10004235 - MAN - FlyLine Zone 2 RevC

FlyLineZone 2 base and optionsDRAFT - FOR INFORM N ONLYUser Manual

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-ATel: +31 184 608 700, Fax: +31 184 608 790, www.NOV Elmar K-Winch FlyLine, MAN-10004235, 18 S

ORATIOmmers, The Netherlandsnov.com Page 1 of 258eptember 2013 Revision C

IGINAL INSTRUCTIONS

FlyLine User Manual

Page 2 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

This document applies to the following parts:

L-6931048158V01 - FLYLINE BASE HD PP ASSY ATX ZONE 2

L-6931034250V01 - FLYLINE BASE PP ASSY ATX ZONE 2

L-6931041412V01 - FLYLINE BASE SD ASSY ATX ZONE 2

L-6931041412V02 - FLYLINE BASE DD ASSY ATX ZONE 2

All standard options available for these base assemblies, see Appendix 5: Unit configuration on page 244

Revision Date Amendments

C 18 September 2013 Added fuel purifier descriptions on pages 17, 18,19, 40, 41, 170. Instructions to tighten essential bolts on page 221. Referenced documents on pages 246, 247. Instructions to use anti-seize compound on page 248. Other minor corrections.

B 8 August 2013 Pictures of pre-engaged hydraulic starter on page 42. Updated pictures of auxiliary drive on page 52. Added instructions to reset the overspeed controller for heavy duty power packs after being activated on pages 47, 95 and 96. Added instructions on selecting approved engine coolant on pages 133 and 238. Added non-standard combigauge options on page 237 and 242.

A3 17 June 2013 Updated sections: Connect hydraulic and pneumatic hoses and Rig down with regard to the line tension control setting when connecting and disconnecting hoses.

A2 26 February 2013 Minor corrections

A1 20 February 2013 Updated Appendix 3; Added Maintenance step 8.20 Check/ fill fuel pump gear drive oil

A 30 January 2013 This is the first revision 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.

FlyLine User Manual

Table of contentsTABLE OF CONTENTS

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Equipment specific safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 PHYSICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.1 Unit overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.3 Winch / Control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274.1 Unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274.2 Unit systems overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.3 Unit access features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.4 Transportation features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.5 Specifications and data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.6 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.7 Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.8 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.9 Auxiliary drive (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.11 Depth and tension measurement systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.12 Winch subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.13 Wellhead pressure control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5 UNIT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665.1 Power pack control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.2 Winch left control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705.3 Winch right control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6 SETUP AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.1 Moving/positioning equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.2 Hoisting modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.3 Rig-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806.4 First-time startup and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 896.5 Rig-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947.1 Emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947.2 Pre-start checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957.3 Power up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 977.4 Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017.5 Normal shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1047.6 Charging hydraulic starter accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078.2 Certified assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078.3 OEM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078.4 Depth and tensioning system maintenance schedule. . . . . . . . . . . . . . . . . . . . 1078.5 FlyLine maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088.6 Prepare for safe maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128.7 Finalise maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1138.8 Change engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 3 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C

Original Instructions

FlyLine User Manual

Tabl

e of

con

tent

s

8.9 Check/adjust brake band tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1168.10 Check/adjust chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1238.11 Check/adjust levelwind chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1268.12 Check/adjust V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1288.13 Check brake band wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1308.14 Check/fill coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1328.15 Check/fill engine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1358.16 Check/fill engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378.17 Check/fill hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398.18 Check/fill reduction gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1418.19 Check/fill wireline oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1438.20 Check/fill fuel pump gear drive oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1458.21 Check/replace hydraulic hoses and couplings . . . . . . . . . . . . . . . . . . . . . . . . . 1478.22 Check/replace shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1498.23 Clean air inlet safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1508.24 Clean air inlet safety valve for heavy duty power packs . . . . . . . . . . . . . . . . . . 1548.25 Clean fuel coarse particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1578.26 Clean/replace air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1588.27 Clean/replace crankcase flame trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1598.28 Clean/replace fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1618.29 Clean spark arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1638.30 Clean unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1658.31 Drain/fill coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1668.32 Drain fuel purifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1708.33 Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1718.34 Drain fuel/water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1728.35 Drain water from hydraulic tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1738.36 Grease unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1758.37 Prime diesel engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1778.38 Remove/replace drum chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1828.39 Replace levelwind chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1858.40 Remove/replace brake band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1878.41 Replace V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1898.42 Replace drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1918.43 Replace fuel fine filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1968.44 Replace fuse or circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1988.45 Replace hydraulic high-pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2028.46 Replace hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2058.47 Replace hydraulic suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2078.48 Replace slip ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2108.49 Replace fuel/water separator filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2128.50 Service compressed air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2148.51 Test maximum engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2168.52 Test drum mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2178.53 Test hydraulic system pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2198.54 Tighten Essential Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2229.1 Troubleshooting principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2229.2 Troubleshooting table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Appendix 1: Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Appendix 2: Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Appendix 3: Unit Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Page 4 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

Table of contentsAppendix 4: Unit hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Appendix 5: Unit configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Appendix 6: Referenced Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246Appendix 7: Tightening conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Appendix 8: Running hours log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Appendix 9: Air transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253Appendix 10: Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

CUSTOMER NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 5 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual


1In

trod

uctio

n

1 INTRODUCTIONTXT-10004540/A

This user manual for the FlyLine 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 FlyLine 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.

FlyLine User Manual

2Safety2 SAFETYTXT-10004141/A1

2.1 General SafetyHigh voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be present in 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 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.

2.1.2 Employer responsibility Define the required competency of personnel working on the equipment (including

supervision) and provide the required consultation, information and training.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 7 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

2Sa

fety 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.Page 8 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

2Safety2.2 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/A1

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. 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 Annex VIII of the Directive. The construction is documented in a confidential Technical Construction File held at the offices of Elmar.

Figure 2.1 Examples of Emergency Stop buttonsNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 9 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

2Sa

fety2.2.4 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.

2.2.5 WirelineTXT-10004564/A

Never allow the number of wraps on a wireline winch drum to go below a minimum of three (3) wraps. When the last layer is unwinding, winch-off slowly, and keep close control on the remaining wraps.

Never allow the wireline to go slack! A slack wireline can be caused by an obstruction that may clear suddenly, with an unexpected and potentially lethal tightening of the wireline as a result.

If the wireline is rigged up but is not going to run for a period, clamp the wire, diminish the tension, and "flag" the wire with signs.

During wireline operations, consider the zone in front of the winch as a danger zone (see the shaded area in Figure 2.2):

Never allow anyone to enter this area when there is tension on the wireline!

Treat this area as a potential danger zone and take extreme care, even when there is no tension on the wireline.

Figure 2.2 Danger zone for wireline operationsPage 10 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

3Physical description3 PHYSICAL DESCRIPTION3.1 Unit overview

This FlyLine consists of the following modules and sub-modules (see Figure 3.1).

Figure 3.1 Unit overview and orientation

1 3.2 Power pack on page 12 Self-sufficient power source for wireline winch operations. Based on diesel engine as primary energy source, the power pack supplies hydraulic power, compressed air, and optionally electrical power.

2 3.3.2 Control console on page 22 Winch operators control console, with controls for the winch integrated in a single control panel.

3 3.3 Winch / Control console on page 21 Wireline winch with one or two selectable wireline drums and depth and tension measurement system. The winch is hydraulic-powered, and controlled pneumatically.

1

2

back

front

right

left

3

NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 11 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.2 Power pack3.2.1 Power pack overview

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

Figure 3.2 Power pack overview

1 3.2.2 Power pack front view on page 13

2 3.2.3 Power pack left view on page 14

3 3.2.4 Power pack left view (heavy duty) on page 15

4 3.2.5 Power pack rear view on page 16

5 3.2.6 Power pack right view (spring starter) on page 17

6 3.2.7 Power pack right view (hydraulic starter) on page 18

7 3.2.8 Power pack right view (air starter) on page 19

8 3.2.9 Power pack right view (heavy duty) on page 20

7

2

4

1

8

65

3


FlyLine User Manual

3Physical description3.2.2 Power pack front view

Figure 3.3 Power pack front view

1 Hydraulic oil tank filler cap (protected by hatch)

2 Hydraulic oil tank

3 Hydraulic oil tank drain valve

4 Hydraulic oil tank isolation valve

5 Hydraulic oil high-pressure filters (2 x)

6 Suction filter

7 Suction filter (option, only with auxiliary drive)

8 Air receiver safety valve

9 Air receiver

10 Air receiver isolation valve

11 Air filter

2

3

10

1

4

11

9

5

76

8



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.2.3 Power pack left view

Figure 3.4 Power pack left view

1 Engine exhaust

2 Engine air intake safety valve (Pyroban)

3 Exhaust gas cooler

4 Belt and pulley guard

5 Radiator fan

6 Radiator stack

7 Fuel filler cap

8 Engine oil dipstick

9 Hydraulic manifold

10 Engine frame shock mount (4 x)

1

7

3

8

2

4 5 6

109


FlyLine User Manual

3Physical description3.2.4 Power pack left view (heavy duty)

Figure 3.5 Power pack left view (heavy duty)

1 Engine exhaust

2 Engine air intake safety valve (Pyroban)

3 Exhaust gas cooler

4 Belt and pulley guard

5 Radiator fan

6 Radiator stack

7 Fuel filler cap

8 Engine oil dipstick

9 Hydraulic manifold

10 Engine frame shock mount (4 x)

1

7

3

8

2

4 5 6

109



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.2.5 Power pack rear view

Figure 3.6 Power pack rear view

1 Radiator filler cap (protected by hatch)

2 Radiator stack

2

1


FlyLine User Manual

3Physical description3.2.6 Power pack right view (spring starter)

Figure 3.7 Power pack right view (spring starter)

1 Exhaust silencer 12 Pneumatic and hydraulic connectors

2 Engine flame trap breather 13 Fuel tank

3 Fuel safety (Sentinel) valve 14 Starter motor

4 Fuel fine filter 15 Electric junction box (optional)

5 Engine air intake filter 16 Battery isolation switch (optional)

6 Control panel 17 Battery (optional)

7 Fuel pump 18 Electrical connector (optional)

8 Engine compressor 19 Auxiliary drive pump (optional)

9 Fuel prefilter & water separator 20 Spring starter crank handle (optional)

10 Engine oil sump pump 21 Fuel purifier (optional, not shown)

11 Engine oil filter

15

9

16 3

12

10

4

6

21

1

5

2

20

1711

18

78

19

13

14NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 17 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.2.7 Power pack right view (hydraulic starter)

Figure 3.8 Power pack right view (hydraulic starter)

15

16 3

12

10

4

61

5

220

1711

18

78

19

13

21

21 20

9

22

14









9 Fuel prefilter & water separator 20 Hydraulic accumulator & isolation valve (optional)

10 Engine oil sump pump 21 Accumulator charge pump & handle (optional)

11 Engine oil filter 22 Fuel purifier (optional, not shown)Page 18 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

3Physical description3.2.8 Power pack right view (air starter)

Figure 3.9 Power pack right view (air starter)









9 Fuel prefilter & water separator 20 Air-in connector (optional)

10 Engine oil sump pump 21 Pneumatic filter for start circuit (optional)

11 Engine oil filter 22 Fuel purifier (optional, not shown)

15

16 3

12

10

4

61

5

2

1711

18

78

19

13

219 20

22



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.2.9 Power pack right view (heavy duty)

Figure 3.10 Power pack right view (air starter)

1 Engine air intake filter

2 Turbocharger

3 Engine overspeed control valve (pneumatic)

4 Air inlet valve (push / pull type)

NOTE: Only additional heavy duty features are mentioned. See sections 3.2.6, 3.2.7 and 3.2.8 for other features.

1

3

2 4Page 20 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

3Physical description3.3 Winch / Control console3.3.1 Winch / Control console overview

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

Figure 3.11 Winch / control console overview

1 3.3.2 Control console on page 22

2 3.3.3 Winch front view (SD) on page 23

3 3.3.4 Winch left view (SD) on page 24

4 3.3.5 Winch right view (SD) on page 25

5 3.3.6 Winch right view (DD) on page 26

42



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.3.2 Control console

Figure 3.12 Control console

5

6

11

2 43

7

8

1 Securing latch pins for roof flap

2 Left control panel

3 CombiGauge

4 Right control panel

5 Operator chair

6 Levelwind wheel

7 Operator seat securing pin

8 Operator safety screenPage 22 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

3Physical description3.3.3 Winch front view (SD)

Figure 3.13 Winch front view (SD)

1 Levelwind guide shaft

2 Winch drum

3 Levelwind chain

4 Measuring head

5 Measuring head guide bar

6 Air-out connector

7 Hydraulic motor and gearbox (behind cover)

8 Drum chain

1

4

6

3

8

2

5

7



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.3.4 Winch left view (SD)

Figure 3.14 Winch left view (SD)

1 Winch drum

2 Cardan shaft for levelwind

3 Drum cover

4 Pillow block bearing

5 Measuring head

6 Measuring head transport securing pin

7 Roof damper

8 Screen damper

9 Fold-in roof

5

4

32 1

6

87

9


FlyLine User Manual

3Physical description3.3.5 Winch right view (SD)

Figure 3.15 Winch right view (SD)

1 Wireline oiler

2 Hydraulic motor/gearbox assembly

2

1



FlyLine User Manual

3Ph

ysic

al d

escr

iptio

n

3.3.6 Winch right view (DD)

Figure 3.16 Winch right view (DD)

1 Front winch drum

2 Rear winch drum

3 Horn

4 Hydraulic motor/gearbox assembly (2x)

5 Drum selection valve

NOTE: Mainly additional double winch drum features are mentioned. See section 3.3.5 for other features.

4

3

1

2

2

5


FlyLine User Manual

4Functional description4 FUNCTIONAL DESCRIPTION4.1 Unit configuration

This design is a split wireline winch unit comprised of a power pack, and a winch module with integrated operator control.

The setup is suitable for cased hole slick line, braided line and mono-conductor operations. The unit is suitable for onshore and offshore operations.

The four cylinder diesel engine in the power pack drives the Elmar's closed loop hydraulic system. See 4.8 Hydraulic system on page 50.

A data plate is attached to the outside of each module, and contains specification information for that module. Check your data plate and refer to Appendix 2: Unit Specifications on page 237 and Appendix 5: Unit configuration on page 244 for more information.

Figure 4.1 Unit configurationNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 27 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.2 Unit systems overview

Figure 4.2 Typical system setup

Drum brake

Engine starter

Diesel engine and

gearbox

Main hydraulic pump

Cooling fan

Coolant pump

Pneumatic compressor

Alternator

Fuel supply

Fuel safetyvalve

Air inlet

Hydraulic circuit

Coolant circuit

Pneumatic circuit

Electric circuit

Radiator

Drum and wireHydraulic motor and gearbox

Drum brakeSelection valve

Drum and wire

Exhaust gas cooler

Combigauge

Measuring head

Air intake

Hydraulic power Pneumatic power Mechanical power Electrical power Fuel Cooling liquid

SmartMonitor

Battery

Hydraulic motor and gearbox

5

3

7

6

2

4

1


FlyLine User Manual

4Functional descriptionFigure 4.2 shows the relationship between the various subsystem.

The Depth and tension measurement systems (1) is attached to the Winch subsystem (2), which guides the wireline in and out of the well, during wireline operations. The (3) supplies hydraulic energy for turning the drum, while the Pneumatic system (4) supplies pneumatic control for the drum brakes.

The Diesel engine (5) powers the Hydraulic system (3), Pneumatic system (4), Electrical system (6) and Cooling systems (7). The Cooling systems are used to cool the diesel engine and the exhaust gases produced by the diesel engine (in Zone 2 certified units). The cabin heater uses the heat from the Cooling systems (7) to warm the cabin. The Electrical system supplies electrical energy for the SmartMonitor in the Depth and tension measurement systems.

1 Depth and tension measurement systems

4.11 Depth and tension measurement systems on page 56

2 Winch subsystem 4.12 Winch subsystem on page 58

3 Hydraulic system 4.8 Hydraulic system on page 50

4 Pneumatic system 4.7 Pneumatic system on page 48

5 Diesel engine 4.6 Diesel engine on page 35

6 Electrical system 4.10 Electrical system on page 54

7 Cooling systems 4.6.7 Cooling systems on page 45NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 29 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.3 Unit access features

9

6

8

5

7

10

112

1

4


FlyLine User Manual

4Functional description1 Power pack right door Protects the engine against environment conditions. Protects from noise and heat.

2 Power pack left door Protects the engine against environment conditions. Protects from noise and heat.

3 Controls and connections hatch Grants access to the power packs controls and connections

4 Winch bay right doors Protects winch components from impact during transport. Keeps loose parts inside winch bay. Protects from moving parts during operation.

5 Winch bay front door Protects winch components from impact during transport. Keeps loose parts inside winch bay.

6 Winch bay left doors Protects winch components from impact during transport. Keeps loose parts inside winch bay. Protects from moving parts during operation.

7 Power pack door handle Turn this handle to open a power pack door.

8 Keyhole Lock the power pack door closed with the supplied key.

9 Tumbler pin Two latch pins are used to secure each winch door

10 Coolant hatch This hatch give access to the coolant filler cap

11 Hydraulic fluid hatch This hatch gives access to the hydraulic fluid filler cap and gauge.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 31 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.4 Transportation features

1

3

5

8 9

2

6

7

41112

10Page 32 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

4Functional description1 Lifting pad eyes (4 per module) Only for lifting module in transport state: all parts stowed and all doors and hatches closed and locked.

WARNING: The single point lifting bar and all fittings must be removed before using the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the lifting chains of the hoist might become entangled in the lifting bar/fittings.

2 ISO corners (4 per module) For storing, transporting, and anchoring each module.

3 Forklift pockets (2 x 2 per module)

For fork lifting of separated modules in the transport state (all parts stowed and all doors and hatches closed and locked).

WARNING: Do not use these forklift pockets for crane hoisting of the module.4 Bracket (2x) for single point lifting

barBrackets to fit the single point lifting bar (5)

5 Single point lifting bar (optional) Only for lifting module in transport state with a single sling: all parts stowed, all doors and hatches closed and locked. The single point lifting bar must be removed for operation.

WARNING: The single point lifting bar must not be used for offshore lifting.

WARNING: The single point lifting bar and all fittings must be removed before using the lifting pad eyes (4x) to hoist the module. If the lifting bar is not removed, the lifting chains of the hoist might become entangled in the lifting bar/fittings.

6 End rail WARNING: The end rail must always be fitted before transporting the unit.7 End rail storage brackets Use these brackets to store the end rail (6) during operations.

8 Jacking wheel (option) Detachable jacking wheel assembly

9 Side wheel (option) Detachable side wheel for jacking wheel assembly

10 Jacking wheel mount point Attachment point for detachable jacking wheel assembly

11 Fold out roof Folds in for transport

12 Retractable latch pin Four latch pins are used to secure the fold out roof in transport and operation position.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 33 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.5 Specifications and data plateA data plate (Figure 4.3) is attached to the outside of the modules and is stamped with specification information for the unit. Check your data plate to see whether your FlyLine is Rig safe, Zone 2 or Zone 2 Arctic. If the field under MARKINGS is empty, it is Rig Safe. If it has ATEX markings, it is Zone 2 certified. Refer to Appendix 2: Unit Specifications on page 237 for other specification details.

Figure 4.3 Data plate layout

MARKINGS

A1107313_A

ASEP

External connections:

NOV ASEP Elmar Netherlands BVEnergieweg 26 - NL 2964LE Groot-Ammers

[email protected] - www.nov.com/ASEPElmarPage 34 of 258 NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The NetherlandsRevision C NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Original Instructions

FlyLine User Manual

4Functional description4.6 Diesel engineThe engine systems are described in the following sections:

4.6.1 Engine oil on page 36

4.6.2 Engine safety features on page 38

4.6.3 Engine fuel system on page 40

4.6.4 Hydraulic engine starter (optional) on page 42,

4.6.5 Pneumatic engine starter (optional) on page 43,

4.6.6 Spring engine starter (optional) on page 44,

4.6.7 Cooling systems on page 45

4.6.8 Additional features of Heavy Duty power packs on page 46

Primary power is generated by a four cylinder diesel engine. The engine is Rig safe or Zone 2 compliant, with features to eliminate any risk of explosion during normal operation, and to shut down the engine when there is risk of explosion.

The engine is available in regular and heavy duty configurations. The latter will include a turbo charger in the engine assembly for additional power output.

The engine is liquid cooled with forced ventilation.

The diesel fuel tank is situated in the power pack, underneath the engine. The fuel is filtered in three stages between the tank and the engine: coarse particle filter, water/fuel separator, and fine particle filter. An isolation valve beside the tank can be closed during maintenance and transport.

The engine air supply is drawn through an air filter in the power pack. An air shut-off valve in the intake kills the engine or prevents it from starting when it is unsafe for the engine to run.

On Zone 2 units, engine exhaust is treated before discharge to prevent an explosion from heat or sparks. The first stage is an exhaust gas cooler, which cools the exhaust gas enough to prevent the ignition of potentially explosive ambient gases. The second stage is a spark arrester, which filters hot solid particles from the exhaust gas.

The engine is started by an electric (Rig safe only), hydraulic, pneumatic or spring starter.

The engine is bolted to a subframe assembly. Four shock mounts attach the subframe assembly to the power pack frame to ensure good vibration control.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 35 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.1 Engine oil

3

25

4

1

1


FlyLine User Manual

4Functional description1 Engine oil filler cap (2x) Use to fill or top up engine oil. One cap is located behind air compressor. Another cap is located in top of the engine. Use a funnel to make filling easier.

2 Engine oil filter Filters the engine oil.

3 Engine oil dipstick Used to check engine oil level. Screw fitting.

4 Engine oil sump pump Hand-operated plunger pump to remove oil from bottom of engine sump.

5 Sump pump isolation valve CLOSED (lever across flow direction) at all times. Only open, when draining the engine oil.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 37 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.2 Engine safety features

6

5

4

7

1


FlyLine User Manual

4Functional description1 Engine fuel safety valve (Shown in operation state). Causes an instant engine shutdown by cutting off the fuel supply. This valve controls the fuel supply to the engine, and is actuated by engine oil pressure. Engine oil under pressure enters and exits through the upper connections. Fuel from the fuel pump enters and exits to the engine injectors through the lower connections. When there is sufficient engine oil pressure, the valve stays open. If the oil pressure drops under approximately 0.5 bar (7.5 psi) the valve will block the supply of fuel, shutting down the engine.Before starting, the valve must be manually disarmed by rotating the lever down. It will arm itself once the engine is running and generating oil pressure.NOTE: Also referred to as sentinel valve or master valve.

2 Air inlet valve Causes an instant engine shutdown by cutting off the air supply. When explosive gases are present in the air, a diesel engine can sometimes continue to run, even when the fuel and electrical supply are cut off. This butterfly valve in the air intake is actuated by engine oil pressure. When there is sufficient engine oil pressure, the valve stays open. The valve is manually latched open before starting, but will be held open automatically once the engine is running and generating oil pressure.See item 14 in Figure 5.2 on page 66. for the air inlet valve control.This component requires periodic maintenance (cleaning).

3 Exhaust temperature shutdown valve (optional, normally open)

This valve is placed in the oil pressure circuit to the engine safety valve. In the event of excessive exhaust temperature (maximum 200 C), the valve will close, triggering the Zone 2 engine shutdown.

4 Crankcase breather flame trap The top opening for the crankcase air breather is connected to a flexible hose that leads to a flame trap device. The flame trap prevents ignition of an explosive atmosphere by a possible flame in the crankcase.This component requires regular inspection and maintenance.

5 Exhaust silencer with spark arrester

The silencer is equipped with a spark arrester to catch glowing soot in the exhaust gases that may still be present after the exhaust gas cooler. The ash is collected in the lower side of the silencer, and can be removed via the plugged cleaning opening on the bottom. This component requires regular inspection and cleaning.

6 Spark arrester cleaning opening During servicing, remove the plug to extract the spark ash through this opening

7 Exhaust gas cooler (optional) The cooler is a box-shaped water jacket that leads the exhaust gas flow through cooling tubes from the engine exhaust manifold to the silencer. The exhaust manifold (not shown) is also water-cooled. The water jacket coolant is itself cooled in the cooling system radiator.This component requires no routine servicing.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 39 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.3 Engine fuel system

124

9

1

8

5

7

2

10

6

3

11


FlyLine User Manual

4Functional description1 Fuel tank cap Located in the right side plinth of the power pack, accessible for filling at a regular service station. Use only diesel fuel of an approved grade (see specifications).

2 Fuel tank Tank installed in power pack.

3 Fuel isolation valve Close during transport, and when servicing filters. Open before starting.

4 Fuel coarse particle filter First cleaning stage for diesel fuel. Cleanable metal Y-filter that sifts coarse contamination from the fuel drawn from the tank. Requires routine servicing.

5 Fuel prefilter & water separator Second cleaning stage of diesel fuel. Accumulated water must be regularly drained (manually). Disposable filter element in upper section.

6 Fuel primer pump Use only when the fuel tank has run empty or when air has entered the fuel system during servicing of filters.Press several times to pump fuel from the tank into the fuel pump before starting.

7 Fuel fine particle filter Third cleaning stage for diesel fuel after the fuel pump. Disposable element.

8 Fuel pump Fuel pump driven by adjacent PTO gearbox (behind compressor).From here, the fuel passes to the engine injectors via the engine safety valve.

9 Fuel return line check valve Prevents fuel from passing through the fuel return line during an emergency shutdown.

10 Engine safety valve (shown in engine running position

For description see 1 Engine fuel safety valve on page 39NOTE: Also referred to as the Sentinel valve

11 Fuel tank breather Ventilates the fuel tank.

12 Fuel gauge Shows fuel level in tank.

13 Fuel purifier Removes suspended water and emulsions from fuel of dubious quality. Requires periodic draining from bottom of vessel.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 41 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.4 Hydraulic engine starter (optional)

1 Hydraulic starter Used to start the engine. Stored pressure in the hydraulic accumulator is released to the starter which in turn starts the engine.

2 Hydraulic accumulator Used to store hydraulic pressure for the hydraulic starter.

3 Accumulator isolation valve Used to isolate the accumulator to store the charge for later starts. Must be opened before starting, and closed before shutting down (or after charging).

4 Engine start button When turned, stored hydraulic pressure from the accumulator is released to the hydraulic starter which in turn starts the engine.

WARNING: Do not activate the starter when the engine is running or within 15 seconds after a failed start attempt.

5 Start pressure gauge Indicates available start pressure in the accumulator.

6 Hand pump Used to manually restore pressure to the hydraulic accumulator.

26

3

54

1


FlyLine User Manual

4Functional description4.6.5 Pneumatic engine starter (optional)

1 Start pressure gauge Indicates available start pressure.

2 Engine start button When depressed, compressed air is delivered to the air starter which in turn starts the engine.


3 Air filter/dryer Compressed air filter/dryer for the starter pneumatic circuit..

4 Pneumatic starter Used to start the engine. Compressed air from the rig/shore or another external source turns the starter which starts the engine.

3

2 1

4



FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.6 Spring engine starter (optional)

1 Hand crank Used to turn the winding nut.

2 Winding nut Turning this winds up the spring.

3 Spring tension sight glass This shows the tension on the spring. Green: not wound White: standard charge for a warm start (ca. six turns) Red: extra charge for a cold start (ca. 8 turns)

4 Spring starter Spring-powered starter assembly

5 Spring trip lever Pulling this down engages the starter with the flywheel, releasing the spring pressure to start the engine.


6 Reset button This button should be pressed every time before winding up the starter, or the starter could be damaged.

4

5

2

1

6

3


FlyLine User Manual

4Functional description4.6.7 Cooling systems

1 Engine coolant & hydraulic fluid radiator

Coolant and hydraulic fluid circulates from this radiator

2 Cooling fan This v-belt driven fan draws cool air over the engine radiator

3 Exhaust gas cooler Lowers the exhaust gas temperature to a safe working temperature.

4 Coolant filling cap Located behind access hatch. Use to fill coolant.

5 Coolant sight glass Use to check coolant level.

6 Coolant filling cap access hatch Protects inside of unit. Use to access coolant filling cap.

1

5

1

2

4

4

5

3

6



FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.6.8 Additional features of Heavy Duty power packs

4 5

2

3

1


FlyLine User Manual

4Functional description1 Turbocharger Allows the engine to produce more power by forcing more air and fuel into the combustion chambers.

2 AIR INLET VALVE (push / pull type)

Override for the automatic valve closure to enable the engine to start. When the engine is running, the valve must be controlled by the Zone 2 safety system. PULL before starting the engine, and hold in place. Then PUSH in when the engine oil pressure reaches 2.0 bar (29 psi), so that the automatic control can take over after the engine start. The air inlet valve is automatically closed to kill the engine when the engine or winch safety systems detect a hazardous condition. Without air, the combustion in the diesel engine cannot take place.WARNING: Do not run the engine with the air inlet valve handle left in the pulled out position. This can prevent the engine from shutting down in a Zone 2 hazardous situation!

3 Engine overspeed control valve (pneumatic)

The tachometer in the main control panel is driven by the cable from the output above the compressor. The cable passes through this pneumatic control valve (NC) which is preset to open at 2500 rpm. The engine normally will run at a lower speed than this. An overspeed may be a sign of an explosive air/gas mixture in the ambient air. When the valve is opened, it triggers the Zone 2 engine shutdown. The overspeed controller features a reset button. The engine cannot be started again until the overspeed controller is manually reset by pressing this button.

4 Larger exhaust gas cooler In addition to the standard functions of the exhaust gas cooler (see Exhaust gas cooler (optional) on page 39) this larger cooler also supplies cooling for the turbocharger.

5 Larger engine radiator In addition to oil and coolant this radiator also cools incoming air for the turbocharger.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 47 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.7 Pneumatic system

9

11

105

1

6

12

2

4

3

14

13

7

8


FlyLine User Manual

4Functional descriptionPneumatic energy supply system1 compressor Water-cooled air compressor driven directly by engine. See specifications.

Air intake is from engine air filter via the flexible metal suction line.

2 governor valve Limits output pressure to a maximum (8 bar).

3 compressor intake line Draws filtered air from engine air intake (after engine air filter).

4 compressor pressure line (Metal-wrapped line). Delivers compressed air to receiver/filter setup.

5 safety valve Relieves overpressure from receiver. Opens automatically at 10 bar.

6 Air receiver Compressed air accumulator for air from compressor only (not rig air).

7 Connection 7 Female connector - air supply to winch

8 Connection 8 Female connector - air EM-stop

9 water separator/filter (optional) Air filter and water separator for air starter systems. mounted on power pack right door.

10 receiver isolation valve Must be open during operations.Close when necessary to store compressed air e.g. for cold start, or for safety during maintenance.

11 Water separator/filter Air filter and water separator for the pneumatic system.12 engine & compressor air filter Disposable-element air filter. See specifications.

13 Rig air in connector Optional connection for rig air. Installed on units with an air starter.

14 Air out connector Located on winch module. Can be used to supply power for pneumatic equipment.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 49 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.8 Hydraulic system

3

12

4

6

2

12

7

13

8

1417

10

918

19

11

1516

5


FlyLine User Manual

4Functional description1 Closed loop hydraulic system This unit uses an NOV Elmar closed loop hydraulic system to transfer mechanical energy from the power source (engine or motor) to the winch and auxiliary control features. When necessary, this primary system may be augmented with one or more additional open loop hydraulic circuits to power additional features, either from the main power source or an auxiliary engine or motor.

2 Hydraulic oil filler cap Hydraulic oil tank filler cap. Strict cleanliness is advised!3 Hydraulic oil tank Main reservoir for all hydraulic functions of the FlyLine.

4 Hydraulic fluid gauge Gauge for hydraulic fluid

5 Connection 5 Male connector - control pressure

6 Hydraulic oil tank drain plug & valve

Used for servicing of the hydraulic system, to drain off condensation water, or to drain out all the oil.

7 Main circuit suction filter Single suction filter to remove contamination from the oil before entering the pump for the main (winch) circuit. The filter must be replaced whenever the condition indicator moves into the yellow zone (with power pack running).NOTE: Never allow the filter condition to move into the red zone. When this happens, the oil is no longer filtered!

8 hydraulic tank isolation valve Dual-head suction filter to remove contamination from the oil before entering the pumps for the auxiliary circuit and cooling fan circuit. Isolation valve = OPEN whenever the power pack is running.Close the isolation valve when servicing the filters.

9 Connection 9 Male connector - drain

10 Connection 10 Male connector - main outhole

11 Connection11 Female connector - main inhole

12 hydraulic pump stack Hydraulic pumps for the main, control and auxiliary circuits, mounted on the drive shaft of the engine.

13 hydraulic oil radiator The oil radiator forms part of the cooling stack in the left side of the power pack. Return flows from the main and auxiliary circuits are combined in a manifold, and pass through the radiator before returning to the hydraulic tank.

14 Auxiliary drive connection See 4.9 Auxiliary drive (optional) on page 52



17 Connection17 Female connector - servo Y1 outhole

18 Connection 18 Male connector - servo Y2 outhole

19 Connection 19 Female - line tension

Figure 4.4 Typical ASEP Closed Loop hydraulic system

oil cooler

suction filter

pump

main circuit

drain

control circuit

winch motor

various actuators

various motors

various controls

hydraulic reservoir

1



FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.9 Auxiliary drive (optional)

4

23

6 1

5

7


FlyLine User Manual

4Functional descriptionThe optional auxiliary drive is an open loop hydraulic circuit intended to power additional equipment, such as a mast. The pump is always operational when the power pack is running, with the flow automatically returned to the oil reservoir unless activated at the control panel. Three quick connectors located at the front of the winch bay are provided for connection to auxiliary equipment. The attached equipment must have its own control features, as the FlyLine only has a simple on/off control for the circuit.

1 P Pressure quick connector

2 D Drain quick connector

3 T Return quick connector

4 AUXILIARY PRESSURE This gauge shows the air pressure in the auxiliary circuit

5 Auxiliary drive lever Use this lever to select between normal operation and auxiliary drive mode

6 Auxiliary drive pump This pump supplies hydraulic pressure for the auxiliary drive

7 Hydraulic filter Additional hydraulic filter for the auxiliary circuitNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 53 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.10 Electrical system4.10.1 Zone 2 units

1

5

4

2

3


FlyLine User Manual

4Functional descriptionNOTE: See the electrical diagram in your documentation package for a full explanation of the electrical system.

1 ECP 2 Controls for most electrical functions.

2 AC IN socket Located on the inside of the winch bay left door

3 Alternator 24 VDC alternator. Generates power when unit running.

4 24 VDC batteries Supply standby power for all electrical functions, and starter power for units with electric starter

5 Battery switch Isolation valve for the batteries

6 Fuses and circuit breakers There are different types of fuses and circuit breakers used in the FlyLine. The type of fuse used depends on the specifications of the electrical system. In general, the following rule applies:

12/24-volt blade type fuses (typical automotive fuse) 115/230-volt cartridge fuses (glass) and circuit breakers

The fuses are marked with an identification number that corresponds with the F number stated on the electrical diagrams. The description on the diagram indicates the trip level in Amps. See 8.44 Replace fuse or circuit breaker on page 198 for information on fuses, and how to change them.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 55 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.11 Depth and tension measurement systems

31

4

2


FlyLine User Manual

4Functional descriptionThe FlyLine can be configured with either an NOV Elmar MP16 II (1) or MP20 (2) MeasureHead, which provides wireline depth and tension signals to a separate remote display. The measuring head is a three wheel wraparound design with two upper wheels and one lower wheel. Wireline replacement can be achieved without cutting the wireline.

An accurate tension display can be achieved, when used together with an NOV Elmar CombiGauge (4). Accurate depth display is provided mechanically via a cable running from the depth gearbox to the CombiGauge. For more detailed tension and depth display, the unit can be equipped with an optional NOV Elmar SmartMonitor (3). The SmartMonitor can visualise and record all ongoing jobs, as well as visualise and record all relevant unit parameters.

1 MP16 II NOV Elmar depth and tension measurement device. See separate measure head MP16 II documentation.

2 MP20 NOV Elmar depth and tension measurement device. See separate measure head MP20 documentation.

3 SmartMonitor (optional) NOV Elmar SmartMonitor display. See separate NOV Elmar-supplieddocumentation.

4 CombiGauge NOV Elmar analogue depth and tension display. See separate measure head MP16 II documentation.

5 USB connection (optional) USB connection to SmartMonitor. See separate SmartMonitor documentation for using the USB functionality.NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 57 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.12 Winch subsystem4.12.1 Overview

NOTE: Picture shows double drum configuration.

4

19

20

16

3

8

13

15

418 2

12

1

6 2117

5

4


FlyLine User Manual

4Functional descriptionSee Appendix 5: Unit configuration on page 244 for available drums and part numbers.

Winch Drums See Appendix 5: Unit configuration on page 244 for drum part numbers1 Front drum Drum nearest wellhead.

2 Drum motor Hydraulic drive motor for each drum.

3 Reduction gearbox Increases torque delivered to drum. Requires periodic maintenance (oil level).

4 Drum drive chain Reduction transmission between the reduction gearbox and the drum. Acts directly on drum rim sprocket. Requires periodic adjustment.

5 Pillow block bearing (2 x) Complete bearing assembly for each end of each drum shaft. Adjusters on the winch frame are used to position the shaft precisely.

6 Drum drive chain guard

7 Drum motor transmission guard Not shown. Covers drum motors and reduction gearboxes from dirt.

8 Drum control Dual-lever control for winch drum direction, speed and torque. Both levers directlycontrol the hydraulic winch drive system. Each lever is continuously adjustable, andcan be locked or released in any position, leaving the operator's hands free.left hand dual control handle: speedright dual control handle: inhole/outhole

9 Gearbox sight glass (2 x) Normal gearbox oil level mid-point of this sight glass (one each gearbox, not shown in this picture).

10 Gearbox filler point (2 x) Filler point with cap for replenishing gearbox oil. (one each gearbox, not shown in this picture).

11 Gearbox drain point Drain point with cap for draining gearbox oil. (one each gearbox, not shown in this picture).

Drum brake system See 4.12.2 Drum brake system on page 60 for a description12 Drum brake cylinder 2 x

13 Drum brake band 2 x

14 Drum brake guard Not shown. Covers drum brakes from dirt.

Level winding system15 Levelwind drive chain The chain is attached to the measuring head, which runs along the levelwind shaft.

Requires periodic maintenance.

16 Levelwind drive chain

17 Levelwind shaft Smoothly polished shaft, that supports the measuring head, and allows it to travel smoothly side to side on a slide bearing.

18 Levelwind control wheel

19 Levelwind guide rail A roller at the rear of the measuring head carrier runs in this rail, keeping themeasuring head perfectly steady during operations. The rail can be removed duringrig-down so that the measuring head can be stowed.

20 Cardan shaft for levelwind

21 Measuring head transport lockNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 59 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.12.2 Drum brake system

32

1

HYDR/PNEUM PRESSURE RELEASED:SPRING (9) EXTENDS, PISTON (5) RETRACTS, BRAKE IS APPLIED

HYDR/PNEUM PRESSURE APPLIED:PISTON (5) EXTENDS,

SPRING (9) IS COMPRESSED,BRAKE IS RELEASED

46

93 7

95

9 8

4


FlyLine User Manual

4Functional descriptionThe drum(s) are braked by a brake system contracting the brake band around the rim of the winch drum. This brake has two functions:

as a parking brake, to prevent the drum from turning due to downhole forces (weight of tool string and wireline)

as an emergency brake, to rapidly and smoothly halt the drum in the event of an emergency or sudden failure of the units systems

The brake is not intended to slow or stop the drum during normal operations.

The brake system is fail-safe and works as follows:

1. A spring (inside a hydraulic brake cylinder) is pre-compressed during assembly and retained by the brake cylinder lid.

2. When pressure is present in the brake pneumatic or hydraulic circuit (BRAKE released), a piston is extended, releasing the brake - this movement compresses the spring. If pressure is lost (BRAKE applied, EMERGENCY OFF pressed or a system failure), the spring will expand, forcing the brake piston back into the cylinder, and applying the brake.

The brake band system is designed to be assisted by the inhole rotation of the drum. The brake is therefore more effective in the inhole than the outhole direction.

Double drum winch frames have separate brake system(s) per drum.

See the maintenance section of this manual for procedures to test, inspect, adjust and replace the brake band(s).

1 Brake band section

2 Lower adjuster with locknut

3 Brake cylinder

4 Brake piston

5 Brake linkage attachment

6 Brake cylinder lid

7 Expansion chamber

8 Brake actuating spring

9 Hydraulic or pneumatic supply connectionNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 61 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.13 Wellhead pressure control systemsThe FlyLine units can be optionally configured with wellhead pressure control equipment. This is used to lower and raise the wireline and tool string into the well safely. It can also be used to hermetically close off the well in an emergency situation (gas escaping).

4.13.1 BOP control (non-standard option)

43

2

16

8

5

7

9


FlyLine User Manual

4Functional descriptionCompressed air is supplied to the combined control panel. The compressed air drives a hydraulic pump (represented by on the control panel). The air supply to the hydraulic pump is controlled by a dial regulator (1), which can be set to achieve the desired hydraulic pressure. The hydraulic pump supplies hydraulic pressure to the BOP. The hydraulic pressure supplied by the pump is displayed on a gauge (2). The hydraulic pressure is backed-up by an accumulator (represented by on the panel), which is mounted in the winch unit. This accumulator can be isolated from the system by closing a valve in the winch module.

When the hydraulic pump is activated, hydraulic fluid from the oil tank (Figure 5.14) is pumped via the high pressure hoses (Figure 5.14) to the BOP assembly, depending on the setting of hydraulic selector valve (3). To control the BOP, hydraulic selector valve (3) can be set to either OPEN, OFF, or CLOSE. Pressure gauges (4) displays the hydraulic pressure that is present at the BOP assembly in either the open or closed positions.

1 Hydraulic accumulator for BOP Upright hydraulic accumulator exclusively for actuation of dual BOP rams. The accumulator has an isolation valve in the underside.

2 Pneumatic booster pump This pump is controlled with the PRESSURE REGULATOR to pressurize the Hydraulic accumulator for BOP

3 Accumulator isolation valve Isolates the pressure in the Hydraulic accumulator for BOP

4 Accumulator pressure gauge Show the pressure stored in the hydraulic accumulator

5 BOP PRESSURE This gauge shows the pressure available to the BOP rams.

6 BOP PORT PRESSURE This gauge shows the pressure available to the BOP port.

7 PRESSURE REGULATOR This control controls the Pneumatic booster pump to build up pressure in the Hydraulic accumulator for BOP

8 BOP CONTROL 3-position valve. Controls the state of the UPPER BOP ram set. Requires sufficient pressure ( 2,000 psi), as indicated in the BOP PRESSURE gaugeCLOSE: Close BOP ram and maintain ram pressure. The OPEN line will drain to the hydraulic tank.OFF: Hold current BOP ram state, isolated from BOP system hydraulic pressure supply or dump.OPEN: Open BOP ram and maintain ram pressure. The CLOSE line will drain to the hydraulic tank.

9 BOP CLOSE Connector for the BOP CLOSE line

10 BOP OPEN Connector for the BOP OPEN lineNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 63 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

4Fu

nctio

nal d

escr

iptio

n

4.13.2 Stuffing box

Figure 4.5 Stuffing box hydraulic pump in cabin and connection point at winch

7

6

2

5

4

3

8


FlyLine User Manual

4Functional descriptionNOTE: The FlyLine stuffing box is a non-standard option.

The stuffing box hydraulic hand pump and the stuffing box isolation valves and gauge are located under the control panel.

The stuffing box hand pump has a built-in one-litre hydraulic oil reservoir that can be replenished if necessary (2). The hand pump to applies pressure to the hydraulic packing nut in the stuffing box.

The stuffing box control hose is connected to the stuffing box quick connector (3) located at the front of the winch bay. The control hose can be found on a reel inside the winch door. A label explains the connection function for the quick connector.

1 Pump handle Insert into the pump handle socket to enable pumping hydraulic pressure.

2 Pressure gauge Indicates pressure in the Stuffing box hydraulic system.

3 Pump handle socket Insert the removable pump handle here.

4 Secondary isolation valve To control pressure in the Stuffing box hydraulic system

5 Primary isolation valve To control pressure in the Stuffing box hydraulic system

6 Hydraulic oil fill point Replenish the hydraulic oil reservoir here

7 Hydraulic oil reservoir sight glass Check the level of hydraulic oil in the reservoir here.

8 Stuffing box quick connector Connect the stuffing box flexible hose quick connector hereNOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 65 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

5U

nit c

ontr

ols

5 UNIT CONTROLS

Figure 5.1 Winch controls

Figure 5.2 Power pack controls

3

21 5

4

7

6


FlyLine User Manual

5U

nit controls1 Winch left control panel See 5.2 Winch left control panel on page 70

2 CombiGauge NOV Elmar analogue depth and tension display. See separate MP20 and MP16 II documentation.

3 Steering wheel This wheel controls the lateral movement of the measuring head when spooling the wire onto the drum. (outhole)

4 SmartMonitor location (optional) NOV Elmar SmartMonitor display. See separate NOV Elmar-supplied documentation.

5 Winch right control panel See 5.3 Winch right control panel on page 72

6 Battery switch (Optional) Switches on the DC circuit for the FlyLine unit

7 Power pack control panel See 5.1 Power pack control panel on page 68NOV Elmar - NL, Energieweg 26, 2964 LE Groot-Ammers, The Netherlands Page 67 of 258NOV Elmar K-Winch FlyLine, MAN-10004235, 18 September 2013 Revision C


FlyLine User Manual

5U

nit c

ontr

ols

5.1 Power pack control panel

1 43

5

9

76

11

8

15

2

12

10

14


FlyLine User Manual

5U

nit controls1 CONTROL PRESSURE This gauge (0 to 41 bar (600 psi)) shows the hydraulic control pressure, which is used for controlling the hydraulic system.

2 AUXILIARY PRESSURE This gauge (0 to 280 bar (4000 psi)) shows the hydraulic pressure in the auxiliary circuit

3 HYDRAULIC OIL TEMPERATURE

This gauge (0 to +120 C (+250 F)) shows the hydraulic oil temperature. The value is measured in the main hydraulic oil reservoir.

4 ENGINE TEMPERATURE This gauge (0 to +120 C (+250 F)) shows the engine temperature. The value is measured in the engine coolant between engine and radiator.

5 ENGINE OIL PRESSURE This gauge (0 to 11 bar (160 psi)) shows the engine oil pressure. The sentinel master valve (fuel shut-off safety valve) will shut down the engine, when this value drops below 0.5 bar (7.2 psi) (approximately). During normal working conditions the oil pressure will be 2.3 bar (33 psi) (approximately); at maximum engine RPM, the oil pressure will be 4 bar (58 psi) (approximately).

6 AIR PRESSURE This gauge (0 to 11 bar (160 psi)) shows the air pressure in the system.

7 START PRESSURE(Only with a

10004235 - MAN - FlyLine Zone 2 RevC

Documents

winch flyline

winch control console

unit configuration

unit overview113

control panel705

base assemblies

winch right control

winch subsystem