6931055734 - MAN - AirPack

AirPack C

DRAFT - FOR User Manual INFORMATION ONLY ORIGINAL INSTRUCTIONS

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Tel: +31 184 608 700, Fax: +31 184 608 790, www.nov.com K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 1 of 150 Revision A

AirPack C User Manual

This manual applies to the following parts: • L-6931055734 - AirPack C Base Assy Zone 2 • All standard options available for this base assembly

WARNING

TXT-10004286/A

DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

Published by: NOV Elmar Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2013 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV Elmar for loss, damage or injury caused by any errors or omissions in this document.

Version

Date

A

26 July 2013

Amendments This is the first version of this manual

REVISION HISTORY

Page 2 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

TABLE OF CONTENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 Unit rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.3 Unit right view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4 Unit right view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.5 Unit right view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.6 Unit front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.7 Unit left view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.8 Unit left view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.9 Unit left view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.4 Compressor (Pneumatic) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.6 Unit grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5 SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.2 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.4 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 6.1 Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 6.2 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.3 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.5 Charge hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.4 Periodic maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.5 Check/adjust V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 7.6 Check/fill compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7.7 Check/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 7.8 Check/fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 7.9 Check/fill engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.10 Check/fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 7.11 Check/fill fuel pump gear drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7.12 Check/replace hoses and couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 7.13 Check shock absorbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 7.14 Clean engine air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 3 of 150 Revision A Original Instructions

AirPack C User Manual

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7.15 Clean auxiliary pneumatic system filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 7.16 Clean fuel coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 7.17 Clean air dryer filter (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 7.18 Clean main compressor air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 7.19 Clean spark arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 7.20 Clean/replace compressor intake air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 7.21 Clean/replace crankcase breather flame trap . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 7.22 Clean/replace engine air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 7.23 Clean/replace fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 7.24 Drain/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 7.25 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 7.26 Drain fuel/water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 7.27 Drain water from hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 7.28 Prime diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 7.29 Replace air-oil separator filter (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 7.30 Change compressor oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 7.31 Change engine oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 7.32 Replace fuel fine filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 7.33 Replace fuel/water separator filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 7.34 Replace hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 7.35 Replace V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 7.36 Test maximum engine speed (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 8.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 8.2 Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Appendix 1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Appendix 2: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Appendix 3: Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Appendix 4: Unit hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Appendix 5: ASEP Elmar tightening conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Appendix 6: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Appendix 7: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Appendix 8: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 CUSTOMER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Page 4 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

1

INTRODUCTION TXT-10004540/A

This user manual for the AirPack C well servicing product is intended for operating, maintenance and supervisory personnel. It contains the following sections: • Safety (important safety aspects) • Description (of components and their function) • Unit Control description • Setup and Removal (including installation and storage) • Operation (startup, run, shutdown) • Maintenance (schedules and procedures) • Troubleshooting • Appendices (reference material) This manual (supplied in digital and printed formats) is part of the AirPack C documentation set and must be read before initial equipment installation and operation. The validity of the manual can be compromised by post-delivery engineering modifications or regulatory changes that affect equipment use, ratings and limits. All NOV Elmar engineering changes are documented in as-built drawings, even after product delivery. This means the latest drawings always take precedence over manuals. If in doubt, contact NOV Elmar.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 5 of 150 Revision A Original Instructions

AirPack C User Manual

2

SAFETY TXT-10004141/A1

2.1

General Safety High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be present in ASEP Elmar equipment. Therefore, pay special attention to safety when working with this equipment. • Meet all applicable codes, laws and local field regulations (including environmental and additional owner/user company policy). This manual contains recommendations, but should not be assumed to satisfy all requirements of legal regulations. • Read and understand each item in this manual and follow all procedures, precautions and advice exactly - never take short cuts. Always consider your safety and that of others. • Only use the equipment within its design scope to avoid damage or dangerous situations. This manual (in its most current revision) is a minimum requirement for all persons working with ASEP Elmar equipment. All other current and applicable documents such as certification, drawings, bill of materials, vendor documentation, etc, should be readily available at the worksite.

2.1.1

Employee responsibility

2.1 General Safety

• Never leave "operation-ready" equipment unattended. • Keep equipment clean (accumulated dirt and dust can hamper unit operations and may increase the risk of ignition). • Correctly maintain and use equipment, apparatus, tools, and dangerous substances. • Wear personal protection equipment (PPE) where necessary; for example gloves and protective footwear. • Never work alone if there is a possibility of an accident. • Keep loose clothing and long hair well away from moving mechanical parts. • Remove rings, wristwatch, etc, before working. • Never disconnect, change or remove safety devices, and use such devices correctly. • Be aware of all emergency equipment and procedures (such as alarms, abandon ship, etc.) and make sure they are in place and valid. • Do not use the equipment after an emergency without verifying that the cause of the emergency has been removed or rectified. • Immediately inform the employer and other workers of any situation that represents a serious danger to safety and health, and of any shortcomings in protection arrangements. • Plan all operations including interdependencies with other equipment operations • If equipment is tied down using rope/line/chains, attach a "flag" to signal their location. • During installation, maintenance and/or equipment inspection:  where possible, make sure electrical/mechanical equipment is switched off completely, and use a decal or similar to prevent unauthorized starting;  always relieve pressure before working on hydraulic and/or pneumatic systems.

Page 6 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

2.1.2

Employer responsibility • Define the required competency of personnel working on the equipment (including supervision) and provide the required consultation, information and training. • Ensure that only trained, qualified and competent personnel can work on the equipment. • Ensure adequate safety equipment and emergency procedures are available (fire extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them. • Ensure a suitable program for installation, operation, maintenance, periodic inspection and testing of the equipment is defined, adhered to and recorded. • Do not allow work to proceed until a thorough examination and risk assessment of the work site and equipment has been done. The examination should assess (as a minimum) the condition of the work site and all critical components, plus the equipment structure. Only give approval to proceed when controls to manage potential causes are in place and measures are taken to mitigate potential consequences.

2.1.3

Warnings, cautions and requirements Equipment handling may involve residual risks which cannot be reasonably reduced by design alterations. To alert the user to potential hazards and recommend safe working practices, additional information is provided as warnings, cautions and/or requirements:

• CAUTION shows a relevant icon and the text CAUTION with a description of the hazard and the best practise to avoid it. Ignoring a caution can result in damage to equipment. • REQUIREMENT shows an icon and a description of the required PPE to minimise possible safety risks. Warnings, cautions and/or requirements are listed in the manual as a preceding step to a potentially dangerous action. Never proceed to following step(s) if you do not comply with or fully understand a Warning/Caution/Requirement. See the following examples:

WARNING

TXT-10004296/A

ELECTRIC SHOCK Connecting/disconnecting an energised (live) electrical cable can cause serious injury and or equipment damage. Always ensure that an electrical cable is electrically de-energized (dead) before connecting/disconnecting it.

CAUTION

TXT-10004378/A

EQUIPMENT DAMAGE Components can be damaged during cleaning. Take care when cleaning components; use appropriate cleaning tools.

Hearing protection Wear ear protection during this procedure.

NOTE: A warning, caution or requirement icon (occasionally with accompanying text) is often also affixed to the equipment at a prominent location. NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 7 of 150 Revision A Original Instructions

2.1 General Safety

• WARNING shows a relevant icon and the text WARNING with a description of the hazard and the best practise to avoid it. Ignoring a warning can result in equipment damage, plus serious injury and/or death.

AirPack C User Manual

2.2

Equipment specific safety

2.2.1

Emergency Stop buttons TXT-10004568/A

Emergency stop buttons are conveniently positioned on equipment and are easily recognized because of their bright red colour. See examples in Figure 2.1.

2.2 Equipment specific safety

Figure 2.1 Examples of Emergency Stop buttons Press the button in an emergency situation to instantly cut primary energy supply (electric, hydraulic or pneumatic) to moving parts. This will disable further equipment movement and reduce danger to the operator. Always notify a supervisor after pressing an EMERGENCY STOP.

2.2.2

Heavy equipment TXT-10004562/A

• Never attempt to move heavy equipment without the aid of a sufficiently dimensioned and certified mechanical device. • Only hoist joined equipment after ensuring that the joined equipment has been certified for single lifting by checking the certification in the Documentation Package that came with your equipment. • Make sure you cannot get trapped between a lifted load and a wall, fixed object, etc. • Never walk under a hanging load or allow heavy objects to rest in an unstable position.

2.2.3

ATEX and zoning TXT-10004560/A

Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the equipment is certified according to ATEX regulations, the following applies: • The power supply, including driven parts, has been manufactured and assessed according to ATEX and tagged with a unique identification number. • Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1, or Zone 2 compliance will be compromised. • Certified explosion safe equipment is suitable for use in gas hazardous classified locations, however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC). Check your unit data plate(s) and the specifications tables in the Appendix for the ATEX classification for your equipment. • The design and manufacturing is based on European Directive no. 94/9/EC following conformity assessment procedure relating to internal control of production according

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NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

Annex VIII of the Directive. The construction is documented in a confidential Technical Construction File held at the offices of ASEP Elmar.

2.2.4

Doors and hatches TXT-10004565/A

• While opening/closing hatches and doors, take account of wind conditions or sudden movement. Hatches and doors may forcibly swing open/shut causing damage or injury. • When open, the hinge side of doors and hatches can create extremely hazardous pinch points for fingers, clothing, hoses and cables. Always check the hinge side before closing any door or hatch. • Always use any built-in retainers to anchor the door or hatch if you need to leave it open or closed while you work.

2.2 Equipment specific safety

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 9 of 150 Revision A Original Instructions

AirPack C User Manual

3

PHYSICAL DESCRIPTION

3.1

Unit overview The following figure shows the naming conventions of the physical views used in the remainder of this section.

1

2 3

3.1 Unit overview

4

6 7 8

5

1

3.2 Unit rear view on page 11

2

3.3 Unit right view (spring starter) on page 12

3

3.4 Unit right view (hydraulic starter) on page 13

4

3.5 Unit right view (air starter) on page 14

5

3.6 Unit front view on page 15

6

3.7 Unit left view (spring starter) on page 16

7

3.8 Unit left view (hydraulic starter) on page 17

8

3.9 Unit left view (air starter) on page 18

Figure 3.1 Unit overview

Page 10 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

3.2

Unit rear view

1

2 3

7 3.2 Unit rear view

4

6 5

1

Exhaust silencer/ spark arrestor

2

Exhaust gas soot collector point

3

Compressor air intake filter

4

Compressor

5

Engine shock absorber

6

Air receiver auxiliary air circuit

7

Air-oil separator element

8

Hydraulic start manifold (optional)

8

Figure 3.2 Unit rear view

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 11 of 150 Revision A Original Instructions

AirPack C User Manual

3.3

Unit right view (spring starter)

3.3 Unit right view (spring starter)

1

2 3 5

4 6

1

Engine air inlet valve

2

Exhaust gas cooler

3

Engine oil dipstick

4

Compressor oil filter

5

Compressed air filter

6

Auto drain valve

Figure 3.3 Unit right view

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NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

3.4

Unit right view (hydraulic starter)

1

7

12

2

9 10 3

17

11

5

4

15 16 13

6

14

1

Engine air inlet valve

12

hydraulic charge hand pump

2

Exhaust gas cooler

13

hydraulic tank drain valve

3

Engine oil dipstick

14

hydraulic tank suction isolation valve w/ coarse particle filter

4

Compressor oil filter (obstructed by inlet hose)

15

Air driven charge pump for hydraulic start circuit. (mounted inside air inlet channel)

5

Compressed air filter

16

Activation valve for air driven charge pump

17

Rig air in connector

6

Auto drain valve (obstructed by inlet hose)

7

Hydraulic tank filler cap

8

hydraulic hand pump handle

9

Hydraulic tank sight glass (max level)

10

Hydraulic tank

11

Hydraulic tank sight glass (min level)

Figure 3.4 Unit right view NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 13 of 150 Revision A Original Instructions

3.4 Unit right view (hydraulic starter)

8

AirPack C User Manual

3.5

Unit right view (air starter)

3.5 Unit right view (air starter)

1

2

3 4

5

7 8 6

1

Engine air inlet valve

2

Exhaust gas cooler

3

Engine oil dipstick

4

Compressor oil filter (obstructed by inlet hose)

5

Compressed air filter

6

auto drain valve (obstructed by inlet hose)

7

Rig air in connector

8

Air filter for starter circuit

Figure 3.5 Unit right view

Page 14 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

3.6

Unit front view

3.6 Unit front view

1

2

1

Cooler stack - consisting of: engine coolant radiator; compressed air cooler; compressor oil cooler

2

Air driven charge pump for hydraulic start circuit.

Figure 3.6 Unit front view (sound-proofed grills removed)

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 15 of 150 Revision A Original Instructions

AirPack C User Manual

3.7

Unit left view (spring starter)

2 3.7 Unit left view (spring starter)

1 4

3 6

7

8

9

5

11

10

12 21

20

14 13

15

19 16

17

18

1

Engine air intake filter

12

Air output

2

Unit control panel

13

Fuel tank access cover

3

Fuel fine filter

14

Engine oil filter

4

Air inlet valve control handle

15

Fuel tank breather

5

Engine compressor (auxiliary pneumatics)

16

Fuel tank isolation valve/

6

Fuel pump gear drive

17

Fuel filler cap

7

Fuel pump

18

Fuel level gauge

8

Fuel prefilter/water separator

19

Auxiliary pneumatic system filter (behind panel)

9

Sentinel master valve (ENGINE SAFETY)

20

Spring starter

10

Compressor (main air system)

21

Spring starter hand crank

11

Air output

Figure 3.7 Unit left view (spring starter) Page 16 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

3.8

Unit left view (hydraulic starter)

2 1

66

7

8 9

5 21

10

11 12

20 19

14

22 13

15

17 18

16

1

Engine air intake filter

12

Air output

2

Unit control panel

13

Fuel tank access cover

3

Fuel fine filter

14

Engine oil filter

4

Air inlet valve control

15

Fuel tank breather

5

Engine compressor (auxiliary pneumatics)

16

Fuel tank isolation valve

6

Fuel pump gear drive

17

Fuel filler cap

7

Fuel pump

18

Fuel level gauge

8

Fuel prefilter/water separator

19

Auxiliary pneumatic system filter (behind panel)

9

Sentinel master valve (ENGINE SAFETY)

20

Hydraulic starter

10

Compressor (main air system)

21

Hydraulic accumulator

11

Air output

22

Hydraulic accumulator isolation valve

Figure 3.8 Unit left view (hydraulic starter) NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 17 of 150 Revision A Original Instructions

3.8 Unit left view (hydraulic starter)

4

3

AirPack C User Manual

3.9

Unit left view (air starter)

2

3.9 Unit left view (air starter)

1

4

3 6

7

8

5

9 11

10

12 20 14 13

19 15

16

17

18

1

Engine air intake filter

12

Air output

2

Unit control panel

13

Fuel tank access cover

3

Fuel fine filter

14

Engine oil filter

4

Air inlet valve control

15

Fuel tank breather

5

Engine compressor (auxiliary pneumatics)

16

Fuel tank isolation valve

6

Fuel pump gear drive

17

Fuel filler cap

7

Fuel pump

18

Fuel level gauge

8

Fuel prefilter/water separator

19

Auxiliary pneumatic system filter (behind panel)

9

Sentinel master valve (ENGINE SAFETY)

20

Air starter

10

Compressor (main air system)

11

Air output

Figure 3.9 Unit left view (air starter) Page 18 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

4

FUNCTIONAL DESCRIPTION

4.1

Introduction The AirPack C produces compressed air for sites requiring large amounts of pneumatic energy. The main energy source is a 54 kW Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. It drives a Rotorcomp EVO9-NK-G compressor that can provide up to 5 m³/min (177 cfm) of air or a nominal pressure of 10 bar (145 psi). The engine is equipped with either spring, pneumatic or hydraulic starter. The engine and exhaust gas are water-cooled and the coolant, along with the compressor’s oil and supply air, are air-cooled over forced-air heat exchangers (radiators). The unit is CE certified for Zone 2 ATEX operation. See Appendix 1: Specifications on page 131 for specifications.

4.1 Introduction

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 19 of 150 Revision A Original Instructions

AirPack C User Manual

4.2 Operator controls

4.2

Operator controls

1

2

6

8

12

7

3

4

13

5

10

11

9

Page 20 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

1 ENGINE TEMPERATURE

This gauge (0 ºC to +120 ºC (+32 °F to +230 °F)) shows the engine coolant temperature.

2 EXHAUST TEMPERATURE

This gauge (0 °C to +250 °C (+450 °F)) shows the engine exhaust temperature.

3 ENGINE OIL PRESSURE

This gauge shows the oil pressure in the engine and the engine safety system.

4 COMPRESSOR TEMPERATURE

This gauge (0 ºC to +120 ºC (+32 °F to +230 °F)) shows the temperature of the main compressor.

5 AIR PRESSURE

This gauge shows the air pressure in the main compressed air system.

6 START PRESSURE

This gauge shows the current starting pressure available for the start system (on air starter and hydraulic starter equipped engines).

7 EMERGENCY STOP

Press this knob to shut down the unit in an emergency. To reset it turn the knob clockwise until it springs back out. • DO NOT restart the unit without checking that the cause for the emergency stop has been resolved. • DO NOT use the emergency stop as a control to stop the unit during normal operations.

8 TACHOMETER

This gauge shows the engine speed in RPM and the engine running hours.

9 ENGINE STOP

Push this button to stop the engine; it releases automatically The engine safety sentinel valve cuts off fuel flow when the engine oil pressure drops below a certain value.Turning lever against the spring-pressure overrides the valve for starting.

11 AIR INLET VALVE

Use this handle to control the engine safety air intake control valve. Push the handle up to bypass the engine oil pressure safety system to allow the engine to be started. Hold the handle in the upper position until the motor oil pressure has risen to approx. 2 bar. Pull the handle down for emergency stop. This will close the air intake valve and stop the engine. For restarting wait 2 minutes for the shutdown-derived vacuum to disappear.

12 ENGINE START

Activator to start the engine. For a pneumatic start system it is a push button, for a hydraulic start system it is a twist knob. (Not present on spring starter units). Refer to 6.2 Power up on page 35 for detailed use.

13 CONTROL PRESSURE

This gauge shows the air pressure in the auxiliary pneumatic system

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 21 of 150 Revision A Original Instructions

4.2 Operator controls

10 ENGINE SAFETY

AirPack C User Manual

4.3

Engine

4.3 Engine

The AirPack C unit’s main power source is a Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. The engine drives a compressor directly (see Figure 4.1) for supplying compressed air. The engine and the exhaust system are water cooled. The OEM documentation for the engine is included in the Documentation Package.

Figure 4.1 Engine/compressor assembly

4.3.1

Engine safety system The engine safety system serves as: • An automatic shut-off system in case of an over-speed situation caused by ingress of hydrocarbon gases. • An automatic shut-off device in case of low engine oil pressure (+100 °C (>+212 °F) and high exhaust temperature >+200 °C (>392 °F) • A manually controlled shut-off device in case of an emergency stop The engine safety system consists of two main sub-systems which monitor the engine oil pressure: 1.

Fuel: The sentinel master valve (fuel shut-off valve) is positioned between the fine particle filter and the fuel injection pump. See Figure 4.2.The sentinel master valve monitors the oil

Page 22 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

pressure in the diesel engine. If the lubrication oil pressure drops under the factory setting of 0.5 bar (7.5 psi), the valve will block the supply of fuel and shut down the diesel engine. The oil pressure is also distributed to the air intake valve.

WARNING

TXT-10004285/A

DANGEROUS MACHINERY Changing factory settings can affect the safety of the system, and result in personal and/or equipment damage. Take extreme care when adjusting factory settings. If in doubt, contact ASEP Elmar

4.3 Engine

Figure 4.2 Engine fuel system safety valve 2.

Air intake:

An air intake filter assembly with disposable elements cleans the input air for the diesel engine. An air inlet safety valve is positioned in the air intake system, and is used to shutdown the diesel engine manually or automatically, by cutting off the air intake supply. It is factory pre-set to trip at desired pressure values and RPM settings. See Figure 4.3 below

WARNING

TXT-10004285/A

DANGEROUS MACHINERY Changing factory settings can affect the safety of the system, and result in personal and/or equipment damage. Take extreme care when adjusting factory settings. If in doubt, contact ASEP Elmar

A lever on the control console is used to open and close this safety valve. See 4.2 Operator controls on page 20. Pushing this lever up before starting the engine will mechanically open the

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 23 of 150 Revision A Original Instructions

AirPack C User Manual

valve, which is normally closed (spring loaded). Once the engine has started, the engine oil pressure will overcome the spring pressure and hold the valve open.

Figure 4.3 Air intake safety valve (roof removed for clarity)

4.3.2

Engine starters

4.3 Engine

The engine has options for either a spring starter, a pneumatic starter, or a hydraulic starter. See Figure 4.4 below for starter examples. a) Spring starter: is activated with a lever on the starter. Activating the lever releases spring tension which turns the starter, which in turn rotates the engine. b) Air starter: is activated from a button on the control panel. Activating the button opens a pneumatic valve, and rig air turns the starter, which in turn rotates the engine. c) Hydraulic starter: is activated from a button on the control panel. Activating the button opens a hydraulic valve, and hydraulic accumulator pressure turns the starter, which in turn rotates the engine. See 6.2 Power up on page 35 for more details on how to start the engine.

Page 24 of 150 Revision A Original Instructions

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AirPack C User Manual

4.3.3

Fuel system The fuel is stored in a fuel tank equipped with a breather. The fuel passes from the fuel tank through to the following components: a) Isolation valve (this valve can be closed for maintenance purposes) b) Coarse particle filter (strains large particles from the diesel) c) Fuel/water separator filter (removes water contamination from the diesel) d) Fuel gear pump e) Fuel primer pump (runs parallel with d above) f) Fuel fine particle filter (removes fine particles from the diesel) g) The sentinel master valve (fuel shut-off valve) h) Injector pump (pressurizes the fuel to the injectors) For an overview of the fuel system see the ‘as built’ FLUID DIAGRAM- ENGINE FUEL & OIL page in the Documentation Package. See Figure 4.5 below. A fuel/water separator (1) separates any water contamination from the diesel fuel. The fuel fine particle filter (2) removes particles larger than 10 µm. The frequency of

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 25 of 150 Revision A Original Instructions

4.3 Engine

Figure 4.4 Starter options: clockwise from top left:, HD spring starter, air starter, hydraulic starter

AirPack C User Manual

water draining or filter element replacement depends on the quality of the fuel. The primer pump (3) is used during the bleeding of the fuel system.

3 2

4.4 Compressor (Pneumatic) system

1

Figure 4.5 Fuel/water separator and primer pump

4.3.4

Exhaust system The exhaust gases are led from the engine through an exhaust gas cooler, flame trap and silencer (muffler) to the exhaust pipe which exits from the side of the unit. These components remove excess heat, soot and sparks from the exhaust which could otherwise ignite an explosive atmosphere near the exhaust outlet. The exhaust gas cooler cools the exhaust by circulating engine coolant through its heat exchanger.

4.4

Compressor (Pneumatic) system Compressed air is provided by a directly driven compressor. Ambient air is drawn into the main compressor through an air intake filter. It is then compressed to 10 bar (145 psi) in compression chamber where cooling/ lubricating oil is injected for supply. The supply air from the compressor passes through a separating tank and an air /oil separator filter to remove excess oil. The air is finally cooled by an air-cooled heat exchanger and further dried by passing through a cyclone air dryer (see Figure 4.6). A part of the compressed air is used to activate a pneumatic cylinder which regulates the engine speed, dependent on air consumption requirements. Two air outputs are available for site consumption use. See belowFigure 4.7. On air starter equipped units, rig air from the site provides air through a separate system for powering the starter system. The auxiliary pneumatic system is used to activate the ENGINE SAFETY system and EMERGENCY STOP circuit. It is powered by a separate 225cc compressor and is equipped with its own air cleaning and regulating components. On hydraulic starter equipped units, an air-operated oil pump can charge the hydraulic accumulator. This air-operated oil pump can be driven by rig air or by the auxiliary pneumatic system.

Page 26 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

NOTE: The ENGINE SAFETY and EMERGENCY STOP circuits must be powered by pneumatic pressure or else the engine will not remain running. .

4.4 Compressor (Pneumatic) system

Figure 4.6 Air-oil separator filters and cyclone air dryer

Figure 4.7 Compressed air outputs

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 27 of 150 Revision A Original Instructions

AirPack C User Manual

The compressor’s lube oil is filtered by a disposable filter element and air-cooled through a separate oil cooler. See Appendix 1: Specifications on page 131 for the compressor specifications. For an overview of the pneumatic system, see the ‘as built’ FLUID DIAGRAM- HYDRAULICS & PNEUMATICS Diagram in the Documentation Package that comes with the unit. For the main compressor details see the supplier documentation also included in the Documentation Package.

4.5

Cooling system The AirPack C unit is equipped with a belt-driven cooling fan. The fan draws ambient air through the radiator stack, which has three separate heat exchangers for the following circuits: • Coolant (engine and exhaust gas cooling) • Compressor oil • Compressed air Maintenance tasks include check/replenish the coolant level, drain/refill and bleed the (coolant) cooling system, check compressor oil level, change filters and to check the system for leaks. These are covered in 7.4 Periodic maintenance schedules on page 47.

4.6

Unit grounding

4.5 Cooling system

The AirPack C unit is equipped with grounding points on the right and left sides. These shall be utilized to ground the unit to the rig or the well-head to prevent static electrical discharge. See Figure 4.8.

Figure 4.8 Unit grounding point

Page 28 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

5

SETUP AND REMOVAL WARNING

TXT-10004286/A

DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

5.1

Moving/positioning equipment

WARNING

TXT-10004271/A

CRUSH HAZARD Heavy objects can trap limbs and cause serious injury or death. Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

WARNING

TXT-10004327/A

The unit may be moved and positioned by hoisting, or with a properly dimensioned forklift. See certification in the Documentation Package that came with this AirPack C unit. Make sure that the lifting equipment to be used is sufficiently dimensioned, has the correct certification, and is marked accordingly. The lifting equipment may only be used by suitably qualified personnel. All equipment lifting equipment must be subject to regular scheduled inspection compliant with EN 12079 for deformation and wear. All lifting equipment repairs must have been carried out compliant with EN 12079. Always use the lifting eyes on the four corners for hoisting. Never use the two eye bolt sockets on the top plate to lift the entire unit. These are for lifting the detached top plate only.

5.1.1

Land transportation When loading and transporting ASEP Elmar modules on a truck, several things need to be taken into consideration (most of these are also specified in the local traffic regulations): • Number of axles on the transport vehicle (to decide where to position one or more units) • Weight of unit(s) (total weight) • Height of the load (bridges, aqueducts, tunnels) • Width of the load (manoeuvring) • Travelling speed • Cornering (dead corner) • Securing modules and securing loose components Check all these before loading and transportation: • Make sure lifting equipment is sufficiently dimensioned.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 29 of 150 Revision A Original Instructions

5.1 Moving/positioning equipment

HOISTING HAZARD Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death. Never use the forklift pockets for hoisting.

AirPack C User Manual

• All equipment used for lifting must have the correct certification and be marked accordingly. • Only qualified personnel are allowed to use lifting equipment. • Before each lift, always ensure that the lifting shackles have been correctly attached to the unit.

5.1.2

Air transportation Standard procedure for air freighting a unit depends on local travel organizations. See Appendix 7: Air transportation on page 144 In general the following should be drained: • Fuel tank • Engine oil • Engine coolant • Gearboxes

5.1 Moving/positioning equipment

• Air tank • Compressor oil sump Other liquids within components will normally remain in the unit: • Fluid/oil coolers • Filters • Hoses

5.1.3

Draining If the carrier requires that all fluids are drained from the reservoirs, systems and components of the machine(s), please refer to 7.4 Periodic maintenance schedules on page 47 for specific instructions on how to drain the fluid from each reservoir, system or component. NOTE: Tag the unit or components to warn against starting before refilling. Photocopy or print the checklist in Appendix 7: Air transportation on page 144 as an aid to ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as follows:

5.1.4

1.

Check off each item as it is drained, adding your initials.

2.

Strike-out the items that are NOT present on the machine.

3.

Add any items that are present on the machine, but not on this list.

4.

Place this checklist in a prominent place on the machine.

Refilling Replenish the fluid in each of the items listed in the checklist. ASEP Elmar recommend that new fluid/oil filters are used when refilling systems that include filters. If you have fitted new filters, please add your initials in the last column. Refer to the APPENDICES on page 130 for the quantity and specifications of the required fluids. Refer to 7 Maintenance on page 47 for the procedures to check and replenish fluids for each of the reservoirs, systems and components. Where applicable, remember to bleed the system of air and refill as required.

Page 30 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

5.2

Site preparation Before positioning the unit at the site, survey the location where it will be used. There should be sufficient room on all sides for opening doors/hatches.

5.3

Rig-up

5.3.1

Positioning and grounding

WARNING

TXT-10004327/A

HOISTING HAZARD Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death. Never use the forklift pockets for hoisting.

WARNING

TXT-10004271/A

CRUSH HAZARD Heavy objects can trap limbs and cause serious injury or death. Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

1.

Move the unit to the operating position.

2.

Secure the unit in place according to site regulations. TXT-10004301/A

3.

5.3.2

Connect ground cables to the grounding points on the unit according to site regulations. Refer to 4.6 Unit grounding on page 28.

Testing

WARNING

TXT-10004358/A

NOISE HAZARD The engine noise can exceed 85 dB, causing possible hearing damage. Always wear suitable hearing protection when working around the running engine.

5.4

1.

Start up and test the unit as described in 6 Operation on page 34.

2.

Shut down the unit by performing 6.3 Normal shut down on page 42.

Rig-down

WARNING

TXT-10004255/A

COMPRESSED AIR Air and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.

To connect/disconnect a compressed air coupling: a) Shut off the nearest valve on the supply side of the coupling.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 31 of 150 Revision A Original Instructions

5.2 Site preparation

WARNING

EXPLOSION HAZARD Electrostatic discharge can cause an explosion. Always ensure that the unit has been correctly grounded before performing any work on the unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.

AirPack C User Manual

b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side. c) Then with eyes protected or at a safe distance from the coupling, carefully connect/ disconnect the coupling.

WARNING

TXT-10004322/A

HIGH PRESSURE (Dis)connecting a pressurized line can cause serious injury and or equipment damage. Never connect or disconnect any quick connectors when the supply line is pressurized.

CAUTION

TXT-10004382/A

5.5 Storage

EQUIPMENT DAMAGE Dirty or damaged quick connectors can leak and cause equipment damage. Before connecting a quick connector, inspect and clean both ends.

5.4.1

1.

Ensure that the unit has been shut down according to 6.3 Normal shut down on page 42.

2.

Disconnect the pneumatic hoses in the AirPack one by one.

3.

With a clean cloth, thoroughly clean the dust caps for the connectors.

4.

Fit the dust caps.

5.

Check that all cables and hoses are correctly stowed.

Finalize

WARNING

TXT-10004270/A

CRUSH HAZARD Closing a door or hatch can crush fingers and cause serious injury. Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.

1.

Make sure all access panels are correctly closed and secured.

2.

Disconnect the ground cables from the grounding points.

5.5

Storage

5.5.1

Short term storage (< 1 year) When storing the system for a short term, always take the following actions: 1.

Complete the rig-down steps as described in 5.4 Rig-down on page 31.

2.

If the machine is going to be stored in temperatures under -18 °C (0 °F): a) Refer to 7.4 Periodic maintenance schedules on page 47 for the procedures to remove water from: • Fuel tank, filters & lines • Engine cooling system & reservoir • Pneumatic anti-frost system b) Completely fill the following fluid reservoirs (if present) with appropriate fluid for expected low temperatures:

Page 32 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

• Fuel tank, filters & lines (fill the diesel tank completely with winter diesel if available) • Engine cooling system & reservoir • Pneumatic anti-frost system c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures. Refill with fluid again to full, if necessary.

5.5.2

3.

Close all panels and hatches on the unit and secure or lock them.

4.

Cover the unit with a suitable protection cover (these can be ordered from ASEP Elmar if required).

Long term storage (> 1 year) When storing the system for long periods, follow the steps in 5.5.1 Short term storage (< 1 year) on page 32, and take the following additional actions: Grease exposed metal surfaces to prevent corrosion.

2.

Grease all rubber seals to prevent damage and cracking.

3.

Fill the diesel tank to prevent condensation.

4.

Drain the coolant tank as described in 7.24 Drain/fill engine coolant on page 91.

5.

See 7 Air transportation on page 144, and the checklist in the appendix, for information on other possible drain points, and how to register your actions.

6.

Refer to your company policy for other possible storage requirements.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

5.5 Storage

1.

Page 33 of 150 Revision A Original Instructions

AirPack C User Manual

6

OPERATION

6.1

Pre-start checklist

WARNING

TXT-10004286/A

DANGEROUS MACHINERY Ignoring the instructions in this manual can result in serious injury or death. All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

1.

Ensure that you have read and understood section 2 Safety on page 6.

2.

Check environment for sufficient ventilation for dispersion of the exhaust gases.

3.

Ensure that the unit has been rigged up as described in 5.3 Rig-up on page 31.

4.

Perform all of the daily maintenance procedures listed in 7.4 Periodic maintenance schedules on page 47.

5.

Ensure that the engine is not running and cannot be started.

6.1 Pre-start checklist

WARNING

TXT-10004360/A

SHARP OBJECT Sharp or rough objects can cause severe cuts. Always wear gloves when handling sharp or rough objects.

6.

Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or components, and structural damage.

7.

Check all tanks and hoses for leaks, and for other visible damage.

8.

Ensure that the cooling air intake and exhaust openings are not obstructed.

9.

Ensure that all components requiring lubrication are serviced as necessary.

10. Check that no unauthorized modifications have been made to the unit.

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AirPack C User Manual

6.2

Power up The engine speed is self-regulating, dependent on the required air output. The speed will be increased when the compressor system senses no pressure build-up. In order to have the engine run at lower speeds until it reaches operating temperature, it is essential to close all air output valves.

WARNING

TXT-10004282/A

DANGEROUS MACHINERY Once the unit is started, all systems are energized and components can move when the controls are operated. Do not start the AirPack C unless: • You are authorized to operate the equipment and have read this manual. • The unit is properly positioned and anchored for operation. • All essential maintenance has been carried out. • There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A

NOISE HAZARD The engine noise can exceed 85 dB, causing possible hearing damage. Always wear suitable hearing protection when working around the running engine.

If starting the AirPack C for the first time, read this entire section thoroughly, and be certain you understand every part before starting the unit, especially sections: • 6.3 Normal shut down on page 42

1.

Ensure that 6.1 Pre-start checklist above has been done before proceeding.

2.

Refer to the figures on the following pages. Check that the EMERGENCY STOP button (6) is not activated (i.e. it is pulled out or reset). If it is activated:  Check that it has not been pushed in to prevent starting the unit, because someone is performing maintenance on it. (Lock out/tag out)  Rectify the problem that caused the emergency before continuing.

WARNING

TXT-10004255/A

COMPRESSED AIR Air and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.

To connect/disconnect a compressed air coupling: a) Shut off the nearest valve on the supply side of the coupling. b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side. c) Then with eyes protected or at a safe distance from the coupling, carefully connect/ disconnect the coupling.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 35 of 150 Revision A Original Instructions

6.2 Power up

• 6.4 Emergency stop on page 43

AirPack C User Manual

3.

If connected, remove at least one hose to the valve air output isolation valves (1) is open the valve. See Figure 6.1.

4.

Alternatively, remove at least one of the blind caps (2) from the output and open the valve. This is necessary to ensure that the compressor offers minimal resistance when starting the engine.

5.

Close the isolation valves of any remaining connected air outputs.

1

6.2 Power up

2

Figure 6.1 Air output valves 6.

6.2.1

Continue below for starter type indicated.

For spring starter equipped engines NOTE: Starting with a spring starter may require two persons. One to activate the starter at the engine, and one to hold open the AIR INLET VALVE.

CAUTION EQUIPMENT DAMAGE Winding the spring starter with an air-hammer or any other type of power tool can seriously damage it. Only use the supplied hand crank to wind the spring starter.

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NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

6

1

Figure 6.2 Start and stop controls

1.

Locate the spring starter on left side of the engine; see Figure 6.3.

2.

Depress and release the reset button (3).

3.

Remove the hand crank from its storage location and fit it to the winding shaft (4).

4.

Using the handle, wind the starter clockwise to the required power output. The maximum number of turns is 39. For most applications 3336 turns of the handle should prove sufficient.

5 4

3

Figure 6.3 Spring Starter

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 37 of 150 Revision A Original Instructions

6.2 Power up

2

AirPack C User Manual

NOTE: Over-winding will reduce the life of the starter. NOTE: It is possible to unwind the starter, should it become necessary, by turning the handle counter-clockwise; additional force will be required to overcome the initial friction. 5.

Remove the handle from the starter, and return it to the storage/transit location. NOTE: The starter should never be tripped with the winding handle in place.

6.

Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (1) clockwise against the spring pressure; see Figure 6.2. NOTE: This will override the diesel safety system, until the engine oil pressure holds the valve open.

7.

Push the AIR INLET VALVE lever (2) on the control panel all the way up, and hold it in that position.

8.

On the starter, pull the trip lever (5) through 90 degrees in the direction shown by the arrow in Figure 6.3, to start the engine.

9.

When the ENGINE OIL PRESSURE gauge (6) shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position. If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

6.2 Power up

10. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up. NOTE: This is necessary to keep the engine from revving too high before it is warmed up. 11. After the engine has run for about one minute check the engine oil pressure again. This should be at least 3 bar. If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot according to section 8 Troubleshooting on page 125.

WARNING

TXT-10004269/A

HIGH PRESSURE Air under high pressure may be ejected at great force causing bodily harm and damage to equipment. When releasing air under pressure: • Prevent access by unauthorized persons. • Wear appropriate personal protective equipment (PPE), especially protective glasses.

12. If required, open the isolation valves on the required air outputs.

6.2.2

For air starter equipped engines

CAUTION

TXT-10004515/A

EQUIPMENT DAMAGE Leaving the pneumatic system under pressure, when the unit is not running can damage it. Always close the rig-air input isolation valve and shut off the rig-air supply point, when the unit is shut down for longer than a few minutes.

Page 38 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

Supply air to the unit as follows: a) Locate the rig air supply input connection on the right side of the unit, and ensure valve (6) is initially closed, as shown in Figure 6.4.

6

NOTE: Rig air is used ONLY for starting the engine. It should never be hooked up to the AirPack C for any other purpose! b) Connect a suitable air supply (7 bar (100 psi) at 25 l/min) to the rig-air connection.

rig air connection

Figure 6.4 Rig air input

c) Open the rig-air supply at the supply point. d) Slowly open the rig-air intake valve (6) on the unit. 1.

Go to the control panel. See Figure 6.5.

5 6.2 Power up

1

4 3 2

Figure 6.5 AirPack C starting and stopping controls 2.

Ensure that the START PRESSURE gauge (1) shows between 7 bar and 10 bar.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 39 of 150 Revision A Original Instructions

AirPack C User Manual

NOTE: A minimum of 7 bar is required to start the engine.

WARNING

TXT-10004270/A

CRUSH HAZARD Closing a door or hatch can crush fingers and cause serious injury. Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.

3.

Close all access panels and doors around the AirPack C, except for the control panel access hatch.

4.

Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure. NOTE: This will override the diesel safety system, until the engine oil pressure holds the valve open.

5.

Push the AIR INLET VALVE lever (3) on the control panel all the way up, and hold it in that position.

6.

Press and hold the ENGINE START button (4) until the engine starts, then release.

7.

When the ENGINE OIL PRESSURE gauge (5) shows a reading above 2 AIR INLET VALVE from its upper position.

bar (29 psi), release the

6.2 Power up

If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125. NOTE: Close the air output you opened to start the unit, and reconnect any hoses you may have disconnected in step 3 of section 6.2 Power up above. NOTE: This is necessary to keep the engine from revving too high before it is warmed up. 8.

After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar. If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125

WARNING

TXT-10004269/A

HIGH PRESSURE Air under high pressure may be ejected at great force causing bodily harm and damage to equipment. When releasing air under pressure: • Prevent access by unauthorized persons. • Wear appropriate personal protective equipment (PPE), especially protective glasses.

9.

If required, open the isolation valves on the required air outputs.

10. Close the rig-air intake valve. 11. Close the shore/rig-air supply at the supply point. 12. Disconnect the shore/rig-air connection.

6.2.3

For hydraulic starter equipped engines 1.

Ensure that the isolation valve for the starter accumulator is open.

2.

Check the START PRESSURE gauge (1) on the power pack control panel to see if the starter accumulator has sufficient pressure to start the unit.

Page 40 of 150 Revision A Original Instructions

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AirPack C User Manual

NOTE: The hydraulic starter needs 120 bar start pressure for one start attempt. 3.

If there is not enough hydraulic pressure to start the unit, charge the accumulator as described in 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45.

5

1

3 2

Figure 6.6 AirPack C starting and stopping controls 4.

Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure; see Figure 6.6. NOTE: This will override the diesel safety system, until the engine oil pressure holds the valve open.

5.

Push the AIR INLET VALVE lever (3) on the control panel all the way up, and hold it in that position.

6.

Turn and hold the ENGINE START knob (4) clockwise until the engine starts, then release.

7.

When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position. If the engine fails to start, perform steps 1 to7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 41 of 150 Revision A Original Instructions

6.2 Power up

4

AirPack C User Manual

8.

Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up above.

NOTE: This is necessary to keep the engine from revving too high before it is warmed up. 9.

After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar. If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125

10. Once the engine is running, the hydraulic starter circuit maybe charged again to save it for the next start. For a detailed explanation, see 6.5.2 Charge starter accumulator using the airoperated oil pump on page 45

WARNING

TXT-10004269/A

HIGH PRESSURE Air under high pressure may be ejected at great force causing bodily harm and damage to equipment. When releasing air under pressure: • Prevent access by unauthorized persons. • Wear appropriate personal protective equipment (PPE), especially protective glasses.

6.3 Normal shut down

11. If required, open the isolation valves on the required air outputs.

6.3

Normal shut down The engine speed is self-regulating, dependent on the required air output. Allow the engine to run at near idle speed before shutdown by closing the air output valves. 1.

Close all isolation valves on the air outputs.

2.

Pull the ENGINE STOP lever (4) to stop the engine, See Figure 6.5

3.

Check the tachometer to ensure the engine speed drops to zero RPM.

WARNING

TXT-10004255/A

COMPRESSED AIR Air and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.

To connect/disconnect a compressed air coupling: a) Shut off the nearest valve on the supply side of the coupling. b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side. c) Then with eyes protected or at a safe distance from the coupling, carefully connect/ disconnect the coupling. 4.

Disconnect one of the hoses, if all three air outputs are connected.

5.

Carefully and slowly open a disconnected air output a few millimetres to bleed off the compressed air left in the unit.

6.

After the gauge shows zero air pressure, close the valve.

7.

Note the shut-down date and time in the running hours log (see Appendix 6: Running hours log book on page 140).

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AirPack C User Manual

8.

Carry out the following daily shut-down tasks, and fix any problems as necessary: a) Inspect all hoses, couplings, and components for signs of air leaks/ oil leaks, wear and damage. b) Check the levels of all fluid reservoirs, replenishing as necessary: • Engine fuel level • Engine oil level • Engine coolant level • Compressor oil level • Pneumatic line lubricator • Hydraulic starter system reservoir c) Check that the pneumatic system automatic water drain is working correctly.

9.

6.4

If shutting down for safe maintenance, activate the EMERGENCY STOP button, and tag it with a maintenance warning.

Emergency stop The AirPack C has two modes of emergency stop:

• System (automatic), which is caused by a system condition

6.4.1

Manual emergency stop The unit has an EMERGENCY STOP button. In an emergency, push this button to immediately stop the engine. This releases the air and oil pressure from the engine safety system, and chokes the diesel air inlet and sentinel fuel valves. After resolving the emergency situation, perform a pre-start inspection (6.1 Pre-start checklist), and then restart the unit (6.2 Power up).

6.4.2

System (automatic) emergency stop For some engine alarms, the system will automatically shut the engine down. This shutdown procedure is triggered by one or combination of the following: • Low oil pressure: System View -> Engine -> Air pressure.

Horn inoperative

Leak or restriction in air line

Repair leak or clear restriction

Horn is damaged

Replace horn

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 129 of 150 Revision A Original Instructions

8.2 Troubleshooting tables

Rig air supply insufficient (if being utilized)

AirPack C User Manual

APPENDICES This section contains the following appendices: Appendix 1: Specifications on page 131 Appendix 2: Quick reference on page 133 Appendix 3: Lubricants on page 135 Appendix 4: Unit hydraulic oils on page 138 Appendix 5: ASEP Elmar tightening conventions on page 139 Appendix 6: Running hours log book on page 140 Appendix 7: Air transportation on page 144 Appendix 8: Contact us on page 146

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AirPack C User Manual

Appendix 1: Specifications Dimensions unit Transport dimensions L x W x H (overall with doors closed)

2940 x 1200 x 1510 mm (115.75 x 47.25 x 59.44 in)

Tare weight

2500 kg (5512 lbs)

Maximum rating

3500 kg (7716 lbs)

Operational conditions Area classification

Zone 2

Operating temperature range

-20 °C to +40 °C (-4 °F to +104 °F) Spring start unit: +5 °C to +40 °C (+41 °F to +104 °F)

Standards conformities

EN 12079/DNV 2.7-1 2006/42/EC Machinery Directive; ATEX

Type

Caterpillar diesel engine, 4-cylinder, liquid cooled, 4.4-litre (269 in³) displacement, naturally aspirated, Ex Zone 2 II 3G IIA

Power output

54 kW (72hp) @ 2200 rpm

Starter types:

Spring, pneumatic, hydraulic Ex Zone 2

Main fuel tank volume

109 l (28.8 US gal)

Air/ pneumatic system Source

Rotorcomp EVO9-NK-G compressor

Compressor power rating

37 kW

Air pressure

10 bar (145 psi) nominal

Compressor flow volume

5 m3/min (177 cfm) Free Air Delivery (FAD) @ 2200RPM

Auxiliary circuit air compressor volume

495 L @ 2200RPM

Auxiliary circuit air receiver volume

10 L (2.6 US gal)

Hoisting Lifting sling set

4-leg, wire rope, SWL 7000 kg (15 432 lb), WL 3 m (118 in), green pin bolt OD 22 mm, EN 12079/DNV 2.7-1, Lloyd’s certified

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 131 of 150 Revision A Original Instructions

Appendix 1: Specifications

Power system

AirPack C User Manual

Fluids Engine fuel

Tank capacity: 109 L (28.8 US gal.) Fuel: EN 590-approved diesel or equivalent. For detailed fuel specification, see Caterpillar engine manual, supplied separately.

Engine oil

Capacity: 11.4 L (3.0 US gal.) Filled with: Mobil Delvac Super 1400 15W-40 For compatible oil types see Appendix 3: Lubricants For detailed engine oil specification, see Caterpillar engine manual, supplied separately.

Hydraulic oil

Tank capacity:20 L (5.3 US gal.) Filled with: Univis N 46 For compatible oil types see Appendix 3: Lubricants

Coolant

Capacity: Filled with: Agip Permanent Fluid LL Alu Protect

Appendix 1: Specifications

Fluid: USE ONLY VW TL- 774-D/F SPEC. COOLANT 50/50 Glycol/water Mix For Aluminum Radiators. Free Of Silicates, Borates, Nitrates, Phosphates. Reduction gearbox (Fuel pump gear drive) oil

Capacity: 100mL (3.3 fl.oz.) Filled with: Mobilgear SHC XMP- 150 For compatible oil types see Appendix 3: Lubricants

Compressor oil

Capacity: 25 l (6.6 US gal) Filled with: Mobil Rarus 426 For compatible oil types see Appendix 3: Lubricants For detailed compressor oil specification, see Rotocomp compressor manual, supplied separately.

NOTE: Data sheets and MSDS for all of the fluids used in the original assembly are found in the unit’s documentation package. Filter elements

Part number

Engine air filter

A0018469

Engine oil filter

A1060581

Engine fuel coarse filter (Y-type)

A0000082

Engine fuel fine particle filter

A1060585

Engine fuel/water separator filter

A1060577

Hydraulic suction filter (bowl type) 10µm

A0000161

Compressor intake air filter

For replacements please contact NOV Elmar After Sales

Compressor oil filter

L-8501059392

Compressor air-oil separator filter

L-8501059391

Page 132 of 150 Revision A Original Instructions

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AirPack C User Manual

Appendix 2: Quick reference WARNING

TXT-10004255/A

COMPRESSED AIR Air and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.

To connect/disconnect a compressed air coupling: a) Shut off the nearest valve on the supply side of the coupling. b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side. c) Then with eyes protected or at a safe distance from the coupling, carefully connect/ disconnect the coupling.

WARNING

TXT-10004358/A

Startup 1.

Ensure the pre-start checklist is completed.

2.

Ensure that one of the air outputs is disconnected and the isolation valve is open. This is necessary, to ensure that the compressor gives as little resistance as possible, when starting the engine.

3.

Determine starter type: For air start engine: a) Supply air to the unit as follows: • Ensure that an air supply (7 bar (100 psi) at 25 l/min) is connected to the rig-air connection on the unit. • Open the shore/rig-air supply at the supply point. • Slowly open the rig-air intake valve on the unit. b) Ensure that the START PRESSURE is between 7 bar and 10 bar. For hydraulic start engine: • Ensure that the START PRESSURE is at least 120 bar. For spring start engine: • Wind starter up fully

4.

Reset the ENGINE SAFETY valve by turning the control lever clockwise against the spring pressure.

5.

Push the AIR INLET VALVE lever on the control panel all the way up, and hold it in that position.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 133 of 150 Revision A Original Instructions

Appendix 2: Quick reference

NOISE HAZARD The engine noise can exceed 85 dB, causing possible hearing damage. Always wear suitable hearing protection when working around the running engine.

AirPack C User Manual

6.

For Air and hydraulic start, press and hold the ENGINE START button/ knob until the engine starts.

7.

For spring starter trip the start lever.

8.

Hold the AIR INLET VALVE lever until the engine oil pressure is above 2 bar (29 psi), then release it.

9.

Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it earlier.

10. After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar.

Appendix 2: Quick reference

Shutdown 1.

Set the engine speed to idle.

2.

Push the ENGINE STOP button to stop the engine.

3.

Check the tachometer to see that the engine has stopped.

4.

Close all isolation valves on the air outputs.

Manual Emergency shutdown 1.

Push the EMERGENCY STOP button on the control panel to kill the engine.

Emergency shutdown recovery 1.

Ensure that the cause of the emergency shutdown has been identified and solved.

2.

Release an activated EMERGENCY STOP button by turning it clockwise until it releases.

3.

Start up the machine as described above in Startup.

Page 134 of 150 Revision A Original Instructions

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AirPack C User Manual

Appendix 3: Lubricants Engine lubricants table TXT-10004503/A

Choosing the right engine lubricant is critical to the proper functioning of the engine, to avoid damage and/ or costly repairs. Refer to the maintenance section for the change intervals required. Select a good quality lubricant that is suitable for the ambient temperature where the machine is used. NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at the time of delivery. Data sheets and MSDS for all of the fluids used in the original assembly are found in the unit’s documentation package.

Ambient temperature -30 °C (-20 °F)

-20 °C (-2 °F)

-10 °C (+14 °F)

0 °C (+32 °F)

+10 °C (+50 °F)

+20 °C (+68 °F)

+30 °C (+86 °F)

+40 °C (+104 °F)

SAE 5W20

Appendix 3: Lubricants

SAE 5W30 SAE 10W40 SAE 10W30 SAE 15W50 SAE 15W40 SAE 20W50 SAE 20W40 SAE 10 SAE 20 SAE 30 SAE 40

Engine lubricants

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 135 of 150 Revision A Original Instructions

AirPack C User Manual

Gearbox lubricants table TXT-10004505/A

Gearboxes include final drive reduction gearboxes and fuel pump gear drives. Choosing the right gearbox lubricant is critical to the proper functioning of the gearboxes, to avoid damage and/ or costly repairs. Refer to the maintenance section for the change intervals required. NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at the time of delivery. Data sheets and MSDS for all of the fluids used in the original assembly are found in the unit’s documentation package.

Appendix 3: Lubricants

Ambient temperature -20 °C to +5 °C (-2 °F to +41 °F) IV 95

+5 °C to +40 °C (+41 °F to +104 °F) IV 95

+40 °C to +55 °C (+104 °F to +131 °F) IV 95

-30 °C to +65 °C (-20 °F to +149 °F) IV 165

ISO 3448

VG 100

VG 150

VG 320

VG 150-220

AGIP

Blasia 100

Blasia 150

Blasia 320

Blasia S 220

ARAL

Degol BG 100

Degol BG 150

Degol BG 320

Degol GS 220

BP MACH

GR XP 100

GR XP 150

GR XP 320

SGR XP 220 Enersyn HTX 220

CASTROL

Alpha SP 100

Alpha SP 150

Alpha 320

Alpha SN 150 Alpha SN 6

CHEVRON

non leaded gear compound 100

non leaded gear compound 150

non leaded gear compound 320

ELF

Reductelf SP100

Reductelf SP150

Reductelf SP320

Elf ORITIS 125 MS Elf Syntherma P 30

ESSO

Spartan EP 100

Spartan EP 150

Spartan EP 320

Comp. oil LG 50

FINA

Giran 100

Giran 150

Giran 320

Giran 220

EP lub. HD 150

EP lub. HD 320

GULF I.P.

Mellana 100

Mellana 150

Mellana 320

Telesia Oil 150

KLUEBER

Gem 1-100

Gem 1-150

Gem 1-320

Synteso D 220

Mobilgear SHC XMP150 Mobilgear 629

Mobilgear 632

Glygoyle 22 Glygoyle 30 SHC 630

MOBIL

Q8

Goya 100

Goya 150

Goya 320

Greco 228

SHELL

Omala Oil 100

Omala Oil 150

Omala Oil 320

Tivela Oil SA

TOTAL

Carter EP 100 N

Carter EP 150 N

Carter EP 320 N

Gearbox lubricants

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AirPack C User Manual

NOTE: Select a lubricant that is suitable for the ambient temperature in which the machine is to be operated.

Compressor oils compatibility table The lubricating oil is critical to the proper operation of the rotary screw type compressor. Select an oil that is suitable for the ambient temperature in which the machine is to be operated. Operating temperature of compressor oil will increase during operation. Mineral oils are generally less expensive but require more frequent change intervals (up to 2000 hrs). Synthetic oils are more expensive but change intervals can be increased (6000-8000 hrs). NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at the time of delivery. Data sheets and MSDS for all of the fluids used in the original assembly are found in the unit’s documentation package. Operating temperatures -10 °C to +110 °C (+14 °F to +230 °F) Oil type

Synthetic

ISO 26 oils

no

no

ISO 46 oils

no

yes

Recommended

Recommended

BP

See Castrol

See Castrol

Castrol

Aircol PD 68

Aircol SR 68 or Tribol 890/68

ISO VG 68 oils

Chevron/ Texaco Total/Fina/ELF Esso/ Exxon Mobil Q8

Cetus PAO 68 Total DACNIS 68 Compressor Oil 68 Rarus 426

CPC Summit

Rarus SHC 1026

Schumann 68

Shell Kluber

Total DACNIS SH 68

Corena S4 R 68 Summit PS 200

Summit SH 68

SC-68 Ultima-68 ASEP Elmar recommended compressor oils

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 137 of 150 Revision A Original Instructions

Appendix 3: Lubricants

Mineral

AirPack C User Manual

Appendix 4: Unit hydraulic oils TXT-10004700/A

Hydraulic oils compatibility table Select an oil that is suitable for the ambient temperature in which the machine is to be operated. Operating temperature of hydraulic oil will increase during operation. Machines fitted with a winterization package may have an oil heater to pre-heat the oil before operations.

Appendix 4: Unit hydraulic oils

NOTE: Refer to the unit specifications for the specific oil supplied in the unit by NOV Elmar at the time of delivery. Data sheets and MSDS for all of the fluids used in the original assembly are found in the unit’s documentation package.

Low temperatures below -15 °C (+5 °F)

Normal temperatures -5.0 °C to +60 °C (+25 °F to +142 °F)

Very high temperatures to +75 °C (+167 °F)

ISO 26 oils

yes

no

no

ISO 46 oils

no

yes

no

ISO 68 oils

no

no

yes

BP

Energol H:LP 46

Castrol

Hyspin AWS 46

Chevron

Mechanism LPS 46

ELF

Visga 46

Esso / Exxon

Univis HVI26

Univis N46

Mobil

ATF 220

Q8

Haydn 46

Shell

Tellus T 46

Texaco

Rando HD 46 NOV Elmar recommended hydraulic oils for main power and control circuits

NOTE: Select an oil that is suitable for the ambient temperature in which the machine is to be operated. Operating temperature of hydraulic oil will increase during operation. Machines fitted with a winterization package may have an oil heater to pre-heat the oil before operations.

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AirPack C User Manual

Appendix 5: ASEP Elmar tightening conventions TXT-10004458/A

This section provides recommended torque to be applied to bolted connections in this unit. The fasteners used in this unit are normally either stainless steel (quality A2/70) or plain high tensile steel (quality 8.8 or better). These values are for dry (non lubricated) connections. Use lower torque values for lubricated connections. NOTE: When tightening a cover panel with a soft joint seal or gasket, e.g. for a tank inspection opening, use lower torques than specified in the table below.

M8

M10

M12

M14

M16

M20

M24

Comment

A2/70 (SS)

15

30

50

80

120

250

340

use spring washer or self-locking nut

8.8 (plain)

20

40

70

110

175

350

600

use self-locking nut

10.9 (plain)

30

60

100

160

250

490

850

use self-locking nut

12.9 (plain)

35

70

120

195

300

580

1000

use self-locking nut

Appendix 5: ASEP Elmar tightening conventions

Metal grade

Recommended bolt tightening torques (Nm)

Examples: • M10×25 DIN933A2-70, apply a torque of 30 Nm • M12×65 DIN925-10.9, apply a torque of 100 Nm

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

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Appendix 6: Running hours log book TXT-10004509/A

Like all machinery, the AirPack C needs to be serviced at regular intervals. The work to be performed at each interval is described in more detail in the Maintenance section of this manual. The specific service intervals are: • Daily (once every 24 hours when the AirPack C is in use) • After job maintenance (after completion of each wireline job) • 300-hour service (after 300 hours of wireline winch operation) • 600-hour service • 900-hour service • 1200-hour service

Appendix 6: Running hours log book

• 1500-hour or annual service Even if there is automatic logging of the number of hours the AirPack C is in operation, it is still important to manually record all hours that the wireline winch is "running". It is also important to record the number of hours and the date at which each of the services (100, 300, etc.) is actually carried out. To make this easier, ASEP Elmar provides with this manual (see page 143) a blank form for recording the running hours, and the interval-based services planned and actually carried out. NOTE: Every organization has its own rules and systems for logging running hours and service activity. The form and procedures described here are no more than a suggestion for a simple running hours and service logging system. Because the service intervals are primarily aimed at the mechanical components, we recommend logging all hours that mechanical components are in use. In other words, from the moment the AirPack C enters stand-by prior to operations, to the moment the AirPack C is shut down. NOTE: If the running hours for major subsystems of the AirPack C are different (e.g. the power pack or engine are run for longer hours than the winch module), then log the usage hours for each subsystem on separate forms, so that the service is carried out no earlier than needed on the less-used subsystem. Keep all log forms in a special folder, and make sure that the maintenance engineer knows where to find this folder. Make sure that the lower section is properly filled-in whenever the UniTruck gets an interval service (100, 300, etc… hours). The figure on page 141 shows a filled-in ASEP Elmar usage & service log form, for a wireline unit that has already been running for 1823 hours before this sheet was opened. The hours have been carried forward from the previous form.

Page 140 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

Appendix 6: Running hours log book

Example running hours & service log form

Open a new running hours and service log form: 1.

Carry the hours forward from the last row of the previous form (or enter zero for a new unit).

2.

Identify the AirPack C (e.g. registration plate).

3.

Enter the date the form was opened.

4.

Calculate or carry forward the running hours at which the next service is scheduled (for 100, 300, 900, 1200, and 1500 hours).

File the previous form in a running hours and service log folder.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

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Log session running hours 1.

At the start of the session, once the mechanical system is started, enter the start date and time.

2.

At the end of the session, when the mechanical system is stopped (or if there is an unscheduled halt due to job problems or corrective maintenance activity): a) Enter the stop date and time. b) Calculate and enter the session hours between the start and stop time. c) Calculate and enter the cumulative hours by adding the session hours to the previous cumulative hours. d) Enter any remarks about the session that may be relevant to future problem diagnosis or service activity (e.g. chain tension tightened, hydraulic oil topped up).

Log scheduled service activity

Appendix 6: Running hours log book

On completion of the service activity, on the currently open running hours and service log form: 1.

Enter the actual running hours at which the service was carried out.

2.

Enter the actual date at which the service was carried out.

3.

Enter any remarks about the service activity that may be relevant to future problem diagnosis or service activity (e.g. brake band inspected and OK, must be replaced at next service).

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AirPack C User Manual

Unit ID:_____________________________________

Date form opened:_____________________________

Running Hours Start Date

Stop Time

Date

Hours Time

Session

Remarks

Cumul.

carried forward from previous sheet

Appendix 6: Running hours log book

carry forward to next sheet

Service Log Next service (hours)

Due at (hours)

Done at (hours)

On (date)

Remarks

300 600 900 1200 1500/ ann.

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 143 of 150 Revision A Original Instructions

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Appendix 7: Air transportation TXT-10004443/A

If the machine is to be transported by air, the carrier may require that all fluids are drained from the reservoirs, systems and components of the machine(s). Please refer to the maintenance instructions accompanying your product for specific instructions on how to drain the fluid from each reservoir, system or component. On the reverse side of this page, ASEP Elmar provides a checklist as an aid to ensuring that no part is overlooked when draining and refilling the machine.

Appendix 7: Air transportation

Draining: 4.

Check off each item as it is drained, adding your initials.

5.

Strike-out the items that are NOT present on the machine.

6.

Add any items that are present on the machine, but not on this list.

7.

Tag out the unit or component to warn against starting before refilling.

8.

Place this checklist in a prominent place on the machine (e.g. in the cabin, in a weatherproof envelope attached to the main operator station, etc.)

Refilling: 9.

Refer to the maintenance instructions or specifications pages of the manual for this machine, for the quantity and specifications of the required fluids.

10. Refer to the maintenance instructions for the procedure to check and replenish fluids for each of the reservoirs, systems and components. 11. Replenish the fluid in each of the items on the reverse side of this page, remembering to bleed the system of air and again replenish if necessary. 12. ASEP recommends that new oil filters are used when replenishing systems that include filters. If you have fitted new filters, please add your initials in the last column.

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AirPack C User Manual

FLUID RESERVOIRS/SYSTEMS/COMPONENTS DRAINED / REPLENISHED FOR TRANSPORTATION Date drained: Ite m

Description

Date replenished: Bleed

01

Hydraulic tank

Y

02

Fuel tank

Y

03

Engine oil sump

04

Compressor oil sump

Y

05

Engine coolant

Y

06

Gearbox, reduction final drive

07

Gearbox, fuel pump drive

New filter(s) recomm.

INITIALS Drained

Replen.

New filter

Y Y

08 09 Pneumatic line oiler

11

Pneumatic anti-frost system

12

Batteries

13

Grease injection system reservoir

14

Pressure testing reservoir

Appendix 7: Air transportation

10

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013

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Appendix 8: Contact us

Appendix 8: Contact us

TXT-10004145/A1

Manufacturing Locations

Address

Telephone, Fax and E-mail

NOV Elmar

7909 Parkwood Circle Dr., Houston, TX 77036, United States of America

www.nov.com

NOV Elmar - UK

Enterprise Drive, Westhill Ind. Estate, Westhill, Aberdeen AB32 6TQ, Scotland, United Kingdom

Tel.: +44 1224 740261 Fax: +44 1224 743138 [email protected]

NOV Elmar - Netherlands

Energieweg 26, 2964 LE Groot-Ammers, The Netherlands

Tel.: +31 184 608 700 Fax: +31 184 608 790 [email protected]

NOV Elmar - USA

11995 FM 529, Houston, TX77041, United States of America

Tel.: +1 713 983 9281 Fax: +1 713 983 8892 [email protected]

NOV Elmar - UAE

Oilfields Supply Center B-17 Jebel Ali Free Zone P.O. Box 18633 Dubai, United Arab Emirates

Tel.: +971 4 8835 910 Fax: +971 4 883 7087 [email protected]

NOV Elmar - Singapore

7 Loyang Way Singapore 508721 Singapore

Tel.: +65 6546 0928 Fax: +65 6546 0927 [email protected]

NOV Elmar - Russia

26 Chapaeva Nizhegorodka Bashkortostan Republic Ufa Region Russian Federation 450520

Tel.: +7 347 271 9490 [email protected]

NOV Elmar - Canada (DynaWinch Product Line)

6771 - 84 Street SE Calgary, Alberta, T2C 4T6 Canada

Tel.: +1 403 319 2333 Fax: +1 403 319 2337 [email protected]

NOV Elmar - Brazil

Equipmentos E Servicos Para Petroleo LTDA Estrada Projetada 02, LT 07, N° 341 Imboassica, Macaé, RJ 27.925-530

Tel.: +55 22 9731 3384 [email protected]

Regional Sales, Rental & Service

Telephone

E-mail

Al-Khobar, Saudi Arabia

Tel.: +966 3 887 9270

[email protected]

Perth, Australia

Tel.: +61 8 9456 0999

[email protected]

Stavanger, Norway

Tel.: +47 51 81 81 81

[email protected]

Representative Offices

Telephone

Louisiana, USA

Tel.: +1 337 839 0024 ext. 201

Beijing, China

Tel.: +86 10 8485 1973

Moscow, Russia

Tel.: +7 495 287 2691

Fidmash, Minsk, Belarus

Tel.: +375 17 298 24 11

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AirPack C User Manual

CUSTOMER NOTES

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV Elmar K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 147 of 150 Revision A Original Instructions

AirPack C User Manual

Page 148 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV Elmar K-Winch AirPack C, MAN-1055734, 26 July 2013

AirPack C User Manual

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands NOV Elmar K-Winch AirPack C, MAN-1055734, 26 July 2013

Page 149 of 150 Revision A Original Instructions

AirPack C User Manual

Published by: NOV Elmar Energieweg 26 2964 LE Groot-Ammers The Netherlands © 2013 No part of this document may be reproduced by any means without the written consent of the publisher. Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV Elmar for loss, damage or injury caused by any errors or omissions in this document.

Page 150 of 150 Revision A Original Instructions

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands K-Winch AirPack C, MAN-1055734, 26 July 2013