TMT-NMA-033 Typhoon MK2 150 Maintenance

Typhoon MK2 150
System Maintenance Manual
TMT-NMA-033 Total Marine Technology Pty Ltd Revision Number: 3

Document Control Details
Document Control Details

Job Code: 3613
Project Title: Typhoon MK2 150
Subject: System Maintenance Manual
Client: TMT
Doc No: TMT-NMA-033
Date: 20 October 2015
Revision History:
Rev. Date Description Created / Updated By Checked By Approved By
L Licsik
1 17/04/14 First Release R White M de Castro
J Dobra
Updated photos &
2 21/07/14 R White M de Castro M de Castro
layout
Added additional R Azarhoush
filter maintenance
3 20/10/15 R White A Huettner M de Castro
requirements, CB &
sensor S Stankovic
Total Marine Technology Pty Ltd

Disclaimer:
The information contained in this document is provided for the sole use and benefit of the
recipient. No reliance should be placed on such information by any other person and any
other person acting or relying on such information does so at his own risk. In the event such
information is disclosed to and used or relied upon by any other person, then Total Marine
Technology Pty Ltd accepts no liability or responsibility whatsoever, including in contract or
in tort, to that person.
Confidential Information:
The information contained in this document is made available to the recipient on the
express acknowledgment and understanding that such information is to be regarded and
treated by the recipient as strictly confidential. The information contained in this document
is provided for the sole use and benefit of the recipient and should not be disclosed to any
other person.
Copyright:
All rights reserved. No part of the content of this document may be reproduced, published,
transmitted or adapted in any form by any means without the written permission of
Total Marine Technology Pty Ltd.
Requests for technical information or other TMT publications should be made to:
Total Marine Technology

1 Ambitious Link
Bibra Lake WA 6163
PO Box 3054
Success WA 6964
Tel: +61 8 9411 6500
Fax: +61 8 9411 6522
[email protected]
Page 2 of 187 TMT-NMA-033 Revision Number: 3 Total Marine Technology Pty Ltd
Table of Contents
Table of Contents
Document Control Details ..................................................................................................... 2

Table of Contents ................................................................................................................. 3
1. Associated Documentation and Terminology ...............................................................13
1.1 Terminology ............................................................................................................13
1.2 Document Conventions ..........................................................................................16
1.3 Document Tree .......................................................................................................17
2. Overview ......................................................................................................................18
2.1 Maintenance Records.............................................................................................19
3. Safety ...........................................................................................................................20
3.1 Electrical Safety ......................................................................................................20
Electrical Safety Guidelines ............................................................................21
3.1.2 Line Insulation Safety Guidelines .....................................................................23
3.1.3 Fibre Optic .......................................................................................................23
3.1.4 Electrostatic Discharge ....................................................................................24
3.1.5 High Voltage Gloves ........................................................................................24
Umbilical Electrical Safety ..............................................................................25
3.1.7 ROV and TMS Deck Connector Plug Visual Inspection ...................................28
3.2 Isolation of ROV Equipment ...................................................................................29
Risks and Mitigations ......................................................................................29
Prerequisites ...................................................................................................29
Required Documents ......................................................................................29
Required Tools ................................................................................................30
Procedure ........................................................................................................30
Long Term Isolations ......................................................................................31
Removal of Isolations ......................................................................................31
Review .............................................................................................................31
3.3 Hydraulic System Safety ........................................................................................32
Hydraulic Safety Guidelines ............................................................................32
3.4 Lifting Safety ...........................................................................................................35
Repair to Lifting Equipment ............................................................................36
Removing Lifting Equipment from Service .....................................................36
Total Marine Technology Pty Ltd TMT-NMA-033 Revision Number: 3 Page 3 of 187
Table of Contents
4. General Maintenance Requirements ............................................................................37

4.1 Bolt Tightness & Torque Requirements ..................................................................37
4.2 Nyloc Fasteners......................................................................................................39
4.3 Fastener Lubrication ...............................................................................................39
4.4 Removal of Connectors ..........................................................................................40
4.5 O-Rings ..................................................................................................................40
4.6 Fuses......................................................................................................................41
4.6.1 Checking & Replacing Fuses ...........................................................................41
4.7 Seizing (Mousing) Wire Rope .................................................................................42
4.7.1 Method No. 1: ..................................................................................................42
4.7.2 Method No. 2 ...................................................................................................43
4.7.3 The Seizing Wire..............................................................................................43
5. Surface Electrical System.............................................................................................44
5.1 Cabling and Connectors .........................................................................................44
5.2 Fibre Optics ............................................................................................................45
5.3 Air Filters ................................................................................................................46
5.4 Electrical Cabinets ..................................................................................................46
5.5 Circuit Breaker ........................................................................................................47
5.6 Circuit Breaker Operational Issues .........................................................................48
5.6.1 CB Overheating ...............................................................................................48
5.6.2 Failure Due to Capacitive Currents ..................................................................49
5.6.3 Failure Due to High Starting Currents ..............................................................50
5.6.4 Mechanical Failure of Opening Mechanism .....................................................50
5.6.5 Issues with Auxiliary Devices ...........................................................................50
5.6.6 Damage to the CB Outer Casing .....................................................................51
5.7 Preventive Maintenance and Inspection .................................................................51
5.7.1 Inspection of the CB after a Fault.....................................................................52
5.8 Line Insulation Monitors ..........................................................................................53
5.8.1 Test Procedure ................................................................................................54
5.9 Uninterruptible Power Supplies ..............................................................................55
5.10 General Maintenance Requirements ...................................................................55
5.10.1 Visual Checks ...............................................................................................55
5.10.2 Cleaning Requirements ................................................................................55
Table of Contents
6. Electrical Subsurface Components...............................................................................57

6.1 ROV Connectors ....................................................................................................57
6.2 Cabling Assemblies ................................................................................................58
6.2.1 Neoprene Cable Assemblies............................................................................58
6.2.2 Poly-Urethane Cable Assemblies ....................................................................59
6.2.3 Trex-Onics Cables ...........................................................................................59
6.2.4 Oil Filled Cable Assemblies .............................................................................60
6.2.5 Cable Care & Maintenance ..............................................................................61
6.3 HPU Motor ..............................................................................................................62
6.3.1 Temperature Sensor – HPU Motor ..................................................................63
6.4 Lights ......................................................................................................................64
6.4.1 From the Work Bench ......................................................................................65
6.4.2 ROV Method ....................................................................................................68
6.5 Navigation Bottle - TOGSNAV ................................................................................71
6.5.1 General Handling Guidelines ...........................................................................72
6.6 Navigation Bottle – ROVINS - Optional ..................................................................73
6.7 Sonar ......................................................................................................................74
6.8 Oil Compensated Enclosures .................................................................................75
6.8.1 Opening and Closing Oil Compensated Enclosures Instructions .....................75
6.9 One Atmosphere Enclosures ..................................................................................76
6.9.1 Opening and Closing One Atmosphere Enclosures Instructions......................77
6.9.2 Vacuum Test MEE ...........................................................................................78
6.10 Umbilical & Tether ...............................................................................................80
6.11 Armoured Umbilical Re-Termination ...................................................................81
6.11.1 Risks and Mitigations ....................................................................................81
6.11.2 Prerequisites .................................................................................................82
Required Documents ...................................................................................82
6.11.4 Tools Needed ...............................................................................................82
6.11.5 Re-Terminate Armoured Umbilical Instructions ............................................82
6.11.6 TMS Termination ..........................................................................................87
6.11.7 Retermination Test Requirements ................................................................89
6.12 Soft Tether Re-Termination .................................................................................90
6.12.1 Risks and Mitigations ....................................................................................90
Table of Contents
6.12.2 Prerequisites .................................................................................................91

Required Documents ...................................................................................91
6.12.4 Tools Needed ...............................................................................................91
6.12.5 Re-Terminating Soft Tether Instructions .......................................................91
6.1 General Subsurface Maintenance Requirements ...................................................97
6.1.1 Visual Checks ..................................................................................................97
6.1.2 Cleaning Requirements ...................................................................................97
7. Hydraulic System..........................................................................................................99
7.1 General Hydraulic Maintenance .............................................................................99
7.1.1 HPU Surface Operation ...................................................................................99
7.2 Hydraulic Oil .........................................................................................................100
7.2.1 Hydraulic Oil Change .....................................................................................100
7.3 HPU Components.................................................................................................101
7.4 General Guidelines ...............................................................................................101
7.5 Hydraulic Hoses ...................................................................................................102
7.6 Manipulators .........................................................................................................103
7.6.1 Avoiding Manipulator Damage .......................................................................103
7.6.2 General Maintenance Requirements .............................................................104
7.7 Hydraulic Filter Replacement – Norman Filters ....................................................105
7.7.1 Risks and Mitigations .....................................................................................106
7.7.2 Prerequisites ..................................................................................................106
Required Documents ....................................................................................106
Required Tools ..............................................................................................106
7.7.5 Filter Housing Disassembly............................................................................107
7.7.6 Cleaning Filter Housing Bowl .........................................................................107
7.7.7 Filter Housing Head .......................................................................................107
7.7.8 Ring Seal Installation .....................................................................................108
7.7.9 Filter Housing Components............................................................................108
7.7.10 Disposable Elements ..................................................................................108
7.7.11 Cleanable Elements....................................................................................108
7.7.12 Assembly of Filter Housing Head & Bowl ...................................................109
7.7.13 Filter Disposal .............................................................................................109
7.8 Hydraulic Filter Replacement – Cardev Filter .......................................................110
Table of Contents

7.8.2 Prerequisites ..................................................................................................111
Required Documents ....................................................................................111
Required Tools ..............................................................................................111
7.8.5 Filter Housing Disassembly............................................................................112
7.8.6 Filter Housing Assembly ................................................................................112
7.8.7 Filter Disposal ................................................................................................113
7.9 Draining, Filling and Venting the Main Hydraulic System .....................................114
7.9.1 Draining the Main Hydraulic System Instructions ...........................................114
7.9.2 Dry-Testing the Main Hydraulic System Instructions......................................115
7.9.3 Filling and Venting the Main Hydraulic System Instructions ...........................116
7.10 Draining, Filling and Venting the Aux Hydraulic System....................................117
7.10.1 Draining the Aux Hydraulic System Instructions .........................................118
7.10.2 Dry-Testing the Aux Hydraulics System Instructions ..................................118
7.10.3 Filling and Venting the Aux Hydraulic System ............................................118
7.11 Sea Water Contamination of the Hydraulic System ..........................................120
7.11.1 Removing Water from the Hydraulic System ..............................................120
7.12 Suspected Solid Particle Contamination of the Hydraulic System .....................122
7.13 Thrusters - sub-Atlantic .....................................................................................125
7.13.1 Risks and Mitigations ..................................................................................125
7.13.2 Prerequisites ...............................................................................................125
Required Documents .................................................................................125
Required Tools ...........................................................................................125
7.13.5 Removal of Thrusters Procedure ................................................................126
7.13.6 Thruster Assembly Procedure ....................................................................127
7.14 HPU Removal ...................................................................................................128
7.14.2 Prerequisites ...............................................................................................128
7.14.3 Required Documents..................................................................................129
Required Tools ...........................................................................................129
7.14.5 Remove HPU Procedure ............................................................................129
7.14.6 HPU Motor Retest Requirements ...............................................................131
7.15 Hydraulic Main and Aux Pump Removal ...........................................................132
Table of Contents

7.15.2 Prerequisites ...............................................................................................132
7.15.3 Required Documents..................................................................................133
Required Tools ...........................................................................................133
7.15.5 Remove Hydraulic Pump Procedure...........................................................133
7.16 Hydraulic Valve Replacement ...........................................................................134
7.16.2 Prerequisites ...............................................................................................135
Required Documents .................................................................................135
Required Tools ...........................................................................................135
7.16.5 Valve Replacement Procedure ...................................................................135
7.17 Maintenance......................................................................................................137
8. Compensation System ...............................................................................................138
8.1 Draining Filling and Venting Compensation System .............................................139
8.1.1 Draining the Compensation System...............................................................139
8.1.2 Dry-Testing the Compensation System .........................................................141
8.1.3 Filling and Venting the Compensation System...............................................141
8.1 Sea Water Contamination of the Compensation System......................................143
8.1.1 Removing Water from the Compensation System .........................................143
8.2 Maintenance .........................................................................................................144
8.2.1 General ..........................................................................................................144
9. Mechanical Maintenance ............................................................................................145
9.1 ROV Surface Treatment .......................................................................................145
9.2 Galvanic Corrosion ...............................................................................................146
9.3 Flotation................................................................................................................148
9.4 Adding or Removing Flotation Blocks ...................................................................149
9.4.2 Prerequisites ..................................................................................................150
9.4.3 Procedure Adding / Removing Flotation ........................................................150
9.4.1 Procedure Adding / Removing Lead Ballast ..................................................153
9.5 Maintenance .........................................................................................................154
9.6 Flotation Repair ....................................................................................................155
9.6.1 General Requirements ...................................................................................155
Table of Contents
9.6.2 PU Coating.....................................................................................................155
9.6.3 Topcoat ..........................................................................................................156
10. Troubleshooting .......................................................................................................157
10.1 Single Cause Problems .....................................................................................157
10.2 Multiple Cause Problems ..................................................................................157
10.3 General Problem - Solving Model .....................................................................158
10.4 Surface Cabinets Power Issues ........................................................................159
10.5 ROV Instrumentation and Control Issues ..........................................................166
10.6 Pan & Tilt...........................................................................................................170
10.7 Hydraulic System ..............................................................................................171
10.8 Compensation System ......................................................................................172
11. Maintenance Schedule ............................................................................................173
11.1 Monthly..............................................................................................................174
11.2 Quarterly ...........................................................................................................177
11.3 Biannual ............................................................................................................178
11.4 Annual Checks ..................................................................................................179
12. Recommended Tools and Consumables .................................................................180
12.1 Consumables ....................................................................................................180
12.1.1 Electrical Consumables ..............................................................................182
12.2 Recommended General Tools ..........................................................................182
12.2.1 Electrical Tools ...........................................................................................184
12.2.2 Hydraulic Tools ...........................................................................................185
Table of Contents
Table of Figures
Figure 1: Bonding Clamp Attached to ROV & TMS .............................................................22
Figure 2: 3.1.5 High Voltage Gloves..................................................................................24
Figure 3: Example Pilot Operated Cross Check Valves ......................................................34
Figure 4: Bagging Cables ....................................................................................................40
Figure 5: Example of Striker Pin, Extended Indicates Blown ...............................................41
Figure 6: Seizing (Mousing) Wire Rope ...............................................................................42
Figure 7: Fibre Optic Modem Stack .....................................................................................45
Figure 8: Air Filter ................................................................................................................46
Figure 9: Circuit Breaker ......................................................................................................47
Figure 10: Resetting a Circuit Breaker .................................................................................47
Figure 11: Overheated CB due to Poor Phase Connection .................................................48
Figure 12: Higher Temperatures Associated with UVR .......................................................49
Figure 13: CB with Signs of Arcing Due to the Capacitive Switching ...................................49
Figure 14: Welded Contacts ................................................................................................50
Figure 15: Middle Phase Not Energized - Mechanical Failure .............................................50
Figure 16: LIM Display .........................................................................................................53
Figure 17: LIM Test Switches ..............................................................................................53
Figure 18: Neoprene Cable Assemblies ..............................................................................58
Figure 19: Poly-Urethane Cable Assemblies - Camera and the LED 24VDC Lights ...........59
Figure 20: Trex-Onics Cables – Dimmer Bottle & 115VDC Main Lights ..............................59
Figure 21: Oil Filled Cable Assembly ...................................................................................60
Figure 22: MEE 8C Connector.............................................................................................60
Figure 23: HPU Oil Temperature & Wet Sensor ..................................................................63
Figure 24: TOGSNAV ..........................................................................................................71
Figure 25: Sonar Head ........................................................................................................74
Figure 26: Measurements after Initial Cut ............................................................................84
Figure 27: After Removing Armoured Layers ......................................................................84
Figure 28: Spelter Ideal Final Placement .............................................................................86
Figure 29: Umbilical Static Load Test Adaptor.....................................................................89
Figure 30: Kellems Grip Fitted .............................................................................................93
Figure 31: Example of Hydraulic Hose Register Information .............................................102
Figure 32: Hydraulic Filter..................................................................................................106
Table of Contents
Figure 33: Cardev Hydraulic Filter .....................................................................................110

Figure 34: Main Hydraulic Tank .........................................................................................114
Figure 35: Aux Hydraulic Tank ..........................................................................................117
Figure 36: Hydraulic Fluid Contaminated with Water.........................................................120
Figure 37: 380 sub-Atlantic Thruster .................................................................................127
Figure 38: Oil Compensation Bottle ...................................................................................138
Figure 39: Example of Galvanic Corrosion ........................................................................146
Figure 40: Method of Corrosion .........................................................................................146
Figure 41: Example of Different Sacrificial Anodes Supplied .............................................146
Figure 42: Example of Sacrificial Anode ............................................................................147
Figure 43: Flotation Mounting Bolt .....................................................................................148
Figure 44: Typhoon Buoyancy ...........................................................................................149
Figure 45: Extra Flotation ..................................................................................................149
Figure 46: Lead Ballast Layout ..........................................................................................153
Table of Tables
Table 1: Standards Referenced ...........................................................................................13
Table 2: Document Conventions .........................................................................................16
Table 3: Isolation of ROV Equipment - Risks and Mitigations..............................................29
Table 4: Isolation Chart........................................................................................................30
Table 5: Torque Setting for ROV Enclosures.......................................................................37
Table 6: Fuses Located Topside Cabinets ..........................................................................42
Table 7: Suggested Seizing Wire Diameters .......................................................................43
Table 8: Example of Fibre dB Loss Record .........................................................................45
Table 9: Surface Electrical Systems Maintenance ...............................................................56
Table 10: Oil Fill Cable Assemblies .....................................................................................60
Table 11: Electric Motor Specifications ................................................................................62
Table 12: 26VDC Light Addresses and Locations ...............................................................64
Table 13: Armoured Umbilical Re-Termination - Risks and Mitigations ...............................81
Table 14: Tools & Materials Required .................................................................................82
Table 15: Soft Tether Re-Termination - Risks and Mitigations ............................................90
Table 16 Tools & Materials Required Soft Tether Re-Termination ......................................91
Table of Contents
Table 17: Power & Fibre Colours.........................................................................................92

Table 18: Subsurface Electrical Systems Maintenance .......................................................97
Table 19: Hydraulic Oil Properties .....................................................................................100
Table 20: General Manipulator Maintenance .....................................................................104
Table 21: Hydraulic System Norman Filters ......................................................................105
Table 22: Hydraulic Filter Replacement (Norman) - Risks and Mitigations ........................106
Table 23: Cardev System Filters .......................................................................................110
Table 24: Hydraulic Filter Replacement (Cardev) - Risks and Mitigations .........................111
Table 25: Thruster Replacement - Risks and Mitigations ..................................................125
Table 26: HPU Removal & Installation - Risks and Mitigations..........................................128
Table 27: Winding Resistance Measurement ....................................................................131
Table 28: Motor Windings Insulation Resistance Measurement ........................................131
Table 29: Hydraulic Pump Removal - Risks and Mitigations .............................................132
Table 30: Hydraulic Valve Replacement - Risks and Mitigations .......................................134
Table 31: Hydraulic Manifold Drawings .............................................................................136
Table 32: Hydraulic Maintenance ......................................................................................137
Table 33: Compensation System Capacity ........................................................................139
Table 34: Compensation Maintenance ..............................................................................144
Table 35: Adding & Removing Flotation - Risks and Mitigations .......................................150
Table 36: Circuit Breaker Issues........................................................................................159
Table 37: ROV Instrument Power ......................................................................................161
Table 38: ROV HPU Power ...............................................................................................163
Table 39: TMS Instrument Power ......................................................................................164
Table 40: TMS HPU Power ...............................................................................................165
Table 41: ROV Control Issues ...........................................................................................166
Table 42: Pan & Tilt ...........................................................................................................170
Table 43: Hydraulics System .............................................................................................171
Table 44: Compensation System .......................................................................................172
Table 45: General Consumables .......................................................................................180
Table 46: Electrical Consumables .....................................................................................182
Table 47: Recommended General Tools ...........................................................................182
Table 48: Electrical Tools ..................................................................................................184
Table 49: Hydraulic Tools ..................................................................................................185
Associated Documentation and Terminology
1. Associated Documentation and Terminology

Table 1: Standards Referenced
Document No. Rev. Date Description/Title Company

Documents
TMT-NDP-001 3 20/10/15 Typhoon MK2 150 Drawing Pack TMT
TMT-NMA-027 3 20/10/15 ROV Technical Manual TMT
TMT-NMA-032 3 20/10/15 System Operations Manual TMT
TMT-NMA-034 3 20/10/15 Surface Power & Control Manual TMT
TMT-NMA-037 6 20/10/15 Pilot Software Manual TMT
TMT-NMA-041 3 20/10/15 System Overview Manual TMT
TMT-NMA-068 3 20/10/15 Typhoon MK2 150 TMT Acronyms TMT
Drawings*
Manuals and Data Sheets

Technical Description Steel Armoured ROV
RS679 06E 02/03/12 Nexans
Umbilical
Handling/Installation Guidelines for Dynamic
TR-01-01 08 20/05/05 Nexans
Cables
78-8073-7873-8-E 06/11 3M Hot Melt Fiber Optic Connectors ST, SC and 3M
FC
A353-000-027 2 01/08/08 Type 5A TMS Operations Manual Forum
Industry Standards
High Voltage Equipment: Safety Procedures for
IMCA R 005 1 2003 IMCA
Working on ROVs
Document No. Rev. Date Description/Title Company
The Initial and Periodic Examination, Testing and
IMCA R 011 1 2005 IMCA
Certification of ROV Handling Systems
Note: *Drawing revision details are maintained within the TMT-NDP-001 Typhoon MK2
150 Drawing Pack.
1.1 Terminology
ACW Anti-Clockwise
AF Across the Flats
AHRS Attitude Heading Reference System
Aux Auxiliary
CD Compact Disc
CW Clockwise
DOL Direct On Line

DVL Doppler Velocity Log
EPR Ethylene propylene (O-rings)
FR Board FET RPM Board
GFM Ground Fault Monitors
HPU Hydraulic Power Unit
IAW In Accordance With
I/O Input / Output
J-Box Junction Box
JSA Job Safety Analysis
kVA Kilovolts Amperes
L/H Left Hand
LED Light Emitting Diodes
LHS Left Hand Side
LV Low Voltage
LTT Lock, Tag and Try
MEE Main Electrical Enclosure
MSDS Material Safety Data Sheet
MUX Multiplexer
MV Medium Voltage
NDT Non Destructive Testing
OEM Original Equipment Manufacture
PC Board Power Control Board
PCB Printed Circuit Board
PDU Power Distribution Unit
PPE Personal Protective Equipment
PTC Phase Tracking Circuit
PTW Permit To Work
R/H Right Hand
RAM Random Access Memory
RCD Residual Current Device
RHS Right Hand Side
ROV Remotely Operated Vehicle
RTD Resistance Temperature Detector

SWP Safe Work Procedure
TBT Tool Box Talk
TMS Tether Management Systems
TMT Total Marine Technology
TX Transformer
UPS Uninterruptible Power Supply
UV Ultraviolet
1.2 Document Conventions

It is important that you understand the conventions used in this manual in order to use it,
and the system, efficiently.
In addition to general formatting that emphasises a word, some text in this manual has
special formatting so that you can identify it easily as having special meaning. Examples of
these formats are given in Table 2.
Table 2: Document Conventions
Term Meaning
Warnings are operating instructions or practices which, if not correctly followed, can result
Warning: in personnel injury or loss of life.
Cautions are operating instructions or practices which, if not strictly observed, can result in
Caution: damage, destruction of equipment or corruption of data.
Bold text is used to identify text that is important or requires highlighting. For example,
Bold procedure or telephone numbers.
Blue text is used to identify text that is linked to internal or external documents.
Blue To return to previously opened location, press both the Alt + Left Arrow key
simultaneously.
An explanation or condition which it is essential to highlight and deemed necessary for the
Note understanding of the process.
Note: An absence of Warnings or Cautions does not indicate that risks are not present.
When operating and servicing equipment always use the appropriate:
• Equipment
• Personal Protective Equipment (PPE)
• Safety Procedures
Note: Images may vary slightly from actual equipment due to ongoing enhancements and
additions to the Typhoon system.
1.3 Document Tree

This manual is part of a suite that covers the Typhoon MK2 150 ROV System for Typhoon
150 MK2.
Overview
2. Overview
This document outlines procedures to be followed when performing preventive or corrective
maintenance on the Typhoon MK2 150 system.
General procedures for system maintenance are explained within and include:
• Electrical
• Hydraulic
• Mechanical maintenance
o Adding oil
o Cleaning
o Corrosion treatment
o Purging
o Venting
For periodic ROV maintenance checklists, refer to Section 11 Maintenance Schedule on
page 173. Use the checklists as an example to ensure a complete periodic maintenance
program.
The owner-operator is responsible for ensuring that all planned maintenance is performed
on the ROV systems, as operations permit.
Note: All scheduled maintenance must be performed by qualified personnel and be
properly documented.
Maintenance records for vehicle pre and post-dive checks and monthly, semi-annual and
annual scheduled maintenance must be maintained by the system supervisor.
Note: There can be a degree of variation in maintenance requirements. This document
should be considered to be the minimum recommended requirements.
It is the responsibility of the owner-operator to adapt the program of planned
maintenance for each system, depending on conditions encountered.
Overview
2.1 Maintenance Records

Maintenance schedules and maintenance logs should be kept on file for each system and
verified by the system supervisor upon completion.
The planned maintenance log should record all planned maintenance activities that are to
be completed. Refer to section 11 Maintenance Schedule on page 173.
Planned maintenance is scheduled into the following time frames:
• Weekly
• Monthly
• Quarterly (four months)
• Semi-Annually (six months)
• Annually
Planned maintenance checklists contain detailed maintenance tasks to be performed on a
regularly scheduled basis.
Note: Post-Dive and Weekly maintenance is, as required and not considered
preventative. Any maintenance that is not corrective, is then preventive Also, Post-
Dive is only a functionality check and is not considered maintenance.
Caution: The maintenance records must be maintained and available for review by the
manufacturer to validate warranty issues.
Safety
3. Safety
This Safety section describes the TMT recommended safety guidelines and procedures that
must be followed during both the operation and maintenance of the Typhoon ROV System.
Warnings, Cautions and Notes are defined in Table 2 located on page 16.
Operational safety responsibility rests completely with the owner / operator of the Typhoon
system.
Warning: Personal Protective Equipment (PPE) as dictated by on site requirements

must be worn at all times.
Caution: If, at any time, you feel unsafe or unsure about your task, stop the job
immediately. Safety is First.
Note: Job Safety Analysis (JSA) and Tool Box Talk (TBT) are recommended practices to
identify and minimise risks associated with the tasks, being maintenance,
operation, or else.
The Safety section is subdivided into the following:
• Electrical on page 20
• Umbilical Electrical Safety on page 24
• Fibre Optic on page 25
• Electrostatic Discharge on page 24
• Isolation of ROV Equipment on page 29
• Hydraulic on page 32
• Lifting on page 34
Note: Every location can have its own unique hazards. Personnel involved with the
Typhoon must be familiar with the specific requirements and safety procedures
applicable to the equipment and the work location.
3.1 Electrical Safety

Warning: This ROV system uses voltage in excess of 1kV. Safety practices, as dictated
by IMCA R 005 – High Voltage Equipment, Must be followed.
Safety
Electrical Safety Guidelines

The Typhoon system has potentially lethal voltage levels throughout the ROV / TMS
system. The safety information below is a guideline only. Before powering the system, read
this manual entirely in order to understand where potential hazards can be in the electrical
system.
• Always follow the safe work procedures outlined in
IMCA R 005 – High Voltage Equipment: Safety Procedures for Working on ROVs.
• Always install isolation locks on the circuit breakers prior to opening high voltage
electrical equipment.
• Always apply the Lock, Tag and Try (LTT) procedures.
• Follow the vessel’s Electric Cable Tag system, which ensures that all mains power
leads have been inspected and are up to date.
• Follow the vessel’s permit system, such as Hot Work Permit.
• Always isolate and repair circuits that have ground faults before continuing operation.
• Always turn off equipment while troubleshooting high voltage.
• Ensure all power cables are secure and well protected from any mechanical damage.
• Ensure that all earth bonding cables are fitted to the system at the correct termination
points.
• For the safe recovery of the ROV / TMS to deck, always switch off the HPU and
Instrument Power before the system is returned to deck.
• Never operate Medium Voltage (MV) systems that have low insulation to ground. Turn
off power to circuits that have low insulation. Repair the circuit prior to operation.
• Post hazard signs in the working area.
• Shut off power before opening the MV electrical enclosures.
• Under no circumstances should any live work be performed on MV circuits.
• Use the isolation, lock-out, tag-out devices and procedures to prevent LV and MV
circuits being energised while they are being serviced.
• Always verify that no voltage is present before working on the circuits, as per LTT
procedures.
• When working on or near electrical systems, remove watches, rings or other jewellery
that may act as conductors.
MV power to the ROV / TMS must always be switched off before the ROV / TMS arrives
or leaves the deck (lunch and recovery) and both the ROV and TMS ground bonding clamp
securely fitted before the ROV / TMS is handled.
Note the following:
• The ROV & the TMS is to be switched off once the ROV and TMS has left the water to
return to deck.
• The ROV & the TMS is to be switched off when technicians are attaching or removing
the ground bonding clamps to the TMS and the ROV.
• The ground bonding clamp is to remain attached while the ROV and the TMS are on
deck to prevent any hazardous voltage potentials between the deck and the ROV /
TMS frame.
Safety
Bonding Clamp
Figure 1: Bonding Clamp Attached to ROV & TMS
Note: The Perry Type 5 TMS has a special point set aside for bonding; refer to Figure 1.
You must frequently (weekly) check that the resistance of the ground bonding clamp to the
main earth bar is less than 1 Ohm. The thickness of the ground bonding should have a
minimum cross section of 25mm2.
Warning: Failure to attach a ground bonding clamp to the ROV / TMS upon recovery
can potentially result in serious injury or death due to possible lethal voltages
being present in unexpected places.
Safety
3.1.2 Line Insulation Safety Guidelines

The ROV / TMS power is an ungrounded power system. If power is faulted to ground, the
Line Insulation Monitors (LIMs) detect that fault and immediately shuts down the ROV /
TMS.
Warning: Power is to be disconnected before the ROV is taken on deck as the fault can
cause serious injuries or death to personnel handling the ROV.
However, in emergency situations, it is possible to override the LIM so that power remains
on and the ROV / TMS can be recovered.
Warning: The ground fault override should only be used for emergency recovery. The
override can allow lethal voltages to be present anywhere on the ROV / TMS.
In an override situation, before recovering the ROV to the deck, switch Off all
power to the ROV and TMS.
Ground faults must be repaired as soon as possible and before any intervention, i.e.
entering the water. Low resistance ground faults can cause permanent damage to
insulation in the ROV & the TMS MV circuits
In case of emergency, perform additional precautionary measures as delineated in;
IMCA R 005 – High Voltage Equipment: Safety Procedures for Working on ROVs.
3.1.3 Fibre Optic

The Typhoon ROV system includes a fibre optic transmission system that contains a laser
capable of emitting potentially harmful radiation at a wavelength that is not visible to the
human eye.
The following guidelines Must be understood to ensure the safety of all personnel:
• Always use a “Sharps Box” container for discarding fibre off-cuts.
• Never leave a spare or unused fibre loose. Keep all unused fibres sealed and
protected.
• Never look directly into a laser from a fibre connector when the laser is switched on.
Warning: Do Not look directly into the laser beam. Permanent eye damage can occur.
Turning off instruments does not de-energise the surface multiplexer unit. The
surface multiplexer Must be de-energised before attempting any work on the
fiber system; refer to the TMT Manuals\Typhoon MK2 150 Surface Power &
Control Manual folder on the digital technical manual.
Safety
3.1.4 Electrostatic Discharge

Static is a major enemy of electronic components. Static can damage your electronic
components instantly.
Note: One easy way to remove static charge from yourself is to touch a bare metal part
of the workbench.
In general, handle all components by the non-conductive edges. By avoiding touching any
pins, conductive edges, chips or anything else made of metal, the chances that anything is
damaged is greatly reduced. Smaller components such as loose RAM chips and
processors are at the greatest risk.
Whenever possible, leave static-sensitive devices in their original packaging. Transport
circuit boards and peripherals in an anti-static metallized bag, if you do not have the original
packaging material.
3.1.5 High Voltage Gloves

High Voltage (HV) rubber insulating gloves (rated for a minimum of 10kV) must be
inspected prior to each use, according to the glove manufacturer’s instructions and tested
periodically as required.
Note: Most glove manufacturers also recommend or require that leather over-protectors
be worn over insulating gloves to protect them.
For additional comfort, cotton liners may also be considered.
Figure 2: 3.1.5 High Voltage Gloves
Safety
Umbilical Electrical Safety

Due to the physical properties of the umbilical, a potentially lethal charge (in excess of 5MJ)
can be contained within it.
Prior to any work on the ROV or the TMS, the umbilical must be discharged and grounded.
Before commencing fully read, understand all steps, have all parts and tools available.
Warning: Do not work on the ROV or the TMS unless both deck lead plugs are
connected in the umbilical discharge sockets and the umbilical has been
disconnected and grounded.
Warning: De-energise the ROV and the TMS before connecting or disconnecting deck
leads. When moving the ROV or the TMS Deck Connector plug assembly, HV
gloves must be worn; refer to Section 3.1.5 High Voltage Gloves on page 24.
To discharge the umbilical via the deck leads:
1. Verify that both, the ROV and the TMS have been completely de-energised.
2. Verify that the ground bonding clamps are attached to both, the ROV and the TMS.
3. Both Insulation Test Switches (ROV & TMS) located on the LV Cabinets have to be
actuated (Test) for a minimum of 30 seconds in order to provide an initial discharge
path for the power lines: HPU and Instruments for both the ROV and the TMS.
LV Cabinet
ROV Side
LV Cabinet
TMS Side
This eliminates the risk of touching the energized contact pins at front of Deck
Connector Plugs when securing it properly to avoid dropping.
Note: Each of the corresponding LIMs should display a value of 500Kohm.
4. Isolate the PDU Main CB and padlock
Safety
5. Prepare the correct PPE i.e. insulating matt and gloves.

6. Open the MV cabinet doors.
7. Verify that the Deck Lead connector earth strap is connected.
8. Wearing HV gloves, first remove the ROV Deck Connector Plug.
This is due to the physical layout of the cabinet.
9. Remove the locking slide bar. Undo the latches and disconnect the MV Deck
Connector Plug from the Deck Lead Socket.
Interlock Key
Handle Assembly
Safety
10. Transfer the MV connector from the Operational to the Discharge socket.
Discharge & Testing Socket Connector Discharge & Testing Socket Connector
Socket Deck Lead Socket Deck Lead
11. Position the switch in the Discharge position for 30 seconds, then switch to the
Earth position.
12. If testing is planned, position the switch to Testing.
Warning: No testing is to be conducted before discharging and earthing first.

13. Repeat Steps 3 to 7 for the TMS Deck Connector Plug.
14. To reconnect power, reverse the steps, starting first with the TMS Deck Connector
Plug.
For a detailed description of the ROV & TMS MV deck lead plugs; refer to the
TMT Manuals\Typhoon MK2 150 Surface Power & Control Manual folder on the digital
technical manual.
Safety
3.1.7 ROV and TMS Deck Connector Plug Visual Inspection

Whenever the connector is removed always check the connector for any damage and
repair immediately if necessary.
The following parts of the connector should be checked:
• All four (4) latches must be clipped in tight to hold the connector firmly to the socket.
• All pins and sockets should be at the same depth level in the connector; if not, it
indicates that they have lost their captive tabs that lock into the frame and may push
through the back of the connector.
• Each of the plastic connector frames that holds the pins and sockets should be
checked for damage or cracks.
• Inserts and sockets should not be bent or cracked.
• Plug and unplug the connector very carefully, in order to not damage the plastic
connector frames.
• The earth bonding lead must always be joined from the connector housing to the
socket plate before plugging the connector in.
• The pins and sockets are silver-plated. They should have a shiny appearance. If
some pins have gone a dull grey in colour and the silver plating has worn, they
should be replaced.
• The socket cones that accept the pins should not be splayed or oval shaped in
appearance.
• The connector should be clean from dust, water or any chemicals. Never use any
chemical cleaners or lubricants of any kind on the connector, as they can cause
arcing across the connector face. Cleaning details are contained in the Section 5.1
Cabling and Connectors on page 44.
• When the ROV system is in transit, always install the connector cover with silica
desiccant and completely wrap and tape the connectors in a waterproof bag. The
deck cables should be wound up onto a winch in a position where the connector will
not get damaged during transit.
• Whenever the connector has been removed from the socket, install the protective
cover onto the connector face.
Safety
3.2 Isolation of ROV Equipment

This procedure describes the electrical isolation of the ROV to safely conduct specific
maintenance. Follow LTT procedure to isolate the HPU circuit breaker. Check the Main
HPU pressure gauge.
Warning: Some hydraulic functions are equiped with pilot operated cross-check valves
that can hold pressure in hydraulic lines, refer to the hydraulic schematic,
TMT-0009-2216.
After operating a function and shutting down, the hydraulic system pressure
can remain in function line. Run a function while gradually dialing down the
pressure, such as thrusters or tooling functions to reduce system pressure.
Before commencing, fully read, understand all the steps, have all parts and tools available.
Risks and Mitigations

The following are risks and mitigations, to be used in Job Safety Analysis (JSA).
Table 3: Isolation of ROV Equipment - Risks and Mitigations
Risk Mitigations
Electrical:
• Potentially lethal voltage levels • Refer to Section 3.1 Electrical on page 20.
throughout the ROV / TMS
system.
Prerequisites
• All relevant JSA’s, TBT and PTW completed, read and understood by crew.
• Tool box talk is to be performed prior starting procedure. If needed, discuss the
operation with deck personnel.
• TBT to be understood and sheet signed.
• All relevant parties informed.
Required Documents
Refer to the following drawings as an overview located in TMT-NDP-001\Electrical folder
on the digital technical manual:
Table 4: Required Documents
Description Typhoon T12-17 Typhoon T24-29

PDU TMT-0004-7438 TMT-0010-7662
LV Cabinet TMT-0004-7439 TMT-0010-7666
MV Cabinet TMT-0004-7574 TMT-0010-7665
ROV HPU Transformer enclosure TMT-0004-7739 TMT-0010-7670
Safety
Description Typhoon T12-17 Typhoon T24-29

TMS Winch Cable Connection TMT-0002-4586 TMT-0010-7660
ROV Winch Cable Connection TMT-0002-4587 TMT-0010-7661
Required Tools
• Isolation Padlocks
• Personal Danger Tags
• Out of Service Tags
Procedure
1. Ensure work will not interrupt operations if the work is not corrective maintenance.
2. Create / Review the JHA for task.
3. Review the TMT Isolation Matrix.
4. Turn of “Off” equipment from control desk or local control station prior to isolations.
5. Turn off corresponding CB’s to the equipment being isolated.
6. A competent isolations person is to carry out the isolation; attach their “Personal
Danger Tag” PDT to the CB / equipment, and fill out the isolation log.
Caution: Each person working on the equipment is to lock on to the isolation point/s
and place their “PDT” to the lock.
7. Test Isolation/s by trying to start equipment normally after all Isolations are in place.
8. Ensure all MV equipment has been grounded prior to opening enclosures.
9. Ensure any stored energy has been drained off prior to opening equipment:
a. Hydraulic:
i. Hydraulic compensators hold ~ 15psi pressure ii.
b. Electrical:
i. Charge in Tether and Umbilical
ii. Batteries in UPS’s
10. Test before touching:
a. Hydraulic:
i. Verify pressure via gauge or bleed by momentarily activating a
function.
b. Electrical:
ii. Use correct calibrated meter, Check meter prior and after test.
Table 5: Isolation Chart
Equipment Isolation Point Function Location

Winch CB3 Winch HPU Winch Cabinet
Safety
Equipment Isolation Point Function Location

CB2 Winch Auxiliary Power, Brakes & Fans Winch Cabinet
TMS Electrics CB1-4 TMS Electrics Transformer TMS Cabinet
TMS HPU CB1-3 TMS HPU Transformer TMS Cabinet
ROV Electrics CB1-2 ROV Electrics Transformer ROV Cabinet
ROV HPU CB1-1 TROV HPU Transformer ROV Cabinet
Deck HPU S1 Deck HPU, Main Switch Deck HPU Panel
Long Term Isolations

If isolations are required for long period of time, more than one shift, the competent
isolations technician shall replace their Personal Danger Tag “PDT” with an “Out of Service
Tag” on each isolation point with the description of work being carried out. On completion of
work the “Out of Service” tag is to be removed.
Removal of Isolations
On completion of work or end of the shift, each person is to remove their Lock and “PDT”.
When reinstating equipment back into service testing is to be carried out under safe
operating instructions for that item.
Review
• Competent technicians to carry out Isolation.
• Lock-on, Tag-on, Sign-on & Lock-off, Tag-off, Sign-off.
• One “Personal Danger Tag” per person.
• Equipment to be tagged “Out of Service” at the point of isolation, if task has not
been completed at the end of the shift.
Caution: If at any time you feel unsafe or unsure about your task, stop the job
immediately. Safety is First.
Safety
3.3 Hydraulic System Safety

Hydraulics is a means of transmitting power by the use of confined fluids. Hydraulics is part
of the fluid power family that deals with the mechanical properties of fluids used to multiply
force and modify motion.
The Typhoon Hydraulic System operates at potentially lethal pressures of 3000psi (207bar).
The following dangers are present:
• Crushing, blinding and / or cutting due to the mechanical motion of hydraulically
actuated equipment such as thrusters, cylinders, chains, sheaves, manipulators,
motors, cutters, grippers etc.
• Fluid Injection into your body.
• Slips and falls when oil leaks or spills.
Warning: High-pressure fluids can cause physical injury, amputation or death when
injected into the body.
Verify that all hydraulic systems are properly maintained before applying
pressure. Verify that all pressure is removed from the entire system before
performing any maintenance.
Never check tightness of a hydraulic hose or fitting while under pressure.
Never under any circustances, look for leaks using your hands. Thin high
pressure jets are hard to see and are extremally dangerous.
High-pressure safety practices Must always be adhered to.
Hydraulic Safety Guidelines

Hydraulic equipment may develop problems due to normal wear, abuse or unforeseeable
circumstances. Therefore, proper operation and maintenance are required. In the course of
performing these functions, personnel are required to work on or near the equipment.
The following precautions can help personnel avoid injury.
Do not work or perform maintenance on or around hydraulically supported equipment e.g.
manipulators, LARS, A-frame and cranes, unless the load has been secured from falling or
unintentional movement. The release or the leaking of hydraulic fluid may allow a
component to move or fall.
All safety requirements listed below are those generally applicable to hydraulically powered
machinery, but are not all-inclusive. They are intended for qualified, experienced personnel
who are capable of understanding the hazards of machinery operation and maintenance.
The applied safety precautions should be specified by someone in charge of the machinery,
who is capable of carrying out a full risk assessment of the equipment and workplace.
Safety precautions should be included in the comprehensive safety program for the
particular machinery, equipment, work area, plant or process.
General safety precautions when starting hydraulic equipment are:
• All hydraulic connections to be checked to be secure, especially those which may
have been removed, replaced or disconnected during an equipment shutdown.
Safety
• All personnel to be clear of the machinery operating envelope. Such as the area
reached by the fully extended manipulator arms.
• Verify that all valves are in their start-up position.
General safety precaution before shutting down the hydraulic power unit is:
• Block-up or lock-in position any machine members which may move and cause
damage to personnel, product or equipment upon loss of hydraulic flow and/or
pressure.
• To prevent unintentional movement prior to servicing, hydraulically supported loads
must be secured with chain and binders then blocked, chocked or strapped.
• Before removing, tearing down or performing maintenance on any hydraulic
components including: actuators, hoses, filters, valves, piping etc., shut down the
power unit and relieve pressure from all pressurized compensators, actuators and
lines.
• Maintain and keep in place any equipment guards, such as coupling guards, chain
guards or protective cowlings. Do not wear loose clothing, jewellery or long hair
which could get caught in moving parts.
Any personnel observing or working on or adjacent to hydraulically powered equipment
must never place themselves in a location or position that could produce an injury in the
event of:
• Hydraulic line failure
• Power blackout
• Pump / motor failure or
• Movement of machine members within operating envelope as a result of component
malfunction or failure.
• As a general rule, no one should be near the ROV when the hydraulic system is
running.
Warning: Before removing or performing maintenance on any hydraulic system

components that have an electrical interface, solenoid valves, switches,
electric motors etc., Shut Off and Lockout electrical power to the Typhoon
system, following LTT procedures.
Some hydraulic fluids can be irritating or injurious to the eyes and skin. Check the MSDS
for the effects of the fluid that you use and avoid bodily contact with those harmful fluids.
Fire resistant or synthetic fluids should be especially guarded against. In case of skin
contact, wash affected areas and remove any contaminated clothing.
Avoid the use of unauthorized or substitute parts and materials in servicing the equipment.
Substituting parts or materials could produce a hazardous operating condition. In piping the
hydraulic system on the ROV or the TMS, use only material of adequate size and strength
to suit the flows and pressures that are present in the operating system. Use safety factors
in selecting materials for strength, to allow for shock and over-pressure conditions that may
occur.
Safety
Such as, when selecting a hydraulic hose, generally the operating pressure is 1/ 4 the hose
minimum burst pressure, thus meeting the standards of the SAE International
recommended safety factor of 4 to 1. This is where hose lines are rated for continuous
operation at the maximum operating pressures specified for the hose.
As per practise, after the system operating pressure has been determined, the selection of
the hose must be made so that the recommended maximum operating pressure is equal to
or greater than the system operating pressure.
Warning: Some hydraulic functions are equiped with pilot operated cross-check valves
that can hold pressure in the hydraulic lines, refer to the hydraulic schematic,
TMT-0009-2216.
After operating a function and shutting down, the hydraulic system pressure
can remain in function line. Run a function while gradually dialing down the
pressure, such as thrusters or tooling functions to reduce the system
pressure.
Figure 3: Example Pilot Operated Cross Check Valves
Safety
3.4 Lifting Safety

It is beyond the scope of this manual to present overhead safety and rigging operations.
This document should be considered to be the minimum recommended requirements.
It is the responsibility of the owner-operator to develop the necessary procedures for
overhead safety and rigging operations.
Warning: Always observe the onsite requirements for handling and lifting. PPE as
dictated by the on site requirements must be worn at all times.
The follow guidelines are recommended:
• Equipment handling and operations are only to be performed by certified riggers and
crane operators.
• Be aware and follow the vessel’s lifting equipment colour coding, which ensures that
all rigging equipment is inspected and up to date.
• Verify that all certifications lift sling assembly or slings to be operated with the ROV /
TMS are valid and the equipment is fit for purpose. This is to include all:
o Lift-point lugs
o Shackles
o Slings
• Ensure lifting equipment is maintained according to the manufacturers’
recommendations.
• Ensure a record of inspections and maintenance is maintained.
• Maintain a lifting equipment register with the following information entered:
o Date of last test - if applicable
o Date of next test - if applicable
o Date of the last examination
o Date of the next examination
o Individual identification number
o Safe working load
o Type of lifting equipment
• Prior to use all lifting equipment will be visually checked prior to each use to ensure:
o Equipment is appropriate for load to be applied.
o Equipment is correctly tagged.
Safety
o Equipment is in good condition.

o Verify all lifting equipment is clear of entanglement.
Warning: Never use unauthorized lift points.
Repair to Lifting Equipment

Any repairs to lifting equipment, other than the replacement of parts, shall be carried out by
the manufacturer or the manufacturers’ agent. Replacement parts shall be “original” or
verified by a qualified Engineer as meeting the same specifications as the original
components.
Proof loading by an approved authority should be conducted and certified following any
repair other than the replacement of a part.
Note: Refer to manufacturer’s recommendations for any specific requirements following

repairs to lifting equipment.
Standard items of lifting equipment should not be repaired by welding, cutting, grinding or
heating unless approved by the manufacturer or a qualified Engineer.
Removing Lifting Equipment from Service

Any lifting equipment that is found to be damaged or worn, and cannot be satisfactorily
repaired, shall be removed from service. Same applies to equipment with expired
certification, even if it looks good, must be taken out of service until re-inspected and
certified. The Lifting Equipment Register changed to show that the equipment has been
destroyed or removed.
Note: Any lifting equipment that has been damaged from overloading or misuse should
be thoroughly investigated to ascertain how the equipment was damaged.
General Maintenance Requirements
4. General Maintenance Requirements

The intention of the maintenance program is to ensure that maintenance is conducted in
order to greatly increase the reliability and availability of the Typhoon ROV system.
Maintenance should be planned to ensure the optimization of all available materials, time
and resources.
A clean work environment is a critical part of maintenance. It is the responsibility of all ROV
personnel to contribute to that objective.
Caution: Take care to minimize oil spillage and contamination for both safety and
environmental reasons.
4.1 Bolt Tightness & Torque Requirements

Verifying Tightness - Ensures that the bolts are not free to move by hand. No wrenches
are required unless the bolt is not tight.
Verifying Torque - Ensures the bolts are tightened to specified Torques. A calibrated and
up to date torque wrench is required.
Correctly torqued hardware can be critical to avoid leaks, damage, and loss of function.
Torque specifications can be found in engineering drawings and on the
TMT Manuals\Miss\TMT Torque Table. When a torque specification differs between the
TMT Torque Table and the engineering drawing, follow the specification on the drawing. If
no torque specification is present, work to prevailing industry standards.
Table 6: Torque Setting for ROV Enclosures
Tightening
Bolt
Enclosure Drawing Number Torque
Type
(N.m)
Tooling Manifolds
Aux PORT Low Manifold ASM TMT-0001-0779
Low Flow Manifold ASM TMT-0001-0778 M6 5
STBD Horizontal Low Flow Manifold G.A. TMT-0001-0790
Thruster Manifolds
STBD Horizontal Low Flow Manifold G.A TMT-0005-8235
M10 17
PORT 5FN ST Thruster Manifold TMT-0005-8237
Electrical Enclosures
Survey J-box TMT-0004-4785 M6 5
Tether Termination J-Box TMT-0000-9100 M10 17
Transformer Box TMT-0004-1518 M8 10
Sensor Bottle TMT-008-8101 M5 4
Dimmer Bottle TMT-0004-7605 M5 4
Tightening
Bolt
Enclosure Drawing Number Torque
Type
(N.m)
MEE TMT-0004-1647 M8 17
Survey Bottle M5 4
4.2 Nyloc Fasteners

Under ideal conditions, Nyloc fasteners can be reused up to five (5) times.
Due to the difficulty of tracking use, and that operating conditions are always less than
ideal, Nyloc nuts are to be replaced with new ones whenever removed.
Caution: Do not replace patch or locking fasteners with ordinary fasteners.
Standard fasteners may loosen and lead to component failure or loss.
4.3 Fastener Lubrication

Note: Do not use Aqua Lube on fasteners penetrating hydraulic or compensated areas,
unless directed otherwise in a service instruction or an engineering drawing.
The following anti-seize compounds are authorised for subsea use:
1. Loctite Moly Paste (similar recommended products are: Molybond GA50 or Loctite
Marine Grade Anti-Seize) is a lithium based anti-seize. It is a general use non-
metallic, anti-seize compound with MoS2 containing no nickel, no copper and no
graphite. It is non-conductive.
All fasteners (hydraulic fittings included) where stainless steel is used with the
following materials:
o Aluminium
o Carbon steel
o Stainless steel
o Titanium
Note: Loctite Moly Paste helps to reduce dissimilar metal corrosion as well. Exceptions
apply, as in the following paragraphs.
2. Loctite Nickel Anti-Seize (or similar): To be used only when better electrical
connectivity is required. For example, where sacrificial anodes are mounted by bolts
or the fasteners (stainless steel fasteners). It helps to create a better electrical
connection.
Can also be used with titanium.
3. Loctite Zinc Anti-Seize (or similar): Same as Loctite Nickel Anti-Seize but this
product gives better protection for aluminium parts vs. stainless fasteners, if
protection of threads is high priority; reapplication of this anti-seize might be more
frequent. It is especially recommended when soft metal fasteners are used. Can be
used with titanium.
4. Copper based Anti-Seize: For carbon steel parts and fasteners. It is conductive. For
stainless steel fasteners use no.1 – no.3.
Important Notes:
• Aqua Lube and AquaShield grease are not to be used as an anti-seize compound.
• Compound No 1 can reduce friction on bolts significantly – consult with TMT
engineers, if in doubt.
• Compounds must not be applied excessively – this can lead to contamination of the
hydraulic system.
• Anti-seize compound may have to be reapplied during servicing, especially when
used to improve electrical conductivity purposes.
• Compounds No 2 and 3 should not be used as conductive compounds but the metal
and small amount of graphite content does help to enhance electrical conductivity.
However, it is not recommended to use pure graphite anti-seize due to its noble
position in the galvanic series – making the compound very conductive.
4.4 Removal of Connectors
The following applies for both electrical and mechanical connectors:
Note: When removing components from connectors or terminals, ensure that both the
item and its matching fitting are correctly labelled for ease of re-assembly.
This should include:
• Cables
• Conductors
• Hoses
• Plugs
4.5 O-Rings
The following applies for O-Rings:
• Apply a thin layer of silicon lubricant or Aqua-Lube to O-ring and in the groove. In
cold climates, a thin lubricant is recommended.
• Carefully inspect O-rings, discard if suspect.
• Clean O-ring and O-ring groove with solvent and lint-free material, i.e., sponge-type
cotton-tip.
• Whenever reassembling parts, inspect all sealing surfaces.
The following are the Do Nots for O-Rings:
• Do not use force to reassemble items using O-Rings. Excessive force can create a
pinch or cut in the O-ring, creating a leak path.
• Do not use tools to pry items apart; using tools can scratch the mating surfaces.
Note: The end of all power cables should be bagged and coiled to prevent damage or
contamination. All receptacles should have blank plugs and caps installed when
cables are removed.
Figure 4: Bagging Cables
4.6 Fuses
A fuse is a type of low resistance resistor that acts as a sacrificial device to provide
overcurrent protection, of either the load or source circuit. Its essential component is a
metal wire or strip that melts when too much current flows, which interrupts the circuit in
which it is connected. Short circuit, overloading, mismatched loads or device failure are the
main reasons for excessive current.
Note: Fuses protect against overcurrent, not overvoltage.
The Typhoon system uses fuses within the Surface Power Control Cabinets and the
Subsurface ROV.
Striker Pin
extended – fuse
blown
Figure 5: Example of Striker Pin, Extended Indicates Blown
4.6.1 Checking & Replacing Fuses
Warning: Always assume equipment is energised unless proven otherwise.

The correct way to check and replace a fuse:
1. Verify equipment is de-energised.
2. Remove the fuse from its receptacle with a fuse puller.
3. Verify with a continuity tester that the fuse still shows continuity. Never use a
screwdriver or anything else that can cause accidental contact with wiring or socket.
Note: There is a chance that the glass body could shatter if a glass fuse is forcefully pried
out. Be sure you have safety glasses on.
4. If blown, replace with the correct type and value and never bypass a fuse circuit
because a replacement fuse is not available.
5. If the same fuse blows a second time, further investigation of the cause is
recommended.
Note: Blown fuses can usually be identified by a visual inspection of the element and
sometimes discoloration of the glass or ceramic body. Some electronic boards use
auto reset fuses.
Caution: Always replace the fuse with the correct type and value. Never bypass a fuse
circuit because a replacement fuse is not available.
Table 7: Fuses Located Topside Cabinets
Description Manufacture Manufacture Part # Location Comment

5A HV Fuse for TX6KV GE K3PG5 TMS Inst TX
10A HV Fuse for TX6KV GE K3PG10 ROV Inst / TMS HPU
40A HV Fuse for TX6KV GE K3PG40 ROV TX Cabinet
1A HV Fuse for test circuit 6KV Copper Busman BUS5.5AMWNA LV Cabinet
5A HV Fuse for TX6KV RS 412-986 LV Cabinet
5A HV Fuse for TX6KV RS 412-576 LV Cabinet
5A HV Fuse for TX6KV Farnell 1681222 LV Cabinet
5A HV Fuse for TX6KV GE AIR6.6/1 ROV TX Cabinet
4.7 Seizing (Mousing) Wire Rope
If ropes are not seized properly prior to cutting, wires and strands are apt to become slack
and can also cause the end to become distorted or flattened. Subsequently when the rope
is operated, there may be an uneven distribution of loads to the strands, a condition that will
significantly shorten the life of the rope.
Non-rotating ropes regardless of their construction depend on the retention of a built-in

torsion balance for their ability to resist rotation under load. Therefore it is essential that
proper seizing practices be carefully followed.
Figure 6: Seizing (Mousing) Wire Rope
There are two methods of seizing wire rope. The first method is generally used on ropes
larger than 1 inch in diameter whilst the second one applies to ropes one inch and under.
4.7.1 Method No. 1:

One end of the seizing is placed in the valley between two strands; it’s long end is then
turned at right angles to the rope and wound back over itself and the rope in a close tight
winding, in a direction opposite the lay of the rope. The seizing is continued until it is at
least two and a half times the same diameter as the rope. The two ends are then twisted
together and by alternately tightening and twisting they can be drawn tight.
4.7.2 Method No. 2

The seizing wire is wrapped around the rope in a close tight winding in the opposite
direction to the lay of the rope. The seizing is continued until it is at least two and a half
times the same diameter as the rope. The two ends are then twisted together by hand in a
counter-clockwise direction approximately at the centre of the seizing. Alternately twist and
take up slack until the seizing is tight on the rope. Wind the twisted ends into a knot and cut
off the ends of the seizing wire.
4.7.3 The Seizing Wire

The seizing wire should be soft annealed iron wire. Do not use any other wire (copper,
brass, stainless, etc.) for seizing. Seizing wire diameter and length of the seize will depend
on the diameter of the wire rope. The length of the seizing should be at least two and a half
times the diameter of the rope. Proper end seizing, particularly on rotation-resistant wire, is
imperative. Failure to adhere to simple precautionary measure may result in loose strands
and serious rope damage. For seizing wire diameter guidelines please refer to table below.
Table 8: Suggested Seizing Wire Diameters
Rope Diameter Suggested Seizing Wire Diameters
inches mm inches mm
1/8” to 5/16” 3.2 to 8.0 0.032 0.813
3/8” to 9/16” 9.5 to 14.5 0.048 1.21
5/8” to 15/16” 16.0 to 24.0 0.063 1.60
1” to 1-1/16” 26.0 to 24.0 0.080 2.03
1-1/8” to 1-11/16” 35.0 to 43.0 0.104 2.64
1-3/4” and larger 45.0 and larger 0.124 3.15
Surface Electrical System
5. Surface Electrical System

The Surface Electrical System contains electrical and electronic equipment that should be
operated continuously only in an environmentally controlled and clean environment. The
system is designed for operation in an air-conditioned space with adequate circulation for
the cooling system components and the power supplies. The transformers generate a
substantial amount of heat.
For additional technical information; refer to TMT Manuals\Surface Power and
Control\Typhoon MK2 150 folder on the digital technical manual.
5.1 Cabling and Connectors

Multiple types of connectors are used in the surface control and power systems. All
connectors should be kept clear from obstructions. Damage can occur due to cable stress
or unintentional interference or impact. Cables should be kept secure in tie and spiral
wrapped bundles to prevent cable stress. Ensure that adequate service loops are
maintained on cable harnesses that have to travel with the movement of instruments or
instrumentation racks.
For a visual description of the electrical connectors used; refer to
TMT Manuals\Miss\Face-View Connectors Block-Model folder on the digital technical
manual.
5.2 Fibre Optics

Fibre Optic connectors are to be kept clean. When cleaning the fibre optic connectors, use
special fibre cleaning products such as cleaning sticks, swabs “Sticklers” or isopropyl
alcohol. Canned dry air can be used to dry connectors. Dry air can also be used to remove
dust or debris located within the transmitter and receiver cards. It is not recommended to
use contact cleaners, as they may leave a film on the fibre, especially CO contact cleaners.
Caution: Wear eye protection when using canned dry air. Never look at a fibre
connected to an energized source. It can cause severe eye damage.
Figure 7: Fibre Optic Modem Stack
Note: It is recommended that a record be maintained of each section of fibre, to assist in

future troubleshooting.
Table 9: Example of Fibre dB Loss Record
Fibre 1 Fibre 2
Section dB loss Section dB loss
Deck cable Deck cable
Winch Slip-ring Winch Slip-ring
Umbilical Umbilical
TMS Slip-ring TMS Slip-ring
Tether cable Tether cable
8-way Opticon 8-way Opticon
Entire fibre path Entire fibre path
For additional on the Fibre Optic Modem Stack information; refer to the OEM
Manuals\Fibre Optic folder on the digital technical manual
5.3 Air Filters

The surface power cabinets contain air circulation fans for cooling. Each fan has an EZ
Kleen aluminium air filter that must be kept cleared of obstructions and debris. The filter
can be removed and cleaned with compressed air and / or warm soapy water. Allow to fully
dry and reapply super filter coat adhesive before reattaching.
The aluminium filters used in the Typhoon system cabinets are built to withstand occasional
and moderate cleanings between service periods.
Figure 8: Air Filter
Replace the filter when it can no longer be cleaned.

Caution: Wear eye protection when using compressed air.
5.4 Electrical Cabinets

Control and Power components in the cabinets are to be kept clean. Special attention
should be taken to keep MV terminals / connectors clean.
Caution: When cleaning cabinets, take care not to leave any residue on components
that could cause tracking.
5.5 Circuit Breaker

Regular maintenance of circuit breakers plays an important role in ensuring that the circuit’s
protection reacts when it is required.
Figure 9: Circuit Breaker
Equipment that is not regularly maintained can fail in providing its protection service. When
the circuit breaker is inspected (once a month), the test button should be pressed in order
to verify the correct operation of the mechanism.
Figure 10: Resetting a Circuit Breaker
For purpose of circuit breaker testing, CB1 needs to be securely isolated and bypass needs
to be inserted in the inner door interlocks of the LV cabinet (see figure 5 in manual).
Conductivity is to be verified between input and output of the circuit breaker. Resistance of
each phase is expected to be below 2Ω, i.e. usually none or very small value. For further
troubleshooting, consult Section 10.4 Surface Cabinets Power Issues located on page 159.
Warning: When utilizing the door bypass, lethal voltages may be present on energised
end of the circuit breaker and the busbar if CB1 is not isolated.
Only competent electrical personel should conduct these tests.
5.6 Circuit Breaker Operational Issues

Modern circuit breakers (CB) are robust devices and do not provide the user with the ability
to service the internal components. However, there are actions that can be undertaken in
order to ensure that the circuit breaker has a long operational life. All studies in this matter
state that approximately 50% of circuit breakers that were not having preventive
maintenance, fail to perform when required.
There are many physical processes that can adversely influence the life span of a CB. They
are detailed in the following text.
5.6.1 CB Overheating
Based on the IEEE standard requirements, the outer casing of a healthy circuit breaker
should not heat up to more than 50°C above ambient temperature. If the surface of the
circuit breaker casing heats to greater than 50°C above ambient temperature, then it is a
positive indication that the circuit breaker is close to failure.
Loose terminals are one of the main reasons that lead to circuit breakers overheating. They
are also the only problem that can be overcome without removing the circuit breaker from
operation.
Figure 11: Overheated CB due to Poor Phase Connection
The main reason for the CB overheating, however, is the build-up of grime within the circuit
breaker. This can occur due to high-energy fault arcing.
High energy arcing occurs when the CB attempts to open on a very high fault current, or
when it accidentally trips on high currents associated with umbilical charging. These
charging currents can be up to 1000 times higher than its nominal current.
In some instances, higher temperature on a spot of the breaker does not necessarily mean
a fault on one of the phases. Figure 12 shows temperature differences due to the Under-
Voltage Relay (UVR) release installed in the circuit breaker.
Figure 12: Higher Temperatures Associated with UVR
5.6.2 Failure Due to Capacitive Currents

Due to the nature of the ROV system, high capacitive currents can be present with the
switching operations. When the circuit breaker attempts to interrupt the capacitive currents,
it can become prone to a dielectric failure. The problem arises when a zero current occurs.
Voltage at that time is on its maximum value and capacitance is fully charged, which is
opposite to inductive circuit where, on maximum voltage, the current is zero.
Upon release of the contacts, this capacitance raises the supply voltage up to two (2) times
the nominal value. If the arc in the chamber has not been extinguished by the end of this
operation, a restrike can occur. On a restrike, the voltage can be up to five (5) times higher
than nominal.
This collapses the circuit breaker dielectric and can melt the circuit breaker contacts.
Signs of Arcing
Figure 13: CB with Signs of Arcing Due to the Capacitive Switching
5.6.3 Failure Due to High Starting Currents

When high starting currents are present, as in Direct-On-Line (DOL) operation for instance,
contacts of the CB can weld together. This creates a permanent pathway for the current.
These contacts will not open, even after mechanism operation. This is one of the most
dangerous occurrences, as the circuit breaker opens its contacts on the fault currents. If the
fault is not cleared, then equipment can be destroyed.
Wielded Normal Contact

Contact
Figure 14: Welded Contacts
5.6.4 Mechanical Failure of Opening Mechanism

Modern CBs have enclosed parts that are self lubricating. The circuit breaker does not
require much maintenance over its life span. However, if the mechanisam is not operated
over time, it can block in either the open or, more likely, the closed position. CBs that are
not tested, are most likely to fail operating when they are needed the most – interupting the
fault currents. They stay in the closed position, even when the trip unit has given the signal
for the operation.
Middle Phase
Not Closed
Figure 15: Middle Phase Not Energized - Mechanical Failure
5.6.5 Issues with Auxiliary Devices

Auxiliary devices such as the Shunt trips, UVR’s, communication devices and auxiliary
contacts can suffer damage when the CB is operated. After every fault operation, these
devices should be inspected and their correct operation verified.
• Shunt trip devices can stay permanently closed.
• UVR can stop sensing voltage and trip on too high or too low voltage.
• Auxiliary contacts can sieze and stop giving information on the state of the CB.
• Communication units can stop transmiting data.
5.6.6 Damage to the CB Outer Casing

The CBs can sustain mechanical damage because of the contact operation. This occurs
when a high energy fault is cleared.
Damage can be divded into the following four (4) categories:
1. Arcing damage visible in the form of grime. Dark spots on the CB associated with
this are an excellent way of telling that the circuit breaker needs replacement.
If minor builtup is visible on the outside, check the internals before deciding if the CB
needs replacement.
2. Mechanical damage, such as cracks and pieces of the case missing. In case this
occurs, it is unsafe to keep the circuit breaker in operation as the next switching
operation may cause catastrophic failure and CB explosion.
3. Swelling of the CB case, as a consequence of the thermal processes within the CB.
Results of extensive heat should never appear on the CB in the normal operation.
Detailed investigation should be conducted if such marks are visible.
4. Thermal damage on terminals of the CB. They can be associated with loose
terminals. This is the only damage that may not require withdrawal of the CB from
operation.
5.7 Preventive Maintenance and Inspection

Under normal conditions, molded case circuit breakers require preventive maintenance
only. However, when inspections determine an abnormal condition and indicate the
possibility of damage, it may be necessary to perform more detailed inspection. Regular
maintenance inspection should be conducted every three (3) months. Common CB
problems and their solutions are outlined in Table 37 on page 159.
Warning: Hazard of electrical shock or burn. When using the test power supply, do not
touch its terminals or the terminals of the accessory during the test.
Warning: Hazardous voltages in electrical equipment can cause severe personal injury
or death. Turn off the power supplying the equipment before removing the CB
and before performing any of the following operations.
Caution: If applied incorrectly, the voltages utilized by the insulation resistance tester
may damage electronic or other accessory components.
To avoid such damage, do not apply test voltages to any accessory terminals.
5.7.1 Inspection of the CB after a Fault

CBs can perform over 100 000 operations in their lifetime. Most of them can withstand over
20 fault operations per hour.
Still, some of the CB can malfunction long before the end of their nominal lifespan. This
usually happens in the form of an explosion that can damage property and people. In order
to prevent this from happening, care should be taken that after every fault operation, circuit
(hence not only breaker) is inspected in detail before returning it back in operation.
It is understandable that breaker will be only reset when the system is in operation, as
downtime should be kept to a minimum. Once the system is placed on standby, preventive
checks on the CB that has tripped, as outlined in in Table 37 on page 159, should be
undertaken.
All cables in that circuit should be checked for damage, and replaced if any damage is
found. Other elements of the circuit, such as contactors, should be inspected for contact
damage as well.
A good reference is the ABB publication 1SFC101044M0201 – “Guidelines for Contactor
Inspection and Maintenance” for inspection of contactors, this publication is suitable as a
guideline for any manufacturer.
If circuit consist of other conductive elements such as Soft-starter, their bypass contacts
should be inspected as well.
The contacts of circuit breakers and contactors should never be sanded regardless of their
visual appearance because of the following reasons:
• Conductive dust is created that can ignite and weld contacts.
• Contacts will become rough and will not have their full current carrying capacity.
Note: Contacts should always be replaced if damaged.
5.8 Line Insulation Monitors

There are four (4) isolated, individually protected circuits for the ROV / TMS.
LIM Supply Contactor
ROV HPU 3250VAC K1
ROV Instrumentation 2400VAC K2
TMS HPU 2400VAC K3
TMS Instrumentation 2400VAC K4
Each Line Insulation monitor is equipped with a test circuit to confirm the correct operation
of the LIM. When the test button is pressed a 500kohm resistor is connected from the HV
circuit to earth.
Figure 16: LIM Display

The LIM should indicate 500kohm on the display and trip the selected circuit. Each circuit
should be tested at regular intervals, monthly, to confirm its correct operation.
Caution: Never leave either of the LIMs units in the test mode, after testing return the
switch to the run position and remove the key.
Figure 17: LIM Test Switches
5.8.1 Test Procedure

To test the LIMs, refer to Figure 17:
Caution: LIMS should only be tested on deck and not when ROV / TMS are subsea.
1. Start the relevant circuit from the Pilot Control Console.
2. Turn the Test key, hold for one minute and observe the circuit tripping.
Observe the LIM displaying 500k Ohm.
An alarm will display on the Power Monitoring application as well.
3. Turn the LIM circuit switch to O/RIDE and restart the circuit.
Observe that the circuit is working in the O/RIDE mode.
4. Switch OFF the circuit and return the LIM from O/RIDE to OFF mode and remove
the key.
5. To restart, the test switch must be returned to normal position and restart the supply
from the Pilot Control Console.
Caution: Never leave either of the LIM units in the O/RIDE mode; after testing, return
the switch to the OFF position and remove the key.
For additional technical information; refer to TMT Manuals\Surface Power & Control
Manual folder on the digital technical manual
5.9 Uninterruptible Power Supplies

The Uninterruptible Power Supplies (UPS) units have no regular maintenance
requirements. Regular visual monitoring of the front panel display for alarm status is
recommended.
Note: The UPS battery life-expectancy is three to five years for continuous operation.
Recommend replacing is at three years.
5.10 General Maintenance Requirements

5.10.1 Visual Checks
The following are the recommended visual checks:
1. Verify all cabinet and control console panels, doors and structures are well-maintained.
2. Verify all ventilation fans are fully functional.
3. Verify that ventilation openings are not obstructed. Where seals and/or gaskets are
installed, these should be examined and repaired or replaced as necessary.
4. Where a high humidly condition is present, check for the presence of moisture
collecting within the cabinets. Lowering ground resistance may be an indication of this
developing.
5.10.2 Cleaning Requirements
Warning: Always assume equipment is energised, unless proven otherwise.

With the electrical system de-energised and grounded, all cabinets, Pilot Control Console,
computers and racks are to be vacuum cleaned of all loose dirt and debris.
Note: Use of compressed air is not recommended for cleaning inside cabinets as the
pressurised air could cause foreign particles to blow into hard to reach areas or
become embedded in the insulation or damage insulators.
Any build-up of dirt or other contaminates that will not come off with vacuuming, should be
cleaned with lint-free rags using a gentle cleaning agent. If in any doubt, try on a small area
first.
All vents and fan grills are to be cleaned of dust and any accumulations of dirt.
Note: In environments where there is an extreme exposure to adverse conditions, the
frequency of maintenance for the surface electrical system may be increased as
conditions warrant.
Table 10 outlines basic periodic maintenance for the Surface Electrical Systems:
Table 10: Surface Electrical Systems Maintenance
Component Period Action
Electrical Cabinets & Control Console
19” Rack Monthly Clean the PC and UPS filters.
Monthly Touch up paintwork as required.
Monthly Check for loose cables and components.
Monthly Lubricate door hinges and locks.
Monthly Clean electrical cabinet filters and AC filters.

All Electrical Visual inspection for dirt or anything out of ordinary.
Monthly
Cabinets Clean as required.
Monthly Inspect and test circuit breakers and.
Monthly Check door seals.
Monthly Ground straps are in place and in good condition.
Monthly Test the four (4) LIMs.
LV Cabinet Monthly Test the LIM shutdown system.
UPS Annual Test and verify operation.
Electrical Subsurface Components
6. Electrical Subsurface Components

The Typhoon electrical system is designed to operate in the marine environment. The
Typhoon Subsea Electrical system includes both oil-filled, pressure compensated
enclosures that contain electrical circuitry and circuit boards, as well as a one-atmosphere
pressure vessel to contain circuitry that is not suitable for submersion in oil for pressure at
operational depths.
All circuitry within the oil-filled junction boxes and manifolds are rated for operation in oil at
the maximum operational depth.
For additional technical information; refer to TMT Manuals\ROV Technical Manual folder
on the digital technical manual.
6.1 ROV Connectors

ROV Connectors are subject to corrosion due to moisture captured in the contact area,
particularly in a saltwater environment. Routine inspection of electrical connectors and
contacts should be performed to ensure connectivity of all pins within a sealed connector.
These are the ROV connector maintenance requirements:
• For best performance, flush connectors with freshwater at regular intervals, let dry
and apply contact cleaner.
• Keep O-ring grooves clean and avoid cuts, nicks and tears on rubber surfaces.
• Elastomers can be seriously degraded if exposed to direct sunlight or high ozone
levels for extended periods of time.
• Clean plugs and receptacles with soap and fresh water.
• Rinse out with alcohol, allowing connector to air dry.
• Replace O-rings when re-using connectors.
• Lubricate mating surfaces with 3M Silicone Spray or equivalent for easy connection /
disconnection.
Caution: Do not grease. Connectors must be lubricated on a regular basis.
• Lubricate O-rings with Dow Corning #111 Valve Lubricant
• All mounting and sealing surfaces require a 32 finish.
• Always use dust caps and keep connectors clean to prevent damage in storage and
service.
6.2 Cabling Assemblies

Cables are subject to damage due to exposure to UV and the marine environment. Routine
inspection should be performed to ensure reliability of the electrical system.
• Ensure that all system cable harnesses are secure but have sufficient flexibility to
handle movement when required, for example, Pan & Tilt movement.
• Ensure that all system cabling is secure and not free to float into thrusters.
• Prior to operation, inspect all system cabling for damage, cracks or deformation.
• Replace any cable or spiral wrap, if there is any question about the integrity of the
material.
Note: Cabling assemblies are generally covered in spiral wrap as a proven way to help
protect hose, wire, cable, etc., against chaffing, rubbing, crushing, ultraviolet and
other surface and subsea environmental hazards that can cause premature failure.
Always replace any spiral wrap that is removed with the same type.
Four types of cable assemblies are used on the Typhoon ROV:
1. Neoprene
2. Poly-Urethane Cable
3. Trex-Onics cables, a type of Poly-Urethane
4. Oil Filled Cable Assemblies
6.2.1 Neoprene Cable Assemblies

To identify Neoprene; it is usually black in colour and has a soft jacket. The black cables
are used for the Hydraulic Manifolds, Sonar, TOGNAV and the Sensor Bottle.
Figure 18: Neoprene Cable Assemblies
6.2.2 Poly-Urethane Cable Assemblies

To identify Polyurethane; it has a fairly hard jacket covering and coloured green and yellow
on the Typhoon ROVs. The green cables are used for the camera and the LED 24VDC
lights.
Figure 19: Poly-Urethane Cable Assemblies - Camera and the LED 24VDC Lights
6.2.3 Trex-Onics Cables

Trex-Onics cables are also a Poly-Urethane cable but are of a heaver duty version for the
higher voltages found on the Dimmer Bottle and the LED main lights.
To identify Trex-Onics Cables, it has a fairly hard jacket covering and is coloured yellow on
the Typhoon ROVs. The Trex-Onics cables are used for the Dimmer Bottle and the
115VDC LED Main Lights.
Figure 20: Trex-Onics Cables – Dimmer Bottle & 115VDC Main Lights
6.2.4 Oil Filled Cable Assemblies

Electrical cables are run inside oil-filled pressure compensated tubing to protect them from
corrosion in seawater.
Figure 21: Oil Filled Cable Assembly
Whenever refilling, any trapped air will need to be bled from the hose. There is a bleed
screw in the MEE 8C connector, as an example; refer to Figure 22.
Bleed Screw
Figure 22: MEE 8C Connector
Note: The oil used within the cable is generally the same as the hydraulic oil used. Verify
type for your specific system
The following connectors are used on the Typhoon ROV:
Table 11: Oil Fill Cable Assemblies
Connector Description Manufacture Identifier
Optical Connector 8p SM 9/125, 1m tail Seacon Europe 8-4FO,SM,4E-FCR
MEE 8C Seacon Europe 55OF1-R/A-CCP-2420
6.2.5 Cable Care & Maintenance

For Neoprene and Poly-Urethane cable assemblies, the following applies:
• Lubricate mating surface with 3M Silicon Spray or equivalent.
Caution: Do not grease, connectors must be lubricated on a monthly basis.
• Lubricate O-ring with Dow Corning #111 Valve Lubricant or equivalent.
• Replace O-rings when reusing connectors.
• Avoid nicks and cuts around contacts, as these are sealing surfaces.
• Elastomers can be seriously degraded if exposed to direct sunlight for extended
periods of time.
• Do not over-tighten bulkhead nuts.
• Do not pull on cable to disconnect.
• Avoid sharp bends at cable entry to connector.
Note: Cabling assemblies are generally covered in spiral wrap as a proven way to protect
wiring assemblies against chaffing, rubbing, crushing, ultraviolet and other surface
and subsea environmental hazards that cause premature failure. Always replace
any spiral wrap that is removed. Where cables touch sharp corners of the ROV
frame, a piece of rubber is used to wrap the cable, or cable bundles to prevent
damage by rubbing.
6.3 HPU Motor

The Typhoon HPU Motor is a 150hp, three-phase, oil-filled, electrical motor.
Prior to operation:
• Inspect the wire-way hose between the HPU Motor and the Tether Termination Box
for damage, cracks or deformation.
• Ensure that all system cabling & power connections are secure.
• Inspect hydraulic oil regularly.
The specifications for the HPU electric motor are:
Table 12: Electric Motor Specifications
Specification Value
RPM 1750rpm
Phases 3ø
Volts 3000V
Frequency 60H
Horse Power 150Hp
Current 24.4A
Poles 4poles
SF 1.00
PF 0.814
INS Class F
Connection STAR
Stator Resistance (Cold, 25º) 3.17Ω
Stator Resistance (Hot, 27º) 3.18Ω
Caution: There are no field serviceable parts within the HPU electrical motor.
Maintenance is limited to checking the compensation level and changing the hydraulic fluid
as required by the periodic maintenance schedule. Drain a sample of the compensation oil,
underneath the motor, to check for oil contamination water and / or solid particles.
For detailed OEM motor information; refer to OEM Manuals\Hydraulic\Motor folder on the
digital technical manual.
6.3.1 Temperature Sensor – HPU Motor

The following steps describe how to test the RTD in the HPU Motor on Deck, when the
motor is cold.
Figure 23: HPU Oil Temperature & Wet Sensor
Warning: Isolate all power to the ROV/TMS, while doing this test on deck.
1. Disconnect the 4-pin C2, HPU Motor Temp Cable Assembly, at the Sensor Bottle.
2. Plug in a spare 4-pin Bulkhead connector (LPMBH-4-MP) to the cable assembly.
3. Measure resistance of the Motor RTD Sensor between pin 1 and 2 with a Multimeter.
4. Measure the temperature of the Motor with a Temp Gun and compare it with the
equivalent resistance / temperature to the PT100 data sheet DM503 RTD 100 5
located in OEM Manuals\Sensor folder.
5. If the ambient motor temperature does not correspond to the calculated temperature
in the data sheet table, replace this cable assembly and test again and / or test at the
motor bulkhead connector.
6. If this checks out Ok, there may be an issue in the Sensor Bottle. More than likely, it
will be the Motor Temp cable assembly.
For additional technical information on the HPU and sensor as used on the Typhoon; refer
to TMT Manuals\ROV Technical Manual folder on the digital technical manual.
For detailed OEM on the sensor information; refer to OEM Manuals\Sensor folder on the
digital technical manual.
6.4 Lights
The Typhoon Lights are a combination of 115VDC and 26VDC LEDs. Routine inspections
should be performed to ensure reliability of the lighting system.
Caution: There are no field serviceable parts within the light bottles.
Prior to operation:
• Inspect all lights for damage, cracks or deformation.
• Ensure that all bulkhead and light connectors are secure.
• Verify that all the lights are functional.
Warning: After each deployment, carefully check to make sure each light is operational
and has not flooded. If a light is flooded, upon surfacing, the light can become
internally pressurized which may be potentially dangerous.
Additionally, if the power remains on when the light has partially flooded, it is
possible for electrolytic generation of an explosive mixture of hydrogen and
oxygen gases.
If a light appears flooded upon removal from the water, it should be treated as
potentially dangerous. Point the light away from persons and valuable
equipment and make sure that the power is disconnected. See the Flooded
Light Repair procedure in OEM Manuals\Camera & Lights\Lights folder on
the digital technical manual for more information.
For specific information on the SeaLite Sphere; refer to OEM Manuals\Camera &
Lights\Lights folder on the digital technical manual.
Note: The LEDs Id depends on its location on the ROV; it must be addressed and
positioned correctly on the ROV for it to operate.
Table 13: 26VDC Light Addresses and Locations
Addresses Locations
L1 – FWD Floatation Pan and Tilt MEE Connector – 1A
L2 – Rear Pan and Tilt MEE Connector – 2A
L3 – No light connected MEE Connector – 3A
L4 – Conan Arm MEE Connector – 4A
L5 – Port Overview MEE Connector – 5A
L6 – Rear facing Docking MEE Connector – 6A
L7 – Upward facing Docking MEE Connector – 7A
L8 – No light connected MEE Connector – 8A
The following two sections proved a quick instruction on how to program or reprogram the
LED lights either from a test bench or on the ROV.
6.4.1 From the Work Bench

Required Equipment:
• 24VDC power supply
• Camera Light program
• USB/RS485 converter
• Light whip cable
• Misc. leads - 485 twisted pair, 2 wires for 24VDC
• Camera and Light User Manual
• Test Box if available
Note: All new spare LED Lights come defaulted to address #1. The light id is “l” (lower
case L).
Procedure:
1. Connect light to the whip cable (24VDC and RS484). The comms wires connect to
the USB / RS485 converter. Connect the converter to the PC running the Camera &
Light application.
2. Open the Camera & Light application. On the main control window setup the Comms
port by choosing the correct port number in the drop down menu. Set the Baud Rate
to 57600 bps.
3. Turn on the power supply.
4. On the Camera Light program, press Connect.
Note: Verify you have the word Connected and that the word COM turns Green, at the
bottom left of the window before proceeding.
5. At the right hand side of the screen, is displayed the COMs quality at approximately
4%.
6. Disable all the devices not connected, by unchecking the box under each one.
The comms quality will go to 100%.
7. On the Light Control window you should see a light connected at the position
according to the current programmed address. All other Not Connected lights
display NO COMMS.
8. On the Light Control window, turn the brightness up and then dim it down to ensure
proper operation of the light.
9. On the Camera & Light control window, click on the Tools tab and select the Generic
Node option. A Generic Node Interface will appear.
10. In the Id section select Id letter “l” (lower case L). In the address section select the
current address, “1”, or whatever address as seen on the Light Control Screen.
11. Click on the Read buttons. It will display the serial numbers of the unit and the PCB.
This verifies that the address is right and that the light works.
12. Enter the New Address to the required address, e.g. “4”.
13. In the address section, click on the Program button and then, click on the Reset
Node button.
14. Change the Current Address to new value e.g.”4” and then click on the Read buttons
to confirm that the change worked. Will read the same serial numbers as before.
15. Exit the Generic Node window. Make sure that you have enabled the light on the
new desired address on the Light Control window – disabled previously to increase
Coms Quality. Will see the light going green (communicating) on the new position.
16. Test the light. Increase and dim down the light.
17. Install the light on the right place on the ROV, according to the address given and
verify operation.
6.4.2 ROV Method

It is possible to program LED light connected to the ROV, although it is not a preferred
method. Whenever possible, they should be programmed on the bench.
Note: All new LED lights have a default Id/Address “l1”. The Id is “l” (lower case L) and
the address is “1”. Light 1 is assigned for MEE connector 1A so you must use light
1’s cable or a spare camera light cable connected to MEE connector 1A.
If a light has to be replaced or relocated on the ROV it must be readdressed to suit its new
location. If it is not possible to be addressed on the bench it can be done on the ROV as
follows:
1. With power OFF on the ROV, disconnect existing light 1 (FWD floatation Pan & Tilt)
and replace it with the new one on to light 1 cable. Or, disconnect cable from MEE
connector 1A and connect there a spare cable with the new light.
Note: If the faulty light is address 4, as example, disconnect it from its cable.
2. Open up the camera light program on Aux PC 1 and in the main control window
setup the Comms port by choosing the correct one in the drop down window, if not
already defaulted. Set the Baud rate to 57600bps.
3. Power up the ROV electrics.
4. Click on the Connect button on the camera light program.
Note: Ensure you have the word Connected and COM# in green at the bottom left of the
window before proceeding. On the light Control Window you should see all existing
lights connected and operational. Any light not communicating displays
“NO COMMS” in Red.
5. Turn the brightness up and then dim it down to ensure proper operation of the new
light.
6. On the Camera and lights control window click on the Tools tab and then click on
the Generic Node option. A Generic Node Interface will appear.
7. On the Generic Node window select Current Id “l” (lower case L) and address “1”.
8. Click on the Read buttons. The board and unit serial numbers will display.
9. Then, in the Address section enter the new desired address (e.g. 4).
Click on the Program button and then click on the Reset Node button.
10. Verify the change: Change the Current Address to the new one (e.g. 4). Click on the
Read buttons. The board and unit serial numbers will be displayed.
11. Exit the Generic Node window. The Light Control window will recycle and will display
the reprogrammed light on the new address position (e.g. 4).
Note: The light will not be seen / controllable on the position used to program it, “1” in
this case.
12. Power down the ROV electrics and move the new light on its new position (e.g. 4).
13. Reconnect light “1”.
14. Power up the ROV and verify the new light. Increase and dim the light intensity. Also
verify light 1 still works.
6.5 Navigation Bottle - TOGSNAV

The Navigation Bottle fitted to the Typhoon MK2 150 is generally the CDL TOGSNAV.
Verify the type on your system.
Figure 24: TOGSNAV
The CDL TOGSNAV is a self-contained system whifch requires no regular maintenance

other than an annual or regular Attitude Heading Reerence System (AHRS) calibration
check. Details for preforming the AHRS are contained in the TOGSNAV User Manual.
Note: Equipment requiring a recalibration needs to be returned to CDL or an approved
authorised distributor.
Caution: There are no field serviceable parts in the TOGSNAV.
All housings should be checked regularly for signs of damage. All connections on the
surface and subsea units should be checked regularly for fouling, bent pins or signs of
damage.
If the equipment requires a recalibration, it will need to be carried out at the CDL base or an
approved authorised distributor. The equipment will be recalibrated with a full functional
check to ensure continued reliable operation. When returned, the equipment will carry both
function test and calibration check certificates. Contact CDL for current calibration charges
for this equipment. The turn-around time for this service is normally 1-2 days.
6.5.1 General Handling Guidelines

The general handling guidelines for the TOGSNAV are as follows:
• Never set the transducer on a hard or rough surface; the urethane faces may be
damaged.
Urethane
Faces
• Always remove the retaining strap on the underwater-connect cable and dummy plug
when disconnecting them. Failure to do so will break the retainer strap.
• Do not apply any upward force on the end-cap connector while the I/O cable is being
disconnected. Stressing the connector may cause the DVL to flood. Read the
Maintenance section in the TOGSNAV Manual for details on dis-connecting the I/O
cable.
• Do not expose the transducer faces to prolonged sunlight. The urethane faces may
develop cracks. Cover the transducer faces on the TOGS-NAV if it will be exposed to
sunlight.
• Do not expose the I/O connector to prolonged sunlight. The plastic may become
brittle. Cover the connector on the Navigator if it will be exposed to sunlight.
• Do not store the DVL in temperatures over 60º C with the batteries removed. The
urethane faces may be damaged. Check the temperature indicator inside the
shipping case. It changes colour if the temperature limit is exceeded.
• Do not scratch or damage the O-ring surfaces or grooves. If scratches or damage
exists, they may provide a leakage path and cause the DVL to flood. Do not risk a
deployment with damaged O-ring surfaces.
For OEM information including configuration and operation details; refer to OEM
Manuals\Navigation folder on the digital technical manual.
6.6 Navigation Bottle – ROVINS - Optional

The ROVINS system is an Inertial Navigation System (INS). It delivers heading and attitude
information as well as position and speed, to other systems or to displays. It can
incorporate data from other sensors to improve its accuracy. The ROVINS system can also
be used as a gyrocompass coupled with a GPS or a LOCH EM.
ROVINS contains a self-consistent navigation algorithm based on Kalman Filtering. This
structure enables ROVINS to work either as a black box or to be connected to external
sensor systems (GPS, Doppler Velocity Log, Depth sensor, acoustic positioning systems.
All housings should be checked regularly for signs of damage. All connections on the
surface and subsea units should be checked regularly for fouling, bent pins or signs of
damage.
Caution: There are no field serviceable parts in the ROVINS.
Performance verification may be required before being used for multipurpose operations
with multiple integrations; frequent handling and use in harsh environments. Performance
checks may be useful before starting significant new operations.
The OEM recommends to checking performances typically every two (2) years.
However such verification does not require returning system to iXBlue factory. iXBlue
provides customers a “User Acceptance Test” procedure to perform such verification by
themselves refer to .
No specific tools, nor reference table are required. However, such operation must be
conducted onshore since a stable attitude is required.
For OEM information including configuration, operation and troubleshooting details; refer
to OEM Manuals\Navigation folder on the digital technical manual.
In case of test failure, it is recommended to contact your iXBlue local Support
representative to confirm diagnostic and organize the unit return to factory for verification.
6.7 Sonar
The Typhoon ROV uses the Kongsberg 1171 Sonar Head.
Figure 25: Sonar Head
The dual transducer design allows optimized operational frequency selection for different
requirements.
With electrical system de-energised and grounded, clean all surfaces with fresh water.
Caution: There are no field serviceable parts in the sonar head.
For additional technical specification information; refer to TMT Manuals\ROV Technical
Manual folder on the digital technical manual.
For OEM information including configuration and operation details; refer to OEM
Manuals\Sonar folder on the digital technical manual.
6.8 Oil Compensated Enclosures

Typhoon contains the following oil compensated enclosures:
• HPU motor
• Hydraulic Manifolds
• Instrument Transformer Box
• ROV Survey J-Box
• Tether Termination J-Box
6.8.1 Opening and Closing Oil Compensated Enclosures

Instructions
Oil compensated electrical enclosures use a machined cover with an O-ring that seals the
cover to the enclosure.
Caution: Maintenance activities involving the entering of enclosures must be planned
to ensure they are conducted in a clean environment to prevent the possible
ingress of dirt, rust or other unintended materials into the enclosure.
To open an oil filled enclosure:
Warning: First verify that the hydraulic pressure of the system, including that within the
compensation system, is zero.
1. Isolate the ROV and the TMS as per SWP and Lock, Tag and Try procedures and
the vessel’s policy.
2. Drain the enclosure, if required.
3. Inspect the enclosure sealing surface whenever cover is removed.
4. Inspect the O-ring seal and O-ring groove every time the cover is removed.
5. Inspect the cover for damage, cracks or deformation.
6. Replace if there is any question of the integrity of the cover, seal or sealing surface.
To close-out an oil-filled enclosure:
1. Inspect the enclosure sealing surface prior to close-out.
2. Inspect the O-ring seal and O-ring groove prior to close-out.
3. Lubricate O-rings lightly with silicon grease.
4. Inspect the cover for damage, cracks or deformation. Replace if there is any
question of the integrity of the cover, seal or sealing surface.
5. Tighten the bolts in an alternating sequence to ensure that the lid engages evenly
without jamming. Observe the correct torque requirements, refer to Table 5.
6. Fill the enclosure, if required.
7. Vent enclosure of air.
6.9 One Atmosphere Enclosures

The Typhoon ROV contains the following one atmosphere enclosures:
• Cameras and Lights Bottles
• Light Dimmer Bottle
• Main Electronic Enclosure (MEE)
• Sensor Bottle
• Survey Bottle (optional)
Warning: Flooded enclosures can become internally pressurised, which may be

potentially dangerous. Always stay out of the direct path of potential missile or
spray hazard.
Caution: Maintenance activities involving the entering of enclosures must be planned
to ensure they are conducted in a clean environment to prevent the possible
ingress of dirt, rust or other unintended materials into the enclosure.
6.9.1 Opening and Closing One Atmosphere Enclosures

Instructions
Air filled electrical enclosures use a machined cover with an O-ring that seals the cover to
the enclosure. All air-filled enclosures are designed to maintain one atmosphere, 15psi
(1.03bar).
Perform the following inspections to ensure seal integrity during cover removal:
1. Switch off the ROV Electrics on the Pilot Control Console.
2. Open the enclosure, if required.
3. Use the installed cover bolts as “Jacking Bolts” in an alternating sequence to
ensure that the lid disengages evenly without jamming.
Jacking
Screw
Jacking Jacking Holes
Screw Screw
Holes Holes
Warning: If pressurisation or flooding of the enclosure is suspected, attach a pressure

gauge to one of the test ports of the enclosure if included. Always open the
port slowly and carefully.
4. Inspect the enclosure sealing surface whenever the cover is removed.
5. Inspect the O-ring seal and O-ring groove every time the cover is removed.
6. Inspect the cover for damage, cracks or deformation. Replace if there is any
Note: Inspect desiccant bag, replace as required.
Perform the following inspections to ensure seal integrity during close-out:
1. Inspect the enclosure sealing surface prior to close out.
2. Tighten the bolts in an alternating sequence to ensure that the lid engages evenly
without jamming. Observe the correct torque requirements, refer to Table 5.
3. Inspect the cover for damage, cracks, or deformation. Replace if there is any
Note: For the MEE, after close out, a vacuum test must be performed.
Caution: All the one atmosphere enclosures are pressure tested at the factory.
On site, when reassembly is required take care with the close out that the
seals and grove are in good condition and seal properly.
6.9.2 Vacuum Test MEE

The Vacuum Test verifies the seal integrity and must be performed each time any MEE
seal is removed.
Note: If the procedure is not performed and the system floods, thereby causing damage,
the warranty is void.
Caution: At the test end, be sure to refit the test port protective caps securely - finger
tight.
To vacuum test the MEE:
1. Connect the vacuum pump to the following ports each in turn:
Seal Port, V1
Vacuum Test Port

Seal Port, V2
2. On the end of the Cap Seal Port V1, apply a vacuum of -1bar for 10 minutes.
A drop of 2.5% is allowed. This tests the inter-seal space on the end cap.
3. On the Housing Seal Port V2, apply a vacuum of -1bar for 10 minutes.
A drop of 2.5% is allowed. This tests the inter-seal space on the connector
housing.
4. On the Vacuum Port (labeled), apply -1bar for one hour. A drop of 2.5% is
allowed. This tests the entire bottle.
Caution: At completion of the testing the MEE must be vented to atmosphere

pressure. This can be done by removing the hose from the pump side first. At
the test end, be sure to refit the test port protective caps securely - finger tight.
6.10 Umbilical & Tether

The umbilical connects the TMS to the LARS. The umbilical is of a larger diameter than that
used as the tether. The tether connects the TMS to the ROV. Tethers are usually neutrally
buoyant, thinner and more flexible than the umbilical.
Prior to and during operation:
• Visually inspect all for damage, corrosion, cracks or deformation.
• Wash down with fresh water (if available) the umbilical, tether and ROV lift points.
For additional technical information; refer to TMT Manuals\Surface Power & Control
Manual folder on the digital technical manual.
The umbilical outer steel armouring must be kept lubricated. This prevents wire corrosion
and extends the life of the cable. Lubricant must be renewed if white powder spots (zinc
layer corrosion) or brown spots (steel corrosion) appear on the cable.
Caution: Using a wire brush can damage the zinc protective layer.
For specific information on the umbilical or tether; refer to OEM Manuals\Umbilical &
Tether folder on the digital technical manual.
6.11 Armoured Umbilical Re-Termination

Note: Before commencing, fully read, understand all steps and have all parts and tools
available.
It is a good practice to take photos showing all the routing path of the umbilical throughout
the ROV for reference when fitting the new cable. The cable being removed is also a good
measurement reference for the new cable.
Follow the vessel’s permit system, such as Hot Work Permit before starting work.
6.11.1 Risks and Mitigations

Table 14: Armoured Umbilical Re-Termination - Risks and Mitigations
Risk Mitigations
Electrical: • Refer to Section 3.1 Electrical on page 20.
• Follow the vessel’s permit system, such as
• Potentially lethal voltage levels throughout
Hot Work Permit.
the ROV / TMS system.
• Check all fittings for correct tightness.
• Verify that all slings and chains certification
Heavy Object (ROV): are valid and fit for purpose.
• Have additional personnel to assist with
• Potential for crushing - smashing. placement.
• Ensure that correct PPE is worn as dictated
by onsite requirements.
• Check all fittings for correct tightness and
hoses for damage.
• Never check the tightness of a hydraulic
hose or fitting while under pressure.
High Pressure Hydraulic lines:
• Barrier off the ROV / TMS with a 2m
• Potential for high pressure fluid release. exclusion zone for initial hydraulic testing.
• Ensure correct PPE is worn as dictated by
onsite requirements.
• Do not check for leaks with hands or fingers.
• Wear correct PPE when handling equipment:
Moving Mechanical Parts:
o High Impact Gloves
• Potential for dynamic pinch points during • Ensure familiarity with equipment operation,
tool operation. review manual prior to handling.
Sharp wire:
• Potential for puncture wounds
o High Impact Gloves.
6.11.2 Prerequisites
• All relevant JSA’s and PTW to be completed read and understood by crew.
• Tool box Talk to be understood and to be signed.
• All relevant parties to be informed.
Required Documents
• Type 5 TMS Subsea System Wiring Diagram A353-100-109
• Umbilical Routing Kit A353-11-060
• Fixed Junction Box Assembly A353-152-001
• Fixed Junction Box Assembly A353-152-002
• TMS Type 5 Bullet Load Test Assy TMT-0009-4808
• TMS Long Line Wiring Diagram T12-17 TMT-0002-4586, T24-29 0010-7660
• ROV Long Line Wiring Diagramt12-17 TMT-0002-4587, T24-29 0010-7661
• Nexans Handling/Installation Guidelines for Dynamic Cables TR-01-01
• Type 5A TMS Operations Manual A353-000-027
6.11.4 Tools Needed

The following tools and materials are required:
Table 15: Tools & Materials Required
Tools & Materials Required

Hot Work Permit Oil soak pads
5 liters of diesel 2x hose-clamps
Gloves; HV, High Impact Chemical and Standard Electrical Oil
Face Shield Emery Paper
Wire lock pack (in date) Wire Cutters
1
4 / 2 inch grinder CO Contact Cleaner and Lectra Clean
2x Cut off disks Clean Buckets
10m Rope Hacksaw
2
2x 10m length of 0.81mm (0.032”) Mousing Wire Large Heat Shrink
Fibre optic kit 3 Stands
A couple litters of diesel to clean grease Isopropyl alcohol or Contact Cleaner
Rags New bullet insert tube
6.11.5 Re-Terminate Armoured Umbilical Instructions

To Re-Terminate the armoured umbilical:
1. Make sure all Personnel involved check MSDS for substances being used
2. Obtain a hot work permit for grinder.
3. Split the system and land-out the TMS.
Note: Orientate the Stationary J-Box away from the ROV.
5. Turn off the fibre MUX for the ROV in the Control cabin and place an Isolation Tag
on it.
6. Discharge the umbilical via the deck leads; refer to Section 3.1.6 Umbilical Electrical
Safety on page 25.
7. Drain the TMS stationary J-Box into a suitable container, approximately 4 litres for
Perry Type 5a, and remove the cover.
Note: Record phase colours, terminal block positions, fibre colours and positions. Good
practice is to take photos of the wiring before removing the wires from the
terminals.
8. Disconnect the phases, and the fibre optic connections.
9. Using a hacksaw, cut the umbilical at the entry point into the termination box.
10. Unscrew the gland on the termination box. Note down the correct positions as it is
removed for later assembling purpose.
Caution: Incorrect re-installation can result in water ingress.
11. Remove the fasteners on inside roof of TMS where the umbilical is routed.
12. As per working at heights SWP and JSA, attach a harness and undo the potted lift
point.
13. Remove the last bolt on the flange and carefully pull the umbilical through the TMS.
14. Once the umbilical is clear of the TMS, pay out the umbilical as it is pulled down and
lay it on the ground until the damaged part of the umbilical is through far enough to
be cut off.
15. Fit two hose-clamps tightly just above the intended cut location and cut the umbilical.
Refer to Figure 26.
8m 170-180mm
Mousing Mousing
125mm 125mm
Hose Clamps Tape
Figure 26: Measurements after Initial Cut
16. Cut off the bullet and clean the old potted termination from the inside of the taper.
17. Inspect for any damage, cracks or anomalies and thoroughly clean the inside. Once
free from any dirt, clean it with isopropyl alcohol.
18. Mouse (seizing) the wire, according to the measurement diagram, to begin the new
re-termination. Refer to Section 4.7 Seizing (mousing) Wire Rope located on page
42.
19. Carefully cut through the armour and remove; refer to Figure 27.
8m 170-180mm
For F.E.T. Type 5a TMS

Rated iaw drawing: Mousing Mousing
A353-111-060 125mm 125mm
Figure 27: After Removing Armoured Layers
20. Clean the insulated inner core with diesel and followed with isopropyl alcohol and
wrap the dirty moused armoured section in a garbage bag to avoid dirtying the inside
of the bullet.
21. Slide the bullet over the umbilical and temporarily tie it off above the moused section,
using the garbage bag to keep the inside of the bullet clean.
Caution: Wear the High Impact gloves as the wire can be very sharp.
22. Flare out the wire armour, one layer at a time. Clean any loose strands of armour
thoroughly with diesel or thinners to remove any grease.
23. Once cleaned, rub the wires with emery paper and finally clean the flared wire with
Isopropyl Alcohol / Lectra Clean contact cleaner.
24. Slide the bullet insert tube over the insulated core and follow it with a piece of heat-
shrink.
25. Pull the cone over the flared wire, assist by compressing the flared out wires where
necessary and use a ratchet strap on a piece of rope through the eyelets of the bullet
to pull it into place.
Caution: Do not use the winch to pull the umbilical through the spelter core.
26. Once pulled into the lift cone, secure the bullet in the vice in an upright position,
supporting the conductors with rope from above. Ensure it hangs true, and the
umbilical is not coming through the top of the cone at an oblique angle.
27. Wrap Denso tape tightly around armoured umbilical entrance into lifting cone.
This prevents the potting compound resin from flowing out of the bottom.
28. Prepare an In-Date 500cc of Wirelock socket fast resin kit, as per resin kit
instructions. Pour into cone from one side only, to prevent trapping air bubbles. Tap
side of cone with a rubber mallet to allow air bubbles to rise.
Caution: Beware that in cold climates it is necessary to use a manufacturer approved
accelerator additive, as advised on the resin container.
29. Place an empty tin on a metallic surface, as the chemical reaction is hot enough that
it can ignite fires on rags, timber and other combustible materials.
Caution: It is a potential fire hazard. Only dispose of it after the resin has cooled down.
30. Leave potting mix to set for the duration described as per resin kit instructions.
31. Once you are satisfied that the resin is set, put the umbilical back through the lift
point and route it through the TMS as it came out.
32. Fit a hose-clamp over the mousing just above the Spelter and remove excess
mousing wire, extruding out of the cone (dissimilar metals will cause faster
oxidation). Mousing
32mm
170-180mm
1.5m 6.5m
Figure 28: Spelter Ideal Final Placement
33. Remove the hose-clamp and wrap Denso tape over the end. The photo shows the
excess mousing wire not removed.
Note: The excess mousing wire must be removed before applying the Denso tape.
34. Re-install the gland back onto the umbilical and TMS termination box.
Re-terminate the electrical conductors and the fibre-optics.
35. Once all is secure, perform a full TMS and ROV function check prior to filling with oil.
36. Update the Umbilical Log book to keep an accurate record of the actual umbilical
length.
6.11.6 TMS Termination

Installing the umbilical in the TMS:
1. Route the umbilical through the TMS in accordance with Section 3.3.4, Umbilical
Connection, of Forum document A353-000-027, Type 5A TMS Operations Manual
and Forum drawing A353-111-060.
2. Strip the orange thermoplastic outer layer to reveal a sufficient length of the copper
conductors and optical fibres for them to make one loop inside the TMS Fixed
Junction Box.
3. Feed the copper conductors and optical fibres into the Fixed Junction Box; seal the
Fixed Junction Box as shown on Forum drawings A353-152-001 and A353-152-002.
Loop the copper conductors and optical fibres around its inside and secure them with
cable ties.
1. Terminate the active and earth copper conductors ensuring that the conductor
colours are terminated as shown on drawings
o TMS Long Line Wiring Diagram T12-17 TMT-0002-4586, T24-29 0010-7660
o ROV Long Line Wiring Diagramt12-17 TMT-0002-4587, T24-29 0010-7661
o Forum drawing A353-100-109.
Caution: If there is a discrepancy between Forum and the TMT Long Line Diagrams
then the TMT drawings take precedence.
4. 16 mm2, M8 lugs or 4 mm2 M8 lugs are required to terminate the high-voltage

conductors depending on their size. The lugs are to be firstly crimped using an
insulated bootlace crimp tool and then crimped using an uninsulated lug crimp tool.
Following crimping the crimp connection is to be covered using either glue heat
shrink or a layer of suitably-coloured heat shrink underneath a layer of clear heat
shrink.
5. Terminate the single mode optical fibres with single mode ST connectors in
accordance with Nexans document number TR-01-01.
Verify that all six (6) single mode fibres have been terminated. Secure any spare
fibres by connecting them to the spare ST connectors.
6.11.7 Retermination Test Requirements

The following are the tests required after retermination:
• Bullet Load Test
The Bullet Load test is described in IMCA R011:
“Lifting wires and load bearing umbilicals which go into the water should be tested annually
by cutting back a sufficient portion of the rope immediately adjacent to the termination to
provide two samples.
Where the samples are taken for testing, the second sample should only be tested if the
first sample fails due to an unsatisfactory test procedure.
After fitting a new termination, it is recommended that a confidence pull test is carried out.
Kevlar lifting umbilicals should be reterminated at least once every 12 months.”
Only static load test (1.5x SWL) is required to be done on the bullet after re-termination.
Solid weights or water bags together with below shown adaptor need to be used for the
load test; refer to the TMT-NDP-001\Mechanical\Load Test Gear & Accessories\ 0009-
4808 TMS Type 5 Bullet Load Test Assy folder on the digital technical manual.
Figure 29: Umbilical Static Load Test Adaptor
After terminating in the TMS Umbilical Termination box:

1. Insulation / Continuity of power conductors. Ensure that umbilical is disconnected at
both ends before an insulation test is done with a Megger. Also, discharge the
conductors after a Megger test to discharge them.
Caution: Back EMF can provide a shock.
2. Terminate FO cables.
3. Terminate SM fibres. Check for loss in Decibels (dB).
Note: Record all values in the Engineering Logbook for future reference.
6.12 Soft Tether Re-Termination

available.
It is a good practice to take photos showing all the routing path of the umbilical throughout
the ROV for reference when fitting the new cable. The cable being removed can also
provide a good measurement reference for the new cable.

Table 16: Soft Tether Re-Termination - Risks and Mitigations
Risk Mitigations
Electrical:
• Refer to Section 3.1 Electrical on page 20.
• Potentially lethal voltage levels
throughout the ROV / TMS system.
• Never check the tightness of a hydraulic hose
or fitting while under pressure.
Heavy Object: • Verify that all slings and chains certification are
• Potential for crushing - smashing. valid and fit for purpose.
• Have additional personnel to assist with
placement.
hoses for damage.
• Barrier off the ROV / TMS with a 2m exclusion
• Potential for high pressure fluid release. zone for initial hydraulic testing.
• Potential for dynamic pinch points • Ensure familiarity with equipment operation,
during tool operation. review manual prior to handling.
• All relevant JSA’s and PTW to be completed, read and understood by crew.
• Tool Box Talk to be understood and sheet to be signed.
Required Documents
• TMS Long Line Wiring Diagram T12-17 TMT-0002-4586, T24-29 0010-7660
• ROV Long Line Wiring Diagram T12-17 TMT-0002-4587, T24-29 0010-7661
• ROV Tether Termination Box GA Typhoon MK2 TMT-0004-8509
• Handling / Installation Guidelines for Dynamic Cables TR-01-01
6.12.4 Tools Needed

The following tools are required to re-terminate the soft tether:
Table 17 Tools & Materials Required Soft Tether Re-Termination
Tools & Materials Required

Electrical Oil Oil soak pads
Contact Cleaner Clean Buckets
Hacksaw Large adhesive-lined Heat Shrink
Rags Heat gun
Wire Cutters Fibre optic kit
Crimp lugs to suit HV 4x ST single mode Fibre Optic connectors (hot melts)
Gloves; HV
6.12.5 Re-Terminating Soft Tether Instructions

To Re-Terminate the soft tether:
1. Under a controlled manner, the tether can be paid out through the ROV so that
separation of the TMS from the ROV should not be required.
2. Isolate the ROV and TMS, as per SWP; Lock, Tag and Try procedures and
vessel’s policy.
3. Turn off the fibre MUX for the ROV in Control cabin and place an Isolation Tag on
it.
4. Discharge the umbilical via the deck leads; refer to Section 3.1.6 Umbilical
Electrical Safety on page 25.
5. Close the compensator valves on the J-Box, Transformer and the Electric Motor;
because they share a common compensator circuit and will all drain out through
the J-Box.
6. Drain the J-Box into a suitable container, approximately 24.3 litres.
7. Using a hacksaw, cut the tether close to the gland at the J-Box.
8. Unscrew the gland on the J-Box.
Caution: Note down the correct positions, order and orientation as it is removed for
later assembling purpose. Incorrect re-installation may result in water ingress.
9. Remove the J-Box Perspex cover and the O-ring and stow safely.
Caution: Record the phase colours, terminal block positions and fibre colours, single
mode fibres. A good practice is to take a couple of photos of the wiring before
removing the wires.
Table 18: Power & Fibre Colours
Power Fibre
L1 3000V HPU – Orange Fibre 1 – Orange /lines
L2 3000V HPU – White Fibre 2 – White/lines
L3 3000V HPU – Blue Fibre 3 – Blue /lines (Capped spare)
L1 1500V EL – Red Fibre 4 – Yellow/lines (Capped spare)
L2 1500V EL – Green
10. Disconnect the phases and the fibre optic connections.

11. Remove the fasteners retaining the umbilical to the ROV. There are two (2) Stauff
clamps and one (1) shackle fixing the Kellems grip to the ROV lifting pad eye.
Note: It should not be necessary to remove the smaller moused shackle that is looped
through the Kellems grip eyelets.
12. Pay out on the TMS and pull the tether down through the Tether J-Box until the
damaged section is clear and able to be cut and removed.
Continue paying out until enough length is available to re-terminate. If possible,
bring end into a covered area, i.e. the workshop.
13. Inspect the Kellems Grip to ensure it is still serviceable. If so, slide it back up the
tether towards the ROV above where the damaged section will be cut; refer to
measurement map, Figure 30 on page 93.
Kellems Grip
14. Using a hacksaw, cut the tether at the desired re-termination position.
15. Referring to the measurement map in Figure 30, strip the yellow armour from the
tether, cut the Kevlar bradding underneath it. Wipe the orange insulated layer
clean.
16. Apply the adhesive-lined heat shrink, approximately a 200mm length over the
stripped interface between the yellow armour and orange insulation.
17. Apply double sided tape to the tether along the region where the Kellems grip is to
be retained.
18. Reinstall the Kellems grip now, if it has been removed, and reinstall the gland
back onto the umbilical. Fasten the open end of the Kellems grip firmly with hose-
clamps and tape.
19. Strip the orange insulation close to the gland, according to the measurement map.
Allow enough conductor to make one full loop of the Tether Termination Box.
Figure 30: Kellems Grip Fitted
20. Strip the copper foil shield and wipe all debris clean so that it will not contaminate
the J-Box.
21. Extract the fibre tube from the conductor bundle and terminate the fibres
according to procedure.
22. Pull back the tether to the correct position for termination. Hand tighten the gland.
23. Install the stripped and cleaned umbilical in the J-box and secure the gland.
24. Terminate the active copper conductors ensuring that the conductor colours are
terminated as shown on drawings.
6 mm2, M8 lugs or 2.5 mm2 M8 lugs are required to terminate the high-voltage
conductors depending on their size. The lugs are to be firstly crimped using an
insulated bootlace crimp tool and then crimped using an uninsulated lug crimp
tool. Following crimping the crimp connection is to be covered using either glue
heat shrink or a layer of suitably-coloured heat shrink underneath a layer of clear
heat shrink.
Note: The MV wires are coloured, photo was from a workshop setup.
25. The quad conductors are to be terminated using crimped 0.75 mm2 bootlace
ferrules. These are terminated at the earth terminals of the
Tether Termination Box, as shown on:
o TMS Long Line Wiring Diagram T12-17 TMT-0002-4586, T24-29 0010-7660
o ROV Long Line Wiring Diagramt12-17 TMT-0002-4587, T24-29 0010-7661.
o ROV Tether Termination Box GA Typhoon MK2TMT-0004-8509
26. The earth conductors are to be joined together with a single lug and terminated at
the earthing stud in the Tether Termination Box.
27. Cut the stainless steel tubes and terminate the single mode optical fibres with
single mode ST connectors in accordance with Nexans document number
TR-01-01. Confirm that all six single mode fibres have been terminated. Secure
any spare fibres by connecting them to spare ST connectors.
28. Fully tighten the tether gland seal.

Caution: Do not over-tighten the gland; it only needs to be secure against the
compensator pressure.
29. Clean and fit the J-Box O-ring and the Perspex cover.
The Tether Termination Box bolts have to be fitted with a torque of 17Nm.
30. Fill the Tether Termination Box with compensation oil and bleed any air bubbles.
31. Pay in on the TMS if required and re-affix the Kellems grip to the mounting point
inside the ROV.
32. Pay in on the TMS to take tension on the Kellems grip, and then reinstall the
Stauff clamps on the tether, allowing for some slack between where the Kellems
will take the load prior to the first Stauff clamp.
33. De-isolate the ROV and perform the ROV Pre-dive checks.
34. If the system is OK, shut down and fill the J-Box with oil and vent the box,
transformer and electric motor.
35. Verify that the compensator valves to all three (3) enclosures are re-opened.
Note: Torque requirements are contained within Table 5 on page 37.
36. Measure the offcut length of the severed tether and update the Engineering
logbook to keep an accurate record of the length.
6.1 General Subsurface Maintenance Requirements

6.1.1 Visual Checks
Ensure that there is no pressure on the hydraulic system and ensure that the deck ROV
earth clamp is connected to the ROV frame prior to starting inspections.
For visual checks verify all cables, hoses for damage, cracks or deformation. Check for lose
cables, hoses, ropes and rags that could be sucked into the thrusters.
Verify that all the thrusters are not obstructed and that they are tight and spinning freely.
Where seals and / or gaskets are installed, these should be examined and repaired or
replaced as necessary.
6.1.2 Cleaning Requirements
Warning: Always assume equipment is energised unless proven otherwise.

With electrical system de-energised and grounded, clean all surfaces with fresh water.
Table 19 outlines the basic periodic maintenance for the Subsurface Electrical Systems:
Table 19: Subsurface Electrical Systems Maintenance
ROV
Pre-dive and Clean and check lenses. Verify camera lens caps are in
Cameras & Lights
Post-Dive place after the dive. Check cameras for moisture.
Ground Bonding Clamp, ROV Resistance of the ground bonding clamp to the main earth
Weekly
& TMS bar is less than 1 Ohm.
Clean all surfaces with fresh water.
Pre and
All housings should be checked regularly for signs of
ROV Electrical Housing & Post-Dive
damage.
Connections
All connections on the subsea housings should be checked
Monthly
regularly for fouling, bent pins or signs of damage.
Emergency Location Devices Monthly Verify operation.
Check all electrical connectors for (hand) tightness. Clean
All Electrical Connectors Monthly
and lubricate all connectors, as per Section 6.1 on page 57.
Check condition/security of Kellums Grip.
Kellums Grip Monthly
Note: This will require the ROV / TMS system to be split.
All Electrical Connectors Quarterly Remove and clean all cable connectors and pins.
Emergency Location Devices Quarterly Replace batteries in flasher unit.

Vacuum test the MEE seals & the entire enclosure.
MEE Biannual
Replace desiccant Silica Gel bags.
TOGSNAV Annual AHRS calibration check as per OEM manual.
MV Terminals Annual Check the MV terminals for torque in oil filled J-Box’s.
Umbilical & Tether
Weekly or Visually inspect all for damage, cracks, corrosion or

Post-Dive deformation.
Umbilical & Tether
Post-Dive Wash down with fresh water if available.
Annual Umbilical should be reterminated.
Hydraulic System
7. Hydraulic System
7.1 General Hydraulic Maintenance
The Hydraulic System is designed to be reliable and easy to maintain:
• All hydraulic fittings are made of stainless steel.
• All manifolds are aluminium.
Hydraulic systems operate at high pressures and close tolerance, so smooth operation is
dependent on the correct operation and maintenance.
Periodic oil and oil filter changes are detailed in Table 32 or in the event of water ingress,
into the hydraulic system.
Caution: Keep the system clean and change the oil and oil filters at established
intervals.
Warning: Prior to undertaking any work on the hydraulic power, ensure that the
pressure to the system has been released. Whenever disconnecting any
hydraulic hoses or pipes eye protection must be worn.
For additional technical information; refer to the TMT Manuals\ROV Technical Manual
folder on the digital technical manual.
7.1.1 HPU Surface Operation

The pump and motor will quickly heat up if run on-deck (dry). To test functions, the HPU
may be run briefly, three (3) minutes or less or until the pump or motor becomes
uncomfortable to touch with the palm of the hand (120°F / 50°C), whichever occurs first.
Caution: Do not use the ROV HPU to power other hydraulic devices and tools if the
Charge Cart is available.
For detailed information on surface operation; refer to the TMT Manuals\System
Operation Manual located on the digital technical manual.
Hydraulic System
7.2 Hydraulic Oil

The Typhoon ROV and TMS use Shell Tellus S2 M 22 for both the Hydraulic and
Compensation system. Tellus is a high performance hydraulic fluid that resists breakdown
under heat and mechanical stress.
Table 20: Hydraulic Oil Properties
Properties Value
ISO Viscosity Grade 22
ISO Fluid Type HM
Kinematic Viscosity @:
0ºC 180
40ºC 22
100ºC 4.3
Viscosity Index 100
Density 0.866kg/l
Flash Point 210ºC
Pour Point -30ºC
Note: For shallow water operations in warmer climates, use of Shell Tellus S2 M 32 may
be considered.
For a detailed specification sheet and a safety data sheet; refer to the OEM
Manuals\Hydraulics\Oil folder on the digital technical manual.
7.2.1 Hydraulic Oil Change

Changing the hydraulic oil in excess of the recommended schedule can be
counterproductive.
Water and particulates can be present in storage drums and tanks before receipt. Storage
drums are commonly stored outside in the open. If not properly stored on their side water
will settle on the top and can enter the drum during the filling process along with rust and
other potentially damaging contaminants. As ambient temperatures rise and then fall,
moisture can be drawn into the barrel via the original barrel seal.
New oil should be filtered before being introduced into the ROV hydraulic system.
Note: The initial tank level on deck should be 90%, leaving 10% of tank volume for oil
expansion due to oil temperature increment in the hydraulic system.
Caution: Never mix different hydraulic oil types.
Note: The Charge Cart can be used to filter new oil.
Contamination is classified in three basic forms:
• Air
• Particulate
• Water
Particulate is generally classified as “Silt” or “Chip”. Silt is defined as an accumulation over
time of particulates measuring less than five (5) microns.
Hydraulic System
The effect of silt contamination is a slow degradation of system component performance

and failure. Chips (measuring more than five (5) microns) have a more dramatic effect and
can cause immediate, catastrophic, unplanned and costly failures.
Hydraulic oils can only absorb approximately 0.1% of water. Additional water will form an
emulsion, which is indicated by a change to a milky colour. It is around this point that free
water will exist, i.e. the water the oil cannot absorb anymore; refer to Section 7.11 on 120.
Air, when in a liquid system, can exist in either a dissolved (Entrained) or un-dissolved
(Free) state. Dissolved air is generally not a problem while in solution. Free air problems
can occur as it passes through system components. Pressure changes that compress the
air produce large amounts of heat in small air bubbles. This compressibility can result in
loss of system control and system responses become delayed. Also, loss of fluid between
two moving surfaces leads to higher wear of components.
Note: Where there is air there is no oil.
7.3 HPU Components

The Hydraulic Power Unit (HPU) is the main driving component of hydraulic systems.
Comprising an electric motor, two reservoirs and two hydraulic pumps, these units generate
the power to drive the hydraulic system.
Note: Always top up the HPU systems using the same type of oil in the hydraulic system.
Caution: All hydraulic lines must be plugged and connectors capped as disconnected.
Verify that all connects are securely labeled to assist in re-assembly.
7.4 General Guidelines

The following are general guidelines for the Hydraulic System:
• After breaking a connection, cap the connector and plug the line.
• After testing, double check all connections for proper tightness.
• Clean, as required, to eliminate surface contaminants.
• Flush and refill, if any sign of water or debris is present.
• Inspect seals and sealing surfaces of connectors and hydraulic lines.
• Perform hydraulic maintenance, as required.
• Regularly inspect all components for damage and corrosion. Repair immediately.
• Take oil samples from all parts of the system weekly.
• Wipe connection and surrounding area using a degreaser such as Rigwash to clean
the area from any residue of oil.
Note: Cabling assemblies are generally covered in spiral wrap as a proven way to protect
the Hose, Wire, Cable, etc. against chaffing, rubbing, crushing, ultraviolet and other
surface and subsea environmental hazards that cause premature failure. Always
replace any spiral wrap that is removed.
Hydraulic System
If hose or cables rub the edges of the frame, wrap it with a piece of rubber (tied
with cable ties) near to protect against the rubbing.
7.5 Hydraulic Hoses

The Hydraulic Hose Register provides a list of all the hydraulic hoses used on the Typhoon
ROV.
Information included is:
• Hose identification number
• Hose specification
• Hose label
• End types
• Hose working pressure
• Nominal bore size
• Hose length
• Angle
Figure 31: Example of Hydraulic Hose Register Information
To view the Hydraulic Hose Register; refer to the TMT-NDP-001\Mechanical\Hydraulic

System\Hydraulic Hose Register TMT-0009-2024 located on the digital technical manual.
Hydraulic System
7.6 Manipulators
Typhoon can support up to three (3) manipulators on Z Function mounts. The default
manipulator options are:
• Schilling Atlas, 7-function, rate controlled
• Schilling Conan, 7-function, position controlled, Master / Slave
• TMT Z-Function, 2-function, rate controlled
Optional manipulators include:
• Titan
• RigMaster
For OEM information including installation, configuration operation and troubleshooting
details; refer to OEM Manuals\Manipulators folder on the digital technical manual.
7.6.1 Avoiding Manipulator Damage

All the manipulators are all designed with safety factors well in excess of rated capacities.
However, situations can occur in operation where safety factors may be exceeded, placing
the manipulator and the surrounding equipment / personnel at risk. These situations mostly
involve collisions and include:
• Collisions while manipulating extreme loads.
• Collisions and / or extreme loads while at or near the manipulator mechanical limits.
Caution: Avoid damage by anticipating risky situations and plan manipulator use to
avoid or minimise them.
Warning: Use extreme caution when testing a manipulator on deck.

Move all personnel outside the manipulators’ range of motion when hydraulic
pressure is applied and functions are tested.
Direct the manipulator to point away from personnel and critical or sensitive
areas while testing jaw functions.
Hydraulic System
7.6.2 General Maintenance Requirements

General maintenance requirements are listed in Table 21. For detailed OEM maintenance
information; refer to OEM Manuals\Manipulators folder on the digital technical manual.
Note: Periodic checks also include the previous periodic checks, i.e. weekly and includes
daily / after use etc.
Table 21: General Manipulator Maintenance
Period Action
Visual check for oil leaks, kinking or abrasion and any loose or missing
Pre-Dive
fasteners. Function check.
Check for loose or missing fasteners.
Check the hoses for evidence of kinking or abrasion.
Check the hose fittings for leaks.
Post-Dive Check actuator rods for damage and check actuators for signs of
hydraulic leaks.
Thoroughly wash the exterior of the manipulator with fresh water.
Remove any entrapped debris. Function check
1
Check the anodes and replace when / 3 or less remains.
Push on the arm and check for excessive free play which may indicate
Weekly worn bearings or pins.
Torque all external fasteners to specified values. Refer to OEM manual.
Check the jaw actuation bearings and the T-bar plate for damage.
Check all hydraulic fittings for tightness.
Monthly Checks Remove external fasteners individually, re-apply anti-seize and torque to
specified values.
Replace all arm segment bushings.
Every 6 Months Inspect the pivot pins for wear. Replace if wear is significant.
Replace the jaw actuation bearings.
Seals and bearings in all linear actuators.
Seals and bearings in jaw actuator.
Replace Every 2 years Wrist roller bearings, seals, bushings, and O-rings.
Wrist Gerotor.
Hydraulic hoses.
Hydraulic System
7.7 Hydraulic Filter Replacement – Norman Filters

available.
Warning: The Hydrulic System can contain high pressure.

Verify that the system is depressurised before connecting / disconnecting the
filter assemblies.
Table 22: Hydraulic System Norman Filters
Main Hydraulic System Filters

Pressure Filter x 2 Norman Filter Company.
Filter part number 4588AF-B5CN-DR2-S2
Element number 588F-B5CN
Return Filter x 2 Norman filter Company
Filter part number 4588AF-B10AN-R-DR2-S2
Element number 588F-B10AN
Case Drain Filter x1 Norman Filter Company.
Filter part number 4526NAA-10RN-R-DR2-S2
Element number 536A-10RN
Auxiliary Hydraulic System Filters
Pressure Filter, x1 Norman Filter Company
Filter part number 4537AF-B5CN-DR2-S2
Element number 586F-B5CN
Return Filter, x1 Norman Filter Company
Filter part number 4537AF -B10AN-R-DR2-S2
Element number 586F-B10AN
Case Drain Filter, x1 Norman Filter Company
Filter part number 4526NAA-10RN-R-DR2-S2
Element number 536A-10RN
The main case drain filter elements must be replaced:

• After 250 hours of service.
Or
• If differential pressure across the filter reaches 29psi.
Or
• Were a mechanical failure occurred that could affect the hydraulic oil condition.
Note: The filters differential pressure should be checked weekly.
Caution: The differential pressure should be checked after a dive that a mechanical
failure that may affect the oil condition i.e. water contamination.
Detailed instructions are covered in detail in the OEM manual; refer to the OEM
Manuals\Hydraulics\Filters folder on the digital technical manual.
Hydraulic System
O-rings
Filter Bowel
Minimess
Connector
Vent Plug
Filter
Element Head
Figure 32: Hydraulic Filter

Table 23: Hydraulic Filter Replacement (Norman) - Risks and Mitigations
Risk Mitigations
hoses for damage.
• Ensure that correct PPE is worn as dictated by
o Gloves
7.7.2 Prerequisites
• Tool Box Talk understood and sheet to be signed.
Required Documents
Refer to the following drawings as an overview located in TMT-NDP-001\Hydraulic folder on
the digital technical manual:
• Hydraulic schematic, TMT-0009-2216
Required Tools
• Caution Tags
Hydraulic System
• General Tools
• Isolation Permit
• Spanner - 38mm (11/ 2 ”) AF
7.7.5 Filter Housing Disassembly

1. Isolate the ROV and the TMS as per SWP and Lock, Tag and Try procedures and the
vessel’s policy.
2. Be sure to follow all safety rules, such as wearing protective goggles and gloves.
Caution: When service clamps are locked on the hydraulic tanks, the ROV HPU must
be locked out and the Caution tag placed on the Pilot Control Console.
This will prevent accidental start up during maintenance and prevent possible
damage to the hydraulic pumps if they were inadvertently left clamped.
3. Lock the service clamps on the Aux or Main Hydraulic Tank; refer to Figure 34 (Main
Tank) or Figure 35 (Aux).
4. Use a 38mm (11/ 2 ”) AF spanner to engage hex nut on bowl and turn off in ACW
direction.
5. Pull element off the mandrel, exercising caution when removing the element to prevent
damage to pleated media, and remove the O-ring from the element.
6. Remove the O-ring that is engaged in the head that seals the head and bowl.
7.7.6 Cleaning Filter Housing Bowl

1. Assess thread and seal areas for physical damage, inspecting the full areas. The
threads should look smooth with no denting or galled areas and the seal area should
have no scratches or dents. If there is any physical damage to either area, the bowl
should be replaced.
2. Clean, using mild soap and water as the cleaning agent and a fine bristle brush, move
the brush in an ACW direction from the seal area to the end of the thread run. This is
repeated until all lubricants and fluids that entrap debris to the thread and seal area
surfaces are removed. With a clean air source, blow off any debris.
3. Re-inspect the threaded and seal areas again, as above, this time looking for debris as
well.
If the inspection identifies debris in the threaded area, repeat the cleaning as advised
above.
7.7.7 Filter Housing Head

1. Remove the seal rings from the O-ring groove and assess the threads and the O-ring
grooves for physical damage, inspecting the full areas. The threads should look smooth
Hydraulic System
with no denting or galled areas and the seal area should have no scratches or dents. If
there is any physical damage to either area, the head should be replaced.
2. Clean using mild soap and water as the cleaning agent and using a fine bristle brush,
move the brush in an ACW direction from the thread endpoint to the seal groove. The
seal groove should be brushed to clear debris.
3. The seal ring material might require scraping with a plastic scraper.
Caution: Do not use a metal scraper.
4. Repeat until all lubricants and fluids that entrap debris to the thread and the seal area
surfaces are removed. With a clean air source, blow off any debris.
5. Re-inspect the threaded and the seal areas again, as above, this time looking for debris
as well. If the inspection identifies debris in the threaded area, repeat the above
cleaning procedure.
7.7.8 Ring Seal Installation

Caution: New Ring Seals are required anytime a bowl is removed.
The installation of the Ring Seals is critical to the filter housing performance. Only use seals
provided by Norman Filter Company for this filter housing.
Note: Seals may appear to be identical and may have measurements that appear to be
the same. That does not necessarily make them the same.
7.7.9 Filter Housing Components

Installation of the O-ring into the O-ring groove in the filter housing head, is accomplished
by setting one ring seal inner edge into the ring seal groove and progressively rolling the
rest of the ring seal into the groove by sliding your thumb along the surface of the seal,
coaching the seal into the groove. The coaching of the seal into the groove should be done
in either the CW or ACW direction, not both simultaneously. Do not allow any debris to
accumulate on the thread, the seal groove or the seals during the seal installation process.
7.7.10 Disposable Elements

1. Pull the element off mandrel.
2. Lubricate the O-ring in the new element with hydraulic oil..
3. Slip the element over the mandrel.
Note: Teflon™ (M) O-rings are difficult to engage.
7.7.11 Cleanable Elements

Note: The Typhoon comes equipped with disposable filter hydraulic elements. These can
be replaced with cleanable elements.
1. Pull the element off the mandrel, exercising caution when removing the element to
prevent damage to the pleated media.
2. Remove rough external dirt in a separate container with cleaning fluid.
Hydraulic System
3. Soak the filter for thirty minutes in a high quality cleaning fluid.
4. Following the soak, blow through the element from inside to outside with clean
compressed air or similar clean gas.
Note: Do not exceed 150psi (10bar).
5. Lubricate the new O-ring with hydraulic oil and install it into the element seal gland.
6. Slip the element over the mandrel. Teflon™ (M) O-rings are difficult to engage.
7.7.12 Assembly of Filter Housing Head & Bowl
1. Lubricate the element O-ring and the housing seals with hydraulic oil.
2. Lubricate the stainless steel thread with Halocarbon 32 Grease only. Do not use
silicone lubricants on stainless steel threads. Special care must be taken not to mix the
applicators used for silicone & Halocarbon 32 lubricants. The mixed silicone lubricants
can damage the stainless steel threads.
3. Where EPR (E) seals are used, lubricate only the seal with the silicone. If the housing is
aluminium, lubricate the seal and thread with silicone. If the housing is stainless steel,
install the seal to the head seal groove. Lubricate the seal by taking silicone lubricant
and rubbing the lubricant on all surfaces of the seal.
4. Inspect the greased surfaces for bristle fragments and debris. Remove any foreign
objects.
5. After lubrication, insert the filter housing bowl into the filter housing head. Fill the
housing bowel with new oil. When contact of the thread surfaces is made, push the two
parts together and turn ACW until you feel the parts suddenly move closer together.
This is when the entrance threads for each part are ready to engage.
6. Now turn CW until the seats meet the head seal surface; this is distinguished by the
bowl being difficult to turn CW. Use a 38mm (11/ 2 ”) spanner to engage the hex nut on
the bottom of the bowl and torque to 47.5Nm (35ft.lbs).
7. Unlock the service clamps on the Aux or Main Hydraulic Tank; refer to Figure 34 (Main
Tank) or Figure 35 (Aux).
8. Clear Caution tag.
Note: When Teflon™ O-ring is used, the torque will be 122Nm (90ft.lbs). When
tightening, stop every 1/ 4 turn for 15-20 seconds to allow the Teflon™ to form to its
new shape.
7.7.13 Filter Disposal

Caution: Used cartridges should be disposed of in accordance with local regulations.
Hydraulic System
7.8 Hydraulic Filter Replacement – Cardev Filter

available.
Warning: The Hydrulic System can contain high pressure.

Verify that the system is depressurised before connecting / disconnecting the
filter assemblies. Follow LTT procedure to isolate the HPU circuit breaker.
Good practice is to momentarly run a function, such as thrusters to bleed any
possible pressure entrapped in the Pressure lines (P).
Caution: As there is no accurate method to determine the filter’s remaining water
absorbing capacity, it is recommended that the filter be changed after every
200 hours of ROV HPU operation or when the pressure across the filter
gauge reads 5bar, whatever occurs first.
The Cardev Super Duty Filter Cartridge is a depth cartridge made of long fibre cellulose
with a full diameter polyester protection disc. The filter is covered with nylon and encased in
an outer tube, which forms an integral part of the cartridge.
Table 24: Cardev System Filters
Cardev Filter
Part number SDUH350-UW
Element type SDFC
Detailed instructions are covered in detail in the OEM manual; refer to the OEM
Manuals\Hydraulics\Filters folder on the digital technical manual.
Filter
Element
Figure 33: Cardev Hydraulic Filter
Hydraulic System

Table 25: Hydraulic Filter Replacement (Cardev) - Risks and Mitigations
Risk Mitigations
hoses for damage.
• Using the service clamps, lock the Hydraulic
• Potential for low pressure oil leaks when Oil Tank. (Place Warning Tag on the Pilot
opening filter housing. Oil will return Console to remind of clamping).
from Hydraulic Oil Tank. • Disconnect the tank return hose (T7) and
quickly cap it.
o Gloves
7.8.2 Prerequisites
• Tool Box Talk understood and sheet to be signed.
Required Documents
Required Tools
• Caution Tags
• General Tools
• Spanner - 27mm (11/ 16 ”) AF
Hydraulic System
• Torque wrench in calibration (50Nm)
7.8.5 Filter Housing Disassembly

2. Follow all safety rules, such as wearing protective goggles and gloves.
3. Lock the service clamps on the Aux or the Main Hydraulic Tank.
4. Isolate the filter by closing the isolation needle valve on the pressure (P7) line.
Isolation Valve
Viewed from the bottom of ROV
5. Disconnect the hose H6 (Tank – T7) from the filter and quickly cap the connector.
6. Use a spanner - 27mm (11/ 16 ”) AF to engage hex nut on lid and turn off in ACW
direction.
7. Pull the element off the mandrel, exercising caution when removing the element to
prevent damage to the media, and remove the O-ring from element.
8. Remove and inspect the O-ring that is engaged in the head that seals head and
body.
7.8.6 Filter Housing Assembly

1. Follow all safety rules, such as wearing protective goggles and gloves.
2. Inspect and install the O-ring that seals head and body.
3. Use a spanner - 27mm (11/ 16 ”) AF to engage hex nut on lid and turn in CW direction.
Caution: The maximum torque applied on SDUBN bolt is 50Nm (37ft/Lbs.); exceeding
this figure, can damage the filter housing.
4. Use a calibrated torque wrench to tighten to 50Nm SDUBN the bolt of the lid.
5. Reconnect the tank hose T7 (H6).
6. Fully open the isolation needle valve; refer to Section 7.8.5 Step 4.
7. Unlock the service clamps on the Aux or Main Hydraulic Tank; refer to Figure 34
(Main Tank) or Figure 35 (Aux).
Hydraulic System
8. Clear the Caution tag.
7.8.7 Filter Disposal

Used cartridges should be disposed of in accordance with local regulations.
The cartridges are made from fully combustible materials.
Hydraulic System
7.9 Draining, Filling and Venting the Main Hydraulic System

available.
Caution: Never run the HPU if the Main Hydraulic Tank is empty. Follow LTT
procedure to isolate the ROV HPU circuit breaker.
When performing maintenance on the Main Hydraulic system connected to the tank, for
example, the Cardev filter or HPU main pump, service clamps are provided to lock the tank
upper plate to the high level position. Otherwise, spring tension will force the hydraulic oil
out. There is one service clamp per guide post, three (3) on the Main Tank; refer to Figure
34.
Note: The initial Main Hydraulic Tank level on deck should be 90%, leaving 10% of tank
volume for oil expansion due to oil temperature increment in the hydraulic system.
7.9.1 Draining the Main Hydraulic System Instructions

Relief
Valve
Service Clamp
Level Sensor
Fill / Drain
Point
Figure 34: Main Hydraulic Tank
Hydraulic System
To drain the Main Hydraulic System:

2. Verify that the HPU is de-energized. Follow LTT procedure to isolate the HPU circuit
breaker. Check the Main HPU pressure gauge. Good practice is to run some
function, such as thrusters to bleed any possible pressure entrapped in the Pressure
lines (P).
3. Lock the Main Hydraulic Tank with the service clamps.
4. Connect a drain hose onto the 1/ 2 ” Quick-Connect on the main hydraulic reservoir,
ensuring that the free end is placed into a suitable container. The tank will
commence draining as soon as the connection is made.
Note: The total Main Hydraulic system volume is approximately 75 litres.
5. When the tank is completely drained, lift the relief valve on the main hydraulic
reservoir to allow air to enter the reservoir.
6. Continue draining and bleeding air into the tank until the required level is reached or
the main hydraulic reservoir is empty. Remove the drain connection and allow the
relief valve to close.
Note: Some oil will remain in all the vehicle hoses and pipes even after the reservoir has
been drained.
7.9.2 Dry-Testing the Main Hydraulic System Instructions

If the compensation system fittings or the components have been opened or replaced, you
may want to dry-test the compensation system for leaks before filling it with fluid.
Two test methods are outlined below:
1. Fill the compensation system with air to one atmosphere, 15psi (1.0bar). Spray all
connections and compensated components with a mild detergent or window cleaner
to check for leaks. Active bubbles or foam denote a leak.
Or, when some connections are not accessible:
2. Install a pressure gauge on the compensation system. Fill the system with air to one
atmosphere approximately 15psi (1.0bar). Allow the air pressure to stabilize and
monitor the pressure gauge over a period of at least two hours. If any pressure drop
occurs, check for leaks using the method described in step 1, above.
Hydraulic System
7.9.3 Filling and Venting the Main Hydraulic System Instructions

To fill and vent the Main Hydraulic System:
1. Connect a deck power pack by its discharge hose to the ½” Quick-Connect coupling
on the main hydraulic tank.
2. Operate the deck power pack at 50psi (3.45bar) to pump oil into the reservoir.
3. Lift the relief valve on the reservoir to bleed air out of the system. Release / close
when oil emerges from the valve.
4. Observe the rise in the reservoir level and monitor the deck power pack oil level.
Fill as required. Do not allow it to run dry.
5. Fill the reservoir until 100% full.
6. When the desired level is reached, switch Off the deck power pack and remove the
quick-connect coupling and vent the main hydraulic system.
Hydraulic System
7.10 Draining, Filling and Venting the Aux Hydraulic System

Note: Before commencing fully read, understand all steps, have all parts and tools
available.
Caution: Never run the ROV HPU if the Aux Hydraulic Tank is empty. Follow LTT
procedure to isolate the HPU circuit breaker. Check the Main HPU pressure
gauge. Good practice is to run some function, such as thrusters to bleed any
possible pressure entrapped in the Pressure lines (P).
When performing maintenance on the Aux Hydraulic System connected to the tank, for
example, the Cardev filter or HPU Aux pump, service clamps are provided to lock the tank
upper plate, to the high level position. Otherwise spring tension will force the hydraulic oil
out. There is one service clamp per guide post, four (4) on the Aux reservoir tank; refer to
Figure 35.
Note: The initial Aux Hydraulic Tank level on deck should be 90%, leaving 10% of tank
volume for oil expansion due to oil temperature increment in the hydraulic system.
be locked out and Caution tag placed on Pilot Control Console.
Relief
Valve
Level Sensor
Service Clamp
Fill / Drain
Point
Figure 35: Aux Hydraulic Tank
Hydraulic System
7.10.1 Draining the Aux Hydraulic System Instructions

To drain the Aux Hydraulic System:
2. Verify the HPU is de-energized and the umbilical isolated. As per Caution above.
3. Lock the Aux Hydraulic Tank with the service clamps.
4. Connect a drain hose onto the 1/ 2 ” Quick-Connect on the Aux hydraulic tank,
ensuring that the free end is placed into a suitable container. The tank will
commence draining as soon as the connection is made.
Note: The total Aux Hydraulic system volume is approximately 20 litres.
5. When the tank is completely flat, lift the relief valve on the cover to allow air to enter
the reservoir.
6. Continue draining and bleeding air into the tank until the required level is reached or
the reservoir is empty. Remove the drain connection and allow the relief valve to
close.
Note: Some oil will remain in all the vehicle hoses and pipes even after the reservoir has
been drained.
7.10.2 Dry-Testing the Aux Hydraulics System Instructions

If compensation system fittings or components have been opened or replaced, you may
want to dry-test the compensation system for leaks before filling it with fluid.
Caution: Take care in regulating the air supply to ensure no damage to equipment.
1. Fill the compensation system with air to one atmosphere approximately 15psi
(1.0bar). Spray all connections and compensated components with a mild detergent
or window cleaner to check for leaks. Active bubbles or foam denote a leak.
2. Install a pressure gauge on the compensation system. Fill the system with air to one
atmosphere approximately 15psi (1.0bar). Allow the air pressure to stabilize and
monitor the pressure gauge over a period of at least two hours. If any pressure drop
occurs, check for leaks using the method described in step 1, above.
7.10.3 Filling and Venting the Aux Hydraulic System

To fill and vent the main hydraulic system:
1. Connect a deck power pack by its discharge hose to the ½” Quick-Connect coupling
on the main hydraulic tank.
2. Operate the deck power pack at 50psi (3.45bar) to pump oil into the reservoir.
Hydraulic System
3. Lift the relief valve on the reservoir to bleed air out of it. Release when oil emerges
from the valve.
4. Observe the rise in the reservoir level and monitor the deck power pack oil level.
Fill as required. Do not allow it to run dry.
5. Fill the reservoir until 50mm below full.
6. When the desired level is reached, switch off the deck power pack and remove the
quick-connect coupling and vent the main hydraulic system.
Hydraulic System
7.11 Sea Water Contamination of the Hydraulic System

Severe damage to the Hydraulic System components can result from operating the system
with even a small amount of saltwater contamination. Aside from the loss of the lubricating
properties of the oil, the presence of water in the system leads to the formation of
particulate that could affect the proportional valve performance.
Due to fluid velocities and the emulsifying properties of the oil, a very small amount of
seawater (about 0.1%) will contaminate the entire system.
The oil takes on a milky-looking appearance and the system must be thoroughly flushed;
refer to see Figure 36.
Water
Hydraulic Fluid Contaminated

Figure 36: Hydraulic Fluid Contaminated with Water
7.11.1 Removing Water from the Hydraulic System

The best way to remove water from the Hydraulic System is to prevent water from ever
getting into it. Once seawater is introduced into the system, the recovery method is
dependent on time available and the urgency of the situation.
available.
If time is available and the situation is of a low urgency:
1. Locate the leak; the means of the water ingress.
2. Drain all hydraulic fluid as per Section 7.9.1; Draining the Main Hydraulic System
Instructions on page 114.
3. Repair the leak.
4. Replace all of the main hydraulic filters.
5. Refill with fresh hydraulic fluid, as per Section 7.9.3 Filling and Venting the Main
Hydraulic System Instructions on page 116.
6. Run the HPU for three (3) minute intervals for approximately a total of ten (10)
minutes, monitoring the HPU temperatures.
7. Leave for 12hrs (overnight) to allow any remaining water to separate out.
Hydraulic System
8. Drain a sample of oil on the check points, such as under the Tank, under the Pump,
under the motor, etc. Drain until no more water comes out.
9. Inspect hydraulic fluid for the presence of water. If there is any water present, repeat
steps 4 to 6.
If time is short and the situation is of a high urgency:
1. Locate the leak; the means of the water ingress.
2. Drain all hydraulic fluid as per Section 7.9.1; Draining the Main Hydraulic System
3. Repair the leak.
4. Replace all of the main hydraulic filters.
5. Refill with fresh hydraulic fluid as per Section 7.9.3 Filling and Venting the Main
Hydraulic System Instructions on page 116.
6. Run the HPU for three (3) minute intervals for approximately a total of ten (10)
minutes, monitoring the HPU temperatures.
7. Drain and replace all of the hydraulic fluid.
8. Inspect the hydraulic fluid for the presence of water. If there is any water present,
repeat steps 4 to 6.
Hydraulic System
7.12 Suspected Solid Particle Contamination of the Hydraulic

System
While introduced seawater is the most common cause of contamination, solid particles can
also contaminate the hydraulic system. Solid particles can be introduced i.e. new hydraulic
fluid or created i.e. corrosion or wear products from equipment within the hydraulic system.
Solid particles contamination causes damage according to their size. High concentrations of
small particles form silt which erodes the interior mating surfaces of valves, rendering them
inoperable. Contaminating solid particles that are equal in size to the clearance between
two moving surfaces can cause both jamming and wear.
Cycling the valve may clear this contamination, but often clearance can only be achieved by
disassembly and flushing the system.
Larger contaminating particles block ports and orifices, and can cause transient malfunction
when trapped by a mechanism moving from one position to the next. For example, a
particle trapped between a poppet and its seat prevents the closing of a relief valve.
In the event of suspected contamination of the Hydraulic System with solid particles the
following actions are recommended:
1. Remove case drain loop tubes and manifolds.
2. Drain the hydraulic oil as per Section 7.9.1; Draining the Main Hydraulic System
3. Check the oil for any contamination.
4. Clean out the hydraulic lines with a foam pellet (PIG) system i.e. Pneumatic
Systems International tool etc.
PIG
5. Remove the A and B lines going to the thrusters at the joiners.
Hydraulic System
6. Cap the two lines at the thruster and connect a loop hose to the two lines from the
thruster manifold.
A Port
B Port
Case Thruster
mounting
Drain
bolts x4
Motor
Compensator
Case
Drain
Motor
Comp
7. Remove both the pressure and return filter elements from the main hydraulic
system.
8. Check the filter elements for any contamination, replace as necessary.
9. Check the Hydraulic Deck Pack Pressure and Return filters before carrying out
any flushing and replace as necessary.
10. Connect the Hydraulic Deck Pack to the main system to carry out the flushing.
11. Energise the valve for the thruster that is looped and run for 15 minutes.
12. Check the return filter of the deck pack for any contamination, replace as
necessary.
13. Carry out this procedure to all the thrusters.
14. If possible, connect each thruster to the deck pack DCV and run for 10 minutes
checking the return filter element after each thruster had been run.
Hydraulic System
15. When satisfied that the contamination has been removed, refill with fresh hydraulic
fluid, as per Section 7.9.3 Filling and Venting the Main Hydraulic System
Hydraulic System
7.13 Thrusters - sub-Atlantic

The Typhoon propulsion system is comprised of eight thrusters:
• Vertical Thrusters: Four (4) sub-Atlantic SA-300
• Horizontal Thrusters: Four (4) sub-Atlantic SA-380
The horizontal thrusters have a larger propeller with a diameter of 30cm (15.1”), while the
smaller vertical thrusters have a diameter of 20cm (11.8”).
Note: Other than size, there is no apparent difference between the two sub-Atlantic
thrusters; however, they are not interchangeable.

Table 26: Thruster Replacement - Risks and Mitigations
Risk Mitigations
High Pressure Hydraulic lines: • Check all fittings for correct tightness and
hoses for damage.
• Potential for high pressure fluid release.
zone for initial hydraulic testing.
Moving Mechanical Parts: • Wear correct PPE when handling equipment:

o Gloves
• Potential for dynamic pinch points
during operation. • Ensure familiarity with equipment operation,
review manual prior to handling.
• Tool Box Talk to be understood and sheet to be signed.
Required Documents
Required Tools
Hydraulic System

• General Tools
7.13.5 Removal of Thrusters Procedure

available.
To remove thrusters:
Note: Even with the Hydraulic system depressurized, drained and isolated, there can still
be some hydraulic oil leakage; have a tub ready.
2. Follow LTT procedure to isolate the HPU circuit breaker. Check the Main HPU
pressure gauge. Good practice is to run some function, such as thrusters to bleed
any possible pressure entrapped in the Pressure lines (P).
3. Disconnect the Motor Compensator hose, smaller hose, cap hose and drain the
motor.
A Port
B Port
Thruster
mounting
bolts x4
Motor
Compensator
4. Disconnect A & B stainless steel pipe connectors and cap the pipes.
5. Disconnect the Case Drain hose and cap hose; it is the larger of the two hoses
attached to the thruster.
Case Drain Line / Hose,

Larger of the two.
6. Remove all four (4) thruster mounting bolts.
Hydraulic System
To reinstall, reverse the process.
7.13.6 Thruster Assembly Procedure

The thruster motor should always be aligned so that the ports A & B point upwards.
New thrusters may require the motor head to be realigned.
available
Figure 37: 380 sub-Atlantic Thruster
Assemble procedure for the sub-Atlantic thruster:

1. Lubricate both sides of the gasket with silicone grease and push on to the motor spigot.
2. Fit the motor spline into the shaft and align the motor case drain with the pedestal so
ports A & B point upwards.
3. Secure the motor to the pedestal with the screws supplied in the motor kit and tighten to
50nm. Apply lubricant such as Aqua lube.
4. Check for free rotation of the propeller.
5. Pressure test assembly.
To disassemble, reverse the process.
Thruster disassembly instructions are covered in detail in the sub-Atlantic Manual; refer to
the OEM Manuals\Hydraulics\Thrusters folder on the digital technical manual.
Hydraulic System
7.14 HPU Removal

available.

Table 27: HPU Removal & Installation - Risks and Mitigations
Risk Mitigations
• Verify that all slings and chains certifications are
valid and fit for purpose.
• Never check the tightness of a hydraulic hose or
Heavy Object (HPU):
fitting while under pressure.
• Potential for crushing - smashing.
• Have additional personnel to assist with placement.
• Ensure correct PPE is worn as dictated by onsite
requirements.
• High Impact Gloves
• Check all fittings for correct tightness and hoses for

damage.
• Barrier off the ROV / TMS with a 2m exclusion zone
• Potential for high pressure fluid release. for initial hydraulic testing.
• Do not check for leaks with hands or fingers
• Potential for dynamic pinch points • Ensure familiarity with equipment operation, review
during tool operation. manual prior to handling.
• TBT to be understood and sheet to be signed.
Hydraulic System
7.14.3 Required Documents

Refer to the following drawings as an overview located in the Drawings folder on the digital
technical manual:
• ROV Winch Cable Connection; T12-17 TMT-0002-4587,T24-29 0010-7661
• ROV Tether Termination Box General Arrangement Typhoon MK2; TMT-0004-8509
• Hydraulic schematic; TMT-0009-2216
Required Tools
7.14.5 Remove HPU Procedure

Warning: The HPU is extremely heavy. Do not attempt to remove it, the pump or the
motor without suitable lifting / rigging device in place.
To remove the complete HPU:
the vessel’s policy. Discharge the umbilical via the deck leads; refer to Section 3.1.6
Umbilical Electrical Safety on page 25
3. Discharge the umbilical via the deck leads; refer to Section 3.1.6 Umbilical Electrical
Safety on page 25.
4. Discharge the hydraulic system.
5. Drain the Main and Aux hydraulic systems:
o Approx. 75L Total Main System Volume
o Approx. 20L Aux System Volume
6. Remove the AFT guard panel to expose the HPU.
7. Disconnect the motor compensator and drain the motor.
8. Disconnect the suction and discharge pipes and all hydraulic lines and fittings from
both the Main and Aux hydraulic pumps.
9. Remove the pump control line from both the Main and the Aux pumps.
Hydraulic System
10. Disconnect and remove the inlet and outlet manifolds on both the Main and Aux
Hydraulic system. Move the pumps control line from the PC port and rom both the
Main and Aux pumps.
11. Cap and plug all hydraulic ports and lines.
12. Disconnect the HPU power cable from the tether termination J-Box assembly.
contamination. All receptacles should have plugs installed when the cables are
removed.
13. The HPU is ready for removal.
Hydraulic System
7.14.6 HPU Motor Retest Requirements

The following visual checks are to be performed:
1. Check motor for visible damage.
2. Verify ease of rotation.
3. Verify that labelling correct.
4. Inspect the terminal blocks for damage.
5. Inspect for signs of water ingress.
Motor Winding Resistance Measurement
Note: Measure and record the resistance of the windings in the Motor with a low ohm
meter. Record the result to two decimal points.
Table 28: Winding Resistance Measurement
Winding Resistance Measurement

Motor Windings Winding Resistance
Winding ph1 2.9Ω
Winding ph2 2.9Ω
Winding ph3 2.9Ω
Motor Windings Insulation Resistance Measurements

The insulation test is to be performed from a single phase to earth. The phase under test
should not be in contact with any extraneous body or earth.
With a winding voltage between 1000 and 4000VDC, the insulation tester should be set for
2000VDC.
Table 29: Motor Windings Insulation Resistance Measurement
Insulation Resistance Measurement

Motor windings Insulation resistance
Winding Insulation
56GΩ
Resistance
Note: If the is a significant variation form historical reading investigate possible causes.
Operational Test
1. Run the HPU and verify that the hydraulic system pressure is 3000psi (207bar).
Hydraulic System
7.15 Hydraulic Main and Aux Pump Removal

The Hydraulic Pumps are A10V71 Rexroth variable displacement pumps capable of
providing a nominal pressure up to 4500psi (310bar).The two pumps (Main & Aux) only
differ in size and direction of shaft spin. The 140cc Main pump is R/H or CW rotation and
the 45cc Aux pump is L/H or ACW rotation.
available.

Table 30: Hydraulic Pump Removal - Risks and Mitigations
Risk Mitigations
• Never check tightness of a hydraulic hose or fitting
while under pressure.
• Verify that all slings and chains certifications are
Heavy Object (Pump):
valid and fit for purpose.
• Potential for crushing - smashing.
• Have additional personnel to assist with placement.
• Ensure the correct PPE is worn as dictated by
• High Impact Gloves

damage.
High Pressure Hydraulic lines: for initial hydraulic testing.
• Potential for high pressure fluid release. • Ensure that correct PPE is worn as dictated by
during tool operation. manual prior to handling..
• Attendance sheet to be signed.
Hydraulic System
7.15.3 Required Documents

Refer to the following drawings as an overview located in the Drawings folder on the digital
technical manual:
• ROV Winch Cable Connection;
o T12-17 TMT-0002-4587
o T24-29 TMT 0010-7661
• ROV Tether Termination Box General Arrangement Typhoon MK2;
TMT- 0004-8509
Required Tools
contamination. All receptacles should have plugs installed when cables are
removed.
7.15.5 Remove Hydraulic Pump Procedure

To remove the hydraulic pump:
3. Discharge the umbilical via deck leads; refer to Section 3.1.6 Umbilical Electrical
Safety on page 25.
4. Expose the HPU, as per Section 7.14 HPU Removal.
5. Carefully remove and note the position of all pipe-work, cap and plug all hydraulic
ports and lines.
6. Drain the coupling housing and unbolt the two flange fixings before lifting the pump
clear.
Hydraulic System
Warning: Before installing a new Main Hydraulic Pump, ensure that the flow adjustment
has been previously set to 70GPM / 252L/min maximum and the flow
adjustment of the Aux Hydraulic Pump to set to 22.5GPM / 81L/min max.
Retest Requirements
The following retest requirements must be performed:
1. Run the HPU and verify that the hydraulic system pressure is 3000psi (207bar).
7.16 Hydraulic Valve Replacement

Typhoon ROV has seven (7) manifolds containing valves:
• Two (2) Tooling Distribution Manifolds:
o Both are connected to the Aux system.
• One (1) Auxiliary Low Flow Manifold – Port Vertical
• Two (2) Low Flow Tooling Manifolds:
o Horizontal STBD
o Vertical STBD
• Two (2) Thruster Manifolds, each with a high flow tooling port (PORT & STBD).
available.

Table 31: Hydraulic Valve Replacement - Risks and Mitigations
Risk Mitigations
damage.
• Potential for high pressure fluid release. for initial hydraulic testing.
• Ensure that the correct PPE is worn as dictated by
during tool operation. manual prior to handling.
Hydraulic System
Required Documents
• ROV Winch Cable Connection Drawing number:
o T12-17 TMT-0002-4587
o T24-29 TMT-0010-7661
• ROV Tether Termination Box General Arrangement Typhoon MK2; TMT-0004-8509
• Mechanical Drawings; Hydraulic & Propulsion System TMT-0004-4998
Required Tools
7.16.5 Valve Replacement Procedure

To replace hydraulic manifold valves:
pressure gauge. Good practice is to momentarily run a function, such as thrusters to
bleed any possible pressure entrapped in the Pressure lines (P).
3. Discharge the umbilical via deck leads; refer to Section 3.1.6 Umbilical Electrical
Safety on page 25.
4. Isolate the manifolds that are to remain unaffected, otherwise their oil will empty as
well.
5. Drain the valve compartment, via the drain valve adjacent to the enclosure.
6. Remove the lid and carefully store it.
7. Carefully remove the Hydraulic Valves Switch and Control Board (FR02).
Caution: Care should be taken not to snag or pull wires from the board or the wire
harness.
8. Note placement of the valve wiring for ease of reassembly, the valve can then be de-
wired and removed. It is a good practice to take some pictures as record.
Hydraulic System
9. If need to replace / clean more than one valve, do one at a time to avoid mix-up of
wiring and / or the valve .
10. When replacing the valve, take care that all O-rings are in place, and re-torque to the
manufacturers recommendations, as per TMT mechanical drawings in Table 32.
Table 32: Hydraulic Manifold Drawings
Manifold Location Drawing Number

Main, Mounted Front, Centre TMT-0005-8300, ST Distribution Manifold
Mounted Vertically, STBD Front TMT-0001-0778, Vertical STBD Low Flow Manifold ASM
Mounted Vertically, PORT Front TMT-0001-0779, Aux PORT Low Flow Manifold ASM
Mounted Horizontally, STBD, Middle TMT-0001-0790, STBD Horizontal Low Flow Manifold G.A.
STBD Thruster Manifold, STBD Middle TMT-0005-8235, STARBOARD 5FN Thruster Manifold
PORT Thruster Manifold, PORT Middle TMT-0005-8237, PORT 5FN ST Thruster Manifold
Hydraulic System
7.17 Maintenance
Table 33 outlines basic periodic maintenance for hydraulic components:
Table 33: Hydraulic Maintenance
Pre and Post-Dive Oil tank level and air. Charge and bleed as needed.
Hydraulic reservoir
Inspect for contamination, fluid loss and air. Charge and
Weekly
bleed as needed.
Visual inspection for corrosion. Listen for abnormal noise.

Hydraulic pumps Monthly
Service exchange every 2000 hours.
Weekly Filter is to be replaced depending on what happens sooner.

Differential pressure reaches 29psi or the filter has done
ROV Main Case 250 hours.
Post-Dive after a
Filter mechanical failure that The differential pressure should be checked after a dive
may affect the oil that a mechanical failure occurred that may affect the oil
condition. condition i.e. water contamination.
Motor / coupling
Weekly Inspect fluid condition weekly. Replace every 250 hours.
compensation
Hydraulic tank low

Pre and Post-Dive Check operation of all hydraulic tank low level alarms.
level alarms
Supply and return Replace filters every 500 hours or whenever the hydraulic
Quarterly
filters fluid is changed.
Manifolds
Oil Compensator Level. Air ingression. Charge and bleed

Visual Check Pre-Dive
as needed.
Thrusters
Check for oil leaks, propeller play, loose fasteners and

Visual Check Pre-Dive
entangled material (lines, ropes, rags, etc.).
Bearings 4000 hours Replace bearings.
Seals 1000 hours Replace seals.
Note: Thruster checks are based on normal operation with system using clean, water-
free oil.
Compensation System
8. Compensation System
The Compensation System’s purpose is to store and supply hydraulic fluid to electronic,
electrical and mechanical component cavities that require pressure compensation when the
Typhoon ROV is submerged. The cavities will need to be drained before accessing for
maintenance, so it will be necessary to isolate the appropriate tank before draining.
Pressure
Relief & Vent
Quick
Disconnect
Loads
Level
Sensor
Connectors to
Sensor Bottle
Figure 38: Oil Compensation Bottle
For additional technical information on the compensation system; refer to the TMT
Manuals\ROV Technical Manual folder on the digital technical manual.
To view the Compensation Hose Register; refer to the TMT-NDP-001\Mechanical\Comp
System\Compensation Hose Register TMT-0004-8855 located on the digital technical
manual
Compensation System
8.1 Draining Filling and Venting Compensation System

The Compensation System is made up of five (5) separate sub-systems with varying
quantities of fluid.
Note: The five (5) Compensation sub-systems are not interconnected in any way.
Table 34 lists the separate loads and the quantity of fluid for each of the sub-systems.
Table 34: Compensation System Capacity
Compensation Bottles Loads Oil Volume (litre)
Vertical Thrusters, seals 3

Centre, Top
Horizontal Thrusters, seals 3
Transformer Box 12.3
PORT FWD Tether Termination J-Box 24.3
HPU Motor Housing 20
PORT AFT Conan Manipulator 3
STBD Vertical, Tooling Manifold 1.8
STBD FWD STBD Horizontal Tooling Manifold 1.8
PORT Auxiliary Tooling Manifold 1.8
PORT Thruster Manifold 19
STBD AFT STBD Thruster Manifold 19
Survey J-Box 7.9
8.1.1 Draining the Compensation System

To drain one of the compensation enclosures:
2. Follow the LTT procedure to isolate the HPU circuit breaker. Check the Main HPU
3. Discharge the umbilical at the MV cabinet via deck leads; refer to Section 3.1.6
Umbilical Electrical Safety on page 25.
4. Remove the quick-connect coupling on the compensated enclosure to be drained.
5. Connect the drain tool to the enclosure female quick connector and put the other
side of the tool into the bucket.
6. Lift the relief valve located on top of the valve pack to bleed air in and, thereby,
allowing oil to drain faster.
Compensation System
7. Continue draining and venting the air into the tank until the required level is reached
or the enclosure is empty.
8. Remove the drain connection and allow the relief valve to close.
Note: Some oil will remain within the vehicle hoses and pipes even after the enclosure
has been drained.
Compensation System
8.1.2 Dry-Testing the Compensation System

If the Compensation System fittings or components have been opened or replaced, you
may want to dry-test the compensation system for leaks before charging it with fluid.
1. Fill the compensation system with dry air or dry Nitrogen to one atmosphere,
approximately 15psi (1.0bar). Spray all connections and compensated components
with a mild detergent or window cleaner to check for leaks. Active bubbles or foam
denote a leak.
2. Install a pressure gauge on the compensation system. Fill the system with dry air or
dry nitrogen to one atmosphere, approximately 15psi (1.0bar). Allow the air pressure
to stabilize and monitor the pressure gauge over a period of at least two hours. If any
pressure drop occurs, check for leaks using the method described in step 1, above.
8.1.3 Filling and Venting the Compensation System

To fill and vent the Compensation System:
1. Reconnect the quick-connect coupling to the cavity. If the compensator is already
pressurised then the cavity will begin to fill immediately.
2. Connect the hand pump discharge line to the ¼” quick–connect coupling on the
compensator bottle.
Warning: To facilitate and accelerate filling tanks and enclosures some operators use a
deck pack for filling. There are high risks associated with this method of filling
items and sever injury and equipment damage might take place.
The relief valve has very low flow rate and if tank/comp/enclosure is overfilled
when using the deck pack, they might blow up and cause injury or even death.
3. Lift the relief valve to bleed air from the valve pack / junction box as it is filled with oil.
Compensation System
4. Operate the deck pack or hand pump, pumping oil into the compensator. Oil will
automatically transfer into the vessel being filled.
5. Visually check the oil level in the vessel through the transparent Perspex cover. For
junction boxes, lift the relief valve on top of the box to check if the box is full of oil.
6. Monitor the oil level in the deck power pack or hand pump. Re-fill as required.
7. Fill the compensator to 80%. Bleed air from the top of the compensator as required.
8. Inspect the hydraulic manifold / electrical junction box and compensation system for
leaks.
9. Repair as required.
Compensation System
8.1 Sea Water Contamination of the Compensation System

Severe damage to the Typhoon ROV components can result from operating the system
with even a small amount of saltwater contamination. The presence of seawater in the
system can adversely affect electronic / electrical components and accelerate corrosion.
8.1.1 Removing Water from the Compensation System

As there is very little mixing occurring in the Compensation System, the oil / water mixture
will tend to be clearly defined so that purging the system of the saltwater can be relatively
easy, if the situation is resolved in time.
The recovery method is dependent on the time available and the urgency of the situation.
In the event of saltwater contaminating the Compensation System:
1. Inspect the seals and the sealing surfaces and connect the drain line to the fill valve
on the electrical compensation system.
2. Drain the compensator hydraulic oil into the waste container.
3. Drain the manifold covers, junction box, and oil-filled cables.
4. Disconnect the drain line from the fill valve and the cap connector.
5. Disconnect all lines from the compensating system.
6. Blow out all lines with high pressure air. Repeat until all saltwater is out of the lines.
Short lines can be swabbed out. Remove all compensation components and
attempt to remove all salt deposits and water.
Note: High pressure air can carry contaminants from hard-to-reach areas in components.
7. Run clean fluid through each component individually.
8. Remove the compensator, disassemble and clean thoroughly with solvent, if
needed.
9. Re-install and reconnect the compensator.
10. For effected manifolds, remove the valve manifold covers and clean cover, terminal
boards, valves, etc. thoroughly with solvent, if needed. Reinstall the cover and
reconnect to the compensation system.
11. Open the junction box and clean thoroughly with solvent, if required.
12. Reassemble the junction box and the oil-filled cables and reconnect junction box to
the compensating system.
13. Determine the means of saltwater ingress and repair.
14. Ensure that the system is returned to normal and all connections are tight.
15. Fill and vent the Compensation System; refer to Section 8.1.3 Filling and Venting
the Compensation System on page 141.
Compensation System
8.2 Maintenance
Warning: Release of the compensator spring can cause personal injury and damage to
surrounding equipment. It is not necessary to release the spring to replace the
diaphragm and other serviceable components.
8.2.1 General
• Verify that all of the compensation bottles are 80% full, allowing for expansion, prior
to launching the Typhoon ROV.
• Visually verify that the compensation hoses and the connections are all secure.
• After every 500 hours run or every six months (whichever occurs first), change the oil
in all compensation unit enclosures.
Table 35: Compensation Maintenance
Inspect for contamination, fluid loss and air. Verify that the
Compensation Bottle Pre and Post-Dive
bottle is 80% full.
Compensation Visual inspection of hoses. Verify that the connections are

Weekly
Hoses all secure.
Compensation low
Pre and Post-Dive Check the operation of all comp low level alarms.
level alarms
Quarterly or 500 hours

Compensation Oil (whichever occurs Change the oil in all compensation unit enclosures.
first)
For additional maintenance information on the compensation system; refer to the

OEM Manuals\Compensator folder on the digital technical manual.
Mechanical Maintenance
9. Mechanical Maintenance
The ROV must be washed and inspected after each dive, preferably with fresh water.
Inspect the vehicle for debris caught in thrusters and around equipment. A thorough rinsing
with fresh water after each use will keep vehicle clean and free of salt deposits.
Monthly, check the bolts which secure the frame members.
9.1 ROV Surface Treatment

After every dive or when mobilising:
1. Wash down the TMS / ROV with fresh water, removing all saltwater from the vehicle.
2. The umbilical and the tether should be rinsed off, if possible.
3. Examine the ROV for damage, entangled debris and wear & tear.
4. Examine cables, fittings, and connectors; repair or tighten as necessary.
5. Examine the flotation modules for damage and repair as needed. A two part “West
Systems Epoxy” can be used for minor repair of the syntactic foam and resealing of
the painted surface should follow after the epoxy has cured. Dual coatings of two
part epoxy primer paint should be used to seal the flotation and a semi-gloss top
coat. Follow the manufacturer’s instructions for both the epoxy repair and the
urethane coating.
6. Examine the flotation modules for damage. Damage to foam blocks should be
repaired.
7. Check the floatation securing bolts (Belleville washer stacks) after each dive.
8. Touch up vehicle paint routinely. Remove rust, clean and apply suitable primer and
coating.
Caution: Never paint or otherwise coat the anodes.
9. Use a good quality water-resistant lubricant to cover fasteners and hardware that will
be removed periodically; refer to Section 4.3 Fastener Lubrication on page 39.
9.2 Galvanic Corrosion

Galvanic corrosion is an electrochemical action of two dissimilar metals in the presence of
an electrolyte and an electron conductive path. It occurs when dissimilar metals are in
contact. It is recognizable by the presence of a build-up of corrosion at the joint between
dissimilar metals.
Figure 39: Example of Galvanic Corrosion
For example, when aluminium alloys or magnesium alloys are in contact with steel (iron or
stainless steel), galvanic corrosion can occur and accelerate corrosion of the aluminum
alloy.
Figure 40: Method of Corrosion
The Typhoon ROV and TMS are supplied with sacrificial anodes attached to various
locations on the frame.
Figure 41: Example of Different Sacrificial Anodes Supplied
The anodes provide cathodic protection to control corrosion. Cathodic protection (CP) is a
technique to control the corrosion of a metal surface by making it work as a cathode of an
electrochemical cell.
New
Used
Figure 42: Example of Sacrificial Anode
This is achieved by placing another more easily corroded metal in contact with the metal to
be protected, to act as the anode of the electrochemical cell. The anode corrodes, not the
protected metal.
• Inspect all anodes regularly.
• Replace the anode when 1/ 3 or less of its material remains. Ensure good contact and
/ or mating surfaces when installing new anodes.
• Use nickel based anti-seize lubricant on the anode fasteners to ensure good
electrical contact.
Note: There are four (4) anodes hidden just under the ROV lift point. They are accessible
by separation the ROV and TMS. Inspection can be done from underneath where
the tether Kellems grip is terminated, consider the use a torch and mirror.
Caution: Never paint or otherwise coat the anodes.
9.3 Flotation
The flotation blocks are made of syntactic foam with a multi-layer urethane coating. The
main flotation blocks are attached to the upper frame by stainless-steel threaded rods
through the flotation and secured by the mounting bolt; see Figure 43.
Note: The Typhoon MK2 150 main center floatation block is a macrospheres type while
the rest of the blocks are a microsphere type.
Figure 43: Flotation Mounting Bolt
The mounting bolts are tightened on the surface so the stack is in the fully compressed
condition, applying a preload to flotation blocks. Torque requirements are detailed in
drawing TMT-0000-8994 located in TMT-NDP-001\Mechanical\Flotation System.
When the vehicle travels to depth, pressure and temperature will cause the flotation to
contract in three dimensions, the preloading acts as a spring to maintain a sufficient
compressive force to keep the flotation secured to the frame.
Note: Record the size, type and order in which they are stacked when removing, so that
they can be returned to the same state as they were initially.
9.4 Adding or Removing Flotation Blocks

Up to four (4) pairs (require one LHS and one RHS sheet) that can be inserted at the front
and four (4) pairs of sheets that can be added to the rear.
Note: The extra flotation can only be added in pairs, one (1) Right Hand Sheet (RHS) –
one (1) Left Hand Sheet (LHS).
Figure 44: Typhoon Buoyancy
The nominal buoyancy of each pair is approximately 45kg, so the total extra flotation
available is 208kg at the front and 208kg at the rear.
Figure 45: Extra Flotation

available.
Table 36: Adding & Removing Flotation - Risks and Mitigations
Risk Mitigations
• Lift responsibly.
Heavy Object (flotation blocks):
• Wear correct PPE:
• Potential for crushing - smashing. o High Impact Gloves
o Gloves
9.4.2 Prerequisites
9.4.3 Procedure Adding / Removing Flotation

To add or remove the optional extra flotation pairs:
Warning: Before sliding the nose section forward, first check that any electrical cables
that go from the ROV frame to the lights and other equipment that are
mounted on the front flotation have enough slack.
1. Unlatch the cover section; push the small spring wire inwards then pull the latch
mechanism forwards. Make sure that the aluminium cover section is held in place as
it may fall out.
2. Remove the cover section.
3. Undo the over-centre latch that holds the front and rear flotation blocks together.
4. Slide the nose section of the flotation forward on its rails. The nose section must be
slid far enough forward to allow the extra flotation pieces to be rotated into position.
5. Install the extra flotation, one LHS (0000-5278) and one RHS (0000-5277) sheet is
required per pair.
Keys
6. Slide the nose section back in and install & tighten the over-centre latch and re-
install the cover section.
Extra Flotation
Extra Flotation
9.4.1 Procedure Adding / Removing Lead Ballast

The amount of lead can be calculated so that the vehicle is neutral in water.
Note: Having the vehicle neutral buoyant will assist in making the ROV easier to fly.
Certain operations require different vehicle trim, i.e. working close to the seabed. You may
want the vehicle positively buoyant to limit the stirring up of silt which will hinder visibility;
otherwise, you may want the vehicle slightly heavy due to insurance demands or company
policies.
The lead is to be evenly distributed throughout the ROV frame but also placed so that when
the ROV is lifted off deck, it sits as level as possible.
The Typhoon ROV, without a tooling skid, requires about 365Kg of lead. Operation with its
custom tooling skid will require only 70Kg of lead or two packs of two ingots each.
Each lead ingot weighs approximately 16.5kg.
Figure 46: Lead Ballast Layout
9.5 Maintenance
A system for recording the maintenance history for all the ROV system is needed, but it is
up to the user to create his personalized system. The maintenance record is also important
for warranty purposes.
The following maintenance is required:
• After use, wash down with fresh water.
• If the ROV is stored outside, wash weekly with fresh water to remove any salt or dust
residue.
• Damage to the flotation block must be repaired and sealed to prevent water
saturation.
A two part “West Systems Epoxy” can be used for minor repair of the syntactic foam
and resealing of the painted surface should follow after the epoxy has cured. Dual
coatings of two part epoxy primer paint should be used to seal the flotation and a
semi-gloss top coat. Follow the manufacturer’s instructions for both the epoxy repair
and the urethane coating.
• For major foam block repair, it is recommended to have the syntactic foam sent back
to the manufacturer.
Caution: Syntactic Foam must be sealed to control water absorption.
• Maintain Belleville washer stacks by flushing with fresh water and inspecting for
corrosion before and after each dive.
Note: Syntactic foam need not be sealed to control water absorption. So any damage to the
Pu coating will not affect floatation.
9.6 Flotation Repair

Caution: Repair must be carried out with caution.
Repairing molded flotation requires consulting the COSH sheet of chemical
products that are intended to be used for repairing the flotation block in order
make awareness about safety practices to handle / work with these
materials.
9.6.1 General Requirements

Repairing flotation first requires cleaning:
Surface preparation of moulded (Macrosphere type) flotation:
Note: On Typhoon MK2 150, only the main center floatation block is Macrosphere type.
1. Remove all “extras” remaining from the moulding process.
2. Degrease the surface using isopropanol, Isopropyl Alcohol.
3. Whip blast with a new steel “Garnet”.
4. Thoroughly clean the surface using oil free compressed air.
Caution: Wear eye protection when using pressurised air.
5. Inspect the surface to verify surface is clean, dry and free from any dust or grease.
Note: If the fiberglass skin under the PU is damaged then contact TMT for advice specific
to the Macrosphere floatation.
Surface preparation of machined (pure foam type; Microsphere type) flotation:
1. Remove all chips remaining from the moulding process.
2. Degrease the surface using isopropanol, Isopropyl Alcohol.
3. Thoroughly clean the surface using oil free compressed air.
4. Inspect the surface to verify the surface is clean, dry and free from any dust or grease.
9.6.2 PU Coating
Note: Anti-corrosion, water proofing marine grade PU must be used for coating of the
foam after primer is applied. Nukote ST or an equivalent product can be used.
Nukote ST is a two (2) component, 100% solid, pure poly-urea that significantly reduces the
moisture problem that causes pin holing and blistering in most polyurethane or
polyurethane hybrid systems.
Before applying the coating, verify the surface is dry, clean and free from any dust or
grease.
Additional technical specifications are available on the vendor`s data sheet.
Caution: For environmental concerns, the manufacturer’s guidelines for methods of
application and drying time must be followed.
The typical thickness of PU layer is 3-5mm unless otherwise stated on the product drawing.
9.6.3 Topcoat
The preferred topcoat colour of the finish is RAL1003 yellow, unless otherwise specified on
the product drawing.
The topcoat must be UV resistant two (2) part aliphatic. Polu-U-400 (Wattyl) or similar may
be used. Additional technical specifications are available in the vendor`s data sheet.
Typical thickness of the topcoat is 80-100 micron, unless otherwise stated on the product
drawing.
To repair, follow as below:
1. Cut out or cut off the damaged PU Skin area.
2. Clean the exposed block area and lightly sand to help abrade the new Pu Skin.
Blow off any dust.
3. Make sure the surface is clean and dry, free from dust or grease.
4. Mix together the two components, the Yellow (PU) with the Clear (Isocyanate).
Use a 1.55 to 1 ratio by weight.
5. Mix the two materials together and apply to the damaged area. By mixing the two
materials together, it will start a chemical reaction causing the mixture to start curing.
Note: The more the material is mixed, the quicker the material will harden.
6. When applying, the easiest way is to use a plastic spreader.
Example, like plastering walls.
Note: The smoother the finish when applying the PU, the less sanding will be required
before painting it.
Caution: Do not dispense a single layer greater than 2mm thick. If a deeper layer is
required, apply multiple coats allowing each previous layer to be cured before
applying a new layer.
7. Once the material has hardened, after approximately 10 to 20 minutes, sand the new
skin down, making it smooth and blend in with the original finish of the block.
8. When it is blended, paint the repaired area. Blow or wipe the area clean.
Note: More of the PU mix can be applied on top to build up the affected area if the initial
results are not satisfactory.
9. The repaired area can now be painted using a brush, paint roller or spray gun.
Troubleshooting
10. Troubleshooting
The following charts are a general Troubleshooting guide for the Typhoon MK2 150 ROV.
Consult the appropriate OEM manual and the tables in this chapter for more specific
troubleshooting information on the remaining group of causes.
10.1 Single Cause Problems

Troubleshooting consists of determining the nature of a problem and then isolating the
problem to a particular device or component of a device. When a problem has been
isolated and identified, troubleshooting also consists of fixing the problem, usually by
replacing the device, some component of the device, or changing a setting or variable in the
system.
10.2 Multiple Cause Problems

Isolating single component failures which cause reproducible symptoms is relatively
straightforward.
However, many problems only occur as a result of multiple failures or errors. This is
particularly true of fault tolerant systems, or those with built-in redundancy. Features which
add redundancy, fault detection and failover to a system may also be subject to failure, and
enough different component failures in any system will “Take it down”.
Even in simple systems, the troubleshooter must always consider the possibility that there
is more than one fault. Diagnosing all causes can be difficult: One cause may be
intermittent or will vary with temperature or time, one cause may initiate another, or no one
cause alone may be sufficient to produce a recognizable symptom.
Replacing each component, using serial substitution, and then swapping each new
component back out for the old one when the symptom is found to persist, can fail to
resolve such cases.
Note: Replacement of any component with a defective one can actually increase the
number of problems rather than eliminating them.
The general idea of a Troubleshooting Model is to systematically reduce a large set of
possible causes of trouble to a small set of causes or to a single cause. You can then fix
the problem and restore the functionality.
Note: After the problem is resolved, a systematic method of documenting the case helps
to capture, preserve and communicate the troubleshooting experience gained
while solving the problem.
Troubleshooting
10.3 General Problem - Solving Model

When you are troubleshooting in the ROV environment, a systematic approach always
works best. An unsystematic approach (Easter Egging) to troubleshooting can result in a
“Quick Fix” but it can waste valuable time and resources and often make the situation
worse.
A systematic approach employs the following steps:
1. Define the specific symptoms.
2. Identify all potential problems that could be causing the symptoms. Consider
recording observations and actions taken.
3. Systematically eliminate each potential problem (from the most likely to the least
likely) until the symptoms disappear.
4. If trying one parameter does not fix the problem, make sure to revert the attempt to its
original status to avoid creating other problems to the system.
Troubleshooting
10.4 Surface Cabinets Power Issues

The following tables detail potential problems affecting the Typhoon System Surface Power
including the following sub-systems:
• Circuit Breaker Issues
• ROV Instrument Power
• ROV HPU Power
• TMS Instrument Power
• TMS HPU Power
Table 37: Circuit Breaker Issues
Symptom Possible Cause Checks / Actions
The CB resistance is higher than Carbon built up on internal

Replace the circuit breaker.
1Ω when CB is in ON position. contacts due to arcing.
The CB resistance is not infinite in Welded contacts or faulty

the OFF (open) position. mechanism.
High EMF during the mechanism

The CB case is cracked. Replace the circuit breaker.
opening.
Traces of burns and tar built up on

the CB body.
High arcing currents. Replace the circuit breaker.
Blisters on the CB body.
Internal high temperature due to

an increased resistance in the CB Replace the circuit breaker.
contacts.
Troubleshooting
Signs of overheating on the CB

terminals.
Clean terminals with isopropyl

Loose terminals. alcohol and tighten the
terminals.
Clean terminals with isopropyl

Cable falling out of the CB. Loose terminals.
alcohol and tighten terminals.
The feeding cable is damaged.
Inspect the circuit elements

High short circuit currents. and replace the damaged
cable.
Tighten up the bolts on

Loose terminals.
removable trip unit.
The trip unit is malfunctioning
Damage due to operation on high
short circuit currents.
1. Check the voltage with a
multimeter. It may be below or
above the device nominal
voltage range (written on
UVR).
2. Check wiring for the start
If CB has an UVR. circuit. Cable might be out of
the terminal.
3. Check if UVR is changing
The Start Circuit will not lock in. state by disconnecting the
voltage from input.
If the device is faulty, replace it.
circuit. Cable might be out of
the terminal.
If CB has a SHUNT trip. 2. Shunt changing state by
disconnecting voltage from
input.
Troubleshooting

circuit. Cable might be out of
the terminal.
If CB has AUX contact.
2. Operating CB should change
contact state.
Check if any of the
Short circuit. components are in short
circuit.
Verify that the settings are
Trip unit has not been set properly. correct. If problems persist,
consult TMT Engineering.
CB is tripping at the start of the
equipment. Determine cause of voltage
drop. Consult TMT
Voltage drops too low.
Engineering for further actions
bypassing the UVR.
Welded contacts or faulty
Circuit breaker is not opening. Replace circuit breaker.
mechanism.
If there is no phase loss on supply,
Phase loss. then contact in CB did not close Replace circuit breaker.
due to damage in mechanism.
Check if communication unit is
Faulty communication unit.
damaged. If it is, replace it.
Check if some of the cables
Faulty wiring.
Failure to communicate with the are disconnected.
HMI 030.
Set the address to the 40. If
Wrong or repeated device address another device has address
in the system. 40, change the address on
that device.
Table 38: ROV Instrument Power
1. Check the incoming power supply at DMTME 1.

2. Check the PDU power multimeter display.
3. Check if CB1 is closed.
4. Check if CB13, CB14, CB15 and CB16 are
ROV instrument power No power to LV cabinet. closed.
does not switch on or All LV cabinet meters and 5. Check position of the main Emergency Stop
trips. indicators are off. Button (ESTOP) in PDU and RSTOP (on wall).
6. Check the door interlock on the PDU cabinet,
DSW1.
7. Conditioned power CB (CB1.5, CB 11 in PDU).
8. Meter fuses F(14,15,16,17, 31,32,33,34,35,36).
Troubleshooting

1. Check if CB 1.2 ROV INSTR. CB is closed.
2. Check if CB 13 and CB 14 (ROV control) is
closed.
3. Check the door interlocks; MVSW ROV, MVSW
TMS, DSW4, HPU TX SW1, HPU TX SW2,
DSW2 and DSW3.
4. 24V Output from Console “ROV Instrument On
and Off” push button.
5. 24V Control relay R1 and R2, or wiring fault.
6. ROV Instrumentation Insulation Monitor display
LIMR2, <600 kΩ.
Contactor K2 not latching 7. Thermal overload (OL2) tripped on overcurrent
fault or not re-setting.
No MV voltage displayed 8. Transformer over temperature thermistor Lamp
at ROV MV Instrument TRLT2 on. Check transformer, reset circuit at
meter. push button TPB2.
ROV instrument power 9. Under/Overvoltage Relay UOR2 Tripped, reset
does not switch on or circuit at push button, on the device.
trips. 10. Check ROV Emergency Stop Button (E1PB).
11. Check indication of contactor state on the Pilot
(continued) Console, push button light.
12. Check the Pilot Console Estop buttons.
13. Check the MV fuses on Instrument Power and
VT circuit (TX1, TX2).
14. Check the Instrument Transformer or VT open
circuit or faulty wiring to ROV Instrument Power
Meter (DMTME3).
1. Deck plug is not connected in proper socket.

Contactor K2 closed with 2. Deck cable, slip-rings, umbilical or tether are
no power at MEE open circuit.
3. Instrument transformer at ROV is open circuit.
MV voltage displayed at 4. 230VAC and 115VAC fuses at ROV Transformer
ROV MV Instrument Enclosure & MEE open circuit.
meter 5. MEE Power cable assembly open circuit.
6. MEE Power supply faults.
Troubleshooting
Table 39: ROV HPU Power

1. Check the incoming supply at DMTME 1.
Check the PDU power multimeter display.
No power to LV cabinet. closed.
4. Check main Emergency Stop Button (ESTOP)
All LV cabinet meters and in PDU and RSTOP (on wall).
indicators are off. 5. Check the door interlock on PDU cabinet,
DSW1.
6. Check the conditioned power CBs (CB1.5, CB
11 in PDU).
7. Meter fuses F(14,15,16,17, 1,32,33,34,35,36).
1. Check if CB 1.1 ROVHPU CB is closed.
2. Check if CB 13 and CB 14 (ROV control) is
closed.
3. ROV Instrument contactor not latching.
See if K2 is not latching.
4. Door interlocks (MVSW ROV, MVSW TMS,
DSW4, HPU TX SW1, HPU TX SW2, DSW2
and DSW3).
ROV HPU power does
Contactor K1 not latching. 5. 24VDC output from the Pilot Console ROV
not switch on or trips
HPU “On and Off” push button.
No MV voltage displayed 6. 24VDC control relay R1, R2, R3 and R4, or
at ROV MV Instrument wiring fault.
meter. 7. ROV HPU Insulation monitor display LIMR1
<600 kΩ.
8. Check ROV Emergency Stop Button (E1PB).
9. Check indication of contactor state on pilot
console. Push the button light.
10. Check Pilot console Estop buttons.
11. Instrument Transformer or VT open circuit or
faulty wiring to ROV Instrument Power Meter
(DMTME2).

Contactor K1 closed with 2. Check MV fuses on HPU Power and VT circuit
no power at HPU. 3. HPU Transformer or VT open circuit.
MV voltage displayed at 4. Deck cable, Slip-rings, Umbilical or Tether
ROV MV HPU meter. open circuit.
5. Problem with ROV HPU wiring.
Troubleshooting
Table 40: TMS Instrument Power

1. Check the incoming supply at DMTME 1
2. Check the PDU power multimeter display.
No power to LV cabinet. 4. Check if CB13, CB14, CB15 and CB16 are
closed.
All LV cabinet meters and 5. Check main Emergency Stop Button (ESTOP) in
indicators are off. PDU and RSTOP (on wall).
6. Check the door interlock on PDU cabinet, DSW1
7. Conditioned power CBs (CB1.5, CB 11 in PDU).
8. Meter fuses F(14,15,16,17, 31,32,33,34,35,36).
1. Check if CB 1.4 TMS INSTR. CB is closed.
2. Check if CB15 and CB16 (TMS control) is closed
3. Check the door interlocks; MVSW ROV, MVSW
TMS, DSW4, HPU TX SW1, HPU TX SW2,
DSW2 and DSW3.
4. Check the 24VDC output from the Pilot Console
“TMS. Instrument On and Off” push button.
5. Check the 24VDC control relay R9 and R10, or
wiring fault.
6. TMS Instrumentation Insulation monitor display
Contactor K4 not latching. LIMR4, <600kΩ.
TMS instrument power 7. Thermal overload (OL4) tripped on overcurrent
does not switch on or trips No MV voltage displayed fault or not re-setting.
at TMS MV instrument 8. Transformer over temperature thermistor Lamp
meter. TRLT4 on. Check transformer, reset circuit at
push button TPB4.
9. Under/Overvoltage Relay UOR4 Tripped, reset
circuit at push button, on device.
10. Check TMS Emergency Stop Button (E2PB).
11. Check indication of contactor state on pilot
console, Push button light.
12. Check Pilot console Estop buttons.
13. Check MV fuses on Instrument Power and VT
circuit (TX3, TX4) or faulty wiring to TMS
Instrument Power Meter, DMTME6.
Contactor K4 closed with 2. Instrument Transformer or VT open circuit.
no power at instrument 3. Deck cable, Slip-rings, Umbilical or Tether open
bottle on TMS. circuit.
4. Instrument transformer at TMS open circuit.
MV voltage displayed at 5. 230VAC and 110VAC fuses at TMS (Transformer
TMS MV Instrument Enclosure) open circuit.
meter. 6. TMS Power cable assembly open circuit.
7. TMS Power supplies faults.
Troubleshooting
Table 41: TMS HPU Power
1. Check incoming supply DMTME 1.

2. Check PDU power multimeter display.
No power to LV cabinet. closed.
All LV cabinet meters and 5. Check main Emergency Stop Button (ESTOP) in
indicators are off. PDU and RSTOP (on wall).
6. Door interlock on PDU cabinet (DSW1)
7. Conditioned power CBs, CB1.5, CB 11 in PDU.
8. Check fuses
F14,15,16,17, 31,32,33,34,35,36.
1. Check if CB 1.3, TMS INSTR. CB is closed.

2. Check if CB 15, TMS control is closed
3. Door interlocks; MVSW ROV, MVSW TMS,
DSW4, HPU TX SW1, HPU TX SW2, DSW2 and
DSW3.
4. TMS Instrument contactor not latching, see if K4
not latching.
5. 24VDC Output from Console “TMS HPU On and
Off” push button.
6. 24VDC Control relay R7, R8, R9 and R10, or
Contactor K3 is not wiring fault.
TMS HPU Power does not latching. 7. TMS HPU Insulation monitor display LIMR3,
switch on or trips <600 kΩ.
No MV voltage displayed 8. Thermal overload (OL3) tripped on overcurrent
at TMS MV Instrument fault or not re-setting.
Meter. 9. Transformer over temperature thermistor Lamp
TRLT3 on. Check transformer, reset circuit at
push button TPB3.
10. Under/Overvoltage Relay UOR3 Tripped, reset
circuit at push button on device.
11. Check TMS Emergency Stop Button, E2PB.
12. Check indication of contactor state on the Pilot
Console (Push button light).
13. Check Pilot c\Console Estop buttons.
14. TMS HPU Power Meters, DMTME4 and
DMTME5, fuses (F31, 32, 33, 34) or faulty wiring.
1. Check MV fuses on HPU Power and VT circuit

(TX3, TX4).
Contactor K3 closed with 2. HPU Transformer or VT open circuit.
no power at HPU. 3. TMS HPU Power Meter fuses (F33, 34) or faulty
wiring.
MV voltage displayed at 4. Deck plug is not connected in proper socket.
TMS MV HPU meter. 5. Deck cable, Slip-rings, Umbilical or Tether open
circuit.
6. Problem with TMS HPU wiring.
Troubleshooting
10.5 ROV Instrumentation and Control Issues

The following are potential problems affecting the Typhoon ROV instrumentation and
control:
Table 42: ROV Control Issues

Data errors from Check optical couplers, splices and exposed fibre bundles
High optical
ROV during for any visual damage. Measure the total attenuation with an
attenuation.
operations. Optical Fibre Test Kit and compare the values with the
Bursts of noise on default values. -3dB & -15dB
High optical
video monitor The Focal Diagnostic Software is also a good tool to
attenuation.
during operations. troubleshoot the comms.
Depth transducer Check if the pressure port is clean and free of foreign matter.
faulty. Check transducer and replace or repair.
Check if the power relay V8 is enabled on the Pilot Screen.
Power supply faulty. Check MEE Connector 2B: there must be 25VDC across
pins 4/5.
Vertical trim pot circuit Check that trim is on zero.
of console. Check trim pot circuit.
Vertical Thumb strain
Auto depth Check the joystick output.
gauge on joystick.
inoperative or
Console switch
erratic. Check the switch circuit. Repair or replace.
damaged.
Open wire. Check continuity of all relevant circuits.
Gains on depth
controls not properly
Set gains as recommended.
set (proportional and
derivative gain).
Thruster(s)
Refer to Table 44.
inoperative.
Open wire. Check continuity.
Altimeter / DVL
Replace Altimeter / DVL.
damaged.
Check if the power relay V8 is enabled on the Pilot Screen.
No power (26VDC). Check MEE Connector 2B: there must be 25VDC across
Auto altitude pins 4/5.
inoperative or Vertical pots faulty. Repair circuit.
erratic. Gains for altitude
control not set Set gains to Nil point.
properly.
Control switch
Replace switch.
damaged.
Thruster inoperative. Refer to Table 44.
Gyro heading rate
Check operation and replace
sensor inoperative.
Power supply off. Check power supply output.
Auto heading Open wire. Check continuity on gyro circuit.
inoperative or Gains for the heading
erratic. control not set Set gains to recommended values.
properly.
Heading trim. Replace board.
Open wires. Check all relevant circuits.
Troubleshooting

Thruster inoperative. Refer to Table 44.
Loss of Power to
Manifolds, power Check MEE Connector 1C to 5C Check Fuses F10-F14, on
indicator light on PCB the Power Slide.
No thruster control
off.
No Hydraulic power. Verify HPU running, check system pressure
Check if activated on Pilot Interface. Power Slide  check

No Power Supply. Fuse F15, check connector V7 on Power Control Board 2
PC02-B.
Sonar not working Sonar PC  Verify software running

No Comms. Surface Mux  RS232 CH1B
Comms Slide  check Fibre Mux RS232 CH1B.
Device failure. Replace with spare.

Check MEE Connector 1A to 8A
No Power Supply. Power Slide  check Fuse F17, check connectors V1-V4 on
Cameras not
Power Control Board 1 PC02-A.
working
Comms Slide  check coax cable on McMurdo Board,
No Picture.
Video Switch 6-3 and Fibre Mux.
Check MEE Connector 1A to 8A
LED lights 24VDC
No Power Supply. Power Slide  check Fuse F15, check connectors V1-V4 on
not working
Power Control Board 2 PC02-B.
Sub-Electric Transformer Enclosure  Fuses F5 , F6,
Connector C1.
No Power. Power Cable Assembly at 7C faulty.
LED lights 115VDC
not working Power Slide  Fuse F7, Contactor K1 not energized or
faulty.
Device Failure. Replace Dimmer Bottle, Connection Cables or LED Light.
Check if power outputs activated on Pilot Interface.

Power Slide  check Fuse F17, check connector V7 on
No Power. Power Control Board 1PC02-A.
Devices connected
to the Survey J-Box Power Slide  check Fuse F15, check connector V5 on
not working Power Control Board 2 PC02-B.
Comms Slide  check Fibre Mux RS232 CH1A&2A, RS485

No Comms.
CH3B&4B.
Check if power output activated on Pilot Interface.

Tooling Skid not Check MEE Connector 1B
No Power.
working Power Slide  check Fuse F15, check connector V6 on
Troubleshooting

No Power to Sensor Check MEE Connector 3B
Comp level /
Bottle. Power Slide  check Fuse F15, check connector V5 on
temperature
sensors not
working
Replace the Power Node board Sensor Bottle, Connecting
Device Failure.
Cables, Sensors.

No Power. Check MEE Connector 3B.
Aux Tool not Power Slide  check Fuse F8, Contactor K2.
working
No Comms. Comms Slide  check Fibre Mux RS232 CH3A.
Surface MUX  Verify power switched on.

No Power. Comms Slide  Check 5VDC Power Supply at Connector
P290.
Comms not working
Comms Slide  Fibre Mux, APK25 2405 DC/DC Converter,
Connectors P281, 284, 290 and wiring,
Component Failure.
Check fibre comms quality with Focal Mux Diagnostic
Software.
Power Slide  Fuse F18

No Power.
No current read-out Current Sensor Board CS01A Comms Connector.
of manifolds
Component Failure. Current Sensor Board CS01A.
Loss of all
Cameras, Sensor Power Outputs deactivated on Pilot Interface
Bottle, Power Slide  Fuse F17, F2
No Power.
Manipulators, Power Supply PS2
Navigation, Survey Power Control Board 1 PC02-A
J-Box
Loss of all 24VDC Power Outputs deactivated on Pilot Interface.

LED Lights, the Power Slide  Fuse F15, F1.
No Power.
Survey J-Box, Power Supply PS1.
Sonar, Fluid Skid Power Control Board 2 PC02-B.
Comms Slide  No Fault: LEDs remain

LEDs on Relays dimly lit when Off. Will N/A
permanently On go bright when On.
Troubleshooting
When Windows boots

up, it searches for a
serial mouse on any
built in COM ports on
your PC. The way that
it does this is to look
for any data at all 1. Click on the Windows start button.
coming in the serial
2. In the search box, type in: regedit and press the
port at boot time. If
enter key on your keyboard.
Windows sees data
coming in a COM port 3. The Registry editor windows will open.
at boot time, it loads a
4. Navigate to the registry key named:
Mouse pointer mouse driver for that
HKEY_LOCAL_MACHINE\SYSTEM\CurrentContr
starts jumping COM port. The
olSet\Services\sermouse
around on the consequences of this
monitor screen and are that the COM port 5. On the right hand side of the registry editor window
randomly clicking becomes unavailable you should find subkey named: start.
on things. to any other program
6. Double click on the start subkey and modify the
and also, any data
value of the key to:
received through the
4 and click the OK button to return to the registry
COM port could
editor window.
potentially be
interpreted as mouse Note: Setting the start subkey value to 4 will disable
movements and clicks windows from looking for serial mice at startup.
causing your PC’s
mouse cursor to jump 7. Exit the registry editor window
erratically and
uncontrollably. It can
even cause your PC to
crash.
Troubleshooting
10.6 Pan & Tilt

The following are potential problems that could affect the Pan & Tilt Camera mount:
Table 43: Pan & Tilt

Mechanical stop around unit. Remove blockage.
Air in hydraulic line. Vent hydraulic lines.
At the valve connector, verify if the
Open connection on control wires.
valve has power.
Check valve coil for short or open
Solenoid valve defective.
circuit.
No hydraulic pressure. Refer to Table 44.
Pan & Tilt movement not
operational Remove blocked line and flush
Block in hydraulic line.
clean.
Clean hydraulic system; tighten
Hydraulic line open. fitting or replace damaged line.
Check for seawater intrusion.
Refer to OEM manual for
Defective equipment. troubleshooting and repair
procedures.
Troubleshooting
10.7 Hydraulic System

Troubleshooting the Hydraulic System, Table 44, describes general faults in the hydraulic
system encompassing the:
• Control Manifold
• Hardware
• Hoses
• HPU
Refer to the OEM manual supplied with the equipment for detailed troubleshooting and
service information on manipulators and hydraulic tools.
The following are the hydraulic system potential problems:
Table 44: Hydraulics System

Close circuit breaker.
Breaker in PDU is open. Investigate reason for tripped CB
first before switching on.
Console Off. Turn console ON.
Instrumentation power to ROV OFF. Turn instrumentation power ON.
Grounded branch circuit. Find fault
Ground fault interrupt. and repair (connectors, umbilical
HPU does not start, or it etc.)
stops Verify that all cables are
Control cables disconnected.
connected.
Determine reason for overload and
Motor overload tripped (PDU).
repair.
Main or auxiliary reservoir level sensor Check compensator level and
low level shutdown. sensor / trip circuit.
Defective motor. Repair or replace motor.
Ground Fault. Troubleshoot to locate grounds.
Check LED on FET RPM board.
No power. Check power supply to
proportional valve.
Verify control signal present.
Proportional valve stuck.
Clean or replace.
Power cable from MEE housing to Verify cable is properly seated.
Hydraulic Manifold Valve Manifold Enclosure defective. Check continuity.
Inoperative
Defective or flooded connections. Check connectors; clean and dry.
Manifold cable has bad connection. Check continuity from the manifold
to the solenoid driver card.
Valve defective. Replace valve.
Hydraulic fluid contaminated or there Clean and flush hydraulic system.
is water ingress. Reseal manifold.
Troubleshooting
10.8 Compensation System

The following are the compensation system potential problems:
Table 45: Compensation System

Damaged gasket seal on manifold or
Replace gasket.
J-Box.
High loss of compensation Loose fitting feed lines to manifold or
Tighten fittings.
oil. J-Box.
Repair or re-terminate.
Damage to Umbilical line (TMS) or Tether.
Replace gland seal.
Loss of hydraulic oil from
Possible cross leakage. Hydraulic system Identify the leaky valve and
hydraulic system and the
fills up comp system. O-ring failure. replace.
comps are filling up.
Maintenance Schedule
11. Maintenance Schedule

The following is the recommended maintenance for the Typhoon system.
Note: There can be a degree of variation in maintenance requirements. The following
should be considered the minimum recommended requirements.
It is the responsibility of the owner - operator to adapt the program of planned
maintenance for each system depending on conditions encountered.
Month 1 2 3 4 5 6 7 8 9 10 11 12
Monthly TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB TA/TB
3 Monthly TB TA TB TA TB TA TB TA
6 Monthly TA TB TA TB
Annual TA TB
TA and TB indicate Typhoon A or B (two (2) Typhoon ROVs per ship).
Hydraulic Service Schedule by hours of operation:

ROV Main HP Filters 500
ROV Main Return Filters 500
*ROV Main Case Filters 250
ROV Main Pump Change 2000
ROV Main Cardev Filter Change as per manufacturer’s recommendation (200hr)
ROV Thruster Motors According to results of case drain test performed 6 monthly
ROV Aux HP Filters 500
ROV AUX HP
ROV Aux Return Filters 500
ROV Aux Case Filters 500
ROV Aux Cardev Filter Change as per manufacturer’s recommendation (200hr)
ROV Aux Pump Change 2000
TMS HP
TMS HP Filters 500
TMS Return Filters 500
TMS Pump Change 2000
Notes:
• Take oil sample weekly from all enclosure boxes, electric motor and compensators.
• Take oil sample weekly from the charge cart.
• *The filters differential pressure should be checked weekly and be replaced
depending on what happens first. Differential pressure reaches 29psi or the filter has
done 250 hours or there was a mechanical failure occurred that could affect the
hydraulic oil condition.
Caution: If the ROV Main Case Filters differential pressure exceeds 29psi the thruster
motors may be damaged.
11.1 Monthly
Example of recommended monthly checks for ROV, LARS and Winch:
ROV √ LARS √
Check operation of all comp low level alarms Check oil level of gearboxes
Check operation of emergency location devices Check level-wind limit switch operation
Check frame for corrosion and damage Inspect and grease level wind worm drive
Check all electrical connectors for (hand) Grease level wind guide bar and fittings
tightness. Clean and lubricate all connectors as
per chapter 6.1.
Check valve cartridge stems - grease external Check condition of umbilical and coating
Check for loose components, fittings and bolts Check Denso tape, retape as required
Inspect lift point hardware Check main sheave pivot pin retaining plates
Check condition of oil in all filled enclosures Check nut/bolt security – Winch Drum Drive
Check for oil leaks/water ingress Check nut/bolt security – Winch

Motor/Gearbox Units
Check condition of anodes, clean up or replace Check nut/bolt security – Frame members
as required.
Check condition of all hoses and tubing Grease all grease nipples, and auto lube
cartridges
Check cameras for moisture. Clean lens Touch up paintwork as required
Check security of manipulators,

re-torque the fixing bolts as per manufacturer’s
torque figures for Conan & Atlas
Check condition and security of floatation
blocks.
Check for damaged surfaces and check torque
of the bolts / nuts
Clean and lubricate all Manipulator moving parts
Check tether for damage above mushroom

spelter
Check condition of thrusters, propellers and
mounts/thrusters guards are secure
Check condition/security of Kellums Grip

Note: Will require system to be split
Sample hydraulic oil: Change system oil and

filters when run time hour period is
indicated.
HPU Run time hours
Motor serial number
Notes:
Example of recommended monthly checks for TMS, tooling and Control Room:
TMS √
Inspect diamond bar for wear and regrease Check condition of TMS hydraulic oil
Check level wind guide bars Check condition of TMS electric motor oil
Check rotary and static J-Boxs for water
Check for frame corrosion damage
ingress
Check for loose nuts and bolts Check chain tension
Inspect all cables
Check condition of anodes TOOLING PACKAGE √

Check valve cartridge stems - grease
Check tether for damage
external
Check HPU motor compensator oil Check for loose nuts and bolts
Check condition of all hydraulic tubing and
Check condition of anodes and frame
hoses
Check hydraulic fittings for leaks Check cables and connectors are secure
Grease all grease points Check condition of all hoses/fittings
Check tether guide rollers for wear/rotation Check for oil leaks/water ingress
Lubricate lift point swivel, check hold bolts
Check lift umbilical for damage above TMS CONTROL ROOM and WORKSHOP √
Bleed high spots on hydraulic circuits Touch up paintwork as required
Bleed high spots on electrical comp hoses Lubricate door hinges and locks
Check idler pulley for wear and security Clean PDU and AC filters
Check operation of low level comp alarms Clean PC and UPS filters
Check operation of low hydraulic oil level shut
Ensure work areas are clean and tidy
down
Check pawl key Check for water ingress
Check wear / ops of Main and Safety latches

Test LIM shutdown system
Note: Requires ROV / TMS system to be split
Check operation of latch indicators

Check door seals
Note: Requires ROV / TMS system to be split
Check and grease all lubrication

Check air con drain free of obstruction
points/cartridge stems
Manually test RCDs and Circuit Breakers
HPU Run time hours: Test emergency lights
Motor serial number Check Fire Extinguishers are serviceable
Example of recommended monthly checks for Deck HPU and general Housekeeping:
CHARGE CART √ SPARES √
Function test ROV Electric motor - Serial No:
Check for oil leaks TMS Electric motor - Serial No:
Check function of low oil level cut out ROV main pump
Check operation of cooling fans ROV aux/ Deck HPU pump
Check operation of temperature cut out Lateral thruster motor
Vertical thruster motor
Lateral thruster props
Vertical thruster props
HOUSEKEEPING √
Are fire extinguishers in place and clearly
Check condition of the ladders
marked
Are first aid cabinets fully stocked and contents Are emergency eyewash stations available
in date on site
Are pathway accesses to and from the work Are emergency exists clearly marked and
area free of obstacles free of obstructions
Are all the handrails and kick plates in position,
Inspect inertia reel and soft sling
secure and well maintained
Are fire extinguishers in place, in date and Are emergency eyewash stations in date
clearly marked available in Control Van & Workshop
Inspect inertia reel and soft sling, check if are
in date
11.2 Quarterly
The following are the recommended quarterly checks:
ROV √ LARS √
Check all MV terminals for torque in

Remove and clean all cable connectors and pins
PDU and transformer
Replace batteries in flasher unit Drain / clean drip tray
TMS √ CONTROL ROOM and WORKSHOP √
Remove and inspect level wind Pawl, replace if

required
Remove and clean all cable connectors and pins
CHARGE CART √ TOOLING PACKAGE √

Test fit up and operation of back up
fluid skid
HOUSEKEEPING √ SPARES √
11.3 Biannual
The following are the recommended six monthly checks:
ROV √ SPARES √
Case checks - pumps + record ROV Electric motor - Serial No:

Rotate motor shaft and check free
Change burst disks on main and aux tanks
movement
Vacuum test MEE seals & entire enclosure Check insulation and continuity
Remove and strip ROV lift point, inspect
TMS Electric motor - Serial No:
bushes replace if required
Rotate motor shaft and check free
movement
Check insulation and continuity
TMS √ LARS √
Inspect cursor guide bushes, remove/clean
Re-commission TMS (tooling tech req'd)
if required.
pump case drain checks + record Open and inspect terminals and resistors
Vacuum test electronics pod seals inside Brake Resistor Bank
remove and replace level wind Pawl (note Check all rotary and static J-Box's including
check that to see if it was replaced at the 3 motors for water ingress. Replace Silica Gel
monthly checks bag if required
Check and re-torque main lift attachment
bolts 375nm
CHARGE CART √ CONTROL ROOM and WORKSHOP √
Ensure all portable tools have valid test

Deck pack service
tags from the vessel electrician
Pump case drain checks + record
11.4 Annual Checks

The following are the recommended annual checks:
ROV √ LARS √
Sample electrical enclosure compensation oil
and megger test. Drain J-Boxes, elect. motor Drain and replace gearbox oil
and comps.
Path load test required, through main
Check MV terminals for torque in oil filled J- sheave wheel and latching system as per
Box’s LARS latching mechanism SWL and main
sheave wheel pin SWL
Remove, clean and inspect props
Perform thruster case checks and record

Replace MEE seals and vac test
WINCH √
Replace desiccant bags
Load test required, dynamic and static
Load test required on bullet mechanism as
(break and mechanical socket) as per break
per ROV fixing structure SWL
SWL and Bullet SWL
AHRS calibration check
*Replace all high pressure hydraulic hoses
TMS √ CONTROL ROOM and WORKSHOP √

Sample electrical enclosure compensation oil
and Megger test. Drain J-Boxes, elect. motor Discharge test emergency lights Time:
and comps.
Check MV terminals for torque in oil filled J-
Discharge test UPS Time:
Boxes
Replace MEE seals and vac test

Load test required through latching system
as per TMS latching mechanism SWL
UMBILICAL √
Umbilical reterminated.
CHARGE CART √ TOOLING PACKAGE √
HOUSEKEEPING √ SPARES √
*Every second year.
Recommended Tools and Consumables
12. Recommended Tools and Consumables

12.1 Consumables
The following is a list of recommended general consumables:
Table 46: General Consumables
General Consumables
Part # Description
0004-9280 Abrasive Paper "Wet & Dry" 120Grit - Each
0004-9281 Abrasive Paper "Wet & Dry" 60Grit - Each
0004-9282 Araldite 24ml Syringe Tube - Each
0004-9287 Battery 9V pack of 12 - Box
0004-9289 Cable tie, stainless 306, 200mm - Box
0004-9293 Champion CA1861 S/S Circlip kit - Box
0004-9294 Champion Grub Screws S/S CA1862 - Box
0004-9297 Duct Tape, 48mm x 50m - Each
0004-9305 Garbage Bags - 75L - Box
0004-9306 Grease, Silicon, Rocol, 120g Tube - Each
0004-9307 Handsaw - Each
0004-9308 Hole Saw Set 16-51mm - Set
0004-9309 Loctite 243 High Strength Threadlock, 50ml - Each
0004-9310 Loctite 262 High Strength Threadlock, 50ml - Each
0004-9311 Loctite 567 Thread Sealant, 50ml - Each
0004-9322 O-Ring Splicing kit - Imperial - Box
0004-9323 O-Ring Splicing kit - Imperial - Box
0004-9325 Paint Cold Galv - Zinc Aerosol - Each
0004-9326 Paint Satin Black - Aerosol - Each
0004-9327 Paint White Gloss - Aerosol - Each
0004-9328 Paint Yellow Gloss - Aerosol - Each
0004-9329 Plasti-bond Selleys 450gm - Each
0004-9331 Rocol Sapphire Aqua 2 Marine Grease - Each
0004-9332 Rope Dope - Rocol 105 20L Drum - Each
0004-9339 Trefolex 500gm - Each
0004-9340 Window Cleaner, windex spray bottle - Each
0004-9341 Wire Cup Wheel 75mm x 14 x 2 - Each
0004-9283 Battery AA pkt 24 - Box
0004-9288 Bolts, Nuts & Washers- Champion Asstd Kit S/S - Box
0004-9295 Contact Adhesive - Each
General Consumables
Part # Description
0004-9296 Devcon Aluminium Putty - Each
0004-9298 Engineers Chalk - Each
0004-9300 Fast Orange Head Cleaner 4L pump pack - Each
0004-9301 Ferrocraft Low Hydrogen electrodes - Box
0004-9302 Flexovit 115mm x 2.5 x 22 C/off flat wheel) - Each
0004-9303 Flexovit 230mm x 2.5 x 22 C/off Flat - Each
0004-9304 Gaffer Tape - Nashua 357 - Each
0004-9312 Loctite 406- 25ml - Each
0004-9313 Loctite Anti Seize - Each
0004-9314 Loctite Nickel Anti Seize - Each
0004-9319 Masking Tape - Hystik - Each
0004-9320 Molykote 111 Oring Grease - Each
???? Moly bond GA50
0004-9324 O-ring splicing kit - Metric - Box
0004-9334 Self Tapping Screws - S/S Champion - Box
0004-9335 Silastic 732-310 tube - Each
0004-9336 Split pin kit S/S Champion - Box
0004-9337 Stylus Duct Tape - Each
0004-9338 Thread Tape 25mm x 10m - Each
0004-9343 Desgreaser 5L Chemtech - Each
0004-9342 Wirelock Potting Compound - Each
0004-9315 M10 x 1M Threaded rod 316 SS - Each
0004-9316 M12 x 1M Threaded rod 316 SS - Each
0004-9317 M6 x 1M Thread rod 316 SS - Each
0004-9318 M8 x 1M Threaded Rod 316 SS - Each
0004-9284 Battery AAA pct 24 - Box
0004-9285 Battery C pct 12 - Box
0004-9286 Battery, 6V, Suit Dolphin Torch - Each
0004-9299 Fasteners, Socket Head Cap Screw, Stainless A4-70, Metric assortment - Set
0004-9321 Mousing Wire, Roll - Each
0004-9330 Rags, Bag - Each
0004-9333 Rope , 10mm Roll - Each
Silicone Spray
12.1.1 Electrical Consumables

The following is a list of recommended electrical consumables:
Table 47: Electrical Consumables
Electrical Consumables
Part # Description
0004-9273 Electrical Tape - Rainbow pack - Box
0004-9274 Lectra clean Aerosol Pack CRC - Each
0004-9275 Potting Compound Scotchcast - Each
0004-9270 Heat Shrink tube 1.5mm - Each
Scotch Kote
0004-9271 Heat Shrink tube 3mm - Each
0004-9272 Assortment of Cable Ties - Navara - Box
0004-9278 CRC LECTRA Shield - Each
0004-9266 0.5mm Multicore Solder - Each
0004-9267 0.7mm Multicore Solder - Each
0004-9268 Solder Wick 2.8mm bobbin pack - Each
0004-9269 Solder Wick 1.5mm bobbin pack - Each
0004-9276 Treblex Contact Cleaner - Aerosol Can - Each
0004-9277 Fibre Optic Connectors (ST) - Each
0007-9882 3M Self Amalgamating Tape
12.2 Recommended General Tools

The following is a list of recommended general tools:
Table 48: Recommended General Tools
General Tools
Part # Description
0004-9346 300mm Steel Rule - Each
0004-9347 1m Steel Rule - Each
0004-9348 Framing Square - Each
0004-9350 Broom Poly back 14" /350mm - Each
0004-9351 C Spanner adjustable 2-4 1/2" - Each
0004-9352 Carpenter Square Stanley 610mm x 406mm - Each
0004-9354 Chain Block - Each
0004-9356 Copper Mallets 38mm Thor - Each
0004-9359 Cordless Drill Kit, 18V Makita - Each
0004-9360 Cordless Grinder, 18V (no battery) Makita - Each
0004-9362 Deburring Kit, Noga - Set
0004-9363 Drill set, Sutton Metric, VM3 - Each
0004-9364 Drill set, Sutton Imperial, V3 - Each
General Tools
Part # Description
0004-9365 Extension Lead 15amp x 10m - Each
0004-9367 Funnel Nylex 10cm Plastic - Each
0004-9368 Funnel Nylex 22cm plastic - Each
0004-9369 G Clamps - 150mm Irwin / Record - Each
0004-9370 G Clamps - 150mm Record) - Each
0004-9371 Garden Hose 18m x 1/2" Nylex - Each
0004-9372 Grinder Makita 12v 115mm - Each
0004-9373 Hacksaw - Stabley pro - Each
0004-9378 Hes Set, T-Handle, Metric - Set
0004-9382 Metal Dust Pan - Each
0004-9383 Needle File Set - Set
0004-9384 Norbar Torque Wrench 20-100nm - Each
0004-9385 Norma Spray Bottles - Comp Bottles - Each
0004-9386 Padlock, Combination, - Each
0004-9387 Pich Bar 900mm - Each
0004-9388 Pipe Wrench 1500mm RFC New 600mm (0706 2300) - Each
0004-9395 Puller Kit, Hydraulic, JBS HPK-25P - Set
0004-9400 Rivet Gun Kit, Hand, with rivets - Each
0004-9403 Screw Extractor Set, With Drills, Sutton, - Set
0004-9404 Adjustable spanner 300mm - JBS Brand - Each
0004-9405 Adjustable spanner 450mm - JBS Brand - Each
0004-9406 Stepladder - Each
0004-9414 Strap Wrench - Each
0004-9415 T Tapping wrench 2-6mm Sutton - Each
0004-9416 T tapping wrench 7-12mm Sutton - Each
0004-9417 Tin Snips - Wiss Straight - Each
0004-9420 Utility Knife Auto Retracrt - Each
0004-9422 Vice Grip 75mm spring loaded - Each
0004-9423 Vice Grips 250mm - Each
0004-9425 Yard Light/ Twin Light - Each
0004-9345 150mm Steel Rule - Each
0004-9349 Bannister Brush - Each
0004-9353 Caulking/Cartridge drum - Each
0004-9355 Combination Square 300mm - Each
0004-9358 Dolphin Torch - Each
0004-9374 Hammer 225g - Each
0004-9375 Hammer 900g - Each
0004-9376 Hex Set Allen Key - Imperial - Set
0004-9377 Hex Set Allen Key - Metric - Set
0004-9380 Macnaught K29 Grease Gun - Each
0004-9389 Pliers, Circlip, Internal Straight - Each
General Tools
Part # Description
0004-9390 Pliers, Circlip, External Straight - Each
0004-9391 Pliers, Circlip, Internal Bent - Each
0004-9392 Pliers, Circlip, External Bent - Each
0004-9393 Power Boards 240v Surge protected - Each
0004-9394 Pressol Spray Industrial Bottle - Each
0004-9396 Punch Set, combo pin and chisel - Set
0004-9407 Socket Set, 54pc Metric/AF, 1/4" Drive - Set
0004-9410 Spanner Set, Combination, Metric, 17PC, 6mm -> 22mm - Set
0004-9411 Spanner Set, Combination, Imperial, 13PC, 1/4" -> 1" - Set
0004-9412 Spanner Set, Flare Nut, Metric, 9mm -> 17mm - Set
0004-9413 Spanner Set, Flare Nut, Imperial, 3/8" -> 11/16" - Set
0004-9418 Torque Wrench 3/8", 8-60Nm - Each
0004-9419 Torque Wrench 1/2", 60-330Nm - Each
0004-9424 Wire brush 4-row - Each
0004-9357 Digital Camera, Waterproof, Shockproof, SONY CyberShot TX5 - Each
0004-9401 Screwdrivers, thru-shaft with Hex Bolster - Set
0004-9402 Screwdriver Bit set for use with Battery Drill - Set
0004-9379 Kinchrome Tap & Die set - Each
0004-9381 Makita Jigsaw Overhead Handle - Each
0004-9366 File Set, 10" 5pc, Bahco - Set
0004-9397 Rated Shackle 1 Ton - Each
0004-9398 Rated Shackle 3 Ton - Each
0004-9399 Rated Shackle 9.5 Ton - Each
0004-9361 Cordless Torch, 18V Makita BML185 -18V LXT - Each
0004-9421 Utility Knife Spare Blades - Box
12.2.1 Electrical Tools

The following is a list of recommended electrical tools:
Table 49: Electrical Tools
Electrical Tools
Part # Description
0004-9232 Clamp Meter - Each
0004-9233 HAKO Soldering Station - Each
0004-9234 Megger Continuity Tester - Each
0004-9235 Oscilloscope - Each
0004-9236 Fibre Termination Kit - Each
0004-9237 Light and Power source meters - Each
Electrical Tools
Part # Description
0004-9239 Laptop (netbook) - Each
0004-9240 Digital Thermometer - Each
0004-9241 Small Side cutters and Pliers Kit (Sidchrome) - Set
0004-9242 Microscope - Each
0004-9244 Crimping tools: Automotive, Ferrule and Coax - Set
0004-9245 Lindstrom Side cutters - Each
0004-9246 Large Cable cutters - Each
0004-9247 Heat Gun - Each
0004-9248 Pin extraction tool - Each
0004-9250 Mini Vice - Each
0004-9251 PTFE Wire Strippers, Custom Stripmaster, Ideal - Each
0004-9253 Solder Sucker - Each
0004-9254 Tweezers - Each
0004-9255 4mm Nut Drive - Each
0004-9256 3mm Nut Drive - Each
0004-9257 Wire with Crocodile Clip - Each
0004-9258 Precision Temp Sensor - Infra Red - Each
0004-9259 Series 1507 Insulation Tester - Each
0004-9260 Wire Strippers - Knipex 160mm - Each
0004-9261 Series 170 Fluke Multimeter - Each
0004-9262 Electricians Pliers 200mm Knipex 1000v - Each
0004-9263 Side Cutters - Hi Voltage 180mm - Each
0004-9264 Pliers long nose - Hi voltage 1000v 200mm - Each
1758558 HAKKO - FX-838 - Soldering Station, FX-838
1758562 HAKKO Tip. Shape 3.2D
1758570 HAKKO Tip, Shape BL
1758571 HAKKO Tip, Shape BCM2
12.2.2 Hydraulic Tools

The following is a list of recommended hydraulic tools:
Table 50: Hydraulic Tools
Hydraulic Tools
Part # Description
0004-9229 Hydraulic Fittings, assortment - Set
0004-9195 17mm spanner with ring end mod - Each
0004-9197 Spanners all sizes 1/4" TO 1" - Set
0004-9198 Spanner 1 1/16" - Each
0004-9199 Spanner 1 1/8" - Each
Hydraulic Tools
Part # Description
0004-9200 Spanner 1 3/16" - Each
0004-9201 Spanner 1 1/4" - Each
0004-9202 Spanner 1 5/16" - Each
0004-9203 Spanner 1 3/8" - Each
0004-9204 Spanner 1 7/16" - Each
0004-9205 Spanner 1 1/2" - Each
0004-9209 1-5/8" Deep Socket, impact, 3/4" drive - Each
0004-9210 3/4" drive socket set - Set
0004-9211 3/4" drive Universal Joint - Each
0004-9212 Spanner Combination Ring/OE af 1 1/16" - Each
0004-9214 Spanner Combination Ring/OE A/F 1 3/16" - Each
0004-9224 Spanner Combination Ring/OE A/F 2" - Each
0004-9225 Adjustable spanner, 760mm - Each
0004-9226 8mm Allen Key - cut down - Each
0004-9227 3/4" drive, 1-13/16" socket skimmed down to 58.5mm - Each
0004-9207 Parker Tube Spanners - Set
0004-9208 Snap On Crows Foot Spanners, 12pt thin wall, 1/2" drive, 1_1/8" to 2" - Set
0004-9186 3 in 1 Thruster Hub Tool - Each
0004-9188 24V Solenoid Test Kit - Each
0004-9192 Thruster Hub Tool - Each
0004-9193 Slide Hammer for Hub - Set
0004-9194 Thruster Manifold Cartridge Valve Tools - Set
0004-9196 3 Leg Puller, suit 100mm dia - Each
0004-9187 RIDGID Wrench model E-110 - Each
0004-9189 3/8" drive Hex key set - Metric - Set
0004-9190 1/2" drive hex key set - Metric - Set
0004-9191 1/2" Drive Deep Sockets - Metric - Set
0004-9206 Spanner 2" combination - Each

TMT-NMA-033 Typhoon MK2 150 Maintenance

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Typhoon MK2 150

System Maintenance Manual

TMT-NMA-033 Total Marine Technology Pty Ltd Revision Number: 3

Document Control Details

Total Marine Technology Pty Ltd

Total Marine Technology

Document Control Details ..................................................................................................... 2

4. General Maintenance Requirements ............................................................................37

6. Electrical Subsurface Components...............................................................................57

6.12.2 Prerequisites .................................................................................................91

7.8.1 Risks and Mitigations .....................................................................................111

7.15.1 Risks and Mitigations ..................................................................................132

Figure 33: Cardev Hydraulic Filter .....................................................................................110

Table 17: Power & Fibre Colours.........................................................................................92

1. Associated Documentation and Terminology

Document No. Rev. Date Description/Title Company

Manuals and Data Sheets

DOL Direct On Line

RTD Resistance Temperature Detector

1.2 Document Conventions

Table 2: Document Conventions

1.3 Document Tree

2.1 Maintenance Records

Warning: Personal Protective Equipment (PPE) as dictated by on site requirements

3.1 Electrical Safety

Electrical Safety Guidelines

Figure 1: Bonding Clamp Attached to ROV & TMS

3.1.2 Line Insulation Safety Guidelines

3.1.3 Fibre Optic

3.1.4 Electrostatic Discharge

3.1.5 High Voltage Gloves

Figure 2: 3.1.5 High Voltage Gloves

Umbilical Electrical Safety

5. Prepare the correct PPE i.e. insulating matt and gloves.

Warning: No testing is to be conducted before discharging and earthing first.

3.1.7 ROV and TMS Deck Connector Plug Visual Inspection

3.2 Isolation of ROV Equipment

Risks and Mitigations

Table 3: Isolation of ROV Equipment - Risks and Mitigations

Table 4: Required Documents

Description Typhoon T12-17 Typhoon T24-29

Description Typhoon T12-17 Typhoon T24-29

Table 5: Isolation Chart

Equipment Isolation Point Function Location

Equipment Isolation Point Function Location

Long Term Isolations

3.3 Hydraulic System Safety

Hydraulic Safety Guidelines

Warning: Before removing or performing maintenance on any hydraulic system

Figure 3: Example Pilot Operated Cross Check Valves

3.4 Lifting Safety

o Date of last test - if applicable

o Date of next test - if applicable

o Date of the last examination

o Date of the next examination

o Individual identification number

o Safe working load

o Type of lifting equipment

o Equipment is in good condition.

Warning: Never use unauthorized lift points.