WOCS Topside Umbilical Systems - Umbilicals, Winches/Reels ... · the Document BOM in SAP. In some...

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ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy

WOCS Topside Umbilical Systems - Umbilicals, Winches/Reels, Sheaves and

Clamps, Preservation, Storage and Maintenance

Document type Doc.no : PSM-0000021213

Final Documentation Page : 1 of 36

Status Change no. Date Version Revision

Released Version 500000032220 03.08.2004 06 F

Prepared by : IOT Approved by : PWV

FMC Kongsberg Subsea AS Doc.no.: PSM-0000021213

Version : 06 Revision : F Page no. : 2 of 36

T A B L E O F C O N T E N T S

Section Page

1. INTRODUCTION ............................................................................................................. 4

1.1 PURPOSE OF MANUAL........................................................................................ 4

1.2 SYMBOLS AND CONVENTIONS ........................................................................ 5

1.3 SAFETY NOTES ..................................................................................................... 5

1.3.1 Mechanical ........................................................................................................ 5

1.3.2 Electrical............................................................................................................ 6

1.3.3 Hydraulic ........................................................................................................... 6

1.4 ABBREVIATIONS .................................................................................................. 7

1.5 REFERENCE DOCUMENTS ................................................................................. 8

1.6 TEST EQUIPMENT AND SPECIFIC TOOLS....................................................... 8

1.7 CONSUMABLES .................................................................................................... 8

1.8 DEFINITIONS ......................................................................................................... 9

2. PRESERVATION AND STORAGE................................................................................ 10

2.1 PRESERVATION ................................................................................................... 10

2.2 STORAGE............................................................................................................... 10

2.3 REPLACEMENT / REPAIR................................................................................... 11

2.3.1 Reel with Slip Clutch - Recommendations ...................................................... 11

2.4 FAULTFINDING.................................................................................................... 11

3. TESTING .......................................................................................................................... 12

3.1 TEST DETAILS ...................................................................................................... 12

3.1.1 Winch Brake Adjustment (HSLV Winch)........................................................ 12

4. EQUIPMENT MAINTENANCE CHECKLIST .............................................................. 14

4.1 MAINTENANCE CHECKLIST SHEAVES AND CLAMPS ............................... 15

4.1.1 Basic Tasks....................................................................................................... 16

4.1.2 Mobilisation...................................................................................................... 18

4.1.3 De-mobilisation ................................................................................................ 19

4.1.4 Periodic Maintenance ....................................................................................... 20

4.1.5 Mandatory Maintenance ................................................................................... 21

4.1.6 In Storage Maintenance .................................................................................... 22

4.1.7 Incoming Goods Inspection and Test ............................................................... 23



4.2 EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL WINCH AND REEL SYSTEMS......................................................................................................... 24

4.3 MAINTENANCE CHECKLIST UMBILICAL AND WINCH SYSTEMS .......... 25

4.3.1 Basic Tasks....................................................................................................... 26

4.3.2 Mobilisation...................................................................................................... 29

4.3.3 De-mobilisation ................................................................................................ 30

4.3.4 Periodic Maintenance ....................................................................................... 31

4.3.5 Mandatory Maintenance ................................................................................... 32

4.3.6 In Storage Maintenance .................................................................................... 33

4.3.7 Incoming Goods Inspection and Test ............................................................... 34

5. ATTACHMENTS............................................................................................................. 35

F I G U R E S

Page

Figure 1 Brake Adjustment Details ..............................................................................................12

T A B L E S

Page

Table 1 Consumables ....................................................................................................................8 Table 2 Storage Conditions Umbilical Reel System / Sheaves...................................................10



1. INTRODUCTION This manual is for the following equipment supplied by FMC Kongsberg Subsea AS (FKS):

• Workover Control System (WOCS) Umbilical and Winch Systems, with associated equipment.

There may be project specific variations to the standard components.

However, the preservation, storage and maintenance instructions are identical for all components in the different projects.

For project specific details, please refer to the Project Specific Documentation (the scope of which is identical to the Customer's Master Document Register (CMDR)) or use the links set up in SAP. See also Section 1.5 for further information.

• Section 4.1 – "Maintenance Checklists Sheaves and Clamps".

• Section 4.2 – "Maintenance Checklists Umbilical and Winch Systems".

1.1 PURPOSE OF MANUAL This manual provides the service personnel with the necessary information to perform routine preventive maintenance.

Where relevant, a guide to fault finding is included together with instructions for repair.

The manual is intended used by competent, trained personnel.



1.2 SYMBOLS AND CONVENTIONS The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS.

Text set off in this manner provides warning notice that failure to follow these directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment.

Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment.

Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.

1.3 SAFETY NOTES

FKS’s and the Customer’s Health and Safety System must be adhered to at all times.

1.3.1 Mechanical

Never twist an umbilical.

For data on each umbilical's bending radius, refer to relevant drawings referenced in the project specific WOCS Signal List (LIST) document.

For data on maximum umbilical tension, refer to the relevant umbilical drawings given in the relevant WOCS "Hydraulic Schematics Diagram".

Keep clear of rotating parts and avoid sharp edges / corners.



1.3.2 Electrical

Isolate the power supply at source before working on electrical equipment. Allow sufficient time for the internal components to cool before opening Junction Boxes.

Do not switch on power supplies until all electrical isolation permits have been withdrawn.

Never attempt to bypass or override control functions using temporary leads.

Use dust caps on the connectors' interfaces when not in use.

1.3.3 Hydraulic

Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while the fitting is pressurised.

Never attempt to bypass or override control functions using temporary jumpers.

Always wear suitable protective clothing and safety glasses when there is a possibility of contact with hydraulic fluid.

Avoid any contact with chemicals.



1.4 ABBREVIATIONS The following abbreviations are used in this manual:

Abbreviation Description

BOP Blow Out Preventer

CMDR Customer's Master Document Register

DH Down Hole

DnV Det norske Veritas

Dunf. Dunfermline

ESD Emergency ShutDown

ETU Electronic Test Unit

FKS FMC Kongsberg Subsea AS

HFT Hook-up and Function Test

HPU Hydraulic Power Unit

Kbg. Kongsberg

LCP Local Control Panel

LS Landing String

MCP Motor Control Panel

MMT Material Movement Ticket

MSDS Material Safety Data Sheet

N/A Not Applicable

NDT Non Destructive Testing

P/N Part Number (Previous denotation of Material Number)

QN Quality Notification

QS Quality System

RH Relative Humidity

SD ShutDown

WO Work Order

WOCS Work Over Control System

XT Xmas Tree



1.5 REFERENCE DOCUMENTS

The reference documents are listed in the CMDR and are also linked via the Document BOM in SAP.

In some cases, this manual (PSM-0000021213) is supplied as a part of (an attachment to) a Project Specific Preservation, Storage and Maintenance (PSM) Manual. All relevant reference documents will then also be compiled in this Project Specific PSM document.

Always use the latest revision of any document.

Referenced standard FKS procedures:

FKS Doc. No. Title

PRD-0000021584 Washing/Preserving of Subsea Equipment

PRD-0000021662 Bolt Make Up

1.6 TEST EQUIPMENT AND SPECIFIC TOOLS Not Applicable (N/A).

1.7 CONSUMABLES

Table 1 Consumables

Equipment FKS Material No Quantity

Anti Freeze N/A As Required

Black plastic sheet N/A As required

Clycerol N/A As Required

CRC Electra Shield N/A As Required

Dielectric Silicon Oil N/A As required

Filters N/A Specified per system.

Glycerin N/A As Required

Lubricant N/A As Required

Plastic Bubble Sheet N/A As required

Silica Gel N/A As Required



Equipment FKS Material No Quantity

Tarpaulin N/A As Required

WD-40 N/A As Required

1.8 DEFINITIONS

Basic Tasks All scenarios, including after use / before transport / shipping, etc.

Mobilisation When preparing for use offshore.

De-mobilisation When preparing for storage after use offshore.

Periodic Maintenance When performing light preventive maintenance at fixed intervals or number of runs / runtime.

Mandatory Maintenance When performing extensive preventive maintenance included strip-down and re-certification at fixed intervals or numbers of runs / runtime.

In Storage Maintenance When the equipment is in storage

Incoming Goods Inspection

When the equipment is received (First Time Received).



2. PRESERVATION AND STORAGE

2.1 PRESERVATION The purpose of the preservation process is to protect the equipment against accidents normally encountered during handling, transportation and storage.

Preservation is to be carried out in accordance with the instructions given in Section 4 of this document.

2.2 STORAGE The Umbilical Reel System or Sheaves must be preserved in order to provide protection from rain, snow, sea spray, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document.

Table 2 Storage Conditions Umbilical Reel System / Sheaves

Item Condition

Storage Area Indoors/Outdoors in a controlled environment.

Storage Temperature - 30°C to + 50°C

Maximum Air Humidity 98% RH

• If stored outdoors, cover the Umbilical Reel System or Sheaves with a tarpaulin.

• If storage temperature is below 0°C, all hydraulic fluids that are not low temperature resistant must be changed to a suitable fluid.

Do not de-preserve until just prior to use.



2.3 REPLACEMENT / REPAIR In general, any repair is limited to direct replacement of damaged or broken components with new or reconditioned parts.

Damaged components must be returned to FKS for inspection or possible rework. If considered necessary, test the equipment after repair.

2.3.1 Reel with Slip Clutch - Recommendations The original thickness of the clutch lining is 3 mm when the reel is supplied new from the manufacturer.

The manufacturer recommends changing the brake band when mandatory maintenance inspection reveals a minimum brake lining thickness of or near 0,5 mm – or; when based on experience; the operator finds that the lining thickness will reach this limit before it is time to perform the next mandatory maintenance inspection routines.

2.4 FAULTFINDING N/A.



3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Maintenance Checklist, refer to Section 4.

Extended testing due to repair of the equipment is to be clarified with FKS Quality System (QS)/Project prior to testing.

3.1 TEST DETAILS The WOCS in question will be tested as one system.

Refer to the relevant project specific Hook-up and Function Test (alternatively; the corresponding Operation and Maintenance Manual (OMM)) - see the related Referenced Document list or SAP for details.

3.1.1 Winch Brake Adjustment (HSLV Winch) In due course, the brake lining may be worn to such an extent that the required and specified brake torque is no longer achievable. This can easily be compensated by tightening the brake adjustments screws – as shown in Figure 1.

The adjustement screws (2 off) are covered by plastic protective seals which will have to be removed prior to this operation.

-ADJUSTMENT SCREW BOTH SIDES-LOCK NUT BOTH SIDES

Figure 1 Brake Adjustment Details



1) Shut off the brake air supply by closing the air supply or by simply not

operating the winch controllers.

2) Loosen the lock nuts (1) on the brake adjustment screws (2)

3) Adjust (tighten) the brake adjustment screws (2) a few turns, the number of turns depends on how worn the brake lining is. A too tight adjustment does not involve any danger of serious damage; except for an extensive brake lining wear. This will result in considerable noise originating in the brake housing.

4) Release the adjustment bolts (screws) (2) until the noise has disappeared. The brake force is, in any case, limited by the slip hub.

5) Tighten the lock nuts (1) after the adjustment operation has been completed.



4. EQUIPMENT MAINTENANCE CHECKLIST The Equipment Maintenance Checklists are always to be signed out as follows:

1) Allocate a REP number to the Checklist in the company's Service System.

2) Fill in the General Checklist (mandatory).

3) Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.

4) Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.

Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A).

In a service system where a task is given a specified number (individual Service Order Number), the PDF file name must include the identity (number) of this Service Order.



4.1 MAINTENANCE CHECKLIST SHEAVES AND CLAMPS

Scan to PDF format after signing, file document on address REP No:

Product Name: (fill in as applicable)

Maintenance Type:

Mobilisation: De-mobilisation: In Storage Maintenance:

Periodic Maintenance: Mandatory Maintenance: Incoming Goods Inspection:

FMC's (Dunf./Kbg.) Material No.: Serial No.:

Supplier Material No.: Supplier Serial No.:

GENERAL Date Received: Date Shipped: Log No.

Category: Critical Periodic Maintenance: Every 3 months

Mandatory Maintenance: Every 12 months In Storage Maintenance: Every 12 months

REFERENCED DOCUMENTS Assembly Drawing No.:

MAINTENANCE PROGRAM Activity Description Date/sign Remarks

Mobilisation Equipment to be checked in accordance with Section 4.1.2.

De-mobilisation Equipment to be checked in accordance with Section 4.1.3.

Periodic Maintenance

Equipment to be checked in accordance with Section 4.1.4.

Mandatory Maintenance / Complete Overhauling


In Storage Maintenance



Equipment to be inspected in accordance with Section 4.3.7

Signature of personnel responsible: Date:



4.1.1 Basic Tasks


Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Check Work Order (WO).

1.2 Check if there are any Quality Notifications (QNs) on the equipment.

If approved by Client, repair accordingly.

1.3 Check if there are any Service Alerts for the equipment.

1.4 Yearly; check the validity of all applicable certificates.

If the certificates are not valid, initiate a re-certification of all applicable items to be performed by third party in accordance with DnV 2.7-1 or corresponding local regulations.

Relevant items:

Lifting Points and Lifting Components Manometers Pressure Transmitters Flow meters Pressure Safety Valves (PSV) Pressure Regulators

The third party's completed and signed checklists to be included in the maintenance report.

1.5 Check the relevant local Health, Environment and Safety Data Sheet / Requirements.

Return waste must be marked in accordance with local regulations.

1.6 Wash down the equipment. If necessary, wash down with fresh water to remove all traces of salt.

Remove excess water using compressed air.

Refer to FKS document PRD-0000021584 or valid procedure for washing instructions.

1.7 Remove possible non-painted surface protection.

1.8 Check for damage and corrosion.

1.9 Check/tighten bolt connections (spot check).

Refer to FKS document PRD-0000021662 or valid procedure for bolt tightening instructions on Clamps.

1.10 Check movable parts.

"Move up/down" and lubricate/grease if needed.

1.11 Check surface treatment and markings. Repair as necessary.



Step Description Date/Sign. Remarks 2.0 PRODUCT SPECIFIC CHECKS

2.1 Inspect the rolls for damage and tear.

2.2 Inspect and verify the condition of the suspension device.

3.0 ASSEMBLE/DISASSEMBLE 3.1 N/A.

4.0 TESTING 4.1 N/A.

5.0 QS CHECKOUT 5.1 Punch out by QS.

6.0 PRESERVATION 6.1 Store the equipment in the dedicated compartment in

the transport basket.



4.1.2 Mobilisation


Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Perform general checks in accordance with the

information provided in Section 4.1.1 / 1.0.

2.0 PRODUCT SPECIFIC CHECKS 2.1 Perform product specific checks in accordance with

the information provided in Section 4.1.1 / 2.0.

3.0 ASSEMBLE / DISASSEMBLE 3.1 N/A.

4.0 TESTING Electrical Jumpers:

4.1 For electrical lines; perform electrical continuity and megging tests in accordance with relevant instructions; i.e. refer to the Project Specific part of the Maintenance Documentation given for this WOCS for details on how to carry out the jumper megging procedures.

Hydraulic Jumpers:

4.2 Perform Pressure Testing and Flushing in accordance with instructions given in relevant Hook-up and Function Test (HFT) procedure.

5.0 QS CHECKOUT 5.1 Perform the QS checkout in accordance with


6.0 PRESERVATION 6.1 N/A.



4.1.3 De-mobilisation


Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Perform general checks in accordance with





4.0 TESTING 4.1 Perform Pressure Testing and Flushing in accordance

with instructions given in relevant HFT procedure.

Included are tasks as changing the hydraulic fluid and verifying the correct fluid cleanliness class.


5.0 QS CHECKOUT 5.1 Perform QS checkout in accordance with information

provided in Section 4.1.1 / 5.0.

6.0 PRESERVATION 6.1 Preserve equipment in accordance with information




4.1.4 Periodic Maintenance













4.1.5 Mandatory Maintenance

Scan to PDF format after signing, file document on address REP No: Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Perform general checks in accordance with


2.0 PRODUCT SPECIFIC CHECKS 2.1 Initiate a re-certification of the sheave to be

performed by third party in accordance with DnV 2.7-1 or local regulations.


2.2 Yearly – initiate a third party's check of welds in accordance with API or other relevant standard by using NDT.

(Applicable to lifting eyes and all other welded parts in accordance with design criteria.)

The third party's completed report and signed checklists to be included in the maintenance report.

2.3 Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0.

2.4 For Reels with Slip Clutch, inspect (measure) the clutch lining (brake lining) thickness. Refer to Section 2.3.1 for the manufacturer's recommendations.


4.0 TESTING 4.1 Perform Pressure Testing and Flushing in accordance

with instructions given in relevant HFT Procedure.







4.1.6 In Storage Maintenance


Item Description Date/Sign. Remarks 1) Perform basic tasks in accordance with information

provided in Section 4.1.1.

2) Check the validity of all certificates.

Initiate a re-certification of the Sheave to be performed by third party in accordance with DnV 2.7-1 or local regulations.


3) Preserve in accordance with Section 4.1.1 / 6.0.



4.1.7 Incoming Goods Inspection and Test


EQUIPMENT NAME:

MATERIAL NO. QTY / SERIAL NO.

MMT NO./ DELIVERY NOTE

SUPPLIER:

INSPECTION ACTIVITIES Item Description Checked N/A QN Ref 1.0 TRANSPORTATION

1.1 Unpacking of Equipment.

1.2 Transportation Damage.

1.3 Consignment Note Signed.

1.4 Correct Quantity of Received Materials.

2.0 VISUAL INSPECTION

2.1 Equipment Marking.

2.2 Lifting Gear Identification.

3.0 DOCUMENTATION

3.1 Dispatch Dossier.

3.2 Lifting Certificates.

3.3 Material Safety Data Sheet (MSDS).

3.4 Punch List.

OUTSTANDING ITEMS TRANSPORT DAMAGE DESCRIPTION: INSPECTION SITE:

SIGNATURE: DATE:



4.2 EQUIPMENT MAINTENANCE CHECKLIST UMBILICAL WINCH AND REEL SYSTEMS

The Equipment Maintenance Checklists are always to be signed out as follows:

1) Allocate a REP number to the Checklist in the company's Service System.

2) Fill in the General Checklist (mandatory).

3) Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.

4) Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.

Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A).

In a service system where a task is given a specified number (individual Service Order Number), the .PDF file name must include the identity (number) of this Service Order.



4.3 MAINTENANCE CHECKLIST UMBILICAL AND WINCH SYSTEMS


Product Name: (fill in as applicable)

Maintenance Type:

Mobilisation: De-mobilisation: In Storage Maintenance:

Periodic Maintenance: Mandatory Maintenance: Incoming Goods Inspection:

FMC's (Dunf./Kbg.) Material No.: Serial No.:

Supplier Material No.: Supplier Serial No.:

GENERAL Date Received: Date Shipped: Log No.

Category: Critical Periodic Maintenance: Every 3 months or 3 runs

Mandatory Maintenance: Every 12 months In Storage Maintenance:Every 3 months

REFERENCED DOCUMENTS Assembly Drawing No.:

MAINTENANCE PROGRAM Activity Description Date/sign Remarks

Mobilisation Equipment to be checked in accordance with Section 4.3.2

De-mobilisation Equipment to be checked in accordance with Section 4.3.3.

Periodic Maintenance


Mandatory Maintenance / Complete Overhauling


In Storage Maintenance



Equipment to be inspected in accordance with Section 4.3.7

Signature of personnel responsible: Date:



4.3.1 Basic Tasks


Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Check Work Order (WO).

1.2 Check if there are any Quality Notifications (QNs) on the equipment.

If approved by Client, repair accordingly.

1.3 Check if there are any Service Alerts for the equipment.

1.4 Check Lifting Equipment/components' certificates and markings for validity prior to lifting.

Also, refer to the relevant PSM(s) for Transport and Handling Equipment. The manuals are identified in the relevant Document Reference lists.

1.5 Check the validity of applicable certificates. If any certificates are not valid, initiate a re-certification of the Umbilical Reel to be performed by third party in accordance with DnV 2.7-1 or applicable local regulations.


1.6 Wash down the equipment. If necessary, wash down with fresh water to remove all traces of salt.

Remove excess water using compressed air.

Refer to FKS Document PRD-0000021584 or valid procedure for washing instructions.

1.7 Check the relevant local Health, Environment and Safety Data Sheet / Requirements.

Return waste must be marked in accordance with local regulations.

1.8 For the Pneumatic Equipment, check hoses, connection points, valves, etc., for damage, wear, loose components and leakage.

1.9 For Pneumatic Equipment with filters, drain the filter housing and clean as necessary. Check and change filter elements in accordance with manufacturer's recommendation.

Check (differential) pressure indicators if installed.

1.10 Inspect hydraulic components, e.g. fittings/couplings, piping, etc.

Check for damage, loose items, dirt, leakage, etc.

Check that blind plugs/protection caps are installed.



Step Description Date/Sign. Remarks 1.11 Inspect that hydraulic valves, regulators, etc., are

easy operable.

"Move up/down" and lubricate/grease if required.

1.12 Check for proper fastening of mounted components (clamps, etc.).

Check for damage and corrosion.

Check that securing clamps/pins are correctly installed.

1.13 Check/tighten bolt connections (spot check) where applicable.

Refer to FKS Document PRD-0000021662 for bolt tightening instructions, if applicable.

1.14 Inspect electrical components' cables and contacts / connection points.

Change silica gel where required.

Inspect for wear, damage or loose components.

Verify that protection caps are installed where required.

1.15 Inspect seal surfaces, threads on equipment connections (box/pin connections).

Check for damage, tear, debris and corrosion.

Check and update surface treatment.

Check and lubricate all seals available. Replace seals, backup rings, etc., if necessary.

1.16 Check the most recent certification date on all EX-equipment. A yearly certification is required on EX-equipment. Perform a visual inspection. If necessary (apparent damage or fault), call for a third party for examination and repair.

The third party's completed and signed checklists / report to be included in the maintenance report.

1.17 Check movable parts for damage, wear, dirt and corrosion.

"Move up/down" and lubricate/grease if needed.

1.18 Remove possible non-painted surface protection.

Check surface treatment and markings. Repair as necessary.

Check for damage and corrosion.

Check that the remaining protection caps are installed where applicable.



Step Description Date/Sign. Remarks 1.19 If the umbilical is used for Brayco Synthetic Oil, the

lines shall be tested for water content.

If the water content is higher than 500 ppm, the lines must be flushed though an oil drier until 500 ppm has been reached.

If the cleanliness level is worse than AS 4059 Class 6B-F; the lines must be flushed until the required cleanliness level has been achieved.

Some umbilicals used with Brayco Fluid have water saturation in the lines. This causes high water content even a short time after flushing / drying; hence it is mandatory to flush / dry the umbilical lines five (5) working days before mobilisation. During these five days, skilled operators will have to decide the duration of the flushing / drying necessary to maintain a value of 500 ppm in the fluid. Repeating the flushing / drying operation is necessary after a period of time.

1.20 Umbilicals used with water glycol fluid must be checked with regards to cleanliness.

If the cleanliness level is worse than AS 4059 Class 6B-F; the lines must be flushed until the required cleanliness level has been achieved.

2.0 PRODUCT SPECIFIC CHECKS 2.1 Inspect the cogwheels and chain.

2.2 Inspect the air motor.

2.1 Check spooling device. If required, adjust the spooling device in accordance with manufacturer's recommendations.

2.2 Check the brakes. If required, adjust the brakes in accordance with manufacturer's recommendations

3.0 ASSEMBLE/DISASSEMBLE 3.1 N/A.

4.0 TESTING 4.1 Pressure test the equipment in accordance with

relevant procedures. The manuals are identified in the associated Document Reference lists. Preserve after completed test.

5.0 QS CHECKOUT 5.1 Punch out by QS

6.0 PRESERVATION Preserve the equipment (where relevant) in accordance with manufacturer's recommended instructions as follows:

6.1 Grease all lubrication points using the recommended grease.

6.2 Inspect the cogwheels and chain. Grease the cogwheels and chains using the recommended grease.

6.3 Inspect the motor. Inspect the oil level in both motor and gear. If required, add oil of recommended type.



Step Description Date/Sign. Remarks

6.4 Check that the umbilical's subsea end is securely terminated to the termination bracket.

6.5 If possible, lock the reel using the locking pin in order to prevent unintentional rotation during storage.

6.6 Protect external surfaces using plastic mesh, tape or similar in order to prevent damage.

4.3.2 Mobilisation


Step Description Date/Sign. Remarks 1.0 GENERAL 1.1 Perform general checks in accordance with the


2.0 PRODUCT SPECIFIC CHECKS 2.1 Two weeks prior to mobilisation; perform

instructions as given in Section 4.3.1 / 1.19.

2.2 Five working days prior to mobilisation; perform instructions as given in Section 4.3.1 / 1.19.


2.4 Perform instructions as given in Section 4.3.1 / 1.20.



5.0 QS CHECKOUT 5.1 Perform the QS checkout in accordance with





4.3.3 De-mobilisation




2.0 PRODUCT SPECIFIC CHECKS 2.1 If considered necessary unwind the umbilical using a

receiving winch and inspect for vear, tear and damage while winding.


3.0 ASSEMBLE / DISASSEMBLE 3.1 N/A 4.0 TESTING 4.1 Pressure test the equipment in accordance with

associated procedures. The procedures are identified in the relevant Document Reference lists.

4.2 If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.



6.0 PRESERVATION 6.1 Preserve equipment in accordance with information




4.3.4 Periodic Maintenance






2.2 Every three months; perform instructions as given in Section 4.3.1 / 1.19.


4.0 TESTING 4.1 Test the equipment in accordance with the relevant

procedures; identified in the relevant Document Reference lists and SAP.

4.2 If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.






4.3.5 Mandatory Maintenance

Scan to PDF format after signing, file document on address REP No: Step Description Date/Sign. Remarks 1.0 GENERAL

1.1 Perform general checks in accordance with information provided in Section 4.3.1 / 1.0.

2.0 PRODUCT SPECIFIC CHECKS 2.1 Check the log for and initiate a re-certification / re-

calibration of the relevant components in accordance with the manufacture's recommendation if necessary. Yearly calibration is required on Gauges and Check Valves.

Manometers.

Pressure Gauges.

Pressure Transmitters

2.2 Replace air filters. Replace O-rings if damaged.

2.3 Check welds (lifting pad eyes) yearly in accordance with API or other relevant standard by NDT.

2.4 Per



4.0 TESTING 4.1 Test the equipment in accordance with the relevant

HFT procedure.






4.3.6 In Storage Maintenance


Item Description Date/Sign. Remarks 1) Perform basic tasks in accordance with information


2) Check the validity of all certificates yearly.

Initiate a re-certification to be performed by third party in accordance with DnV 2.7-1 or local regulations where applicable.

The third party's completed and signed checklists / reports to be included in the maintenance report.

3) Pay out some meters of the Umbilical to have the air motor cycled and hence circulate the lubricants in order to vary the static load point on the bearing.

4) Preserve in accordance with instructions provided in Section 4.3.1 / 6.0.



4.3.7 Incoming Goods Inspection and Test


EQUIPMENT NAME:

MATERIAL NO. QTY / SERIAL NO.

MMT NO./ DELIVERY NOTE

SUPPLIER:

INSPECTION ACTIVITIES Item Description Checked N/A QN Ref 1.0 TRANSPORTATION

1.5 Unpacking of Equipment.

1.6 Transportation Damage.

1.7 Consignment Note Signed.

1.8 Correct Quantity of Received Materials.

2.0 VISUAL INSPECTION

2.3 Equipment Marking.

2.4 Lifting Gear Identification.

3.0 DOCUMENTATION

3.5 Dispatch Dossier.

3.6 Lifting Certificates.

3.7 Material Safety Data Sheet (MSDS).

3.8 Punch List.

OUTSTANDING ITEMS TRANSPORT DAMAGE DESCRIPTION:

INSPECTION SITE:

SIGNATURE: DATE:



5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT

Fill in the following data if applicable:

• Equipment Name.

• FKS Material Number.

• Reference Document (this is the number of the current PSM manual).

• Reference Drawing Number(s).

CORRECTIVE MAINTENANCE REPORT


Equipment Name:

FKS Material Number:

Fault

Reference Document:

Reference Drawing Number(s):

Task Description Date Comments

Parts Used Date Comments

Discipline Man-hours:

Name: Signature:

Date post:	17-Mar-2020
Category:	Documents
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