Professional Documents
Culture Documents
Operating and
Maintenance Manual
Shaw Lane Industrial Estate, Doncaster South Yorkshire, DN2 4SE ENGLAND
Telephone: 0044 (0) 1302 554480 Facsimile: 0044 (0) 1302 554481
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Revision No: 06
INSTRUCTIONS
MANUAL NUMBER: 1
REVISON 01
Prepared by: Mantovani & Vicentini (MI-SWACO Italy) Project Engineer 03/03/2009
Reviewed by:
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REVISION HISTORY
NOTE: The General Arrangement (GA) drawing in this manual is typical, and may not
reflect the equipment delivered in this project. This manual should be read in
conjunction with the specific GA drawing delivered in this project:
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CONTENTS
Section
Introduction .................................................................. 1
• Importance of the Manual
• General Safety
• Description of Equipment
• Application & Design Parameters
Controller........................................................................ 6
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Section
Drawings ........................................................................ 9
• General Assemblies
• Circuits
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Section 1
SECTION 1
INTRODUCTION
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Section 1
Ensure that any revision received is incorporated in this manual in the correct place
and that the accompanying form is signed and returned.
GENERAL SAFETY
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Section 1
DESCRIPTION OF EQUIPMENT
1 Off Type 1000/300/600 HDP lined Vibratory Feed Chute, c/w Vibrator
Motor and flexible adapter to offshore specification.
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Section 1
Number & Type of Conveying Vessel: Model 8/12 CleanCut Cuttings Blower
Material: Drill Cuttings
Bulk Density: typical range 1500 – 2000 Kg/m³
Liquid Content: Various
Maximum material temperature: 100 °C
Conveying Distance: 0 – 100 metres
Conveying Rate: Typically 25 tonnes/hr
Control Air
Pressure: 6 to 10 barg
Average Airflow: 0.1 Sm3/min
Conveying Air
Power Supply
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Section 2
SECTION 2
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Section 2
INTRODUCTION
This description should be read in conjunction with the following drawings (see Section 9):
The timers and other values given in this description are typical. They may be changed during
commissioning or operations
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Section 2
OVERVIEW
During normal operation of the system, drill cuttings will accumulate in a feed hopper
above the CCB. The drill cuttings will be discharged by gravity to the CCB. The drill
cuttings will then be pneumatically conveyed through pipework to the reception point,
typically the ISO-Pump or Skip Station.
A facility to connect a remote pushbutton station is included within the control panel.
The operation of the lamp and pushbuttons are identical to those fitted to the primary
control panel. If a secondary remote pushbutton station is not required then the
emergency stop and stop signals are to be linked out.
The start pushbutton on the front of the control panel (or the remote cycle start signal,
after the initial cycle) will initiate a conveying cycle. Subsequent cycles will be initiated
by either a cycle timer or a high level probe located above the CCB feed hopper. The
inlet Cuttings Valve will be opened and drill cuttings will fall under gravity into the CCB
vessel. The bin activator motor assists discharge from the feed hopper.
For problematic materials discharge may be further aided with the addition of aeration
nozzles into the bottom of this cone hopper. During filling and whilst at rest the vent
valve will be opened to allow the displaced air to be released from the CCB vessel and
the outlet Cuttings Valve will be closed.
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Section 2
After a timed delay the bin activator will be stopped. Simultaneously or after a further
short delay, the inlet Cuttings Valve will close. When the inlet Cuttings Valve has
closed and sealed, there will be a short timed delay to allow the outlet Cuttings Valve
to fully open. The vent valve will close and simultaneously the conveying air will be
introduced into the CCB vessel. The drill cuttings will be discharged from the CCB
vessel into the pipeline and will be conveyed to the reception point. Short pulses of air
will also be introduced to the CCB vessel at timed intervals via the air sweep nozzles
to help discharge the drill cuttings smoothly during the conveying cycle.
When the drill cuttings have been discharged and the CCB vessel has emptied, a drop
in the conveying pressure indicates most of the useful work of the cycle has been
completed. The conveying air valves will be closed and the vent valve opened. When
the conveying pressure has completely decayed, a ‘Low pressure’ switch will indicate
the cycle is complete.
The bin activator motor will be plug-stopped to prevent ‘running-on’ and possible
compaction of the drill cuttings in the feed hopper. This is achieved by applying reverse
phasing of the supply current thus rotating the motor in the reverse direction to normal
running for a brief time.
The vent from the CCB vessel will be routed into the cuttings ditch or a similar safe
area.
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Section 2
SYSTEM AT REST
When the CCB is stopped and at rest the status of the valves will be as follows:
The CCB vessel should be empty and at zero pressure. The bin activator will be
stopped.
• Note: The inlet Cuttings Valve incorporates an inflating seal. In the event of the
loss of control air pressure, the valve will not be sealed.
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Section 2
Prior to operating the CCB for the first time, or after a period of no use it is
recommended that the adjustable time values be verified as correct for the cycle.
OPERATING SEQUENCE
At the start of each conveying cycle, the sequence controller will check that the
following cycle start interlock conditions are fulfilled:
OR
The conveying cycle is running i.e. the conveying cycle has been started and the
stop pushbutton has not been pressed.
AND
The emergency stop pushbutton (HS1-1) on the control panel is not operated.
CCB vessel pressure is < 0.3 barg (PSL02).
CCB inlet Cuttings Valve is closed and sealed (PSH01).
Cycle frequency timer is not running (see note a below)
AND
OR
AND
Providing the above conditions are true a conveying cycle will be initiated and will
proceed as follows:
Notes:
a. If running on probe the cycle timer must be set to less than 20 seconds. If
the timer setting is greater than this minimum value then the timer will hold
cycle start off until elapsed irrespective of the probe status.
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Section 2
Step 1
The ‘Inlet Cuttings Valve’ is opened and the ‘Outlet Cuttings Valve’ is closed by
energising solenoid number (EV01). The inlet Cuttings Valve open timer (8 seconds),
cycle watchdog timer (40 seconds) and cycle frequency timer (60 seconds) will be
started. Drill cuttings will fall under gravity into the CCB vessel.
Simultaneously, the bin activator run timer (6 seconds) will be started and air to the
feed hopper air sweeps initiated.
On systems that have air sweep aeration devices fitted to the feed hopper then an air
signal is taken from the Inlet cuttings valve opening supply line to operate a Blow Valve
to provide air to three air sweeps in the ‘Vibro’ Hopper to assist the material flow into
the CCB for the duration the CCB inlet Valve is open.
Step 2
When the bin activator run timer has expired and after a short delay (0.5 seconds) the
bin activator will be plug-stopped by reversing the motor current phases for the
duration of the reverse phase plug-stop run timer (0.4 seconds). The bin activator is
interlocked with the inlet Cuttings Valve to prevent the bin activator running with the
inlet Cuttings Valve in the closed position (if the timers are incorrectly set).
The reverse phase plug-stop will not operate if the bin activator run timer value is set to
zero seconds.
Note: The duration of the bin activator run timer is to be less than the duration of the
inlet Cuttings Valve open timer.
Step 3
When the inlet Cuttings Valve open timer has expired, the inlet Cuttings Valve will be
closed and the outlet Cuttings Valve will be opened by de-energising solenoid (EV01).
Step 4
When the inlet Cuttings Valve (PSH01) has closed and sealed, the blow delay timer (3
seconds) will be started.
Step 5
When the blow delay timer has expired, the conveying air valve will be opened and the
vent valve will be closed by energising the solenoid (EV02). The convey secure timer
(20 seconds) will be started. The pulse interval timer (6 seconds) and delay pulse on
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Section 2
timer (5 seconds) will be started simultaneously with this step. When the delay pulse
interval timer expires the air sweep valve will be pulsed open by energising the air
sweep valve solenoid (EV03) for a period of time equal to (pulse interval timer) –
(delay pulse on timer) i.e. 6-5 = 1 second. This introduces pulses of air to the CCB
vessel through the air sweep nozzles at regular intervals throughout the conveying
cycle and helps discharge the drill cuttings smoothly. Air will enter the CCB vessel and
the drill cuttings will be discharged into the conveying pipe.
The drill cuttings will be conveyed through the pipeline to the reception point.
Step 6
When the convey secure timer has expired and the pressure in the CCB vessel has
fallen to less than 1.0 barg (PSL09), most of the useful work of the cycle is complete.
The conveying air valve (PV02) will be closed and the vent valve (PV05) will be
opened by de-energising solenoid (EV02). Simultaneously the air sweep valve (PV03)
will stop being pulsed open by de-energising solenoid (EV03).
Step 7
When the pressure in the CCB vessel has dropped to less than 0.3 barg (PSL02) and
the cycle frequency timer has expired, the ‘cycle-reset’ timer (3 seconds) will be
started.
Step 8
When the ‘cycle-reset’ timer has expired, the conveying cycle is complete.
Note:
If during the cycle any start interlocks become untrue, then that cycle will be permitted
to continue and end. The system will then stop until all of the start interlocks conditions
again become true.
Similarly, where an event has to occur to permit the cycle to proceed to the next step,
then the progress of the cycle will be halted until that interlock condition has become
true. The cycle will then proceed to the next step. The progress of the cycle to the next
step will be latched for the remainder of the cycle, so that in the event of the interlock
condition subsequently becoming untrue, the cycle will not stop or regress. The latches
are released at the end of the cycle during the cycle-reset timer.
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Section 2
Therefore
= (6) – (5)
= 1 second
Convey secure The convey secure timer is to allow 20 sec 0 – 120 sec
timer time for the pressure in the CCB N
vessel to rise before both vessel low
pressure switches (PSL02) & (PSL09)
are interrogated.
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Section 2
Cycle reset The cycle reset timer provides time 3 sec 0 – 20 sec
timer for the pressure in the CCB vessel N
and conveying pipework to be
completely released before the start
of the next conveying cycle.
Bin activator This allows a delay for the bin 0.3 sec 0 – 20 sec
fault timer activator-running signal to be received N
when requested to ‘run’.
Blow delay This timer provides a delay for the 3 sec 0 – 20 sec
timer outlet Cuttings Valve to be opened N
before the conveying air valve is
opened.
Reverse This sets the duration of the reverse 0.4 sec 0 – 20 sec
phase plug- phase plug-stop on the bin activator N
stop timer motor.
It shall be noted that the actual wording for each of the above Adjustable Timers on the
controller display, due to a limit on the number of characters, is abbreviated as shown below:
Note:
It is only possible to view or adjust the timer values when the CCB is not in a
conveying cycle. The preferred procedure for this action is:
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Section 2
Note:
The timer values are displayed on the text display of the sequence controller
(viewed through the window in the door).
Note:
Each press of the pushbutton will increment / decrement the selected timer value
by one second.
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Section 2
The pneumatic control panel at the CCB vessel houses the solenoid valves and the
inlet Cuttings Valve closed (PSH01) pressure switch.
The sequence controller located in the electrical control panel will control the CCB. The
operator interface is by means of pushbuttons, a selector switch, a lamp and the text
display of the sequence controller.
Pushbuttons
When the emergency stop pushbutton is pressed, the sequence controller will stop and
reset the sequence, all outputs will be ‘off’ (the position of the valves will be as for loss
of electrical supply). Pull to reset the emergency stop pushbutton.
Start (HS2-1)
When the start pushbutton is pressed, the conveying cycle will be started
(when the start interlock conditions are fulfilled). This will also reset the bin
activator fault alarm and will cancel the operation of the stop pushbutton.
Stop (HS2-3)
When pressed this will enable the conveying cycle to continue, and then stop
at the end of the cycle.
Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will increment the selected
adjustable timer by one second with every ‘press’ of the pushbutton.
Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will decrement the selected
adjustable timer by one second with every ‘press’ of the pushbutton.
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Section 2
Selector Switch
Lamps
Running (XI3-0)
Lamp status is as follows:
Note:
If the ‘lamp pulse on’ and ‘lamp pulse off’ conditions are required at the
same time, then the higher priority condition will be displayed.
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Section 2
TIMING DIAGRAM
END OF CYCLE
FULLY OPEN
VALVE AND MOTOR
CYCLE
STATUS
VENT VALVE
OPEN (EV02)
INLET CUTTINGS VALVE
OPEN (EV01)
BIN ACTIVATOR MOTOR
RUNNING (M001)
CONVEYING AIR
VALVE OPEN (EV02)
OUTLET CUTTINGS VALVE
OPEN (EV01)
AIR SWEEP VALVE
OPEN (EV03)
TIMERS
PRESSURES
VESSEL
PRESSURE 1 BARG
0.3 BARG
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Section 2
Definition:
Control Action:
Definition:
The cycle watchdog timer has expired and a conveying cycle is still in progress.
Control Action:
Definition:
Control Action:
Visual alarm and inhibit the start of cycle until the conveying cycle start conditions are
fulfilled.
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Section 3
SECTION 3
INSTALLING AND
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Section 3
IMPORTANT
The CleanCut Cuttings Blower conveying vessel is, for insurance purposes, classed
as a pressure vessel.
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Section 3
INSTALLATION
The CleanCut Cuttings Blower is installed beneath a feed chute with an allowance of
25mm made on overall height to allow the CleanCut Cuttings Blower to be slid into
position and raised on the jacking screws provided.
The CleanCut Cuttings Blower does not normally require bolting down since there is
no reaction or vibration during conveying. However in offshore applications after
installation. The vessel may be welded as necessary to the deck using the four
sacrificial mounting pads provided
Lifting
Care must be taken during any lifting of the CleanCut Cuttings Blower during
installation. Damage may be caused to the Cuttings Valve sealing head if any bar or
lifting device is placed inside the Cuttings Valve in order to obtain a lifting point. It is
recommended that the lifting lugs provided or eyebolts be used to lift the CleanCut
Cuttings Blower. Refer also to the erection and installation procedure
A gasket is fitted between the CleanCut Cuttings Blower and the vibratory feed
chute. An air tight seal is required on all equipment above the CleanCut Cuttings
Blower since the air displaced from the material chamber during the Cuttings Valve
open period will tend to 'blow out' material from any loose fitting flange or simple
slide type isolating valve.
Air Supply
The air supply line size may appear larger than that required for the stated air
consumption, this is due to the fluctuating usage of air by the CleanCut Cuttings
Blower. Airflow is approximately twice the average air consumption stated for a brief
period during each conveying cycle.
Each CleanCut Cuttings Blower™ is equipped with its own air strainer to prevent
pipe scale and dirt from causing pressure regulator malfunction. An automatic drain
filter and oil fog lubricator set is fitted into the airline that is used for the pneumatic
controls.
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Section 3
Any air line stop valves which are fitted into the air supply to the CleanCut Cuttings
Blower must be of the 'gate' or 'ball' type which do not cause a restriction to air flow
when open.
Airline filters with fine mesh porous elements should not be fitted as these cause an
airflow restriction during peak air demand periods.
The CCB once installed should be operated in fully automatic mode in conjunction
with the high level probe located within the feed hopper.
For a detailed description of the working cycle of the CCB section 2 of this manual
should be observed.
1. Ensure compressor is operational and on load and the 2” CCB pilot operated
regulator is set to 6.0 barg.
2. Ensure the electrical supply is healthy and the main isolator ion the CCB is
switched to the ON position.
3. With the CCB set at rest check the timer settings are as in accordance with
section 2 of this manual.
5. Start the system by pressing the green start push button. CCB cycle will
commence as soon as the high level probe is covered or to check depress the
level probe override button.
6. The CCB will now cycle at a frequency relative to the cuttings rate of
production.
7. To bring the unit to a controlled stop press the red stop button or alternatively
if an upset or fault condition occurs the CCB can be brought to an immediate
stop by depressing the Emergency Stop button.
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Section 3
1. Close isolating valve above CleanCut Cuttings Blower (if installed) , run the
vessel until empty by pressing the probe override button located on front of
operator control panel (where fitted). Turn relevant selector switch to 'OFF'
position.
2. Shut off mains air supply valve to the vessel (lock off if it is mounted remotely)
3. Shut off control air supply to the pneumatic panel and drain through the filter
on filter/ lubricator set, if venting has not been achieved in the normal through
the venting isolating valve.
1. Remove the lid from the large remote control pot (blue aluminium housing). As
the unit is IS Rated this operation can be conducted with the system running.
2. On the side of the electronics unit there is a Fail-Safe High/Fail-Safe Low selector
switch. Ensure this is set to Fail Safe High (upper most switch position).
Notes
• The LED on indicates the normal condition (i.e. LED will be extinguished when
material is covering the probe)
• Turning the adjustment pot clockwise will raise the level at which the LED
operates and turning counter clockwise will lower the level at which the LED
will operate.
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Section 3
Method 1
Requires the material level to be physically above the probe or for the hopper to be
empty of cuttings (Swaco/CleanCut Engineers will need to verify this work as a team)
Method 2
Calibration completed
Calibration completed
Method 2
Calibration completed
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Section 3
Note:
1. Fully close isolating valve and run the CleanCut Cuttings Blower until
empty.
3. Disconnect and mark nylon pneumatic pipework to the cylinder (12) and
limit switch (26).
6. Lower vessel by means of the jacking bolts on the feet of the vessel
(25mm). Where vessels are welded locally to the deck remove the flexible
adaptor
Note:
1. Remove setscrews from top plate/adaptor (16), lift out the sealing head
assembly consisting of top plate/adaptor (16), insert seal (19), insert ring (18)
and spigot ring (17).
2. Note the number and thickness of gaskets (13, 14 & 15) under the spigot ring
(17). Combinations of 0.4mm, 0.8mm and 1.5mm thickness gaskets are fitted
to achieve the required seal gap (between the seal and the dome).
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Section 3
3. Separate the seal (19) from the insert ring (18) and inspect for wear or
damage. Replace immediately if necessary.
4. Rotate the dome (2) by hand to check the condition of the bearings (4). If the
bearings (4) are seized or due for replacement proceed to
'Removal/Replacement of Cuttings Valve Bearings'.
5. When re-assembling the valve ensure that the underside of the top
plate/adaptor is free from corrosion. All surfaces should be clean in order to
form an airtight seal.
6. Lower the gaskets (13. 14 & 15) onto the valve body (1) followed by the spigot
ring (18) and insert seal/ring (18/19).
7. Lower the top plate/adaptor into position taking care not to trap the seal, and
tighten down.
8. Check the gap between the dome (2) (when in the closed position) and the
seal is correct using feeler gauges. The gap required is shown on the
relevant catalogue drawings in this section.
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Section 3
Note:
3. Remove the nearside circlip on the front clevis assembly (42) and lightly tap
the pin out.
5. Turn the valve through 180°; remove grease nipples (41 & 23).
6. Punch out the two inner spring pins (9) securing the dome (2) to the shafts (3)
and remove torque arm (10) if necessary.
8. Withdraw the shafts (3) and lift out the dome (2). Note if there are any shims
present on the shafts. The shims are occasionally fitted at the factory for
centralising the dome and should therefore be refitted on subsequent
overhauls.
9. Bearings and seals can now be removed by driving them towards the centre
of the valve.
11. Check for surface irregularities in the dome (2) and shafts (3) and replace if
necessary. Also de-burr the edges to prevent damage to the replacement
seals and bearings on re-assembly.
12. Press the replacement shaft seal (7) (never put old seals/bearings back) into
the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore; align the grease hole in the bearing with 1/8" NPT hole
in the body. Press squarely until the bearing sits 5mm below the face of the
flange. Repeat for other side.
13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB grease or equivalent.
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Section 3
14. Re-fit the shim(s) (if applicable) and slide a new 'O' ring (11) over the shafts
(3) up to the boss.
15. Slide the shaft (3) through the bearing (4) until it touches the first seal.
Repeat for the other side.
16. Hold the dome (2) adjacent to the bores and drive the shaft through the seals
and the dome using a plastic/hide mallet. Re-fit the grease nipples (23 & 41).
17. Rotate the shafts (3) until the holes in the shaft and dome (2) align. Grease
the spring pins (9) and drive in.
19. Re-fit the cylinder assembly steps 2 to 7 in reverse order. Secure the guard in
position.
Loosen the lock nut on the striker arm (25) and wind up the setscrew. With the
dome (2) fully closed wind out the screw until the hex-head touches the
plunger on the limit switch (26). Turn the screw a further 4mm (3.25 turns) to
depress the plunger.
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Section 3
1. If fitted, fully close isolating valve and run the CleanCut Cuttings Blower until
empty.
4. Disconnect air supply above the non-return valve on the stub pipe - at the
union.
5. Isolate air supply to air injection point and remove hose at crows foot
coupling. Remove whipcheck from hose side only.
8. Using suitable lifting tackle, the Cuttings Valve can now be removed.
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Section 3
Note! The 125mm outlet valve does not have an insert seal assembly
Note:
1. Disconnect the bottom adaptor (33) from the Dome Valve body (1).
3. Rotate the dome (2) until it resets in a position halfway between open and
closed.
4. Remove the setscrews that attach the actuator mounting (21) to the valve
body (1) and withdraw.
7. Punch out the two inner spring pins (11) securing the dome (2) to the shafts
(3).
8. Withdraw the shafts (3) and lift out the dome (2).
9. The bearings and seals can now be removed by driving them towards the
centre of the valve, using a hide mallet
11. Check for surface irregularities in the dome (2) and shafts and replace if
necessary. Also de-burr the edges of the two holes and the leading edge of
each drive shaft to prevent damage to the replacement seals/bearings on re-
assembly.
12. Press the replacement shaft seal (9) (never put old seals or bearings back)
into the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore. Align the grease hole in the bearing with 1/8" NPT
hole until the bearing sits 5mm below the face of the flange. Repeat for other
side.
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Section 3
13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB or equivalent.
14. Re-fit a new 'O' ring (12) over the shafts (3) up to the boss.
15. Slide the shaft (3) through the bearing (4) until it reaches the first seal in the
bore.
16. Hold the dome (2) adjacent to the bores and drive the shafts (3) through the
seals and the dome (2) using a plastic/hide mallet.
17. Rotate the shafts (3) until the holes in the shaft and the dome (2) align.
Grease the spring pins (11) and drive in.
19. Fit the grease nipples (19 & 20) and the actuator (13).
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Section 4
SECTION 4
FAULT DIAGNOSIS
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Section 4
WARNING: Prior to Fault Finding on System, Check Air & Electrical Supplies
CCB starts, vessel fills, Inlet 1. Pneumatic limit switch 1. Adjust as per maintenance
Valve closes but does not not making. manual. Replace if faulty.
convey
2. Cuttings Valve not 2. Isolate electrics and
closing completely, pneumatics. Remove pipe
foreign object trapped from bottom bend to clear.
in Cuttings Valve or Clear vessel. Disconnect
shafts seized. actuator and operate
manually, checking limit
switch operation.
CCB starts to convey then 1. Conveying pipe 1. Check air and power supply.
stops with high vessel blocked (see conveying
pressure pipe blocked section). Check piping from valve to
control panel.
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Section 4
Air leaks through Cuttings 1. Seal air pressure 1. Check air supply lines.
Valve or Vent Valve during dropping to near
conveying conveying pressure.
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Section 4
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Section 5
SECTION 5
ROUTINE MAINTENANCE
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Section 5
ROUTINE MAINTENANCE
NOTE! Before starting any routine maintenance ensure the system is isolated
both electrically and pneumatically, and vented of any residual pressure.
It shall be noted that before starting any routine maintenance ensure the
system is isolated both electrically and pneumatically. Conveying pipes and
CCB/ISO Pump vessels must also be vented of any residual pressure.
DAILY MAINTENANCE
The daily system check is an attempt to identify the possible onset of component
failure before the event effects system performance and ultimately impacts the
overall system reliability.
Unlike the weekly and monthly maintenance routines there are no planned activities
for this regime. The check, assuming a live operational system, is intended to verify
the operational health of the equipment with corrective actions only taking place
should problems or the onset of possible component failure be identified.
In order for the following checklist to be purposefully administered the system should
ideally be operational. If so a combination of pressure readings, pressure settings
and valve functionality tests will be read or determined.
2 CCB vessel pressure at rest < 0.15 If pressure >0.15 barg check:
barg
Condition of vent line and vent
valve.
Ensure accuracy of vessel gauge.
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Section 5
3 Air manifold and pneumatic signal If any leaks are found take
tubes have no air leaks necessary corrective action.
4 Ensure all Poppet Style air manifold Burkert valve heads enclose a
valves are functioning. Each valve yellow open/closed indicator
indicator button to be checked: button. The status of each valve
• Vent line purge air valve should be individually observed
• Conveying pipe ABR valve through a complete cycle
• Cycling Air sweep valve
5 Vessel pressure during convey Pressure should rise, typically >
cycle 2.5 barg, and momentarily
increase and decay as the
airsweep valves cycle.
Lack of significant vessel pressure
could be symptomatic of:
• Shortage of cuttings delivery
• CCB choked with cuttings
• Vent valve failed
• Lack of conveying air
6 Vessel pressure when system Decay in pressure down to <0.15
vented barg should take no longer than
two to three seconds. If vent time
exceeds this check:
• Vent valve operation
• Vent pipe for restrictions
7 Cuttings inlet valve opens and
closes with a single smooth action
8 Cuttings outlet valve opens and
closes with a single smooth action
9 Blow phase of the cycle is Check apparent switch point of
terminated when the end of blow pressure switch.
pressure switch is made with a <1.0
barg falling pressure level.
10 Ensure cuttings inlet valve only Check vessel pressure and hence
opens with a vessel pressure of pressure switch setting at valve
<0.2 barg. open instant.
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Section 5
WEEKLY MAINTENANCE
Cuttings Inlet and Outlet Valves
Grease Valve shafts and bearings (hydraulic grease nipples located on Valve body)
using Shell Malleus JB Grease.
Check lubricator units mounted on outside of pneumatic panels and on control air
supply and top up lubricators as required. Monitor condition of filters and clean as
required (normally annually).
Caution!
MONTHLY MAINTENANCE
Cuttings Inlet Valve
Check settings on cuttings Inlet Valve limit switches where applicable. Refer to
drawings in Section 9.
Remove strainer insert from convey airline strainers, clean and replace. General
functional checks of ball valves on system.
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Section 5
ANNUAL MAINTENANCE
The following maintenance is required for long term rental machines else this
maintenance shall only be conducted at the relevant time when the units are
returned to shore between rentals.
Remove Cuttings Inlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.
Check Cuttings Inlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.
Remove Cuttings Outlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.
Check Cuttings Outlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.
Inspect cylinder shaft for score marks scratches, pitting, rust etc. as this can lead to
premature failure of cylinder seals.
Control Panels:
All manifold pipes will be inspected for damage and any corrosion.
Flexible hoses will be inspected for any signs of degradation of the hose wall, which
is manufactured from a nitrile rubber. Degradation will include wall softening, an
increase in outside hose diameter or delamination of the hose fabric.
Valves will be inspected for operational performance and the head will be removed to
assess the condition of the valve seat and seal.
The regulator shall be opened and the diaphragm checked for signs of degradation
and wear. The unit shall then be connected with a compressed air source >7.0 barg
and the unit assessed for ease of setting the desired pressure set point.
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Section 6
SECTION 6
CONTROLLER
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Section 6
The following displays mimic the physical display generated on the LCD Millennium
unit.
In viewing these screens it is possible to identify which PLC Inputs and/or Outputs
are required for healthy CCB operation and the conveying cycle advances.
Timer Decrement
Timer Increment
Timer Selection
Stop
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
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Revision No: 06
Section 6
Timer Decrement
Timer Increment
Timer Selection
Level Probe Operation:
Start
Stop
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
as shown.
Vibro Motor Running
Inlet valve Closed
Timer Decrement
Timer Increment
Timer Selection
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
Timer Decrement
Timer Increment
Timer Selection
Pulse Air:
The pulse air output No 6 will oscillate at the
frequency selected with the combination of pulse
Start
Stop
Outputs
1 2 3 4 5 6 7 8
Inlet Valve open
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
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Section 6
Timer Decrement
Timer Increment
Timer Selection
vessel pressure has reduced to less than 1.0 barg
as indicated by the input signal 5. The Blow
Valves will close and the vent line open.
Start
Stop
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC
Outputs
1 2 3 4 5 6 7 8
Inlet Valve open
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
Timer Decrement
Timer Increment
Timer Selection
Stop
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC
Outputs
1 2 3 4 5 6 7 8
Inlet Valve open
Pulse Air
Reverse Plug Stop
Conveying Air
System Running
Vibro Motor
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Section 7
SECTION 7
RECOMMENDED SPARES
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Section 7
For a detailed and tailored spares listing this spreadsheet should be utilised,
however as a general guideline the following spares listing is provided.
This listing represents the full spares list for a single CCB.
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Section 7
Feed Hopper
Feed Chute Skirt P32267E-00 1
Tensioning wire P32262E-00 1
Bottom Gasket ( 300 Isol V/V) P32259E-00 3
Flex adapter Sleeve P32249D-03 1
Band Clamp-300mm P20306E-03 1
Bottom Gasket P2122A-12 2
Inlet Valve
Inlet Dome Valve Spares Kit P33074D-03 M3232 1
Cylinder P34675E-00 1
Cylinder Seal kit A2214 1
300mm Dome V/V Gasket Set P2120A-03 2
Dome Insert Seal P1826C-05 1
Adapter Plate Gasket ( P32201D-00) (V to D) P32206E-00 2
Air Limit Switch (inlet) A1011 1
Quick Exhaust Valve A1067 1
Exhaust Silencer P17951E-00 4
Outlet Valve
Outlet Dome Valve Spare Kit P32541D-00 M3226 1
Actuator A4374 1
Actuator Seal Kit A2201 1
100/125mm Dome Gasket Set P2120A-01 1
Outlet Bend to V/V Gasket P2120A-83 1
Manifold Assembly
Pressure Regulator 2" A2973 1
Seal Kit Pressure Regulator 2" A4445 1
Pilot Regulator for 2" Reg A4359 1
Seal Kit Pilot Regulator for A4359 A4467 1
Pressure Gauge A1058 1
1 1/2" Blow Valve A4373 1
Silencers A1590 4
Pressure Switch A4287 1
Pressure Gauge A4285 1
1/2" Non Return Valve A3527 1
2" Non Return Valve P33043E-00 1
2" NRV Discs P33045E-02 4
Clamps M6870 2
Vent Valve (Butterfly v/v) A4151 1
Fluidising P33442D-00 1
8mm Nylon (1 m ) A1570 25
12mm Nylon (1 m ) A1571 25
"O" Ring (from M2817) M2817 1
Enots Pneumatic fittings 5855006 1
Dunlop gacord hose 3/4"NB M3542 5
Dunlop gacord hose 1 1/2"NB M2780 5
Dunlop gacord hose 1"NB M2781 10
Dunlop gacord hose 2"NB M3079 10
Pneumatic Control Panel
Solenoid Valve CC0067 1
Coils CC0068 2
Silenc A1968 5
Pressure Switch A4097 1
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Section 7
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Section 8
SECTION 8
PROPRIETARY PARTS
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Section 8
ACTUATOR
MANUFACTURER Kinetrol
FURTHER INFORMATION
Operating Temperature: Min –40°C (-40°F) Max 80°C (176°F)
Operating Pressure: Max 7 bar (100psi)
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Section 8
BLOW VALVE
MANUFACTURER Burkert
FURTHER INFORMATION
Operating Temperature - Ambient: -40° to + 100°C
- Fluid: -40° to + 180°C
Operating Pressure: Max 10 bar
Design: 2/2 way piston operated valve, normally closed, spring return, 50mm actuator
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Section 8
BUTTERFLY VALVE
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Section 8
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Section 8
CYLINDER
MANUFACTURER Norgren
FURTHER INFORMATION
Operating Temperature: -40° to + 80°C
Operating Pressure: Min 1 bar, Nominal 10 bar
Design: Single Acting cylinder with spring return
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Section 8
FILTER
MANUFACTURER Norgren
FURTHER INFORMATION
Operating Temperature: -20° to + 80°C
Operating Pressure: Maximum inlet pressure 17 bar
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Section 8
LEVEL SWITCH
MANUFACTURER Drexelbrook
MANUFACTURER’S PART No
FURTHER INFORMATION
Operating Temperature: -40° to + 60°C
Output: 4-10mA covered; 14-20 mA uncovered
Sensitivity: 0.1pF
Design: Level Control Transmitter; Point level; Radio Frequency (RF); Analogue output
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Section 8
LIMIT SWITCH
FURTHER INFORMATION
Operating Temperature: -20° to + 75°C
Operating Pressure: 0.7 – 10 bar
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Section 8
FURTHER INFORMATION
Operating Temperature: -20° to 40°C
Design: 480 Volts, 3 Phase, 60 Hz
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Section 8
PRESSURE GAUGE
Three gauges are used on the CCB:
GAUGE 1
CLEANCUT PART NO A1008
MANUFACTURER Schrader
FURTHER INFORMATION
Port: G ¼”
Diameter: 50mm
Mounting: Centre back
GAUGE 2
CLEANCUT PART NO A1058
MANUFACTURER Norgren
FURTHER INFORMATION
Port: R 1/8”
Diameter: 50mm
Mounting: Centre back
GAUGE 2
CLEANCUT PART NO A4285
MANUFACTURER Budenburg
FURTHER INFORMATION
Port: ½” BSP
Diameter: 100mm
Mounting: Bottom entry
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Revision No: 06
Section 8
FURTHER INFORMATION
Operating Conditions: Max pressure 12.5 bar at 150°C
Minimum temperature -40°C
Design: Full Lift Safety Relief Valve
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Section 8
PRESSURE REGULATOR
FURTHER INFORMATION
Operating Conditions R18: Max pressure 31 barg
Minimum temperature -20°C
Maximum temperature +80°C
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Section 8
PRESSURE SWITCH
MANUFACTURER Sirco
MANUFACTURER Sirco
FURTHER INFORMATION
Operating Temperature: -20° to + 60°C
Operating Pressure: 0.7 – 10 bar
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Section 8
STRAINER
FURTHER INFORMATION
Operating Range: 0 – 20 barg at 210°C
0 – 25 barg at 60°C
Minimum operating temperature -198°C
Screen: Stainless Steel, 0.8mm perforations
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Section 9
SECTION 9
DRAWINGS
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Section 9
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72
73
74
75
76
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Section 9
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79
80
81
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Section 9
CIRCUIT DRAWINGS
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Section 9
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Section 9
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Section 9
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Section 9
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Section 9
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P34838D NOTES
ON SETTING UP OF PX1-10
CLYDE CUTTINGS I/S CABLE
E 25 26 27 (TERMINALS) PROBE
OVERRIDE
(GREEN PUSHBUTTON) LEVEL SWITCH LSH01
60/1 61/1 62/1
60/2 61/2 64/1 63/1 63/2 64/2 60/3 61/3 61/4 62/2
12 11 7 8 Y1 Y2 A2 A1 15 18 21 22
- +
(BLUE) + -
(FLYING LEAD BLUE
FROM ELEMENT)
(RED)
TRANSMITTER
RED EXTERNAL
SCREEN TERMINATED
LEVEL IN THE GLAND
ELEMENT
LEH 01
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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Section 9
NOTE:
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