Comissionamento do Sistema de Pull in.PDF

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:

Commissioning Procedure Riser Pull In System

Rev. No.

A

Rev. Date

11.02.2011

Table of Contents:

1

General .............................................................................................................. 3 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Purpose of this document ................................................................................. 3 Changes to previous revisions .......................................................................... 3 Abbreviations & Document Conventions........................................................... 4 Relevant Documents......................................................................................... 5 Attached Documents......................................................................................... 6 Control of Installation prior to Commissioning Reporting .................................. 6 Commissioning principles ................................................................................. 6 Scope of supply................................................................................................. 6 HSE (health safety environment) ...................................................................... 7

2

System Description .......................................................................................... 7

3

Pre Commission Tasks .................................................................................... 8 3.1 3.2 3.2.1 3.2.2

4

Installation Control, before function testing .................................................. 9 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10 4.7.11 4.7.12 4.7.13 4.7.14 4.7.15 4.8

5

Manual Operation of moveable parts .............................................................. 24 Linear Winch (KTC-400) ................................................................................. 25 (SU) Wire Storage Unit & (1200HWP) Auxiliary Winch................................... 25 Air Winches ..................................................................................................... 26

System Test .................................................................................................... 27 6.1 6.2

7

Review of Installation Checklists....................................................................... 9 Transport Protection & Strapping...................................................................... 9 Preservation ...................................................................................................... 9 Check List for Hydraulic Power Unit HPUs. .................................................... 10 Check list for Linear Winch (KTC - 400).......................................................... 11 Check list Air Winches .................................................................................... 12 Check list Sheaves.......................................................................................... 13 Imenco Commissioning and Start Up Procedure 37219 01 MA 041............... 13 Type 1 sheaves............................................................................................... 13 Type 2 sheaves............................................................................................... 14 Type 3 sheaves............................................................................................... 15 Type 4 sheaves............................................................................................... 15 Type 5 sheaves (with load cell)....................................................................... 16 Type 6 sheaves............................................................................................... 16 Type 7 sheaves............................................................................................... 17 Type 8 sheaves............................................................................................... 18 Type 9 sheaves............................................................................................... 19 Type 10 sheaves............................................................................................. 19 Type 11 sheaves............................................................................................. 20 Type 12 sheaves............................................................................................. 20 Type 19 sheaves............................................................................................. 21 Special sheaves 1580 & 1080 Ø..................................................................... 21 Check list Control Cabin.................................................................................. 22

Function checks ............................................................................................. 24 5.1 5.2 5.3 5.4

6

Load Cell fitting and Set-up............................................................................... 8 Venting (clearing trapped air from the Hydraulic System)................................. 8 Parking disc brakes (SU & HWP 1200s)........................................................... 8 Main cylinders (Linear Winch)........................................................................... 8

Scope of Test .................................................................................................. 27 Comments....................................................................................................... 27

Preservation after Commissioning ............................................................... 27

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Document Name:


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Rev. Date

11.02.2011

8

Attachment 1................................................................................................... 28

9

Attachment 2................................................................................................... 52

1 General 1.1 Purpose of this document The commissioning of the Riser Pull-in system supplied by Aker Pusnes AS falls in to three well defined areas, separated in time and function: 1. HPU commissioning, the filling and testing of basic functions have to be completed to allow other work to progress. 2. Mooring System commissioning, manual running and simple mechanical functions are carried out such as making sure trapped air is expelled and that there has been no damage to the equipment during transportation and installation. 3. Control System commissioning, this final phase of commissioning fully checks the interaction between the various sub-units and verifies sensors, set-points and alarms. This document specifies the guidelines for the commissioning of the Riser Pull-in system and covers those parts of step 2 that were not done during installation procedure and all of phase 3. To maintain the precision needed for a satisfactory commissioning and future trouble free operation all the reference documents and drawings should be studied closely before starting this work. To secure traceability and correct positioning of tagged equipment, all supporting documentation must be made available to the commissioning personnel as and when required. Commissioning activities can take place onshore as well as offshore. This procedure is general and can be used where ever is most appropriate. 1.2 Changes to previous revisions Rev. Change ID Description of change 00 NA First issue of document to client

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1.3 CC CCR CP FAT GA HPU HSE

Document Id.:

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Document Name:


Rev. No.

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Rev. Date

11.02.2011

Abbreviations & Document Conventions Control Cabin Central Control Room Control Panel Factory Acceptance Test General Arrangement (drawing) Hydraulic Power Unit Health Safety Environment

LCC NA

Local Control Column Not applicable

PLC HWP

Programmable Logic Controller Hydraulic Wire Pull-in Winch

Note: General information or best practice Safety Note: Advice on an issue of safety Warning: Advice as to a potential error or hazardous situation Safety Warning: A clear statement that the procedure contains a potentially hazardous situation to either personnel or equipment (i.e. fail safes or interlocks are disabled)

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1.4

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Document Name:


Rev. No.

A

Rev. Date

11.02.2011

Relevant Documents

Client Document no.

Pusnes Document no.

Description:

I-MA-P55-009-KFR-066

4786-04-PUS-J-KA-1056

Lubrication Chart

I-DE-P55-009-KRF-004

002764.01600

I-DE-P55-009-KFR-066

654 H 0000 & 1000

I-DE-P55-009-KFR-002

114607.00000

I-DE-P55-009-KFR-074

654 H 2000

I-DE-P55-009-KFR-005

114606.00000

I-DE-P55-009-KFR-076

194149

I-DE-P55-009-KFR-006

328158.00000_0

GA Drawing, Service Winch 5T

I-DE-P55-009-KFR-007 I-DE-P55-009-KFR-010

328159.00000_0

GA Drawing, Service Winch 10T

114562.00000

General Arrangement - 4x200 HPU

I-DE-P55-009-KFR-075

Servi 1078020

Hydraulic System HPU 4x200

I-DE-P55-009-KFR-003

114615.00000

GA Drawing HPU 2x140

I-DE-P55-009-KFR-063

1099325, 1072028 & Servi dwg.1071427

I-DE-P55-009-KFR-008

114147, 193321

I-DE-P55-009-KFR-009

114148, 193322

I-LI-P55-009-KFR-032

4786-04-PUS-J-LA-1031

I-DE-P55-009-KFR-025

327484-327485 & 328177 Single Line Diagram

GA Drawing, Linear winch Hydraulic Diagram Linear Winch GA Drawing, Storage Unit Hydraulic System, Storage Unit GA Drawing, 1200 HWP Aux Winch Hydraulic System, 1200 HWP

Hydraulic System HPU 2x140 GA Drawing, Control Cabin - Linear Winch. GA Drawing, Control Cabin - 120 HWP Instrument Set Point List

I-DE-P55-009-KFR-027

328246 - 328256

External Connection Diagram

I-DE-P55-009-KFR-037

654 E 1100

Loop Diagram, Linear Winch

I-DE-P55-009-KFR-026 I-DE-P55-009-KFR-032

328368-328379 328667-328669 328340-328354 328644-328650

Electric Circuit Diagram, Linear Winch Electric Circuit Diagram, 1200HWP Technical & Functional Description Riser Pull-in

I-MD-P55-009-KFR-001

4786-04-PUS-J-SA-1002

I-MA-P55-009-KFR-024

4786-04-PUS-J-MB-1003 Operating Instruction, English

I-MA-P55-009-KFR-022 I-ET-P55-009-KFR-008 I-MA-P55-009-KFR-078

4786-04-PUS-J-MB-1002 Maintenance Instruction - English 4786-04-PUS-J-KA-1007 Surface Prep. & Protective Coating Commissioning Procedure – HPU 4786-04-PUS-J-KA-1070 2x140

I-MA-P55-009-KFR-077

4786-04-PUS-J-KA-1068

Commissioning Procedure – HPU 4x200

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1.5

Document Id.:

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Document Name:


Rev. No.

A

Rev. Date

11.02.2011

Attached Documents

Supplier Document no.

Pusnes Document no.

I-MA-P55-009-KFR-084

Description: Imenco Commissioning and Start Up Procedure

37219 01 MA 041

1.6

1015

4786-04-PUS-J-KA-1075

Commissioning Procedure – 1200HWP & SU

Control of Installation prior to Commissioning Reporting

Before commissioning can commence a quality control exercise is to be carried out confirming the correct installation practices have been used. The yards work will be inspected and signed off by both the Aker Pusnes commissioning engineer and customer representatives. Control sheets are provided in chapter 3.0 of this document. It is important that prior to pressurising the hydraulic system, all external piping has been flushed to the required cleanliness and that all the interface connections have been properly cleaned. If you are unable to immediately connect a pipe to the equipment ensure that they are capped. Aker Pusnes AS should have received completed copies of the Installation & Erection check lists provided in the installation documentation package prior to the commissioning engineers visit. If the checklists have not been completed or the work is unsatisfactory the customer/yard should note that they are liable for any costs incurred at our normal published rates. 1.7

Commissioning principles

This document deals with the work needed to bring the Riser Pull-in system into service and as such falls into 3 parts:  Installation Control  Tasks to be completed by the Commissioning Team  Commissioning adjustments and functional checks It is assumed that the onboard utility supplies are all available and the HPU commissioning has been completed. Preservation after Commissioning is to be carried out after all 3 stages are completed or if the commissioning has any extended interruption to the process. 1.8 Scope of supply In this contract for the P55 Riser Pull-in/out system, Aker Pusnes AS is only responsible for individual equipment items. It has produced and supplied these items to the appropriate regulations and standards listed in the specifications provided by Petrobras and Quip. Aker Pusnes AS is not responsible for the overall system design, specification, or the method of operation.

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1.9

Document Id.:

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Document Name:


Rev. No.

A

Rev. Date

11.02.2011

HSE (health safety environment)

The primary concern when carrying out the operations described in this document, is to ensure that the work is carried out in such a way that the preparations, checks and tasks are done without injury or equipment damage. To help achieve this, everyone participating is strongly urged to have at all times his or her minds focused on their own and colleagues’ personal safety. During these processes some situations are naturally hazardous, because of:  High Pressures hydraulics and high torque mechanics  Operating cranes with hanging cargo  Clamping hazards around many parts, such as: straps, chains, hydraulic cylinders and clutches  Rotating shafts, wheels, gears and moving chain  High voltage and electric current on some equipment Each participant must:  Wear protective footwear  Wear safety glasses  Wear a helmet The general rules are:  Stay clear (a safe distance) from hanging cargo, high pressure hoses and moving parts  High-pressure hydraulic systems (hoses, valves, fittings etc). Skin puncture hazard, resulting in possible loss of limbs, never use bare hands when checking for leaks. Aker Pusnes AS consider their employee who is responsible for the commissioning as having the highest authority during these operations and he or she is fully backed by the company to:  

Dismiss from the work area any participant breaking HSE rules without further notice! Stop the operation at any point he or she feels that good HSE practices are compromised.

2 System Description There are 3 main working winches in the riser pull in system, are all hydraulically driven and safe for use in zone 2 areas: The main lifting capability is provided by the linear winch and storage unit combination. Both parts are capable of handling 2 different wire sizes. The linear winch can pull the 88mm Ø wire at 350T & the 72mm Ø at 250T at a maximum speed of 4m per minute. The storage unit has been supplied preloaded with 1000 meters of each wire size. The equipment group contains a dedicated HPU and Control Cabin. The two self contained 120T auxiliary winches are fitted with a 1000metres of 54mm diameter wire and provide auxiliary lifting capability or provide the directional pull required during the installation of sub-sea risers into their location bays. The winches has its own HPU and a common Control Cabin. Seventy three sheave, both fixed and movable have been provided to guide the wires to where the work is required on the vessel. One sheave is fitted with load cell (BLS-01). Smaller (10t and 5T) air winches are provided pre-equipped with wire to aid equipment movement and wire handling;  5T Winch = Ø 5/8” x 350m wire rope  10T Winch = Ø 1” x 350m wire rope

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Document Name:


Rev. No.

A

Rev. Date

11.02.2011

3 Pre Commission Tasks 3.1 Load Cell fitting and Set-up The loadcells for the two auxiliary winches where dismounted for transportation and need to be correctly installed under Aker Pusnes supervision. This is to be done prior to the inspections 3.2 Venting (clearing trapped air from the Hydraulic System) Practically this can only be done after the HPU’s are switched on and the machines are run up prior to the initial test program 3.2.1

Parking disc brakes (SU & HWP 1200s)

It is important for correct operation that the air is bled from the parking disk brakes. These are a fail safe device type and rely on the application of hydraulic pressure to open. The brake line is the pipe at the top behind the motor pipes. This is to be done after the inspections, when the HPUs are running 3.2.2

Main cylinders (Linear Winch)

Before the initial movement of the machine’s parts, air should be bled at locations M1206 (2x4), see the Operating Instructions for details.

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Document Name:


Rev. No.

A

Rev. Date

11.02.2011

4 Installation Control, before function testing 4.1 Review of Installation Checklists Aker Pusnes AS should have received completed copies of the documents below prior to the commissioning engineers visit. If the checklists have not been done or the work is unsatisfactory the customer/yard should be aware they are liable for any costs incurred at our normal published rates. Instructions for Erection & Installation, Signed: Date: Riser Pull-in Packages: I-MA-P55-009-KFR-011 Aker I-MA-P55-009-KFR-069 Pusnes I-MA-P55-009-KFR-059 I-MA-P55-009-KFR-053 I-MA-P55-009-KFR-010 I-MA-P55-009-KFR-052 I-MA-P55-009-KFR-075 Client I-MA-P55-009-KFR-009 I-MA-P55-009-KFR-028 Inspected and accepted? The supporting documentation proving flushing and cleaning the hydraulic piping should also be available if the commissioning engineer requests. Provided

Aker Pusnes

Client

Sign: Date: 4.2 Transport Protection & Strapping With the exception of the hoses protecting the bearing joints the transport protection & strapping should be removed. To protect the equipment from contamination caused by normal dockyard activities such as welding, grinding and painting it is important to cover all equipment with tarpaulins, immediately after the installation process. Action:

Transport Strapping and coverings removed

Approval Aker Pusnes

Client

Sign: Date: 4.3 Preservation Damaged paint work and other surface finishes should be repaired as soon as possible after discovery. The Cortec VpCI CorrLube protection for unpainted surfaces should be renewed from time to time dependant on local conditions and exposure to weather. Action:

Preservation

Approval Aker Pusnes

Client

Sign: Date:

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4.4

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Rev. Date

11.02.2011

Check List for Hydraulic Power Unit HPUs.

A copy must be used for each unit and an electronic version has to be retained / sent to Aker Pusnes AS. Item 1 2 3

Action

OK

Verify all connections - are correct to hydraulic & piping diagrams Confirm that “I-MA-P55-009-KFR- 078 Commissioning Procedure – HPU 2x140” is completed and signed off by all parties (2 units) Confirm that “I-MA-P55-009-KFR- 077 Commissioning Procedure – HPU 4x200” is completed and signed off by all parties

PHOTOGRAPHS Any damages/defects/errors should be reported with supporting digital photographs. (include file names in the space provided)

Yard / Customer authorised person:

Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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4.5

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Rev. Date

11.02.2011

Check list for Linear Winch (KTC - 400)

A copy must be used for each unit and an electronic version has to be retained / sent to Aker Pusnes AS. Serial no: Winch No:

Tag No:

Item Action 1 All covers and transport strapping has been removed 2 The equipment has to be visually checked for damage. All findings to be assessed and recorded. All damage to the surface protection system must be repaired immediately Note: all damage should be photographed prior to repair. 3 Lubrication nipples should be inspected for transport damage 4 Check that proximity sensors have not come loose or moved during transport M 1509A (2) M1701A (2) M1703A (2) 5 Check grease is applied to the whole unit as specified in the first section of the lubrication requirements chapter (Maintenance manual) 6 Verify alignment with Storage Unit & 1st Sheave 7 Foundation bolts are fastened to the correct torque. 8 The hydraulic oil supply is connected correctly and pipe flushing paperwork is in order (yard flushing) 9 Check hydraulic motors/hoses/connections for leakage. 310bar 10minutes 10 Check that the Control system is connected correctly to the diagrams, also including an inspection of the equipment earthing cables/points. 11 If the equipment has been standing unused for some time, run through a maintenance lubrication cycle. 12 Equipment and wire cleanliness

PHOTOGRAPHS Any damages/defects/errors should be reported with supporting digital photographs. (include the file ref. in the space provided)


Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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4.6 Check list Air Winches FA5: I-MA-P55-009-KFR-011 and FA10: I-MA-P55-009-KFR-069 Ingersoll Rand guide Installation Checks Air Line Lubricator (Not part of Aker Pusnes scope of supply)  Lubricator should be located no more than 10 ft (3 m) from motor.  Shut off air supply before filling air line lubricator. The air line lubricator should be replenished before a work session and then daily during an ongoing session. Set to provide 6 to 9 drops per minute of ISO VG 32 (SAE 10W) oil. A fine mist will be exhausted from control valve when air line lubricator is functioning properly. Air Line Filter (Not part of Aker Pusnes scope of supply) It is recommended that an air line strainer/filter be installed before the lubricator to prevent dirt from entering the motor. The strainer/filter should provide 20 micron filtration and include a moisture trap. Clean the strainer/filter periodically to maintain its operating efficiency. Mufflers Ensure mufflers are installed in winch exhaust manifold and control valve exhaust port. A copy must be used for each unit and an electronic version must be retained and sent to Aker Pusnes AS. Winch No:

Tag No:

Item

Action

OK FA10

1 2 3 4 5 6 2

Is there an airline filter? (Yes / No) If so is it clean? (OK / NA) Is there an Air line lubricator fitted? (Yes / No) Air line lubricator within 3 m ISO VG 32 (SAE 10W) oil 6-9 drop per min (OK / NA) Ensure the muffler is fitted before trying to drive the winch Wire Condition (no signs of damage or corrosion) Equipment and wire cleanliness



Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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4.7 Check list Sheaves It is assumed that the shipyard by signing this inspection is confident that all sheaves are installed according to procedure and/or drawings and all bolts fastened to the required torque. All sheaves should be inspected for damage, lubrication and given a simple spin test:  The equipment should be visually checked for signs of damage. Any painting system defects shall be rectified as soon as possible  The sheave shall rotate freely and it is possible to rotate the sheave by hand  Where appropriate the inspection will include a test of the pivot 4.7.1

Imenco Commissioning and Start Up Procedure 37219 01 MA 041

One sheave of each type must be fully tested, using the largest size of wire the sheave is made to accommodate. (Note: because this commissioning process requires wire handling equipment, this by necessity will be one of the last acts of commission to be done) 4.7.2

Type 1 sheaves

Type No: Dwg. Item 1 2 3 4 5 6 7 8 9 10 11

1, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

Equipment cleanliness



Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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OK

4.7.3

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11.02.2011

Type 2 sheaves

Type No: Dwg. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

2, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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OK

4.7.4

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Rev. Date

11.02.2011

Type 3 sheaves

Type No: Dwg. Item 1 2 3 4 5 6

3, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

OK


PHOTOGRAPHS Any damages/defects/errors should be reported with supporting digital photographs. (include the file ref. in the space provided) 4.7.5

Type 4 sheaves

Type No: Dwg. Item 1

4, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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OK

4.7.6

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Type 5 sheaves (with load cell)


5, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

OK

Check load cell orientation & output signal (imenco 1-2130) Equipment cleanliness


Type 6 sheaves

Type No: Dwg. Item 1 2 3 4

6, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 16 of 65

OK

4.7.8

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Type 7 sheaves

Type No: Dwg. Item 1 2 3 4 5 6

7, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 17 of 65

OK

4.7.9

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Type 8 sheaves

Type No: Dwg. Item 1 2 3 4 5 6 7 8

8, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 18 of 65

OK

4.7.10

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Type 9 sheaves

Type No: Dwg. Item 1 2 3

9, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

OK



Type 10 sheaves

Type No: Dwg. Item 1 2 3 4 5 6 7 8

10, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 19 of 65

OK

4.7.12

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Type 11 sheaves


11, ø88mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

OK



4.7.13

Type 12 sheaves


12, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:




Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 20 of 65

OK

4.7.14

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Type 19 sheaves


19, ø54mm wire

Damage free

Lubrication

Function: Spin

Inspection Tag No:

OK



4.7.15

Special sheaves 1580 & 1080 Ø


ø1580mm & ø1080mm

Damage free

Lubrication

Function: Spin

Inspection Tag No:

1080 Equipment cleanliness



Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

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4.8 Check list Control Cabin The most appropriate time for these tests is after all the separate parts of the system are connected and the equipment is ready to be powered up. We therefore recommend that this is done just before the functions tests described in section 5. The PLC cabinet is designed for Zone 2. The purge controller will energize the PLC cabinet after 29 minutes of purging with an airflow >2.0 l/sec. After which, if pressure drops below 1 mbar an alarm is activated. The control system will stay energized. When the pressure rises above 1mbar again the alarm the relay is de-energized. The alarm in the PLC systems HMI display will stay active until acknowledged on the screen. Procedure to power up the system: Close the door properly if open, and make sure 220VAC power is available. 1) Check that purging air supply is at the correct pressure on the manometer. Approximately 2.7 Bar. 2) Check that status on the circuit breaker in the service hatch is ok. 3) Turn on power. 4) The purging procedure then begins, and the timer starts counting down the 29 minutes prior to powering-up the PLC cabinet. (If the positive pressure cannot be maintained the timer will reset)

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Linear Winch Control Cabin: Item 1 2 3 4

KA-

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Tag No: Action

OK

General condition Visual inspection of equipment. Foundation bolts, paint finish etc Screen Washers and Wiper Check the function of all washers and wipers Lighting Normal and emergency lighting to be checked Air-conditioning Set a reasonable temperature and check that the thermostat is functioning (switching the compressor on and off)

5

Purging Air supply

bar

6

Purging process (29min)

7

PLC Powers-up

8

PLC Remains ON After the initial purging the PLC power should remain ON when the cabinet door is opened and or the purging air supply is turned off Auxiliary Winch Control Cabin:

Item 1 2 3 4

Tag No: Action

OK

General condition Visual inspection of equipment. Foundation bolts, paint finish etc Screen Washers and Wiper Check the function of all washers and wipers Lighting Normal and emergency lighting to be checked Air-conditioning Set a reasonable temperature and check that the thermostat is functioning (switching the compressor on and off)

5

Purging Air supply

bar

6

Purging process (29min)

7

PLC Powers-up

8

PLC Remains ON After the initial purging the PLC power should remain ON when the cabinet door is opened and or the purging air supply is turned off


Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 23 of 65

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

5 Function checks If you are not the person who has carried out the earlier inspections, confirm that they have been done and are signed off. Do not progress with these tests unless the individual commissioning and inspections are complete. Pre-test Inspection:  Confirm that the winch zone has a test exclusion zone marked (permanent barrier or warning tape).  Inspect the area and winches are clear of loose items, packing and tools.  Confirm all locking bolts / transport fixings have been removed  If it has been some time since the earlier inspections, confirm there has been no damage or contamination to any of the equipment before progressing. The SU can only be operated manually from the valve block if the wire is free of the Linear Winch. Initially any movement of the drums on the winches or storage unit must be done very cautiously. Minimal energy should be put into the movement:   

Start the HPU with only one pump running. Operate each function in turn; Position an observer where each part’s movement can be watched.

It should be noted that the first few cycles of any function may not be smooth, and can be noisy as the air is forced from the hydraulic system. Repeat each function until it runs smoothly. 5.1 Manual Operation of moveable parts As explained in the earlier chapters; in some cases there will be preparation work and adjustments to be done prior the running a machine. Full function testing of the equipment cannot be done until the units are under the control of the PLC. Therefore the following sections only deal with the simplest aspects of the equipment.

Page 24 of 65

5.2

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

Linear Winch (KTC-400)

There is no guidance given in the manuals regarding operating the linear winch separate from the PLC. Before progressing to the Control System Commissioning activities on the Linear Winch are limited to inspection of the installation and the bleeding of air from locations M1206 (2x4). Commissioning document The Linear Winch commissioning procedure, Kley France document: 654 D 0019 is attached to the Control System commissioning procedure and will be done at that time. 5.3

(SU) Wire Storage Unit & (1200HWP) Auxiliary Winch

Important note with regard to the brake module: During the check and with no tension on the wire, blank off the hydraulic connection TA1 (3/8 BSP) on the valve unit, operate slowly in haul-in direction. The drum should not move, if there is any rotation the brake modules should be replaced. The engaging speed of brake must be checked to minimize wear. The timer in PLC is set so the brake is engaging after the rotation has stopped. The speed that the brake is applied is adjusted by the nozzle/check valve pos 207 in dwg 194149; Clockwise for slower engaging speed, Counter Clockwise for a quicker closure. Commissioning document The independent commissioning of both of the HWP winches and the Storage Unit are detailed with in the Aker Pusnes document which is issued as a separate document but for convenience is attached at the end: I-MA-P55-009-KFR-084 (4786-04-PUS- J-KA-1075) Commissioning Procedure 1200HWP & SU Some test may only be possible after the Control System Commissioning

Page 25 of 65

5.4

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

Air Winches

A copy must be used for each unit and an electronic version has to be retained / sent to Aker Pusnes AS. Detailed information on the initial test/checks can be found in the Maintenance and Product information documentation supplied with the: I-MA-P55-009-KFR-022 Maintenance InstructionEnglish. When running the winch’s motor for the first time, inject a small amount of light oil (ISO VG 32– SAE 10W) into the inlet connection. This is to provide the initial lubrication to the motor. Winch No: Item

Tag No: Activity

OK

1

Check motor oil level

2

Check disc brake fluid level

Activity

OK

Check reduction gear oil level

3

Operate the winch in both directions (no load) 1-2 minutes

4

Check brake operation

5

Test emergency stop valve

5

Check safety shut-off valve if fitted?

5

Check any other safety devises fitted; limiters / locking mechanisms

5

Check foundation fasteners at the end of the test period


Aker Pusnes AS

Signature:

Signature:

Position:

Date:

Comments:

Page 26 of 65

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

6 System Test 6.1

Scope of Test

Outside of the Aker Pusnes AS scope of work 6.2

Comments

It is recommended by Aker Pusnes AS that a test is devised that proves the functionally of the system as a whole and imitates the system in operational use, Aker Pusnes AS wish to make the following points with regard to any such test: The tests should be done with a minimal load Each machine operator should have practiced and simulated the tasks required a number of times Possible problems should be planned for and contingency / emergency drills practiced Warning and Failure signals agreed Emergency – Stop signals and actions documented and trained for Aker Pusnes AS service personnel are available to review / assist / attend at any phase of such a test programme should the customer wish. Contact:

Aker Pusnes Lifecycle services Postboks 732, Stoa 4808 Arendal Norway Phone: +47 37 08 73 00 Fax: +47 37 08 73 20 South America Office Phone:+55 2 2773 9019 Mobile +55 22 92835650 Email: [email protected]

7 Preservation after Commissioning At the end of the commissioning process (all 3 phases) all equipment should be cleaned and protected as instructed in the individual Instructions for Preservation Packing & Storage documents. If normal dockyard activities such as grinding, welding, spraying etc are still in progress then suitable heavy tarpaulins must be used to completely cover and protect the equipment from any contamination.

Page 27 of 65

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

8 Attachment 1 37219 01 MA 041 Imenco Commissioning and Start Up Procedure

Page 28 of 65

Department

:

Bergen

Signature legend Originator Checker Approver

: : :

Vidar Eriksen Are Folkestad Reidar Heggholmen

Copy No.: Distributed to:

Senior Engineer Senior Engineer Project Manager Distribution date:

Classification:

Restricted

0

Issued For Impementation Revisions

Client:

Aker Pusnes AS

24.08.10 VER AFO RHE Date

Orig.

Chk.

Appr.

Client Logo:

Client Appr.

Project Title:

Roncador Field Development – Petrobras 55 (P55) Document Title:

Commissioning and Start Up Procedure Project:

Document Number.:

37219 01 MA 041 Project No.

Sub. No.

Seq. No.

0

23

Rev.

Total Pages

Page 29 of 65

TABLE OF CONTENTS 1.

INTRODUCTION ............................................................................................................................ 3 1.1. 1.2. 1.3. 1.4. 1.5.

2.

PREAMBLE ................................................................................................................................... 5 2.1. 2.2. 2.3.

3.

PROJECT DESCRIPTION ................................................................................................................................... 5 COMMISSIONING AND START UP PHILOSOPHY ................................................................................................... 6 PROCEDURE TASKS ........................................................................................................................................ 6

COMMISSIONING.......................................................................................................................... 7 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. 3.10. 3.11. 3.12. 3.13. 3.14. 3.15. 3.16.

4.

SCOPE ........................................................................................................................................................... 3 OBJECTIVES ................................................................................................................................................... 3 RESPONSIBILITIES........................................................................................................................................... 3 DEFINITIONS ................................................................................................................................................... 3 REFERENCES ................................................................................................................................................. 3

TYPE 1: FIXED HORIZONTAL SHEAVE. 350TE. 88MM WIRE ROPE ......................................................... 7 TYPE 2A: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE ....................................................... 8 TYPE 2A BLS 37: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE ............................................ 9 TYPE 2B: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE ..................................................... 10 TYPE 2C: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE ..................................................... 11 TYPE 3: SWIVEL FIXED SHEAVE. 350TE. 88MM WIRE ROPE.................................................................... 12 TYPE 4: FIXED VERICAL DOUBLE SHEAVE. 350TE. 88MM WIRE ROPE .......................................................... 13 TYPE 5: VERICAL FIXED SHEAVE. 350TE. 88MM WIRE ROPE ....................................................................... 14 TYPE 6: TRIANGLE BLOCK. 350TE. 88MM WIRE ROPE ................................................................................ 15 TYPE 7: VERTICAL FIXED SHEAVE. 120TE. 54MM WIRE ROPE ..................................................................... 16 TYPE 8: SWIVEL BLOCK. 120TE. 54MM WIRE ROPE.................................................................................... 17 TYPE 9: SWIVEL FIXED SHEAVE. 120TE. 54MM WIRE ROPE ........................................................................ 18 TYPE 10: SWIVEL TRAVELLING BLOCK. 120TE. 54MM WIRE ROPE ............................................................... 19 TYPE 11: SWIVEL TRAVELLING SHEAVE. 350TE. 88MM WIRE ROPE ............................................................. 20 TYPE 12: SWIVEL TRAVELLING SHEAVE. 120TE. 54MM WIRE ROPE ............................................................. 21 TYPE BLS-19: SLIDING SHEAVE HOUSE. 120TE. 54MM WIRE ROPE ............................................................. 22

WHITNESSING PROCEDURE .................................................................................................... 23 4.1.

PROCEDURE TASKS ...................................................................................................................................... 23

Page 30 of 65

1. 1.1.

INTRODUCTION

SCOPE This document contain a procedure for how to perform Commissioning and Start Up for sheave blocks produced by Remsod (R), Poland on behalf of Imenco AS (IM), Bergen and under the purchase order no. 155351-2 between Akers Pusnes AS (AP), Arendal and Imenco.

1.2.

OBJECTIVES This document shall provide information to participating parties in order to make plans for Commissioning and start up of the equipment of the Pull-in/Pull out Package for Petrobras Project Rondacor Field Development – P55.

1.3.

RESPONSIBILITIES It is the (originator) who is responsible for the preparation of this document. It is the (checker) who is responsible for the checking of this document. It is the (approver) who is responsible for the implementation and revising of this document.

1.4.

DEFINITIONS Definitions used in this document are CSUP AP IM

1.5. Ref. # 1

Commissioning and Start Up Procedure Aker Pusnes Imenco

REFERENCES Document No. 1-2136

2

1-2135

3

1-2292

4

1-2196

5

1-2199

REVISION

Document Title GA FIXED HORIZONTAL SHEAVE TYPE 1, BLS 03-07 / BLS 09-14 350Te FOR 88MM WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 2A - BLS 36, 38-47 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 2A - BLS 37 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 2B - BLS 18,22 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE

Page 31 of 65

6

1-2134

7

1-2133

8

1-2132

9

1-2183

10

1-2130

11

1-2129

12

1-2128

13

1-2127

14

1-2126

15

1-2125

16

1-2122

TYPE 2C - BLS 21, 23-25 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 3 - BLS 15, BLS 16, BLS 29,30,32,33 350Te FOR 88mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 4 - BLS 02, BLS 08 350Te FOR 88mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 5 - BLS 01 350Te FOR 88mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 6 - BLS 53 A-D 120Te FOR 88mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 7 - BLS 17 / BLS 20 / BLS 26 / BLS 28 / BLS 48 / BLS 49 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 8 - BLS 52 A-A1/ B-B1 / C-C1 / DD1 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 9 - BLS 27 / BLS 31 / BLS 50 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 10 - BLS 51 / A/A1 B/B1 C/C1 D/D1 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 11 - BLS 34 A / B / C 350Te FOR 88mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE 12 - BLS 35 A / B / C 120Te FOR 54mm WIRE ROPE GA FIXED HORIZONTAL SHEAVE TYPE BLS 19 120Te FOR 54mm WIRE ROPE

Page 32 of 65

2. 2.1.

PREAMBLE

PROJECT DESCRIPTION The Semi-Sub. Production Unit P55 at the Roncador Field outside Brazil shall have a permanent Riser Pull-In system. The pull-in system consists of winches, guides and deflection sheaves to guide the wire from the winches to dedicated directions in order to support the pull-in of the risers into dedicated landing porches. The project covered by this Purchase order has produced loose sheaves, sheave blocks and fairleads with the following characteristics.

1.

11 ea. Fixed Horizontal Sheave Type 1, 350Te for 88mm wire rope. Tag no. BLS-03; 04; 05; 06; 07; 09; 10; 11; 12; 13 ;14.

2.

11 ea. Fixed Horizontal Sheave Type 2a, 120Te for 54mm wire rope. Tag no. BLS-36; 38; 39; 40; 41; 42; 43; 44; 45; 46; 47.

3.

1 ea. Fixed Horizontal Sheave Type 2a, 120Te for 54mm wire rope. Tag no. BLS-37.

4.

2 ea. Fixed Horizontal Sheave Type 2b, 120Te for 54mm wire rope. Tag no. BLS-18; 22.

5.

4 ea. Fixed Horizontal Sheave Type 2c, 120Te for 54mm wire rope. Tag no. BLS-21; 23; 24; 25.

6. 7.

6 ea. Swivel Fixed Sheave Type 3, 350Te for 88mm wire rope. Tag no. BLS-15; 16; 29; 30; 32; 33. 1 ea. Fixed Vertical Double Sheave Type 4, 350Te for 88mm wire rope. Tag no. BLS-02; 08.

8.

1 ea. Vertical Fixed Sheave Type 5, 350Te for 88mm wire rope. Tag no. BLS-01.

9.

4 ea. Triangle Block Type 6, 350Te for 88mm wire rope. Tag no. BLS-53A; 53B; 53C; 53D.

10.

6 ea. Vertical Fixed Sheave Type 7, 120Te for 54mm wire rope. Tag no. BLS-17; 20; 26; 28; 48; 49.

11.

8 ea. Swivel Block Type 8, 120Te for 54mm wire rope. Tag no. BLS-52A; 52A1; 52B, 52B1, 52C; 52C1; 52D; 52D1.

12.

3 ea. Swivel Fixed Sheave Type 9, 120Te for 54mm wire rope. Tag no. BLS-27; 31; 50.

13.

8 ea. Swivel Travelling Block Type 10, 120Te for 54mm wire rope. Tag no. BLS-51A; 51A1, 51B; 51B1; 51C; 51C1; 51D; 51D1.

14.

3 ea. Swivel Travelling Sheave Type 11, 350Te for 88mm wire rope. Tag no. BLS-34A; 34B, 34C.

15.

3 ea. Swivel Travelling Sheave Type 12, 120Te for 54mm wire rope. Tag no. BLS-35A; 35B, 35C.

16.

1 ea. Sliding Sheave House Type BLS-19, 120Te for 54mm wire rope. Tag no. BLS-19.

Page 33 of 65

2.2.

COMMISSIONING AND START UP PHILOSOPHY This instruction for commissioning and start up shall be performed to ensure that the items listed operated as specified.

2.3.

PROCEDURE TASKS Yard has full responsibility for Commissioning and start up of sheave blocks according to this procedure.

Page 34 of 65

3.

COMMISSIONING

This chapter describes a plan how commission and start up shall be performed for all types of sheave blocks and how personnel involved shall carry it out. Plan includes checklists listing each type of sheave blocks, and what shall be checked, and how many times each operation shall be tested, and what shall be noticed. 3.1.TYPE 1: FIXED HORIZONTAL SHEAVE. 350TE. 88MM WIRE ROPE Type 1 has Tag. No BLS-03; 04; 05; 06; 07; 09; 10; 11; 12; 13 ;14, and drawing no. 1-2136. CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G.A. drawing 1-2136. Before threading the wire, there is a need for removal of selected sidewall tray and tray post depending on wrapping angle, ref. dwg 1-2136. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 35 of 65

3.2.

TYPE 2A: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE Type 2A has Tag. No BLS-36; 38; 39; 40; 41;42; 43; 44; 45; 46; 47,and drawing no. 1-2135.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G.A. drawing 1-2135. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 36 of 65

3.3.

TYPE 2A BLS 37: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE Type 2A BLS-37 has Tag. No BLS-37, and drawing no. 1-2292.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2292. Before threading the wire, there is a need for removal of selected sidewall tray and tray post depending on wrapping angle, ref. dwg 1-2292. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 37 of 65

3.4.

TYPE 2B: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE Type 2B has Tag. No BLS-18 / 22 and drawing no. 1-2196.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G.A. drawing 1-2196. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 38 of 65

3.5.

TYPE 2C: FIXED HORIZONTAL SHEAVE. 120TE. 54MM WIRE ROPE Type 2C has Tag. No BLS-21; 23; 24; 25, and drawing no. 1-2199.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G.A. drawing 1-2199. Before threading the wire, there is a need for removal of selected sidewall tray and tray post depending on wrapping angle, ref. dwg 1-2199. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 39 of 65

3.6.

TYPE 3: SWIVEL FIXED SHEAVE. 350TE. 88MM WIRE ROPE Type 3 has Tag. No BLS-15; 16; 29; 30; 32; 33, and drawing no. 1-2134.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2134. Check sideways movement. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 40 of 65

3.7.

TYPE 4: FIXED VERICAL DOUBLE SHEAVE. 350TE. 88MM WIRE ROPE Type 4 has Tag. No BLS-02; 08, and drawing no. 1-2133.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheaves, both externally, edges and grooves. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2133. Before threading the wire, there is a need for removal of threaded rod item 6 on G.A. drawing 1-2133. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 41 of 65

3.8.

TYPE 5: VERICAL FIXED SHEAVE. 350TE. 88MM WIRE ROPE Type 5 has Tag. No BLS-01 and drawing no. 1- 2132.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2132. No visual damage on load cell. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 42 of 65

3.9.

TYPE 6: TRIANGLE BLOCK. 350TE. 88MM WIRE ROPE Type 6 has Tag. No BLS-53A; 53B; 53C; 53D and drawing no. 1-2183.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2183. Before threading the wire, there is a need for removal of wire locking device item 9 on G.A. drawing 12183. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 43 of 65

3.10.

TYPE 7: VERTICAL FIXED SHEAVE. 120TE. 54MM WIRE ROPE Type 7 has Tag. No BLS-17; 20; 26; 28; 48; 49, and drawing no. 1-2130.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G.A. drawing 1-2130. Before threading the wire, there is a need for removal of wire locking device item 4 on G.A. drawing 12130, depending on wrapping angle. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 44 of 65

3.11.

TYPE 8: SWIVEL BLOCK. 120TE. 54MM WIRE ROPE Type 8 has Tag. No BLS-52A; 52A1; 52B, 52B1, 52C; 52C1; 52D; 52D1, and drawing no. 1-2129.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2129. Before threading the wire, there is a need for removal of wire guide, item 5 on G.A. drawing 1-2129. Oval eye, details on drawing 1-2267 is possible to rotate. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 45 of 65

3.12.

TYPE 9: SWIVEL FIXED SHEAVE. 120TE. 54MM WIRE ROPE Type 9 has Tag. No BLS-27; 31; 50, and drawing no. 1-2128.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and groove. Wire sheave including wire socket is threaded through sheave house according to G. A. drawing 1-2128. Check sideways movement. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 46 of 65

3.13.

TYPE 10: SWIVEL TRAVELLING BLOCK. 120TE. 54MM WIRE ROPE Type 10 has Tag. No BLS-51A;51A1;51B; 51B1; 51C; 51C1; 51D; 51D1, and drawing no. 1-2127.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheaves, both externally, edges and grooves. Locking bolt item 29 is secured by means of (washer item 25) + (spring washer item 26), and that item 29 is torqued up by correct moment. (2 places) Check that securing wire is connected to (locking bolt item 29). Wire (including wire socket) is threaded through sheave house according to G.A. drawing 1-2127. Check sideways movement. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 47 of 65

3.14.

TYPE 11: SWIVEL TRAVELLING SHEAVE. 350TE. 88MM WIRE ROPE Type 11 has Tag. No BLS-34A; 34B, 34C, and drawing no. 1-2126.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheaves, both externally, edges and grooves. Locking bolt item 20 is secured by means of (washer item 28)+(spring washer item 36), and that item 20 is torqued up by correct moment. Securing wire is connected to (locking bolt item 20). Wire (including wire socket) is threaded through sheave houses according to G.A dwg 1-2126. Locking plate item 15 is secured by (locking bolt item 20). Check sideways movement. Make sure that (snatch block item 18 on dwg 1-2126) is possible to rotate and have a loose fit. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 48 of 65

3.15.

TYPE 12: SWIVEL TRAVELLING SHEAVE. 120TE. 54MM WIRE ROPE Type 12 has Tag. No BLS-35A; 35B, 35C, and drawing no. 1-2125.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used.. Ref. Maintenance Instruction’ Wire sheave rotates freely. No damage to wiresheave, both externally, edges and grooves. Locking bolt item 20 is secured by means of (washer item 28)+(spring washer item 36), and that item 20 is torqued up by correct moment. Securing wire is connected to (locking bolt item 20). Wire (including wire socket) is threaded through sheave houses according to G.A dwg 1-2125. Locking plate item 13 is secured by (locking bolt item 20). Check sideways movement. Make sure that (snatch block item 18 on dwg 1-2126) is possible to rotate and have a loose fit. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 49 of 65

3.16.

TYPE BLS-19: SLIDING SHEAVE HOUSE. 120TE. 54MM WIRE ROPE Type BLS-19 has Tag. No BLS-19 and drawing no. 1- 2122.

CHECK LIST ITEM Grease point filled on sheave. Grease Shell Alvania EP2 to be used.. Ref. Maintenance Instruction Wire sheave rotates freely. No damage to wiresheave, both externally, edges and grooves. Make sure that wire (including wire socket) is threaded through sheave houses according to G.A dwg 12122. Before threading the wire, there is a need for removal of (wire guide tube item 2 on dwg 1-2122). After wire is threaded, remember to apply grease on (slide brackets item 7 & 8 on dwg 1-2122). Wiresheave to be locked by (lock bolt item 14) and (hex nut item 6) either in upper or lower position. NA = Not Applicable MR = Meet requirements AN = Action Needed

NA

MR

AN

ACTION

INITIALS

COMPLETION DATE

COMMENTS

Page 50 of 65

4.

WHITNESSING PROCEDURE All sheave blocks have now being handed over to the owner or operator and be able to operate normally according to specifications.

4.1.

PROCEDURE TASKS • Class surveyor (XX) to sign for all tasks for each Type of Sheave Blocks. • All parties present on test site, to sign on dedicated area in bottom of each page including stamp from class society. • Finally all parties witnessing the tests to write their name with block letters and sign in table under chapter 4.

WITHNESSED BY:(name in block letters)

COMPANY:

DATE:

SIGNATURE:

YARD

Page 51 of 65

Document Id.:

4786-04-

PUS-

J-

KA-

1015

Document Name:


Rev. No.

A

Rev. Date

11.02.2011

9 Attachment 2 I-MA-P55-009-KFR-084 (4786-04-PUS- J-KA-1075) Commissioning Procedure 1200HWP & SU

Page 52 of 65

Project:

SEMI-BR P-55 Customer:

Aker Pusnes AS

QUIP S.A

www.akersolutions.com/pusnes

Customer Project No.:

Pusnes Project No.:

P55-09-03-009

4786-04

Document Title:

Commissioning Procedure 1200HWP & SU Aker Pusnes Doc. No.:

4786 -04

PUS -

Project

Originator

Total Pages: J

-

KA

Discipline

-

1075

Doc.Type

13

Department:

OM

Discipline:

Multi

Sequence Revision history:

1

06.01.2011

Re-issued for approval

TMu

0 Rev. Code

KØH

09.12.10

Issued for approval

CAn

BGi/PST/HXL

KØH

Date:

Reason for issue

Author

Check

Approved

Customer Approval: SUBMITTED FOR

P-55 PROJECT

: INFO

REVIEW

CERTIFIED

REVIEW DOES NOT CONSTITUTE ACCEPTANCE OF DESIGN DETAILS, CALCULATIONS, TEST METHODS OR MATERIALS DEVELOPED OR SELECTED BY SUPPLIER, NOR DOES IT RELIEVE SUPPLIER FROM FULL COMPLIANCE WITH CONTRACTUAL OR OTHER OBLIGATIONS.

1. 2.

RELEASED. RELEASED. PROCEED WITH WORK AND INCORPORATE COMMENTS AND RESUBMIT

3.

NOT ACCEPTED. WORK MAY NOT PROCEED REVISE AND RESUBMIT.

4.

FOR INFORMATION – NO SIGNATURE REQUIRED

5.

CANCELLED

6.

CANCELLED AND REPLACED

NAME: .......................................

RONCADOR FIELD DEVELOPMENT VENDOR NAME

Aker Solutions, Pusnes PO NUMBER:

VDRL CODE:

P55-09-03-009

K03

QUIP NUMBER:

REVISION:

I-MA-P55-009-KFR-084

0

PACKAGE DESCRIPTION :

Riser Pull In System DATE: .........................

SIGNATURE: .....................................................................

EQUIPMENT TAG NUMBER(S) :

GN-5268001-02 GN-5268002 A/B

Page 53 of 65

Commissioning Procedure 1200HWP & SU

Date

Table of Contents:

1

General ..............................................................................................................3 1.1 1.2 1.3 1.4 1.5 1.6

2 3

HSE (Health Safety Environment)....................................................................6 Pre-Commissioning ..........................................................................................7 3.1 3.2 3.3

4

Check list...........................................................................................................7 Check list...........................................................................................................8 Check list...........................................................................................................9

Commissioning ............................................................................................... 10 4.1 4.2 4.3

5

Responsibility and Safety ..................................................................................3 Changes to previous revision............................................................................3 Abbreviations ....................................................................................................3 Reference drawings ..........................................................................................4 Reference documents .......................................................................................5 List of components ............................................................................................6

Function Test 1200HWP 1 ..............................................................................10 Function Test 1200HWP 2 ..............................................................................11 Function Test SU ............................................................................................12

Storage ............................................................................................................ 13

Aker Pusnes AS Page 2 of 13 CONFIDENTIAL SHOULD NOT BE DISTRIBUTED AND / OR BE MADE AVAILABLE TO THIRD PARTIES WITHOUT OUR WRITTEN CONSENT

Page 54 of 65


Date

1 General This document specifies the guidelines for the commissioning of the 1200 HWP and SU. Documents and drawings used as reference must be studied closely in order to maintain the precision needed for a satisfactory commissioning and future operation. To secure traceability and correct positioning of tagged equipment, all necessary documentation must be available for the commissioning personnel. 1.1 Responsibility and Safety The commissioning responsible must carry out the commissioning activities described in this document. All participants of the commissioning team must carefully study the activities and take the necessary safety precautions. Activities described in this document may require work platforms, railings or other safety measures. It is the commissioning responsible to assess the need for such measures. 1.2

Changes to previous revision

Rev

Change Id.

Description of Change

0

NA

Initial issue

1.3

Abbreviations

Abbreviation

Description

1200HWP

120T Hawser Winch, Pull in

SU

Storage Unit

GA

General Arrangement

AP

Aker Pusnes

NA

Not applicable


Page 55 of 65


Date

1.4 Reference drawings The drawings listed below contain vital data & information regarding one or more of the following chapters, and should be studied before commissioning. Ref.

Project Document No.

Drawing

Description

Hawser Winch 1 2 3 4

I-DE-P55-009-KFR-005 I-DE-P55-009-KFR-002 -

114606.00000

GA dwg 1200HWP

194160.10100

Final Assembly 1200HWP

114607.00000

GA dwg SU

194161.10100

Final Assembly SU

Electro system 5

I-DE-P55-009-KFR-064

327636.00000

Control Room Control Panel

Hydraulic system 6

I-DE-P55-009-KFR-003

114615.00000

Hydraulic Power Unit (HPU) 1200HWP

7

I-DE-P55-009-KFR-010

114562.00000

Hydraulic Power Unit (HPU) SU

8

I-DE-P55-009-KFR-001

194119.10100

Piping Diagram

9

I-DE-P55-009-KFR-076

194149.10100

Hyd. System, 1200HWP

10

I-DE-P55-009-KFR-074

654H2000

Hyd. System, SU


Page 56 of 65


Date

1.5 Reference documents The documents listed below contain vital data & information regarding one or more of the following chapters, and should be studied before commissioning. Ref.

Project Document No.

Description

11

I-MA-P55-009-KFR-010

Instruction for Erection & Installation 1200HWP

12

I-MA-P55-009-KFR-052

Instruction for Erection & Installation SU

13

I-MA-P55-009-KFR-024

Operating instructions English

14

I-FD-P55-009-KFR-005

Datasheet 1200HWP

15

I-FD-P55-009-KFR-001

Datasheet SU

16

I-MA-P55-009-KFR-005

Instruction for Lifting, Handling & Transportation 1200HWP

17

I-MA-P55-009-KFR-002

Instruction for Lifting, Handling & Transportation SU

18

I-MA-P55-009-KFR-022

Maintenance Instruction English

19

I-RL-P55-009-KFR-002

Factory Acceptance Test (FAT) Report 1200HWP

20

I-RL-P55-009-KFR-006

Factory Acceptance Test (FAT) Report SU

21

I-MA-P55-009-KFR-013

Instruction for Preservation, Packing & Storage 1200HWP

22

I-MA-P55-009-KFR-058

Instruction for Preservation, Packing & Storage SU

I-DE-P55-009-KFR-027 Electrical Connection Diagram

23 I-DE-P55-009-KFR-089 24

I-LI-P55-009-KFR-008

Commissioning material list

25

I-MA-P55-009-KFR-066

Lubrication Chart


Page 57 of 65

Commissioning Procedure 1200HWP & SU 1.6

Date

List of components

Component

Tag No

1200HWP

GN-5268002 A, GN-5268002 B

Ø54mm wire for the 1200HWP SU

GN-5268001-02

Ø88mm and Ø72mm wire for the SU Hydraulic Power Unit

UH-GN-5268002A/B, UH-GN-5268001

2 HSE (Health Safety Environment) The primary concern when carrying out the commissioning described in this document, must be that all preparations and actual tests are carried out without any kind of injury. To achieve this everyone participating is strongly urged to have his or her mind set on personal safety at all times during the commissioning. For safety reasons, only persons directly involved with the commissioning work should be nearby the “working area” during commissioning (“Working area” to be defined by personnel responsible for commissioning). All commissioning work should follow written instructions/guidelines. Whenever deviations from instructions/guidelines are necessary, it is recommended that AP is consulted. For this Pre-Commissioning/Commissioning, some situations can result in danger, due to:  High pressures.  Hot oil (approx. 60˚C)  Operated winches and spooling gear.  Clamp hazards in nearness of spooling gear, measuring device, gear wheel and wire drum. Rules for participants: Each participant should: 1. Wear protective footwear. 2. Wear safety glasses. 3. Wear helmet. 4. Stay in safety areas during the commissioning operation. During commissioning activities the commissioning responsible is also responsible for the safety of all personnel involved.


Page 58 of 65


Date

3 Pre-Commissioning Before commissioning, the 1200HWP and SU has to be checked. The results shall be recorded in the lists included in this procedure. The checklists are to be signed by technical supervisor (alternatively representatives of Aker Pusnes) and commissioning responsible. Any findings/comments shall be duly recorded and assessed on an individual basis. 3.1

Check list

Project:

P-55 QUIP Riser pull-in

Equipment Type: 1200HWP Item

4786-04

Project no.: Tag no.: Serial no.:

GN-5268002A

52804 OK *Remark

Check Activity

1

The equipment is installed according to Ref. 1 and 11 (Sid 4).

2

Verify alignment of Winch Drum with Sheave. Check that minimum distances to sheave and maximum offload angles are within limits indicated on Ref. 1 (Sid 4). All bolts are fastened with the required torque. The hydraulic oil supply is connected to the hydraulic connections on the valve unit according to Ref. 1 and 9 (Sid 4). Check that the Control Panel is installed and electrically connected according to Ref. 23 (Sid 5). Check hydraulic piping/hoses/connections for leakage. Check that the oil cleanliness is accordance with NAS 1638, class 7 or better. Sample to be taken by commissioning responsible from winch return line in front of HPU return filter before commissioning test.

3 4 5 6 7 8 9 10 11 12

Check that grease is applied in all grease points. Ref 25 (Sid 5) The equipment has to be visually checked for any damages. All findings to be reported and assessed. Any defects in the painting system shall be rectified. Check tooth contact shall be min. 80%. Tooth contact must be checked with blue dye

Item

Acceptance

Remarks

Technical Supervisor

Commissioning Responsible

Sign: Date:


Page 59 of 65


Date

Check list

Project:


Equipment Type: 1200HWP Item

4786-04


GN-5268002B

52805 OK *Remark

Check Activity

1


2

Verify alignment of Winch Drum with Sheave. Check that minimum distances to sheave and maximum offload angles are within limits indicated on Ref. 1 (Sid 4). All bolts are fastened with the required torque. The hydraulic oil supply is connected to the hydraulic connections on the valve unit according to Ref. 1 and 9 (Sid 4). Check that the Control Panel is installed and electrically connected according to Ref. 23 (Sid 5). Check hydraulic piping/hoses/connections for leakage. Check that the oil cleanliness is accordance with NAS 1638, class 7 or better. Sample to be taken by commissioning responsible from winch return line in front of HPU return filter before commissioning test.

3 4 5 6 7 8 9 10 11 12

Check that grease is applied in all grease points. Ref 25 (Sid 5). The equipment has to be visually checked for any damages. All findings to be reported and assessed. Any defects in the painting system shall be rectified. Check tooth contact shall be min. 80%. Tooth contact must be checked with blue dye

Item

Acceptance

Remarks



Sign: Date:


Page 60 of 65


3.3

Date

Check list

Project:


Equipment Type: SU Item

4786-04

Project no.: Tag no.:

GN5268001-02

52803 OK *Remark

Serial no.: Check Activity

1


2

Verify alignment of Winch Drum with Sheave. Check that minimum distances to sheave and maximum offload angles are within limits indicated on Ref. 3 (Sid 4). All bolts are fastened with the required torque. The hydraulic oil supply is connected to the hydraulic connections on the valve unit according to Ref. 3 and ref 10 (Sid 4). Check that the Control Panel is installed and electrically connected according to Ref. 23 (Sid 5). Check hydraulic piping/hoses/connections for leakage. Check that the oil cleanliness is accordance with NAS 1638, class 7 or better. Sample to be taken by commissioning responsible from winch return line in front of HPU return filter before commissioning test.

3 4 5 6 7 8 9 10 11 12

Check that grease is applied in all grease points. Ref 25 (Sid 5). The equipment has to be visually checked for any damages. All findings to be reported and assessed. Any defects in the painting system shall be rectified. Check tooth contact shall be min. 80%. Tooth contact must be checked with blue dye

Item

Acceptance

Remarks



Sign: Date:


Page 61 of 65


4

Date

Commissioning

As test results are monitored and recorded in the following tables, they are to be signed by: Technical Supervisor (alternatively representatives of Aker Pusnes). Commissioning Responsible. 4.1

Function Test 1200HWP 1 P-55 QUIP Riser pull-in

Project:

Equipment Type: 1200HWP

2 3 4 5

6

GN-5268002A

52804 OK. *Remark

Test activity

Item 1

4786-04


Static Brake

During operation of the 1200HWP.  Check that the drum stops before the static brake is engaging.  Check that the static brake is disengaging before the drum starts rotating. Proximity Switches at the gear wheel The open / close signal from the proximity switches to be checked. Proximity Switches on the spooling gear The open / close signal from the proximity switches to be checked. Spooling Gear The spooling gear to be manually operated. Function Test - Haul In The 1200HWP to be manually operated for full speed (Min. 4 m/min) in haul in direction for 1 minute. The speed of the spooling gear, pos 202 on dwg 194149, must be tuned. During this operation some check points have to be done:  Check that the 1200HWP and Spooling gear are running smooth.  Perform an Emergency Stop. Function Test – Pay Out The 1200HWP to be manually operated for full speed (Min. 4 m/min) in pay out direction for 1 minute. (4 m/min (first layer of wire) corresponds to 1,12 rpm of the drum) During this operation some check points have to be done:  Check that the 1200HWP and spooling gear are running smooth.  Perform an Emergency Stop.  Check length and speed function.  Measure the speed by counting the rpm. rpm Rotary velocity

Item

Acceptance

Remarks



Sign: Date: Aker Pusnes AS Page 10 of 13 CONFIDENTIAL SHOULD NOT BE DISTRIBUTED AND / OR BE MADE AVAILABLE TO THIRD PARTIES WITHOUT OUR WRITTEN CONSENT

Page 62 of 65


Date

Function Test 1200HWP 2 P-55 QUIP Riser pull-in

Project:

Equipment Type: 1200HWP

2 3 4

5

6

GN-5268002B

OK. *Remark

Test activity

Item 1

4786-04


Static Brake

During operation of the 1200HWP.  Check that the drum stops before the static brake is engaging.  Check that the static brake is disengaging before the drum starts rotating. Proximity Switches at the gear wheel The open / close signal from the proximity switches to be checked. Proximity Switches on the spooling gear The open / close signal from the proximity switches to be checked. Spooling Gear The spooling gear to be manually operated. Function Test - Haul In The 1200HWP to be manually operated for full speed (Min. 4 m/min) in haul in direction for 1 minute. The speed of the spooling gear, pos 202 on dwg 194149, must be tuned. During this operation some check points have to be done:  Check that the 1200HWP and spooling gear are running smooth.  Perform an Emergency Stop Function Test – Pay Out The 1200HWP to be manually operated for full speed (Min. 4 m/min) in pay out direction for 1 minute. (4 m/min (first layer of wire) corresponds to 1,12 rpm of the drum) During this operation some check points have to be done:  Check that the 1200HWP and spooling gear are running smooth.  Check length and speed function.  Perform an Emergency Stop  Measure the speed by counting the rpm. rpm Rotary velocity

Item

Acceptance

Remarks



Sign: Date:


Page 63 of 65


Function Test SU P-55 QUIP Riser pull-in

Project: Equipment Type:

2 3 4

5

6

SU

4786-04

Project no.: Tag no.:

GN5268001-02

52803 OK. *Remark

Serial no.:

Test activity

Item 1

Date

Static Brake

During operation of the SU.  Make sure that the end of wire is fastened on drum before test is performed.  Check that the drum stops before the static brake is engaging.  Check that the static brake is disengaging before the drum starts rotating.  Check brake OFF feedback signal from pressure switch. Proximity Switches at the gear wheel The open / close signal from the proximity switches to be checked. Proximity Switches on the spooling gear The open / close signal from the proximity switches to be checked. Spooling Gear The spooling gear to be manually operated. Function Test - Haul In The SU to be manually operated for full speed (Min. 4 m/min) in haul in direction for 1 minute. (4 m/min (first layer of wire) corresponds to 1,12 rpm of the drum) The speed of the spooling gear, pos 316A on dwg 654H2000, must be tuned During this operation some check points have to be done:  Check that the SU and spooling gear is running smooth.  Perform an Emergency Stop Function Test – Pay Out WARNING: NO HANGING LOAD DURING TEST! The SU to be manually operated for full speed (Min. 4 m/min) in pay out direction for 1 minute. (4 m/min (first layer of wire) corresponds to 1,12 rpm of the drum) During this operation some check points have to be done:  Check that the SU is running smooth.  Check length and speed function.  Perform an Emergency Stop.  Check that SU follows the linear winch in auto mode.  Measure the speed by counting the rpm. rpm Rotary velocity

Item

Remarks

Acceptance



Sign: Date:


Page 64 of 65

Document Id.:

4786-04

PUS-

J-

KA-

1075

Document Name:


Rev. No.

0

Rev. Date

09.12.2010

5 Storage After commissioning is completed wire socket to be secured by suitable strap/rope to one of the lifting lugs on the frame of the winch. Further storage and maintenance preservation to be performed according to Ref. 21 and 22 (Sid 5), “Instruction for Preservation, Packing & Storage 1200 HWP / SU”.


Page 65 of 65

Comissionamento do Sistema de Pull in.PDF

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