hose reel unit - amazon web services...1 introduction this manual is for the kos supplied hose reel...

This document is the property of Kongsberg Offshore a.s and is not to be reproduced or disclosedto any party without the written consent of Kongsberg Offshore a.s.

OPERATION AND MAINTENANCEMANUAL

Doc.No.: OMM-0011747

Hose Reel Unit, OMM

Yes No

Discipline: TECHNIC Configuration control: X

Access: KOS

Rev. Purpose Date Prep. Check. Appr. Changeorder No.

02 AS BUILT 111298 ID MHA OBO ECN-0010107

0 ISSUED FOR REVIEW 120398 ID MHA OBO

Summary:

Hose Reel Unit

Kongsberg Offshore asÅsgard OMM-0011747

DOC12078.001, Rev. 2

CONTENTS

1 Introduction ........................................................................................................... 1

1.1 Purpose of Equipment ........................................................................................... 1

1.2 Location of Equipment .......................................................................................... 1

1.3 Related KOS Documents....................................................................................... 1

1.4 Abbreviations ........................................................................................................ 1

2 Technical Data....................................................................................................... 3

3 Technical Description............................................................................................ 4

3.1 Physical Description.............................................................................................. 6

3.2 Functional Description .......................................................................................... 7

3.2.1 Assembly of HPU/HRU ........................................................................................ 7

3.2.2 Disassembly of HPU/HRU.................................................................................... 8

4 Handling and Transportation................................................................................. 8

4.1 Lifting Instructions ................................................................................................ 8

4.1.1 Lifting Data ........................................................................................................... 9

4.2 Transportation Instructions.................................................................................... 11

5 Preservation ........................................................................................................... 11

5.1 Standard................................................................................................................. 11

5.2 Equipment Specific ............................................................................................... 11

6 Storage................................................................................................................... 11

7 Maintenance .......................................................................................................... 12

7.1 Preventive Maintenance for Equipment in Storage............................................... 12

7.2 Preventive Maintenance for Equipment in Use..................................................... 12

7.3 Repair .................................................................................................................... 13

7.3.1 Repair of paint work.............................................................................................. 13

7.3.2 Repair of components............................................................................................ 13

FIGURES

1 Intervention Control System Overview................................................................. 2

2 Hose Reel Unit, General Arrangement.................................................................. 5

3 Lifting Arrangement.............................................................................................. 10

Hose Reel Unit OMM-0011747

DOC12078.001, Rev. 2

1 Introduction

This manual is for the KOS supplied Hose Reel Unit (HRU).

1.1 Purpose of Equipment

The purpose of a Hose Reel Unit is to accumulate and store the hose used under FCMRT operations.

1.2 Location of Equipment

The equipment is located on deck of the rig or vessel, as shown in Figure Intervention Control SystemOverview.

1.3 Related KOS Documents

Reference has been made to the following documents:

• OMM-0011748 Hose Reel Unit, Operations

• OMM-0011749 HPU, Deck Unit, Operation and Maintenance Manual

Reference has been made to the following drawings:

• 211772 - Hose Reel Unit, GA

• 213453 - Hydraulic schematic, Hose Reel Unit

• 213454 - Multi Sheave Block, GA

Any other drawings related to the equipment may be found in the Intervention System Drawing File.

1.4 Abbreviations

The abbreviations used are listed in KOS Abbreviation List.


DOC12078.001, Rev. 2 Page 1 of 13

Fig. 1 Intervention Control System Overview

Hose Reel UnitOMM-0011747

Page 2 of 13 DOC12078.001, Rev. 2

2 Technical Data

KOS Part Number(s):

Hose Reel Unit: 7300150

Umbilical Clamps: 7303692 (Not KOS scope of supply)

Multi Sheave Block: 7303514

Hose Connection Adapter Assy: 7603655

Dimensions and Weights:

Frame Unit

Length: 2,040 mm (80.3")

Width: 1,460 mm (55.1")

Height w/Reel Unit: 2,160 mm (85")

Reel Unit

Diameter: 1,850 mm (72.8")

Total Weight:

Total weight (Frame and Reel): 3,650 kg (8,050 lbs)

Mechanical Data:

Maximum normal pull:

1500 kg on first layer

405 kg on top layer with 550m umbilical

Drum Capacity: 6 x 3/8" x 550 m cable (5 lengths of á 100 m)

Motor: 1600 ccm (2 off)

Normal Speed: Max. 20 m/min. (first layer)

Connections to HPU:

1/2" ISO.B female Quick Connector (Pressure 'P') - 1 off, 4 m

3/4" ISO.B female Quick Connector (Return 'T') - 1 off, 4 m

3/8" ISO.B female Quick Connector (Drain 'D') - 1 off, 4 m


DOC12078.001, Rev. 2 Page 3 of 13

3/8" ISO.B male Quick Connector (6 off)

Hydraulic Data:

Work pressure: 207 Bar

Hydraulic Oil: Castrol Transaqua HT

Cleanliness: NAS class 6 (worst operating class 8)

Flow: 48 l./min.

Environmental Data:

Design Life: 25 years

Water ingress protection: IP15

Ambient Temperature Ranges

Storage: -30° to +55°C

Transportation: -20° to +40°C

Air temperature offshore: -18° to +40°C

Sea temperature: 2° to +30°C

3 Technical Description

Electronic copies of engineering drawings referenced in the following description may be retrieved fromthe Intervention System Drawing File. The location of documents listed below can be found by referenceto the Documentation User Guide.


Page 4 of 13 DOC12078.001, Rev. 2

Fig. 2 Hose Reel Unit, General Arrangement


DOC12078.001, Rev. 2 Page 5 of 13

3.1 Physical Description

The Hose Reel Unit comprises the following subassemblies:

• Frame

• Reel

• Motor (2 off)

• Umbilical Clamps

• Multi Sheave Block

• Hose Connection Adapter Assy

The Hose Reel Unit, as shown in Figure Hose Reel Unit, General Arrangement, is mounted on a steelprotection Frame consisting of SQR 80x80 profiles. The Hose Reel Unit can be lifted by crane or forklift truck.

For ease of handling, the Hydraulic Power Unit (HPU) for the HRU is mounted on a separate skid (referto OMM-0011749 HPU, Deck Unit, Operation and Maintenance Manual)) and is connected by flexiblehoses for the hydraulic system and cables for the control signals.

The Hose Reel Unit is equipped with a Hose Connection Adapter Assy which contains:

• 1/2" ISO.B female Quick Connectors (Pressure 'P'), 4m (1 off)

• 3/4" ISO.B female Quick Connector (Return 'T'), 4m (1 off)

• 3/8" ISO.B female Quick Connector (Drain 'D'), 4m (1 off)

• 3/8" ISO.B male Quick Connector, 4m (6 off)

The Hose Reel Unit is equipped with two motors attached to the centre of the Reel which also functionas support and bearings. The Unit is supplied with a Multi Sheave Block of the correct size for the liftwire/umbilical.

The Hose Reel Unit is designed for operation in Zone 2, Gas Group IIB areas.


Page 6 of 13 DOC12078.001, Rev. 2

3.2 Functional Description

The Unit is run by hydraulic cam ring motors (2 off), mounted in the centre of the drum. A multidiscbrake is assembled on each of the two motors. The rotation of the motor housing is achieved by feedingpressurized oil through the motor inlet port to the oil distributor. The distributor directs the oil flow tothe pistons, which are on a power stroke, driving the pistons and cam rollers outwards against the curveof the cam rings. This causes rotation of the cam ring housing assembly. When the pistons reach the endof their stroke, the distributor closes the inlet port and opens the outlet port. The next cam lobe pushesthe piston back into the center of the cylinder block in preparation of the next outward power stroke.Reverse rotation is achieved by changing the direction of oil flow.

The reel is operated from a directional valve which is physically secured by a manual safety lock. Flowregulated through the directional valve runs to the motors through a dual load holding valve with ashuttle valve for brake release. It is also equipped with a mechanical lock/pin for transportation.

Connection is made to the HPU through Quick Connectors, type ISO.B (3 off - marked 'P', 'T' and 'D').

Connections to the Umbilical is made through Quick Connectors, type ISO.B (6 off), which are locatedon the Reel.

3.2.1 Assembly of HPU/HRU

1. Assemble the hoses 'P', 'T' and 'D' (4 meter bundle) from the HPU to the Quick Connectors on theDirectional Valve on the HRU.

2. Shut down the Flow Valve on the HPU control panel.

3. Verify that the HPU is connected to the correct voltage and check the level of fluid in the tank, refill iflow.

4. Remove the mechanical transportation pin.

5. Start the HPU by pushing the 'Green Push Button' on the Electrical Motor Starter.

6. Wheel out the needed Umbilical length using the Directional Valve and stop the Reel in a positionwith access to the Quick Connectors (6 off) on the Reel.

7. Lock the Handle on the Directional Valve with the Safety Lock Pin.

8. Assemble the six Umbilical Line (4 meter bundle) to the HRU Quick Connectors.

The Equipment is now ready for operation of subsea Tool with the Flow- and Directional Valves on theHPU control panel.


DOC12078.001, Rev. 2 Page 7 of 13

3.2.2 Disassembly of HPU/HRU

1. Close the Flow Valve on the control panel.

2. Disconnect the six Line Umbilical (4 meter bundle) from the HRU Quick Connectors.

3. Wheel in the Umbilical using the Directional Valve. Guide the Umbilical and spool it on the Reel inaccurate and compact layers.

4. Park the Reel in a position so that the Lock Pin for transportation can be positioned.

5. Stop the HPU by pushing the 'Red Push Button' on the Electrical Motor Starter.

6. Secure the Handle on the Directional Valve with the Safety Lock and place the pin to secure the reelduring operation.

7. Disconnect the hoses 'P', 'T' and 'D' (4 meter bundle) from the Quick Connectors on the HRU controlpanel.

4 Handling and Transportation

WARNING!

ALWAYS ENSURE THAT ALL LIFTING EQUIPMENT IS CERTIFIED AND HAS A SWL INEXCESS OF THE EQUIPMENT WEIGHT.

CAUTION:

Avoid all kind of shocks. Keep the equipment in an upright position during transport and handling.Use only certified lifting gear and certified personnel to operate lifting equipment.

4.1 Lifting Instructions

1) Securely attach the 4-legged lifting slings (KOS P/N: 7603625) with shackles to the lifting eyepads on top of the Lifting Frame.

NOTE: The mechanical lock/pin must be entered before transport.

The Lifting Frame can also be handled by a forklift. Standard pockets are made in the foundation base.


Page 8 of 13 DOC12078.001, Rev. 2

4.1.1 Lifting Data

Name: Hose Reel Unit:

Weight without Umbilical: 3,650 kg

Length: 2,040 mm

Width: 1,460 mm

Height: 2,160 mm


DOC12078.001, Rev. 2 Page 9 of 13

Fig. 3 Lifting Arrangement


Page 10 of 13 DOC12078.001, Rev. 2

4.2 Transportation Instructions

CAUTION:

Always ensure that the equipment is secured to its transportation equipment. Prevent movement bywooden blocks, bracing and straps. Never stack the equipment.

5 Preservation

5.1 Standard

The purpose of preservation and protection is to guard the equipment against all external actionsnormally encountered during shipment, handling, transportation and storage.

• Carry out a thorough, visual inspection of all pipes and connections. Check for loose or damagedcomponents and report any defects found.

• If necessary, hose down the equipment with fresh water to remove all traces of salt. Removeexcess water using compressed air.

• Protect external surfaces with plastic mesh, electrical tape or other protection to prevent damage.

• Non-metallic materials and corrosion resistant materials such as Xylan, Inconel, Stainless Steel,Al-Bronze, etc. are not to be coated with any preservatives unless specifically instructed.

• Repair any damage to the painted surfaces in accordance with KOS Specification KOS-MDS-0037and NORSOK STD-U-CR-008, "Subsea Colour and Marking".

• Do not remove preservatives until just prior to use.

5.2 Equipment Specific

The specific Preservation and Protection procedure is as follows:

1) Flush the system at start-up, after repair etc.

2) Remove excess water using compressed air.

3) Quick Connectors must be clean and without damage.

4) Some oil in lubrication point for the Valve Handle, when needed.

5) Repair, as necessary.

Make a written report on abnormal observation, and correct all divergences from normal.

6 Storage

Storage area : In an area not exposed to rain, snow, sea-spray or excessive dust.


DOC12078.001, Rev. 2 Page 11 of 13

Jumpers can be stored outdoor or indoor as long as they are protected from damage.

All units to be stored in a warehouse for long-term storage.

Storage temperature : 5°C to 20°C.

Maximum air humidity : 95%

The following general instructions applies for storage:

• Ensure that the recommended preservatives are in good condition. Re-apply as necessary, andwipe off excess preservative.

• For future reference and correction, make a written report on any abnormal observations made.

7 Maintenance

7.1 Preventive Maintenance for Equipment in Storage

At six months intervals, visually inspect the equipment for:

• Loose or damaged components.

• Damage to paint work.

• Cleanliness and moisture.

• Corrosion, etc.

Once a year, the following is to be carried through:

• The Lifting Gear and Baskets shall be re-certified.

Make a written report on abnormal observations, and correct all divergencies from normal.

7.2 Preventive Maintenance for Equipment in Use

• Maintenance of the hydraulic components is very important in order to avoid any stops.

• Routine checks must be made based on running time or in intervals.

• The daily control should be done by the operator.

• Prior to start check the test movement, in both directions, of the directional Valve Handle. It shallbe easily moved to full stroke and automatically return to neutral position when released.

• When doing the control/repair, it is important to have the flow diagram available.

• Always remember to keep the system clean.


Page 12 of 13 DOC12078.001, Rev. 2

• It can often be an advantage to keep a log of what was wrong, and which precaution were taken.

7.3 Repair

Repair, which is described in subsequent paragraphs, is limited to:

• Repair of paint work.

• Repair of components.

7.3.1 Repair of paint work

Repair any damage to painted surfaces in accordance with KOS Specification KOS-MDS-0037 andNORSOK STD-U-CR-008, "Subsea Colour and Marking".

7.3.2 Repair of components

Repair components by replacing them with new or reconditioned components. Replacement isstraightforward, so no procedures are necessary in addition to the general engineering rules in currentuse.


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