WRT - Maintenance Instruction

Maintenance Instructions
Wireline Riser Tensioners

Beacon Pacific
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Beacon Pacific / Y14-H1305 L6764 Wireline Riser Tensioners
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5.3 63 This document contains proprietary and confidential National Oilwell Varco Norway AS
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© Copyright National Oilwell Varco - 2015
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
L6764-Z-MA-005 0
Document number L6764-Z-MA-005
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REVISION HISTORY
0 25-Nov-2015 For Information KVTR ANMO JABK

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change description

0 First issue
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TABLE OF CONTENTS
1 MAINTENANCE INSTRUCTIONS .................................................................................... 5

1.1 Introduction ............................................................................................................. 5
1.2 Abbreviations .......................................................................................................... 6
2 SAFETY SUMMARY ......................................................................................................... 7
3 ROUTINE INSPECTIONS ................................................................................................. 9
3.1 Daily inspections ..................................................................................................... 9
3.2 Weekly inspections ................................................................................................. 9
3.3 Monthly inspections .............................................................................................. 10
4 PERIODIC MAINTENANCE SCHEDULE ....................................................................... 11
4.1 Follow-up of inspections ....................................................................................... 11
4.2 Maintenance routine after first 100 operating hours .............................................. 11
4.3 Lubrication routine ................................................................................................ 11
4.4 2-weekly maintenance routine .............................................................................. 11
4.5 Monthly maintenance routine ................................................................................ 12
4.6 3-monthly maintenance routine ............................................................................. 12
4.7 6-monthly maintenance routine ............................................................................. 13
4.8 Yearly maintenance routine .................................................................................. 13
4.9 2-yearly maintenance routine ................................................................................ 13
5 PERIODIC MAINTENANCE PROCEDURES.................................................................. 15
5.1 Lubrication ............................................................................................................ 15
5.2 Checking the quality of the air ............................................................................... 16
5.3 Type and quantity of tensioner fluid ...................................................................... 17
5.4 HP accumulator illustrations.................................................................................. 18
5.5 Checking purity and chemical properties of tensioner fluid ................................... 21
5.6 Houghton recommendation ................................................................................... 22
5.7 Overview of fluid fill unit ........................................................................................ 24
5.8 Cleaning fluid in HP accumulators ........................................................................ 27
5.9 Changing fluid in HP accumulators ....................................................................... 30
5.10 Checking fluid level in HP accumulators ............................................................... 33
5.11 Changing filter elements on anti-recoil valves ....................................................... 35
5.12 Inspection and change of support wires ................................................................ 36
5.12.1 Acceptance criteria for wire inspection .................................................... 36
5.12.2 Accumulated Ton Cycles wire monitoring ................................................ 37
5.12.3 Changing the support wires ..................................................................... 38
5.12.4 Cut & slip of support wires ....................................................................... 41
5.13 Sheave maintenance ............................................................................................ 43
5.14 Pressure relief valve maintenance ........................................................................ 44
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5.15 Bolt torque and secondary retention ..................................................................... 48

6 CORRECTIONS AND MINOR REPAIRS ....................................................................... 49
6.1 Checking for air leaks ........................................................................................... 49
6.2 Checking for fluid leaks ......................................................................................... 49
6.1 Cylinder position sensor ........................................................................................ 50
6.1.12 Disassembly and assembly of encoder and drum unit ............................. 52
6.1.13 Disassembly and assembly of the encoder.............................................. 53
6.1.14 Mechanical disassembly and assembly of the drum unit: ........................ 54
6.1.15 Mounting wire rope to the front sheave house ......................................... 55
7 MAJOR REPAIRS AND MODIFICATIONS .................................................................... 56
8 MAINTENANCE NOT NORMALLY DONE BY USER .................................................... 56
9 FAULT FINDING ............................................................................................................. 57
10 STORAGE AND PRESERVATION ................................................................................. 58
11 SPECIAL TOOLS ............................................................................................................ 59
12 SPARE PARTS ............................................................................................................... 59
13 LUBRICATION CHARTS ................................................................................................ 59
14 MAINTENANCE RECORD FOR WIRELINE RISER TENSIONER SYSTEM ................. 60
14.1 Bi-Weekly Maintenance ........................................................................................ 60
14.2 Monthly Maintenance ............................................................................................ 61
14.3 Monthly Maintenance (cont.) ................................................................................. 62
14.4 Yearly Maintenance .............................................................................................. 63
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1 MAINTENANCE INSTRUCTIONS
1.1 Introduction
This document gives maintenance instructions for the National Oilwell Varco TM Wireline
Riser Tension System (WRT system) for rig/vessel stated on the front page of this
document.
A Maintenance Log must be established for this equipment, and all maintenance,
special observations and repairs must be logged. Upon request, the log should be made
available to supplier’s service personnel.
Supplier is keeping and maintaining a failure database for its offshore equipment. It is of
great importance and much appreciated that user is reporting failures and problems to
supplier. This information is essential for supplier to identify critical items prone to failure
or replacement, and it will highlight components that require a design review to improve
safety and reliability. Areas of major concern shall without hesitancy be brought to the
attention of supplier. If urgent deficiencies appear after the equipment is taken into use,
supplier will issue product bulletins to user as necessary.
3D Model of Beacon Pacific with the WRT-system enhanced.

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1.2 Abbreviations
The following abbreviations may be used in this document.
AISI American Iron and Steel Institute (material standards)
APV Air pressure vessel
ARV Anti recoil valve
ATC Accumulated ton cycles (= maintenance parameter for support wires)
AW Auxiliary well
BOP Blow-out preventer (installed on wellhead at the seabed)
CAPV Composite air pressure vessel (versus conventional steel APV)
CMC Crown mounted compensator (= drillstring compensator)
CPU Central processing unit (part of PLC)
DCR Drilling control room (= driller’s cabin)
DSV Digital smart valve (DSV card = controller card of anti-recoil valve)
EDS Emergency disconnect sequence
FAT Factory acceptance test
FFU Fluid fill unit
H Hydraulic component (used in position numbers)
HP High pressure
HPU Hydraulic power unit
LER Local equipment room (= LIR)
LIR Local instrument room (= LER)
LMRP Lower marine riser package (installed at lower end of riser string)
LP Low pressure
LPT Linear position transducer
MCC Motor control centre
MW Main well
N2 Nitrogen
NOV National Oilwell Varco Norway AS (= the system supplier)
NS Norwegian Standard
OD Outer diameter
PLC Programmable logic controller
PPM Parts per million
RAR Riser anti recoil
RARS Riser anti recoil system
RIT Riser tensioner
ROV Remotely operated vehicle (subsea)
RT Riser tension
SD Shutdown
SP Setpoint
UPS Uninterruptible power supply
WC Wellcentre
WRT Wireline riser tension
WT Wireline tensioner
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2 SAFETY SUMMARY
The following types of safety messages may appear in this
document:
A warning contains essential information related to potentially hazardous

conditions, procedures, and/or practices which, if not strictly followed or
observed, could result in fatalities, personnel injury or severe damage to
equipment.
A caution contains essential information related to potentially hazardous

conditions, procedures, and/or practices which if not followed or observed could
result in damage to equipment or material.
A note contains essential or useful information related to conditions, procedures,

practices, and/or equipment. Sequence of tasks, or to provide clarification of a
specific portion of the manual contents.
It is the responsibility and duty of all personnel involved in the operation and
maintenance of this equipment to fully understand the SAFETY measures, by which
hazards are reduced or eliminated. Personnel must familiarize themselves with all
aspects of safety and operation of the equipment before starting any operation or
maintenance.
The following points summarize the safety aspects related to maintenance:
x Only qualified personnel are allowed to carry out maintenance and fault finding.
x Qualified personnel are defined as individuals with characteristics or abilities gained

through theory and training and/or experience as measured against the relevant
standards, directives, accident prevention regulations and manufacturer’s
established guidelines for use. Personnel performing tasks using the equipment
must have authorization from persons responsible for that equipment, and must be
capable of recognizing and avoiding potential hazards. Knowledge of first aid and
local rescue equipment is essential.
x Only the prescribed maintenance may be carried out by user. Anything else must be
approved by supplier’s service department before carried out.
x A maintenance warning sign must be placed in driller’s cabin before maintenance is

started.
x Dropped objects are potential killers. Make sure that no loose objects (tools or
equipment) are dropped from or forgotten at high places. In cold waters make sure
that ice and snow cannot fall on people below.
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x Crushing hazard: Beware of the equipment’s moving parts. Stay away from cylinder
rods, support wires and wire sheaves during operation.
x Grease splashing from the support wires may make walkways slippery. Prevent
skidding/slipping accidents by regularly removing any grease spots from the
walkways.
x The equipment makes use of high-pressure hydraulic oil, tensioner fluid and air.
Beware of the risk of pipe/hose burst. Pipe/hose connections must not be loosened
or tightened before the system is fully depressurized.
x If anyone gets hydraulic oil or tensioner fluid into the eyes or open wounds, wash at
once with lots of fresh water. Consult a doctor if necessary.
x If APVs (air pressure vessels) need to be isolated, make sure that the correct APVs
are isolated. Isolating the wrong APVs can cause serious damage to equipment and
people.
x When opening valves manually, always open slowly to avoid pressure shocks.
x Always use eye protection while working with fluids and air under pressure.
x Use ear protection while bleeding down air pressures.
x Hydraulic oil, tensioner fluid and lubricants may contain toxic additives that by
repeated skin contact or inhalation can be dangerous to your health. Study the
safety data sheets for the different compounds, and protect yourself as required.
x Be especially aware of the danger involved with hydraulic oil under pressure. It can
be injected under the skin without the victim being aware.
x Adjustable valves that have been set and sealed by supplier are not to be adjusted
by user without approval and guidelines from supplier.
x No welding of lugs, brackets etc. must take place on the equipment.
x Heat or excessive force must not be used to move a part, unless it is beyond repair.
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3 ROUTINE INSPECTIONS
3.1 Daily inspections

x Ask the operators if any abnormalities have been observed. All such observations
must be logged for follow-up.
x Read and log the total riser tension. Compare the reading with the reading the last
days to verify that the system is stable.
x Read the tension on each tensioner, and verify that the total load is distributed
evenly. If one tensioner has low tension, keep an eye on this tensioner the next days
to spot leaks or malfunction.
x Inspect the overall equipment to verify smooth operation. Check for abnormal noise
and vibrations in all moving parts.
x Look and listen for air leaks. Generally no leaks are acceptable.
x Look and listen for leaks in the fluid system. Generally no leaks are acceptable.
After two months operation, when the equipment has proved stable and reliable through
field experience, the daily inspections can be transferred to the list of weekly
inspections.
3.2 Weekly inspections

x During system operation, check the cylinder rods visually for mechanical damage,
dirt and corrosion.
x During system operation, verify that the cylinder rods are being lubricated by a thin
film of tensioner fluid.
x Check visually for fluid leaks outside the anti-recoil valves and the HP accumulators.
Verify that tensioner fluid is not running down the cylinder casings, which would be
an indication of worn cylinder seals.
See the Checking for fluid leaks section for more info.
x Inspect the wire sheaves at both ends of the tension cylinders, and all idler sheaves,
to verify smooth operation. Verify that the wire enters the sheave groove in a proper
way, and that all sheaves are rotating.
x Inspect the ropes of the cylinder position sensors. Splintery ropes must be changed
as described in separate procedure.
x Inspect all wire anchor clamps at the fixed sheave houses. Verify visually that the
clamp bolts are tight, and that there is no sign of wire slipping.
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x Check visually for corrosion, wear, damage, and loose bolts and parts.
x At the air control skid, inspect the filter regulator for the instrument air supply. Verify
that the pressure out is 8 bar, and that the filter bowl is empty. If necessary the bowl
must be emptied manually of precipitated water.
x At the Accumulated Ton Cycles (ATC) display, verify that the ATC counters and the
belonging alarm limits are correctly set for each support wire. The ATC parameters
are important maintenance parameters, and tell the operators when to most
efficiently change the support wires. See more info at the description of the display
(in the Operating Instructions) and at the Accumulated Ton Cycles wire monitoring
section. After this point is known to be taken care of, it no longer needs be checked
this often.
3.3 Monthly inspections

x Inspect the support wires to verify that they are well greased, not corroded, and have
no visible mechanical damage. Careful greasing extends the service life of the wires.
Reference is also made to the Acceptance criteria for wire inspection section.
x Inspect the open spelter socket type wire terminations at the riser tension ring. Look
for deformations, cracks, corrosion and loose bolts.
x Inspect the walkways below and around the support wires to see if grease splashes
have made them slippery. Skidding/slipping accidents can be prevented by keeping
the walkways clean.
x Check that the breather filters are in place at the top of all fluid drain tanks (two
tanks at each fixed sheave house).
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4 PERIODIC MAINTENANCE SCHEDULE
4.1 Follow-up of inspections

x If the routine inspections revealed any abnormal conditions, these must be followed
up. How fast depends on the nature of the abnormality.
4.2 Maintenance routine after first 100 operating hours

x Take a sample of the tensioner fluid in one third of the HP accumulators and the
belonging cylinders, and check (by the on-board particle counter) that the fluid
purity satisfies ISO 4406:99, Class 19/17/14. See more details in the Checking
purity and chemical properties of tensioner fluid section.
belonging cylinders, and have it analysed by a laboratory. See more details in the
Checking purity and chemical properties of tensioner fluid section, including the
Houghton Recommendation.
4.3 Lubrication routine

x Lubricate the equipment as specified in the lubrication charts referred to at the end
of the document. Also see info in the Lubrication section.
4.4 2-weekly maintenance routine

x Clean and lubricate the rods of the tension cylinders as described in the Lubrication
section.
x Check the fluid levels in all HP accumulators as described in the Checking fluid level
in HP accumulators section. After reliable operation is proven through field
experience (after minimum four weeks of normal operation), this point can be
transferred to the 6-monthly maintenance routine.
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4.5 Monthly maintenance routine

x Keep the equipment clean.
x Touch up any paint damage.
x Grease the support wires as described in the Lubrication section.
x Clean and lubricate the cylinder rods as described in the Lubrication section.
x Keep all other unpainted metal surfaces covered by suitable anti-corrosion oil.
x Take a sample of the tensioner fluid in half of the HP accumulators and the
belonging cylinders, and check (by the on-board particle counter) that the fluid
purity satisfies ISO 4406:99, Class 19/17/14. See more details in the Checking
purity and chemical properties of tensioner fluid section. If no abnormalities are
observed the first six months of operation, this point may be transferred to the 3-
monthly maintenance routine and combined with the laboratory sampling.
x Check the fluid drain tanks (two tanks at each fixed sheave house). Verify that the
breather filter is in place, and write down the fluid level in the tank. Compare the fluid
level with earlier recordings and with the recordings from the other drain tanks to
spot any abnormalities. Drain the tank manually if it is more than half full. If a tank
remains empty for a longer period; inspection of the anti-recoil valve and pipe lines is
needed. The drain tank fluid volume equals the leakage from the HP accumulator
and can be used to decide if fluid needs to be added on the HP accumulator (at the
underside of the accumulator piston).
x Drain to safe location all working APVs by opening each APV’s drain valve for a
short while. Use ear and eye protection during the draining. Careful, the APVs
are pressurized!
x Test the operation of each anti-recoil valve by running a test sequence four or five
times. The test sequence is explained in the Description of controls section in the
Operating Instructions.
4.6 3-monthly maintenance routine

x Keep the equipment clean.
belonging cylinders, and have it analysed by a laboratory. See more details in the
Checking purity and chemical properties of tensioner fluid section.
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x Change the elements of the three small filters on each anti-recoil valve as described
in separate section. After the first half year of operation, this point only needs to be
carried out 6-monthly.
x Maintain the wire sheaves as described in the Sheave maintenance section.
4.7 6-monthly maintenance routine

x Using ear and eye protection; drain all working APVs of any precipitated water.
Careful, the APVs are pressurized!
x At the APVs, check that the quality of the air supplied from the compressors satisfies
ISO 8573-1, Class 3.3.3. See Checking the quality of the air section for procedure.
4.8 Yearly maintenance routine

x Wash the entire equipment thoroughly and allow it to dry.
x Perform all the routine inspections listed in the Routine inspections section and
complete an inspection report. A signed copy of the inspection report must be filed in
the maintenance log, and the remarks must be followed up.
x Test the opening setpoint of the pressure relief valve on top of each HP accumulator
as described in the Pressure relief valve maintenance section. Verify that the valves
are clean and in good working condition. Write down the results in the maintenance
log.
x Maintain the pressure relief valve on each working APV as described in the Pressure
relief valve maintenance section.
x Check/retighten all terminal blocks and other electrical connection points, including
earthing.
x Check for moisture inside all outdoor junction boxes and panels. Add new drying
agent as required.
x Check the condition of the oily Denso tape fitted to protect the fluid tubing fittings
against corrosion. If the tape is drying out, soak it with hydraulic oil to maintain the
corrosion preventing effect.
4.9 2-yearly maintenance routine

x At the fluid drain tanks (two tanks at each fixed sheave house), change the breather
filter.
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x Change all support wires, unless they have been changed the last three years, due
to wear, damage or corrosion. See more info in the Changing the support wires
section.

x Change all hydraulic hoses. Only hoses of the original type must be used.
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5 PERIODIC MAINTENANCE PROCEDURES
5.1 Lubrication
Wireline tensioners: The tensioners are to be lubricated according to the lubrication
charts referred to at the end of this document. The charts show intervals, where to
lubricate and what kind of lubricant to use. A grease gun is used for the nipple greasing,
and the greasing should each time continue until fresh grease is seen oozing out
between the shaft and the bushing/bearing. The greasing can normally take place while
the system is operating. Always take necessary safety precautions while the system is
operating.
Cylinder rods: The rods of the tension cylinders are lubricated by tensioner fluid while
the cylinders are fully retracted. During system operation the cylinders normally operate
around mid-stroke only, and the outer end of the rods may be left without lubrication for
a longer period. If the on-going operations allow it, it is recommended to retract the
cylinders fully at least 2-weekly. If this is not practical, it is recommended to clean
(remove salt and mud) and preserve the rods with the same tensioner fluid as is used in
the cylinders. This routine will reduce the risk of corrosion on the cylinder rods, protect
the scraper rings and seals, and increase the service life of the cylinders.
Idler sheaves: Lubricate all idler sheaves according to their lubrication chart. The chart
shows intervals, where to lubricate and what kind of lubricant to use. A grease gun is
used for the nipple greasing, and the greasing should each time continue until fresh
grease is seen oozing out between the shaft and the bushing/bearing. The greasing can
take place while the system is operating, provided that the sea is calm.
Support wires: Grease each support wire by using a suitable brush on a rod (for safe
distance to the moving wires). It is of particular importance to keep well-greased the
areas where the wire bends over the sheaves. The greasing can take place while the
system is operating. Be aware of the safety issues of greasing a moving wire. Brilube 70
or equivalent wire grease is recommended for this lubrication.
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5.2 Checking the quality of the air

The quality of the air supplied from the compressors must satisfy ISO 8573-1, Class
3.3.3.
The compressors supplied by NOV initially satisfy this requirement. After the system has
been taken into use, the air must be checked to verify that it is clean. In case of
unusually high oil consumption of one of the compressors the air must be checked
immediately.
The recommended measuring equipment is DRÄGER AEROTEST SIMULTAN HP
(NOV item no. 204172) or equivalent, which is supposed to exist on board.
The procedure is as follows:
Bleed
Minimess
Block and bleed valve on working APV
On the block and bleed valve make sure the block valve is open, close the bleed valve,
connect the measuring instrument to the minimess and open bleed.
When the measuring is completed, close the bleed valve and remove the measuring
instrument from the minimess.
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5.3 Type and quantity of tensioner fluid

Tensioner fluid types: Erifon 818 TLP (green colour), or
Houghto-Safe 273 CTF (red colour)
Fluid quantity per HP accumulator: Approx. 490 litres
Total system fluid quantity: Approx. 3920 litres (= 490x8)
Required fluid purity: ISO 4406:99, Class 19/17/14
Fluid operating pressure: Max 207 bar
Both fluid types are water-glycol based and well suited as tensioner fluid, but are
not to be mixed. The maintenance supervisor must keep track of what type is used and
order new fluid of the same type. If the rig is changing from one fluid type to the other,
all old fluid must be drained first. Only these types of fluid may be used. The equipment
supplier (NOV) refuses all responsibility for damage caused by the use of non-approved
fluids and damage caused by mixing fluids of different types.
The tensioner fluid is filled on the HP accumulators. During system operation the fluid is
circulating between the HP accumulator and the (lower) piston side of the tension
cylinder. On the way the fluid passes back and forth through the open anti-recoil valve.
The specified fluids are highly resistant to fires and explosions, which is important when
fluids are in contact with high-pressure air (ref. the diesel effect). They also lubricate and
protect against corrosion, and in a closed system the fluid vapour prevents corrosion
even above the fluid surface. The fluids are very resistant to biological attacks from
bacteria and fungi; have no significant negative effect on the rubber seals, and are not
aggressive on the commonly used offshore paints. From a toxicological point of view the
fluids are more acceptable than most similar fluids. Fluid spill can be flushed away with
water, and there is no need for special cleaning chemicals. During fluid change the old
fluid shall still not be disposed into the sea, but returned to a licensed waste contractor
and treated according to the applicable environment protection regulations.
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5.4 HP accumulator illustrations

Drawing: Detail “A” Schematic Flow Diagram
The following illustrations of the HP accumulators are useful while carrying out the
different procedures in the next sections:
Vent valve HPA

Air side (BV03)
Needle valve
(NV03)
Safety relief valve

HPA (PSV01)
Bypass needle valve

HPA (NV01)
Air inlet valve

HPA (BV01)
High Pressure
Accumulator (HPA)
Top view of cylinder & accumulator assembly
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Filter
Anti-recoil valve
Anti-recoil valve
Drain port
Anti-recoil valve
Drain valve
HPA (BV04)
High Pressure
Accumulator (HPA)
Bottom view of cylinder & accumulator assembly

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Dip Tube
Sectional view of HP accumulator

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5.5 Checking purity and chemical properties of tensioner fluid

Drawing: Detail “A” Schematic, Flow Diagram (H1003)
The tension cylinders are exposed to extreme working conditions, and it is important
that the tensioner fluid remains clean and according to specification. Compliance with
specification is verified by regularly taking samples of the fluid in the HP accumulators.
The sampling intervals and type of sample are stated in the Periodic Maintenance
Schedule. If a sample is not satisfactory, the fluid must be cleaned or changed soonest.
Separate samples are taken for purity checking and for analysis of the fluid’s
chemical properties. The purity checks can normally be done by the on-board particle
counter, and the fluid purity must satisfy ISO 4406:99, Class 19/17/14 (NAS 8). The
chemical properties analysis must take place at a laboratory. The laboratory will
compare the result with the recommendation from the fluid manufacturer, and decide if
the fluid is suited for continued use.
The fluid analysis may have three different results:
x The fluid is OK. No further action is needed.

x The fluid purity does not satisfy ISO 4406:99, Class 19/17/14 (NAS 8), but the
chemical properties are otherwise OK. The fluid must be cleaned.
x The chemical properties are not acceptable. The fluid must be changed.
During system running-in the first six months of operation, purity samples are required
more frequently than later. During all sampling it is each time sufficient to take samples
from half (not all) of the tensioners. Which tensioners the samples are taken from must
be logged and marked on the sample bottles, and the next sampling must be from the
other half of the tensioners. After two rounds all tensioners have been sampled. If
unexpected impurities are found in a tensioner, this tensioner must be checked each
time thereafter. If necessary, the supplier must be contacted.
Taking samples from the cylinders:
1. Starting point: The system operates normally

2. Make sure the bleed valve of the Block & Bleed valve BB01 at the bottom of the
cylinder is closed.
3. Connect a clean ¼” hose to the minimess test point after the bleed valve.
4. Carefully open the bleed valve and drain a sample from BB01
5. Close the bleed valve
6. Seal the sample bottle and mark it with date and origin.
7. Remove the hose
8. Depending on the type of samples (for particle counting or analysis of the
chemical properties, ref the Periodic maintenance schedule), check the samples
on board or have them analysed in a laboratory. Some particle counters may
even be connected directly to the minimess test point on the B&B valve.
The samples must be taken according to the recommendation which is shown on the
next 2 pages.
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5.6 Houghton recommendation

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5.7 Overview of fluid fill unit

Drawing: L6764-D1112-G0001
If the tensioner fluid no longer satisfies the purity requirement, but the chemical
properties otherwise are OK, the fluid must be cleaned in the fluid fill unit (FFU).
An extract of the flow diagram for the FFU is shown below. The extract gives an
overview of the FFU’s (atmospheric) main tank and the belonging LP filling pump (H01).
The skid mounted fluid fill unit (FFU) consists of an atmospheric fluid tank, a vane
pump, piping, valves, instrumentation and a local control panel. The unit is used for
filling tensioner fluid on the tensioners’ HP accumulators, and for draining the same fluid
from the accumulators when the fluid quality no longer is acceptable. If only the purity is
unacceptable, the fluid will be cleaned in the unit and refilled on the accumulators. If the
chemical properties are unacceptable, the fluid will be drained further to external waste
fluid containers, and replaced with new clean fluid. The fluid fill unit is shown in the
illustration below and on the next pages. The WRTS hookup to the FFU via the FFU’s
connections F and D. Both connections are hard-piped to the bottom fill/drain valve of
all the HP accumulators of the WRT. The fluid will be drained into the main tank via
connection D, and later pumped back via connection F using the LP filling pump.
Inspection hatch
Breather filter
Control panel
Pump motor
LP filling pump
FFU with the main tank and LP filling pump.

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Local control panel of the Fluid Fill Unit.See Operating Instructions for a detailed description.
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Flow diagram of Fluid Fill Unit (G6764-D1112-H0011)

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5.8 Cleaning fluid in HP accumulators

Drawing: L6764-D1105-H1003
The fluid is cleaned because the purity no longer satisfies ISO 4406:99 19/17/14. The
cleaning will continue until Class 19/17/14 is obtained.
It is recommended that the WRTS is unloaded and shut down first. It is also
recommended to clean the fluid from one pair of diametrically opposite tensioners at a
time. This is the base case described in the procedure.
The procedure for cleaning the fluid in the HP accumulators includes the following
steps:
x Draining the HP accumulator
x Cleaning the fluid
x Refilling cleaned fluid on the HP accumulator
Draining the HP accumulators

Starting point: The WRTS is shut down as described in the Operating Instructions. The
riser tension ring is suspended below the diverter casing and the support wires are
slack. The tension cylinders are fully retracted, and the air inlet valves (and their
bypass valves) on top of the HP accumulators are closed. The main tank of the fluid fill
unit is capable of collecting the fluid from both accumulators without overflowing, and
valves H14, H16 and H17 are closed.
x Have an assistant observing the level gauge at the FFU tank
x At the fluid fill unit, close valve H15.
x Close valve BV03 at the top of the pair’s first HP accumulator to be drained.
x Open valve BV04 and the drain valve below the HP accumulator to be drained.
x Open valve NV01 at the top of the HP accumulator.
x Allow the fluid to be drained completely from the HP accumulator and into the tank.
The fluid enters the tank via return filter H07.
x Close valve NV01
x Unplug and open valve NV03 at the top of the cylinder, This will make sure that all
the fluid is drained from the cylinder and into the pipe system.
x Close and plug valve NV03 and open valve NV01 again to drain the fluid in the pipe
system further to the tank.
x Close valve BV04. Keep the drain valve open .
x Close valve NV01.
x Continue by draining the pair’s second HP accumulator the same way.
x Continuation below
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Cleaning the fluid

Starting point: Continuation from above. All the dirty fluid to be cleaned has been
drained into the tank.
x At the bottom of the first HP accumulator open the fill valve. The drain valve should
still be open from the draining. If not, open the drain valve too.
x At the fluid fill unit open valve H15. Keep valve H17 closed.
x Start the cleaning by starting the fill pump on the FFU. This can be done using the
local control panel of the FFU, or the local control panel of the WRT system in the
moonpool area. The fluid in the tank will then repeatedly be circulated from the FFU,
through the pump’s pressure filter, all the way through the fill and drain valves at the
bottom of the HP accumulator, through the tank return filter, and back to the tank.
(Some of it will be passing through pressure control valve H09.)
By keeping valve H17 closed while keeping the fill valve and the
drain valve at the bottom of the accumulator open, all the fluid in
the pipe system will be included in the cleaning process. Valve
BV04 must be closed.
x Throughout the cleaning, observe the local clogging (pressure drop) indicator at
return filter H07. When the indicator is in the red area, stop the pump and change
the elements of both the return filter and the pressure filter. Then restart the pump
and continue the cleaning. Repeat this as long as the cleaning goes on. Several
element changes may be needed before the fluid is clean enough.
x The fluid circulates through the pipes leading to the first HP accumulator. Go on for
approx. 20 minutes. Then, while the pump is running, carefully and slowly open the
fill valve and the drain valve below the second HP accumulator. Then carefully and
slowly close the fill valve and the drain valve below the first HP accumulator. The
fluid will now circulate through the pipes leading to the second HP accumulator.
x Run the pump for about 45 minutes, and then take a sample of the circulated fluid.
The sample can be taken while the pump is running by connecting a Minimess hose
to Minimess connector H12, or via the tank top breather hole H08. Check the purity
of the sample fluid by an on-board particle counter. If the sample satisfies ISO
4406:99 19/17/14, the fluid has been cleaned enough. If the sample doesn’t satisfy
this purity class, go on for 45 more minutes, and take a new sample. Continue
circulating and cleaning the fluid until ISO 4406:99 19/17/14 is obtained.
x When the fluid has reached the desired cleanliness class, stop the pump and
change the elements of both the return filter and the pressure filter one last time.
x Close the fill valve and the drain valve below the HP accumulator.
x Continuation below.
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Refilling cleaned fluid on the HP accumulators

Starting point: Continuation from above. The fluid in the main tank is cleaned, and ready
to be pumped back on the accumulator. The belonging tension cylinders are fully
retracted.
x If the fluid quantity in the main tank is believed to be insufficient for proper refilling,
add some more (new) fluid to the tank via the “Oil filling” connection F and valve
H16. See Filling the main tank in the Changing fluid in the accumulators section.
x Prepare the FFU for refilling as follows: Verify that valve H15 is open. Verify that
valve H17 is closed.
It is recommended to fill the HP accumulators one at a time. This

is the base case described below.
x At the bottom of the first HP accumulator to be filled open valve BV04 and the fill
valve beneath it.
x At the top of the cylinder, connect a hose to valve NV03, and point the other end of
the hose into a bucket. Open valve NV03.
x Start filling fluid on the cylinder by starting the filling pump from the local control
panel of the FFU or the WRT system. Go on filling until there is fluid coming out of
valve NV03. Then stop the pump. Close and plug valve NV03.
x At the top of the accumulator connect a hose to the dip tube outlet and point the
other end of the hose into a bucket. Carefully open valve NV02.
x Study the above Sectional view of HP accumulator illustration. As the fluid is filled on
the HP accumulator it will eventually meet the dip tube which is positioned in the
accumulator. When the fluid has reached the outlet of the dip tube, the fluid level is
correct.
the dip tube outlet. Then stop the pump.
x Close the fill valve and valve BV04.
x Close and plug valve NV02 on the dip tube outlet.
x Refill the second HP accumulator the same way.
After all refilling is completed; return the fluid fill unit to normal as follows:
Verify that valves H17 and H16 are closed.
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5.9 Changing fluid in HP accumulators

Drawing: L6764-D1105-H1003
The HP tensioner fluid is changed in much the same way as described above for the
fluid cleaning, and the same illustrations apply. The major difference is that after the
old fluid is drained into the main tank of the fluid fill unit, the fluid will be drained from the
tank and new fluid filled, instead of cleaning the fluid in the tank. Here as well it is
recommended that the WRTS is unloaded and shut down first. This is the base case
described in the procedure.
The procedure for changing the fluid includes the following steps:
x Draining the HP accumulators

x Draining the main tank
x Filling the main tank
x Filling new fluid on the HP accumulator
Draining the HP accumulators

Starting point: The WRTS is shut down as described in the Operating Instructions. The
riser tension ring is suspended below the diverter casing and the support wires are
slack. The tension cylinders are fully retracted, and the air inlet valves (and their
bypass valves) on top of the HP accumulators are closed. The main tank of the fluid fill
unit is capable of collecting the fluid from both accumulators without overflowing, and
valves H14, H16 and H17 are closed.
x Have an assistant observing the level gauge at the FFU tank
x At the fluid fill unit, close valve H15.
x Close valve BV03 at the top of the pair’s first HP accumulator to be drained.
x Open valve BV04 and the drain valve below the HP accumulator to be drained.
x Open valve NV01 at the top of the HP accumulator.
x Allow the fluid to be drained completely from the HP accumulator and into the tank.
The fluid enters the tank via return filter H07.
x Close valve NV01
x Unplug and open valve NV03 at the top of the cylinder, This will make sure that all
the fluid is drained from the cylinder and into the pipe system.
x Close and plug valve NV03 and open valve NV01 again to drain the fluid in the pipe
system further to the tank.
x Close valve BV04 and the drain valve beneath it.
x Close valve NV01.
x Continue by draining the pair’s second HP accumulator the same way.

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Draining the FFU tank

x Starting point: Continuation from above.
x Place one or more empty fluid containers at a lower elevation than the fluid fill unit,
and connect a drain hose between the tank drain valve (H14) and one of the
containers.
x Open the drain valve and drain all fluid from the tank.
x If there is any reason to believe that the inside of the tank is not clean, unscrew the
tank top inspection hatch and inspect and clean the tank as necessary. Then
reinstall the hatch.
x Close the drain valve, remove the drain hose, and plug the valve outlet.
x Have the old fluid returned to a licensed waste contractor for environmentally correct
disposal.
Filling the FFU tank

x Bring the containers with the new fluid. The new fluid must be of the original type, as
specified in the Type and quantity of tensioner fluid section.
x Unplug the fluid fill unit’s “Oil filling” connection F, and connect a clean filling hose
between the first container and the F-connection. A portable and clean fluid pump
(supplied by others) must be fitted at the container end of the hose. A 3-micron
particle filter is recommended at the HPU end of the hose.
x At the fluid fill unit, verify that valves H14, H15 and H17 are closed. Open fill valve
H16.
x Using the portable pump, fill up the tank with the required fluid quantity (probably a
little more than what was drained from the tank). The fluid enters the tank via return
filter H07.
x Disconnect the filling hose, close filling valve H16, and plug connection F.
x Write down the filled fluid quantity in the maintenance log.
x Change the element of return filter H07.
x Continuation below.
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Filling new fluid on the HP accumulator

x Starting point: Continuation from above. The fluid in the tank is changed, and ready
to be pumped on the HP accumulators. The tension cylinders are fully retracted.
x Prepare the fluid fill unit for refilling as follows: Verify that valve H15 is open. Verify
that valve H17 is closed.
It is recommended to fill the HP accumulators one at a time. This

is the base case described below.
x At the bottom of the first HP accumulator to be filled open valve BV04 and the fill
valve beneath it.
x At the top of the cylinder, connect a hose to valve NV03, and point the other end of
the hose into a bucket. Open valve NV03.
valve NV03. Then stop the pump. Close and plug valve NV03.
x At the top of the accumulator connect a hose to the dip tube outlet and point the
other end of the hose into a bucket. Carefully open valve NV02.
x Study the above Sectional view of HP accumulator illustration. As the fluid is filled on
the HP accumulator it will eventually meet the dip tube which is positioned in the
accumulator. When the fluid has reached the outlet of the dip tube, the fluid level is
correct.
the dip tube outlet. Then stop the pump.
x Close the fill valve and valve BV04.
x Close and plug valve NV02 on the dip tube outlet.
x Refill the second HP accumulator the same way.
x After all refilling is completed; return the fluid fill unit to normal as follows:
Verify that valves H17 and H16 are closed.
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5.10 Checking fluid level in HP accumulators

The fluid level in the HP accumulators must be checked at the intervals prescribed in
the Periodic maintenance schedule, and more fluid added if the level is low. One pair of
diametrically opposite tensioners is checked at a time, and the WRT system can remain
operating normally on the other pairs. Each tensioner pair is checked as follows:
1. Starting point: The WRT system operates normally with all tensioner pairs activated.
2. Select and deactivate the pair of diametrically opposite tensioners to be checked by
closing the common main air valve for these tensioners.
3. Retract the cylinders of these two tensioners by venting to safe location the
common air pressure in the pair. Verify that both cylinders are fully retracted.
4. Close the manual air inlet valves on top of the two HP accumulators.
5. Consider the need for raising the working air pressure in the other tensioner pairs, in
order to keep the tension on the riser at the original level.
6. Carefully unplug and open valve NV02 at the top of the first HP accumulator in the
pair. (Some pressure may still be left.)
7. If the fluid just reaches to the outlet of the dip tube, the fluid level is OK and no
topping up is needed.
8. If there is no fluid at the outlet of the dip tube, the fluid filling is low and topping up
more fluid is needed. This is done with the help of the fluid fill unit and as follows:
i. Connect the fluid fill unit to the WRT system, and check that there is sufficient
fluid in the tank.
ii. Prepare the fluid fill unit for the topping up according to the fluid fill unit’s
operating instructions.
iii. Open the fill/drain valve BV04 at the underside of the HP accumulator to be
topped up.
iv. Open the fill valve of the belonging HP accumulator on the fixed pipes.
v. Prepare correct filling of the first HP accumulator by studying the Sectional view
of HP accumulator illustration. As fluid is filled on the accumulator through the
fill/drain valve the fluid level will rise and will eventually meet the dip tube in the
HP accumulator. The filling is correct when the fluid has reached the outlet of
needle valve NV02 at the top of the dip tube.
vi. Start filling fluid on the cylinder by starting the filling pump from the local control
panel of the FFU or the WRT system.
vii. Go on filling until the fluid level is at the specified height. Then stop the pump.
viii. Close the fill/drain valve at the bottom of the HP accumulator.
ix. Close the fill valve on the fixed pipes.
x. Close and plug valve NV02 at the top of the HP accumulator.
9. Check the fluid level in the second HP accumulator in the same way.
10. When the fluid levels in both HP accumulators are OK, return the tensioners to
normal operation as follows:
11. Pressurize both tensioners from the working APVs by opening their main air valve.
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12. Slowly extend the cylinder of the first tensioner by opening the (smaller) bypass
valve of the air inlet valve (at the accumulator top). When the cylinder is
approximately at mid-stroke, the support wire will be tensioned. Then open the air
inlet valve to the HP accumulator and close the inlet valve’s bypass valve.
13. Extend the second cylinder in the same way as the first.
14. Adjust the working air pressure for this tensioner pair to the same level as the other
pairs. Select all pairs at the (Cyberbase) Wireline Tensioners display, and fine tune
the working air pressures as necessary to return to the target total tension.
Tensioners with deviating fluid levels must be checked more frequently the next months.
Check for leaks, and also check the drain tanks to see if the fluid is escaping this way.
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5.11 Changing filter elements on anti-recoil valves

Drawing: Detail “A” Schematic Flow Diagram (H1003)
Each anti-recoil valve (which actually is a valve block) has three small filters identified
as F1, F2 and F3 in the flow diagram. The elements of these filters must be changed at
the intervals specified in the Periodic maintenance schedule.
Ear and eye protectors must be used while the filters are
changed.
Some pressure may be left at the filters, and may be bled off
when the filters are loosened.
Change the filters as follows:
1. Starting point: The system is shut down and all pressure vented.
2. Close the V1 valve on the anti-recoil valve.
3. Clean the areas around the filters, so that impurities will not easily enter the system
when the filters are unscrewed.
4. Carefully loosen and unscrew the (large) hex nut filter caps.
5. Remove the dirty elements, and check them for abnormal contamination. Also make
sure that no old seal rings remains inside the valve.
6. Install new elements of the original type, along with any new seal rings supplied with
them. Wet the seals with clean tensioner fluid before reinstallation.
7. Attach a note to each filter, stating date of change. Also write it down in the
maintenance log. Remember to open the V1 valve when done!
Filters
V1 valve
Typical anti-recoil valve, with arrows pointing at the three filter caps and the V1 valve
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5.12 Inspection and change of support wires
5.12.1 Acceptance criteria for wire inspection

The acceptance criteria for the tensioner wires are based on the F.E.M. Rules for
Design of Hoisting Appliances. The wires are classified as belonging to group M5 of
these rules. The examination is based on counting visible broken wires/strands over a
specified wire length, selected at the most exposed parts of the wire. If the number of
broken wires at any spot check exceeds the maximum allowed number, the wire must
be changed.
The maximum number of visible broken wires is given by the below table. The table is
reproduced from “Table 2” of ISO 4309, second edition 1990-08-15: Cranes, Wire
Ropes, Code of Practice for Examination and Discard.
Number of visible broken wires (1) related to the fatigue of a

rope in the crane (winch) which gives rise to rejection.
Classification Group: M5
Over a length (2) of
6d 30 d
4 8
(1) = A broken wire may have two ends.

(2) d = Nominal diameter of the rope.
“Table 2”
Example: To check if the wire is acceptable, choose a wire length of 6 times the wire
diameter (see wire diameter in the Product Data Sheet document or at the wire sheave
assembly drawings), chosen at the most worn place. If the number of visible broken
wires within the length is 4 or more, the wire must be replaced.
If the wire doesn’t pass the inspection, it must be changed soonest.

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5.12.2 Accumulated Ton Cycles wire monitoring

Monitoring the accumulated tension load on each tensioner’s support wire is an
alternative way of deciding when the wires must be changed (or thoroughly inspected).
The accumulated load per wire varies with the tension and the heave, but may typically
(as an example only) increase by 6 metric tons per heave cycle. The sum of these loads
tells the operator what stress the wire has endured. This also illustrates the advantage
of not using higher than necessary tension on each wire. Lower tension per cycle gives
a slower increase of the accumulated load.
An Accumulated Ton Cycles (ATC) counter is included for each wire, and the result is
displayed at the Cyberbase Accumulated Ton Cycles screen display. An ATC
maintenance alarm can be set to announce when the ATC value/load has reached the
wire change limit, which alternatively can be a thorough wire inspection limit. The
controls for (re)setting the counters and (re)setting the alarm limits are described in the
Operating Instructions.
When this is manual is prepared, no accumulated wire change limit based on field
experience exists. The initial recommendation is therefore to zero all counters to when
the system is commissioned, and to inspect the wires regularly as described in the
preceding section. When the inspectors conclude that the wires need to be changed, or
a wire breaks, the accumulated value at that time must be logged. After the wires are
changed, this figure minus a suitable safety discount can be set as the new alarm limit.
From then on the monitoring system will be a good help in estimating the remaining
operating life of the installed wires.
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5.12.3 Changing the support wires

There is one support wire per single tensioner, and type and length are specified in the
Product Data Sheet. The supplied length is more than the required minimum, and during
installation the excess length will be coiled up next to the tensioner. (No wire reel for the
excess length is initially supplied by NOV, but available upon request.) The excess
length may then later by “cut & slip” be used to replace the most worn parts of the
working length, typically the parts repeatedly being bent over the wire sheaves, and the
next wire supply may thereby be postponed. Cut & slip is described in a separate
section below.
The support wire has an open spelter socket in one end and a needle eye in the other.
The spelter socket is for connection to the riser tension ring, and the needle eye for the
pulling rope used during installation. When a new wire is supplied on board, the needle
eye will be at the outer end on the transport drum.
Each support wire is changed as follows:
Removing the old wire:

x Starting point: The WRT system is shut down normally, the riser tension ring is
suspended at its parking place at the underside of the diverter casing (below the
drillfloor), the tension cylinders are fully retracted, and the support wires are slack.
No other work takes place in the moonpool. An empty transport drum on a motor-
driven reel is ready to receive the old wire, and suitable pulling ropes are available.
The ropes must be strong enough to hold the weight of the wire if the wire gets out
of control.
x Carefully release the riser tension ring from its parking suspension and extend all
tension cylinders exactly to mid-stroke. The tension ring will then be exactly at the
“design position” set at the initial working length calibration of the support wires
(during commissioning). Leave the tension ring here (kept in position by the wires
from the other tensioners) throughout the wire change, as this position also is used
for working length calibration at the final stages of the installation of the new wire.
x Retract the tension cylinder w the wire to be changed, just a little to slacken this one
wire, and disconnect the spelter socket from the tension ring. Connect this wire end
to the transport drum, if necessary by a pulling rope, so that this end is ready to be
reeled on the transport drum.
x Extend the tension cylinder back out to the exact mid-stroke position.
x Prepare the coiled-up excess wire length (length coiled up by the tensioner) to be
pulled through and out of the tensioner. Attach a pulling rope to the needle eye wire
end to control this end during the pulling-out, and secure the pulling rope as
necessary to remain in control.
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x At the fixed sheave house, unscrew the six bolts of the wire anchor clamp
(“deadman”), and remove the bolts and the clamp top.
x Start removing the old wire from the tensioner by reeling in wire on the transport
drum. Follow up at the needle eye end and feed wire and rope into the tensioner.
x Continue transferring wire to the

transport drum until the entire wire
length is reeled on the drum. Fasten
the wire end to the drum flange and
remove the pulling rope.
x Remove the drum with the old wire

from the transport drum reel to make
room for the transport drum with the
new wire.
x Clean the wire clamp at the fixed

sheave house and lubricate the clamp
bolts.
x Check the emptied wire sheaves

(including the idler sheave) for bearing
slackness and smooth running and
carry out maintenance as necessary.
x Consider the need for having parts of

the old wire cut from the overall length
for examination
by the wire manu-
facturer or other
specialist. The
report from such
examination may
prove useful for
safe and cost
effective wire
management.
Wire reeving arrangement of dual wireline tensioner

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Installing the new wire:

x Install the transport drum with the new wire in the empty transport drum reel.
x Attach a pulling rope to the needle eye of the new wire, and route the rope through
the idler sheave, through the tensioner sheaves, three turns around the snubber
drum, past the open wire anchor clamp, over to a suitable utility winch, and secure
the rope end to the drum of the winch. The winch must be able to pull in the wire on
the tensioner.
x Start pulling in the wire on the tensioner by the winch, and follow up by the transport
drum reel (paying out).
x Go on pulling in until the wire is off the transport drum. Then attach a pulling rope to
the spelter socket and guide this wire end over to the riser tension ring and connect
it at the designated location for this wire.
x Assuming that the riser tension ring still is exactly at the “design position” and that
the tension cylinder is exactly at mid-stroke, reel in any slack by the winch but don’t
pull the tension ring out of position. The working wire length is now correctly
calibrated.
x While the winch keeps the wire tight at the present position, torque up the wire
anchor clamp on the wire. (See torque table at assembly drawing for fixed sheave
house.)
x Mark the wire on both sides of the clamp to make it easier to spot any slipping at
future inspections.
x Unload the pulling winch, unreel the excess wire from the winch drum, and coil it up
and secure it next to the tensioner. If there is sufficient excess length, this length can
later be utilised in a cut & slip operation.
x In the driller’s cabin, at the Cyberbase Accumulated Ton Cycles display, read and
write down the accumulated tons value for the old wire. Then zero the counter to
prepare it for counting the accumulated value of the new wire. Based on experience
from the old wire, adjust the maintenance alarm limit for the new wire as necessary,
so that the next change (or cut & slip) is announced safely and economically.
x Repeat the overall procedure for any other tensioners needing a wire change.
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5.12.4 Cut & slip of support wires

The inspection of a support wire may reveal that it is much worn at certain places, most
typically where it repeatedly bends over the wire sheaves. Instead of changing the entire
wire too early there is then the option of “cut & slip”, provided that there is sufficient
excess wire coiled up by the tensioner. Cut & slip includes cutting the open spelter
socket from the wire end, removing the worn part of the wire, and reinstalling (casting)
the spelter socket at the cut end. The wire cutting and socket casting is a specialist job
and requires the assistance of a licensed wire service contractor.
The cut & slip operation takes place as follows:
Preparations:
x Starting point: The WRT system is unloaded, the riser tension ring is suspended at
its parking place below deck, and the support wires are slack. No other work takes
place in the moonpool. A sufficiently empty transport drum on a motor-driven reel is
ready to receive the worn wire length to be removed, and suitable pulling ropes are
available. The pulling ropes must be strong enough to hold the full weight of the
wire, if the wire gets out of control.
x Check that there is sufficient excess wire coiled up by the tensioner to replace the
worn length to be removed.
x Carefully release the riser tension ring from its parking suspension, and extend all
tension cylinders exactly to mid-stroke. The tension ring will then be exactly at the
“design position” set at the initial working length calibration of the support wires.
Leave the tension ring here (kept in position by the wires from the other tensioners)
until after working length calibration of subject wire (after it has been cut).
x Retract the tension cylinder of the wire to be cut, just a little to slacken this one wire,
and disconnect the spelter socket from the tension ring. Connect this wire end to the
transport drum, if necessary by a pulling rope, so that this end is ready to be reeled
on the transport drum. Remember that the spelter socket must remain accessible, as
it later will be cut from the wire.
x Adjust the tension cylinder of subject tensioner back to exactly mid-stroke.
x Prepare the coiled-up excess wire length to be uncoiled and pulled through the
tensioner. Arrangements must be made to keep suitably tight the excess (needle
eye) wire end entering the tensioner, and to hold the entire wire if the other end gets
out of control. This may involve the use of a pulling rope at the needle eye end.
x At the tensioner’s fixed sheave house, unscrew the six bolts of the wire anchor
clamp (“deadman”), and remove the bolts and the clamp top.
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Removing the worn length:

x Start “slipping” worn wire out of the tensioner by reeling in wire on the transport drum
and at the same time paying out wire at the needle eye end, so that the wire part
upstream of the tensioner remains suitably tight.
x Continue transferring wire to the transport drum until the last worn part is suitably
past the idler sheave. Then stop the transport drum.
x Mark the place the wire is to be cut, secure both sides of the mark (by suitable
ropes), and cut the wire.
x Measure the cut length and write it down in the maintenance log.
x Cut the spelter socket from the cut length and prepare it for reinstallation at the end
of the remaining wire.
x Inspect the cut ends and look for internal corrosion and any other damage that
indicates weakening of the wire. Make a new cut at the most worn part of the cut
wire and inspect here as well. If deemed necessary, cut a small length from the wire
and have it examined by the wire manufacturer or other specialist. Write down all
input from the inspections in the maintenance log and use the info for planning the
next wire changes in a safe and cost effective way.
Positioning the fresh length:

x Have the spelter socket installed at the cut end of the remaining support wire.
x Connect the spelter socket to the riser tension ring, which still is at the “design
position”.
x Using the winch, tighten up the wire from the spelter socket. Don’t tighten so much
that the tension ring is pulled out of the design position. When the wire is just tight,
the calibration of the working wire length is exactly right. Then stop the winch and
hold the wire there.
x At the tensioner’s fixed sheave house, clean the wire clamp, lubricate the six bolts,
and torque up the clamp on the wire.
x Mark the wire on both sides of the clamp to make it easier to spot any slipping at
future inspections.
x Unload the winch, unreel the remaining wire and pulling rope from the winch drum,
disconnect the rope, and coil up and secure the remaining wire next to the tensioner.
x Repeat the overall procedure for any other tensioners needing the described
maintenance.
x File the job report from the licensed wire service contractor in the maintenance log.
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5.13 Sheave maintenance
The wire sheaves (including the idler sheaves) require maintenance at the intervals
specified in the Periodic maintenance schedule. The sheave maintenance is the
following:
x Remove caked wire grease from the sheaves.

x Check visually for cracks in sheaves.
x Check nuts, fasteners and support beams.
x Check the bearing wear and slackness by the lateral arc movement of the
sheaves.
x Verify that the sheaves rotate freely.
x Measure and log the wear of the sheave grooves. (See below.)
x Lubricate according to the Lubrication section.
Definition: X = outer diameter of the support wires. This diameter is stated in the
Product Data Sheet document and/or at the wire sheave assembly drawings.
Wear of sheave grooves

Groove diameter
The maximum acceptable groove diameter =
X+14%. The minimum acceptable groove
diameter is X+4%. For easy measuring there has
to be made (by user) gauge rings marked with the
wire diameter plus the % increase of diameter. 8
rings must be available, marked with the diameter
plus: 2%, 4%, 6%, 8%, 10%, 12%, 14% and 16%.
The gauge rings should be kept in toolpusher’s
office. The result of the measurements must be
logged in the maintenance log.
If a sheave bearing becomes excessively slack or Wire diameter (X)

no longer rotates freely, the sheave requires
overhaul maintenance. In that case shut down the
belonging pair of diametrically opposite tensioners
(the rest of the system may continue operating
normally), and unload the sheave. If the bearing
cannot be tightened where it is, remove the entire
sheave and service it at the workshop. There
dismantle, clean, inspect, lubricate, reassemble
and tighten the bearing. If the bearing is too worn
to reuse, change the entire bearing. Then reinstall
the sheave.
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5.14 Pressure relief valve maintenance

Drawing: Detail “A” Schematic, Flow Diagram (H1003)
Working APVs, Flow Diagram (D1157-H1008)
The pressure relief valves on the HP accumulator and the APVs are of different types
and must not be mixed. The different maintenance procedures are described below.
HP accumulators
Each HP accumulator is equipped with a pressure relief valve as shown in the
illustration below. The opening setpoints can be found on the belonging flow diagram.
Pressure relief valve on HP accumulator
The opening setpoint of each valve is to be checked yearly, preferably in a test bench,
and the setpoint adjusted (or valve changed) if necessary.
The valve adjustment takes place as follows:

x Use ear and eye protection
x Disassembly:
1. Break the thread seal
2. Unscrew the top screw cap
3. Loosen the lock nut
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x Adjusting:
1. Apply pressure and adjust the adjusting screw until the opening pressure
is just correct
2. Depressurize
x Assembly:
1. Lock the lock nut
2. Reinstall the screw cap
3. Reinstall the lock wire and seal the wire
x Write down the adjustment in the maintenance log

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APVs
Each working APV is equipped with a pressure relief valve as shown in the illustration
below. The opening setpoints can be found on the belonging flow diagram.
Pressure relief valve on APVs
The valve maintenance takes place as follows:

x Use ear and eye protection
x Pressure venting:
1. Make sure that the main isolation valve is closed before relieving the APV
from all pressure, according to the Operating Instructions
2. Vent all pressure from the APV
3. Remove the valve from the APV
x Dissasambly:
1. Break the wire lock seal
2. Remove the setscrew cover
3. Unlock locking nut
4. Turn setscrew fully counter clockwise
5. Loosen the spring housing
6. Remove spring housing, set spring, spring guide (2x)
7. Remove valve housing
8. Remove seat
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x Inspection of disassembled parts:

1. Replace damaged parts
2. Make sure the valve is smoothly guided through the valve housing
x Assembly precautions:
1. Components must be handled carefully
2. Components must be reassembled on a test bench with all the usual facilities
available
3. New O-rings of the correct specification must be fitted on re-assembly
4. Use the correct lubricants
5. Carry out pressure leak test after re-assembly and before re-setting the relief
valve
6. All components must be clean and dry before assembly
x Assembly:
1. Reassemble the valve by reversing disassembly instructions
x Recommended torque for all threads:

1. Spring housing to housing: 100Nm
2. Cap to spring housing, 30 Nm
x Write down the adjustment in the maintenance log

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5.15 Bolt torque and secondary retention

The table below lists recommended torque values for bolts commonly used in equipment
from National Oilwell Varco Norway. More precisely, the table applies for steel bolts with
hexagonal heads and course metric threads. Before assembly the fastening connection,
the bearing surface, the bolt / stud and nut threads must be lubricated with a MoS2
(molybdenum sulfide grease). NOVN shall apply MOLYKOTE® G-RAPID PLUS paste. If
a bolt originally had any type of secondary retention, the secondary retention must be re-
established after the tightening.
TIGHTENING OF BOLTS
ALL BOLTS LUBRICATED WITH
MOLYKOTE® G-RAPID PLUS
Size Torque [Nm]
Black / tZn (HDG) Stainless Steel
Thread Pitch
Property Class Property Class A
d [M] P[mm] 8.8 10.9 70 80
M8 1,25 20,6 28,4 15,4 19,8
M 10 1,5 40 56 30,8 40,7
M 12 1,75 70 98 52,8 70,4
M 14 2,0 110 156 84 112
M 16 2,0 169 238 130 173
M 18 2,5 237 332 180 240
M 20 2,5 331 465 252 337
M 22 2,5 445 626 339 453
M 24 3,0 572 804 436 581
M 27 3,0 826 1161 630 840
M 30 3,5 1127 1582 859 1146
M 33 3,5 1522 2133 1155 1543
M 36 4,0 1961 2761 1497 1995
M 39 4,0 2520 3543 1922 2560
M 42 4,5 3130 4395
Note:
Stainless steel Material Property Class 50 shall not be used; Material Property Class 80
may be used. Preferred property class in A4 is 70 which is the international available
trade property.
Black steel / tZn Material Property Class 4.6, 5.8 and 12.9 shall not be used by NOVN!
Only the given Property Classes shall be used!
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6 CORRECTIONS AND MINOR REPAIRS

This section describes how to carry out a selection of corrections and minor repairs.
User is not supposed to carry out corrections or minor repairs other than those
described below. User is however welcome to contact supplier’s service department to
discuss any corrections and repairs. If authorised by the service department, work
permits and procedures will be issued as required.
6.1 Checking for air leaks

No air is vented from the tension system during normal system operation.
If one diametrically opposite tensioner pair repeatedly appears to be carrying a lower

load than the others (significantly lower tension read for this pair at the control panel),
an air leak is likely to be the cause.
To find the leak it is recommended to use soap water. Apply the soap water to all pipe
connections and fittings belonging to this pair of cylinders, including piping at the air
control skid. When the leak is found, deactivate this pair as described in the Shutting
down pair of tensioners section in the Operating Instructions. The system operation can
continue without interruption.
Repair the leak while the involved piping is fully depressurized. After the repair, return
the tensioner pair to service as described in the Returning pair of tensioners to
operation section (in the Operating Instructions). Procedure points that are known to be
OK or not applicable can be omitted.
6.2 Checking for fluid leaks

Leaks in the tensioner fluid system are most typically detected by unexpected pressure
drop in a pair of diametrically opposite tensioners. This pair will then carry lower tension
than the other pairs. (The pressure drop may also be caused by air leaks, as described
above.)
Check visually for leaks at the tension cylinders. The cylinder rods are lubricated by
tensioner fluid, and as the rods are retracted and out, a thin fluid film should normally be
visible on the rod surface. If the rod is wetter than this, and fluid is seen running down
the cylinder casing, the sealing inside the cylinder is worn. In that case the entire
cylinder must be repaired or changed, and supplier must be contacted. Tension
cylinders shall not be repaired on board.
If leaks are suspected, check the fluid levels as described in the Checking fluid level in
HP accumulators section.
Also check the fluid level in the drain tanks. High level here is most likely just caused by
the late resetting of the anti-recoil valves.
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6.1 Cylinder position sensor
Each tension cylinder is equipped with a position sensor of the FSG Rope Length
Transmitter type. The sensor measures the cylinder stroke and transmits an electric
position signal to the WRT system’s control system.
The position sensor is housed in a stainless steel box as

shown in the photo below. The box is installed at the front
end of the cylinder’s HP accumulator, next to the cylinder’s
front end (and moving) sheave house.
The inside sensor is (from the left) composed of encoder,
drum unit, and pull-back spring housing.
The drum contains 10.2 m of OD 1.35 mm steel wire rope
which exits below the drum.
During installation the rope is pulled out of the box and the ring is hooked to a bracket at
the cylinder’s front end sheave house. See illustration above with arrow at the bracket.
When the cylinder later is extended, the rope will be paid out accordingly.
Bracket
Rope ring
Typical position sensor box for tension cylinder

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Cross-section of typical drum unit.
Junction box
Encoder Drum unit Spring housing
Nuts for mounting plate
Inside sensor box, from Left: Encoder, drum unit, spring housing and junction box (black box).
4x nuts M8 for mounting plate.
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The wire rope is subject to wear, and when getting splintery, damaged or broken it must be
replaced by a new drum unit of the original type.
6.1.12 Disassembly and assembly of encoder and drum unit
Pos Description
1 Screws for mounting the adapter
2 Screws for mounting the encoder
3 Coupling
4 Round ring in the adapter
5 Adapter
6 Encoder
7 Drum unit
8 Spring housing
9 Bellow
10 Screws for mounting the bellow
11 Lock ring/ Plug socket
12 Pulley
13 Wire
14 Brush
15 Ring eye
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6.1.13 Disassembly and assembly of the encoder

- Remove 4x cylinder screws (1) between adapter and rope length mechanic (partially
difficult to access).
- Pull Encoder (6) and Adapter (5) backwards.
- Measure and note the distance of the coupling disk to the end of the shaft. This
measurement is used to define correct encoder in case of replacement.
Encoder series Measured distance

SL30…/GS80 10mm
SL30…/GS130 8,2mm
SL30…/GS190 8,2mm
- Remove 3x cylinder screws (2) of the encoder.

- Remove coupling (3) of the old encoder.
- Mounting in reverse order
The coupling must be mounted in the same position as before (5).

When replacing encoder in position again please ensure that
coupling elements fit exactly).
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6.1.14 Mechanical disassembly and assembly of the drum unit:

- Pull out the wire (13) with bellow (9) approx. 20 cm.
- Loosen and remove 2x cylinder screws M3 (10) on the flange of the bellow.
- Loosen and remove the Lock ring 15mm / plug socket (11) at the wire outlet of the box.
- End of measuring wire/ring eye (15) to be returned carefully to box outlet (to be guided
around the pulley and through the brushes (14)).
- Remove 2x hexagon screws M6 (12) of the pulley traverse and remove the traverse.
- End of measuring wire to be threaded into the box inlet. Rewind it carefully up to wire
outlet at wire mechanism.
- Disconnect the black connection cable and if necessary the protective conductor from
the customer.
- Open the cable anchorage (cable straps).
- Loosen 4x nuts M8 (orange rectangles on picture “Inside sensor box”) on the mounting
plate.
- Lift up the complete mounting plate.
- Remove the encoder as described in chapter 1.1.1.
Mounting must be done according to above illustration (wire

outlet on top). When mounting this way the wire cannot jump off
the drum.
- Remove protective conductor at the drum unit (screw M4)

- To loosen the drum unit loosen and remove the rear cylinder screws M8
- Mounting is done in reverse order (please note: the wire outlet of the drum unit must
align with the wire outlet of the box)
- Pull out the wire completely at least two times to make sure the spring is working.
Never release the rope after pulling it out. Free back-running wire
will damage the device and there is also a danger of injury.
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6.1.15 Mounting wire rope to the front sheave house

- Pull out the rope by the ring and fasten it to the bracket at the tension cylinder’s front
sheave house shown in the image at the beginning of this chapter.
To prevent damage of the measuring wire, the following handling instructions

must be observed:
1. Never release the rope after pulling it out. Free back-running wire will damage
the device and there is also a danger of injury.
2. Don´t pull the wire directly. The wire may be bent and this will cause trouble in
the pull-back mechanism.
3. Don´t pull the wire along of edges. The wire will be damaged.
- At the Cyberbase, or at the local control panel, the reference position of the position
indicator (encoder) must now be reset as described in the Operating instructions.
- Verify correct position indication at the local control panel and at the Cyberbase.
- At the Cyberbase operator station, re-enable the position sensor by un-checking the
Disabled for Maintenance, Position checkbox at the Tensioner display for this tensioner.
- Return the tensioner to normal operation as described in the Operating Instructions.
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7 MAJOR REPAIRS AND MODIFICATIONS

All major repairs and modifications must be discussed with and approved by supplier’s
service department before the work can start. The service department will involve
supplier’s design engineers as necessary, and a conclusive report and proposal will be
issued.
8 MAINTENANCE NOT NORMALLY DONE BY USER

The repair/modification work listed below shall specifically not be carried out by user
without approval and instructions from supplier’s service department. The list is not
exhaustive, and the general rule is still that maintenance/repair not described in the
Maintenance Instructions requires supplier approval before being carried out.
x Adjustments, repairs and replacements of parts belonging to the tension cylinders.
x Adjustments, repairs and replacements of mechanical, electrical, or hydraulic

components with load carrying or safety functions.
x Adjustments, repairs and replacements of components sealed by the supplier.
x Reprogramming the PLC.

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9 FAULT FINDING
In the case of malfunction, try the following solutions before contacting supplier’s service
department:
Fault Solution
x General fault. x Check detailed alarm info at the alarm
displays.
x Check all fuses.
x Check/retighten all terminal blocks and
other electrical connection points,
including earthing.
x A tension cylinder is locked. x The anti-recoil valve has been activated

due to high speed, possibly due to wire
break. See the Wire breaks section in
the Operating Instructions.
x An anti-recoil valve is not x Check out by running a test sequence

opened fully after the RARS on the valve. (See the Description of
recoil mode is reset. controls section in the Operating
Instructions.)
x Change clogged filters (3 of) on the
anti-recoil valve.
x The total riser tension is low. x Increase the working air pressures.
x One tensioner carries lower x Check and tighten air leaks.
load than the others. x Check and tighten fluid leaks.
x Reset the reference position of the
position sensor for this cylinder. (See
procedure at the description of the
Reset Position R-button in the
Operating Instructions.)
x A tension cylinder cannot be x Check the fluid level in the HP
fully extended (during accumulator, and add fluid as
testing, while the system is necessary.
unused). x Reset the reference position of the
position sensor for this cylinder. (See
procedure at the description of the
Reset Position R-button in the
Operating Instructions.)
x The compensation stroking x Adjust the working length of the support
of the tension cylinders does wires (distance between riser and wire
not take place around mid- anchor). See more info in the Changing
stroke. the support wires section.
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10 STORAGE AND PRESERVATION

Preserve the equipment as follows if it, after it has been taken into use, will not be used
for more than a month / four weeks:
x Before the storage, test the operation of each anti-recoil valve by running a test
sequence four or five times. The test sequence is explained in the Description of
controls section in the Operating Instructions.
x Verify that the entire system is shut down as described in the Operating Instructions.
(All tension cylinders must be fully retracted.)
x Clean all dirty parts of the equipment, and allow it to dry.
x Go through the lubrication charts, and verify that the equipment is well lubricated.
x Apply a coating of anticorrosion oil on all unpainted surfaces, except the cylinder
rods. Coat the support wires with grease.
x Fill the HPA 100% with hydraulic fluid. If the HPA has a piston, fluid can be added on
top of the piston to evacuate all air from the HPA.
x Verify that the equipment is protected against mechanical damage, and arrange
suitable protection as necessary.
x Verify that unauthorized personnel have no access to the equipment.
x Every three months of storage:

check the preservation
x Every 12 months of storage:

test the operation of the anti-recoil valves
Before starting up the WRTS after storage, make sure that the fluid level in the HPAs
are calibrated according to section 5.10 Checking fluid level in HP accumulators.
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11 SPECIAL TOOLS
No special tools are supplied or required for user maintenance.
12 SPARE PARTS
Please refer to Spare parts lists in the user manual.
Only original spare parts ordered through National Oilwell Varco (NOV) must be used,
as modifications may have been performed by NOV on standard parts. Non-modified
parts may interfere with the original performance. Use of non-modified parts will also
influence the terms of warranty.
13 LUBRICATION CHARTS
The following lubrication charts are attached in the manual’s Procedures section, and
form an integrated part of the maintenance instructions:
x L6764-D1105-L2504 Lubrication Chart, Wireline Riser Tensioners

x L6764-D1105-L2505 Lubrication Chart, Wireline Riser Tensioner Idlers
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14 MAINTENANCE RECORD FOR WIRELINE RISER TENSIONER SYSTEM
14.1 Bi-Weekly Maintenance

Equipment: Riser Tensioner Cylinders, High Pressure Accumulator, Fixed Sheave House,
Front Sheave House, Working APVs.
Record page 1 of 4
Period: From: To: Date & Initials
Activity Interval
Description 1 2 3 4 5 6 7 8 9 10 11 12
No. (weeks)
Clean and lubricate the rods of the tension cylinders as described in
1 2
the Lubrication section.
Check the fluid levels in all HP accumulators as described in the
Checking fluid level in HP accumulators section. After reliable
2 2 operation is proved through field experience (after minimum four weeks
of normal operation), this point can be transferred to the 6-monthly
maintenance routine.
Performed by: Accepted by:
Date/Sign: ________________________________ Date/Sign: ________________________________
Maintenance log must be sent to NOV address RS-NOR-RecordReceive@nov.com every 12 months.
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14.2 Monthly Maintenance

Record page 2 of 4
Year: Month & Initials
Activity Interval
Description 1 2 3 4 5 6 7 8 9 10 11 12
No. (months)
Clean and lubricate the rods of the tension cylinders as described in
3 1
the Lubrication section.
Test the operation of each anti-recoil valve by running a test
4 1 sequence four or five times. The test sequence is explained in the
Description of controls section in the Operating Instructions.
Keep the equipment clean. Touch up any paint damage. Keep all
5 1
other unpainted metal surfaces covered by suitable anti-corrosion oil
Grease the support wires and clean and lubricate the cylinder rods as
6 1
described in the Lubrication section.
Test the operation of each anti-recoil valve by running a test
7 1 sequence four or five times. The test sequence is explained in the
Description of controls section in the Operating Instructions.
Take a sample of the tensioner fluid in one half of the cylinders, and
check (by the on-board particle counter) that the fluid purity satisfies
ISO 4406:99, Class 19/17/14. See more details in the Checking
purity and chemical properties of tensioner fluid section. If no
8 1
abnormalities are observed the first six months of operation, this
point may be transferred to the 3-monthly maintenance routine and
combined with the laboratory sampling.
Check the fluid drain tanks (two tanks at each fixed sheave house).
Verify that the breather filter is in place, and write down the fluid level
in the tank. Compare the fluid level with earlier recordings and with
the recordings from the other drain tanks to spot any abnormalities.
Drain the tank manually if it is more than half full. If a tank remains
9 1 empty for a longer period; inspection of the anti-recoil valve and pipe
lines is needed. The drain tank fluid volume equals the leakage from
the HP accumulator and can be used to decide if fluid needs to be
added on the HP accumulator (at the underside of the accumulator
piston).
NOTE: This table continues on the next page

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14.3 Monthly Maintenance (cont.)

Record page 3 of 4
Year: Month & Initials
Activity Interval
Description 1 2 3 4 5 6 7 8 9 10 11 12
No. (months)
Drain to safe location all working APVs by opening each APVs drain
10 1 valve for a short while. Use ear and eye protection during the
draining. Careful, the APVs are pressurized!
Take a sample of the tensioner fluid in one half of the cylinders, and
11 3 have it analyzed by a laboratory. See more details in the Checking
purity and chemical properties of tensioner fluid section
Change the elements of the three small filters on each anti-recoil
12 3 valve as described in separate section. After the first half year of
operation, this point only needs to be carried out 6-monthly.
Maintain the wire sheaves as described in the Sheave maintenance
13 3
section.
At the APVs, check that the quality of the air supplied from the
14 6 compressors satisfies ISO 8573-1, Class 3.3.3. See Checking the
quality of the air section for procedure.
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14.4 Yearly Maintenance

Record page 4 of 4
Year: Year & Initials
Activity Interval
Description 1 2 3 4 5
No. (years)
15 1 Wash the entire equipment thoroughly and allow it to dry.
Perform all the routine inspections listed in the Routine inspections
section and complete an inspection report. A signed copy of the
16 1
inspection report must be filed in the maintenance log, and the
remarks must be followed up.
Test the opening setpoint of the pressure relief valve on top of each
HP accumulator as described in the Pressure relief valve
17 1
maintenance section. Verify that the valves are clean and in good
working condition. Write down the results in the maintenance log.
Maintain the pressure relief valve on each working APV as described
18 1
in the Pressure relief valve maintenance section.
Check/retighten all terminal blocks and other electrical connection
19 1
points, including earthing.
Check for moisture inside all outdoor junction boxes and panels. Add
20 1
new drying agent as required.
Check the condition of the oily Denso tape fitted to protect the fluid
21 1 tubing fittings against corrosion. If the tape is drying out, soak it with
hydraulic oil to maintain the corrosion preventing effect.
At the fluid drain tanks (two tanks at each fixed sheave house),
22 2
change the breather filter
Change all support wires, unless they have been changed the last
23 3 three years, due to wear, damage or corrosion. See more info in the
Changing the support wires section.
Change all hydraulic hoses. Only hoses of the original type must be
24 5
used. Change all fluid fill/drain hoses.

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Maintenance Instructions

Wireline Riser Tensioners

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

0 25-Nov-2015 For Information KVTR ANMO JABK

Revision Change description

1 MAINTENANCE INSTRUCTIONS .................................................................................... 5

5.15 Bolt torque and secondary retention ..................................................................... 48

3D Model of Beacon Pacific with the WRT-system enhanced.

A warning contains essential information related to potentially hazardous

A caution contains essential information related to potentially hazardous

A note contains essential or useful information related to conditions, procedures,

The following points summarize the safety aspects related to maintenance:

x Qualified personnel are defined as individuals with characteristics or abilities gained

x A maintenance warning sign must be placed in driller’s cabin before maintenance is

x Use ear protection while bleeding down air pressures.

x No welding of lugs, brackets etc. must take place on the equipment.

3.1 Daily inspections

3.2 Weekly inspections

3.3 Monthly inspections

4 PERIODIC MAINTENANCE SCHEDULE

4.1 Follow-up of inspections

4.2 Maintenance routine after first 100 operating hours

4.3 Lubrication routine

4.4 2-weekly maintenance routine

4.5 Monthly maintenance routine

x Touch up any paint damage.

x Grease the support wires as described in the Lubrication section.

4.6 3-monthly maintenance routine

x Touch up any paint damage.

x Maintain the wire sheaves as described in the Sheave maintenance section.

4.7 6-monthly maintenance routine

4.8 Yearly maintenance routine

4.9 2-yearly maintenance routine

4.10 3-yearly maintenance routine

4.11 5-yearly maintenance routine

5 PERIODIC MAINTENANCE PROCEDURES

5.2 Checking the quality of the air

The procedure is as follows:

Block and bleed valve on working APV

5.3 Type and quantity of tensioner fluid

Fluid quantity per HP accumulator: Approx. 490 litres

Total system fluid quantity: Approx. 3920 litres (= 490x8)

Required fluid purity: ISO 4406:99, Class 19/17/14

Fluid operating pressure: Max 207 bar

5.4 HP accumulator illustrations

Vent valve HPA

Safety relief valve

Bypass needle valve

Air inlet valve

Bottom view of cylinder & accumulator assembly

Sectional view of HP accumulator

5.5 Checking purity and chemical properties of tensioner fluid

The fluid analysis may have three different results:

x The fluid is OK. No further action is needed.

Taking samples from the cylinders:

1. Starting point: The system operates normally

5.6 Houghton recommendation

5.7 Overview of fluid fill unit

FFU with the main tank and LP filling pump.

Flow diagram of Fluid Fill Unit (G6764-D1112-H0011)

5.8 Cleaning fluid in HP accumulators

Draining the HP accumulators