Aasta Hansteen Topside EPC Project Aasta Hansteen Topsides EPC Project Engineering Review Status 1 Accepted By : LSCHOK Date : 20/08/2015 04 08/10/2015 Issued for Construction D.Y.Kang H.R.Jo S.H.Kim 03 07/03/2015 Issued for Review D.Y.Kang D.Y.Kang H.R.Jo 02 04/24/2015 Issued for Review M.H.Kang D.Y.Kang W.S.Choi 01 10/10/2014 Issued for Review D.Y.Kang H.R.Jo W.S.Choi Rev Date Description Prepared Verified Approved Document Title Installation, Operation and Maintenance Manual for Lapping Machine Document number PO No. : Tag No. : QE536A1WE1 93MZ009 C134-FS-079901-MA-0012 04 Supplier Doc. No JSMT-WS-0041 Sup. Rev. Proj. Code Orig. Code Req ref. Doc. Code Seq. no. Rev - 1 -
Lapping Machine Maker : Ventil / Netherlands Model No. : OPTIC 24-2-
Lapping Machine / IOM Manual Lapping techniques The Optic 24 is manufactured and tested according to strict V-Tec standard specifications, to give your machine a long and trouble free lifetime. Prior to use the following should be considered: 1. The parts are not damaged. 2. All parts are cleaned from dirt and grinding dust. 3. No missing parts. Logbook (Please refer an appendix as below.) To ensure a good process every time it s advised to set up a logbook for record keeping. The log book chronicles both the machine and your processes. The date, operator, remarks and part process will be enough. Plate flatness. Every time a reading of the plate s flatness is made, record it. Take readings regularly, at least once during every shift the machine is used. Make a note in the log book when correcting the flatness, mostly by repositioning a conditioning ring. When you change your compound formula or substitute a new brand write it down. Not all abrasives are sized equally and will give a different finish. Record changing of a plate or rings and the origin and material. Lapping tips: 1. First time lapping is advised to let the machine rotate four about 10 minutes with only the conditioning rings on. This run will remove any burrs, sharp edges, or scratches and produce a uniform gray surface to the lap plate. 2. Measure the external diameter of the product to be lapped and the internal diameter of the conditioning ring. Make sure the object has enough space to rotate within the conditioning ring. -3-
3. The parts must be deburred before lapping to avoid damage to the machine parts and the part itself. 4. Pressure on the parts can be made with the pressure weights(optional). When applying pressure on small parts the allowable difference in height is 0.050mm (0.002 ). Note that smaller parts will not be lapped clean until the biggest parts is lapped down to the smallest one. 5. When small parts are lapped multiple can be placed in one ring. The parts must be protected for bouncing to each other or against the ring. There are several ways to protect the sides. a. Use a carrier/work holder of a hard plastic. Examples tufnol, teflon or epratex. Give the objects 0.5-1mm space to move in the holes of the carrier. b. Wrap the edges with vinyl tape. c. Slip on o-ring around the part. NOTE: a minimum of parts is 3, for equally contact pressure. 6. When multiple parts are lapped in one ring, or when lapping a scratch sensitive part a felt pad can be used to compensate slight difference in height / protection. -4-
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7. The timing of the lubricator and diamond slurry intervals are dependent on the part to be lapped. However, a general recommendation is: a. Diamond slurry: i. Interval 60 seconds ii. Duration 3-4 seconds Note that the setting off is per 10seconds, and the setting on per seconds. b. Lubrication: i. Interval 120 seconds ii. Duration 1-2 seconds Note that the setting off is per 10seconds, and the setting on per seconds. Ageneral check for proper set up: the lapping plate must not be wet but just moisture. c. Machine process timer: as required. The setting process timer is perminute with a max. of 30 minutes. 8. Before placing the parts on the lapping plate check whether the diamond slurry is mixed well or not. If not let the machine on four a couple of minutes without the conditioning rings or parts on. The mixer will mix the diamond slurry. 9. The optic 24 can be supplied with two different types of lapping plates. a. Composite iron (standard), basic purpose LAPPING. Result will be a cross hatch micro scratch pattern 14μ - 25μ. b. Composite copper, basic purpose POLISHING. Result will be a reflective surface 3μ - 14μ. 10. Make sure the spray system is pointed on the lapping plate and sprays the diamond slurry & lubrication directly on the plate. -6-
Plate flatness In order to make flat parts it is critical to have a flat lapping plate. The plates of every lapping machine wear out of flatness. Cause of this can be that there are often processed parts with the same shape. These parts will rotate on more or less the same spot on the lapping plate which will result that spot to wear more. There are two types of un flatness: concave and convex. There are three methods to measure the plate flatness. Straight edge Astraight laid across the center of the lap plate allows the operator to compare the actual plate to what it should be. With a feeler gauge or a piece of thin ring (shim) the establish the difference. Flatness gauge With a flatness gauge the difference on various points on the lap plate can be measured. "Zero" reading - plate is flat "Negative" reading - plate is concave "Positive" reading - plate is convex Test plug Apiece of material on which flatness can be easily read with a monochromatic light and optical flat. It is lapped along with your parts and gives a direct comparison to the parts. -7-
Correct plate flatness To correct the plate flatness you can use the conditioning rings. The original purpose of the conditioning rings is to keep your lap plate flat under normal circumstances. When measured a concave lap plate the conditioning rings have to be moved slightly outwards. If the lap plate is convex move the conditioning rings slightly inwards. To move the conditioning rings loosen the conditioning ring guides with the stainless steel knobs. Make sure the flat plate is totally clean from residue or dust before measuring! -8-
Working with The following pages contain information and instructions for the set up of the machine. Before starting with lapping parts make sure that all machine parts and lapping objects are clean. For cleaning use a non aggressive fluid. The black plate can be adjusted in height so that the conditioning rings can overlap the lapping plate diameter. When encountering that many lapping residue is tossed over the black plate you can decide to set the black plate higher than the lapping plate so all the residue will pour in the residue collector on the left side in the cabinet. With the three stainless steel knobs you can slide the conditioning rings outwards or inwards. The angle of the conditioning ring guides can be changed by unscrewing the black mount, the bolts are located underneath the black plate. The spray time can be set with the timers on the front, note that it may take a few seconds before the system pumps the fluid into the pipes so you maybe have to change the duration a few seconds longer. -9-
When everything is set up, place your parts to be lapped inside the conditioning rings. Depending on the size of the parts, choose to use a carrier / felt pad / pressure weight. If the parts are big and heavy enough pressure weights are not recommended, these are only for small discs. This machine is engineered for heavy parts, so overall there is no need to use the pressure weights and that s why these pressure weights are only available on request. Depending on the operation, size of parts and size of damage the lapping speed can be adjusted from 0 60 rpm. The cycle time is the total time that the machine will run. Set this time, and the interval and duration of the diamond slurry & lubricator. Then press the start button and the machine will begin with the lapping job. It is advised to run the machine without parts for a few minutes with lubricator on, to prepare your plate. Keep your lapping plate a little bit moist, too wet will slow the lapping process. Too dry (scraping sound) will result in scratches in the plate. The machine can be stopped every time by pressing the stop button or when encountering a dangerous situation: hit the emergency stop. Spray system The spray system contains a diamond liquid and a lubricator. The spray system works with two electric pumps. The diamond liquid can be refilled behind the door at the left side of the machine. The lubricator can be refilled behind the door at the right side of the machine. The liquid reservoirs are covered with a white cap. -10-
Maintenance Please ensure that before and after every process the machine and the parts are cleaned from dirt and grindings. Also remove any adhesive that is on the parts to be lapped. Use only a dry, soft cloth for wiping the unit. Do not use a damp cloth, thinner, benzene or other volatile solvents for cleaning. Regularly clean the whole machine with a dry, soft cloth to extend lifetime and keep all parts in good condition. Note that this machine must be placed in a separate room, away from places that can cause danger, dust, steel chips. Always work under room temperature to ensure quality lapping and ensure that there is a proper air-extraction installed in the room where you work in. Safety Instructions General safety Prior to the first operation, read the manual carefully. Ensure that all persons handling the grinding & lapping machine are familiar with the functions and controls. All users should first read and understand this manual and its assembly and operation instructions before working with the machine. Instructions and tips should be strictly followed. V-Tec is not responsible for any damage to the machine or seat caused by inappropriately handling by operator. Do not operate the equipment if safety is questionable! -11-
The working area Keep work area clean. Consider work area environment. Don t expose the grinding machine to wet conditions. Keep work area under adequate lighting. Check wires/cables, air hoses and extension cords, regularly! Keep wires/cables and air hoses clear from heat, oil and sharp objects. The machine Prior to use, ensure that all components are operational and in good condition in accordance with regulations and safety and danger notices. Immediate correct faults that may impair safety! Operating with the machine without these precautions may result in injury to the operator. Handle the machine with care; mishandling can affect the machine s capacity to grind with the necessary accuracy. Do not use the machine for any different applications or procedures than those described in this manual. Not obeying this can cause life threatening danger, always use the machine with full attention and do take all measures to avoid dangerous situations. Before operating check for misplaced parts or possible danger. Remove adjusting keys and wrenches before starting the machine. Caution All electric equipment should be handled with care. Do not open machine parts. Serious injury may result from electric shock or damage to the equipment. Always adhere to safety instructions applied to the workplace. Note: this machine must be placed in a separate room, away from places that can cause danger, dust or steel chips. Always work under room temperature to ensure quality lapping and ensure that there is a proper air-extraction installed in the room where you work in. -12-
Electrical Connection (Wiring Diagram) 9$& 82E L12 4-519 Upstreampowersupply 230V AC,1PH+N,L2 16A,30mA -13-
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Appendix. Log Book Date Technician Work Done Next Date -15-