Forum Bop at 300 mkii Manual

PART NUMBER

PART DESCRIPTION

SRTS-066-PRMA/01

BOP AT 300 OPERATION & MAINTENANCE MANUAL

CURRENT ISSUE

RECORD OF FIRST

ISSUE

ASA

DRAWN/ALT

JFO

DO CHECKED

JFO

TOCHECKED

DOCUMENT TITLE

JFO

TOAPPROVED

BOP AT 300 OPERATION &

MAINTENANCE MANUAL

PROD

STATUS

02 Feb 2023

06/07/2012

ISSUE DATE

Confidentiality Category: C2

In accordance with Forum Energy Technologies (UK) LTD Procedure Q001-

005-002. Confidential Forum Energy Technologies (UK) LTD, disclosure to

third parties only with signed confidentiality agreement. This document

contains confidential Information, property of Forum Energy Technologies

(UK) LTD. Copyright Forum Energy Technologies (UK) LTD, all rights

reserved

DOCUMENT NUMBER

ISSUE

SRTS-066-PRMA

SUPERSEDES

SUPERSEDED BY

Page 1 of 56

KMS A4 Document.

BOP Actuation Tool 300 MkII

(BOP AT 300 MkII)

Operation & Maintenance Manual

DRAWING NUMBER

ISSUE

SRTS-066-PRMA

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Confidentiality Category: C2 In accordance with Forum Energy Technologies (UK) LTD Procedure Q001-005-002. Confidential Forum Energy Technologies

(UK) LTD, disclosure to third parties only with signed confidentiality agreement. This document contains confidential information, property of Forum Energy

KMS A4 Document.

CONTENTS

1INTRODUCTION 3

1.1 SCOPE 3

2SAFETY RECOMMENDATIONS 3

2.1 GENERAL –OPERATIONS 3

2.2 GENERAL –HYDRAULICS 3

2.3 GENERAL –MECHANICAL 4

3QUALITY, HEALTH, SAFETY AND ENVIRONMENT (QHSE) 4

3.1 QUALITY 4

3.2 HEALTH AND SAFETY 4

3.3 ENVIRONMENTAL 5

4CONTACT DETAILS 5

5DESCRIPTION 6

6SPECIFICATIONS 6

7CONNECTION TO ROV 7

7.1 SEAWATER CONNECTION 8

8OPERATION 8

8.1 PRESSURE TESTING 9

8.2 ADJUSTING MAXIMUM OUTPUT PRESSURE 10

9MAINTENANCE 11

10 SPARES 12

11 TROUBLESHOOTING 12

11.1 PUMP 12

11.1.1 HPW-Pump does not work. 12

11.1.2 HPW-Pump works but does not deliver water flow. 12

11.1.3 HPW-Pump does not receive pumping fluid. 12

11.1.4 Water pressure line blocked 13

11.1.5 Water flow rate too small 13

11.1.6 Water pressure too low 13

11.1.7 Intense pulsating of water pressure 13

11.1.8 Closing the water pressure line does not drop pressure to free circulation mode 13

11.1.9 Leakages 14

11.2 UN-STICKING DYNASET PROCEDURE 14

12 SCHEMATICS & DRAWINGS 15

13 ADDITIONAL DRAWINGS 15

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Confidentiality Category: C2 In accordance with Forum Energy Technologies (UK) LTD Procedure Q001-005-002. Confidential Forum Energy Technologies

(UK) LTD, disclosure to third parties only with signed confidentiality agreement. This document contains confidential information, property of Forum Energy

KMS A4 Document.

1 INTRODUCTION

1.1 SCOPE

The scope of this manual is to provide information regarding assembly and set

up/operating instructions for the BOP Actuation Tool 300 MkII (BOPAT-300 MkII).

2 SAFETY RECOMMENDATIONS

2.1 GENERAL –OPERATIONS

Only authorised people and qualified personnel should work on the system and take

suitable precautions to prevent injury.

Always adhere to authorised working practices and use the correct tools for the job.

To facilitate this, make sure that these are available before commencing.

Ensure that overalls and other garments are kept clean and free of oil or chemicals.

Ensure that any cuts or skin abrasions are protected before handling oil or chemicals

to prevent ingress into the body. Protect the hands and arms with a suitable barrier

cream and gloves and ensure that all system fluids or chemicals are removed from the

skin as soon as possible.

Ensure that the working area is kept clear and uncluttered.

2.2 GENERAL –HYDRAULICS

Do not work on pressurised systems. Hydraulic systems contain a large amount of

stored energy when pressurised, therefore the system (including any accumulators)

should be de-pressurised, and the power pack switched off, prior to working on the

system. Exceptions to this would be system adjustments to components requiring the

presence of pressure and/or flow.

Any personnel authorised to work on the system must have a complete understanding

of the operation of the hydraulic system, so that they will be aware of any system liable

to remain pressurised or hazardous in any other way.

Ensure that all personnel are clear of any mechanical/hydraulic system likely to move

if pressure to system actuators is released or applied.

Do not attempt to tighten any leaking fittings whilst under pressure. A rupture could

result, leading to injury from flying components and/or oil jets.

Regularly inspect fittings and pipe-work for mechanical damage. If any such damage

is found, the item must berepaired or replaced asnecessary before pressure is applied

to the system. Do not allow damaged fittings to remain in service.

Take care when inspecting, commissioning, repairing or maintaining the system to

avoid jets of oil issuing from open orifices; pipe ends etc. if pressure is applied. Care

should be taken to protect the eyes.

Hydraulic components may be heavy and slippery when covered in oil. Ensure that

adequate protective clothing and footwear is used.

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KMS A4 Document.

Any moving component should be treated with caution when the system is pressurised

during operation, and especially during on-deck testing and repair. Keep clear of all

moving components and take all necessary precautions to avoid injury when working

on these systems by preventing movement of any components likely to cause injury.

2.3 GENERAL –MECHANICAL

Ensure that all the guards are in place before applying power to the system. The power

must be turned off and any potential movement prevented before removal of any

guard.

Beware of and keep clear of all moving components. Do not work on the system whilst

power is applied, or if there is any potential for components to move.

Ensure that all load bearing components are adequately and regularly inspected. If

damage is foundthe component mustbe repaired/replaced as necessary.Do not allow

damaged components to remain in service.

Some mechanical components/assemblies are heavy and, if covered in oil/water, also

slippery. Always ensure that items are correctly and adequately supported before

removal, and that authorised lifting equipment and procedures are used.

Note: trying to lift heavy components in an awkward position by hand without

the assistance of correct lifting equipment, or lifting any component without

adopting the correct stance, can lead to serious injury.

Ensure that when working within or underneath the machine that your

presence is known to your supervisor. If working underneath the machine,

always ensure that there are no loose or unsupported assemblies,

components or tools above.

3 QUALITY,HEALTH,SAFETY AND ENVIRONMENT (QHSE)

3.1 QUALITY

It is the prime objective of Forum Subsea Tooling to perform all work safely and

efficiently in accordance with our Quality Procedure, Legislative and Client

specifications and requirements. In performing this work, the quality system of Forum

Subsea Tooling shall be adhered to, to ensure that Client requirements are met.

3.2 HEALTH AND SAFETY

The company considers that prevention of accidents incidents and hazardous

occurrences resulting in injury to personnel, damage to equipment and the

environment is essential to ensure employees safety. Reducing injuries and ill health,

protecting the environment and reducing unnecessary losses and liability contributes

to a good safety record which, goes hand in hand with safe operating practices and

high-quality standards.

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KMS A4 Document.

The Company is committed to continuous improvement involving the constant

development of procedures, approaches to implementation and techniques of risk

assessment and control.

To meet these criteria all personnel will be trained to identify, eliminate or control the

effects of hazards in their area of work.

It is expected that all employees will exercise a personal responsibility in preventing

injury to themselves, their fellow workers, the general public and the environment.

Only through close communication and co-operation by all personnel can safety

performance be established and maintained.

It is the duty of all employees to confirm to the Company Safety Policies, codes, plans,

procedures and manuals and to accept and undertake their responsibilities.

All employees and those of our sub-contractors have a legal duty to take reasonable

care of themselves and any other person who may be affected by their acts and

omissions whilst at work and to co-operate with the Company and any persons directly

or indirectly involved in the Company’s activities.

3.3 ENVIRONMENTAL

Forum SubseaTooling pledges tocomply with current environment legislation andbest

environmental practices, and achieve a balance between economic, social and

environmental responsibilities. We are committed to avoiding damage to the

environment by any of our actions and operations.

Forum Subsea Tooling is committed to continual improvement, and efficient use of

resources, which will be achieved by setting and ensuring successful implementation

of environmental objectives.

4 CONTACT DETAILS

All technical enquiries relating to the tooling should be addressed to:

Web: www.f-e-t.com/subsea/hardware-tooling-and-components/tooling/

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Confidentiality Category: C2 In accordance with Forum Energy Technologies (UK) LTD Procedure Q001-005-002. Confidential Forum Energy Technologies

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KMS A4 Document.

5 DESCRIPTION

The BOP-AT300 MkII is a unique tool designed to achieve maximum flow and

maximum pressure from an ROV system which has a limited amount of power to give

and is specifically designed to function BOPs.

A BOP-AT300 MkII can effectively double the input flow of the ROV system giving up

to 300 L/min output of a secondary media.

The system is based on a 2-stage pumping circuit.

Circuit 1 - High flow at 1500 psi

Circuit 2 - High pressure up to 5000 psi

Combining these circuits provides a unit which can fully activate a BOP quickly and

effectively in a very short space of time.

This unit can pump various types of media being seawater, glycol, mineral oils and

various types of gels.

The BOP-AT unit can be fitted on to ROV system and setup to pump seawater or can

be fitted on to a Specialist ROV Skid assembly and can discharge up to 400 litres of

Glycol.

6 SPECIFICATIONS

Specification

Measure

ROV Input

Pressure

150-210 bar (2200-3000psi)

Flow

100-150 l/min

Pilot Pressure

210 bar (3000psi)

BOP-AT 300 Output

Pressure

350 bar (5000psi)

Fluids

Seawater

Mineral Oil

Water based Glycol

Dimensions (approx.)

(without hoses)

(L) 970mm

(W) 465mm

(H) 375mm

Weight (approx.)

(in air)

150kg

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KMS A4 Document.

7 CONNECTION TO ROV

The unit is housed in anROV friendly frame which can be bolted in position and hosed

connections are as detailed in the following.

ROV Pressure

5kpsi Pilot

High Flow Pump

Pilot

3kpsi Pilot

ROV Return

BOP Output

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KMS A4 Document.

7.1 SEAWATER CONNECTION

8 OPERATION

The BOP AT-300 consists of a high flow pump, a high-pressure pump and two

unloader valves set at 3000psi and 5000psi respectively.

The high flow pump will achieve approximately 300 lpm and produce 1200 to

1500psi. The high-pressure pump will generate up to 5000psi (limited by the

unloader valve).

To operate the high flow system, first activate the high flow pump by applying

pressure to the “HIGH FLOW PILOT” port. This runs the high flow pumps. Once

1200 –1500 psi is reached these pumps will stall. Remove the pressure from

the “HIGH FLOW PILOT” port before operating the high-pressure pump.

To operate the high-pressure system, apply pressure to the “HIGH PRESSURE

PILOT” port, this starts the high-pressure pump is limited by the 3000psi

unloader valve. If the pressure drops below 1200psi the high flow pumps may

be restarted.

To achieve 5000psi pressure should be applied to the “MAX PRESSURE

PILOT” port which switches to the 5000psi unloader valve, whilst maintaining

pressure to the “HIGH PRESSURE PILOT”.

See schematic in Section 13 for more detail.

ENSURE UNIT IS FLUSHED AND CLEANED AFTER EVERY

OPERATION!

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KMS A4 Document.

8.1 PRESSURE TESTING

When pressure testing with the BOP AT-300 MkII ensure the manipulator operated ball

valve (below) is in the CLOSE position. On completion of pressure test turn ball valve

to OPEN in order to vent pressure in the line.

When using a reservoir bag connect the bag into the 16JIC port marked suction. To

avoid water ingress when not using a reservoir bag ensure the cap is securely

tightened on the suction port.

ROV operated ball

valve connection

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KMS A4 Document.

8.2 ADJUSTING MAXIMUM OUTPUT PRESSURE

Take 2 x 17 mm spanners and slacken lock nut.

Adjust nut nearest spring clockwise for higher pressure and counterclockwise for lower

pressure.

Hydraulic flow control

valve

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KMS A4 Document.

9 MAINTENANCE

Due to small number of moving parts, in normal operating conditions HPW-pump do

not require any other service, except replacement of seals or occasionally of water

valves, which depends on content of abrasives in pumping fluid, as well as on

cleanliness of hydraulic oil. (For changing seals guide, please refer to “CHANGING

THE SEALS” Section of this manual).

Check constantly whether the fluid dropping from pump’s leakage detectors is growing

and replace seals in

proper time to exclude intermixing of hydraulic oil and pumping fluid.

WHEN CARRYING OUT ANY SERVICE DISSASSEMBLING OR REPAIR

OF HPWPUMP, ABSOLUTE CLEANLINESS MUST BE MAINTANED TO

ENSURE RELIABLE AND TROUBLE-FREE OPERATION OF YOUR

EQUIPMENT

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10 SPARES

Please contact Forum Subsea Tooling for all spares requirements.

Code

Item

HYD-0555

CKEBXCN Check valve

HYD-0556

CKGBXCN Check valve

HYD-0557

2FR95 Flow priority valve

HYD-1220

NV1220A Flow Control Valve

HYD-0740

4.5” 0- 10000psi Subsea gauge

HYD-0550

HPW90 Seal kit

HYD-0551

HPW90 Water valve kit

HYD-0548

HPW460 Seal kit

HYD-0549

HPW460 Water valve kit

HYD-0552

Seawater Filter

11 TROUBLESHOOTING

11.1 PUMP

11.1.1

HPW-Pump

does not

work.

Too small hydraulic flow.

Enable or adjust the hydraulic flow

Hydraulic pressure too low

Adjust the hydraulic pressure.

Hydraulic flow reversed

Check and reconnect hydraulic

hoses. Pressure hose should be

connected to P-port and return hose

to T-port.

Hydraulic piston damaged

mechanically

Replace damaged part.

11.1.2

HPW-Pump

works but

does not

deliver water

flow.

Water intake and pressure valves

are open (jammed with debris) or

damaged.

Check water valves and clean them

thoroughly or replace when

damaged.

Regulator’s unloader valve open

from intake to pressure.

Check the valve and repair failure.

11.1.3

HPW-Pump

does not

receive

pumping

fluid.

Intake hose detached or hose

breathes.

Check and fix the hose and

connectors.

Water supply line clogged.

Check strainer or water filter and

clean thoroughly.

Suction head to high.

Check the performance with

pressurised water supply when

possible.

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11.1.4

Water

pressure line

blocked

Nozzle clogged.

Check the nozzle and clean

thoroughly.

Regulator’s check valve damaged,

pressure line blocked.

Check the valve and repair failure.

11.1.5

Water flow

rate too small

Insufficient hydraulic flow or

pressure.

Adjust the hydraulic flow to the

demanded level at required

pressure.

Nozzle of your pressure tool

undersized.

Verify the nozzle sizing and replace

with proper one.

Pressure loss in delivery hose.

Verify the hose sizing and replace

with proper one.

11.1.6

Water

pressure too

low

Insufficient hydraulic pressure or

flow.

Adjust the hydraulic pressure to the

demanded level at required

hydraulic oil flow.

Pressure loss should be minimized

–do not use hoses of too small

diameter or/and of an excessive

length.

Wear-out of nozzle.

Replace the nozzle.

Water pressure unloader valve set

too low.

Check and re-adjust to

specification.

11.1.7

Intense

pulsating of

water

pressure

Some of water intake and pressure

valves are open or damaged.

Check water valves, clean

thoroughly or repair.

Water intake line breathes causing

pump cavitation.

Check water intake line and fix the

problem.

Water intake line’s diameter to

small, resulting in pump cavitation.

Verify the hose sizing and replace

with proper one.

11.1.8

Closing the

water

pressure line

does not drop

pressure to

free

circulation

mode

Insufficient hydraulic pressure in

relation to pumping fluid pressure,

adjusted with water pressure

unloader valve.

Adjust the hydraulic pressure up as

much as necessary to enable

proper operation of water pressure

unloader valve.

Note that the maximum hydraulic

pressure should not be overrun! If

boosting the hydraulic pressure is

not possible, the water unloader

pressure setting should be dropped.

Defective water pressure unloader

valve.

Repair or replace water pressure

unloader valve.

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11.1.9

Leakages

Hydraulic oil leakages.

Check the tightness of component

mating, tighten screws.

Replace when necessary sealings of

pump’s mated surfaces.

Check and tighten/replace couplings.

Pumping fluid leakages.

Hydraulic-pumping fluid commixture

dropping from leakage detecting

bores

If the draining from leakage detectors

exceeds rate of 10 drops per minute,

pump’s sealings should be replaced.

11.2 UN-STICKING DYNASET PROCEDURE

Sometimes when a Dynaset is new it is prone to sticking a couple of times, after

procedure is complete and Dynaset is running again this rarely happens.

The procedure to un-stick is:

Remove side plate from Dynaset, there is no preferable side.

You will see the piston in the middle of pump.

The piston will either need pushing forward or pulling back about 10mm.

Holding the pump steady push the piston forward, if it does not move then it will need

to be pulled back.

Screw one of the bolts removed from side plate into the piston.

Use a lever to prise the piston back.

Place side plate back in position being careful not to trap any seals and tighten bolts.

Ensure correct flow (min 30 l/min) and pressure (200bar) is set on hydraulic system

and the pump continues to operate.

It may be necessary to do this a couple of times.

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12 SCHEMATICS &DRAWINGS

Drawing Ref.

Title

SRTS-066-GA

BOPAT 300 Mk II General Assembly

SRTS-066

BOPAT 300 Mk II Assembly

SRTS-066-SCH

BOPAT 300 Mk II Schematic

13 ADDITIONAL DRAWINGS

Dynaset HPW460 Pump Information

Unloader Valve Assembly

Dynaset HPW90 Pump Information

Dynaset Seal Changing

Dynaset Water Valve Replacement

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