Installation Procedure
Wireline Riser Tensioners
RIG/PLANT
REFERENCE
REFERENCE DESCRIPTION
Norshore Atlantic
EQ-16630-100A
Wireline Riser Tensioner
ADDITIONAL CODE
SDRL CODE
TOTAL PGS
29
REMARKS
MAIN TAG NUMBER
CLIENT PO NUMBER
20190108
CLIENT DOCUMENT NUMBER
DISCIPLINE
This document contains proprietary and confidential
information which belongs to National Oilwell Varco; it is
loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in
part; or use of this design or distribution of this information
to others is not permitted without the express written
consent of National Oilwell Varco. This document is to be
returned to National Oilwell Varco upon request and in
any event upon completion of the use for which it was
loaned.
© Copyright National Oilwell Varco - 2020
National Oilwell Varco Norway AS
P.O. Box 2037
3103 Tønsberg
NORWAY
Phone +47 38192000
DOCUMENT NUMBER
REV
EQ-16630-100A-Z-KA-003
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REVISION HISTORY
02
30-Mar-2020
Reissued for Information
EISO
IONO
EISO
01
30-Jan-2019
For Information
BRHO
TAGJ
JABK
Rev
Date
Prepared
Checked
Approved
Reason for issue
CHANGE DESCRIPTION
Revision
02
01
Change description
Electrical info removed/edited
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TABLE OF CONTENTS
1
2
3
GENERAL ......................................................................................................................... 4
1.1
Purpose................................................................................................................... 4
1.2
Safety ...................................................................................................................... 4
1.3
Necessary installation equipment ........................................................................... 5
1.4
Weights, handling and lifting operations.................................................................. 5
1.5
Tightening of bolts ................................................................................................... 5
1.6
References.............................................................................................................. 6
TENSIONER INSTALLATION .......................................................................................... 7
2.1
Fixed Sheave House ............................................................................................... 8
2.1.1 Chockfast Orange Installation Procedure .................................................... 9
2.1.2 Junction Box .............................................................................................. 10
2.2
Front Mounting Bracket ......................................................................................... 11
2.3
Riser Tension Cylinder .......................................................................................... 12
2.4
Front Sheave House ............................................................................................. 15
2.4.1 Position Measuring System ....................................................................... 16
2.4.2 Front Sheave House lubrication................................................................. 17
2.5
Grounding of WRT assembly ................................................................................ 18
2.6
Dual Idler Sheave House ...................................................................................... 19
WIRE ROPE INSTALLATION ......................................................................................... 25
3.1
Mechanical Preparation Check List ....................................................................... 25
3.2
Wire rope spooling ................................................................................................ 26
3.2.1 Idler sheave house .................................................................................... 27
3.2.2 Riser Tensioner ......................................................................................... 28
3.2.3 Fixed Sheave House ................................................................................. 29
3.2.4 Remount the wire rope clamp .................................................................... 29
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GENERAL
1.1
Purpose
The purpose of this procedure is to ensure a proper installation of the equipment without
any damage to the equipment or injuring incident to personnel attending.
1.2
Safety
For safety reasons, all instructions listed in this document shall be adhered to.
Installation activities may involve personnel working above ground level, consequently
ground situated personnel shall be aware of the dropped object risk.

Involved personnel shall be familiar with the contents of this procedure.
This can be managed in a review meeting.

Only qualified workers shall perform installation work.

Only certified lifting gears rated for the actual load shall be used.

To avoid any damage to equipment it is recommended to have a National Oilwell
Varco Supervisor present during installation.
The following types of safety messages may appear in this document:
A warning contains essential information related to potentially hazardous
conditions, procedures, and/or practices which if not strictly followed or
observed, could result in personnel injury, death or catastrophic damage to
equipment.
A caution contains essential information related to potentially hazardous
conditions, procedures, and/or practices which if not followed or observed could
result in damage to equipment or material.
A note contains essential or useful information related to conditions, procedures,
practices, and/or equipment. Sequence of tasks, or to provide clarification of a
specific portion of the manual contents.
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1.3
Necessary installation equipment
Lifting gears for the individual equipment.
Open end spanner (wrench) set.
Hydraulic torque equipment.
1.4
Weights, handling and lifting operations
Weights refer to drawings. Details about handling and lifting operation please refer to
Handling, Preservation and Storage Procedure documents, see section 1.6.
1.5
Tightening of bolts
The table below lists recommended torque values for bolts commonly used in
equipment from National Oilwell Varco Norway. More precisely, the table applies for
steel bolts with hexagonal heads and course metric threads. The threads must be
greased with Molykote® G-Rapid Plus before the tightening.
If a bolt has any type of secondary retention, the secondary retention must be
established after the tightening.
ALL BOLTS LUBRICATED WITH
MOLYKOTE® G-RAPID PLUS
IF A BOLT IS TO BE SECURED WITH SECONDARY
RETENTION, IT MUST BO DONE ACCORDING TO
DOC. NO D44100342-SPC-001 AND HLA-04A
Size
Torque [Nm]
Black/tZn (HDG) Stainless steel
Thread Pitch
Property Class Property Class A
d [M]
M8
M 10
M 12
M14
M 16
M 18
M 20
M 22
M 24
M 27
M 30
M 33
M 36
M 39
M 42
P [mm]
1,25
1,50
1,75
2,00
2,00
2,50
2,50
2,50
3,00
3,00
3,50
3,50
4,00
4,00
4,50
8.8
20,6
40
70
110
169
237
331
445
572
826
1127
1522
1961
2520
3130
10.9
28,4
56
98
156
238
332
465
626
804
1161
1582
2133
2761
3543
4395
70
80
15,4
30,8
52,8
84
130
180
252
339
436
630
859
1155
1497
1922
-
19,8
40,7
70,4
112
173
240
337
453
581
840
1146
1543
1995
2560
-
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References
References are made to:
General Arrangement Drawings
Wireline Riser Tensioner
Idler Sheave
Air Control Skid
Working Pressure Vessels
Hydraulic Schematic Drawings
Piping Diagram, Hydraulic Snubberdrum
Hydraulic Snubberdrum
Wireline Riser Tensioners, P&ID
Piping Diagram, HP Air & Fluid Lines
Hydraulic Cylinders
Working Pressure Vessels
Air Control Skid, P&ID
Electric Block Diagrams
Wireline Riser Tensioners
Air Control Skid
Termination Drawings
Wireline Riser Tensioners
Air Control Skid
Handling, Preservation & Storage Procedure
Sheave Houses
Hydraulic Cylinders
Pressure Vessels
Air Control Skid
Wire Rope
Installation Procedure
Pressure Vessels
Air Control Skid
Drawing number
17917635-GAD
17918782-GAD
17918511-GAD
17920063-GAD
Drawing number
17919074-DIA
17919075-DIA
17919076-DIA
17919077-DIA
17919078-DIA
17919079-DIA
17919080-DIA
Drawing number
17920369-DIA (NA)
17920376-DIA
Drawing number
17920375-DIA (NA)
17920377-DIA
Document number
EQ-16630-100A-Z-KA-002B
EQ-16630-100A-Z-KA-002C
EQ-16630-100A-Z-KA-002D
EQ-16630-100A-Z-KA-002A
EQ-16630-100A-Z-KA-002W
Document number
EQ-16630-100A-Z-KA-003D
EQ-16630-100A-Z-KA-003A
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TENSIONER INSTALLATION
Front sheave house
Front mounting bracket
High Pressure
accumulator
Low Pressure
accumulator
(If applicable)
Cylinder
Fixed sheave house
Dual Idler sheave house
Snubber drum
hydraulic
motor
Snubber drum
Wire rope clamp
Picture of a typical Wireline Riser Tensioner system
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Fixed Sheave House
For position/numbering of the tensioner units, see General Arrangement Drawing
Fixed Sheave House. It is of outmost importance that the tag number on Fixed Sheave
House and Idler Sheave House is corresponding.
Fixed Sheave House in stored position
Turn and lift the Fixed Sheave House by lifting gears. See handling preservation &
storage procedure Sheave houses. Mount the Fixed Sheave House to structure. See
GA drawing for type of bolts, bolts are supplied by others. Nominal torque: see torquetable in section 1.5.
Connect the Snubber drums hydraulic motor accordance to Hydraulic drawing.
Fixed Sheave House turned and in installation position
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2.1.1 Chockfast Orange Installation Procedure
Before filling the cavity between the Fixed Sheave House and rig structure with
chockfast, apply grease on the Fixed Sheave House and rig structure. Then fill the
cavity with Chockfast Orange (PR-610TCF) or equivalent material.
The material must have a minimum compressive strength of 530 kg/cm 2
(7538 PSI).
Hatched area to be filled with
Chockfast Orange
Required amount of Chockfast Orange (PR-610TCF)
Type of fixed sheave
house
120 Kips dual
200/225 Kips dual
250/280 Kips dual
Required amount pr.
Sheave house
(approximately)
16 Liters
41 Liters
43 Liters
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2.1.2 Junction Box
For each tensioner pair there is one junction box, which contains electrical circuits for
both anti recoil valve and positioning measuring system. This is to be disregarded.
Junction box
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Front Mounting Bracket
The Riser Tensioner Cylinders are to be mounted to the Fixed Sheave House
before mounting of the Dual Front Mounting Bracket.
The block washer shall be placed under the bolts head.
Ref. GA drawing for type of bolts for mounting the bracket to the cylinder. Bolts are
supplied by NOV. Nominal torque: see torque-table in section 1.5.
When the Cylinder unit have been installed with fixed sheave house and front sheave
house it is important to adjust the cylinder to be in centreline and to adjust the bracket
with shims.
Mount the Front Mounting Bracket to rig structure. See GA drawing for type of bolts.
Bolts are supplied by others. Nominal torque: see torque-table in section 1.5.
The correct operating position for front sheave house is rotated 5-7° relative to fixed
sheave house.
Available shims for adjusting the Cylinder: 1shim thickness 5 mm and 2 shims thickness
2 mm. Maximum shim elevation = 9 mm.
Shims
Block Washer
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Riser Tension Cylinder
Remove the cylinder from the wooden platform and leave packaging materials like:
plastic wrapping foil on the anti recoil valve, cylinder rod protection. Lift the cylinder, use
hoisting-points near the cylinder bottom and cylinder head. See Handling preservation &
storage procedure Cylinder and below figure.
Lifting
The slings must go clear from
sensitive equipment when lifting
When lifting the riser tensioner cylinder without wooden support blocks and with
slings in lifting lugs, the cylinder may rotate a little due to the weight of the builton accumulators before the cylinder get balance.
Lifting for installation
Attach slings to cylinder lifting lugs and lift the cylinder into right position.
Use two cranes.
Maximum angle between the lifting legs are 30 degrees.
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Lift the cylinder and stabilize any
movement around COG
When lifting the riser tensioner
cylinder from horizontal position use
only the lifting lugs on top of the
cylinder. Lifting by the lugs below the
cylinder in vertical and close to vertical
position can lead to damage on the
cylinder by shackles and lifting slings.
Slowly tilt the cylinder
Position the cylinder into vertical
position. Use the two lower slings
for guiding.
Attach additional upper sling to
allow the cylinder to stabilize inn a
close to vertical position
Lifting of riser tensioner cylinder
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Lift the rod end of the cylinder and lower the bottom end until the cylinder is in vertical
position.
Connect two hoisting cables to the lifting-lugs near the rod end and lift the cylinder.
Lift slowly and synchronous by two cables into position on the Fixed Sheave House.
Check that the cylinder is orientated correct related to the Fixed Sheave House and the
Front Mounting Bracket, ref. Riser Tensioner Cylinder General Arrangement Drawing.
Dual Front
Mounting Bracket
is to be mounted
to the Riser
Tension Cylinder
after mounting of
the Cylinder unit.
See section 2.2
Bolt the cylinder to the Fixed Sheave House. Ref. GA-drawing for type of bolts. Bolts are
supplied by NOV. Nominal torque: see torque table in section 1.5.
The cylinder is now mounted to the steel structure by its bottom flange and a bracket
between the cylinder head and the steel structure.
Keep the Densotape on the rod end in order to prevent rust. Spray the top of rod
(that part that never go in to cylinder) with Hougto safe once a week to prevent
rust on top of rod.
If there be in a ring of excess of Houghto safe around the rod wiper seal remove
such excess with a soft rag.
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Front Sheave House
Before installing the Front Sheave House assembly, perform the following steps:



Remove the bracket that protects the rod from extending. Do not stand in line
with rod and maintain a safe distance between the rod and equipment.
Remove the packaging material in the sheave house interface protecting the rod.
Add grease to the top of piston rod and the bolt holes in the front sheave house
for corrosion protection.
Don’t extend the cylinder in grinding or welding area and don’t leave the
rod stroked out overnight.
Lifting for installation
Lift the Front Sheave House assembly to correct location (top of piston rod)
Bolts
Mount the front sheave house carefully to the piston rod. Ref. GA drawing for type of
bolts. Bolts are supplied by NOV. Nominal torque: see torque-table in section 1.5.
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2.4.1 Position Measuring System
Length transmitter unit
The position measuring system (length transmitter unit) is installed on the bracket
located on each cylinders High Pressure accumulator.
Length Transmitter unit
Length transmitter bracket
On the Front Sheave House, the bracket for attaching the wire is located in transport
position, (i.e. parallel to the sheave house). This must be mounted as shown in figure
below.
Length Transmitter bracket
As this system is for the control system, the transmitter unit and bracket is to be
disregarded and can be removed.
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2.4.2 Front Sheave House lubrication
The central lubrication shall be mounted on board to make it easier to grease the
bearing in the front sheave house. The hose shall be mounted on the front sheave
house by using hose clamps and M6 bolts. Front sheave house on dual riser tensioners
shall be mounted with the central lubrication at the opposite of each other.
Connect the hose to the grease track in the shaft by replacing the pre-mounted grease
nipples with the male stud connectors. Then connect the hose with the 90 degrees bend
to the male stud connectors.
Connect the bulkhead, pressure gauge connector and the grease nipple to the
lubrication plate. Mount the lubrication plate on the rig so it’s placed mid-stroke, using
the U-bolts. If there is no possibility to mount the lubrication plate mid-stroke, use a pipe
and weld it onto the rig structure to move the fixed position for the hose from the
lubrication plate to a mid-stroke position.
Finally connect the hose to the lubrication plate. Use straps and a hose clamp to wind
up and place the left-over hose at the lubrication plate.
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Grounding of WRT assembly
25mm2 cable to be use (yard supply). Connect ground from cylinder to fixed sheave
house, and ground from sheave house to rig structure. Check that grounding between
accumulator body and cylinder body is ok.
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Dual Idler Sheave House
Turn the Idler sheave house and lift it in accordance to Handling procedure, use suitable
lifting gear. Transport safety device must be installed in order to perform the lifting
operation.
Transport safety
Dual idler sheave house
Single idler sheave house
Solid shaft
Hollow shaft
For position/numbering of the tensioner houses, see GA Drawing Idler Sheave House.
It is of outmost importance that the tag number on Dual Fixed Sheave House and
Dual Idler Sheave House is corresponding.
Before mounting Dual Idler Sheave house, the sheave housing with sheaves needs to
be dismounted from the Idler footplate. This is to allow mounting inside the footplate.
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Disassembly of Dual Idler Sheave
1. Secure the idler sheave by holding them up with the soft slings.
2. Dismount idler sheave bolts from both sides.
3. Dismount bolts and remove end covers.
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4. Remove oil seals, radial bearings, idler shafts and thrust bearings.
Radial bearing
Shaft
Oil seal

Thrust bearing
Pay attention to handling and interim storage of the oil seals, bearings and
shafts.
5. Use soft slings to lift sheave houses from the idler footplate.
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Mounting of footplate
Lift the idler sheave footplate into position by use of suitable lifting gear, according to
handling procedure.
Ensure that the Dual Idler Sheave Unit (bearing holes of the footplate) is centred correct
to the wire outlet of the Fixed Sheave House. See Figure above
Maximum angle on wire rope related to wire sheaves are 0.15°
Mount the footplate to the rig structure. Ref. GA drawing for type of bolts. Bolts are
supplied by others. Nominal torque: see torque-table in section 1.5.
Assembly of the Idler Sheaves
Before mounting, ensure housing for bearings and bolt holes are free from debris, and
are not damaged during installation of footplate.
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1. Mount the inner seals in the direction as shown in the pictures below, this to allow
the grease to be squeezed through the bearing, paste the oil seal in to the thrust
bearing’s lubrication groove side. Mount the radial bearings.
Riser Tensioner side
Moon Pool side
M30 holes
Complete assembly of dual idler sheave house.
2. Hoist the Idler Sheave carefully in position. If needed the three M30 holes on each
side of the Sheave House can be used to fit lifting lugs. The Idler sheave must be
mounted according to the general arrangement drawing.
Assembly of hollow shaft (Riser Tensioner side)
Assembly of solid shaft (Moon pool side)
3. Note the position of set bolt hole in both Idler shafts, and orientate this hole
according to the set bolt hole in the Idler Sheave before driving the Idler shafts in
position. Mount the Solid Idler Shaft on the side of the Idler facing the moon pool.
The Hollow Idler Shaft is to be mounted on the side of the Idler facing the Fixed
Sheave House. Mount the thrust bearings with the lubrication groove facing the
bearing.
4. Mount the last oil seal on the riser tensioner side, and end covers on both sides and
apply its bolts and washers. Make sure the hollow end cover is mounted on the riser
tensioner side.
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Assembled hollow shaft (Riser Tensioner side)
Assembled solid shaft (moon pool side)



Be sure that the Transport Safety Devices not are installed when idler
sheave house is mounted to the rig structure.
Be sure that the wire rope lines between the Fixed Sheave Housing and the
Idler Sheave house are centric.
Be sure that the “hollow shaft” is at the direction out from well center.
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WIRE ROPE INSTALLATION
Mechanical Preparation Check List






Verify that preservations are removed
Verify that equipment are externally clean
Make sure the cylinder is retracted
Make sure HP air inlet valve is closed on the other cylinder in pair
Make sure the wire rope is lubricated as described in the user manual
Remove the wire rope clamp on fixed sheave house
When installing wire ropes, extra care must be taken that the ropes are unwound
from the ring or reel without torsions and without any outer damage.
Do not pull the wire rope of the end of the drum, this will twist and damage the
wire rope.
It is important to be able to stop the drum while spooling off the wire rope – when
the wire rope comes over the idler sheave the wire rope weight may cause the
drum to start rotating. One man must always stand prepared to brake or stop the
storage reel, in case of emergency.
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Wire rope spooling
Remove the wire rope anchor clamp on fixed sheave house. The wire rope has to pass
without any contact stress between the wire rope and the anchor clamp.
Wire rope anchor clamp
For the wire rope spooling it is recommended to use a rope with a cable pulling device
to help with the installation. Start mounting the wire rope from the moon pool area, one
tensioner at the time.
Connect one end of the pulling rope to the wire rope, pull the other end of the pulling
rope through the idler sheave house (see section 3.2.1) and then to the tensioner (see
picture Wire reeving arrangement and section 3.2.2) and connect the pulling rope to
snubber drum or to a utility winch. Use the snubber drum or the utility winch and pull the
rope so the wire rope comes through the tensioner pull the wire rope to the
recommended length.
Always inspect wire ropes for wear, damage or abuse during installation.
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Typical view: Wire rope reeving arrangement
3.2.1 Idler sheave house
The idler sheave house is mounted to the ceiling near the moon pool and contains
sheave/sheaves.
Idler sheave house
Single idler sheave house
Pull the pulling rope trough the idler sheave house, as shown in the illustration below.
Make sure to pull the rope underneath the support plate and trough the bearing hole.
And then pull the rope to the underneath fixed sheave house.
Support plate
Hollow shaft
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3.2.2 Riser Tensioner
The riser tensioner consists of a front sheave house, cylinder with a front mounting
bracket and fixed sheave house. See General Arrangement Drawing.
Step 1-2
Pull the rope from idler house trough fixed sheave house along sheave and directly
upwards to sheave, on front sheave house. Direct the rope over sheave and pull down,
thru front mounting bracket, towards fixed sheave house.
Step 3
Pull the rope trough fixed sheave house along sheave and directly upwards to sheave,
on front sheave house. Direct the rope over sheave and pull down, thru front mounting
bracket, towards fixed sheave house.
Step 4
Pull the rope 3 turns around snubber drum (see section fixed sheave house) use the
snubber drum or a winch and pull the wire rope to the recommended length remount the
wire rope clamp and fix the wire rope. (See section Remount the wire rope clamp).
Clearance between hole
in bracket and wire rope
3
2
4
1
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3.2.3 Fixed Sheave House
The fixed sheave house contains sheaves and Snubber Drum.
Snubber Drum
Wire rope turned
three turns around
Snubber Drum
3.2.4 Remount the wire rope clamp
When the wire rope has been pulled to the recommended length, clean the wire rope
anchor clamp. Lubricate the clamp bolts remount the wire rope clamp on fixed sheave
house. Tighten the bolts cross-wise and fix the wire rope. Nominal torque: see torquetable in section 1.5.
After installations of the riser tensioner system make sure that all preservation is
intact or warranty will void. NOV I&C personnel will remove the preservation
before and during pre-commission.