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TECHNICALMANUAL

COMPENSATOR - 2.75 LITRESMD P/N’S EV_4003-28 ONWARDS

REVISION 2 - NOVEMBER 2017

Refer to the ‘Applicability’ section on Page 2 for units covered by this manual

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Confidential, copyright property of Soil Machine Dynamics Limited. All rights reserved.

TECHNICAL MANUAL

ABOUT CURVETECH®With over 20 years’ knowledge and experience of providing integrated solutions for subsea and marine applications, Curvetech® subsea component products provide cost-effective and reliable solutions for use with marine and subsea operators, system integrators and original equipment manufacturers (OEMs). We have a dedicated team of engineers who specialise in the design and testing of SMD’s Curvetech® components, to deliver world-leading products that enable customers to maximise on remote subsea operations.

For more information go to: www.smd.co.uk/product-category/curvetech-components/

CONFIDENTIALITY STATEMENT

NOTICE:

The information in this document is confidential and is the property of Soil Machine Dynamics Limited. It is to be held strictly in confidence by the recipient. Disclosure of any such information is to be made only to those employees of the recipient who need to use the information and is the responsibility of the recipient to bind any such employees to retain such information in strict confidence.Copyright in this document is the property of Soil Machine Dynamics Limited. No copy is to be made without the written permission of Soil Machine Dynamics Limited.Any patent applications, patents and/or registered design applications, registered designs or design rights arising from this document or information contained in it are the absolute property of Soil Machine Dynamics Limited and as such are subject to the obligation of confidence on the recipient set out above.Soil Machine Dynamics reserve the right to revise, change, modify or otherwise alter any part or parts of the document(s) or information contained herein without prior notice.

APPLICABILITYThe information provided in this manual is applicable to the following Curvetech® Compensator units:

Description Part NumberASSEMBLY COMPENSATOR 2.75 LITRE EV_4003-28

ASSEMBLY COMPENSATOR 2.75 LITRE EV_4003-29
















ASSEMBLY COMPENSATOR 2.75 LITRE AJ7933


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REVISION CONTROL REVISION APPROVALChecked by: Approved by:

CHANGE LOGThe table below details the changes made to the document revision.

Description Date Created by Checked by Approved by Revision

6543

Amended specification table

November 2017

SAR PM MVZ 2

Added safety section. Updated contact email address.

October 2016 MJ *** *** 1

Initial Release September 2016

MJ PM MvZ 0

TITLE Compensator-2.75 Litre SMD P/N’s EV_4003-28 OnwardsID 8101-1241623

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TABLE OF CONTENTSAbout Curvetech® Page 2

Confidentiality Statement Page 2

Applicability Page 2

Revision Control Page 3

Revision Approval Page 3

Change Log Page 3

Cautions & Warnings Key Page 5

Safety Page 5

Description Page 6

Specification Page 7

Mounting Arrangement Page 9

Accessories Page 10

Maintenance Page 13

Daily/Pre and Post Dive Checks Page 13

Weekly Page 13

Monthly Page 13

Yearly Page 13

Every 2 Years (after heavy use) Page 13

Filling Compensator Page 14

Replacing the Rolling Diaphragm Page 15

Reassembly Page 16

Cleaning Page 17

Storage Page 17

Disposal / Scrappage Page 17

Service and Spare Parts Page 18

Service Return Procedure Page 18

Spare Parts Page 18

Distributors Page 18


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CAUTIONS & WARNINGS KEY

DANGER:Indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

WARNING:Indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

CAUTION:!

Indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.

NOTICE:

Indicates a potential risk of damage to the supported product, property, SMD confidentiality and copyright.

SAFETYSMD Statement on Product Safety and COSHH material safety data sheets can be found on the Safety & COSHH CD (SMD Part No. AC8901).

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DESCRIPTION

Within a subsea hydraulic system, oil volume changes as a result of pressure and temperature.Compensators are included in these closed systems to account for this volume change. As the system volume lowers, the compensator piston can move. Typical uses of compensator are:

• Compensation of electrical boxes (ie. valve packs, electrical junction boxes, electrical terminations).

• Compensation of enclosed cavities such as bearing housings and seal cavities.

• Reservoirs as part of open and closed loop hydraulic systems.

Important considerations required in the use of compensators in subsea hydraulic systems:

• Correct compensator size for the oil volume under compensation. The main parameters that affect oil volume are pressure and temperature. If required, SMD can advise further on compensator sizings.

• Relief valve included to limit system maximum internal pressure (see accessories section).

• Mounting is secure (see accessories section).

• Space is available for the lower piston guide to move through its full range. Mounting is protected from inadvertent damage of components. Component is readily accessible for maintenance purposes.

Figure 1 - 2.75L Compensator

(3D Model. Click to Activate)

CAUTION:!

Compensator shall be fitted with a relief valve sized in accordance with installation. Pressure rating of the relief valve shall be in accordance with installation but shall be no greater than 50psi.


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SPECIFICATION• Type: Rolling diaphragm with internal spring.

• Oil Volume: 2.75L (4.8 imperial pints).

• Maximum Working Pressure: 2 Bar / 30psi (relative to atmosphere).

• Diaphragm: Nitrile Rubber.

• Diameter#: 181mm.

• Length# (Empty): 430mm.

• Length# (Full): 545mm.

• Recommended Oil Types:

• HVI type hydraulic mineral oils (ie. Shell Tellus, Mobil DTE 10).

• Transformer type oils (ie. Mobilect 39).

• Environmental/HEES Oils (ie. Panolin HLP Synth, Panolin Atlantis).

# See approved general arrangement drawing for component layout. Please request latest copy from SMD sales.

Weights:

Materials

• Top Plate and Spring – Stainless Steel

• Bottom Plate and Coupling Flanges – Acetal (Plastic)

(Continued on next page)

Weight (kg)*In Air In Water

Pressure Variant Empty Full Empty FullHigh Pressure - 15-30 psi 11.2 13.5 7.5 7.0Medium Pressure - 6-12 psi 9.4 11.7 6.3 5.8Low Pressure - 2.5-5 psi 8.2 10.5 5.4 4.9

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General

Compensator Variant(EV_4003-XX)

28 29 30 31 32 33 34 35 36

Pressure Variant

Low Pressure

Low Pres-sure

MediumPressure

Low Pressure

High Pressure

Low Pressure

High Pressure

High Pressure

High Pressure

Pressure at Max. Volume*

0.34 bar (5 psi)

0.34 bar (5 psi)

0.8 bar(12 psi)

0.34 bar (5 psi)

2 bar (29 psi)

0.34 bar (5 psi)

2 bar (29 psi)

2 bar (29 psi)

2 bar (29 psi)

Hydraulic Connections 5 x SAE #6 5 x SAE #6

2 x SAE #12Female

5 x SAE #6 5 x SAE #6 5 x SAE #6 5 x SAE #6 5 x SAE #6 5 x SAE #6

Electrical Connector

Subconn / Impulse N/A Subconn /

Impulse Burton Burton Subconn / Impulse

Subconn / Impulse Seacon N/A

Electrical Output 0-10V N/A 0-10V 0-10V 0-10V 0-10V 0-10V 0-10V N/A

General

Compensator Variant(Unique Part Number)

38 39 40 41 42 43 AJ7933

Pressure Variant Low Pressure Low Pressure Low Pressure Medium

Pressure Low Pressure Medium Pressure Low Pressure

Pressure at Max. Volume*

0.34 bar (5 psi)

0.34 bar (5 psi)

0.34 bar (5 psi)

0.8 bar(12 psi)

0.34 bar (5 psi)

0.8 bar(12 psi)

0.34 bar (5 psi)

Hydraulic Connections 5 x SAE #6 3 x SAE #4

2 x SAE #6 5 x SAE #6 3 x SAE #42 x SAE #6 6 x SAE #6 6 x SAE #6 5 x SAE #6

Electrical Connector Seacon Subconn /

ImpulseSubconn / Impulse

Subconn / Impulse

Subconn / Impulse

Subconn / Impulse

Subconn / Impulse

Electrical Output 0-10V 4-20mA 0-10V 4-20mA 0-10V 0-10V 4-20mA

Note: Compensator variant 27 and below are an old design requiring external transducer. Variant 28 onwards is the current MK2 design with internal transducer.

* Values are engineering estimates and may vary between units. See latest GA for approved estimates.


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MOUNTING ARRANGEMENT

The compensator is best mounted vertically. Standard procedure is to mount the base to a bottom mounting boss and secure the top of the compensator using the top mounting bracket / handle. The mounting bracket / handle is designed to be held using x1 M8 bolt, fastened through a captive nut plate. This allows quick and easy removal of the compensator simply by loosening the bolt, manoeuvring the compensator and lifting off by the handle. See accessories section below or contact SMD for further details.

Mounting holes are also provided at the base and at the top of the unit which can be used to directly mount the compensator to the vehicle. See the relevant General Arrangement drawing.

The mounting arrangement should ensure that the compensator has suitable sea-water drainage via the holes provided in the lower housings. Also the central guide requires room to extend as the compensator is filled.

Figure 2 - 2.75L Compensator Mounting Arrangement

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Compensator Mounting KitAJ9157 for high pressure variant.AJ9084 for medium and low pressure variant.

Transducers.SMD compensators are designed for simple retro-fit of level transducers. These are available with a variety of connectors (Im-pulse, Subconn, Burton, Seaconn) and outputs (4-20mA or 0-10V).

ACCESSORIES


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Seals Kit EV_4003-SP Mk2(Diaphragm and O-Ring Seals).

Spring Compres-sion Tool Kit AJ7395(Also compatible for 3L and 6L Compensators).

Assembly Oil Dispenser Bottle AJ6841.

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Assembly Air Compressor 23ltr AJ6840.


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MAINTENANCE

MONTHLY

• Thorough visual inspection. Removal of any vehicle components to aid this inspection.

• Oil contamination check - Particle count (NAS level or ISO level), oil water content and oil condition (if required).

• Confirm relief valve is free to move.

YEARLY

• No specific actions.

EVERY 2 YEARS (AFTER HEAVY USE)

• Full strip and inspect. Replace rolling diaphragm.

DAILY/PRE AND POST DIVE CHECKS

• Visual inspection of unit. Confirmation that unit fixings and hoses are secure. Confirmation that oil level is correct and no evidence of leaks.

WEEKLY

• No specific actions.

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FILLING COMPENSATOR

• Always fill the compensator in a slow and controlled manner.

• Monitor the fill level at all times to prevent overfilling. It’s recommended to fill to 80-90% maximum volume to leave room for some expansion.

• Fill the system through a check-valve or quick-release coupling. Once filled, the system pressure is raised above atmospheric pressure.

• After filling, leave the system to settle and bleed trapped air from system. For vertically mounted compensators, the air bleed valve can be loosened and the cap depressed (see Fig 3). Horizontally mounted units are best mounted at a slight inclination and air bleed value at the highest point. Alternatively they can be filled vertically prior to installation.

CAUTION:!

Uncontrolled filling or filling at high flow rates may over-pressurise the compensator and cause damage and injury.

• Monitor system oil levels during operation to prevent leaks and protect against component failures.

Figure 3 - Compensator Air Bleed Valve


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REPLACING THE ROLLING DIAPHRAGMReplace the rolling diaphragm using the Curvetech® Compensator Spring Compression Tool Kit (AJ7395).

• Assemble the tool kit by threading the threaded bars through the inner tapped holes of the bottom plate.

• Attach the rubber buffers to the threaded bosses and assemble to the threaded bar to lock it against the base plate. Tighten with a spanner.

• Place the tool kit vertical on the rubber feet and place the compensator inside it. The transducer can be left in the compensator and will be protected by the tool kit.

• Fit the tool top plate over the compensator and fit the nuts and washers to retain it.

WARNING:Internal spring remains compressed even with unit empty. If this is not restrained, as noted below, the parts can separate with sufficient force to cause a major injury.

To replace the rolling diaphragm, please follow the instructions below. The relevant general assembly drawing should also be used for reference. If in doubt, stop and contact SMD for assistance.

Figure 4 - 2.75L Compensator, 2bar variant with spring load released using tool kit AJ7395.

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• Orientate the compensator to match the alignment holes and fit the bolts top and bottom.

• Carefully remove 4 off M6 nuts and washers from the 4 tie bars - the spring load will transfer onto the tooling.

• Use the ratchet spanner to release the spring load evenly across three threaded bars.

• Once the load is released, the nuts can be removed by hand.

• Remove the base plate and the spring.

• Remove the clear piston housing.

• Undo the 12 off nuts, bolts and washers to separate the coupling flange.

• Remove the piston and diaphragm assembly.

• Undo the 4 off bolts from the diaphragm retainer plate and separate the diaphragm from the piston.

• Clean all residue from all parts before re-assembly, checking all o-rings for damage and replacing as necessary.

REASSEMBLY

• Apply a light coat of silicone spray or Molykote 111 to both sides of the diaphragm.

• Assemble the diaphragm to the piston ensuring the O-ring is correctly seated and lubricated, fit the diaphragm retainer plate and tighten the 4 off bolts.

• Place the piston and diaphragm assembly inside the piston housing so that the sealing lip fits into the coupling flange groove (coat with Molykote 111).

• Fit the coupling flange and clamp using the nuts, bolts and washers.

• Fit the clear housing and spring.

• Fit the base plate attached to the tooling top plate, ensuring correct orientation.

• Compress spring by hand and wind the nuts and washers onto the threaded bars until hand tight.

• Use the spanner to evenly compress the spring until the base plate fits over the tie bars.

• Fit the nuts and washers to transfer the spring load back onto the base plate and tie bars.

• Remove and disassemble the spring compression tool kit.


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STORAGEFor storage, the following actions should be taken:

• Unit cleaned externally. Full strip, clean and rebuild if use may have caused particles to enter internal cavities.

• Unit drained of oil. If oil is contaminated (dirt or water content), the unit should be flushed with clean oil.

• All ports blanked.

• Store at relatively constant temperature (+5°C to +25°C) and out of direct sunlight.

DISPOSAL / SCRAPPAGEIn the event that the unit is no longer required, it should be stripped down and cleaned to remove oil and other contaminants. The constituent parts should be sent to dedicated local waste disposal units or appropriate recycling facilities.

Waste oil must always be disposed of in appropriate facilities. If in doubt, contact your local oil supplier.

If in doubt, contact SMD who can arrange environmentally acceptable scrappage.

CLEANING

NOTICE:

Only clean using warm water with weak soap solution. Other chemicals may reduce the appearance and service life of plastic and rubber components.

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SERVICE AND SPARE PARTS

SERVICE RETURN PROCEDUREStandard return procedure is:

• Compensator should be suitably packaged and returned to SMD freight paid after advising SMD of the required service work.

• A maintenance/failure report by the customer is required.

• A quotation for service/repair will be provided by SMD.

• An order to service/repair the unit is required before work can commence.

SPARE PARTSRefer to the GA Drawing for part numbers. Ordering by SMD part number reduces the risk of wrong parts being provided.

Use of non-approved SMD parts will invalidate the warranty.

DISTRIBUTORSContact SMD Limited for a current list of distributors:

Telephone: +44 (0) 191 234 2222

Fax: +44 (0) 191 234 8599

E-mail: [email protected]

Web Site: http://www.smd.co.uk

Address: Soil Machine Dynamics Limited

Turbinia Works

Davy Bank

Wallsend

Tyne & Wear

United Kingdom

NE28 6UZ

SMD has a network of distributors that can provide in-field support for Curvetech® Products in their relative areas.

mailto:support%40smd.co.uk?subject=

http://www.smd.co.uk

Documents

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