Installation Procedures offshore jacket- Compiled

THIS DOCUMENT AND ALL INFORMATION CONTAINED HEREIN ARE THE CONFIDENTIAL AND EXCLUSIVE PROPERTY OF SOFEC, INC., AND MAY NOT BE REPRODUCED, USED, DISCLOSED OR MADE PUBLIC IN ANY MANNER PRIOR TO EXPRESS WRITTEN AUTHORIZATION BY SOFEC, INC. THIS DOCUMENT IS ACCEPTED BY RECIPIENT PURSUANT TO AGREEMENT TO THE FOREGOING, AND MUST BE RETURNED UPON DEMAND.

RECORD OF ISSUE

F

E

D

C

B

A 75298 JP XH 24 Sep 13

REV. ECN REVIEWED APPROVED DATE

OFFSHORE YOKE HEAD ASSEMBLY PROCEDURE

1603-OM-0370 REVISION A

1603-OM-0370

OFFSHORE YOKE HEAD ASSEMBLY PROCEDURE 2 REVISION A

REVISION HISTORY REVISION A Original issue of procedure

1603-OM-0370


TABLE OF CONTENTS

1.0 SCOPE ........................................................................................................................... 4 2.0 REFERENCE DOCUMENTS .......................................................................................... 4 3.0 BEARING BLOCK LINK AND PIN ASSEMBLY PRIOR TO OFFSHORE YOKE

INSTALLATION .............................................................................................................. 4 4.0 OFFSHORE YOKE HEAD INSTALLATION .................................................................... 5 5.0 BEARING BLOCK ASSEMBLY AFTER OFFSHORE YOKE INSTALLATION ................ 5

1603-OM-0370


1.0 SCOPE

This procedure provides the general guidelines for assembling and installing the Yoke Head Assembly onto the Turntable.

2.0 REFERENCE DOCUMENTS

Reference Assembly Drawings: 3206-DG-01-01-00040

3214-DG-01-01-00025

3214-DG-09-01-00032

1601-DG-01-01-00276

1601-DG-02-01-00300

3.0 BEARING BLOCK LINK AND PIN ASSEMBLY PRIOR TO OFFSHORE YOKE INSTALLATION

NOTE: Preparation of the Bearing Block Link and Pin assemblies can be executed in the ship yard prior to transfer of the tower structure offshore if desired. If this section of the procedure is conducted prior to arriving offshore it is imperative that all loose components (Pins, Caps, Fasteners, Installation Aids, and rigging) are correctly stored for transit offshore to prevent loss of or damage to any of the associated components and equipment.

1. Remove cap screws (3214-DG-01-01, Item 11) connecting the Links (3214-DG-01-01, Item 03 and 04) and Bearing Block Caps (3214-DG-01-01, Items 01 and 02).

2. Remove Pins (3214-DG-01-01, Item 07) furthest from the center of Turntable. Do this by using the Caps (3214-DG-01-01, Item 06) or similar plate to react against the Support Tray (1601-02-01, Item 02), and the Installation Rod (1601-02-01, Item 01) as a jackscrew to remove the Pins from the Links. Use the Support Tray to support the Pin on disassembly.

3. Rotate the Link 90 to the vertical position and insert the M36 cap screw (1601-DG-02-01, Item 05) to temporarily hold the link in the vertical position for removal of the caps.

4. Remove the Bearing Block Caps using M36 eyebolts (1601-DG-02-01, Item 08). Parts should be set aside in a secure location until final assembly. The Blocks are now ready for Yoke Installation.

1603-OM-0370


4.0 OFFSHORE YOKE HEAD INSTALLATION

1. Ensure that the Bearing Block Caps are removed. See Section 3.0. In order to use the links as guides for the Yoke Head, timbers should be placed between the center plate on the link and the bearing block as shown in 1601-DG-02-01. Remove the M36 cap screw (1601-DG-02-01, Item 05) and rotate the link back (5-10) on the timbers. This will provide a cushion and a guide for the Yoke Head installation.

2. The Yoke Head should be lowered into the Bearing Blocks with the Yoke in a level position (+/-5). The Links and guides on the Thrust Plates (3214-DG-01-01, 3214-DG-09-01) will serve as guides in positioning the Yoke Head.

3. Remove the Retaining Plates (1601-DG-01-01, Item 01) on the Bushing Carrier before attempting to completely lower or rotate the Yoke. Make sure that the keyway in the bushing carrier is facing straight up in the 12 oclock position. After the Retaining plates are removed, the Yoke may be lowered into the water.

5.0 BEARING BLOCK ASSEMBLY AFTER OFFSHORE YOKE INSTALLATION

1. Ensure that the Retaining Plates on the Yoke Head are removed before rotating the Yoke. Make sure that the keyway in the bushing carrier is facing straight up in the 12 oclock position.

2. Coat the Bearing Block and Bearing Cap (3214-DG-01-01, Items 01 and 02) mating surfaces (5 milled surface) with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06), and replace the Bearing Block Caps (make sure that they are orientated correctly in the corresponding matched sets).

3. Remove the holding cap screw in the Links if not already removed and lower the Links on the Bearing Blocks.

4. Ensure the Pin Caps (3214-DG-01-01, Item 06) are properly installed on the Links (3214-DG-01-01, Items 03 and 04). If required lift the Caps into place on the Links with a M36 eyebolt (1601-DG-02-01, Item 08). Center the caps on the Pin holes and fasten with M24 x 75 long cap screws (3214-DG-01-01, Item 13) and washers (3214-DG-01-01, Item 19). Torque to 597 N-m.

5. Lubricate the Pins (3214-DG-01-01, Item 07) and Pin holes with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06).

6. Ensure the Support Trays (1601-DG-02-01, Item 02) are assembled on the links with M20 cap screws (1601-DG-02-01, Item 03) and washers (1601-DG-02-01, Item 04). Ensure the height of the tray is set so that it will center the Pin on the Pin holes.

7. Using M42 eyebolts (1601-02-01, Item 09) in the M42 tapped hole, place the Pin on the Support Tray so that the leading edge (with the chamfer) is pointed toward the hole.

8. Insert the Installation Rod (1601-DG-02-01, Item 01) through the Pin and thread it into the Cap. Using a M36 nut (3214-DG-01-01, Item 15), washer (3214-DG-01-01, Item 17), and the Installation Rod as a jackscrew, pull the Pin into the hole until it seats against the Cap. Use the flats on the end of the Rod to keep the Rod from rotating. If the Pin binds, DO NOT force it: back it out, line it up and try again. The Pin does not have a press fit.

1603-OM-0370


9. Remove the Installation Rod and the Support Tray.

10. Insert the Retaining Rod (3214-DG-01-01, Item 05) into the Pin and thread it into the Cap. Place the washer (3214-DG-01-01, Item 17) on the Rod and thread the M36 nut (3214-DG-01-01, Item 15) onto the Rod. Tighten to 2000 N-m.

11. Repeat Steps 5.5 5.10 for the remaining Pin.

12. Thread the M36 x 90 long cap screws (3214-DG-01-01, Item 10) and washers (3214-DG-01-01, Item 17) through the Links and into the Bearing Block Caps. Torque to 2000 N-m with a socket.

13. Thread the M36 x 140 long cap screws (3214-DG-01-01, Item 11) into the Bearing Block Caps. They should line up with and be inserted into the keyways on the bushing carrier. Torque to 2000 N-m with a socket.

14. Tighten the Thrust Plate set screws (3214-DG-01-01, Item 12) in turn increments to 110 N-m in a symmetrical pattern to set the Bushing Carrier. Torque the lock nuts (3214-DG-01-01, Item 16) to 610 N-m.

15. The Bearing Block Assembly is now complete. Grease any unprotected threads and store the assembly aids in a secure location for possible future use.


RECORD OF ISSUE

F

E

D

C

B

A 76644 JP XH 24 Sep 13


BEARING BLOCK ASSEMBLY PROCEDURE


1603-OM-0383

BEARING BLOCK ASSEMBLY PROCEDURE 2 REVISION A


1603-OM-0383


TABLE OF CONTENTS

1.0 SCOPE ........................................................................................................................... 4 2.0 REFERENCE DRAWINGS ............................................................................................. 4 3.0 THRUST RING AND PLATE INSTALLATION ................................................................ 4 4.0 BEARING BLOCK AND CAP INSTALLATION ................................................................ 5 5.0 BEARING BLOCK LINK AND PIN ASSEMBLY .............................................................. 5

1603-OM-0383


1.0 SCOPE

This procedure provides the general guidelines for assembling the Bearing Block Assemblies on the Turntable to verify proper fit up of the Bearing Block Assembly components and prepare the assembly for shipment and offshore yoke installation (Ref. 1603-OM-0370, Offshore Yoke Head Assembly Procedure).

2.0 REFERENCE DRAWINGS

3214-DG-01-01-00025 Bearing Block Assembly 1601-DG-02-01-00300 Connector Pin Installation 5110-DG-05-02-00325 Turntable Machining

3.0 THRUST RING AND PLATE INSTALLATION

3.1 Chase the M30 tapped holes in the Bearing Blocks (Ref. 5110-DG-05-02) and purge with air to make sure that the threads are clean. Thread all but the upper two M30 Studs (3214-DG-01-01, Item 14) completely into the Bearing Block. Prior to assembly, make sure all mating surfaces are clean and free of debris.

3.2 Lift the Thrust Ring (3214-DG-01-01, Item 08) by placing straps (shop supplied) through the two upper holes and place the Thrust Ring on the studs and remove lifting straps.

3.3 While using straps or M36 Eyebolts (1601-DG-02-01, Item 08) placed in the M36 tapped holes, lift and place the Thrust Plate (3214-DG-01-01, Item 09) on the Studs and pull the Ring and Plate to the Block by threading two nuts down on the Plate.

3.4 Thread the remaining studs into the Bearing Block, assemble Washers (3214-DG-01-01, Item 18) and Nuts (3214-DG-01-01, Item 16) on the studs and tighten nuts by hand.

3.5 Use hydraulic tensioner part 9108-00142 (3214-DG-01-01, Item 20) with pump unit 9108-00008 and hose assembly 9108-00009 from the main bearing tensioner assembly 9108-00145 to tension two studs at a time while alternating in a symmetrical pattern (Ref. Figure 1). Tension the studs in two steps: (1) Tension all of the studs to 260 KN (16,700 psi or 1,150 Bar) and then (2) Tension all the studs to 335 KN (21,300 psi or 1,470 Bar). Do NOT exceed 21,300 psi on the pump. Tighten the nuts during each step.

3.6 After 24 hours re-check the studs at 300 KN (19,250 psi or 1325 Bar) to make sure the studs are tensioned to at least 75% of yield. If result is not satisfactory repeat steps 3.4 and 3.5.

3.7 Thread M30 Nuts (3214-DG-01-01, Item 16) on M30 Cap Screws (3214-DG-01-01, Item 12) and then thread the Cap Screws into the Thrust Plate until they are flush on the backside. Tighten the Nuts to temporarily secure the Cap Screws to the plate. The Thrust Ring and Plate Assembly are ready for Yoke Head Installation.

1603-OM-0383


4.0 BEARING BLOCK AND CAP INSTALLATION

4.1 Verify that the Bearing Blocks, Bearing Caps, and Bearing Block Links have been machined as left and right matched sets. Locate and identify left and right matched sets. Make sure that the parts are assembled in the same orientation as when they were machined.

4.2 Coat the Bearing Block and Bearing Cap (3214-DG-01-01, Items 01 and 02) mating surfaces (5 milled surface) with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06).

4.3 Using M36 Eyebolts (1601-DG-02-01, Item 08), place the matched (Left or Right Hand) Bearing Cap onto the corresponding Bearing Block with the edges flush.

4.4 Thread two M36 x 140 long Cap Screws (3214-DG-01-01, Item 11) into each bearing block cap. Do not tighten until bushing carrier is installed during the offshore installation procedure.

5.0 BEARING BLOCK LINK AND PIN ASSEMBLY

5.1 Using M36 Eyebolts (1601-DG-02-01, Item 08) in the M36 tapped hole, lift the Pin Caps (3214-DG-01-01, Item 06) and place on Links (3214-DG-01-01, Items 03 and 04). Center the caps on the Pin holes and fasten with M36 x 140 long Cap Screws (3214-DG-01-01, Item 11) and Washers (3214-DG-01-01, Item 17). Torque to 2000 N-m.

5.2 Assemble the Support Trays (1601-DG-02-01, Item 02) on the links with M20 Cap Screws (1601-DG-02-01, Item 03) and Washers (1601-DG-02-01, Item 04). Set the height of the tray so that it will center the Pin on the Pin holes.

5.3 Using straps (shop supplied) around the center plate, place the matched Links (Left or Right Hand) on the Bearing Blocks. Shim the links so that the Pin holes in the Link are aligned with the Pin holes in the Block.

5.4 Lubricate the Pins (3214-DG-01-01, Item 07) and Pin holes with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06).

5.5 Using M42 Eyebolts (1601-DG-02-01, Item 09) in the M42 tapped hole, place the Pin on the Tray so that the leading edge (with the chamfer) is pointed toward the hole.

1603-OM-0383


5.6 Insert the Installation Rod (1601-DG-02-01, Item 01) through the Pin and thread it into the Cap. Using a M36 Nut (3214-DG-01-01, Item 15), a Washer (3214-DG-01-01, Item 17), and the Installation Rod as a jackscrew, pull the Pin into the hole until it seats against the Cap. Use the flats on the end of the Rod to keep the Rod from rotating. If the Pin binds, DO NOT force it; back it out, line it up and try again. The Pin does not have a press fit and should slide in smoothly.

5.7 Remove the Installation Rod.

5.8 Insert the Retaining Rod (3214-DG-01-01, Item 05) into the Pin and thread it into the Cap. Place the Washer (3214-DG-01-01, Item 17) on the Rod and thread the M36 Nut (3214-DG-01-01, Item 15) onto the Rod. Tighten to 2000 N-m.

5.9 Repeat Steps 5.2 5.8 for the remaining Pins.

5.10 Thread the M36 x 90 long Cap Screws (3214-DG-01-01, Item 10) and Washers (3214-DG-01-01, Item 17) through the Links and into the Bearing Block Caps. Torque to 2000 N-m using a socket.

Figure 1 Tensioning Sequence

THIS DOCUMENT AND ALL INFORMATION CONTAINED HEREIN ARE THE CONFIDENTIAL AND EXCLUSIVE PROPERTY OF SOFEC, INC., AND MAY NOT BE REPRODUCED, USED, DISCLOSED, OR MADE PUBLIC IN ANY MANNER PRIOR TO EXPRESSED WRITTEN AUTHORIZATION FROM SOFEC, INC. THIS DOCUMENT IS LOANED PURSUANT TO THE FOREGOING AND MUST BE RETURNED UPON DEMAND.

RECORD OF ISSUE

F

E

D

C

B

A 75958 QD XH 20-AUG-2013


COUPLER PIN INSTALLATION PROCEDURE


HLNG NO. 100-710-0067

PGN FSRU LAMPUNG TOWER YOKE MOORING SYSTEM

PROJECT: 2617

1603-OM-0379

COUPLER PIN INSTALLATION PROCEDURE 1 REVISION A

REVISION A Original Issue of Procedure

COUPLER PIN INSTALLATION PROCEDURE

REVISION HISTORY

1603-OM-0379


TITLE

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................. 4 2.0 REFERENCE DRAWINGS ............................................................................................... 4 3.0 INSTALLATION PROCEDURE ......................................................................................... 4 4.0 COUPLER PIN REMOVAL PROCEDURE ........................................................................ 6

4.1 SAFETY ................................................................................................................ 6

APPENDIX A - ORKOT BEARING FITTING METHOD

1603-OM-0379


1.0 SCOPE

The objective of this procedure is to provide the recommended installation method for installing a Coupler Pin into any U-Joint assembly. It also provides the recommended procedure for Coupler Pin removal.

Notes:

This procedure requires that the Coupler Pin Bearings have been installed according to bearing manufacturers standards (Appendix A).

This procedure requires that the Bearing bores are clean and completely free of any lubricant. The Bearing bores may only be cleaned with alcohol.


1601-DG-04-01 : U-Joint Coupler Pin Installation Assembly

3205-DG-01-02 : Upper U-Joint Assembly

3205-DG-20-02 : Lower U-Joint Assembly

3.0 INSTALLATION PROCEDURE

Reference Drawing - 1601-DG-04-01

Make sure that the Bearing bores have been aligned with the Alignment Sleeve (Item 05). Remove Alignment Sleeve once bores are aligned and components are secured.

Attach the Pin Box (Item 01) to the side of the U-Joint Clevis with 4x M20 hex screws (Item 08) and washers (Item 09). Torque the screws to the value shown.

Install the UHMW Rub Strips (Item 04) in the Pin Box (Item 01).

Install the M5 socket head cap screws (Item 10) to fasten the Rub Strips to the Pin Box.

Attach the Winch Mount (Item 02) to the side of the Clevis opposite the Pin Box (Item 01) by installing the M20 hex screws (Item 08) and washers (Item 09). Torque the screws to the value shown on the drawing. Ensure that the Hand Winch (Item 06) is installed to the Winch Mount prior to being attached to the Clevis.

Lay the Coupler Pin in the Pin Box (Item 01) as far away from the Clevis as possible.

1603-OM-0379


Place the Coupler Pin Guide (Item 03) on the end of the Coupler Pin that is next to the Clevis. Ensure that the pilot diameter on the Coupler Pin Guide fits in the pilot bore in the end of the Coupler Pin.

Screw a Shoulder Eye Bolt (Item 07) tightly up against the Coupler Pin Guide (Item 03) and screw it into the end of the Coupler Pin. Tighten the Shoulder Eye Bolt until it locks the Pin Guide to the end of the Coupler Pin.

Slowly payout the hand winch wire rope into the U-joint Clevis. The wire rope and spelter socket must not touch the inside diameter of the Clevis bearings. To do so will damage the inside polymer surface of the bearing.

Connect the open spelter socket from the hand winch wire rope to the Shoulder Eye Bolt (Item 07).

Support the loose end of the hand winch wire rope so that it does not touch the inside diameter of the Clevis Bearing.

Slowly retract the hand winch wire rope until the end of the Coupler Pin, opposite from the pin guide, is 20 mm from the face of Clevis that is next to the Pin Box (Item 01).

Remove the Pin Box (Item 01).

Reference Drawings - 3205-DG-01-02 and 3205-DG-20-02

Install the M36 studs in the end of the Coupler Pin.

Install the Coupler Pin Retainer.

Install the M36 Nuts and washers. Torque the nuts to the value shown.

Reference Drawing: 1601-DG-04-01

Use Hand Winch (Item 06) to pull on the Coupler Pin until the Coupler Pin Retainer (Item 06 on drawings 3205-DG-01-02 and 3205-DG-20-02) is pulled up against the side of the Clevis. The Coupler Pin is now fully engaged.

Disconnect the spelter socket from the Shoulder Eye Bolt (Item 07) and remove the Pin Guide (Item 03) from the Coupler Pin.

Remove the Winch Mount (Item 02) from the side of the Clevis.

Reference Drawings: 3205-DG-01-02 and 3205-DG-20-02

Install the remaining M36 Studs in the Coupler Pin.

Install the Coupler Pin Retainer.

1603-OM-0379


Install the remaining M36 Nuts and Washer. Torque the Nuts to the value shown on the drawing.

The Coupler Pin is now fully installed in the U-Joint.

4.0 COUPLER PIN REMOVAL PROCEDURE

Note:

1. The operator must completely understand this section of the procedure before proceeding to remove a Coupler Pin.

2. The technique to remove a Coupler Pin that is described in this section of the procedure can be used on any Coupler Pin in a U-Joint assembly, whether the Upper or Lower U-Joint assembly.

3. The hand winch (Item 06) on Drawing 1601-DG-04-01 must be assembled and installed on the Winch Mount prior to attach at the end of the Pin Box.

4.1 SAFETY

Before a Coupler Pin is removed, the weight of the U-Joint assembly components below the Coupler Pin that is to be removed must be setting on the shop floor or otherwise safely supported in some manner.

Before pulling the upper Coupler Pin from a U-Joint Assembly that is supported (hung) from an overhead crane, the Coupler block must be supported so that as the Coupler Pin is removed the Coupler block will not rotate (flip) over the lower Coupler Pin and injure someone. This can be accomplished by wedging several wooden blocks between the bottom of the Coupler block and the lower most clevis.


This drawing is only used as an example.

Remove the M36 Nuts (Item 10) and Washers (Item 09) from each end of the Coupler Pin (Item 05).

Remove the Coupler Pin Retainer (Item 06) from each end of the Coupler Pin (Item 05).

Remove the M36 studs (Item 08) from each end of the Coupler Pin.

1603-OM-0379


Reference Drawing 1601-DG-04-01

Bolt the Pin Box (Item 01) to one side of the clevis from which the Coupler Pin is to be removed. Torque the M20 Hex Cap Screws (Item 08) with Washers (Item 09) to the value shown on the drawing.

Install the Winch Mount (Item 02) and Hand Winch (Item 06) at the end of the Pin Box.

Install the Rub Strips (Item 04) on the Pin Box and secure them in place by installing the M5 Hex Cap Screws (Item 10).

Screw a Shoulder Eye Bolt (Item 07) into the end of the Coupler Pin and tighten it to 10 N-m.

Slowly payout the hand winch wire rope and connect the open spelter socket from the hand winch rope to the Shoulder Eye Bolt (Item 07)

Slowly retract the hand winch wire rope until the Coupler Pin is fully withdrawn from the U-Joint Clevis.

Remove the Coupler Pin from the Pin Box (Item 01) and store the Coupler Pin in such a manner that the outside surface of the Coupler Pin is protected from the elements and from being scratched.

The Pin Box (Item 01), Winch Mount (Item 02) and Hand Winch (Item 06) can now be removed by removing the M20 Hex Cap Screws (Item 08) and Washers (Item 09).

The Coupler Pin has been completely removed and now the Coupler and the U-Joint Clevis can be separated by raising the U-Joint clevis above the Coupler.

1603-OM-0379


APPENDIX A

ORKOT BEARING FITTING METHOD

1603-OM-0379



RECORD OF ISSUE

F

E

D

C

B

A 75958 QD XH 20-AUG-2013


UPPER AND LOWER U-JOINT INSTALLATION PROCEDURE


HLNG NO. 100-710-0066


PROJECT: 2617

1603-OM-0378

UPPER AND LOWER U-JOINT INSTALLATION PROCEDURE 1 REVISION A


UPPER AND LOWER U-JOINT INSTALLATION PROCEDURE

REVISION HISTORY

1603-OM-0378


TITLE

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................. 4 2.0 REFERENCE DRAWINGS ............................................................................................... 4 3.0 PREP WORK .................................................................................................................... 4

3.1 BEARING CLEANING ........................................................................................... 4 3.2 PRE-INSTALLATION PREPARATION .................................................................. 4

4.0 UPPER U-JOINT AND MOORNG SUPPORT CLEVIS ASSEMBLY ................................. 5 4.1 MOORING SUPPORT CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE ................................................................................................................... 5 4.2 UPPER ARM LINK CLEVIS TO MOORING SUPPORT CLEVIS/ COUPLER/ COUPLER PIN ASSEMBLY ............................................................................................. 5

5.0 LOWER U-JOINT AND YOKE-CLEVIS ASSEMBLY ......................................................... 6 5.1 LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE ................................................................................................................... 6 5.2 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE ............................................................................................... 8

APPENDIX A - ORKOT BEARING FITTING METHOD

1603-OM-0378


1.0 SCOPE

The first objective of this procedure is to provide the recommended assembly method for attaching the Upper U-Joint Assembly to the Mooring Support Clevis, including trial fit.

The second objective of the procedure is to provide the recommended assembling method for attaching the Lower U-Joint Assembly in the Yoke, including trial fit.




1601-DG-03-01 : U-Joint Connector Pin Installation Assembly


3.0 PREP WORK

WARNING:

Do not allow lubricant, Acetone, Methyl Ethyl Ketone or cutting tool fluids to come in contact with the bearing.

3.1 BEARING CLEANING

The bearing should only be cleaned with Alcohol and then allowed to dry.

3.2 PRE-INSTALLATION PREPARATION

The entrance to the bearing bores must have all burrs removed.

The outside diameter of all bearings must be cleaned and all burrs removed.

1603-OM-0378


4.0 UPPER U-JOINT AND MOORNG SUPPORT CLEVIS ASSEMBLY

4.1 MOORING SUPPORT CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE


Completely clean the Mooring Support Clevis (Item 02) bearing bores.

Install the Flanged Radial Bearings (item 07) in the Mooring Support Clevis (Item 02) according to bearing manufactures standards (Appendix A).

Set the Mooring Support Clevis (Item 02) on supports as shown in Figure 1.

Install the Pin Box and Winch Mount as shown in Figure 2. Ensure that the Hand Winch is installed to the Winch Mount prior to attaching to the Clevis. See 1603-OM-0379 for details.

Set the Coupler (Item 03) on supports with the centerline of the Coupler Pin bearing bores in the horizontal position as shown in Figure 3.

Completely clean the Coupler Bearing bores.

Install the Flanged Radial Bearings (item 07) in the Coupler (Item 03) according to bearing manufactures standards (Appendix A).

Place 2 slings around the Coupler (at least 300mm apart) and lift the Coupler with the two slings and level it as shown in Figure 4. It may be necessary to block the two slings apart to prevent them from sliding together.

Position the Coupler inside the Mooring Support clevis as shown in Figure 5 until the Bearing bores in the Clevis are aligned with the Bearing bores in the Coupler. Ensure the alignment of the bearing bores by installing an Alignment Sleeve (Item 05 of drawing 1601-DG-04-01) into both the Clevis and Coupler bearings on each side of the assembly. Hydraulic leveling jacks should be used to aid in alignment of the bearing bores

Install the Coupler Pin (Item 04) into the Clevis and Coupler as shown in Figure 5, and according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06) and Retainer Studs (Item 08) according to 1603-OM-0379.

The Mooring Support Clevis, the Coupler and Coupler Pin are now fully assembled. Repeat the above procedure for the second assembly.

1603-OM-0378


1603-OM-0378


4.2 UPPER ARM LINK CLEVIS TO MOORING SUPPORT CLEVIS/ COUPLER/ COUPLER PIN ASSEMBLY


Set the Arm Link (Item 01) on the shop floor in the up-right position as shown on the Assembly drawing. For safety the Arm Link will have to be supported in this up-right position by bracing. Ensure that the centerline of the bearing bores is level

Completely clean the bearing bores of the Arm Link.


Raise the Mooring Support Clevis/Coupler/Coupler Pin assembly and ensure that the centerline of the lower set of Coupler bearings is level.

Move the Mooring Support Clevis/Coupler/Coupler Pin assembly over the top of the Upper Arm Link Clevis and slowly lower the assembly down into the Upper Arm Link Clevis. Ensure that the bearing bores in the Coupler are aligned with the bearing bores in the Upper Arm Link Clevis. This is done by installing an Alignment sleeve (Item 05) in the bearing bores located in the clevis and Coupler on both sides of the assembly. Remove the Alignment Sleeves.

1603-OM-0378


Install the Coupler Pin (Item 05 on drawing 3205-DG-01-02) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06 on drawing 3205-DG-01-02) and Retainer Studs (Item 08 on drawing 3205-DG-01-02) according to 1603-OM-0379.

Note: The Upper U-Joint Assembly trial fit is now complete. Remove the pin according to 1603-OM-0379 and disconnect the Arm Link from the Mooring Support Clevis/Coupler/Coupler Pin Assembly.

5.0 LOWER U-JOINT AND YOKE-CLEVIS ASSEMBLY

Note: Completely clean all parts before they are assembled.

5.1 LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE

Referencing Drawing - 3205-DG-20-02

Completely clean the Lower Clevis (Item 01) and Coupler (Item 03) bearing bores (with Alcohol only).

Install the Flanged Radial Bearings (item 09) in the Lower Clevis (Item 01) and Coupler (Item 03) according to bearing manufactures standards (Appendix A).

Erect some support timbers or other support such that the top of the support is 700-725mm high and no wider than 750mm. This will allow the clevis section of the Lower Arm Link Clevis (Item 01) to sit on the support without touching the floor later in the assembly process.

Set the Swivel Shaft Retainer (Item 08) on the support timbers. Make sure that two of the bolt holes can be accessed for later assembly of the M20 Cap Screws (Item 19).

Set the Radial Bearing (Item 11) around the Swivel Shaft (Item 05).

Set the Swivel Shaft and Radial Bearing on top of the Swivel Shaft Retainer (Item 08). Center the Swivel Shaft in the middle of the Swivel Shaft Retainer.

Set the Thrust Washer (Item 10) on top of the Swivel Shaft. See Figure 6.

Set the Bearing Ring Plate (Item 14) on top of the Thrust Washer.

Lower the Lower Arm Link Clevis (Item 01) down over the Swivel Shaft (Item 05) and set it down on the Bearing Ring Plate (Item 14). The clevis must not touch the floor (See Figure 7). Be careful to make sure that the Radial Bearing and Thrust Washer are centered during installation and that the bolt holes are aligned. Bolt two of the

1603-OM-0378


M20 Cap Screws (Item 19) and Washers (Item 20) to attach the Retainer to the Lower Arm Link Clevis.

Pump EP2 grease in to the 4 grease fittings (Item 22) on the Lower Arm Link Clevis until the grease appears around the Swivel Shaft.

Lower the Arm Link down over the Swivel Shaft (Item 05) and set the Arm Link Connector down on the Lower Arm Link Clevis. Ensure that the connector pin holes in the Arm Link Connector are aligned with the connector pin hole in the Swivel Shaft.


Install the Connector Pin (Item 04 on drawing 3205-DG-20-02) and the Connector Pin Retainers (Item 07 on drawing 3205-DG-20-02) according to Assembly Procedure 1603-OM-0376.

Note: This completes the trial fit of the Connector Pin installation. Remove the Connector Pin (Item 04 on drawing 3205-DG-20-02) and Arm Link.

Attach the Lifting Guide (Item 01 on drawing 1601-DG-03-01) to the Swivel Shaft (Item 05 of drawing 3205-DG-20-02) according to 1603-OM-0376 and use the Lifting Guide to raise the Lower Arm Link Clevis/Swivel Shaft assembly.

Install the remaining M20 Cap Screws (Item 19) and Washers (Item 20). See Figure 8.

Set the Coupler (Item 03 on drawing 3205-DG-20-02) on the shop floor with the centerlines of the Coupler Pin bearing bores in the horizontal position.

Completely clean the Coupler Bearing bores (with Alcohol only).

Slowly lower the Lower Arm Link Clevis/Swivel Shaft assembly down over the Coupler (Item 03 on drawing 3205-DG-20-02) until the Bearing bores in the Clevis are aligned with the Bearing bores in the Coupler. Ensure the alignment of the bearing bores by installing an Alignment Sleeve, (Item 05 on drawing 1601-DG-04-01) into both the Clevis and Coupler bearings on each side of the assembly.

Remove Alignment Sleeve once aligned.

Install the Coupler Pin (Item 12 on drawing 3205-DG-20-02) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06 on drawing 3205-DG-20-02) and Retainer Studs (Item 15 on drawing 3205-DG-20-02) according to Assembly Procedure 1603-OM-0379. A timber may be placed between the Clevis and Coupler in order to keep the Clevis from rotating.

1603-OM-0378


Note: The Lower Arm Link Clevis, Coupler and Coupler Pin are now fully assembled.

5.2 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE


Set the Yoke Clevis (Item 02) on the shop floor in the up-right position as shown on the Assembly drawing. For safety the Yoke Clevis will have to be supported in this up-right position by bracing. Ensure that the centerline of the bearing bores is level.

Completely clean (with Alcohol only) the bearing bores of the Yoke Clevis.

Install the Flanged Radial Bearings (Item 09) in the Yoke Clevis (Item 02) according to bearing manufacturers standards (Appendix A).

Raise the Lower Arm Link Clevis/Coupler/Coupler Pin assembly and ensure that the centerline of the lower set of Coupler bearings is level.

Move the Lower Arm Link Clevis/Coupler/Coupler Pin assembly over the top of the Yoke Clevis and slowly lower the assembly down into the Yoke Clevis. Ensure that the bearing bores in the Coupler are aligned with the bearing bores in the Yoke Clevis. This is done by installing an Alignment sleeve (Item 05 on drawing 1601-DG-04-01) in the bearing bores located in the clevis and Coupler on both sides of the assembly. Remove the Alignment Sleeves.

Install the Coupler Pin (Item 13) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06) and Retainer Studs (Item 15) according to 1603-OM-0379.

Note: This completes the Yoke Clevis/Lower Arm Link trial fit. Remove Coupler Pin (Item 13) and Yoke Clevis from Lower Arm Link Clevis/Coupler/Coupler Pin Assembly.

Install the Yoke Clevis in the Yoke Structure and weld out the structure according to the Yoke Structure drawings.

Raise the Lower Arm Link Clevis/Coupler/Coupler Pin assembly with the Lifting Guide and ensure that the centerline of the lower set of Coupler bearings is level.

Move the Lower Arm Link Clevis/Coupler/Coupler Pin assembly over the top of the Yoke Clevis and slowly lower the assembly down into the Yoke Clevis. Ensure that the bearing bores in the Coupler are aligned with the bearing bores in the Clevis Yoke. This is done by installing an Alignment sleeve (Item 05 on drawing 1601-DG-04-01) in the bearing bores located in the clevis and Coupler on both sides of the assembly. Remove the Alignment Sleeves.

1603-OM-0378


Install the Coupler Pin (Item 13) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06) and Retainer Studs (Item 15) according to 1603-OM-0379. A timber may be placed between the Clevis and Coupler in order to keep the assembly from rotating over.

Note: The Lower U-Joint Assembly is now completely installed in the Yoke. See Figure 9. Repeat for the second assembly.

1603-OM-0378


1603-OM-0378


APPENDIX A

ORKOT BEARING FITTING METHOD

1603-OM-0378



RECORD OF ISSUE

F

E

D

C

B

A 75958 QD XH 20-AUG-2013


U-JOINT ASSEMBLY INSTALLATION PROCEDURE


HLNG NO. 100-710-0065


PROJECT: 2617

1603-OM-0377

U-JOINT ASSEMBLY INSTALLATION PROCEDURE 1 REVISION A


U-JOINT ASSEMBLY INSTALLATION PROCEDURE

REVISION HISTORY

1603-OM-0377


TITLE

TABLE OF CONTENTS

1.0 U-JOINT ASSEMBLY PROCEDURE ................................................................................ 4 1.1 SCOPE ................................................................................................................. 4 1.2 BEARING CLEANING ........................................................................................... 4

2.0 UPPER U-JOINT ASSEMBLY .......................................................................................... 4 2.1 MOORING SUPPORT CLEVIS TO THE COUPLER/COUPLER PIN ASSEMBLY 4 2.2 UPPER ARM LINK CLEVIS TO COUPLER/COUPLER PIN ASSEMBLY .............. 5

3.0 LOWER U-JOINT ASSEMBLY.......................................................................................... 6 3.1 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY ...................................................................................................................... 7

4.0 COUPLER PIN REMOVAL ............................................................................................... 8 4.1 SAFETY ................................................................................................................ 8

1603-OM-0377


1.0 U-JOINT ASSEMBLY PROCEDURE

1.1 SCOPE

The primary objective of this procedure is to provide the recommended assembly methods for both the Upper and Lower U-Joint Assemblies. This procedure also provides the method to be used to remove any Coupler Pin from any U-Joint Assembly.

This procedure requires that the Coupler Pin Bearings have been already installed according to bearing manufacturers standards.

Reference Drawings





Warning:

Do not allow a lubricant, Acetone, Methyl Ethyl Ketone or cutting tool fluids to come in contact with the bearing.

1.2 BEARING CLEANING

The bearing should only be cleaned with Alcohol and then allowed to dry.

Pre-Installation Preparation:

The entrance to the bearing bores must have all burrs removed.

The outside diameter of all bearings must be cleaned and all burrs removed.

2.0 UPPER U-JOINT ASSEMBLY

2.1 MOORING SUPPORT CLEVIS TO THE COUPLER/COUPLER PIN ASSEMBLY

Referencing Drawings - 3205-DG-01-02 and 3205-DG-20-02

Hang the Mooring Support Clevis (Item 02 on drawing 3205-DG-01-02) from the overhead crane. Ensure that the clevis is hanging level.

1603-OM-0377


Completely clean the clevis bearing bores.

Set the Coupler (Item 03 on drawings 3205-DG-01-02 and 3205-DG-20-02) on the shop floor with the centerline of the Coupler Pin bearing bores in the horizontal position.

Completely clean the Coupler Bearing bores.

Slowly lower the Mooring Support Clevis (Item 02 on drawing 3205-DG-01-02) down over the Coupler (Item 03 on drawings 3205-DG-01-02 and 3205-DG-20-02) until the Bearing bores in the Clevis are aligned with the Bearing bores in the Coupler. Ensure the alignment of the bearing bores by installing an Alignment Sleeve (Item 05 on drawing 1601-DG-04-01) into both the Clevis and Coupler bearings on each side of the assembly

Install the Coupler Pin (Item 04 on drawing 3205-DG-01-02 and item 13 on drawing 3205-DG-20-02) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06 on drawings 3205-DG-01-02 and 3205-DG-20-02) and Retainer Studs (Item 08 on drawing 3205-DG-01-02 and item 15 on drawing 3205-DG-20-02) according to Assembly Procedure 1603-OM-0379.

Note: The Mooring Support Clevis, the Coupler and Coupler Pin are now fully assembled.

2.2 UPPER ARM LINK CLEVIS TO COUPLER/COUPLER PIN ASSEMBLY


Set the Upper Arm Link Clevis (Item 01) on the shop floor in the up-right position as shown on the Assembly drawing. For safety the Upper Clevis will have to be supported in this up-right position by bracing. Ensure that the centerline of the bearing bores is level.

Completely clean the bearing bores of the Upper Clevis.

Reference Drawings - 1601-DG-04-01 and 3205-DG-01-02

Raise the Mooring Support Clevis/Coupler/Coupler Pin assembly and ensure that the centerline of the lower set of Coupler bearings is level.

Move the Mooring Support Clevis/Coupler/Coupler Pin assembly over the top of the Upper Arm Link Clevis and slowly lower the assembly down into the Upper Arm Link Clevis. Ensure that the bearing bores in the Coupler are aligned with the bearing

1603-OM-0377


bores in the Upper Arm Link Clevis. This done by installing an Alignment sleeve (Item 05 on drawing 1601-DG-04-01) in the bearing bores located in the clevis and Coupler on both sides of the assembly. Remove the Alignment Sleeves.

Install the Coupler Pin (Item 05 on drawing 3205-DG-01-02) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06 on drawing 3205-DG-01-02) and Retainer Studs (Item 08 on drawing 3205-DG-01-02) according to Assembly Procedure 1603-OM-0379.

Note: The Upper U-Joint Assembly is now complete.

3.0 LOWER U-JOINT ASSEMBLY


Note: Completely clean all parts before they are put into the U-Joint assembly.

Erect some support timbers or other support such that the top of the support is 700-725mm high and no wider than 750mm. This will allow the clevis section of the Lower Arm Link Clevis (Item 01) to sit on the support and not touch the shop floor later in the assembly process.

Set the Swivel Shaft Retainer (Item 08) on the support timbers. Make sure that two of the bolt holes can be accessed for later assembly of the M20 Cap Screws (Item 19).

Set the Swivel Shaft (Item 05) on top of the Swivel Shaft Retainer (Item 08). Center the Swivel Shaft in the middle of the Swivel Shaft Retainer.

Set the Radial Bearing (Item 11) around the Swivel Shaft (Item 05) and the Thrust Washer (Item 10) on top of the Swivel Shaft.

Lower the Lower Arm Link Clevis (Item 01) down over the Swivel Shaft (Item 05) and set it down on the Thrust Washer (Item 10). The clevis must not touch the floor. Be careful to make sure that the Radial Bearing and Thrust Washer are centered during installation and that the bolt holes are aligned. Bolt two of the M20 Cap Screws (Item 19) and Washers (Item 20) to attach the Retainer to the Swivel Shaft.

Lower the Arm Link Connector, P/N 3205-00223, down over the Swivel Shaft (Item 05) and set the Arm Link Connector down on the Lower Arm Link Clevis. Ensure that the connector pin hole in the Arm Link Connector is aligned with the connector pin hole in the Swivel Shaft.

1603-OM-0377



Install the Connector Pin (Item 04) and the Connector Pin Retainers (Item 07) according to Assembly Procedure 1603-OM-0376.

Note: This completes the trial fit of the Connector Pin installation.


Using the Swivel Hoist Rings M36 on the Connector (Handling Hole) and the overhead crane raise the Lower Arm Link Clevis (Item 01).

Install the remaining M20 Cap Screws (Item 19) and Washers (Item 20).

Set the Coupler (Item 03) on the shop floor with the centerlines of the Coupler Pin bearing bores in the horizontal position.

Completely clean the Coupler Bearing bores (with Alcohol only).

Slowly lower the Lower Arm Link Clevis (Item 01) down over the Coupler (Item 03) until the Bearing bores in the Clevis are aligned with the Bearing bores in the Coupler. Ensure the alignment of the bearing bores by installing an Alignment Sleeve, (Item 05 of drawing 1601-DG-04-01) into both the Clevis and Coupler bearings on each side of the assembly.

Install the Coupler Pin (Item 12) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06) and Retainer Studs (Item 15) according to Assembly Procedure 1603-OM-0379.

Note: The Lower Clevis-Arm Link, the Coupler and Coupler Pin are now fully assembled.

3.1 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY


Set the Yoke Clevis (Item 02) on the shop floor in the up-right position as shown on the Assembly drawing. For safety the Yoke Clevis will have to be supported in this up-right position by bracing. Ensure that the centerline of the bearing bores is level.

Completely clean (with Alcohol only) the bearing bores of the Yoke Clevis.

1603-OM-0377



Raise the Lower Arm Link Clevis/Coupler/Coupler Pin assembly and ensure that the centerline of the lower set of Coupler bearings is level.

Move the Lower Arm Link Clevis/Coupler/Coupler Pin assembly over the top of the Yoke Clevis and slowly lower the assembly down into the Yoke Clevis. Ensure that the bearing bores in the Coupler are aligned with the bearing bores in the Yoke Clevis. This is done by installing an Alignment sleeve (Item 05 on drawing 1601-DG-04-01) in the bearing bores located in the clevis and Coupler on both sides of the assembly. Remove the Alignment Sleeves.

Install the Coupler Pin (Item 13 on drawing 3205-DG-20-02) into the Clevis and Coupler according to Assembly Procedure 1603-OM-0379. Also assemble the Coupler Pin Retainers (Item 06 on drawing 3205-DG-20-02) and Retainer Studs (Item 15 on drawing 3205-DG-20-02) according to Assembly Procedure 1603-OM-0379.

Note: The Lower U-Joint Assembly is now complete.

4.0 COUPLER PIN REMOVAL

Note: The operator must completely understand this section of the procedure before proceeding to remove a Coupler Pin.

1. The technique to remove a Coupler Pin that is described in this section of the procedure can be used on any Coupler Pin in a U-Joint assembly, whether the Upper or Lower U-Joint assembly.

2. The hand winch on drawing 1601-DG-04-01 must be assembled and installed on the Winch Mount prior to attach at the end of the Pin Box.

4.1 SAFETY

1. Before a Coupler Pin is removed, the weight of the U-Joint assembly components below the Coupler Pin that is to be removed must be setting on the shop floor or otherwise safely supported in some manner.

2. Before pulling the upper Coupler Pin from a U-Joint Assembly that is supported (hung) from an overhead crane, the Coupler block must be supported so that as the Coupler Pin is removed the Coupler block will not rotate (flip) over the lower Coupler Pin and injure someone. This can be accomplished by wedging several wooden blocks between the bottom of the Coupler block and the lower most clevis.

1603-OM-0377



This drawing is only used as an example.

Remove the M36 Nuts (Item 10) from each end of the Coupler Pin (Item 04).

Remove the Coupler Pin Retainer (Item 06) from each end of the Coupler Pin (Item 04).

Remove the M36 studs (Item 08) from each end of the Coupler Pin (Item 04).

Reference Drawing 1601-DG-04-01

Bolt the Pin Box (Item 01) to one side of the clevis from which the Coupler Pin is to be removed. Torque the M20 Hex Cap Screws (Item 08) with Washers (Item 09) to the value shown on the drawing. Ensure that the Hand Winch (Item 06) is installed at the end of the Pin Box.

Install the Rub Strips (Item 04) and secure them in place by installing the M5 Hex Cap Screws (Item 10). Torque the Cap Screws to the value shown on the drawing.

Screw a Shoulder Eye Bolt (Item 07) into the end of the Coupler Pin and tighten it to 10 N-m.

Slowly payout the hand winch wire rope and connect the open spelter socket from the hand winch rope to the Shoulder Eye Bolt (Item 07)

Slowly retract the hand winch wire rope until the Coupler Pin is fully withdrawn from the U-Joint Clevis.

Remove the Coupler Pin from the Pin Box (Item 01) and store the Coupler Pin in such a manner that the outside surface of the Coupler Pin is protected from the elements or from being scratched.

The Pin Box (Item 01) can now be removed by removing the M20 Hex Cap Screws (Item 08) and Washers (Item 09).

The Coupler Pin has been completely removed and now the Coupler and the U-Joint Clevis can be separated by raising the U-Joint clevis above the Coupler.


RECORD OF ISSUE

F

E

D

C

B

A 75958 QD XH 20-AUG-2013


MOORING YOKE (LOWER U-JOINT) TO ARM LINK INSTALLATION PROCEDURE


HLNG NO. 100-710-0064


PROJECT: 2617

1603-OM-0376

MOORING YOKE (LOWER U-JOINT) TO ARM LINK INSTALLATION PROCEDURE 1 REVISION A


MOORING YOKE (LOWER U-JOINT) TO ARM LINK INSTALLATION PROCEDURE

REVISION HISTORY

1603-OM-0376


TITLE

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................. 4 2.0 REFERENCE DRAWINGS ............................................................................................... 4 3.0 NOTE................................................................................................................................ 4 4.0 PROCEDURE ................................................................................................................... 4

1603-OM-0376


1.0 SCOPE

The objective of this procedure is to attach the Mooring Yoke (Lower U-Joint Assembly) to the Arm Link. Listed below are the steps that are required to complete this connection.


1020-DG-01-01 : Mooring Yoke Structure Assembly



3.0 NOTE

This procedure must not be attempted until all of the following tasks are completed:

1. The Mooring Yoke must be assembled as shown on Drawing 1020-DG-01-01.

2. The Upper U-Joint must be assembled on the Mooring Support Structure per Assembly Procedure 1603-OM-0378.

3. The Lower U-Joint must be assembled on the Mooring Yoke as shown on Drawing 1020-DG-01-01 per Assembly Procedure 1603-OM-0378.

4. The Arm Link must be assembled and installed on the Mooring Support Structure per Assembly Procedure 1603-OM-0380.

5. The Swivel Shaft in the Lower U-Joint Assembly must be raised and temporally secured in a position that is approximately 16 degrees from vertical.

4.0 PROCEDURE

Reference Drawing - 1601-DG-03-01.

Prior to pulling the Swivel Shaft into the Arm Link Connector, Align the Connector Pin bore in the Swivel Shaft as close as possible with the Connector Pin bore in the Arm Link Connector.

Make sure the Lifting Guide (Item 01) is installed on the Swivel Shaft with the M12 Screws (Item 08) and Washers (Item 09). Torque to the value shown on the drawing.

1603-OM-0376


Align both the Swivel Shafts as close as possible with the Connector bores in the Arm Link Connectors.

Pull the Yoke up to engage the Swivel Shafts into the Arm Link Connectors. This task should be accomplished by following the FSRU installation procedures. The Arm Link should bottom out on the Lower Arm Link Clevis.

Using the pad eyes on the Arm Link, install the Connector Pin Box (Item 03) on one side of the Arm Link Connector and the Puller Support (Item 02) on the other side of the Arm Link Connector. Secure them in place by installing the M20 Hex Cap Bolts (Item 05), Nuts (Item 06) and Washers (Item 07). Torque the Hex Nuts to the value shown on the drawing.

Rig a 1 Ton Cable Puller (come-a-long) supplied by the installation contractor to the Puller Support as shown for pulling in the Connector Pin.

Using a small jack, lift/rotate the Swivel Shaft until the Connector Pin bore in the Swivel Shaft is aligned with the bore in the Arm Link Connector.

Install the Connector Pin Guide (Item 04) on the end of the Connector Pin using the M20 Hex Cap Bolts (Item 08) and Washers (Item 09).

Lay the Connector Pin in the Connector Pin Box (Item 03).

Using the Cable Puller, pull the Connector Pin through the Swivel Shaft until the end of the Connector Pin is 1 inch into the Puller side of the Arm Link Connector.

Remove the Connector Pin Box (Item 03).


Install four M36 studs (Item 16) into the Connector Pin end opposite the Puller.

Install the Connector Pin Retainer (Item 07).

Install four M36 Nuts (Item 18) and Washers (Item 17).

Using the Cable Puller, finish pulling the Connector Pin up into the Swivel Shaft until it bottoms out on the Connector Pin Retainer.

Remove the four M12 Bolts and the Pin Guide.

Remove the Puller Support.

Repeat steps for the other Retainer.

Repeat steps for the other U-joint. The Mooring Yoke to Arm Link installation is complete.


RECORD OF ISSUE

F

E

D

C

B

A 75875 JP XH 31 May 13


YOKE HEAD ASSEMBLY PROCEDURE


1603-OM-0374

YOKE HEAD ASSEMBLY PROCEDURE 2 REVISION A


1603-OM-0374


TABLE OF CONTENTS

1.0 SCOPE .............................................................................................................................. 42.0 REFERENCE DOCUMENTS ............................................................................................ 43.0 BUSHING AND THRUST WASHER INSTALLATION ....................................................... 44.0 YOKE HEAD BEARING INSTALLATION .......................................................................... 55.0 YOKE HEAD TO YOKE STRUCTURE ASSEMBLY ......................................................... 55.1 HORIZONTAL ASSEMBLY ............................................................................................... 55.2 VERTICAL ASSEMBLY ..................................................................................................... 6 APPENDIX A ..................................................................................................................... 7

1603-OM-0374


1.0 SCOPE

This procedure provides the general guidelines for assembling the Yoke Head Assembly prior to offshore Yoke installation.

Note: Bushing assembly is to be achieved by qualified personnel properly trained for using liquid nitrogen and wearing the appropriate personal protective equipment.

2.0 REFERENCE DOCUMENTS

Reference Assembly Drawings: 3206-DG-01-01-00040

3206-DG-01-02-00041

1601-DG-01-01-00276

3.0 BUSHING AND THRUST WASHER INSTALLATION

1. Lift the Bushing Carrier (3206, Item 03) and position it so that the Thrust Washer mating surface is facing upward. Use the M20 eyebolts or M20 swivel hoist rings (shop supplied) in the M20 handling holes (or use the M20 holes on the opposite side if needed) for handling and lifting the Bushing Carrier. Make sure the ID of the Bushing Carrier is clean and free of debris. Chase the (12x) M20 tapped holes, purge with air and degrease to make sure that the threads are clean.

2. Lift the Bushing (3206, Item 04) with a spreader bar and clamps and slowly submerge the Bushing completely in Liquid Nitrogen for at least one minute to contract the Bushing. Measure the O.D. of the Bushing and verify that it is less than 560.0 mm before insertion into the Bushing Carrier. If it fails to measure less than 560.0 mm, then re-submerge the Bushing for a longer period of time and repeat the measurement. Carefully insert the Bushing into the Bushing Carrier before it expands. Make sure that the Bushing is completely seated against the shoulder of the Carrier. Reference the bushing manufacturers guideline for freeze fitting, method 1 as attached in Appendix A.

3. Repeat Step 2 for the other Bushing.

4. Place the Thrust Washer (3206, Item 05) on the Bushing Carrier and align the countersunk holes over the M20 tapped holes.

5. Thread the M20 stainless steel Flathead Capscrews (3206, Item 12) into the Carrier to make sure that they will start and make sure that the Thrust Washer is positioned correctly. Apply LOCTITE (3206, Item 13) to the threads and torque to 100 N-m.

6. Using M20 eyebolts or M20 swivel hoist rings in the M20 handling holes, lift the Bushing Carrier into a horizontal position. Make sure that the Trunnion Sleeve is clean. Align the bushing with the Trunnion Sleeve and slide the Carrier over the Sleeve. Be careful not to damage the ID of the Bushing. Rotate the Carrier on the sleeve to align the Retaining Plate (1601, Item 01) holes. Make sure Bushing Carrier is orientated so that the key slot is facing upward when the Trunnion is in the horizontal position as shown in 1601-DG-01-01. Do NOT lubricate the bushing or thrust washer.

7. Place the Retaining Plate (1601, Item 01) on the Trunnion and Carrier and fasten with M20 Capscrews and washers (1601, Item 02, 03) in order to keep the Carrier attached to the Trunnion during shipment and installation.

8. Repeat Steps 3.4-3.7 for the other Bushing Carrier and Thrust Washer.

1603-OM-0374


4.0 YOKE HEAD BEARING INSTALLATION

1. Remove the Bearing (3206, Item 01) from its packaging. Clean the Trunnion (3206, Item 02) bearing mounting surface and remove any surface corrosion.

2. Rotate the bearing 360 in both directions to ensure smooth operation. 3. Chase the M64 tapped holes in the Trunnion and purge with air to make sure that the

threads are clean.

4. Position the Trunnion so that the bearing mounting surface is facing upward.

5. Place four 580 mm long, M64 studs (3206, Item 08) in the M64 tapped holes in the Trunnion. They will serve as guide pins for the placement of the Bearing. Take care not to damage the studs.

6. Place the Bearing (3206, Item 01) on the Trunnion by matching the pilots on each part (Ref. Figure 1). Indicate the Bearing so that the Bolt holes are aligned. Align the 0 marks as indicated on 3206-DG-01-02. Use feeler gauges to ensure that the bearing face is set completely flat (less than 0.20 mm gap) and centered on the Trunnion within 0.4 mm.

7. Thread the 580 mm long, M64 studs (3206, Item 08) into the Trunnion until they are full seated. Set the studs so that they protrude above the bearing as shown on drawings 3206-01-01 or 3206-01-02.

8. Place the Washers (3206, Item 10) over the studs and thread the Nuts (3206, Item 09) down hand tight.

9. Tension the M64 studs according to 3206-DG-01-02.

10. Install the Sap Caps filled with grease (3206, Item 14) on 36 x M64 studs (3206, Item 08).

11. Rotate the bearing 360 in both directions to ensure smooth operation. 12. Protect the tapped holes in the Yoke Structure mating surface with corrosion resistant

grease. Wrap the bearing in protective plastic for shipment.

5.0 YOKE HEAD TO YOKE STRUCTURE ASSEMBLY

5.1 HORIZONTAL ASSEMBLY

1. If the Trunnion and Bearing are to be mounted to the Bearing Support Ring (3206, Item 06) and yoke in the horizontal position, weld the alignment plates (150mm x 430mm x 30mm) onto the Bearing Support Ring to help locate the Bearing on the Bearing Support Ring as shown on 1601-01-01.

2. Lift the Trunnion for horizontal assembly to the Yoke. Make sure that the bolt holes are aligned. Set the Bearing onto the alignment plates flush with the Bearing Support Ring do NOT put the full weight of the Trunnion onto the alignment plates. Thread the 530 mm long, M64 studs (3206, Item 07) completely into the Bearing and place the washers and nuts (3206, Item 09 and 10) on the studs. The studs should not protrude out of the Bearing Support Ring more than 150 mm.

3. Tension the studs according to 3206-DG-01-02. The full weight of the Trunnion may be released after Tensioning Round #1 is accomplished.

4. Remove the alignment plates and grind the surface smooth. Repair the coating.

1603-OM-0374


5. Install the Sap Caps filled with grease (3206, Item 14) on 48 x M64 studs (3206, Item 07). The assembly is complete and ready for offshore installation.

5.2 VERTICAL ASSEMBLY

6. If the Trunnion and Bearing are to be mounted to the Bearing Support Ring (3206, Item 06) in the vertical position, the alignment plates (150mm x 430mm x 30mm) are not required. With the vertical assembly, a portion of the Yoke structure (at least the end cone) must be welded to the bearing support ring before assembly. No welding near the Bearing is permitted. All welding after the Bearing is assembled requires (3x) grounding cables.

7. Lift the portion of the Yoke structure that is welded to the bearing support ring for vertical assembly on the Bearing. Make sure that the bolt holes are aligned. Set the bearing support ring onto the bearing so that the outer diameters of both parts are concentric. Thread the 530 mm long, M64 studs (3206, Item 07) completely into the Bearing and place the washers and nuts (3206, Item 09 and 10) on the studs. The studs should not protrude out of the Bearing Support Ring more than 150 mm.

8. Tension the studs according to 3206-DG-01-02. Once the tensioning is complete, the assembly may be fitted to the remaining Yoke structure.

9. Install the Sap Caps filled with grease (3206, Item 14) on 48 x M64 studs (3206, Item 07). The assembly is complete and ready for offshore installation.

Figure 1 Pilot

1603-OM-0374


APPENDIX A

Bushing Manufacturers Guideline for Freeze Fitting

1603-OM-0374


1.0 SCOPE2.0 Reference Documents3.0 Bearing Block Link and Pin Assembly Prior to Offshore Yoke Installation4.0 Offshore Yoke Head Installation5.0 Bearing Block Assembly After Offshore Yoke Installation1603-OM-0383, Rev A.pdf1.0 Scope2.0 Reference Drawings3.0 thrust Ring and Plate Installation4.0 Bearing Block and Cap Installation4.1 Verify that the Bearing Blocks, Bearing Caps, and Bearing Block Links have been machined as left and right matched sets. Locate and identify left and right matched sets. Make sure that the parts are assembled in the same orientation as when they...4.2 Coat the Bearing Block and Bearing Cap (3214-DG-01-01, Items 01 and 02) mating surfaces (5 milled surface) with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06).4.3 Using M36 Eyebolts (1601-DG-02-01, Item 08), place the matched (Left or Right Hand) Bearing Cap onto the corresponding Bearing Block with the edges flush.4.4 Thread two M36 x 140 long Cap Screws (3214-DG-01-01, Item 11) into each bearing block cap. Do not tighten until bushing carrier is installed during the offshore installation procedure.

5.0 Bearing Block Link and Pin Assembly5.1 Using M36 Eyebolts (1601-DG-02-01, Item 08) in the M36 tapped hole, lift the Pin Caps (3214-DG-01-01, Item 06) and place on Links (3214-DG-01-01, Items 03 and 04). Center the caps on the Pin holes and fasten with M36 x 140 long Cap Screws (3214-D...5.2 Assemble the Support Trays (1601-DG-02-01, Item 02) on the links with M20 Cap Screws (1601-DG-02-01, Item 03) and Washers (1601-DG-02-01, Item 04). Set the height of the tray so that it will center the Pin on the Pin holes.5.3 Using straps (shop supplied) around the center plate, place the matched Links (Left or Right Hand) on the Bearing Blocks. Shim the links so that the Pin holes in the Link are aligned with the Pin holes in the Block.5.4 Lubricate the Pins (3214-DG-01-01, Item 07) and Pin holes with a thin coat of KOPR-KOTE Anti-Seize (1601-DG-02-01, Item 06).5.5 Using M42 Eyebolts (1601-DG-02-01, Item 09) in the M42 tapped hole, place the Pin on the Tray so that the leading edge (with the chamfer) is pointed toward the hole.5.65.6 Insert the Installation Rod (1601-DG-02-01, Item 01) through the Pin and thread it into the Cap. Using a M36 Nut (3214-DG-01-01, Item 15), a Washer (3214-DG-01-01, Item 17), and the Installation Rod as a jackscrew, pull the Pin into the hole unti...5.7 Remove the Installation Rod.5.8 Insert the Retaining Rod (3214-DG-01-01, Item 05) into the Pin and thread it into the Cap. Place the Washer (3214-DG-01-01, Item 17) on the Rod and thread the M36 Nut (3214-DG-01-01, Item 15) onto the Rod. Tighten to 2000 N-m.5.9 Repeat Steps 5.2 5.8 for the remaining Pins.5.10 Thread the M36 x 90 long Cap Screws (3214-DG-01-01, Item 10) and Washers (3214-DG-01-01, Item 17) through the Links and into the Bearing Block Caps. Torque to 2000 N-m using a socket.

1603-OM-0379, Rev A.pdf1.0 SCOPE2.0 REFERENCE DRAWINGS3.0 INSTALLATION PROCEDURE4.0 COUPLER PIN REMOVAL PROCEDURE4.1 SAFETY

1603-OM-0378, Rev A.pdf1.0 SCOPE2.0 REFERENCE DRAWINGS3.0 PREP WORK3.1 BEARING CLEANING3.2 PRE-INSTALLATION PREPARATION

4.0 UPPER U-JOINT AND MOORNG SUPPORT CLEVIS ASSEMBLY4.1 MOORING SUPPORT CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE4.2 UPPER ARM LINK CLEVIS TO MOORING SUPPORT CLEVIS/ COUPLER/ COUPLER PIN ASSEMBLY

5.0 LOWER U-JOINT AND YOKE-CLEVIS ASSEMBLY5.1 LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE5.2 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY PROCEDURE

1603-OM-0377, Rev A.pdf1.0 U-JOINT ASSEMBLY PROCEDURE1.1 SCOPE1.2 BEARING CLEANING

2.0 UPPER U-JOINT ASSEMBLY2.1 MOORING SUPPORT CLEVIS TO THE COUPLER/COUPLER PIN ASSEMBLY2.2 UPPER ARM LINK CLEVIS TO COUPLER/COUPLER PIN ASSEMBLY

3.0 LOWER U-JOINT ASSEMBLY3.1 YOKE CLEVIS TO LOWER ARM LINK CLEVIS/COUPLER/COUPLER PIN ASSEMBLY

4.0 COUPLER PIN REMOVAL4.1 SAFETY

1603-OM-0376, Rev A.pdf1.0 SCOPE2.0 REFERENCE DRAWINGS3.0 NOTE4.0 PROCEDURE

Installation Procedures offshore jacket- Compiled

Documents

bearing block assembly

pin assembly

bearing block link

bearing block caps

final assembly

revision history revision

installation aids

installation rod