Subsea Wire Saw User`s Manual
Contents
1. 60 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 2 0801252 p 2 08 011253 PLATE 253 2 08011254 CLAMP COLLAR LIFTING FRAME 2 oscuros roos 1 08051080 PLATEOSOC 1 080510800 PLATE 030D 6 08 011 054A WHEEL PLATE OS4A E H Wachs Part No 08 051 MAN Rev 1 0709 61 Subsea Wire Saw User s Manual 6 08 011 063 RETAINER DRIVEN WHEEL SEAL 1 os osi o23c rovo 1 08 011 026 ROD 026 1 08 051260 BAR260 62 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 6 08051281 COVER GUIDE WHEEL MAIN FRAME ASSEMBLY a FEMAEJC SESTDEG SMVELG 7 REAMNGRNGEXIRNALIBLSHATT U U 77 RETAINING RING INTERNAL 1 850 HOUSING 4 CLAMP COLLAR Y ID 316 55 8 CLAMP COLLAR 1 1 4 ID E H Wachs Part No 08 051 MAN Rev 1 0709 63 Subsea Wire Saw User s Manual 64 BEARING 20mm ID x 47mm OD x 14 mm 440 SS SINGLE SEALED WASHER THRUST 30mm ID x 47mm OD x 1mm BUSHING FLANGE 1 ID x 1 1 8 OD x 1 LNG wm BUSHING FLANGE 1 1 4 ID x 1 4 OD x 1 LNG Nm ES E EN 4 4 3 4 4 2 FITTING BULKHEAD 1 2 NPT x 1 2 JIC 2 FITTING BULKHEAD 1 NPT x 1 JIC 4 NUT BULKHE2. pr P 5 7 p L lI am ama CY Clamping Clamping arm motion pivots to con Le tact pipe Clamping cylinder Figure 1 6 The photo shows the wire saw in position for clamping on a test workpiece When the hydraulic cylinder is extended the clamp arm pivots and closes on the pipe Both clamping arms operate together be r Figure 1 7 The photo shows the clamping cylinder extended and the clamp arm secured against the pipe The frame of the machine has clamp shoes attached that the machine rests upon when installed on the pipe These shoes are made of a compressible composite material that deforms slightly under pressure to create a secure slip free grip on the pipe when the machine is clamped Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw Equipment Description Figure 1 8 The front mounting shoes are shown Topside Control Panel Figure 1 9 illustrates the controls used to operate the subsea wire saw Chapter 3 includes detailed instructions Clamp pressure gauges Cutter pressure gauge Feed speed Feed pressure gauge sii Feed speed CONTROL PANEL LINIV Clamp direction w L TS Clamping flow levers engage Cutter flow lever Feed flow lever both at once shown closed shown open shown open under pressure Figure 1 9 The photo shows the controls on the top side control unit The fourth circui
3. See Rigging the Machine in Chapter 1 for instructions on lifting the machine to position it for horizontal or vertical cuts e Attach lifting shackles to the appropriate lift eyes for the orientation of the machine e Before lowering the machine subsea to the cutting loca tion make sure the clamping arms are fully open Set the controls on the TCP as follows All flow levers up flow off Cutter speed knob to 17 5 gpm Feed speed knob to 1 5 gpm Clamp flow is preset to 4 gpm e Clamp direction to ENGAGE Feed direction to FORWARD Cutter direction is preset to forward Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Performing the Cut 1 Align the machine at the desired cut line perpendicu lar to the center axis of the pipe The clamping arms should extend around the pipe and the mounting shoes should be against the pipe or close to it 2 Start the hydraulic power unit Set it to provide 22 gpm flow at 3000 psi 3 Push both clamping flow levers down simultaneously Watch the clamping pressure gauges to ensure that the pressure is within 1900 2200 psi 4 When the clamping arms are fully clamped and the pressure is within 1900 2200 psi pull both clamping flow levers up to lock the holding pressure The pres sure will drop quickly to 1850 psi and then slowly to about 1600 psi D Repeat the clamp sequence three times The pressure should hold above 1700 ps
4. 2 CRIMP FITTING 4 HOSE x 4 JIC P 1 CRIMP FITTING 4 HOSE x 4 JIC F x 45 DEG o 1 CRIMP FITTING 4 HOSE x 4 JIC F x 90 DEG HOSE Fitting 3 8 JIC F x 3 8 JIC F Fitting Tee 3 8 JIC M x 3 8 JIC M x 1 4 ORB M CRIMP FITTING 6 HOSE x 8 JIC F a 5 CRIMP FITTING GHOSEx 6JIC F o HOSEB B _ 4 SPRING 72 OD x 586 ID x 2 LNG 6 SPACER 328 ID x 875 OD x 06 066 THICK CFatees O aty MAIN FRAME ASSEMBLY FHCS 1 4 20 x 5 8 LNG 18 SS FHCS 5 16 18 x 3 4 LNG 18 8 SS FHCS 3 8 16 x 2 1 4 LNG 18 8 SS FHCS 5 8 11 x 1 1 2 LNG 18 8 SS HHCS 1 4 20 x 1 2 LNG 8 HHCS 1 4 20 x 1 1 2 LNG 18 8 SS E H Wachs Part No 08 051 MAN Rev 1 0709 73 Subsea Wire Saw User s Manual 24 4 HHCS 1 2 13 x 1 1 2 LNG 18 8 SS 2 28 1 4 HHCS 5 8 11 x 6 LNG 18 8 SS 2 HHCS 7 16 14 x 3 LNG 18 8 SS 4 7 NUT NYLOCK 1 2 13 18 8 SS 13 51 PIN DOWEL 1 4 DIA X 5 8 LNG PIN DOWEL 1 4 DIA X 7 8 LNG PIN DOWEL 5 16 DIA X 1 LNG PIN DOWEL 5 16 DIA X 1 1 2 LNG 63 4 65 127 32 N 2 WASHER 5 8 AN 18 8 SS 74 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 4 SHCS 8 32 x 3 LNG 18 8 SS PIN DOWEL 1 4 DIA X 5 8 LNG 12 WASHER 3 8
5. E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com Subsea Wire Saw User s Manual E H Wachs Part No 08 051 MAN Rev 1 0709 July 2009 Revision History Original March 2009 Rev 1 July 2009 Copyright 2009 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs Subsea Wire Saw User s Manual Part No 08 051 MAN Rev 1 0709 E H Wachs Table of Contents Table of Contents Chapter 1 About the Subsea Wire Saw 1 Purpose of ub di eee ies Re ew Rates Elie Ree ed dd tee I Howdxo Use Ehe ui hapas az rah qua kakun pay kus h l and WOES IERI wha eda RUE telle 2 Manual Updates and Revision Tracking 3 Equipment Description 25 92 93 US Ree Ed EA RS a uhaq 3 S bsea Wire Saw Models s aiunt pum ie bee da oed HP bd deer da id Pur bd dep 4 Cutting Wire Drive System 2 a aao daveb ee CLERC Shae BAe eae a eed 4 J oO Sle rata Shee Du u ear ne eres ents 5 Champine oye eae ooh o idee Dr ee Ra PA eee ae Ra deed d dest Hed os 7 Topside Control Panel 25 242m EIER ENCORE S RUE Eqs END BUS eee 9 Rresing the Machine 2o dog qapsan ee RELIER up dn 10 Lating for Vertical Ct ose usato S e ned ee rex c D re b e re e 10 Lattine Tor Horntzontal
6. DIA X 3 4 LNG 2 PIN HAIRPIN COTTER 177 DIA X 3 1 4 LNG 2 STUD 5 8 11 x 2 1 2 LNG ASHER 1 4 AN ASHER 5 16 AN ASHER 3 8 AN ASHER 1 2 AN 2 GREASE 1 4 28 303 SS 7 HCS 8 32 x 3 LNG SHCS 10 24 x 1 1 2 LNG SHCS 1 4 28 x 5 8 LNG IN SPRING 3 32 DIA x 3 8 LNG 420 SS IN CLEVIS 1 4 OD x 1 1 2 LNG 316SS IN DOWEL 1 4 DIA X 5 8 LNG IN DOWEL 1 4 DIA X 1 3 8 LNG gt NI m A G A rm gt WN rm W O W un Z A SE ns L ns HG HG TT TU o IZ J A G gt un gt I N CO W O O C A J 14 ASHER 3 8 AN 1 SHCS 1 4 28 x 1 1 2 LNG SHCS 1 4 28 x 5 8 LNG ASHER 1 2 18 8 SS SHOULDER BOLT 1 2 DIA X 1 LNG HCS 1 4 28 x 1 LNG PIN DOWEL 3 16 DIA X 1 1 4 LNG EN ER E EN ES EN N AA IU LII IO n t SS bo x x ST 10 gt O CH T LE C un gt O N I x UT 09 E H Wachs Part No 08 051 MAN Rev 1 0709 59 Subsea Wire Saw User s Manual 1 Ess 1 4 20 x 3 8 LNG 2 SHCS 1 4 20 x 1 LNG 2 SHCS 1 4 20 x 1 LNG 2 HRGS 5 16 18 x 3 4 LNG 4 8 32 x 3 4 LNG WS 3616 MAIN FRAME ASSEMBLY 2 os osi 201 Pue 21 2 080512018 PLATE 201B 2 08 051202 PLATE202 9 08011209 roD 209 6 0805121 BAR 211 6 08011218 ROD 215
7. tions How TO USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your equipment Each page Is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer to it for safety notes and other information E H Wachs Part No 08 051 MAN Rev 1 0709 Chapter 1 About the Subsea Wire Saw In This Chapter PURPOSE OF THIS MANUAL How TO UsE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING EQUIPMENT DESCRIPTION Throughout this manual refer to this column for warnings cautions and notices with supplementary information Subsea Wire Saw User s Manual WARNING A WARNING alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in seri ous injury or death CAUTION gt A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa tion that could result in minor or moderate injury CAUTION CAUTION alert with the damage alert symbol indi cates a situation that will result in damage to the equipment IMPORTANT g An IMPORTANT alert with the damage alert symbol
8. 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Removing the Machine 2 Push the feed flow lever down to open the feed circuit pd n cp LL 8 F igure 3 18 Push the feed flow lever down to supply power to the feed drive 3 Push the feed speed knob down to 6 5 gpm maximum flow E H Wachs Part No 08 051 MAN Rev 1 0709 35 Subsea Wire Saw User s Manual It will take about 30 minutes to retract the feed drive on a 36 inch pipe 36 Figure 3 19 Push the feed speed knob down to the maximum setting 4 When the saw bow is back at its home position pull the feed flow lever up to stop the feed drive ri a ar ORGU Figure 3 20 Pull the feed flow lever up to turn off the feed drive 5 Rig the shackles to the overhead lift Lift just enough to put tension on the chains and secure the machine 6 Push the clamping direction knob to the RETRACT position Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Removing the Machine 1 Figure 3 21 Set the clamping direction knob to RETRACT 7 Pushboth clamping flow levers down simultaneously until the clamp arms are fully open The right return pressure gauge reading will equal the system pres sure Pull the clamping flow levers back up Q Lift the machine off the pipe Move it to the next cut ting location or bring it topside
9. National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 812 6 Hearing Protectors SAFETY LABELS There 1s no safety labeling on the subsea wire saw E H Wachs Part No 08 051 MAN Rev 1 0709 Chapter 2 Safety Safety Labels 21 Subsea Wire Saw User s Manual 22 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Chapter 3 Operating Instructions In This Chapter TENSIONING THE CUTTING WIRE TENSIONING THE CUTTING WIRE SETTING THE CLAMP ARMS FOR You should have the wire installed according to the mainte THE PIPE SIZE nance instructions in Chapter 4 CONNEGENGUERESDERUDG HOSES 1 At the tension wheel fixture check the start lines on MOUNTING THE MACHINE ON the feed control actuator When there is no tension on THE PIPE the wire the actuator rod will be retracted and the start lines will be offset PERFORMING THE CUT REMOVING THE MACHINE Figure 3 1 With n
10. drive Part No 08 051 MAN Rev 1 0709 E H Wachs 5 10 2 Chapter 3 Operating Instructions Performing the Cut Start with the cutting speed knob at 18 gpm Visually ensure that the wheels are spinning igure 3 14 Push the cutting speed knob up to increase the drive wheel speed Push the feed flow lever down to start feeding the wire into the pipe The feed speed knob should be at 2 5 As the wire enters the cut increase the cutting speed by moving the cutting speed knob Do not go above 19 During cutting the feed control actuator on the ten sion wheel fixture adjusts the feed rate to keep the saw from overfeeding It should not be necessary to adjust the feed rate at the TCP Continue until the wire has completely severed the pipe Pull the feed flow lever up to turn off the feed drive E H Wachs Part No 08 051 MAN Rev 1 0709 e NOTE At the minimum operating speed the drive wheel will be spinning at about 1500 RPM 4 NOTE The feed drive will travel about 2 inches beyond the bottom of the largest pipe size 33 Subsea Wire Saw User s Manual 34 F igure 3 15 Push the feed flow lever up to 0 and pull the feed flow lever up to turn off the feed drive 11 Pull the cutter flow lever up to turn off the cutter drive igure 3 1 6 Pull the cutter flow lever up to turn off the cutter REMOVING THE MACHINE 1 Set the feed direction knob on the TCP to REVERSE Part No 08
11. from the workpiece Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw Equipment Description The feed system has a self adjusting speed control feature A hydraulic actuator on the tension wheel fixture measures the deflection of the wire as it cuts If the feed speed 1s too fast the increased wire deflection trips the actuator which slows down the feed rate This allows the cutting action of the wire to catch up At maximum deflection of the wire the actuator will stop the feed motion for as long as necessary 4 gt E 4 Feed control actuator Tension spring Tension wheel Figure 1 5 The actuator controls the feed rate by measuring the deflection of the cutting wire Clamping System An adjustable clamping system allows you to configure the machine for pipe sizes within each model s range The two clamping arms are attached to the main frame with two pronged forked pins that are removable to reposition the arms The clamping arms are engaged by hydraulic cylinders mounted to the frame When the cylinder rods are extended the clamps pivot inward to grip the underside of the pipe and hold the machine securely to it Figure 1 6 illustrates the clamping operation See the end of this chapter for drawings that illustrate clamp position settings for the range of each wire saw model E H Wachs Part No 08 051 MAN Rev 1 0709 7 Subsea Wire Saw User s Manual
12. operating the subsea wire saw It contains important safety instructions and recom mendations OPERATOR SAFETY WARNING The cutting wire spins at very high speed If the wire breaks segments of the wire can fragment and be thrown from the machine at dangerous speeds When oper ating the machine topside stay a safe distance from the machine or behind a protective barrier Divers should stay a safe distance from the machine when it is running Seri ous injury or death could result from contact with the wire or as a result of the wire breaking Follow these guidelines for safe operation of the equip ment READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation E H Wachs Part No 08 051 MAN Rev 1 0709 Chapter 2 Safety In This Chapter OPERATOR SAFETY SAFETY LABELS Look for this sym N bol throughout the manual It indicates a personal injury hazard Subsea Wire Saw User s Manual 20 Properly maintaining the machine can greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs Company KEEP CLEA
13. second pair of digits is the smallest For example the WS 3616 saw will cut pipes from 16 to 36 406 to 914 mm O D Separate controls and gauges for each circuit are provided on the TCP described later in this chapter Subsea Wire Saw Models Various wire saw models are available each designed to cut a range of pipe sizes The only significant difference in the models is size all operate in a similar manner The follow ing table lists the models and capacities Table 1 Subsea Wire Saw Models Min Pipe Max Pipe Capacity Capacity WS 3012 12 305 mm 30 762 mm WS 3616 16 406 mm 36 914 mm WS 5230 30 762 mm 52 1321 mm Cutting Wire Drive System The cutting wire drive system consists of four wheels mounted on the bow of the machine Figure 1 1 illustrates the drive system components Idler wheels Tensioning knob Drive wheel Diamond wire Tension spring Tension wheel Figure 1 1 The photo shows the cutting wire drive system components Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw Equipment Description The drive wheel is operated by the hydraulic drive motor to turn the wire around the cutting system loop It is mounted on a pivoting fixture used to adjust the tension of the wire The tension is set using a knob on the fixture which also positions the wheel for installing and removing the cutting wire The tension wheel is on a pivoting s
14. t bed ba b er oad iq acd rater 11 SOn the Mache i 5 d debat t ua ee ate aru S uD uu S sana ya GERE S 3 11 Chapter uyay apay ets diee P AERE ee ire 19 O ror AO cor a dca a uq q uu pov MIU 19 Sal Iy SVINDOIS sacs gk tot exor de RUE ataca dens dh tame ha 20 Protective Equipment Requirements 21 SPAN a pu ba bu ph eae E cep ge 21 Chapter 3 Operating Instructions s eso ww q s ERST ROS EA Ee RR EAE RE PEE tea ie 23 Tensrontne the Cumin Wire 2 35 Ride Dor dcos cale ere meh Pr tva m d E RS 23 Setting the Clamp Arms for the Pipe Size 25 WiS 3012 PIDE S176 Senes 4400644 boc bes I RR E eT HEREIN EAS eI Eu d sa 25 Wo 616 Pip SIZS 26 WS 5250 Pipe Size SCuINGS ue ud dote E Mimi demon Mees kue au a 27 Positonme the C lamp Aris ood ob ot HE ae BESS EAS Cee eee ee ee ads Eu 28 Connecting the Hydraulic Hoses 29 Mounting the Machine on the Pipe 30 PS ret rr iS he C UE sad uos Me tee ah aaa Ne us God Ne el oe 31 ISemovine the o bagay Sam on eee hee yuy am iba kl 34 Chapter 4 Wiaintenance 2e oC den oie Me ate eh ie ae ees 39 iii VETO c er Aceh toa Beret Se nc pena Me cia arch 39 Replace the C
15. we will include a revised manual when we return the equipment to you EQUIPMENT DESCRIPTION The subsea wire saw is designed to cut submerged pipe of varying materials and thicknesses The machine operates on hydraulic power and is controlled remotely using the Wachs topside control panel TCP The saw uses a continuous loop diamond cutting wire and a hydraulic feed system that advances the cutting wire through the pipe Using a wire rather than a blade provides more reliable cutting on varied pipe materials and helps avoid binding of the cutting mechanism if the pipe bends and pinches while the saw is engaged The subsea wire saw has three hydraulic drive circuits e Cutting drive operates the drive wheel that drives the cutting wire Feed drive operates the bow holding the wire drive sys tem to feed the wire through the pipe and retract the bow when finished cutting Clamp drive operates the clamping arms that secure the machine to the pipe during cutting E H Wachs Part No 08 051 MAN Rev 1 0709 c NOTE A NOTE provides supple mentary information or oper ating tips Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy of this manual by emailing customer service at sales ehwachs com Subsea Wire Saw User s Manual The model name indicates the pipe size capacity The first two digits are the largest pipe and the
16. 2 864mm 30 to 34 762 864 mm o 34 to 40 864 1016 mm 40 to 46 1016 1168 mm 46 to 52 1168 1321 mm E H Wachs Part No 08 051 MAN Rev 1 0709 27 Subsea Wire Saw User s Manual WARNING Do not attempt to change the clamp arm positions while the saw is in a vertical position The clamp arms may fall when the pins are removed resulting in personal injury and equipment damage 28 Figure 3 7 The photo shows the size stamps on the WS 5230 model The pin is in the 46 52 position Positioning the Clamp Arms Make sure the saw is sitting horizontally on a level surface before you adjust the clamp arms Remove the spring clips from both pin ends of the forked pin then pull the forked pin out of the frame Figure 3 8 Remove the spring clips from both ends of the forked pin then pull the pin out from the other side 2 Slide the clamp arm assembly so that the mounting holes line up with the appropriate hole pair for the pipe size you are cutting Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Connecting the Hydraulic Hoses 3 Insert the forked pin through the back of the machine Figure 3 9 Insert the forked pin through the hole pair for the pipe size range in this case 46 52 you are cutting 4 Insert the spring clips in the forked pin on the front of the machine 5 Set the position of the other clamp arm to the same location CONNECTIN
17. 209 TUBE210 O 08 011 207 ROD 207 0 08 011 208 ROLLER 08 011 209 ROD 209 0 08 011 210 TUBE 210 08 011 211 BAR 211 N 08 011 213 SPACER 213 BAR 211 S 8 011 212 08 011 215 08 011 220 08 011 221 08 011 222 08 011 223 08 011 224 08 011 224B 08 011 230 230 gt ROD 230 083 011 231 083 011 242 083 011 243 083 051 246 08 051 2468 08 011 247 08 011 248 CYLINDER CLAMP 08 011 250 TUBE LIFTING 08 011 251 ROD 251 E H Wachs Part No 08 051 MAN Rev 1 0709 53 N E F es 1 Subsea Wire Saw User s Manual 1 0801030 pareo 1 080110308 PLATE 0308 4 4 2 0801103 PLATE 081 6 08 011 054A WHEEL PLATE 0544 6 08 011 063 RETAINER DRIVEN WHEELSEAL 54 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 1 06052460 pore ree ooo 1 06 052 161 BUSHING FEEDCLUTCH 1 06 052 1818 BPROCKET 2 40x 375 PITCH 1 08 051 270 Ro 1 o amp o512721 PLATE 271 _ 1 08051272 Brock 272 _ 1 0805127 Ronz 1 08051277 BLock 277 2 08051278 ROD 278 E H Wachs Part No 08 051 MAN Rev 1 0709 55 Subsea Wire Saw User s Manual 56 8 FEMALEJIC SAE37DEG SWIVEL G B 8HOSE SAELOOR16 TYPES B BHOSE SAEIODRIGTYPES O 8 LAMP COLLAR 8 BE
18. 4 2 A HHCS 5 8 11 x 1 1 2 LNG HHCS 5 8 11 x 1 3 4 LNG HHCS 3 4 10 x 2 LNG 12 SHCS 1 4 20 x 3 4 LNG SHCS 1 4 20 x 7 8 LNG 4 SHCS1 420x5 8 ING 7 NUT NYLOCK 1 4 20 4 NUT PIN gt N 4 45 UT NYLOCK 5 8 11 IN DOWEL 1 4 DIA X 5 8 LNG PIN DOWEL 1 4 DIA X 7 8 LNG PIN DOWEL 5 16 DIA X 1 LNG PIN DOWEL 5 16 DIA X 1 1 2 LNG 24 45 50 WASHER 7 16 AN 28 WASHER 1 2 AN 30 WASHER 5 8 AN 2 WASHER 3 4 AN 45 106 16 7 33 3 N 66 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings FEED SCREW ASSEMBLY FASTENERS HHCS 3 8 16 x 1 LNG 6 HHCS 3 8 16 x 1 1 8 LNG SHCS 8 32 x 3 LNG 4 SHCS 10 24 x 1 1 2 LNG 6 SHCS 1 4 28x5 8 LNG FEED RELIEF ASSEMBLY FASTENERS SHCS 1 4 28 x 1 LNG SHOULDER BOLT 1 2 DIA X 1 LNG 4 SHCS 8 32 x 3 4 LNG OPTIONAL WHEEL COVER ASSEMBLIES FHCS 5 16 18 x 1 LNG NUT NYLOCK 5 16 18 12 OPTIONAL REPLACEMENT DRIVE WHEEL GRIP KIT SHCS 1 4 20 x 1 1 4 LNG SSS 1 4 20 x 3 8 LNG E H Wachs Part No 08 051 MAN Rev 1 0709 67 Subsea Wire Saw User s Manual WS 5230 2 08 01107 ROD 207 2 09011208 ROLLER 6 08 011212 SPACER 222 6 0 amp 011215 ROD 215 68 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Inf
19. AD LOCK 08 2 NUT BULKHEAD LOCK 16 1 4 NULBULKHEADLOCK 16 4 EYEBOLT 5 811 1 2 13 FEED SCREW ASSEMBLY HYDRAULIC MOTOR SNAP RING 3 4 O D SHAFT SNAP RING 1 5 8 I D BORE BEARING 75 x 1 625 x 438 WASHER BELLEVILLE SPRING 2 OD x 1 ID x 065 THICK PLANET SET 3 1 KEYWAY 3 16 x 3 4 LNG ROUND ENDS KEYWAY 1 8 x 1 LNG ROUND ENDS STANDOFF 3 8 OD x 5 8 LNG SPECIFY 10 24 THD FITTING 1 4 TUBE x 1 8 NPT M FITTING TEE 1 4 TUBE F x 1 4 TUBE F x 1 8 NPT M BALL VALVE 1 8 NPT F x 1 8 NPT F Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings FITTING 1 8 NPT M x 3 8 HOSE BARB TUBING 3 8 CLEAR PVC FITTING 1 8 NPT F x 3 8 HOSE BARB FITTING 1 8 NPT M x 1 4 JIC M AIR VENT 1 8 NPT M Hose ay HOSE 1 4 Fitting 3 8 JIC F x 3 8 JIC F Fitting Tee 3 8 JIC M x 3 8 JIC M x 1 4 ORB M nose 3 5 1 SPRING 720D x 586IDx2 ING 1 CYLINDER 2 5 STROKE OPTIONAL WHEEL COVER ASSEMBLIES 6 SPACER 328 ID x 875 OD x 06 066 THICK x CFatenes MAIN FRAME ASSEMBLY FHCS 1 4 20 x 5 8 LNG FHCS 5 16 18 x 3 4 LNG FHCS 5 8 11 x 1 1 2 LNG HHCS 1 4 20 x 5 8 LNG 8 HHCS 1 4 20x1 1 2 ING E H Wachs Part No 08 051 MAN Rev 1 0709 65 Subsea Wire Saw User s Manual 2 2 HHCS 3 8 16 x 4 1 2 LNG 24
20. AN 18 8 SS EN KA EA SHCS 1 4 28 x 1 1 2 LNG SHCS 8 32 x 3 4 LNG 12 FHCS 1 4 20 x 1 2 LNG 8 SHCS 1 4 20 x 1 1 4 LNG E H Wachs Part No 08 051 MAN Rev 1 0709 75 Subsea Wire Saw User s Manual 76 Part No 08 051 MAN Rev 1 0709 E H Wachs handed J 80 EU 1 Jia ee ONE i E I a WS 3012 GENERALARRANG EMENT DIMENSIONS AND FEATURES iJ Lightweight Aluminum plate spacerframe assemblies Constant tension bow feed frame module Fourreplaceable clamp contact pads Indexable clamp pin locator Indexable clamp arm assembly Two synchronized clamp cylinders Clamp am contact rollers Wire tension spring Wire tension adjustment 10 Removable wire guide wheels 11 Large diameter high contact area removable wire drive wheel 12 Hydraulic wire drive motor with overhung bearing support 13 Three adjustable inner guide rail assemblies 14 Single feed screw nut assembly 15 Manualfeed override lever 16 Feed overload clutch 17 Lightweight planetary feed drive 18 Liftinterface for vertical cut deployment 19 Liftinterface forhorizontal cut deployment 20 Hydraulic interface fittings D 30 35 3 16 WONAUBWNE 69 3 4 92 1 2 l p nj F v A A O MM M Ll ULU l _ e _ LEM ee e D 36 43 3 4 WS 3616 GENERAL ARRANGEMENT DIMENSIONS AN
21. ARING 20mm ID x 47mm OD x 14 mm 440 55 SINGLE SEALED 4 BusHING FLANGE 1 ID x 1 1 8 OD x 1 LNG 1 DIE SPRING 1 2 ID x 1 OD x 12 FREE LENGTH 1 FITTING TEE 3 8 JIC F x 3 8 JIC M x 3 8 JIC M OUPLING FEMALE 08 NPT 4 KOUPUNG MALE 0BNPT O 2 COUPLING MAL 2NPT A4 FITTING BULKHEAD 1 2 NPT x 1 2 JIC 2 FITTING BULKHEAD 3 4 NPT x 3 4 JIC FEED SCREW ASSEMBLY 1 SNAP RING 3 4 O D SHAFT NAP RING 1 5 8 I D BORE LAMP ON COLLAR 3 4 16 303 SS 1 BEARING 75 x 1 625 x 438 ASHER BELLEVILLE SPRING 2 OD x 1 ID x 065 THICK Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 2 PLANET SET 3 1 2 PLANET SPACER 1 PLANET SET 4 1 2 KEYWAY 3 16 x 3 4 LNG ROUND ENDS 1 KEYWAY 1 8 x 1 LNG ROUND ENDS 4 STANDOFF 3 8 OD x 5 8 LNG SPECIFY 10 24 THD 24 35 CHAIN SS 34 links long 1 H35 CHAIN CONNECTING LINK 2 FEMALE JIC SAE 37 DEG SWIVEL 6 FEED TENSION SWITCH ASSEMBLY 4 FITTING 1 4 TUBE x 1 8 NPT M 2 FITTING TEE 1 4 TUBE F x 1 4 TUBE F x 1 8 NPT M 2 FITTING TEE 1 8 NPT F x 1 8 NPT F x 1 8 NPT M 2 BALL VALVE 1 8 NPT F x 1 8 NPT F 1 FITTING 1 8 NPT M x 3 8 HOSE BARB UBING 3 8 CLEAR PVC 1 FITTING 1 8 NPT F x 3 8 HOSE BARB 2 FITTING TEE 1 8 NPT F x 1 8 NPT F x 1 8 NPT F 4 FITTING 1 8 NPT M
22. D FEATURES Lightweight Aluminum plate spacer frame assemblies 7 Constant tension bow feed frame module Four replaceable clamp contact pads Indexable clamp pin locator Indexable clamp am assembly Two synchronized clamp cylinders Clamp arm contact rollers Wire tension spring Wire tension adjustment 10 Removable wire guide wheels 11 Large diameter high contact area removable wire drive wheel 12 Hydraulic wire drive motor with overhung bearing support 13 Three adjustable inner guide rail assemblies 14 Single feed screw nut assembly 15 Manualfeed override lever 16 Feed overload clutch 17 Lightweight planetary feed drive 18 Liftinterface for vertical cut deployment 19 Lift interface for horizontal cut deployment 20 Hydraulic interface fittings OONOUBWNE 87 1 4 127 WS 5230 GENERAL ARRANGEMENT DIMENSIONS AND FEATURES o Lightweight Aluminum plate spacer frame assemblies Constant tension bow feed frame module Fourreplaceable clamp contact pads Indexable clamp pin locator Indexable clamp arm assembly Two synchronized clamp cylinders Clamp am contact rollers Wire tension spring Wire tension adjustment 10 Removable wire guide wheels 11 Large diameter high contact area removable wire drive wheel 12 Hydraulic wire drive motor with overhung bearing support 13 Three adjustable inner guide rail assemblies 14 Single feed screw nut assembly 15 Manualfeed ovemde lever 16 Feed overlo
23. G THE HYDRAULIC HOSES Connect the hydraulic hoses from the topside control panel TCP to the hydraulic bulkhead on the machine as indi cated 1n Figure 3 10 E H Wachs Part No 08 051 MAN Rev 1 0709 EE CAUTION Make sure both clamping arms are set at the same position If they are not the same the machine may not clamp securely on the pipe Damage to the machine could result 20 Subsea Wire Saw User s Manual WARNING The cutting wire spins at very high speed If the wire breaks segments of the wire can fragment and be thrown from the machine at danger ous speeds Stay a safe dis tance from the machine or behind a protective barrier when operating it topside Serious injury or death could result from contact with the wire or as a result of the wire breaking EL CAUTION Lift the machine ONLY on the lifting eyes provided Lifting on any other component could damage the machine The flow on the clamp circuit Is set internally at 4 gpm 30 Before lowering the machine subsea test all three drive cir cuits to make sure they are working Clamp circuit Feed circuit Cutting drive pressure pressure circuit pressure Clamp circuit Feed circuit Cutting drive return return circuit return Figure 3 10 Attach the hydraulic hoses as shown The ports marked A are pressure lines from the TCP the ports marked B are return lines to the TCP MOUNTING THE MACHINE ON THE PIPE
24. No 08 051 MAN Rev 1 0709 49 Subsea Wire Saw User s Manual 50 1 3 Slide the wheel and motor assembly plates into place in the saw bow and line up the pivot pin holes 14 Set the stop collars in place between the plates Insert the pivot pin through the top plate the stop collars and the bottom plate 15 Holding the pivot pin in place position the stop col lars against the mounting plates and tighten the set SCICWS Pivot pin Qi f ES Stop collars Set screw m V4 gt Pc t re d i j a k i ine ii gor M Fr y Figure 4 19 Make sure the pivot pin is through both plates then position the stop collars and tighten the Set screws Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Chapter 5 Parts List and Ordering Information ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs products call us at one of the following numbers U S 800 323 8185 International 847 537 8800 You can also visit our Web site at www ehwachs com Ordering Replacement Parts When ordering parts refer to the parts lists in this chapter Please provide the part description and part number for all parts you are ordering Repair Information Please call us for an authorization number before returning any equipment for repair or factory service We will ad
25. R OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts Always turn machine off before doing any adjustments Or service SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area Safety Symbols This icon is displayed with any safety alert that indicates a personal injury hazard N WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that 1f not avoided could result in minor or moderate injury Part No 08 051 MAN Rev 1 0709 E H Wachs Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87 1 is available from the American
26. ad clutch 17 Lightweight planetary feed drive 18 Liftinterface for vertical cut deployment 19 Lift interface for horizontal cut deployment 20 Hydraulic interface fittings o oo Ur IS UN E
27. e 4 13 Put the new wheel liner on the wheel J ri f If you removed the shaft replace it through the center of the wheel Figure 4 14 Replace the shaft through the center of the wheel Q Replace the side plate making sure that the keys in the shaft fit into the slots in plate Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance Replacing the Wheel Liners Figure 4 15 Make sure the shaft keys are in the slots on both side plates of the wheel Q Fasten the side plate with the 6 screws Snug each screw then tighten them in a criss cross pattern to secure the wheel evenly Figure 4 16 Replace the screws in the side plate _ Replace the wheel into its mounting fixture Put the bolt through the top of the fixture and install the nut on the bottom Tighten the nut securely E H Wachs Part No 08 051 MAN Rev 1 0709 47 Subsea Wire Saw User s Manual 48 Drive Wheel Remove the cutting wire before taking off any of the wheels To replace the drive wheel liner you must first remove the wheel and motor assembly from the saw bow using the fol lowing procedure 1 Hold or support the drive wheel and hydraulic motor assembly so that it does not fall when you remove the fasteners holding it to the saw bow 2 Loosen the set screws in the stop collars on the pivot pin and remove the pin from the frame Be careful not to lose the stop collars Pivot pin c Z Sto
28. es swe FEMALE JIC SAE 37 DEG SWIVEL 3 8 HOSE CLAMP COLLAR 1 2 ID 316 SS 8 CLAMP COLLAR 1 1 4 ID EN BEARING 20mm ID x 47mm OD x 14 mm 440 SS SINGLE SEALED WASHER THRUST 30mm ID x 47mm OD x Imm BUSHING FLANGE 1 ID x 1 1 8 OD x 1 LNG BUSHING FLANGE 1 1 4 ID x 1 4 OD x 1 LNG LINEAR BEARING SYSTEM RAIL CARRIAGE E H Wachs Part No 08 051 MAN Rev 1 0709 71 Subsea Wire Saw User s Manual 12 DIE SPRING 1 2 ID x 1 OD x 12 FREE LENGTH FITTING BULKHEAD 1 2 NPT x 1 2 JIC FITTING BULKHEAD 1 NPT x 1 JIC NUT BULKHEAD LOCK 08 NUT BULKHEAD LOCK 16 FITTING TEE 3 8 JIC F x 3 8 JIC M x 3 8 JIC M 37 DEG BULKHEAD TEE FITTING KNOB 1 2 13 SNAP RING 1 5 8 I D BORE PLANET SET 4 1 KEYWAY 3 16 x 3 4 LNG ROUND ENDS KEYWAY 1 8 x 1 LNG ROUND ENDS STANDOFF 3 8 OD x 5 8 LNG SPECIFY 10 24 THD FITTING 1 4 TUBE x 1 8 NPT M FITTING TEE 1 4 TUBE F x 1 4 TUBE F x 1 8 NPT M FITTING TEE 1 8 NPT F x 1 8 NPT F x 1 8 NPT M BALL VALVE 1 8 NPT F x 1 8 NPT F FITTING 1 8 NPT M x 3 8 HOSE BARB TUBING 3 8 CLEAR PVC FITTING 1 8 NPT F x 3 8 HOSE BARB FITTING TEE 1 8 NPT F x 1 8 NPT F x 1 8 NPT F FITTING 1 8 NPT M x 1 4 JIC M Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings AIR VENT 1 8 NPT M 2 tuBecampP 5 3 O
29. hly then cover it with a waterproof cover You can leave the wire installed on the machine during stor age Keep a normal amount of tension on the wire to hold it in place E H Wachs Part No 08 051 MAN Rev 1 0709 11 Subsea Wire Saw User s Manual 12 Part No 08 051 MAN Rev 1 0709 E H Wachs 3012 Wire Saw CLAMP POSITION 1 30 26 AS SHOWN Clamp Arm Positions 26 22 18 14 14 12 3012 Wire Saw CLAMP POSITION 5 14 12 AS SHOWN Position Pipe Dia Range Clamp Arm Positions 30 E 26 ERA 22 18 18 14 3616 Wire Saw CLAMP POSITION 1 36 32 AS SHOWN Clamp Arm Positions Position Pipe Dia Range 36 32 32 28 24 20 3616 Wire Saw CLAMP POSITION 5 20 16 AS SHOWN Clamp Arm Positions Pipe dia Range 36 32 5230 Wire Saw CLAMP CONFIGURATION 1 52 46 AS SHOWN Clamp Arm Positions Configuration Pipe Dio Ronge 52 46 46 4 40 34 34 28 5230 Wire Saw CLAMP CONFIGURATION 4 34 28 AS SHOWN Clamp Arm Positions Configuration Pipe Dia Range 52 46 46 40 40 34 34 28 EE Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a top priority In the design of all our products Read this chapter carefully before
30. i PERFORMING THE CUT q Push the feed flow lever down to open the feed circuit Figure 3 1 Push the feed flow lever down to supply power to the feed drive 2 Set the feed speed knob to 2 5 gpm E H Wachs Part No 08 051 MAN Rev 1 0709 Ms CAUTION As you operate the machine check the clamping pressure frequently to make sure it stays above 1700 psi If it gets too low stop the machine and reclamp it to the pipe N WARNING The cutting wire spins at very high speed If the wire breaks segments of the wire can fragment and be thrown from the machine at danger ous speeds Make sure all personnel are at a safe dis tance before starting the cut ting drive Serious injury or death could result from contact with the wire or as a result of the wire break ing 3l Subsea Wire Saw User s Manual The larger the pipe size the longer it will take to feed the cutting wire close to the pipe This is because smaller pipes fit closer between the mount ing shoes 22 Figure 3 12 Push the feed speed knob down to 2 5 gpm 3 Visually monitor the position of the cutting wire as the bow feeds toward the pipe When the wire is within 1 4 of the pipe surface pull the feed flow lever up to turn off the feed drive 4 Push the cutting drive flow lever down to open the cutting drive circuit Figure 3 13 Push the cutting flow lever down to sup ply power to the cutting
31. if you are finished E H Wachs Part No 08 051 MAN Rev 1 0709 37 Subsea Wire Saw User s Manual 38 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance LUBRICATION Every time you use the machine lubricate the following components 1 Slowly pump multi purpose No 2 EP marine grease into the grease fittings on each of the 4 wheel hubs Do NOT use AquaLube on the wheel hubs Figure 4 1 Each wheel hub has a grease fitting Pump AquaLube into the grease fittings on the feed 2 p Aq 8 gears feed motor and feed block 4 fittings E H Wachs Part No 08 051 MAN Rev 1 0709 Chapter 4 Maintenance In This Chapter LUBRICATION REPLACING THE CUTTING WIRE REPLACING THE MOUNTING SHOES REPLACING THE WHEEL LINERS CAUTION Do not directly apply lubricant to the feed screw 39 Subsea Wire Saw User s Manual Feed block Feed motor Feed gears Figure 4 2 Grease the feed components shown at the top of the feed system 3 Pump AquaLube into the grease fitting on the feed screw mount at the bottom of the screw Figure 4 3 Grease the fitting at the bottom of the feed screw 4 Pump AquaLube into the grease fittings on the cylin der rod ends until grease 15 visible 40 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance Replacing the Cutting Wire gt A vo 1 z 37 em Figure 4 4 Both clamping cyli
32. indi cates a situation that may result in damage to the equipment N SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This is the equipment damage alert symbol It is used to alert you to poten tial equipment damage situations Obey all messages that follow this sym bol to avoid damaging the equipment or workpiece on which it is operating Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw Manual Updates and Revision Tracking NOTE This symbol indicates a user note Notes provide additional information to supple ment the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary When a manual is revised we will update the revision history on the title page You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures
33. nders have a grease fit ting on the rod end REPLACING THE CUTTING WIRE Start with the saw bow retracted all the way to the top of the frame q Turn the tension knob on the drive wheel fixture all the way down to release the tension on the wire CAUTION Wear gloves when handling the wire The abrasive sur faces are sharp and could cut your hands gt L j iem x I i b 1 a f T lt d AZ Figure 4 5 Turn the tensioning knob all the way down on the screw to loosen the wire 2 Slip the wire off the drive wheel then remove it from the other wheels E H Wachs Part No 08 051 MAN Rev 1 0709 41 Subsea Wire Saw User s Manual 4 NOTE The drive wheel fixture is stamped with an arrow show ing the direction of rotation 42 3 Different brands of wire have different markings to indicate cutting direction Look at the new wire closely to determine direction a w P 2 Ww 2 tr X OG a d AGAT 2 N b a cT f A a amp e al Z ps AY vo r C 10 i T v A 3 Eun f dem We Fi a Al RE ar 1 Figure 4 6 This wire has molded arrows indicating the cutting direction Arrowhead Cutting direction Shoulders Figure 4 7 This type of wire has arrowheads molded into the plastic coating The dark sho
34. o tension on the wire the feed actuator start lines will be offset E H Wachs Part No 08 051 MAN Rev 1 0709 23 Subsea Wire Saw User s Manual 2 Tighten the drive wheel tensioning knob as shown in Figure 3 2 until you can see the line on the spring loaded driver wheel Figure 3 3 Figure 3 2 Turn the tension knob on the drive wheel fixture to increase the tension on the wire Depending on the exact length of the wire about 3 4 of the screw will be visible when the tension is set correctly Figure 3 3 When the wire is properly tensioned the start lines will be lined up together 3 You should be able to deflect the wire fairly easily by pushing it up between the idler wheels Push it in far enough to compress the tension spring and make sure the actuator rod extends into the slot in the shaft 24 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Setting the Clamp Arms for the Pipe Size Jn n r we n m Figure 3 4 When you push the wire to deflect it the actuator rod will extend SETTING THE CLAMP ARMS FOR THE PIPE SIZE The clamp arms are attached to the main frame using forked pins that go through two holes in the frame Multiple sets of holes allow the arms to be mounted in five positions The hole pairs for each position are stamped with the size of the largest pipe for that position Refer to the following sec
35. ormation Parts Lists and Layout Drawings roos 2 08 011282 PLATE 282 2 08011253 PLATE 258 BOW FRAME ASSEMBLY 4 0801024 spacer o2 2 08011005 ROD 025 1 08 021030 PLATE 030 2 oosros par 032 1 08 021034 PLATE 034 1 08011036 NULTENSION 1 08 051 0030 PLATE 093 1 0805104 ROD 044 1 0801162 RODEND 6 08 01 054A WHEEL PLATE 0544 ruses 2 08011056 TUBE 056 1 08 011 057 SCREW 057 WHEEL E H Wachs Part No 08 051 MAN Rev 1 0709 69 Subsea Wire Saw User s Manual 6 08 011 063 RETAINER DRIVEN WHEEL SEAL FEED ASSEMBLY 1 06 052 160 voke reo 1 06052161 BUSHING FEED CLUTCH 1 06 0521818 SPROCKET 240x 375PITCH 1 08 051 270 Ro 1 08051271 PLATE 271 1 08051272 BLOCK 272 1 eeosze 1 08 051277 BOCK 277 2 08 051278 ROD 278 70 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 6 08 051281 COVER GUIDE WHEEL DNDRAUUCCHUNDERCONTNUED Lave ane 8 6 sae ons roc o0 pes Ls hvo aoe e6 sae ors Tones 2 Lao ave 6eriemicsones La FeMave sic sae 37 DEG swivet gt remme nesae ay o
36. p collars x Set screw t Caa t le AN A Wm 2 5 z r h k j Fi Figure 4 17 Loosen the set screws in the stop collars to remove the pivot pin 3 Remove the nut from the bolt holding the wheel assembly to the tension rod then remove the bolt The wheel and motor assembly will be free from the saw bow Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance Replacing the Wheel Liners Tension rod Spacer bolt Hub bolt Top plate mounting bolt Figure 4 18 Remove the nut on the bottom of the tension rod mounting bolt and remove the bolt Remove the hub bolt and spacer bolt from the wheel assembly as shown in Figure 4 18 Be careful not to lose the spacer 5 Pull the top plate off the wheel 6 Pullthe wheel up off the motor shaft Note the side of the wheel that mounts onto the motor the wheel 1s not reversible 7 Disassemble the wheel and replace the liner as described in the previous section Tension and Idler Wheels 8 Replace the wheel on the motor shaft making sure the correct side is toward the motor O Replace the top plate Insert the spacer bolt through the spacer and snug it down 10 Replace the hub bolt and snug it 1 1 Replace the tension rod mounting bolt through the plates and tension rod end Put the nut on the end of the bolt and tighten it securely 12 Tighten the spacer bolt and hub bolt securely E H Wachs Part
37. pring loaded fixture that maintains wire tension The other two idler wheels are fixed at the bottom of the bow where the cutting wire engages the pipe The wire is a custom made loop for the size of the saw Spare wires can be ordered from E H Wachs Feed System A feed drive mechanism on the main frame of the machine drives the bow and cutting system up and down to perform the cut and retract the bow after cutting The bow rides on three feed rails and 1s driven by a feed screw in the center of the frame Figure 1 2 and Figure 1 3 show the main feed system components Saw bow Feed screw Feed rails Figure 1 2 The saw bow moves on three feed rails on the frame The feed screw along the center rail drives the bow E H Wachs Part No 08 051 MAN Rev 1 0709 5 Subsea Wire Saw User s Manual Feed block Feed screw Manual feed nut m T w Ia a Pe A E Feed motor Drive chain Figure 1 3 The feed system components are shown The feed block is attached to the saw bow The top of the feed screw has a drive nut to allow the feed to be operated manually and a clutch in the top coupling dis engages the feed screw if the feed drive jams or reaches the end of travel Figure 1 4 Use the manual feed nut to move the saw bow if it cannot be operated using hydraulic power Turn the nut clockwise to retract the bow away
38. t 44 aged if the saw malfunctions If necessary replace them using the following procedure The tension wheel and 2 idler wheels are identical The drive wheel is assembled differently than the others Tension and Idler Wheels Remove the cutting wire before taking off any of the wheels J Remove the nut on the end of the hub bolt and pull the bolt out of the wheel mounting fixture Figure 4 10 Remove the hub bolt to take off the wheel The bolt head is on top in this view with the nut on the bottom of the fixture 2 Remove the wheel from its mounting fixture and set it on a work surface You can work on either side of the wheel 3 Remove the 6 screws holding the side plate in place You only need to remove one side plate Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance Replacing the Wheel Liners Figure 4 11 Remove the screws from the side plate to take it off Remove the side plate 5 Remove the old wheel liner You may have to pry it loose with a screwdriver DENT Figure 4 12 Pull the liner off the wheel You may have to pry it with a screwdriver to get it loose E H Wachs Part No 08 051 MAN Rev 1 0709 45 Subsea Wire Saw User s Manual 46 6 Place the new liner on the wheel and press it down into place di 27 4 M FA f E y i nmm x 4 a m r 7 I m CES 1 Ti Ea ud Pa Lr Figur
39. t to the far right is not used with the subsea wire saw E H Wachs Part No 08 051 MAN Rev 1 0709 9 Subsea Wire Saw User s Manual 10 Rigging the Machine A rigging instruction label 1s attached to the top of the machine frame FOR HORIZONTAL CUT LIFT BY 3 EYEBOLTS F R VERTICAL CUT LIFT BY 2 PLATE HOLES ONLY Alm Figure 1 10 The rigging label is on top of the frame Lifting for Vertical Cut Attach the machine to the lifting device using chains on the top lift hooks Tip the machine up to a vertical position then pick it up Make sure the chains are the appropriate length to hold the machine reasonably straight IMPORTANT Do not attach to this hook when lifting the machine vertically lt Figure 1 11 To position the machine vertically on the pipe attach to the two top lift hooks Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw Equipment Description Lifting for Horizontal Cut With the machine positioned horizontal on the floor or deck attach a lift to the two hooks on the lift bar and the front hook on top of the frame Figure 1 12 To position the machine horizontally on the pipe attach to the two lift bar hooks and the front hook on the top Storing the Machine Store the machine sitting horizontal with the front of it the side with the Wachs logo facing up For long term storage clean and dry the machine thoroug
40. tions for the pipe size settings for each saw model WS 3012 Pipe Size Settings Table 1 and Figure 3 5 describe the pipe size settings for the WS 3012 model Table 1 Pipe Size Ranges for Clamping Arm Positions WS 3012 Size Stamp Pipe Diameter Range 12 to 14 305 356 mm 14 to 18 356 457 mm 18 to 22 457 559 mm E H Wachs Part No 08 051 MAN Rev 1 0709 25 Subsea Wire Saw User s Manual 26 Table 1 Pipe Size Ranges for Clamping Arm Positions WS 3012 ELM Pipe Diameter Range 22 to 26 559 660 mm En 26 to 30 660 762 mm Figure 3 5 The photo shows the size stamps on the WS 3012 model The pin is in the 26 30 position WS 3616 Pipe Size Settings Table 2 and Figure 3 6 describe the pipe size settings for the WS 3616 model Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 3 Operating Instructions Setting the Clamp Arms for the Pipe Size Table 2 Pipe Size Ranges for Clamping Arm Positions WS 3616 see Sum Peeler ange m sers e werom 32 to 36 813 914 mm Figure 3 6 The photo shows the size stamps on the WS 3616 model The pin is in the 16 20 position WS 5230 Pipe Size Settings Table 3 and Figure 3 7 describe the pipe size settings for the WS 5230 model Table 3 Pipe Size Ranges for Clamping Arm Positions WS 5230 Size Stamp PipeDiameterRange Pipe Diameter Range 34 301034 76
41. uine WHG UD edad weak bo uke ta YES ERE RENTA 41 Replacing the Mounting Shoes 43 Replacing the Wheel Liners som EUER REESE PES T ea xe eR sd 43 Tension and Idler WHEEIS uuu oor Qa Pa spa Spam pachita t E dA 44 lam du TTC 48 E H Wachs Part No 08 051 MAN Rev 1 0709 1 Subsea Wire Saw User s Manual Chapter 5 Parts List and Ordering Information 51 Ordering Inlorm of eun a hee ope xr a a bdo died a Dd pda died ds 51 Orderine Replacement Paris u y bea oe gagu awama ua Gey ac ow qp aa saa P AO a eE d obeunda ee ane eee ian 51 Waiiantylilonnaliogl 25 LL san ena Qamqa edes Mai Hab eR aa S enr Wu 52 Return Goods pp Vela v eee ed pee 52 Parts Lists and Layout Drawings sessies xXREETE Wee E se tees Geka RR 92 RE PR e x desi dd 53 NV tert ar pas uenia dui a D a en EE E 60 NS Os rr TEE 68 li Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 1 About the Subsea Wire Saw PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the sub sea wire saw It includes instructions for set up operation and maintenance It also contains parts lists diagrams and service information to help you order replacement parts and perform user serviceable repairs Before operating the subsea wire saw you should read through this manual and become familiar with all instruc
42. ulder of the cutting bead should trail the bead as the wire cuts 4 Place the new wire over the wheels In reverse order of removing the wire Be sure to mount it so that the arrows are in the direction of travel Figure 4 6 Install the wire so that the arrows point in the direction of travel as shown Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 4 Maintenance Replacing the Mounting Shoes 5 Turn the drive wheel tension knob until the wire starts to tighten and stays on the wheels 6 To prepare the machine for a new cut set the wire ten sion as described in the operating instructions in Chapter 3 REPLACING THE MOUNTING SHOES You may have to replace the mounting shoes if they are damaged or worn Four screws attach each shoe to the frame Figure 4 9 The four screws indicated hold the shoe to the machine frame 1 Remove the nuts on the four screws holding the shoe in place 2 Remove the shoe 3 Putthe new shoe in place and replace the screws 4 Replace the nuts and tighten them securely REPLACING THE WHEEL LINERS The liners on the cutting wire wheels are durable and long lasting They may wear out after extensive use or be dam E H Wachs Part No 08 051 MAN Rev 1 0709 43 Subsea Wire Saw User s Manual It may be easier to work on the wheel if you set it on something that supports the side plate with a gap for the hub shaft to keep it from sit ting on the shaf
43. vise you of shipping and handling When you send the equip ment please include the following information Your name company name Your address Your phone number E H Wachs Part No 08 051 MAN Rev 1 0709 In This Chapter ORDERING INFORMATION PARTS LISTS AND LAYOUT DRAWINGS 51 Subsea Wire Saw User s Manual 22 e Adescription of the problem or the work to be done Before we perform any repair we will estimate the work and inform you of the cost and the time to complete it Warranty Infor mation Enclosed with the manual Is a warranty card Please fill out the registration card and return to E H Wachs Retain the owner s registration record and warranty card for your information Return Goods Address Return equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA PARTS LiSTS AND LAYOUT DRAWINGS The tables on the following pages list the parts for the WS 3012 WS 3616 and WS 5230 subsea wire saws The drawings at the end of the chapter illustrate the layout and dimensions of the subsea wire saw models Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings WS 3012 Manufactured Parts Oty PartNo Description MAIN FRAME ASSEMBLY 08 011 201B 08 011 202 08 011 202B 08 011 203 08 011 203B 08 011 204 08 011 205 8 011 206 ROD 207 ROLLER ROD
44. x 1 4 JIC M 4 MR VENT 1 8 NPT M hose yam 2 Fitting 3 8 JIC F x 3 8 JIC F 2 Fitting Tee 3 8 JIC M x 3 8 JIC M x 1 4 ORB M 1 CRIMP FITTING 6 HOSE x 8 JIC F 2 ERIMP FITTING 6 HOSE x 6 JIC F x 90 DEG 5 CRIMP FITTING GHOSEx 6JIC F HOSE 8 S 1 BPRING 72 OD x 586 1Dx2 ING 2 KYUNDER2S STROKE MAIN FRAME ASSEMBLY 72 FHCS 1 4 20 x 5 8 LNG 30 FHCS 5 16 18 x 3 4 LNG E H Wachs Part No 08 051 MAN Rev 1 0709 57 Subsea Wire Saw User s Manual 58 16 FHcs 3 8 16 x 1 1 4 LNG 32 FHCS 5 8 11 x 1 1 2 LNG 20 HHCS 1 4 20 x 5 8 LNG 4 24 HHCS 3 8 16 x 3 4 LNG 2 24 HHCS 7 16 14 x 3 LNG H 5 2 1 4 4 4 4 3 1 2 16 HHCS 5 8 11 x 1 1 2 LNG 1 4 2 2 4 1 4 20 x 3 4 LNG 1 5 1 4 20 x 7 8 LNG 24 KHCS 1 4 20 x 1 1 4 LNG 12 HCS 1 420x5 8 lNG 6 HCS 5 16 18x5 8LNG 42 HCS 5 16 18 x 1 1 4 LNG 2 HCS 7 16 14x 1 LNG SSS CUP POINT 1 4 20 x 7 8 LNG 7 NUT NYLOCK 1 4 20 NUT I PIN 4 UT NYLOCK 5 8 11 IN DOWEL 1 4 DIA X 5 8 LNG PIN DOWEL 1 4 DIA X 7 8 LNG 2 PIN DOWEL 5 16 DIA X 1 LNG 12 42 2 54 107 16 35 3 Part No 08 051 MAN Rev 1 0709 E H Wachs Chapter 5 Parts List and Ordering Information Parts Lists and Layout Drawings 2 PIN DOWEL 5 16 DIA X 1 1 2 LNG 2 PIN SPRING 3 16
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