slimsplit_1.0 Manual.pdf

SlimSplit C

User Manual

NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Tel:+31184608700,Fax:+31184608790,www.nov.com ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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211 Version 1.00

SlimSpli t User Manual

WARNING DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with the unit must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain the unit.

Published by: ASEP Group B.V. Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2009 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by ASEP Group B.V. for loss, damage or injury caused by any errors or omissions in this document.

Version

Date

1.0

Sep. 2009

Amendments This is the first version of this manual

REVISION HISTORY

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NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch

SlimSplit C , Project no. 8951, 23 September 2009

SlimSplit User Ma nual

TABLE OF CONTENTS 1

2

3

4

5

6

7

8

9

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1 Scope of this User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2 How to use this User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 Documentation Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 General safety responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 ATEX and zoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.2 PowerPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.3 Cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.4 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.1 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.2 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.3 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 4.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5 Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4.6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4.7 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.8 Zone 2 safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 UNIT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 5.1 Cabin controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 5.2 PowerPack controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.2 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 6.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 6.4 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 6.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 7.1 Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 7.2 Power up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.3 Pre-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 7.4 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 7.5 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 7.6 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 8.2 Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 9.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 9.2 Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Appendix 1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Appendix 2: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Appendix 3: Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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Appendix Appendix Appendix Appendix Appendix


4: Hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 5: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 6: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 7: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8: Customer feedback form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204




LIST OF FIGURES Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 Figure 4.1 Figure 4.2 Figure 4.3 Figure 4.4 Figure 4.5 Figure 4.6 Figure 4.7 Figure 4.8 Figure 4.9 Figure 4.10 Figure 4.11 Figure 4.12 Figure 4.13 Figure 4.14

Overview of SlimSplit C in example setup . . . . . . . . . . . . 15 Cabin exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PowerPack rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PowerPack rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PowerPack left (cover removed) . . . . . . . . . . . . . . . . . . . . 20 Cabin exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cabin exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cabin interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Winch front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PowerPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine/pump connection . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Spring-driven starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Sentinel valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel/water separator and primer pump . . . . . . . . . . . . . . . 30 Air inlet valve and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Typical ASEP ClosedLoop hydraulic system . . . . . . . . . . . 32 Connect valve on front of PowerPack . . . . . . . . . . . . . . . . 34 Mast lever and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Air receiver and dryer/filter . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pneumatic driven throttle . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Winch with ASEP BC06 drum . . . . . . . . . . . . . . . . . . . . . . 39

Figure 4.15 Figure 4.16 Figure 4.17 Figure 4.18 Figure 4.19 Figure 4.20 Figure 4.21 Figure 6.1 Figure 6.2 Figure 6.3 Figure 6.4 Figure 6.5 Figure 6.6 Figure 6.7 Figure 6.8 Figure 6.9 Figure 6.10 Figure 6.11 Figure 6.12 Figure 6.13 Figure 6.14 Figure 6.15 Figure 6.16 Figure 7.1 Figure 7.2 Figure 7.3

Drum control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Drum brake components and working principle . . . . . . . . . 41 Levelwind movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Spooling speed knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removable front beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Pressurization gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Flowchart of the Zone 2 safety system. . . . . . . . . . . . . . . . 47 Ground cable connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SlimSplit C electrical connections . . . . . . . . . . . . . . . . . . . 61 PowerPack/Cabin electrical connection points. . . . . . . . . . 61 Winch/Cabin signal connection points . . . . . . . . . . . . . . . . 62 SlimSplit C hydraulic/pneumatic connections . . . . . . . . . . 63 Connect valve on the front of the PowerPack . . . . . . . . . . 64 Winch/PowerPack hydraulic and pneumatic connections . 64 Cabin/PowerPack hydraulic and pneumatic connections. . 65 Winch/Cabin hydraulic and pneumatic connections . . . . . . 66 PowerPack air out connection with closed isolation valve . 67 Isolation valve in PowerPack . . . . . . . . . . . . . . . . . . . . . . . 67 Removable front beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Measurehead carrier transport position . . . . . . . . . . . . . . . 68 Levelwind chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . 69 Levelwind movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Removable front beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Engine primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Control joystick in middle position . . . . . . . . . . . . . . . . . . . 74 Spring-driven starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75


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Figure 7.4 Figure 8.1 Figure 8.2 Figure 8.3 Figure 8.4 Figure 8.5 Figure 8.6 Figure 8.7 Figure 8.8 Figure 8.9

Control panels in PowerPack . . . . . . . . . . . . . . . . . . . . . . . 76 Air dryer filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Brake band wear indication. . . . . . . . . . . . . . . . . . . . . . . . . 93 coolant filler cap at top of radiator. . . . . . . . . . . . . . . . . . . . 94 Coolant drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Diesel sight glasses and filler cap. . . . . . . . . . . . . . . . . . . . 97 Engine oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Engine oil filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Engine oil drain and oil pump . . . . . . . . . . . . . . . . . . . . . . 100 Engine oil filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Figure Figure 8.10 8.11 Figure 8.12 Figure 8.13 Figure 8.14 Figure 8.15 Figure 8.16 Figure 8.17 Figure 8.18 Figure 8.19 Figure 8.20 Figure 8.21 Figure 8.22 Figure 8.23 Figure 8.24 Figure 8.25 Figure 8.26

Engine oil filter . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 102 Rear view of gearbox 103 Hydraulic tank upper sight glass (example) . . . . . . . . . . . 104 Guard in front of V-belts and pulleys. . . . . . . . . . . . . . . . . 1 08 V-belts and pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Shock absorber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Diesel tank isolation valve (typical example) . . . . . . . . . . 111 Coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Diesel tank breather (typical example) . . . . . . . . . . . . . . . 1 13 Water diesel separator drain plug. . . . . . . . . . . . . . . . . . . 115 Hydraulic oil tank drain valve (two different types) . . . . . . 116 Winch bearings (2x) on right/left of winch. . . . . . . . . . . . . 1 18 Door bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant filler cap at top of radiator . . . . . . . . . . . . . . . . . . 120 Coolant drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Removing safety element . . . . . . . . . . . . . . . . . . . . . . . . . 122

Figure 8.27 Figure 8.28 Figure 8.29 Figure 8.30 Figure 8.31 Figure 8.32 Figure 8.33 Figure 8.34 Figure 8.35 Figure 8.36 Figure 8.37 Figure 8.38 Figure 8.39 Figure 8.40 Figure 8.41 Figure 8.42 Figure 8.43 Figure 8.44 Figure 8.45 Figure 8.46 Figure 8.47 Figure 8.48 Figure 8.49 Figure 8.50 Figure 8.51 Figure 8.52

Removing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Diesel tank isolation valve. . . . . . . . . . . . . . . . . . . . . . . . . 1 24 Diesel fine particle filter element . . . . . . . . . . . . . . . . . . . . 125 Diesel engine primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Diesel pre-filter and water separator. . . . . . . . . . . . . . . . . 127 Diesel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Hose at the top of the diesel pump . . . . . . . . . . . . . . . . . . 128 Drum brake band components . . . . . . . . . . . . . . . . . . . . . 132 Removing drum guard . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Master link in drive chain (split pin or clip locking) . . . . . . 135 Drum alignment and adjustment bolts . . . . . . . . . . . . . . . 135 Drum bearing alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Replacing slipring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 9 Removing logging wiring. . . . . . . . . . . . . . . . . . . . . . . . . . 140 Removing slipring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Drum brake band components . . . . . . . . . . . . . . . . . . . . . 141 Removing drum guard . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Free play in chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Drum bearing alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Drum bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Gearbox sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Pillow block, non-driven side of drum . . . . . . . . . . . . . . . . 148 Gearbox sprocket attachment (example) . . . . . . . . . . . . . 1 50 Attachment of hydraulic motor/gearbox assembly . . . . . . 151 Reduction gearbox and hydraulic motor . . . . . . . . . . . . . . 152 Hydraulic oil tank drain valve (two examples). . . . . . . . . . 156




Figure 8.53 Figure 8.54 Figure 8.55 Figure 8.56 Figure 8.57 Figure 8.58 Figure 8.59 Figure 8.60 Figure 8.61 Figure 8.62

Hydraulic suction filters. . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Hydraulic pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Blade fuses and block . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Swing-out cartridge fuse holder . . . . . . . . . . . . . . . . . . . . 166 Pull-out cartridge fuse holder . . . . . . . . . . . . . . . . . . . . . . 167 Automatic circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . 168 Water/diesel separator filter . . . . . . . . . . . . . . . . . . . . . . . 169 End view of exhaust gas cooler . . . . . . . . . . . . . . . . . . . . 173 Cleaning tool inside PowerPack door. . . . . . . . . . . . . . . . 173

Figure Figure 8.63 8.64 Figure 8.65 Figure 8.66 Figure 8.67 Figure 8.68

Contaminated cooler .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 175 174 Flame trap assembly Coolant supply hose at top of cooler . . . . . . . . . . . . . . . . 178 Exhaust gas cooler attachment bolts . . . . . . . . . . . . . . . . 178 Gas detector (open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 ATEX explosion proof cabinet . . . . . . . . . . . . . . . . . . . . . 182


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1

INTRODUCTION The SlimSplit C is one of the many ASEP products used in the well servicing industry.

1.1

Scop e of t his User Manual This User Manual is part of the Documentation Package (see 1.3 below) supplied with every ASEP product. It is intended for operating, maintenance, and supervisory personnel, and provides information on installing, operating, and maintaining your SlimSplit C unit. The manual is divided into the following sections: • Introduction - (this section). • Safety - Describes all safety aspects required when working with ASEP equipment. • Description - Physical descriptions of major components in the unit, plus brief fun ctional descriptions. • Setup and Removal - How to prepare the unit for transport, prepare the site for the unit, rig-up the unit including making power, air, hydraulic and other connections between separate modules of the unit and to site supplies, plus how to rig-down, remove and (if required) store the unit. • Operation - How to start up, run, use, and shut down the unit. • Maintenance - Specifically for qualified maintenance personnel for use in service and repair of the equipment. Includes periodic maintenance schedules, routine servicing and corrective maintenance procedures. • Troubleshooting - Tables listing potential problems, possible causes and suggested solutions. • Ap pendi ces - Extensive product specifications, tables of recommended lubricants, hydraulic oils and other fluids, running hours logbook pages (for registering maintenance and error actions), quick reference sheets for everyday procedures, other supplementary information, and a contact form plus contact details for supplying feedback to ASEP.

1.2

How t o u se th is User Manual Normally this manual is supplied to customers both as a printed document and as a digital document in Adobe Acrobat format, also known as a PDF (Portable Document Format). To avoid needless repetition, the manual makes extensive use of cross-referencing with page numbers to information given elsewhere in the manual. When viewing the manual in Adobe Acrobat, any cross-reference can be clicked on to jump immediately to the referenced page. This is also possible from the table of contents, list of figures and (if present) subject index at the end of the manual. You can then use the “back” button in Acrobat to return to the page where you were previously. Before installing, operating or maintaining your unit for the first time, always read the Safety section to familiarize yourself with the safety aspects of this manual and your ASEP product. To gain a thorough understanding of your ASEP product and its principles of operation, first read the complete Description section. Read Setup and Removal and Operation from start to finish to become familiar with the steps required to setup and run the product. If necessary, refer to Troubleshooting to find solutions to setup/operating problems. When performing scheduled maintenance on your unit, use the periodic maintenance tables at the front of the Maintenance section to view the schedules and locate the required maintenance





procedures. Corrective maintenance is guided from the tables in the Troubleshooting section. Use the Drawings Package (supplied in the Documentation Package) to trace electrical, hydraulic, pneumatic and heating/cooling circuits and components.

1.3

Docu mentati on Pack age This User Manual is just one part of a comprehensive documentation package that is supplied as an integral part of your unit. The Documentation Packageincludes: 1.

Certificates

2.

Datasheets

3.

Manuals

4.

Drawings

5.

Reports

6.

Parts lists

Refer to the Parts List when ordering replacement components during maintenance. OEM components forming part of your ASEP product (complete assemblies and subsystems, e.g. air conditioning, engines, etc.) are not covered in detail in the ASEP User Manual for your product. For maintenance and troubleshooting of these components, please refer to the supplier documentation included in the Documentation Package.


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2

SAFETY This section describes the safety aspects that apply when working with ASEP equipment. The safety aspect can relate to potential equipment damage or to danger to personnel working with this equipment or in the vicinity: • When installing, operating or maintaining equipment, closely follow the prescribed instructions in this manual, and use common sense at all times. • Preventing accidents is an objective affecting all company levels and operations. It is, therefore, a basic requirement that each supervisor makes the safety of all employees an integral part of their regular management function. It is equally the duty of each employee to accept and follow established safety regulations and procedures. • Every effort should be made to provide adequate training to employees. However, if an employee is ever in doubt about how to do a job or task safely, they should always ask a qualified person for assistance. Employees are expected to assist management in accident prevention activities. Unsafe conditions must be reported immediately. Fellow employees that need help should be assisted. • Every injury that occurs on the job, even a slight cut or strain, must be immediately reported to management and/or the Responsible Safety Officer. Never leave the work site without reporting an injury, except for emergency trips to the hospital.

2.1

General safety resp on si bi li ti es High voltages, mechanical, chemical, thermal, noise and stored energy hazards are present in ASEP systems. Therefore, pay special attention to safety when operating and maintaining each system, including: • Meet all applicable codes, laws and field regulations. • Read and und erstand each item in this manual. • Follow the procedures and advice in this manual exactly. • Perform all testing procedures exactly as specified. • Ensure that only trained and qualified personnel are allowed to work on the system. Please note that rigging up and rigging down is also a part of unit operations. • Ensure that adequate sa fety equipment is installed (fire extinguishers, escape routes, shut off valves, etc.), and that personnel are trained to use the equipment. • Always use the correct tools for the job. • Take recommended precautions - never take short cuts. • Never work alone if there is a possibility of an accident. • Wear personal protection equipment(PPE), where necessary. • Do not attempt to use the equi pment for purposes outside its design scope. This may lead to damage and/or dangerous situations. • Do not restart ASEP equipment after an emergency stop without verifying that the cause of this stop has been removed or rectified.

2.1.1

Work ing w ith o pen doo rs a nd ha tch es • While opening/closing hatches and/or doors on the unit, be aware of wind conditions. Hatches and/or doors might forcibly swing open/shut and cause damage or injury.





• When open, the hinge side of most doors and hatches can create an extremely hazardous pinch point for fingers, clothing, hoses and cables. Always check the hinge side before closing any door or hatch. • Always use the built-in door or hatch retainers to anchor the door or hatch if you need to leave it open while you work. Wind or sudden movement of the unit can cause the door or hatch to swing shut with great force, resulting in possible injury or equipment damage.

2.1.2

Transp ort /Inst alla tio n • Only hoist all joined modules (single lift) after ensuring that the unit has be en certified for single lifting by checking the certification in the Documentation Package that came with your unit. • When lifting a module by crane, make sure you cannot get trapped between the load and a wall, fixed object, etc. • If possible, position yourself so that you are vis ible to the crane ope rator. If not pos sible, make sure a flagman can signal the crane operator. • Never walk under a hanging load. • Make sure that lifting gear is sufficiently dimensioned and certified. • Never leave an "operation-ready" unit unattended. • Do not operate damaged equipment. This may lead to further damage and/or dangerous situations. • Respect and maintain your working environment. Dispose of waste correctly. • Keep the unit and connected components clean. Accumulated dirt can hamper unit operations and might jeopardize safety. • To prevent accidents, keep all safety guards in position while operating ASEP equipment. • When engaged in maintenance and/or performing checks on the unit:

2.2

−

First consider your safety and that of others.

−

Make sure that the equipment is switched off completely, and use a decal or similar to prevent unauthorized starting during maintenance or check up.

−

Never work on hydraulic and/or pneumatic systems under pressure. Always relieve system pressure to prevent dangerous situations.

−

Never attempt to move heavy parts without the aid of a mechanical device.

−

Do not allow heavy objects to rest in an unstable position.

ATEX and zoning The various ASEP equipment is certified as Rig safe, Zone 1, or Zone 2, and with ATEX certification or not. If the unit is certified according to ATEX regulations, the following applies: • The engine, including driven parts, has been manufactured and assessed according to ATEX. All driven parts have been tagged with a unique identification number. ONLY trained personnel may service the assembly. Failure to follow this may impair suitability for Rig safe, Zone 1, or Zone 2. • In its explosion safe version, the unit is suitable for use in gas hazard ous classified locations however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC). Hereto the unit is designated amongst other as Ex II 3G, IIB T3. The design and manufacturing has been based on European Directive no. 94/9/EC following conformity assessment procedure relating to internal control of production according Annex VIII of


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the Directive. The construction is documented in a confidential Technical Construction File held at the offices of ASEP BV.

2.3

Warnings and cautions The following alerts are used in this manual: • WARNINGS alert users of potentially dangerous situations. Failure to obey a warning can result in serious injury and/or death. • CAUTIONS alert users of potential equipment damage. Ignoring a caution can result in damage to equipment. Warnings and cautions in this manual, are indicated by: • An icon • The text WARNING or CAUTION • A textual description, which states the hazard and how to avoid it. See following examples:

WARNING FALLING FROM HEIGHT Falling from the top of the unit can cause serious injury or death. When working on top of the unit: make sure the roof is locked, and always attach a safety line to one of the safety bars.

CAUTION EQUIPMENT DAMAGE The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked). Never block (cap) the fuel tank breather.





2.3.1

Warn in g and c aut io n ic on s This manual uses the following icons to highlight safety aspects during operating and maintenance steps. These same icons are attached to ASEP systems at appropriate locations to warn of a safety aspect. GeneralCautionorWarning

Hotobject

Corrosiveliquidsoradhesive

Movingparts

Dangerous voltage

Groundingrequired

Potentially explosive substances or environments

Inflammablesubstances

Auto matically starting and stopping o f machine parts

Liftingwithforklift-bewareof falling loads

Danger of falling from height

Hoistedobjectthatcanfall

Crushing danger


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2.3.2

Rest ri ct io n ic on s Other icons may be used on your machine and in the manual to indicate that restrictions are in place. For example the following PPE (Personal Protection Equipment) may be required:

Eye protection Wear protective glasses to prevent eye damage

Brea thing protection Wear a full respiratory mask if working with toxic vapours

Ear protection Wear ear protection during this procedure

Wear prot ective gloves Wear latex gloves to protect your skin when performing this procedure

Electro-Static Discharge (ESD) Make sure you are sufficiently equipped to prevent ESD hazards

Wear pro tective helmet Always wear a helmet to protect your head when performing this procedure

Wear prot ective shoes Always wear protective shoes to protect your ankles and feet when performing this procedure





3

PHYSICAL DESCRIPTION

3.1

Unit overview SlimSplit C (Powe rPack/cabin/winch u nit, diesel driv en, -20 °C certif ied, Zone 2 The ASEP SlimSplit C is a purpose-designed three-piece wireline winch for cased hole and open hole operations, and consists of a PowerPack module, a cabin module and a winch module. The modules are linked by hydraulic, electric and signal cabling.

PowerPack

Cabin Winch

Figure 3.1 Overview of SlimSplit C in example setup The SlimSplit C is suitable for use in Zone 2 areas. The cabin has a single door for operator access; the winch and Powerpack have doors or hatches on all sides to give full access to all compartments. The winch module has a removable front beam to allow free travel for the wireline and easy access to the measuring head and drum. The basic units consist of -20 °C certified aluminium frames with integrated lifting pad eyes and fork lift pockets (H x W = 90 x 310 mm). An integrated ladder on the side of the cabin gives access to the components on the cabin roof. The frames are painted with a high-quality ASEP/ Hempel developed offshore paint coat, which is a single colour, 200 microns thick, consisting of three-layers. The unit decals, markings and ID plates are in accordance with regulations. Installation/rig hook up/interface is provided by means of cable leads and connectors. The electrical system consists of a power distribution panel, signals and power supply. The Powerpack module is partially sound-proofed to ensure outside noise level of the unit at nominal operation conditions will be minimally more than 90 dB (A). The noise level inside the cabin area at nominal operation conditions is 65 dB(A). The Iveco 4-cylinder diesel engine drives ASEP's ClosedLoop hydraulic system, enabling stable logging speeds, combined with fast acceleration and high speeds. The cabin interior is 2100 mm high. The operator window is laminated double glazed for safety. During transport the cabin window has a removable metal cover that can be later stored in slots on the left side of the cabin exterior. Lighting ensures a minimum adjustable luminance level of 400 LUX. The floor has an antislip material covering. Ducting is provided for mounting optional


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mechanical ventilation. The cabin has heating and air conditioning. A SmartMonitor provides depth and tension measurement. The winch bay has an enclosed drip pan with drain plugs integrated into the base of the frame structure. The winch bay has a single drum mount with an ASEP BC06 drum. The unit is equipped with a SmartHead straight through type measuring head.

3.1.1

Uni t da ta pl ates Data plates are attached to the outside of each module (PowerPack, cabin, winch) and contain specification information for that module (see the example data plate below). Check your data plates and refer to Appendix 1: Specifications on page 188 for all your system specification details.





3.2

PowerPack

3.2.1

Overview The following 3-dimensional drawing shows the orientation and some external features of the PowerPack. The working side of the PowerPack is the side of the PowerPack module containing the control panel. Detailed views of the left, rear and working side of the module are shown in following sections (the right side only contains the radiator).

1

Rear

Right

Left

Workingside

2 4

3

1

Lifting eyes

2 3

Exhaust Forklift pockets (2 on each side)

4

Hydraulic oil filler caps and gauge

Figure 3.2 Cabin exterior


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3.2.2

Pow erPack - Rear

1

2

3 5 4

1 2

Pneumatic components (air tank, air dryer, air valve) - see 4.5 Pneumatic system on page 35 Hydraulic oil tank (and sightglasses) - see 4.3 Hydraulic system on page 32

3

Electrical junction box - see 4.6 Electrical system on page 37

4

Diesel fuel tank - see 4.2.2 Fuel system on page 28

5

Generator - see 4.6 Electrical system on page 37

Figure 3.3 PowerPack rear





3.2.3

Pow erPack - Fro nt

1

2 3

4

7

5

6

1

Air inlet valve and filter - see 4.2.4 Air intake on page 31

2

Engine sentinel valve - see 4.2.2 Fuel system on page 28

3

Exhaust gas cooler - see 4.2.5 Exhaust system (zone 2) on page 31

4

Spring starter - see 4.2.1 Engine starter on page 27

5

Radiator and fan - see 4.4 Cooling system on page 34

6

Fuel components (filters, breather, filler) - see 4.2.2 Fuel system on page 28

7

Mast control (optional - see 4.3.3 Hydraulic mast (optional) on page 34

Figure 3.4 PowerPack rear NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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3.2.4

Pow erPack - left

1

2 3 5

4

1

Hydraulic oil tank

2

Hydraulic lines (with isolation valves)

3

Hydraulic oil suction filters

4

Generator

5

Hydraulic oil high pressure filter

Figure 3.5 PowerPack left (cover removed)





3.3

Cabin

3.3.1

Cabi n - E xt eri or r ear

Front

Right

Left

Rear

2 1

5 4

3 4

1

Air conditioning unit

2

Gas sensor and pressurizing pump

3

Compartment for electrical connections

4

Forklift pockets (2 on each side)

5

Ladder for accessing roof - on inside of door - door shown open

Figure 3.6 Cabin exterior NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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3.3.2

Cabi n - Ext erio r fr on t

Right

Rear

Front

Left

1

2 4 3 5 5

1

Air conditioning unit

2

Window/window cover

3

Pneumatic/hydraulic connectors

4

Compartment for electrical connections

5

Forklift pockets (2 on each side)

Figure 3.7 Cabin exterior





3.3.3

Cabi n - Int eri or

1

2

3

4

1

JB2 (Gas and Fire panel) controls

2

Heatingcontrols

3

SmartDisplay

4

Control panel

See See

5.1.4 JB2 (Gas and Fire panel) controls on page 52 5.1.6 Thermostat on page 55

SeeSmartDisplayUserManual See

5.1 Cabin controls on page 49

Figure 3.8 Cabin interior


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3.4

Winch

3.4.1

Overview The following 3-dimensional drawing shows the orientation and some external features of the winch. Detailed views of the left, rear and front side of the module are shown in following sections.

Rear

Right

2 Left

Front

1

3

4

1

Levelwind arms

2 3

Frame Slip ring

4

Motor and reduction gearbox

Figure 3.9 Winch





3.4.2

Winch - fro nt

1

2

3 5

4

1 2

Drum - see 4.7.1 Drum on page 40 Hydraulic levelwind motor with chain attachment - see 4.7.2 Winch motor and reduction gearbox on page 40

3

SmartHead - see 4.7.5 Measuring head on page 43

4

Cover over winch motor and reduction gearbox

5

Levelwind arms - see 4.7.4 Levelwind system on page 42

Figure 3.10 Winch front


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4

FUNCTIONAL DESCRIPTION This chapter gives an overview of the functions of major components and subsystems.

4.1

Power pack See following figure.

6 5

3 4 2 1 7

1

Engine - see 4.2 Engine on page 27

2

Radiator (for cooling system) - see 4.4 Cooling system on page 34

3 4

Air receiver (for pneumatic system) - see 4.5 Pneumatic system on page 35 Gas cooler for exhaust system - see 4.2.5 Exhaust system (zone 2) on page 31

5

Exhaust with spark arrestor - see 4.2.5 Exhaust system (zone 2) on page 31

6

Hydraulic tank (for hydraulic system) - see 4.3 Hydraulic system on page 32

7

Diesel tank (for fuel system) - see 4.2.2 Fuel system on page 28

Figure 4.1 PowerPack





4.2

Engine The SlimSplit C unit uses an Iveco 4-cylinder diesel engine as the main power source (see Figure 4.2). The engine drives a hydraulic pump (for supplying power to the hydraulic system).The engine is water cooled. The coolant is pumped through a radiator, which is cooled by a hydraulically driven fan. See 4.4 Cooling system on page 34.

Figure 4.2 Engine/pump connection

4.2.1

Eng in e st art er The engine has a spring-activated starter motor, which is activated from a starter handle on the starter motor (see Figure 4.3). The starter spring must first be wound to sufficient pressure with a hand crank to provide the kinetic energy required to turn over the diesel engine. See 6.2 Power up on page 73 for how to start the engine.


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tension indication window

winding nut

reset button spring starter handle

hand crank

Figure 4.3 Spring-driven starter The spring starter allows slow cranking of the engine (useful for timing adjustments and bleeding the fuel line, etc.). To do this:

4.2.2

1.

Press and release the reset button

2.

Turn the hand crank clockwise twice on its winding nut - this will engage the pinion with the flywheel.

3.

Activate the starter handle.

4.

Turn the crank to slowly crank the eng ine without activating the spring pack.

5.

When finished engine adjustments, unwind the crank handle or press the reset button.

Fuel sy st em The diesel is stored in a fuel tank that has a combined tank top/breather. After leaving the fuel tank, the diesel passes through the following components: • Isolation valve (this valve can be closed for maintenance purposes) • Coarse particle filter (removes large particles from the diesel) • Diesel primer pump • Water/diesel separator filter (removes water contamination from the diesel) • Two-stage fine particle filter (removes fine particles from the diesel) • Injection pump (injects diesel into the diesel engine)





fuel pump

breather fuel/water separator coarse particle filter filler cap

Figure 4.4 Fuel system For an overview of the fuel system see the Fluid diagram in the Documentation Package.

4.2.2.1 Sentinel maste r valve (die sel shut-off valve ) The sentinel master valve (diesel shut-off valve) is positioned between the fine particle filer and the fuel injection pump. See Figure 4.5. This valve will block the supply of fuel and shut down the diesel engine if the lubrication oil pressure drops under 0.5 bar (7.5 psi).

sentinel valve

valve override switch

Figure 4.5 Sentinel valve


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The sentinel master valve monitors the oil pressure in the diesel engine. Pressure is also distributed to the air intake valve. If the oil pressure drops, the sentinel master valve will close, immediately shutting down the engine. When starting the engine, the valve needs to be overridden by turning the override switch.

WARNING DANGEROUS MACHINERY Changing factory settings can seriously affect the safety of the system, and result in personal and/or equipment damage. Take extreme care when adjusting factory settings. If in doubt, contact ASEP the Netherlands.

The adjustable orifice, on the other end of the engine oil pressure hose that is connected to the Sentinel valve, is factory set. Do not adjust it without first consulting an ASEP engineer. If the orifice is turned, the engine's safety system might not work correctly. 4.2.2.2 Fuel/wa ter se parator and primer pump This filter unit separates any water contamination from the diesel fuel. The frequency of water draining or filter element replacement depends on the quality of the fuel. The primer pump is used to remove air from the diesel system.

primer pump

fuel/water separator

Figure 4.6 Fuel/water separator andprimer pump

4.2.3

Eng in e co ol in g sy st em The diesel engine is a water-cooled type engine. It uses a forced air flow through the radiator to keep the engine temperature at a controlled level. The air flow is generated using the V-belt driven ventilator. See 4.4 Cooling system on page 34.





The cooling fan cools: • The intake air (see 4.2.4 Air intake on page 31) • The coolant of the combined cooling system (engine and exhaust manifold)

4.2.4

Air i ntake The engine draws its air for combustion in via the air filter in the large black canister in the upper section of the PowerPack. See Figure 4.7. An air inlet valve (Pyroban) is also positioned in the air intake system and is used as: • An automaticcharged engine shut-off system in gasses case of over-speeding due to operating in an atmosphere with hydrocarbon • A manually controlled engine shut-off device in case of an emergency stop • An automatic shut-off device in case of low diesel engine oil pressure (<0.5 bar (7.25 psi)) • A shut-off device for engine protection (high coolant temperature >200 °C (>212 °F) and high exhaust temperature >100 °C (>146 °F)

air filter air inlet valve

Figure 4.7 Air inlet valve and filter

4.2.5

Exha ust sys tem (zone 2) Engine exhaust is treated in two stages to prevent an explosion risk from heat or sparks. The first stage takes place in the water-cooled exhaust gas cooler (see Figure 4.1, item 4), which brings the temperature of the gas and exhaust pipe down to a level that will not cause ignition of potentially explosive ambient gases. It also eliminates much of the ash from the exhaust gas.


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The se cond stage is a spark arrester (5), which eliminates residual hot solid particles from the gas. Clean, cool exhaust gas is emitted from the exhaust pipe in the roof of the power pack.

4.3

Hydraulic system

power pack

winch

hydraulic reservoir oil cooler quick connector

suction filter

drain

pump

main circuit

pressure filter

winch motor

various motors

various controls

control circuit various actuators

Figure 4.8 Typical ASEP ClosedLoop hydraulic system This unit employs an ASEP Closed LoopTM hydraulic system to transfer mechanical energy from the power source (engine or motor) to the winch and auxiliary control features. This system forms the basis of virtually all standard ASEP wireline winches. When necessary, there may be one or more additional open loop hydraulic circuits to power additional features, either from the main power source or an auxiliary engine or motor. Main circuit Hydraulic oil is circulated through the main circuit between the main pump and the winch motor, which both have a continuously variable displacement. This circuit is bidirectional, with the speed and direction of the pump and winch motor being governed by valves and control of the angle of the swash plate in the pump and motor. These components are actuated by the controls at the winch control panel, or by an automatic winch control system. Requiring neither a clutch nor variable-ratio gearbox, this system provides infinite control over the winch performance, enabling the winch to be run inhole or outhole at high speed, but also at extremely low speed with great precision. To prevent overheating of the hydraulic oil in the main circuit, the closed loop forms part of an open loop which draws oil from the hydraulic reservoir and returns it to the reservoir via a radiator with forced air cooling. The charge pump attached to the main pump constantly introduces cooled oil to the main circuit, and the drain lines from the main pump and winch motor return hot oil to the cooler and reservoir via a manifold. Suction filters mounted either below or inside (strainers) the hydraulic reservoir ensure that the pump and motor are not exposed to harmful particles.





Modular (split) wireline winches are subject to frequent opening of the connection points between the power pack and the winch module. Because of the heightened risk of introducing abrasive particles into the hydraulic system via the couplings, these units are normally also equipped with high pressure filters on the power pack side of the connection interface. NOTE: On units with dual winch motors, a ball valve in the winch bay is used to redirect the flow in both directions to the second motor. Control circuit The control circuit is supplied with a high pressure flow using the excess capacity of the charge pump of the main pump. In most ASEP units, this circuit powers a variety of important auxiliary control features, via circulating flow and static pressure, which can include the following: • main pump and winch motor control valves • winch gearbox gear change mechanism • levelwind drive motor • winch drum brakes (apply or release) • levelwind support arms (raise/lower cylinders) • winch frame slewing mechanism • generator The return flow of the control circuit is combined with the flow from the main circuit in the manifold for cooling and return to the hydraulic reservoir. Please refer to the hydraulic and pneumatic diagram in the documentation package for more information.

4.3.1

Hyd raul ic o il c oo li ng Hydraulic oil is cooled parallel to the engine water cooling system. The hydraulic oil cooler is circulated through a radiator mounted in the PowerPack, which is cooled by the same cooling fan (see 4.4 Cooling system on page 34) as the engine radiator. The high-capacity oil cooler in the hydraulic system ensures that the viscosity of the oil stays within operational specifications even at high ambient temperatures.

4.3.2

Hydr auli c ho se con nect v alve

CAUTION INTERRUPTED HYDRAULIC FLOW IS HAZARDOUS TO THE MACHINE. Hydraulic lines must be properly connected and the flow must be available to ensure correct operation of the hydraulic components. Always make sure connections are secure, and the ‘connect’ valve is in the normal position before running the machine.

The hydraulic hose connections between the PowerPack and the winch module are under high pressure. When connecting the hoses to the connections, always set the connect valve on the front of the PowerPack to the ‘disconnect/connect’ position. When hoses are (dis)connected, set


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the valve back to the ‘normal’ position (never run the motor when the valve is in the (dis)connect position).

(dis)connect position

valve

normal position

Figure 4.9 Connect valve on front of PowerPack

4.3.3

Hydr auli c mast (opt ion al) Some SlimSplit C units have an optional mast control circuit consisting of a mast control lever, an extra pump on the front side of the motor, and hydraulic connector(s) on the front of the cabin (check the hydraulic schematics for your setup). See Figure 4.10. If the mast option is available, refer to the mast documentation for how to operate.

mast pump

lever

Figure 4.10 Mast lever and pump

4.4

Cooling system The SlimSplit C PowerPack is equipped with a belt driven cooling fan (see Figure 4.11. The fan draws ambient air through the radiator stack (engine coolant radiator and hydraulic oil cooling). This combined cooling system cools the following components: • Engine block • Exhaust manifold • Hydraulic oil





For an overview of the cooling system see the Fluid diagram in the documentation package. The cooling fan system also contains the following: • Safety valve • Thermostat

radiators belt driven fan

Figure 4.11 Cooling fan

4.5

Pneumatic system Air for the pneumatic system is drawn from the PowerPack-mounted compressor, and stored in the air receiver (see Figure 4.12). Air pressure in the receiver is maintained at 7 bar (100 PSI), and is regulated at specific system points. Air flow from the compressor is activated when the receiver pressure falls below this value. Because compressed air contains moisture and abrasive solids which can damage equipment, the supply from the compressor passes through an air dryer/filter before it reaches the receiver. The filter is periodically automatically regenerated by a reverse air flow from the air receiver, whereby the incoming air to the filter is shut off and the moisture drain valve is opened. The regeneration flow blows the moisture from the dryer/filter out through the drain. Compressed, dried air from the unit receiver passes through the PowerPack/cabin/winch module air connectors to a manifold in the winch module, where it is directed to the wire spray assembly, safety valves and brake system, as well as the levelwind support arm raise/lower mechanism. Air from the receiver is also flowed from the PowerPack to the cabin where it is used for the pneumatic throttle control and the horn.


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escape valve air receiver

air valve

air dryer/filter

moisture drain

Figure 4.12 Air receiver and dryer/filter For an overview of the pneumatic system, see the pneumatic schematics in the documentation package.

4.5.1

Pneum ati c dri ven thr ot tle The throttle unit (see Figure 4.13) for the PowerPack engine is pneumatic driven and controlled by the throttle knob in the cabin. Opening and closing the throttle knob will adjust the air flow from the throttle air cylinder that moves the throttle rods and adjust the amount of fuel injected into the motor from the fuel pump.

air cylinder

fuel pump

throttle rods

Figure 4.13 Pneumatic driven throttle





4.6

Electrical s ystem The SlimSplit C obtains its electrical power from the integrated 2 x 115 VAC (60 Hz) generator unit or from a rig power source. The two 115 VAC circuits, each with a maximum rating of 50 Amps, supplies power to auxilliary devices inside the cabin and provides a stable platform for the winch control circuitry: • The 230 VAC system supplies major interior appliances, including the air conditioning units and equipment in the computer rack, as well as sockets in the cabin and winch bay. • The 115 VAC system supplies 115 VAC equipment in the computer rack, as well as wall sockets in the cabin. The cabin obtains its 24 DC power via two 12 V batteries in series, enclosed within a box in the cabin (under the dashboard). The 24 VDC from the batteries is used for the unit control equipment, including the SmartMonitor, SmartDisplay in the cabin, and the encoders and load pin in the winch These batteries are continuously charged by the power supply from the PowerPack (or rig supply). If the machine has been idle for a long time, or the batteries have been run down without the engine running, then the batteries can be recharged directly from a rig 24 VDC power source. Junction boxes in the cabin and PowerPack hold the following functions: • Main power control switch • On/off selection switches for the electrical components • Power variables display (frequency, voltage, current, hours) • Over and under voltage signalling lights • Power-on indicator • Fuse system for each electric component • Under and over voltage controllers • Generator activation switch The unit is also equipped with a voltage control system. With under or over voltage the warning indicator will light up. If the warning indication stays on, consult ASEP for maintenance actions. With a certain electrical component not working, and with the component not damaged, check the fuses in the control box. See maintenance section. NOTE: Ensure that the power supply to a junction box is disconnected before attempting to perform maintenance or repair work on the electrical system components. Do not change the settings on the under/over voltage safety controller (Carlo Gavazzi) without approval from an ASEP engineer. For the settings of the over/under voltage controller refer to the electrical diagram. For further details also refer to the electrical diagrams in the documentation package. NOTE: Before resetting a fuse, determine the cause of the fuse trip, and take action to prevent future system failures.

4.6.1

Generator The SlimSplit C unit is equipped with a generator. Th e hydraulic power for the hydraulic motor is taken from the secondary pump connected to the main hydraulic pump. The controller for the generator can be found in the electric control box in the power pack. This controller requires an initial 24 VDC power input for start up. This power supply is generated in the v-belt driven


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alternator attached to the Iveco motor. Once the motor is running, start up the generator using the control buttons on the side of the control box. To ensure proper generator functioning the control box is equipped with 8 capacitors. Three automatic fuse systems are installed to protect the electrical system; these fuses can be reset when tripped. For a detailed description of the generator controller, please refer to the separately supplied manufacturer's manual. The generator controller settings are ASEP factory-preset, and may not be modified without approval from an ASEP engineer.

4.6.2

Fuse s and c irc uit bre akers There are different types of fuses and circuit breakers in use in the SlimSplit C . The type of fuse used depends on the specifications of the electrical system. In general, the following rule applies: • 12 volt blade type fuses (typical automotive fuse) • 115/230 volt cartridge fuses (glass) and circuit breakers • 380/440 volt mesh type fuses, circuit breakers and cartridge fuses. The fuses are marked with an identification number that corresponds with the "F" number stated on the electrical diagrams. The description on the diagram indicates the trip level in Amps.





4.7

Winch The wireline winch assembly comprises the winch frame, drum, drive train, brake, levelwind and measuring head carrier.

6

5

4

1

2

3

1 2

Drum - see 4.7.1 Drum on page 40 Brake system - see 4.7.3 Drum brake system on page 40

3

Reduction gearbox and winch motor - see 4.7.2 Winch motor and reduction gearbox on page 40

4

Measuring head - see 4.7.5 Measuring head on page 43

5

Levelwind system - see 4.7.4 Levelwind system on page 42

6

Hydraulic motor for levelwind system - see 4.7.4 Levelwind system on page 42

Figure 4.14 Winch with ASEP BC06 drum


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4.7.1

Drum The wireline is spooled on a drum, which is driven directly using a drive chain between drum and hydraulic motor (and reduction gear). The size of the wireline used depends on the drum. The minimum bending radius of the wire requires a certain minimum core diameter of the drum. The outer dimensions of the drum determine the widths and lengths of the wireline that can be used.

4.7.2

Winc h mo tor a nd re duc tio n ge arbo x The reduction gear between the hydraulic motor and the drum reduces the motor revolutions to provide the required torque. This depends on the reduction ratio and is determined by the design specifications of the unit. Pressure created by the main hydraulic pump drives the hydraulic motor. The pump is driven by the engine. The speed and direction of the drum are controlled by the drum control levers (see Figure 4.15) or (optional) SmartMonitor in the cabin: • The right dual control lever on the cabin control panel regulates how much power is delivered to the hydraulic motor. It controls both direction and the amount of power available to the motor by changing the angle of the swash plate in the pump. • The left hand dual control lever varies the speed of the motor, regulating the pressure on the swash plate in the motor, thereby determining the torque/speed of the drum.

Figure 4.15 Drum control levers

4.7.3

Dru m br ake sy st em All drums in ASEP winch units are equipped with a spring-loaded, fail-safe brake system. This brake has two functions: • As a parking brake, to prevent the drum from turning, due to downhole forces (weight of tool string and wireline) or uphole forces (well pressure), when stationary • As an emergency brake, to halt the drum rapidly and smoothly in an emergency or sudden failure of the unit’s systems The drum brake is not for stopping the drum during normal operations. The drum control levers on the control panel in the cabin are for that purpose. NOTE: The lining used on ASEP brake bands is an asbestos-free composite, woven from yarns containing brass wire. The drum brake on the SlimSplit C is based on a brake band app lied by spring power to the rim of the winch drum at one or both sides of the drum. The brake's design has a spring inside a hydraulic or pneumatic brake cylinder. See Figure 4.16. This spring is pre-compressed during





assembly and retained by the brake cylinder lid. When pressure is present in the brake pneumatic or hydraulic circuit (BRAKE released), the piston extends, releasing the brake. If pressure is lost (BRAKE applied, EMERGENCY OFF pressed, or a system failure), the spring will pull the brake piston back into the cylinder, applying the brake. Dual-drum winch frames have a separate brake system for each drum. The brake actuation type for the SlimSplit C is listed in Appendix 1 Specifications on page 179. See the 7.1 Periodic maintenance schedules on page 84 for procedures to: • Test the brake - see 7.7 Test drum brake on page 95 • Inspect the brake band condition - see 7.38 Check drum brake band(s) on page 163 • Adjust the brake - see 7.40 Adjust drum brake on page 168 • Replace the brake band(s) - see 7.15 Replace brake band(s) on page 112 .

brake band sections

lower adjuster with locknut

brake piston

brake cylinder

winch frame mounting point

brake cylinder lid

brake linkage attachment

expansion chamber

brake actuating spring

HYDR/PNEUM PRESSURE APPLIED: PISTON EXTENDS, SPRING IS COMPRESSED, BRAKE IS RELEASED

hydraulic or pneumatic supply connection HYDR/PNEUM PRESSURE RELEASED: SPRING EXTENDS, PISTON RETRACTS, BRAKE IS APPLIED

Figure 4.16 Drum brake components and working principle


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4.7.4

Levelw in d s ys tem The wire spooling system ensures that the wireline is spooled evenly on or off the drum. The system works via a hydraulic motor fitted to the levelwind arms. This motor turns a chain which is connected to the measuring head. As the chain turns, the measuring head is transported backwards and forwards along its support shaft between the levelwind arms. The left and right movement of the measuring head on the shaft correctly position the wireline to (un)wind evenly onto the drum. The hydraulic motor movements can be controlled manually via the SPOOLING CONTROL joystick, or automatically by the SmartMonitor (the AUTOSPOOLING switch on the cabin control panel must be set to ONon ). Automatic control of levelwinding (AUTOSPOOLING set to ONon ) isthe done with the help of sensors the measuring head, which respond to sideways pressure wireline. These replace the joystick, causing the motor to turn one way or the other moving the measuring head, and therefore the wireline, left or right while (un)winding on the drum. Manual control always overrides automatic control. Even when AUTOSPOOLING is ON, moving the joystick will immediately switch to manual control. When the joystick returns to the middle position, autospooling will be active again.

hydraulic motor movements

hydraulic motor

measuring head

chain

support shaft

measuring head movements

Figure 4.17 Levelwind movements NOTE: The levelwind arm can be raised/lowered with theLEVELWIND UP/DOWN button (on the control panel) to align the arm to the correct operational height. If the unit has (optional) autospooling, the measuring head will be equipped with lateral deflection sensors in the wireline guide rollers of the measuring head. As the wire tends to follow the previous “valley” in the underlying wraps on the drum, it will press against the roller on one side, triggering the sensor and initiating a movement of the levelwind chain drive. Manual control





always overrides the (optional) autospooling system. On release of the manual control, the autospooling will again take over. The levelwind arms are supported by two pneumatic struts which raise and lower the arms. The fleet angle is at a predetermined angle where the arms are lowered and locked into position. 4.7.4.1 Measuring head carrier The measuring head is loaded onto a carrier that is attached via a bearing block (4) to the levelwind support shaft (5). The measuring head carrier has an operating position and a transportation position: • In thea transportation position, it is turned towards the levelwind arm and locked in place with lynchpin. • In the operating position, the measuring head is attached via a bearing block to the levelwind shaft, where it is free to move laterally along the shaft. 4.7.4.2 Spooling speed knob Adjust the spooling speed of the levelwind system by turning the small knob on the right side of the winch frame (clockwise to decrease speed; counter-clockwise to increase speed). This adjusts the hydraulic flow to the levelwind motor.

spooling speed knob

Figure 4.18 Spooling speed knob

4.7.5

Measu ri ng head The Smarthead II measuring head is a combined hydro-mechanical wireline depth and tension measurement system enabling both wireline depth and tension signals to be provided to a separate remote display. An accurate tension display can be achieved when used in conjunction with an ASEP SmartMonitor (or SmartDisplay as backup). The wireline can be replaced in the measuring head without cutting the wire. The Smarthead is described extensively in the separate Smarthead User Manual.

4.7.6

Remo vabl e fro nt b eam To gain access to the winch bay when exchanging drums and performing large scale maintenance, or when working with the wireline at an extremely high angle, the front top beam of the winch module can be lifted out (see Figure 4.19). If the beam is jammed, tap the beam loose


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(if necessary, with a rubber mallet). The beam can be stored in the storage slots under its normal position.

front beam

Figure 4.19 Removable front beam

4.8

Zone 2 safety s ystem The SlimSplit C Zone 2 variant has many features to ensure safe operation and rapid intervention in the event of an emergency: • There are two emergency stop push-buttons (one on the PowerPack, plus one inside on the cabin control panel) • The drum brake is spring-actuated, and can only be disengaged if there is pneumatic pressure in the control circuit, ensuring that in the event of a pressure loss or power failure, the brake is automatically applied • The exhaust has a special gas cooler and spark arrester to minimize the risk of fire • Gas, fire and overpressure control - see 4.8.1 Gas and fire safety systems on page 45 Whenever the SlimSplit C is used in ZONE 2 safety areas with non-EX equipment present in the cabin module, the cabin must be purged and pressurized by an overpressure fan. The unit also has a gas, and a smoke-and-fire alarm detection system. See Figure 4.21 for an overview of this system. Pressurization is started as follows: 1.

Open the cabin interior ventilation ports.

2.

At JB2 (the Combined Pressurization, Fire Detection & Gas System), turn the PURGE mode switch to the NORMAL position and turn on the START PRESSURIZING switch See 5.1.4 JB2 (Gas and Fire panel) controls on page 52





This will activate the overpressure fan, the pressure sensor and the gas detection system. Once activated and working correctly, electrical power will be available to all non-EX equipment inside the cabin module. With the door closed and ventilation ports open and unobstructed, it will take approx. 22 minutes to purge the unit and build up the required overpressure. The cabin overpressure is monitored on the gauge beside the control panel. See Figure 4.20.

gauge

Figure 4.20 Pressurization gauge The safety system will terminate the power supply to the non-EX equipment under any of the following three conditions: • No overpressure present in cabin module (i.e. the cabin door is left open for too long) • Presence of explosive gases inside or outside the cabin module • Smoke contamination inside the cabin module NOTE: The SlimSplit C unit is setup for 60Hz. If the unit is connected to shore power at 50Hz, it may be necessary to manually adjust the air flow through the vents to allow correct pressurization. NOTE: The purge cycle must be allowed to complete without interruption. If pressure should be lost (e.g. due to opening the cabin door) during the purge cycle, the alarm will not sound, but the entire purge cycle will restart, and will again take 22 minutes. NOTE: Under operating conditions, a loss of cabin overpressure will cause an alarm to sound. If the overpressure is not restored within 30 seconds, all non-EX electrical power will be shut-down. The system cannot be restarted until a full purge cycle has again taken place

4.8.1

Gas and f ire safety s yst ems (See also vendor documentation in the Documentation Package.) The unit gas and smoke-and-fire alarm detection system is always on when the unit is powered, and cannot be turned off. If smoke or fire is detected (smoke detection in the cabin or heat detection in the power pack): • A message will be displayed on the Smart Monitor. The unit will not automatically shut down. • The alarm generator in the cabin will sound (and cannot be reset until the cause of the smoke or fire has been resolved).


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Gas Alarm If a gas alarm is triggered: • A message for low or high gas alarm will be displayed on the SmartMonitor. The unit will not automatically shut down; ventilation will stop. • The alarm generator in the cabin will sound (and can be reset by briefly pressing the RESET button on the orange gas smoke and fire panel. • If a yellow lamp is required (required by some custom ers), a beacon lamp will also switch on. In both cases, the unit will send a signal to the rig, and the alarm station will be activated. There are two levels of gas alarm (these depend on norms and customer request). • Gas level 1, Low Gas Alarm, will activate the alarm when a set percentage (usually 10 to 30% of the LEL-value) is reached • Gas level 2, High Gas Alarm, will activate the alarm and shutdown the system, the Safe System relay will switch off, when a set percentage (usually 30 to 60% of the LEL-value) is reached The status indicators on JB2 will flash for either 'Low Gas Alarm' or 'High Gas Alarm'. Smoke Alarm If the smoke detector senses smoke, the system will shut down and the Safe System relay will switch off. When the alarm is activated, the fan will switch off and the fire dampers will close, the sounder will switch on and the SmartView display will give a message 'Smoke Alarm'. If a yellow lamp is required (required by some customers), a beacon lamp will also switch on General Fault A general fault will occur when a signal is lost, for instance when a wire or contact is damaged. When a general fault occurs, the 'General Fault' status indicator light on JB2 will switch on, and the SmartView display will show a message 'General Fault at xxx'. (xxx specifies where the fault has occurred, for instance the Gas Detector, or Manual Call Point). Pressure too l ow If the unit loses pressure, a sounder will give an alarm after 10 sec, and the main contact will be switched off after 30 sec. The SmartView display will show the message 'Loss of Pressure'. If this happens during purging, the purging process must be started again.





Over pressure system

Normal

Purge Override

Start

Start

Fan spooling 22 min purge

Maintenance

Start

Fan spooling

Electrics on

Electrics on

Stop

Electrics on After 22 min

Low Gas alarm

High Gas alarm+

Smoke alarm + light

+ light signal and signal to the rig

light signal and signal to the rig

signal and signal to the rig

High cabin pressure

Low cabin pressure

No AC power

30 sec timer

Fan shut off

Non EX electrics off

Sounder

Reset sounder lights and rig alarm remains as long there is still an alarm

Figure 4.21 Flowchart of the Zone 2 safety system


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5

UNIT CONTROLS

5.1

Cabin controls

5.1.1

Cabin con tro l panel (left)

2

1

3

4

5 8 6

9

7

1

MAIN PRESSURE

This gauge (0 to 400 bar (5800 psi)) shows the hydraulic pressure generated by the main hydraulic pump.

2

CONTROL PRESSURE

This gauge (0 to 40 bar (580 psi)) shows the hydraulic control pressure, which is used for controlling the hydraulic system.

3

AIR PRESSURE

This gauge shows the air pressure in the system.

4

TACHOMETER

This gauge shows the rpm of the engine.

5

THROTTLE

Thisdialcontrolsthe engine speed.

6

EMERGENCY STOP

Push this button in case of an emergency. This will automatically stop the engine and immediately shut down the unit.

7

HORN

Pushthisbuttontosoundthehorn

8

DUAL CONTROL LEVER

This lever controls the speed and torque obtained from the hydraulic motor. The maximum up or down position will generate the fastest drum speed (greatest hydraulic flow) with the least available torque.

9

DUAL CONTROL LEVER This lever controls the direction of the drum (flow of hydraulic fluid). Push the lever forward to spool off wire; pull the lever backwards to spool on wire. Spooling in hole at high speed can entangle the wireline in the hole. Therefore, high drum speeds should only be used to Pull the wireline Out Of Hole (POOH).


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5.1.2

Cabin con tro l pa nel (centr e)

2 1

3

1

SMART MONITOR

The SmartMonitor digitally displays the depth, speed, and tension of the wireline. For more information, see the separate SmartMonitor manual.

2

SMART MONITOR BUTTONS

Use these buttons to control the SmartMonitor.

3

SMART MONITOR ARROWS

Use these buttons to navigate within the SmartMonitor screens.





5.1.3

Cabin con tro l panel (rig ht)

1

2

3

4 5 1

AUTOSPOOLING ON/OFF

Autospooling on/off switch. OFF: spooling of wireline onto drum is manually controlled by SPOOLING CONTROL joystick. ON: spooling of wireline onto drum is automatic, but is overridden by moving SPOOLING CONTROL joystick.

2

LEVELWIND UP/DOWN

Up/Down motion of levelwind arm is by paired pneumatic actuators (down motion of levelwind arm is damped by air struts)

3

SPOOLING CONTROL

Controls spooling of wireline onto drum. Left/right motion of levelwind carriage is by hydraulic motor with direct chain transmission. LEFT: levelwind carriage moves left, winds wireline to left side. RIGHT: levelwind carriage moves right.

4

BRAKE ON/OFF

This switch operates the brake. Move the brake ON/OFF switch down to activate the reel brake; move the brake ON/OFF switch up to release the brake.

5

WINCH SAFETY

Rotary control (+…-) that regulates the maximum wireline tension by controlling the maximum torque output of the hydraulic winch motor when spooling outhole (onto the drum) under manual control. If high tension is permitted, then the wire can be spooled at higher speed to extract the wire and tools faster in the deeper subsurface zone. In this case increase the tension, and increase the speed using the drum control joystick. When the tool string approaches the surface it is important to avoid damaging the tools and BOP. Here the wireline and iswire speed should be kept to a minimum, so that extraction of thetension tool string steady and controlled. + increase tension - decrease te nsion NOTE: To avoid any risk of wireline breakage, you should limit the line tension to no higher than you are able to properly control (using the joystick) and monitor on the line tension display of the winch. Always stay below the percentage of wireline breaking strain specified for your equipment and purpose. CAUTION: Prolonged operation with the WINCH CONTROL set high can cause the hydraulic oil to overheat beyond the capability of the cooling system to keep it below the maximum safe temperature. In this case, the winch will automatically shut down. Restart only once the hydraulic has cooled sufficiently.


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5.1.4

JB2 (Gas and Fire panel) cont rols

1

2

3 4

5

21

8

7

6

11

9

13

12

14

18

17

16

10

15

19


20

21




1

POWER COMPUTER RACK

Indicator is on, when the 240 VAC electrical system for the computer rack is active.

2

GENERAL FAULT

Indicator is on, when there is a general error - see systems on page 45

3

LOW GAS ALARM

Indicator is on, when there is a low gas alarm - see systems on page 45

4

HIGH GAS ALARM

Indicator is on, when there is a high gas alarm - see systems on page 45

5

FIRE/SMOKE ALARM

Indicator is on, when there is a fire/smoke alarm - see systems on page 45

6

SMARTVIEW MENU BUTTON

SmartView MENU selection button (see SmartView User Manual)

7

SMARTVIEW BUTTON

SmartView selection button (see SmartView User Manual)

8

SMARTVIEW BUTTON

Refer to the CANTRAK documentation supplied with this unit.

9

SMARTVIEW BUTTON


10

SMARTVIEW BUTTON


11

VOLTAGE ERROR

Indicator is on, when there is a voltage error on the main electrical system (2 x 110 VAC)

12

VOLTAGE OK

Indicator is on, when the main electrical system is active

13

POWER ON (PHASE 1)

Indicator is on, when there is a voltage error on the phase 1 electrical system (230 VAC)

14

POWER ON (PHASE 2)

Indicator is on, when there is a voltage error on the phase 2 electrical system (230 VAC)

15

START PRESSURING

ON button for the cabin pressurizing fan

16

PURGE

Setsthesafetymode: NORMAL is for normal operation in zone 2 areas PURGE OVERRIDE skips the purging cycle MAINTENANCE is for doing maintenance, and for operation in a rig safe area

17

STOP PRESSURING

18

RESET ALARM

Press to clear an alarm condition. Will only work, if the condition causing the alarm has been fixed.

19

CABINLIGHT

ON/OFFswitchforthecabinlight

20

MAIN SWITCH

This switch activates the AC electrical system to the cabin (from rig)

21

DASHBOARD LIGHT

ON/OFF switch for the cabin control console light

22

SMARTVIEW

SmartView display (see SmartView User Manual)

4.8.1 Gas and fire safety 4.8.1 Gas and fire safety 4.8.1 Gas and fire safety 4.8.1 Gas and fire safety

For more information, see 4.8 Zone 2 safety system on page 44 OFF button for the cabin pressurizing fan


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5.1.5

Pressure gauge and SmartD ispla y

1

2

1

SMARTDISPLAY

Used as a backup for the SmartMonitor to measure depth and tension of the wireline. See SmartDisplay documentation for how to operate.

2

PRESSURE GAUGE

Records the pressure in the cabin during pressurization for a Zone 2 EX environment.





5.1.6

Thermostat

1

2

1

FAN CONTROL

Controls the operation and fan speed of the air conditioning unit (roof-mounted) for heating and cooling. FAN HIGH: high fan speed when heating (WARMER) FAN LOW: low fan speed when heating (WARMER) COOL HIGH: high fan speed when cooling (COOLER) COOL LOW: low fan speed when cooling (COOLER) OFF: Air conditioning is off.

2

TEMPERATURE CONTROL

Thermostat to set the cabin temperature as measured by the sensor wire below the control panel. When heating (WARMER) set the fan speed to FAN HIGH or FAN LOW. When cooling, set the fan speed to COOL HIGH or COOL LOW. NOTE: the actual temperature in the cabin will be affected by the radiator below the winch control panel. When using the air conditioning for cooling, shut off the thermostatic valve on the radiator.


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5.2

PowerPack controls

2

3

1 4

5

8

6

9

7 10

12

13

11

14

1

AIR INLET VALVE

Use this handle to control the engine safety air intake control valve. Push the handle up to bypass the diesel engine motor oil pressure safety system to allow the engine to be started. Hold the handle in the upper position until the motor oil pressure has risen to approx. 2 bar. Pull the handle down to emergency stop the diesel engine. Pulling the handle down will close the diesel air intake valve. For restart wait for the engine derived vacuum to disappear.

2

CONTROL PRESSURE

This gauge (0 to 40 bar (580 psi)) shows the hydraulic control pressure, which is

3

HYDRAULIC OIL TEMPERATURE

4

AUXIL PRESSURE

This gauge shows the air pressure in the auxiliary air circuit

5

AIR PRESSURE

This gauge shows the air pressure in the system

6

ENGINE STOP

Pull out this switch to switch off the diesel engine; push it in again once the engine is stopped

7

EMERGENCY STOP

Push this button in case of an emergency. This will automatically stop the engine and immediately shut down the unit


used for controlling the hydraulic system Shows the temperature of the hydraulic oil




8

ENGINE OIL PRESSURE

This gauge shows the oil pressure in the engine

9

ENGINE TEMPERATURE

This gauge shows the temperature in the engine

10

TACHOMETER

Thisgauge showsthe rpmofthe engine

11

EXHAUST TEMPERATURE

This gauge shows the temperature of the engine exhaust

12

GENERATOR START

ON switch for the generator

13

GENERATOR RUNNING

Indicator is on, when the generator is running

14

GENERATOR STOP

OFF switch for the generator


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6

SETUP AND REMOVAL

6.1

Mov in g/po si ti on in g equ ip ment

WARNING CRUSH HAZARD Heavy objects can trap limbs and cause serious injury or death. Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

• Make sure that lifting equipment to be used is suffici ently dimensioned, has the cor rect certification, and is marked accordingly. The lifting equipment may only be used by suitably qualified personnel. • All equipment lifting equipment must be subject to regular scheduled inspection compliant with EN 12079 for deformation and wear. • The individual SlimSplit C modules (PowerPack, cabin, winch) may be lifted using the lifting eyes. The eyes are angled towards the center for correct transfer of the weight of the module to the shackles and lifting cables, without twisting forces being applied.

6.1.1

Land tra ns po rt ati on When loading and transporting ASEP modules on a truck, several things need to be taken into consideration (most of these are also specified in the local traffic regulations): • Number of axles on the transport vehicle (to decide where to position one or more units) • Weight of unit(s) (total weight) • Height of the load (bridges, aqueducts, tunnels) • Width of the load (manoeuvring) • Travelling speed • Cornering (dead corner) • Securing modules and securing loose components Check all these before loading and transportation: • Make sure lifting equipment is sufficiently dimensioned. • All equipment used for lifting must have the correct certification and be marked accordingly. • Only qualified personnel are allowed to use lifting equipment. • Before each lift, always ensure that the shackles have been correctly attached to the unit.

6.1.2

Ai r t rans po rt ati on Standard procedure for air freighting a unit depends on local travel organizations. In general the following liquids should be drained: • Hydraulic tank • Fuel tank • Engine oil • Engine cooling fluid





• Air tank • Wire lubrication system Other liquids within components will always remain in the unit: • Hydraulic system • Fluid/oil coo lers • Filters • Hoses

6.1.3

Draining If the carrier requires that all fluids are drained from the reservoirs, systems and components of the machine(s), please refer to 8 Maintenance on page 85 for specific instructions on how to drain the fluid from each reservoir, system or component. Photocopy or print the checklist in Appendix 6 Air transportation on page 200 as an aid to ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as follows:

6.1.4

1.

Check off each item as it is drained, adding your initials.

2.

Strike-out the items that are NOT present on the machine.

3.

Add any items that are present on the machine, but not on this list.

4.

Place this checklist in a prominent place on the machine (e.g. in the cabin, in a weatherproof envelope attached to the outside of the Cabin door).

Refilling Refer to Appendix 1 Specifications on page 188 for the quantity and specifications of the required fluids. Refer to 8 Maintenance on page 85 for the procedures to check and replenish fluids for each of the reservoirs, systems and components. Replenish the fluid in each of the items listed in the checklist. Remember to bleed the system of air and again replenish if necessary. ASEP recommends that new fluid/oil filters are used when replenishing systems that include filters. If you have fitted new filters, please add your initials in the last column.

6.2

Site preparation Before positioning the unit at the site, survey the location where it will be used. • The unit should be aligned with the centreline of its operating arc. • The distance from the front of the unit to the lower hay pulley should not be less than 15 m (50 ft) for optimum line spooling, and to provide a safe distance to the wellhead. • There should be sufficient room on all sides for opening doors/hatches.


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6.3

Rig-up 1.

Move the modules to the operating position.

WARNING RISK OF EXPLOSION Electrostatic discharge can cause an explosion. Always ensure that the unit has been properly grounded using a suitable grounding cable before performing any other work whatsoever on the unit, including connecting or disconnecting any hoses or cables, refuelling the unit, operating the unit, or carrying out maintenance on the unit.

2.

Connect the brass grounding points for module to rig - in total 3 points at ground level on the left side of each module. See Figure 6.1.

NOTE: Use only the supplied brass nuts to attach the ground strap (non-brass nuts can cause electrolytic corrosion, so that the grounding becomes ineffective).

module to rig ground points

Figure 6.1 Ground cable connector

6.3.1

3.

If the drum and wire line are not installed or need to be replaced, load the drum as described in NOTE: A new brake band must be fitted every time a new drum is fitted to the unit. See related topic. on page 114, and the wire as described by the supplier.

4.

Connect the electrical and signal cabling - see 6.3.1 Electrical rig-up on page 60.

5.

Connect the hydraulic and pneumatic cabling - see 6.3.2 Hydraulic & pneumatic rig-up on page 62.

6.

Setup the levelwind and measurehead - see 6.3.4 Setup the levelwind and measurehead on

7.

page 67. Startup the unit for the first time - see 6.3.3 First time startup on page 67.

Elect ri cal rig -up In the following steps, refer to the electrical connections diagram in Figure 6.2. The following steps assume that the 2-phase 110 VAC power supply to the cabin will be from the 30 KW generator on the PowerPack. If it is decided to use rig/shore 2-phase power, then the cabin 2-phase cable must be connected to rig/shore 2-phase.





rig supply (optional) gas and fire signals

(optional)

power (2 x 110 VAC)

JB 1

JB 2

PowerPack

Winch

Cabin

JB 12

signal cable

JB 10

Figure 6.2 SlimSplit C electrical connections 6.3.1.1 Cabin to Powe rPack (or optiona l rig/shore ) 1.

Open the stowage recess on the cabin module (left side) and carefully uncoil the 2-phase 110 VAC cable from its storage location.

2.

Lay the cable along the ground from the cabin module to the PowerPack.

3.

Uncoil the short electrical cable (2-phase 110 VAC) from its holder in the storage recess.

4.

Remove the caps from the 2-phase VAC cable sockets and the connector in the cabin recess and on the PowerPack.

gas and fire signal cable connector

2-phase 110 VAC connector

Cabin

PowerPack

Figure 6.3 PowerPack/Cabin electrical connection points


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5.

Remove the dust caps from each end of the cable, and plug the cable into the corresponding connector in the cabin and the PowerPack (if connecting to a rig/shore 2-phase 110 VAC supply, connect the cable to the appropriate rig/shore connector).

6.

Secure the cable in the connector sockets with the clamping feature.

7.

Optionally, connect a signal cable from the fire and gas signal connector in the cabin recess to the appropriate rig/shore connector.

6.3.1.2 Cabin mod ule to winch 1.

Uncoil the signal cable (for slip ring and encoders) on the roof of the winch module.

2.

Lay the cable along the ground to the front of the cabin so that it can easily reach the signal connector on the front left of the cabin.

signal connector from winch

winch signal connector

pneumatic and hydraulic connectors

Winch

Cabin

Figure 6.4 Winch/Cabin signal connection points 3.

6.3.2

Remove the dust ca p from the cable and sockets, and plug the cable into th e sockets, securing it with the retaining feature.

Hydr auli c & pne uma tic rig -up In the following procedures, refer to the hydraulic/pneumatic connections diagram in Figure 6.5.





Hydraulic

19 10 5 11 17 18 9 1 20 11

90 50

10

Winch

Cabin

PowerPack

6 7 12

80

3 14 8 15 16

Pneumatic

air out (accessories)

Figure 6.5 SlimSplit C hydraulic/pneumatic connections

CAUTION EQUIPMENT DAMAGE Hydraulic systems and components are extremely sensitive to contaminants such as grit and metal fragments, which can be accidentally introduced during servicing activity. Apply maximum standards of cleanliness when servicing hydraulic components. Before reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.

WARNING HIGH PRESSURE (Dis)connecting a pressurized line can cause serious injury and or equipment damage. Never connect or disconnect any quick connectors when the supply line is pressurized.


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1.

Set the connect valve on the front of the PowerPack to the ‘(dis)connect’ position.


valve

normal position

Figure 6.6 Connect valve on the front of the PowerPack 6.3.2.1 Winch module to PowerP ack 1.

Remove the hoses from their transport positions on the roof of the PowerPack and winch modules, and lay the hoses along the ground to the appropriate connection points on the winch and PowerPack. See Figure 6.7.

hydraulic hoses

hydraulic/pneumatic hose connectors

PowerPack Winch

Figure 6.7 Winch/PowerPack hydraulic and pneumatic connections 2.

Connect each of the hydraulic hoses to the connection points in the winch as follows (make sure you have an unused, clean cloth on hand): a) Check the connection number near the hose connection ferrule. b) Identify the corresponding coupling on the winch and PowerPack. c) Remove the protection cap on the coupling, and clean the coupling carefully and thoroughly (allow no dust or sand to be present).





d) Remove the protection cap from the hose, and again clean the coupling scrupulously. e) Make the connection, and pull on it to be sure it is secure. 3.

Make certain the air OUT isolation valve at the front of the PowerPack is closed. See Figure 6.10.

4.

With equal attention to avoid contamination, make the pneumatic connections between the winch and PowerPack, pulling gently on the connection to check it is secure.

6.3.2.2 Cabin to PowerPack 1.

Remove the hoses from their transport positions on the roof of the PowerPack and lay the hoses along the ground to the appropriate connection points on the cabin. See Figure 6.8.

hydraulic/pneumatic hoses


PowerPack Cabin

Figure 6.8 Cabin/PowerPack hydraulic and pneumatic connections 2.

Connect each of the hydraulic hoses to the connection points on the cabin as follows (make sure you have an unused, clean cloth on hand): a) Check the connection number near the hose connection ferrule. b) Identify the corresponding coupling on the cabin. c) Remove the protection cap on the coupling, and clean the coupling carefully and thoroughly (allow no dust or sand to be present). d) Remove the protection cap from the hose, and again clean the coupling scrupulously. e) Make the connection, and pull on it to be sure it is secure.

3.

Make certain the air OUT isolation valve at the front of the PowerPack is closed. See Figure 6.10.

4.

With equal attention to avoid contamination, make the pneumatic connection between the PowerPack and cabin, pulling gently on the connection to check it is secure.


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6.3.2.3 Winch modul e to C abin 1.

Remove the hoses from their transport positions on the roof of the winch (if not already removed), and lay the hoses along the ground to the appropriate connection points on the cabin and winch. See Figure 6.9.


hydraulic hose connectors

Winch

Cabin

Figure 6.9 Winch/Cabin hydraulic and pneumatic connections 2.

Connect each of the hy draulic hoses to the c onnection points on the winch and cab in as follows (make sure you have an unused, clean cloth on hand): a) Check the connection number near the hose connection ferrule. b) Identify the corresponding coupling on the winch and cabin. c) Remove the protection cap on the coupling, and clean the coupling carefully and thoroughly (allow no dust or sand to be present). d) Remove the protection cap from the hose, and again clean the coupling scrupulously. e) Make the connection, and pull on it to be sure it is secure.

3.

With equal attention to avoid contamination, make the pneumatic connections between the winch and PowerPack, pulling gently on the connection to check it is secure.

6.3.2.4 PowerPack auxiliary air ou tput If air is required for auxiliary equipment, connect the auxiliary connector as follows: 1.

Make sure that the RIG OUT valve behind the crowsfoot connection on the front of the PowerPack is closed.

2.

Find a rig air supply with suitable pressure and flow (7 bar at 25L/min.), and use a hose (with correct dimensions) to connect the air supply to the rig air connection. See Figure 6.10.

3.

Open the shore/rig air supply at the supply point, then slowly open the rig air intake valve on the PowerPack so that it is parallel with the connector.





isolation valve (closed)

crowsfoot connector

Figure 6.10 PowerPack air out connection with closed isolation valve 4.

6.3.3

Slightly open the air OUT valve and verify that there is pressure here, then close the valve.

Fir st ti me st art up 1.

Set the isolation valve to the ‘normal’ position (never run the motor when the valve is in the (dis)connect position).


valve

normal position

Figure 6.11 Isolation valve in PowerPack

6.3.4

2.

Check that all power switches in the cabin and PowerPack are switched off.

3.

Power up the engine as described in 7.2 Power up on page 74.

4.

Test the unit as described in 7 Operation on page 73.

5.

Shut down the unit by performing 7.5 Normal shut down on page 82.

Setup the levelwind a nd me asure head

WARNING MOVING PARTS Moving parts (drum, gearbox, chain) can cause serious injury or death. Make sure the winch cannot be operated during maintenance or rig-up activity.

1.

Remove the front beam from the winch.


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front beam

Figure 6.12 Removable front beam 2.

Release the measurehead carrier from its transport position. a) Withdraw the lynchpin from the transport mounting pin of the carrier. See Figure 6.13. b) Slide the measurehead carrier off the transp ort mounting pin, and reins ert the lynchpin through the transport mounting pin. c) Remove the rotation lock pin and rotate the measurehead carrier into the operations position (with the guide rollers towards the drum). Re-insert the rotation lock pin through the measurehead carrier at the swivel point.

transport mounting pin rotation lock pin lynch pin

Figure 6.13 Measurehead carrier transport position 3.

If not already loaded, load the measurehead onto the carrier as described in the Smarthead User Manual.

4.

Tighten the chain tensioner for the levelwind until the chain is tight. See Figure 6.14.





chain tensioner

Figure 6.14 Levelwind chain tensioner

6.4

5.

Thread the wireline through the measurehead as described in the Smarthead documentation.

6.

If necessary, turn the LEVELWIND knob to UP to raise the levelwind support arms into the correct position to satisfy the fleet angle.

Rig-down 1.

Turn the LEVELWIND knob to DOWN to lower the levelwind support arms into the transport position.

2.

Loosen the chain tensioner for the levelwind until the chain is loose. See Figure 6.14.

3.

Lock the Smarthead in its transport position as follows: a) Remove the rotation lock pin from the swi vel point, and rotate the measu rehead carrier into the transport position (parallel to the drum). See Figure 6.13. b) Re-insert the rotation lock pin. c) Withdraw the lynchpin from the transport mounting pin. d) Slide the measurehead carrier onto the transport mounting pin, and reinsert the lynchpin through the transport mounting pin.

4.

Ensure that the system is completely shut down by performing 7.5 Normal shut down on page 82.

5.

Switch off all power switches in cabin and PowerPack.

6.

Make absolutely certain that: a) The hydraulic system is depre ssurized. b) The pneumatic system is depressurized and all isolation valves are closed.

7.

Check the hydraulic and pneumatic systems for leaks and or damage.


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8.

Set the isolation valve to the to the ‘(dis)connect’ position.


valve

normal position

Figure 6.15 Levelwind movements 9.

Perform hydraulic and pneumatic rig-down as follows: a) Disconnect the auxiliary air output hose (if con nected in winch), and fit the pro tective cap to the connector. b) Disconnect the hydraulic and pneumatic hoses in the winch module one by one: c) With a clean cloth, thoroughly clean the dust caps for each side of the connection. d) Disconnect the quick-connector, and with a clean cloth, wipe all dust and oil off the connector male and female side. e) Fit the dust cap to each side. f) Gather the hose into loops, and lay them neatly on the roof of the PowerPack and the winch module. g) If required, fasten the hoses using tie-wraps or tape to prevent damage during transportation. h) If connected, disconnect the auxiliary air supply from the crows foot co nnector on the PowerPack and fit the crowsfoot cap.

10. Perform electrical rig-down as follows: a) Ensure the SlimSplit C is electrically shut down: b) At the recess in the left of the cabin module, disconnect the signal and power cables. c) At the front left of the cabin module, disconnect the signal cable from the winch. d) At the PowerPack, disconnect the electrical cable (if rig 2-phase was used, dis connect at the rig). e) With a clean cloth, thoroughly clean the dust caps for each side of the connection. f) Wipe the connector and socket with a clean, dry cloth. g) Close the dust cap on each side. h) Gather the cables into loops and hang them on the s towage hook inside the recess in the cabin module. 11. Check all fluid levels, and perform maintenance as required. Page 70 of 211 Version 1.00




12. In the operator cabin, stow all loose items and close the door securely. 13. Replace the front beam on the winch module (if removed).

front beam

Figure 6.16 Removable front beam 14. Make sure all access doors and panels are correctly closed. 15. Lock the operator cabin door and all external unit doors. 16. Dismantle and stow any barriers or warnings around the operational danger zone.

6.5

Storage

6.5.1

Shor t te rm st ora ge (< 1 year) When storing the system for a short term, always take the following actions: 1.

Complete the rig-down steps as described in 6.4 Rig-down on page 69.

2.

If the machine is going to be stored in temperatures under -18 °C (0 °F): a) Refer to 6 Maintenance on page 69 for the procedures to remove water from: • Fuel tank, filters & lines • Engine cooling system & reservoir • Hydraulic system & reservoir • Pneumatic anti-frost system • Wellhead pressure control system reservoirs (grease injection, stuffing box, etc.) • Pressure testing reservoir • Drinkable water tank (if present) b) Completely fill the fol lowing fluid reservoirs (if present) with appropriate fluid for expect ed low temperatures: • Fuel tank, filters & lines (fill the diesel tank completely with winter diesel if available) • Engine cooling system & reservoir • Hydraulic system & reservoir • Pneumatic line oiler • Pneumatic anti-frost system • Wire spray system & reservoir


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• Grease injection system reservoir • Pressure testing reservoir • Standby heater kerosene (paraffin) tank • Wellhead pressure control system reservoirs (grease injection, stuffing box, etc.) c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures. Refill with fluid again to full, if necessary.

6.5.2

3.

Switch off all circuit breakers and power switches.

4.

Grease exposed metal surfaces (such as drum, electrical connectors and cylinder rods that are extended) to prevent corrosion.

5.

Close all doors and hatches on the unit and secure or lock them.

6.

Cover the unit with a suitable protection cover (these can be ordered from ASEP if required).

Lon g te rm st ora ge (> 1 year) When storing the system for long periods, follow the steps in 6.5.1 Short term storage (< 1 year) on page 71, and take the following additional actions: 1.

Disconnect and remove any batteries in the un it and store them where they will not be affected by large changes in temperature.

2.

Grease all rubber seals to prevent them perishing and cracking.

3.

Protect hydraulic hoses outside the unit from direct sunlight and extreme temperatures, and plug open connections

4.

Refer to your company policy for other possible storage requirements.





7

OPERATION NOTE: Before attempting to start the SlimSplit C , first read this entire section thoroughly and make certain you understand every part. Do not startup the SlimSplit C unless you know how to perform a controlled shutdown.

7.1

Pre-start checklist If you have not already done so, please read section 2 Safety on page 10 completely before proceeding.


WARNING SHARP OBJECT Sharp or rough objects such as broken or frayed wire strands can cause severe cuts. Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never use your bare hands.

1.

Ensure that the SlimSplit C has been correctly installed and is ready for operations. See 6.3 Rig-up on page 60.

2.

Ensure that the engine is stopped and the engine start is disabled.

3.

Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or components, and structural damage.

4.

Check all tanks and hoses for leaks, and for other visible damage.

5.

Check all mounting bolts on the w inch module (drum bearings/supports).

6.

Inspect the main hydraulic pump group and lines for damage, leaks and/or insecure attachment.

7.

Check all hydraulic oil filters for leaks.

8.

Check the hydraulic filter indicators. Clean and/or replace the element as necessary. See 7.5 Replace hydraulic suction filter on page 92.

9.

Ensure that the cooling air intake and exhaust openings are not obstructed.

10. Ensure that all components requiring lubrication are serviced as necessary. See 8.2 Periodic maintenance scheduleon page 86. 11. Check that no unauthorized modifications have been made to the unit. 12. Check the engine fuel level. If required, fill with the correct fuel for the climate. See NOTE: Before using the unit, always check the diesel level; also regularly check the diesel level during operations.on page 159. 13. Check the hydraulic oil level by performing 7.32 Check/fill hydraulic oil on page 139. 14. Check the reduction gearbox oil level by performing 8.2.11 Check/fill reduction gearbox oil on page 103.


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7.2

Power up 1.

Prime the diesel engine by pumping the diesel engine primer ( Figure 7.1) several times.

diesel engine primer

Figure 7.1 Engine primer 2.

On the cabin control panel, ensure that the drum control levers for the hydraulic pump and motor is in the middle position. See Figure 7.2.

Figure 7.2 Control joystick in middle position 3.

Make sure the BRAKE control switch is in the ON position. See 5.1.3 Cabin control panel (right) on page 51 for location.

4. 5.

Press the reset button on the spring starter. See Figure 7.3. Wind up the spring starter by fitting the hand crank (wind lever) to the winding nut, and crank clockwise until the tension indication window turns red.

NOTE: If it is required to relieve the spring pressure later without starting the engine, turn the crank handle counter-clockwise until the tension indication window turns green.





tension indication window winding nut reset button spring starter handle hand crank

Figure 7.3 Spring-driven starter 6.

Remove the hand crank from the winding nut and store it in its holder.

7.

Check and, if necessary, reset the sentinel master valve by turning the control lever against the spring pressure. This will reset the diesel safety system to allow diesel flow. NOTE: Repeat step 7 for every start attempt. If the engine has just been maintained, you might have to bleed the entire diesel system (see 6.40 Prime diesel engine on page 158).

8.

Push the AIR INLET VALVE fully up to the UP FOR START position, and hold it in place. See section 5.2 PowerPack controls on page 56 for location.

9.

Activate the spring starter handle (by pushing upwards) to start the eng ine. See Figure 7.3.

10. When the hydraulic ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position. If the engine fails to start, troubleshoot the system. 11. Check that the hydraulic CONTROL PRESSURE gauge stabilizes between 20 bar and 28 bar. If the pressure is less than 15 bar, see 9 Troubleshooting on page 184. NOTE: The control pressure will vary slightly with the rpm of the engine. 12. On new units, thos e recently overhauled, or after chang ing hydraulic oil, operate all systems a minimum of two complete cycles, and then re-check for oil leaks. 13. Check the MAIN PRESSURE gauge in the cabin. This should be at least 20 bar. 14. If using the 30 kW generator to supply power: a) On the tachometer, check the engine speed is at least 1500 rpm. If nec essary, increase engine speed to 1500 rpm using the THROTTLE button on the cabin control panel (see 5.1.1 Cabin control panel (left) on page 49).


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b) Start the generator by pressing and holding the GENERATOR START button on the PowerPack control panel. c) Once the GENERATOR RUNNING lamp lights up on the control panel, the generator is running. d) Turn on the SlimSplit C main power switch on JB2 in the cabin. See Figure 7.4. e) Check that the generator status lamps on JB2 are OK (green lamps on and red VOLTAGE ERROR lamp out). If the red VOLTAGE ERROR button is on, see 9 Troubleshooting on page 184

general error and gas/fire status lamps

generator status lamps

zone 2 purge switch

main power switch

Figure 7.4 Control panels in PowerPack 15. Check that all gauges, SmartView display and status lights in the cabin and Power Pack are all working and no errors are displayed. If the generator fails to start or generate sufficient voltage, refer to 9 Troubleshooting on page 184. 16. If using the Smar tDisplay and/or SmartMonitor, power up these sy stems as described in their respective User Manuals.





17. If operating the SlimSplit C in ZONE 2 safety areas with non-EX equipment present in the cabin module: a) Open the cabin interior ventilation ports. b) At JB2 (the Combined Pressurization, Fire Detection & Gas System), turn the PURGE mode switch to the NORMAL position and turn on the START PRESSURIZING switch. See Figure 7.4. If required, remove the key from the PURGE mode switch. This will activate the overpressure fan, the pressure sensor and the gas detection system. Once activated and working correctly, electrical power will be available to all nonEX equipment inside the cabin module. With the door closed and ventilation ports open and unobstructed, it will take approx. 22 minutes to purge the unit and build up the required over-pressure. The cabin overpressure is monitored on the gauge beside the control panel. See Figure 5.1.5.

7.3

Pre-run Before using the unit for the first time:

7.3.1

1.

Ensure that the operator site is free from oil, fuel, dirt and other debris.

2.

Check for smooth and correct operation of all unit functions.

3.

Test the hydraulic drive system and brake system by doing 7.3.1 Hydraulic pressure test on page 77.

4.

Perform a running test by doing 7.3.2 Running test on page 78.

Hyd raul ic pr ess ur e te st 1.

Ensure that the drum brake is ON.

2.

If not already connected, secure the inhole wireline end to the dru m and make sure the wireline can rotate freely with the drum.

3.

Ensure the WINCH SAFETY knob is fully open (screwed counter-clockwise all the way to ‘-’). See 5.1.3 Cabin control panel (right) on page 51.

4.

Pull back the DRUM CONTROL levers for the pump direction and hold th em in the half-way back position. See 5.1.1 Cabin control panel (left) on page 49.

5.

Use the THROTTLE control button to increase the motor speed to its maximum.

WARNING HIGH PRESSURE If the hydraulic system pressure exceeds 400 bar (5800 psi), hydraulic components might rupture and cause serious injury or damage equipment. Never allow the hydraulic system pressure to exceed 400 bar (5800 psi).

6.

Turn the WINCH SAFETY knob clockwise to slowly increase the main hydraulic system pressure.

7.

Check the MAIN PRESSURE gauge on the cabin display. The pressure should increase to a maximum of approximately 150 bar. Hold this pressure for approximately 30 seconds. • If the drum starts to break free of the drum brake, check the braking system components for signs of wear, and re-adjust the brake tensioning lever setting if necessary. See 7.40 Adjust drum brake on page 168.


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• If the MAIN PRESSURE does not reach 150 bar, increase the position of the hydraulic control lever to the full position, and repeat this procedure. • If the CONTROL PRESSURE falls below 15 bar during testing, contact ASEP. 8.

After testing, check the hydraulic system hoses and couplings for leaks.

9.

Repeat the above procedure, this time moving the DRUM CONTROL lever for the pump directional control towards the fully forward position until 150 bar pressure is reached.

NOTE:

7.3.2

When reeling inhole, the position of the WINCH SAFETY valve does not influence the performance of the system.

Run nin g test 1.

If not already connected, secure the inhole wireline end to the drum and make sure the wireline can rotate freely with the drum.

2.

Ensure that the drum brake is OFF.

3.

Ensure the WINCH SAFETY knob is fully open (screwed counter-clockwise all the way to ‘-’). See 5.1.3 Cabin control panel (right) on page 51.

4.

While observing the CONTROL PRESSURE gauge on the display: a) Increase engine speed to mid range (1800 RPM) using the THROTTLE control. b) Maximize MAIN PRESSURE: turn WINCH SAFETY knob fully clockwise (+). c) Slowly move the DRUM CONTROL joystick fully in OUTHOLE direction to obtain maximum drum speed. The drum will "reel-in". d) Slowly return the DRUM CONTROL levers to the neutral position. e) Slowly move the DRUM CONTROL levers fully in INHOLE direction to obtain maximum drum speed. The drum will "reel-out". f) Slowly return the DRUM CONTROL levers to the neutral position. g) Turn the WINCH SAFETY knob fully anticlockwise (-). h) Return engine speed to the standby range (1500 RPM) using the THROTTLE control.

5.

After testing, check: • The hydraulic system hoses and couplings for leaks. • The mechanical winch components for loose bolts/nuts.

7.3.3

Levelw in d s ys tem t est Test the correct functioning of the levelwind autospooling and manual override as follows. Observe the response, and refer to the troubleshooting guide if the levelwind fails to perform as it should. Au to sp oo li ng tes t 1.

Set the spooling control speed lever in the w inch to its m iddle position - see 4.7.4.2 Spooling speed knob on page 43.

2.

Set the AUTOSPOOLING switch ON.






3.

Position one person by the winch module.

4.

Ensure that the measuring head is unlocked from transport position.

5.

Take a position where you are certain you or your clothing cannot be trapped by the moving levelwind carriage and measuring head.

6.

Simulate the lateral pressure effect of the wireline on the levelwind carriage by pressing the carriage first to one side, then the other.

7.

This should activate the levelwind autospooling control, by automatically moving the levelwind carriage and measurehead to the left or right. If this does not happen, consult the troubleshooting section.

8.

Leave the winch module and return to the winch cabin.

Manual override test 9.

With the AUTOSPOOLING switch still on, move the SPOOLING CONTROL joystick in each direction (left, right).

10. This should result in corre sponding movement of the level wind carriage (left/right). If this does not happen, consult the troubleshooting section. 11. Set the AUTOSPOOLING switch OFF.

7.4

Run

WARNING RISK OF EXPLOSION Applying the winch brake on a running drum can cause sparks and/or heat, which can cause an explosion. Do not apply the winch brake, while the drum is moving.

During unit operations, the hydraulic oil temperature must not exceed +70 °C (+158 °F). If the temperature goes higher than this, remove the load from the unit, and wait for the hydraulic oil to cool down. If the oil does not cool down, check the cooling system for damage and/or contamination. Also check the hydraulic system for leaks. If required, perform maintenance on the system to prevent further overheating of the hydraulic oil. 1.

If not already connected, run the wireline through the measuring head as specified in the Smarthead User Manual and attach the tools as required.

2.

Ensure that the wire cannot snag in or behind the levelwind as the drum rotates.

3.

If using the SmartMonitor for full system control, refer to the SmartMonitor User Manual for how to fully automatically control the winch. If you are running the winch manually, move the DRUM CONTROL levers and WINCH SAFETY knob in the appropriate direction to spool the wireline on or off the drum at the desired speed: • The WINCH SAFETY knob controls the velocity and/or torque obtained from the hydraulic motor (the maximum right position will generate the biggest flow and drum speed with the least available torque).


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• The right DRUM CONTROL lever controls the direction of the hydraulic pump; push this joystick forward to spool off wire, pull the joystick backwards to spool on wire. The left lever position will control the amount of flow; the maximum up or down position will generate the fastest drum speed (greatest hydraulic flow) with the least available torque. For high torque (maximum pull), only use this lever to POOH (pull out of hole). • If the engine speed decreases during operation, increase it (and the power output) by adjusting the THROTTLE. • If AUTOSPOOLING is set to ON, the wire will be evenly spooled on/off the drum by the levelwind system. If AUTOSPOOLING is set to OFF, use the SPOOLING joystick to manually move the drum. measuring head leftadjust and right the levelwind shaft to SPOOLING wind the wire evenly or off the If necessary, the on spooling speed with the SPEED knobon (see 4.7.4.2 Spooling speed knob on page 430). Refer to 7.4.1 below for an overview of the different run modes using these levers.

7.4.1

4.

Continually check the system status. See 7.4.2 Check status and react to status changes on page 81.

5.

When finished with wireline operations, shut down t he system as described in 7.5 Normal shut down on page 82.

Run m odes

7.4.1.1 Manual winch ope ration a t normal spe ed 1.

Make sure that the wireline is free of snags or loops in the path from the drum to the measuring head.

2.

Ensure that the diesel engine is running correctly (check displays on the cabin and

3.

PowerPack displays). Use the THROTTLE control to set the engine speed to 1800 rpm.

4.

Check and if necessary set the following switches on the control panel: • BRAKE = ON • AUTOSPOOLING = OFF • EMERGENCY STOP = out

5.

Turn the WINCH SAFETY knob to maximum tension (+).

6.

Switch the BRAKE switch to OFF.

7.

Spool wire in the desired direction as fo llows: • To spool wire off (INHOLE direction), gradually move the right DRUM CONTROL joystick to INHOLE. The speed of the winch will increase, the further the left joystick is moved. DRUM CONTROL joystick • To spool wire on (OUTHOLE direction), gradually move rightthe to OUTHOLE. The speed of the winch will increase, the the further left joystick is moved.

NOTE: If the engine speed drops during winching (see tachometer), use the THROTTLE control (+) to increase engine speed to ± 1800 rpm. NOTE: As the winch speed is increased, the torque delivered by the hydraulic motor will decrease - in other words, it will have less pulling-power. At higher speeds, the winch will therefore have more difficulty when it encounters resistance.





7.4.1.2 Manual winch opera tion with variable wireline tension The SlimSplit C controls enable you to finely control winch operation as required for the well logging activity. The four controls used to manually control winch speed and pulling power are: • Left and right DRUM CONTROL joysticks - speed and direction of spoo ling (like “accelerator” & forward/reverse gear) in one) • WINCH SAFETY knob - limits wireline tension (works by restricting output torque of winch motor) • THROTTLE control button (up/down) - regulates engine speed and available power. NOTE: ASEP advises against using the LINE TENSION knob to regulate the winch speed. A situation that calls for careful drum speed control is when raising a tool string through constrictions in the well or wellhead, such as the BOP. The objective is to raise the tool string through the BOP with a minimum of force and speed, so that the correct functioning of all parts is not disrupted, and no parts are damaged. A typical way to do this is as follows (manual operation): 1.

Raise the tool string to a small depth below the constriction

2.

Turn the WINCH SAFETY knob counter-clockwise (-) until the drum does not turn at the set speed.

3.

Turn the WINCH SAFETY knob clockwise (+) until the drum begins to turn. At this point there is only just enough power to overcome the weight of the wireline and tool string.

4.

Turn the WINCH SAFETY knob clockwise a half-turn further. This should pull just hard enough on the tool string to extract it through the constriction. If the constriction is too tight at this setting for the tool string to pass, then the excess hydraulic pressure will be diverted, and the drum will stop without any harm being done. (You should increase the WINCH SAFETY further, in this case.)

NOTE: Avoid prolonged use of the winch with the WINCH SAFETY set too high. This can lead to overheating of the hydraulic oil. 7.4.1.3 Levelwind spooli ng The levelwind system can be used to spool the wire evenly onto the drum during running. This can be done automatically or manually: • Set the AUTOSPOOLING button to ON to spool automatically • Set to OFF to manually move the SPOOLING CONTROL joystick carefully left and right to move the measuring head on its carriage

7.4.2

Check sta tus a nd re act to st atus ch ange s 1.

Regularly check the gauges on the control panels to ensure that the system is operating within its limits (check the specifications in Appendix 1 Specifications on page 188 for the normal operating ranges).

2.

If the SmartView shows an exceptional condition, stop the machine and troubleshoot the potential cause. If the exception condition is extreme, push one of the EMERGENCY STOP buttons (see section 2.2 ATEX and zoning on page 11) to immediately stop the engine and cut system power. The engine also has the following built-in safeguards to shut down automatically and prevent system damage:


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• Engine over-speed (>2200 rpm) • High engine coolant temperature (exceeds 106°C) • Low oil pressure (< 0.5 bar (<7.25 psi))

7.5

Normal shut down Proceed as follows to shut down the SlimSplit C in an orderly manner, and have it ready for operations the next day. 1.

Make certain that the brake is applied: switch the DRUM BRAKE to ON.

2.

In the cabin module: a) Set the DRUM CONTROL levers to the neutral (middle) position. b) Set the SPOOLING CONTROL joystick to the neutral (middle) position. c) Set the following switches on the control panel: • BRAKE = ON • AUTOSPOOLING = OFF d) Reduce the engine speed to idle (± 1100 RPM) using the THROTTLE control. e) Turn off all electrical appliances, accessories and ECLIPS circuit breakers at the electrical panels. f) If using the SmartDisplay and/or SmartMonitor, power down these systems as described in their respective User Manuals. g) Turn off the CABIN LIGHT, DASHBOARD LIGHT and FLOODLIGHTS on JB2. h) Press the STOP PRESSURIZING switch on JB2.

3.

i)

Close the cabin interior ventilation ports.

j)

Turn off the MAIN SWITCH on JB2.

If the PowerPack generator is running, press the GENERATOR STOP button on the PowerPack control panel. Check the GENERATOR RUNNING light goes out. If the unit is connected to a rig power supply, switch off the rig power supply.

4.

At the PowerPack, pull the ENGINE STOP lever to stop the engine. Check the tachometer to ensure the engine speed reduces to zero rpm.

5.

Depressurize the hydraulic system: • Set WINCH SAFETY to minimum (-). • Operate the SPOOLING CONTROL joystick a few times between LEFT and RIGHT until the residual control pressure is depleted. • Operate the DRUM CONTROL joystick a few times between INHOLE and OUTHOLE until the residual main pressure is depleted. • Check the control panel gauges to verify that there is no residual hydraulic pressure.

6.

Depressurize the pneumatic system: a) Release air from the system by slowly opening then closing the air output valve at the PowerPack.





b) Check the pneumatic pressure gauges ( AIR PRESSURE, START PRESSURE) on the control panel, to verify that there is no pressure. 7.

Note the shut-down date and time in the running hours log (see 5 Running hours log book on page 196).

8.

Carry out the following daily shut-down tasks, taking measures to rectify faults as necessary: a) Inspect all hydraulic hoses, couplings, valves, control blocks, motors and pumps for signs of oil leakages, wear and damage to hoses, etc. b) Inspect major mechanical components (levelwind system, chain transmission, drum pillow blocks) for possible looseness, loss of adjustment or mechanical interference. c) Inspect all suction filter condition indicators. d) Check the levels of all fluid reservoirs, replenishing as necessary: • Engine fuel level; • Engine oil level; • Hydraulic fluid level; • Engine coolant level; • Pneumatic line lubricator; • Winch gearbox oil level; e) Check that the pneumatic system automatic water drain is working correctly. f) Wipe down the levelwind support shaft. g) Check the winch drip tray: if necessary, unscrew the plug and drain the drip tray into a shallow waste oil container. h) Remove all dirt, salt, oil, grease, hydraulic fluid etc. from the surf aces in the winch module. i)

Rinse the exterior of the SlimSplit C and interior of the winch module with fresh water.

j)

Lubricate moving mechanical components as required.

k) In the cabin module, clean the interior with a soft cloth and appropriate spray cleaner. Wipe down the window, control panel (plus gauges, switches and joysticks), electrical panel, cabinet and mop the floor clean. Check in-cabin consumables and replenish where necessary.

7.6

Emergency s top The SlimSplit C has two modes of emergency stop: • Manual, which is initiated by a person pushing one of the Emergency stop buttons on the unit. Pushing one of these buttons will choke the diesel air inlet and immediately stop the engine. • System (automatic), which is caused by a sys tem condition. For some engine alarms, the system will automatically shut the engine down. This shutdown procedure is triggered by one of the following: −

Low oil pressure: <0.5 bar (<7.25 psi)

−

High engine coolant temperature (exceeds 106°C)


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−

An engine overspeed situation: >2400 rpm. Excessive rpm will create increased intake vacuum causing the Pyroban air input valve to trip and cut off intake air.

After resolving the emergency situation, perform a pre-start inspection and then restart the unit.





8 8.1

MAINTENANCE Introduction Only qualified and trained personnel should perform maintenance on ASEP Zone 2 equipment. Maintenance can be described as, but not limited to: • Checking and testing components • Cleaning the unit and individual components - accumulated dirt can hamper unit operations and might jeopardize Zone 2 safety • Installing and removing parts from the unit • Filling up the fluid levels on the unit • Lubricating moving parts • Troubleshooting any malfunctions that may occur on the unit before, during and after operations • Calibrating and adjusting settings on the unit's hydraulic, pneumatic, mechanical, electrical and diesel systems Certain scheduled maintenance is required on a regular basis. Inspections and tests should be carried out daily before working with the SlimSplit C unit, but regular maintenance should be performed according to the number of running hours the SlimSplit C has been used. Running hours should be logged by the SlimSplit C operator following a strict discipline (see Appendix : Log session running hours on page 198). Failure to accurately log the running hours can mean that certain maintenance and service activities are not carried out in a timely manner, and can lead to damage to the equipment, and potentially even hazardous situations. The SlimSplit C carries a powerful winch that e xerts extreme forces on its own mountings, on the frame, the mounting points, and (optional) track & pivot base. Furthermore, powerful shocks to the entire unit are possible, when sudden resistance is encountered during winching operation, or when jarring the wireline for an effect in the hole. It is essential to service and maintain the SlimSplit C at intervals at least as frequent as suggested by ASEP in section 8.2 below. ASEP recommends basing the service intervals on hours of running. You may prefer to use calendar time (weeks, months) to dictate the service interval. That is up to the customer to decide, as long as the minimum frequencies recommended here are observed.


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8.2

Peri od ic m ain tenanc e s ch edu le Service interval (hours)

Maintenanceactivity

Page y l i a d

0 0 3

0 0 6

0 0 9

0 0 2 1

l a u n n a / 0 0 5 1

d e r i u q e r s a

See the numbered footnotes below the table for additional information where indicated NA

(2)

Check modules for dirt, damage and leaks (clean/repair if required) Check/fill coolant

94



Check/fill diesel

94

Check/fill engine oil

98

Check/fill hydraulic oil

104

Inspect electrical system



164

 

Air conditioning unit (300 hours service) Check drum brake band

 

110

Check shock absorbers(2)



90 93

 

Check/fillreductiongearboxoil

103



Checkreplacehydraulichoses&couplings

106



Clean diesel coarse particle filter

111

(5)

Clean/replacefueltankbreather Drain water diesel separator

113



115

(5)

Lubricate unit

118

Test drum brake band



148 171

Drainwaterfromhydraulicoiltank

 

129

Check drum alignment(1) Testhydraulicsystempressure





 

116





Cleanexhaustgascoolerflame / trap

172





Drain diesel tank

114





Replaceengineoilandoilfilter

100



Replace diesel fine particle filter element(5) Adjust drum brake band Check/adjust drum chain

124



141



144 149

Test drum mounting(1)



 

Replacehydraulicsuctionfilter

157





Replacehydraulichighpressurefilter

160





Replacewater/dieselseparatorfilter


169






Service interval ( hours )

Maintenanceactivity

Page y l i a d

0 0 3

0 0 6

0 0 9

Zero gas detectors(1)

180



Air conditioning unit (900 hours service)

91



Check/replace engine belt

108

Drain/fill coolant

155

Test engine overspeed safety (during ATEX certification)

d e r i u q e r s a





120

Replace hydraulic oil

0 0 2 1

l a u n n a / 0 0 5 1



 

171





Replace engine air filter

122





Replace air dryer filter

92





Performgeneralelectricalinspection Drain diesel tank

89



114

Prime diesel engine Replace drum brake band Replace drum



126



132



134



Remove/replace slipring

139



Replacehydraulicmotor/gearboxassembly

150



Replace shock absorber

163

Replacefuseor circuitbreaker

165

Replace exhaust gas cooler

177

Check ATEX explosion proof cabinets (during ATEX certification)

  

182



Footnotes to m aintena nce schedule (1) (2) (3) (4) (5)

Also after each transport Also after first 50 running hours Also after first 100 running hours Also every 3 years. More frequent servicing may be necessary, depending on operating conditions and fuel quality


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8.2.1

Safe maint enance shu tdo wn Related topics: • 7.5 Normal shut down on page 82 Before carrying out any maintenance on or around the hazardous parts of the SlimSplit C , it is essential to ensure that the unit is fully shut down, the winch drum brake is applied (and not under tension), and that there is no residual energy in the hydraulic or pneumatic system. Proceed as follows to shutdown the SlimSplit C for safe maintenance. 1.

Complete the wireline service operation, and spool all wire onto the drum.

NOTE: If it is necessary to perform maintenance with the wire inhole, then you must apply the brake and clamp the wire to a rigid structure, such that the wire is relieved of all tension, and no incident in the hole or BOP can cause the wire to come under tension. 2.

Perform a normal shutdown. See related topic.

3.

Release any residual oil pressure from the hydraulic system: a) Close the isolation valve in the line to any hydraulic accumulators. b) Check every hydraulic pressure gauge to ver ify that the residual pressure is zero.

4.

Release any residual air pressure from the pneumatic system: a) Disconnect any rig air connection from the rig air supply, and open the rig air inp ut valve to let the air escape from the unit. b) Close the isolation valve in the line to any air receiver.

5. 6.


c) Check every air pressure gauge to verify that the residual pressure is zero. If you intend to work on any hydraulic component, allow the system time to cool down, and do not open any hydraulic connection unless you are certain that the hydraulic oil is cool. If you intend to work on any electrical component, make absolutely certain that the main power switch is OFF, and that there is no rig AC connected to the unit.




8.2.2

Perform general electrica l ins pection To ensure reliable and safe operation of the SlimSplit C , the electrical system should be thoroughly inspected at regular intervals. Inspect as follows, noting items for repair or adjustment. 1.

Inspect the gro unding cable reel, cable and te rminals at both en ds for good, clean connection.

2.

Inspect all exposed cables for: a) Condition of insulation (damage, cracking, corrosive fluids, moisture penetration); b) Condition of entry glands at cabinets, terminal boxes, controls; c) Condition of labels on cables; d) Exposure to moving parts that may cause damage to the cable.

3.

Inspect all control panels, cabinets and junction boxes for condition of labels, tags and signs. Replace all damaged labels, tags and signs.

4.

Check the mountings of all cabinets, armatures and control devices, and tighten where necessary.

5.

During the 1200-hour service, check continuity/insulation resistance of cables.


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8.2.3

Air co nditioni ng un it (300 hours service ) The air conditioning unit is specially designed for explosion-hazardous area use. There are no components requiring daily service. The following service activities are recommended every 300 running hours or monthly, whichever comes first.


For detailed instructions on the air conditioning unit, please refer to the supplier documentation supplied separately. 1.

Clean air input filter.

2.

Grease condenser motor shaft at point where it enters motor body.

3.

Check tightness of condenser fan im peller and grub screws; tighten if necessary.

4.

Spray condenser fan motor body with heavy duty corrosion inhibitor.





8.2.4

Air co nditionin g un it (900 hours service ) The air conditioning unit is specially designed for explosion-hazardous area use. There are no components requiring daily service. The following service activities are recommended every 900 running hours or every 6 months, whichever comes first.


For detailed instructions on the air conditioning unit, please refer to the supplier documentation supplied separately. Check each of the following points and rectify if necessary. 1.

Check tightness of the following mounting points: a) Condenser b) Compressor c) Evaporator fan d) Evaporator fan im peller

2.

With unit running on cooling, check: a) Unusual noise and vibration b) Refrigerant level: liquid sight glass must be clear with no bubbles showing

3.

Inspect the entire unit for corrosion.

4.

Check for contamination buildup on/in: a) Condenser fins and tube heat exchanger b) Evaporator fins and tube heat exchanger c) Condensate drain (water must be able to drain freely)

5.

Check for refrigerant leakage from joints and couplings (use leak-finding solution or soapy water).

6.

Check electrical connections for tightness and evidence of burning or arcing.

7.

Check electrical wiring for damage to insulation and glands.

8.

Check grounding points for damage to straps, and ensure they are tightly fastened.

9.

Check that evaporator temperature drop is s ufficient for proper cooling. Factory setting: air on

Δ

= 30°C, air off

Δ=

14-16°C.


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8.2.5

Replace air dryer filter Related topics: • 8.2.1 Safe maintenance shutdown on page 88 The air dryer filter is periodically automatically regenerated by a reverse air flow from the regeneration vessel. The incoming air to the filter is shut off and the moisture drain valve is opened. The regeneration flow blows the moisture from the dryer/filter out through a drain. 1.

Shut down the unit for safe maintenance. See related procedure.

2.

Locate the air dryer filter in the PowerPack. See Figure 8.1.

3.

Release all pneumatic pressure from the system by slowly opening the rig air inlet valve.

4.

Unscrew the air dryer filter as a complete unit.

5.

Firmly screw the new air dryer filter onto the filter body.

air dryer filter

Figure 8.1 Air dryer filter

CAUTION ENVIRONMENTAL HAZARD Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site regulations and obey local environmental by-laws.

6.


Dispose of the used air dryer filter according to local environmental regulations.




8.2.6

Check dr um b rake band Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.27 Replace drum brake band on page 132 1.

Shut the unit down for safe maintenance. See related procedure.

2.

Open the appr opriate access doors so that y ou can access the drum brake band(s).

3.

Secure the doors in place with the door catches.


4.

Inspect each brake band for wear. See Figure 8.2. The brake band should be replaced just before the rivet heads embedded in the brake band make contact with the drum

NOTE: The brake band must also be exchanged each time the drum is exchanged.

Figure 8.2 Brake band wear indication 5.

If necessary, replace the brake band. See related procedure.

6.

Remove all tools and materials from the work area.

WARNING CRUSH HAZARD Closing a door or hatch can crush fingers and cause serious injury. Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.

7.

Close all access doors.


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8.2.7

Check /fil l co ol ant Related topics: • 8.2.1 Safe maintenance shutdown on page 88 This procedure describes how to check and top up the cooling system from the filling cap at the top of the radiator. On some units new coolant can be pumped into the cooling system from the lower drain point. This method is normally preferred when the coolant has been completely drained, because the cooling system can be bled at the same time and the risk of introducing air pockets into the cooling system (especially the exhaust gas cooler) is reduced. For optimum cooling, regularly check the coolant level. When filling the radiator always keep in mind that the volume will increase when the engine/coolant is hot. Therefore, take care not to overfill the radiator. If the radiator is overfilled, excess coolant will be forced out of the coolant overflow during operations. 1.

Shut the unit down for safe maintenance. See related topic.

2.

Remove the coolant access panel at the top of the unit (optional). If the unit does not have an coolant access panel, open the working side PowerPack door instead, and secure in place with the door catch.

3.

Wait for the coolant to cool down.

WARNING HOT OBJECT Releasing pressure from the cooling system while the coolant is still hot can result in serious burns. Before loosening thecoolant coolanthas fillercooled cap, ordown. other components, make sure the engine/ motor has stopped and the

4.

Carefully remove the coolant filler cap at the top of t he coolant radiator. See Figure 8.3.

coolant filler cap

Figure 8.3 coolant filler cap at top of radiator 5.

Look inside the radiator and check if the coolant level is approximately 2 cm from the top of the filling point.

6.

If the coolant is low, fill the cooling system with coolant by performing following steps; if the coolant level is OK, refit the filler cap.





Fill from top of unit

WARNING HOT OBJECT Releasing pressure from the cooling system while the coolant is still hot can result in serious burns. Before loosening the coolant filler cap, or other components, make sure the engine/ motor has stopped and the coolant has cooled down.

7.

Make sure the filler cap is removed.

8.

Place a funnel in the inlet. If necessary for easier access, attach a flexible hose to the funnel

9.

and place it in the inlet. Pour coolant into the cooling system until the coolant is approximately 2 cm from the top of the filling point.

10. Remove the funnel (and hose) from the inlet.

CAUTION EQUIPMENT DAMAGE Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate the working area and environment. Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are properly tightened.

11. Replace the coolant filler cap. 12. Clean any spilled coolant from around the inlet. Fill from drain plug (optional) 1.

If the unit has an exhaust gas cooler, open the air breather on top of the exhaust cooler assembly.

2.

Make sure the coolant drain valve is closed (valve at 90 degrees to the drain tube). See Figure 8.4 for an example.

3.

Remove the coolant drain plug.

4.

Attach a flexible hose and pump to the coolant drain tube.

coolant drain valve (in closed position)

coolant drain plug

Figure 8.4 Coolant drain 5.

Open the coolant system drain valve (valve in line with the drain tube).


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6.

Pump coolant into the cooling system until the coolant is approximately 2 cm from the top of the filling point.

7.

Close the coolant system drain valve.

8.

If the unit has an exhaust gas cooler, close the air breather on top of the exhaust cooler assembly.

9.

Remove the flexible hose and coolant pump from the drain tube.

10. Refit the coolant drain plug.





8.2.8

Check /fi ll di esel Related topics: • 8.2.1 Safe maintenance shutdown on page 88 NOTE: Before using the unit, always check the diesel level; also regularly check the diesel level during operations. 1.

Open the working side PowerPack door, and secure in place with the door catch.

2.

Locate the plastic fuel tank. See Figure 8.5.

3.

Check the diesel fuel level. The fuel should be visible through the transparent plastic tank.

transparent plastic fuel tank

diesel filler cap

Figure 8.5 Diesel sight glasses and filler cap NOTE: To ensure that the diesel engine functions correctly, always use En590 approved diesel. 4.

If necessary, refill the diesel as follows: a) Shut the unit down for safe maintenance. See related topic.

WARNING RISK OF EXPLOSION Electrostatic discharge can cause an explosion. Always ensure that the unit has been properly grounded using a suitable grounding cable before performing any other work whatsoever on the unit, including connecting or disconnecting any hoses or cables, refuelling the unit, operating the unit, or carrying out maintenance on the unit.

b) Make sure both the unit and the refuelling facility are correctly grounded. c) Remove the diesel filler cap. d) Fill the fuel tank with En590 approved diesel. e) Replace the diesel filler cap. f) Clean any spilled diesel from around the filling point.


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8.2.9

Check /fil l eng in e oi l Related topics: • 8.2.1 Safe maintenance shutdown on page 88 Refer to the diesel engine manual for detailed servicing instructions. 1.


2.


3.

Wait for the engine oil to drain into the engine oil sump (approximately 10 minutes).

4.

Unscrew the dipstick by turning it in an anticlockwise direction. See Figure 8.6 The dipstick is secured in position by a screw thread.

engine oil dipstick

Figure 8.6 Engine oil dipstick 5.

Clean the dipstick, and screw it back into position.

6.

Unscrew the dipstick, and check the oil level.


7. Replace the dipstick, and screw it back into position. Fill engine oil (if required)

CAUTION EQUIPMENT DAMAGE Overfilling the engine oil can damage the seals in the engine. Add the oil slowly and wait until it has run into the engine before rechecking the oil level.

8.


Make sure the working side PowerPack door is open and secured in place.




9.

Unscrew the oil filler cap at the top of the engine. See Figure 8.7.

10. Place the tube in the inlet at the top of the engine. 11. Insert the funnel into the other end of the tube. 12. Slowly add a small amount of oil.

oil filler cap

Figure 8.7 Engine oil filler cap 13. Wait a short while for the oil to run into the engine. 14. Recheck the oil level and add oil as required. 15. Remove the funnel and tube from the inlet.


16. Replace the oil filler cap. 17. Clean any spilled oil from the engine.


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8.2.10 Replace engine oil and oil filter Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.9 Check/fill engine oil on page 98 NOTE: Refer to the Iveco diesel engine manual for detailed servicing instructions. 1.

Shut the unit down for safe maintenance,. See related topic.

2.

Ensure that the diesel engine cannot be started.

3.


4.

Place the open end of the flexible hose in a plastic container. See Figure 8.8.

oil pump handle

flexible hose (place open end in plastic container)

drain valve

Figure 8.8 Engine oil drain and oil pump

WARNING HOT OBJECT Hot engine oil can cause serious burns. Take care when draining hot engine oil. Always wear appropriate Personal Protective Equipment (PPE), such as gloves.

5.

Open the drain valve by turning it upwards (in-line with the tubing). See Figure 8.8.

6.

Remove the oil filler cap. See Figure 8.7. This will prevent air locks from forming when the oil is pumped out of the engine.





oil filler cap

Figure 8.9 Engine oil filler cap 7.

Use the oil pump handle to pump the oil from the engine sump.

8.

Close the drain valve by turning it downwards (perpendicular to the tu bing).

9.

Remove the plastic container.

10. Stow the flexible hose in the unit.


11. Dispose of the oil according to local environmental regulations. 12. Place some rags underneath the engine oil filter. 13. Unscrew and remove the engine oil filter. See Figure 8.10.


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rear of exhaust gas cooler

engine oil filter

Figure 8.10 Engine oil filter 14. Dispose of the filter according to local environmental regulations. 15. Fit the new oil filter. 16. Clean the area around the oil filter, and remove the rags. 17. Refill the oil, and check the oil level. See related topic.


18. Replace the filler cap. 19. Start the engine and let it run until it is warm. 20. Shut down the engine. 21. Check and refill the oil as r equired. See related topic.





8.2.11 Check/fill reduction ge arbox oil Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.



2.

Locate the viewing hole at the rear of the gearbox. See Figure 8.11.

3.

Check the oil level. The oil level should be at th e middle of the sight glass.

fixed cover plate at front of winch module

oil inlet plug

oil level sight glass

oil level

Figure 8.11 Rear view of gearbox 4.

If necessary, fill the gearbox with oil. See following steps.

5.

Remove the oil inlet plug. See Figure 8.11.

6.

Place a tube in the inlet at the top of the gearbox.

7.

Insert a funnel into the other end of the tube.

8.

Slowly pour oil into the gearbox until the oil is visible at the middle of the sight glass.

9.

Remove the funnel and tube from the inlet.


10. Refit and tighten the oil inlet plug. 11. Clean any spilled oil from around the oil inlet and gearbox.


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8.2.12 Check/fill hydra ulic oil Related topics: • 8.2.1 Safe maintenance shutdown on page 88

WARNING RISK OF BURNS If the unit has been running, the hydraulic oil and components can be at an extremely high temperature. Never attempt to dismantle hydraulic connections or replace hydraulic filters until the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or less. Check the hydraulic oil temperature gauge (usually the reservoir temperature), then carefully check the temperature of the applicable component by touch before you start maintenance.



1.

Ensure that the unit is safe for hydraulic maintenance: • The unit is completely shut down; • The unit cannot be inadvertently started (e.g. starter key is removed); • There is zero hydraulic pressure in the hydraulic circuits (check pressure gauges!); • The hydraulic oil is cooled sufficiently to avoid burns (check temperature gauge!).

2.

If the unit is equipped with hydraulic accumulators, depressurize the accumulators.

3.

Inspect the oil level in the sight glass(es) of the h ydraulic oil tank. The correct oil level is mid-point in the upper sight glass of the hydraulic oil tank. .

correct hydraulic oil level: mid-point of sight glass

Figure 8.12 Hydraulic tank upper sight glass (example)





4.

If the oil level is below the correct level: a) Remove the hydraulic oil tank filler cap (see description section). b) Carefully remove accumulated dust and gri t from around the fi ller using a clean cloth. c) Add hydraulic oil of the correct grade (see specifications) until the level is at the mid-point of the upper sight glass. d) Carefully wipe the filler cap clean using a clean cloth, and fit it back on the filler.


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8.2.13 Check repla ce hydra ulic hoses & cou plings Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 7.3.1 Hydraulic pressure test on page 77 The complete hydraulic system should be subjected to a thorough inspection: • every day before duty (described in the operations section); • on a regular basis (see maintenance schedule). Inspect the system as described below, noting which components need to be repaired, replaced or tightened. NOTE: Make a list of all required repairs, and perform these once the inspection is complete, the system has been pressure-tested, and the winch has then been fully shut down and depressurized.

WARNING HOT OBJECT Hot hydraulic oil under pressure can cause serious burns. Before working on components containing hydraulic oil, make sure: - the engine has been stopped. - the pressure has been released from the hydraulic system. - the hydraulic oil has cooled down.


1.


2.

Ensure that the unit is safe for hydraulic maintenance: • There is zero hydraulic pressure in the hydraulic circuits. • The hydraulic oil is cooled enough to avoid burns.

3.

Inspect the general condition of all hydraulic lines and hoses. Look for visible damage, leakage, and “sweating” or “swelling” of hoses.

4.

Inspect the entire unit for signs of leakage, such as oil drips, oily dust build-up, etc., around: • Tanks • Hoses and lines • Couplings/connectors • Control levers • Valves • Filters • Pumps • Motors





5.

Pressure test the hydraulic system. See related procedure.

6.

Make the unit safe for hydraulic maintenance as described in step 1 above.

CAUTION EQUIPMENT DAMAGE Dirty or damaged quick connectors can leak and cause equipment damage. Before connecting any quick connectors, inspect and clean both the male and female parts of the quick connector.

7.

Replace/repair components as necessary.


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8.2.14 Chec k/re pla ce engine be lt Related topics: • 8.2.1 Safe maintenance shutdown on page 88 NOTE: Refer to the Iveco 4-cylinder diesel engine manual in the documentation package for detailed servicing instructions. 1.


WARNING MOVING PARTS Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death. Make sure the engine cannot be started during maintenance.

2.

Ensure that the diesel engine cannot be st arted.

3.


4.

Unscrew all the mounting bolts, and remove the V-belt guard(s). See Figure 8.13.

5.

Put the V-belt guard(s) in a safe place.

bolt

guard in front of V-belts and pulleys bolt

Figure 8.13 Guard in front of V-belts and pulleys

WARNING MOVING PARTS Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death. Make sure the engine cannot be started during maintenance.

6.

Make sure the belts are not damaged or worn. See Figure 8.14.

7.

Make sure the belts are firmly tightened.





Figure 8.14 V-belts and pulleys 8.

If necessary, replace the belts. See the Iveco maintenance manuals for detailed maintenance instructions.

9.

Refit the V-belt guard(s).


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8.2.15 Check shock absorbe rs Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.38 Replace shock absorber on page 163 1.


2.

Open the app ropriate door(s) so that you can easily access all shock absorbers.

3.

Secure the door(s) in place with the door catch(es).

4.

Check the four shock absorbers at each corner of the engine. See Figure 8.15 for an example location. Pay particular attention for loose mounting bolts or uneven wear.

shock absorber

Figure 8.15 Shock absorber 5.

Tighten any loose mounting bolts.

6.

Replace any damaged or w orn shock absorbers. See related procedure.

7.



8.

Close all access doors.





8.2.16 Clean die sel coarse partic le filter Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.25 Prime diesel engine on page 126 1.


2.

Close the di esel tank is olation valve (valve perpendicular to the tub ing). See Figure 8.16 for a typical example.

diesel tank isolation valve (in OPEN position)

coarse particle filter blind cap

Figure 8.16 Diesel tank isolation valve (typical example) 3.

Place some rag underneath the blind cap.

4.

Unscrew the blind cap and remove the coarse particle filter (in-line filter between diesel reservoir and first fine particle filter). See Figure 8.17.

coarse particle filter

blind cap for filter

Figure 8.17 Coarse particle filter 5.

Place the filter in a plastic container and clean with diesel.

6.

Refit the cleaned particle filter, and tighten the blind cap.

7.

Open the diesel tank isolation valve (valve in-line with the tubing).


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8.

Remove the rag from underneath the blind cap

9.

Use a clean rag to clean any spilled diesel.


10. Dispose of used materials according to local environmental regulations. 11. Remove all tools and materials from the work area. 12. Prime the diesel system. See related procedure.


13. Close all a ccess doors.





8.2.17 Clean/replace fue l tank breather Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.


2.

Locate the breather. See Figure 8.18 for a typical example.

diesel tank breather

mesh

diesel tank

Figure 8.18 Diesel tank breather (typical example) 3.

Remove the mesh from the breather.

4. 5.

Place the mesh in a plastic container and clean with diesel. Refit the cleaned/new mesh to the breather.

CAUTION EQUIPMENT DAMAGE The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked). Never block (cap) the fuel tank breather.

6.

Make sure the fuel tank breather is not capped (blocked).


7.

Dispose of used m aterials according to local environmental regulations.

8.



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8.2.18 Drain diesel ta nk Related topics: • 8.2.1 Safe maintenance shutdown on page 88 This procedure describes how to drain the diesel tank in preparation for air transport or if the unit is to be stored for a lengthy period. 1.

Make sure the unit has been shut down for safe maintenance - see related procedure.

2.

Open the appropriate door(s) so that you can easily access the diesel filler cap.

3. 4.

Carefully remove the diesel filler cap at the top of the tank. Uncouple all hoses and cables, and separate the PowerPack from the cabin/winch module (if they are joined).

5.

Place one end of a clean flexible hose in the fuel tank and make sure the hose is fed far enough into the tank to reach the bottom of the tank.

6.

Place the ot her end of the fle xible hose in a conta iner large enough to contain the fuel remaining in the fuel tank.

7.

Siphon or pump the fuel through the hose into the container.

8.

Wait until the fuel is siphoned as much as possible from the fuel tank.

9.

Remove the flexible hose and container.

10. Locate the two fuel tank threaded drain plugs on the sides of the tank. 11. Remove one, and if possible both drain plugs (take care to collect any dripped fuel with absorbent cleaning rags). 12. Using a crane or by levering in the forklift slots, tilt the PowerPack gently to the rea r and the right, until the last of the fuel drips from the drain holes. 13. Replace the dr ain plugs. 14. Replace the diesel filler cap. 15. Dispose of the drained diesel according to local environmental regulations. 16. The system is now ready to be air transported. 17. If the unit has been running on ‘summer’ diesel and is to be stored for a period in cold temperatures, flush the lines and diesel pump with ‘winter’ diesel as follows: a) Carefully remove the diesel filler cap at the top of the tank. b) Fill the tank with 4 liters (1 gallon) of ‘winter’ diesel. c) Replace the diesel filler cap. d) Start the engine and run it at idle speed for 5 minutes. This will flush any remaining ‘summer’ diesel through the diesel pump and diesel lines. e) Switch off the engine.





8.2.19 Drain water diese l sepa rator Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.


2.


3.

Place the plastic container underneath the bowl of the of the water/diesel separator.

4.

Drain the accumulated water by loosening the drain plug at th e bottom of the bo wl. See Figure 8.5.

water/diesel separator drain plug

Figure 8.19 Water diesel separator drain plug 5.

Wait until the bowl is completely drained.

6.

Close the drain plug.

7.

Remove the plastic container.

8.

Clean any moisture from around the water/diesel separator.


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8.2.20 Drain wate r from hydraulic oil ta nk Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.12 Check/fill hydraulic oil on page 104 Water can accumulate in the hydraulic oil tank. Being heavier than the hydraulic oil, it settles to the bottom of the tank when the system is not running, and should be periodically drained.

WARNING HOT OBJECT Hot hydraulic oil under pressure can cause serious burns. Before working on components containing hydraulic oil, make sure: - The engine has been stopped. - The pressure has been released from the hydraulic system. - The hydraulic oil has cooled down.


1.

Shut down the unit so it is safe for hydraulic maintenance. See related procedure.

2.

Check that: • There is zero hydraulic pressure in the hydraulic circuits • The hydraulic oil is cooled sufficiently to avoid burns

3.


4.

Open the right-hand Power Pack door, so that you can easily access the underside of the hydraulic oil tank and drain valve. See Figure 8.20.

blind cap

blind cap

Figure 8.20 Hydraulic oil tank drain valve (two different types) 5.

Unscrew the cap from the drain valve at the bottom of the h ydraulic oil tank.





6.

Attach an open ended hose to the drain valve.

7.

Lead the hose into a suitable collection tank, but make sure you can see the fluid that flows from the hose.

8.

Slowly open the drain valve, and allow the water to run out.

9.

When pure oil starts to flow, close the valve.

10. Remove the hose, and replace the cap. 11. Check the oil level and replenish if necessary. See related procedure.


12. Dispose of all filters and used oil as prescribed by site regulations. 13. Remove all tools and materials from the work area.




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8.2.21 Lubrica te unit Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.



2.

Using a grease gun, apply grease to the drum bearings in the pillow blocks on the right and left side of the winch. Inject grease until it emerges from the sides of the bearing. See Figure 8.21.

3.

Use the rag to remove any excess grease.

grease nipple

winch bearings

Figure 8.21 Winch bearings (2x) on right/left of winch Grease door bearings 4.

Use the grease gun to apply grease to the bearings of the doors. See Figure 8.22.

5.


grease point

Figure 8.22 Door bearings





Grease all other grease points 6.

Use the grease gun to apply grease to all other lubrication points in the system.

7.


8.

Check the Smarthead User Manual for all grease points for the measuring head.

9.

Check the Iveco documentation for grease points for the engine.


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8.2.22 Drain/fill coola nt Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.7 Check/fill coolant on page 94 This procedure describes how to drain the coolant from the drain point at the bottom of the radiator and then refill it from the same point using a hand pump. The coolant can also be topped up from the filling cap at the top of the radiator. NOTE: When filling the radiator always keep in mind that the volume will increase when the engine/coolant is hot. Therefore, take care not to overfill the radiator. If the coolant is overfilled, excess coolant will be forced out of the coolant overflow valve during operations. 1.


2.

Remove the coolant access panel at the top of the unit (optional). If the unit does not have a coolant access panel, open the working side PowerPack door instead, and secure in place with the door catch.

3.

Wait for the coolant to cool down.


4.

Carefully remove the coolant filler cap at the top of t he coolant radiator. See Figure 8.3.

coolant filler cap

Figure 8.23 Coolant filler cap at top of radiator





5.

Make sure the coolant drain valve is closed (valve at 90 degrees to the drain tube). See Figure 8.4 for an example.

coolant drain valve (in closed position)

coolant drain plug

Figure 8.24 Coolant drain 6.

Remove the coolant drain plug.

7.

Connect a flexible hose to the drain tube.

8.

Place the other end of the flexible hose in a plastic container.

9.

Open the drain valve (in-line with the tubing).

10. Wait until the coolant has dr ained from the cooling system, and then close the drain valve (perpendicular to the tubing). 11. Remove the flexible hose and plastic container. 12. Refit the coolant drain plug.


13. Dispose of the coolant according to local environmental regulations. Fill coolant 14. Fill the cooling system and check the coolant level. See related topic.


15. Refit the coolant filler cap at the top of the coolant radiator. See Figure 8.3. 16. Refit the coolant access panel (optional). 17. Use a cleaning rag to clean any spilled coolant.


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8.2.23 Replace engine air filter Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.


2.


3.

Locate the air filter. See Figure 8.5 for an example of an air filter.

4.

Loosen the securing nut, and remove the cover.

NOTE: For easy access, the entire air filter housing can be removed by removing the two securing straps.

securing strap

cover securing nut

Figure 8.25 Air filter 5.

Loosen the securing nut, and remove the safety element. See Figure 8.26.

safety element securing nut

Figure 8.26 Removing safety element





6.

Loosen the securing nut, and remove the filter element. See Figure 8.27.

filter element securing nut

Figure 8.27 Removing filter element Clean/replace filter compon ents 7.

Clean/replace the filter element and safety element.

8.

Refit the filter element, and tighten the securing nut.

9.

Refit the safety element, and tighten the securing nut.

10. Refit the cover, and tighten the securing nut. 11. If the entire air filter housing was removed, reposition the filter housing, and refit the securing straps.


12. Dispose of used materials according to local environmental regulations.


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8.2.24 Replace diese l fin e particle filt er element Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.25 Prime diesel engine on page 126 1.


2.

Open the PowerPack working side access door so that you can easily access the diesel tank isolation valve. See Figure 8.28 for a typical example.

3.

Close the diesel tank isolation valve (valve perpendicular to the tu bing).

diesel tank isolation valve (in open position)

Figure 8.28 Diesel tank isolation valve Remove diesel fine partic le filt er 4.

Place a rag underneath the filter element.

5.

Remove the filter element from the mounting head. See Figure 8.5.


6.

Discard the filter element according to local regulations.





mounting head

filter element

Figure 8.29 Diesel fine particle filter element Fit new diesel fine particle fil

ter ele ments

7.

Lubricate the top seal of the new filter element with clean diesel fuel or engine oil.

8.

Fill the new filter element with clean diesel fuel.

9.

Fit the filter element to the mounting head. Turn the filter element until it contacts the top seal, and then hand-tighten an additional third to half turn. Do not over tighten.

10. Open the diesel tank isolation valve, and check the fine particle filter for leaks. 11. Rectify any problems. 12. Purge the diesel system. See related topic. 13. Start the di esel engine. 14. Check for correct operation, and recheck the fine particle filter for any leaks. 15. Rectify any problems.


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8.2.25 Prime diese l engine The diesel engine can be primed in 2 ways depending on how long it has been idle: • Quick prime - if the engine has only been idle for a few hours. See steps 1 to 3. • Prime entire system - if the engin e does not start af ter using the quick prime method, the tank was allowed to run empty, or after maintenance on the fuel system. See steps 4 to . Quick prim e diese l engine NOTE: Use the quick prime method each time the engine is started. 1. 2.

Open the working side PowerPack door, and secure in place with the door catch. Push the spring loaded diesel engine primer several times. Diesel will be pumped out of the tank and into the system.

diesel primer

Figure 8.30 Diesel engine primer 3.

Clean any spilled diesel form around the engine.

Bleed entire diesel syst em 4.

Ensure the di esel engine cannot be star ted. Inform personnel, place warning signs.

5.

Make sure the working side PowerPack door is open and secured in place.

6.

Bleed the fuel line to the diesel pre-filter and water separator as follows: a) Loosen the bleed screw on the diesel pre-filter and water separator. See Figure 8.31.





bleed screw

Figure 8.31 Diesel pre-filter and water separator a) Push the spring loaded diesel primer until fuel appears at the bleed screw. b) Tighten the bleed screw. 7.

Bleed the fuel line to the diesel fine filter as follows: a) Loosen the bleed screw on the diesel fine filter. See Figure 8.32.

bleed screw

Figure 8.32 Diesel fine filter

a) Push the spring loaded diesel primer until fuel appears at the bleed screw. b) Tighten the bleed screw.


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8.

Bleed the fuel line to the diesel pump as follows: a) Disconnect the hose at the top of the diesel pump. See Figure 8.33 for an example.

hose

hose connection point

diesel primer

Figure 8.33 Hose at the top of the diesel pump a) Connect a flexible hose to the top of the pump. b) Place the other end of the tube in a plastic container. c) Push the spring loaded diesel primer until fuel flows into the container. d) Disconnect the flexible hose from the top of the pump. e) Reconnect the hose at top of t he diesel pump. 9.

If applicable, bleed the injector lines as follows: a) Slightly loosen the injector lock nuts on the eng ine block (approximately one turn). Use two wrenches to prevent the steel lines from twisting. Usually, it is enough to bleed half of the lines at a time. b) Attempt to start the engine. This will force air out of the injector lines. c) When all air has been forced out of an ejecto r line and diesel fuel is present, tighten the injector locknut. d) Repeat steps b through c until all lines have been bled or the engine starts. e) Run the engine unt il it runs smoothly. This will ensure that all injectors are sufficiently bled.

10. Clean any spilled diesel form around the engine.





8.2.26 Test drum brake band Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.30 Adjust drum brake band on page 141 • 8.2.27 Replace drum brake band on page 132 It is vital for correct and safe operation that the winch drum brake functions correctly. The brake should be tested on a periodic basis and after any maintenance to the winch and brake subsystems. Perform the three tests described below on each drum in the winch unit. NOTE: The test refers to the MAIN PRESSURE. This is the system pressure in the main hydraulic circuit, and is indicated by a pressure gauge on the winch control panel. See related topic. Drum brake free- runnin g test The drum is correctly adjusted when there is no contact between the brake band and the drum with the brake released.

WARNING MOVING PARTS Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause serious injury or death. Take care when working with moving parts. Warn others of the danger, and cordon off the dangerous area.

1.

Wind in all wireline cable and secure it to the drum.

2.

Start the unit for operations.

3.

Put the unit into manual mode. If applicable, disable the automatic winch control program (e.g. SmartMonitor).

4.

Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.

5.

Release the BRAKE.

6.

Using the DRUM CONTROL joystick(s), start to turn the drum slowly INHOLE, and allow it to continue to turn at a low speed.

7.

At the winch, listen (or have an assistant listen) for sounds that may indicate that the drum is in contact with the brake band(s). If applicable, check both brakes.

8.


9.

Apply the BRAKE.

10. If there was no br ake-contact noise from the drum in step 7, then the brake has passed the free-running test. Continue with the drum brake slip test (next section). If brake-contact noise was heard, then the brake needs adjustment. See related topic. Drum brake slip test The drum is correctly adjusted when the drum slips in the applied brake at a MAIN PRESSURE of about 210 bar.


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WARNING HIGH PRESSURE If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components might rupture and cause serious injury or damage equipment. Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).

1.

If applicable, wind in all wireline cable and secure it to the drum.

2.


3.


4.

Put the DRUM CONTROL joystick(s) into the neutral ( STOP) position.

5.

Apply the BRAKE.

6.

If applicable, select HIGH speed ratio and medium LINE TENSION.

7.

On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine speed to the maximum torque range.

8.

Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE until the drum slips in the brake.

9.

Check the MAIN PRESSURE gauge and note the brake slip pressure.

10. Put the DRUM CONTROL joystick(s) into the neutral ( STOP) position. 11. On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed to the idling range. 12. Apply the BRAKE. 13. If the MAIN PRESSUREwhen the drum slipped in step 17 was within the range of approximately 180 to 240 bar, then the brake has passed the slip test. Continue with the drum brake stopping test (next section). If the drum slipped below 180 bar (too slack) or above 240 bar (too tight) of MAIN PRESSURE, then the brake needs adjustment. See related topic. Drum brake stopp ing test This brake must quickly stop the drum in a controlled, smooth manner. i.e. without juddering or causing extreme shock to the winch and other equipment. The effect during actual operations will be different, depending on: • the amount of wire on the drum (a fully loaded drum has more momentum); • the weight of the tool string; • the effect of wellbore pressure and resistance on the tool string and wire; • the direction of operation (inhole or outhole); • the speed and torque of the drum (selected gear, engine speed, etc.); • moisture and oil on the drum rim. The test is conducted in one specific situation. It is recommended to always conduct the test in the same situation and under the same conditions. 1.

If applicable, wind in all wireline cable and secure it to the drum.





2.


3.


4.


5.

Release the BRAKE.

6.

If applicable, select LOW speed ratio and medium LINE TENSION.

7.

On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine speed to the maximum torque range.

8.

Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE to about 100 bar, so that the drum is rotating at a fairly high speed.

9.

Apply the BRAKE. The brake should quickly and smoothly halt the drum rotation.

10. Put the DRUM CONTROL joystick(s) into the neutral (STOP) position. 11. On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed to the idling range. 12. If the drum stopped quickly and smoothly at step 9, then th e brake has passed the stopping test. If the drum did not completely stop, or did not stop smoothly, then the brake needs adjustment. See related topic. 13. Shut down the unit.


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8.2.27 Replace drum brake ba nd Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.30 Adjust drum brake band on page 141 This procedure applies to winches with either a single brake (one rim) or a dual brake (two rims). On larger drums, to ease installation and removal, the brake band is a two-piece assembly joined with a turnbuckle connection at the top.


NOTE: On a dual-brake drum, always replace both bands at the same time. Ensure this locknut is tightened against the threaded block in the brake band

upper turnbuckle with locknut (larger drums only)

adjuster at the cylinder

NOTE: The setup can differ slightly from one winch to another. For example, the brake cylinder can be mounted vertically or horizontally. The brake piston may act directly, or via a linkage.

Figure 8.34 Drum brake band components Proceed as follows, referring to Figure 8.34. 1.






2.

Apply the BRAKE.

3.


4.

For each brake on the drum, remove each of the old brake bands: Observe how the existing brake is assembled, and which parts belong where. a) Remove all guards surrounding the winch drum and brakes. b) Completely loosen and detach the lower brake band adjuster at the brake cylinder. c) Remove the pivot pin and detach the other end of the brake band from the brake cylinder assembly. d) If applicable (split band): completely loosen and detach the upper turnbuc kle between the two brake band segments. e) Withdraw the old brake band segments from around the drum. f) If applicable (split band): remove the retaining clips and pivot pins from the turnbuckle attachment blocks. g) Remove the blocks from both ends of each brake band segment.

5.

Discard the used brake band.

6.

For each brake on the drum, install the new brake band by proceeding through the removal steps in reverse order. If applicable (split band): leave sufficient play in the turnbuckle so that the ends of the assembled brake band are easier to connect at the brake cylinder. NOTE: Ensure the retaining pins are inserted through the pivot points in both turnbuckle attachments.

7.

With the brake still applied under spring pressure from the brake cylinder, tighten each brake at the lower adjuster until it presses firmly against the drum, then tighten the locknut against the threaded block.

NOTE: This is only an initial adjustment. the brake must now be properly adjusted. 8.

Perform the brake adjustment procedure. See related topic.


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8.2.28 Replace drum Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.27 Replace drum brake band on page 132 • 8.2.31 Check/adjust drum chain on page 144 • 8.2.33 Test drum mounting on page 149 • 8.2.34 Replace hydraulic motor/gearbox assembly on page 150 • 8.2.29 Remove/replace slipring on page 139 NOTE: A new brake band must be fitted every time a new drum is fitted to the unit. See related topic.


1.

Remove the wireline from the measuring head assembly and secure it to t he drum.

2.

Set the brake to ON.

3.

Lower the levelwind arm (if not already lowered) using the switch on the cabin control panel.

4.


5.

Open the access door(s) on either side of the winch module.

6.

Remove the attachment bolts, and remove the drum guards. See Figure 8.35.

NOTE: There is a drum guard on either side of the drum.

drum guard

drum guard attachment bolt

Figure 8.35 Removing drum guard






7.

Start up the unit. See Operation section.

8.

Set the brake to OFF.

9.

Slowly push the dual control levers forward until the master link in the drive chain can be easily accessed. See Figure 8.36.

master link

clip locking type

split pin locking type

Figure 8.36 Master link in drive chain (split pin or clip locking) 10. Shut the uni t down fo r safe maintenance. See related topic. 11. If an encoder/slip ring is fitted to the drum, remove the encoder/slipring. See related topic. 12. Remove the brake band. See related topic. NOTE: To allow for easy access to the drum, remove the winch front beam. 13. Turn the drum alignment bolts (2x for each bearing) until the threaded end of the bolts are clear of the drum bearing housing. See Figure 8.37.

drum attachment bolt

drum bearing housing

drum alignment bolt

Figure 8.37 Drum alignment and adjustment bolts


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14. Remove the drum attachment bolts (2x for each bearing).

WARNING HOISTING HAZARD Incorrectly hoisted loads can fall down causing serious injury or death. Support the assembly at both ends, using two lifting straps and a hoist rated for the given weight. Carefully control movements to avoid damaging other components.

15. Place the lifting straps at either end of the drum, and attach the straps to a hoist. 16. Use the hoist to slide/move the drum assembly forward just enough to slacken the chain. 17. Remove the locking device and master link from the chain, and then remove the chain from the drum. See Figure 8.36. 18. Reposition the master link and locking device, and store the chain inside the winch.


19. Use the hoist to lift the drum out of t he unit. 20. If the drum is being stored for any period, apply high quality multipurpose grease to the dr um journals and bearings. 21. Store the drum in a suitable shipping container. Refit dr um 22. Check the condition of the drive sprocket on the gearbox. If nec essary, replace the drive sprocket. See related topic. 23. Check the condition of the winch frame. Report any damage. 24. Use a rag to clean any excess grease or dirt from the winch frame.


25. Place the lifting straps at either end of the drum, and attach the straps to the hoist.


26. Use the hoist to lift the drum out of the shipping container. 27. Carefully lower the drum so that the bearing blocks rest on the winch frame. 28. Insert the drum attachment bolts, and tighten to finger-tight.





29. Position the chain around the drive sprocket and drum sprocket. 30. Refit the master link and secure with the locking device. See Figure 8.36. If the chain is secured with split pins, make sure to use new split pins. 31. Make sure the locking device is correctly secured. 32. Adjust the chain. See related topic. 33. Make sure the distances (a) and (b) between the bearing housing adjustment block and the bearing housing are the same on both sides of the drum. See Figure 8.38. This will ensure that the drum is correctly aligned in the winch module.

bearing housing

bearing housing adjustment block

bearing housing adjustment block

distance (a) should be the same on both sides of the drum

distance (b) should be the same on both sides of the drum

Figure 8.38 Drum bearing alignment

WARNING MOVING PARTS An incorrectly adjusted brake band can result in hazardous operating conditions. Before operating the unit, make sure the brake band has been correctly adjusted. When the brake is set to off, it must not rub against the drum, otherwise sparks might be generated. When the brake is set to on, it must hold the drum firmly in position.

34. Make sure the drum attachment bolts on both sides of the drum are securely tightened. 35. Remove the lifting straps and hoist, and store in a safe place. 36. Refit the brake band. See related topic. 37. Refit the drum guards and tighten the drum guard attachment bolts. NOTE: There is a drum guard on either side of the drum. 38. If an encoder/slip ring is fitted to the drum, refit the encoder/slipring. 39. Lubricate the drum bear ings on both side s with high quality multipurpose grease. Inject grease using a grease gun until excess grease appears outside the bearings. 40. Use a rag to clean any excess grease or dirt from the bearings and work area. 41. Remove all tools and materials from the work area.


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42. Start up the unit as described in the Operation section. 43. Slowly rotate the dru m in both d irections. 44. Check for correct drum movement and operation of the brake. Rectify any problems. 45. Perform the drum mount test. See related topic.





8.2.29 Remove/ repla ce slipring Related topics: • 8.2.1 Safe maintenance shutdown on page 88


Shut down the unit for safe maintenance. See related procedure. Remove 1.

Remove the ground cable (1) on the slipring. See Figure 8.39.

2.

Loosen any attachment brackets (4) on the slipring.

3.

Remove all the attachment bolts (2) on the casing (3) of the slip ring.

2 3

2

4

1

Figure 8.39 Replacing slipring 4.

Carefully slide the casing off the slipring.

5.

Remove the screws (1) holding the plastic attachment cap (2) on the end of the slipring to expose the logging wire connectors (3). See Figure 8.40.

6.

Loosen all the logging wires from their connectors (3) on the slipring. The number of logging wires is customer specific.

7.

Loosen all the bolts (1) holding the base of the slipring to the drum attachment. See Figure 8.41.

8.

Remove the slipring while carefully feeding the logging wires through the centre hole of the ring.

9.

Lay the slipring to one side, or remove it completely by disconnecting the slipring connector at the cabin wall.


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3

3

2 1

Figure 8.40 Removing logging wiring

1

Figure 8.41 Removing slipring Replace 1.

If attached, remove the casing and the plastic top cap on the slipring. See Figure 8.39 and Figure 8.40.

2.

Position the slipring against the drum mounting while feeding the logging wires through the centre of the slipring.

3.

Tighten the bolts attaching the slipring to the drum mounting. See Figure 8.41.

4.

Connect all the logging wires to the applicable connectors on the top of the slip ring (see Figure 8.41). The wires should be connected according to your customer specific logging wirie diagram.

5. 6.

Attach the plastic cap to the top of th e slipring using the attachment screws. See Figure 8.41. Carefully slide the casing over the slipring, making sure not to damage any of the logging wires.

7.

Tighten all the attaching bolts on the casing. See Figure 8.39.

8.

Attach the ground cable to the slipring.

9.

Tighten any attachment brackets to the slipring.





8.2.30 Adjust drum brake band Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.27 Replace drum brake band on page 132 It is vital for correct and safe operation that the brake band is correctly tensioned. Correct adjustment is when the drum breaks free of the applied brake at about 210 bar of hydraulic system main pressure, and there is no contact between the brake band and the drum when the brake is released.

adjuster at the cylinder

X X

d >1½d

minimum thread female section Xdepth in adjuster

Figure 8.42 Drum brake band components The adjuster has two threaded ends, and a locknut on one side of the central hexagon which must be tightened against the female block of the adjuster on the same side. It is vital to ensure that the male part on each side of each adjuster has sufficient length in the female part to avoid it being pulled out when the brake is applied. The length inside the female part must be a minimum of 1.5x the diameter of the male section. (Applies to points marked ‘X’ in Figure 8.34).


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Adjust the brake when: • The unit fails one of the brake tests; • The brake bands have been replaced; • The brake has been dismantled and reassembled for any reason. During adjustment, the drum brake slip test is applied. NOTE: During adjustment, the acceptable range is narrower (210 ± 15 bar) than during the routine slip test (210 ± 30 bar). Proceed as follows to adjust brake tension.


1.


2.

Turn the BRAKE on.

3.

Shut down the unit for safe maintenance. See related topic.


4.

Remove all guards surrounding the winch drum and brake(s).

5.

If the drum has a single brake, skip to step 11. If the drum has two brakes, then continue with step 6.

6.

Turn the BRAKE off.

7.

Loosen the brake on both sides by completely slackening the adjusters sufficiently for the brake bands to be free of the drum rim.

8.

Switch the BRAKE on and check again that the brake bands are still free of the drum rim; if not, repeat step 7.

9.

Tighten the adjusters equally on both brake bands until the brake band makes initial contact with the drum rim and you get initial slight resistance when tightening.

10. Tighten the adjusters again equally by half a turn, and tig hten the locknuts at the adjus ters. 11. Start the unit for operations. 12. Put the unit into manual mode. If applicable, disable the automatic winch control program (e.g. SmartMonitor). 13. Put the DRUM CONTROL joystick(s) into the neutral ( STOP) position.





CAUTION EQUIPMENT DAMAGE With a multi-speed gearbox, the brake and drum supports can be severely damaged if the brake is tested at LOW or MEDIUM speed ratio. Always select HIGH speed ratio when testing the brake.

14. For a multi-speed gearbox, select HIGH speed ratio (never LOW or MEDIUM speed ratio). 15. On units powered by a diesel engine or truck PTO: set the THROTTLE to idle. 16. Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE until the drum slips in the brake. 17. Check the MAIN PRESSURE gauge and note the brake slip pressure. 18. Immediately return the DRUM CONTROL lever(s) to the neutral (STOP) position as prolonged pressure may damage the seals. 19. If the MAIN PRESSUREwhen the drum slipped in step 17 was within the range of approximately 195 to 225 bar, then the brake has passed the adjustment slip test. Continue from step 23. If the drum slipped below 195 bar (too slack) or above 225 bar (too tight) of test pressure, continue with the next step. 20. Shut the unit down for safe maintenance. See related topic. 21. Loosen the locknut on the ad juster(s), then: a) Brake band too tight: loosen the brake adjuster (both sides equally for double brakes). Brake band too loose: tighten the brake adjuster (both sides equally for double brakes). b) Tighten the locknuts at the adjuster. 22. Repeat the test and adjustment again from step 11 through step 21 until the adjustment is correct. NOTE: Correct adjustment is when the drum breaks free of the applied brake at about 210 bar of hydraulic system main pressure, and there is no contact between the brake band and the drum when the brake is released. If the correct adjustment cannot be reached or there is no adjustment left in the adjuster, replace the brake band(s) of this drum. See related topic. 23. Shut the unit down for safe maintenance. See related topic. 24. Reinstall the guards surrounding the drum and brakes.


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8.2.31 Check/a djust drum c hain Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.27 Replace drum brake band on page 132 • 8.2.33 Test drum mounting on page 149 1.

If necessary, lower or raise the levelwind arm, depending on the chain you want to check/ adjust.

2. 3.

Set the BRAKE to OFF. Shut the unit down for safe maintenance. See related procedure.


4.

Remove the drum guard so that you can easily access the chain. See example in Figure 8.43.

drum guard

attachment bolt

Figure 8.43 Removing drum guard 5.

Check the chain is firmly tightened with approximately 2 cm (0.75 in) total free play at the middle point. See Figure 8.44.

6.

Check the drum is correctly aligned to the gearbox: • the drum axis should be parallel with the gearbox axis. • the distances (a) and (b) between the bearing housing adjustment block and the bearing housing should be approximately the same on both sides of the drum. This will ensure that the drum is correctly aligned in the winch. See Figure 8.45.





2 cm (0.75 in)

Figure 8.44 Free play in chain

bearing housing bearing housing adjustment block bearing housing adjustment block

distance (b) distance (a)

Figure 8.45 Drum bearing alignment 7.

If the chain tension or alignment is not correct, adjust the chain tension and alignment by performing steps 8 to 19. Otherwise, continue at step 20.

Ad ju st ch ain ten si on and ali gn ment 8.

Make sure the drum alignment bolts (2x for each bearing) are fully tightened against the bearing housing. See Figure 8.46.

9.

Make sure the drum attachment bolts (2x for each bearing) are fully tightened.


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drum attachment bolt drum attachment bolt

drum alignment bolt

drum alignment bolt

Figure 8.46 Drum bearing 10. If applicable, remove the cover plate on the left side of the winch module, and put it in a safe place. 11. Loosen the lock nut, and then turn the gear box lower adjustment bolt until it fully contacts the adjustment bracket. See Figure 8.47. NOTE: On some systems, the lower adjustment bolt is facing upwards. 12. Slightly loosen the reduction gearbox attachment bolts (2x), approximately a half to a full turn. The gearbox will now be partially supported by the lower adjustment bolt.

reduction gearbox attachment bolts (2x)

gearbox sprocket

adjustment bracket

adjustment bolt lock nut

gearbox lower adjustment bolt

Figure 8.47 Gearbox sprocket 13. Adjust the chain by tightening or loosening the gearbox lower adjustment bolt. This will cause the gearbox to move up or down.





14. Lock the adjustment bolt in place with the lock nut.

WARNING DANGEROUS MACHINERY If attachment bolts and locknuts are incorrectly tightened, components can work loose during operation, resulting in dangerous situations. Always make sure all attachment bolts and locknuts are correctly tightened.

15. Re-tighten the reduction gearbox attachment bolts (2x). 16. Check the chain tension and alignment again, and readjust if necessary. 17. Check the condition of the chain, and lubricate if necessary. 18. Test the mounting of the drum. See related procedure. 19. Rectify any problems. 20. Use a rag to remove any excess oil or grease from the work area. 21. Remove all tools and materials from the work area. 22. Refit the cover plate on the left side of the winch module.




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8.2.32 Check drum alignme nt Related topics: • 8.2.31 Check/adjust drum chain on page 144 To ensure that the drum mountings can be depended upon even when subjected to the highest winch forces, e.g. during jarring, perform the following test. 1.

Spool the wire fully onto the drum and anchor it to the drum so that it can turn with the drum.

2.

Lock the measurehead into its transport position.

3.

Inspect the drum shaft pillow blocks on each side of the winch. The position on each side must be identical, to ensure that the drum shaft is not out of alignment. Adjust the alignment if necessary: see the chain adjustment procedure.

4.

On each side (left, right) of the winch drum, inspect the pillow block mounting and adjustment bolts, tigtening if necessary: • The pillow block mounting bolts must be securely tightened. • The front and rea r drum adjustment bolt must be screwed tightly against the pillow block and the locknut must also be tight on each bolt.

5.

Start the winch into operations mode.

6.

Simulate a jarring action using the drum.

7.

Disable winch movement using the controls, and apply the drum brake.

8.

Repeat steps 3 through 7 two more times, checking the pillow block mounts carefully each time.

wellhead

check tightness of bolts, nuts and locknuts front and rear on both left and right side of drum

same distance on left and right side of drum

Figure 8.48 Pillow block, non-drivenside of drum





8.2.33 Test drum mounting Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.31 Check/adjust drum chain on page 144 • 8.2.32 Check drum alignment on page 148 The test drum mounting procedure must be performed every time a drum is exchanged or the chain is adjusted. This procedure describes how to test the drum mounting of one drum. If your unit has two drums, you must repeat this procedure for both drums, making sure the correct drum and brake are selected each time.


1.

Open the appropriate winch access door(s) so that you can easily access the drum.

2.

If necessary, remove the wireline from the measuring head and secure it to the drum.

3.

Start up the unit. See Operation section.

4.

If the unit has two drums, make sure: • The appropriate drum is selected in the winch module. • The appropriate brake is selected on the control panel, either FRONT DRUM or REAR DRUM.

5.

Set the brake to OFF.

6.

Slowly push the dual control handles forwards and then backwards to simulate an in-hole/ out-hole action.

7.

Press the emergency stop button to shutdown the engine and disable all winch movement.

WARNING DANGEROUS MACHINERY If attachment bolts and locknuts are incorrectly tightened, components can work loose during operation, resulting in dangerous situations. Always make sure all attachment bolts and locknuts are correctly tightened.

8.

Check the drum alignment and mounting, and readjust if necessary. See related procedure.

9.

Check the chain tension, and readjust if necessary. See related procedure.

10. Repeat steps 3 through 9 two more times, making sure to check the drum alignment and mounting, and chain tension each time.



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8.2.34 Replace hydr aulic motor/gea rbox assembly Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.27 Replace drum brake band on page 132 • 8.2.31 Check/adjust drum chain on page 144 • 8.2.28 Replace drum on page 134 • 8.2.11 Check/fill reduction gearbox oil on page 103 • 8.2.12 Check/fill hydraulic oil on page 104 • 8.2.33 Test drum mounting on page 149 1.

Remove the drum, including chain. See related topic.

2.



3.

Open the access door(s) on either side of the winch module.

4.

If applicable, remove the metal cover in front of the sprocket.

5.

Locate the sprocket at the side of the winch. See Figure 8.5 for an example.

6.

Measure the distance (a) from the end of the s haft to the side of the sprocket. This measurement will be used later in this procedure when aligning the sprocket to the chain drive.

7.

Remove the sprocket lock bolt.

sprocket shaft distance a

measure this distance before removing the sprocket sprocket

key

sprocket lock bolt

Figure 8.49 Gearbox sprocket attachment (example)

WARNING RISK OF EXPLOSION Using a heat source (naked flame) in a zone 2 area can cause an explosion. Before using a heat source, make sure a "hot work permit" has been issued.





8.

Place heat resistant material behind the sprocket, and then heat the sprocket so that it can be removed from the shaft.

WARNING HOT OBJECT The sprocket and sprocket shaft are hot and can burn your hands. Always wear appropriate Personal Protective Equipment (PPE), such as gloves.

9.

Remove the sprocket from the shaft, and place it in a safe location.

10. Make sure all pressure has been released from the hydraulic system. 11. Remove all hydraulic hoses from the hydraulic motor/gearbox assembly. 12. Blank off the open hydraulic lines. 13. Remove any electrical connectors from the hydraulic motor/gearbox assembly. 14. Cap electrical connectors where necessary.

Remove hydr aulic moto r/gearbox assembly


15. Position the hoist above the hydraulic motor/gearbox assembly. 16. Place the lifting straps at either end of the hydr aulic motor/gearbox assembly, and attach the straps to the hoist. See Figure 8.50. 17. Tension the hoist so that the hy draulic motor/gearbox assembly will be supported when the gearbox attachment bolts are removed. 18. Remove the gearbox attachment nuts, and then remove the ring of gearbox attachment bolts. See Figure 8.50.

hydraulic motor/ gearbox assembly

gearbox attachment bolts

gearbox attachment nuts

Figure 8.50 Attachment of hydraulic motor/gearbox assembly


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19. Use the chain hoist to lift the hyd raulic motor/gearbox assembly out of the wi nch module. Separate hydraulic motor from gearbox (as required)


20. Place the hydraulic motor/gearbox assembly on a clean flat surface. 21. Remove the bolts that at tach the hydraulic motor to the reduction gearbox. See Figure 8.51. 22. Separate the hydraulic motor from the reduction gearbox.

hydraulic motor attachment bolts

reduction gearbox hydraulic motor

hydraulic motor attachment bolts

Figure 8.51 Reduction gearbox and hydraulic motor

As sem bl e hy dr aulic mo to r and r educt io n g earbox (as r equir ed) 23. Make sure the mating faces of the hydraulic motor and reduction gearbox have been cleaned. 24. Align the hydraulic motor with the reduction gearbox. 25. Refit the attachment bolts.





Refit hy draulic mot or/gea rbox assembly


26. Place the lifting straps at either end of the hydr aulic motor/gearbox assembly, and attach the straps to the hoist.


27. Lift the hydraulic motor/gearbox assembly from the flat surface, and position it inside the winch module. 28. Refit the gearbox bolts, and tighten the ring of attachment nuts. See Figure 8.50. 29. Remove the winch and straps, and store them in a safe place. 30. Reconnect the hydraulic hoses of the hydraulic motor/gearbox assembly. 31. Reconnect any electrical connectors of the hydraulic motor/gearbox assembly. 32. Check the level of the gearbox oil (and fill if necessary). See related topic. 33. Make sure the sprocket shaft and sprocket are clean.

WARNING RISK OF EXPLOSION Using a heat source (naked flame) in a zone 2 area can cause an explosion. Before using a heat source, make sure a "hot work permit" has been issued.

34. Heat the sprocket so that it can be fitted to the shaft.

WARNING HOT OBJECT The sprocket and sprocket shaft are hot and can burn your hands. Always wear appropriate Personal Protective Equipment (PPE), such as gloves.

35. Slide the sprocket onto the shaft, maki ng sure it is correctly aligned for the chai n and drum. Refer to the measurement made in step 6. 36. Tighten the sprocket attachment bolt. Finalize 37. Refit the drum and chain. See related topic. 38. Recheck the alignment of the sprocket, and adjust if necessary. 39. Adjust the chain. See related topic.


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40. Remove all tools and materials from the work area. 41. Check the level of the system hydraulic oil, and refill if necessary. See related topic. 42. Start up the unit. 43. Bleed the hydraulic system. 44. Slowly rotate the dru m in both d irections. 45. Checking for correct drum movement and operation of the brake. 46. Rectify any problems. 47. Check if the drum is correctly secured. See related topic. 48. The drum mount procedure must be done every time a drum is exchanged or the chain is adjusted.


49. Lubricate the drum bear ings on both sides with high quality multipurpose grease. Inject grease using a grease gun until excess grease appears outside the bearings. 50. Use a rag to clean any excess grease or dirt from the bearings and work area.





8.2.35 Replace hydraulic oil Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.36 Replace hydraulic suction filter on page 157 • 8.2.12 Check/fill hydraulic oil on page 104

WARNING HOT OBJECT Hot hydraulic oil under pressure can cause serious burns. Before working on components containing hydraulic oil, make sure: - The engine has been stopped. - The pressure has been released from the hydraulic system. - The hydraulic oil has cooled down.



NOTE: Always replace the suction filters whenever you replace the hydraulic oil. 1.

Ensure that the unit is safe for hydraulic maintenance: • The unit is shut down for safe maintenance. See related procedure. • The unit cannot be inadvertently started (e.g. starter key is removed); • There is zero hydraulic pressure in the hydraulic circuits; • The hydraulic oil is cooled sufficiently to avoid burns.

2.


3.

Open covers to gain access to the underside of the hydraulic oil tank and drain valve.

4.

Unscrew the cap from the drain valve built into the bottom of the hydraulic oil tank. See Figure 8.52.

5. 6.

Attach an open ended hose to the drain valve. Lead the hose into a suitable waste oil collection tank of the same capacity as the hydraulic oil tank

7.

Open the drain valve and drain all oil from the hydraulic oil tank into the waste oil collection tank.

8.

If excessive contamination is suspected (e.g. due to the condition of the drained oil), flush the hydraulic oil tank once with clean hydraulic oil.


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9.

Close the drain valve, remove the hose, and re-fit the cap.

10. Replace all suction filters in the hydraulic system. See related procedure. 11. Fill the tank with oil of the correct grade. See related procedure. 12. Dispose of all filters and used oil as prescribed by site regulations.

Figure 8.52 Hydraulic oil tank drain valve (two examples)





8.2.36 Replace hydraulic suction filt

er

Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.12 Check/fill hydraulic oil on page 104 • Appendix 4 Hydraulic oils on page 279 The suction filter should be replaced just before the contamination indicator goes into the red zone. Note that on dual-filter filter heads there is a single contamination indicator. See Figure 8.53.

Typical single-filter head, with intake valve closed. Filter is mounted horizontally, and oil will flow out when it is loosened.

Typical dual-filter head, with intake valve open. The contamination indicator is mounted on the outlet side (obscured). The filters are mounted vertically, and there should be only minimal spillage when the filters are loosened.

Typical disposable filter canister. The rubber seal is correctly located in its seating on the filter.

Underside of filter head showing threaded nipple onto which the filter is screwed hand-tight. This flange must be carefully cleaned before the filter is fitted!

Figure 8.53 Hydraulic suction filters NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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1.

Open the appropriate Power Pack door(s) so that you can easily access the hydrau lic suction filters.

2.

Secure the doors in place with the door catches.

3.

Ensure that the unit is safe for hydraulic maintenance: • The unit is completely shut down. See related procedure. • The unit cannot be accidentally started. • There is zero hydraulic pressure in the hydraulic circuits. • The hydraulic oil is cooled enough to avoid burns.

4.

Shut the valve on the intake side of the filter head. The valve is usually - but not always adjacent to the filter head. The valve is shut when the lever is at right angles to the flow direction.

5.

Place a waste oil container below the filter assembly to catch the oil that may flow from the filter head. On horizontally-mounted filters, the filter will completely drain out when loosened.

6.

Turn the filter anticlockwise to unscrew it from the filter head.

7. 8.

Drain all the oil from the filter into a waste oil container, and discard the filter. Using a clean cloth, clean the filter head and the seal flange.

9.

Take a new filter (see spare parts list for this unit for correct type), and half fill it with hydraulic oil for the duty and climate. See related topics.

10. Apply a thin film of hydraulic oil to the new seal supplied with the filter. 11. Place the seal on the filter, and screw the filter by hand up onto the filter head. NOTE: Do not use tools to tighten the filter! It should be firmly tightened only by hand. 12. If the filter head is a dual-type, then repeat steps 5 through 11 for the second filter. 13. Open the valve in the intake side of the filter head. 14. Repeat the above steps for any other suction filters that are due for replacement. 15. Dispose of all filters and used oil as prescribed by site regulations. 16. When all filters have been replaced and al l hydraulic maintenance has been car ried out: a) Check that all filter intake valves are open (levers aligned with flow direction). b) Start the unit. c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that th e pressure stabilizes at the pressure gauges of the SmartView control panel. d) With the unit running, check each filter head: • The contamination indicator should be in the green zone.





• There should be no leakage from the filter seals. If there are leaks, shut the unit down as described in step 1, and attempt to hand-tighten the filter further until the leak stops. If necessary, remove the filter, clean the facing parts and the seal, and re-fit the filter. e) Inspect the seals again fo r leakage after operating for several hours, taking remedial action if necessary. 17. Check and replenish the hydraulic oil in the tank. See related procedure. 18. Remove all tools and materials from the work area.




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8.2.37 Replace hydra ulic high p ressure filte r Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.12 Check/fill hydraulic oil on page 104 • Appendix 4 Hydraulic oils on page 279 Pressure filters should be serviced at regular intervals. These filters are often present in the power packs of closed-loop hydraulic systems, to catch contamination that may be introduced into the system downstream of the main suction filters, and which can cause damage to the hydraulic components. Contamination can be introduced at quick coupling connectors or at certain mechanical components, such as gearboxes. See Figure 8.54. The disposable filter element inside the filter should be replaced at fixed service intervals, or more frequently if required. Each filter assembly is normally equipped with a filter condition indicator which shows red when the filter is clogged and the system is under pressure. Inspect the filter indicator regularly when the unit is running, preferably just before shutting down the unit. Proceed as follows to replace the filter element at the scheduled service interval or when the filter is clogged (indicator showing red).

WARNING RISK OF BURNS If the unit has been running, the hydraulic oil and components can be at an extremely high temperature. Never attempt to dismantle hydraulic connections or replace hydraulic filters until the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or less. Check the hydraulic oil temperature gauge (usually the reservoir temperature), then carefully check the temperature of the applicable component by touch before you start maintenance.



1.


2.

Shut all supply valves in the hydraulic system. These valves are usually - but not always - below the hydraulic oil tank. Shut every valve in the hydraulic lines of the power pack or unit. The valve is shut when the lever is at right angles to the flow direction.

3.

Shut the valve of every hydraulic accumulator in the hydraulic system. These valves are usually - but not always - below the accumulator tank. Shut every valve in the hydraulic lines of the power pack or unit. The valve is shut when the lever is at right angles to the flow direction.





Verically-mounted high pressure hydraulic filter, with close-up of condition indicator.

Horizontally-mounted high pressure hydraulic filter, condition indicators located on opposite side of mounting bracket from filter head.

Typical disposable filter element. The rubber seal on the inside should be lightly lubricated with hydraulic oil to ease installation

Filter bowl showing O-ring, and below it, the synthetic support ring.

Complete high pressure hydraulic filter (Parker type). The condition indicator (optional) is mounted on the top of the filter head.

Underside of filter mounting spigot.

head

showing

element

Figure 8.54 Hydraulic pressure filter 4.

Relieve all pressure from all hydraulic circuits using the unit controls.

NOTE: All hydraulic gauges must read zero pressure.


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5.

Place a waste oil container or plenty of rags below the filter assembly to catch the oil that will spill from the filter head when the bowl is removed. On horizontally-mounted filters, the filter will completely drain out when loosened.

6.

Unscrew the bowl using a suitable wrench applied to the h exagonal nut at t he end of the bowl.

7.

Where sufficient clearance exists: a) Remove the bowl over the contaminated element. b) Remove the contaminated element from the filter head spigot. Where there is insufficient clearance to allow the bowl to be removed over the element: a) WIthdraw the bowl as far as possible. b) Loosen the element from the filter head spigot. c) Remove the element and bowl together.

8.

Drain all the oil from the filter into a waste oil container, and discard the filter element.

9.

Remove and discard the O-ring from the bowl. NOTE: Some pressure filters have a separate synthetic O-ring support ring. Take care not to damage or lose this ring, as there is no replacement in the filter element set.

10. Using a clean cloth, thoroughly clean the filter he ad, screw thread, spigot and seal flange . 11. Using a clean cloth, thoroughly clean the filter bowl inside and out, in partic ular the O-ring seating, support ring and screw thread. 12. Take a new filter element of the specified type (see spare parts list for this unit), and lubricate the element nose seal, the new O-ring and the support ring with clean hydraulic fluid. 13. Carefully reposition the element and bowl on the spigot and filter head, by repeating the removal step in reverse. If you have sufficient clearance, fit the filter element first before fitting the bowl over the element; otherwise you will have to fit both at the same time. 14. Using a suitable wrench, firmly tighten the bowl. 15. If the filter head is a dual-type, then repeat steps 5 through 13 for the second filter. 16. Repeat the above steps for any other pressure filters that are due for servicing. 17. Dispose of all used filter elements and oil as prescribed by site regulations. 18. When all filters have been replaced and al l other hydraulic maintenance has been carried out: a) Check that all hydraulic supply valves are open (levers aligned with flow direction). b) Start the unit. c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that th e pressure stabilizes at the pressure gauges of the unit control panel. d) With the unit running, check each filter head for leakage. If there are leaks, shut the unit down for safe maintenance, remove the filter bowl and element as described above, clean the facing parts and the seal, and re-fit the filter. e) Inspect the seals again for leakage after operating for several hours, taking remedial action if necessary. Page 162 of 211 Version 1.00




19. Check and if necessary fill the hydraulic oil in the tank. See related topic.

8.2.38 Replace shock absorbe r Related topics: • 8.2.1 Safe maintenance shutdown on page 88 1.


2.

Open the app ropriate door(s) so that you can easily access all shock absorbers.

3.

Secure the door(s) in place with the door catch(es).

4.

Place a support block underneath the engine.

5.

Remove the engine attachment bolt. See Figure 8.55.

engine attachment bolt

shock absorber attachment bolt

shock absorber (with metal cover)

shock absorber attachment bolt

Figure 8.55 Shock absorber 6.

Remove the shock absorber attachment bolts (2x).

7.

Use a jack to slightly raise the engine.

8.

Remove the shock absorber with metal cover.

9.

Position the new shock absorber with metal cover underneath the engine mounting bracket.

10. Tighten the shock absorber attachment bolts (2x). 11. Use the jack to slowly lower the engine. 12. Tighten the engine attachment bolt. 13. Remove the engine support block and jack from underneath the engine. 14. Remove all tools and materials from the work area.


15. Dispose of the old shock absorber according to local site regulations. NOV ASEP Elmar - Netherlands , Energieweg 26, 2964 LE Groot-Ammers, The Netherlands ASEP K-Winch SlimS plit C, Project no. 8951, 23 September 2009

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8.2.39 Inspe ct ele ctrical system To ensure reliable and safe operation of the SlimSplit C , the electrical system should be thoroughly inspected at regular intervals. Inspect as follows, noting items for repair or adjustment. 1.

Inspect the gro unding cable reel, cable and te rminals at both en ds for good, clean connection.

2.

Inspect all exposed cables for: a) Condition of insulation (damage, cracking, corrosive fluids, moisture penetration); b) Condition of entry glands at cabinets, terminal boxes, controls; c) Condition of labels on cables; d) Exposure to moving parts that may cause damage to the cable.

3.

Inspect all control panels, cabinets and junction boxes for condition of labels, tags and signage. Replace all damaged labels, tags and signs.

4.

Check the mountings of all cabinets, armatures and control devices, and tighten where necessary.

5.

During the 1200-hour service, check continuity/insulation resistance of cables.





8.2.40 Replace fuse or circuit breake r Your ASEP equipment may have up to 4 different types of fuses and circuit breakers to protect the electrical circuits and components from electrical overload. The type of fuse used depends on the specifications of the electrical system. In general, the following rule applies: • 12-24VDC: blade type fuses (typical automotive fuse) • 110-240 VAC: cartridge fuses (glass) and circuit breakers • 380V and higher 3 phase: mesh type fuses, cartridge fuses and circuit breakers The fuses are marked with an identification number that corresponds to the "F" number stated on the electrical diagrams. The description on the diagram states the trip level in Amps. Before restoring a blown fuse or tripped circuit breaker: 1.

Identify and rectify the situation that caused the circuit to overload.

2.

Shut down the electrical system.

3.

Replace/restore the fuse/circuit breaker (see following paragraphs).

4.

Re-start the electrical system.

5.

Re-start the component or circuit that failed. Verify that the component or circuit is working correctly.

6.

Replenish the stock of spare fuses, and also make sure that there is a new spare fuse stowed in cartridge type fuse holders (see below).

NOTE: Not every type of fuse and circuit breaker described below may be present in your equipment. Blade type fuses

Figure 8.56 Blade fuses and block Blade type fuses are the same type as used in the automotive industry. The fuses are color coded to indicate the rating. To replace a blade type fuse: 1.

Pull the fuse from the fuse block and discard it.


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2.

Insert a spare fuse of the same color / rating. See Table 8.1. Rating (amps) 3

Colour

ASEPpart no.

purple

A0015291

5

lightbrown

A0015284

7.5

darkbrown

A0015285

10

red

A0015286

15

blue

A0015287

20

yellow

A0015288

30

green

A0017156

Table 8.1 Blade type fuse specifications Cartrid ge fuses - swing-out holder

spare fuse

live fuse

Figure 8.57 Swing-out cartridge fuse holder Cartridge (glass) fuses are clamped between contacts in a swing-out holder. See Figure 8.57. The swing-out holder also contains a spare fuse. ASEP equipment uses standard 5 mm x 20 mm cartridge fuses with the ratings specified in Table 8.2. To replace the cartridge fuse in a swing-out holder: 1.

Swing the holder out and up to give access to the holder side cover.

2.

Carefully open the cover - this also ejects the blown fuse from the contacts.





3.

Remove the blown fuse and replace it with a new fuse (see Table 8.2). If you have no other, use the spare inside the holder, but insert a new spare at the first opportunity.

4.

Carefully close the cover - this will press the new fuse between the contacts.

5.

Swing the holder back into position.

Ratin g (amps)

ASEP part no.

0.50

-

1.00 1.50

A0000934 A0011260

2.00

A0015219

3.15

A0015306

5.00

A0015575

6.30

A0010259

10.00

A0014805

Table 8.2 Cartridge type fuse specifications Cartri dge fuses - pull-out hold er

spare fuse live fuse

Figure 8.58 Pull-out cartridge fuse holder


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Cartridge (glass) fuses are clamped between contacts in a pull-out holder. See Figure 8.58. The pull-out holder also contains a spare fuse. The same standard 5 mm x 20 mm cartridge fuses are used as in the swing-out type, as specified in Table 8.2. To replace the cartridge fuse in a pull-out holder: 1.

Grip the tab and pull out the holder.

2.

Prise open the small side cover.

3.

Remove the blown fuse and replace it with a new fuse (see Table 8.2). If you have no other, use the spare inside the holder, but insert a new spare at the first opportunity.

4.

Close the cover.

5.

Push the holder back into position.

Circuit breake rs

red

green OFF

ON

circuit isON (live)

circuit isOFF (dead)

Figure 8.59 Automatic circuit breaker Automatic circuit breakers are the easiest to control / reset. When OFF shows, the circuit has been overloaded or short circuited. To reset the circuit breaker, switch it to ON. NOTE: Always replace a damaged automatic circuit breaker with an identical unit, i.e. same rating, phase characteristic and voltage. Only a qualified electrical technician may perform maintenance / repairs to automatic circuit breakers.





8.2.41 Replace wa ter/die sel sepa rator fi lter Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.19 Drain water diesel separator on page 115 1.


2.


3.

Close the diesel tank isolation valve (valve at right angles to the tubing).

4.

Unscrew the filter element from the mounting head with the bowl still connected. See Figure 8.60.

mounting head behind engine mounting bracket water/diesel separator filter element

bowl

Figure 8.60 Water/diesel separator filter 5.

Remove the bowl from the filter element.


6.

Discard the old fi lter element and O -ring according to local regulations.

7.

Clean the bowl. NOTE: The bowl is reusable, do not discard it.

Fit water/diese l s eparator filt er 8.

Lubricate the new top seal with clean diesel fuel or motor oil, and fit it to the recess in the mounting head.

9.

Lubricate the new O-ring with clean diesel fuel or motor oil and fit it to the recess in the bowl.


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10. Gently turn the bowl onto the new filter element by hand. Do not use tools to fit the bowl to the filter. 11. Fill the filter element (with bowl attached ) with clean diesel fuel. 12. Fit the filter element (with bowl attached) to the mounting head. Keep turning the filter element until it contacts the top seal, and then hand-tighten an additional third to half a turn. Do not over tighten. 13. Remove all tools and materials from the work area. 14. Open the diesel tank isolation valve, and check for any leaks. 15. Rectify any problems. 16. Prime the diesel system. by pressing the primer lever a number of times. 17. Rectify any problems. 18. Start the diesel engine, and check for correct operation and any leaks. 19. Rectify any problems. 20. Close all a ccess doors.





8.2.42 Test engine overspe ed safety ( during ATEX certification) As part of the ATEX certification, the engine overspeed safety should be verified once a year.

WARNING DANGEROUS MACHINERY Changing factory settings can seriously affect the safety of the system, and result in personal and/or equipment damage. Take extreme care when adjusting factory settings. If in doubt, contact ASEP the Netherlands.

NOTE: The engine speed is factory preset and must not be set to a higher value. 1.

Start the unit up.

2.

Run the engine at maximum throttle settings.

3.

Record the RPM on the Tachometer in the cabin or on the working side of the PowerPack.

4.

Shut the unit down.

5.

Compare the maximum engine speed with the unit specifications - if the maximum speed is outside specification, contact ASEP at: [email protected]

8.2.43 Test hydraulic system pre

ssure

Related procedures/topics: • 8.2.13 Check replace hydraulic hoses & couplings on page 106 This test procedure places the entire hydraulic system under high pressure for a short period (10 seconds) to expose leaks and weak points in the entire system. The test relies on the drum remaining stationary while the pressure increases. If the drum brake fails to keep the drum stationary, troubleshoot the brake system, then repeat the test once the brake has been repaired. This test may be carried out either with or without a wireline threaded through the measuring head. NOTE: If the CONTROL PRESSURE falls below the minimum required during testing, contact ASEP at: [email protected].


1.

Make the winch operational.

2. 3.

Apply the drum BRAKE. Test the hydraulic pressure in the OUTHOLE direction as follows: a) Minimize the main hydraulic system pressure by setting the LINE TENSION to the minimum. b) Move the left DRUM CONTROL lever (speed) fully forward or backwards. c) Move the right DRUM CONTROL lever all the way in the OUTHOLE direction.


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d) Without going over 400 bar, gradually increase the LINE TENSION until the main pressure stops rising. e) Hold the pressure for 10 seconds. 4.

Return the DRUM CONTROL levers to neutral.

5.

Test the hydraulic pressure in the INHOLE direction: a) Minimize the main hydraulic system pressure by setting the LINE TENSION to minimum. b) Move the left DRUM CONTROL lever fully forward or backwards. c) Move the right DRUM CONTROL lever all the way in the INHOLE direction. d) Without going over 400 bar, gradually increase the LINE TENSION until the main pressure stops rising. e) Hold the pressure for 10 seconds.

6.

Return both DRUM CONTROL levers to neutral.

7.

Re-inspect all hydraulic system hoses and couplings for leaks, and repair as necessary. See related procedure.

8.

Repeat the t est after carrying out any repairs.

8.2.44 Clean exhaust ga s cooler / flame trap Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.45 Replace exhaust gas cooler on page 177 NOTE: This procedure describes how to clean the exhaust gas cooler and flame trap with the cooler still fitted to the system. The cooler can also be thoroughly cleaned by removing it from the system (see related topic). NOTE: This procedure does not require the coolant hose to be disconnected from the exhaust cooler. 1.


2.

Open the working side PowerPack door, and secure it in place with the door catch.

3.

Wait until the exhaust system has cooled down.

Remove the flame trap cover (and flame trap) 4.

Disconnect probesSee or sensors that may be present on the flame trap assembly. Remove tie wraps asany required. Figure 8.5.

5.

Spread a plastic sheet over the entire area below the exhaust gas cooler, so that contamination will fall outside the PowerPack.

6.

Loosen the exhaust pipe clamp(s) of the flame trap assembly.

7.

Loosen the flame trap/cooler flange clamp sufficiently so that the clamp can be moved to one side.





8.

Carefully pull the flame trap assembly down and out of the exhaust pipe, and set it to one side. The O-ring should remain in place in the flange of the cooler. If it comes loose, set it carefully to one side, as you will need it when you reassemble the exhaust system.

exhaust pipe clamp

flame trap/cooler flange clamp

exhaust pipe clamp

flame trap cover

Figure 8.61 End view of exhaust gas cooler Clean exhaust gas cooler 9.

Take the exhaust gas cooler cleaning tool from its holder in the PowerPack door. See Figure 8.62 for an example.

exhaust gas cooler cleaning tool

Figure 8.62 Cleaning tool inside PowerPack door


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WARNING HAZARDOUS PARTICLES Hazardous particles such as carbon dust can damage your eyes. Always wear appropriate Personal Protective Equipment (PPE), such as safety goggles, when working in particle contaminated environments.

CAUTION EQUIPMENT DAMAGE Components can be damaged during cleaning, and complete assemblies may need replacing. Take care when cleaning components. Use appropriate cleaning tools.

10. Clean out each tube in the exhaust gas cooler. Make sure the cleaning tool does not penetrate the turbocharger, otherwise the complete assembly will have to be replaced. Turn the cleaning tool and feed it in and out, until no more soot comes out of each hole. Much of the soot will accumulate in the manifold at the inner end. See Figure 8.63. ASEP recommends working from bottom to top, with one person cleaning the tubes, one at a time, and the other holding a vacuum cleaner over the lowest tubes. This way, the falling soot at the opposite end of the cooler will be drawn through the cleaned tubes into the vacuum cleaner. The higher, uncleaned tubes will allow less air to be drawn through beca use they are still fouled with soot.

tubes in cooler

contamination

Figure 8.63 Contaminated cooler 11. Use the vacuum cleaner to extract as much soot as possible from the tubes. 12. If the O-ring has been removed from the end flange of the cooler, re-fit it into its groove. 13. Place the flame trap assembly back against the open end of the exhaus t gas cooler, with the exhaust opening facing the rear of the PowerPack. The flame trap element will be used to filter out the residual soot ejected through the tubes from the manifold area. 14. Fit the flange clamp around the joint and tighten it firmly.





WARNING HIGH SOUND LEVELS Prolonged exposure to high sound levels can damage your hearing. Always wear appropriate Personal Protective Equipment (PPE), such as ear defenders.

15. Start the engine, and run it for no more than 2 minutes. The engine will sound louder than usual, because the silencer is removed. 16. Shut the uni t down fo r safe maintenance. See related topic. 17. Carefully release the flange clamp, and remove the flame trap body from the exhaust gas cooler, taking care to leave the O-ring in place.

CAUTION EQUIPMENT DAMAGE Any contact with the core of the flame trap element can bend the metal foil, and damage the part. Only handle the flame trap element by the rigid edges.

18. Remove the element from the flame trap as follows (see Figure 8.64): a) Inspect the flame trap element, and observe which side faces the exhaust gas cooler. b) Support the flame trap assembly above a flat surface, with wooden blocks under the flange, and with the open side down. c) Tap the body of the assembly using a plastic hammer, to release the element. d) If the element does not drop out, carefully lift and drop the assembly one or more times with the open side down, until the element falls out. The element can now be cleaned. See steps 19 to 27. To save time a spare clean element can be fitted to the flame trap and the dirty element cleaned once the unit is back in operation. If you decide to do this, you should continue from step 28.

flame trap body

lock screw

complete flame trap element

flame trap element core

Figure 8.64 Flame trap assembly


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Clean the flame trap assembly

WARNING HAZARDOUS CHEMICAL Decarburizing fluid can cause severe injury to the eyes and skin. Always wear appropriate Personal Protective Equipment (PPE), such as safety goggles and chemical-resistant gloves when cleaning parts.

19. Place the complete flame trap element in a containe r of decarburizing fluid, and move it around so that the fluid can penetrate all parts of the element. Leave it in the fluid for at least 1 hour. 20. Remove the element from the fluid and allow most of the fluid to drain out. 21. Rinse the element in clean water.

WARNING COMPRESSED AIR IS HAZARDOUS. Compressed air from an air pistol can cause severe injury or death if the air penetrates the skin. Always wear appropriate Personal Protection Equipment (PPE), such as safety goggles. Never point a compressed air pistol at exposed skin surfaces.

22. Blow the element clean using a compressed air pistol. 23. Wipe the frame of the element with a dry cloth. 24. Clean the flame trap body as follows: a) Immerse the flame trap body in the container of decarburizing fluid. b) Using a Scotchbrite pad, scrub the soot from the inside of the body, including the outlet. c) Wipe the residual fluid and soot from the entire body with a dry cloth. 25. Wash the cleaning tool in the dec arburizing fluid, dry it and place it in it s holders in the PowerPack door. 26. Carefully remove the plastic sheet and the collected soot from the PowerPack. 27. Clean the area thoroughly using the vacuum cleaner.

Reassemble the exhaust system 28. Fit the clean flame trap element into the body, with the sam e side facing the cooler as whe n you removed it. 29. Fit the exhaust pipe clamp loosely over the outlet of the flame trap assembly. 30. Insert the flame trap assembly up into the exhaust pipe, but do not tighten it. 31. Offer the flame trap assembly up to the flange of the exhaust gas cooler, ensuring that the O-ring is in place between the two faces. 32. Bring the flange clamp over the two parts, and firmly tighten the clamp. 33. Firmly tighten the e xhaust pipe clamp. 34. Reconnect any probes or sensors that may be present on the flame trap assembly. Fit tie wraps as required See Figure 8.5.





35. Run the engine for a short time, just long enough to check for exhaust leaks at the exhaust pipe clamp and the flame trap flange. 36. If any exhaust leak is detected, rectify the leak and repeat the reassembly steps.


37. Dispose of used materials according to local environmental regulations.

8.2.45 Repla ce exhaust gas coole r Related topics: • 8.2.1 Safe maintenance shutdown on page 88 • 8.2.44 Clean exhaust gas cooler / flame trap on page 172 • 8.2.7 Check/fill coolant on page 94 NOTE: Although it is not recommended, the exhaust gas cooler can be removed and then thoroughly cleaned outside the unit. 1.


2.

Open the working side PowerPack door, so that you can easily access the exhaust gas cooler and flame trap. See Figure 8.65.

3.

Secure the door in place with the door catch.


4.

Drain the coolant. See related topic.

5.

Loosen the clamp, and remove the coolant supply hose at the top of the cooler. See Figure 8.65.


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coolant supply hose

clamp at top of cooler (not visible in photograph)

flame trap cover

Figure 8.65 Coolant supply hose at top of cooler 6.

Remove any probes/connectors at the top of the cooler.

7.

Open the rea r PowerPack door so that y ou can easily access the rear of th e exhaust gas cooler. See Figure 8.66.

8.

Remove the muffler assembly.

9.

Remove the coolant supply pipe.

10. Remove any other components as required that may restrict the removal of the exhau st gas cooler. 11. Support both ends of the cooler. 12. Remove the attachment bolts at the rear of the cooler. See Figure 8.66.

muffler assembly

coolant supply pipe

attachment bolt

Figure 8.66 Exhaust gas cooler attachment bolts





WARNING HEAVY OBJECT Incorrect lifting of heavy objects can cause serious injury. Some heavy objects must not be individually lifted by hand. Lifting equipment or additional personal may be required. Before lifting any heavy object, always check your local safety regulations.

13. Carefully remove the cooler from the unit, and put it in a safe location.

Refit exhaust gas cool er 14. Make sure th e cooler has been cleaned. See related topic.. 15. Clean the ma nifold connection points. 16. Fit a new gasket between the cooler and the manifold. Use ‘Loctite 574’ to ensure proper sealing.

WARNING HEAVY OBJECT Incorrect lifting of heavy objects can cause serious injury. Some heavy objects must not be individually lifted by hand. Lifting equipment or additional personal may be required. Before lifting any heavy object, always check your local safety regulations.

17. Position the cooler using adequate supports, and then tighten the attachment bolts. 18. Refit the coolant supply hose at the top of the co oler and then tighten the clamp. See Figure 8.65. 19. Refit all connectors at the to p of the coo ler. 20. Refit the flame trap cover (and flame trap). 21. Refit the coolant supply pipe. 22. Refit the muffler assembly. 23. Refit any other components that were removed to access the exhaust gas cooler. 24. Refill the cooling system with coolant, and bleed the cooling system as required. See related topic. 25. Remove all tools and materials from the work area. 26. Close all a ccess doors. 27. Prime and then start the engine. 28. Test run the engine for at least 15 minutes. 29. Check that the cooling system works correctly. Rectify any problems.


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8.2.46 Zero gas detecto rs Related topics: • 8.2.1 Safe maintenance shutdown on page 88 The following procedures describe how to zero and test the gas detectors. For a more detailed description, please refer to the separately supplied manufacturer’s documentation. The following steps apply to both the interior and exterior gas detectors. Both detectors should be zeroed at the same time. 1.

Locate the gas detector and remove the retaining grub screw in the lid.

2.

Open the junction box of the detector by unscrewing the lid in an anti-clockwise direction

3.

Check that all electrical connections have been made and are correct. See Figure 8.3

4.

Measure the voltage across the ‘+’ and ‘-‘ terminals and check that there is a minimum supply of 10 VDC. present. See Figure 8.3.

Figure 8.67 Gas detector (open) 5.

Allow the detector to stabilise for at least 1 hour.

6.

Balance the pellistors as follows:





a) Set the DVM to the dc mV range. b) Remove the PCB cover. c) Connect the DVM to the test points marked ‘TP3’ and ‘TP4’ on the amplifier PCB, d) Adjust potentiometer marked ‘VR3’ until the DVM reads 0.00 mV. e) Re-fit the PCB cover. 7.

Connect the DVM to the test points marked ‘TP1’ and ‘TP2’ on the a mplifier PCB.

NOTE: At the test points, Zero will read 40 mV = 4 mA. Full scale deflection (100%LEL) will read 200 mV = 20 mA. There is a current clamp of 25 mA on the 4-20 mA output. 8.

Ensure you are in clean air.

9.

Using a very small screwdriver, adjust the ‘ZERO’ pot on the amplifier (which is accessible via a hole in the PCB cover) until the DVM reads 40 mV.

10. On the SmartMonitor, check that the re levant channel (1=interior, 2=exterior) reads zero. 11. Remove the DVM. 12. Re-fit the lid on the gas detector and retighten the grub-screw. 13. Repeat all the above steps for the second gas detector. Test t he gas detectors 1.

Perform the following steps to verify correct working of each gas detector.

2.

Ensure that you are in clean air (non-zone environment).

3. 4.

Perform a normal start of the SlimSplit C as described in the Operations section. Start the EX system as described in the Operations section.

5.

On the SmartMonitor display, verify that both channels 1 and 2 re ad zero.

6.

If either channel reads a value other than zero, repeat the zeroing procedure for that channel


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8.2.47 Chec k ATE X explosion proof cabine

ts

Related topics: • 8.2.1 Safe maintenance shutdown on page 88 As part of the ATEX certification, the covers of the explosion proof cabinets should be checked for correct tightness once a year. If they have been opened for maintenance, they must always be sealed in the correct manner. NOTE: This unit has explosion proof cabinets in the Cabin and thePower Pack. Use this procedure to check each of these cabinet(s). 1.

Shut down the unit for safe maintenance. See related procedure.

2.

Loosen all cover bolts, and swing out the cover. See example cabinet in Figure 8.3.

ATEX explosion proof cabinet

tighten all bolts according to the value specified in the vendor documentation

Figure 8.68 ATEX explosion proof cabinet

WARNING RISK OF EXPLOSION An incorrectly sealed ATEX explosion proof cabinet can cause a dangerous, uncontrolled explosion. Make sure all ATEX explosion proof cabinets are correctly sealed and that all bolts are tightened to the correct torque value as specified in the vendor documentation.

3.

Use a clean cloth to clean the connection flange surfaces of the cab inet and cover.

4.

Check the condition of the seal. If the s eal is damaged, it must be replaced.

5.

Check the condition of the connection flange. If the surface is severely damaged, the seal will not work correctly, which can result in dangerous situations. In this case the cabinet must be replaced.

6.

Apply a thin new layer of multipurpose grease to the flange surface. NOTE: ASEP recommend Molykote® Longterm W2.

7.

Clean the bolts and re-insert them by hand.





8.

Use a calibrated torque wrench to tighten each bolt, according to the value specified in the vendor documentation.


9.

Dispose of used m aterials according to local environmental regulations.


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9

TROUBLESHOOTING

9.1

Tro ublesh oot in g p ri nci pl es This section offers information for troubleshooting operating problems with the equipment. However, it is not a substitute for a thorough knowledge of the SlimSplit C unit and its related systems. If you strike a problem that is not covered, or is not corrected by the suggested remedy, please contact ASEP for qualified technical guidance on how to proceed further. Support contact information is provided near the front of this manual. The troubleshooting guide is divided into sections according to components or group that may need troubleshooting. Within each section, problem symptoms and their possible causes are described, plus a suggested remedy that should enable you to get that component operational once more. Always review the complete list of possible causes for each problem, before selecting which remedy to apply. More detail on the remedies is frequently available in the maintenance section of this manual. Most of the problems you may encounter in this equipment will arise in the hydraulic and electrical systems. We have therefore attempted to anticipate every likely malfunction in these systems, and provide diagnostic and remedial information for these. For all other parts of the SlimSplit C , this troubleshooting guide is restricted to those problems that may be symptoms of more serious problems or which have more than one possible cause and remedy. In other words, problems with an obvious cause and remedy are not included in this guide. However, if you should encounter a problem that you feel should be included in this troubleshooting guide, please notify ASEP of this problem, the possible causes you considered, and the remedy/remedies you applied. We will be very grateful for your feedback. Contact details for the ASEP documentation department are providedat the back of this manual.





9.2

Troubleshooting t able

ELECTRICAL PROBLEM

POSSIBLECAUSE

Engine stops when pump engaged

Failure to follow correct starting sequence Defective switches

No electrical power

Failure to follow correct starting sequence Loose connection Faulty AC DC generator/shore isolator

ENGINEPROBLEM

POSSIBLECAUSE

Enginestops

Fueltankisempty Engine exhaust is blocked Emergency stop button is pushed Air inlet valve is closed Sentinel valve is activated

Diesel engine creates excessive noise and vibration

Worn shock mount diesel engine shock mount

SUGGESTEDREMEDY Switch all electrical panel switches off as well as DC isolator, and start again, following correct sequence. Follow correct starting sequence, and carefully check status at each step, in order to isolate the defect. Switch all appliances and circuits off. Reset circuit breaker Unplug/replug connection firmly Check functioning of isolator, and replace if necessary

SUGGESTEDREMEDY Fill fuel tank with diesel and restart engine Remove obstruction from exhaust and restart engine Release emergency stop button and restart engine Open air inlet valve Reset sentinel valve Replace faulty shock mount

Engine temperature too high

Coolant too low Fan malfunction Thermostat malfunction

Replenish coolant as necessary Replace fan or V-belts Replace thermostat

Engine oil pressure too low

Engine oil too low Oil pump malfunction

Replenish engine oil as necessary Replace oil pump

Engine does not cutout at the preadjusted over speed setting

Wrong setting of the over speed controller

Otherengineproblems

Checkthesupplierdocumentation

HYDRAULICPROBLEM

POSSIBLECAUSE

Hydraulic pump(s) noisy.

Air bubbles in oil Contaminated oil filters.

Zero hydraulic control pressure

Change setting of the over speed controller adjustment screw

Hydraulic system oil level low Broken coupling between motor and pump group Major leak in pressure lines (hose/coupling) Restricted or broken suction line Worn or broken pump drive shaft coupling or drive plate.

SUGGESTEDREMEDY Check hydraulic oil level. Replenish oil as necessary. Clean and/or replace oil filter(s) as necessary Replenish hydraulic oil as necessary Inspect through hole in coupling body. Repair/replace coupling. Repair as required Remove line and clear obstruction or replace line Replace pump drive shaft, coupling or drive plate


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TRANSMISSIONPROBLEM

POSSIBLECAUSE

Oil leaks

SUGGESTEDREMEDY

Worn seals Leakage at plugs

Excessive noise from final reduction gearbox

Low gearbox oil level

Drum does not move when DRUM CONTROL lever is operated

Brake applied Hydraulic problem

Replace seals Replace/re-tighten plugs Fill final reduction gearbox with oil Disengage drum brake See HYDRAULICS Check air compressor and air

Pneumatic pressure loss (indicated by pressure gauge on control panel) Defective controller or open controller power circuit Drum continues turning with DRUM CONTROL levers in neutral

LEVELWINDPROBLEM

Excessive temperature caused by contaminated oil Valve spool sticking due to scored spool. Valve spool sticking due to weak or broken return spring Valve spool sticking due to excess pressure caused by defective relief valve. Valve spool sticking due to binding control rod or lever

POSSIBLECAUSE

Juddering movement or jamming of levelwind carriage while spooling

SMARTHEADPROBLEM

Change oil using recommended viscosity and flush system. Remove valve and repair or replace as necessary. Remove valve and repair or replace as necessary. Check pressure across relief valve and repair or replace as necessary. Repair or replace control rod or lever as necessary

SUGGESTEDREMEDY

Side forces on levelwind carriage caused by excessive fleet angle Slack in levelwind drive chain Levelwind drive chain too tight Worn sleeve bearing Broken drive chain Measure head to drive chain connection bolts broken Levelwind drive chain sprockets damaged Hydraulic motor defective

POSSIBLECAUSE

receivers. Repair if defective. Check all pneumatic lines in body and control panel. Inspect/repair controller section. Check/replace in-line 7.5A fuse.

Reposition winch to reduce fleet angle Tighten the levelwind drive chain Slightly slacken the drive chain Replace sleeve bearing Replace drive chain Replace connection bolts Replace sprockets and chain Have hydraulic motor replaced

SUGGESTEDREMEDY

Refer to the SmartHead User Manual





APPENDICES This section contains the following appendices: Appendix 1: Specifications Appendix 2: Quick reference Appendix 3: Lubricants Appendix 5: Running hours log book Appendix 6: Air transportation Appendix 7: Contact us Appendix 8: Customer feedback form


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Appendix 1: Spec ifications

Dimensions PowerPa ck Transport dimensions L x W x H (overall with doors closed) Tareweight

2210 x 1370 x 1725 mm (7.25 x 4.49 x 5.66 ft) 1875kg(4134lbs)

Dimensions Cabin Transport dimensions L x W x H (overal with doors closed)

2130 x 2000 x 2880 mm (83.9 x 78.7 x 113.4 in)

Tare weight

1400 kg (3086 lbs)

Maximumrating

1820kg(4012lbs)

Dime nsions Winch unit Transport dimensions L x W x H (overall with doors closed) Tareweight

1875 x 1375 x 1325 mm (6.15 x 4.51 x 4.35 ft)

900kg(1984lbs)

Operational conditions Area classification

Ex Zone 2

Operating temperature range

-20 °C to +40 °C (-4 °F to +104 °F)

Environmental control

Air Conditioner (115 VAC, 60 Hz, cooling 15,000 BTU/h, electric driven, Ex Zone 2, roof mounted, marine environments) 3 Pressurization (115V, 60Hz, Ex Zone 2, ATEX, 10 m /min, fan, exchangeable heavy duty air filter) Centrifugal ventilator (0.37 kW, 120 /1 / 60, IP 55 ATEX EEx d)

Standard conformities

98/37/EC Machinery Directive 97/23/EC Pressure Equipment Directive 89/336/EC Electromagnetic Compatibility Directive

Power system Type Poweroutput Starter Fueltankvolume


Diesel engine (Iveco, 4 Cylinder, 59 kW (79 hp) @ 2,500 rpm, liquid cooled, 3.9 natural aspirated, Ex Zone 2, ATEX) 150kW(204hp)@2200rpm Spring (rig safe or Ex zone 2, with hand crank, suitable for 6 Litre displacement engine) 300 l(79.3USgal)




Pneumatic system Source Compressorpowerrating

On-boardbelt-drivencompressororrig-air 3kW

Compressorpressure

7b arnominal(102psi)

Compressor flow volume

250 litre/min @ 10 bar (8.8 cfm @ 145 psi)

Air receiver capacity

30 l (7.9 US gal)

Electrical systems Source

Shore-suppliedoron-boardgenerator

On-board generator

2x120 VAC / 240 VAC, 60 Hz, 2 ph, 15 kW, 1800 rpm, hydraulic driven, Ex Zone 2

Cabin voltages

24 VDC, Ex zone 1, ATEX rig power input 2x 115 VAC, 60 Hz, switch box, use when generator is selected)

Power supply

Type: QS 20.241 (110 - 230 VAC / 20A, 50/60 Hz, 24 VDC / 20 A / 480 W, E x Zone 2

Batterycapacity

24V DC@12A h,ATEXII3GZone2 - 20°C

Lights

Cabin 18 ( W, 24 VDC) Dash board ( 2 x 18 W, 115 V)

Hydraulic system Type

PatentedASEPclosedloop

Source

Variabledisplacementhydraulicpumpandmotor

Mainpressure

400 bar(5801 psi)max

Tankvolume

175 (46.2 l USgal)

Auxiliary drive

Hydraulic, 45 litre/min @ 200 bar, volume 20 litre, open loop, control valve, quickconnectors

Depth and tension m easuri ng SmartMonitor

SmartMonitor 12 (12 / 24 VDC, Standard, 12" display, touch screen, Ex Zone 2, ATEX)

Transmission

Encoder (Incremental, 1024 PPR, Ex Zone 1, ATEX, signaltype xxx)

Measuring head

SmartHead basic (tension range 0-10,000 kg (0-22.050 lbs), measure wheel 7.64", Ex Zone 1, ATEX)

Load pin

Stainless steel, 1 ton, single signal, 4-20 mA, integrated amplifier, 12 m of 4 wire cable, Ex Zone 1, ATEX

Winch drums Mounting type

Modular, Single drum frame, 700D-700W, Chain drive, Aluminium)


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Winch drums Supplied drum

BC06 (ODxIDxW=700x260x700mm, chain driven

Brake

Singlebrakerim(FailSafe,PneumaticActuated)

Slipring

1200 VAC, 7.5 A, number of rings 2, without cable glands, stainless steel, IP66, Ex Zone 1, ATEX

Gearbox

ChainDrive, Planetary reduction gear, ratio i=20

Levelwind arms

Pneumatic

Fire and gas safety Detection system

115 VAC, 60 Hz, Ex Zone 1, ATEX, Control panel, PLC, Display, Smoke/Gas detectors, max. 100 A 1 ph switchable

Smokedetector

OpticalEEX-IA(Orbis)includedbase

Gasdetector

Xgard5(C2H4)

Hoisting Lifting sling sets (3x)

Lifting sling set (4-leg, wire rope, SWL 2.5 ton, WL 3 m, Greenpin bolt OD 12 mm, EN 12079 / DNV 2.7-1, Lloyds certified)

Fluids NOTE: The fluid specifications stated below applied at the moment that the unit was delivered by ASEP to the customer. Climate, duty and local availability may require alternative lubricants or hydraulic oils. Use only the approved alternatives listed in the Lubricants and Hydraulic oils Appendices. Main hydraulic fluid reservoir

• Reservoir capacity = 175 l (46.2 US gal) • Fluid = Tellus T46 (Shell product code 65402, MSDS)

Coolantreservoir

• Fluid=AGIPKSVSPECIAL

Enginedieseltank

• Capacity=300l (79.3USgal) • Fuel = Diesel

Engineoiltank

• Capacity=seeIvecodocumentation • Oil = DELVAC SUPER 1400 15W40

Winch transmission reduction gearbox

• Capacity = 3 litre (0.8 gal) • Oil = Spirax S (product code 59226, MSDS)

For measurehead fluids, see SmartHead II specifications





Appendix 2: Quick reference WARNING DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with the unit must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain the unit.

Startup 1. 2.

Ensure the pre-start checklist is completed. Initialize the pneumatic system.

3.

Prime the engine by pumping the engine primer several times.

4.

Ensure that the control joysticks on the cabin control panel are in the middle position.

5.

Set the brake switch to ON.

6.

Push the reset button on the s pring starter and wind up the starter with the hand crank .

7.

Push the AIR INLET VALVE fully up to the UP FOR START position, and hold it in place.

8.

Reset the sentinel master valve by turning the control lever against the spring pressure.

9.

Remove the crank handle and activate the s pring starter handle to start the eng ine.

10. Release th e AIR INLET VALVE When the hydraulic ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi). 11. <15 Check that the hydraulic bar, troubleshoot theCONTROL system. PRESSURE stabilizes between 25 bar and 28 bar; if 12. Increase the engine speed with the THROTTLE to at lea st 1500 rpm. 13. If using the 30 kW generator to supply power, start the generator with the GENERATOR START button. If using rig power, turn on the rig power at source. 14. Turn the main power switch on JB2 in the cabin to ON. 15. Before using non-EX electrical functions inside the cabin module, purge and press urize the cabin as follows: a) Open the cabin interior ventilation ports b) Set the PURGE mode switch on JB2 to NORMAL c) Press the START PRESSURIZING button 16. Wait until the cabin has been suc cessfully purged and pressurized (approx 22 minutes). 17. Turn on all required switches in the cabin, and all required electrical appliances. Shutdown 1.

Turn off all electrical accessories.

2.

Move both control joysticks to the middle position.

3.

Make sure the drum is stopped, then set the brake switch to ON.

4.

Set the engine THROTTLE control to idle.

5.

Turn the engine off with the STOP lever on the control panel.


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6.

Stop the generator with the GENERATOR STOP button (if using rig power, turn off at source).

7.

Turn the MAIN SWITCH on JB2 to OFF.

8.

Close the cabin interior ventilation ports

Emergency sto p recovery 1.

Ensure that the ca use of the emergency shutdown has been identified and solved.

2.

Release an activated emergency stop button by pulling it firmly out until it releases.

3.

Start up the machine as described above in Startup.





Appendix 3: Lubricants Am bi ent tem per atu re -30 °C (-20 °F)

-20 °C (-2 °F)

-10 °C (+14 °F)

0 °C (+32 °F)

+10 °C (+50 °F)

+20 °C (+68 °F)

+30 °C (+86 °F)

+40 °C (+104 °F)

SAE 5W20 SAE 5W30 SAE 10W40 SAE 10W30 SAE 15W50 SAE 15W40 SAE 20W50 SAE 20W40 SAE 10 SAE 20 SAE 30 SAE 40

Engine lubricants NOTE: Select a good quality lubricant that is suitable for the ambient temperature where the machine is used.

Am bi ent tem per atu re -20 °C to + 5 °C (-2 °F to +4 1 °F) IV 95 ISO 3448

VG 100

+5 °C to + 40 °C (+41 °F to + 104 °F) IV 95 VG 150

+40 °C to +5 5 °C (+104 °F to +1 31 °F) IV 95

VG 320

-30 °C to +6 5 °C (-20 °F to + 149 °F) IV 165

VG 150-220

AGIP

Blasia 100

Blasia 150

Blasia 320

Blasia S 220

ARAL

Degol BG 100

Degol BG 150

Degol BG 320

Degol GS 220

BPMACH

GRXP100

GRXP150

GRXP320

SGRXP220 Enersyn HTX 220

CASTROL

AlphaSP100

AlphaSP150

Alpha320

AlphaSN150

CHEVRON

nonleaded gear compound 100

ELF

ReductelfSP100

ESSO

SpartanEP100

SpartanEP150

SpartanEP320

Comp.oilLG50

FINA

Giran 100

Giran 150

Giran 320

Giran 220

Alpha SN 6 non leaded gear compound 150 ReductelfSP150

non leaded gear compound 320 ReductelfSP320

ElfORITIS125MS Elf Syntherma P 30

Gearbox lubricants


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Am bi ent tem per atu re -20 °C to + 5 °C (-2 °F to +4 1 °F) IV 95 GULF

+5 °C to + 40 °C (+41 °F to + 104 °F) IV 95 EP lub. HD 150

+40 °C to +5 5 °C (+104 °F to +1 31 °F) IV 95

-30 °C to +6 5 °C (-20 °F to +14 9 °F) IV 165

EP lub. HD 320

I.P.

Mellana100

Mellana150

Mellana320

TelesiaOil150

KLUEBER

Gem1-100

Gem1-150

Gem1-320

SyntesoD220

MOBIL

Mobilgear XMP 150

Mobilgear 632

Mobilgear 629 Q8

Goya 100

Goya 150

SHELL

OmalaOil100

TOTAL

CarterEP100N

Glygoyle22 Glygoyle SHC 630 30

Goya 320

Greco 228

OmalaOil150

OmalaOil320

TivelaOilSA

CarterEP150N

CarterEP320N

Gearbox lubricants NOTE: Select a lubricant that is suitable for the ambient temperature in which the machine is to be operated.





Appendix 4: Hydraulic oils Hydra ulic oils for main power and control circuit

s

Select an oil that is suitable for the ambient temperature in which the machine is to be operated. Operating temperature of hydraulic oil will increase during operation. Machines fitted with a winterization package may have an oil heater to pre-heat the oil before operations. NOTE: Refer to the unit specifications for the specific oil supplied in the unit by ASEP at the time of delivery. Low temperatures below -15 °C (+5 °F) ISO 26 oils

Normal temperatures -5.0 °C to +60 °C (+25 °F to +142 °F)

X

ISO 46 oils

X

ISO 68 oils

X

BP

Energol H:LP 46

Castrol

Hyspin AWS 46

Chevron

Mechanism LPS 46

ELF Esso / Exxon

Very high temperatures to +75 °C (+167 °F)

Visga 46 UnivisHVI26

UnivisN46

Q8

Haydn 46

Shell

Tellus T 46

Texaco

Rando HD 46

ASEP recommended hydraulic oils for main power and control circuits


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Appendix 5: Running hours log book Like all machinery, the SlimSplit C needs to be serviced at regular intervals. The work to be performed at each interval is described in more detail in the Maintenance section of this manual. The specific service intervals are: • Daily (once every 24 hours when the SlimSplit C is in use) • After job maintenance (after completion of each wireline job) • 300-hour service (after 300 hours of wireline winch operation) • 600-hour service • 900-hour service • 1200-hour service • 1500-hour or annual service Even if there is automatic logging of the number of hours the SlimSplit C is in operation, it is still important to manually record all hours that the wireline winch is "running". It is also important to record the number of hours and the date at which each of the services (100, 300, etc.) is actually carried out. To make this easier, ASEP provides with this manual (see page 199) a blank form for recording the running hours, and the interval-based services planned and actually carried out. NOTE: Every organization has its own rules and systems for logging running hours and service activity. The form and procedures described here are no more than a suggestion for a simple running hours and service logging system. Because the service intervals are primarily aimed at the mechanical components, we recommend logging all hours that mechanical components are in use. In other words, from the moment the SlimSplit C enters stand-by prior to operations, to the moment the SlimSplit C is shut down. NOTE: If the running hours for major subsystems of the SlimSplit C are different (e.g. the power pack or engine are run for longer hours h t an the winch module), then log the usage hours for each subsystem on separate forms, so that the service is carried out no earlier than needed on the less-used subsystem. Keep all log forms in a special folder, and make sure that the maintenance engineer knows where to find this folder. Make sure that the lower section is properly filled-in whenever the UniTruck gets an interval service (100, 300, etc… hours). The figure on page 197 shows a filled-in ASEP usage & service log form, for a wireline unit that has already been running for 1823 hours before this sheet was opened. The hours have been carried forward from the previous form.





Example running hours & service log form


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Open a new runni ng hours and se rvic e log form: 1.

Carry the hours forward from the last row of the previous form (or enter zero for a new unit).

2.

Identify the SlimSplit C (e.g. registration plate).

3.

Enter the date the form was opened.

4.

Calculate or carry forward the running hours at which the next service is scheduled (for 100, 300, 900, 1200, and 1500 hours).

File the previous form in a running hours and service log folder. Log session running hours 1. At the start of the session, once the mechanical system is started, enter the start date and time. 2.

At the end of the session, when the mechanical system is stopped (or if there is an unscheduled halt due to job problems or corrective maintenance activity): a) Enter the stop date and time. b) Calculate and enter the session hours between the start and stop time. c) Calculate and enter the cumulative hours by adding the session hours to the previous cumulative hours. d) Enter any remarks about the session that may be releva nt to future prob lem diagnosis or service activity (e.g. chain tension tightened, hydraulic oil topped up ).

Log scheduled service activity On completion of the service activity, on the currently open running hours and service log form: 1.

Enter the actual running hours at which the service was carried out.

2.

Enter the actual date at which the service was carried out.

3.

Enter any remarks about the service activity that may be relevant to future problem diagnosis or service activity (e.g. brake band inspected and OK, must be replaced at next service).





Unit ID:_____________________________________

Date fo rm op ened: _____________________________

Running Hours Start Date

Stop Time

Date

Hours Time

Session

Remarks

Cumul.

carried forward from previous sheet

carry forward to next sheet

Servic e Log Next service (hours)

Due at (hours)

Done at (hours)

On (date)

Remarks

300 600 900 1200 1500/ ann.


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Appendix 6: Air transportation If the machine is to be transported by air, the carrier may require that all fluids are drained from the reservoirs, systems and components of the machine(s). Please refer to the maintenance instructions accompanying your product for specific instructions on how to drain the fluid from each reservoir, system or component. On the reverse side of this page, ASEP provides a checklist as an aid to ensuring that no part is overlooked when draining and refilling the machine. Draining: 4.

Check off each item as it is drained, adding your initials.

5.

Strike-out the items that are NOT present on the machine.

6.

Add any items that are present on the machine, but not on this list.

7.

Place this checklist in a prominent place on the machine (e.g. in the cabin, in a weatherproof envelope attached to the main operator station, etc.)

Refilling: 8.

Refer to the maintenance instructions or specifications pages of the manual for this machine, for the quantity and specifications of the required fluids.

9.

Refer to the maintenance instructions for the procedure to check and replenish fluids for each of the reservoirs, systems and components.

10. Replenish the fluid in each of the items on the reverse side of this page, remembering to bleed the system of air and again replenish if necessary. 11. ASEP recommends that new oil fi lters are used when replenishing systems that include filters. If you have fitted new filters, please add your initials in the last column.





FLUID RESERVOIRS/SYSTEMS/COMPONENTS DRAINED / REPLENISHED FOR TRANSPORTATION (excludes vehicle of self-propelled units) Date drained: Ite m

Description

01

Fueltank,filters&lines

02

Enginecoolingsystem&reservoir

03

Engine sump oil

04

Hydraulicsystem&reservoir

05

Winch motor & hoses

06

Winch gearboxes

07

Levelwind motor

08

Pneumatic line oiler

09

Pneumatic anti-frost system

10

Batteries

11

Wire spray system & reservoir

12

Winch oil collection tray

13

Grease injection system reservoir

14

Pressure testing reservoir

15

Drinking water tank

Date replenished: Bleed

New filter(s) recomm.

INITIALS Drained

Replen.

New filter

Y Y Y Y

Y

Y

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


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Appendix 7: Contact us Facili ty

Disc ipli ne(s)

Addr ess

Telephon e numb er, Fax number and E-mail address(es)

ASEP Holding B.V.

Sales Marketing Service

Energieweg 26 2964 LE Groot-Ammers The Netherlands

Tel.: +31 184 608 700 Fax: +31 184 608 790 [email protected] [email protected] [email protected]

ASEP AP B.V.

Sales Service

Energieweg 26 2964 LE Groot-Ammers The Netherlands

Tel.: +31 184 608 700 Fax: +31 184 608 790 [email protected] [email protected]

ASEP USA, Inc.

Sales

1600-B Brittmoore Road 1600-B Brittmoore Road Houston, TX 77043 United States

Tel.: +1 713 932 8400 Fax: +1 713 932 7705 [email protected] [email protected]

ASEP Lafayette, Inc.

Rental

119 Row 1 Lafayette, Louisiana 70508 United States

Tel.: +1 337 235 4222 Fax: +1 337 235 4228 [email protected]

ASEP UK Ltd.

Sales Rental Service

Europa House, Exploration Drive, Bridge of Don, Aberdeen AB23 8GX United Kingdom


ASEP Middle East FZE


P.O. BOX 17949, Jebel Ali Dubai United Arab Emirates


ASEP Far East


Loyang Offshore Supply Base Loyang Crescent, Box 5192 1200, Loyang Alley, Singapore 508988, Singapore

Tel.: +65 6546 0928 Fax: +65 6546 0927 [email protected] [email protected] [email protected]

ASEP China


Room 1005, No. 15 Building Ou Lu Jing Dian Garden No. 172 Beiyuan Road, Chaoyang District Beijing 100101, China


ASEP FSU

Sales Rental

World Trade Center, Office No. 327 Mezhdunarodnaya-2 Building

Tel.: +7 495 258 1473 Fax: +7 495 258 1474

Service

12, Krasnopresnenskaya nab. Moscow 123610, Russia

[email protected] [email protected] [email protected]


8, Mount View Terrace Mount Pleasant, Perth, Western Australia, Australia


ASEP ANZ

ASEP contact information





Facil ity

Disc ipl ine (s)

Addr ess

Telephon e numb er, Fax number and E-mail address(es)

ASEP Malaysia


Kiara Green Town House 7, 1-12 Taman Tun Dr. Ismail 60000 Kuala Lumpur Malaysia

Tel.: +60 13931 8869 [email protected] [email protected] [email protected]

ASEP India


Villa No 1 Ferns Nest Phase II Hennur Road, Bangalore 560043 India

Tel.: +91 998 007 5353 [email protected] [email protected] [email protected]

ASEP contact information


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Appendix 8: Customer feedback form Manual:

Date (d/m/y) :

Build number:

Title:

Iratethismanualasfollows:

Excellent

Good

Fair

Poor

Accuracy (product works as manual says)

Completeness (enough information)

Clarity (easy to understand)

Organization (structure of subject matter)

Figures (useful)

Examples (useful)

Index (ability to find topic)

Page layout (easy to find information)

Size (physical)

What do yo u like about thi s manual?

What do you di slike about this m anual?





Which additional inform ation would you li ke to ha ve in this manua l?

Is this manual and the content dif

ferent (unique) from o thers you h ave used?

An y ad di ti on al c om ments :

Thank you for your comments and suggestions! Please post or fax a printed copy of this form (with your comments) to: ASEP Service Department Energieweg 26 2964 LE Groot-Ammers The Netherlands Fax: +31 184608790


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Published by: ASEP Group B.V. Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2009 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by ASEP Group B.V. for loss, damage or injury caused by any errors or omissions in this document.




slimsplit_1.0 Manual.pdf

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