take a clean wet cloth, finish cleaning the top section of thesolenoid housing.

4. Inspect the O-rings; if they are damaged, replace them withnew ones.

5. Coat the O-rings with petroleum jelly and place them in the O-ring slots on top section of the housing.

6. Lay the cover over with the bottom facing up.

7. Take a couple of clean cloths, get them wet and begin cleaningthe covers edge. Clean inside the insert area where thepressure compensator fits. The bladders O-rings will sit in thisarea so it is very important that all grit and grime is removed

from this area.

8. Take a dry clean cloth and wipe down the cover.

Figure 6-6 Wipe Down Cover With Wet Cloth

9. Take the stainless steel compensation port and wipe it downwith a clean, wet cloth until all of the mud and grit have beenremoved.

Figure 6-7 Remove all Grit

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Placing a New Bladder in Cover1. Coat the threads of all of the cap screws with Never Seez.

2. Take the new bladder and set it on a work bench.

3. Screw the cleaned compensation port into the top of the

bladder.4. Set the cover with the back side facing up next to the bladder.

5. Place the bladder inside the cover.

Figure 6-8 Inserting New Bladder

6. Press the compensation bladder in to the solenoid housingcover and screw in cap screws.

Figure 6-9 Securing Bladder to Cover

7. Torque the cap screws to 120 in-lbs.

8. Turn the cover with the bottom up and place the stainless steelplate over the bottom of the cover.

9. Insert the cap screws and begin tightening them down.

Notes

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Figure 6-10 Reassembling Stainless Steel Plate

10. Torque these cap screws to 70 in-lbs.

11. Attach the vacuum port to the compensation port and collapse

the bladder.

Figure 6-11 Collapsing the Compensation Bladder

12. Remove the vacuum pump.

13. Place the round plate over these cap screws and insert the nextset of cap screws.

14. Torque these cap screws to 120 in-lbs also.

Reattach Cover to Solenoid Housing1. Re-attach 1/4" shackles to the top of the cover.

2. Take the lifting strap and run it through the two shackles.

3. Attach the strap to the hoist and lift the cover.

4. Set the cover on the housing paying attention to not causemisalignment with the O-rings.

5. Lower the hoist and remove the strap and 1/4" shackles.

6. Take the cap screws and begin tightening the bolts to torquevalue of 190 in-lbs.

Notes

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NotesChapter 7

Shear Seal Valves

ScopeThe purpose of this procedure is to describe the proper methods toremove, disassemble, maintain, assemble, and install the sheal seal valve.

Figure 7-1 Shear Seal Valve

Required Tools and Accessories (2) 1/4" shackles



3/8" drive ratchet

3/8" drive extension

5/16" Allen wrench

3/16" Allen wrench

1/4" Allen wrench

1" open ended wrench

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CHAPTER7Shear Seal Valves

Notes O-ring pick

Needle nose pliers

Small flat-head screwdriver

Armature gauge tool

Wire brush Paint pen

Petrolem jelly


WD-40 residual cleaner

Clean cloths

Removing the Solenoid Housing Cover1. Attach a 1/4" shackle to each of the two lifting ears on the

solenoid housing cover.2. Thread the lifting strap through each shackle and attach the

ends of the strap to the hoist.

3. Using the 5/16" Allen wrench, remove all of the cap screws fromthe solenoid housing cover. Place the screws in a clean container.

4. Slowly raise the hoist, and lift the cover off the solenoid housing.

5. Place the housing cover in a safe location.

Removing the Shear Seal Valve1. Using the 3/8" drive ratchet, the 3/8" drive extension, and the 3/16"

Allen wrench, remove the two cap screws that hold the shearseal valve to the solenoid housing.

2. Place the cap screws in a clean cup or container.

3. Pull the shear seal valve from the solenoid housing, and place iton a clean work table.

4. Using the paint pen, mark the shear seal valve with its podposition number (the number is stamped on the housing justabove each shear seal valve).

5. Inspect the armature and the solenoid bore for corrosion. Ifthere is little or no corrosion, clean the armature and thesolenoid bore with a cloth rag (or similar) and dry the parts.

Did You Know...The solenoid bore and the armature aremanufactured from nearly pure iron and arevery susceptible to corrosion, thus both arespecially coated.

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Figure 7-2 Moderate (Left) and Minor (Right) Corrosion

6. If there is some corrosion, but it is not extensive, it may becleaned with emery cloth. Use care not to remove anyremaining coating. Clean the armature and the solenoid boreand dry the parts.

7. If there is extensive corrosion, replace the parts. If it is notpossible to replace the parts that have corrosion, then cleanthe parts with emery cloth to remove the corrosion. Use care soas not to remove any remaining coating.

Disassembling the Shear Seal Valve1. Remove the two seal subs from the shear seal valve.

2. Remove the two O-rings from each seal sub.

3. Support the plunger on a padded wooden block or other firmsurface that is the same height as the shear seal valve when itis laid on its side. Be sure to keep the plunger and the valve levelduring the cotter pin removal.

Remember... The solenoid armature position is critical to

the proper functioning of the solenoid shearseal valve assembly.

If the position is off by as little as 0.015", thesolenoid may not function as intended.

Excessive pressure on the armature willbend the spool rod and effect the armatureposition.

Notes

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Notes 4. Straighten the armature cotter pin, taking care not to applyexcessive pressure to the armature.

Figure 7-3 Straightening the Cotter Pin

5. Remove the cotter pin from the armature.

Figure 7-4 Removing the Cotter Pin

6. Unscrew the armature from the spool rod using acounterclockwise motion.

Figure 7-5 Removing the Armature

7. Using a 1/4" Allen wrench, remove the four, 1/4"-20UNC x 21/4"cap screws holding the outlet plate to the assembly.

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Figure 7-6 Removing the Cap Screws

8. Remove the four 1/4" lock washers.

9. Set the screws and lock washers aside.

10. Remove the inlet plate from the valve body.

11. Remove the O-ring from the inlet plate.

12. Remove the outlet plate from the valve body.

13. Remove the O-ring from the outlet plate.

Figure 7-7 Outlet and Inlet Plates Removed

14. Remove the inlet and outlet shear seal plates.

Figure 7-8 Inlet and Outlet Shear Seal Plates

15. Remove the O-rings from the inlet and outlet shear seal plates.

Notes

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Notes 16. Remove the shear seal cage and seals from the seal carrierspool.

Figure 7-9 Removing the Shear Seal Cage

17. Remove one of the shear seals from the cage.

18. Remove the spring from the cage.19. Remove the other shear seal from the cage.

20. Remove the O-rings from the inside diameter of the cage.

21. Use either a 1" open ended wrench or 1" deep socket to removethe seal bushing.

22. Remove the filter element from the seal bushing.

23. Remove the O-ring from the seal bushing.

24. Remove the rod seal from the seal bushing.

25. Remove the shear seal rod spool and carrier assembly from thebody.

Figure 7-10 Removing the Rod Spool and Carrier Assembly

26. Remove the dowel pin from the seal carrier spool.

27. Separate the rod spool from the seal carrier.

28. Use either a 1" open ended wrench or 1" socket to remove thecheck valve from the shear seal body.

29. Remove the O-rings from the check valve.

30. Remove the O-rings from the shear seal valve body.

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Inspecting the Shear Seal Valve

Figure 7-11 Shear Seal Valve Components

1. Inspect all seal surfaces for damage.

2. Inspect all parts for cleanliness. Clean and dry if necessary.

3. Inspect all O-rings for damage and replace if necessary. If thevalve is to be rebuilt, always replace elastomer seals; these arecontained in the seal kit.

4. Ensure that all valve interior and mating surfaces are free fromdamage, dirt, metal shavings, burrs, or any other foreignmaterial.

5. If a shear seal valve is to be re-assembled with a new seal kit,perform the following steps:

Inspect the shear seals for any indications of wear orsurface imperfections. The shear seals must NOT haveanything unusual on the shear seal surface. If there are anyindications of wear, replace the shear seal. Do not attemptto polish or buff out any imperfections on the shear sealsurfaces; such a procedure would not meet the flatnessrequirements to operate properly.

Clean the shear seal plates with non-residual cleaner. Inspectthe shear seal surface for scoring, galling, or distortion. Theshear seal surface is very flat, and should have a mirror-likefinish. If there are any indications of wear, replace the shearseal plates. Do not attempt to polish or buff out anyimperfections on the shear seal surface; such a procedure

would not meet the flatness requirement to operate properly.

Remember... If the shear seals indicate any wear, replace

the shear seals and the shear plates.

If the shear seal plate indicates any wear,replace the shear seals and the shear sealplates. (If one of the parts is worn, the otheris also worn).

Notes

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Notes

Reassembling the Shear Seal Valve1. Lubricate all the seals with petroleum jelly.

2. Lubricate all threads prior to assembly, including the collarcontact area.

3. Install the O-rings onto the check valve assembly.

4. Install the check valve into the valve body until it is snug. Do notovertighten this part .

Figure 7-12 Installing the Check Valve

5. Attach the spool rod to the spool seal carrier using the dowelpin.

Figure 7-13 Assembling the Spool Seal Carrier

6. Insert the spool carrier into the valve body until it is stopped bythe check valve.

Remember... Replacing only the shear seals or only the

shear seal plate will lead to premature wearand reduced service life.

The repair kit includes both the shear sealsand the shear seal plates.

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Figure 7-14 Installing the Spool Seal Carrier

7. Install the filter element onto the seal bushing .

Figure 7-15 Installing the Filter Element

8. Install O-ring onto the seal bushing.

9. Install the rod wiper seal into the seal bushing.

10. Install the spring into the seal bushing.

11. Install the seal bushing with spring into the valve body bythreading the rod spool through the seal bushing and spring.

Figure 7-16 Installing the Seal Bushing and Spring

12. Tighten to 40 ft-lbs (54 Nm) to ensure that the seal bushing isbottomed into the seal body.

13. The filter is designed to be retained once the seal bushing istightened. If the filter is not secure, verify that the seal bushingis properly tightened. If the filter is still loose, replace the filter.

14. Install two O-rings into the seal cage.

Notes

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Notes

15. Taking care not to damage the seals, install one shear seal , thespring , and the other shear seal into the center of the sealcage.

Figure 7-17 Seal Cage Assembly

16. Install this assembly into the spool seal carrier through theopening for the inlet seal plate.

17. Install O-ring into the valve body at the seal plate outlet.

18. Install the outlet seal plate and the orientation pin into thevalve body.

Figure 7-18 Outlet Seal Plate Installation

19. Install O-ring into the valve body at the seal plate inlet.

20. Install the inlet seal plate into the valve body.

Be Careful...When assembling the seal cage, DO NOT pushthe shear seals through the cage, as they willdamage the O-rings inside the cage.

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Figure 7-19 Inlet Seal Plate Installation

21. Install face seal O-ring into the outlet plate .

22. Install face seal O-ring into the inlet plate.

23. Reposition the valve body assembly and carefully align the inlet

plate and the outlet plate with the body.

24. Verify that the inlet plate and outlet plate port orientations arecorrect.

Figure 7-20 Inlet (Left) and Outlet (Right) Plates

25. Apply nickel-plated Never Seez thread lubricant to the four,1/4"-20UNC x 21/4" cap screws.

26. Install the four lock washers and four cap screws.

Figure 7-21 Installing the Cap Screws

Notes

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Notes 27. Using a 1/4" Allen wrench, install the four, 1/4"-20UNC x 21/4" capscrews.

28. Using a torque wrench and a 1/4" Allen wrench socket, torquethe cap screws to 40 in-lbs (5 Nm).

29. Thread the solenoid armature onto the rod spool.

Figure 7-22 Installing the Armature

30. Use the armature gauge tool and screw on the armature sothat the gauge is touching, with no play. Do not over tighten.

Figure 7-23 Armature Gauge Tool

31. Remove the gauge tool. There should be no movementbetween the armature and the valve when the gauge tool was

removed. If there was, or if not sure, re-gap the armature usingthe gauge tool.

32. Install cotter pin. If the cotter pin does not line up with the holein the valve stem, rotate the armature CLOCKWISE (toward thevalve) until the cotter pin can be inserted. This will take lessthan of one turn. If the armature is rotated more than turn,re-gap the armature using the gauge tool to ensure that theproper armature position is obtained.

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Figure 7-24 Installing the Cotter Pin

33. Center the cotter pin in the armature. It is only necessary tobend one ear of the cotter pin, bending both just makes it moredifficult to remove.

34. Verify that the cotter pin does not extend past the armature; if itdoes it will remove the coating from the solenoid bore andcause corrosion and valve sticking.

35. Install two O-rings onto each seal sub. Install the seal subs intotheir respective ports.

Figure 7-25 Installing the Seal Subs

36. Install O-ring onto the valve body.

37. Perform a quick check that the valve is assembled properly bypulling on the armature. Actuation force is typically less than 35lbs.

Did You Know...The subsea valve has two seal subs, the surfacevalve has one seal sub.

Notes

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Notes Installing the Shear Seal Valve

1. If the manifold and solenoids have been removed from thesolenoid housing, use an alignment tool provided by Hydril.Place one alignment tool at one end of the manifold andanother at the other end, and mount the manifold to thesolenoid housing. Proceed to Step 4.

2. If the manifold and solenoids are still mounted on the solenoidhousing, perform the following:

Remove the shear seal valves.

Ensure that the manifold is loose. If re-installing themanifold, only use 4 cap screws, and tighten hand tight(only 2 cap screws are needed for a small manifold). Each

manifold has 8 to 40 cap screws to mount the manifold tothe solenoid housing. If adjusting a manifold, loosen all ofthe cap crews, and remove the corner cap screws.

Using two alignment tools, place one alignment tool at oneend of the manifold and another at the other end, andtighten some cap screws.

3. If it is absolutely necessary to align the manifolds without analignment tool:

Remove the shear seal valves.

Ensure that the manifold is loose. If re-installing themanifold, only use 4 cap screws, and tighten hand tight

(only 2 cap screws are needed for a small manifold). Eachmanifold has 8 to 40 cap screws to mount the manifold tothe solenoid housing. If adjusting a manifold, loosen all ofthe cap crews, and remove the corner cap screws.

Visually line up the bolt holes in the manifold with thetapped holes in the solenoid housing. Perform thisalignment for all corner bolt holes as a minimum. For alarge manifold, also remove some of the cap screws fromthe center of the manifold to ensure proper alignment.

Check to See...For subsea control systems, ensure that themanifolds are centered on the solenoid housing

openings. If the manifolds are not correctlycentered, it may not be possible to install thearmature or the armature may not functionproperly. If the manifold has been removedfrom the solenoid housing, the armatures arenot moving freely, or if the armatures aresticking, use the following procedures to ensurethat the manifolds are centered. Manifoldalignment procedures do not apply to surfacecontrol pods.

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Once the manifold is aligned, tighten the cap screws toaround 100 in-lbs (11 Nm). Verify that alignment is stillcorrect and install the remaining cap screws. Torque all capscrews to 150 to 160 in-lbs (17 to 18 Nm), starting from thecenter of the manifold and moving out.

4. Coat the solenoid bore and the solenoid armature (which isattached to the shear seal valve) with LPS 3 Heavy Duty RustInhibitor or similar product.

5. Lubricate the cap screws with Moly-lube TS70 or equivalent.

6. Install the shear seal valve into the solenoid using the capscrews and lock washers . The armature should have a snug fit,but should slide freely and not bind.

Figure 7-26 Installing the Shear Seal Valve

7. If the armature does not fit correctly, inspect the parts andverify the manifold is correctly aligned. Correct any deficiencies.Note that the shear seal valve cap screws pass through themanifold and thread into the solenoid.

8. Tighten these cap screws evenly (to prevent binding) to 140 in-lbs (16 Nm).

Installing the Solenoid/Shear Seal Housing Cover1. Lift cover and set in place.

2. Brush the threads of the housing cover cap screws with nickel-plarted Never Seez.

3. Using the 5/16" Allen wrench, install the cap screws.



Notes

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NotesChapter 8

Solenoids

ScopeThe purpose of this procedure is to demonstrate the proper methodsused to remove, maintain, and install the solenoid.

Figure 8-1 Solenoid

Required Tools and Accessories (2) shackles

(2) lifting straps


3/8" drive ratchet

3/8" drive extension

5/16" Allen socket head



O-ring pick

Needle nose pliers

(2) medium flat-head screwdrivers

Syringe plunger

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CHAPTER8Solenoids

Notes Repair kit

Torque wrench

Ohmmeter

DC200 dielectric fluid

Paint pen Clean cloths

Petroleum jelly


WD-40 residual cleaner

Draining the Solenoid Housing1. Vent the solenoid housing.

2. Locate the needle valve on the bottom of the solenoid housing.

3. Place an appropriately-sized drain pan under the needle valve.

4. Remove the nut from the end of the needle valve, and open thevalve.

5. Once the dielectric fluid has fully drained from the solenoidhousing, close the needle valve.

Removing the Solenoid/Shear Seal Housing Cover1. Attach a shackle to each of the two lifting ears on the solenoid

housing cover.

2. Thread a lifting strap through each shackle and attach the endsof the straps to the hoist.

3. Using the 5/16" Allen wrench, remove all of the cap screws fromthe solenoid housing cover. Place the screws in a clean cup orcontainer.

4. Slowly raise the hoist, and lift the housing cover off the solenoidhousing.

5. Place the housing cover in a safe location.

Removing the Shear Seal Valve

1. Using the3

/16

" Allen wrench, remove the two cap screws thathold the shear seal valve to the solenoid housing.

2. Place the cap screws in a clean cup or container.

3. Pull the shear seal valve from the solenoid housing, and place iton a clean work table.

4. Using the paint pen, mark the shear seal valve with its podposition number (the number is stamped on the housing justabove each shear seal valve).

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CHAPTER8Solenoids



Removing the Solenoid1. Remove the solenoid maintenance covers located on the sides

of the housing.

2. Reach through the opening on one side and disconnect theelectrical leads attached to the solenoid.

3. Remove the two 1/4" cap screws that hold the solenoid to thehousing.

4. Carefully pull the solenoid from the inside of the solenoidhousing. If the solenoid is stuck, insert a broom handle throughthe shear seal opening and tap the solenoid loose.

Solenoid Maintenance1. Place the solenoid on a clean work table.

2. Remove the solenoid O-rings and discard them.

3. Measure the electrical resistance of the solenoid coil with theohmmeter.

4. If the measured resistance ranges from 129 to 139 ohm,proceed to Step 5. If the measured resistance does not rangefrom 129 to 139 ohms, return the solenoid to Hydril forrefurbishing.

5. Visually inspect the indicator piston to determine the solenoidfluid level. If 1/2" of the piston is not visible, the solenoid requiresfluid.

Figure 8-2 Fluid Level Indicator

6. Stand the solenoid up on a stable work bench or flat surfacewith the pressure balance cap facing up.

7. Using a flat head screwdriver, remove the two pan head screwsfrom the pressure balance cap.

8. Remove the pressure balance cap from the pressure balanceholder.

9. Remove the indicator piston and the compression spring fromthe pressure balance holder.

Notes

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CHAPTER8Solenoids

Notes 10. Locate the self-sealing screw on the side of the solenoid base.Remove the screw using a flat head screwdriver.

11. Lay the solenoid on its side with the fill port facing up.

12. Fill the syringe with DC-200 dielectric fluid.

13. Screw the syringe onto the solenoid oil fill port. Ensure theconnection is sealed to prevent the fluid from leaking as thesyringe is compressed.

14. Using your finger, press on the top of the diaphragm seal tocompress it .

Figure 8-3 Manually Compressing the Diaphragm

15. Pull gently on the syringe plunger to apply a vacuum to thesolenoid. As fluid is pulled from the solenoid, watch for ai

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