If the engine is running, the hydraulic starter circuit can be charged by as described in
7.6.1 Charge starter accumulator using engine on page 105.
WARNING
TXT-10004322/AHIGH PRESSURE
(Dis)connecting a pressurized line can cause serious injury and or equipment damage. Never connect or disconnect any quick connectors when the supply line is pressurized.
7
O
peratio
n
This should be done before shutting down the unit, and preferably with 2 persons. One at the winch controls and one to observe START PRESSURE on the control panel of the powerpack: 1. Ensure that the engine is running.
2. Ensure that the isolation valve of the starter accumulator is open. 3. Set the BRAKE to ON.
4. Note the position of the LINE TENSION knob on the cabin control panel (so that you can return it to this position), and then turn it fully clockwise (towards + ).
5. Increase the engine throttle to >1500 RPM.
6. Push the left DRUM CONTROL lever (motor speed control) to the fully forward position and lock it there.
7. Slowly move the right DRUM CONTROL lever (direction control) forward.
8. Ask an assistant to observe the START PRESSURE gauge on the power pack until the start pressure is reached: 120 bar (1740 psi). Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2466 psi).
9. Ask an assistant to close the isolation valve of the starter accumulator. This will store the charge so that the accumulator is fully charged for the next engine start.
10. Return the DRUM CONTROL levers to the neutral position.
11. Return the LINE TENSION knob to the position you noted in step 4. 12. Return the throttle to idle.
WARNING
TXT-10004321/AHIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
WARNING
TXT-10004358/ANOISE HAZARD
The engine noise can exceed 85 dB, causing possible hearing damage.
7
O
peratio
n
7.6.2
Charge starter accumulator using hand pump
1. Ensure that the isolation valve of the starter accumulator is open. 2. Remove the pump handle from the holder and insert it into the pump.
3. Turn the pump isolation lever to the lower position (on some units this is already factory preset).
4. Operate the pump.
5. Observe the START PRESSURE gauge on the power pack until the minimum start pressure is reached: 120 bar (1740 psi). Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2466 psi).
6. Close the isolation valve of the starter accumulator to store the charge in case immediate starting is not desired.
8 M ain tenance
8
MAINTENANCE
TXT-10004206/A18.1
Introduction
Only qualified and trained personnel should perform maintenance on Elmar wireline winch units. The maintenance procedures described here include:
• Scheduled periodic (e.g. cleaning, inspecting and testing components, filling fluid levels and lubricating moving parts)
• Corrective (troubleshooting and repairing any malfunctions, plus calibrating/adjusting) • Exchanging parts (for different operation requirements)
The FlyLine can experience extreme forces and rugged conditions, so certain scheduled maintenance is regularly required to prevent damage to the equipment and potential hazards. Inspections and tests should be carried out daily before working with the FlyLine unit, but regular maintenance must be performed according to the number of hours the FlyLine has been run. Running hours should be logged by the FlyLine operator following a strict discipline to ensure maintenance activities are carried out on time (an example running hours log form is provided in the Appendices to this manual). Elmar recommends basing the service intervals on hours of running; you may prefer to use calendar time (weeks, months).
Refer to the Appendix ‘Tightening Conventions’ for instructions on tightening nuts and bolts when doing preventive or corrective maintenance.
8.2
Certified assemblies
Your FlyLine may include assemblies which are certified separately from the complete unit certification (all certificates are included in the Documentation Package for your unit). These assemblies (examples are winch drive motors and power unit transformers) may only be serviced by Elmar service personnel, otherwise the certification (and possibly the warranty) for the complete unit becomes invalid. A certified assembly is identified by its own data plate with serial number, and is listed as a single top-level part number in the drawings and spare parts lists. If a fault is detected in a certified assembly, do not attempt a repair yourself, but always contact Elmar Service for advice (see Contact Us in the appendices).
8.3
OEM components
Certain components of your FlyLine are complete assemblies or subsystems supplied by Original Equipment Manufacturers (OEM) than Elmar. Examples are measuring heads, air conditioning units, motor-generator sets. The routine servicing schedules and instructions for these
components are usually not included in this User Manual, but supplied separately in the Documentation Package for your unit. Ensure you can find this supplementary documentation, and make yourself familiar with its contents, particularly the required periodic maintenance schedules for these components.
8.4
Depth and tensioning system maintenance schedule
Refer to the MP20 User Manual or the MP16 II User Manual for the maintenance procedures and tables for the CombiGauge and measuring head used in your unit.
8
M
ain
tenance
8.5
FlyLine maintenance schedules
Some maintenance activities comprise both checking and servicing procedures. The service interval mentioned in the maintenance schedules relates in this case only to the checking procedure. The outcome of the checking procedure determines whether the servicing is required.
NOTE: On a new unit, the engine oil should be changed after the first 50 running hours. The hydraulic oil should be changed after the first 100 hours.
8.5.1
Alphabetical list of procedures
Maintenance activity se ct io n numbe r p a ge nu mb er
Service interval (running hours) da il y 300 600 900 1200 15 00/ye arly as required
Prepare for safe maintenance 8.6 112
Finalise maintenance tasks 8.7 113
Change engine oil and filter 8.8 114
Check/adjust brake band tension 8.9 116
Check/adjust chain tension 8.10 123
Check/adjust levelwind chain tension 8.11 126
Check/adjust V-belts 8.12 128
Check brake band wear 8.13 130
Check/fill coolant 8.14 132
Check/fill engine fuel 8.15 135
Check/fill engine oil 8.16 137
Check/fill hydraulic oil 8.17 139
Check/fill reduction gearbox oil 8.18 141
Check/fill wireline oil 8.19 143
Check/fill fuel pump gear drive oil 8.20 145
8
M
ain
tenance
Clean spark arrester 8.29 163
Clean unit 8.30 165
Drain/fill coolant 8.31 166
Drain fuel purifier 8.32 170
Drain fuel purifier 8.32 170
Drain fuel tank 8.33 171
Drain fuel/water separator 8.34 172
Drain water from hydraulic tank 8.35 173
Grease unit 8.36 175
Prime diesel engine 8.37 177
Remove/replace drum chain 8.38 182
Replace levelwind chain 8.39 185
Remove/replace brake band 8.40 187
Replace V-belts 8.41 189
Replace drum 8.42 191
Replace fuel fine filter element 8.43 196
Replace fuse or circuit breaker 8.44 198
Replace hydraulic high-pressure filter 8.45 202
Replace hydraulic oil 8.46 205
Replace hydraulic suction filter 8.47 207
Replace slip ring 8.48 210
Replace fuel/water separator filter 8.49 212
Service compressed air filter 8.50 214
Test maximum engine speed 8.51 216
Test drum mounting 8.52 217
Test hydraulic system pressure 8.53 219
Tighten Essential Bolts 8.54 221
Maintenance activity sec tion nu mb er p a g e numbe
r Service interval (running hours)
da ily 30 0 60 0 90 0 12 00 1 500 /yea rly as re q u ir e d
8.5.2
Maintenance schedules
Daily maintenance section page chk Comment Check/adjust levelwind chain tension 8.11 126
Check/fill coolant 8.14 132
Check/fill engine fuel 8.15 135
Check/fill hydraulic oil 8.17 139
Check/fill wireline oil 8.19 143
Check/replace hydraulic hoses and couplings 8.21 147
Clean unit 8.30 165
Table 8.1 Daily maintenance
300 running hours maintenance interval section page chk Comment
Change engine oil and filter 8.8 114
Check/adjust chain tension 8.10 123
Check/adjust V-belts 8.12 128
Check brake band wear 8.13 130
Check/fill engine oil 8.16 137
Check/fill reduction gearbox oil 8.18 141 Check/replace shock absorber 8.22 149 Clean fuel coarse particle filter 8.25 157 Clean/replace crankcase flame trap 8.27 159
Clean spark arrester 8.29 163
Drain fuel/water separator 8.34 172
Replace fuel fine filter element 8.43 196 Replace hydraulic suction filter 8.47 207 Replace fuel/water separator filter 8.49 212 Test hydraulic system pressure 8.53 219
Tighten Essential Bolts 8.54 221
Table 8.2 Every 300 hours running
600 running hours maintenance interval section page chk Comment
1500 running hours maintenance interval section page chk Comment Clean air inlet safety valve 8.23 150
Clean air inlet safety valve for heavy duty power packs 8.24 154
Test maximum engine speed 8.51 216
8 .6 P repare for sa fe main tenance
8.6
Prepare for safe maintenance
Before carrying out any maintenance on or around the FlyLine unit, ensure that the unit is fully shut down, the winch drum brake is applied, the drum is not under tension, and that there is no residual energy in the hydraulic or pneumatic systems.
Proceed as follows to shutdown the FlyLine for safe maintenance.
1. Complete the wireline service operation, and spool all wire onto the drum.
NOTE: If it is necessary to perform maintenance with the wireline and tools downhole, then it is critical to apply the brake and clamp the wire to a rigid structure to relieve it of tension to the unit.
2. Perform a regular shutdown. See 7.5 Normal shut down on page 104.
3. Push in and tag one of the EMERGENCY STOP buttons. See 7.1.1 Manual emergency stop on page 94.
4. When working on engine or exhaust system components, allow the system time to cool down to hand-touch or cooler.
5. When working on hydraulic components, allow the system time to cool down. Do not open any hydraulic connections unless you are certain that the hydraulic oil is sufficiently cooled off.
6. Relieve all pressure from the hydraulic system:
a) Close the isolation valves for the hydraulic accumulators (e.g. start accumulator) and tag them to prevent accidental opening.
b) Check the control and main hydraulic pressure gauges to verify that the system pressure is zero.
c) Relieve residual hydraulic pressure in the control or main circuits by operating the DRUM CONTROL levers a few times between INHOLE and OUTHOLE, and re-check the gauges. 7. Before opening pneumatic connections for maintenance, release all air pressure from the
pneumatic system:
a) Isolate the rig air supply and close the rig air input valve.
b) Disconnect the supply from the unit’s rig air input, then slowly open the rig air input valve to bleed off the air from the unit.
c) Close the isolation valves for the air receivers.
d) Check all air pressure gauges to verify that the residual pressure is zero.
8.7 F inalise mainten ance ta sks
This procedure should be performed at the end of each maintenance session (a maintenance session consisting of one or more maintenance procedures).
1. Remove all tools and materials from the work area.
2. If the unit is not immediately required for operations, make sure the unit has been correctly shut down. See 7.5 Normal shut down on page 104.
3. Make sure the unit and the work area around the unit is left in a safe state as described in Safety. See 2 Safety on page 7.
4. Dispose of used materials/liquids according to local environmental regulations.
5. Close access doors, panels, and hatches, as required.
6. Record the maintenance task in the running-hours log. See Appendix 8: Running hours log book on page 249.
7. Report any unit damage or discrepancies.
CAUTION
TXT-10004376/AENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste items in a responsible way according to local laws and regulations.
WARNING
TXT-10004270/ACRUSH HAZARD
Closing a door or hatch can crush fingers and cause serious injury.
Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.
8.8 C ha nge engi ne oil a nd filter
8.8
Change engine oil and filter
Refer to the Caterpillar documentation included in the Documentation Package that came with your FlyLine for detailed servicing instructions.
1. Ensure that the unit has been shut down for safe maintenance, as described in 7.5 Normal shut down on page 104.
2. Connect a hose to the drain tube (1).
Figure 8.1 Engine oil filter and drain/ fill points (alternate fill points shown)
2
5
4
3
3
1
8.8 C ha nge eng ine oil a nd filter
8. Place some rags underneath the engine oil filter (5). 9. Carefully unscrew and remove the engine oil filter. 10. Fit the new oil filter.
11. Clean the area around the oil filter, and remove the rags.
12. Refill the oil, and check the oil level. See 8.16 Check/fill engine oil on page 137.
13. Replace the filler cap.
14. Clean any spilled oil from the engine.
15. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.
CAUTION
TXT-10004376/AENVIRONMENTAL HAZARD
Petroleum products and other chemicals are harmful to the environment. Dispose of waste items in a responsible way according to local laws and regulations.
8.9 C he ck/adj ust brake band tens ion
8.9
Check/adjust brake band tension
For correct and safe operation the brake band must be correctly tensioned.This procedure describes how to check and adjust the brake band tension of one drum. If your unit has two drums, you must repeat this procedure for both drums, making sure the correct drum and brake are selected each time.
NOTE: The ‘Brake slip-hold pressures’ necessary for adjusting the drum brakes are available in the unit’s Factory Acceptance Test (FAT).
For the following tests it is critical that the drum drive chain is tensioned correctly. Perform 8.10 Check/adjust chain tension on page 123.
8.9.1
Check brake band tension
The brake should be tested periodically and especially after performing maintenance to the winch and brake subsystems. Perform the three tests described below on each drum in the winch unit.
NOTE: The test refers to the MAIN PRESSURE. This is the system pressure in the main hydraulic circuit, and is indicated by the MAIN PRESSURE pressure gauge on the winch control panel. See Section 5 Unit controls.
Drum brake free-running test
The drum is correctly adjusted when there is no contact between the brake band and the drum when the brake is released.
1. Start the unit for operations. See 7.3 Power up on page 97.
2. Spool in all wireline cable and secure it to the drum.
3. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
4. If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable, disable the automatic winch control program.
WARNING
TXT-10004355/AMOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger, and cordon off the dangerous area.
WARNING
TXT-10004355/AMOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger, and cordon off the dangerous area.
8.9 C he ck/adj ust brake band tens ion
11. Apply the BRAKE.
12. If there was no brake-contact noise from the drum in step 7, then the brake has passed the free-running test. Continue with the drum brake slip test (next section).
13. If brake-contact noise was heard, or there is indication that the MAIN PRESSURE increases during the test, then the brake needs adjustment. See 8.9.2 Adjust Brake band
tension on page 119.
Drum brake slip test
1. Refer to the winch specifications to identify the drum model currently being tested. See
Appendix 2: Unit Specifications on page 237.
2. Refer to the recommended drum brake slip pressures in the FAT for the slip pressure range for this drum. The FAT values are found in your documentation pack under the section
‘Quality Documents / Start Up Script / Brake slip-hold pressures’ (in older documentation
packages - refer to ‘Quality Documents / Hydraulic Fat / Brake System’). 3. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
4. If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable, disable the automatic winch control program.
5. For a multi-speed gearbox, select HIGH speed ratio (never LOW or MEDIUM speed ratio). 6. Apply the BRAKE.
7. On units powered by a diesel engine or truck PTO: use the THROTTLE to set engine speed to idle.
8. Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE until the drum slips in the brake.
9. Check the MAIN PRESSURE gauge and note the brake slip pressure. 10. Put the DRUM CONTROL lever(s) into the neutral (STOP) position.
11. If the MAIN PRESSURE in step 9 was within the range as described in the FAT, then the brake for this drum has passed the slip test. Continue with the drum brake stopping test (next section).
12. If the drum slipped below therange (too slack) or above the range (too tight), then the brake needs adjustment. See 8.9.2 Adjust Brake band tension on page 119.
WARNING
TXT-10004321/AHIGH PRESSURE
If the hydraulic system main pressure exceeds 400 bar (5800 psi), hydraulic components might rupture and cause serious injury or damage equipment.
Never allow the hydraulic system main pressure to exceed 400 bar (5800 psi).
CAUTION
TXT-10004395/AEQUIPMENT DAMAGE
With a multi-speed gearbox, the brake and drum supports can be severely damaged if the brake is tested at LOW or MEDIUM speed ratio.
8.9 C he ck/adj ust brake band tens ion
Drum brake stopping test
The brake must stop quickly the drum in a controlled, smooth manner. i.e. without juddering or causing extreme shock to the winch and other equipment. The effect during actual operations will differ, depending on:
• The tension and condition of the drum drive chain;
• The amount of wire on the drum (a fully loaded drum has more momentum); • The weight of the tool string;
• The effect of well pressure and resistance on the tool string and wire; • The direction of operation (inhole or outhole);
• The speed and torque of the drum (selected gear, engine speed, etc.); • Moisture and oil on the drum rim;
• The degree of wear on the brake band lining.
The test is conducted in one specific situation. It is recommended to always conduct the test in the same situation and under the same conditions.
1. If the unit is equipped with a SmartMonitor, put the unit into manual mode. If applicable, disable the automatic winch control program.
2. Put the DRUM CONTROL lever(s) into the neutral (STOP) position. 3. Release the BRAKE.
4. If applicable, select HIGH speed ratio and medium LINE TENSION.
5. On units powered by a diesel engine or truck PTO: use the THROTTLE to increase engine speed to the maximum torque range.
6. Gradually move the DRUM CONTROL lever(s) INHOLE, increasing the MAIN PRESSURE to about
WARNING
TXT-10004355/AMOVING PARTS
Moving parts (such as drum, gearbox, chain, levelwind mechanism) can cause
serious injury or death. Take care when working with moving parts. Warn others of the danger, and cordon off the dangerous area.
WARNING
TXT-10004751/ADANGEROUS MACHINERY
A loose or misaligned chain can lead to equipment damage or personal injury. Ensure that the drum drive chain is tensioned correctly.
8.9 C he ck/adj ust brake band tens ion
adjustment. See Section 8.9.2 Adjust Brake band tension.
10. Shut down the unit.
8.9.2
Adjust Brake band tension
For correct and safe winch operation the brake band must be correctly tensioned for your drum type as follows:
• The drum breaks free of the applied brake when the winch motor is accelerated to a predefined pressure/torque setting (‘pressure’ for a hydraulic driven winch motor; ‘torque’ for an electric driven winch motor)
• There is no contact between the brake band and the drum when the brake is released The predefined pressure/torque settings for releasing the brake on your drum type is listed in the FAT - refer to your documentation pack under ‘Quality Documents / Start Up Script / Brake slip-
hold pressures’ (in older documentation packs - refer to ‘Quality Documents / Hydraulic Fat / Brake System’).
If required, check with Elmar Service group for a complete list of brake release pressures/torques