Version : / 00 / Revision : / ## / Page no. : / 2 of 19
Hose Reel Unit for HPU
Preservation, Storage and Maintenance
Document type / Doc.no : / PSM-0000020806Final Documentation / Page : / 1 of 19
Status / Change no. / Date / Version / Revision
In preparation / 500000009693 / ## / 00 / ##
T A B L E O F C O N T E N T S
1. INTRODUCTION 4
1.1 PURPOSE OF MANUAL 4
1.2 SYMBOLS AND CONVENTIONS 4
1.3 SAFETY NOTES 4
1.3.1 Mechanical 5
1.3.2 Electrical 5
1.3.3 Hydraulic 5
1.4 ABBREVIATIONS 5
1.5 REFERENCE DOCUMENTS 6
1.6 TEST EQUIPMENT AND SPECIFIC TOOLS 6
1.7 CONSUMABLES 6
1.8 DEFINITIONS 6
2. PRESERVATION AND STORAGE 7
2.1 PRESERVATION 7
2.2 STORAGE 7
2.3 REPLACEMENT / REPAIR 7
2.4 FAULTFINDING 7
3. TESTING 8
3.1 TEST DETAILS 8
4. EQUIPMENT MAINTENANCE CHECKLIST 9
4.1 MAINTENANCE CHECKLIST 10
4.1.1 Basic Tasks 11
4.1.2 Mobilisation 13
4.1.3 De-mobilisation 14
4.1.4 Periodic Maintenance 15
4.1.5 Mandatory Maintenance 16
4.1.6 In Storage Maintenance 17
4.1.7 Incoming Goods Inspection and Test 18
5. ATTACHMENTS 19
TABLES
PageTable 1 Storage Conditions 7
1. INTRODUCTION
This manual is for the following equipment supplied by FMC Kongsberg Subsea (FKS):
· Hose Reel Unit for Hydrualic Power Unit (HPU).
There may be project specific variations to the standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File, which this PSM normally is part of.
1.1 PURPOSE OF MANUAL
This manual provides the service personnel with the necessary information to perform routine preventive maintenance. A guide to fault finding is included together with instructions for the repair or replacement of individual components where relevant.
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
N/A.
1.3.2 Electrical
N/A.
1.3.3 Hydraulic
/ Never attempt to connect, disconnect or tighten a leaking hydraulic fitting while it 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.
1.4 ABBREVIATIONS
The following abbreviations are used in this manual:
DnV / Det norske VeritasDunf. / Dunfermline
FKS / FMC Kongsberg Subsea AS
Kbg. / Kongsberg
MF / Maintenance File
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
WO / Work Order
1.5 REFERENCE DOCUMENTS
This manual is supplied as a part of a Hose Reel Unit for HPU Maintenance File (MF). All relevant reference documents will be compiled in this MF.
/ Always use the latest revision of any documents.1.6 TEST EQUIPMENT AND SPECIFIC TOOLS
Equipment / FKS Material No / Quantity /HPU / N/A / 1
1.7 CONSUMABLES
Equipment / FKS Material No / Quantity /CRC 556 / N/A / N/A
Degreasing fluid / N/A / N/A
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 HPU Hose Reel is to be preserved in order to provide protection from rain, snow, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document.
Table 1 Storage Conditions
Item / Condition /Storage area / Indoors
Storage temperature / - 30°C to + 50°C
Maximum air humidity / 98% RH
· If stored outdoors, cover the HPU Hose Reel Unit with a tarpaulin or similar.
/ 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 HPU Hose Reel Unit after repair.
2.4 FAULTFINDING
N/A.
3. TESTING
Testing of the equipment is to be performed in accordance with the Equipment Checklist, refer to Section 4.
Extended testing due to repair of the equipment is to be clarified with the FKS Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS
N/A.
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's 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: / Hose Reel Unit for Hydrualic Power Unit (HPU).
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: Non Critical Periodic Maintenance: Every 6 months
Mandatory Maintenance: Every 12 months In Storage Maintenance: Every 6 months
REFERENCED DOCUMENTS
Assembly Drawing No.:
MAINTENANCE PROGRAM
Activity / Description / Date/sign / RemarksMobilisation / Equipment to be checked in accordance with Section 4.1.2.
De-mobilisation / Equipment to be checked in accordance with Section 4.1.3.
In Storage Maintenance / Equipment to be checked in accordance with Section 4.1.6.
Periodic Maintenance / Equipment to be checked in accordance with Section 4.1.4.
Mandatory Maintenance / Complete Overhauling / Equipment to be checked in accordance with Section 4.1.5.
Incoming Goods Inspection / Equipment to be inspected in accordance with Section 4.1.7
Signature of personnel responsible: Date:
4.1.1 Basic Tasks
Scan to PDF format after signing, file document on address REP No:Step / Description / Date/Sign. / Remarks /
5) / GENERAL
6) / Check Work Order (WO).
7) / Check if there are any Quality Notifications (QNs) on the equipment.
If approved by Client, repair accordingly.
8) / Check if there are any Service Alerts for the equipment.
9) / Check all Lifting points and lifting components. (Including Lifting-subs, etc., if any) prior to lifting.
10) / Check the validity of applicable certificates. If the certificates are not valid, initiate a re-certification of Hose Reel Unit for Hydrualic Power Unit (HPU).to be performed by third party in accordance with DnV 2.7-1 or applicable local regulations.
11) / Check Yrkeshygienisk (YH) datablad, (Safety Data Sheet).
Return waste must be marked according to regulations.
12) / 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.
13) / Check for wear, debris and corrosion.
Update preservation if needed.
14) / Check/tighten bolt connections (spot check).
Refer to FKS Document PRD-0000021662 for bolt tightening instructions.
15) / Inspect hydraulic fittings/couplings.
Check for damages, unfixed items, leakage, etc.
Check that blind plugs/protection caps are installed.
16) / Check that all movable parts such as cylinders, mechanical transmissions, joints, bushings, chains, etc., are healthy. Apply appropriate grease and replace resilient materials such as O-rings, gaskets, where necessary.
17) / Check the hydraulic fluid for cleanliness in accordance with AS 4059; 6B-F. Flush the lines if necessary; report to be issued.
18) / Check that all labels and instructions are still in place and readable. Replace if necessary.
2.0 / PRODUCT SPECIFIC CHECKS
19) / N/A
3.0 / ASSEMBLE/DISASSEMBLE
20) / N/A
4.0 / TESTING
21) / Hook up and function test hydraulic motor w/ gear by running the hose reel.
5.0 / QS CHECKOUT
22) / Punch out by QS
6.0 / PRESERVATION
23) / Clean and thoroughly dry the unit.
24) / Clean the unit with standard de- greasing fluid.
25) / Spray hydraulic valves and connections with
CRC 556 or equivalent light lubricating oil.
26) / Store the unit inside or ouside covered by a purpose made storage and transportation cover.
4.1.2 Mobilisation
Scan to PDF format after signing, file document on address REP No:Step / Description / Date/Sign. / Remarks /
1.0 / GENERAL
27) / Perform general checks in accordance with the information provided in Section 4.1 / 1.0.
2.0 / PRODUCT SPECIFIC CHECKS
28) / Perform product specific checks in accordance with the information provided in Section 4.1 / 2.0.
2.2 / Clean hydraulic connections and reconnect protection caps.
2.3 / Check Lifting Equipment/component certificates and marking.
3.0 / ASSEMBLE / DISASSEMBLE
29) / N/A.
4.0 / TESTING
4.1 / Test the HPU Hose Reel Unit in accordance with the information provided in Section 4.1/4.0.
5.0 / QS CHECKOUT
30) / Perform the QS checkout in accordance with information provided in Section 4.1 / 5.0.
6.0 / PRESERVATION
31) / If applicable, preserve equipment in accordance with information provided in Section 4.1 / 6.0.
4.1.3 De-mobilisation
Scan to PDF format after signing, file document on address REP No:Step / Description / Date/Sign. / Remarks /
1.0 / GENERAL
32) / Perform general checks in accordance with information provided in Section 4.1 / 1.0.
2.0 / PRODUCT SPECIFIC CHECKS
33) / Perform product specific checks in accordance with the information provided in Section 4.1 / 2.0.
3.0 / ASSEMBLE / DISASSEMBLE
34) / N/A
4.0 / TESTING
4.1 / Test the HRU in accordance with the information provided in Section 4.1/4.0.
4.2 / If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 / QS CHECKOUT
35) / Perform QS checkout in accordance with information provided in Section 4.1 / 5.0.
6.0 / PRESERVATION
36) / Preserve equipment in accordance with information provided in Section 4.1 / 6.0.
4.1.4 Periodic Maintenance
Scan to PDF format after signing, file document on address REP No:Step / Description / Date/Sign. / Remarks /
1.0 / GENERAL
37) / Perform general checks in accordance with information provided in Section 4.1 / 1.0.
2.0 / PRODUCT SPECIFIC CHECKS
38) / Perform product specific checks in accordance with the information provided in Section 4.1 / 2.0.
3.0 / ASSEMBLE / DISASSEMBLE
39) / Perform assembly/disassembly in accordance with the information provided in Section 4.1 / 3.0.
4.0 / TESTING
40) / Test the HRU in accordance with the information provided in Section 4.1/4.0.
41) / If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 / QS CHECKOUT
42) / Perform QS checkout in accordance with information provided in Section 4.1 / 5.0.
6.0 / PRESERVATION
43) / Preserve equipment in accordance with information provided in Section 4.1 / 6.0.
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
44) / 45) / Perform general checks in accordance with information provided in Section 4.1 / 1.0.
2.0 / PRODUCT SPECIFIC CHECKS
46) / Perform product specific checks in accordance with the information provided in Section 4.1 / 2.0.
3.0 / ASSEMBLE / DISASSEMBLE
47) / Perform assembly/disassembly in accordance with the information provided in Section 4.1 / 3.0.
4.0 / TESTING
48) / Test the HPU Hose Reel Unit in accordance with the information provided in Section 4.1/4.0.
49) / If any extended testing is required due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 / QS CHECKOUT
50) / Perform QS checkout in accordance with information provided in Section 4.1 / 5.0.
6.0 / PRESERVATION
51) / Preserve equipment in accordance with information provided in Section 4.1 / 6.0 (if applicable).
4.1.6 In Storage Maintenance
Scan to PDF format after signing, file document on address REP No:Item / Description / Date/Sign. / Remarks /
52) / Perform basic tasks in accordance with information provided in Section 4.1.
53) / Check for corrosion, damages and humidity.
Check for dirt build-up.
54) / Check and reapply preservatives as required.
55) / Make a written report on any abnormal observations done.
56) / Preserve in accordance with Section 4.1.
4.1.7 Incoming Goods Inspection and Test
Scan to PDF format after signing, file document on address REP No:EQUIPMENT NAME:
MATERIAL NO. / QTY / SERIAL NO.
MMT NO./ DELIVERY NOTE
SUPPLIER:
INSPECTION ACTIVITIES