Uts-Eng-pro-081_c2 Air Diving System Lars Operational and Emergency Proc

UNDERWATER TECHNOLOGY SERVICES (S) Pte Ltd

AIR DIVING SYSTEM LAUNCH & RECOVERY OPERATIONAL AND EMERGENCY PROCEDURE

UTS/ENG/PRO/081

Revision Record (no signature on electronic versions) C2 27/02/2011 Revised and reissued C1 20/11/2010 Issued for use JB JB RDC A2 27/10/2010 For Internal Approval JB JB RD’C Rev Date Reason for Issue Responsible Accountable Endorsed

UTS

35 Pioneer Rd Unit J7 Singapore 628503 Tel.: +65 68618006, 68624634 Fax: +65 68632865 E-mail: [email protected]

Office Address: 12 Jalan Kelulut

Singapore 809030 Tel.: +65 6484 1245

Underwater Technology Services (S) Pte Ltd Doc No: UTS/ENG/PRO/081 Rev C2

AIR SYSTEM LAR OPERATIONAL & EMERGENCY PROCEDURE

Date: 27/02/2011 Page: 2 of 21

REVISION HISTORY

REV COMMENT A2 Issued for review C1 Issued for use after internal review C2 Addition of LR Accreditation details



Date: 27/02/2011 Page: 3 of 21

CONTENTS 1.0 Introduction

1.1 Abbreviations

2.0 Safety

3.0 Stage LARS Specifications

3.1 Stage Winch Specification

3.2 Guide Wire Winch Specification

3.3 LARS Hydraulic Power Pack Specification

3.4 “A” Frame Specification

4.0 LARS Set Up and Operational Procedure

5.0 Hydraulic Power Pack & LARS System Maintenance

6.0 Stage LARS Emergency Procedures

6.1 Recovery of Stage by the Guide Wire System

Appendix A LARS Testing Procedure

Appendix B Accreditation



Date: 27/02/2011 Page: 4 of 21

1.0 Introduction This procedure is for use by the operators of the UTS Air Diving Systems to which it is specific, for the safe operation of the system. The procedure gives guidance for the operation of the Launch & Recovery System (LARS) in normal operational mode and under various emergency situations. 1.2 Abbreviations

Abbreviation Description GA General Arrangement GWW Guide Wire Weight IMCA International Marine Contractors Association HPP Hydraulic Power pack LAR Launch and Recovery LARS Launch and Recovery System NDT Non Destructive Testing SWL Safe Working Load TRA Task Risk Assessment ALARP As Low As Reasonably Practicable

2.0 Safety Any of the various activities that may be called upon to execute the operation, maintenance and testing of the LARS may have a risk associated with it. The work scope will be risk assessed and with the assistance of procedures and competent, trained personnel the risks will be ALARP. • Most accidents which occur during the operation, maintenance and testing of machinery are as a result

of the failure to observe basic safety rules or precautions. Recognizing a situation that is potentially hazardous can often prevent an accident.

• When handling, operating, carrying out maintenance or testing, personnel must observe safe engineering practices and all relevant local regulations.

• UTS cannot anticipate every possible circumstance which might represent a potential hazard. The WARNINGS in this manual are therefore not all inclusive. Client’s and our employees must use the appropriate operating procedures. However if an item of equipment or a method of working which is not specifically recommended by UTS is to be employed then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property.

• Failure to observe these precautions given under "Safety Precautions" may be considered dangerous practice or misuse of the equipment.

• Read and understand all WARNINGS, CAUTION AND MANDATORY LABELS on the equipment before operating or carrying out maintenance servicing or testing.

2.1. Warnings, Cautions & Notes • The following details for this Safety Section relate to the ESSENTIAL SAFETY REQUIREMENTS

referred to in Directive 89/392/EEC, Amended 91/286/EEC. • Warnings call for attention to operation procedures involving specific hazards which could cause injury

or death and are identified by the following:-



Date: 27/02/2011 Page: 5 of 21

RISK OF DANGER

RISK OF ELECTRIC SHOCK

RISK OF HIGH PRESSURE

RISK OF HOT SURFACE

RISK OF GAS EXHAUST

CONSULT MANUAL



Date: 27/02/2011 Page: 6 of 21

2.2 General Safety Precautions • When using cleaning solvents, provide good ventilation and use suitable protection such as a breathing

filter mask, safety glass, protective apron and gloves. • Safety footwear is compulsory in all worksites. Safety helmets must be worn if there is any risk of falling

objects. • If using compressed air for cleaning purposes, ensure safety regulations are complied with and

appropriate clothing worn. • Never direct compressed air onto your skin or at other people. Never use compressed air to clean

loose dirt from clothing. • Before releasing compressed air through a hose make sure the free end is held securely so that it

cannot whip and cause injury. • Avoid injury by using a hoist, fork lift or other lifting aid to lift heavy loads. Check that all chains, hooks,

shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to UTS requirements.

• Never place yourself under a suspended load • Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or

hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended.

• When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits.

3.0 Stage LARS Specifications The Launch & Recovery System (LARS) is an “A” Frame system. See Fig 3 of this procedure. The LARS is used to deploy and recover the Guide Wire Weight (GWW) and the Dive Stage to and from the water. To mitigate risk to the divers in case of failure of the primary functions the system has secondary (redundant) functions. There are several integral parts to the LARS system. They are;

• LARS “A” frame • Main winch • Guide Wire Winch • Hydraulic Power Pack

The LARS “A” frame lifts and translates the Stage or Wet Bell from the storage position to the launch and recovery position by hydraulic cylinders, one each on each leg of the “A” frame. From the “A” frame top beam is suspended the main Stage/Wet Bell wire sheave, Guide Wire sheave and Guide Wire end termination . The Stage winch is used to raise and lower the Stage in and out of the water. The Guide Wire winch is used to raise and lower the Guide Wire Weight. The Guide Wire Weight is used to stabilize the Stage from rotating around the main wire and stabilizing the pitching of the Stage, especially when travelling through the water/air interface. The Guide Wire System is also used as a secondary recovery system of the Stage in case of failure of the main Stage lifting system The hydraulic power pack located on the LARS provides the motive power for the winches and “A” Frame translation. The hydraulic power pack has a primary and secondary electrical power supply. The winches are controlled from the control station at the hydraulic power pack. The winch operator has a clear view of the winches and the Stage during operation.



Date: 27/02/2011 Page: 7 of 21

Fig 1 - Overall view of LARS in Transport Arrangeme nt Fig 2 - End View of LARS



Date: 27/02/2011 Page: 8 of 21

Fig -3 LARS General Arrangement

FRONT VIEW1

6

2



Date: 27/02/2011 Page: 9 of 21

1 LARS Base Frame 2 LARS “A” Frame 3 Guide Wire Weight 4 Hydraulic Power Pack 5 Diver stage (2 divers) 6 Stage Winch 7 Guide Wire Winch 8 Hydraulic Control Valves

3.1 STAGE Winch Specification The Stage winch has a designed pull force of 4,000 kg at the top layer at a speed of 30 m/min at the top layer in either direction. In forward rotation the output from the hydraulic motor is transmitted to the primary reduction stage through an input shaft. The rotation is transmitted to the cable drum through the planetary gear reduction system. The winch is fitted with two fail safe automatic disc static brakes. The brakes are spring applied and hydraulically released. During hoisting the brakes remain on. The input shaft is connected to the brakes through an over-running clutch. The clutch permits free rotation in the hoisting direction, but does not permit rotation of the output shaft in the reverse direction. When hoisting stops the shaft locks against the disc brake and the load is held. In reverse rotation (lowering) hydraulic pressure releases the brake against the heavy duty brake springs and the lowering speed is controlled against the counterbalance valve with the winch control valve. The brakes will be fully released at 21 bar pressure. The winch has a drum capacity of 217meters of ½” wire, 146 meters of 5/8” wire and 96 meters of ¾” wire. Generally the wire used is galvanized non-rotating. The wire will have a minimum breaking force of 8 x the SWL of the application. The wire is secured to the drum by an appropriately sized grip. The size of the wire may vary due to the application. For example if a wet bell is being used, then a ¾” wire will be used, whereas on a stage operation ½” may be utilized. The winch is driven by a heavy duty gear motor which will operate to a maximum flow rate of 200 lpm @ 200bar. The counterbalance valve is factory set and cannot be adjusted in the field. Actual Stage weight in air fully equipped and with 2 divers and equipment, including two 50 liter cylinders is < 800kg. 3.2 Guide Wire Winch Specification The Stage winch has a designed pull force of 4,000 kg at the top layer at a speed of 30 m/min at the top layer in either direction. In forward rotation the output from the hydraulic motor is transmitted to the primary reduction stage through an input shaft. The rotation is transmitted to the cable drum through the planetary gear reduction system. The winch is fitted with two fail safe automatic disc static brakes. The brakes are spring applied and hydraulically released. During hoisting the brakes remain on. The input shaft is connected to the brakes through an over-running clutch. The clutch permits free rotation in the hoisting direction, but does not permit rotation of the output shaft in the reverse direction. When hoisting stops the shaft locks against the disc brake and the load is held. In reverse rotation (lowering) hydraulic pressure releases the brake against the heavy duty brake springs and the lowering speed is controlled against the counterbalance valve with the winch control valve. The brakes will be fully released at 21 bar pressure. The winch has a drum capacity of 217meters of ½” wire, 146 meters of 5/8” wire and 96 meters of ¾” wire. Generally the wire used is galvanized non-rotating. The wire will have a minimum breaking force of 8 x the SWL of the application. The wire is secured to the drum by an appropriately sized grip. The size of the wire may vary



Date: 27/02/2011 Page: 10 of 21

due to the application. For example if a wet bell is being used, then a ¾” wire will be used, whereas on a stage operation ½” may be utilized. The winch is driven by a heavy duty gear motor which will operate to a maximum flow rate of 200 lpm @ 200bar. The counterbalance valve is factory set and cannot be adjusted in the field. Actual Stage weight plus Guide Wire weight in air f ully equipped and with 2 divers and equipment, including two 50 liter cylinders is < 1100kg. 3.3 LARS Hydraulic Power Pack Specification The hydraulic system is an open circuit hydraulic system supplying from a variable displacement pump at a maximum flow rate of 110 lpm, with filtration and relief valve protection. Maximum operating pressure is 200bar. Two sources of electrical power are provided from the machinery van, which should be backed up by and emergency power supply. The electric motor is a 3ph 415/460V 22kW motor. When two LARS are used, the two LARS power packs act as back up to each other. If only one LARS is used then the machinery van tool power pack is used to back up the LARS. The interconnection of the power packs is by hoses stored for that purpose. The winches and “A” frame is controlled from a three part directional control valve station at the power pack location. The hydraulic reservoir holds 400 liters of Tellus 37 hydraulic oil

3.4 “A” Frame Specification

The A frame supports the Stage and the Guide Wire Weight. The “A” frame is rated to carry 1,5000kg, consisting of the following weights. The load on the “A” frame is greatest just after the Stage has left the water being raised on the GWW winch with the weight of the GWW included..

• Stage fully loaded maximum 800kg • Guide wire Weight maximum 250 kg

4.0 LARS Set Up and Operational Procedures The LARS will be secured to the deck of the vessel to which it is mobilized by dogs secured over the pads welded to the bottom LARS beams. After securing the LARS to the deck the LARS will be Static load tested to 1.5 x maximum SWL of 1500 kg, and the tie down weld visually and NDT inspected/tested. Connect power to the hydraulic power pack. Check the oil level in the tank and that there has been no damage during transport and mobilization. Function test the hydraulic power pack by starting the pump and checking correct rotation. An arrow on the pump arrangement indicates correct rotation. The three directional control valves have their functions identified and the “UP” – “DOWN” functions shown. One of the LARS hydraulic cylinders will be used to erect the “A” frame. Connect one of the cylinders to the light weight pad eye on the “A” frame and extend the cylinder until the second cylinder can be connected to the main pad eye. Disconnect the first cylinder and reconnect to the main pad eye. Extend the “A” frame out and in several times to check correct function. Connect the stage to the main lift wire. Secure the connection pin. Lift the stage and assemble the guide wire in the stage guides.



Date: 27/02/2011 Page: 11 of 21

The stage and guide wire weight can now be raised off the deck and translated out over the side of the vessel and raised and lowered as appropriate to function test the system. During normal operations, the stage will be parked at the end of the LARS so that the diver can step in and out of the stage. The guide wire weight will be lowered and parked just below the planned stage depth. The guide wire weight may remain at the park depth while the stage is used to transport the divers up and down from the surface to/from the dive work site. The 2 x 50 liter stage cylinders are provided for emergency air supply for two divers per stage.

Fig 4 - View of Power Pack, Stage Winch and control valves



Date: 27/02/2011 Page: 12 of 21

Fig 5 – Hydraulic Schematic

0-500PSI

CLUMPWINCH

BREAK1

BREAK2

DRAIN TO TANK 1/4" x .035 SS Break Line

1/4" x .035 SS Break Line



1/2" x .049 Pressure line1/2" x .049 pressure line

FLOW CONTROLVALVE

SPRING RETURN VALVE


1/4"

x .0

35 S

S B

reak

Lin

e

HAND PUMP

FL

OW

CO

NT

RO

L

1/2" x .049 Pressure Line

1" x .083 Tank Line

0-500PSI

BASKETWINCH

BREAK1

BREAK2




1/2" x .049 Pressure line1/2" x .049 pressure line

FLOW CONTROL VALVE

SPRING RETURN VALVE


HAND PUMP

FLO

W C

ON

TR

OL

1/2" x .049 Pressure Line

1" x .083 Tank Line

1/4" x .035 SS Break Line 1/4" x .035 SS Break Line

FLOW CONTROL VALVE

SPRING RETURN VALVE

SECONDARY RETURN

PRV

HYDRAULICPUMP

PRV0-500 PSI

CHECK VALVE

FILTER

HYDRAULIC TANK

FILTER

1" x .083 Tank Line

1 1/

4" S

UC

TIO

N H

OSE

ISO

LA

TIO

N V

AL

VE


ISO

LA

TIO

N V

AL

VE

M

VALVE A

VALVE C

VALVE D

VALVE B

VALVE A

VALVE B

VALVE D

VALVE C

B

A

COUNTER BALANCE VALVECOUNTER BALANCE VALVE

8151617

12

32

31

19

1313

7202122

23

SECONDARY SUPPLY

33

27 28

26

25

36

9 10

1439

6965

61

6060

61

6965

16

5250

16

50

5050

53

52

53

52

52

53

55

49

585554

54

38

54

52

37

4

37

56

37

57

5250

5253

525050

5052

52

53

53

55

59

49

5152

55

54

52

57

37

52

70

7172

1772

73 73

7474

777777

35

77

56

76

80 80

67

75

66

54

62 63

5

6

6

29

38

18

13

38

37

62 63

1314

1314

13 1313 13

5



Date: 27/02/2011 Page: 13 of 21

5.0 Hydraulic Power Pack and LARS System Maintenanc e Electrical Motors and Components The electrical motors and electrical components will be inspected and tested every six months as described in IMCA D018 Section 11. “Visual examination, function test of unit (including protective devices) plus continuity and resistance testing of any cables”. Thus this will satisfy electrical systems maintenance and compliance with IMCA requirements.

Hydraulic System Due to the low expected running hours and the safety critical nature of the services provided by the hydraulic system, maintenance will be based periodical rather than running hours.

During daily walk around inspections the general condition of the hydraulic system must be visually checked. Check for leaks, loose bolts & fittings, corrosion hydraulic oil level.

During normal operation of the hydraulic system listen for uncharacteristic noises and monitor the pressure gauges for changes in operating pressures, either high or low.

Function test all valves monthly.

Hydraulic Oil The hydraulic oil will be visually inspected monthly for contamination particularly by water and particulates from the hydraulic system which might indicate degradation of any of the hydraulic components. This can be achieved by draining a sample form the reservoirs. Replace the oil and clean the tanks annually.

Hydraulic Filters After commissioning the system change the inline filters after one month of operation. Subsequently filters will be changed every 6 months, unless monthly visual inspection of the hydraulic oil indicates that there may be cause to change more often. Replaced filters will be cut open and visually inspected for contaminants. If there is visually recognizable contaminants and investigate into the cause will be initiated.

Hydraulic Pumps The flexible coupling and hardware will be visually inspected every 6 months for integrity.

Every 5 years, the pumps will be removed for inspection and overhaul.

Relief Valves Relief valves will be maintained as prescribed by IMCA D018 Sect 24.3. They will be visually inspected at least every 6 months and tested to verify that they are working at the correct relief pressure every 12 months.

Hydraulic Hoses & Fittings Conduct a thorough visual inspection of the flexible hoses monthly. Check for damage or deterioration. Check all quick connects are securely tightened. Test to 1.25 x working pressure annually. Hydraulic Motors There is no specific in field maintenance for the hydraulic motors other than described in general above. Winch Drums & Brakes The winch brakes are checked every 6 months as prescribed by IMCA D018 Sect 22.2. Every 6 months a visual examination and function test at maximum SWL is conducted. Independent static load test on each brake system at 1.25 times maximum SWL is conducted. Every 12 months Independent static load test on each brake system at 1.5 times maximum SWL. NDT to be carried out afterwards on critical areas. Visually inspect the wire rope bitter end grips every month. Check the bolts are tight every 6 months. Wire Ropes

The wire ropes will be maintained in accordance with IMCA recommendations



Date: 27/02/2011 Page: 14 of 21

Every 6 months; Static test at 1.25 times SWL plus function test at SWL as an integral part of the lifting system and visual examination of that part of the wire that is deployed during normal operations at that time. 12 Months: Cut back beyond first sheave and test to destruction to prove safety factor. Re-terminate and apply static load test at 1.5 times SWL. LARS A Frame Grease all sheaves and hinge joints monthly. Keep hydraulic cylinder rods clean of corrosive substance build up Load test in accordance with IMCA D018 Sect 22.1. 6 monthly: Visual examination and function test at maximum SWL. Independent static load test at 1.25 times maximum SWL 12 monthly; Static load test at 1.5 times maximum SWL. NDT to be carried out afterwards on critical areas. Gauges and other indicators Visual examination for physical condition and Function Test throughout normal operating range every 6 months. This includes digital and other indicators/alarms.



Date: 27/02/2011 Page: 15 of 21

6.0 Stage LARS Emergency Procedures The following have been assessed by risk assessment as potential failures of the primary lifting systems which may cause risk to the divers.

Item Description 1.0 Failure of a hydraulic drive motor on the Stage main winch 2.0 Failure of the main Stage winch to an extent that it cannot

raise the Stage 3.0 Failure of the Stage main winch sheave on the “A” frame 4.0 Broken Stage main lift wire 5.0 Failure of the hydraulic power pack 6.0 Loss of power supply to the hydraulic power pack

It is determined that a failure of the guide wire winch does not in itself cause a direct risk to the divers of significant probability given that the probability of it failing in conjunction with the stage winch is very low A robust preventative maintenance system and inspection and testing regime will make the probability of any failure of the LARS system to an extent that it will compromise the safety of the divers in the water to be very low. Emergency Procedure 01 – Failure of a hydraulic motor on the Stage winch main lift winch Recover the stage on the Guide Wire Weight Winch Emergency Procedure 02 – Failure of a Stage winch to a degree that it cannot raise the Stage. It should be noted that historically most winch failures are gradual and so a catastrophic failure from fully operational is a very low probability. However if such a failure does occur the Stage will be recovered on the Guide Wire Weight Winch Emergency Procedure 03 – Failure of a Stage winch wire sheave on the “A” frame It should be noted that historically most sheave failures are gradual and so a catastrophic failure during diving operations from fully operational is a very low probability. However if such a failure does occur the Stage will be recovered on the Guide Wire Weight Winch Emergency Procedure 04 – Failure of the Stage lift wire Recover the stage on the Guide Wire Weight Winch Emergency Procedure 05 – Failure of Hydraulic Power Pack. Change over hydraulic supply to the LARS to the alternative power pack. Emergency Procedure 06 – Loss of Power Supply to the Hydraulic Power Pack. If the loss of power is caused by a loss of power to the dive system change over to the emergency power supply. If the loss of power is due to a failed component in the air dive system, change over power supplies from the main distribution panel to the power pack. 6.1 Recovery of Stage by the Guide Wire System In the above scenarios where the Stage has to be recovered by the Guide Wire Winch system the following procedure will be followed. The GWW system is designed to lift the Guide Wire Weight and the Stage into the “A” frame.



Date: 27/02/2011 Page: 16 of 21

The reasons the GWW system may be used to lift the Stage to the surface are:

• The hydraulic motive system of the Stage winch has failed catastrophically • The mechanical system of the Stage winch has failed catastrophically • The Stage wire “A” frame sheave has failed catastrophically • The Stage lift wire has failed or is damaged to an extent that the dive supervisor considers it unsafe to

lift the Stage on the wire. This procedure will commence after the diver has returned to the stage and verified that the stage is ready for lifting on the Guide Wire System and upon the instructions of the diving supervisor. Step Action Comments/Warnings The hydraulic system of the SDC winch has failed ca tastrophically 1.0 Ensure the integrity of the hydraulic pump supplying the

GWW winch Replace the in line filter elements.

2.0 Start hydraulic power pack NOTE The combined weight of the loaded Stage and GWW in water

is less than 1100 kg

3.0 Pickup on the GWW until the Stage is supported by the GWW 4.0 By normal operation of the controls at the winch control

station recover the Stage with the guide wire weight while recovering the diver/s umbilical.

The slack Stage wire may have to be recovered by use of another on site asset. This will be determined by site conditions

5.0 Recover the Stage to the “A” frame.


AIR SYSTEM LAR OPERATIONAL & EMERGENCY

PROCEDURE

Date: 27/02/2011 Section:

Page: Appendix 1of 21

Appendix A – LARS Testing Procedure

1. Static Load Test: The Static Load Test will be conducted to 1.5 x the SWL on all functions. 2. Dynamic Load Test: The Dynamic Load Test will be conducted to 1.25 x the SWL on all functions. 1. On the UTS air diver LARS with stage the operating SWL of the components are as follows;

a. Stage Winch = 1000 kg b. Guide Wire Winch (Loaded Stage + Guide Weight) = 1250 kg c. A Frame (Loaded Stage + Guide weight ) = 1500 kg

The UTS air diving LARS winches have the following brake system:

1. Hydraulic system “Brake Valve”. This valve comes on automatically when the control lever for the circuit is returned to neutral. This valve “locks” the hydraulic system at the motor. All hydraulic systems have a certain amount of leakage, so this valve acts as a primary stop while the mechanical valves activate.

2. Disc Brake 1; this static brake is housed within the drum flange of the winch. It is a spring loaded disc brake with a minimum designed holding capacity of 10,000 kilograms. This brake activates when the hydraulic pressure in the system degrades 21 bar (300 psi).

3. Disc Brake 2; this static brake is between the flange of the drum and the hydraulic motor. It is also a spring loaded brake with a designed holding capacity of 10,000 kilograms. This Brake activates similarly to Brake 1 at 21 bar (300 psi)

The LARS will have been function tested during commissioning and confirmed to be correctly functional in all ways prior to planning the Load Test. Ensure 440 V 3 PH power is connected from a circuit breaker of 40 amps. Check that the stage and guide wire clump weight are correctly connected to their respective wires. In particular ensure the rigging up of the wedge socket is correct. Check the opposite end of the wire is terminated on the drum correctly and secure. Function Test Inspect the LARS to ensure all is in good order.

1. Hydraulic Power Pack. a) Check the oil level in the hydraulic oil reservoir to be at least ¾ the way up the sight glass. b) Open the suction valve fully. c) Start and stop (jog) the electric motor to ensure the electric motor is running in the correct direction, by

inspecting the rotating motor at the fan end. When looking at this end the motor must rotate in a clock wise direction. Check the direction arrow is correct.

d) If the direction of rotation is correct start the electric motor and listen for unusual noises. If present shut down the motor and have a technician attend to the unit to trouble shoot and rectify. If the motor is rotating in the wrong direction have an electrician change two phase wires.

2. The brake valve panel should be set as follows for normal operation ; a) Close valves D & C b) Open valves A & B

3. Operating Function Test

a) Operate the A Frame lever in the in and out directions and confirm the A Frame is operating correctly – record the pressure.

b) Operate the Clump Weight lever in the up and down directions and confirm the Clump Weight winch is operating correctly.

c) Operate the Stage lever in the up and down directions and confirm the Stage winch is operating correctly.

4. Rig up the function test weight (min 200 kg to simulate the weight of divers & tool) to simulate a loaded stage to/in the stage. Function test at max SWL



PROCEDURE



5. Function test the A Frame and main winch through the full operating functions including brake stops.

6. Function test the Guide Wire winch by lifting the Stage with the 200 kg weight. (Maintain slight slack on the main winch wire).

Dynamic Load Test

The dynamic load test will be conducted in three functions;

• lifting the stage with the main winch, • lifting the guide weight and stage as a complete assembly with the guide wire winch, • Booming the A Frame in and out while supporting the stage and guide wire weight.

The stage and stage winch will by dynamically tested (1000 kg x 1.25) with the addition of a test weight to the stage Function Test weight. I.e. Test weight will bring the total weight to 1250 kg. Stage weight of 500 kg + Test weight 750 kg. The guide wire weight and guide wire winch will be tested (1250 kg x 1.25) with the addition of a further test weight of to bring the total weight to 1565 kg. I.e Total weight of stage & guide wire plus function test weight + dynamic test weight of stage + addition of guide wire test weight = total test weight of 1565 kg. The system will be tested by lifting the stage initially and then the stage with the guide wire with the dynamic test weight as above in or hanging from the stage so that the stage pad eye and associated welds and the guide wire weight sheaves and welds are tested. The A frame will be dynamically tested to 1500 kg x 1.25 with the addition of a test weight to the A Frame to bring the total weight suspended on the A frame to 1875 kg.

NOTE: Suspending the A Frame test weight from the stage does not test the A Frame to 1500 kg as the load is shared by the winches. Brake Tests During the dynamic load test the function of the three braking systems will be tested. This procedure and the valve assembly on the LARS are designed to enable the technician to function one each of the three brakes independently. This procedure applies to both winches. Always test the counterbalance valve last.

1. To test spring loaded Brake 1

a) Open the counter balance valve cap and remove the spring. The counterbalance valve is now non functional.

b) Open valves D & A c) Close valves B & C

Using the hand pump apply and maintain up to 27 Bar (400 psi) to Brake 2 through Valve D to release Brake 2. Now the winch is being held by Brake 1 only. Operate the winch several times to test the brake.



PROCEDURE



Relieve the pressure from the hand pump. Close valves D & A.

2. To test spring loaded Brake 2 a) The counter balance remains non functional with the spring removed. a) Open valves C & B b) Close Valves D & A

Using the hand pump apply up to 27 Bar (400 psi) to Brake 1 through Valve C to release Brake 1. Now the winch is being held by Brake 2 only. Operate the winch several times to test the brake. Relieve the pressure from the hand pump. Close valves C & B

3. To test the counterbalance valve. a) Replace the spring in the counterbalance valve and tighten the cap. b) Open valves D & C c) Close valves A & B d) Using the hand pump apply and maintain up to 27 Bar (400 psi) to Brake 1 & 2 through Valves D & C to

release Brakes 1 & 2. e) The winch is now being held by the counterbalance (brake) valve only. A small amount of creep is

acceptable on a counterbalance valve. Bleed the pump pressure and close all valves.

4. Remove the pump and reset the valves for normal operation as below; a) Close valves D & C b) Open valves A & B

Fig – 6 Brake Test panel Schematic

HYDRAULICPUMP

To Counterbalance Valve

To Brake 2

To Brake 1

To Shuttle Valve

0-500PSI

VALVE

A

VALVEB

VALVED

VALVE

C



PROCEDURE



Static Load Test The static load test will be conducted on the individual components of stage, guide wire winch and A Frame. The Static Load Test will be conducted with the A Frame fully extended out to test the holding of the A Frame cylinders. The A Frame test weight will be increased from the dynamic test weight by adding weight to bring the total test weight on the A Frame to 1500 x 1.5 = 2250 kg. The static test of the stage and guide wire weight will consist of the stage supported by the guide wire weight + a test weight of to bring the total weight to 1500 kg. This weight will be first supported by the GWW winch wire and transferred to the stage winch wire. All three brakes of the Guide weight winch must be tested as described in the Dynamic Load Test and confirmed to hold. The amount of creep in the counterbalance valve will be more than as seen during the Dynamic Brake Test. By carefully lowering the Guide wire weight from below the stage so that the stage wire and winch fully supports the static test weight the main winch and wire is tested. All three brakes of the main winch must be tested as described in the Dynamic Load Test and confirmed to hold. The amount of creep in the counterbalance valves will be more than as seen during the Dynamic Load Test. Visually inspect all welds and components for damage, failure or deformation. MPI all load critical welds as detailed in the NDT plan. NOTE: During the testing of the brakes, without the counterbalance valve spring in place, the brakes m ay shudder when lowering. This is caused by the follow ing. By removing the brake valve spring the hydraul ic system has no back pressure to work against. Thus t he hydraulic pressure will not build up enough to f ully release the brake. The shuddering is caused by the low hydraulic pressure acting against the spring lo aded brake at marginal operating pressure. So long as the testing in this mode is not excessiv e, no damage will be caused.



PROCEDURE



Appendix B LR Accreditation UTS Accreditation

Documents

Uts-Eng-pro-081_c2 Air Diving System Lars Operational and Emergency Proc