Beruflich Dokumente
Kultur Dokumente
UserManual
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
Tel: +31 184 608 700, Fax: +31 184 608 790, www.nov.com
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with the unit must read and understand this manual. Only qualified
personnel are allowed to rig up, rig down, operate, or maintain the unit.
Published by:
ASEP Group B.V.
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2009 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 ASEP Group B.V. for
loss, damage or injury caused by any errors or omissions in this document.
Version
Date
1.0
Sep. 2009
Amendments
This is the first version of this manual
REVISION HISTORY
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NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
TABLE OF CONTENTS
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Scope of this User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 How to use this User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 General safety responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 ATEX and zoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 PowerPack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.7 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8 Zone 2 safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
UNIT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 Cabin controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 PowerPack controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4 Rig-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.1 Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.2 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Pre-run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.4 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.5 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.6 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2 Periodic maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.2 Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Appendix 1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Appendix 2: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Appendix 3: Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
LIST OF FIGURES
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
Figure 3.7
Figure 3.8
Figure 3.9
Figure 3.10
Figure 4.1
Figure 4.2
Figure 4.3
Figure 4.4
Figure 4.5
Figure 4.6
Figure 4.7
Figure 4.8
Figure 4.9
Figure 4.10
Figure 4.11
Figure 4.12
Figure 4.13
Figure 4.14
Figure 4.15
Figure 4.16
Figure 4.17
Figure 4.18
Figure 4.19
Figure 4.20
Figure 4.21
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
Figure 6.7
Figure 6.8
Figure 6.9
Figure 6.10
Figure 6.11
Figure 6.12
Figure 6.13
Figure 6.14
Figure 6.15
Figure 6.16
Figure 7.1
Figure 7.2
Figure 7.3
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
15
17
18
19
20
21
22
23
24
25
26
27
28
29
29
30
31
32
34
34
35
36
36
39
40
41
42
43
44
45
47
60
61
61
62
63
64
64
65
66
67
67
68
68
69
70
71
74
74
75
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Figure 7.4
Figure 8.1
Figure 8.2
Figure 8.3
Figure 8.4
Figure 8.5
Figure 8.6
Figure 8.7
Figure 8.8
Figure 8.9
Figure 8.10
Figure 8.11
Figure 8.12
Figure 8.13
Figure 8.14
Figure 8.15
Figure 8.16
Figure 8.17
Figure 8.18
Figure 8.19
Figure 8.20
Figure 8.21
Figure 8.22
Figure 8.23
Figure 8.24
Figure 8.25
Figure 8.26
Figure 8.27
Figure 8.28
Figure 8.29
Figure 8.30
Figure 8.31
Figure 8.32
Figure 8.33
Figure 8.34
Figure 8.35
Figure 8.36
Figure 8.37
Figure 8.38
Figure 8.39
Figure 8.40
Figure 8.41
Figure 8.42
Figure 8.43
Figure 8.44
Figure 8.45
Figure 8.46
Figure 8.47
Figure 8.48
Figure 8.49
Figure 8.50
Figure 8.51
Figure 8.52
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NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Figure 8.53
Figure 8.54
Figure 8.55
Figure 8.56
Figure 8.57
Figure 8.58
Figure 8.59
Figure 8.60
Figure 8.61
Figure 8.62
Figure 8.63
Figure 8.64
Figure 8.65
Figure 8.66
Figure 8.67
Figure 8.68
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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161
163
165
166
167
168
169
173
173
174
175
178
178
180
182
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INTRODUCTION
The SlimSplit C is one of the many ASEP products used in the well servicing industry.
1.1
1.2
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
procedures. Corrective maintenance is guided from the tables in the Troubleshooting section.
Use the Drawings Package (supplied in the Documentation Package) to trace electrical,
hydraulic, pneumatic and heating/cooling circuits and components.
1.3
Documentation Package
This User Manual is just one part of a comprehensive documentation package that is supplied as
an integral part of your unit. The Documentation Package includes:
1.
Certificates
2.
Datasheets
3.
Manuals
4.
Drawings
5.
Reports
6.
Parts lists
Refer to the Parts List when ordering replacement components during maintenance.
OEM components forming part of your ASEP product (complete assemblies and subsystems,
e.g. air conditioning, engines, etc.) are not covered in detail in the ASEP User Manual for your
product. For maintenance and troubleshooting of these components, please refer to the supplier
documentation included in the Documentation Package.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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SAFETY
This section describes the safety aspects that apply when working with ASEP equipment. The
safety aspect can relate to potential equipment damage or to danger to personnel working with
this equipment or in the vicinity:
When installing, operating or maintaining equipment, closely follow the prescribed
instructions in this manual, and use common sense at all times.
Preventing accidents is an objective affecting all company levels and operations. It is,
therefore, a basic requirement that each supervisor makes the safety of all employees an
integral part of their regular management function. It is equally the duty of each employee
to accept and follow established safety regulations and procedures.
Every effort should be made to provide adequate training to employees. However, if an
employee is ever in doubt about how to do a job or task safely, they should always ask a
qualified person for assistance. Employees are expected to assist management in
accident prevention activities. Unsafe conditions must be reported immediately. Fellow
employees that need help should be assisted.
Every injury that occurs on the job, even a slight cut or strain, must be immediately
reported to management and/or the Responsible Safety Officer. Never leave the work
site without reporting an injury, except for emergency trips to the hospital.
2.1
2.1.1
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
When open, the hinge side of most doors and hatches can create an extremely
hazardous pinch point for fingers, clothing, hoses and cables. Always check the hinge
side before closing any door or hatch.
Always use the built-in door or hatch retainers to anchor the door or hatch if you need to
leave it open while you work. Wind or sudden movement of the unit can cause the door
or hatch to swing shut with great force, resulting in possible injury or equipment damage.
2.1.2
Transport/Installation
Only hoist all joined modules (single lift) after ensuring that the unit has been certified for
single lifting by checking the certification in the Documentation Package that came with
your unit.
When lifting a module by crane, make sure you cannot get trapped between the load and
a wall, fixed object, etc.
If possible, position yourself so that you are visible to the crane operator. If not possible,
make sure a flagman can signal the crane operator.
Never walk under a hanging load.
Make sure that lifting gear is sufficiently dimensioned and certified.
Never leave an "operation-ready" unit unattended.
Do not operate damaged equipment. This may lead to further damage and/or dangerous
situations.
Respect and maintain your working environment. Dispose of waste correctly.
Keep the unit and connected components clean. Accumulated dirt can hamper unit
operations and might jeopardize safety.
To prevent accidents, keep all safety guards in position while operating ASEP equipment.
When engaged in maintenance and/or performing checks on the unit:
First consider your safety and that of others.
Make sure that the equipment is switched off completely, and use a decal or similar to
prevent unauthorized starting during maintenance or check up.
Never work on hydraulic and/or pneumatic systems under pressure. Always relieve
system pressure to prevent dangerous situations.
Never attempt to move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
2.2
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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2.3
WARNING
FALLING FROM HEIGHT
Falling from the top of the unit can cause serious injury or death.
When working on top of the unit: make sure the roof is locked, and always attach a safety line
to one of the safety bars.
CAUTION
EQUIPMENT DAMAGE
The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked).
Never block (cap) the fuel tank breather.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2.3.1
Hot object
Moving parts
Dangerous voltage
Grounding required
Inflammable substances
Crushing danger
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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2.3.2
Restriction icons
Other icons may be used on your machine and in the manual to indicate that restrictions are in
place. For example the following PPE (Personal Protection Equipment) may be required:
Eye protection
Wear protective glasses to prevent eye damage
Breathing protection
Wear a full respiratory mask if working with toxic vapours
Ear protection
Wear ear protection during this procedure
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
PHYSICAL DESCRIPTION
3.1
Unit overview
SlimSplit C (PowerPack/cabin/winch unit, diesel driven, -20 C certified, Zone 2
The ASEP SlimSplit C is a purpose-designed three-piece wireline winch for cased hole and open
hole operations, and consists of a PowerPack module, a cabin module and a winch module.
The modules are linked by hydraulic, electric and signal cabling.
PowerPack
Cabin
Winch
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mechanical ventilation. The cabin has heating and air conditioning. A SmartMonitor provides
depth and tension measurement.
The winch bay has an enclosed drip pan with drain plugs integrated into the base of the frame
structure. The winch bay has a single drum mount with an ASEP BC06 drum. The unit is equipped
with a SmartHead straight through type measuring head.
3.1.1
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.2
PowerPack
3.2.1
Overview
The following 3-dimensional drawing shows the orientation and some external features of the
PowerPack. The working side of the PowerPack is the side of the PowerPack module containing
the control panel. Detailed views of the left, rear and working side of the module are shown in
following sections (the right side only contains the radiator).
Rear
Right
Left
Working side
2
4
Lifting eyes
Exhaust
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3.2.2
PowerPack - Rear
3
5
4
Pneumatic components (air tank, air dryer, air valve) - see 4.5 Pneumatic system on page 35
Hydraulic oil tank (and sightglasses) - see 4.3 Hydraulic system on page 32
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.2.3
PowerPack - Front
2
3
Air inlet valve and filter - see 4.2.4 Air intake on page 31
Fuel components (filters, breather, filler) - see 4.2.2 Fuel system on page 28
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3.2.4
PowerPack - left
2
3
5
Generator
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.3
Cabin
3.3.1
Front
Right
Left
Rear
2
1
5
4
3
4
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3.3.2
Right
Rear
Front
Left
2
4
3
5
5
Window/window cover
Pneumatic/hydraulic connectors
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.3.3
Cabin - Interior
Heating controls
SmartDisplay
Control panel
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3.4
Winch
3.4.1
Overview
The following 3-dimensional drawing shows the orientation and some external features of the
winch. Detailed views of the left, rear and front side of the module are shown in following sections.
Rear
Right
2
Left
Front
Levelwind arms
Frame
Slip ring
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.4.2
Winch - front
3
5
4
Hydraulic levelwind motor with chain attachment - see 4.7.2 Winch motor and reduction gearbox on page 40
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
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FUNCTIONAL DESCRIPTION
This chapter gives an overview of the functions of major components and subsystems.
4.1
Power pack
See following figure.
6
5
3
4
2
1
7
Air receiver (for pneumatic system) - see 4.5 Pneumatic system on page 35
Gas cooler for exhaust system - see 4.2.5 Exhaust system (zone 2) on page 31
Exhaust with spark arrestor - see 4.2.5 Exhaust system (zone 2) on page 31
Hydraulic tank (for hydraulic system) - see 4.3 Hydraulic system on page 32
Diesel tank (for fuel system) - see 4.2.2 Fuel system on page 28
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
4.2
Engine
The SlimSplit C unit uses an Iveco 4-cylinder diesel engine as the main power source (see
Figure 4.2). The engine drives a hydraulic pump (for supplying power to the hydraulic
system).The engine is water cooled. The coolant is pumped through a radiator, which is cooled
by a hydraulically driven fan. See 4.4 Cooling system on page 34.
4.2.1
Engine starter
The engine has a spring-activated starter motor, which is activated from a starter handle on the
starter motor (see Figure 4.3). The starter spring must first be wound to sufficient pressure with
a hand crank to provide the kinetic energy required to turn over the diesel engine. See 6.2 Power
up on page 73 for how to start the engine.
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tension indication
window
winding nut
reset button
spring starter
handle
hand crank
4.2.2
1.
2.
Turn the hand crank clockwise twice on its winding nut - this will engage the pinion with the
flywheel.
3.
4.
Turn the crank to slowly crank the engine without activating the spring pack.
5.
When finished engine adjustments, unwind the crank handle or press the reset button.
Fuel system
The diesel is stored in a fuel tank that has a combined tank top/breather.
After leaving the fuel tank, the diesel passes through the following components:
Isolation valve (this valve can be closed for maintenance purposes)
Coarse particle filter (removes large particles from the diesel)
Diesel primer pump
Water/diesel separator filter (removes water contamination from the diesel)
Two-stage fine particle filter (removes fine particles from the diesel)
Injection pump (injects diesel into the diesel engine)
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fuel pump
breather
fuel/water
separator
coarse particle
filter
filler cap
sentinel valve
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The sentinel master valve monitors the oil pressure in the diesel engine. Pressure is also
distributed to the air intake valve.
If the oil pressure drops, the sentinel master valve will close, immediately shutting down the
engine. When starting the engine, the valve needs to be overridden by turning the override switch.
WARNING
DANGEROUS MACHINERY
Changing factory settings can seriously 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 the Netherlands.
The adjustable orifice, on the other end of the engine oil pressure hose that is connected to the
Sentinel valve, is factory set. Do not adjust it without first consulting an ASEP engineer. If the
orifice is turned, the engine's safety system might not work correctly.
4.2.2.2 Fuel/water separator and primer pump
This filter unit separates any water contamination from the diesel fuel. The frequency of water
draining or filter element replacement depends on the quality of the fuel.
The primer pump is used to remove air from the diesel system.
primer pump
fuel/water separator
4.2.3
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4.2.4
Air intake
The engine draws its air for combustion in via the air filter in the large black canister in the upper
section of the PowerPack. See Figure 4.7.
An air inlet valve (Pyroban) is also positioned in the air intake system and is used as:
An automatic engine shut-off system in case of over-speeding due to operating in an
atmosphere charged with hydrocarbon gasses
A manually controlled engine shut-off device in case of an emergency stop
An automatic shut-off device in case of low diesel engine oil pressure (<0.5 bar
(7.25 psi))
A shut-off device for engine protection (high coolant temperature >200 C (>212 F) and
high exhaust temperature >100 C (>146 F)
air filter
air inlet valve
4.2.5
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The second stage is a spark arrester (5), which eliminates residual hot solid particles from the
gas. Clean, cool exhaust gas is emitted from the exhaust pipe in the roof of the power pack.
4.3
Hydraulic system
power pack
winch
hydraulic reservoir
oil cooler
quick
connector
suction
filter
drain
pump
main circuit
pressure
filter
winch
motor
various
motors
various
controls
control circuit
various
actuators
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Modular (split) wireline winches are subject to frequent opening of the connection points between
the power pack and the winch module. Because of the heightened risk of introducing abrasive
particles into the hydraulic system via the couplings, these units are normally also equipped with
high pressure filters on the power pack side of the connection interface.
NOTE: On units with dual winch motors, a ball valve in the winch bay is used to redirect the flow
in both directions to the second motor.
Control circuit
The control circuit is supplied with a high pressure flow using the excess capacity of the charge
pump of the main pump. In most ASEP units, this circuit powers a variety of important auxiliary
control features, via circulating flow and static pressure, which can include the following:
main pump and winch motor control valves
winch gearbox gear change mechanism
levelwind drive motor
winch drum brakes (apply or release)
levelwind support arms (raise/lower cylinders)
winch frame slewing mechanism
generator
The return flow of the control circuit is combined with the flow from the main circuit in the manifold
for cooling and return to the hydraulic reservoir.
Please refer to the hydraulic and pneumatic diagram in the documentation package for more
information.
4.3.1
4.3.2
CAUTION
INTERRUPTED HYDRAULIC FLOW IS HAZARDOUS TO THE MACHINE.
Hydraulic lines must be properly connected and the flow must be available to ensure correct
operation of the hydraulic components.
Always make sure connections are secure, and the connect valve is in the normal position
before running the machine.
The hydraulic hose connections between the PowerPack and the winch module are under high
pressure. When connecting the hoses to the connections, always set the connect valve on the
front of the PowerPack to the disconnect/connect position. When hoses are (dis)connected, set
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the valve back to the normal position (never run the motor when the valve is in the (dis)connect
position).
(dis)connect
position
valve
normal
position
4.3.3
mast pump
lever
4.4
Cooling system
The SlimSplit C PowerPack is equipped with a belt driven cooling fan (see Figure 4.11. The fan
draws ambient air through the radiator stack (engine coolant radiator and hydraulic oil cooling).
This combined cooling system cools the following components:
Engine block
Exhaust manifold
Hydraulic oil
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For an overview of the cooling system see the Fluid diagram in the documentation package.
The cooling fan system also contains the following:
Safety valve
Thermostat
radiators
belt driven fan
4.5
Pneumatic system
Air for the pneumatic system is drawn from the PowerPack-mounted compressor, and stored in
the air receiver (see Figure 4.12). Air pressure in the receiver is maintained at 7 bar (100 PSI),
and is regulated at specific system points. Air flow from the compressor is activated when the
receiver pressure falls below this value.
Because compressed air contains moisture and abrasive solids which can damage equipment,
the supply from the compressor passes through an air dryer/filter before it reaches the receiver.
The filter is periodically automatically regenerated by a reverse air flow from the air receiver,
whereby the incoming air to the filter is shut off and the moisture drain valve is opened. The
regeneration flow blows the moisture from the dryer/filter out through the drain.
Compressed, dried air from the unit receiver passes through the PowerPack/cabin/winch module
air connectors to a manifold in the winch module, where it is directed to the wire spray assembly,
safety valves and brake system, as well as the levelwind support arm raise/lower mechanism. Air
from the receiver is also flowed from the PowerPack to the cabin where it is used for the
pneumatic throttle control and the horn.
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escape valve
air receiver
air valve
air dryer/filter
moisture drain
4.5.1
air cylinder
fuel pump
throttle rods
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4.6
Electrical system
The SlimSplit C obtains its electrical power from the integrated 2 x 115 VAC (60 Hz) generator
unit or from a rig power source. The two 115 VAC circuits, each with a maximum rating of
50 Amps, supplies power to auxilliary devices inside the cabin and provides a stable platform for
the winch control circuitry:
The 230 VAC system supplies major interior appliances, including the air conditioning
units and equipment in the computer rack, as well as sockets in the cabin and winch bay.
The 115 VAC system supplies 115 VAC equipment in the computer rack, as well as wall
sockets in the cabin.
The cabin obtains its 24 DC power via two 12 V batteries in series, enclosed within a box in the
cabin (under the dashboard). The 24 VDC from the batteries is used for the unit control
equipment, including the SmartMonitor, SmartDisplay in the cabin, and the encoders and load pin
in the winch
These batteries are continuously charged by the power supply from the PowerPack (or rig
supply). If the machine has been idle for a long time, or the batteries have been run down without
the engine running, then the batteries can be recharged directly from a rig 24 VDC power source.
Junction boxes in the cabin and PowerPack hold the following functions:
Main power control switch
On/off selection switches for the electrical components
Power variables display (frequency, voltage, current, hours)
Over and under voltage signalling lights
Power-on indicator
Fuse system for each electric component
Under and over voltage controllers
Generator activation switch
The unit is also equipped with a voltage control system. With under or over voltage the warning
indicator will light up. If the warning indication stays on, consult ASEP for maintenance actions.
With a certain electrical component not working, and with the component not damaged, check the
fuses in the control box. See maintenance section.
NOTE: Ensure that the power supply to a junction box is disconnected before attempting to
perform maintenance or repair work on the electrical system components.
Do not change the settings on the under/over voltage safety controller (Carlo Gavazzi) without
approval from an ASEP engineer.
For the settings of the over/under voltage controller refer to the electrical diagram. For further
details also refer to the electrical diagrams in the documentation package.
NOTE: Before resetting a fuse, determine the cause of the fuse trip, and take action to prevent
future system failures.
4.6.1
Generator
The SlimSplit C unit is equipped with a generator. The hydraulic power for the hydraulic motor is
taken from the secondary pump connected to the main hydraulic pump. The controller for the
generator can be found in the electric control box in the power pack. This controller requires an
initial 24 VDC power input for start up. This power supply is generated in the v-belt driven
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alternator attached to the Iveco motor. Once the motor is running, start up the generator using the
control buttons on the side of the control box. To ensure proper generator functioning the control
box is equipped with 8 capacitors. Three automatic fuse systems are installed to protect the
electrical system; these fuses can be reset when tripped.
For a detailed description of the generator controller, please refer to the separately supplied
manufacturer's manual. The generator controller settings are ASEP factory-preset, and may not
be modified without approval from an ASEP engineer.
4.6.2
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4.7
Winch
The wireline winch assembly comprises the winch frame, drum, drive train, brake, levelwind and
measuring head carrier.
Reduction gearbox and winch motor - see 4.7.2 Winch motor and reduction gearbox on page 40
Hydraulic motor for levelwind system - see 4.7.4 Levelwind system on page 42
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4.7.1
Drum
The wireline is spooled on a drum, which is driven directly using a drive chain between drum and
hydraulic motor (and reduction gear). The size of the wireline used depends on the drum. The
minimum bending radius of the wire requires a certain minimum core diameter of the drum. The
outer dimensions of the drum determine the widths and lengths of the wireline that can be used.
4.7.2
4.7.3
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assembly and retained by the brake cylinder lid. When pressure is present in the brake pneumatic
or hydraulic circuit (BRAKE released), the piston extends, releasing the brake. If pressure is lost
(BRAKE applied, EMERGENCY OFF pressed, or a system failure), the spring will pull the brake piston
back into the cylinder, applying the brake.
Dual-drum winch frames have a separate brake system for each drum.
The brake actuation type for the SlimSplit C is listed in Appendix 1 Specifications on page 179.
See the 7.1 Periodic maintenance schedules on page 84 for procedures to:
Test the brake - see 7.7 Test drum brake on page 95
Inspect the brake band condition - see 7.38 Check drum brake band(s) on page 163
Adjust the brake - see 7.40 Adjust drum brake on page 168
Replace the brake band(s) - see 7.15 Replace brake band(s) on page 112
.
lower adjuster
with locknut
brake piston
brake cylinder
winch frame
mounting
point
brake linkage
attachment
expansion
chamber
hydraulic or
pneumatic supply
connection
HYDR/PNEUM PRESSURE RELEASED:
SPRING EXTENDS,
PISTON RETRACTS,
BRAKE IS APPLIED
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4.7.4
Levelwind system
The wire spooling system ensures that the wireline is spooled evenly on or off the drum. The
system works via a hydraulic motor fitted to the levelwind arms. This motor turns a chain which is
connected to the measuring head. As the chain turns, the measuring head is transported
backwards and forwards along its support shaft between the levelwind arms. The left and right
movement of the measuring head on the shaft correctly position the wireline to (un)wind evenly
onto the drum.
The hydraulic motor movements can be controlled manually via the SPOOLING CONTROL joystick,
or automatically by the SmartMonitor (the AUTOSPOOLING switch on the cabin control panel must
be set to ON). Automatic control of levelwinding (AUTOSPOOLING set to ON) is done with the help
of sensors on the measuring head, which respond to sideways pressure on the wireline. These
replace the joystick, causing the motor to turn one way or the other moving the measuring head,
and therefore the wireline, left or right while (un)winding on the drum.
Manual control always overrides automatic control. Even when AUTOSPOOLING is ON, moving the
joystick will immediately switch to manual control. When the joystick returns to the middle
position, autospooling will be active again.
hydraulic
motor
measuring
head
chain
support shaft
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always overrides the (optional) autospooling system. On release of the manual control, the
autospooling will again take over.
The levelwind arms are supported by two pneumatic struts which raise and lower the arms. The
fleet angle is at a predetermined angle where the arms are lowered and locked into position.
4.7.4.1 Measuring head carrier
The measuring head is loaded onto a carrier that is attached via a bearing block (4) to the
levelwind support shaft (5). The measuring head carrier has an operating position and a
transportation position:
In the transportation position, it is turned towards the levelwind arm and locked in place
with a lynchpin.
In the operating position, the measuring head is attached via a bearing block to the
levelwind shaft, where it is free to move laterally along the shaft.
4.7.4.2 Spooling speed knob
Adjust the spooling speed of the levelwind system by turning the small knob on the right side of
the winch frame (clockwise to decrease speed; counter-clockwise to increase speed). This
adjusts the hydraulic flow to the levelwind motor.
spooling
speed knob
4.7.5
Measuring head
The Smarthead II measuring head is a combined hydro-mechanical wireline depth and tension
measurement system enabling both wireline depth and tension signals to be provided to a
separate remote display. An accurate tension display can be achieved when used in conjunction
with an ASEP SmartMonitor (or SmartDisplay as backup). The wireline can be replaced in the
measuring head without cutting the wire. The Smarthead is described extensively in the separate
Smarthead User Manual.
4.7.6
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(if necessary, with a rubber mallet). The beam can be stored in the storage slots under its normal
position.
front beam
4.8
2.
At JB2 (the Combined Pressurization, Fire Detection & Gas System), turn the PURGE mode
switch to the NORMAL position and turn on the START PRESSURIZING switch See 5.1.4 JB2
(Gas and Fire panel) controls on page 52
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This will activate the overpressure fan, the pressure sensor and the gas detection system.
Once activated and working correctly, electrical power will be available to all non-EX
equipment inside the cabin module. With the door closed and ventilation ports open and
unobstructed, it will take approx. 22 minutes to purge the unit and build up the required overpressure. The cabin overpressure is monitored on the gauge beside the control panel. See
Figure 4.20.
gauge
4.8.1
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Gas Alarm
If a gas alarm is triggered:
A message for low or high gas alarm will be displayed on the SmartMonitor. The unit will
not automatically shut down; ventilation will stop.
The alarm generator in the cabin will sound (and can be reset by briefly pressing the
RESET button on the orange gas smoke and fire panel.
If a yellow lamp is required (required by some customers), a beacon lamp will also switch
on.
In both cases, the unit will send a signal to the rig, and the alarm station will be activated.
There are two levels of gas alarm (these depend on norms and customer request).
Gas level 1, Low Gas Alarm, will activate the alarm when a set percentage (usually 10 to
30% of the LEL-value) is reached
Gas level 2, High Gas Alarm, will activate the alarm and shutdown the system, the Safe
System relay will switch off, when a set percentage (usually 30 to 60% of the LEL-value)
is reached
The status indicators on JB2 will flash for either 'Low Gas Alarm' or 'High Gas Alarm'.
Smoke Alarm
If the smoke detector senses smoke, the system will shut down and the Safe System relay will
switch off.
When the alarm is activated, the fan will switch off and the fire dampers will close, the sounder
will switch on and the SmartView display will give a message 'Smoke Alarm'. If a yellow lamp is
required (required by some customers), a beacon lamp will also switch on
General Fault
A general fault will occur when a signal is lost, for instance when a wire or contact is damaged.
When a general fault occurs, the 'General Fault' status indicator light on JB2 will switch on, and
the SmartView display will show a message 'General Fault at xxx'. (xxx specifies where the fault
has occurred, for instance the Gas Detector, or Manual Call Point).
Pressure too low
If the unit loses pressure, a sounder will give an alarm after 10 sec, and the main contact will be
switched off after 30 sec. The SmartView display will show the message 'Loss of Pressure'.
If this happens during purging, the purging process must be started again.
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Over pressure
system
Normal
Purge Override
Start
Start
Fan spooling 22
min purge
Fan spooling
Electrics on
Maintenance
Start
Electrics on
Stop
Electrics on
After 22 min
Low
Gas
alarm
+ light
signal
and
signal
to the
rig
High
Gas
alarm+
light
signal
and
signal
to the
rig
Smoke
alarm
+ light
signal
and
signal
to the
rig
High
cabin
pressure
Low
cabin
pressure
No AC
power
30 sec
timer
Sounder
Reset sounder lights and rig alarm remains as long there is still an alarm
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UNIT CONTROLS
5.1
Cabin controls
5.1.1
5
8
6
7
1
MAIN PRESSURE
This gauge (0 to 400 bar (5800 psi)) shows the hydraulic pressure generated by the main
hydraulic pump.
CONTROL PRESSURE
This gauge (0 to 40 bar (580 psi)) shows the hydraulic control pressure, which is used for
controlling the hydraulic system.
AIR PRESSURE
TACHOMETER
THROTTLE
EMERGENCY STOP
Push this button in case of an emergency. This will automatically stop the engine and
immediately shut down the unit.
HORN
DUAL CONTROL LEVER This lever controls the speed and torque obtained from the hydraulic motor. The maximum
up or down position will generate the fastest drum speed (greatest hydraulic flow) with the
least available torque.
DUAL CONTROL LEVER This lever controls the direction of the drum (flow of hydraulic fluid). Push the lever forward
to spool off wire; pull the lever backwards to spool on wire. Spooling in hole at high speed
can entangle the wireline in the hole. Therefore, high drum speeds should only be used to
Pull the wireline Out Of Hole (POOH).
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5.1.2
2
1
3
SMART MONITOR
The SmartMonitor digitally displays the depth, speed, and tension of the wireline.
For more information, see the separate SmartMonitor manual.
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5.1.3
4
5
1
AUTOSPOOLING ON/OFF
LEVELWIND UP/DOWN
SPOOLING CONTROL
BRAKE ON/OFF
This switch operates the brake. Move the brake ON/OFF switch down to activate
the reel brake; move the brake ON/OFF switch up to release the brake.
WINCH SAFETY
Rotary control (+-) that regulates the maximum wireline tension by controlling the
maximum torque output of the hydraulic winch motor when spooling outhole (onto
the drum) under manual control. If high tension is permitted, then the wire can be
spooled at higher speed to extract the wire and tools faster in the deeper
subsurface zone. In this case increase the tension, and increase the speed using
the drum control joystick.
When the tool string approaches the surface it is important to avoid damaging the
tools and BOP. Here the wireline tension and wire speed should be kept to a
minimum, so that extraction of the tool string is steady and controlled.
+ increase tension
- decrease tension
NOTE: To avoid any risk of wireline breakage, you should limit the line tension to no
higher than you are able to properly control (using the joystick) and monitor on the
line tension display of the winch. Always stay below the percentage of wireline
breaking strain specified for your equipment and purpose.
CAUTION: Prolonged operation with the WINCH CONTROL set high can cause
the hydraulic oil to overheat beyond the capability of the cooling system to keep it
below the maximum safe temperature. In this case, the winch will automatically
shut down. Restart only once the hydraulic has cooled sufficiently.
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5.1.4
21
11
Version 1.00
20
10
14
18
17
16
19
13
12
15
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21
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Indicator is on, when the 240 VAC electrical system for the computer rack is active.
GENERAL FAULT
Indicator is on, when there is a general error - see 4.8.1 Gas and fire safety
systems on page 45
Indicator is on, when there is a low gas alarm - see 4.8.1 Gas and fire safety
systems on page 45
Indicator is on, when there is a high gas alarm - see 4.8.1 Gas and fire safety
systems on page 45
FIRE/SMOKE ALARM
Indicator is on, when there is a fire/smoke alarm - see 4.8.1 Gas and fire safety
systems on page 45
SMARTVIEW BUTTON
SMARTVIEW BUTTON
SMARTVIEW BUTTON
10
SMARTVIEW BUTTON
11
VOLTAGE ERROR
Indicator is on, when there is a voltage error on the main electrical system (2 x
110 VAC)
12
VOLTAGE OK
13
POWER ON (PHASE 1)
Indicator is on, when there is a voltage error on the phase 1 electrical system
(230 VAC)
14
POWER ON (PHASE 2)
Indicator is on, when there is a voltage error on the phase 2 electrical system
(230 VAC)
15
START PRESSURING
16
PURGE
17
STOP PRESSURING
18
RESET ALARM
Press to clear an alarm condition. Will only work, if the condition causing the alarm
has been fixed.
19
CABIN LIGHT
20
MAIN SWITCH
This switch activates the AC electrical system to the cabin (from rig)
21
DASHBOARD LIGHT
22
SMARTVIEW
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5.1.5
SMARTDISPLAY
Used as a backup for the SmartMonitor to measure depth and tension of the
wireline. See SmartDisplay documentation for how to operate.
PRESSURE GAUGE
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5.1.6
Thermostat
FAN CONTROL
Controls the operation and fan speed of the air conditioning unit (roof-mounted) for heating
and cooling.
FAN HIGH: high fan speed when heating (WARMER)
FAN LOW: low fan speed when heating (WARMER)
COOL HIGH: high fan speed when cooling (COOLER)
COOL LOW: low fan speed when cooling (COOLER)
OFF: Air conditioning is off.
TEMPERATURE
CONTROL
Thermostat to set the cabin temperature as measured by the sensor wire below the control
panel.
When heating (WARMER) set the fan speed to FAN HIGH or FAN LOW.
When cooling, set the fan speed to COOL HIGH or COOL LOW.
NOTE: the actual temperature in the cabin will be affected by the radiator below the winch
control panel. When using the air conditioning for cooling, shut off the thermostatic valve on
the radiator.
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5.2
PowerPack controls
1
4
7
10
12
13
11
14
Use this handle to control the engine safety air intake control valve.
Push the handle up to bypass the diesel engine motor 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 to emergency stop the diesel engine. Pulling the handle down
will close the diesel air intake valve.
For restart wait for the engine derived vacuum to disappear.
CONTROL PRESSURE
This gauge (0 to 40 bar (580 psi)) shows the hydraulic control pressure, which is
used for controlling the hydraulic system
AUXIL PRESSURE
This gauge shows the air pressure in the auxiliary air circuit
AIR PRESSURE
ENGINE STOP
Pull out this switch to switch off the diesel engine; push it in again once the engine
is stopped
EMERGENCY STOP
Push this button in case of an emergency. This will automatically stop the engine
and immediately shut down the unit
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ENGINE TEMPERATURE
10
TACHOMETER
11
EXHAUST TEMPERATURE
12
GENERATOR START
13
GENERATOR RUNNING
14
GENERATOR STOP
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6.1
Moving/positioning equipment
WARNING
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.
Make sure that 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.
The individual SlimSplit C modules (PowerPack, cabin, winch) may be lifted using the
lifting eyes. The eyes are angled towards the center for correct transfer of the weight of
the module to the shackles and lifting cables, without twisting forces being applied.
6.1.1
Land transportation
When loading and transporting ASEP 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.
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 shackles have been correctly attached to the unit.
6.1.2
Air transportation
Standard procedure for air freighting a unit depends on local travel organizations.
In general the following liquids should be drained:
Hydraulic tank
Fuel tank
Engine oil
Engine cooling fluid
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Air tank
Wire lubrication system
Other liquids within components will always remain in the unit:
Hydraulic system
Fluid/oil coolers
Filters
Hoses
6.1.3
Draining
If the carrier requires that all fluids are drained from the reservoirs, systems and components of
the machine(s), please refer to 8 Maintenance on page 85 for specific instructions on how to drain
the fluid from each reservoir, system or component.
Photocopy or print the checklist in Appendix 6 Air transportation on page 200 as an aid to
ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as
follows:
6.1.4
1.
2.
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 (e.g. in the cabin, in a weatherproof
envelope attached to the outside of the Cabin door).
Refilling
Refer to Appendix 1 Specifications on page 188 for the quantity and specifications of the required
fluids. Refer to 8 Maintenance on page 85 for the procedures to check and replenish fluids for
each of the reservoirs, systems and components.
Replenish the fluid in each of the items listed in the checklist. Remember to bleed the system of
air and again replenish if necessary.
ASEP recommends that new fluid/oil filters are used when replenishing systems that include
filters. If you have fitted new filters, please add your initials in the last column.
6.2
Site preparation
Before positioning the unit at the site, survey the location where it will be used.
The unit should be aligned with the centreline of its operating arc.
The distance from the front of the unit to the lower hay pulley should not be less than 15 m
(50 ft) for optimum line spooling, and to provide a safe distance to the wellhead.
There should be sufficient room on all sides for opening doors/hatches.
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6.3
Rig-up
1.
WARNING
RISK OF EXPLOSION
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been properly grounded using a suitable grounding cable
before performing any other work whatsoever on the unit, including connecting or
disconnecting any hoses or cables, refuelling the unit, operating the unit, or carrying out
maintenance on the unit.
2.
Connect the brass grounding points for module to rig - in total 3 points at ground level on the
left side of each module. See Figure 6.1.
NOTE: Use only the supplied brass nuts to attach the ground strap (non-brass nuts can cause
electrolytic corrosion, so that the grounding becomes ineffective).
module to rig
ground points
6.3.1
3.
If the drum and wire line are not installed or need to be replaced, load the drum as described
in NOTE: A new brake band must be fitted every time a new drum is fitted to the unit. See
related topic. on page 114, and the wire as described by the supplier.
4.
Connect the electrical and signal cabling - see 6.3.1 Electrical rig-up on page 60.
5.
Connect the hydraulic and pneumatic cabling - see 6.3.2 Hydraulic & pneumatic rig-up on
page 62.
6.
Setup the levelwind and measurehead - see 6.3.4 Setup the levelwind and measurehead on
page 67.
7.
Startup the unit for the first time - see 6.3.3 First time startup on page 67.
Electrical rig-up
In the following steps, refer to the electrical connections diagram in Figure 6.2.
The following steps assume that the 2-phase 110 VAC power supply to the cabin will be from the
30 KW generator on the PowerPack. If it is decided to use rig/shore 2-phase power, then the
cabin 2-phase cable must be connected to rig/shore 2-phase.
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(optional)
JB 1
JB 2
PowerPack
Winch
Cabin
JB 12
signal
cable
JB 10
Open the stowage recess on the cabin module (left side) and carefully uncoil the 2-phase
110 VAC cable from its storage location.
2.
Lay the cable along the ground from the cabin module to the PowerPack.
3.
Uncoil the short electrical cable (2-phase 110 VAC) from its holder in the storage recess.
4.
Remove the caps from the 2-phase VAC cable sockets and the connector in the cabin recess
and on the PowerPack.
Cabin
PowerPack
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5.
Remove the dust caps from each end of the cable, and plug the cable into the corresponding
connector in the cabin and the PowerPack (if connecting to a rig/shore 2-phase 110 VAC
supply, connect the cable to the appropriate rig/shore connector).
6.
Secure the cable in the connector sockets with the clamping feature.
7.
Optionally, connect a signal cable from the fire and gas signal connector in the cabin recess
to the appropriate rig/shore connector.
Uncoil the signal cable (for slip ring and encoders) on the roof of the winch module.
2.
Lay the cable along the ground to the front of the cabin so that it can easily reach the signal
connector on the front left of the cabin.
signal connector
from winch
Winch
Cabin
6.3.2
Remove the dust cap from the cable and sockets, and plug the cable into the sockets,
securing it with the retaining feature.
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Hydraulic
19
10
5
11
17
18
9
1
20
11
10
90
50
Winch
Cabin
6
7
12
3
PowerPack
80
14
8
15
16
Pneumatic
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
WARNING
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.
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1.
Set the connect valve on the front of the PowerPack to the (dis)connect position.
(dis)connect
position
valve
normal
position
Remove the hoses from their transport positions on the roof of the PowerPack and winch
modules, and lay the hoses along the ground to the appropriate connection points on the
winch and PowerPack. See Figure 6.7.
hydraulic hoses
PowerPack
Winch
Connect each of the hydraulic hoses to the connection points in the winch as follows (make
sure you have an unused, clean cloth on hand):
a) Check the connection number near the hose connection ferrule.
b) Identify the corresponding coupling on the winch and PowerPack.
c) Remove the protection cap on the coupling, and clean the coupling carefully and
thoroughly (allow no dust or sand to be present).
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d) Remove the protection cap from the hose, and again clean the coupling scrupulously.
e) Make the connection, and pull on it to be sure it is secure.
3.
Make certain the air OUT isolation valve at the front of the PowerPack is closed. See
Figure 6.10.
4.
With equal attention to avoid contamination, make the pneumatic connections between the
winch and PowerPack, pulling gently on the connection to check it is secure.
Remove the hoses from their transport positions on the roof of the PowerPack and lay the
hoses along the ground to the appropriate connection points on the cabin. See Figure 6.8.
hydraulic/pneumatic hoses
PowerPack
Cabin
Connect each of the hydraulic hoses to the connection points on the cabin as follows (make
sure you have an unused, clean cloth on hand):
a) Check the connection number near the hose connection ferrule.
b) Identify the corresponding coupling on the cabin.
c) Remove the protection cap on the coupling, and clean the coupling carefully and
thoroughly (allow no dust or sand to be present).
d) Remove the protection cap from the hose, and again clean the coupling scrupulously.
e) Make the connection, and pull on it to be sure it is secure.
3.
Make certain the air OUT isolation valve at the front of the PowerPack is closed. See
Figure 6.10.
4.
With equal attention to avoid contamination, make the pneumatic connection between the
PowerPack and cabin, pulling gently on the connection to check it is secure.
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Remove the hoses from their transport positions on the roof of the winch (if not already
removed), and lay the hoses along the ground to the appropriate connection points on the
cabin and winch. See Figure 6.9.
Winch
Cabin
Connect each of the hydraulic hoses to the connection points on the winch and cabin as
follows (make sure you have an unused, clean cloth on hand):
a) Check the connection number near the hose connection ferrule.
b) Identify the corresponding coupling on the winch and cabin.
c) Remove the protection cap on the coupling, and clean the coupling carefully and
thoroughly (allow no dust or sand to be present).
d) Remove the protection cap from the hose, and again clean the coupling scrupulously.
e) Make the connection, and pull on it to be sure it is secure.
3.
With equal attention to avoid contamination, make the pneumatic connections between the
winch and PowerPack, pulling gently on the connection to check it is secure.
Make sure that the RIG OUT valve behind the crowsfoot connection on the front of the
PowerPack is closed.
2.
Find a rig air supply with suitable pressure and flow (7 bar at 25L/min.), and use a hose (with
correct dimensions) to connect the air supply to the rig air connection. See Figure 6.10.
3.
Open the shore/rig air supply at the supply point, then slowly open the rig air intake valve on
the PowerPack so that it is parallel with the connector.
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isolation valve
(closed)
crowsfoot connector
Figure 6.10 PowerPack air out connection with closed isolation valve
4.
6.3.3
Slightly open the air OUT valve and verify that there is pressure here, then close the valve.
Set the isolation valve to the normal position (never run the motor when the valve is in the
(dis)connect position).
(dis)connect
position
valve
normal
position
6.3.4
2.
Check that all power switches in the cabin and PowerPack are switched off.
3.
4.
5.
Shut down the unit by performing 7.5 Normal shut down on page 82.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
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front beam
transport
mounting pin
rotation lock pin
lynch pin
If not already loaded, load the measurehead onto the carrier as described in the Smarthead
User Manual.
4.
Tighten the chain tensioner for the levelwind until the chain is tight. See Figure 6.14.
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chain tensioner
6.4
5.
6.
If necessary, turn the LEVELWIND knob to UP to raise the levelwind support arms into the
correct position to satisfy the fleet angle.
Rig-down
1.
Turn the LEVELWIND knob to DOWN to lower the levelwind support arms into the transport
position.
2.
Loosen the chain tensioner for the levelwind until the chain is loose. See Figure 6.14.
3.
4.
Ensure that the system is completely shut down by performing 7.5 Normal shut down on
page 82.
5.
6.
7.
Check the hydraulic and pneumatic systems for leaks and or damage.
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8.
(dis)connect
position
valve
normal
position
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12. In the operator cabin, stow all loose items and close the door securely.
13. Replace the front beam on the winch module (if removed).
front beam
6.5
Storage
6.5.1
2.
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6.5.2
3.
4.
Grease exposed metal surfaces (such as drum, electrical connectors and cylinder rods that
are extended) to prevent corrosion.
5.
Close all doors and hatches on the unit and secure or lock them.
6.
Cover the unit with a suitable protection cover (these can be ordered from ASEP if required).
Disconnect and remove any batteries in the unit and store them where they will not be
affected by large changes in temperature.
2.
3.
Protect hydraulic hoses outside the unit from direct sunlight and extreme temperatures, and
plug open connections
4.
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OPERATION
NOTE: Before attempting to start the SlimSplit C, first read this entire section thoroughly and
make certain you understand every part. Do not startup the SlimSplit C unless you know
how to perform a controlled shutdown.
7.1
Pre-start checklist
If you have not already done so, please read section 2 Safety on page 10 completely before
proceeding.
WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with the unit must read and understand this manual. Only qualified
personnel are allowed to rig up, rig down, operate, or maintain the unit.
WARNING
SHARP OBJECT
Sharp or rough objects such as broken or frayed wire strands can cause severe cuts.
Always wear appropriate Personal Protective Equipment (PPE), such as gloves. Never use
your bare hands.
1.
Ensure that the SlimSplit C has been correctly installed and is ready for operations. See
6.3 Rig-up on page 60.
2.
Ensure that the engine is stopped and the engine start is disabled.
3.
Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks
from lines or components, and structural damage.
4.
Check all tanks and hoses for leaks, and for other visible damage.
5.
6.
Inspect the main hydraulic pump group and lines for damage, leaks and/or insecure
attachment.
7.
8.
Check the hydraulic filter indicators. Clean and/or replace the element as necessary. See
7.5 Replace hydraulic suction filter on page 92.
9.
Ensure that the cooling air intake and exhaust openings are not obstructed.
10. Ensure that all components requiring lubrication are serviced as necessary. See 8.2 Periodic
maintenance schedule on page 86.
11. Check that no unauthorized modifications have been made to the unit.
12. Check the engine fuel level. If required, fill with the correct fuel for the climate. See
NOTE: Before using the unit, always check the diesel level; also regularly check the diesel
level during operations. on page 159.
13. Check the hydraulic oil level by performing 7.32 Check/fill hydraulic oil on page 139.
14. Check the reduction gearbox oil level by performing 8.2.11 Check/fill reduction gearbox
oil on page 103.
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7.2
Power up
1.
Prime the diesel engine by pumping the diesel engine primer (Figure 7.1) several times.
diesel engine
primer
On the cabin control panel, ensure that the drum control levers for the hydraulic pump and
motor is in the middle position. See Figure 7.2.
Make sure the BRAKE control switch is in the ON position. See 5.1.3 Cabin control panel
(right) on page 51 for location.
4.
Press the reset button on the spring starter. See Figure 7.3.
5.
Wind up the spring starter by fitting the hand crank (wind lever) to the winding nut, and crank
clockwise until the tension indication window turns red.
NOTE: If it is required to relieve the spring pressure later without starting the engine, turn the
crank handle counter-clockwise until the tension indication window turns green.
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tension indication
window
winding nut
reset button
spring starter
handle
hand crank
Remove the hand crank from the winding nut and store it in its holder.
7.
Check and, if necessary, reset the sentinel master valve by turning the control lever against
the spring pressure. This will reset the diesel safety system to allow diesel flow.
NOTE: Repeat step 7 for every start attempt. If the engine has just been maintained, you
might have to bleed the entire diesel system (see 6.40 Prime diesel engine on
page 158).
8.
Push the AIR INLET VALVE fully up to the UP FOR START position, and hold it in place. See
section 5.2 PowerPack controls on page 56 for location.
9.
Activate the spring starter handle (by pushing upwards) to start the engine. See Figure 7.3.
10. When the hydraulic 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, troubleshoot
the system.
11. Check that the hydraulic CONTROL PRESSURE gauge stabilizes between 20 bar and 28 bar. If
the pressure is less than 15 bar, see 9 Troubleshooting on page 184.
NOTE: The control pressure will vary slightly with the rpm of the engine.
12. On new units, those recently overhauled, or after changing hydraulic oil, operate all systems
a minimum of two complete cycles, and then re-check for oil leaks.
13. Check the MAIN PRESSURE gauge in the cabin. This should be at least 20 bar.
14. If using the 30kW generator to supply power:
a) On the tachometer, check the engine speed is at least 1500 rpm. If necessary, increase
engine speed to 1500 rpm using the THROTTLE button on the cabin control panel (see
5.1.1 Cabin control panel (left) on page 49).
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b) Start the generator by pressing and holding the GENERATOR START button on the
PowerPack control panel.
c) Once the GENERATOR RUNNING lamp lights up on the control panel, the generator is
running.
d) Turn on the SlimSplit C main power switch on JB2 in the cabin. See Figure 7.4.
e) Check that the generator status lamps on JB2 are OK (green lamps on and red VOLTAGE
ERROR lamp out). If the red VOLTAGE ERROR button is on, see 9 Troubleshooting on
page 184
generator status
lamps
zone 2 purge
switch
main power
switch
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17. If operating the SlimSplit C in ZONE 2 safety areas with non-EX equipment present in the
cabin module:
a) Open the cabin interior ventilation ports.
b) At JB2 (the Combined Pressurization, Fire Detection & Gas System), turn the PURGE
mode switch to the NORMAL position and turn on the START PRESSURIZING switch. See
Figure 7.4. If required, remove the key from the PURGE mode switch.
This will activate the overpressure fan, the pressure sensor and the gas detection
system. Once activated and working correctly, electrical power will be available to all nonEX equipment inside the cabin module. With the door closed and ventilation ports open
and unobstructed, it will take approx. 22 minutes to purge the unit and build up the
required over-pressure. The cabin overpressure is monitored on the gauge beside the
control panel. See Figure 5.1.5.
7.3
Pre-run
Before using the unit for the first time:
7.3.1
1.
Ensure that the operator site is free from oil, fuel, dirt and other debris.
2.
3.
Test the hydraulic drive system and brake system by doing 7.3.1 Hydraulic pressure test on
page 77.
4.
2.
If not already connected, secure the inhole wireline end to the drum and make sure the
wireline can rotate freely with the drum.
3.
Ensure the WINCH SAFETY knob is fully open (screwed counter-clockwise all the way to -).
See 5.1.3 Cabin control panel (right) on page 51.
4.
Pull back the DRUM CONTROL levers for the pump direction and hold them in the half-way back
position. See 5.1.1 Cabin control panel (left) on page 49.
5.
Use the THROTTLE control button to increase the motor speed to its maximum.
WARNING
HIGH PRESSURE
If the hydraulic system pressure exceeds 400 bar (5800 psi), hydraulic components might
rupture and cause serious injury or damage equipment.
Never allow the hydraulic system pressure to exceed 400 bar (5800 psi).
6.
Turn the WINCH SAFETY knob clockwise to slowly increase the main hydraulic system
pressure.
7.
Check the MAIN PRESSURE gauge on the cabin display. The pressure should increase to a
maximum of approximately 150 bar. Hold this pressure for approximately 30 seconds.
If the drum starts to break free of the drum brake, check the braking system components
for signs of wear, and re-adjust the brake tensioning lever setting if necessary. See
7.40 Adjust drum brake on page 168.
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If the MAIN PRESSURE does not reach 150 bar, increase the position of the hydraulic control
lever to the full position, and repeat this procedure.
If the CONTROL PRESSURE falls below 15 bar during testing, contact ASEP.
8.
After testing, check the hydraulic system hoses and couplings for leaks.
9.
Repeat the above procedure, this time moving the DRUM CONTROL lever for the pump
directional control towards the fully forward position until 150 bar pressure is reached.
NOTE:
7.3.2
When reeling inhole, the position of the WINCH SAFETY valve does not influence the
performance of the system.
Running test
1.
If not already connected, secure the inhole wireline end to the drum and make sure the
wireline can rotate freely with the drum.
2.
3.
Ensure the WINCH SAFETY knob is fully open (screwed counter-clockwise all the way to -).
See 5.1.3 Cabin control panel (right) on page 51.
4.
5.
7.3.3
Set the spooling control speed lever in the winch to its middle position - see 4.7.4.2 Spooling
speed knob on page 43.
2.
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WARNING
DANGEROUS MACHINERY
Ignoring the instructions in this manual can result in serious injury or death.
All personnel that work with the unit must read and understand this manual. Only qualified
personnel are allowed to rig up, rig down, operate, or maintain the unit.
3.
4.
5.
Take a position where you are certain you or your clothing cannot be trapped by the moving
levelwind carriage and measuring head.
6.
Simulate the lateral pressure effect of the wireline on the levelwind carriage by pressing the
carriage first to one side, then the other.
7.
This should activate the levelwind autospooling control, by automatically moving the
levelwind carriage and measurehead to the left or right. If this does not happen, consult the
troubleshooting section.
8.
With the AUTOSPOOLING switch still on, move the SPOOLING CONTROL joystick in each
direction (left, right).
10. This should result in corresponding movement of the levelwind carriage (left/right). If this
does not happen, consult the troubleshooting section.
11. Set the AUTOSPOOLING switch OFF.
7.4
Run
WARNING
RISK OF EXPLOSION
Applying the winch brake on a running drum can cause sparks and/or heat, which can cause
an explosion.
Do not apply the winch brake, while the drum is moving.
During unit operations, the hydraulic oil temperature must not exceed +70 C (+158 F). If the
temperature goes higher than this, remove the load from the unit, and wait for the hydraulic oil to
cool down. If the oil does not cool down, check the cooling system for damage and/or
contamination. Also check the hydraulic system for leaks. If required, perform maintenance on
the system to prevent further overheating of the hydraulic oil.
1.
If not already connected, run the wireline through the measuring head as specified in the
Smarthead User Manual and attach the tools as required.
2.
Ensure that the wire cannot snag in or behind the levelwind as the drum rotates.
3.
If using the SmartMonitor for full system control, refer to the SmartMonitor User Manual for
how to fully automatically control the winch.
If you are running the winch manually, move the DRUM CONTROL levers and WINCH SAFETY
knob in the appropriate direction to spool the wireline on or off the drum at the desired speed:
The WINCH SAFETY knob controls the velocity and/or torque obtained from the hydraulic
motor (the maximum right position will generate the biggest flow and drum speed with the
least available torque).
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The right DRUM CONTROL lever controls the direction of the hydraulic pump; push this
joystick forward to spool off wire, pull the joystick backwards to spool on wire. The left lever
position will control the amount of flow; the maximum up or down position will generate the
fastest drum speed (greatest hydraulic flow) with the least available torque. For high
torque (maximum pull), only use this lever to POOH (pull out of hole).
If the engine speed decreases during operation, increase it (and the power output) by
adjusting the THROTTLE.
If AUTOSPOOLING is set to ON, the wire will be evenly spooled on/off the drum by the
levelwind system. If AUTOSPOOLING is set to OFF, use the SPOOLING joystick to manually
move the measuring head left and right on the levelwind shaft to wind the wire evenly on
or off the drum. If necessary, adjust the spooling speed with the SPOOLING SPEED knob
(see 4.7.4.2 Spooling speed knob on page 430).
Refer to 7.4.1 below for an overview of the different run modes using these levers.
7.4.1
4.
Continually check the system status. See 7.4.2 Check status and react to status changes on
page 81.
5.
When finished with wireline operations, shut down the system as described in 7.5 Normal
shut down on page 82.
Run modes
Make sure that the wireline is free of snags or loops in the path from the drum to the
measuring head.
2.
Ensure that the diesel engine is running correctly (check displays on the cabin and
PowerPack displays).
3.
Use the THROTTLE control to set the engine speed to 1800 rpm.
4.
Check and if necessary set the following switches on the control panel:
BRAKE = ON
AUTOSPOOLING = OFF
EMERGENCY STOP = out
5.
6.
7.
NOTE: If the engine speed drops during winching (see tachometer), use the THROTTLE control
(+) to increase engine speed to 1800 rpm.
NOTE: As the winch speed is increased, the torque delivered by the hydraulic motor will
decrease - in other words, it will have less pulling-power. At higher speeds, the winch will
therefore have more difficulty when it encounters resistance.
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2.
Turn the WINCH SAFETY knob counter-clockwise (-) until the drum does not turn at the set
speed.
3.
Turn the WINCH SAFETY knob clockwise (+) until the drum begins to turn. At this point there is
only just enough power to overcome the weight of the wireline and tool string.
4.
Turn the WINCH SAFETY knob clockwise a half-turn further. This should pull just hard enough
on the tool string to extract it through the constriction. If the constriction is too tight at this
setting for the tool string to pass, then the excess hydraulic pressure will be diverted, and the
drum will stop without any harm being done. (You should increase the WINCH SAFETY further,
in this case.)
NOTE: Avoid prolonged use of the winch with the WINCH SAFETY set too high. This can lead to
overheating of the hydraulic oil.
7.4.1.3 Levelwind spooling
The levelwind system can be used to spool the wire evenly onto the drum during running. This
can be done automatically or manually:
Set the AUTOSPOOLING button to ON to spool automatically
Set to OFF to manually move the SPOOLING CONTROL joystick carefully left and right to
move the measuring head on its carriage
7.4.2
Regularly check the gauges on the control panels to ensure that the system is operating
within its limits (check the specifications in Appendix 1 Specifications on page 188 for the
normal operating ranges).
2.
If the SmartView shows an exceptional condition, stop the machine and troubleshoot the
potential cause. If the exception condition is extreme, push one of the EMERGENCY STOP
buttons (see section 2.2 ATEX and zoning on page 11) to immediately stop the engine and
cut system power.
The engine also has the following built-in safeguards to shut down automatically and prevent
system damage:
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7.5
Make certain that the brake is applied: switch the DRUM BRAKE to ON.
2.
3.
If the PowerPack generator is running, press the GENERATOR STOP button on the PowerPack
control panel. Check the GENERATOR RUNNING light goes out.
If the unit is connected to a rig power supply, switch off the rig power supply.
4.
At the PowerPack, pull the ENGINE STOP lever to stop the engine. Check the tachometer to
ensure the engine speed reduces to zero rpm.
5.
6.
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b) Check the pneumatic pressure gauges (AIR PRESSURE, START PRESSURE) on the control
panel, to verify that there is no pressure.
7.
Note the shut-down date and time in the running hours log (see 5 Running hours log book on
page 196).
8.
Carry out the following daily shut-down tasks, taking measures to rectify faults as necessary:
a) Inspect all hydraulic hoses, couplings, valves, control blocks, motors and pumps for signs
of oil leakages, wear and damage to hoses, etc.
b) Inspect major mechanical components (levelwind system, chain transmission, drum
pillow blocks) for possible looseness, loss of adjustment or mechanical interference.
c) Inspect all suction filter condition indicators.
d) Check the levels of all fluid reservoirs, replenishing as necessary:
Engine fuel level;
Engine oil level;
Hydraulic fluid level;
Engine coolant level;
Pneumatic line lubricator;
Winch gearbox oil level;
e) Check that the pneumatic system automatic water drain is working correctly.
f) Wipe down the levelwind support shaft.
g) Check the winch drip tray: if necessary, unscrew the plug and drain the drip tray into a
shallow waste oil container.
h) Remove all dirt, salt, oil, grease, hydraulic fluid etc. from the surfaces in the winch
module.
i) Rinse the exterior of the SlimSplit C and interior of the winch module with fresh water.
j) Lubricate moving mechanical components as required.
k) In the cabin module, clean the interior with a soft cloth and appropriate spray cleaner.
Wipe down the window, control panel (plus gauges, switches and joysticks), electrical
panel, cabinet and mop the floor clean. Check in-cabin consumables and replenish
where necessary.
7.6
Emergency stop
The SlimSplit C has two modes of emergency stop:
Manual, which is initiated by a person pushing one of the Emergency stop buttons on the
unit. Pushing one of these buttons will choke the diesel air inlet and immediately stop the
engine.
System (automatic), which is caused by a system condition. For some engine alarms, the
system will automatically shut the engine down. This shutdown procedure is triggered by
one of the following:
Low oil pressure: <0.5 bar (<7.25 psi)
High engine coolant temperature (exceeds 106C)
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An engine overspeed situation: >2400 rpm. Excessive rpm will create increased intake
vacuum causing the Pyroban air input valve to trip and cut off intake air.
After resolving the emergency situation, perform a pre-start inspection and then restart the unit.
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MAINTENANCE
8.1
Introduction
Only qualified and trained personnel should perform maintenance on ASEP Zone 2 equipment.
Maintenance can be described as, but not limited to:
Checking and testing components
Cleaning the unit and individual components - accumulated dirt can hamper unit
operations and might jeopardize Zone 2 safety
Installing and removing parts from the unit
Filling up the fluid levels on the unit
Lubricating moving parts
Troubleshooting any malfunctions that may occur on the unit before, during and after
operations
Calibrating and adjusting settings on the unit's hydraulic, pneumatic, mechanical,
electrical and diesel systems
Certain scheduled maintenance is required on a regular basis. Inspections and tests should be
carried out daily before working with the SlimSplit C unit, but regular maintenance should be
performed according to the number of running hours the SlimSplit C has been used. Running
hours should be logged by the SlimSplit C operator following a strict discipline (see
Appendix : Log session running hours on page 198). Failure to accurately log the running hours
can mean that certain maintenance and service activities are not carried out in a timely manner,
and can lead to damage to the equipment, and potentially even hazardous situations.
The SlimSplit C carries a powerful winch that exerts extreme forces on its own mountings, on the
frame, the mounting points, and (optional) track & pivot base. Furthermore, powerful shocks to
the entire unit are possible, when sudden resistance is encountered during winching operation,
or when jarring the wireline for an effect in the hole. It is essential to service and maintain the
SlimSplit C at intervals at least as frequent as suggested by ASEP in section 8.2 below. ASEP
recommends basing the service intervals on hours of running. You may prefer to use calendar
time (weeks, months) to dictate the service interval. That is up to the customer to decide, as long
as the minimum frequencies recommended here are observed.
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8.2
as required
1200
900
600
300
Page
daily
Maintenance activity
1500/annual
See the numbered footnotes below the table for additional information where indicated
Check modules for dirt, damage and leaks (clean/repair if required) (2)
NA
Check/fill coolant
94
Check/fill diesel
94
98
104
110
164
90
93
103
106
111
113
115
Lubricate unit
118
129
148
171
116
172
114
100
124
141
144
149
157
160
169
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as required
1200
900
600
300
Page
daily
Maintenance activity
1500/annual
180
91
108
Drain/fill coolant
120
155
171
122
92
89
114
126
132
Replace drum
134
Remove/replace slipring
139
150
163
165
177
182
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8.2.1
Complete the wireline service operation, and spool all wire onto the drum.
NOTE: If it is necessary to perform maintenance with the wire inhole, then you must apply the
brake and clamp the wire to a rigid structure, such that the wire is relieved of all tension,
and no incident in the hole or BOP can cause the wire to come under tension.
2.
3.
4.
5.
If you intend to work on any hydraulic component, allow the system time to cool down, and
do not open any hydraulic connection unless you are certain that the hydraulic oil is cool.
6.
If you intend to work on any electrical component, make absolutely certain that the main
power switch is OFF, and that there is no rig AC connected to the unit.
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8.2.2
Inspect the grounding cable reel, cable and terminals at both ends for good, clean
connection.
2.
3.
Inspect all control panels, cabinets and junction boxes for condition of labels, tags and signs.
Replace all damaged labels, tags and signs.
4.
Check the mountings of all cabinets, armatures and control devices, and tighten where
necessary.
5.
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8.2.3
WARNING
FALLING FROM HEIGHT
Falling from the top of the unit can cause serious injury or death.
When working on top of the unit: make sure the roof is locked, and always attach a
safety line to one of the safety bars.
For detailed instructions on the air conditioning unit, please refer to the supplier documentation
supplied separately.
1.
2.
3.
Check tightness of condenser fan impeller and grub screws; tighten if necessary.
4.
Spray condenser fan motor body with heavy duty corrosion inhibitor.
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8.2.4
WARNING
FALLING FROM HEIGHT
Falling from the top of the unit can cause serious injury or death.
When working on top of the unit: make sure the roof is locked, and always attach a
safety line to one of the safety bars.
For detailed instructions on the air conditioning unit, please refer to the supplier documentation
supplied separately.
Check each of the following points and rectify if necessary.
1.
2.
3.
4.
5.
Check for refrigerant leakage from joints and couplings (use leak-finding solution or soapy
water).
6.
7.
8.
Check grounding points for damage to straps, and ensure they are tightly fastened.
9.
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8.2.5
Shut down the unit for safe maintenance. See related procedure.
2.
Locate the air dryer filter in the PowerPack. See Figure 8.1.
3.
Release all pneumatic pressure from the system by slowly opening the rig air inlet valve.
4.
5.
Firmly screw the new air dryer filter onto the filter body.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
6.
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Dispose of the used air dryer filter according to local environmental regulations.
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8.2.6
Shut the unit down for safe maintenance. See related procedure.
2.
Open the appropriate access doors so that you can access the drum brake band(s).
3.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
4.
NOTE: The brake band must also be exchanged each time the drum is exchanged.
6.
WARNING
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.
7.
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8.2.7
Check/fill coolant
Related topics:
8.2.1 Safe maintenance shutdown on page 88
This procedure describes how to check and top up the cooling system from the filling cap at the
top of the radiator.
On some units new coolant can be pumped into the cooling system from the lower drain point.
This method is normally preferred when the coolant has been completely drained, because the
cooling system can be bled at the same time and the risk of introducing air pockets into the
cooling system (especially the exhaust gas cooler) is reduced.
For optimum cooling, regularly check the coolant level. When filling the radiator always keep in
mind that the volume will increase when the engine/coolant is hot. Therefore, take care not to
overfill the radiator. If the radiator is overfilled, excess coolant will be forced out of the coolant
overflow during operations.
1.
Shut the unit down for safe maintenance. See related topic.
2.
Remove the coolant access panel at the top of the unit (optional).
If the unit does not have an coolant access panel, open the working side PowerPack door
instead, and secure in place with the door catch.
3.
WARNING
HOT OBJECT
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, make sure the engine/
motor has stopped and the coolant has cooled down.
4.
Carefully remove the coolant filler cap at the top of the coolant radiator. See Figure 8.3.
coolant filler
cap
Look inside the radiator and check if the coolant level is approximately 2 cm from the top of
the filling point.
6.
If the coolant is low, fill the cooling system with coolant by performing following steps; if the
coolant level is OK, refit the filler cap.
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WARNING
HOT OBJECT
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, make sure the engine/
motor has stopped and the coolant has cooled down.
7.
8.
Place a funnel in the inlet. If necessary for easier access, attach a flexible hose to the funnel
and place it in the inlet.
9.
Pour coolant into the cooling system until the coolant is approximately 2 cm from the top of
the filling point.
CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
If the unit has an exhaust gas cooler, open the air breather on top of the exhaust cooler
assembly.
2.
Make sure the coolant drain valve is closed (valve at 90 degrees to the drain tube). See
Figure 8.4 for an example.
3.
4.
Open the coolant system drain valve (valve in line with the drain tube).
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6.
Pump coolant into the cooling system until the coolant is approximately 2 cm from the top of
the filling point.
7.
8.
If the unit has an exhaust gas cooler, close the air breather on top of the exhaust cooler
assembly.
9.
Remove the flexible hose and coolant pump from the drain tube.
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8.2.8
Check/fill diesel
Related topics:
8.2.1 Safe maintenance shutdown on page 88
NOTE: Before using the unit, always check the diesel level; also regularly check the diesel level
during operations.
1.
Open the working side PowerPack door, and secure in place with the door catch.
2.
3.
Check the diesel fuel level. The fuel should be visible through the transparent plastic tank.
transparent
plastic fuel tank
diesel filler cap
WARNING
RISK OF EXPLOSION
Electrostatic discharge can cause an explosion.
Always ensure that the unit has been properly grounded using a suitable grounding cable
before performing any other work whatsoever on the unit, including connecting or
disconnecting any hoses or cables, refuelling the unit, operating the unit, or carrying out
maintenance on the unit.
b) Make sure both the unit and the refuelling facility are correctly grounded.
c) Remove the diesel filler cap.
d) Fill the fuel tank with En590 approved diesel.
e) Replace the diesel filler cap.
f) Clean any spilled diesel from around the filling point.
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8.2.9
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, and secure in place with the door catch.
3.
Wait for the engine oil to drain into the engine oil sump (approximately 10 minutes).
4.
6.
CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
7.
CAUTION
EQUIPMENT DAMAGE
Overfilling the engine oil can damage the seals in the engine. Add the oil slowly and wait until
it has run into the engine before rechecking the oil level.
8.
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Make sure the working side PowerPack door is open and secured in place.
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9.
Unscrew the oil filler cap at the top of the engine. See Figure 8.7.
10. Place the tube in the inlet at the top of the engine.
11. Insert the funnel into the other end of the tube.
12. Slowly add a small amount of oil.
CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
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Shut the unit down for safe maintenance,. See related topic.
2.
3.
Open the working side PowerPack door, and secure in place with the door catch.
4.
Place the open end of the flexible hose in a plastic container. See Figure 8.8.
flexible hose
(place open end in
plastic container)
drain valve
WARNING
HOT OBJECT
Hot engine oil can cause serious burns.
Take care when draining hot engine oil. Always wear appropriate Personal Protective
Equipment (PPE), such as gloves.
5.
Open the drain valve by turning it upwards (in-line with the tubing). See Figure 8.8.
6.
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Use the oil pump handle to pump the oil from the engine sump.
8.
9.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
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CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
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Shut the unit down for safe maintenance. See related topic.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
2.
Locate the viewing hole at the rear of the gearbox. See Figure 8.11.
3.
Check the oil level. The oil level should be at the middle of the sight glass.
oil level
5.
6.
7.
8.
Slowly pour oil into the gearbox until the oil is visible at the middle of the sight glass.
9.
CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
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WARNING
RISK OF BURNS
If the unit has been running, the hydraulic oil and components can be at an extremely high
temperature. Never attempt to dismantle hydraulic connections or replace hydraulic filters until
the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or less. Check the
hydraulic oil temperature gauge (usually the reservoir temperature), then carefully check the
temperature of the applicable component by touch before you start maintenance.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
1.
2.
3.
Inspect the oil level in the sight glass(es) of the hydraulic oil tank.
The correct oil level is mid-point in the upper sight glass of the hydraulic oil tank..
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4.
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WARNING
HOT OBJECT
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, make sure:
- the engine has been stopped.
- the pressure has been released from the hydraulic system.
- the hydraulic oil has cooled down.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
1.
Shut the unit down for safe maintenance. See related procedure.
2.
3.
Inspect the general condition of all hydraulic lines and hoses. Look for visible damage,
leakage, and sweating or swelling of hoses.
4.
Inspect the entire unit for signs of leakage, such as oil drips, oily dust build-up, etc., around:
Tanks
Hoses and lines
Couplings/connectors
Control levers
Valves
Filters
Pumps
Motors
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
5.
6.
Make the unit safe for hydraulic maintenance as described in step 1 above.
CAUTION
EQUIPMENT DAMAGE
Dirty or damaged quick connectors can leak and cause equipment damage.
Before connecting any quick connectors, inspect and clean both the male and female parts of
the quick connector.
7.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
WARNING
MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Make sure the engine cannot be started during maintenance.
2.
3.
Open the working side PowerPack door, and secure in place with the door catch.
4.
Unscrew all the mounting bolts, and remove the V-belt guard(s). See Figure 8.13.
5.
bolt
WARNING
MOVING PARTS
Moving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.
Make sure the engine cannot be started during maintenance.
6.
Make sure the belts are not damaged or worn. See Figure 8.14.
7.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
If necessary, replace the belts. See the Iveco maintenance manuals for detailed
maintenance instructions.
9.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related procedure.
2.
Open the appropriate door(s) so that you can easily access all shock absorbers.
3.
4.
Check the four shock absorbers at each corner of the engine. See Figure 8.15 for an
example location.
Pay particular attention for loose mounting bolts or uneven wear.
shock absorber
6.
7.
WARNING
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.
8.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related procedure.
2.
Close the diesel tank isolation valve (valve perpendicular to the tubing). See Figure 8.16 for
a typical example.
4.
Unscrew the blind cap and remove the coarse particle filter (in-line filter between diesel
reservoir and first fine particle filter). See Figure 8.17.
6.
Refit the cleaned particle filter, and tighten the blind cap.
7.
Open the diesel tank isolation valve (valve in-line with the tubing).
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
8.
9.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
WARNING
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.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related procedure.
2.
mesh
diesel tank
4.
5.
CAUTION
EQUIPMENT DAMAGE
The fuel tank and fuel lines can be damaged if the fuel tank breather is capped (blocked).
Never block (cap) the fuel tank breather.
6.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
7.
8.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Make sure the unit has been shut down for safe maintenance - see related procedure.
2.
Open the appropriate door(s) so that you can easily access the diesel filler cap.
3.
Carefully remove the diesel filler cap at the top of the tank.
4.
Uncouple all hoses and cables, and separate the PowerPack from the cabin/winch module
(if they are joined).
5.
Place one end of a clean flexible hose in the fuel tank and make sure the hose is fed far
enough into the tank to reach the bottom of the tank.
6.
Place the other end of the flexible hose in a container large enough to contain the fuel
remaining in the fuel tank.
7.
Siphon or pump the fuel through the hose into the container.
8.
Wait until the fuel is siphoned as much as possible from the fuel tank.
9.
10. Locate the two fuel tank threaded drain plugs on the sides of the tank.
11. Remove one, and if possible both drain plugs (take care to collect any dripped fuel with
absorbent cleaning rags).
12. Using a crane or by levering in the forklift slots, tilt the PowerPack gently to the rear and the
right, until the last of the fuel drips from the drain holes.
13. Replace the drain plugs.
14. Replace the diesel filler cap.
15. Dispose of the drained diesel according to local environmental regulations.
16. The system is now ready to be air transported.
17. If the unit has been running on summer diesel and is to be stored for a period in cold
temperatures, flush the lines and diesel pump with winter diesel as follows:
a) Carefully remove the diesel filler cap at the top of the tank.
b) Fill the tank with 4 liters (1 gallon) of winter diesel.
c) Replace the diesel filler cap.
d) Start the engine and run it at idle speed for 5 minutes.
This will flush any remaining summer diesel through the diesel pump and diesel lines.
e) Switch off the engine.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, and secure in place with the door catch.
3.
Place the plastic container underneath the bowl of the of the water/diesel separator.
4.
Drain the accumulated water by loosening the drain plug at the bottom of the bowl. See
Figure 8.5.
water/diesel separator
drain plug
6.
7.
8.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HOT OBJECT
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, make sure:
- The engine has been stopped.
- The pressure has been released from the hydraulic system.
- The hydraulic oil has cooled down.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
1.
Shut down the unit so it is safe for hydraulic maintenance. See related procedure.
2.
Check that:
There is zero hydraulic pressure in the hydraulic circuits
The hydraulic oil is cooled sufficiently to avoid burns
3.
4.
Open the right-hand PowerPack door, so that you can easily access the underside of the
hydraulic oil tank and drain valve. See Figure 8.20.
blind cap
blind cap
Figure 8.20 Hydraulic oil tank drain valve (two different types)
5.
Unscrew the cap from the drain valve at the bottom of the hydraulic oil tank.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
6.
7.
Lead the hose into a suitable collection tank, but make sure you can see the fluid that flows
from the hose.
8.
Slowly open the drain valve, and allow the water to run out.
9.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
12. Dispose of all filters and used oil as prescribed by site regulations.
13. Remove all tools and materials from the work area.
WARNING
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.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
2.
Using a grease gun, apply grease to the drum bearings in the pillow blocks on the right and
left side of the winch. Inject grease until it emerges from the sides of the bearing. See
Figure 8.21.
3.
grease nipple
winch bearings
Use the grease gun to apply grease to the bearings of the doors. See Figure 8.22.
5.
grease point
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Use the grease gun to apply grease to all other lubrication points in the system.
7.
8.
Check the Smarthead User Manual for all grease points for the measuring head.
9.
Check the Iveco documentation for grease points for the engine.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
2.
Remove the coolant access panel at the top of the unit (optional).
If the unit does not have a coolant access panel, open the working side PowerPack door
instead, and secure in place with the door catch.
3.
WARNING
HOT OBJECT
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, make sure the engine/
motor has stopped and the coolant has cooled down.
4.
Carefully remove the coolant filler cap at the top of the coolant radiator. See Figure 8.3.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
5.
Make sure the coolant drain valve is closed (valve at 90 degrees to the drain tube). See
Figure 8.4 for an example.
7.
8.
9.
10. Wait until the coolant has drained from the cooling system, and then close the drain valve
(perpendicular to the tubing).
11. Remove the flexible hose and plastic container.
12. Refit the coolant drain plug.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
CAUTION
EQUIPMENT DAMAGE
Fluid leaks can cause mechanical components to run dry and sieze, as well as contaminate
the working area and environment.
Always thoroughly clean dipsticks, filler caps, drain plugs and their seatings before re-fitting
them. Make sure screwed caps and plugs have undamaged gaskets or O-rings, and are
properly tightened.
15. Refit the coolant filler cap at the top of the coolant radiator. See Figure 8.3.
16. Refit the coolant access panel (optional).
17. Use a cleaning rag to clean any spilled coolant.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, and secure in place with the door catch.
3.
Locate the air filter. See Figure 8.5 for an example of an air filter.
4.
NOTE: For easy access, the entire air filter housing can be removed by removing the two
securing straps.
securing strap
cover
securing nut
Loosen the securing nut, and remove the safety element. See Figure 8.26.
safety element
securing nut
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
6.
Loosen the securing nut, and remove the filter element. See Figure 8.27.
filter element
securing nut
8.
9.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
2.
Open the PowerPack working side access door so that you can easily access the diesel tank
isolation valve. See Figure 8.28 for a typical example.
3.
Close the diesel tank isolation valve (valve perpendicular to the tubing).
5.
Remove the filter element from the mounting head. See Figure 8.5.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
6.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
mounting head
filter element
Lubricate the top seal of the new filter element with clean diesel fuel or engine oil.
8.
9.
10. Open the diesel tank isolation valve, and check the fine particle filter for leaks.
11. Rectify any problems.
12. Purge the diesel system. See related topic.
13. Start the diesel engine.
14. Check for correct operation, and recheck the fine particle filter for any leaks.
15. Rectify any problems.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Open the working side PowerPack door, and secure in place with the door catch.
2.
Push the spring loaded diesel engine primer several times. Diesel will be pumped out of the
tank and into the system.
diesel primer
Ensure the diesel engine cannot be started. Inform personnel, place warning signs.
5.
Make sure the working side PowerPack door is open and secured in place.
6.
Bleed the fuel line to the diesel pre-filter and water separator as follows:
a) Loosen the bleed screw on the diesel pre-filter and water separator. See Figure 8.31.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
bleed screw
bleed screw
a) Push the spring loaded diesel primer until fuel appears at the bleed screw.
b) Tighten the bleed screw.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
8.
hose
hose connection
point
diesel primer
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of
the danger, and cordon off the dangerous area.
1.
2.
3.
Put the unit into manual mode. If applicable, disable the automatic winch control program
(e.g. SmartMonitor).
4.
Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
5.
6.
Using the DRUM CONTROL joystick(s), start to turn the drum slowly INHOLE, and allow it to
continue to turn at a low speed.
7.
At the winch, listen (or have an assistant listen) for sounds that may indicate that the drum
is in contact with the brake band(s). If applicable, check both brakes.
8.
Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
9.
10. If there was no brake-contact noise from the drum in step 7, then the brake has passed the
free-running test. Continue with the drum brake slip test (next section).
If brake-contact noise was heard, then the brake needs adjustment. See related topic.
Drum brake slip test
The drum is correctly adjusted when the drum slips in the applied brake at a MAIN PRESSURE of
about 210 bar.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
1.
2.
3.
Put the unit into manual mode. If applicable, disable the automatic winch control program
(e.g. SmartMonitor).
4.
Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
5.
6.
7.
On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine
speed to the maximum torque range.
8.
Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE until
the drum slips in the brake.
9.
Check the MAIN PRESSURE gauge and note the brake slip pressure.
10. Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
11. On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed
to the idling range.
12. Apply the BRAKE.
13. If the MAIN PRESSURE when the drum slipped in step 17 was within the range of approximately
180 to 240 bar, then the brake has passed the slip test. Continue with the drum brake
stopping test (next section).
If the drum slipped below 180 bar (too slack) or above 240 bar (too tight) of MAIN PRESSURE,
then the brake needs adjustment. See related topic.
Drum brake stopping test
This brake must quickly stop the drum in a controlled, smooth manner. i.e. without juddering or
causing extreme shock to the winch and other equipment. The effect during actual operations will
be different, depending on:
the amount of wire on the drum (a fully loaded drum has more momentum);
the weight of the tool string;
the effect of wellbore pressure and resistance on the tool string and wire;
the direction of operation (inhole or outhole);
the speed and torque of the drum (selected gear, engine speed, etc.);
moisture and oil on the drum rim.
The test is conducted in one specific situation. It is recommended to always conduct the test in
the same situation and under the same conditions.
1.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2.
3.
Put the unit into manual mode. If applicable, disable the automatic winch control program
(e.g. SmartMonitor).
4.
Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
5.
6.
7.
On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine
speed to the maximum torque range.
8.
Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE to
about 100 bar, so that the drum is rotating at a fairly high speed.
9.
10. Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
11. On units powered by a diesel engine or truck PTO: use the THROTTLE to reduce engine speed
to the idling range.
12. If the drum stopped quickly and smoothly at step 9, then the brake has passed the stopping
test.
If the drum did not completely stop, or did not stop smoothly, then the brake needs
adjustment. See related topic.
13. Shut down the unit.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
NOTE: On a dual-brake drum, always replace both bands at the same time.
Ensure this locknut is
tightened against the
threaded block in the
brake band
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2.
3.
Shut the unit down for safe maintenance. See related topic.
4.
For each brake on the drum, remove each of the old brake bands:
Observe how the existing brake is assembled, and which parts belong where.
a) Remove all guards surrounding the winch drum and brakes.
b) Completely loosen and detach the lower brake band adjuster at the brake cylinder.
c) Remove the pivot pin and detach the other end of the brake band from the brake cylinder
assembly.
d) If applicable (split band): completely loosen and detach the upper turnbuckle between the
two brake band segments.
e) Withdraw the old brake band segments from around the drum.
f) If applicable (split band): remove the retaining clips and pivot pins from the turnbuckle
attachment blocks.
g) Remove the blocks from both ends of each brake band segment.
5.
6.
For each brake on the drum, install the new brake band by proceeding through the removal
steps in reverse order.
If applicable (split band): leave sufficient play in the turnbuckle so that the ends of the
assembled brake band are easier to connect at the brake cylinder.
NOTE: Ensure the retaining pins are inserted through the pivot points in both turnbuckle
attachments.
7.
With the brake still applied under spring pressure from the brake cylinder, tighten each brake
at the lower adjuster until it presses firmly against the drum, then tighten the locknut against
the threaded block.
NOTE: This is only an initial adjustment. the brake must now be properly adjusted.
8.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
Remove the wireline from the measuring head assembly and secure it to the drum.
2.
3.
Lower the levelwind arm (if not already lowered) using the switch on the cabin control panel.
4.
Shut the unit down for safe maintenance. See related topic.
5.
6.
Remove the attachment bolts, and remove the drum guards. See Figure 8.35.
drum guard
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of
the danger, and cordon off the dangerous area.
7.
8.
9.
Slowly push the dual control levers forward until the master link in the drive chain can be
easily accessed. See Figure 8.36.
master link
Figure 8.36 Master link in drive chain (split pin or clip locking)
10. Shut the unit down for safe maintenance. See related topic.
11. If an encoder/slip ring is fitted to the drum, remove the encoder/slipring. See related topic.
12. Remove the brake band. See related topic.
NOTE: To allow for easy access to the drum, remove the winch front beam.
13. Turn the drum alignment bolts (2x for each bearing) until the threaded end of the bolts are
clear of the drum bearing housing. See Figure 8.37.
drum bearing
housing
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
14. Remove the drum attachment bolts (2x for each bearing).
WARNING
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
15. Place the lifting straps at either end of the drum, and attach the straps to a hoist.
16. Use the hoist to slide/move the drum assembly forward just enough to slacken the chain.
17. Remove the locking device and master link from the chain, and then remove the chain from
the drum. See Figure 8.36.
18. Reposition the master link and locking device, and store the chain inside the winch.
WARNING
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.
19. Use the hoist to lift the drum out of the unit.
20. If the drum is being stored for any period, apply high quality multipurpose grease to the drum
journals and bearings.
21. Store the drum in a suitable shipping container.
Refit drum
22. Check the condition of the drive sprocket on the gearbox. If necessary, replace the drive
sprocket. See related topic.
23. Check the condition of the winch frame. Report any damage.
24. Use a rag to clean any excess grease or dirt from the winch frame.
WARNING
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
25. Place the lifting straps at either end of the drum, and attach the straps to the hoist.
WARNING
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.
26. Use the hoist to lift the drum out of the shipping container.
27. Carefully lower the drum so that the bearing blocks rest on the winch frame.
28. Insert the drum attachment bolts, and tighten to finger-tight.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
29. Position the chain around the drive sprocket and drum sprocket.
30. Refit the master link and secure with the locking device. See Figure 8.36.
If the chain is secured with split pins, make sure to use new split pins.
31. Make sure the locking device is correctly secured.
32. Adjust the chain. See related topic.
33. Make sure the distances (a) and (b) between the bearing housing adjustment block and the
bearing housing are the same on both sides of the drum. See Figure 8.38.
This will ensure that the drum is correctly aligned in the winch module.
bearing housing
bearing housing
adjustment block
bearing housing
adjustment block
distance (a)
should be the
same on both
sides of the drum
distance (b)
should be the
same on both
sides of the drum
WARNING
MOVING PARTS
An incorrectly adjusted brake band can result in hazardous operating conditions.
Before operating the unit, make sure the brake band has been correctly adjusted.
When the brake is set to off, it must not rub against the drum, otherwise sparks might
be generated. When the brake is set to on, it must hold the drum firmly in position.
34. Make sure the drum attachment bolts on both sides of the drum are securely tightened.
35. Remove the lifting straps and hoist, and store in a safe place.
36. Refit the brake band. See related topic.
37. Refit the drum guards and tighten the drum guard attachment bolts.
NOTE: There is a drum guard on either side of the drum.
38. If an encoder/slip ring is fitted to the drum, refit the encoder/slipring.
39. Lubricate the drum bearings on both sides with high quality multipurpose grease. Inject
grease using a grease gun until excess grease appears outside the bearings.
40. Use a rag to clean any excess grease or dirt from the bearings and work area.
41. Remove all tools and materials from the work area.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of
the danger, and cordon off the dangerous area.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
Shut down the unit for safe maintenance. See related procedure.
Remove
1.
Remove the ground cable (1) on the slipring. See Figure 8.39.
2.
3.
Remove all the attachment bolts (2) on the casing (3) of the slip ring.
2
3
5.
Remove the screws (1) holding the plastic attachment cap (2) on the end of the slipring to
expose the logging wire connectors (3). See Figure 8.40.
6.
Loosen all the logging wires from their connectors (3) on the slipring. The number of logging
wires is customer specific.
7.
Loosen all the bolts (1) holding the base of the slipring to the drum attachment. See
Figure 8.41.
8.
Remove the slipring while carefully feeding the logging wires through the centre hole of the
ring.
9.
Lay the slipring to one side, or remove it completely by disconnecting the slipring connector
at the cabin wall.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2
1
If attached, remove the casing and the plastic top cap on the slipring. See Figure 8.39 and
Figure 8.40.
2.
Position the slipring against the drum mounting while feeding the logging wires through the
centre of the slipring.
3.
Tighten the bolts attaching the slipring to the drum mounting. See Figure 8.41.
4.
Connect all the logging wires to the applicable connectors on the top of the slip ring (see
Figure 8.41). The wires should be connected according to your customer specific logging
wirie diagram.
5.
Attach the plastic cap to the top of the slipring using the attachment screws. See Figure 8.41.
6.
Carefully slide the casing over the slipring, making sure not to damage any of the logging
wires.
7.
Tighten all the attaching bolts on the casing. See Figure 8.39.
8.
9.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
X X
d
>1d
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
1.
2.
3.
Shut down the unit for safe maintenance. See related topic.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
4.
5.
6.
7.
Loosen the brake on both sides by completely slackening the adjusters sufficiently for the
brake bands to be free of the drum rim.
8.
Switch the BRAKE on and check again that the brake bands are still free of the drum rim; if
not, repeat step 7.
9.
Tighten the adjusters equally on both brake bands until the brake band makes initial contact
with the drum rim and you get initial slight resistance when tightening.
10. Tighten the adjusters again equally by half a turn, and tighten the locknuts at the adjusters.
11. Start the unit for operations.
12. Put the unit into manual mode. If applicable, disable the automatic winch control program
(e.g. SmartMonitor).
13. Put the DRUM CONTROL joystick(s) into the neutral (STOP) position.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
CAUTION
EQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the
brake is tested at LOW or MEDIUM speed ratio.
Always select HIGH speed ratio when testing the brake.
14. For a multi-speed gearbox, select HIGH speed ratio (never LOW or MEDIUM speed ratio).
15. On units powered by a diesel engine or truck PTO: set the THROTTLE to idle.
16. Gradually move the DRUM CONTROL joystick(s) INHOLE, increasing the MAIN PRESSURE until
the drum slips in the brake.
17. Check the MAIN PRESSURE gauge and note the brake slip pressure.
18. Immediately return the DRUM CONTROL lever(s) to the neutral (STOP) position as prolonged
pressure may damage the seals.
19. If the MAIN PRESSURE when the drum slipped in step 17 was within the range of approximately
195 to 225 bar, then the brake has passed the adjustment slip test. Continue from step 23.
If the drum slipped below 195 bar (too slack) or above 225 bar (too tight) of test pressure,
continue with the next step.
20. Shut the unit down for safe maintenance. See related topic.
21. Loosen the locknut on the adjuster(s), then:
a) Brake band too tight: loosen the brake adjuster (both sides equally for double brakes).
Brake band too loose: tighten the brake adjuster (both sides equally for double brakes).
b) Tighten the locknuts at the adjuster.
22. Repeat the test and adjustment again from step 11 through step 21 until the adjustment is
correct.
NOTE: Correct adjustment is when the drum breaks free of the applied brake at about 210
bar of hydraulic system main pressure, and there is no contact between the brake
band and the drum when the brake is released.
If the correct adjustment cannot be reached or there is no adjustment left in the adjuster,
replace the brake band(s) of this drum. See related topic.
23. Shut the unit down for safe maintenance. See related topic.
24. Reinstall the guards surrounding the drum and brakes.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
If necessary, lower or raise the levelwind arm, depending on the chain you want to check/
adjust.
2.
3.
Shut the unit down for safe maintenance. See related procedure.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
4.
Remove the drum guard so that you can easily access the chain. See example in
Figure 8.43.
drum guard
attachment bolt
Check the chain is firmly tightened with approximately 2 cm (0.75 in) total free play at the
middle point. See Figure 8.44.
6.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2 cm (0.75 in)
bearing housing
bearing housing
adjustment block
bearing housing
adjustment block
distance (b)
distance (a)
If the chain tension or alignment is not correct, adjust the chain tension and alignment by
performing steps 8 to 19. Otherwise, continue at step 20.
Make sure the drum alignment bolts (2x for each bearing) are fully tightened against the
bearing housing. See Figure 8.46.
9.
Make sure the drum attachment bolts (2x for each bearing) are fully tightened.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
drum attachment
bolt
drum attachment
bolt
drum alignment
bolt
drum alignment
bolt
reduction gearbox
attachment bolts (2x)
gearbox sprocket
adjustment bracket
adjustment bolt
lock nut
gearbox lower
adjustment bolt
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
14. Lock the adjustment bolt in place with the lock nut.
WARNING
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in dangerous situations.
Always make sure all attachment bolts and locknuts are correctly tightened.
WARNING
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.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Spool the wire fully onto the drum and anchor it to the drum so that it can turn with the drum.
2.
3.
Inspect the drum shaft pillow blocks on each side of the winch. The position on each side
must be identical, to ensure that the drum shaft is not out of alignment.
Adjust the alignment if necessary: see the chain adjustment procedure.
4.
On each side (left, right) of the winch drum, inspect the pillow block mounting and adjustment
bolts, tigtening if necessary:
The pillow block mounting bolts must be securely tightened.
The front and rear drum adjustment bolt must be screwed tightly against the pillow block
and the locknut must also be tight on each bolt.
5.
6.
7.
Disable winch movement using the controls, and apply the drum brake.
8.
Repeat steps 3 through 7 two more times, checking the pillow block mounts carefully each
time.
wellhead
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
Open the appropriate winch access door(s) so that you can easily access the drum.
2.
If necessary, remove the wireline from the measuring head and secure it to the drum.
3.
4.
5.
6.
Slowly push the dual control handles forwards and then backwards to simulate an in-hole/
out-hole action.
7.
Press the emergency stop button to shutdown the engine and disable all winch movement.
WARNING
DANGEROUS MACHINERY
If attachment bolts and locknuts are incorrectly tightened, components can work loose during
operation, resulting in dangerous situations.
Always make sure all attachment bolts and locknuts are correctly tightened.
8.
Check the drum alignment and mounting, and readjust if necessary. See related procedure.
9.
Check the chain tension, and readjust if necessary. See related procedure.
10. Repeat steps 3 through 9 two more times, making sure to check the drum alignment and
mounting, and chain tension each time.
WARNING
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.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2.
Shut the unit down for safe maintenance. See related topic.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
3.
4.
5.
Locate the sprocket at the side of the winch. See Figure 8.5 for an example.
6.
Measure the distance (a) from the end of the shaft to the side of the sprocket. This
measurement will be used later in this procedure when aligning the sprocket to the chain
drive.
7.
sprocket shaft
distance a
key
WARNING
RISK OF EXPLOSION
Using a heat source (naked flame) in a zone 2 area can cause an explosion. Before
using a heat source, make sure a "hot work permit" has been issued.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
8.
Place heat resistant material behind the sprocket, and then heat the sprocket so that it can
be removed from the shaft.
WARNING
HOT OBJECT
The sprocket and sprocket shaft are hot and can burn your hands.
Always wear appropriate Personal Protective Equipment (PPE), such as gloves.
9.
Remove the sprocket from the shaft, and place it in a safe location.
10. Make sure all pressure has been released from the hydraulic system.
11. Remove all hydraulic hoses from the hydraulic motor/gearbox assembly.
12. Blank off the open hydraulic lines.
13. Remove any electrical connectors from the hydraulic motor/gearbox assembly.
14. Cap electrical connectors where necessary.
WARNING
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
hydraulic motor/
gearbox assembly
gearbox attachment
bolts
gearbox attachment
nuts
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
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.
19. Use the chain hoist to lift the hydraulic motor/gearbox assembly out of the winch module.
Separate hydraulic motor from gearbox (as required)
WARNING
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.
hydraulic motor
attachment bolts
reduction gearbox
hydraulic motor
hydraulic motor
attachment bolts
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HOISTING HAZARD
Incorrectly hoisted loads can fall down causing serious injury or death.
Support the assembly at both ends, using two lifting straps and a hoist rated for the given
weight. Carefully control movements to avoid damaging other components.
26. Place the lifting straps at either end of the hydraulic motor/gearbox assembly, and attach the
straps to the hoist.
WARNING
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.
27. Lift the hydraulic motor/gearbox assembly from the flat surface, and position it inside the
winch module.
28. Refit the gearbox bolts, and tighten the ring of attachment nuts. See Figure 8.50.
29. Remove the winch and straps, and store them in a safe place.
30. Reconnect the hydraulic hoses of the hydraulic motor/gearbox assembly.
31. Reconnect any electrical connectors of the hydraulic motor/gearbox assembly.
32. Check the level of the gearbox oil (and fill if necessary). See related topic.
33. Make sure the sprocket shaft and sprocket are clean.
WARNING
RISK OF EXPLOSION
Using a heat source (naked flame) in a zone 2 area can cause an explosion. Before
using a heat source, make sure a "hot work permit" has been issued.
WARNING
HOT OBJECT
The sprocket and sprocket shaft are hot and can burn your hands.
Always wear appropriate Personal Protective Equipment (PPE), such as gloves.
35. Slide the sprocket onto the shaft, making sure it is correctly aligned for the chain and drum.
Refer to the measurement made in step 6.
36. Tighten the sprocket attachment bolt.
Finalize
37. Refit the drum and chain. See related topic.
38. Recheck the alignment of the sprocket, and adjust if necessary.
39. Adjust the chain. See related topic.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
40. Remove all tools and materials from the work area.
41. Check the level of the system hydraulic oil, and refill if necessary. See related topic.
42. Start up the unit.
43. Bleed the hydraulic system.
44. Slowly rotate the drum in both directions.
45. Checking for correct drum movement and operation of the brake.
46. Rectify any problems.
47. Check if the drum is correctly secured. See related topic.
48. The drum mount procedure must be done every time a drum is exchanged or the chain is
adjusted.
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
49. Lubricate the drum bearings on both sides with high quality multipurpose grease. Inject
grease using a grease gun until excess grease appears outside the bearings.
50. Use a rag to clean any excess grease or dirt from the bearings and work area.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HOT OBJECT
Hot hydraulic oil under pressure can cause serious burns.
Before working on components containing hydraulic oil, make sure:
- The engine has been stopped.
- The pressure has been released from the hydraulic system.
- The hydraulic oil has cooled down.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
NOTE: Always replace the suction filters whenever you replace the hydraulic oil.
1.
2.
3.
Open covers to gain access to the underside of the hydraulic oil tank and drain valve.
4.
Unscrew the cap from the drain valve built into the bottom of the hydraulic oil tank. See
Figure 8.52.
5.
6.
Lead the hose into a suitable waste oil collection tank of the same capacity as the hydraulic
oil tank
7.
Open the drain valve and drain all oil from the hydraulic oil tank into the waste oil collection
tank.
8.
If excessive contamination is suspected (e.g. due to the condition of the drained oil), flush
the hydraulic oil tank once with clean hydraulic oil.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
9.
Close the drain valve, remove the hose, and re-fit the cap.
10. Replace all suction filters in the hydraulic system. See related procedure.
11. Fill the tank with oil of the correct grade. See related procedure.
12. Dispose of all filters and used oil as prescribed by site regulations.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
MOVING PARTS
Moving parts (drum, gearbox, chain) can cause serious injury or death.
Make sure the winch cannot be operated during maintenance or rig-up activity.
1.
Open the appropriate PowerPack door(s) so that you can easily access the hydraulic suction
filters.
2.
3.
4.
Shut the valve on the intake side of the filter head. The valve is usually - but not always adjacent to the filter head. The valve is shut when the lever is at right angles to the flow
direction.
5.
Place a waste oil container below the filter assembly to catch the oil that may flow from the
filter head.
On horizontally-mounted filters, the filter will completely drain out when loosened.
6.
7.
Drain all the oil from the filter into a waste oil container, and discard the filter.
8.
Using a clean cloth, clean the filter head and the seal flange.
9.
Take a new filter (see spare parts list for this unit for correct type), and half fill it with hydraulic
oil for the duty and climate. See related topics.
10. Apply a thin film of hydraulic oil to the new seal supplied with the filter.
11. Place the seal on the filter, and screw the filter by hand up onto the filter head.
NOTE: Do not use tools to tighten the filter! It should be firmly tightened only by hand.
12. If the filter head is a dual-type, then repeat steps 5 through 11 for the second filter.
13. Open the valve in the intake side of the filter head.
14. Repeat the above steps for any other suction filters that are due for replacement.
15. Dispose of all filters and used oil as prescribed by site regulations.
16. When all filters have been replaced and all hydraulic maintenance has been carried out:
a) Check that all filter intake valves are open (levers aligned with flow direction).
b) Start the unit.
c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that the pressure
stabilizes at the pressure gauges of the SmartView control panel.
d) With the unit running, check each filter head:
The contamination indicator should be in the green zone.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
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.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
RISK OF BURNS
If the unit has been running, the hydraulic oil and components can be at an extremely high
temperature. Never attempt to dismantle hydraulic connections or replace hydraulic filters until
the hydraulic oil has cooled to a safe temperature of 50 degrees Celsius or less. Check the
hydraulic oil temperature gauge (usually the reservoir temperature), then carefully check the
temperature of the applicable component by touch before you start maintenance.
CAUTION
EQUIPMENT DAMAGE
Hydraulic systems and components are extremely sensitive to contaminants such as grit and
metal fragments, which can be accidentally introduced during servicing activity.
Apply maximum standards of cleanliness when servicing hydraulic components. Before
reassembling, thoroughly clean all plugs, couplings, O-rings, seals, etc. using a clean cloth.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
1.
Shut the unit down for safe maintenance. See related topic.
2.
3.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Underside of filter
mounting spigot.
head
showing
element
Relieve all pressure from all hydraulic circuits using the unit controls.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
5.
Place a waste oil container or plenty of rags below the filter assembly to catch the oil that will
spill from the filter head when the bowl is removed.
On horizontally-mounted filters, the filter will completely drain out when loosened.
6.
Unscrew the bowl using a suitable wrench applied to the hexagonal nut at the end of the
bowl.
7.
8.
Drain all the oil from the filter into a waste oil container, and discard the filter element.
9.
10. Using a clean cloth, thoroughly clean the filter head, screw thread, spigot and seal flange.
11. Using a clean cloth, thoroughly clean the filter bowl inside and out, in particular the O-ring
seating, support ring and screw thread.
12. Take a new filter element of the specified type (see spare parts list for this unit), and lubricate
the element nose seal, the new O-ring and the support ring with clean hydraulic fluid.
13. Carefully reposition the element and bowl on the spigot and filter head, by repeating the
removal step in reverse. If you have sufficient clearance, fit the filter element first before
fitting the bowl over the element; otherwise you will have to fit both at the same time.
14. Using a suitable wrench, firmly tighten the bowl.
15. If the filter head is a dual-type, then repeat steps 5 through 13 for the second filter.
16. Repeat the above steps for any other pressure filters that are due for servicing.
17. Dispose of all used filter elements and oil as prescribed by site regulations.
18. When all filters have been replaced and all other hydraulic maintenance has been carried
out:
a) Check that all hydraulic supply valves are open (levers aligned with flow direction).
b) Start the unit.
c) Activate the hydraulic circuits (winch, control circuits, etc.) and check that the pressure
stabilizes at the pressure gauges of the unit control panel.
d) With the unit running, check each filter head for leakage.
If there are leaks, shut the unit down for safe maintenance, remove the filter bowl and
element as described above, clean the facing parts and the seal, and re-fit the filter.
e) Inspect the seals again for leakage after operating for several hours, taking remedial
action if necessary.
Page 162 of 211
Version 1.00
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
19. Check and if necessary fill the hydraulic oil in the tank. See related topic.
Shut the unit down for safe maintenance. See related procedure.
2.
Open the appropriate door(s) so that you can easily access all shock absorbers.
3.
4.
5.
engine attachment
bolt
shock absorber
(with metal cover)
shock absorber
attachment bolt
7.
8.
9.
Position the new shock absorber with metal cover underneath the engine mounting bracket.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
15. Dispose of the old shock absorber according to local site regulations.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Inspect the grounding cable reel, cable and terminals at both ends for good, clean
connection.
2.
3.
Inspect all control panels, cabinets and junction boxes for condition of labels, tags and
signage. Replace all damaged labels, tags and signs.
4.
Check the mountings of all cabinets, armatures and control devices, and tighten where
necessary.
5.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Identify and rectify the situation that caused the circuit to overload.
2.
3.
4.
5.
Re-start the component or circuit that failed. Verify that the component or circuit is working
correctly.
6.
Replenish the stock of spare fuses, and also make sure that there is a new spare fuse stowed
in cartridge type fuse holders (see below).
NOTE: Not every type of fuse and circuit breaker described below may be present in your
equipment.
Blade type fuses
Pull the fuse from the fuse block and discard it.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
2.
Insert a spare fuse of the same color / rating. See Table 8.1.
Rating (amps)
Colour
purple
A0015291
light brown
A0015284
7.5
dark brown
A0015285
10
red
A0015286
15
blue
A0015287
20
yellow
A0015288
30
green
A0017156
spare fuse
live fuse
Swing the holder out and up to give access to the holder side cover.
2.
Carefully open the cover - this also ejects the blown fuse from the contacts.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
3.
Remove the blown fuse and replace it with a new fuse (see Table 8.2). If you have no other,
use the spare inside the holder, but insert a new spare at the first opportunity.
4.
Carefully close the cover - this will press the new fuse between the contacts.
5.
Rating (amps)
0.50
1.00
A0000934
1.50
A0011260
2.00
A0015219
3.15
A0015306
5.00
A0015575
6.30
A0010259
10.00
A0014805
spare fuse
live fuse
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Cartridge (glass) fuses are clamped between contacts in a pull-out holder. See Figure 8.58. The
pull-out holder also contains a spare fuse. The same standard 5 mm x 20 mm cartridge fuses are
used as in the swing-out type, as specified in Table 8.2.
To replace the cartridge fuse in a pull-out holder:
1.
2.
3.
Remove the blown fuse and replace it with a new fuse (see Table 8.2). If you have no other,
use the spare inside the holder, but insert a new spare at the first opportunity.
4.
5.
Circuit breakers
red
green
OFF
ON
circuit is ON (live)
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, and secure in place with the door catch.
3.
Close the diesel tank isolation valve (valve at right angles to the tubing).
4.
Unscrew the filter element from the mounting head with the bowl still connected. See
Figure 8.60.
bowl
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
6.
Discard the old filter element and O-ring according to local regulations.
7.
Lubricate the new top seal with clean diesel fuel or motor oil, and fit it to the recess in the
mounting head.
9.
Lubricate the new O-ring with clean diesel fuel or motor oil and fit it to the recess in the bowl.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
10. Gently turn the bowl onto the new filter element by hand. Do not use tools to fit the bowl to
the filter.
11. Fill the filter element (with bowl attached ) with clean diesel fuel.
12. Fit the filter element (with bowl attached) to the mounting head. Keep turning the filter
element until it contacts the top seal, and then hand-tighten an additional third to half a turn.
Do not over tighten.
13. Remove all tools and materials from the work area.
14. Open the diesel tank isolation valve, and check for any leaks.
15. Rectify any problems.
16. Prime the diesel system. by pressing the primer lever a number of times.
17. Rectify any problems.
18. Start the diesel engine, and check for correct operation and any leaks.
19. Rectify any problems.
20. Close all access doors.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
DANGEROUS MACHINERY
Changing factory settings can seriously 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 the Netherlands.
NOTE: The engine speed is factory preset and must not be set to a higher value.
1.
2.
3.
Record the RPM on the Tachometer in the cabin or on the working side of the PowerPack.
4.
5.
Compare the maximum engine speed with the unit specifications - if the maximum speed is
outside specification, contact ASEP at: support@asepgroup.com
WARNING
HIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components
might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
1.
2.
3.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
d) Without going over 400 bar, gradually increase the LINE TENSION until the main pressure
stops rising.
e) Hold the pressure for 10 seconds.
4.
5.
6.
7.
Re-inspect all hydraulic system hoses and couplings for leaks, and repair as necessary. See
related procedure.
8.
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, and secure it in place with the door catch.
3.
Disconnect any probes or sensors that may be present on the flame trap assembly. Remove
tie wraps as required. See Figure 8.5.
5.
Spread a plastic sheet over the entire area below the exhaust gas cooler, so that
contamination will fall outside the PowerPack.
6.
7.
Loosen the flame trap/cooler flange clamp sufficiently so that the clamp can be moved to one
side.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
8.
Carefully pull the flame trap assembly down and out of the exhaust pipe, and set it to one
side.
The O-ring should remain in place in the flange of the cooler. If it comes loose, set it carefully
to one side, as you will need it when you reassemble the exhaust system.
exhaust pipe
clamp
flame trap/cooler
flange clamp
exhaust pipe
clamp
Take the exhaust gas cooler cleaning tool from its holder in the PowerPack door. See
Figure 8.62 for an example.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HAZARDOUS PARTICLES
Hazardous particles such as carbon dust can damage your eyes.
Always wear appropriate Personal Protective Equipment (PPE), such as safety
goggles, when working in particle contaminated environments.
CAUTION
EQUIPMENT DAMAGE
Components can be damaged during cleaning, and complete assemblies may need replacing.
Take care when cleaning components. Use appropriate cleaning tools.
10. Clean out each tube in the exhaust gas cooler. Make sure the cleaning tool does not
penetrate the turbocharger, otherwise the complete assembly will have to be replaced. Turn
the cleaning tool and feed it in and out, until no more soot comes out of each hole. Much of
the soot will accumulate in the manifold at the inner end. See Figure 8.63.
ASEP recommends working from bottom to top, with one person cleaning the tubes, one at
a time, and the other holding a vacuum cleaner over the lowest tubes. This way, the falling
soot at the opposite end of the cooler will be drawn through the cleaned tubes into the
vacuum cleaner. The higher, uncleaned tubes will allow less air to be drawn through because
they are still fouled with soot.
tubes in cooler
contamination
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HIGH SOUND LEVELS
Prolonged exposure to high sound levels can damage your hearing.
Always wear appropriate Personal Protective Equipment (PPE), such as ear
defenders.
15. Start the engine, and run it for no more than 2 minutes.
The engine will sound louder than usual, because the silencer is removed.
16. Shut the unit down for safe maintenance. See related topic.
17. Carefully release the flange clamp, and remove the flame trap body from the exhaust gas
cooler, taking care to leave the O-ring in place.
CAUTION
EQUIPMENT DAMAGE
Any contact with the core of the flame trap element can bend the metal foil, and damage the
part. Only handle the flame trap element by the rigid edges.
18. Remove the element from the flame trap as follows (see Figure 8.64):
a) Inspect the flame trap element, and observe which side faces the exhaust gas cooler.
b) Support the flame trap assembly above a flat surface, with wooden blocks under the
flange, and with the open side down.
c) Tap the body of the assembly using a plastic hammer, to release the element.
d) If the element does not drop out, carefully lift and drop the assembly one or more times
with the open side down, until the element falls out.
The element can now be cleaned. See steps 19 to 27. To save time a spare clean
element can be fitted to the flame trap and the dirty element cleaned once the unit is back
in operation. If you decide to do this, you should continue from step 28.
flame trap
body
lock screw
complete flame
trap element
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HAZARDOUS CHEMICAL
Decarburizing fluid can cause severe injury to the eyes and skin.
Always wear appropriate Personal Protective Equipment (PPE), such as safety
goggles and chemical-resistant gloves when cleaning parts.
19. Place the complete flame trap element in a container of decarburizing fluid, and move it
around so that the fluid can penetrate all parts of the element. Leave it in the fluid for at least
1 hour.
20. Remove the element from the fluid and allow most of the fluid to drain out.
21. Rinse the element in clean water.
WARNING
COMPRESSED AIR IS HAZARDOUS.
Compressed air from an air pistol can cause severe injury or death if the air penetrates the
skin. Always wear appropriate Personal Protection Equipment (PPE), such as safety goggles.
Never point a compressed air pistol at exposed skin surfaces.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
35. Run the engine for a short time, just long enough to check for exhaust leaks at the exhaust
pipe clamp and the flame trap flange.
36. If any exhaust leak is detected, rectify the leak and repeat the reassembly steps.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
Shut the unit down for safe maintenance. See related topic.
2.
Open the working side PowerPack door, so that you can easily access the exhaust gas
cooler and flame trap. See Figure 8.65.
3.
WARNING
HOT OBJECT
Releasing pressure from the cooling system while the coolant is still hot can result in serious
burns. Before loosening the coolant filler cap, or other components, make sure the engine/
motor has stopped and the coolant has cooled down.
4.
5.
Loosen the clamp, and remove the coolant supply hose at the top of the cooler. See
Figure 8.65.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
coolant supply
hose
7.
Open the rear PowerPack door so that you can easily access the rear of the exhaust gas
cooler. See Figure 8.66.
8.
9.
10. Remove any other components as required that may restrict the removal of the exhaust gas
cooler.
11. Support both ends of the cooler.
12. Remove the attachment bolts at the rear of the cooler. See Figure 8.66.
muffler assembly
attachment bolt
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
WARNING
HEAVY OBJECT
Incorrect lifting of heavy objects can cause serious injury. Some heavy objects must not be
individually lifted by hand. Lifting equipment or additional personal may be required.
Before lifting any heavy object, always check your local safety regulations.
13. Carefully remove the cooler from the unit, and put it in a safe location.
WARNING
HEAVY OBJECT
Incorrect lifting of heavy objects can cause serious injury. Some heavy objects must not be
individually lifted by hand. Lifting equipment or additional personal may be required.
Before lifting any heavy object, always check your local safety regulations.
17. Position the cooler using adequate supports, and then tighten the attachment bolts.
18. Refit the coolant supply hose at the top of the cooler and then tighten the clamp. See
Figure 8.65.
19. Refit all connectors at the top of the cooler.
20. Refit the flame trap cover (and flame trap).
21. Refit the coolant supply pipe.
22. Refit the muffler assembly.
23. Refit any other components that were removed to access the exhaust gas cooler.
24. Refill the cooling system with coolant, and bleed the cooling system as required. See related
topic.
25. Remove all tools and materials from the work area.
26. Close all access doors.
27. Prime and then start the engine.
28. Test run the engine for at least 15 minutes.
29. Check that the cooling system works correctly. Rectify any problems.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Locate the gas detector and remove the retaining grub screw in the lid.
2.
Open the junction box of the detector by unscrewing the lid in an anti-clockwise direction
3.
Check that all electrical connections have been made and are correct. See Figure 8.3
4.
Measure the voltage across the + and - terminals and check that there is a minimum supply
of 10 VDC. present. See Figure 8.3.
6.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Connect the DVM to the test points marked TP1 and TP2 on the amplifier PCB.
NOTE: At the test points, Zero will read 40 mV = 4 mA. Full scale deflection (100%LEL) will read
200 mV = 20 mA. There is a current clamp of 25 mA on the 4-20 mA output.
8.
9.
Using a very small screwdriver, adjust the ZERO pot on the amplifier (which is accessible
via a hole in the PCB cover) until the DVM reads 40 mV.
10. On the SmartMonitor, check that the relevant channel (1=interior, 2=exterior) reads zero.
11. Remove the DVM.
12. Re-fit the lid on the gas detector and retighten the grub-screw.
13. Repeat all the above steps for the second gas detector.
Test the gas detectors
1.
Perform the following steps to verify correct working of each gas detector.
2.
3.
4.
5.
On the SmartMonitor display, verify that both channels 1 and 2 read zero.
6.
If either channel reads a value other than zero, repeat the zeroing procedure for that channel
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Shut down the unit for safe maintenance. See related procedure.
2.
Loosen all cover bolts, and swing out the cover. See example cabinet in Figure 8.3.
WARNING
RISK OF EXPLOSION
An incorrectly sealed ATEX explosion proof cabinet can cause a dangerous, uncontrolled
explosion.
Make sure all ATEX explosion proof cabinets are correctly sealed and that all bolts are
tightened to the correct torque value as specified in the vendor documentation.
3.
Use a clean cloth to clean the connection flange surfaces of the cabinet and cover.
4.
Check the condition of the seal. If the seal is damaged, it must be replaced.
5.
Check the condition of the connection flange. If the surface is severely damaged, the seal
will not work correctly, which can result in dangerous situations. In this case the cabinet must
be replaced.
6.
7.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
8.
Use a calibrated torque wrench to tighten each bolt, according to the value specified in the
vendor documentation.
CAUTION
ENVIRONMENTAL HAZARD
Fuels, oils, grease and similar petroleum products are harmful to the environment. Dispose of
used or excess oil, oily rags, used filters and other waste items in a responsible, environmentfriendly manner. Separate recyclable products from other, non-recyclable waste. Heed site
regulations and obey local environmental by-laws.
9.
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TROUBLESHOOTING
9.1
Troubleshooting principles
This section offers information for troubleshooting operating problems with the equipment.
However, it is not a substitute for a thorough knowledge of the SlimSplit C unit and its related
systems.
If you strike a problem that is not covered, or is not corrected by the suggested remedy, please
contact ASEP for qualified technical guidance on how to proceed further. Support contact
information is provided near the front of this manual.
The troubleshooting guide is divided into sections according to components or group that may
need troubleshooting. Within each section, problem symptoms and their possible causes are
described, plus a suggested remedy that should enable you to get that component operational
once more. Always review the complete list of possible causes for each problem, before selecting
which remedy to apply. More detail on the remedies is frequently available in the maintenance
section of this manual.
Most of the problems you may encounter in this equipment will arise in the hydraulic and electrical
systems. We have therefore attempted to anticipate every likely malfunction in these systems,
and provide diagnostic and remedial information for these. For all other parts of the SlimSplit C,
this troubleshooting guide is restricted to those problems that may be symptoms of more serious
problems or which have more than one possible cause and remedy. In other words, problems with
an obvious cause and remedy are not included in this guide.
However, if you should encounter a problem that you feel should be included in this
troubleshooting guide, please notify ASEP of this problem, the possible causes you considered,
and the remedy/remedies you applied. We will be very grateful for your feedback. Contact details
for the ASEP documentation department are providedat the back of this manual.
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9.2
Troubleshooting table
ELECTRICAL PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Defective switches
No electrical power
ENGINE PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Engine stops
HYDRAULIC PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
TRANSMISSION PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
Oil leaks
Worn seals
Leakage at plugs
Replace seals
Replace/re-tighten plugs
Brake applied
Hydraulic problem
LEVELWIND PROBLEM
POSSIBLE CAUSE
SUGGESTED REMEDY
POSSIBLE CAUSE
SUGGESTED REMEDY
SMARTHEAD PROBLEM
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APPENDICES
This section contains the following appendices:
Appendix 1: Specifications
Appendix 2: Quick reference
Appendix 3: Lubricants
Appendix 5: Running hours log book
Appendix 6: Air transportation
Appendix 7: Contact us
Appendix 8: Customer feedback form
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Appendix 1: Specifications
Dimensions PowerPack
Transport dimensions
L x W x H (overall with doors closed)
Tare weight
Dimensions Cabin
Transport dimensions
L x W x H (overal with doors closed)
Tare weight
Maximum rating
Tare weight
Operational conditions
Area classification
Ex Zone 2
Environmental control
Air Conditioner (115 VAC, 60 Hz, cooling 15,000 BTU/h, electric driven, Ex Zone 2,
roof mounted, marine environments)
Pressurization (115V, 60Hz, Ex Zone 2, ATEX, 10 m3/min, fan, exchangeable
heavy duty air filter)
Centrifugal ventilator (0.37 kW, 120 /1 / 60, IP 55 ATEX EEx d)
Standard conformities
Power system
Type
Diesel engine (Iveco, 4 Cylinder, 59 kW (79 hp) @ 2,500 rpm, liquid cooled, 3.9
natural aspirated, Ex Zone 2, ATEX)
Power output
Starter
Spring (rig safe or Ex zone 2, with hand crank, suitable for 6 Litre displacement
engine)
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Pneumatic system
Source
3 kW
Compressor pressure
30 l (7.9 US gal)
Electrical systems
Source
On-board generator
2x120 VAC / 240 VAC, 60 Hz, 2 ph, 15 kW, 1800 rpm, hydraulic driven, Ex Zone 2
Cabin voltages
24 VDC, Ex zone 1, ATEX rig power input 2x 115 VAC, 60 Hz, switch box, use
when generator is selected)
Power supply
Type: QS 20.241 (110 - 230 VAC / 20A, 50/60 Hz, 24 VDC / 20 A / 480 W, Ex Zone
2
Battery capacity
Lights
Cabin ( 18 W, 24 VDC)
Dash board ( 2 x 18 W, 115 V)
Hydraulic system
Type
Source
Main pressure
Tank volume
Auxiliary drive
Hydraulic, 45 litre/min @ 200 bar, volume 20 litre, open loop, control valve,
quickconnectors
Transmission
Measuring head
SmartHead basic (tension range 0-10,000 kg (0-22.050 lbs), measure wheel 7.64",
Ex Zone 1, ATEX)
Load pin
Stainless steel, 1 ton, single signal, 4-20 mA, integrated amplifier, 12 m of 4 wire
cable, Ex Zone 1, ATEX
Winch drums
Mounting type
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Winch drums
Supplied drum
Brake
Slipring
1200 VAC, 7.5 A, number of rings 2, without cable glands, stainless steel, IP66, Ex
Zone 1, ATEX
Gearbox
Levelwind arms
Pneumatic
115 VAC, 60 Hz, Ex Zone 1, ATEX, Control panel, PLC, Display, Smoke/Gas
detectors, max. 100 A 1 ph switchable
Smoke detector
Gas detector
Xgard 5 (C2H4)
Hoisting
Lifting sling sets (3x)
Lifting sling set (4-leg, wire rope, SWL 2.5 ton, WL 3 m, Greenpin bolt OD 12 mm,
EN 12079 / DNV 2.7-1, Lloyds certified)
Fluids
NOTE: The fluid specifications stated below applied at the moment that the unit was delivered by ASEP to the customer.
Climate, duty and local availability may require alternative lubricants or hydraulic oils. Use only the approved alternatives
listed in the Lubricants and Hydraulic oils Appendices.
Main hydraulic fluid reservoir
Coolant reservoir
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Startup
1.
2.
3.
4.
Ensure that the control joysticks on the cabin control panel are in the middle position.
5.
6.
Push the reset button on the spring starter and wind up the starter with the hand crank .
7.
Push the AIR INLET VALVE fully up to the UP FOR START position, and hold it in place.
8.
Reset the sentinel master valve by turning the control lever against the spring pressure.
9.
Remove the crank handle and activate the spring starter handle to start the engine.
10. Release the AIR INLET VALVE When the hydraulic ENGINE OIL PRESSURE gauge shows a
reading above 2 bar (29 psi).
11. Check that the hydraulic CONTROL PRESSURE stabilizes between 25 bar and 28 bar; if
<15 bar, troubleshoot the system.
12. Increase the engine speed with the THROTTLE to at least 1500 rpm.
13. If using the 30 kW generator to supply power, start the generator with the GENERATOR START
button. If using rig power, turn on the rig power at source.
14. Turn the main power switch on JB2 in the cabin to ON.
15. Before using non-EX electrical functions inside the cabin module, purge and pressurize the
cabin as follows:
a) Open the cabin interior ventilation ports
b) Set the PURGE mode switch on JB2 to NORMAL
c) Press the START PRESSURIZING button
16. Wait until the cabin has been successfully purged and pressurized (approx 22 minutes).
17. Turn on all required switches in the cabin, and all required electrical appliances.
Shutdown
1.
2.
3.
Make sure the drum is stopped, then set the brake switch to ON.
4.
5.
Turn the engine off with the STOP lever on the control panel.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
6.
Stop the generator with the GENERATOR STOP button (if using rig power, turn off at source).
7.
8.
Ensure that the cause of the emergency shutdown has been identified and solved.
2.
Release an activated emergency stop button by pulling it firmly out until it releases.
3.
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Appendix 3: Lubricants
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
SAE 5W30
SAE 10W40
SAE 10W30
SAE 15W50
SAE 15W40
SAE 20W50
SAE 20W40
SAE 10
SAE 20
SAE 30
SAE 40
Engine lubricants
NOTE: Select a good quality lubricant that is suitable for the ambient temperature where the
machine is used.
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
ELF
Reductelf SP100
Reductelf SP150
Reductelf SP320
ESSO
Spartan EP 100
Spartan EP 150
Spartan EP 320
Comp. oil LG 50
FINA
Giran 100
Giran 150
Giran 320
Giran 220
Gearbox lubricants
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ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Ambient temperature
-20 C to +5 C
(-2 F to +41 F)
IV 95
GULF
+5 C to +40 C
(+41 F to +104 F)
IV 95
+40 C to +55 C
(+104 F to +131 F)
IV 95
EP lub. HD 150
EP lub. HD 320
-30 C to +65 C
(-20 F to +149 F)
IV 165
I.P.
Mellana 100
Mellana 150
Mellana 320
KLUEBER
Gem 1-100
Gem 1-150
Gem 1-320
Synteso D 220
Mobilgear 632
Glygoyle 22
Glygoyle 30
SHC 630
MOBIL
Q8
Goya 100
Goya 150
Goya 320
Greco 228
SHELL
Tivela Oil SA
TOTAL
Carter EP 100 N
Carter EP 150 N
Carter EP 320 N
Gearbox lubricants
NOTE: Select a lubricant that is suitable for the ambient temperature in which the machine is to
be operated.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Normal temperatures
-5.0 C to +60 C (+25 F to +142 F)
ISO 46 oils
ISO 68 oils
BP
Energol H:LP 46
Castrol
Hyspin AWS 46
Chevron
Mechanism LPS 46
ELF
Esso / Exxon
Visga 46
Univis HVI26
Univis N46
Q8
Haydn 46
Shell
Tellus T 46
Texaco
Rando HD 46
ASEP recommended hydraulic oils for main power and control circuits
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Carry the hours forward from the last row of the previous form (or enter zero for a new unit).
2.
3.
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.
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).
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).
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Unit ID:_____________________________________
Running Hours
Start
Date
Stop
Time
Date
Hours
Time
Session
Remarks
Cumul.
Service Log
Next
service
(hours)
Due at
(hours)
Done at
(hours)
On
(date)
Remarks
300
600
900
1200
1500/
ann.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
5.
6.
Add any items that are present on the machine, but not on this list.
7.
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:
8.
Refer to the maintenance instructions or specifications pages of the manual for this machine,
for the quantity and specifications of the required fluids.
9.
Refer to the maintenance instructions for the procedure to check and replenish fluids for
each of the reservoirs, systems and components.
10. 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.
11. 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.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Description
Date replenished:
Bleed
01
02
03
04
05
06
Winch gearboxes
07
Levelwind motor
08
09
10
Batteries
11
12
13
14
15
New
filter(s)
recomm.
INITIALS
Drained
Replen.
New filter
Y
Y
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Appendix 7: Contact us
Facility
Discipline(s)
Address
Telephone number,
Fax number and
E-mail address(es)
Sales
Marketing
Service
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
ASEP AP B.V.
Sales
Service
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
Sales
ASEP Lafayette,
Inc.
Rental
119 Row 1
Lafayette, Louisiana 70508
United States
ASEP UK Ltd.
Sales
Rental
Service
Europa House,
Exploration Drive, Bridge of Don,
Aberdeen AB23 8GX
United Kingdom
Sales
Rental
Service
Sales
Rental
Service
ASEP China
Sales
Rental
Service
ASEP FSU
Sales
Rental
Service
ASEP ANZ
Sales
Rental
Service
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Facility
Discipline(s)
Address
Telephone number,
Fax number and
E-mail address(es)
ASEP Malaysia
Sales
Rental
Service
ASEP India
Sales
Rental
Service
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Date (d/m/y):
Build number:
Title:
Excellent
Good
Fair
Poor
Figures (useful)
Examples (useful)
Size (physical)
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Is this manual and the content different (unique) from others you have used?
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009
Published by:
ASEP Group B.V.
Energieweg 26
2964 LE Groot-Ammers
The Netherlands
2009 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 ASEP Group B.V. for
loss, damage or injury caused by any errors or omissions in this document.
NOV ASEP Elmar - Netherlands, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands
ASEP K-Winch SlimSplit C, Project no. 8951, 23 September 2009