Test Procedure For PTS - Latest Edition

SAS project : P101345 MANUAL
Document : Manual, rev. 1.3

Date : February 2011 Pipe Tensioning System
Status : Released
7 TEST PROCEDURES
7.1 Objective ...................................................................................................................2
7.2 Visual Inspection .....................................................................................................2
7.2.1 Inspection of Tensioners............................................................................................2
7.2.2 Inspection of Winch ...................................................................................................2
7.2.3 Inspection of Measuring Sheave ...............................................................................2
7.2.4 Inspection Bead Stall Supports .................................................................................3
7.2.5 Inspection of Drive Cabinets ......................................................................................3
7.2.6 Inspection of Remote Control Consoles ....................................................................3
7.2.7 Inspection of Brake Resistors ....................................................................................3
7.3 Functional Inspection..............................................................................................4
7.3.1 Before start-up ...........................................................................................................4
7.3.2 Starting up .................................................................................................................4
7.3.3 Tensioners .................................................................................................................4
7.3.4 Winch System ............................................................................................................7
7.3.5 Automatic Operation ..................................................................................................9
7.4 Introduction Functional Test ................................................................................12
7.4.1 General ....................................................................................................................12
7.4.2 Required materials ...................................................................................................12
7.5 Functional Test Tensioner ....................................................................................12
7.5.1 Calibration of the loadpins of the tensioners ...........................................................12
7.5.2 Static testing of the control system of the tensioners ..............................................15
7.5.3 Dynamic testing of the control system of the tensioner ...........................................17
7.6 Functional Test Mearsuring Sheave ....................................................................20
7.6.1 Calibration of the loadpin of the Measuring Sheave. ...............................................20
7.7 Functional Test A&R Winch..................................................................................21
7.7.1 Static testing of the control system of the A&R Winch ............................................21
7.7.2 Dynamic testing of the control system of the A&R Winch .......................................21
7.8 Functional Test Automatic Tension Transfer System .......................................22
7.8.1 Transfer from tensioner to winch (Abandonment) ...................................................22
7.8.2 Transfer from winch to tensioner (Recovery) ..........................................................22
7.9 Acceptance Protocol .............................................................................................24
7.9.1 Report ......................................................................................................................24
7.9.2 Comments and actions ............................................................................................24
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7.1 OBJECTIVE
The following procedures can be used after installation, repair, major maintenance or
overhaul of any part of the Pipe Tensioning System.
In general these steps can be made:
a) Visual inspection of the part involved.

b) Functional test of the part involved or of the entire Pipe Tensioning System.
Note: It is recommended to have a SAS Service Representative present the first time these
test procedures are performed.
7.2 VISUAL INSPECTION

Note: Before starting the visual inspection make sure that the main power to all components
is switched off so it is safe to open electrical cabinets. The 230V auxiliary power may be
connected so that cabinet lights are functioning.
7.2.1 Inspection of Tensioners
Description Checked Remarks

Motor/gearbox combination
Trackbodies
Adjust system
Clamping System
Corner Supports
Local Control Console
Hydraulic Power Unit
7.2.2 Inspection of Winch

Motor/gearbox combination with brakes
Drum
Steel Wire Rope
Spooling Device
Local Control Console
7.2.3 Inspection of Measuring Sheave

Sheave
Sensors
Load cell
Junction box
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7.2.4 Inspection Bead Stall Supports

Lubrication points
Rollers for any debris or damage
Oil level Hydraulic Jack
7.2.5 Inspection of Drive Cabinets

DRC-PT
DRC-WC
DRC-DBx
7.2.6 Inspection of Remote Control Console

Touch Screens
Pushbuttons
Indicators
7.2.7 Inspection of Brake Resistors

Cooling
Junction box
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7.3 FUNCTIONAL INSPECTION

This chapter describes the functional test to be carried out.
7.3.1 Before start-up

Before starting make sure that:
1. Main supply is connected to the DRC’s, LCC’s and RCC.

2. Auxiliary supply is connected to the DRC’s, LCC’s and RCC.
3. Oil levels of HPU’s and gearboxes are correct.
4. All E-stop buttons are released and all alarms accepted and reset.
7.3.2 Starting up

Turn off all cabinets main switches.
Check that the auxiliary supply indication is on.
Turn on the main switch. This will power the DRC’s,
LCC’s and RCC.
Reset all alarms on the RCC.
Check functioning of lamptest on RCC.
7.3.3 Tensioners
• Hydraulic Power Unit

Select local operation.
Start the pump.
Check for smooth running and indication
RUNNING.
Stop the pump.
• Adjust System

Adjust the PS trackbody with the joystick in & out.
Adjust the SB trackbody with the joystick in & out.
Select remote operation.
Browse to the Adjust T1 page on the touchscreen.
Set the maximum pipe OD.
Push the TRACKS ADJUST button. The tracks will
automatically move to the target position.
Note: When moving outwards the clamp cylinders
will also automatically move outwards.
During adjusting push the TRACKS OPEN button
once. The adjusting will stop.
Push and hold TRACKS OPEN to move the
trackbodies open. Release the button to stop
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movement.
Push the TRACKS ADJUST button again. Check
that the target position is reached (within
bandwidth).
Set a smaller pipe OD (close to max.).
Press and hold the port side AUTO ADJUST. Check
that target position is reached (ON POSITION).
Press and hold the starboard AUTO ADJUST.
Check that target position is reached (ON
POSITION).
Adjust the PS trackbody with the joystick outwards
until the limit switch. Check indication light. Adjust
the PS trackbody inwards till indication light is off.
Adjust the SB trackbody with the joystick outwards
the SB trackbody inwards till indication light is off.
Move both trackbodies inwards till indication limits
dim.
Select remote operation from LCC.
Set the minimum pipe OD.
Press TRACKS ADJUST button.
Adjust the PS trackbody with the joystick inwards
the PS trackbody outwards till indication light is off.
Adjust the SB trackbody with the joystick inwards
the SB trackbody outwards till indication light is off.
Move both trackbodies outwards till indication limits
dim.
• Clamping System
Note: Before starting, set the tensioner tracks to a pipe OD of 400 mm. In that position it is
possible to clamp the cylinders to the end of their stroke without a pipe.

Press and hold CLAMPS CLOSE. Indication will
flash until actual pressure is above setpoint
pressure, then it is continuously on.
Press and hold CLAMPS OPEN. Indication will flash
until trackbodies rest on the frame, then it is
continuously on.
Close the clamps again.
Simulate a tension > 5 ton and check that opening
of the clamps is not possible.
Check that opening of the clamps is possible when
the lock function is overruled on the touchscreen (=
password protected).
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Remove simulated tension.
Browse to the clamping page on the touchscreen.
Check that minimum settable clamping setpoint is
80 bar and maximum is 165 bar. Set clamping
setpoint at 100 bar.
Press CLAMPS CLOSE. Indication will flash until
actual pressure is above setpoint pressure +10 bar,
then it is continuously on.
Adjust setpoint to 112 bar. Check that cylinders are
pressurized again to setpoint +10 bar.
Adjust setpoint to 80 bar. Check that indication
DECREASE is on. Now it is possible to decrease
the clamping cylinders to setpoint +10 bar. Check it
by pushing and holding the button.
Check that when clamps are CLOSED, adjusting of
the tracks is not possible.
Press CLAMPS OPEN once. Now the Automatic
Clamping Control is off. Indication CLAMPS CLOSE
off.
Press and hold CLAMPS OPEN. Indication will flash
until trackbodies rest on the frame, then it is
continuously on.
• Drive System

Select TENSIONER operation.
Press DRIVE ON. Check that light starts flashing
and is continuously on after a few seconds when
drives are ready.
Check indications on DRC.
Check that cooling fans of motors are running.
Select local operation. Check indication DRIVE ON
on LCC.
Move the joystick slowly to pay-in. Now the brakes
are released automatically and the tracks starts
running. Check the direction.
Move the joystick to pay-out. Tracks will run in
opposite direction.
are released automatically and the tracks starts
running. Check indications on MAIN page.
Move the joystick to pay-out. Tracks will run in
opposite direction.
Check the maximum speed of the tensioner, 25
m/min (1 rev. = 62 x 228,6 mm = 14,2 m).
Press DRIVE OFF. Check that indication starts
flashing. This is for cooling the motors and drives
and will continue for 10 minutes. After that DRIVE
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OFF is continuously on.
• Drive system Interlocks T0 – T1 – T2

Select TENSIONER operation.
Press DRIVE ON for T0.
Press DRIVE OFF for T1.
Clamp all tensioners.
Check that it is not possible to rotate the tracks.
Check it is not possible to rotate the tracks of T2.
Check that it is possible to rotate the tracks.
Select local operation T0 + T1 + T2.
Open the clamps of T2.
Check that only T2 can rotate independently.
Re- clamp T2.
Open the clamps of T1.
7.3.4 Winch System
• Winch Drive

Select WINCH operation.
Press DRIVE ON. Check that light starts flashing
and is continuously on after a few seconds when
drives are ready.
Check indications on DRC.
Check that cooling fans of motors are running.
Check that it is not possible to select DRIVE ON for
a tensioner.
Select local operation. Check indication DRIVE ON
on LCC.
are released automatically and the winch starts
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running. Check the direction.
Move the joystick to pay-out. Drum will rotate in
opposite direction.
are released automatically and the drum starts
rotating. Check indications on MAIN page.
Check that panelmeters are functioning:
• Motor Current
• Motor RPM
Check the maximum speed of the winch, 25 m/min
@ outer layer, pay-out. (1 rev. = 1416 x PI = 4,5 m)
(1210 RPM)
Press DRIVE OFF. Check that indication starts
flashing. This is for cooling the motors and drives
and will continue for 10 minutes. After that DRIVE
OFF is continuously on.
• Spooler System (Level Winder)

Press DRIVE ON for the winch.
Select Level Winder MANUAL operation.
Check movement of spooling device with joystick.
Check functioning of both limit switches and
indications.
Note: Spooling device should stop when moving
towards the triggered switch.
Select Level Winder AUTOMATIC operation.
Check that spooling device moves when rotating
the drum.
Press CHANGE LAYER and check that spooling
device moves to the opposite direction.
Browse to the LEVEL WINDER page on the touch
screen and check functionality.
Check the distance of spooling device movement by
rotating the drum 5 revolutions. Distance should be
320 mm (= 5 x cable diameter (set at 64 mm)).
Check functioning of both limit switches, spooling
device should switch to manual mode on either
switch.
• Measuring Sheave

Press DRIVE ON for the winch.
Rotate the measuring sheave and check that
panelmeters are functioning:
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• Line Speed (gauge and recorder).
Reset the paid-out length counter on the
touchscreen.
Turn the sheave one full revolution.
Check that the display shows 3,7m (= 1,184 x PI).
7.3.5 Automatic Operation
• Tensioner Automatic Torque Mode

Select TENSIONER operation and REMOTE
operation for all tensioners.
Press T0 ON DRIVE.
Adjust the tensioner to a pipe OD of 400 mm.
Press CLAMPS CLOSE. When closed the ON
SERVICE light is on.
Press AUTOMATIC for the tensioners.
Note: T1 and T2 must be CLAMPS OPEN or also
On Service.
Make sure that the torque setpoint (with dial) is 0.
Press AUTOMATIC TORQUE on the touchscreen.
Slowly increase the torque setpoint. Tensioner
should accelerate in pay in direction. Decrease
torque setpoint again. Tensioner should stop.
Check that it is not possible to:
• Select local operation
• Open the clamps
• Select off drive
• Set other tensioner on drive.
Switch back to MANUAL mode.
• Tensioner Automatic Tension Mode

Press T0 ON DRIVE.
Adjust the tensioner to a pipe OD of 400 mm.
Note: T1 and T2 must be CLAMPS OPEN or also
On Service.
Simulate a tension with a loop calibrator.
Slowly increase the tension setpoint. Tensioner
should increase speed in pay in direction. Decrease
tension setpoint lower than actual tension.
Tensioner should stop and start paying out.
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• Open the clamps
• Select off drive
• Set other tensioner on drive.
Check functioning of:
• Gain
• Feed forward
• Deadband.
• Add / Remove Tensioner

Press T2 ON DRIVE.
Adjust the tensioner to a pipe OD of 400mm.
Note: T0 and T1 must be CLAMPS OPEN.
Make sure that the tension setpoint (with dial) is the
same as simulated tension. Press AUTOMATIC
TENSION on the touchscreen.
Press ADD TENSIONER T1 on touch screen.
Check that tensioner is clamped to the pipe and ON
DRIVE.
Press REMOVE TENSIONER T2. Check that
tensioner is opened and tracks pipe OD position is
bigger than 400mm.
DRIVE.
bigger than 400mm.
DRIVE.
bigger than 400mm.
• Winch Automatic Torque Mode

Select WINCH operation and REMOTE operation
for winch.
Press W ON DRIVE.
Check that the ON SERVICE light is on.
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Press AUTOMATIC for the winch.
Make sure that the torque setpoint (with dial) is 0.
Press AUTOMATIC TORQUE on the touchscreen.
Slowly increase the torque setpoint. Winch should
accelerate in pay in direction. Decrease torque
setpoint again. Winch should stop.
• Select off drive.
• Winch Automatic Tension Mode

Select WINCH operation and REMOTE operation
for winch.
Press W ON DRIVE.
Check that the ON SERVICE light is on.
Press AUTOMATIC for the winch.
Make sure that the tension setpoint (with dial) is the
same as simulated tension. Press AUTOMATIC
TENSION on the touchscreen.
Slowly increase the tension setpoint. Winch should
increase speed pay in direction. Decrease tension
setpoint lower than actual tension. Winch should
stop and start paying out.
• Select off drive.
Check functioning of:
• Gain
• Feed forward
• Deadband.
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7.4 INTRODUCTION FUNCTIONAL TEST
7.4.1 General
This test consists of three (3) parts:
1. The calibration test, i.e. testing (and correcting when required) of the tension read-out as
generated by the loadpin to a calibrated reference.
2. The static pulling test, i.e. testing the functioning of the control system with the SWR or
pipe fixed to the dead man anchor on the barge.
3. The dynamic pulling test, i.e. testing the functioning of the control system. For this the
SWR will be pulled by an external force, such as anchor winch or crane, to verify that the
Tensioner or Winch follows the movement in an effort to maintain the set tension.
7.4.2 Required materials

1. A recently calibrated and certified dynamometer with a capacity up to 70t.
2. Various shackles and steel wire ropes (slings) for connecting the SWR or pipe according
to the schematic sketch of the test rigging given below.
3. An external device which can be used to pull on the pipe or SWR, like an anchor winch,
crane or similar, able to reach 200t S.W.L.
4. A pad eye (“dead-man-anchor”) for connecting the pipe or SWR and dynamometer to a
fixed point on the barge.
Note: The rigging should be such, that the sling from the stern pulling head on the SWR is
directly connected to the dynamometer without passing over any support roller.
7.5 FUNCTIONAL TEST TENSIONER
7.5.1 Calibration of the loadpins of the tensioners

Connect the calibrated loadcell (dynamometer) to the pulling eye on the one side and to the
dead man anchor on the other side.
Note: Make sure that the connection in between the dynamometer and the pipe is not
obstructed by pipe support rollers, or other material or equipment. All movements are to be
done in Constant Torque mode or Manual mode.
1. Select load pin system “A” and start pulling, paying in with the tensioner until all slack is
taken out of the rigging, followed by paying out for approx. 0.5 meter This paying out is
done to make sure that no external tension is applied to the dynamometer. The
dynamometer should be reading “zero” tension and so should the tension read-out of the
tensioner.
2. If required adjust the “TARE” of the load pin amplifier to ensure the proper zero reading.
3. Pay-in with the tensioner to take up all the slack.
4. Slowly increase the tension on the pipe up to the maximum, by paying in.
5. The reference load cell (calibrated dynamometer) should indicate a value which is close
to, or over the nominal pulling capacity (Tensioner 67t).
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6. When required adjust the “SPAN” of the load pin amplifier to correct the tension read-out
of the tensioner.
7. Lower the tension by paying out the pipe, until again ‘zero’ tension is indicated.
Repeat the above procedure and once the reading is correct, the actual calibrating test may
begin.
Repeat the above described increasing and decreasing for a second recording.
• Tensioner 0
Tensioner 0 CALIBRATION LOADPIN 1 SYSTEM “A”

Dynamometer Tension reading (ton) Dynamometer Torque setting (%)
20t 20t
40t 40t
50t 50t
60t 60t
67t 67t
60t 60t
50t 50t
40t 40t
20t 20t
Tensioner 0 load pin measuring system “A” has now been calibrated and tested.
Repeat above mentioned action points but now select measuring system “B”.
Tensioner 0 CALIBRATION LOADPIN 1 SYSTEM “B”

20t 20t
40t 40t
50t 50t
60t 60t
67t 67t
60t 60t
50t 50t
40t 40t
20t 20t
Tensioner 0 load pin measuring system “B” has now been calibrated and tested.
• Tensioner 1

20t 20t
40t 40t
50t 50t
60t 60t
67t 67t
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60t 60t
50t 50t
40t 40t
20t 20t

20t 20t
40t 40t
50t 50t
60t 60t
67t 67t
60t 60t
50t 50t
40t 40t
20t 20t
• Tensioner 2

20t 20t
40t 40t
50t 50t
60t 60t
67t 67t
60t 60t
50t 50t
40t 40t
20t 20t

20t 20t
40t 40t
50t 50t
60t 60t
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67t 67t
60t 60t
50t 50t
40t 40t
20t 20t
7.5.2 Static testing of the control system of the tensioners
Note: For operating procedures refer to the operating manual.
Testing the control system of one, two of three tensioners in Automatic Tension mode. In
Manual mode, check the proper functioning of the tensioners by paying in and paying out.
Attach the pipe to the dead man anchor at the stern side.
Following combinations of testing are possible:
- Testing of one tensioner (T0, T1 or T2)

- Testing of two tensioners (T0+T1, T0+T2 or T1+T2)
- Testing of three tensioners (T0+T1+T2)
• Automatic Tension Control one tensioner
Note: The illustration is used as reference in which T0 is being tested. The same can be
done with T1 and T2.
1. Adjust the tension setpoint with the dial to 20 ton.

2. Pay in, in Manual mode, until a tension of 20 ton is reached and then switch over to the
Automatic Tension mode. The tensioner must keep the tension at the set 20 ton.
3. Change the setpoint and verify that the tensioner follows this change.
4. If necessary adjust the tensioner controller parameters.
5. Record the setting of the control parameters.
Setpoint Filter Deadband Deadband Gain Dynamic Offset

(ton) Off / Normal / High High (%) Low (%) (%) (%)
20t
40t
50t
60t
67t
60t
50t
40t
20t
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Test this up to the maximum tension of approximately 67t. Decrease the tension to the
minimum, switch over to Manual and slacken off the pipe.
• Automatic Tension Control two tensioners
Note: The illustration is used as reference in which T0 + T2 are being tested. The same can
be done with T0 + T1 or T1 + T2.

Automatic Tension mode. The tensioners must keep the tension at the set 40 ton.
3. Change the setpoint and verify that the tensioners follows this change.
4. If necessary adjust the tensioners controller parameters.

40t
80t
100t
120t
134t
120t
100t
80t
40t
Test this up to the maximum tension of approximately 134t. Decrease the tension to the
• Automatic Tension Control three tensioners

3. Change the setpoint and verify that the tensioners follow this change.
4. If necessary adjust the tensioners controller parameters.
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60t
100t
140t
180t
200t
180t
140t
100t
60t
Test this up to the maximum tension of approximately 200 ton. Decrease the tension to the
7.5.3 Dynamic testing of the control system of the tensioner
In Manual mode, check the proper functioning of the tensioners by paying in and paying out.
Attach the pipe to the external device, which must be able to apply a dynamic pulling force of
3 x 67t +10 tons towards the stern. (This rigging is almost identical to the calibration rigging,
but this time without the dynamometer, and the dead man anchor is replaced by the SWR
from an anchor winch or crane).
Following combinations of testing are possible:
- Testing of one tensioner (T0, T1 or T2)

- Testing of two tensioners (T0+T1, T0+T2 or T1+T2)
- Testing of three tensioners (T0+T1+T2)
• Automatic Tension Control one tensioner
Note: The illustration is used as reference in which T0 is being tested. The same can be
done with T1 and T2.
1. Adjust the setpoint with the dial to 20 ton.

Automatic Tension mode. The tensioner must keep the tension at the set 20 ton.
3. Raise the tension by pulling the pipe toward the stern with the external device. The
tensioner should pay out the pipe and maintain a constant tension within reasonable
limits (taking into consideration that the total test rigging is very ‘stiff’, with only the very
limited flexibility of the short rigging).
4. If necessary adjust the tensioner controller parameters. Start values are:
a. Deadband low = 0 (Off)
b. Deadband high = 0 (Off)
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c. Gain = 0,5
d. Filter = Off
e. Dynamic Offset = 50%

(ton) Off/Normal/High High (%) Low (%) (%) (%)
20t
40t
50t
60t
67t
60t
50t
40t
20t
6. Slack off on the external device and the tensioner must react by paying in and
maintaining a constant tension.
7. Change the setpoint and verify that the tensioner follows the change.
8. Test this up to the maximum tension of approximately 67t.
9. Decrease the tension to the minimum, switch over to manual and slacken off the pipe.
• Automatic Tension Control two tensioners
Note: The illustration is used as reference in which T0 + T2 are being tested. The same can
be done with T0 + T1 or T1 + T2.

tensioners should pay out the pipe and maintain a constant tension within reasonable
c. Gain = 0,5
d. Filter = Off
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40t
80t
100t
120t
134t
120t
100t
80t
40t
6. Slack off on the external device and the tensioners must react by paying in and
7. Change the setpoint and verify that the tensioners follow the change.
8. Test this up to the maximum tension of approximately 2 x 67t.
• Automatic Tension Control three tensioners

tensioners should pay out the pipe and maintain a constant tension within reasonable
f. Deadband low = 0 (Off)
g. Deadband high = 0 (Off)
h. Gain = 0,5
i. Filter = Off
j. Dynamic Offset = 50%

60t
100t
140t
180t
200t
180t
140t
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100t
60t
6. Slack off on the external device and the tensioners must react by paying in and
7. Change the setpoint and verify that the tensioners follow the change.
8. Test this up to the maximum tension of approximately 3 x 67t.
7.6 FUNCTIONAL TEST MEARSURING SHEAVE
7.6.1 Calibration of the loadpin of the Measuring Sheave.
Note: Before starting the calibration ensure that the SWR is correctly spooled on the winch
with sufficient back tension.
- Bring the pipe or SWR in position with the pulling eye at the stern side.
- Connect the calibrated loadcell (dynamometer) to the pulling eye on the one side
and to the dead man anchor on the other side.
Note:
a) Make sure that the connection in between the dynamometer and the SWR is not
obstructed by pipe support rollers, or other material or equipment.
b) All movements are to be done in Automatic Torque mode or Manual mode!
1. Start pulling, paying in with the A&R Winch until all slack is taken out of the rigging,
followed by paying out for approx. 0.5 meter. This paying out is done to make sure that
no external tension is applied to the dynamometer. The dynamometer should be reading
“zero” tension and so should the tension read-out of the winch.
2. If required adjust the “TARE” of the load pin amplifier to ensure the proper zero reading.
3. Pay-in with the A&R Winch to take up all the slack.
4. Slowly increase the tension on the SWR up to the maximum, by paying in.
5. The reference load cell (calibrated dynamometer) should indicate a value which is close
to, or over the nominal pulling capacity of 200t. When required adjust the “SPAN” of the
load pin amplifier to correct the tension read-out of the winch.
6. Lower the tension by paying out the SWR or pipe, until again ‘zero’ tension is indicated.
Repeat the above procedure and once the reading is correct, the actual calibrating test may
begin. Repeat the above described increasing and decreasing for a second recording.
Measuring sheave CALIBRATION LOADPIN SYSTEM

60t 60t
100t 100t
140t 140t
180t 180t
200t 200t
180t 180t
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Measuring sheave CALIBRATION LOADPIN SYSTEM

140t 140t
100t 100t
60t 60t
Measuring sheave load pin system has now been calibrated and tested.
7.7 FUNCTIONAL TEST A&R WINCH
7.7.1 Static testing of the control system of the A&R Winch
Testing the control system of the A&R Winch in Automatic Tension mode. In Manual mode,
check the proper functioning of the A&R Winch by paying in and paying out. Attach the SWR
to the dead man anchor at the stern side.
• Automatic Tension control

Automatic Tension mode. The A&R Winch must keep the tension at the set 40 ton.
3. Change the setpoint and verify that the A&R Winch follows.
4. If necessary adjust the A&R Winch controller parameters. Start values are:
c. Gain = 0,5
d. Filter = Off
6. Decrease the tension to the minimum, switch over to Manual and slacken off the SWR.
7.7.2 Dynamic testing of the control system of the A&R Winch
Check, in Manual mode, the proper functioning of the A&R Winch by paying in and paying
out. Attach the SWR to the external device, which must be able to apply a dynamic pulling
force of 200t towards the stern (This rigging is almost identical to the calibration rigging; But
this time without the dynamometer, and the dead man anchor is replaced by the SWR from
an anchor winch or crane).
• Automatic Tension control

Automatic Tension mode. The A&R Winch must keep the tension at the set 40 ton.
3. Raise the tension by pulling the SWR toward the stern with the external device.
The A&R WINCH should pay out the cable and maintain a constant tension within
reasonable limits. (taking into consideration that the total test rigging is very ‘stiff’, with
only the very limited flexibility of the short rigging).
4. If necessary adjust the A&R Winch controller parameters. Start values are:
© SAS 2011 21 / 24
TEST PROCEDURES
Status : Released

c. Gain = 0,5
d. Filter = Off
5. Slack off on the external device and the A&R Winch must react by paying in and
6. Change the setpoint and verify that the A&R Winch follows this change.
8. Decrease the tension to the minimum, switch over to Manual mode and slacken off the
SWR.
7.8 FUNCTIONAL TEST AUTOMATIC TENSION TRANSFER SYSTEM

This system takes care of the automatic transfer of the tension from the tensioner to the
winch or from the winch to the tensioner. During this transfer certain steps will be followed.
7.8.1 Transfer from tensioner to winch (Abandonment)

The tensioner must be in Automatic Tension mode.
The next steps have to be made:
1. Hook up the SWR to the pulling head of the pipe.

2. Pay in a little with the winch until most of the slack is out of the SWR but the tensioner is
still free to compensate for movement of the barge.
3. Start the transfer procedure by pressing the button START transfer.
The automatic transfer is followed by the next steps:
1. Winch will switch to Automatic Tension mode and automatically take the remaining slack
of the cable.
2. The tension will be distributed equally over the tensioner and winch.
3. Tensioner will go off drive after all tension is transferred to the winch.
4. Clamps open.
5. Tracks open and the tensioner switches to Manual mode.
During transfer the status can be monitored at the transfer control screen.
7.8.2 Transfer from winch to tensioner (Recovery)

The winch must be in Automatic Tension mode.
1. Start the transfer procedure by pressing the button START transfer.
The automatic transfer is followed by the next steps:
1. Tensioner will switch to Automatic Tension mode.

2. Trackbodies close followed by the clamps.
3. Tensioner drives on.
4. The tension will be transferred from the winch to the tensioner.
5. Winch pays out to slack the cable.
6. Winch switches to Manual mode.
© SAS 2011 22 / 24
TEST PROCEDURES
Status : Released
During the transfer the status can be monitored at the transfer control screen.
The next steps have to be made:
1. Pay out a little with the winch until there is enough slack to hook off the SWR and the
tensioner is free to compensate for movement of the barge.
2. Hook off the SWR from the pulling head of the pipe.
© SAS 2011 23 / 24
TEST PROCEDURES
Status : Released
7.9 ACCEPTANCE PROTOCOL

If the test procedure is used as a SAT, this chapter can be used as indication.
7.9.1 Report
The Pipe Tensioning System was tested on board on …………………. (dd/mm/yyy) and is
declared fit for operation.
The present parties agree that the test has been preformed to satisfaction and any
comments or outstanding points that were noted during the inspection are listed in the
comments and actions list.
INSPECTION PERFORMED BY INSPECTION WITNESSED BY
7.9.2 Comments and actions
NO. COMMENT ACTION
© SAS 2011 24 / 24
TEST PROCEDURES

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SAS project : P101345 MANUAL

Document : Manual, rev. 1.3

In general these steps can be made:

a) Visual inspection of the part involved.

7.2 VISUAL INSPECTION

7.2.1 Inspection of Tensioners

Description Checked Remarks

7.2.2 Inspection of Winch

Description Checked Remarks

7.2.3 Inspection of Measuring Sheave

Description Checked Remarks

7.2.4 Inspection Bead Stall Supports

Description Checked Remarks

7.2.5 Inspection of Drive Cabinets

Description Checked Remarks

7.2.6 Inspection of Remote Control Console

Description Checked Remarks

7.2.7 Inspection of Brake Resistors

Description Checked Remarks

7.3 FUNCTIONAL INSPECTION

7.3.1 Before start-up

1. Main supply is connected to the DRC’s, LCC’s and RCC.

Description Checked Remarks

• Hydraulic Power Unit

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

• Drive system Interlocks T0 – T1 – T2

Description Checked Remarks

7.3.4 Winch System

Description Checked Remarks

Description Checked Remarks

• Spooler System (Level Winder)

Description Checked Remarks

Description Checked Remarks

Description Checked Remarks

7.3.5 Automatic Operation

• Tensioner Automatic Torque Mode

Description Checked Remarks

• Tensioner Automatic Tension Mode

Description Checked Remarks

Description Checked Remarks

• Add / Remove Tensioner

Description Checked Remarks

• Winch Automatic Torque Mode

Description Checked Remarks

Description Checked Remarks

• Winch Automatic Tension Mode

Description Checked Remarks

7.4 INTRODUCTION FUNCTIONAL TEST

7.4.2 Required materials

7.5 FUNCTIONAL TEST TENSIONER

7.5.1 Calibration of the loadpins of the tensioners

Tensioner 0 CALIBRATION LOADPIN 1 SYSTEM “A”

Tensioner 0 CALIBRATION LOADPIN 1 SYSTEM “B”

Tensioner 1 CALIBRATION LOADPIN 1 SYSTEM “A”

Tensioner 1 CALIBRATION LOADPIN 1 SYSTEM “A”

Tensioner 1 CALIBRATION LOADPIN 1 SYSTEM “B”

Tensioner 2 CALIBRATION LOADPIN 1 SYSTEM “A”