6931055734 - man - airpack

AirPack CDRAFT - FOR INFORMATION ONLYUser ManualNOV Elmar - NL, Energieweg 26, 2964 LE Groot-ATel: +31 184 608 700, Fax: +31 184 608 790, www.K-Winch AirPack C, MAN-1055734, 26 July 2013

ORmmers, The Netherlandsnov.com Page 1 of 150

Revision A

IGINAL INSTRUCTIONS

AirPack C User Manual

Page 2 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions

This manual applies to the following parts:

L-6931055734 - AirPack C Base Assy Zone 2

All standard options available for this base assembly

WARNING TXT-10004286/ADANGEROUS MACHINERYIgnoring the instructions in this manual can result in serious injury or death.All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

Version Date Amendments

A 26 July 2013 This is the first version of this manual

REVISION HISTORY

Published by:NOV ElmarEnergieweg 262964 LE Groot-AmmersThe Netherlands

2013 No part of this document may be reproduced by any means without the written consent of the publisher.Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV Elmar for loss, damage or injury caused by any errors or omissions in this document.

AirPack C User ManualTABLE OF CONTENTS

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Unit rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.3 Unit right view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.4 Unit right view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.5 Unit right view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.6 Unit front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.7 Unit left view (spring starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.8 Unit left view (hydraulic starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.9 Unit left view (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204.3 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.4 Compressor (Pneumatic) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264.5 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.6 Unit grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5 SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.2 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.4 Rig-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.1 Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.2 Power up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.3 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436.5 Charge hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.4 Periodic maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.5 Check/adjust V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497.6 Check/fill compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517.7 Check/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537.8 Check/fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567.9 Check/fill engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597.10 Check/fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617.11 Check/fill fuel pump gear drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647.12 Check/replace hoses and couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667.13 Check shock absorbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687.14 Clean engine air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 3 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A

Original Instructions

AirPack C User Manual7.15 Clean auxiliary pneumatic system filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747.16 Clean fuel coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777.17 Clean air dryer filter (air starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787.18 Clean main compressor air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807.19 Clean spark arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827.20 Clean/replace compressor intake air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847.21 Clean/replace crankcase breather flame trap . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.22 Clean/replace engine air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887.23 Clean/replace fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907.24 Drain/fill engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917.25 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 967.26 Drain fuel/water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 987.27 Drain water from hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007.28 Prime diesel engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027.29 Replace air-oil separator filter (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067.30 Change compressor oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087.31 Change engine oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1117.32 Replace fuel fine filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1137.33 Replace fuel/water separator filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1157.34 Replace hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1177.35 Replace V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1197.36 Test maximum engine speed (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1258.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1258.2 Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Appendix 1: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Appendix 2: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Appendix 3: Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Appendix 4: Unit hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Appendix 5: ASEP Elmar tightening conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Appendix 6: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Appendix 7: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Appendix 8: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

CUSTOMER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Page 4 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions

AirPack C User Manual1 INTRODUCTIONTXT-10004540/A

This user manual for the AirPack C well servicing product is intended for operating, maintenance and supervisory personnel. It contains the following sections:

Safety (important safety aspects)

Description (of components and their function)

Unit Control description

Setup and Removal (including installation and storage)

Operation (startup, run, shutdown)

Maintenance (schedules and procedures)

Troubleshooting

Appendices (reference material)

This manual (supplied in digital and printed formats) is part of the AirPack C documentation set and must be read before initial equipment installation and operation.

The validity of the manual can be compromised by post-delivery engineering modifications or regulatory changes that affect equipment use, ratings and limits. All NOV Elmar engineering changes are documented in as-built drawings, even after product delivery. This means the latest drawings always take precedence over manuals. If in doubt, contact NOV Elmar.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 5 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



2.1

Gen

eral

Saf

ety2 SAFETYTXT-10004141/A1

2.1 General SafetyHigh voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be present in ASEP Elmar equipment. Therefore, pay special attention to safety when working with this equipment.

Meet all applicable codes, laws and local field regulations (including environmental and additional owner/user company policy). This manual contains recommendations, but should not be assumed to satisfy all requirements of legal regulations.

Read and understand each item in this manual and follow all procedures, precautions and advice exactly - never take short cuts. Always consider your safety and that of others.

Only use the equipment within its design scope to avoid damage or dangerous situations.

This manual (in its most current revision) is a minimum requirement for all persons working with ASEP Elmar equipment. All other current and applicable documents such as certification, drawings, bill of materials, vendor documentation, etc, should be readily available at the worksite.

2.1.1 Employee responsibility Never leave "operation-ready" equipment unattended.

Keep equipment clean (accumulated dirt and dust can hamper unit operations and may increase the risk of ignition).

Correctly maintain and use equipment, apparatus, tools, and dangerous substances.

Wear personal protection equipment (PPE) where necessary; for example gloves and protective footwear.

Never work alone if there is a possibility of an accident.

Keep loose clothing and long hair well away from moving mechanical parts.

Remove rings, wristwatch, etc, before working.

Never disconnect, change or remove safety devices, and use such devices correctly.

Be aware of all emergency equipment and procedures (such as alarms, abandon ship, etc.) and make sure they are in place and valid.

Do not use the equipment after an emergency without verifying that the cause of the emergency has been removed or rectified.

Immediately inform the employer and other workers of any situation that represents a serious danger to safety and health, and of any shortcomings in protection arrangements.

Plan all operations including interdependencies with other equipment operations

If equipment is tied down using rope/line/chains, attach a "flag" to signal their location.

During installation, maintenance and/or equipment inspection:

where possible, make sure electrical/mechanical equipment is switched off completely, and use a decal or similar to prevent unauthorized starting;

always relieve pressure before working on hydraulic and/or pneumatic systems.Page 6 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


2.1G

eneral Safety2.1.2 Employer responsibility Define the required competency of personnel working on the equipment (including

supervision) and provide the required consultation, information and training.

Ensure that only trained, qualified and competent personnel can work on the equipment.

Ensure adequate safety equipment and emergency procedures are available (fire extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them.

Ensure a suitable program for installation, operation, maintenance, periodic inspection and testing of the equipment is defined, adhered to and recorded.

Do not allow work to proceed until a thorough examination and risk assessment of the work site and equipment has been done. The examination should assess (as a minimum) the condition of the work site and all critical components, plus the equipment structure. Only give approval to proceed when controls to manage potential causes are in place and measures are taken to mitigate potential consequences.

2.1.3 Warnings, cautions and requirementsEquipment handling may involve residual risks which cannot be reasonably reduced by design alterations. To alert the user to potential hazards and recommend safe working practices, additional information is provided as warnings, cautions and/or requirements:

WARNING shows a relevant icon and the text WARNING with a description of the hazard and the best practise to avoid it. Ignoring a warning can result in equipment damage, plus serious injury and/or death.

CAUTION shows a relevant icon and the text CAUTION with a description of the hazard and the best practise to avoid it. Ignoring a caution can result in damage to equipment.

REQUIREMENT shows an icon and a description of the required PPE to minimise possible safety risks.

Warnings, cautions and/or requirements are listed in the manual as a preceding step to a potentially dangerous action. Never proceed to following step(s) if you do not comply with or fully understand a Warning/Caution/Requirement. See the following examples:

NOTE: A warning, caution or requirement icon (occasionally with accompanying text) is often also affixed to the equipment at a prominent location.

WARNING TXT-10004296/AELECTRIC SHOCKConnecting/disconnecting an energised (live) electrical cable can cause serious injury and or equipment damage. Always ensure that an electrical cable is electrically de-energized (dead) before connecting/disconnecting it.

CAUTION TXT-10004378/AEQUIPMENT DAMAGEComponents can be damaged during cleaning.Take care when cleaning components; use appropriate cleaning tools.

Hearing protectionWear ear protection during this procedure.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 7 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



2.2

Equi

pmen

t spe

cific

saf

ety2.2 Equipment specific safety2.2.1 Emergency Stop buttons

TXT-10004568/A

Emergency stop buttons are conveniently positioned on equipment and are easily recognized because of their bright red colour. See examples in Figure 2.1.

Press the button in an emergency situation to instantly cut primary energy supply (electric, hydraulic or pneumatic) to moving parts. This will disable further equipment movement and reduce danger to the operator. Always notify a supervisor after pressing an EMERGENCY STOP.

2.2.2 Heavy equipmentTXT-10004562/A

Never attempt to move heavy equipment without the aid of a sufficiently dimensioned and certified mechanical device.

Only hoist joined equipment after ensuring that the joined equipment has been certified for single lifting by checking the certification in the Documentation Package that came with your equipment.

Make sure you cannot get trapped between a lifted load and a wall, fixed object, etc.

Never walk under a hanging load or allow heavy objects to rest in an unstable position.

2.2.3 ATEX and zoningTXT-10004560/A

Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the equipment is certified according to ATEX regulations, the following applies:

The power supply, including driven parts, has been manufactured and assessed according to ATEX and tagged with a unique identification number.

Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1, or Zone 2 compliance will be compromised.

Certified explosion safe equipment is suitable for use in gas hazardous classified locations, however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC). Check your unit data plate(s) and the specifications tables in the Appendix for the ATEX classification for your equipment.

The design and manufacturing is based on European Directive no. 94/9/EC following conformity assessment procedure relating to internal control of production according

Figure 2.1 Examples of Emergency Stop buttonsPage 8 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


2.2Equipm

ent specific safetyAnnex VIII of the Directive. The construction is documented in a confidential Technical Construction File held at the offices of ASEP Elmar.

2.2.4 Doors and hatchesTXT-10004565/A

While opening/closing hatches and doors, take account of wind conditions or sudden movement. Hatches and doors may forcibly swing open/shut causing damage or injury.

When open, the hinge side of doors and hatches can create extremely hazardous pinch points for fingers, clothing, hoses and cables. Always check the hinge side before closing any door or hatch.

Always use any built-in retainers to anchor the door or hatch if you need to leave it open or closed while you work.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 9 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



3.1

Uni

t ove

rvie

w3 PHYSICAL DESCRIPTION3.1 Unit overview

The following figure shows the naming conventions of the physical views used in the remainder of this section.

Figure 3.1 Unit overview

1 3.2 Unit rear view on page 11

2 3.3 Unit right view (spring starter) on page 12

3 3.4 Unit right view (hydraulic starter) on page 13

4 3.5 Unit right view (air starter) on page 14

5 3.6 Unit front view on page 15

6 3.7 Unit left view (spring starter) on page 16

7 3.8 Unit left view (hydraulic starter) on page 17

8 3.9 Unit left view (air starter) on page 18

8

3

5

1

76

4

2Page 10 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


3.2U

nit rear view3.2 Unit rear view

Figure 3.2 Unit rear view

1 Exhaust silencer/ spark arrestor

2 Exhaust gas soot collector point

3 Compressor air intake filter

4 Compressor

5 Engine shock absorber

6 Air receiver auxiliary air circuit

7 Air-oil separator element

8 Hydraulic start manifold (optional)

4

5

72

6

1

8

3NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 11 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



3.3

Uni

t rig

ht v

iew

(spr

ing

star

ter)3.3 Unit right view (spring starter)

Figure 3.3 Unit right view

2

1

3

4 5

6

1 Engine air inlet valve

2 Exhaust gas cooler

3 Engine oil dipstick

4 Compressor oil filter

5 Compressed air filter

6 Auto drain valvePage 12 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


3.4U

nit right view (hydraulic starter)3.4 Unit right view (hydraulic starter)


2

1

3

10

7

8

13

9

11

15

4 5

6

12

1416

17

1 Engine air inlet valve 12 hydraulic charge hand pump

2 Exhaust gas cooler 13 hydraulic tank drain valve

3 Engine oil dipstick 14 hydraulic tank suction isolation valve w/ coarse particle filter

4 Compressor oil filter (obstructed by inlet hose) 15 Air driven charge pump for hydraulic start circuit. (mounted inside air inlet channel)

5 Compressed air filter 16 Activation valve for air driven charge pump

6 Auto drain valve (obstructed by inlet hose) 17 Rig air in connector

7 Hydraulic tank filler cap

8 hydraulic hand pump handle

9 Hydraulic tank sight glass (max level)

10 Hydraulic tank

11 Hydraulic tank sight glass (min level)NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 13 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



3.5

Uni

t rig

ht v

iew

(air

star

ter)3.5 Unit right view (air starter)


2

1

3

87

4 5

6

1 Engine air inlet valve

2 Exhaust gas cooler

3 Engine oil dipstick

4 Compressor oil filter (obstructed by inlet hose)

5 Compressed air filter

6 auto drain valve (obstructed by inlet hose)

7 Rig air in connector

8 Air filter for starter circuitPage 14 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


3.6U

nit front view3.6 Unit front view

Figure 3.6 Unit front view (sound-proofed grills removed)

1 Cooler stack - consisting of: engine coolant radiator; compressed air cooler; compressor oil cooler

2 Air driven charge pump for hydraulic start circuit.

1




3.7

Uni

t lef

t vie

w (s

prin

g st

arte

r)3.7 Unit left view (spring starter)

Figure 3.7 Unit left view (spring starter)

10

12

3

5

18

21

21

11

17161513

14 20

879

4

6

19

1 Engine air intake filter 12 Air output

2 Unit control panel 13 Fuel tank access cover

3 Fuel fine filter 14 Engine oil filter

4 Air inlet valve control handle 15 Fuel tank breather

5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve/

6 Fuel pump gear drive 17 Fuel filler cap

7 Fuel pump 18 Fuel level gauge

8 Fuel prefilter/water separator 19 Auxiliary pneumatic system filter (behind panel)

9 Sentinel master valve (ENGINE SAFETY) 20 Spring starter

10 Compressor (main air system) 21 Spring starter hand crank

11 Air outputPage 16 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


3.8U

nit left view (hydraulic starter)3.8 Unit left view (hydraulic starter)

Figure 3.8 Unit left view (hydraulic starter)

10

12

5

1822

21

11

17161513

14

20

879

4

21

3

66

19




4 Air inlet valve control 15 Fuel tank breather

5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve




9 Sentinel master valve (ENGINE SAFETY) 20 Hydraulic starter

10 Compressor (main air system) 21 Hydraulic accumulator

11 Air output 22 Hydraulic accumulator isolation valveNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 17 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



3.9

Uni

t lef

t vie

w (a

ir st

arte

r)3.9 Unit left view (air starter)

Figure 3.9 Unit left view (air starter)

10

12

5

18

21

11

17161513

14

20

879

43

6

19




4 Air inlet valve control 15 Fuel tank breather

5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve




9 Sentinel master valve (ENGINE SAFETY) 20 Air starter

10 Compressor (main air system)

11 Air outputPage 18 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


4.1Introduction4 FUNCTIONAL DESCRIPTION4.1 Introduction

The AirPack C produces compressed air for sites requiring large amounts of pneumatic energy. The main energy source is a 54 kW Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. It drives a Rotorcomp EVO9-NK-G compressor that can provide up to 5 m/min (177 cfm) of air or a nominal pressure of 10 bar (145 psi). The engine is equipped with either spring, pneumatic or hydraulic starter. The engine and exhaust gas are water-cooled and the coolant, along with the compressors oil and supply air, are air-cooled over forced-air heat exchangers (radiators).

The unit is CE certified for Zone 2 ATEX operation.

See Appendix 1: Specifications on page 131 for specifications.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 19 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



4.2

Ope

rato

r con

trol

s4.2 Operator controls

1

11

9

7

6 5

432

10

12

13



4.2O

perator controls1 ENGINE TEMPERATURE This gauge (0 C to +120 C (+32 F to +230 F)) shows the engine coolant temperature.

2 EXHAUST TEMPERATURE This gauge (0 C to +250 C (+450 F)) shows the engine exhaust temperature.

3 ENGINE OIL PRESSURE This gauge shows the oil pressure in the engine and the engine safety system.

4 COMPRESSOR TEMPERATURE

This gauge (0 C to +120 C (+32 F to +230 F)) shows the temperature of the main compressor.

5 AIR PRESSURE This gauge shows the air pressure in the main compressed air system.

6 START PRESSURE This gauge shows the current starting pressure available for the start system (on air starter and hydraulic starter equipped engines).

7 EMERGENCY STOP Press this knob to shut down the unit in an emergency. To reset it turn the knob clockwise until it springs back out.

DO NOT restart the unit without checking that the cause for the emergency stop has been resolved.

DO NOT use the emergency stop as a control to stop the unit during normal operations.

8 TACHOMETER This gauge shows the engine speed in RPM and the engine running hours.

9 ENGINE STOP Push this button to stop the engine; it releases automatically

10 ENGINE SAFETY The engine safety sentinel valve cuts off fuel flow when the engine oil pressure drops below a certain value.Turning lever against the spring-pressure overrides the valve for starting.

11 AIR INLET VALVE Use this handle to control the engine safety air intake control valve.Push the handle up to bypass the engine oil pressure safety system to allow the engine to be started. Hold the handle in the upper position until the motor oil pressure has risen to approx. 2 bar.Pull the handle down for emergency stop. This will close the air intake valve and stop the engine. For restarting wait 2 minutes for the shutdown-derived vacuum to disappear.

12 ENGINE START Activator to start the engine. For a pneumatic start system it is a push button, for a hydraulic start system it is a twist knob. (Not present on spring starter units). Refer to 6.2 Power up on page 35 for detailed use.

13 CONTROL PRESSURE This gauge shows the air pressure in the auxiliary pneumatic systemNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 21 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



4.3

Engi

ne4.3 EngineThe AirPack C units main power source is a Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. The engine drives a compressor directly (see Figure 4.1) for supplying compressed air. The engine and the exhaust system are water cooled. The OEM documentation for the engine is included in the Documentation Package.

4.3.1 Engine safety systemThe engine safety system serves as:

An automatic shut-off system in case of an over-speed situation caused by ingress of hydrocarbon gases.

An automatic shut-off device in case of low engine oil pressure (+100 C (>+212 F) and high exhaust temperature >+200 C (>392 F)

A manually controlled shut-off device in case of an emergency stop

The engine safety system consists of two main sub-systems which monitor the engine oil pressure:

1. Fuel:

The sentinel master valve (fuel shut-off valve) is positioned between the fine particle filter and the fuel injection pump. See Figure 4.2.The sentinel master valve monitors the oil

Figure 4.1 Engine/compressor assemblyPage 22 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


4.3Enginepressure in the diesel engine. If the lubrication oil pressure drops under the factory setting of 0.5 bar (7.5 psi), the valve will block the supply of fuel and shut down the diesel engine. The oil pressure is also distributed to the air intake valve.

2. Air intake:

An air intake filter assembly with disposable elements cleans the input air for the diesel engine.

An air inlet safety valve is positioned in the air intake system, and is used to shutdown the diesel engine manually or automatically, by cutting off the air intake supply. It is factory pre-set to trip at desired pressure values and RPM settings. See Figure 4.3 below

A lever on the control console is used to open and close this safety valve. See 4.2 Operator controls on page 20. Pushing this lever up before starting the engine will mechanically open the

WARNING TXT-10004285/A DANGEROUS MACHINERYChanging factory settings can affect the safety of the system, and result in personal and/or equipment damage.Take extreme care when adjusting factory settings. If in doubt, contact ASEP Elmar

Figure 4.2 Engine fuel system safety valve

WARNING TXT-10004285/A DANGEROUS MACHINERYChanging factory settings can affect the safety of the system, and result in personal and/or equipment damage.Take extreme care when adjusting factory settings. If in doubt, contact ASEP ElmarNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 23 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



4.3

Engi

nevalve, which is normally closed (spring loaded). Once the engine has started, the engine oil pressure will overcome the spring pressure and hold the valve open.

4.3.2 Engine startersThe engine has options for either a spring starter, a pneumatic starter, or a hydraulic starter. See Figure 4.4 below for starter examples.

a) Spring starter: is activated with a lever on the starter. Activating the lever releases spring tension which turns the starter, which in turn rotates the engine.

b) Air starter: is activated from a button on the control panel. Activating the button opens a pneumatic valve, and rig air turns the starter, which in turn rotates the engine.

c) Hydraulic starter: is activated from a button on the control panel. Activating the button opens a hydraulic valve, and hydraulic accumulator pressure turns the starter, which in turn rotates the engine.

See 6.2 Power up on page 35 for more details on how to start the engine.

Figure 4.3 Air intake safety valve (roof removed for clarity)Page 24 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


4.3Engine4.3.3 Fuel systemThe fuel is stored in a fuel tank equipped with a breather. The fuel passes from the fuel tank through to the following components:

a) Isolation valve (this valve can be closed for maintenance purposes)

b) Coarse particle filter (strains large particles from the diesel)

c) Fuel/water separator filter (removes water contamination from the diesel)

d) Fuel gear pump

e) Fuel primer pump (runs parallel with d above)

f) Fuel fine particle filter (removes fine particles from the diesel)

g) The sentinel master valve (fuel shut-off valve)

h) Injector pump (pressurizes the fuel to the injectors)

For an overview of the fuel system see the as built FLUID DIAGRAM- ENGINE FUEL & OIL page in the Documentation Package.

See Figure 4.5 below. A fuel/water separator (1) separates any water contamination from the diesel fuel. The fuel fine particle filter (2) removes particles larger than 10 m. The frequency of

Figure 4.4 Starter options: clockwise from top left:, HD spring starter, air starter, hydraulic starterNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 25 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



4.4

Com

pres

sor (

Pneu

mat

ic) s

yste

mwater draining or filter element replacement depends on the quality of the fuel. The primer pump (3) is used during the bleeding of the fuel system.

4.3.4 Exhaust systemThe exhaust gases are led from the engine through an exhaust gas cooler, flame trap and silencer (muffler) to the exhaust pipe which exits from the side of the unit. These components remove excess heat, soot and sparks from the exhaust which could otherwise ignite an explosive atmosphere near the exhaust outlet.

The exhaust gas cooler cools the exhaust by circulating engine coolant through its heat exchanger.

4.4 Compressor (Pneumatic) systemCompressed air is provided by a directly driven compressor. Ambient air is drawn into the main compressor through an air intake filter. It is then compressed to 10 bar (145 psi) in compression chamber where cooling/ lubricating oil is injected for supply. The supply air from the compressor passes through a separating tank and an air /oil separator filter to remove excess oil. The air is finally cooled by an air-cooled heat exchanger and further dried by passing through a cyclone air dryer (see Figure 4.6).

A part of the compressed air is used to activate a pneumatic cylinder which regulates the engine speed, dependent on air consumption requirements.

Two air outputs are available for site consumption use. See belowFigure 4.7.

On air starter equipped units, rig air from the site provides air through a separate system for powering the starter system.

The auxiliary pneumatic system is used to activate the ENGINE SAFETY system and EMERGENCY STOP circuit. It is powered by a separate 225cc compressor and is equipped with its own air cleaning and regulating components.

On hydraulic starter equipped units, an air-operated oil pump can charge the hydraulic accumulator. This air-operated oil pump can be driven by rig air or by the auxiliary pneumatic system.

Figure 4.5 Fuel/water separator and primer pump

1

2



4.4C

ompressor (Pneum

atic) systemNOTE: The ENGINE SAFETY and EMERGENCY STOP circuits must be powered by pneumatic pressure or else the engine will not remain running.

.

Figure 4.6 Air-oil separator filters and cyclone air dryer

Figure 4.7 Compressed air outputsNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 27 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



4.5

Coo

ling

syst

emThe compressors lube oil is filtered by a disposable filter element and air-cooled through a separate oil cooler. See Appendix 1: Specifications on page 131 for the compressor specifications.

For an overview of the pneumatic system, see the as built FLUID DIAGRAM- HYDRAULICS & PNEUMATICS Diagram in the Documentation Package that comes with the unit. For the main compressor details see the supplier documentation also included in the Documentation Package.

4.5 Cooling systemThe AirPack C unit is equipped with a belt-driven cooling fan. The fan draws ambient air through the radiator stack, which has three separate heat exchangers for the following circuits:

Coolant (engine and exhaust gas cooling)

Compressor oil

Compressed air

Maintenance tasks include check/replenish the coolant level, drain/refill and bleed the (coolant) cooling system, check compressor oil level, change filters and to check the system for leaks. These are covered in 7.4 Periodic maintenance schedules on page 47.

4.6 Unit groundingThe AirPack C unit is equipped with grounding points on the right and left sides.

These shall be utilized to ground the unit to the rig or the well-head to prevent static electrical discharge. See Figure 4.8.

Figure 4.8 Unit grounding pointPage 28 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


5.1M

oving/positioning equipment5 SETUP AND REMOVAL

5.1 Moving/positioning equipment

The unit may be moved and positioned by hoisting, or with a properly dimensioned forklift. See certification in the Documentation Package that came with this AirPack C unit.

Make sure that the lifting equipment to be used is sufficiently dimensioned, has the correct certification, and is marked accordingly. The lifting equipment may only be used by suitably qualified personnel. All equipment lifting equipment must be subject to regular scheduled inspection compliant with EN 12079 for deformation and wear. All lifting equipment repairs must have been carried out compliant with EN 12079.

Always use the lifting eyes on the four corners for hoisting. Never use the two eye bolt sockets on the top plate to lift the entire unit. These are for lifting the detached top plate only.

5.1.1 Land transportationWhen loading and transporting ASEP Elmar modules on a truck, several things need to be taken into consideration (most of these are also specified in the local traffic regulations):

Number of axles on the transport vehicle (to decide where to position one or more units)

Weight of unit(s) (total weight)

Height of the load (bridges, aqueducts, tunnels)

Width of the load (manoeuvring)

Travelling speed

Cornering (dead corner)

Securing modules and securing loose components

Check all these before loading and transportation:

Make sure lifting equipment is sufficiently dimensioned.


WARNING TXT-10004271/ACRUSH HAZARDHeavy objects can trap limbs and cause serious injury or death.Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

WARNING TXT-10004327/AHOISTING HAZARDHoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death.Never use the forklift pockets for hoisting.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 29 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



5.1

Mov

ing/

posi

tioni

ng e

quip

men

t All equipment used for lifting must have the correct certification and be marked accordingly.

Only qualified personnel are allowed to use lifting equipment.

Before each lift, always ensure that the lifting shackles have been correctly attached to the unit.

5.1.2 Air transportationStandard procedure for air freighting a unit depends on local travel organizations. See Appendix 7: Air transportation on page 144

In general the following should be drained:

Fuel tank

Engine oil

Engine coolant

Gearboxes

Air tank

Compressor oil sump

Other liquids within components will normally remain in the unit:

Fluid/oil coolers

Filters

Hoses

5.1.3 DrainingIf the carrier requires that all fluids are drained from the reservoirs, systems and components of the machine(s), please refer to 7.4 Periodic maintenance schedules on page 47 for specific instructions on how to drain the fluid from each reservoir, system or component.

NOTE: Tag the unit or components to warn against starting before refilling.

Photocopy or print the checklist in Appendix 7: Air transportation on page 144 as an aid to ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as follows:

1. Check off each item as it is drained, adding your initials.

2. Strike-out the items that are NOT present on the machine.

3. Add any items that are present on the machine, but not on this list.

4. Place this checklist in a prominent place on the machine.

5.1.4 RefillingReplenish the fluid in each of the items listed in the checklist. ASEP Elmar recommend that new fluid/oil filters are used when refilling systems that include filters. If you have fitted new filters, please add your initials in the last column.

Refer to the APPENDICES on page 130 for the quantity and specifications of the required fluids.

Refer to 7 Maintenance on page 47 for the procedures to check and replenish fluids for each of the reservoirs, systems and components. Where applicable, remember to bleed the system of air and refill as required.Page 30 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


5.2Site preparation5.2 Site preparationBefore positioning the unit at the site, survey the location where it will be used. There should be sufficient room on all sides for opening doors/hatches.

5.3 Rig-up5.3.1 Positioning and grounding

1. Move the unit to the operating position.

2. Secure the unit in place according to site regulations.

3. Connect ground cables to the grounding points on the unit according to site regulations. Refer to 4.6 Unit grounding on page 28.

5.3.2 Testing

1. Start up and test the unit as described in 6 Operation on page 34.

2. Shut down the unit by performing 6.3 Normal shut down on page 42.

5.4 Rig-down

To connect/disconnect a compressed air coupling:

a) Shut off the nearest valve on the supply side of the coupling.

WARNING TXT-10004327/AHOISTING HAZARDHoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death.Never use the forklift pockets for hoisting.

WARNING TXT-10004271/ACRUSH HAZARDHeavy objects can trap limbs and cause serious injury or death.Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

WARNING TXT-10004301/AEXPLOSION HAZARDElectrostatic discharge can cause an explosion.Always ensure that the unit has been correctly grounded before performing any work on the unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.

WARNING TXT-10004358/ANOISE HAZARDThe engine noise can exceed 85 dB, causing possible hearing damage.Always wear suitable hearing protection when working around the running engine.

WARNING TXT-10004255/ACOMPRESSED AIRAir and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 31 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



5.5

Stor

ageb) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side.

c) Then with eyes protected or at a safe distance from the coupling, carefully connect/disconnect the coupling.

1. Ensure that the unit has been shut down according to 6.3 Normal shut down on page 42.

2. Disconnect the pneumatic hoses in the AirPack one by one.

3. With a clean cloth, thoroughly clean the dust caps for the connectors.

4. Fit the dust caps.

5. Check that all cables and hoses are correctly stowed.

5.4.1 Finalize

1. Make sure all access panels are correctly closed and secured.

2. Disconnect the ground cables from the grounding points.

5.5 Storage5.5.1 Short term storage (< 1 year)

When storing the system for a short term, always take the following actions:

1. Complete the rig-down steps as described in 5.4 Rig-down on page 31.

2. If the machine is going to be stored in temperatures under -18 C (0 F):

a) Refer to 7.4 Periodic maintenance schedules on page 47 for the procedures to remove water from:

Fuel tank, filters & lines

Engine cooling system & reservoir

Pneumatic anti-frost system

b) Completely fill the following fluid reservoirs (if present) with appropriate fluid for expected low temperatures:

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.

CAUTION TXT-10004382/AEQUIPMENT DAMAGEDirty or damaged quick connectors can leak and cause equipment damage.Before connecting a quick connector, inspect and clean both ends.

WARNING TXT-10004270/ACRUSH HAZARDClosing 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.Page 32 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


5.5Storage Fuel tank, filters & lines (fill the diesel tank completely with winter diesel if available)

Engine cooling system & reservoir

Pneumatic anti-frost system

c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures. Refill with fluid again to full, if necessary.

3. Close all panels and hatches on the unit and secure or lock them.

4. Cover the unit with a suitable protection cover (these can be ordered from ASEP Elmar if required).

5.5.2 Long term storage (> 1 year)When storing the system for long periods, follow the steps in 5.5.1 Short term storage (< 1 year) on page 32, and take the following additional actions:

1. Grease exposed metal surfaces to prevent corrosion.

2. Grease all rubber seals to prevent damage and cracking.

3. Fill the diesel tank to prevent condensation.

4. Drain the coolant tank as described in 7.24 Drain/fill engine coolant on page 91.

5. See 7 Air transportation on page 144, and the checklist in the appendix, for information on other possible drain points, and how to register your actions.

6. Refer to your company policy for other possible storage requirements.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 33 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



6.1

Pre-

star

t che

cklis

t6 OPERATION6.1 Pre-start checklist

1. Ensure that you have read and understood section 2 Safety on page 6.

2. Check environment for sufficient ventilation for dispersion of the exhaust gases.

3. Ensure that the unit has been rigged up as described in 5.3 Rig-up on page 31.

4. Perform all of the daily maintenance procedures listed in 7.4 Periodic maintenance schedules on page 47.

5. Ensure that the engine is not running and cannot be started.

6. Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or components, and structural damage.

7. Check all tanks and hoses for leaks, and for other visible damage.

8. Ensure that the cooling air intake and exhaust openings are not obstructed.

9. Ensure that all components requiring lubrication are serviced as necessary.

10. Check that no unauthorized modifications have been made to the unit.


WARNING TXT-10004360/ASHARP OBJECTSharp or rough objects can cause severe cuts.Always wear gloves when handling sharp or rough objects.Page 34 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


6.2Pow

er up6.2 Power upThe engine speed is self-regulating, dependent on the required air output. The speed will be increased when the compressor system senses no pressure build-up. In order to have the engine run at lower speeds until it reaches operating temperature, it is essential to close all air output valves.

If starting the AirPack C for the first time, read this entire section thoroughly, and be certain you understand every part before starting the unit, especially sections:

6.3 Normal shut down on page 42

6.4 Emergency stop on page 43

1. Ensure that 6.1 Pre-start checklist above has been done before proceeding.

2. Refer to the figures on the following pages. Check that the EMERGENCY STOP button (6) is not activated (i.e. it is pulled out or reset). If it is activated:

Check that it has not been pushed in to prevent starting the unit, because someone is performing maintenance on it. (Lock out/tag out)

Rectify the problem that caused the emergency before continuing.



b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side.


WARNING TXT-10004282/ADANGEROUS MACHINERYOnce the unit is started, all systems are energized and components can move when the controls are operated. Do not start the AirPack C unless:

You are authorized to operate the equipment and have read this manual. The unit is properly positioned and anchored for operation. All essential maintenance has been carried out. There are no unauthorized persons within the danger zone.

WARNING TXT-10004358/ANOISE HAZARDThe engine noise can exceed 85 dB, causing possible hearing damage.Always wear suitable hearing protection when working around the running engine.

WARNING TXT-10004255/ACOMPRESSED AIRAir and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 35 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



6.2

Pow

er u

p3. If connected, remove at least one hose to the valve air output isolation valves (1) is open the valve. See Figure 6.1.

4. Alternatively, remove at least one of the blind caps (2) from the output and open the valve.

This is necessary to ensure that the compressor offers minimal resistance when starting the engine.

5. Close the isolation valves of any remaining connected air outputs.

6. Continue below for starter type indicated.

6.2.1 For spring starter equipped engines NOTE: Starting with a spring starter may require two persons. One to activate the starter at

the engine, and one to hold open the AIR INLET VALVE.

CAUTIONEQUIPMENT DAMAGEWinding the spring starter with an air-hammer or any other type of power tool can seriously damage it. Only use the supplied hand crank to wind the spring starter.

Figure 6.1 Air output valves

2



6.2Pow

er up1. Locate the spring starter on left side of the engine; see Figure 6.3.

2. Depress and release the reset button (3).

3. Remove the hand crank from its storage location and fit it to the winding shaft (4).

4. Using the handle, wind the starter clockwise to the required power output. The maximum number of turns is 39. For most applications 33-36 turns of the handle should prove sufficient.

Figure 6.2 Start and stop controls

1

2

6

4

3

5

Figure 6.3 Spring Starter NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 37 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



6.2

Pow

er u

pNOTE: Over-winding will reduce the life of the starter.

NOTE: It is possible to unwind the starter, should it become necessary, by turning the handle counter-clockwise; additional force will be required to overcome the initial friction.

5. Remove the handle from the starter, and return it to the storage/transit location.

NOTE: The starter should never be tripped with the winding handle in place.

6. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (1) clockwise against the spring pressure; see Figure 6.2.

NOTE: This will override the diesel safety system, until the engine oil pressure holds the valve open.

7. Push the AIR INLET VALVE lever (2) on the control panel all the way up, and hold it in that position.

8. On the starter, pull the trip lever (5) through 90 degrees in the direction shown by the arrow in Figure 6.3, to start the engine.

9. When the ENGINE OIL PRESSURE gauge (6) shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position.

If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

10. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up.

NOTE: This is necessary to keep the engine from revving too high before it is warmed up.

11. After the engine has run for about one minute check the engine oil pressure again. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot according to section 8 Troubleshooting on page 125.

12. If required, open the isolation valves on the required air outputs.

6.2.2 For air starter equipped engines

WARNING TXT-10004269/AHIGH PRESSUREAir under high pressure may be ejected at great force causing bodily harm and damage to equipment. When releasing air under pressure:

Prevent access by unauthorized persons. Wear appropriate personal protective equipment (PPE), especially protective glasses.

CAUTION TXT-10004515/AEQUIPMENT DAMAGELeaving the pneumatic system under pressure, when the unit is not running can damage it.Always close the rig-air input isolation valve and shut off the rig-air supply point, when the unit is shut down for longer than a few minutes.Page 38 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


6.2Pow

er upSupply air to the unit as follows:

a) Locate the rig air supply input connection on the right side of the unit, and ensure valve (6) is initially closed, as shown in Figure 6.4.

NOTE: Rig air is used ONLY for starting the engine. It should never be hooked up to the AirPack C for any other purpose!

b) Connect a suitable air supply (7 bar (100 psi) at 25 l/min) to the rig-air connection.

c) Open the rig-air supply at the supply point.

d) Slowly open the rig-air intake valve (6) on the unit.

1. Go to the control panel. See Figure 6.5.

2. Ensure that the START PRESSURE gauge (1) shows between 7 bar and 10 bar.

Figure 6.5 AirPack C starting and stopping controls

Figure 6.4 Rig air input

rig air connection

6

2

3

5

1




6.2

Pow

er u

pNOTE: A minimum of 7 bar is required to start the engine.

3. Close all access panels and doors around the AirPack C, except for the control panel access hatch.

4. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure.



6. Press and hold the ENGINE START button (4) until the engine starts, then release.

7. When the ENGINE OIL PRESSURE gauge (5) shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position.

If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

NOTE: Close the air output you opened to start the unit, and reconnect any hoses you may have disconnected in step 3 of section 6.2 Power up above.


8. After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125


10. Close the rig-air intake valve.

11. Close the shore/rig-air supply at the supply point.

12. Disconnect the shore/rig-air connection.

6.2.3 For hydraulic starter equipped engines1. Ensure that the isolation valve for the starter accumulator is open.

2. Check the START PRESSURE gauge (1) on the power pack control panel to see if the starter accumulator has sufficient pressure to start the unit.

WARNING TXT-10004270/ACRUSH HAZARDClosing 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.


Prevent access by unauthorized persons. Wear appropriate personal protective equipment (PPE), especially protective glasses.Page 40 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


6.2Pow

er upNOTE: The hydraulic starter needs 120 bar start pressure for one start attempt.

3. If there is not enough hydraulic pressure to start the unit, charge the accumulator as described in 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45.

4. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure; see Figure 6.6.



6. Turn and hold the ENGINE START knob (4) clockwise until the engine starts, then release.

7. When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR INLET VALVE from its upper position.

If the engine fails to start, perform steps 1 to7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

Figure 6.6 AirPack C starting and stopping controls

2

3

5

1




6.3

Nor

mal

shu

t dow

n8. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up above.


9. After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125

10. Once the engine is running, the hydraulic starter circuit maybe charged again to save it for the next start. For a detailed explanation, see 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45


6.3 Normal shut downThe engine speed is self-regulating, dependent on the required air output. Allow the engine to run at near idle speed before shutdown by closing the air output valves.

1. Close all isolation valves on the air outputs.

2. Pull the ENGINE STOP lever (4) to stop the engine, See Figure 6.5

3. Check the tachometer to ensure the engine speed drops to zero RPM.



b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side.


4. Disconnect one of the hoses, if all three air outputs are connected.

5. Carefully and slowly open a disconnected air output a few millimetres to bleed off the compressed air left in the unit.

6. After the gauge shows zero air pressure, close the valve.

7. Note the shut-down date and time in the running hours log (see Appendix 6: Running hours log book on page 140).


Prevent access by unauthorized persons. Wear appropriate personal protective equipment (PPE), especially protective glasses.

WARNING TXT-10004255/ACOMPRESSED AIRAir and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.Page 42 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


6.4Em

ergency stop8. Carry out the following daily shut-down tasks, and fix any problems as necessary:

a) Inspect all hoses, couplings, and components for signs of air leaks/ oil leaks, wear and damage.

b) Check the levels of all fluid reservoirs, replenishing as necessary:

Engine fuel level

Engine oil level

Engine coolant level

Compressor oil level

Pneumatic line lubricator

Hydraulic starter system reservoir

c) Check that the pneumatic system automatic water drain is working correctly.

9. If shutting down for safe maintenance, activate the EMERGENCY STOP button, and tag it with a maintenance warning.

6.4 Emergency stopThe AirPack C has two modes of emergency stop:

Manual, which is initiated by a person pushing the EMERGENCY STOP button

System (automatic), which is caused by a system condition

6.4.1 Manual emergency stopThe unit has an EMERGENCY STOP button. In an emergency, push this button to immediately stop the engine. This releases the air and oil pressure from the engine safety system, and chokes the diesel air inlet and sentinel fuel valves.

After resolving the emergency situation, perform a pre-start inspection (6.1 Pre-start checklist), and then restart the unit (6.2 Power up).

6.4.2 System (automatic) emergency stopFor some engine alarms, the system will automatically shut the engine down. This shutdown procedure is triggered by one or combination of the following:

Low oil pressure:


6.5

Cha

rge

hydr

aulic

sta

rter

acc

umul

ator6.5.1 Charge starter accumulator using hand pump

1. Locate the hydraulic start system reservoir (3) and hand pump (5) on the inside of the left door.

2. Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic oil on page 61.

3. Locate the hydraulic accumulator (1) on the inside of the right door.

4. Ensure that the accumulator isolation valve (2) and reservoir isolation valve (7) are open.

5. Ensure the hand pump activation knob (6) is fully closed (pointing down).

NOTE: This knob should ALWAYS be in the closed (fully clockwise) position, otherwise the charging system will not work properly.

6. Remove the pump handle (4) from the holder and insert it into the pumps handle socket.

7. Operate the pump and observe the START PRESSURE gauge on the power pack control panel until the minimum start pressure is reached: 120 bar (1740 psi).

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465 psi).

8. Remove the pump handle, and store it in the holder.

9. Close the isolation valve of the starter accumulator to store the charge in case immediate starting is not required.

Figure 6.7 Hydraulic starter accumulator and reservoir w/ hand pump.

2

1 3

5

4

6



6.5C

harge hydraulic starter accumulator6.5.2 Charge starter accumulator using the air-operated oil pumpThe air-operated oil pump can be used when the engine is running or when rig air is connected. To charge the accumulator using the hand pump refer to 6.5.1 Charge starter accumulator using hand pump.

1. Locate the hydraulic start system reservoir (3) on the inside of the left door.

2. Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic oil on page 61.

3. When charging the starter accumulator with the engine:

a) Start up the unit according to section 6.2 Power up on page 35.

b) Continue to step 5.

4. When charging the starter accumulator with rig air:

a) Connect an air supply with a pressure between 7 bar (100 psi) and 10 bar (145 psi) to the rig air in connector.

b) Open the rig air in isolation valve on the AirPack C.

5. Locate the hydraulic accumulator (1) on the inside of the right door.

6. Ensure that the accumulator isolation valve (2) and the reservoir isolation valve (4) are open.

Figure 6.8 Hydraulic starter accumulator, reservoir and air-operated oil pump.

2

1

3

46




6.5

Cha

rge

hydr

aulic

sta

rter

acc

umul

ator7. Ensure the hand pump activation knob (5) is fully closed (fully clockwise, pointing down).

8. Open the input air isolation valve (76) to activate the air-operated oil pump.

9. Operate the pump and observe the START PRESSURE gauge on the control panel until the minimum start pressure is reached: 120 bar (1740 psi).

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465 psi).

10. Close the input air isolation valve to deactivate the pump and keep it from starting unexpectedly.

11. Close the isolation valve on the starter accumulator to store the charge.Page 46 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision A K-Winch AirPack C, MAN-1055734, 26 July 2013 Original Instructions


7.1Introduction7 MAINTENANCETXT-10004206/A

7.1 IntroductionOnly qualified and trained personnel should perform maintenance on ASEP 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 AirPack C 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 AirPack C unit, but regular maintenance must be performed according to the number of hours the AirPack C has been run. Running hours should be logged by the AirPack C 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). ASEP Elmar recommends basing the service intervals on hours of running; you may prefer to use calendar time (weeks, months).

7.2 Certified assembliesYour AirPack C 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 ASEP 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 ASEP Elmar Service for advice (see Contact Us in the appendices).

7.3 OEM componentsCertain components of your AirPack C are complete assemblies or subsystems supplied by Original Equipment Manufacturers (OEM) than ASEP 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.

7.4 Periodic maintenance schedulesUse the tables on the following pages to plan routine maintenance for your unit. NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 47 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



PageReviOrig

7.4

Perio

dic

mai

nten

ance

sch

edul

esMaintenance activity

man

ual

sect

ion

Service interval (hours)

as re

quire

d

daily

300

600

900

1200

1500

/yea

rly

Check/adjust V-belts 7.5 Check/fill compressor oil (1) 7.6 Check/fill engine coolant (1) 7.7 Check/fill engine oil (1) 7.8 Check/fill engine fuel 7.9 Check/fill hydraulic oil 7.10 Check/fill fuel pump gear drive oil 7.11 Check/replace hoses and couplings 7.12 Check shock absorbers (1) 7.13 Clean engine air inlet valve 7.14 Clean auxiliary pneumatic system filter 7.15 Clean fuel coarse particle filter 7.16 Clean/replace compressor intake air filter 7.20 Clean main compressor air dryer 7.18 Clean/replace crankcase breather flame trap 7.21 Clean/replace engine air filter 7.22 Clean/replace fuel tank breather 7.23 Clean spark arrestor 7.19 Drain/fill engine coolant 7.24 Drain fuel tank 7.25 Drain fuel/water separator 7.26 Drain water from hydraulic tank 7.27 Prime diesel engine 7.28 Replace air-oil separator filter (compressor) 7.29 Change compressor oil and filter 7.30 Change engine oil and filter(2) 7.31 Replace fuel fine filter element 7.32 Replace fuel/water separator filter 7.33 Replace hydraulic oil 7.34 Replace V-belts 7.35 Test maximum engine speed (if applicable) 7.36 (1) After each transport (2) After first 50 running hours

Table 7.1 48 of 150 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlandssion A K-Winch AirPack C, MAN-1055734, 26 July 2013 inal Instructions


7.5C

heck/adjust V-belts7.5 Check/adjust V-beltsThis procedure describes how to inspect the V belts of the Caterpillar diesel engine.

Related topics:


7.35 Replace V-belts on page 119

Ensure that the unit has been shut down for safe maintenance, as described in 6.3 Normal shut down on page 42.

1. Refer to fig Figure 7.1 below. Remove the right side belt guards, upper (1) and lower (2).

2. Check the belts for damage or excessive wear.

3. Replace belts where necessary. See 7.35 Replace V-belts on page 119.

WARNING TXT-10004348/AMOVING PARTSMoving parts (cooling fan, pulleys, V-belts) can cause serious injury or death.Ensure that the engine cannot be started during maintenance.

Figure 7.1 V-belt protective guards and v-belt adjustment assembly

1

24

3




7.5

Che

ck/a

djus

t V-b

eltsNOTE: Double V-belts (V-belts installed in pairs) should always be replaced in pairs, to avoid premature wear and slippage.

4. Refer to Figure 7.1.Check the belts for correct tension: Apply 110 Nm (25 ft-lb) against the midpoint (3) between idler pulley and the crankshaft pulley. There should be 9 to 15mm (0.35 to 0.6 in) deflection.

5. If necessary, adjust the belts as follows:

a) Loosen the locknut on the adjustment plate securing bolt (4).

b) Loosen the hinge locknut (5).

c) Adjust the belts to the proper tension.

d) Tighten the adjustment plate securing bolt.

e) Tighten the hinge locknut.

f) Recheck the tension of the belt and adjust again as required.

6. Replace the guards.

7. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

8. Close any panels you opened.

CAUTION TXT-10004376/AENVIRONMENTAL HAZARDPetroleum products and other chemicals are harmful to the environment. Dispose of waste items in a responsible way according to local laws and regulations.



7.6C

heck/fill compressor oil7.6 Check/fill compressor oilThe compressor was filled with approx. 25 l (6.6 US Gal) of Mobil Rarus 426 at the factory. Always use the same type oil as specified in the Appendix 3: Lubricants on page 135.

Related topics:

Appendix 3: Lubricants on page 135


1. Ensure that the unit is shut down for safe maintenance, as described in 6.3 Normal shut down on page 42, and cannot be accidentally started.

2. Release all pneumatic pressure from the system by slowly opening one of the air outputs. Verify that the air pressure is completely released by checking the AIR PRESSURE gauge.

3. To avoid burns ensure the compressor oil is cooled off sufficiently by checking COMPRESSOR TEMPERATURE gauge.

7.6.1 Check compressor oil level1. Open the right access door and locate the compressor oil filler cap (2) behind the air dryer

filter (1).

2. Carefully remove accumulated dust and grit from around the filler using a clean cloth.

3. Remove the filler cap and inspect the oil level; oil level should be between filler cap threads and the bottom of the filler neck. See Figure 7.2.

4. If the oil level is below the correct level go to the next procedure.

Figure 7.2 Engine oil filler cap and level

2

1

2

MAX

MINNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 51 of 150K-Winch AirPack C, MAN-1055734, 26 July 2013 Revision A



7.6

Che

ck/fi

ll co

mpr

esso

r oil7.6.2 Fill compressor oil1. Remove the oil filler cap (3).

2. Add compressor oil until the oil level is above the MIN and below the MAX marks. Refer to Appendix 3: Lubricants on page 135 for recommended compressor oils

.

3. Replace the oil filler cap and tighten it.

4. Clean any spilled oil.

5. Remove all tools and materials from the work area, and dispose of used materials according to local environmental regulations.

6. Close any access panels you opened.

CAUTION TXT-10004386/A1EQUIPMENT DAMAGEFluid leaks can cause mechanical components to fail, as well as contaminate the local environment. Thoroughly clean dipsticks, filler caps, drain plugs and their seatings before refitting them. Make sure screwed caps and plugs have undamaged gaskets or O-rings and are correctly tightened.

CAUTION TXT-10004376/AENVIRONMENTAL HAZARDPetroleum products and other chemicals are harmful to the environment. Dispose of waste items in a responsible way according to local laws and regulations.



7.7C

heck/fill engine coolant7.7 Check/fill engine coolantFor optimum engine cooling, regularly check the coolant level. When filling the radiator always keep in mind that the volume will increase when the engine coolant is hot. Therefore, only fill to the bottom third of the coolant sight glass. If the coolant is overfilled, excess coolant will be forced out of the coolant overflow valve during operations.

NOTE: For cold weather operations, ensure the cooling system is filled with anti-freeze rated to the minimum temperature expected; for example -20 C or -40 C.

6931055734 - man - airpack

Documents