IKM P7644 User manual

USER MANUAL FOR SUBSEA DIAMOND WIRE SAW 0-320mm
Document title : UMA-7644-001/005 Subsea Diamond Wire Saw
IKM TECHNOLOGY AS ref. : P7644
Customer ref. : Subsea Tool
Rev.
Date
Reason For Issue
Prepared
Checked
Approved
01
13.05.2014
Issued for use
JHR
KOS
EN
02
16.06.2016
Update
KF
EN
KG
03
03.09.2020
Re-issued for Use
OG
TSH
OG

BTE.12-26 User Manual
Page 2 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
USER MANUAL FOR SUBSEA DIAMOND WIRE SAW 0-320MM ................................. 1
1GENERAL INFORMATION........................................................................... 3
1.1 Abbreviations................................................................................................ 4
1.2References................................................................................................... 5
2TECHNICAL SPECIFICATION..................................................................... 6
3SAFETY ....................................................................................................... 7
3.1 General - Operations.................................................................................... 7
3.2 General - Hydraulic....................................................................................... 7
3.3 General - Mechanical.................................................................................... 7
3.4 Special note to the DWS............................................................................... 8
4OPERATIONAL DESCRIPTION................................................................... 9
4.1 Preparation on the vessel prior to operations................................................ 9
4.2 Step by Step Procedure.............................................................................. 10
5MAINTENANCE.......................................................................................... 11
6SPARE PART LIST .................................................................................... 13
7REVISION CHANGES................................................................................ 14
8CONTACT INFORMATION ........................................................................ 14
9APPENDIX ................................................................................................. 15

BTE.12-26 User Manual
Page 3 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
1 GENERAL INFORMATION
This manual is a user manual for the IKM Technology 190mm and 320mm Diamond Wire Saw
(DWS).
The DWS system consists of a hydraulic motor, drive system, chassis and a Diamond wire.
The DWS is designed to be handled by an ROV, with typical a Schilling 7 function manipulator.

BTE.12-26 User Manual
Page 4 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
1.1 Abbreviations
BSP
British standard pipe
CCM
Cubic centimetre
CCW
Counter clockwise
DWS
Diamond Wire Saw
HPU
Hydraulic Power Unit
JIC
Joint Industry Council
kg
Kilo gram
LPM
Litre per minute
mm
Milli meter
Nm
Newton meter
ROV
Remotely Operated Vehicle

BTE.12-26 User Manual
Page 5 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
1.2 References
Doc no.
Description
Rev.
Issued
Can be found
7644-001
Drawing Subsea Diamond Wire Saw 190mm
04
06.11.15
Appendix A
7644-005
Drawing Subsea Diamond Wire Saw 320mm
05
06.11.15
Appendix B
IKM-1044812
Feed Clamp for 7644-001
01
04.11.17
Appendix C
IKM-1044551
Feed Clamp for 7644-005
01
11.07.17
Appendix D

BTE.12-26 User Manual
Page 6 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
2 TECHNICAL SPECIFICATION
The DWS is designed for use by ROV and for various cutting where a diamond wire surpasses the
use of conventional rotating blades.
Hydraulic supply is by means of and controlled by ROV.
When hydraulic system pressure is directed into the motor, this will make the motor rotate and the
system will make the diamond wire following the direction of the hydraulic flow.
The direction of the diamond wire must be the same as the marking on the tool.
The system is delivered in transport boxes and ROV handles to be attached at site. Attached
drawings in Appendix A, B, C and D to be used for guidance for assembly.
Main components for DWS are frame/chassis, motor, wire wheels and diamond wire.
Weight:
DWS:
In air:
In water:
7644-001
33 kg
23 kg
7644-005
42 kg
27 kg
Maximum dimensions:
DWS:
Length:
Width:
Height:
7644-001
716 mm
532 mm
293 mm
7644-005
954 mm
716 mm
293 mm
Hydraulic/Motor:
Motor: 46cc
Working pressure 97 bar (103 max).
Flow: 45 LPM.
RPM: 969 RPM
Hydr. Connections: JIC ¾ -16” Male. Connections are directly on the motor.
The feed is controlled by the manipulator.
As an option, the tool can be fitted with clamp to secure the DWS against the cut object and the
clamp will have a feed-function in form of a cylinder.
The feed is controlled in small steps by the operator to apply a firm push/engagement of the
running wire against the cut object.
IKM-1044812 is the clamp for DWS 7644-001 (Ø185)
IKM-1044551 is the clamp for DWS 7644-005 (Ø320)

BTE.12-26 User Manual
Page 7 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
3 SAFETY
3.1 General - Operations
Only authorised people and qualified personnel should work on the system, and take suitable
precautions to prevent any potential injuries. 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 the test.
Ensure that the working area is kept clear and uncluttered.
3.2 General - Hydraulic
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 hose/fitting 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 be repaired or replaced as necessary 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. Particular 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.
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.
3.3 General - Mechanical
Ensure that all the relevant 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
found the component must be repaired/replaced as necessary. Do not allow damaged components
to remain in service.

BTE.12-26 User Manual
Page 8 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
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.
3.4 Special note to the DWS
The DWS can cut through all possible items if started in vain. It is utterly important to keep the tool
disconnected until it is intended to be used and also keep safe distance during testing.
Rotating Machinery - Caution when operating and testing the tool as the DWS may damage
personnel and equipment if it is not secured properly. Note! that it might cut through a human leg in
seconds.
Keep Clear from the diamond wire as it may grab onto clothes etc. and thereby carry bodies until
the jam.
High pressure - Use safety glasses and protect skin from hydraulic oil if any leakage should occur.

BTE.12-26 User Manual
Page 9 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
4 OPERATIONAL DESCRIPTION
The following description is a generic description of preparation and use of the DWS. Customers
are advised to adapt the following information to their own specific operations and specific work
area.
4.1 Preparation on the vessel prior to operations
➢Unpack all parts and check for transport damages
➢Verify all parts on equipment list is present
➢Adjust the tension of the wire to suit the requirements
➢Install ROV handle in the required position
➢Connect DWS hydraulic hoses as appropriate. The direction of the wire must follows the
rotation marking on the tool.
➢Verify that the ROV hydraulic supply is max 103bar and optimum flow 45 liter/minute
➢Connect motor hydraulic hoses to the selected ROV valve.
➢Perform function test by open valve. Note direction of rotation
➢Secure DWS in manipulator claw or store in ROV Tool tray
➢Commence operation as per operators’ procedures
➢If Clamp assembly is used with the DWS tool; connect clamp and feed function cylinders to
the ROV. Recommended pressure is 180-200 Bar, only low flow is required.
➢Function test and note direction of functions. (Close/open –feed/retract).
7644-001 –Rotation marking
Hydraulic connections directly on
the motor
7644-005 –Rotation marking

BTE.12-26 User Manual
Page 10 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
4.2 Step by Step Procedure
General
Perform SJA/Toolbox talk for the operation as required by client/ROV contractor’s own procedures.
Operation
The following steps are to be regarded as guidelines for operation. Operator of the tooling must
adapt the steps into their own operations procedure.
➢Maneuver ROV to worksite
➢Stabilize ROV at worksite and in good position for commencing work
➢Verify visual by means of ROV camera that the DWS is free to rotate
➢Place the DWS over/on the object to be cut and start operation. Use low feed in the
beginning of the cut to see how the tool reacts to current material being cut. With close
inspection by the ROV camera, operators should verify that grains/”dust”from the cut object
is present when wire is running and sufficient pressure, (feed force), is applied against the
object.
➢Operating with grab/feed clamp:
➢Retract Feed function fully before engaging tool against object.
➢Place clamp in position to grab and lock around the cut object. Keep clamp close function
activated during the cutting process.
➢Activate feed function to get diamond wire near the cut object. Start rotation of wire.
➢With diamond wire spinning; activate feed function in small increments to engage and apply
enough force against cut object to see cut debris escape from the cut object. A good
indicator of sufficient feed force is to see the wire rotation slow down some from free
spinning –but not stalling rotation.
➢Maintain feed/pressure against cut object throughout the cut by small increments on the
feed function. (Look for cut debris escaping + watch speed of diamond wire).
➢When cut is performed, the DWS should preferable be rotating until feed function is
completely retracted.

BTE.12-26 User Manual
Page 11 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
5 MAINTENANCE
Maintenance of the DWS is limited to flushing with fresh water and oil after use for corrosion
protection.
However, if multiple cuts are performed and wires are to be replaced;
pump grease in drive- and lead wheels bearings for every second wire change.
For the drive-wheel bearing: remove bleed-plug before filling gear-house with grease.
Hoses and fitting must be carefully inspected prior to use and after operations. Cut or sharp bends
indicates that the hoses should be replaced.
In case of field repairs, please consult the attached manufacturer’s information.
Replacement of diamond wire:
Remove plastic covers, release tension on spring (picture). When wire is loose, remove and
replace with new wire. Make sure the orientation of new wire is correct. The diamond wire
itself is marked with direction arrows, and these must match the direction marked on DWS
tool. Re-tension spring, ref note 1 on drawings, (appendix A), and attach plastic covers.

BTE.12-26 User Manual
Page 12 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS

BTE.12-26 User Manual
Page 13 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
6 SPARE PART LIST
➢Diamond wire
➢Hydraulic hoses and connections
➢Nuts and bolts
➢Motor

BTE.12-26 User Manual
Page 14 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
7 REVISION CHANGES
8 CONTACT INFORMATION
All enquiries relating to the tooling should be addressed to:
IKM Technology AS
Nordlysvegen 7,
N-4340 Bryne
Norway
Phone, 24/7 : [phone]
Mail : [e-mail]
Revision
Procedure change
Author
01
Original version
JHR
02
Update
KF
03
Update including Feed Clamp
OG

BTE.12-26 User Manual
Page 15 of 21
Dok.ID:
010984
Issue date:
2014.12.29
Approved date:
2015.02.13
Rev.no:
002
Author:
Gabrielsen Trine (Technique)
Owner:
IKM Administrator
Approved by:
Reinsnos Jostein (Technique)
Company:
IKM Technique AS
9 APPENDIX
Doc number
Description
Rev
Appendix A
7644-001
Drawings of DWS 185mm
04
Appendix B
7644-005
Drawings of DWS 320mm
05
Appendix C
IKM-1044812
Clamp assembly with DWS 185mm
01
Appendix D
IKM-1044551
Clamp assembly with DWS 320mm
01

Appendix A

Appendix A

Appendix A

Appendix A

Appendix A