OP-7847.18-001 Volume II Rev X0

F&G Doc. No.: OP-7847.
18-001
Revision X0 (Final As-Built)
28 May 2014
F&G VFD-750 Jacking System

Operations Manual
Volume II
Maintenance
Dalian Shipbuilding Industries Co.
Hull JU2000E13
Friede & Goldman Ltd.

Project 7847.18
JACKING SYSTEM
OPERATIONS MANUAL
VOL II - MAINTENANCE
Tasha
FOR FRIEDE & GOLDMAN
MAY 2014
GMH-7766-3113 | REVISION 0
Table of Contents
Document Details
1. INTRODUCTION ....................................................2
Report Title
1.1 PURPOSE ......................................................................................2 JACKING SYSTEM OPERATIONS
1.2 RIG PARTICULARS .......................................................................2 MANUAL VOL II - MAINTENANCE
1.3 REFERENCE DOCUMENTS ..........................................................2 Author

N. Kyser
1.4 ABBREVIATIONS ...........................................................................3
GM Doc. No.
1.5 WARRANTY/CONTACT DETAILS..................................................3 GMH-7766-3113 | REVISION 0
File Name
2. SAFETY PRECAUTIONS .......................................4
GMH-7766-3113_REV 0 7847-JACKING
2.1 OVERVIEW ....................................................................................4 SYSTEM MAINTENANCE MANUAL
28MAY2014 - FNG.DOCX
2.2 GENERAL NOTES .........................................................................5
Issue Record
2.3 GENERAL CAUTIONS ...................................................................5
Date Rev Checked Approved
2.4 GENERAL WARNINGS ..................................................................6
28May2014 0
3. JACKING UNIT/JACKING FRAME ........................7
3.1 GENERAL ......................................................................................7
3.2 JACKING FRAME .........................................................................10
3.3 MAINTENANCE INTERVALS .......................................................10
4. GEARBOX............................................................11 Notes
4.1 CHECKS PRIOR TO FIRST OPERATION AND AFTER LONG-

TERM STORAGE .........................................................................11
4.2 DAILY CHECKS............................................................................12
4.3 MAINTENANCE INTERVALS .......................................................12 These materials are the Work Product of
American Global Maritime. No reliance on
4.4 LUBRICATION..............................................................................13
this work product is authorized by
4.5 TROUBLESHOOTING ..................................................................15 American Global Maritime. American
Global Maritime accepts no liability for any
4.6 ASSEMBLY AND DISASSEMBLY ................................................17 reliance by any person on the work
4.7 HELICAL STAGE PARTS LIST .....................................................19 product contained herein.
4.8 PLANETARY STAGE PARTS LIST ..............................................20 © This document is the property of
American Global Maritime Consultancy Ltd
4.9 GEARBOX RECOMMENDED SPARE PARTS .............................21 and is not to be copied, nor shown, to third
parties without prior consent.
5. DRIVE SYSTEM COMPONENTS .........................23
5.1 PREVENTIVE MAINTENANCE.....................................................23
5.2 GENERAL GUIDANCE FOR MAINTENANCE ..............................24
5.3 MOTORS/BRAKES/ENCODERS/BRAKE RESISTORS................24
5.4 PLC, VFD, AND TOUCHSCREEN HARDWARE/SOFTWARE ......25 American Global Maritime Inc.
11767 Katy Freeway Suite 660
5.5 2-YEAR RECOMMENDED SPARE PARTS ..................................26
Houston, Texas 77079
USA
APPENDICES................................................................30
Telephone: +1 281-558-3690
Fax +1 281-558-0541
www.globalmaritime.com
APPENDIX I
CALTEX MAROPA 320 OIL SPEC SHEET
APPENDIX II
E&I COMPONENT DATASHEETS
APPENDIX III
INCREMENTAL (SPEED) ENCODER MAINTENANCE
APPENDIX IV
SOFTWARE RESTORATION PROCEDURES
Figures
FIGURE 3-1 JACK UNIT HELICAL/PLANETARY STAGE CROSS-SECTION ...7
FIGURE 3-2 HELICAL STAGE CROSS-SECTION ............................................8
FIGURE 3-3 PLANETARY STAGE CROSS-SECTION ......................................8
FIGURE 3-4 JACKING UNIT DIMENSIONS ......................................................9
FIGURE 3-5 GEARBOX/SHIM RETAINER BOLT TORQUE ..............................9
FIGURE 4-1 LUBRICATION DIAGRAM ...........................................................14
FIGURE 4-2 HELICAL STAGE PARTS DIAGRAM ..........................................17
FIGURE 4-3 PLANETARY STAGE PARTS DIAGRAM ....................................18
Tables
TABLE 1-1 RIG PARTICULARS ........................................................................2
TABLE 3-1 JACKING UNIT/JACKING FRAME MAINTENANCE INTERVALS .10
TABLE 4-1 GEARBOX OPERATIONAL TEST CHECKLIST ............................11
TABLE 4-2 GEARBOX DAILY CHECKS ..........................................................12
TABLE 4-3 GEARBOX MAINTENANCE INTERVALS .....................................12
TABLE 4-4 TROUBLESHOOTING I.................................................................15
TABLE 4-5 TROUBLESHOOTING II................................................................16
TABLE 5-1 MAINTENANCE INSTRUCTIONS .................................................23

Document Issue Record
Revision Date Section(s) Page(s) Brief Description of Change Author of

Number Change
0 28May2014 Original Issue to Client NRK
INTRODUCTION
JACKING SYSTEM OPERATIONS MANUAL VOL II - MAINTENANCE
GLOBAL MARITIME | GMH-7766-3113 | REVISION 0
ISSUED FOR FRIEDE & GOLDMAN 1
1. INTRODUCTION
1.1 Purpose
This maintenance manual provides procedures and information to maintain the jacking
system of the Tasha drilling jack-up. Volume I (Operations) contains all necessary
system information, hardware descriptions, functional specifications, and procedures to
operate the Tasha jacking system. Volume II (Maintenance) and Volume III
(Installation) contain necessary information for proper maintenance and installation of
the jacking system, respectively. In the event of possible or apparent conflict between
elements of this manual or with elements of other manuals, F&G should be contacted.
1.2 Rig Particulars

Rig Name Tasha
Builder: Dalian Shipyard, China
Year Built: 2013
Class: ABS
Classification: A1 Self-Elevating Drill Unit
Table 1-1 Rig Particulars
1.3 Reference Documents

Document No. Document Name
GMH-7766-3113 Vol I Jacking System Operations Manual
GMH-7766-3113 Vol III Jacking System Installation Manual
INTRODUCTION
1.4 Abbreviations
ABS American Bureau of Shipping
AC Alternating Current
BCU Brake Chopper Unit
CCC Central Control Console
CSV Comma Separated Values
DSIC Dalian Shipbuilding Industry Offshore Company
EDS Electrical Drive System
FWD Forward
GA General Arrangement
GUI Graphical User Interface
IGBT Insulated Gate Bipolar Transistor
I/O Input/Output
LCC Local Control Console
LED Light Emitting Diode
LT-LCC Load Transfer-Local Control Console
MCC Motor Control Center
PLC Programmable Logic Controller
RPD Rack Phase Differential
RPD-LCC Rack Phase Differential-Local Control Console
RPM Revolutions Per Minute
STBD Starboard
UVA Under-Voltage Assembly
VCMS Visual Content Management System
VFD Variable Frequency Drive
1.5 Warranty/Contact Details

Terms of the warranty are covered in the contract No. DSIC-JU2000E13-PO-004
signed between Dalian Shipbuilding Industry Offshore Co. and Friede & Goldman
Marketing B.V. on 30 June 2012.
For Service Requests, contact:

Friede & Goldman LLC
10375 Richmond Ave., Suite 1600
Houston, Texas, USA 77042
Phone: + 1-713-952-3444
Fax: + 1-713-952-3443
www.fng.com
INTRODUCTION
2. SAFETY PRECAUTIONS
2.1 Overview
This section summarizes various health, safety, and environmental precautions that
should be followed during operation of the jacking system. Precautions related to
specific hardware or operations are included in the relevant sections of this document.
The following symbols are used throughout this operations manual:
Provides supplemental information to advise the operator of ways in

which specific tasks or operations can be completed.
Note
Possible damage to the jacking system, components, or the

environment may occur if the operator does not follow instructions
carefully.
Caution
Possible serious injury to personnel or catastrophic damage to the

jacking system may occur if the operator does not follow instructions
carefully.
Warning
Care has been taken with the design of the products described herein to ensure that
they are safe. However, in common with all products of these types, misuse can result
in injury or death. Therefore, it is critical that the instructions in this manual and on the
products themselves are observed at all times.
This Maintenance Manual should be considered as part of the product. It should be
stored with the product and passed on to any subsequent user or owner. Local safety
laws and regulations must always be observed. Persons working on the products
described herein must be suitably skilled and should have been trained in that work for
these products.
SAFETY PRECAUTIONS
Product approvals and certifications will be invalidated if the product is transported,
used, or stored outside its ratings or if the instructions in this manual or attached
manuals are not observed.
2.2 General Notes

 This instruction manual should be distributed to all personnel operating
or maintaining the jacking system.
 Ensure that all instructions are read and clearly understood.
 Ensure that personnel comply with all relevant rules and regulations
regarding health, safety, and the environment.
 Maintain the jacking system, spare parts, machinery, and tools as
described in this manual.
 Maintain a log, noting and dating all inspections, maintenance, repairs,
and adjustments.
 Maintain a log, noting and dating any failures, including cause of failure
Note and corrective actions taken.
 Use solvents sparingly. Use of non-recommended solvents can cause
damage to parts.
 Only use recommended lubricants, tools, and test equipment (or
permitted alternatives).
2.3 General Cautions

 Only use the jacking system for its intended purpose and within
specified operational limits.
 Personnel authorized to operate or maintain the jacking system must be
qualified to perform their respective tasks.
 Personnel are obligated to operate the jacking system with due caution.
 Lubricants, solvents, or other chemicals harmful to the environment may
never be discarded overboard.
 Old lubricants must be handled in a manner consistent with applicable
environmental legislation.
Caution  Personnel must operate machinery and handle tools/dangerous
materials in a professional and correct manner.
 Personnel should never modify, bypass, or remove safeguards from the
machinery.
 This manual only addresses maintenance of the jacking system. For
maintenance of other system components please refer to the
appropriate documentation.
SAFETY PRECAUTIONS
2.4 General Warnings
 Modifications to the system shall only be made by the manufacturer.
Only genuine replacement parts approved by the manufacturer shall be
used.
 Unauthorized modifications to the system and/or use of spare parts not
approved by the manufacturer will immediately void any warranties and
disclaim responsibility by the manufacturer in the event of damage or
accident.
 Recommended/mandated safety equipment should always be worn
when performing operations, maintenance, and repairs.
 Verify personnel are not present within danger zones around moving
parts when the jacking system is in operation.
 Never work on, or in the vicinity of, moving parts unless it is impossible
to perform the task by alternate means.
Warning  Always verify proper lockouts are in place during maintenance and
repair of the jacking system.
 Always re-install safety covers/devices prior to operational checks of
hardware that has undergone maintenance or repair.
 In the event of suspected accidental loading above design loads (e.g.
punch through), the system should immediately be inspected for
damage before continuing the operation.
 If damage to the jacking system is observed, operations must be
discontinued until the defective part(s) are repaired/replaced or after
approval from Class and/or the manufacturer.
SAFETY PRECAUTIONS
3. JACKING UNIT/JACKING FRAME
The rack must be greased at all times when jacking system is operational.
Warning
3.1 General
Each jacking unit consists of an electric variable speed motor, gearbox, brake
assembly, and pinion. The jacking unit is designed to be removable from the
supporting frame as a single unit. Static loading will deteriorate the bearings of the
jacking units. To achieve the life expectancy of the bearings, the jacking system should
be briefly run every 6 months.
Figure 3-1 Jack Unit Helical/Planetary Stage Cross-Section
JACKING UNIT/JACKING FRAME

Figure 3-2 Helical Stage Cross-Section
Figure 3-3 Planetary Stage Cross-Section

Figure 3-4 Jacking Unit Dimensions
The gear retainer bolts, shim retainer bolts, and shims are supplied with each jacking unit.
Correct tightening torque on all bolts should be checked at regular intervals.
Figure 3-5 Gearbox/Shim Retainer Bolt Torque

3.2 Jacking Frame
The jacking frame requires an annual visual inspection of the condition of the frame
guides and for paint damage to any structure/component. Cables and connections for
grounding terminals must be checked regularly to ensure they are secure, and if
necessary, secured/tightened. Cabling should also be checked for any defects.
Defective parts must be replaced immediately.
3.3 Maintenance Intervals

The table below provides an overview of required maintenance and associated intervals
for the jacking units and jacking frames.
Component Action Interval Document
Jacking Unit Static load run Semi-annually
General Overall Annually
inspection,
including painted
surfaces
Rack/Pinion Greased Each lowering/lifting
throughout the
jacking operation
Pinion Sliding Bearing Each nipple: one Each lowering/lifting
stroke of grease
Jacking Frame Check cable and Semi-annually
ground terminals
Jacking Frame Guides Check wear and Annually
bolt torque
Table 3-1 Jacking Unit/Jacking Frame Maintenance Intervals

4. GEARBOX
 Ensure that all motion of the gearbox has ceased and

power has been removed from the unit prior to beginning
maintenance.
Warning  Inspection covers should not be removed while the
gearbox is in operation. Hot oil can be ejected from the
unit, causing severe burns.
 Gearboxes will be extremely hot after operation, caution

should be exercised when handling.
 If maintenance is to occur immediately following operation, a
2 hour wait period should be observed to allow adequate
Caution time for the gearbox to cool.
 Always ensure that all tools are accounted for after
maintenance/repairs prior to resuming gearbox operation.
4.1 Checks Prior to First Operation and After Long-Term Storage
 Verify that the gearbox is correctly connected to the jack case

 Check that mounting bolts are properly tightened
 Check that the revolution of the pinion is correct for the direction of lifting/lowering
After completing the above checks, operate the gear unit with no load, slowly
increasing load, while completing the checklist provided below. In the event any
issues are found, stop operations and contact the gear unit sales team or the office.
Operational Test Checklist

Is the mounting surface twisted?
Is there any abnormal Is the strength of the mounting structure short?
noise or vibration? Is there resonance?
Is the vibration of the main body transmitted to the gear unit?
Is the surface Does the motor current exceed the rated current specified on
temperature of the the nameplate?
gear unit abnormally Is the voltage of the motor going up and down in relief?
high?
Is the lubricant level appropriate?
Table 4-1 Gearbox Operational Test Checklist
GEARBOX
4.2 Daily Checks
These checks are to be performed on a daily basis during jacking operations.
Check list Details

Abnormal noise Is there any abnormal noise from the gear unit while operating?
Vibration Is there any abnormal vibration of the gear unit?
Surface Is the surface temperature of the gear unit abnormally high

(over 90°C)?
Temperature
Has it increased rapidly?
Oil level Is there any drop in the oil level?
Oil leakage Is there any oil leakage from oil seals of both input side and
output side?
Mounting bolts Do any mounting bolts appear to be loosened?
Table 4-2 Gearbox Daily Checks
If any issue is discovered during the daily checks, corrective action as specified in
Section 4.5 Troubleshooting should be taken. If the issue cannot be readily solved,
contact the manufacturer.
4.3 Maintenance Intervals

Action Interval
Gear oil sample
Annually
analysis
Bolt torque check Annually
Apply grease to
Monthly
all grease points
Periodic use, run
5 min. every 3 months*
gearbox
Table 4-3 Gearbox Maintenance Intervals
* If it is anticipated that the jacking units will not be used for a period of more than 6
months, rust preventative oil should be added to the gearbox.
GEARBOX
4.4 Lubrication
The helical and the planetary stages of the gearbox use the same type and quality of
lubricant.
 Recommended Lubricant: Caltex Meropa 320 (or equivalent)
For further details, see spec sheet in Appendix I
 Quantity: approx. 265 liters (middle line of the upper oil level gauge)
4.4.1 Lubricant Requirements

The oils must be neutral in behavior towards shaft seal elements, non-ferrous metals,
sealing compounds and cements, and protective finishes (on a synthetic resin basis)
generally used in gear construction. The oil should have properties as follows:
 ISO Grade: 320
 AGMA Lubricant No.: 6EP
 David Brown Grade: 12
 Pour Point: -24 °C
 Timken OK Load: 34kg
 Viscosity: 306 mm3/s at 40°C, 23.7 mm3/s at 100°C
 Viscosity Index: 97
4.4.2 Lubricant
For long-life lubrication and/or continuous temperatures in excess of 100°C, synthetic
lubricants may be used such as:
 Great Wall L-CKT 320
 Caltex Meropa Synthetic EP 320
 Shell Omala HD 320
 Mobil Mobilgear SHC XMP 320
If the ambient temperature is outside the limits indicated, a suitable viscosity class
should be selected for the application. Care should be taken to ensure the solidifying
point is not above the minimum startup temperature. Further information can be
obtained from the lubricant manufacturer.
4.4.3 Change of Lubricant
Although the original lubricant is rated for the expected life of the gear unit after the
initial wear-in period, it is recommended that oil samples be taken and analyzed
annually to ensure the oil has maintained its lubrication qualities.
Refer to Figure 4-1 Lubrication Diagram, as a visual aid to the following sections.
GEARBOX
4.4.4 Recommended Lubricant Change Intervals
If there has been an event(s) that has caused rapid temperature
changes or the gearbox has been exposed to corrosive gases, the
lubricant will age more rapidly. This should be considered when
Caution determining the maintenance schedule.
Lubricant should be disposed of in accordance with the relevant

environmental regulations.
Note
Wear-in Period:
 1st Change: After 10 hours of use or 2 months after entering service, whichever
comes first.
 2nd Change: After 100 hours of use or 6 months after entering service, whichever
comes first.
Changes thereafter:
 If continuous lubricant temperature is less than 70°C:
After 100 hours of use.
 If continuous lubricant temperature is greater than 70°C:
After 50 hours of use.
Lubricant should be added through the filler on the top of the gearbox main body.
When changing lubricant, verify the correct level of lubricant has been added using the
oil level gauge. Incorrect oil level can damage the gears and the bearings.
4.4.5 Draining of Lubricant
Lubricant should be drained via the drain plug at the bottom of the gearbox main body
when the lubricant is warm.
Figure 4-1 Lubrication Diagram
GEARBOX
4.5 Troubleshooting
The following tables provide a brief guide to possible troubleshooting in the event an
abnormal condition exists with the jacking unit.
Issue Possible Cause Action

Overload operation Operate with proper load
Adjust it, referring to the scale of the oil
Too little or too much lubricant
level gauge
Replace old or contaminated lubricant with
Defective or improper lubricant
new lubricant
Small bearing gap (taper roller) Adjust the bearing gap
Over-heating
Defective oil seals Replace the oil seals
Ventilation for the motor is interfered. Remove the cause for interference
A single phase is faulty. Check the connection.
Stator coil is damaged Repair

Voltage is not balanced Check the transformer and the circuits
Coil ground issue Check the transformer and the circuits

The shaft is bent Check the center of the shaft
Defective bearing (worn-out, rough) Replace
Friction of parts Disassemble, check, and modify

Regular noise – Defective tooth mesh Replace the gear and the bearings, and
and damaged bearing refill or replace the lubricant
High metal noise - A lack of lubricant Refill or replace the lubricant
Abnormal Noise
Irregular noise (foreign noise) – Input of Remove the foreign object and replace the
foreign object or damaged bearings bearings
The rotor is touched by the stator Repair
The fan is contacting the hood. Repair
3-phase motor is running on one phase. Check the circuit

Component is improperly mounted Check after disassembling, repair and/or
(shaft and gear, flange connecting part) replace
Table 4-4 Troubleshooting I
GEARBOX
Issue Possible Cause Action
Worn-out gears Replace the gears
Foreign objects are found. Remove foreign objects and replace oil
Excessive Vibration
Worn-out and damaged bearings Replace the bearings
Mounting and fixing bolts are loosened. Tighten the bolts

Assembled parts (shaft, gear) are loose. Disassemble to check and re-assemble
The center of the shaft is not straight

Check status of the load and reconnect
(poor balance)
Check bearings, insert washers, and re-

The end-play of the motor is too big
assemble
The case and the connecting part are
Replace
damaged
Damaged oil seals Replace the oil seals
Oil Leaking
Defective packing (connecting part) Replace the packing and re-seal
The oil drain plug is loose Strongly tighten (Teflon tape)

The oil level gauge is damaged or loose Replace
Worn-out output shaft (sealing part) Replace the output shaft
A lack of driving torque Replace driving type or increase capacity

Motor Malfunction
The fuse is cut Verify correct fuse capacity and replace

Short-circuit of coil Repair
Power failure or abnormal power Check the power
Overload Measure the current and check the load

Bearings and parts are caught Reassemble or replace
Table 4-5 Troubleshooting II
GEARBOX
4.6 Assembly and Disassembly
 Defective components must be replaced with components from
the manufacturer.
Caution  Temporary or incorrect exchange of parts can damage the
entire gear unit.
4.6.1 Assembly of Helical Stage

1) Assemble the bearings, gears, and spacers onto their respective shafts as shown
in the diagram below.
2) The assemblies from step 1 should then be positioned into the lower casing.
3) After attaching the upper casing, install the end covers (7, 15, 24), motor bracket
(39), and brake flange (34).
Figure 4-2 Helical Stage Parts Diagram
GEARBOX
4.6.3 Assembly of Planetary Stage (Refer to Figure 4-3)
1) Bearings and accessories should be assembled onto the pinion shaft.
2) Bearings, planetary gears, and accessories should be assembled onto the carrier.
3) The torque flange and ring gear should be installed with the assembly from step 2).
4) The pinion and entire stage should then be assembled.
4.6.4 Assembly of Helical and Planetary Stage
1) Assembled helical stage and planetary stage should be joined.
2) The motor and brake can then be installed.
3) Oil should be added to the level of the gauge, followed by installation of the fill plug
and air breather.
4.6.5 Disassembly
The procedures above should be performed in reverse for disassembly.
Figure 4-3 Planetary Stage Parts Diagram
GEARBOX
4.7 Helical Stage Parts List
GEARBOX
4.8 Planetary Stage Parts List
GEARBOX
4.9 Gearbox Recommended Spare Parts
(These parts are not within the scope of supply. Listing provided for consideration.)
GEARBOX
GEARBOX
5. DRIVE SYSTEM COMPONENTS
5.1 Preventive Maintenance

For serviceable components in the cabinets, maintenance instructions can be found in
the corresponding equipment manuals listed in the table below. It is recommended that
all instructions are reviewed prior to first use of the jacking system and are observed at
all times throughout operation of the system.
Component Document Location

Drive System
VFD Components Volume I, Appendix V-3
Inverters Volume I, Appendix V-3
Chopper Volume I, Appendix V-3

Brakes Volume III, Appendix III
CCC
PLC Volume I, Appendix V-5
Sensors
Leg Height/RPD Encoder Volume II, Appendix II-3
Volume II, Appendix III
Speed/Direction Encoder
Volume II, Appendix II-2d
Inclinometer Volume II, Appendix II-1
Table 5-1 Maintenance Instructions
Regular checks:
 Check and test the protective circuits.
 Inspect switches and indicating lamps to ensure they are functioning properly.
 Inspect fuses to ensure they are intact.
 Inspect bolts at the wiring terminals to ensure they are not loose.
 Inspect conductive wires to ensure there is no damage to the insulation layer.
 Inspect motor starters, contactors, and relays to ensure they are functioning well.
 Inspect and clean cabinets and internal components to be free of dust.
 Inspect and remove any moisture from cabinets, investigate and remove source.
Check the electrical drive system in its entirety before operation. The above mentioned
maintenance should be carried out on a regular basis to minimize potential hazards and
ensure optimal operating conditions.
DRIVE SYSTEM COMPONENTS

5.2 General Guidance for Maintenance
Some components require unique settings by means of DIP-

switches or other means. Before a component is removed, the
Caution settings should be checked and noted
5.2.1 Dust Deposits

Dust inside cabinets and components must be removed at regular intervals (minimum
annually) by qualified personnel in accordance with applicable safety regulations.
Components inside cabinets should be cleaned using a brush and vacuum cleaner, or
dry compressed air for areas that are not easily accessible.
5.2.2 Ventilation
Ventilation openings must never be obstructed. Fans should be checked regularly to
ensure proper functionality. After any fan replacement, ensure that the direction of
rotation is correct.
5.2.3 Filters
Filter mats must be checked at regular intervals (minimum semi-annually). If mats are
contaminated such that proper air flow is no longer provided, they must be replaced.
5.2.4 Anti-Condensation Heaters
Heater functionality should be verified every 3 months and at least once prior to first
operation.
5.2.5 Cable and Terminals
Cables and terminals must be checked regularly to ensure they are properly
secured/installed. Cabling should be checked for defects and replaced if any defects
are discovered.
5.3 Motors/Brakes/Encoders/Brake Resistors

Refer to Table 5-1 for specified procedures. VFD cabinets should be de-energized prior
to performing any maintenance activities. To de-energize the VFD cabinets, do the
following:
 Press the e-stop button on the CCC
 Open circuit breaker QF1 for each leg and lock them out.

5.4 PLC, VFD, and Touchscreen Hardware/Software
Hardware/software changes by unauthorized personnel will void

the warranty and may lead to dangerous situations causing
catastrophic damage to the rig and possible serious injury to
Warning personnel.
5.4.1 Consistency of Hardware (PLC Related)

If an incorrect module type is installed (i.e. exchanged due to module failure), LEDs on
the PLC will provide an indication. For further detail, consult the Siemens S7-400 user
manual, found in Volume I, Appendix V.
5.4.2 Consistency of Hardware (Drive Related)
If a replacement module, or an incorrect module, is installed (i.e. exchanged due to
upgrade or module failure), the VFD will recognize the change and generate a fault
code. The exact fault codes and resolution can be found in the VFD Faults and
Troubleshooting table found in Volume I, Appendix VI.
5.4.3 Software Upgrades and Modifications
Software should only be modified by authorized personnel/representatives. In the event
of software issues, the manufacturer should be contacted for service.
A backup CD and/or CF cards are provided to the rig containing the latest installed
versions of the touchscreen OS (Windows), HMI Project software, and PLC software.
Procedures to restore from backup are provided in Appendix IV of this manual.

5.5 2-Year Recommended Spare Parts
Recommen
Description F&G Part No. ded
Quantity
MOTOR JS-MECH-FLS225M-4P 2
BRAKE JS-MECH-BRAKES_STEARNS 2
OVERSPEED LS &
JS-MECH-ENCODER_BAUMER 1
ENCODER
RECTIFIER JS-ELEC-NXN06506B0T0NSV 1
INVERTER JS-ELEC-NXI09206A0T0ISGA1A2 1
BRAKE CHOPPER UNIT JS-ELEC-NXB04166A0T08SGA1A2 1
CONTROL CARD.OPT-A1 JS-ELEC-VB00253 1
CONTROL CARD.OPT-C3 JS-ELEC-VB00257 1
FAN INVERTER BOARD JS-ELEC-VB00299 1
FUSE(APQ8) JS-ELEC-PP20202 2
CIRCUIT
JS-ELEC-70CPE00790 1
BREAKER(OSMC32N2C3)
FUSE BASE(US 1021) JS-ELEC-70CPE00504 1
KEY SWITCH JS-ELEC-70CPE03910 1
AUX. CONTACT JS-ELEC-70CPE00845 1
PANEL ON DOOR JS-ELEC-PAN-A-A-MP 1
DU/DT FILTER JS-ELEC-3DUT-0820-6-0-P 1
FUSE JS-ELEC-PP20220 4
FUSE JS-ELEC-PP20247 2
CIRCUIT BREAKERR JS-ELEC-PP20561 1
PUSHBUTTON JS-ELEC-70CPA00185 1
EMERGENCY
JS-ELEC-70CPE04742 1
PUSHBUTTON
INDIACTOR JS-ELEC-PP23028 1
INDIACTOR JS-ELEC-PP23029 1
TERMINAL WITH FUSE JS-ELEC-70CPE05899 4
HUB JS-ELEC-6GK5204-2BB10-2AA3 1
HUB JS-ELEC-6GK5212-2BB00-2AA3 1
POWER SUPPLY MODULE JS-ELEC-6ES7307-1KA02-0AA0 1
POWER SUPPLY MODULE JS-ELEC-6ES7407-0DA02-0AA0 1
S7-400-H CPU JS-ELEC-6ES7414-4HM14-0AB0 1
SIMENS S7-400
JS-ELEC-6ES7400-1JA11-0AA0 1
BASEBOARD
OPTICAL MODULE JS-ELEC-6GK1503-3CB00 2
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ET200M-H JS-ELEC-6ES7153-2AR03-0XA1 2
DI MODULE JS-ELEC-6ES7321-1BL00-4AA1 2
DO MODULE JS-ELEC-6ES7322-1HH01-4AA1 2
AI MODULE JS-ELEC-6ES7331-7KF02-4AB1 1
YLINK MODULE JS-ELEC-6ES7197-1LA04-0XA0 2
SIMENS S7-300
JS-ELEC-6ES7195-1GF30-0XA0 1
BASEBOARD
TOUCH SCREEN JS-ELEC-HMIPSF7DP03 2
SERVER JS-ELEC-HMIPUFND1P01 1
RPD TOUCH SCREEN JS-ELEC-XBTGT6330 1
DP BOARD FOR RPD
JS-ELEC-XBTZGDP 1
TOUCH SCREEN
JS-ELEC-E2S1600R1600PR121/P-LI 3P F
MAIN CIRCUIT BREAKER 1
HR - NST -YU(220VAC)
MAIN CIRCUIT BREAKER JS-ELEC-S1N-125/R40 3P F FC 2CO 1
MAIN CIRCUIT BREAKER JS-ELEC-S1N-125/R63 3P F FC 2CO 1
CIRCUIT BREAKER JS-ELEC-S202-C3 1
MOTOR STARTER JS-ELEC-MS116-4 6
MOTOR STARTER JS-ELEC-MS116-6.3 1
AUX. CONTACT JS-ELEC-S2C-H6R 5
AUX. CONTACT JS-ELEC-HKF1-11 11
AUX. CONTACT JS-ELEC-HK1-11 6
AUX. CONTACT JS-ELEC-HKF-11 1
AUX. CONTACT JS-ELEC-HK4-11 7
500VAC FUSE JS-ELEC-FB-1A 125
690VAC FUSE JS-ELEC-HL-1A 9
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RC FOR
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RC FOR
JS-ELEC-RC5-2 6
CONTACTOR/RELAY
AUX. CONTACT,NO JS-ELEC-CA5-10 10
AUX. CONTACT,NC JS-ELEC-CA5-01 1
JS-ELEC-MY2NJ/AC220V/PYF08A/PYC-
RELAY 2
A1
JS-ELEC-MY4NJ/AC220V/PYF14A/PYC-
RELAY 1
A1
RELAY JS-ELEC-.MY4NJ/DC24V/PYF14A/PYC-A1 3
RELAY JS-ELEC-MY2NJ/DC24V/PYF08A/PYC-A1 3
TIME RELAY JS-ELEC-CT-ERE(220V, 0.1-10S) 1
PUSHBUTTON JS-ELEC-XB2-BA21C 10
PUSHBUTTON JS-ELEC-XB2-BG21C 1
PUSHBUTTON WITH LED JS-ELEC-XB2BW33B1C 1
SELECT SWITCH JS-ELEC-XB2-BD21C 1
SELECT SWITCH WITH KEY JS-ELEC-XB2-BG61C 1
INDICATOR JS-ELEC-XB2-BVB3C 14
INDICATOR JS-ELEC-XB2-BVM1C 1
INDICATOR JS-ELEC-XB2-BVM5C 1
SELECT SWITCH WITH KEY JS-ELEC-XB2-BG45C 1

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JS-ELEC-XB2BS542C 2
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NO AUX RELAY JS-ELEC-ZB2-BE101C 2
NC AUX RELAY JS-ELEC-ZB2-BE102C 2
BUZZER APT.AD16-22M/K23 1
ABS ENCODER JS-ELEC-ISA_698.827376-01 2
690/220 50KVA
JS-ELEC-SG-50KVA 1
TRANSFORMER
BRAKE RESISTOR BANK
JS-ELEC-ZX20A-B1-SG-2.65/400K 1
COMPLETE
220/220
JS-ELEC-JBK3-1.6KVA 1
1.6KVATRANSFORMER
220/220
JS-ELEC-JBK3-5KVA 1
5KVATRANSFORMER
BRAKE RESISTOR
JS-ELEC-.T35-11-3.55/1100W 2
BLOWER COMPLETE
WIND PRESSURE SWITCH JS-ELEC-WPS 2
24-PULSE TRANSFORMER
JS-ELEC-1250KVA 1
COMPLETE
INCLINOMETER UNIT JS-ELEC-NS-5/DMG2-U 1
MOTOR CT UNIT JS-ELEC-JSIT102/80 6
SWITCHING INVERTER
JS-ELEC-DR-120-24 2
MEANWELL UNIT
SWITCHING INVERTER
JS-ELEC-DRP-240-24 1
MEANWELL UNIT
SWITCHING INVERTER
JS-ELEC-DRP-480-24 1
MEANWELL UNIT
SIEMENS PLC UNIT CP443-
JS-ELEC-6GK7443-1EX20-0XE0 1
1
SHAFT COUPLING RPD 4
JS-ELEC-ZPMC.J7796.18-RPD-00B
ABSOLUTE ENCODER 4
PROFIBUS CONNECTOR JS-ELEC-6ES7972-0BA42-0XA0 2
VACON CONTROL BOARD JS-ELEC-CPBV0000000000-MP 1
DONGLE & SOFTWARE JS-ELEC-DS 1
CF MEMORY CARD FOR
JS-ELEC-MPCYN00CF400N 6
TOUCH SCREEN
BATTERY JS-ELEC-6ES7971-0BA00 4
INSULATION
JS-ELEC-PP23037 1
MONITOR.IRDH275-435

APPENDICES
APPENDICES
APPENDIX I
Caltex Maropa 320 Oil Spec Sheet
APPENDIX II
E&I Component Datasheets
1. Inclinometer Datasheet
2. Speed/Direction Encoder Schematic, Spec Sheet
3. Leg Height/RPD Encoder
4. Touchscreen Display Datasheet
5. Current Transformer (CT) Datasheet
6. Max Wear Indicator Datasheet
7. Proximity Switch Datasheet
8. Thermal Protector Datasheet
9. Elements Inside the Cabinet of Jacking Control System
APPENDIX III
Incremental (Speed) Encoder Maintenance
APPENDIX IV
Software Restoration Procedures
1. How to modify system time and timezone

2. How to replay history files offline
3. How to restore the operating system
4. How to retrieve data from jacking system HMI
5. How to setup system
6. How to update the HMI project
7. Installation of the CF card with PLC backup
APPENDIX LISTING
ISSUED FOR FRIEDE & GOLDMAN A-1
DOCUMENT END

OP-7847.18-001 Volume II Rev X0

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OP-7847.18-001 Volume II Rev X0

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F&G Doc. No.: OP-7847.

F&G VFD-750 Jacking System

Dalian Shipbuilding Industries Co.

Friede & Goldman Ltd.

FOR FRIEDE & GOLDMAN

1.3 REFERENCE DOCUMENTS ..........................................................2 Author

3.2 JACKING FRAME .........................................................................10

3.3 MAINTENANCE INTERVALS .......................................................10

4.1 CHECKS PRIOR TO FIRST OPERATION AND AFTER LONG-

4.2 DAILY CHECKS............................................................................12

5.2 GENERAL GUIDANCE FOR MAINTENANCE ..............................24

5.3 MOTORS/BRAKES/ENCODERS/BRAKE RESISTORS................24

FIGURE 3-2 HELICAL STAGE CROSS-SECTION ............................................8

FIGURE 3-3 PLANETARY STAGE CROSS-SECTION ......................................8

FIGURE 3-4 JACKING UNIT DIMENSIONS ......................................................9

FIGURE 3-5 GEARBOX/SHIM RETAINER BOLT TORQUE ..............................9

FIGURE 4-1 LUBRICATION DIAGRAM ...........................................................14

FIGURE 4-2 HELICAL STAGE PARTS DIAGRAM ..........................................17

FIGURE 4-3 PLANETARY STAGE PARTS DIAGRAM ....................................18

TABLE 3-1 JACKING UNIT/JACKING FRAME MAINTENANCE INTERVALS .10

TABLE 4-1 GEARBOX OPERATIONAL TEST CHECKLIST ............................11

TABLE 4-2 GEARBOX DAILY CHECKS ..........................................................12

TABLE 4-3 GEARBOX MAINTENANCE INTERVALS .....................................12

TABLE 4-4 TROUBLESHOOTING I.................................................................15

TABLE 4-5 TROUBLESHOOTING II................................................................16

TABLE 5-1 MAINTENANCE INSTRUCTIONS .................................................23

Revision Date Section(s) Page(s) Brief Description of Change Author of

0 28May2014 Original Issue to Client NRK

1.2 Rig Particulars

1.3 Reference Documents

1.5 Warranty/Contact Details

For Service Requests, contact:

Provides supplemental information to advise the operator of ways in

Possible damage to the jacking system, components, or the

Possible serious injury to personnel or catastrophic damage to the

2.2 General Notes

2.3 General Cautions

Figure 3-1 Jack Unit Helical/Planetary Stage Cross-Section

JACKING UNIT/JACKING FRAME

Figure 3-3 Planetary Stage Cross-Section

Figure 3-5 Gearbox/Shim Retainer Bolt Torque

JACKING UNIT/JACKING FRAME

3.3 Maintenance Intervals

Table 3-1 Jacking Unit/Jacking Frame Maintenance Intervals

JACKING UNIT/JACKING FRAME

 Ensure that all motion of the gearbox has ceased and

 Gearboxes will be extremely hot after operation, caution

4.1 Checks Prior to First Operation and After Long-Term Storage

 Verify that the gearbox is correctly connected to the jack case

Operational Test Checklist

Check list Details

Surface Is the surface temperature of the gear unit abnormally high

4.3 Maintenance Intervals

4.4.1 Lubricant Requirements

Lubricant should be disposed of in accordance with the relevant

Figure 4-1 Lubrication Diagram

Issue Possible Cause Action

Defective oil seals Replace the oil seals

Stator coil is damaged Repair

Coil ground issue Check the transformer and the circuits

Friction of parts Disassemble, check, and modify

The fan is contacting the hood. Repair

3-phase motor is running on one phase. Check the circuit

Worn-out gears Replace the gears