Clean Cut Trainning Manual

CLEANCUT
(ISO PUMP, R‐VALVE and CCB)
Training Manual
Customer‐focused, solutions‐driven

Drill Cuttings Handling System
3
15m ISO Pump
Operating & Maintenance

Instructions
Date: August 2002
Rev: 03
Page 2 of 73

OPERATING & MAINTENANCE
INSTRUCTIONS
SYSTEM: Drill Cuttings Handling System
PRESSURE VESSEL TYPE: ISOPump
MANUAL ISSUE NUMBER: 1
REVISON 03
Signature Position Date
Prepared by: S. Brough Project Engineer Aug 2002
Reviewed by: L. Martin Project Manager April 2003
Authorised for use R. Bingham

by:
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Date: August 2002
Rev: 03
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REVISION HISTORY
ISSUE DATE REVISION DATE COMMENT

01 Aug 2002 03 April 03 Reformat document to
reflect new Logo’s .
Pulse Air & Oil Injection
Additions
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CONTENTS
Section
Introduction ................................................... 1
Importance of the Manual
General Safety
Description of Equipment
Application & Design Parameters
Functional Design Specification .................. 2
ISOPump ......................................................... 3
Fault Diagnosis .............................................. 4
Routine Maintenance .................................... 5
Recommended Spares ................................. 6
Proprietary Parts ........................................... 7
Drawings ......................................................... 8
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SECTION 1
INTRODUCTION
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IMPORTANCE OF THE MANUAL
The manual shall be regarded as an essential part of the product.
The manual shall be kept for the life of the product.
Ensure that any revision received is incorporated in this manual in the correct place
and that the accompanying form is signed and returned.
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GENERAL SAFETY
2. THIS MANUAL MUST BE READ BY PERSONNEL BEFORE

OPERATING THE EQUIPMENT OR CARRYING OUT MAINTENANCE
WORK.
2. ANY MAINTENANCE OPERATION MUST BE CARRIED OUT ONLY

BY QUALIFIED AND COMPETENT PERSONNEL.
2. BEFORE CARRYING OUT ANY OPERATION OR MAINTENANCE

WORK PERSONNEL ARE TO FAMILIARISE THEMSELVES WITH ON SITE
REGULATIONS AND PRECAUTIONARY INFORMATION REGARDING
HEALTH AND SAFETY AND HAZARDS ASSOCIATED WITH CONVEY
MATERIAL.
2. PRIOR TO CARRYING OUT MAINTENANCE WORK INVOLVING

PARTIALLY DISMANTLING EITHER THE PRESSURE VESSEL OR
PIPEWORK, ENSURE THAT THE CONTROL AND CONVEYING AIR
ISOLATION VALVES ARE FULLY CLOSED AND THAT THE PRESSURE
WITHIN THE VESSEL HAS BEEN FULLY VENTED.
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DESCRIPTION OF EQUIPMENT
1 Off 15m 3 ISOPump manufactured to BS5500 Category II, stainless steel

pressure vessel , designed for a working pressure of 7 barg, complete
with 125mm discharge valve. The vessel is built into a 20’ offshore
container framework complying to DNV 2.7-1
Equipment supplied with the ISOPump include conveying air

distribution manifold and lifting sets to perform horizontal, rotational
and vertical lifts.
Suitable for the transfer of material with temperatures up to 50ºC

maximum.
The ISOPump is suitable for road and rail transport in the UK and
mainland Europe. (refer to separate section for transportation
guidelines
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APPLICATION & DESIGN PARAMETERS
Number & Type of Conveying Vessel : 15m 3 ISOPump

Material : Drill Cuttings
Bulk Density : typically 1.8 – 2.0 t / m 3
Moisture Content : Various
Maximum Temperature : 50 oC
Max Conveying Distance : approx 120m (pipe route dependant)
Conveying Rate : typically 25 – 40 tonnes/hr
Control Air
Pressure : 6<7 barg

Average Airflow : 0.1 Sm3/min
Conveying Air
Pressure : 7 barg
Peak Airflow : 18 Sm3/min
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SECTION 2
FUNCTIONAL DESIGN SPECIFICATION
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CONTENTS
1. INTRODUCTION
2. CLEANCUT ISO PUMP
2.1 OVERVIEW
2.2 STORAGE MODE - OPERATIONS
2.3 DISCHARGE MODE - OPERATIONS
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INTRODUCTION
This description should be read in conjunction with the following drawings:
P&ID RIG BASED ISO PUMP WITH WEIGH FRAME - P32689D-00
2.2 CLEANCUT ISO PUMP

2.2 OVERVIEW
The ISO Pump has a dual role in its function as a storage and discharge system of
drilled cuttings.
Valve configuration and subsequent operations are unique to these two operating
modes (Storage Mode and Discharge Mode).
2.2 STORAGE MODE
As a receptor for the drilled cuttings conveyed from the CCB the ISO Pump will be
stood vertically. Whilst Rig mounted the ISO Pump will be sat directly on a hydraulic
load cell platform (Weigh Frame – WF). The WF provides indication of the actual
weight of material handled by each ISO Pump.
As material is delivered into the ISO Pump the transportation air is separated from
the cuttings and subsequently vented to atmosphere through a 5” vent line.
It shall be noted that all valves and functionality of the ISO Pump is manually
controlled. There are no electrical interfaces with the ISO Pump for standard
operations.
SYSTEM AT REST
When the ISO Pump is at rest in the Reception Mode the status of the valves will be
as follows:
Valve Description Status
Cuttings Outlet Valve Closed and sealed

Line Air Hand Valve (HV81) Closed
Tank Air Hand valve (HV 91) Closed
Vent line Open
Weight Indicator Current weight
Tank Pressure < 0.1 barg
Pulse Air System Off
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ISO PUMP OPERATING SEQUENCE

With the outlet of the ISO Pump closed and sealed and the vent line open the unit is
ready to receive cuttings from the feed system, typically the CCB.
Cuttings will gradually fill the ISO Pump until a predetermined weight is recorded on
the Weight Indicator (WI 85). At this stage cuttings flow is transferred to the next
available and empty ISO Pump.
SYSTEM WITH ISO PUMP FULL
When the ISO Pump has been filled to the target weight the status of the valves will
be as follows:

Vent line Open
Weight Indicator Target weight
Tank pressure < 0.1 barg
Pulse Air System Off
The valves will be left in the above positions until the time to discharge the cuttings
from the ISO Pump. This is to ensure the ISO Pump cannot become unintentionally
pressurised whilst at rest.
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2.3 DISCHARGE MODE
When loaded with drill cuttings the ISO Pump is reconfigured as a pressure vessel
and as such pneumatically conveys the cuttings to the desired reception point.
Compressed air is introduced into the ISO Pump at strategic positions to enable the
transfer of material from the vessel into the conveying pipe. As with the Storage
Mode the procedures are fully manual and there are no electrical interfaces with the
Rig.
SYSTEM AT REST
When the ISO Pump is at rest in the Discharge Mode the status of the valves will be
as follows:

Vent line Closed
Conveying Pressure < 0.1 barg
Regulator settings
• Line pressure 6.5 barg
• Tank pressure 6.0 barg
Pulse Air Off
With the outlet pipe and hose assembly secured to the ISO Pump and this pipeline
fully pressure tested than the following procedure can commence.
The conveying air valve (HV91) is opened and airflow established through the
conveying pipe. An air only pressure drop of between 0.2 – 0.8 barg can be
expected.
When this flow is established then the Cuttings Outlet valve is opened and the Tank
air is initiated via valve (HV 81).
At a material dependant tank pressure material will begin to discharge from the tank.
The line pressure will increase as the line loading improves.
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SYSTEM STATUS DURING DISCHARGE
When the ISO Pump is conveying cuttings in the Discharge Mode the status of the
valves will be as follows:
Cuttings Outlet Valve Open

Line Air Hand Valve (HV81) Open
Tank Air Hand valve (HV 91) Open
Vent line Closed
Weight Indicator Weight reducing
Tank Pressure ~ 5.8 – 6.0 barg
Conveying Pressure ~ 5.0 – 6.0 barg
Regulator settings
Pulse Air On
Material will continue to be discharged in this manner until the weight in the ISO
Pump has reached the original zero position.
It shall be noted that during the discharge cycle should there be a need to pause the
material flow then the ISO Pump outlet valve can be opened and closed without
concern.
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SYSTEM STATUS ON COMPLETION OF DISCHARGE
When the ISO Pump has been emptied of cuttings during in the Discharge Mode the
status of the valves will be as follows:

Vent line Closed
Weight Indicator Zero Weight
Regulator settings
Pulse Air On
With the ISO Pump empty the tank and line pressure should both record the same
value.
The air shall be left running for a sufficient period to enable the conveying line to be
completely purged of material. At this point the expected line pressure should be
approximately 0.2 – 0.8 barg.
The tank and line air can at this stage be closed.
The outlet valve is closed.
The vent valve (HV 84) is opened to ensure any residual pressures are vented to
atmosphere.
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SYSTEM STATUS ON SHUT DOWN OF DISCHARGE PROCEDURE
When the ISO Pump has been emptied of cuttings and all airflows isolated the status
of the valves will be as follows:
Cuttings Outlet Valve Closed

Vent line Open
Tank Pressure 0.0 barg
Conveying Pressure 0.0 barg
Regulator settings
Pulse Air Off
OIL INJECTION FACILITY
Incorporated in the ‘Pulse Air ‘ Manifold on the ISO Pump is a connection point into
which Base Oil can be injected.
The purpose of this injection point is:
• To provide a method whereby oil can be injected at the end of the transfer
period for ‘in-situ’ cleaning of the conveying pipe without the need to
dismantle the system
• Similar to above when conveying materials that tend to adhere to and coat the
inside of the pipe, therefore reducing the effective bore diameter. It is possible
to stop the conveying cycle and inject base oil in to the conveying line to clean
it out and return to the clean line flow condition of 0.2-.08 barg pressure
• To enable the interior of the vessel to be coated with a fine film of oil prior to
first use by operating the pulse air system for 10 cycles with oil injection with
the vessel vent open.
The oil is injected using a suitable pump at the manifold
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SECTION 3
ISOPUMP
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IMPORTANT
The ISOPump conveying vessel is, for insurance purposes, classed as a pressure
vessel.
The ISOPump must be connected to an air supply that has a suitable safety valve
complying with BS 6759 Part 2, or similar equivalent standard and adjusted so that
air is allowed to escape as soon as the safe working pressure has been exceeded.
The valve should be capable of discharging more air than the system can supply to
the receiver.
ISOPump Design : BS5500 Category II
Design Pressure : 7 barg
Hydraulic Test Pressure : 8.75 barg
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LIFTING PROCEDURE
The following lifting procedure method statement provides information to achieve a

safe system of lifting ISOPump, P32486D-00.
All lifting equipment supplied i.e. shackles, slings and attachments are of adequate
strength and stability for lifting the ISOPump having particular regard to the stress
induced at it’s mounting and fixing point.
All lifting procedures detailed must be controlled and supervised by a competent

person i.e. trained banksman.
Attached lifting shackles and lifting points welded to framework have been tested to
the required Safe Working Load (SWL) by an approved third party on behalf of Clyde
Materials Handling.
Only vertical or horizontal lifts may be used when transferring ISOPumps from PSV
to rig, or vice versa. The rotational lift should only be utilised either on shore or on
rig to rotate the ISOPump into position.
The ISOPump has been designed and tested to accommodate offshore lifts, PSV to
rig, when empty, and onshore lifts when full to a maximum of 32,500kg.
ISOPumps and all attached lifting equipment are designed to be operated in an

offshore environment and therefore all lifting shackles and lifting points welded to the
framework must have a safe system set up to have regular and recorded inspection
and examination. A copy of the most up to date certificates should be held in the
document holder found on the ISOPumps.
The procedure to follow to lift an ISOPump from a horizontal position to a vertical

position is fully detailed on drawing P33896D-00
The procedure to follow to lift an ISOPump from a vertical position to a horizontal
position is fully detailed on drawing P33897D-00
Also detailed on the drawings are tie back points for the individual slings which must
be made for road transit.
A copy of both of these drawings should be held in the document holder found on the
ISOPumps.
Load Specification
Height Width Depth Weight

6058mm 2591mm 2438mm 5850kg
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OPERATION
Material enters the ISOPump through one of three inlets.
i. DN 125 (5”) material inlet pipe – situated on the left hand side of the
ISOPump, this is used to fill the vessel when the unit stands vertically.
ii. DN 125 (5”) material inlet / vent pipe – situated on the right hand side of the
ISOPump, this is used as an alternative to the main material inlet pipe.
iii. DN 150 (6”) material inlet branch – situated in the dished end between the
two DN 125 (5”0 branches, this si used to fill the vessel when the unit is
mounted horizontally.
Material discharge from the ISOPump is through a discharge valve mounted directly
onto the bend at the bottom of the vessel’s conical section.
All material inlet and outlet connections, with the exception of the DN150 branch for
horizontal feed, are grooved to accept a grooved pipe coupling. The DN 150 (6”)
branch has an ASA 150lb flange and blanking flange.
The conveying air distribution manifold controls the amount of air entering the
ISOPump vessel and conveying line. DN 50 (2”) ‘snaplock’ connectors are
employed to join the conveying air distribution manifold to the Pressure Regulator
Unit (PRU) for a single ISOPump, or to the air header assembly for a multiple
ISOPump installation.
During transportation of the ISOPump, all inlets and outlets will be blanked off to
prevent material escaping, using blanks suitable for the couplings which are attached
with chains so they cannot be lost.
On a single ISOPump installation, the material feed hose is connected directly from
the CCB on a rig installation, or from another ISOPump on a rig to boat transfer.
Multiple ISOPump installations utilise a convey pipe manifold, allowing the operator
to select which vessel is to be filled by positioning the R Valves to either through or
divert.
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SECTION 4
FAULT DIAGNOSIS
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FAULT DIAGNOSIS – ISO PUMP

WARNING: Prior to Fault Finding on System, Check Air Supplies
SYMPTOM PROBABLE CAUSE REMEDIAL ACTION
Material displaced through 1. ISO Pump™ overfilled. 1. Check the “Density versus
vent line on filling of the maximum weight” chart within
ISO Pump™ this O& M manual or attached
to the ISO Pump™to
determine maximum Pump
full weight for material.
DO NOT EXCEED THIS
WEIGHT UNIT
With hand valve HV 82 1. No compressed air 1. Check supply and make

(conveying line air) open no available healthy
airflow is established
2. Pressure regulator 2.
PVC81 set at zero Adjust regulator setting in
accordance with O &M
manual
3. Non return valve NV82 3.
failed
Remove NRV and check for
mechanical failure or material
blockage. Clean or replace if
necessary.
With hand valve HV83 (tank 1. No compressed air 1. Check supply and make
pressurisation air) open no available healthy
air flow is established into
the tank 2. Pressure regulator 2.
PVC80 set at zero Adjust regulator setting in
accordance with O &M
3. Non return valve NV83 3. manual
failed
Remove NRV and check for
mechanical failure or material
blockage. Clean or replace if
necessary.
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With gas flows established 1. Cuttings loading pipe 1. Close loading valve HV50
and main material open ie hand valve
discharged valve open HV50 remains open.
(HV85) no pressure is 2. Vent line remains open 2. Secure plug to vent line thus
recorded within the tank blanking & preventing
( PI 83) pressure loss.
3. Manual drain open 3. Close HV84
(HV84)
ISO Pump™ pressure high 1. Outlet valve HV85 1. Open HV85

accompanied with no closed.
weight loss
2. Line valve HV82 2. Open HV82
closed.
3. 3. See line blocked section
Line blocked
ISO Pump™ pressure drops 1. Cuttings bridged within 1. Close outlet valve HV85,
low with a significant vessel close tank pressurisation
weight remaining of valve HV83.
cuttings Allow ISO Pump™ to stand
for a short duration (5 mins)
2 before resuming conveying.
With gas flows still healthy
repeatedly open & close
outlet valve HV85 to
encourage material flow.
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Maximum Material Weight Relative to Product Density

(ISO Pump and frame weight tared to zero)
26
24
22
Displayed ISO Pump Weight (tonnes)
20
18
16
14
12
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600
Product Density (Kg/m3)
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SECTION 5
ROUTINE MAINTENANCE
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ROUTINE MAINTENANCE OF ISO PUMPS
NOTE! BEFORE STARTING ANY ROUTINE MAINTENANCE ENSURE THE SYSTEM IS

ISOLATED BOTH ELECTRICALLY AND PNEUMATICALLY, AND VENTED OF ANY
RESIDUAL PRESSURE.
Daily Maintenance
It shall be noted that as with the CCB the daily system check is an attempt to identify
the possible onset of component failure before the event affects system performance
and ultimately impacts the overall system reliability.
Unlike the weekly and monthly maintenance routines there are no planned activities
for this regime. The check, assuming a live operational system, is intended to verify
the operational health of the equipment with corrective actions only taking place
should problems or the onset of possible component failure be identified.
In order for the following checklist to be purposefully administered the system should
ideally be operational. If so a combination of pressure readings, pressure settings
and valve functionality tests will be read or determined.
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Daily Inspection Check List for the ISO Pump

Item No Check Description Comments
1 Pressure Regulator setting should be See P&ID Drawing for any amendment to
approximately: this set value.
Line Air
Line Air at 6.0 barg with system at rest. Note two pressure should be near
No flow pressure (system at rest) Pnf barg. identical. If the differential between Pf
Air flowing condition (system conveying and Pnf is > than 0.75 barg check supply
Cuttings) Pf barg air source and system flow
plates/nozzles.
Tank Air
Tank Air at 5.0 barg with system at rest.
No flow pressure (system at rest) Pnf barg.
Air flowing condition (system conveying
Cuttings) Pf barg
2 ISO Pump vessel pressure at rest < 0.15 If pressure >0.15 barg check:
barg
Vent line is open to atmosphere.
Vent line is clear of any obstruction.
R-Valve is in correct position
Ensure accuracy of vessel gauge.
3 Air manifold and pneumatic signal tubes If any leaks are found take necessary
have no air leaks corrective action.
4 Vessel pressure during convey cycle Pressure should rise, typically > 4.0 barg.
Lack of significant vessel pressure could
be symptomatic of:
• Cuttings discharge problem from the
ISO Pump
• vent valve failed
• lack of conveying air
5 Cuttings discharge valve opens and closes

with a single smooth action
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ISOPUMPS
1. Weekly
Cuttings Discharge Valves

Grease Valve shafts and bearings (hydraulic grease nipples located on Valve
body) using Shell Malleus JB Grease.
2. Monthly
See weekly requirements
3. Yearly
The following maintenance is required for long term rental machines else this
maintenance shall only be conducted at the relevant time when the units are
returned to shore between rentals.
Cuttings Discharge Valves
Remove Cuttings Discharge Valve as described in section 3 of the O&M

Manual and check head of dome and seal for signs of wear.
Check Cuttings Discharge Valve shafts for wear and replace bearings and
seals as described in section 3 of the O&M Manual if required.
Inspect cylinder shaft for score marks scratches, pitting, rust etc. as this can
lead to premature failure of cylinder seals.
Manifold Pipe, Flexible Hoses And Valves
All manifold pipes will be inspected for damage and any corrosion.
Flexible hoses will be inspected for any signs of degradation of the hose wall,
which is manufactured from a nitrile rubber. Degradation will include wall
softening, an increase in outside hose diameter or delamination of the hose
fabric.
Valves will inspected for operational performance and the head will be removed
to assess the condition of the valve seat and seal.
Inspection Hatch Door Seal And Hold Down Swing Bolts
Door seal to be checked for failure or degradation that would result in loss of
operating pressure whilst discharging from the ISOPumps. The swing bolts to
be inspected for thread integrity or damage.
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ASSOCIATED EQUIPMENT - PRESSURE REGULATOR UNIT
1. Weekly
Regulator Set and main air strainer
Ensure both Tank and Line pressure regulators can be readily adjusted and
maintain a no airflow set point to within 0.5 barg when air is flowing. Clean
strainer to avoid excess pressure drop as a result of contaminate build up.
Caution!
When it is necessary to remove a strainer or regulator cleaning

purposes/renewal, the air supply to the assembly must be isolated.
2. Yearly
Pressure Safety Relief Valves
These shall be tested in accordance with manufacturers and/or insurance test

schedule. Each valve, as a minimum, shall be visually inspected for signs of
damage.
Pressure Control Valves For Tank And Line Air (Pilot Operated
Regulator)
The regulators shall be opened and the diaphragm checked for signs of
degradation and wear. The unit shall then be connected with a compressed air
source >7.0 barg and the unit assessed for ease of setting the desired pressure
set point.
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SECTION 6
RECOMMENDED SPARES
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RECOMMENDED SPARES
DESCRIPTION PART NUMBER QTY
Outlet Valve
Outlet Cuttings Valve Spare Kit P32541D- M3226 1
00
Actuator A4374 1
Actuator Seal Kit A2201 1
100/125mm Dome Gasket Set P2120A-01 1
Outlet Bend to V/V Gasket P2120A-83 1
Manifold
2" Non Return Valve P33043E-00 1
2" NRV Discs P33045E-02 1
Air Spray Nozzle 3/4" P35838D-00 1
Air Spray Nozzle 1" P35443D-00 4
Pressure Gauge A4285 1
Exhaust Silencer A1942 1
NB.For additional information on Spare see spare calculator spread sheet
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SECTION 7
PROPRIETARY PARTS
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PROPRIETARY PARTS
Section
Actuator...................................................................... 7.1
Filter............................................................................ 7.2
Operating Valve ......................................................... 7.3
Pressure Gauge ....................................................... 7.4
Quick Release Couplings ......................................... 7.5
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SECTION 7.1
ACTUATOR
CMH DESCRIPTION MANU- MANUFACTURER’S

PART NO FACTURER PART NO
A4374 ¼ turn, low temperature (-40C) Kinetrol 090 – 100 low temp
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SECTION 7.2
FILTER

A1160 Air filter, ½” Schrader 4539D
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SECTION 7.3
OPERATING VALVE

A4292 5/2 lever operating valve, G1/4” Norgren SPGB/31759
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SECTION 7.4
QUICK RELEASE COUPLING

M6895 Adapter, bronze, 2” NPT Snaplock Part A

(Female thread)
- Adapter, bronze, 1½” NPT Snaplock Part F
(Male thread)
- Quick release coupling, 1” NPT Snaptite SVHN16-16F
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SECTION 7.5
PRESSURE GAUGE

A4285 Pressure Gauge, 0-11bar, Budenburg

½” BSP, Glycerine filled, Grout
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SECTION 8
DRAWINGS
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DRAWINGS
DRAWING NO REV TITLE
P32486D-00 11 IS0Pump General Arrangement

P32689D-00 03 ISOPump P&ID
P32925D-00 03 ISOPump Pneumatic Circuit
P35673D-00 02 ISOPump Manifold
P35672D-00 03 ISOPump Conveying Pipe Air – sub assembly
P33039D-00 07 ISOPump Top Air – sub assembly
P35621D-00 05 ISOPump Vessel Aeration – hose assembly
P33040D-00 05 ISOPump Pneumatic Fittings
P33896D-00 01 ISOPump Lifting Procedure – horizontal to vertical
P33897D-00 01 ISOPump Lifting Procedure – vertical to horizontal
P36061E-00 03 ISO Pump Pulse Air Feed
CC10118D-00 04 Pulse Air Panel Pneumatic Circuit
P35371D-00 01 Overboard Hose Aeration Arrangement
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SNAPLOCK ADAPTOR AND

DUST CAP MUST BE SUPPLIED
CHAINED TOGETHER
SNAPLOCK ADAPTOR AND

DUST CAP MUST BE SUPPLIED
CHAINED TOGETHER
ITEM 18 ADDED
ITEM 5 WAS 2 OFF ITEMS 10 & 11 ADDED
M3009 ITEM 17 WAS 2 ITEM 6 WAS SWAGED
OFF M6885 ITEM 6 BOTH ENDS
WAS 2m M3079
MANIFOLD REDESIGNED
ITEM 5 WAS 2 OFF
ITEM 21 ADDED ITEMS 19 AND 20 ADDED
HOSE WAS PARALLEL
BOTH ENDS
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ITEM 15 WAS STEEL

PRESSURE CAP NOW ITEM 6 WAS 5 OFF
MANIFOLD REDESIGNED
PLASTIC ITEM 16 WAS S/S ITEM 12 ADDED
NOW BRONZE
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Appendix 1
PULSE AIR SYSTEM
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Contents
Section 1: Introduction
Section 2: Functional Description
Section 3: Proprietary Equipment
Section 4: Drawings
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Section 8
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Section 1 – INTRODUCTION
A ‘Pulse Air System’ has been introduced to increase the efficiency of

material transfer.
The system is similar in principle to the air sweeps fitted to the CCB pressure
vessel and is fitted to all new build ISO pumps and retro fitted to the existing
fleet as required.
The system can also be fitted to the underside of the material fall line of feed
chutes and around feed hoppers to assist in the migration of material to the
required collection point.
The use of the Pulse air system should be considered to mitigate the effects
of a materials/formations, which have:
1. A Tendency to bridge
2. A Low flow Characteristics
3. A Low OOC Value
4. A Tendency to Nest
5. Through experience exhibited properties which have proved to be
problematic in terms of pneumatic conveying; e.g. Tertiary Reactive
Clays
And;
ISO tanks which have been filled and remained static for extended periods,
such that there is a possibility of material being compacted or adhering to
the vessel shell
The system can be used as both a proactive method to mitigate the effects of
the above or as a reactive measure to overcome ISO Pump discharge or CCB
feed problems
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Section 8
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Page 54of 73
Section 2 – FUNCTIONAL DESCRIPTION
The System is comprised of a number of Air Sweeps connected via a fixed flexible
hose manifold to a ‘Blow Valve’ controlled by pneumatic timers in the Control
Panel.
Typically the Pulse Air system is supplied from the Pressure Regulator Unit ‘Top
Air ‘ (Tank air) regulated 6 barg. To make the connection it is necessary to Use
either a 2” Tee or Cross Assembly
Each individual Air Sweep has a flow restriction device to regulate the flow to
2m3/m at 6barg.
The Pneumatic timers are set to give a cycle of six seconds with ‘1second air on’
and 5 seconds air off.
Filter
Membrane
Dryer
Pilot
Valves
Timers
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Section 8
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Page 55of 73
This is achieved by setting the timers as in table one below:
Pulse Air on This sets the duration of the Blow 5 x 0.2 0 – 999
Timer =1 sec
sec 0.2
secon
d
increm
ents
Pulse Air Off This sets duration of the ‘OFF’ from the 25 x 0 – 999
timer end of the Blow. before the pulse air 0.2 = 5 sec
blow is turned on. sec 0.2
Therefore secon
d
increm
ents
Table 1
NB : Due to volume of air required to pressurise the supply manifold to achieve the
0.5 barg differential to open the ‘Air Sweeps’ upon ‘Blow Valve’ actuation. It may be
necessary to increase the duration of the blow to 1.5 –2 seconds to compensate
and achieve a true 1 second opening of the ‘Air Sweeps’
OPERATING PROCEDURES
2.3 DISCHARGE MODE - With Continuous use of Pulse air
When loaded with drill cuttings the ISO Pump is reconfigured as a pressure vessel
and as such pneumatically conveys the cuttings to the desired reception point.
Some formations properties are such that it is operationally desirable to use pulse
air continuously when discharging an ISO Pump
Compressed air is introduced into the ISO Pump at strategic positions together
with pulse air to enable the transfer of material from the vessel into the conveying
pipe.
As with the Storage Mode the procedures are fully manual and there are no
electrical interfaces with the Rig.
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Section 8
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Page 56of 73
SYSTEM AT REST
When the ISO Pump is at rest in the Discharge Mode the status of the valves will
be as follows:

Vent line Closed
Regulator settings
Pulse Air Off
With the outlet pipe and hose assembly secured to the ISO Pump and this pipeline
fully pressure tested than the following procedure can commence.
expected.
When this flow is established then the Cuttings Outlet valve is opened.
Open Pulse Air Supply Valve and the Tank Air (Top Air) valve (HV 81).
At a material dependant tank pressure material will begin to discharge from the
tank. The line pressure will increase as the line loading improves.
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Section 8
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Page 57of 73
SYSTEM STATUS DURING DISCHARGE
When the ISO Pump is conveying cuttings in the Discharge Mode the status of the
valves will be as follows:

Vent line Closed
Weight Indicator Weight reducing
Tank Pressure ~ 5.8 – 6.0 barg
Conveying Pressure ~ 5.0 – 6.0 barg
Regulator settings
Pulse Air On
Material will continue to be discharged in this manner until the weight in the ISO
Pump has reached the original zero position.
It shall be noted that during the discharge cycle should there be a need to pause
the material flow then the ISO Pump outlet valve can be opened and closed
without concern.
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Section 8
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Page 58of 73
SYSTEM STATUS ON COMPLETION OF DISCHARGE
When the ISO Pump has been emptied of cuttings during in the Discharge Mode
the status of the valves will be as follows:

Vent line Closed
Regulator settings
Pulse Air On
With the ISO Pump empty the tank and line pressure should both record the same
value.
The air shall be left running for a sufficient period to enable the conveying line to be
completely purged of material. At this point the expected line pressure should be
approximately 0.2 – 0.8 barg.
The tank and line air can at this stage be closed.
The outlet valve is closed.
The vent valve (HV 84) is opened to ensure any residual pressures are vented to
atmosphere.
Sheet Rev No. 03

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Section 8
Rev: 03
Page 59of 73
SYSTEM STATUS ON SHUT DOWN OF DISCHARGE PROCEDURE
When the ISO Pump has been emptied of cuttings and all airflows isolated the status of the valves
will be as follows:
Cuttings Outlet Valve Closed

Vent line Open
Tank Pressure 0.0 barg
Conveying Pressure 0.0 barg
Regulator settings
Pulse Air Off
Please Refer to CleanCut Drawing Numbers:
• CC1018D Pulse Air Panel Pneumatic Circuit

• CC1024E 2” Cross Assembly
• CC1017E 2” Tee Assembly
• P35621D-00 Vessel Aeration Assembly
• P33790D-00 PRU Assembly
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Section 8
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Page 60of 73
ALTERNATIVE USES OF PULSE AIR
ASSISTANCE IN STARTING OR RE-STARTING ISO PUMP DISCHARGE
Pulse Air may also be used as a reactive measure to assist in the discharge of
material from an ISO pump that has ‘Stalled’ during transfer or is proving difficult to
initiate the transfer of cuttings under normal operation without the continuous use
of pulse air as described above.
If when starting a transfer the ‘Top Air’ pressure reaches 4barg and the ISO Pump
has not started to discharge material. The discharge should be stopped and the
vessel should be depressurised and the following procedure carried out:
Close material Discharge Valve and Vent Line
Open pulse air system and observe Tank Air pressure gauge
expected.
The use of Pulse Air will break up / fluidise the material and detach it from the walls
of the cone
When the application of Pulse Air has pressurised the vessel to ‘1barg rising’ the
Discharge Valve and Tank Air Valve should be opened.
At ‘Material Dependant’ pressure the material will start to discharge.
If as above the ‘Top Air’ pressure reaches 4 barg without discharge starting then
the procedure should be stopped and resumed from the beginning.
When Discharge has been initiated the procedures are the same as for normal
discharge of an ISO tank as detailed in Section 3 of ISO Pump O&M Manual
Sheet Rev No. 03

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Section 8
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Page 61of 73
FEED HOPPER AIR SWEEP SYSTEM
On systems fitted with the air sweep modification the an air signal is taken from the
Inlet cuttings valve opening supply line to operate a ‘Burkett’ Blow Valve to provide
air to three air sweeps in the ‘Vibro’ Hopper to assist the material flow into the CCB
for the duration the CCB inlet Valve is open.
Please refer to CleanCut Drawing Numbers in CCB O&M Manual:
• P33175D-00 P&ID
• P35461D-00 Air Spray Nozzle Assembly
• P35469D-00 Feed Hopper Supply Assembly
• P35501D-00 Vibro Feed Hopper modifications
• P35532D-00 Feed Hopper Air Sweep Supply Assembly
Sheet Rev No. 03

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Section 8
Rev: 03
Page 62of 73
AIR SWEEP ADDITION FEED CHUTE
Where a feed chute or a diverter is used to direct cuttings to a collection point, Air
Sweeps can be fitted to assist the migration of material, where there is a tendency
for the material to adhere to the surface, or to Nest and Pile up where a material
with a low Flow Characteristic is experienced.
These systems are typically bespoke and project specific but employ the same
basic equipment set up and settings as described.
Typically these systems are operated independently of the CCB and ISO Pump
Pulse air systems and normally supplied from Rig Service Air.
An example of a diverter Chute is Shown Below (Air Sweep Circled):
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Section 8
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Section 3
Proprietary Parts
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Section 4
Drawings
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Rev: 03
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Page 67of 73
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Page 68of 73
ITEM 15 WAS STEEL

PRESSURE CAP NOW ITEM 6 WAS 5 OFF
MANIFOLD REDESIGNED
PLASTIC ITEM 16 WAS S/S ITEM 12 ADDED
NOW BRONZE
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Sheet Rev No. 03

R Valve
Operating & Maintenance

Instructions
Date: August 2002
Rev ;03
Page 2 of 29

INSTRUCTIONS
CMH PROJECT NUMBER:
DATE: August 2002
MANUAL ISSUE NUMBER: 2
REVISON 03
Prepared by: S. Brough Project Engineer
Reviewed by: L . Martin Project Manager
Authorised for use R. Bingham

by:
Sheet Rev No. 03

Date: August 2002
Rev ;03
Page 3 of 29

REVISION HISTORY
ISSUE DATE REVISION DATE COMMENT

02 Aug 02 03 04/03 Document updated to
reflect new company
Logo’s. Drawing
References Updated
Sheet Rev No. 03

Date: August 2002
Rev ;03
Page 4 of 29

CONTENTS
Section
Introduction ................................................... 1
Importance of the Manual
General Safety
Description of Equipment
Application & Design Parameters
R Valve ............................................................ 2
Description............................................ 2.1
Installation ............................................ 2.2
Operation .............................................. 2.3
Fault Diagnosis .............................................. 3
Routine Maintenance .................................... 4
Recommended Spares ................................. 5
Proprietary Parts ........................................... 6
Drawings ......................................................... 7
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 1
Page 1 of 29
SECTION 1
INTRODUCTION
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 1
Page 2 of 29
Ensure that any revision received is incorporated in this manual in the correct place and that
the accompanying form is signed and returned.
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 1
Page 3 of 29
GENERAL SAFETY
1. THIS MANUAL MUST BE READ BY PERSONNEL BEFORE OPERATING THE

EQUIPMENT OR CARRYING OUT MAINTENANCE WORK.
2. ANY MAINTENANCE OPERATION MUST BE CARRIED OUT ONLY BY

QUALIFIED AND COMPETENT PERSONNEL.
3. BEFORE CARRYING OUT ANY OPERATION OR MAINTENANCE WORK

PERSONNEL ARE TO FAMILIARISE THEMSELVES WITH ON SITE
REGULATIONS AND PRECAUTIONARY INFORMATION REGARDING HEALTH
AND SAFETY AND HAZARDS ASSOCIATED WITH CONVEY MATERIAL.
4. PRIOR TO CARRYING OUT MAINTENANCE WORK INVOLVING PARTIALLY

DISMANTLING EITHER THE PRESSURE VESSEL OR PIPEWORK, ENSURE
THAT THE CONTROL AND CONVEYING AIR ISOLATION VALVES ARE FULLY
CLOSED AND THAT THE PRESSURE WITHIN THE VESSEL HAS BEEN FULLY
VENTED.
5. ENSURE THAT THE SYSTEM IS FULLY ELECTRICALLY ISOLATED BEFORE

DISMANTLING.
6. ON ASSEMBLY ENSURE EARTH CONTINUITY TEST IS CARRIED OUT
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 1
Page 4 of 29
Clyde Materials Handling “R –Valve”5”(125mm) nb. Pneumatically actuated rotary valve.

Stub pipe terminations suitable for 5”(125mm) size victaulic couplings.
“R - Valve” operating device- locally mounted (P33717D-00)
Filter/Regulator assembly for “R - Valve” operating device locally mounted (P33734D-00).
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 1
Page 5 of 29
Drill Cuttings Handling System “R –Valve”
Material: Drill Cuttings

Bulk Density: TBA
Moisture Content: Various
Maximum Temperature: Ambient
Conveying Distance: N/A
Conveying Rate: 40 tonnes/hr
Control Air
Pressure: 6<7 barg

Average Airflow: 0.1 Sm3/min
Conveying Air
Pressure: 7 barg
Peak Airflow: 18 Sm3/min
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 2

SECTION 2
R-VALVE
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 2

2.1 Description of Equipment
The Clyde Materials Handling R-Valve is a pneumatically actuated rotary valve

suitable for an off-shore environment. It is controlled using a manually operated
lever mounted in a suitable location in the vicinity of the valve.
The Clyde Materials Handling R-Valve is used extensively within the ISO Pump
arrangement and on skip loading stations, but can also be used as an in line valve
set to “ D- divert” or “T- through”. The valve is provided with a direction of flow
indicator. The valve is mounted on channels for transit purposes, although these
can be utilised as R Valve supports if required.
The Pneumatic actuator can be mounted on either side of the assembly to suit
direction of flow of material
Pipe stubs for the valve terminate with a groove suitable for a 5”size grooved
coupling.
The valve assembly weighs approx 200Kg and is provided with 2OFF M16 tapped
holes suitable for M16 lifting eyes and is mounted on channel sections for transit
purposes.
Refer to Cat 5453,Cat 5461 & Cat 5466.
2.2 Installation
Remove any protective packaging and visually inspect for signs of damage during
transit.
Using a suitable lifting shackle, position the valve as required.
Note! The actuator should be mounted upper most refer Cat 5453,Cat 5461 & Cat
5466. for guidance.
Using 12mm .O/Dia’. nylon tube, connect the inlet and outlet ports of the pneumatic
actuator using the two 12mm tube nuts provided on the lever-operated valve (Item
2). Located on the R- valve-operating panel Cat 5462. Which should be located as
close as feasible to the R- valve.
Again, using 12mm O/Dia’ nylon tube, connect the operating valve to the filter
regulator panel. Use tees to split the air supply to more than one R Valve operating
valve.
Check filter lubricator level and top up if required.
Connect compressed air supply to lever- operated inlet ball valve (½” NPT).
Energise the system and check the function of the R- Valve noting the position of it’s
indicator tab in relation to the position of the lever handle on the operating control
panel , It may be necessary reverse the tube connections .
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 2

If the R-Valve actuator requires repositioning at site prior to installation due to

direction of material flow, follow the steps below
1. Remove all pneumatic feeds to actuator – control airlines

2. Remove the two side guards from the actuator-mounting bracket.
This gives access to the actuator setscrews on the underside of mounting
bracket.
3. Note the position (from the indicator plate)
4. Support the actuator and remove the setscrews.
5. Remove the guards from the other side of the R- Valve and fit the actuator.
6. Replace guards
7. Undo the indicator and nameplate and fit to other side of valve.
8. Connect control airlines to actuator and monitor the movement to ensure
D (divert) & T (through) correspond on the function on the control panel and
indicator plate. It may be necessary to connect the air lines to opposite ports
on the actuator to ensure that the correct movement of the R- valve rotor.
Check the function of the R-valve rotor by looking inside the R-valve seal
assemblies
Using inspection torch if required.
Danger: Do not introduce hands or fingers inside the seal assemblies
2.3 Operation
The R Valve is incorporated into total containment systems, which utilise some or all
of CCB’s, Rig ISO Pumps, Skip loading and Platform Supply Vessel (PSV) ISO
Pumps.
Rig applications
Generally, a CCB is used to convey cuttings from the shakers to a designated

storage area on the rig. This storage facility could comprise of a series of ISO
Pumps or skips. In either case, R Valves are used to route the cuttings into each
ISO Pump or skip in turn.
A Clyde Cutting Blower fills a series of ISO-Pumps™ via manually operated

R- Valves. The Clyde Cutting Blower automatically cycles until the first ISO-Pump™
in line reaches a pre-determined weight. The Clyde Cutting Blower stop button is
pressed and its cycle is allowed to finish.
The R-Valve for that ISO- Pump™ is then set to the “through” position and the next
R- Valve In line is set to “divert” position routing material to the next ISO-Pump™,
and the Clyde Cutting Blower is started again.
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 2

Support Ship applications
ISO-Pump™ containers on board boats are not mounted on weigh frames.
Each ISO-Pump™ on board the support vessel is filled by pressurising it’s

corresponding ISO- Pump™ on the rig, then opening the outlet valve and pre setting
the appropriate R-Valve to “Divert”. As each of the ISO-Pump™ on board the vessel
reaches capacity it’s R-Valve is then set to the “through position and the next R-
Valve is set to the “Divert” position ready for the next down load. The operating
panel for the shipboard “R-Valves are mounted on board also.
Sheet Rev No. 03

Aug 2002
Revision No:03
Section3

SECTION 3
FAULT DIAGNOSIS
Sheet Rev No. 03

Aug 2002
Revision No:03
Section3

FAULT DIAGNOSIS – R -VALVE
WARNING: Prior to Fault Finding on System, Check Air Supplies
R-Valve actuator fails to 1. ½”ball valve air supply 1. Check air supply & turn
operate when manual lever in isolate position valve lever to open position
“through / divert” lever is
moved to chosen position 2. lose connection or 2. Inspect joints using brushed
damaged nylon tube on soapy water
3. lever operated valve 3. Isolate air supply & replace

on control panel valve
damaged or faulty
4. Regulator set to wrong 4. Check pressure gauge and
pressure adjust
5. Pneumatic actuator on 5. Remove and replace

R-Valve faulty Pneumatic actuator after
Isolating control air to
actuator and convey
6. Build up of convey 6. material .
material inside R -valve Remove 1”NPT plugs Flush
out R Valve Caution do not
insert fingers
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section: 4

SECTION 4
ROUTINE MAINTENANCE
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section: 4

ROUTINE MAINTENANCE
Note! Before starting any routine maintenance ensure the system is isolated
both pneumatically and electrically (where applicable), and vented of
any residual pressure.
On site the R-Valve requires little in the way of routine maintenance other than after
the valve has been used for conveying of material, Remove two of the four 1” NPT
drain plugs one located in the top plate and the bottom most plug in the Valve body.
Connect a water hose to the R-Valve and flush out any residual material. Ensure
plugs are replaced after use.
Control panel:- Check filter-regulator periodically & clean filter bowl if required.
Refer to Cat 5462 for typical control panel layout.
Strip Down
It is recommended after use in service on three wells that the R-Valve is stripped
down and serviced
Procedure for R- Valve strip down

Read in conjunction with Cat 5461
Take the R-Valve off line and remove for service
1. Remove 1” NPT plugs and flush out any residual material and refit plugs.
2 Remove bolting (item 19), from each of the three stub pipe retaining plates
and remove the seal assemblies, renew “O” ring (item 36), and “O”– ring
chord (item 13), check seal sleeve (item 10) for undue signs of wear replace
with new sleeve if required replace compression ring (item 14) and renew
springs (item 12)16 springs total per/stub pipe assembly.
2. ‘Matchmark’ top plate and valve body, Undo bolting from LH & RH guards
( item 32, and 33)
Note! Two guards have a chamfer on the edges and these are to denote that
they are to be fitted to the side of the R-Valve with the mechanical stops
(Opposite side of valve to top plate). Refer to Cat 5466
1. Remove remaining guard / actuator mounting bracket , and remove actuator

and service. (Refer to proprietary parts section for details of actuator)
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section: 4

6. Remove M12 setscrews from top plate and carefully remove top plate (item 2)
and top plate gasket (item 15).
7. Match mark rotor with valve body.
8. Remove dia. 14 x 80 lg spring pin (item 5) from shaft boss (item 4), the drive
shaft and rotor assembly can now be removed by tapping with a hide mallet.
Inspect shaft for signs of wear Clean and inspect rotor
9. Remove shaft bearing (item 6), “0”seal (item 7), and shaft wiper seal (item 8),
inspect bronze spacer plate (item 9)
Re – assembly
10. Inspect shaft bearing and renew as required always renew and “O”seals (item
7, and shaft wiper seal (item 8) refit spacer plate(item9) Replace Shaft & rotor
assembly to match marks before fitting ‘Stubpipe’ seal assemblies.
11. Refit the rebuilt stub pipe seal assemblies and renew the stub pipe end plate
retaining gaskets (item16), refit retaining plate bolting do not over tighten,
check gap settings as shown on Cat5461 and re-grease .
12. Renew top plate gasket (item 15), refit top plate (item 2) and guards (item
32,33) and actuator mounting bracket (item23), and actuator.
13. Danger! Keep hands and fingers out of stub pipes

Connect actuator to an air supply source and functionally test completed
assembly. Adjust gaps if necessary and re test. Also check bore for correct
alignment.
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 5

SECTION 5
RECOMMENDED SPARES
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 5

See separate Calculation Sheet
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 6

SECTION 6
PROPRIETARY PARTS
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 6

PROPRIETARY PARTS
Section
Actuator .................................................................... 6.1

Filter Regulator ........................................................ 6.2
Valve 5/2 ................................................................... 6.3
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 6

SECTION 6.1
ACTUATOR

PREFERRED
Double Acting 180o actuator with Air Torque ATX400 - DA
A4297 F12 mounting
Sheet Rev No. 03

CMH Issue No: 1
Revision No: 00
Section 5.2

SECTION 6.2
FILTER REGULATOR

A4290 Filter Regulator G1/2” Norgren B74G GKAD 3RMG +

Complete with pressure gauge 18-103-013
50mm 1 – 10 Bar
Sheet Rev No. 03

CMH Issue No: 1
Revision No: 00
Section 5.3

SECTION 6.3
VALVE 5/2

A4292 Valve ISO 5/2 G1/4” – Super “X” Norgren SPGB / 31759
manual type
Lever Operated fitted with heavy
duty lever
Service Kit 03- 8602- 02
Sheet Rev No. 03

Aug 2002
Revision No: 03
Section 7

SECTION 7
DRAWINGS
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 7
Page 1 of 1
DRAWINGS
P33730D-00 R Valve General Arrangement

P33716D-00 R Valve Operating Device and Mounting Plate Assembly
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 7
Page 1 of 1
Sheet Rev No. 03

Aug 2002
Revision No:03
Section 7
Page 1 of 1
Sheet Rev No. 03

CleanCut Cuttings Blower
Operating and
Maintenance Manual
Shaw Lane Industrial Estate, Doncaster South Yorkshire, DN2 4SE ENGLAND
Telephone: 0044 (0) 1302 554480 Facsimile: 0044 (0) 1302 554481
Revision No: 04
INSTRUCTIONS
MANUAL NUMBER: 1
REVISON 05
Prepared by: S.L.. Brough Project Engineer
Reviewed by: L. Martin Project Manager
Authorised for use R. Bingham CleanCut

by: Manager
Page 2 of 102
Revision No: 04
REVISION HISTORY
REVISION DATE COMMENT

01 30 Mar 2001 First release.
02 06 July 2001 FDS updated.
03 25 March 2003 Inlet Valve trademark ref
removed.
04 02 April 2003 Air Sweeps on feed chute
And level probe operation
additions.
05 10 Dec 2003 Component specifications
updated.
06 14 August 2004 New logo added
Page 3 of 102
Revision No: 04
CONTENTS
Section
Introduction .................................................................. 1
• Importance of the Manual
• General Safety
• Description of Equipment
• Application & Design Parameters
Functional Design Specification .................................. 2

• Introduction
• Overview
• System at Rest
• Operating Sequence
• Timer Definitions and Values
• Operator Controls and Indications
• Timing Diagram
• Summary of Alarm Conditions
Installation and Operation ........................................... 3

• Installation
• System Start-up Procedure
• System Shut-down Procedure
• Level Probe Calibration Procedure
• Procedure for Removal of 300mm Inlet Cuttings Valve
• Cuttings Valve Maintenance Instructions
• Removal/Replacement of 300mm Cuttings Valve Bearings
• Procedure for Removal of 125mm Outlet Cuttings Valve
• Removal/Replacement of 125mm Cuttings Valve Bearings
Fault Diagnosis ............................................................. 4
Routine Maintenance ................................................... 5

• Daily Maintenance
• Weekly Maintenance
• Monthly Maintenance
• Annual Maintenance
Controller ........................................................................ 6
Recommended Spares ................................................ 7
Page 4 of 102
Revision No: 04
Section
Proprietary Parts .......................................................... 8

• Actuator
• Blow Valve
• Butterfly Valve
• Cylinder
• Filter/Lubricator
• Level Switch
• Limit Switch
• Motor (Vibrator)
• Pressure Gauge
• Pressure Relief Valve
• Pressure Regulator
• Pressure Switch
• Strainer
Drawings ........................................................................ 9
• General Assemblies
• Circuits
Page 5 of 102
Revision No: 04
Section 1
SECTION 1
INTRODUCTION
Page 6 of 102
Revision No: 04
Section 1
Ensure that any revision received is incorporated in this manual in the correct place
and that the accompanying form is signed and returned.
GENERAL SAFETY
1. PERSONNEL MUST READ THIS MANUAL BEFORE OPERATING THE

EQUIPMENT OR CARRYING OUT MAINTENANCE WORK.
2. ONLY QUALIFIED AND COMPETENT PERSONNEL MUST CARRY OUT ANY

MAINTENANCE OPERATION.
3. BEFORE CARRYING OUT ANY OPERATION OR MAINTENANCE WORK

PERSONNEL ARE TO FAMILIARISE THEMSELVES WITH ON SITE
REGULATIONS AND PRECAUTIONARY INFORMATION REGARDING
HEALTH AND SAFETY AND HAZARDS ASSOCIATED WITH CONVEY
MATERIAL.
4. PRIOR TO CARRYING OUT MAINTENANCE WORK INVOLVING PARTIALLY

DISMANTLING EITHER THE PRESSURE VESSEL OR PIPEWORK, ENSURE
THAT THE CONTROL AND CONVEYING AIR ISOLATION VALVES ARE
FULLY CLOSED AND THAT THE PRESSURE WITHIN THE VESSEL HAS
BEEN FULLY VENTED.
5. ENSURE THAT THE SYSTEM IS FULLY ELECTRICALLY ISOLATED BEFORE

DISMANTLING.
Page 7 of 102
Revision No: 04
Section 1
1 Off Model 8/12 CleanCut Cuttings Blower manufactured to PD5500

Category II and in accordance with the Pressure Equipment Directive
97/23/EC. Standard mild steel pressure vessel, designed for a working
pressure of 7 barg. Complete with 300mm Inlet Cuttings Valve, 1-1/2”
Poppet Valve (Blow Valve) and 50mm Butterfly type vent valve and
125mm Outlet valve. Pneumatic controls housed in an attached,
weatherproof, lockable cabinet with air lubricator and filter set, and
attached lockable Electric & PLC control panel
Suitable for the transfer of material with temperatures up to 100ºC

maximum.
1 Off Type 1000/300/600 HDP lined Vibratory Feed Chute, c/w Vibrator
Motor and flexible adapter to offshore specification.
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Section 1
Number & Type of Conveying Vessel: Model 8/12 CleanCut Cuttings Blower
Material: Drill Cuttings
Bulk Density: typical range 1500 – 2000 Kg/m³
Liquid Content: Various
Maximum material temperature: 100 °C
Conveying Distance: 0 – 100 metres
Conveying Rate: Typically 25 tonnes/hr
Control Air
Pressure: 6 to 10 barg
Average Airflow: 0.1 Sm3/min
Conveying Air
Pressure: 7 barg (minimum)

Peak Airflow: 21 Sm3/min (maximum instantaneous)
Power Supply
Voltage supply: 3 phase, 440 VAC, 50 Hz

Current drain: 10 Amps maximum
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Section 2
SECTION 2
FUNCTIONAL DESIGN SPECIFICATION
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Section 2
INTRODUCTION
This description should be read in conjunction with the following drawings (see Section 9):
P&ID MODEL 8/12 CLEANCUT CUTTINGS BLOWER P32688D-00
The timers and other values given in this description are typical. They may be changed during
commissioning or operations
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Section 2
OVERVIEW
During normal operation of the system, drill cuttings will accumulate in a feed hopper
above the CCB. The drill cuttings will be discharged by gravity to the CCB. The drill
cuttings will then be pneumatically conveyed through pipework to the reception point,
typically the ISO-Pump or Skip Station.
A facility to connect a remote pushbutton station is included within the control panel.
The operation of the lamp and pushbuttons are identical to those fitted to the primary
control panel. If a secondary remote pushbutton station is not required then the
emergency stop and stop signals are to be linked out.
Operator facilities on the control panel include:
Emergency stop pushbutton (HS1-1)

Start pushbutton (HS2-1)
Stop pushbutton (HS2-3)
Status lamp (XI3-0)
Timer selection switch (ZS2-10)
Timer increment pushbutton (HS2-8)
Timer decrement pushbutton (HS2-9)
Sequence controller text display – indication of timer values and I/O
Operator facilities on the remote pushbutton station include:
Emergency stop pushbutton (HS1-2)

Start pushbutton (HS2-2)
Stop pushbutton (HS2-4)
Running lamp (XI3-1)
Probe Override (XS2-2 – Fitted at operating position remote station 1 only)
For operation with the remote pushbutton station NOT connected:
The start pushbutton on the front of the control panel (or the remote cycle start signal,
after the initial cycle) will initiate a conveying cycle. Subsequent cycles will be initiated
by either a cycle timer or a high level probe located above the CCB feed hopper. The
inlet Cuttings Valve will be opened and drill cuttings will fall under gravity into the CCB
vessel. The bin activator motor assists discharge from the feed hopper.
For problematic materials discharge may be further aided with the addition of aeration
nozzles into the bottom of this cone hopper. During filling and whilst at rest the vent
valve will be opened to allow the displaced air to be released from the CCB vessel and
the outlet Cuttings Valve will be closed.
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Section 2
After a timed delay the bin activator will be stopped. Simultaneously or after a further
short delay, the inlet Cuttings Valve will close. When the inlet Cuttings Valve has
closed and sealed, there will be a short timed delay to allow the outlet Cuttings Valve
to fully open. The vent valve will close and simultaneously the conveying air will be
introduced into the CCB vessel. The drill cuttings will be discharged from the CCB
vessel into the pipeline and will be conveyed to the reception point. Short pulses of air
will also be introduced to the CCB vessel at timed intervals via the air sweep nozzles
to help discharge the drill cuttings smoothly during the conveying cycle.
When the drill cuttings have been discharged and the CCB vessel has emptied, a drop
in the conveying pressure indicates most of the useful work of the cycle has been
completed. The conveying air valves will be closed and the vent valve opened. When
the conveying pressure has completely decayed, a ‘Low pressure’ switch will indicate
the cycle is complete.
The bin activator motor will be plug-stopped to prevent ‘running-on’ and possible
compaction of the drill cuttings in the feed hopper. This is achieved by applying reverse
phasing of the supply current thus rotating the motor in the reverse direction to normal
running for a brief time.
The vent from the CCB vessel will be routed into the cuttings ditch or a similar safe
area.
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Section 2
SYSTEM AT REST
When the CCB is stopped and at rest the status of the valves will be as follows:
Control air off Control air on Control air on

Electrical off Electrical off Electrical on
power power power
Controller off Controller off Controller run
mode mode mode
Inlet Cuttings Valve Last position* Closed Closed
Vent valve Last position Open Open
Conveying air valve Closed Closed Closed

(PV02)
Air sweep valve Closed Closed Closed
(PV03)
Outlet Cuttings Last position Open Open
Valve
The CCB vessel should be empty and at zero pressure. The bin activator will be
stopped.
• Note: The inlet Cuttings Valve incorporates an inflating seal. In the event of the
loss of control air pressure, the valve will not be sealed.
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Section 2
Prior to operating the CCB for the first time, or after a period of no use it is
recommended that the adjustable time values be verified as correct for the cycle.
OPERATING SEQUENCE
At the start of each conveying cycle, the sequence controller will check that the
following cycle start interlock conditions are fulfilled:
The start pushbutton is pressed (HS2-1).
OR
The conveying cycle is running i.e. the conveying cycle has been started and the
stop pushbutton has not been pressed.
AND
The emergency stop pushbutton (HS1-1) on the control panel is not operated.
CCB vessel pressure is < 0.3 barg (PSL02).
CCB inlet Cuttings Valve is closed and sealed (PSH01).
Cycle frequency timer is not running (see note a below)
AND
The remote cycle start signal is active:
Feed hopper high level probe covered (LSH01)
OR
Probe override pushbutton pressed (XS2-2)
AND
Not high level at the reception point (XS2-1)
Providing the above conditions are true a conveying cycle will be initiated and will
proceed as follows:
Notes:
a. If running on probe the cycle timer must be set to less than 20 seconds. If
the timer setting is greater than this minimum value then the timer will hold
cycle start off until elapsed irrespective of the probe status.
b. The remote signals are ‘linked out’ if not required.
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Section 2
Step 1
The ‘Inlet Cuttings Valve’ is opened and the ‘Outlet Cuttings Valve’ is closed by
energising solenoid number (EV01). The inlet Cuttings Valve open timer (8 seconds),
cycle watchdog timer (40 seconds) and cycle frequency timer (60 seconds) will be
started. Drill cuttings will fall under gravity into the CCB vessel.
Simultaneously, the bin activator run timer (6 seconds) will be started and air to the
feed hopper air sweeps initiated.
Feed Hopper Air Sweep System
On systems that have air sweep aeration devices fitted to the feed hopper then an air
signal is taken from the Inlet cuttings valve opening supply line to operate a Blow Valve
to provide air to three air sweeps in the ‘Vibro’ Hopper to assist the material flow into
the CCB for the duration the CCB inlet Valve is open.
Please refer to CleanCut Drawing Numbers:
• P33175D-00 Pneumatic Circuit

• P35461D-00 Air Spray Nozzle Assembly
• P35469D-00 Feed Hopper Supply Assembly
• P35501D-00 Vibro Feed Hopper modifications
• P35532D-00 Feed Hopper Air Sweep Supply Assembly
Step 2
When the bin activator run timer has expired and after a short delay (0.5 seconds) the
bin activator will be plug-stopped by reversing the motor current phases for the
duration of the reverse phase plug-stop run timer (0.4 seconds). The bin activator is
interlocked with the inlet Cuttings Valve to prevent the bin activator running with the
inlet Cuttings Valve in the closed position (if the timers are incorrectly set).
The reverse phase plug-stop will not operate if the bin activator run timer value is set to
zero seconds.
Note: The duration of the bin activator run timer is to be less than the duration of the
inlet Cuttings Valve open timer.
Step 3
When the inlet Cuttings Valve open timer has expired, the inlet Cuttings Valve will be
closed and the outlet Cuttings Valve will be opened by de-energising solenoid (EV01).
Step 4
When the inlet Cuttings Valve (PSH01) has closed and sealed, the blow delay timer (3
seconds) will be started.
Step 5
When the blow delay timer has expired, the conveying air valve will be opened and the
vent valve will be closed by energising the solenoid (EV02). The convey secure timer
(20 seconds) will be started. The pulse interval timer (6 seconds) and delay pulse on
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Section 2
timer (5 seconds) will be started simultaneously with this step. When the delay pulse
interval timer expires the air sweep valve will be pulsed open by energising the air
sweep valve solenoid (EV03) for a period of time equal to (pulse interval timer) –
(delay pulse on timer) i.e. 6-5 = 1 second. This introduces pulses of air to the CCB
vessel through the air sweep nozzles at regular intervals throughout the conveying
cycle and helps discharge the drill cuttings smoothly. Air will enter the CCB vessel and
the drill cuttings will be discharged into the conveying pipe.
The drill cuttings will be conveyed through the pipeline to the reception point.
Step 6
When the convey secure timer has expired and the pressure in the CCB vessel has
fallen to less than 1.0 barg (PSL09), most of the useful work of the cycle is complete.
The conveying air valve (PV02) will be closed and the vent valve (PV05) will be
opened by de-energising solenoid (EV02). Simultaneously the air sweep valve (PV03)
will stop being pulsed open by de-energising solenoid (EV03).
Step 7
When the pressure in the CCB vessel has dropped to less than 0.3 barg (PSL02) and
the cycle frequency timer has expired, the ‘cycle-reset’ timer (3 seconds) will be
started.
Step 8
When the ‘cycle-reset’ timer has expired, the conveying cycle is complete.
Note:
If during the cycle any start interlocks become untrue, then that cycle will be permitted
to continue and end. The system will then stop until all of the start interlocks conditions
again become true.
Similarly, where an event has to occur to permit the cycle to proceed to the next step,
then the progress of the cycle will be halted until that interlock condition has become
true. The cycle will then proceed to the next step. The progress of the cycle to the next
step will be latched for the remainder of the cycle, so that in the event of the interlock
condition subsequently becoming untrue, the cycle will not stop or regress. The latches
are released at the end of the cycle during the cycle-reset timer.
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Section 2
TIMER DEFINITIONS AND VALUES
Timer name Purpose of timer Default Timer Adjustable

Timer ‘Typical timer
setting Range’
Bin activator During the filling of the CCB vessel, 6 sec 0 – 60 sec
run timer the bin activator will ‘run’ for the 1 second A
duration of the bin activator run timer. increments
Note a value for this timer greater
than the Inlet Valve open timer will not
be accepted by the controller
Inlet Cuttings This sets the period of time that the 8 sec 0 – 60 sec
Valve open inlet Cuttings Valve is open and 1 second A
timer duration of Feed Hopper Air Sweep increments
Blow (if Fitted)
Cycle The cycle watchdog timer provides a 40 sec 0 – 600 sec N
watchdog fault alarm if the conveying cycle is 1 second
timer not completed within the pre-set time increments
period.
Cycle This regulates the maximum 60 sec 0 – 600 sec
frequency conveying cycle frequency. 1 second A
timer increments
Pulse Air This sets the total cycle frequency of 30 x 0.2 0 – 999 sec
Cycle timer the pulse air arrangement. = 6 sec 0.2 second A
increments
Delay Pulse This sets the delay duration from the 25 x 0.2 0 – 999 sec A
On timer beginning of the “Pulse Air Cycle = 5 sec 0.2 second
Timer” before the pulse air is turned increments
on.
Therefore
On time = (Pulse Air Cycle timer) -

(Delay Pulse On timer)
= (6) – (5)
= 1 second
Convey secure The convey secure timer is to allow 20 sec 0 – 120 sec
timer time for the pressure in the CCB N
vessel to rise before both vessel low
pressure switches (PSL02) & (PSL09)
are interrogated.
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Section 2
Cycle reset The cycle reset timer provides time 3 sec 0 – 20 sec
timer for the pressure in the CCB vessel N
and conveying pipework to be
completely released before the start
of the next conveying cycle.
Bin activator This allows a delay for the bin 0.3 sec 0 – 20 sec
fault timer activator-running signal to be received N
when requested to ‘run’.
Blow delay This timer provides a delay for the 3 sec 0 – 20 sec
timer outlet Cuttings Valve to be opened N
before the conveying air valve is
opened.
Reverse This sets the duration of the reverse 0.4 sec 0 – 20 sec
phase plug- phase plug-stop on the bin activator N
stop timer motor.
A – Adjustable Timer from control panel

N – Non-adjustable Timer from control panel (timer settings adjustable via PLC)
It shall be noted that the actual wording for each of the above Adjustable Timers on the
controller display, due to a limit on the number of characters, is abbreviated as shown below:
Timer Number Timer Description Control Display wording
1 Bin Activator Run Bin A

2 Cuttings Inlet Valve Open Dome
3 Pulse Air Cycle Pulse Air Cycle >Pulses .2x
4 Cycle Frequency Freq
5 Delay Pulse On Delay Pulse On .2x
Note:
It is only possible to view or adjust the timer values when the CCB is not in a
conveying cycle. The preferred procedure for this action is:
1 View the selected timer value.

2 Adjust the selected timer value, up or down as required.
3 View the selected timer value.
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Section 2
To view the timer values:
1 Timer select switch (ZS2-10) in the ‘off’ position.

2 Turn the timer select switch (ZS2-10) to select the timer value to be viewed.
Note:
The timer values are displayed on the text display of the sequence controller
(viewed through the window in the door).
3 Return the timer select switch (ZS2-10) to the ‘off’ position.
To adjust the timer values:
1 Timer select switch (ZS2-10) in the ‘off’ position.

2 Turn the timer select switch (ZS2-10) to select the timer value to be adjusted.
3 To increase the selected timer value, press the ‘increment timer value’
pushbutton.
To decrease the selected timer value, press the ‘decrement timer value’
pushbutton.
Note:
Each press of the pushbutton will increment / decrement the selected timer value
by one second.
4 Return the timer select switch (ZS2-10) to the ‘off’ position.
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Section 2
OPERATOR CONTROLS AND INDICATIONS
PNEUMATIC CONTROL PANEL
The pneumatic control panel at the CCB vessel houses the solenoid valves and the
inlet Cuttings Valve closed (PSH01) pressure switch.
ELECTRICAL CONTROL PANEL
The sequence controller located in the electrical control panel will control the CCB. The
operator interface is by means of pushbuttons, a selector switch, a lamp and the text
display of the sequence controller.
Pushbuttons
Emergency stop (HS1-1)
When the emergency stop pushbutton is pressed, the sequence controller will stop and
reset the sequence, all outputs will be ‘off’ (the position of the valves will be as for loss
of electrical supply). Pull to reset the emergency stop pushbutton.
Start (HS2-1)
When the start pushbutton is pressed, the conveying cycle will be started
(when the start interlock conditions are fulfilled). This will also reset the bin
activator fault alarm and will cancel the operation of the stop pushbutton.
Stop (HS2-3)
When pressed this will enable the conveying cycle to continue, and then stop
at the end of the cycle.
Increment timer value (HS2-8)
Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will increment the selected
adjustable timer by one second with every ‘press’ of the pushbutton.
Decrement timer value (HS2-9)
Providing the timer adjust selector switch (ZS2-10) is not in the ‘off’ position and a
conveying cycle is not in progress, this pushbutton will decrement the selected
adjustable timer by one second with every ‘press’ of the pushbutton.
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Section 2
Selector Switch
Timer adjust (ZS2-10)

Providing a conveying cycle is not in progress, this allows one of the
adjustable timers to be selected, in order to view or adjust the timer value.
Lamps
Running (XI3-0)
Lamp status is as follows:
Condition Priority Indication

Off none lamp off
Cycle running low lamp on
Bin activator fault alarm high lamp pulse on
Cycle watchdog fault alarm high lamp pulse on
Stop pushbutton pressed low lamp pulse off
Cycle start fault high lamp pulse on
Lamp pulse on = 0.3 seconds lit and 1.2 seconds unlit

Lamp pulse off = 1.2 seconds lit and 0.3 seconds unlit
Note:
If the ‘lamp pulse on’ and ‘lamp pulse off’ conditions are required at the
same time, then the higher priority condition will be displayed.
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Section 2
TIMING DIAGRAM
CONVEYING COMPLETE PRESSURE <

CUTTINGS VALVE CLOSED AND
VESSEL PRESSURE LOW <

START INTERLOCKS HEALTHY
EARLIEST START OF NEXT

OUTLET CUTTINGS VALVE
INLET SEALED (PSH01)
0.3 BARG (PSL02)

1.0 BARG (PSL09)
END OF CYCLE
FULLY OPEN
VALVE AND MOTOR
CYCLE
STATUS
VENT VALVE
OPEN (EV02)
INLET CUTTINGS VALVE
OPEN (EV01)
BIN ACTIVATOR MOTOR
RUNNING (M001)
CONVEYING AIR
VALVE OPEN (EV02)
OUTLET CUTTINGS VALVE
OPEN (EV01)
AIR SWEEP VALVE
OPEN (EV03)
TIMERS
BIN ACTIVATOR RUN 6 SEC

TIMER
REVERSE PHASE 0.4 SEC
PLUG-STOP TIMER
INLET CUTTINGS VALVE 8 SEC
OPEN TIMER
BLOW DELAY 3 SEC
TIMER
CONVEY SECURE 20 SEC
TIMER
CYCLE RESET 3 SEC
TIMER
CYCLE FREQUENCY 60 SEC
TIMER
CYCLE WATCHDOG 40 SEC
TIMER
PULSE AIR CYCLE 6 SEC 6 SEC
TIMER
DELAY PULSE ON
TIMER6 SEC
PRESSURES
VESSEL
PRESSURE 1 BARG
0.3 BARG
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Section 2
SUMMARY OF ALARM CONDITIONS
BIN ACTIVATOR FAULT ALARM
Definition:
Thermal overload tripped (automatic reset with the start pushbutton).

Thermistor tripped (automatic reset with the start pushbutton).
Circuit breaker tripped (manual reset).
Control Action:
Visual alarm (only when the bin activator is requested to run).
CYCLE WATCHDOG FAULT ALARM
Definition:
The cycle watchdog timer has expired and a conveying cycle is still in progress.
Control Action:
Visual alarm only
CYCLE START FAULT
Definition:
Failed to start a conveying cycle.
Control Action:
Visual alarm and inhibit the start of cycle until the conveying cycle start conditions are
fulfilled.
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Section 3
SECTION 3
INSTALLING AND
OPERATING THE CCB
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Section 3
IMPORTANT
The CleanCut Cuttings Blower conveying vessel is, for insurance purposes, classed
as a pressure vessel.
CleanCut Cuttings Blower™ Vessel Design: PD5500 Category II
Design Pressure: 7 barg
Hydraulic Test Pressure: 10.9 barg
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Section 3
INSTALLATION
25mm Jacking Allowance
The CleanCut Cuttings Blower is installed beneath a feed chute with an allowance of
25mm made on overall height to allow the CleanCut Cuttings Blower to be slid into
position and raised on the jacking screws provided.
The CleanCut Cuttings Blower does not normally require bolting down since there is
no reaction or vibration during conveying. However in offshore applications after
installation. The vessel may be welded as necessary to the deck using the four
sacrificial mounting pads provided
Lifting
Care must be taken during any lifting of the CleanCut Cuttings Blower during
installation. Damage may be caused to the Cuttings Valve sealing head if any bar or
lifting device is placed inside the Cuttings Valve in order to obtain a lifting point. It is
recommended that the lifting lugs provided or eyebolts be used to lift the CleanCut
Cuttings Blower. Refer also to the erection and installation procedure
Pipework & Connections
A gasket is fitted between the CleanCut Cuttings Blower and the vibratory feed
chute. An air tight seal is required on all equipment above the CleanCut Cuttings
Blower since the air displaced from the material chamber during the Cuttings Valve
open period will tend to 'blow out' material from any loose fitting flange or simple
slide type isolating valve.
Air Supply
The air supply line size may appear larger than that required for the stated air
consumption, this is due to the fluctuating usage of air by the CleanCut Cuttings
Blower. Airflow is approximately twice the average air consumption stated for a brief
period during each conveying cycle.
Normally no special water removal or dirt removal equipment is required associated

with the air supply unless the material being conveyed is hygroscopic or adversely
effected by moisture.
Each CleanCut Cuttings Blower™ is equipped with its own air strainer to prevent
pipe scale and dirt from causing pressure regulator malfunction. An automatic drain
filter and oil fog lubricator set is fitted into the airline that is used for the pneumatic
controls.
Page 27 of 102
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Section 3
Any air line stop valves which are fitted into the air supply to the CleanCut Cuttings
Blower must be of the 'gate' or 'ball' type which do not cause a restriction to air flow
when open.
Airline filters with fine mesh porous elements should not be fitted as these cause an
airflow restriction during peak air demand periods.
SYSTEM START UP PROCEDURE

The CCB once installed should be operated in fully automatic mode in conjunction
with the high level probe located within the feed hopper.
For a detailed description of the working cycle of the CCB section 2 of this manual
should be observed.
The basic start up checks are however detailed below:
1. Ensure compressor is operational and on load and the 2” CCB pilot operated
regulator is set to 6.0 barg.
2. Ensure the electrical supply is healthy and the main isolator ion the CCB is
switched to the ON position.
3. With the CCB set at rest check the timer settings are as in accordance with
section 2 of this manual.
4. Check calibration of the level probe as detailed in following sub section.
5. Start the system by pressing the green start push button. CCB cycle will
commence as soon as the high level probe is covered or to check depress the
level probe override button.
6. The CCB will now cycle at a frequency relative to the cuttings rate of
production.
7. To bring the unit to a controlled stop press the red stop button or alternatively
if an upset or fault condition occurs the CCB can be brought to an immediate
stop by depressing the Emergency Stop button.
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Section 3
SYSTEM SHUT DOWN PROCEDURE
1. Close isolating valve above CleanCut Cuttings Blower (if installed) , run the
vessel until empty by pressing the probe override button located on front of
operator control panel (where fitted). Turn relevant selector switch to 'OFF'
position.
2. Shut off mains air supply valve to the vessel (lock off if it is mounted remotely)
3. Shut off control air supply to the pneumatic panel and drain through the filter
on filter/ lubricator set, if venting has not been achieved in the normal through
the venting isolating valve.
4. Isolate electrical control panel(s). Use warning legends to inform other

personnel of the work being carried out
5. CAUTION before working on vessel, ensure vessel pressure gauge is

reading zero, which is located on vessel or on pneumatic panel.
Level Probe Calibration Procedure

1. Remove the lid from the large remote control pot (blue aluminium housing). As
the unit is IS Rated this operation can be conducted with the system running.
2. On the side of the electronics unit there is a Fail-Safe High/Fail-Safe Low selector
switch. Ensure this is set to Fail Safe High (upper most switch position).
Notes
• The LED on indicates the normal condition (i.e. LED will be extinguished when
material is covering the probe)
• Turning the adjustment pot clockwise will raise the level at which the LED
operates and turning counter clockwise will lower the level at which the LED
will operate.
Two methods can be employed
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Section 3
Method 1
Requires the material level to be physically above the probe or for the hopper to be
empty of cuttings (Swaco/CleanCut Engineers will need to verify this work as a team)
Method 2
Relies on initially an empty condition and then a full level condition.
Method 1a – Hopper full above probe
1. Ensure probe is completely covered with cuttings.

2. Rotate the pot to find the operating point of the material i.e. until the LED is just
extinguished.
3. Now rotate the pot counter clockwise 1 turn
Calibration completed
Method 1b – Hopper empty below the probe
1. Ensure probe is completely empty/clear of cuttings.

2. Rotate the pot to find the operating point of the material i.e. until the LED is just
extinguished.
3. Now rotate the pot clockwise 1 turn
Method 2
1. Ensure material level is below probe.

2. Rotate set point pot full counter clockwise (CCW)
3. Turn pot slowly clockwise (CW) until the LED just changes state. Although it is
uncovered, this adjustment causes the probe to give a ‘just covered’ output and
gives one extreme of the operating range.
4. Mentally note the position of the adjustment tool pointer.
5. Ensure probe is now covered with cuttings.
6. Counting the number of turns, rotate CW until LED changes state once more.
This gives the sensing point where a covered probe gives a ‘just uncovered’
output. This gives us the other extreme of the operating range.
7. Turn the pot back CCW half the total number or turns that were counted leave the
probe at mid-range sensitivity.
8. Record half the number of turns value as the “Preload” on the inside of the lid.
PROCEDURE FOR REMOVAL OF 300mm INLET CUTTINGS VALVE
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Section 3
Note:
Numbers in brackets refer to catalogue drawing P33074D-00.
Inlet Cuttings Valve
1. Fully close isolating valve and run the CleanCut Cuttings Blower until
empty.
2. Shut down and isolate system as shown in Section 3.
3. Disconnect and mark nylon pneumatic pipework to the cylinder (12) and
limit switch (26).
4. Remove setscrews securing isolating valve to adaptor if fitted to Cuttings

Valve top plate.
5. Remove setscrews from Cuttings Valve bottom flange to vessel.
6. Lower vessel by means of the jacking bolts on the feet of the vessel
(25mm). Where vessels are welded locally to the deck remove the flexible
adaptor
7. Remove Cuttings Valve by sliding sideways using lifting equipment if

possible
CUTTINGS VALVE MAINTENANCE INSTRUCTIONS
Replacement/Inspection of Cuttings Valve Insert Seal
Note:
1. Remove setscrews from top plate/adaptor (16), lift out the sealing head
assembly consisting of top plate/adaptor (16), insert seal (19), insert ring (18)
and spigot ring (17).
2. Note the number and thickness of gaskets (13, 14 & 15) under the spigot ring
(17). Combinations of 0.4mm, 0.8mm and 1.5mm thickness gaskets are fitted
to achieve the required seal gap (between the seal and the dome).
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Section 3
3. Separate the seal (19) from the insert ring (18) and inspect for wear or
damage. Replace immediately if necessary.
4. Rotate the dome (2) by hand to check the condition of the bearings (4). If the
bearings (4) are seized or due for replacement proceed to
'Removal/Replacement of Cuttings Valve Bearings'.
5. When re-assembling the valve ensure that the underside of the top
plate/adaptor is free from corrosion. All surfaces should be clean in order to
form an airtight seal.
6. Lower the gaskets (13. 14 & 15) onto the valve body (1) followed by the spigot
ring (18) and insert seal/ring (18/19).
7. Lower the top plate/adaptor into position taking care not to trap the seal, and
tighten down.
8. Check the gap between the dome (2) (when in the closed position) and the
seal is correct using feeler gauges. The gap required is shown on the
relevant catalogue drawings in this section.
Page 32 of 102
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Section 3
REMOVAL/REPLACEMENT OF 300mm CUTTINGS VALVE

BEARINGS
Note:
1. Remove the sealing head assembly.
2. Remove cylinder guard front cover.
3. Remove the nearside circlip on the front clevis assembly (42) and lightly tap
the pin out.
4. The cylinder (12) can now be removed.
5. Turn the valve through 180°; remove grease nipples (41 & 23).
6. Punch out the two inner spring pins (9) securing the dome (2) to the shafts (3)
and remove torque arm (10) if necessary.
7. Remove rear guard.
8. Withdraw the shafts (3) and lift out the dome (2). Note if there are any shims
present on the shafts. The shims are occasionally fitted at the factory for
centralising the dome and should therefore be refitted on subsequent
overhauls.
9. Bearings and seals can now be removed by driving them towards the centre
of the valve.
10. All machined surfaces should be thoroughly cleaned/degreased and

inspected.
11. Check for surface irregularities in the dome (2) and shafts (3) and replace if
necessary. Also de-burr the edges to prevent damage to the replacement
seals and bearings on re-assembly.
12. Press the replacement shaft seal (7) (never put old seals/bearings back) into
the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore; align the grease hole in the bearing with 1/8" NPT hole
in the body. Press squarely until the bearing sits 5mm below the face of the
flange. Repeat for other side.
13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB grease or equivalent.
Page 33 of 102
Revision No: 04
Section 3
14. Re-fit the shim(s) (if applicable) and slide a new 'O' ring (11) over the shafts
(3) up to the boss.
15. Slide the shaft (3) through the bearing (4) until it touches the first seal.
Repeat for the other side.
16. Hold the dome (2) adjacent to the bores and drive the shaft through the seals
and the dome using a plastic/hide mallet. Re-fit the grease nipples (23 & 41).
17. Rotate the shafts (3) until the holes in the shaft and dome (2) align. Grease
the spring pins (9) and drive in.
18. Turn the valve through 180°.
19. Re-fit the cylinder assembly steps 2 to 7 in reverse order. Secure the guard in
position.
20. Re-fit the sealing head assembly.
21. Setting of Limit Switch
Loosen the lock nut on the striker arm (25) and wind up the setscrew. With the
dome (2) fully closed wind out the screw until the hex-head touches the
plunger on the limit switch (26). Turn the screw a further 4mm (3.25 turns) to
depress the plunger.
Page 34 of 102
Revision No: 04
Section 3
PROCEDURE FOR REMOVAL OF 125mm OUTLET CUTTINGS

VALVE
Outlet Cuttings Valve
1. If fitted, fully close isolating valve and run the CleanCut Cuttings Blower until
empty.
2. Shut down and isolate system as shown in Section 3.
3. Disconnect and mark nylon pneumatic pipework to the actuator.
4. Disconnect air supply above the non-return valve on the stub pipe - at the
union.
5. Isolate air supply to air injection point and remove hose at crows foot
coupling. Remove whipcheck from hose side only.
6. Support outlet Cuttings Valve assembly to avoid damage to casting.

Disconnect 125mm Victualic coupling
7. Remove set screws securing Cuttings Valve to cast outlet bend.
8. Using suitable lifting tackle, the Cuttings Valve can now be removed.
Page 35 of 102
Revision No: 04
Section 3
REMOVAL/REPLACEMENT OF 125mm CUTTINGS VALVE

BEARINGS
Vane Type Actuator Version
Note! The 125mm outlet valve does not have an insert seal assembly
Note:
1. Disconnect the bottom adaptor (33) from the Dome Valve body (1).
2. Remove the sealing head assembly (17).
3. Rotate the dome (2) until it resets in a position halfway between open and
closed.
4. Remove the setscrews that attach the actuator mounting (21) to the valve
body (1) and withdraw.
5. Remove the grease nipples (19 & 20).
6. Turn the valve upside down (through 180°).
7. Punch out the two inner spring pins (11) securing the dome (2) to the shafts
(3).
8. Withdraw the shafts (3) and lift out the dome (2).
9. The bearings and seals can now be removed by driving them towards the
centre of the valve, using a hide mallet
10. All machined surfaces should now be thoroughly cleaned/degreased and

inspected.
11. Check for surface irregularities in the dome (2) and shafts and replace if
necessary. Also de-burr the edges of the two holes and the leading edge of
each drive shaft to prevent damage to the replacement seals/bearings on re-
assembly.
12. Press the replacement shaft seal (9) (never put old seals or bearings back)
into the bore, followed by the spacer (8) and the remaining seal (7). Offer the
bearing (4) to the bore. Align the grease hole in the bearing with 1/8" NPT
hole until the bearing sits 5mm below the face of the flange. Repeat for other
side.
Page 36 of 102
Revision No: 04
Section 3
13. Liberally pack the space between the seals and coat the bearings with Shell
Malleus JB or equivalent.
14. Re-fit a new 'O' ring (12) over the shafts (3) up to the boss.
15. Slide the shaft (3) through the bearing (4) until it reaches the first seal in the
bore.
16. Hold the dome (2) adjacent to the bores and drive the shafts (3) through the
seals and the dome (2) using a plastic/hide mallet.
17. Rotate the shafts (3) until the holes in the shaft and the dome (2) align.
Grease the spring pins (11) and drive in.
18. Turn the valve right way up again (through 180°).
19. Fit the grease nipples (19 & 20) and the actuator (13).
20. Re-fit the sealing head assembly.
Page 37 of 102
Revision No: 04
Section 4
SECTION 4
FAULT DIAGNOSIS
Page 38 of 102
Revision No: 04
Section 4
FAULT DIAGNOSIS - CLEANCUT CUTTINGS BLOWER
WARNING: Prior to Fault Finding on System, Check Air & Electrical Supplies
CCB does not start, 1. Electrical. 1. Check start signal on terminal

Cuttings Valve remains to CCB panel, if no signal
static. trace through on electrical
Open on N/Open, closed on circuit.
N/Closed
2. Solenoid valve faulty. 2. Check power to appropriate
coil. If power satisfactory
strip valve, clean and check
3. Vessel Pressure Low 3. pneumatic line.
Pressure switch faulty Check pressure switch and
set point
CCB starts, vessel fills, Inlet 1. Pneumatic limit switch 1. Adjust as per maintenance
Valve closes but does not not making. manual. Replace if faulty.
convey
2. Cuttings Valve not 2. Isolate electrics and
closing completely, pneumatics. Remove pipe
foreign object trapped from bottom bend to clear.
in Cuttings Valve or Clear vessel. Disconnect
shafts seized. actuator and operate
manually, checking limit
switch operation.
3. Blow valve not working. 3. Check air supply to valve. If

satisfactory repair or replace
valve. If no air supply, check
blow solenoid operation
(N/Closed system) or limit
switch (N/Open system).
4. No conveying air 4. Check compressor and pilot

regulator
5. Supply air, Pressure 5. Replace regulator and check

regulator failed pressure setting
CCB starts to convey then 1. Conveying pipe 1. Check air and power supply.
stops with high vessel blocked (see conveying
pressure pipe blocked section). Check piping from valve to
control panel.
2. Outlet valve failed to 2. Check solenoid valve

open. connection. Check quick
valve on the outlet valve is
operational
Page 39 of 102
Revision No: 04
Section 4
3. Vessel blocked. 3. Air passing into conveying

pipe but vessel is blocked
and pressurised. Isolate air
and electrics. Release
pressure from vessel using
manual drain valve. Remove
pipe to outlet bend and
investigate possible wet or
oversize material and foreign
object.
Air leaks through Cuttings 1. Seal air pressure 1. Check air supply lines.
Valve or Vent Valve during dropping to near
conveying conveying pressure.
2. Inlet Valve inflatable 2. Renew seal, checking gap

seal ruptured. between dome and seal as
per maintenance manual.
3. Vent valve seal split. 3. Fit new valve or seal.
4. Control air Filter 4. Strip and clean.

Lubricator blocked.
Air exhausts continuously 1. Solenoid not working 1. Strip and clean.

through open/closed full travel.
solenoid
2. Inlet Valve actuator 2. Fit new seals.
seals leaking.
Page 40 of 102
Revision No: 04
Section 4
Conveying pipe blocked 1. Incorrect regulator 1. Adjust or replace regulator.

setting or faulty
regulator.
2. Oversized material 2. Investigate
3. Blow valve malfunction. 3. Strip and check.
4. Pipe misalignment. 4. Check at block point.
5. Insufficient air 5. Check air supply
6. Electrics cut off mid 6. Investigate cause e.g.,

cycle. operators fingers!
7. Pulse Air settings in 7. Check and/or adjust settings

appropriate.
Pressure relief valve 1. Incorrect regulator 1. Adjust or replace regulator.

operates setting or faulty For the PRV to operate there
regulator. is probably also a blocked
line. Check vessel pressure
and use manual vent if
necessary.
Page 41 of 102
Revision No: 04
Section 5
SECTION 5
ROUTINE MAINTENANCE
Page 42 of 102
Revision No: 04
Section 5
ROUTINE MAINTENANCE
NOTE! Before starting any routine maintenance ensure the system is isolated
both electrically and pneumatically, and vented of any residual pressure.
General Notes on all Routine Maintenance
It shall be noted that before starting any routine maintenance ensure the
system is isolated both electrically and pneumatically. Conveying pipes and
CCB/ISO Pump vessels must also be vented of any residual pressure.
DAILY MAINTENANCE
The daily system check is an attempt to identify the possible onset of component
failure before the event effects system performance and ultimately impacts the
overall system reliability.
Unlike the weekly and monthly maintenance routines there are no planned activities
for this regime. The check, assuming a live operational system, is intended to verify
the operational health of the equipment with corrective actions only taking place
should problems or the onset of possible component failure be identified.
In order for the following checklist to be purposefully administered the system should
ideally be operational. If so a combination of pressure readings, pressure settings
and valve functionality tests will be read or determined.
Daily Inspection Check List

Item Check Description Comments
No
1 Pressure Regulator setting should See P&ID Drawing for any

be approximately 6.0 barg with amendment to this set value.
system at rest.
No flow pressure (system at rest) Note two pressure should be near

Pnf barg. identical. If the differential
Air flowing condition (system between Pf and Pnf is > than 0.75
conveying Cuttings) Pf barg barg check supply air source and
system flow plates/nozzles.
2 CCB vessel pressure at rest < 0.15 If pressure >0.15 barg check:
barg
Condition of vent line and vent
valve.
Ensure accuracy of vessel gauge.
Page 43 of 102
Revision No: 04
Section 5
3 Air manifold and pneumatic signal If any leaks are found take
tubes have no air leaks necessary corrective action.
4 Ensure all Poppet Style air manifold Burkert valve heads enclose a
valves are functioning. Each valve yellow open/closed indicator
indicator button to be checked: button. The status of each valve
• Vent line purge air valve should be individually observed
• Conveying pipe ABR valve through a complete cycle
• Cycling Air sweep valve
5 Vessel pressure during convey Pressure should rise, typically >
cycle 2.5 barg, and momentarily
increase and decay as the
airsweep valves cycle.
Lack of significant vessel pressure
could be symptomatic of:
• Shortage of cuttings delivery
• CCB choked with cuttings
• Vent valve failed
• Lack of conveying air
6 Vessel pressure when system Decay in pressure down to <0.15
vented barg should take no longer than
two to three seconds. If vent time
exceeds this check:
• Vent valve operation
• Vent pipe for restrictions
7 Cuttings inlet valve opens and
closes with a single smooth action
8 Cuttings outlet valve opens and
closes with a single smooth action
9 Blow phase of the cycle is Check apparent switch point of
terminated when the end of blow pressure switch.
pressure switch is made with a <1.0
barg falling pressure level.
10 Ensure cuttings inlet valve only Check vessel pressure and hence
opens with a vessel pressure of pressure switch setting at valve
<0.2 barg. open instant.
Page 44 of 102
Revision No: 04
Section 5
11 Feed hopper vibro motor should Take necessary corrective action if

rotate for a brief period before found to operate out side of these
coming, instantly to rest via the specifications
reverse plug stopping contactor.
Whilst rotating the motor should
generate only minimal noise
typically associated with a running
electrical motor.
WEEKLY MAINTENANCE
Cuttings Inlet and Outlet Valves
Grease Valve shafts and bearings (hydraulic grease nipples located on Valve body)
using Shell Malleus JB Grease.
Filter Lubricator and main manifold strainer
Check lubricator units mounted on outside of pneumatic panels and on control air
supply and top up lubricators as required. Monitor condition of filters and clean as
required (normally annually).
Caution!
When it is necessary to remove a filter for cleaning purposes/renewal, the air

supply to the control panel must be isolated.
MONTHLY MAINTENANCE
Cuttings Inlet Valve
Check settings on cuttings Inlet Valve limit switches where applicable. Refer to
drawings in Section 9.
Pneumatic Control Panel
Inspect condition of exhaust silencers (located on underside of panel) renew as

required. Clean out filter where applicable.
Air manifold strainer
Remove strainer insert from convey airline strainers, clean and replace. General
functional checks of ball valves on system.
Page 45 of 102
Revision No: 04
Section 5
ANNUAL MAINTENANCE
The following maintenance is required for long term rental machines else this
maintenance shall only be conducted at the relevant time when the units are
returned to shore between rentals.
Cuttings Inlet and Outlet Valves:
Remove Cuttings Inlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.
Check Cuttings Inlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.
Remove Cuttings Outlet Valve as described in section 3 of the O&M Manual and
check head of dome and seal for signs of wear.
Check Cuttings Outlet Valve shafts for wear and replace bearings and seals as
described in section 3 of the O&M Manual if required.
Inspect cylinder shaft for score marks scratches, pitting, rust etc. as this can lead to
premature failure of cylinder seals.
Control Panels:
Visual inspection of electrical and pneumatic connections and condition of equipment

within the enclosures.
Pressure Safety Relief Valves:
These shall be tested in accordance with manufacturers and/or Insurance test

schedule. Each valve, as a minimum, shall be visually inspected for signs of
damage.
Manifold Pipe, Flexible Hoses and Valves:
All manifold pipes will be inspected for damage and any corrosion.
Flexible hoses will be inspected for any signs of degradation of the hose wall, which
is manufactured from a nitrile rubber. Degradation will include wall softening, an
increase in outside hose diameter or delamination of the hose fabric.
Valves will be inspected for operational performance and the head will be removed to
assess the condition of the valve seat and seal.
Pressure Control Valve (Pilot Operated Regulator):
The regulator shall be opened and the diaphragm checked for signs of degradation
and wear. The unit shall then be connected with a compressed air source >7.0 barg
and the unit assessed for ease of setting the desired pressure set point.
Page 46 of 102
Revision No: 04
Section 6
SECTION 6
CONTROLLER
Page 47 of 102
Revision No: 04
Section 6
CROUZET MILLENIUM CONTROLLER Part No E4988
System Voltage: 24VDC
Control Voltage: 24VDC
Software Version Used: Factory Programmed
Interface Required: None
EEPROM Required: Clyde Materials Handling Part No E4889
This is a non- repairable throwaway unit on failure
The following displays mimic the physical display generated on the LCD Millennium
unit.
In viewing these screens it is possible to identify which PLC Inputs and/or Outputs
are required for healthy CCB operation and the conveying cycle advances.
1.0 System at Rest - Waiting for start signal

Status:
Vessel Press < 0.3 barg
With the status as shown the system is healthy

Remote Cycle Enable
Vibro Motor Running
and is waiting on three conditions becoming true.

Inlet valve Closed
Timer Decrement
Timer Increment
Timer Selection
Level Probe Operation:

If the system is running with probe then Input 12
is required to be true. (Note frequency timer
Start
Stop
should be set to zero seconds to esure probe only

control)
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
Timer Operation:
PLC
If the CCB is operating in timer mode then either
Outputs the level probe should be linked out (across
1 2 3 4 5 6 7 8 terminal numbers 26 & 28) or the probe should be
Conveying Air
Vibro Motor
Reverse Plug Stop
Pulse Air
Inlet Valve open
System Running
set Fail safe low providing a permenant signal to

input 12.
= Output/Input low
= Output/Input high Start Request:

Start push button pressed providing input 1
Page 48 of 102
Revision No: 04
Section 6
2.0 Start Conditions Satisfied - cycle commenced

Status:
Remote Cycle Enable

Vibro Motor Running
Inlet valve Closed

and has initiated the next cycle.
Timer Decrement
Timer Increment
Timer Selection
Level Probe Operation:
Start
Stop
If the system is running with probe then Input 12

will now be true.
Inputs
1 2 3 4 5 6 7 8 9 10 11 12 Timer Operation
PLC
If the CCB is operating in timer mode then either
Outputs
1 2 3 4 5 6 7 8 the level probe should be linked out (across
Conveying Air
Vibro Motor
Reverse Plug Stop
Pulse Air
Inlet Valve open
System Running
terminal numbers 26 & 28) or the probe should be

set Fail safe low providing a permenant signal to
input 12.
3.0 CCB Filling Status:
CCB filling will commence with the system status

Remote Cycle Enable

Vibro Motor Running
as shown.
Inlet valve Closed
Timer Decrement
Timer Increment
Timer Selection
Vent Valve Status:
The vent valve is is directly reverse logic

Start
Stop
controled from the blow valve signal output 2.
Inputs Blow Valve closed - Vent Valve open

1 2 3 4 5 6 7 8 9 10 11 12 Blow Valve open - Vent Valve closed
PLC
CCB Outlet Valve:
Outputs
1 2 3 4 5 6 7 8
Conveying Air
Vibro Motor
Pulse Air
Inlet Valve open
Reverse Plug Stop
System Running
The Outlet Valve is is directly reverse logic

controled from the Inlet Valve signal output 1.
Inlet Valve closed - Outlet Valve open

Inlet Valve open - Outlet Valve closed
4.0 CCB Conveying Material

Status:

Remote Cycle Enable
Vibro Motor Running
and conveying is in process.

Inlet valve Closed
Timer Decrement
Timer Increment
Timer Selection
Pulse Air:
The pulse air output No 6 will oscillate at the
frequency selected with the combination of pulse
Start
Stop
frequency and delay off timers set by the

Operator.
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC
Outputs
1 2 3 4 5 6 7 8
Conveying Air
Vibro Motor
Reverse Plug Stop
Pulse Air
Inlet Valve open
System Running
Page 49 of 102
Revision No: 04
Section 6
5.0 Conveying Cycle Completed

Status:
Remote Cycle Enable

Vibro Motor Running
With the status as shown the system has
Inlet valve Closed

successfully completed a conveying cycle. The
Timer Decrement
Timer Increment
Timer Selection
vessel pressure has reduced to less than 1.0 barg
as indicated by the input signal 5. The Blow
Valves will close and the vent line open.
Start
Stop
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC
Outputs
1 2 3 4 5 6 7 8
Conveying Air
Vibro Motor
Reverse Plug Stop
Pulse Air
Inlet Valve open
System Running
6.0 CCB Cycle Completed and Reset Status:
The CCB has now completed the entire cycle,

Remote Cycle Enable

Vibro Motor Running
with the vessel pressure now below 0.3 barg.

Inlet valve Closed
The unit is rest and awaits the next remote cycel

Timer Decrement
Timer Increment
Timer Selection
enable or cycle frequency timer to initiate the next

cycle.
Start
Stop
Inputs
1 2 3 4 5 6 7 8 9 10 11 12
PLC
Outputs
1 2 3 4 5 6 7 8
Conveying Air
Vibro Motor
Reverse Plug Stop
Pulse Air
Inlet Valve open
System Running
Page 50 of 102
Revision No: 04
Section 7
SECTION 7
RECOMMENDED SPARES
Page 51 of 102
Revision No: 04
Section 7
The spares required for a CCB can be dependant on a number of issues:
1. Total number of CCB on the Installation

2. The requirement of each CCB (redundancy or dual simultaneous running)
3. The level of safety stock held on shore
To automate the required spares relative to the variables identified above an

interactive spreadsheet has been developed.
For a detailed and tailored spares listing this spreadsheet should be utilised,
however as a general guideline the following spares listing is provided.
This listing represents the full spares list for a single CCB.
Page 52 of 102
Revision No: 04
Section 7
Description Part Number Quantity
Feed Hopper
Feed Chute Skirt P32267E-00 1
Tensioning wire P32262E-00 1
Bottom Gasket ( 300 Isol V/V) P32259E-00 3
Flex adapter Sleeve P32249D-03 1
Band Clamp-300mm P20306E-03 1
Bottom Gasket P2122A-12 2
Inlet Valve
Inlet Dome Valve Spares Kit P33074D-03 M3232 1
Cylinder P34675E-00 1
Cylinder Seal kit A2214 1
300mm Dome V/V Gasket Set P2120A-03 2
Dome Insert Seal P1826C-05 1
Adapter Plate Gasket ( P32201D-00) (V to D) P32206E-00 2
Air Limit Switch (inlet) A1011 1
Quick Exhaust Valve A1067 1
Exhaust Silencer P17951E-00 4
Outlet Valve
Outlet Dome Valve Spare Kit P32541D-00 M3226 1
Actuator A4374 1
Actuator Seal Kit A2201 1
100/125mm Dome Gasket Set P2120A-01 1
Outlet Bend to V/V Gasket P2120A-83 1
Manifold Assembly
Pressure Regulator 2" A2973 1
Seal Kit Pressure Regulator 2" A4445 1
Pilot Regulator for 2" Reg A4359 1
Seal Kit Pilot Regulator for A4359 A4467 1
1 1/2" Blow Valve A4373 1
Silencers A1590 4
Pressure Switch A4287 1
1/2" Non Return Valve A3527 1
2" Non Return Valve P33043E-00 1
2" NRV Discs P33045E-02 4
Clamps M6870 2
Vent Valve (Butterfly v/v) A4151 1
Fluidising P33442D-00 1
8mm Nylon (1 m ) A1570 25
12mm Nylon (1 m ) A1571 25
"O" Ring (from M2817) M2817 1
Enots Pneumatic fittings M7057 1
Dunlop gacord hose 3/4"NB M3542 5
Dunlop gacord hose 1 1/2"NB M2780 5
Dunlop gacord hose 1"NB M2781 10
Dunlop gacord hose 2"NB M3079 10
Pneumatic Control Panel
Solenoid Valve A2106 1
Coils A4130 2
Silencers A1968 5
Pressure Switch A4097 1
Page 53 of 102
Revision No: 04
Section 7
Electrical Control Panel

Millenium Unit E4988 1
Power Supply Unit E4987 1
EEPROM - Millenium E4989 1
Bulb 24V DC E5553 2
Contactor E5600 1
Overload E5601 1
Circuit Breaker E5602 1
Fuse Link - 5A E5603 3
Fuse 2A E4121 3
Relay E5604 1
Actuator E5605 1
Switch E5606 1
Pushbuttons (normally open) M-0429/V 1
Pushbutton (normally closed) M-0429/R 1
E-Stop M-0045 1
Mounting Feet-Vessel 8/12 "ES" P32698D-00 1
Vibro Motor CC0003 1
Level probe CC0014 1
Probe remote electronic unit CC0013 1
Probe cable and glands CC0012 1
Level Monitor and Transformer Isolator CC0007 1
Page 54 of 102
Revision No: 04
Section 8
SECTION 8
PROPRIETARY PARTS
Page 55 of 102
Revision No: 04
Section 8
ACTUATOR
CLEANCUT PART NO A4374
DESCRIPTION Double Acting Actuator
MANUFACTURER Kinetrol
MANUFACTURER’S PART No 090-100 Low Temp
FURTHER INFORMATION
Operating Temperature: Min –40°C (-40°F) Max 80°C (176°F)
Operating Pressure: Max 7 bar (100psi)
Page 56 of 102
Revision No: 04
Section 8
BLOW VALVE
DESCRIPTION 1 ½” NPT Blow Valve
MANUFACTURER Burkert
MANUFACTURER’S PART No 155682
FURTHER INFORMATION
Operating Temperature - Ambient: -40° to + 100°C
- Fluid: -40° to + 180°C
Operating Pressure: Max 10 bar
Design: 2/2 way piston operated valve, normally closed, spring return, 50mm actuator
Page 57 of 102
Revision No: 04
Section 8
BUTTERFLY VALVE

50mm Butterfly Valve - ANSI 150lb – Nitrile
DESCRIPTION
Seal c/w Double Acting Actuator
MANUFACTURER Bray
MANUFACTURER’S PART No Series 20
FURTHER INFORMATION (VALVE)

Operating Temperature: -18° to + 100°C
Max Shut-off Pressure: 10 bar
Velocity Limit (Gases): 54m/s
Unseating Torque: 15Nm (at 7 bar)
Weight: 2.95kg
FURTHER INFORMATION (ACTUATOR)
Description: Bray GT Series Double Acting Actuator
Rack and Pinion, Opposed Piston
Operating Temperature: -25° to 95°C
Maximum Pressure: 10 Bar
Torque (constant): 15.9 Nm (at 7 bar)
Weight: 0.6kg
Page 58 of 102
Revision No: 04
Section 8
Page 59 of 102
Revision No: 04
Section 8
CYLINDER
CLEANCUT PART NO P34675E-00
DESCRIPTION Cylinder 160 x 250 Stk C/Trun (suit. for -40°C)
MANUFACTURER Norgren
MANUFACTURER’S PART No SPC/010318/250 -40°C
FURTHER INFORMATION
Operating Pressure: Min 1 bar, Nominal 10 bar
Design: Single Acting cylinder with spring return
NB: This is a typical cylinder for information only
Page 60 of 102
Revision No: 04
Section 8
FILTER
DESCRIPTION Filter/Lubricator ½” NPT
MANUFACTURER’S PART No FL 64-408 EX
FURTHER INFORMATION
Operating Pressure: Maximum inlet pressure 17 bar
Page 61 of 102
Revision No: 04
Section 8
LEVEL SWITCH
CLEANCUT PART NO CC0016
DESCRIPTION Level Switch 400mm
MANUFACTURER Drexelbrook
MANUFACTURER’S PART No
FURTHER INFORMATION
Output: 4-10mA covered; 14-20 mA uncovered
Sensitivity: 0.1pF
Design: Level Control Transmitter; Point level; Radio Frequency (RF); Analogue output
Level Probe Assembly
Page 62 of 102
Revision No: 04
Section 8
LIMIT SWITCH
DESCRIPTION Limit Switch ¼” BSP
MANUFACTURER IMI Norgren
MANUFACTURER’S PART No S-1340/14
FURTHER INFORMATION
Operating Pressure: 0.7 – 10 bar
Design: 3/2 way mechanically operated poppet valve, normally closed.
Page 63 of 102
Revision No: 04
Section 8
MOTOR (VIBRATORY CHUTE)
CLEANCUT PART NO CC0003 (E4986)
DESCRIPTION Vibratory Motor EBK21-5/4
MANUFACTURER Invicta Vibrators
MANUFACTURER’S PART No EBK21-5/4
FURTHER INFORMATION
Operating Temperature: -20° to 40°C
Design: 440 Volts, 3 Phase, 60 Hz
Page 64 of 102
Revision No: 04
Section 8
PRESSURE GAUGE
Three gauges are used on the CCB:
GAUGE 1
DESCRIPTION Pressure Gauge 0-14 bar
MANUFACTURER Schrader
MANUFACTURER’S PART No 802M-20D
FURTHER INFORMATION
Port: G ¼”
Diameter: 50mm
Mounting: Centre back
GAUGE 2
MANUFACTURER’S PART No 18-013-013
FURTHER INFORMATION
Port: R 1/8”
Diameter: 50mm
Mounting: Centre back
GAUGE 2
MANUFACTURER Budenburg
MANUFACTURER’S PART No Grout 100mm
FURTHER INFORMATION
Port: ½” BSP
Diameter: 100mm
Mounting: Bottom entry
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Section 8
PRESSURE RELIEF VALVE
CLEANCUT PART NO A3837-CERT
DESCRIPTION Pressure Relief Valve
MANUFACTURER IMI Bailey Burkett
MANUFACTURER’S PART No 716 ESL
FURTHER INFORMATION
Operating Conditions: Max pressure 12.5 bar at 150°C
Minimum temperature -40°C
Design: Full Lift Safety Relief Valve
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Section 8
PRESSURE REGULATOR
The Pressure Regulator is an assembly of two parts:
CLEANCUT PART NO A2973 A1178
DESCRIPTION Pilot (Slave) Regulator 2” NPT Pilot Regulator ¼” NPT
MANUFACTURER IMI Norgren IMI Norgren
MANUFACTURER’S PART No R18 – C00 NNXA R40 – 200 - BNLA
FURTHER INFORMATION
Operating Conditions R18: Max pressure 31 barg
Maximum temperature +80°C
Operating Conditions R40: Max pressure 20 barg

Maximum temperature +80°C
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Section 8
PRESSURE SWITCH
Two pressure switches are used on the CCB:
DESCRIPTION Pressure Switch 0.7 – 7 bar
MANUFACTURER Sirco
MANUFACTURER’S PART No E (X) 4000RC-LO
DESCRIPTION Pressure Switch 0.14 – 14 bar
MANUFACTURER Sirco
MANUFACTURER’S PART No E (X) 4000RB-AO
FURTHER INFORMATION
Operating Pressure: 0.7 – 10 bar
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Section 8
STRAINER
DESCRIPTION Strainer 2 ½” NPT (Suitable for –40°C)
MANUFACTURER Spirax Sarco
MANUFACTURER’S PART No Fig 12GM
FURTHER INFORMATION
Operating Range: 0 – 20 barg at 210°C
0 – 25 barg at 60°C
Minimum operating temperature -198°C
Screen: Stainless Steel, 0.8mm perforations
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SECTION 9
DRAWINGS
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Section 9
GENERAL ARRANGEMENT DRAWINGS
P32260D-00 07 1000/300/60 Vibrating Feed Chute, GA Offshore Spec.
P32541D-00 08 Outlet Cuttings Valve GA
P32675D-00 05 Vent Valve Assembly

Itemised G.A. CCB with Nozzles – 125mm Bore Conveying
P33004D-00 05
Line Vent Valve Assy
P33005D-00 07 CCB manifold assembly with 6 nozzles.
P33056D-00 07 CCB Assembly fittings
P33074D-00 05 Inlet Cuttings Valve GA
P33109D-00 01 CCB Outline GA
P35461D-00 02 Airsweep Nozzle Assembly
P35469D-00 01 Feed Hopper Airsweep Supply Assembly
P35501D-00 01 Feed Hopper Modifications for Airsweep Nozzles
P35532D-00 01 Feed Hopper Airsweep Supply Assembly with Extension
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CIRCUIT DRAWINGS
P32688D-00 02 P&ID Model 8/12 CleanCut Cuttings Blower
CleanCut Cuttings Blower - motor and supply wiring

P33088D-00 03
diagram.
P33089D-00 02 CleanCut Cuttings Blower - input wiring diagram
P33090D-00 01 CleanCut Cuttings Blower - Output wiring diagram
P33091D-00 02 CleanCut Cuttings Blower - Block diagram
P33092D-00 01 CleanCut Cuttings Blower - Pneumatic Panel
P33175D-00 05 CleanCut Cuttings Blower - Pneumatic Circuit
CleanCut Cuttings Blower level switch LSH01-wiring

P34838D-01 01
details.
CleanCut Cuttings Blower remote pushbutton stations 1 &
P35395D-01 01
4 wiring diagram.
P35396D-01 01
4 wiring diagram.
CleanCut Cuttings Blower remote pushbuttons stations
P35397D-01 01
1,2,and 4 wiring diagram.
CleanCut Cuttings Blower remote pushbutton stations 1-4
P35398D-01 01
wiring diagram
CleanCut Cuttings Blower remote pushbutton station 1
P35399D-01 01
wiring diagram.
P35444D-01 01
2 wiring diagram
CleanCut Cuttings Blower remote pushbutton stations 1 –
P35445D-01 01
3 wiring diagram
CleanCut Cuttings Blower remote pushbutton stations –
P35519D-01 01
block diagram.
CleanCut Cuttings Blower Typical remote pushbutton
P35520D-01 01
stations – wiring diagram
CleanCut Cuttings Blower remote pushbutton station 4 –
P35521D-01 01
wiring diagram
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Clean Cut Trainning Manual

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CLEANCUT

Drill Cuttings Handling System

Operating & Maintenance

OPERATING & MAINTENANCE

SYSTEM: Drill Cuttings Handling System

PRESSURE VESSEL TYPE: ISOPump

MANUAL ISSUE NUMBER: 1

Signature Position Date

Prepared by: S. Brough Project Engineer Aug 2002

Reviewed by: L. Martin Project Manager April 2003

Authorised for use R. Bingham

Sheet Rev No. 00

ISSUE DATE REVISION DATE COMMENT

Sheet Rev No. 03

Sheet Rev No. 03

Sheet Rev No. 03

IMPORTANCE OF THE MANUAL

The manual shall be regarded as an essential part of the product.

The manual shall be kept for the life of the product.

Sheet Rev No. 03

2. THIS MANUAL MUST BE READ BY PERSONNEL BEFORE

2. ANY MAINTENANCE OPERATION MUST BE CARRIED OUT ONLY

2. BEFORE CARRYING OUT ANY OPERATION OR MAINTENANCE

2. PRIOR TO CARRYING OUT MAINTENANCE WORK INVOLVING

Sheet Rev No. 03

1 Off 15m 3 ISOPump manufactured to BS5500 Category II, stainless steel

Equipment supplied with the ISOPump include conveying air

Suitable for the transfer of material with temperatures up to 50ºC

Sheet Rev No. 03

APPLICATION & DESIGN PARAMETERS

Drill Cuttings Handling System

Number & Type of Conveying Vessel : 15m 3 ISOPump

Pressure : 6<7 barg

Sheet Rev No. 03

FUNCTIONAL DESIGN SPECIFICATION

Sheet Rev No. 03

2. CLEANCUT ISO PUMP

2.2 STORAGE MODE - OPERATIONS

2.3 DISCHARGE MODE - OPERATIONS

Sheet Rev No. 03

This description should be read in conjunction with the following drawings:

P&ID RIG BASED ISO PUMP WITH WEIGH FRAME - P32689D-00

2.2 CLEANCUT ISO PUMP

2.2 STORAGE MODE

Valve Description Status

Cuttings Outlet Valve Closed and sealed

Sheet Rev No. 03

ISO PUMP OPERATING SEQUENCE

SYSTEM WITH ISO PUMP FULL

Valve Description Status

Cuttings Outlet Valve Closed and sealed

Sheet Rev No. 03

2.3 DISCHARGE MODE

Valve Description Status

Cuttings Outlet Valve Closed and sealed

ISO PUMP OPERATING SEQUENCE

Sheet Rev No. 03

SYSTEM STATUS DURING DISCHARGE

Valve Description Status

Cuttings Outlet Valve Open

Sheet Rev No. 03

SYSTEM STATUS ON COMPLETION OF DISCHARGE

Valve Description Status