application method statement for seashield 2000fd this ... -denso product/ss 2000 fd... ·...

14/11/2007

Application Method Statement for SeaShield 2000FD

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Author: S. Pearce Issue 1a

This document details the specification for fitting of a one piece 2000FD SeaShield Jacket onto steel piles. Any deviation from this method statement must be by prior approval from Winn & Coales (Denso) Ltd. Materials Required.

• Hand tools scrapers • Dry abrasive blast equipment (optional). • Ultra high pressure water jetting (UHPWJ) equipment (optional). • Denso S105 Paste (for pits greater than 2mm and flap lubrication). • Denso Marine Piling Tape. • SeaShield Jackets designed and sized for the job. • Stainless 316 Nyloc Nuts, Bolts and Washers supplied by Denso. • PPE according to the task (see individual Material Safety Data Sheet). Note

UHPWJ requires extra special precautions. Handling & Storage.

• Denso Paste and Denso Marine Piling Tape shall be stored in a cool dry place out of direct sunlight between 5° and 25°C.

• SeaShield Jackets shall be stored upright in the packing they arrived in out of direct sunlight until they are required. Then they shall be rolled and taped to prevent damage for transportation to the installation site. Care shall be taken to avoid sudden impact that may tear or damage the jacket.

• Stainless 316 nuts, bolts and washers shall be kept securely in a dry place. These should then be bagged in packs for each jacket to ensure no contamination with dust and dirt.

Surface Preparation Methods & Equipment

The following methods can be used. The choice will depend on a number of factors and will need to take into account the most practical with regard to site conditions and any environmental constraints imposed due to site location.

1. Abrasive blast cleaning 2. High pressure water jetting.

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3. Pneumatically or hydraulically driven tools such as scabblers, wire brushes, rotary scrapers and needle guns.

4. Hand tools such as wire brushes, scrapers, chipping hammers etc. Procedures – Cleaning Methods to ensure that all thick layers of rust are removed from all steel surfaces.

• Remove from the area to be protected all marine growth. • Areas of firmly adhering rust scale must be removed by chipping

hammers and/or hand power tools. • Remove corrosion products from the bottom of any deep pitting deeper

than 2mm. • Weld scars and protrusions of any kind (other than the welded seam on

the pile) must be cut away and the surfaces ground smooth to remove sharp edges and sudden changes of profile.

• Wire brush and remove any loose and flaking paint. • Wash off surface with seawater and bucket.

Environmental

• During removal of the existing coating measures should be taken to reduce the amount of debris – paint flakes, old coating etc. – from being deposited into the marine environment. Local rules may dictate certain environmental conditions as part of these works.

Surface pre-Treatment after cleaning.

• Areas of deep pitting. Deep pitting is defined as pits of 2.0mm or deeper where there is a danger of the tape wrapping ‘bridging’ the pits and leaving a void. These areas must be treated with a liberal coating of Denso Paste S105 to fill up any voids. If a very deep pit occurs then cut a patch of Denso Marine Piling Tape and press firmly in the area after pasting. Paste can be applied with rag, glove, roller or brush.

• Weld Scars. Apply a liberal coat of Denso Paste S105 over these areas. After wrapping the pile with tape examine the area where scars occur. If there is any bridging cut with a sharp knife and press down to remove air. Patch with additional tape if required.

• Spiral and Vertical Welds. Apply a liberal amount of paste to the weld and smooth down by hand to create a fillet of paste either side of the weld. Sufficient should be used to avoid any bridging when the tape is applied.

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The cleaned pile showing the vertical application of paste down either side of the vertical weld seam and into pits. Note this is a hexagon pile shown but the procedure is the same for round and square piles.

Denso Marine Piling Tape (DMPT) Application. The pile is wrapped from the top down or the bottom up depending on access and the order in which the jackets are to be fitted. There is not a preferred direction and any weather boarding effect can be ignored as the DMPT is deformed under the jacket anyway when properly fitted.

• It is important to apply the DMPT with the correct side facing the pile.

This will mean that the backing film, which is not removed, is the side that will come into contact with the jacket and is the side that faces away from the pile surface. See photo below.

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The photo shows the backing facing away from the pile surface and the first circumferential wrap being positioned.

• Start with 2 full circumferential wraps of the DMPT and then proceed to wrap down the pile progressing with a 55% overlap. This means that there will be a minimum of 2 layers of tape around the entire pile. Carry on until the roll runs out. Start the next roll and overlap the last roll by the same length as the tape width. So if it is 300mm wide DMPT the overlap will be 300mm.

Photo shows overlap of roll ends.

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• As the DMPT is wrapped around the pile it shall be smoothed into position and the edges blended together. This process is repeated all the way down the pile for the prescribed protective length finishing again with 2 complete horizontal turns of the DMPT.

• It may be worthwhile assessing the number of jackets that can be applied and the tidal conditions so that only enough tape is applied for the same number of jackets that can be fitted in a day. The DMPT that is then left exposed temporarily should be protected with a spare jacket or some spare HDPE sheet until the job can be finished. Do not leave DMPT only exposed to the elements and the sea as it may get dislodged before the job can be completed and will have to be discarded and the job re-wrapped.

Jacket Installation - Preparation

• Prepare the jacket and the correct number of Stainless 316 nut bolts and washers in a dry calm area before taking the jacket for fitting. It may also be handy to have a spanset lashing which can be used to hold the jacket in place before tightening. A pair of 19mm ring spanners or air wrench with 19mm deep sockets will be required to do up the M12 bolts and also a small amount of thread lubricant - Molyslip or copper grease will do. Some S105 paste may be required to lubricate the pass over flap of the jacket during fitting

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Hydraulic Equipment Assembly and Jacket Fitting/Tensioning Instructions These instructions are for the Winn & Coales (Denso) Ltd hydraulic tensioning kit used to tension and fit the SeaShield 2000FD system. This equipment should not be used for any other task without the authority of Winn & Coales. The following parts make up one kit. Three kits are required to fit one 1.9m tall SeaShield 2000FD jacket. Check you have all the parts before starting assembly or the job. Also required is some PTFE tape, a 14mm spanner and an adjustable spanner.

Description W & C Code Number

Part Number Qty Check

Hydraulic Tensioner Cylinder Mount

WC00537b (attached) 1

Hydraulic Tensioner Pulling Bars WC00538b (attached) 2 Hydraulic Tensioner Jacking Bars WC00539b (attached) 2 M12 Full Nut - 4 M12 Plain Washer

- 4 Enerpac Gauge 10000psi GP-10S 1 Enerpac 5 ton s/a Cylinder RC-59 1 Enerpac Gauge Adaptor GA-4 1 Enerpac Hand Pump Two Speed 10000psi (pre-filled with hydraulic oil)

P-142 1

Enerpac 5m Hose 3/8” NPT EH110500B 1 Enerpac Male Half Coupler

CH604 1

8651058

8651059

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The kit of parts.

Assembly Instructions. Remove the hand pump from its packaging and check that the Oil filler/vent cap is firmly closed. Also ensure that the flow control screw, which is the 3 bladed plastic knob, is firmly closed in a clockwise direction. This is to prevent hydraulic fluid flowing out of the end of the pump as you assemble the components. Remove the plug which is firmly screwed into the end of the pump. A 14mm spanner is required for this.

The photo shows the plug (ringed) to be removed. The gauge adaptor is then screwed into the end of the hand pump and the gauge then fitted so that it faces the operator when they are using the unit. PTFE/Teflon tape or high quality sealing compound should be used on the threads to ensure a hydraulic seal. Never wrap the first thread with tape and always in a winding direction so that it does up with the thread.

The gauge and adaptor in place.

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Next fit the hose into the end of the adaptor again using Teflon tape or high quality sealing compound.

Hose connected to adaptor. The set is supplied with quick release self sealing couplings between the hose and the cylinder. These also come with dust caps which need to be removed before the 2 assemblies can be connected.

The dust caps in position. The hose end is pushed upto the female coupler and the free spinning nut is done up securing the 2 parts together.

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The assembled hose to cylinder connector. Note the stowage of the dust caps. The next procedure is to bleed the system of any air.

1. Vent pump reservoir and close release valve. 2. Position pump at higher elevation than cylinder. 3. Position cylinder with the plunger end down. 4. Operate pump to fully extend the cylinder. 5. Open release valve to retract cylinder. This will force the air trapped to move

up to the pump reservoir. 6. Repeat the above steps as necessary. 7. Add oil if necessary (Enerpac hydraulic oil is recommended). 8. Return vent/fill cap to operating position.

Now fit the front hydraulic cylinder mount to the cylinder. (You will need to remove the protective cap to do this).

Front mount fitted to cylinder.

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The next stage is to fit the tool to the jacket which will have been applied to the pile and being held temporarily with a spanset lashing according to the published method statement for the job. The method statement will also include all fitting instructions for the jacket which will supersede these wherever there is a conflict between the two documents. Tensioning the Jacket. The bolting holes on the jacket must be fully aligned before insertion of the slide rods can take place. It is important to fit the middle clamp first and use it to tension the jacket enough so that the spanset lashing can be removed if it is being used. Fit the slide rods to one of the clamping bars so that the M12 nut is right up against the shoulder and the washer can slide nicely on the shaft.

Nut to shoulder & Washer on shaft. Now offer the clamping bar up to the jacket and slide the 2 bars through the ∅14mm holes. The shaft is 13mm so is quite a good fit. Once they have been passed through both bolting bars the other clamping bar can be slid over the threaded ends. After this the hydraulic cylinder tensioner mount can be slid over the shafts and the M12 washers and nuts fitted. Again it is important to ensure the nut is screwed right upto the shoulder and the washer can slide freely on the shaft. Failure to do this could result in uneven tensioning of the jacket bars and possible failure or danger to the operator.

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The photo above shows the arrangement of cylinder and steel clamps while below they have been installed onto the jacket at the 3 correct positions.

The photo shows the 3 hydraulic clamps in position ready to tension the jacket.

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The tuck under flap of the jacket must be lubricated with Denso S105 paste to ensure a smooth tensioning procedure.

The S105 paste on the flap. It may also be necessary to gently tap the flap as the jacket is tensioned to make sure the flap passes under the opposite side of the jacket.

Tapping the flap to ease it under the opposite side of the jacket (not always required)

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The assemblies are fitted so that there are 2 exposed bolt holes at the top and bottom of the jacket and 2 holes between each of the 3 clamps. Apply pressure evenly to each hand pump which will show about 1500psi whilst jacking. Bring all of the bolting bars together evenly until you see approximately 5000psi on the gauge. At this point the stainless M12 x 90 bolts with washers and nuts (supplied with the jackets) can be fitted into the exposed empty ∅14mm holes and tightened up so that the bars are compressed and the nut has either reached the end of the thread or cannot be tightened further.

Photo showing top bolt inserted ready for tightening. Now the hydraulic clamps can be removed and the remainder of the bolts, nuts and washers fitted and tightened up. These should be tightened so as to use all the thread on the bolt. No further tightening or torque is then required.

Photo shows hydraulic clamp released exposing 2 further bolt holes to insert fixings into and do up.

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The finished jacket with all fixings in place.

Contact Details for Technical Queries: - Winn & Coales (Denso) Ltd Denso House, Chapel Road West Norwood London SE27 0TR Tel 020 8670 7511 (Main Line) Tel 020 8655 9444 (SeaShield Manager) Mobile 07711131001 General E-mail: - mail@denso.net SeaShield Manager E-mail: - spearce@denso.net

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Denso Marine Piling Tape Data Sheet

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Denso S105 Paste

application method statement for seashield 2000fd this ... -denso product/ss 2000 fd... ·...

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