WOCS UmbilicalJumpers and Test Equipment Preservation ... · WOCS UmbilicalJumpers and Test...

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WOCS UmbilicalJumpers and Test Equipment

Preservation, Storage and Maintenance

Document type Doc.no : PSM-0000020965

Final Documentation Page : 1 of 25

Status Change no. Date Version Revision

Released Version 500000016718 01.11.2002 02 A

FMC Kongsberg Subsea AS Doc.no.: PSM-0000020965

Version : 02 Revision : A Page no. : 2 of 25

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.................................................................. 4

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

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

1.3.2 Electrical ................................................................................................. 5

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

1.4 ABBREVIATIONS............................................................................................ 6

1.5 REFERENCE DOCUMENTS ........................................................................... 7

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

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

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

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

4. EQUIPMENT MAINTENANCE CHECKLIST ......................................................... 13

4.1 MAINTENANCE CHECKLIST........................................................................ 14

4.1.1 Basic Tasks ............................................................................................. 15

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

5. ATTACHMENTS........................................................................................................ 24



T A B L E S

Page

Table 1 Electrical Jumpers ...................................................................................................8

Table 2 Hydraulic Jumpers ..................................................................................................8

Table 3 Electrical Jumpers / Umbilicals Storage Conditions.............................................10

Table 4 Hydraulic Jumpers / Umbilcals Storage Conditions .............................................10



1. INTRODUCTIONThis manual is for the following equipment supplied by FMC KongsbergSubsea AS (FKS) for the Work Over Control System (WOCS) Topside System:

� Electrical Jumpers.

� Hydraulic Jumpers.

� Pneumatic Jumpers / Hoses.

� Electrical / Hydraulic Jumpers.There may be project specific variations to the standard components. However,the preservation, storage and maintenance instructions are identical for allcomponents. For project specific details, please refer to the Maintenance File(MF), which this PSM normally is part of.

1.1 PURPOSE OF MANUALThis manual provides the service personnel with the necessary information toperform routine preventive maintenance.

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

The manual is intended used by competent, trained personnel.

1.2 SYMBOLS AND CONVENTIONSThe following words and symbols found throughout this manual mark specialmessages to alert the operator of specific information concerning of thePERSONNEL, the EQUIPMENT or the PROCESS.

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

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

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



1.3 SAFETY NOTES

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

1.3.1 Mechanical

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

Do not twist a jumper hose more than 360° over a 3 metre length(measured at termination).

Do not apply snags to a jumper hose. Avoid sharp edges and contact withchemicals.

Avoid locating the jumper hoses near ozone producing equipment, e.g.electric motors, batteries, welding equipment, etc.

Do not apply tension to a jumper hose using more than 500 N for morethan 10 minutes.

Do not exceed 150 mm bending radius of a jumper hose.

Avoid dropping the connectors, use dust caps for protection.

1.3.2 Electrical

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

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

Never attempt to bypass or override control functions using temporaryleads.

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



Electrical jumpers are pressurised with silicone oil and are not to beopened without using special tools.

1.3.3 Hydraulic

Never attempt to connect, disconnect or tighten a leaking hydraulic fittingwhile it is pressurised.

Never attempt to bypass or override control functions using temporaryjumpers.

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

Avoid any contact with chemicals.

1.4 ABBREVIATIONSThe following abbreviations are used in this manual:

Abbreviation Description

BOP Blow Out Preventer

DH Down Hole

DnV Det norske Veritas

Dunf. Dunfermline

ESD Emergency ShutDown

ETU Electronic Test Unit

FKS FMC Kongsberg Subsea AS

HPU Hydraulic Power Unit

Kbg. Kongsberg

LCP Local Control Panel

LS Landing String

LV Lubricator Valve

MCP Motor Control Panel

MF Maintenance File



Abbreviation Description

MMT Material Movement Ticket

MSDS Material Safety Data Sheet

N/A Not Applicable

N/A Not Applicable

NDT Non Destructive Testing

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

QN Quality Notification

QS Quality System

R/R Running / Retrieval

RH Relative Humidity

SD ShutDown

WO Work Order

WOCS Work Over Control System

XT Xmas Tree

1.5 REFERENCE DOCUMENTSThis manual is supplied as a part of a WOCS Maintenance File (MF). Allrelevant reference documents will be compiled in this MF.

Always use the latest revision of any documents.



1.6 TEST EQUIPMENT AND SPECIFIC TOOLS

Table 1 Electrical Jumpers

Equipment FKS P/N Quantity

Electrical Test Connector N/A 2

Multimeter N/A 1

Megger N/A 1

Table 2 Hydraulic Jumpers

Equipment FKS P/N Quantity

MQC Flushing Plate N/A 2

1.7 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

Hydraulic Fluid N/A As Required

Hydraulic Oil N/A As Required

Lubricant N/A As Required

Nitrogen Gas N/A As Required

Plastic Bubble Sheet N/A As required

Silica Gel N/A As Required

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 atfixed intervals or number of runs / runtime.

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

In Storage Maintenance When the equipment is in storage

Incoming GoodsInspection

When the equipment is received (First TimeReceived).



2. PRESERVATION AND STORAGE

2.1 PRESERVATIONThe purpose of the preservation process is to protect the equipment againstaccidents normally encountered during handling, transportation and storage.

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

2.2 STORAGEThe equipment must be preserved in order to provide protection from rain,snow, ice, dust, solar radiation or sand in accordance with instructions given inSection 4 of this document.

Table 3 Electrical Jumpers Storage Conditions

Item Condition

Storage area Indoor/Outdoor in acontrolledenvironment.

Maximum air humidity 100% RH

Short Term (< 2 months ) storage Temperature - 20o C to + 50oC

Medium Term (< 6 months ) storage Temperature - 20o C to + 30oC

Long Term (> 6 months ) storage Temperature - 20o C to + 25oC

� If there is sunlight present in the storage area, cover the assemblies withblack plastic or similar protection.

� It is recommend during long term storage that the assemblies are stored inthe original packing crate. If re-use of original packing crates is notfeasible, the assemblies should be coiled and stored in a horizontal position.

� If stored outdoors cover the assemblies with a tarpaulin or similar.

Table 4 Hydraulic Jumpers Storage Conditions

Item Condition

Storage area: Indoor

Storage temperature: - 14°C* to + 60°C

* Note check the hydraulic fluid actually installed.

Maximum airhumidity:

95% RH



Always store hydraulic jumpers filled with the recommended controlfluid.

Unless for inspection purposes or preparation for offshore use, the HydraulicJumpers must remain in their preserved condition.

2.3 REPLACEMENT / REPAIRIn general, any repair is limited to direct replacement of damaged or brokencomponents with new or reconditioned parts.

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

2.4 FAULTFINDINGN/A.



3. TESTINGTesting of the equipment is to be performed in accordance with the EquipmentMaintenance Checklist, refer to Section 4.

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

3.1 TEST DETAILSThe equipment (WOCS) in question will be tested as one system. Refer to therelevant Hook-up and Function Test (see the MF for each project specificreferance) for details.

For the hydraulic jumpers, Pressure Test and Flushing to be carried out beforeuse, in accordance with the relevant procedure referenced in section 4 of theMF.



4. EQUIPMENT MAINTENANCE CHECKLISTThe 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 fileusing the REP number as filename.

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

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



4.1 MAINTENANCE CHECKLIST

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

Product Name:

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.:

GENERALDate Received: Date Shipped: Log No.

Category: Critical Periodic Maintenance: Every 6 months

Mandatory Maintenance: N/A In Storage Maintenance: Every 6 months and every 12 months.

REFERENCED DOCUMENTSAssembly Drawing No.:

MAINTENANCE PROGRAMActivity Description Date/sign Remarks

Mobilisation Equipment to be checked inaccordance with Section 4.1.2.

De-mobilisation Equipment to be checked inaccordance with Section 4.1.3.

PeriodicMaintenance

Equipment to be checked inaccordance with Section 4.1.4.

MandatoryMaintenance /CompleteOverhauling

N/A

In StorageMaintenance

Equipment to be checked inaccordance with Section 4.1.6.

IncomingGoodsInspection

Equipment to be inspected inaccordance with Section 4.1.7

Signature of personnel responsible: Date:



4.1.1 Basic Tasks


Step Description Date/Sign. Remarks1.0 GENERAL 1.1 Check Work Order (WO).

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

If approved by Client, repair accordingly.

1.3 Check if there are any Service Alerts for theequipment.

1.4 Check the relevant local Health, Environment andSafety Data Sheet / Requirements.

Return waste must be marked in accordance withlocal regulations.

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

Remove excess water using compressed air.

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

1.6 Remove possible non-painted surface protection.

Check and lubricate all seals available.

1.7 Check for proper fastening of mounted components.

Check for damage and corrosion.

Check that securing clamps/pins are installed.

1.8 Inspect hydraulic fittings/couplings.

Check for damage, unfixed items, leakage, etc.

Check that blind plugs/protection caps are installed.

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

1.9 Inspect that the hydraulic oil is according tospecifications regarding water contents, particles andbacteria level.

Perform flushing of hydraulic lines and componentsif necessary.



Step Description Date/Sign. Remarks 1.10 Inspect electrical components (control panels /

junction boxes), cables and contacts / connectionpoints.

Change silica gel where required.

Inspect for damage or unfixed (loose) items.

Verify that protection caps are installed whererequired.

1.11 Check the most recent certification date on all Ex-equipment.A yearly certification is required on Ex-equipment.Perform a visual inspection of EX-equipment. Ifnecessary (apparent damage or fault), call for a thirdparty examination and repair.

1.12 Check surface treatment and markings. Repair ifnecessary.

2.0 PRODUCT SPECIFIC CHECKS2.1 Inspect and check all interface connection to rig or

installation supplies - i.e. electrical, hydraulic, air andwater supplies.

3.0 ASSEMBLE/DISASSEMBLE3.1 N/A.

4.0 TESTING4.1 N/A

5.0 QS CHECKOUT5.1 Punch out by QS.

6.0 PRESERVATION6.1 Fill the hydraulic system using the recommended

fluid.

6.2 Cover QCs, filling nipples and couplers using plasticbags.

6.3 Coil hoses with QC neatly, store inside the HPUContainer or in the associated shipping basket.

6.4 Apply dielectric silicone oil to connector matingsurfaces.

6.5 Fit dust and protection caps.

6.6 Wrap connectors in bubble plastic secured withadhesive tape.During medium and long term storage, coverassemblies if exposed to sunlight

6.7 Protect external surfaces using plastic mesh,electrical tape or other protective measures in orderto prevent damage.

6.8 Non-metallic materials and corrosion resistantmaterials (e.g. Xylan, Inconel, Stainless Steel, Al-Bronze, etc.) are NOT to be coated usingpreservatives unless specifically instructed.



Step Description Date/Sign. Remarks6.9 Arrange the different parts in order to prevent direct

metal-to-metal contact.

6.10 Arrange for protection against moisture andcondensation.

6.11 Ensure all Quick Connectors are protected by caps inorder to prevent ingress of contamination.

6.12 For storage areas with varying temperatures, ensurethat there is sufficient ventilation to keep theequipment condensation free.

6.13 Cover each jumper end with plastic mesh, securedwith adhesive tape to protect the stabs/end interface.

6.14 During storage / transport, the jumpers must beprotected from damage caused by the following:- Sharp edges and corners

- Falling and moving objects

- Welding and grinding operations

- Prolonged exposure to direct sunlight.

Always store the hydraulic jumpers filled with control fluid.



4.1.2 Mobilisation


Step Description Date/Sign. Remarks1.0 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 TESTINGUbilical and Jumpers

4.1 Test the equipment in accordance with the relevanttest procedure (associated document referenced in theMF, chapter 4 ).

5.0 QS CHECKOUT 5.1 Perform the QS checkout in accordance with


6.0 PRESERVATION 6.1 Preserve equipment in accordance with information

provided in Section 4.1.1 / 6.0.



4.1.3 De-mobilisation


Step Description Date/Sign. Remarks1.0 GENERAL 1.1 Perform general checks in accordance with




2.2 For a storage period of more than two weeks, fill thehydraulic system with the recommended hydraulicfluid.

3.0 ASSEMBLE / DISASSEMBLE 3.1 N/A

4.0 TESTING 4.1 Test the equipment in accordance with the relevant

procedure (associated document referenced in theMF, chapter 4).

4.2 If any extended testing is necessary due to repair ofthe equipment, get in touch with FKS QS/Project fordetailed instructions.

5.0 QS CHECKOUT 5.1 Perform QS checkout in accordance with information




6.2 Place in original Packing case if the equipment is tobe stored long term



4.1.4 Periodic Maintenance


Step Description Date/Sign. Remarks1.0 GENERAL 1.2 Perform general checks in accordance with




2.4 For a storage period of more than two weeks, fill thehydraulic system with the recommended hydraulicfluid.

3.0 ASSEMBLE / DISASSEMBLE 3.1 N/A

4.0 TESTING 4.3 Test the equipment in accordance with the relevant

procedure (associated document referenced in theMF, chapter 4).

4.4 If any extended testing is necessary due to repair ofthe equipment, get in touch with FKS QS/Project fordetailed instructions.

5.0 QS CHECKOUT 5.2 Perform QS checkout in accordance with information




6.4 Place in original Packing case if the equipment is tobe stored long term



4.1.5 Mandatory MaintenanceN/A.



4.1.6 In Storage Maintenance

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

Every 12 months:1) Perform basic tasks in accordance with information

provided in Section 4.1.1 / 1.0.2) Operate MQC plate mechanism and verify correct

function.

3) Preserve in accordance with Section 4.1.1/ 6.0.

Every 6 months4) Perform basic tasks in accordance with information

provided in Section 4.1.1/1.0.5) Re-fill the hydraulic system with the recommended

hydraulic fluid, if neccary.

6) 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 ACTIVITIESItem Description Checked N/A QN Ref1.0 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 INSPECTION2.1 Equipment Marking.2.2 Lifting Gear Identification.

3.0 DOCUMENTATION3.1 Dispatch Dossier.3.2 Lifting Certificates.3.3 Material Safety Data Sheet (MSDS).3.4 Punch List.

OUTSTANDING ITEMSTRANSPORT DAMAGE DESCRIPTION:

INSPECTION SITE:

SIGNATURE: DATE:



5. ATTACHMENTSCORRECTIVE 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:

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