Lawson TXLS ROV Manual

LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

LAWSON

ENGINEERS LTD

Mechanical & Structural Engineers

Carlisle, England, 44 (0) 1228-711470

E-Mail: - [email protected]

OPERATION & MAINTENANCE MANUAL

TXLS ROV

LAUNCH & RECOVERY SYSTEM

EQUIPMENT REFERENCE

LAWSON ENGINEERS LTD : PJ1682

PSSI ORDER REF : PO 61917

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

INDEX.

________________________________________________________________________

1GENERAL DESCRIPTION................................................................................................................... 3

1.1 WINCH .......................................................................................................................................... 3

1.2 POWER PACK .............................................................................................................................. 3

1.3 A-FRAME ...................................................................................................................................... 7

1.4 SNUBBER...................................................................................................................................... 7

2SYSTEM LEADING PARTICULARS ................................................................................................. 9

2.1 DESIGN ENVIRONMENT ........................................................................................................... 9

2.2 'A' FRAME & SKID....................................................................................................................... 9

2.3 SNUBBER...................................................................................................................................... 9

2.4 WINCH .......................................................................................................................................... 9

2.5 POWER PACK ............................................................................................................................ 10

2.6 PUMP ........................................................................................................................................... 10

2.7 MOTORS ..................................................................................................................................... 11

2.8 COILER MOTOR ........................................................................................................................ 11

2.9 SNUBBER ROTATE MOTOR.................................................................................................... 11

2.10 RESERVOIR................................................................................................................................ 11

2.11 COOLER ...................................................................................................................................... 11

2.12 FILTERS ...................................................................................................................................... 11

2.13 CYLINDERS................................................................................................................................ 12

2.14 SNUBBER AIR SPRINGS .......................................................................................................... 13

3LIFT POINTS....................................................................................................................................... 14

4SYSTEM ASSEMBLY PROCEDURE ............................................................................................... 15

5SAFETY PRECAUTIONS................................................................................................................... 20

6SYSTEM OPERATING INSTRUCTIONS ......................................................................................... 22

6.1 POWER PACK START UP......................................................................................................... 22

6.2 WINCH ........................................................................................................................................ 22

6.3 A-FRAME .................................................................................................................................... 23

6.4 SNUBBER.................................................................................................................................... 23

6.5 HPU CONTROLS and SYSTEM MONITORING. ..................................................................... 25

6.6 SAFETY CIRCUIT ...................................................................................................................... 26

7TROUBLE SHOOTING. ..................................................................................................................... 27

7.1 THE HYDRAULIC SYSTEM. .................................................................................................... 27

7.2 THE ELECTRICAL CIRCUIT .................................................................................................... 29

7.3 AUTOMATIC GREASING SYSTEM ........................................................................................ 48

8MAINTENANCE................................................................................................................................. 49

8.1 HYDRAULIC MAINTENANCE PROCEDURES...................................................................... 49

8.2 MANUAL LUBRICATION SCHEDULE................................................................................... 50

8.3 AUTOMATIC LUBRICATION SYSTEM.................................................................................. 51

9SUBSYSTEM DISASSEMBLY / ASSEMBLY.................................................................................. 52

9.1 WINCH DISASSEMBLY PROCEDURE. .................................................................................. 52

9.2 WINCH ASSEMBLY PROCEDURE.......................................................................................... 53

9.3 A-FRAME / SKID DISASSEMBLY PROCEDURE................................................................... 53

9.4 A-FRAME / SKID ASSEMBLY PROCEDURE. ........................................................................ 54

9.5 SNUBBER DIS-ASSEMBLY PROCEDURE. ............................................................................ 54

9.6 SNUBBER ASSEMBLY PROCEDURE..................................................................................... 55

10 STORAGE PROCEDURES............................................................................................................. 56

10.1 MONTHLY STORAGE MAINTENANCE SCHEDULE........................................................... 56

10.2 START-UP AFTER STORAGE. ................................................................................................. 56

11 RECOMMENDED SPARES ........................................................................................................... 57

12 DRAWINGS & PARTS LISTS........................................................................................................ 58

13 MANUFACTURER’S INFORMATION......................................................................................... 59

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

1 GENERAL DESCRIPTION.

1.1 WINCH

See drawings SW1618A-0001 Winch Assembly

The winch consists of a fabricated drum mounted on a large ring bearing together with a

smaller support bearing at the slipring end. On the internal diameter of the ring bearing

are gear teeth which mesh with the pinions of the main drive motors. The drive motors,

ring bearing and support bearing are mounted on a bed frame. Also mounted on the bed

frame are the control junction boxes and the bump (collision) frame. The coiling

(spooling) gear is mounted on the bump frame. The bump frame is completely removable

along with the coiling gear and guards.

The automatic coiling gear is a hydraulic powered, electrically actuated, system. The

coiler box is moved left to right when initiated by the umbilical cable.

Left to right movement is achieved by hydraulically driving a shaft with a standard

trapezoidal screw thread. A captive nut then drives the coiler box.

Movement of the coiler box is initiated by the amount of offlead angle of the umbilical

cable from the coiler box itself.

The horizontal travel-sensing frame is mounted on the back of the box.

The coiler box is constructed with an open top to allow the umbilical to pass through to

accommodate the change in vertical offlead angle as the A-frame moves and when

connecting the umbilical to the drum.

1.2 POWER PACK

See drawings SW1673X-0002 Hydraulic schematic

SW1618B-0001 Power pack assembly

SW1673X-0008 Electrical schematic

SW1673X-0007 Electrical Cabling Diagram

Enclosed in a R.H.S. bump frame, the power pack provides hydraulic oil to run the

winch, A-frame and snubber. The two-stage electric motor driven pumps are mounted

directly below the reservoir and have flooded suction inlets.

Stage 1. An axial displacement variable swash plate piston pump with load sensing

and power limiting facilities. It provides main power to the winch and A-

frame. A relief valve is fitted to the winch control manifold to provide a

maximum pressure cut off. A pressure reducer is fitted to this manifold to

reduce the pressure to the A-Frame supply

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

Stage 2. An axial displacement variable swash plate piston pump. It supplies the

coiling gear on the winch, and the various functions on the A-Frame and

Snubber.

Pump Stage 1 has a feedback loop from the Winch Drive and the Winch/A-Frame Stack

to ensure the pump pressure stays at only 20 bar above the required drive pressure, (Load

sensing control).

This is done to reduce heating in the pump when the system is not operating but the pack

is running.

The pump drain line and winch brakes return line are connected direct to the reservoir.

The pump self relieves at 230 bar which prevents the winch circuit from seeing excessive

pressure.

Other power pack equipment includes: -

Seawater oil cooler with external bypass check.

Pressure & return line filters, 10µ abs.

Relief valves for stages 1 & 2.

4 - off lockable suction line isolation valve.

Tank filler point - 1/2" male quick release coupling (mating female half supplied loose

with system)

Tank filler filter 10 µ abs.

Twin 75 kW Star-Delta starter.

Reservoir equipment - Suction strainer 125 µ

Return line diffuser

Level gauge

Reservoir breather

Heater 2 kW

Oil level/temp switch.

The following is a brief description to the operation of the major valves in the hydraulic

circuit reference drawing SW1673X-0002

Winch Counterbalance valves Item 16. These valves are fitted to give dynamic

and static control of the load on the winch. The valves also prevent runaway in the event

of a burst hose. They provide pilot pressure to release the brakes but only when sufficient

pressure is available to control the load, in a hoisting or lowering direction.

Brake sequence valves Item 30. These valves are piloted by the signal

from the Winch Counterbalance valves or motor return line and ensure the brake is not

released prematurely. When the signal decays they open and divert brake pressure direct

to tank thus giving a fast response to brake operation.

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

Coiler DCV Stack Item 91,92 and 93. The sensors on the coiler

control this valve electrically; it moves the coiler in either direction. A pressure reducer

controls the pressure to the coiler motor.

Winch Stack Items 84,85 . This valve controls the flow to the winch motors. The

joystick on the desk proportionally controls them.

A-Frame Stack Items 87,88 and 97. This valve controls the flow to the Luff,

Leg Extend/Retract and Skid Extend/Retract. The joystick on the desk proportionally

controls them. A relief valve is fitted to prevent excessive pressure to the A-Frame

circuit.

Overload Isolation Valve Items 113 and 114 An overload protection valve is fitted

which is connected to the load cell output, it will only allow oil through this valve when

the load cell is working within the system parameters. If overload occurs the valve closes

stopping flow to the full bore area of the cylinder but allowing flow to the annulus area of

the cylinder allowing the rod to be retracted.

Latch Drain Check Valve Item 15. Fitted in the drain line from the latch sequence valve

this valve prevents any backpressure in the drain line from opening the latches.

Latch Sequence Valve Item 31. This valve will only allow the latches to open when

sufficient pressure has built up in the latch open line. When the pressure decays the valve

returns the oil in the latch cylinders to drain giving a fast response.

Snubber Raise/Lower Pressure Reducing Valves Item 80. These valves are set at a very

low pressure to prevent the Snubber Raise/Lower Cylinders from exerting excessive

force, causing damage to the flotation on the ROV or TMS.

Snubber Raise/Lower Counter Balance valve Item 81. These valves are fitted to

control the flow in and out of the Snubber Raise/Lower Cylinders and prevent the

cylinders from extending if there is a burst hose.

Snubber In/Out Stack Items 103,104 and 106. This is part of the 5-stack manifold on the

Snubber. Push buttons on the control desk control it. Dual Relief Valves are fitted which

allows the snubber to swing if the load induces a pressure exceeding the counterbalance

valve setting.

Snubber Lock/Damping Stack Items 94,95 and 96. This valve is located close to

the 5-stack manifold on the Snubber and is Teed into the A and B lines of the Snubber

In/Out Stack. In the energised condition the spool is all ports blocked allowing the

Snubber In/Out Stack to operate normally. In the de-energised condition it allows oil

from the Snubber Damping Cylinders to flow through the flow control slices giving

control of the speed of swing of the snubber.

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

Snubber Raise/Lower Stack Items 103,104 and 106. This is part of the 5-stack

manifold on the A-Frame. Push buttons on the control desk control it. Dual Relief Valves

are fitted to limit the pressure to the Snubber Raise and Lower Cylinders

Snubber Left/Right Stack Items 103,104 and 106. This is part of the 5-stack

manifold on the A-Frame. Push buttons on the control desk control it. Dual Relief Valves

are fitted to limit the pressure to the Snubber Raise and Lower Cylinders

Rotate Stack Items 103,105,107 and 108. This is part of the 5-stack manifold on the

A-Frame. Push buttons on the control desk control it. A Pressure reducer limits the

pressure to the Snubber Rotate Motor. Dual Flow Control Valves limit the flow of oil to

the Snubber Rotate Motor controlling the speed of rotation.

Latches Stack Items 103,105 and 107. This is part of the 5-stack

manifold on the A-Frame. Push buttons on the control desk control it. A Pressure reducer

limits the pressure to the latch cylinders.

Main Pressure line check valves Item 14. If only one pump set is running these

valves stop oil being pushed in reverse direction through the stationary pump.

Auxiliary line check valve Item 23. If only one pump set is running these

valves stop oil being pushed in reverse direction through the stationary pump.

Leg Extend Cylinders Item 109 are fitted with dual counterbalance valves These valves

are fitted to give dynamic and static control of the load on the cylinders. The valves also

prevent runaway in the event of a burst hose.

Skid Extend Cylinders Item 111 are fitted with dual counterbalance valves Item 110.

These valves are fitted to give dynamic and static control of the trolley cylinders. The

valves also prevent runaway in the event of a burst hose.

Trolley Extend Flow Control Valve Item 120 limits the flow of oil to the Trolley Extend

Cylinder controlling the speed of movement.

A-frame erection valve & auxillary cct. RV. Item 115 This valve is used to erect the A-

Frame from the stowed position prior to Lifting the Winch onto the Rear of the Skid.

A/Frame Hoses C1 and C2 are of sufficient length to stretch to the Powerpack and have

the same QRC’s fitted

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

1.3 A-FRAME

See drawing SW1618C-0001 ‘A’ Frame Assembly

The base (skid) is manufactured as a weldment from universal column and rolled steel

channel. The floor surface is covered with chequer plate which has a non-slip coating

applied under the topcoat of paint. The skid has the capability of extending outboard to

provide extra space for maintenance and to allow for the storage of the T.M.S. when

separated from the R.O.V.

Note - In the extended position the trolley is capable of supporting the full SWL (ROV +

TMS + Work Package). We recommend however that the trolley be not loaded thus

Offshore. The trolley is capable of supporting the TMS offshore.

The skid is capable of having the umbilical winch mounted in two positions, either

directly on top at the rear, or separate from the skid at some distance behind.

The skid is fitted with four lifting eyes for transport as well as lashing down points for

securing the ROV during transit voyages. The lifting eyes are rated for lifting the skid,

‘A’ frame and snubber but not the ROV or TMS.

The ‘A’ Frame is manufactured from rectangular hollow section and is capable of

handling various T.M.S. / R.O.V. / toolskid combinations. This is achieved by

hydraulically powered extension pieces that vary the length of the ‘A’ frame legs.

The cross beam has pinned connections for the snubber assembly.

Lift eyes are provided for the lifting of the legs and each sub assembly of the A-frame.

External face of leg pieces fitted with ladder rungs to permit access to the docking /

snubber and pulley assemblies.

Static guides are welded to the legs to aid guidance of the R.O.V. / toolskid assembly as it

moves between the legs during recovery.

The legs are moved by hydraulic rams that feature built-in counterbalance valves. The

ram mounting brackets have two positions on the skid to achieve a lower stowed position

for transport.

1.4 SNUBBER

See drawing SW1673D-0001 Snubber Assembly

The function of the snubber is twofold – firstly to capture the vehicle on mechanical

latches in order to take the strain off the umbilical cable during launch/recovery

operations, and secondly to align the vehicle and hold it in position while passing it

between the ‘A’ frame legs.

The assembly comprises of a damping frame pinned to the crossbeam that controls the

fore and aft swing. The sheave is pinned to the damping frame and articulates

transversely. The lower frame is suspended from the damping frame by a pair of hoist

cylinders and also guides the sheave. The hoist cylinders control both the side-to-side

motion of the snubber and the up and down motion. Mounted to the lower frame by a ring

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

bearing is the rotating frame. The rotating frame realigns the vehicle assembly to permit

recovery through the legs of the A-frame.

Mounted to the rotating frame is the docking box. This safely captures the vehicle

system, removing lift forces from the umbilical cable, by means of two mechanical

latches that are sprung on and hydraulically released. Also mounted to the rotating frame

is the sprung frame that cushions the vehicle during latching operations.

There is a facility to pass the umbilical assembly over the sheave and through the snubber

assembly without major disassembly. The removable flare pieces must be unbolted from

the sheave and the plastic umbilical guides must be removed from the docking box. The

docking box is sized to pass the umbilical termination without any further disassembly.

There is also an overload protection facility. This is controlled by a loadcell that supports

the sheave. Once the tension in the umbilical rises above the set point an alarm sounds

and further movement of the A frame outboard is impossible.

Rotational movement 200 degrees.

Vertical movement 600mm

Transverse movement +/- 20 degrees

CAUTION – The 20 degrees sideways motion is

only limited by proximity switches. If

these fail the structure will be damaged as

the cylinders over extend. Check the

function of the proximity switches

regularly and keep a good visual check if

operating close to the limit of the swing.

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

2 SYSTEM LEADING PARTICULARS

2.1 DESIGN ENVIRONMENT

Air Temperature -20 + 40ºC

Sea State 6 Significant Wave Height 6.0m

Wind Speed Beaufort 6 - 13.9 m/s.

2.2 'A' FRAME & SKID

SWL 9550 kg in Air ROV weight

Design Load 28650 kg

Inboard reach, max leg extension 4300mm

Inboard reach, min leg extension 3100mm

Deployed reach, max leg extension 4650mm

Deployed reach, min leg extension 3277mm

Height (Stowed) 2440mm

Length 8000mm

Width 2900mm

Height under A-frame at inboard position

max leg extension 4750mm

min leg extension 2200mm

Width between A-frame legs 2300mm

Weight 16000kg

2.3 SNUBBER

Raise/lower 600mm

Lateral tilt +/- 20°

CAUTION – The 20 degrees sideways motion is

only limited by proximity switches. If

these fail the structure will be damaged as

the cylinders over extend. Check the

function of the proximity switches

regularly and keep a good visual check if

operating close to the limit of the swing.

Longitudinal tilt +/- 15° beyond ‘A’ frame luffing motion

Rotate 200°

2.4 WINCH

SWL Top layer 9550 Kg

Design load 28650 Kg

Maximum line speed 70 m/min @ ROV in water

on top layer.

Length of umbilical coiled 3300m on 13 layers

Umbilical Dia. (outer) 42.5 to 45.5mm

Umbilical minimum dynamic bend diameter 1300mm

Umbilical weight in air 5.0 Kg/m

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LAWSON ENGINEERS LTD Ref : PJ1682

Issue Date : 06.06.2006

Umbilical weight in sea water 3.6 Kg/m

Winch width 2900 mm

Height 3435 mm

Length 3000mm with coiler in top

position

Weight excluding umbilical 12 Tonnes

Fabricated Drum dia. 1565mm

‘Lebus’ Shell dia 1577mm

Drum flange dia. 2875mm

Drum width between flanges 1784mm (1814mm with

spacer removed for 45.5

cable)

Motor pressure at SWL 210 bar

2.5 POWER PACK

Drive Motor

Power 2 x 75kW @ 50 Hz, 85 kW @ 60 Hz

Speed @ 60 Hz 1780 r.p.m. @ FLC

Current at max. load 132A @ 440V

122A @ 480V

Voltage range @ 60Hz 380 - 480v

Ingress Protection IP 56

Width 1800mm

Length 2500mm

Height 1800mm

PUMP OUTPUT AT 60Hz

Variable Displacement Axial Piston Pumps

Stage 1

Max. Flow 210 l/min.

Max. Pressure 312 bar

Stage 2

Max. Flow 25 l/min.

Max. Pressure 120 bar continuous

2.6 PUMP

Stage 1

Variable displacement axial piston type

Max. operating pressure 420 bar

Capacity 140.9 cc/rev.

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