1 Cryostat assembly, integration and commissioning procedures M.Olcese Version: 07 May 2008.
Commissioning of Subsea Hydraulic Systems...• Pre-Commissioning - Checks on all components off...
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SUBSEA CONTROL SYSTEMS • Flushing - Hygeinic assembly practices - Flushing at a sufficeint pressure and flow rate to ensure turbulent flow is achieved • Testing - Confirm fluid cleanliness via patch test kit - Remove sensitive equipment prior to flushing - Loop hoses to reduce flushing time - Use non-bypass filters • Fluid Compatability - Component material - Seal material - Operating conditions • Fluid Contamination - Bacteria growth - Gas migration/ contamination (emulsification) - Moisture contamination (humidity/ emulsification) • Fluid Cleanliness Standards - NAS1638 - SAE AS4059 Rev E - ISO (ISO4406-1999) COMPONENT CONSIDERATIONS • Pipework - Cleanliness during manufacture is critical • Hoses - Pig hoses before end fittings are applied - Installation is critical (abrasion/ kinking/ environmental issues) • Accumulators - Store with partial fill - Charge gas slowly • Pumps & Motors - Pre-charge/ bleed to provide adequate lubrication - Ensure motor case is full - Perform rotation checks with no load • Cylinders - Ensure system is fully bled • Regulators - Screw down to near maximum pressure - Prime at a low pressure - Cycle to check repeatability • Pressure Relief Valves - Remove from systems during flushing and testing - Set and certify off-line www.pressuredynamics.com START-UP RISK REDUCTION • Initial build cleanliness • Factory Acceptance Testing (FAT) - Individual component is tested • System Integrity Testing (SIT) - Full stack up testing • Pre-Commissioning - Checks on all components off line • Commissioning Procedures - Detailed procedures and check lists should be developed in consultation wtih the OEM’s for each system and subsystem. - Staged commissioning - Baseline HPU systems • Post Start-up - Ongoing Monitoring Fluid Cleanliness is the key to success Commissioning of Subsea Hydraulic Systems Poor preparation and processes at start-up/ commissioning can result in damage to hydraulic components. This damage can be catastrophic at start-up, or may not become apparent until many years later. Damage can be prevented by:
Transcript of Commissioning of Subsea Hydraulic Systems...• Pre-Commissioning - Checks on all components off...
SUBSEA CONTROL SYSTEMS
• Flushing - Hygeinic assembly practices -Flushingatasufficeintpressureandflowratetoensure turbulentflowisachieved• Testing -Confirmfluidcleanlinessviapatchtestkit -Removesensitiveequipmentpriortoflushing -Loophosestoreduceflushingtime -Usenon-bypassfilters
• FluidCompatability -Componentmaterial - Seal material -Operatingconditions• FluidContamination -Bacteriagrowth -Gasmigration/contamination(emulsification) -Moisturecontamination(humidity/emulsification)• FluidCleanlinessStandards - NAS1638 -SAEAS4059RevE -ISO(ISO4406-1999)
COMPONENT CONSIDERATIONS
• Pipework -Cleanlinessduringmanufactureiscritical• Hoses -Pighosesbeforeendfittingsareapplied -Installationiscritical(abrasion/kinking/environmental issues)• Accumulators -Storewithpartialfill -Chargegasslowly• Pumps&Motors -Pre-charge/bleedtoprovideadequatelubrication -Ensuremotorcaseisfull -Performrotationcheckswithnoload
• Cylinders -Ensuresystemisfullybled• Regulators -Screwdowntonearmaximumpressure -Primeatalowpressure -Cycletocheckrepeatability• PressureReliefValves -Removefromsystemsduringflushingandtesting -Setandcertifyoff-line
www.pressuredynamics.com
START-UP RISK REDUCTION
• Initialbuildcleanliness• FactoryAcceptanceTesting(FAT) -Individualcomponentistested• SystemIntegrityTesting(SIT) -Fullstackuptesting• Pre-Commissioning -Checksonallcomponentsoffline
• CommissioningProcedures -Detailedproceduresandchecklistsshouldbe developedinconsultationwtihtheOEM’sfor eachsystemandsubsystem. -Stagedcommissioning - Baseline HPU systems• PostStart-up -OngoingMonitoring
Fluid Cleanliness is the key to success
Commissioning of Subsea Hydraulic Systems
Poorpreparationandprocessesatstart-up/commissioningcanresultindamagetohydrauliccomponents.Thisdamagecanbecatastrophicatstart-up,ormaynotbecomeapparentuntilmanyyearslater.Damagecanbepreventedby:
