Minibooster Hc6d2w Operations and Maintenance

Fugro-impROV Pty Ltd
10K psi Injection Skid

Operations and Maintenance Manual
Table of Contents
1 Change History ............................................................................................................................ 4
2 Introduction .................................................................................................................................. 5
2.1 Scope .................................................................................................................................... 5
2.2 Operation .............................................................................................................................. 5
2.3 Maintenance Program ........................................................................................................... 5
2.4 Acronyms and Abbreviations ................................................................................................. 5
2.5 Reference Documents........................................................................................................... 6
3 System Overview ......................................................................................................................... 7
3.1 System Specifications ........................................................................................................... 8
3.1.1 Injection Skid ............................................................................................................. 8
3.1.2 ROV Valve Panel ....................................................................................................... 8
3.2 System Components ............................................................................................................. 8
4 Saftey and Risk ............................................................................................................................ 9
4.1 General ................................................................................................................................. 9
4.2 Personnel Safety ................................................................................................................... 9
4.3 Potential Hazards ................................................................................................................ 10
4.4 Job Safety/Hazard Analysis................................................................................................. 11
4.5 Handling and Transport ....................................................................................................... 11
5 Operating Procedures ................................................................................................................ 12
5.1 Pre Dive Checks ................................................................................................................. 12
5.2 During the Dive ................................................................................................................... 14
5.3 Flow Rate Data Logging Program ....................................................................................... 14
5.4 Post Dive Checks ................................................................................................................ 16
5.4.1 Storing ..................................................................................................................... 17
6 Equipment & Spares .................................................................................................................. 17
6.1 Fluid Injection Skid Manifest ................................................................................................ 17
6.1.1 Transportation case manifest ................................................................................... 17
6.2 Spare Parts ......................................................................................................................... 17
6.2.1 10K Water Injection Unit Spares Kit ......................................................................... 17
7 Fault finding and troubleshooting ............................................................................................... 18
8 Maintenance Procedures ........................................................................................................... 19
8.1 Post Operation Maintenance Checklist ................................................................................ 19
8.2 Post Offshore Maintenance Checklist .................................................................................. 19
8.3 Preventative Maintenance ................................................................................................... 19
Appendix A: miniBooster HC6D2W Operations and Maintenance Manual ........................................ 21
FiP-ENG-011 rev 01 20201-9800 Rev 01 Page 2 of 28


Appendix B: Post Operation Maintenance Checklist ......................................................................... 22

Appendix C: Post Offshore Maintenance Checklist ........................................................................... 24
Appendix D: Maintenance Report Sheet ........................................................................................... 26
Appendix E: Drawings ....................................................................................................................... 28


1 CHANGE HISTORY
The purpose of this section is to record and detail the history of the document, what has changed and also
why it has changed.
Table 1 – Amendments
Revision Change Reason For Change
0A Document Created Issued for internal review
01 No changes made Issued for Use


2 INTRODUCTION
This document provides all information required to operate and maintain the 10k psi Injection Skid.
2.1 SCOPE
The scope of this document is to describe the operation of the 10k psi Injection Skid and the
maintenance required to confirm it is fit for use.
2.2 OPERATION
The 10k psi Injection Skid is used to inject glycol based fluids at high pressure (up to 690 bar / 10,000
psi) from an independent reservoir. The skid has two output ports (A and B) which can be selected via a
pilot operated directional control valve. Pressure from each port can be monitored via inbuilt pressure
gauges. Output flow from the skid can be recorded and displayed on a computer installed with the
software package supplied with the skid.
2.3 MAINTENANCE PROGRAM

The maintenance section of the manual is split into the following parts:
• Post operation maintenance
• Post offshore maintenance programme
• Periodic maintenance programme for extended use offshore or storage onshore
2.4 ACRONYMS AND ABBREVIATIONS

Acronyms and Abbreviations should be listed clearly in the table and conform to 20000-9802 Acronyms,
Symbols and Units.
Table 2 – Acronyms and Abbreviations

Acronym or Abbreviation Full Description
FIPTY Fugro impROV Pty Ltd
AS Australian Standard
AS/NZS Australia Standards/New Zealand Standards
DCV Directional Control Valve
HPW High Pressure Water
ISO International Organisation for Standardisation
kg Kilogram
l litre
lpm Litres per minute
m Metres
mm Millimetres
PPE Personal Protective Equipment
psi Pounds per square inch
ROV Remotely Operated Vehicle


2.5 REFERENCE DOCUMENTS

Any documents referenced throughout this document are listed in Table 3 below.
Table 3 – Reference Documents

rd
Fugro- 3 Party Document
impROV/Supplier Client Document No No Document Description
Document No
n/a n/a AS1336:1997 Recommended Practices For
Occupational Eye Protection
n/a n/a AS/NZS1337.0:2010 Personal Eye Protection
n/a n/a AS/NZS1338.1:2012 Filters For Eye Protectors
n/a n/a AS1470 Health And Safety At Work
n/a n/a HC62DWIOM miniBooster Installation/Operation/
Maintenance Manual
n/a n/a ISO 13628-8 Design and Operation of Subsea
Production Systems Part 8: Remotely
Operated Vehicle (ROV) Interfaces on
Subsea Production Systems
n/a n/a AS/NZS 4233.1:1999 High Pressure Water (Hydro) Jetting
Systems Part 1: Guidelines for Safe
Operation and Maintenance


3 SYSTEM OVERVIEW
The 10k psi Injection Skid is a hydraulically powered sub-sea tool. Water based fluids (such as glycol) are
supplied to the unit from an independent source reservoir which are then pressurised using a dual media
hydraulic intensifier.
Figure 1 – Injection Unit Overview Figure 2 – ROV Valve Panel

The hydraulic intensifier used is a miniBooster HC6D2W dual media. Refer to miniBooster HC6D2W
Operations and Maintenance Manual, Appendix A, for additional pump details.
The high pressure water passes through a flowmeter which has an RS232 output that can be connected to
any computer installed with software to allow the display and recording of the output flow from the pump
unit. A pilot controlled directional control valve (DCV) allows either the A or B output port to be selected.
This 10k psi Injection Skid is designed for use on work class ROV’s. It requires a hydraulic supply of 40lpm
at a maximum pressure of 200 bar (2900 psi).
A separate valve ROV operable valve panel (Figure 2) can be connected to the skid unit to enable
pressure to be locked into the output lines of both A and B ports. The de-mountable pressure gauges on
the skid unit can be connected to this valve panel to monitor pressure during operations such as seal
testing on equipment.
Performance characteristics of the unit are as below:
Figure 3 – Performance Curve


3.1 SYSTEM SPECIFICATIONS

3.1.1 Injection Skid
System Specifications
Overall Length 720 mm
Overall Width 465 mm
Overall Height 325 mm
In Air Weight 58 kg
In Water Weight 42 kg
Input Hydraulic Fluid Flow 40 lpm
Max Input Hydraulic Pressure 200 bar / 2,900psi
Max Hydraulic Pilot Pressure 200 bar / 2,900 psi
Max Output Flow 8.7 lpm
Max Sea Water Delivery Pressure 690 bar / 10,000 psi
Hydraulic Fluid Mineral oil or water based fluids.
Hydraulic Pressure Connection -12 JIC Male
Hydraulic Tank Connection -12 JIC Male
Hydraulic Pilot X Connection 7/16” JIC Male
Hydraulic Pilot Y Connection -4 JIC Male
Mounting to ROV Frame N/A
Depth Rating 3000m
Material of Fittings 316 Stainless Steel
Material of Baseplate/ Front Panel Aluminium
Material of Cover Plastic / Delrin
3.1.2 ROV Valve Panel

System Specifications
Overall Length 400 mm
Overall Width 350 mm
Overall Height 170 mm
In Air Weight 10 kg
In Water Weight 7.5 kg
Input Pressure Connections -12 JIC Male
Output Pressure Connections -12 JIC Male
Test Port Connections Test 20
Depth Rating 3000m
Material of Fittings 316 Stainless Steel
Material of Baseplate/ Front Panel 316 Stainless Steel
Material of Cover Plastic / Delrin
3.2 SYSTEM COMPONENTS

Component Description
Hydraulic Pump miniBooster HC6D2W
Hydraulic Flow Control Pressure Compensated Flow Control
Pilot operated check valve Pilot Operated Check Valve
Pressure Relief Valve Direct-acting pressure relief valve
Suction Filter 40 micron stainless steel element


Component Description
10,000psi 2 Posn / 4 Ported Stainless steel Valve With Hydraulic
Directional Control Valve
Actuator
10,000psi 316 stainless body, 2-20 l/min, Fitted with PPW-RS232
Flow Meter
pick up, 24 vdc loop supply , RS232 output
Gauge Span 3 ½” subsea gauge
Deck Box 20201-0090-01
ROV Valve Panel 2 x 10,000psi 2 way ball valves
4 SAFTEY AND RISK
4.1 GENERAL
This section of the Manual addresses the safety issues that arise while setting up, operating and
maintaining the 10k Injection Skid.
Safety is of prime importance when undertaking any work. Non essential personnel shall be kept clear of
the area. Only fully trained and qualified personnel should work on the system, and the following safety
rules should be adhered to.
Refer to miniBooster HC6D2W Operations and Maintenance Manual, Appendix A, for specific pump
considerations.
4.2 PERSONNEL SAFETY

This equipment is designed to be operated remotely in underwater applications. Where operations are
not in the immediate vicinity of personnel or divers then personnel safety is not a consideration for this
equipment. This makes normal operation of this equipment much safer than diver operated unit water
jetting.
When performing any task on this equipment a Risk Assessment should be performed.
This equipment is remotely operated therefore it should always be considered “live” until the hydraulic
system is de-pressurised. Never place any part of your body in line with the high pressure water jet
nozzle.
Never place any part of your body in line with the high pressure water output.
Where operation of the unit is required in the vicinity of personnel (including divers) appropriate PPE
should be used. Recommendations for PPE can be found in AS/NZ 4233.1: High Pressure Water Jetting
Systems Part 1 – Guidelines for safe operation and maintenance.
Where maintenance is required then PPE should be worn that is appropriate to the task. The
recommended minimum is PPE for on-shore work is:
Safety Glasses
Safety Boots
Overalls


Gloves to be worn at appropriate times.
Ear Protection when required
The recommended minimum is PPE for off-shore work is:
Safety Glasses
Safety Boots
High Visibility Overalls
Hard Hat
Gloves to be worn at appropriate times.
Ear Protection when required
4.3 POTENTIAL HAZARDS

In development of this manual the following personnel hazards have been identified, with mitigating
measures identified.
Hazard Control
High Pressure Injection
Injury. Operation and maintenance of this equipment should be in accordance with
the requirements of AS 4233.1 This includes Training, PPE, Operation and
maintenance requirements.
High Pressure Cutting

Injury Operation and maintenance of this equipment should be in accordance with
the requirements of AS 4233.1 This includes Training, PPE, Operation and
maintenance requirements.
High pressure projectile

(fitting) Operation and maintenance of this equipment should be in accordance with
the requirements of AS 4233.1. Standard pressure testing requirements limit
the risks of pressure failure.
Jamming/pinch injuries to
Personnel to be aware of load handling and set up configuration before
hands
starting operations. Ensure good communications with all personnel before
lifting and operations proceed.
Falling injuries from

slipping or tripping Any loose equipment, items or hydraulic oil spilt is to be cleaned up
immediately in the appropriate manner.


Hazard Control
High pressure oil and high
pressure water. The hydraulic system should be fitted and checked by a qualified hydraulic
fitter using caution and care. All none essential personnel to be clear during
maintenance.
Fire
No naked flames, flammable liquids or materials allowed around the Torque
Tools during servicing or operation.
Damaged Equipment Never use an item of equipment that is damaged or has defective
components. Handle equipment with care not to damage any components
especially hydraulic fittings or connections.
Safety related equipment There are a number of pressure relief safety features supplied with this
settings. equipment. Unauthorised tampering or adjustment of these safety related
settings may lead to equipment failure and consequential damage or injury.
Hazard from material being JSA is to cover the health and environmental aspects of the task.
cleaned becoming water-
borne.
4.4 JOB SAFETY/HAZARD ANALYSIS

Before any maintenance, testing or operations of the equipment a Risk Assessment shall be performed
and will address the hazards associated with the system set up and associated with environmental
protection.
The Key considerations are highlighted below:
• High pressure output.
• Injuries to hands.
• Usage of hydraulic oil at pressure.
• Moving and handling of equipment.
• Flammable liquids and materials
• Material becoming water-born
4.5 HANDLING AND TRANSPORT

Onshore: For general workshop handling, care should be taken when moving the unit or
any tooling. Always wear gloves to protect your hands from cuts and abrasions. Be careful
not to spill hydraulic fluid. If fluid is spilt, clean up as soon as possible using the correct
method for the spill. The Injection Unit shall only be transported or stored in its designated
Transport Case supplied.
Offshore: Only experienced personnel shall be involved with the handling of the
equipment. Always wear gloves to protect your hands from cuts and abrasions. Be careful
not to spill hydraulic fluid. If fluid is spilt, clean up as soon as possible using the correct
method for the spill. When the unit is not in use it shall be cleaned and stored in its
designated Transport Case supplied.

5 OPERATING PROCEDURES
The following section describes the steps required to operate the Injection Unit.
5.1 PRE DIVE CHECKS

The following section describes the checks required before the operation takes place.
Step Description Check
1 Ensure software provided is installed on a windows PC / laptop and the computer is connected to
the flow meter via serial communication (use RS232 to USB converter).
Setup file are provided on a USB pen drive or CD. The file is in .exe format. Note that the installer
will install the National Instruments Labview Runtime software.
User should double click on the setup file and follow the instructions on the setup page.
Once installed, user can launch the program via the desktop named “10kpsi Injection Skid”.
2 Visually inspect the Injection Unit for any signs of damage or wear.
3 Ensure the ROV Hydraulic system is de-pressurised and de-energised.
4 Remove the hydraulic transport caps and attach the hydraulic hoses to the connection panel on the
injection skid. (See figure 4 for details of connection panel)
5 Remove the supply line (P1) transport cap and connect a hydraulic pressure (supply) hose to the
ROV. Where possible the pressure input should be connected directly to the ROV supply, rather
than through a DCV/manifold system.
6 Remove the tank line cap (T1) and drain line cap (DRAIN) connect a hydraulic tank and drain hose
to the ROV. Where possible the tank line should be directly connected to the ROV return system
rather than through a DCV/manifold system.
7 Remove the pilot lines (PILOT and X (DCV)) transport cap and connect hydraulic pilot line hoses to
the ROV.
Figure 4 – Injection skid connection panel

8 If using the injection skid without the ROV valve panel then connect the required hotstab and
hose(e.g. dual port hotstab) direct to the output ports, A and B.
If using the skid with the valve panel (e.g. for seal test operations) then connect the supplied hoses
from ports A and B on the skid to the respective ports A and B on the ROV valve panel.
WARNING: Ensure the hoses and equipment are rated to the correct pressure i.e. 11,500psi
9 Carefully place the main body of the injection unit into a large container of fresh/ potable water
ensuring that the suction intake is fully immersed.
NOTE: There is no internal filter on the suction side of the injection skid; it is the operators’
responsibility to ensure the intake fluid is suitably filtered so as to avoid potential damage
to the pump.
10 Secure the output line hotstab and point the outputs in a safe direction facing away from any
personnel.


11 Ensure miniBooster start up preparations have been carried out as per section 4.2 of miniBooster
HC6D2W Operations and Maintenance Manual, Appendix A.
WARNING: It is important that this step is carried out to ensure that the pump is properly
primed prior to starting.
12 Connect the electrical lead from the flowmeter into the relevant connection on the Deck Test Box
(20201-0090) ensuring that the deck box is kept out of the water. See figure below:
Figure 5 – Deck Box Connection

13 Energise the ROV hydraulic system.
WARNING: Once the hydraulic system is energised the Injection Unit may be operated
remotely. Identify, assess and control the risks associated with this prior to energising the
hydraulic system of the ROV.
14 Select which output port is required (A or B). The default output is A: output port B is selected by
energising pilot X (DCV).
Note – The DCV has a spring return so if using output port B, the pressure will need to be
maintained on the pilot line (X) to prevent the DCV returning to the default position (port A)
16 Test the operation of the Injection Unit by activating the pilot line (PILOT).
17 Ensure proper functionality of the injection unit (i.e there is flow on the output line; A being the
default output that can be swapped to output B when Pilot X is activated).
Check that the software is interfacing and reading from the flow meter properly (refer to section 5.2
step 5 for guide on using the software or press “Help” on the software for more information).
18. The output pressure can be checked either by installing a 10,000 psi rated valve on the output
ports and slowly closing the valve whilst the pump is running (if the ROV valve panel is not
installed) alternatively if using the ROV valve panel then the valves on this can be used to throttle
the output flow (gauges have to be connected to the output of the injection skid).
The pressure can be monitored on the relevant gauge (A or B); the gauges can either be
connected to the outputs on the injection skid or to the outputs on the ROV valve panel (see figure
6 below:
Figure 6 – Injection Unit and Valve Panel Test Point Connections

19. Any pressure that has been locked into output line A can be relieved by activating the DCV pilot (X)
to select port B and, if the ROV valve panel has been installed, by opening the paddle valve A.
If output port B is being used and pressure that has been locked in the output line then this can be
relieved by de-energising the pilot line to re-direct flow to the default A port and, if the ROV valve
panel has been installed, by opening the paddle valve B.


20. De-energise the pilot ‘PILOT Y’ and de-energise the ROV hydraulic system.
21. Carefully remove the main body of the Injection Unit from the water container.
22 Remove the electrical lead connected to the flowmeter from the deck box unit.
23. Secure the Injection Skid Unit to the ROV.
24. Connect the electrical lead from the flow meter to the relevant electrical connection on the ROV.
25. If required, secure the ROV valve panel to a suitable location on the ROV.
26. If required, remove the pressure gauge dashboard and secure it in a suitable location on the ROV
where the gauges can be easily monitored via the ROV cameras.
Connect the gauges either directly to the injection skid or to the test ports on the ROV valve Panel.
5.2 DURING THE DIVE

The following section describes how to utilise the 10k psi Injection Unit during a dive.
1 When the ROV has reached the point of operation, insert the hotstab connected to the Injection
Unit into the desired receptacle.
2 If installed, ensure that both ball valves on the ROV valve panel are open
3 Output A is the default pressure line; if output B is required activate Pilot X (DCV).
4 Activate “PILOT Y” to start the Injection Unit pump.
5 Monitor the pressure via pressure gauge dashboard.
6 If required, for example during seal leak testing, lock the pressure in the output line (A or B) by
closing the relevant valve on the ROV valve panel.
7 Output flow can be monitored and recorded on the provided program that has been installed onto
the relevant laptop or PC (see section 5.1 for information on how to install the software).
User should follow the guide provide in section 5.3 for operation of the program.
8 When the subsea operation has been completed and sufficient data has been recorded the
Program can be stopped.
9 To release the pressure locked in the output line open the valves on the ROV valve panel and
activate the DCV pilot.
5.3 FLOW RATE DATA LOGGING PROGRAM

1 Output flow can be monitored and recorded on the provided program that has been installed onto
the relevant laptop or PC (see section 5.1 for information on how to install the software).
(the numbers below relate to the numbers shown in Figure 7):
1. User is to select the required COM port and serial COM set up parameters. Click
"Default" button to revert COM parameters to original values.
2. To setup the recording path, the user needs to click the folder icon, navigate to the
required path, and input a name for the file. No extension (.csv or .txt) is required. As an
example, end result would be "C:\Users\UserName\Desktop\abc".
File path will be defaulted to program path if left blank.
3. The panel underneath describes the status of the program. First column describes if the
program is on idle, running or booting. Second column describes status of RS232
communication with the flow meter. Third column describes status of data logging, and
fourth column describes file path of the logged data.
4. Once Recording Path is setup, user can start viewing the data displayed on the pane by
going to the "Run" tab.


4
1
Figure 7 – Flowmeter Program Screenshot

1. To start viewing data from serial, click "Connect" button.
User can pause program by un-clicking the "Connect" button.
Resume by clicking "Connect" again.
Note that clicking "Connect" will disable functionality of setting up recording paths and
COM ports.
2. User should activate "Record" button for the program to do any data logging and
deactivate "Record" button to stop recording.
User can toggle "Record" button anytime to start or pause recordings while data viewing
on right pane is still active.
3. User can input notes into the recorded file anytime when the recording starts. Click “add
note” button to record the note into the file. The text input section will be cleared to
indicate it has been recorded.
4. Stop the program from running any time by clicking “Quit” button


1
2
Figure 8 – Flowmeter Program Screenshot

2 When the subsea operation has been completed and sufficient data has been recorded the
program can be stopped.
5.4 POST DIVE CHECKS

The following section describes the checks that should be carried out after the 10k psi Injection unit has
been operating subsea.
1 Ensure the ROV Hydraulic system is de-pressurised and de-energised.
2 Remove electrical cable connection between injection unit and the ROV and store it.
3 Remove the Injection Unit from the ROV.
4 Carefully place the unit into a container of fresh water/ potable water.
5 Remove the output nozzle / hotstab from the Injection Unit.
6 Ensure the output ports are not capped and are submerged in water.
Energise the ROV hydraulic system.
WARNING : Once the hydraulic system is energised the Water Injection Unit may be
operated remotely. Identify, assess and control the risks associated with this prior to
energising the hydraulic system of the ROV.
7 Either keep the Injection Unit connected to the ROV HPU or connect it to a deck HPU.
8 Operate the Water Injection Unit for 5 min to flush the system through with fresh water.
9 De-energise the ROV or deck HPU hydraulic system.
9 Wash all equipment down with fresh water.
10 Disconnect and remove hydraulic hoses from the ROV or deck HPU and re-install the transport
caps.
11 Disconnect and remove the hydraulic hoses from the connection panel on the Injection Unit and re-
install transport caps.
12 Inspect the water injection unit and hoses for damage as per the Post Operation Maintenance
Check List


5.4.1 Storing
The following section describes the how to store the 10kpsi injection unit after use.
1 Disengage the Hydraulic Hoses from the ROV if not already done.
2 Flush clean hydraulic fluid through the hydraulic input side of the Injection Unit.
3 Perform all checks as per the Pre and Post Dive Check sections.
4 Disconnect the hydraulic hoses, drain, clean and store.
5 Drain all fluid from the tool.
6 Store the Injection Unit in a suitable storage/transport box. Refer to the Contents List in section 6
of this Manual.
6 EQUIPMENT & SPARES
6.1 FLUID INJECTION SKID MANIFEST

The 10K Water Injection Unit will be delivered on a suitable transport pallet. There will be a photographic
manifest included. Below is a manifest of what should be delivered.
6.1.1 Transportation case manifest
Description Part Number QTY

10k psi Water Injection Unit 20201-0200 1
Electrical Test Deck Box 20201-0090 1
Flow Meter Whip Cable 20201-0091 1
Operations and Maintenance Manual 20201-9800 1
6.2 SPARE PARTS

The 10K Water Injection Unit will be delivered with the spares listed in the table below
6.2.1 10K Water Injection Unit Spares Kit
Description Part Number QTY

Minibooster seal kit SealkitW-3,9HH 1
Filter SF23662/40um 1


7 FAULT FINDING AND TROUBLESHOOTING
For Troubleshooting and fault finding please refer to the miniBooster HC6D2W Manual which is attached
as appendix A.
Description Possible Cause Possible Remedy
No hydraulic fluid flow or hydraulic flow too low. Check hydraulic flow to unit.
Hydraulic pressure is too low Check hydraulic pressure to unit.
Hydraulic flow is reversed Confirm that unit is connected correctly.
Confirm that pilot port is connected
Pilot port is not pressurised.
10K Water Injection properly and is being activated.
Unit does not function Unit may have mechanical damage that is visible Remove the strainer screen and visually
at all. externally. inspect the unit for damage.
Return to FIPTY for repair of the unit, or
Unit may have mechanical damage to the internal
disassemble and inspect high pressure
piston components.
water pump.
Hydraulic check valve malfunction. Return to FIPTY for repair of the unit.
10K Water Injection
Pilot port is not being de-energised correctly.
Unit functions but does Confirm that pilot port is connected
Pressure needs to be removed from this port to
not turn off when properly and is de-energising correctly.
turn the unit off.
expected.
Reservoir port is blocked. Visually inspect the water reservoir port.
Flow control valve has been tampered
Flow control valve is causing insufficient flow of with. Do not adjust the flow control valve
hydraulic pressure. setting; this has been set to protect the
10K Water Injection unit.
Unit functions but no or Leakage of hydraulic fluid Inspect the unit for leakage
insufficient water flow
delivered. Leakage of delivered water Inspect the unit for leakage.
Check and adjust the hydraulic pressure
Insufficient hydraulic pressure or flow.
or flow.
Check the reservoir port and any
Insufficient water flow.
suction filters.
Relief valve has been tampered with.
Relief valve is causing unloading of the hydraulic Do not adjust the relief valve setting;
pressure. this has been set to protect the unit.
Return to FIPTY for repair of the unit.
with. Do not adjust the flow control valve
Flow control valve is causing insufficient flow of setting; this has been set to protect the
hydraulic pressure. unit.
Return to FIPTY for repair of the unit.
10K Water Injection
Unit functions but water Leakage of delivered water Inspect the unit for leakage.
pressure is too low. Unit is being operated at shallow depth or on the
surface and a suction blockage is causing pump Clear any blockages in suction line.
cavitations (is unlikely to occur when pump is Operate pump at deeper depth
deeply submerged).
Excessive hydraulic flow, HC6 pump runs too fast. setting; this has been set to protect the
unit.
Hydraulic fluid mixture The pumps seals should be replaced.

detected leaking from If the leakage is unacceptable (recommend less
leakage detection than 10 drops per minute).
bores.


Description Possible Cause Possible Remedy

Some of the water intake and pressure valves are Check the water valves, clean
open or damaged thoroughly or repair.
Unit is being operated at shallow depth or on the Check and clean strainer and filter.
surface and a suction blockage is causing pump
Intense pulsating of cavitations (is unlikely to occur when pump is
water pressure deeply submerged).
Excessive hydraulic flow, HC6 pump runs too fast. Flow control valve has been tampered
setting; this has been set to protect the
unit.
Ensure computer has an operating system of Use computer or laptop with Windows 7
Windows XP and above. or latest version of Windows operating
Windows 7 or latest is recommended. system installed.
Linux or MacOS operating systems are not
supported.
Flow display software Program or computer crashes. Restart computer or restart program.
not functioning Computer has outdated hardware. Use computer with latest hardware.
End the program in task manager, or
close the program and open again.
Program has crashed.
User should follow instruction on how to
User error.
operate the program in section 5.2 step
7.
8 MAINTENANCE PROCEDURES
8.1 POST OPERATION MAINTENANCE CHECKLIST

• The Post Operation Maintenance checklist is included in Appendix B of this document.
• The checks listed in the programme should be performed after each Subsea Operation and the list
signed off recording that the checks have been completed.
• Any significant repairs made, spares used or other comments regarding the [insert name here]
should be noted on a Maintenance Report Sheet (in Appendix D) and appended to the operations
log for client information.
8.2 POST OFFSHORE MAINTENANCE CHECKLIST

• When the 10K Water Injection Unit is demobilised, the Post Offshore Maintenance Program
(Appendix C) is to be carried out as soon as practical after arrival onshore.
• As each schedule is completed, the technician should sign a copy of the schedule and program as
completed, noting any spares used in the appropriate place. The completed documentation is to be
passed to Fugro impROV.
8.3 PREVENTATIVE MAINTENANCE

• When the 10K Water Injection Unit is in use offshore for extended periods then a “Post offshore
maintenance checklist” should be performed every 3 months.
• When the unit is in storage onshore then the “Post offshore maintenance checklist” should be
performed prior to deployment offshore and at six (6) month intervals onshore.
• Any significant repairs made, spares used or other comments regarding the tooling should be noted
on a Maintenance Report Sheet (in Appendix D). The completed documentation is to be passed to
Fugro impROV.

• The pressure gauges should be re-calibrated annually by Fugro impROV

• The pressure relief valve should be re-tested annually by Fugro impROV.
• All Stainless steel tubing and tube fittings shall be removed and discarded/replaced at three (3)
year intervals by Fugro impROV. This is to reduce the risk of stress corrosion cracking failure.
• The hard copy of the operating and maintenance manual shall be discarded and replaced at three
(3) year intervals by Fugro impROV
• All perishable spares (O rings, seals etc) shall be discarded and replaced at five (5) year intervals
by Fugro impROV.
• A major overhaul/rebuild of the system shall be done at ten (10) year intervals or following a
significant failure. The Overhaul will involve complete disassembly, replacement of all perishable
items (O rings hoses, paint, seals, etc), inspection of all non-perishable components (steel
components), gauging of all threads and re-assembly to return the system to “as new”
specifications from the fabrication drawings. The major overhaul shall be conducted by Fugro
impROV and its suppliers.


APPENDIX A: MINIBOOSTER HC6D2W OPERATIONS AND MAINTENANCE

MANUAL


APPENDIX B: POST OPERATION MAINTENANCE CHECKLIST


POST OPERATION MAINTENANCE CHECKLIST
Serial Number: _______________________________________________________________________
Point Description Notes Sign Off

1 Investigate, repair or adjust anything
untoward noticed during the operation.
2 Examine all loose hoses, cables, etc for
damage or wear.
3 Flush fluid through all ports and hoses
(including pump) using clean oil/water as
appropriate.
4 Check equipment for damage and repair if
necessary.
5 Check all bolts and fittings are secure.
6 Wash the equipment down with fresh water
prior to storage.
7 Fill out a Maintenance Report Sheet
(Appendix D) if any major repairs or spares
are required or if any item requires
additional explanation
8 If a Maintenance Report Sheet is required
attach it to the Operation Log.
Completed by
Signature Position Name Date

Approval / Acceptance


APPENDIX C: POST OFFSHORE MAINTENANCE CHECKLIST


POST OFFSHORE AND PERIODIC MAINTENANCE CHECKLIST
Serial Number: ________________________________________________________________
Point Description Notes Sign Off

1 Examine the entire equipment for damage or corrosion,
especially:
Bolts
Hydraulic Fittings & Hoses
Electrical Fittings & Cables
Pump
Valves
Flow meter
And repair as required.
2 Flush fluid through all ports and hoses using clean
oil/water as appropriate.
3 Function test the equipment as detailed in Section 5.1.
4 During tests check for leakage at all hydraulic
connection & fittings.
5 Check for leakage at the water pump leakage/weep
ports.
6 Fill out a Maintenance Report Sheet (Appendix D) if any
major repairs or spares are required or if any item
requires additional explanation
7 If a Maintenance Report Sheet is required pass
documentation to the Client representative.
Completed by

Approval / Acceptance


APPENDIX D: MAINTENANCE REPORT SHEET


MAINTENANCE REPORT SHEET
Item Maintenance Date
Symptoms
Troubleshooting Details/Results
Diagnosis
Rectification Work
Parts Used
Report By: Signature: Date:


APPENDIX E: DRAWINGS
Item No. Description Number
1 10K Water Injection Unit Hydraulic Schematic 20201-0040
2 10K Water Injection Unit Assembly 20201-0200
3 10K Water Injection Unit Deck Test Box Electrical Schematic 20201-0090
4 Flow Meter Whip Cable 20201-0091

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Fugro-impROV Pty Ltd

10K psi Injection Skid

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10K psi Injection Skid

Appendix B: Post Operation Maintenance Checklist ......................................................................... 22

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2.3 MAINTENANCE PROGRAM

2.4 ACRONYMS AND ABBREVIATIONS

Table 2 – Acronyms and Abbreviations

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2.5 REFERENCE DOCUMENTS

Table 3 – Reference Documents

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Figure 1 – Injection Unit Overview Figure 2 – ROV Valve Panel

Figure 3 – Performance Curve

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3.1 SYSTEM SPECIFICATIONS

3.1.2 ROV Valve Panel

3.2 SYSTEM COMPONENTS

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4 SAFTEY AND RISK

4.2 PERSONNEL SAFETY

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Gloves to be worn at appropriate times.

Ear Protection when required

The recommended minimum is PPE for off-shore work is:

High Visibility Overalls

Gloves to be worn at appropriate times.

Ear Protection when required

4.3 POTENTIAL HAZARDS

High Pressure Cutting

High pressure projectile

Falling injuries from

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4.4 JOB SAFETY/HAZARD ANALYSIS

4.5 HANDLING AND TRANSPORT

10K psi Injection Skid

5.1 PRE DIVE CHECKS

Figure 4 – Injection skid connection panel

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Figure 5 – Deck Box Connection

Figure 6 – Injection Unit and Valve Panel Test Point Connections

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5.2 DURING THE DIVE

5.3 FLOW RATE DATA LOGGING PROGRAM

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Step Description Check