USER MANUAL VESTDAVIT TYPE TDB-3602
VESTVINSJ TYPE C - 356 - 1
Customer
:
Neptune Offshore
Vestdavit project no.
:
8050
Date of delivery
:
July 2009
Prepared by H.Laupsa
Approved by P.C.Møgster
Doc. No. VDT-UMT-8050
Rev.No. 0
Date 31.05.10
Page 1 of 41
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 2 of 40
TABLE OF CONTENTS List of illustration ................................................................................................................... ....................................................... ............................................................................................................ ................................................ 3 Part I INTRODUCTION ...................................................... ................................................................................................................. ........................................................................................ .............................4 4 Part MAIN DATA........................................................................................................................................................5 2.1II Conditions of guarantee..............................................................................................................................................5 2.2 Technical data ..................................................................................................................... .......................................................... .................................................................................................. ....................................... 5 2.3 Restrictions in use.......................................................................................................................................................6 2.4 Main connections connections and requirements requirements for connect connected ed system systemss .......................................................... ....................................................................................... .............................6 6 2.5 Weight and outline dimensions...................................................................................................................................6 PART III TECHNICAL DESCRIPTION...........................................................................................................................7 3.1 Davit functions .................................................................................................................... ......................................................... .................................................................................................. ....................................... 7 3.2 Winch ............................................................................................................... ................................................... ...................................................................................................................... .......................................................... 7 3.3 Hydraulic system...................................................... system ................................................................................................................. .................................................................................................. ....................................... 8 PART IV INSTALLATION AND PREPARATION .................................................................................................... .................................................... ................................................ 9 4.1 General ....................................................................................................................... ........................................................... ............................................................................................................ ................................................ 9 4.2 Storage........................................................................................................................................................................9 4.3 Float chart installation ................................................................................................................... ........................................................ ...................................................................................... ...........................10 10 4.4 Welding to deck........................................................................................................................................................11 4.5 Maneuvering equipment location ........................................................... ...................................................................................................................... ..................................................................11 .......11
4.6 4.7 4.8 4.9 4.11 4.12 4.13| 4.14 4.15 4.15 Part V 5.1 5.2 5.3 5.4 5.5
Maneuvering valveonconnections .............................................................................................................. ................................................... ............................................................................12 .................12 Hydraulic system ship..........................................................................................................................................13 Filling of hydraulic oil..............................................................................................................................................17 Starting the system....................................................................................................................................................18 Threading of wire .......................................................... ..................................................................................................................... ...................................................................................... ...........................19 19 Maintenance of piston rods on the hydraulic cylinders on the TDB-Davit..........................................................20 Lubrication oil and drain connections for win winch ch ................................................................................................. ................................................... .............................................. 22 Instruction for activating shockabsorber..............................................................................................................23 Instructions for refilling nitrogen on shock absorber accumulator.......................................................................24 Test Procedures .............................................................................................................. ................................................... ................................................................................................ ..................................... 25 OPERATING AND CONTROL ............................................................................................................... .................................................... ..................................................................26 .......26 Checking before start................................................................................................................................................26 Starting ....................................................................................................................... ........................................................... .......................................................................................................... .............................................. 26 Special notes regarding the winch ..................................................................................................................... .......................................................... ..................................................................26 .......26 Lowering operation ............................................................................................................. .................................................. ................................................................................................ ..................................... 27 Hoisting operation .................................................... ............................................................................................................... ................................................................................................ ..................................... 27
5.6 Emergency push out and lowering operation............................................................................................................28 5.7 Emergency hoisting operation (see Hydraulic diagram)....................... diagram).................................................................................. ..................................................................29 .......29 5.6 Charging of accumulator .................................................... ............................................................................................................... ...................................................................................... ...........................30 30 Part VI INSPECTION AND MAINTENANCE ........................................................................................................... ................................................... ........................................................ 31 6.1 General ....................................................................................................................... ........................................................... .......................................................................................................... .............................................. 31 6.2 Inspection routines....................................................................................................................................................31 6.3 Disturbance of operations.........................................................................................................................................34 6.4 Long term stop and new start....................................................................................................................................37 PART VII SPARE PARTS ............................................................................................................. .................................................. ................................................................................................ ..................................... 38 APPENDIX A - DRAWINGS ........................................................ ................................................................................................................... ...................................................................................... ...........................39 39 APPENDIX B - CERTIFICATES ........................................................... ...................................................................................................................... ............................................................................40 .................40
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 2 of 40
User Manual TDB-3602
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VDT-UMT-8050 00 0-JUL-09 3 of 40
List of illustratio illustration n Figure 1 F Float loat chart installation ................................................................................................................... ........................................................ ...................................................................................... ...........................10 10 Figure 2 Man Maneuvering euvering valve connections .............................................................................................................. ................................................... ............................................................................12 .................12 Figure 3 Piping exanple .......................................................... ..................................................................................................................... ................................................................................................ ..................................... 16 Figure 4 Threadin Threading g of wire ................................................................................................................ ..................................................... ................................................................................................ ..................................... 19 Figure 5 Piston rod on cylinder...............................................................................................................................................20 Figure 6 Cylinder....................................................................................................................................................................21 Figur 7 Guiding cylinder.........................................................................................................................................................21 Figur 8 Winch lubrications points...........................................................................................................................................22 Figure 9 Activating shockabsorber ................................................... .............................................................................................................. ...................................................................................... ...........................23 23 Figure 10 C Charging harging of accumulator .................................................. ............................................................................................................. ...................................................................................... ...........................30 30
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 3 of 40
User Manual TDB-3602
Part I
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 4 of 40
INTRODUCTION
This manual contains description of all necessary details needed for installation, operation and maintenance of the davit. The manual consist of the following parts:
PART I
Introduction
PART II
Main data
PART III
Technica Technicall descriptio description n
PART IV
Installation and Preparation
PART V
Operation and Control
PART VI
Inspection and maintenance
PART VII
Spare parts
APPENDIX A
Drawin Drawings gs
APPENDIX B
Certificates
Any questions regarding the manual or the davit should be directed to:
Vestdavit A/S Damsgårdsveien Damsgårdsvei en 143 5162 Laksevåg, Norway Telephone: 47 55 54 92 00 Telefax : 47 85 02 85 29 E-mail:
[email protected]
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 4 of 40
No.: Rev.: Date: Page:
User Manual TDB-3602
Part II
VDT-UMT-8050 00 0-JUL-09 5 of 40
MAIN DAT DATA
2.1
Conditions of guarantee 24 months provided commissioning supplied by Vestdavit AS.
2.2
Technical data DAVIT: Davit type Max. load ,SWL : Test load in work shop Wire Hydraulic cylinder davit Shock Absorber Accumulator for shock absorber
Vestdavit TDB-3602 3600 kg 7920 kg ø18mm, L=29 m HMT2-V-D-100/90x70/ HMT2-V-D-100/90x70/40x3700-S-R-SP 40x3700-S-R-SP CP4BG 80 x 400 10L, loaded 120 bar N2
WINCH: Winch type Max. wire pull 2. Layer Drum dim. Max. Hoisting speed Max lowering speed Oil pressure Required oil flow Hydraulic motor, type Gear, type Gear reduction
Vestvinsj C-356-1 3600 kg Ø356 mm 50 m/m m/min in 50 m/m m/min in 220 bar 110 l/min F12-110-MS Brevini ED 2090/ FL 450MN 1:30,3
MANOEUVRE EQUIPMENT: Maneuvering valve Valve Block
HPV-O-77M190-41C80 Linde 94
HYDRAULIC POWER UNIT: Electric motor, Oil tank volume Oil flow Oil type Operation temperat temperature ure
Bevi-motor Bevi-motor,, 54kw, 440V, 60Hz 350 L 145 L/Min at 200 bar Shell Tellus T32 or similar Max. 55 C °
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 5 of 40
User Manual TDB-3602
2.3
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VDT-UMT-8050 00 0-JUL-09 6 of 40
Restrictions in use
1
The davit is only to be used in lowering/hoisting operation with boat connected to hook.
2
The davit is not to be used as a crane, i. e. cargo net is not allowed.
3
The davit shall not exceed SWL for the davit arrangement.
Any violation to these restrictions will invalidate the guarantee conditions.
2.4
Main connections and requirements for connected systems
If the davit hydraulic system is connected to external hydraulic supply, i.e. constant pressure system, load-sensing etc., hook up valve arrangements should be stated in hydraulic diagram. If not, contact Vestdavit A/S.
2.5
Weight and outline dimensions
Davit weight
App. 2250 [kg]
Davit outline dimensions
App. 400 x 150 x 120 [cm]
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 6 of 40
User Manual TDB-3602
PART III
3.1
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VDT-UMT-8050 00 0-JUL-09 7 of 40
TECHNICAL DESCRIPTION DESCRIPT ION
Davit functions TDB -davit is a hydraulic operated single point davit designed for effective safe launching of Man Overboard Boats or Work boat. All operations of the davit are hydraulic driven which benefits control of the boat position at all stages during the operation and, in contrast to a gravity davit, gives the opportunity to bring the boat back onboard in any position required at any time.
In stowed position the boat is resting on supports and secured by lashings. Embarkation of the boat can take place in parked position or in a position on ship's side in deck level. The davit is operated by one person from the operator’s console and should have a clear view to the boat when launching. Launching of the boat is done by pushing the cylinder from its parked position to a position where it is free of the ship's side and then lowered by means of the winch. This two-step operation makes it possible to move the davit backwards after lowering the boat below deck level, allowing it to rest along the ship's side and prevent it from excessive movements in rough weather conditions, or to park the boat along the ship's side for embarkation. The Shock absorber is a fully f ully automatic/passive hydraulic device, that ensure smooth lowering and hoisting operation of the boat.
3.2
Winch
The winch consists of five main elements: Frame with wire drum Wire drum is connected directly to the gear shaft. The winch frame is mounted to the davit by 4 bolts. Gear The reduction gear is a planetary gear flanged directly to frame. Mechanical brake Between gear and motor there is a automatic spring-loaded disc brake functioning as parking brake and a mechanical brake. The brake is released by hydraulic pressure. Hydraulic motor The motor is an axial piston motor connected to a hydraulic pump in open circuit. Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
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Hydraulic control unit The hydraulic control unit controls the hydraulic brake at dynamic stop of the winch. It functions as an automatic controller of the disc brake, hydraulic brake and the maximum speed. 3.3
Hydraulic system
The winch system consists of hydraulic motor, valve block flanged to motor and hydraulic operated brake. Hydraulic double acting cylinders for swing out / in, with throttle-check valves. Hydraulic shock absorber for smooth lowering and hoisting. The Maneuvering unit is a lever operated directional valve. Spring centered 2 spools valve. First bank closed center for operating cylinder, second bank open center for winch motor.
The hydraulic power unit consist of a closed reservoir and following equipment: An electric motor which drives a gear pump through a flexible coupling. A hydraulic return filter for oils flowing from davit. An air breather filter for preventing dirt and dust to enter the tank and vapors to leave. An oil level gauge. A temperature indicator.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 8 of 40
User Manual TDB-3602
PART IV
4.1
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VDT-UMT-8050 00 0-JUL-09 9 of 40
INST INS TALLA ALLATIO TION N AND PREPARATION PREPARATION
General
Correct installation is a prerequisite for safe operation. If any questions arise during the installation, contact the Vestdavit supervisor at site or contact a Vestdavit engineer by telephone or telefax. The davit has been tested and all the components are controlled prior to shipment. Before starting the installation, check that no part of the system or any components have been damaged under transportation. If any damages have occurred, contact immediately Vestdavit for replacements. The davit is complete for installation on board. The davit system consists of the following components: -
4.2
Three structure tructure and two inner tubes.square tubes. One outer to be fixed to the ship s Winch Maneuvering console. Hydraulic cylinders. Shock absorber. Hydraulic Wire hauler Hydraulic Power Unit Hydraulic piping on ships deck (Yard delivery)
Storage
Davit steel structure Outdoors unprotected normally 3 months. Normal position is two legs and davit head to ground.
Power unit Submerged Stainless Steel Tank, no preservation, time unlimited.
Hydraulic components Indoors, dry conditions.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
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User Manual TDB-3602
4.3
VDT-UMT-8050 00 0-JUL-09 10 of 40
Float chart installation
Installation of davit
Installation of man.
Airing of system
consol/hand pump
Hydraulic piping
Thread readin in of wire wire
on deck Flushing
Installation of
of s stem
wedge lock
Fillin of System oil
Function tests
Charging of Accumulators
Starting of system
Load tests
Installation completed
Figure 1 Float chart installation
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 10 of 40
User Manual TDB-3602
4.4
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VDT-UMT-8050 00 0-JUL-09 11 of 40
Welding to deck
The davit is delivered with brackets for welding under ship’s deck. Correct position for the brackets are given in the davit arrangement drawing. correctly orrectly levered and that they do not twist during NOTE! Check that the brackets are c welding. 4.5
Maneuvering equipment location
Maneuvering valve should be located in a position in view to the t he MOB boat during launching. A spring-loaded control valve to be installed in the return line as close as possible to the maneuvering valve. Opening pressures 2-3 Bar. Valve is to prevent loss of oil and is for that reason very important. Check valve in pressure line close as well.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 11 of 40
User Manual TDB-3602
4.6
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VDT-UMT-8050 00 0-JUL-09 12 of 40
Maneuvering valve connections
Br evi vini ni valve c ce en tral HPV
Lever movement (from picture position) gives oil to port: Port A
Port B
Pul l l ever
Pus h l ever
Plug for P
Port A
Port P
Port B
Port T Pressur Pres sure e adjustm adjustment ent valve valve
Figure 2 Maneuvering valve connections
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 12 of 40
User Manual TDB-3602
4.7
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 13 of 40
Hydraulic system on ship.
General Keep all pipe connections from winch, pump, cylinders etc. plugged until final system connecting is complete. Only plastic plugs or covers must be used. Do not use paper plugs or cotton waste. The system is designed for minimum pressure loss. Pipe sizes as shown on system drawings are based on short distance between hydraulic users. Max. 10m pipe distance between davit and maneuvering valve. Idle pressure measured at maneuvering valve shall not exceed 5 bar.
Choice of pipes On long distance pipelines the velocity must be reduced by increasing the diameter. Pressure head loss and oil velocities must be kept to a minimum in pipelines for leakage oil from pumps motors. not be connected to the and return line. These pipelines should go direct to the tank and Forming the pipelines, bends must be achieved by cold bending without sand- or lead filling. If welding cannot be avoided, the joints should be placed so that t hat they are easy accessible for maintenance.
Fittings In hydraulic installations, un-welded couplings are preferable. For external diameters up to 42 mm, cutring-couplings may be used. First condition of a tight joint is pipe cutting at correct angle, using a jig. External and internal grades must be removed. Debris must be thoroughly removed using white spirit, compressed air or clean textile cloths. (Do not use paper or waste cotton). Cutring are to be assembled according to the manufacture specification. The pipes must be properly adjusted/fitted prior to installation. The conring armature cannot pull together pipes that are too short or straighten distorted bends. When the system has been used for a period, the couplings should be re -tightened. The flange couplings must consist of one male and one female part with ”O-ring”.
Threaded connections Threaded connections do not give complete sealing, therefore sealant is required. Teflon tape is not recommended, especially for cast iron. Furthermore, surplus Teflon can enter the system and create functional problems. Loctite should be used rather than thread tape. Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 13 of 40
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VDT-UMT-8050 00 0-JUL-09 14 of 40
Cleaning of pipes when hen the assembly is finished. This is very important. NB! All pipes must be cleaned w
Arrangement of pipes The distance between pump, valves and motors should be kept to a minimum. It is preferable using formed pipes rather than elbows due to loss of efficiency.
Clamping The clamps shall prevent the pipes from vibrating and at the same time allow longitudinal movements. The clamps should be lined with plastic or rubber to prevent wearing of the pipes and reduce the noise level. Normal distance between clamps is 25-50 time outerdiameter.
Longitudinal Longitudi nal expansion Pipe bends or hoses can be used for compensation of thermal expansion.
Noise Noise may occur in high-pressure hydraulic systems, but correct installation can reduce this substantially: - The pump must have adequate supply of oil. - Flexible suction line can be an advantage. - The suction line must be absolute tight to prevent air entering into the oil. In some cases it can be necessary to install an accumulator on the compression side. - Hoses can be used in the t he system functioning as shock absorbers and elongation compensators. - No metallic contact between pipes and clamps.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 14 of 40
User Manual TDB-3602
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VDT-UMT-8050 00 0-JUL-09 15 of 40
Flushing of the system Prior to assembly of the main components it is recommended that the pipe system is flushed. The main components may be by-passed when flushing. The flushing f lushing power pack should give an oil flow not less than the capacity of the hydraulic system. The flushing should go on for 4-8 hours, depending of the number of joints and pipe lengths. During the flushing operation the filter must be checked regularly and replaced if required. The filter grade must be at least equal to the system filter. NAS-class 7 to be achieved. The oil used for flushing shall be of the same type as that used under operation.
Pressure testing Pressure testing of the pipes must be achieved prior to starting operation of the system. According to The Norwegian Maritime Directorate regulations a normal testing pressure equals 1,5 x operation pressure.
motors, ors, cylinders and valves are NB! Only the pipe system must be tested. Pumps, mot not normally tested. Nitrogen to be used as test gas.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 15 of 40
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VDT-UMT-8050 00 0-JUL-09 16 of 40
PIPING EXAMPLE
Flexible hoses should be installed according to specifications on the diagram. The hoses can not stand sharp bends or torsion. The bending radius must be checked to make sure that it is sufficient and that the hose is long enough to be moved freely.
Wrong
Right
Hose to short and turned The hose must not be turned in bending
Use a big bend
Remember smallest bending radius
Make the hose long enough Never use sharp bendings Use hose connections giving the hose right direction Figure 3 Piping exanple
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 16 of 40
User Manual TDB-3602
4.8
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VDT-UMT-8050 00 0-JUL-09 17 of 40
Filling of hydraulic oil
Tank, pumps and motors must be filled with correct type of oil according to manufacture specifications.
Oil types For emergency systems of this type it is important that the hydraulic oil has a correct viscosity at all times and at all temperature conditions. A hydraulic oil of good quality and high viscosity index is recommended. Oil with viscosity grade 22-68 cSt at 40° 40°C, C, running 13-54 cSt, will assure a good result under normal temperature conditions. The following table indicates the temperature extremes between which the viscosity grades can be used to remain within start-up and running viscosity range recommendations. Viscosity 22 is recommended with ambient tem temperature perature from +5 to -10° -10°C. C. _______________ _______ _______________ _______________ _______________ _______________ ________________ _______________ _______________ ________ Viscosity Grade @ 40°C 22 cS cStt 32 cS cStt 46 cS cStt 68 cSt cS t
Start up 860 cSt -2 -22° 2°C C -1 -12° 2°C C -6 -6° °C 0°C 0°C
Start up 220 cSt --5° 5°C C 6° 6°C C 12 12° °C 19° 19 °C
Start up 110 cSt 8° 8°C C 14 14° °C 22 22° °C 29° 29 °C
Running 54 cSt Max. 18 18° °C 27 27° °C 34 34° °C 42° 42 °C
Running 13 cSt Min 55° 55 °C 62° 62 °C 71° 71 °C 81 81° °C
In special Arctic condition the use of synthetic oil is recommended. Shell Tellarctic Oil or equal. The gearbox should use gear oil EP 80W/90 or equal.
Operation temperature For continuous operation the temperature should not exceed 65° 65°C C anywhere in the system. Normally Norm ally the best resul results ts are achieved at 55° 55°C. C. Lubricant chart
BRAND SHELL ESSO/EXXON MOBIL CASTROL FINA ELF
HYDRAULIC OIL BRAKE TELLUS T-32 UNIVIS N 32 MOBIL DTE 13 M HYSPIN AWH 32 HYDRAN HV
GEAR OIL OMALA OIL 150 SPARTAN EP 150 MOBILGEAR 629 ALPHA SP 150 GIRAN REDUCTELF SP150
NIPPLE LUBRIC. (Also davit arm and cylinder) ALVANIA EP BEALON EP2 MOVILLUX EP LM GREASE MARSON
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Page 17 of 40
User Manual TDB-3602
4.9
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VDT-UMT-8050 00 0-JUL-09 18 of 40
Starting the system
Preparation before starting After mounting, flushing and oil filling, the following 7 points have to be controlled: 1.
The oil level in tanks.
2.
Circuit- and steering voltage.
3.
Turning direction of pump and motor.
4.
Over-pressure valves, throttle valves and mass control valves have to be completely open.
5.
Valves in the suction line have to be open.
6
All pipe couplings have to be securely tightened.
7
The accumulator on chock absorber must be charged.
Starting
The test run can start when all above 7 points are controlled and found in order. The system shall be run at low pressure and aired carefully. Airing should start close to the pump and end at the driving gea. (Winch, cylinder). The different components to be tested at low pressure. Cylinders and motor shall be run several times in both directions. If everything is satisfactory, the system to be slowly brought up to normal operating pressure. The pressure is increased by keeping the maneuvering valve for cylinder in POs ”in” and at the same time tighten the safety valve (at the inlet side of the maneuvering valve). When the operating pressure has been reached, the pipeline must be checked for tightness. When all connections are found tight, all valves shall be set at correct pressure and oil level. – See hydraulic diagram. During starting period, the filter inner parts should be replaced after 10 hours of operation.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
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VDT-UMT-8050 00 0-JUL-09 19 of 40
4.11
Threading of wire
1.
Lead the wire through the inner wire sheave (item 1), then below the next wire sheave(item 2).
2.
Run the wire through the shock absorber wire sheave(item 3), and then back to the winch(item 4).
3.
Run the wire around the winch and into the winch wedge socket.
4.
Fasten wire rope in wedge socket firmly.
Figure 4 Threading of wire
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 19 of 40
User Manual TDB-3602
4.12
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 20 of 40
Maintenance of piston rods on th the e hydr hydraulic aulic cylinders on th the e TDB TDB-Davit -Davit
Piston rod on cylinder is made of chrome plated stainless steel. It is very important to keep the piston rod clean to avoid seal damage. Piston rods exposed to salt and marine environment may cause failure on the chrome layers on the piston rods. If the chrome layer get pitting/cratering the sealings inside the cylinder will fail, and a leakage may occur. All cylinders have projection of the piston rod. (See pictures) This area is to be cleaned once a week. This area will always be exposed to salt and marine m arine environment.
Figure 5 Piston rod on cylinder.
Projection (Exposed all time) To prevent damage on the chrome layer the davit must be in parked position when its not in use. This means all cylinders on the davit all in. If some of the cylinders must be in out position for some days, the piston rod must be cleaned also then once a week.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
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VDT-UMT-8050 00 0-JUL-09 21 of 40
Figure 6 Cylinder
Rod to be cleaned once a week.
Guiding cylinders (if included): The guiding cylinder rod is exposed to the salt and marine environment . To prevent damage on the chrome layer on rod the rod must be cleaned once a week.
Figur 7 Guiding cylinder
Rod to be cleaned
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 21 of 40
User Manual TDB-3602
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VDT-UMT-8050 00 0-JUL-09 22 of 40
4.13| Lubrication oil and drain connections for winch
VESTWINCH
Figur 8 Winch lubrications points
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Page 22 of 40
User Manual TDB-3602
4.14
Instruction for activating shockabsorber
Item 1. 2. 3. 4.
Description - Filling connection - Ball valve - Accumulator - Cylinder
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VDT-UMT-8050 00 0-JUL-09 23 of 40
Figure 9 Activating shockabsorber
DESCRIPTION The damping element consists mainly of a one-acting cylinder which is connected to a preloaded accumulator. ACTIVATING
1.
Start the system, idle running.
2.
Loosen fitting at filling connection. Make sure that the wire is unloaded.
3.
Open the ball valve slowly until the cylinder is in out position and oil is flowing out of the fitting. Then shut the ball valve, and tighten the fitting. It may also be useful to air at the breather on the accumulator. Repeat the operation until the system is de-aired. The damping element is now ready for use. The accumulator is charged with nitrogen. The pressure is calculated according to the weight to be suspended in the davit. With no load on the hook, the pressure should be checked twice a year.
4.
Draining the system: Stop the system, and open the ball valve. The oil will flow back to the tank when the cylinder is compressed. Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
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Page 23 of 40
VDT-UMT-8050 00 0-JUL-09 24 of 40
No.: Rev.: Date: Page:
User Manual TDB-3602
ACCUMULATOR FILLING UP
If the N2 pressure in the accumulator is too low, it can be filled by use of a special t tool.
4.15
Instructions for refilling nitrogen on shock absorber accumulator.
For refilling nitrogen on shock absorber accumulator we recommend using a Filling- and checking equipment. This equipment can be obtained from Vestdavit AS . Operational weight is boat weight + 3 crew members. mem bers.
PRESSURE-LOAD GRAPH Ø80 SHOCKABSORBER PRELOADING ACCUMULATOR IN BAR/ TON
250
216 bar 200
150
151,5
100 86
50 1
2
3
4
5
STATIC LOAD
6
7
ton
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Page 24 of 40
User Manual TDB-3602
4.15
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 25 of 40
Test Procedures
DELIVERY TEST PROCEDURES FOR THE FIRST INSTALLATION ONBOARD.
General The Davit to be installed according to Vestdavit’s General Arrangement drawing and hydraulic diagram. Accumulator to be pre charged to recommended pressure, hydraulic system pressure tested, function tested and wire spooled on winch drum. Representative from classification societies or other authorities may be present. The tests normally to be carried out by the yards staff.
Load Tests Load tests are done with ” Dummies ” in the hook. Do not use the boat.
1
LOWERING TEST (Brake test) Load = SWL x 1.1 = 3600 x 1,1 = 3960 kg The load to be lowered, with the hydraulic power unit running, and stopped three times by the brake during one lowering sequence.
2
HOISTING Load = SWL Minimum hoisting speed = 50 m/min (+/- 10%)
3
LIGHT LOWERING TEST Load: Boat with normal eq equipment. uipment. The Hydraulic power unit to be running. The load placed in stored position. Swing out the load and lower it. Minimum lowering speed = 50m/min. (+/- 10%)
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Page 25 of 40
User Manual TDB-3602
Part V 5.1
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 26 of 40
OPERA OPERATING TING AND CONTROL Checking before start
Installation and oil filling is completed. System vented. The following must be checked: Oil level in tank. Relief valves, throttle valves and control valves to be open according to hydraulic diagram. All valves in the suction line must be open. Accumulator on shock absorber must be charged with Nitrogen. 5.2
Starting
Start the Hydraulic Power Unit and circulate the oil for several minutes. Release lashings. Do a visual check of the equipment before operating a maneuvering handle. Observe the sound from the t he hydraulic power unit and the winch when operating the davit. 5.3
Special notes regarding the winch
Maneuvering handle in hoisting position: If the oil pressure in the steering line exceeds the release pressure the automatic brake opens. The oil flows from f rom aggregate, maneuvering valve, straight through steering valve, winch and back to the tank. Winch will hoist with desired speed.
Maneuvering handle in stop (0-position). When there is a main power pack, the return line in the maneuvering valve is plugged, and there is no oil-flow through the valve in stop position. The oil pressure from the power pack does not influence the pressure of the circuit in the winch.
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Page 26 of 40
User Manual TDB-3602
5.4
5.5
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 27 of 40
Lowering operation
1.
Start power unit.
2.
Release slip hook and lashings. Check that sea painter line is connected to the Work boat.
3.
Push the davit outwards far enough to give the work boat the best position for launching. A throttle valve may adjust the speed. No people onboard during the initial push out.
4.
Launch the boat by means of the winch.
5.
When the boat is afloat, release first the hook and then the painter line.
Hoisting operation
1.
Push the davit outwards far enough to give the boat the best position when hoisting. Lower the hook in position for the boat.
2.
Fasten the Sea painter line first, then the hook.
3.
Hoist the boat by means of the winch and stop at deck level so the people can disembark
4.
Move the davit inwards to parking position when the boat has passed deck level.
5.
Fasten lashings.
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Page 27 of 40
User Manual TDB-3602
5.6
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 28 of 40
Emergency push out and lowering operation
General When an emergency situation has occurred, the davit arm may be moved out by means of stored energy. Oil pressure from the preloaded accumulator connected to hydraulic cylinder circuit, is used for the purpose. The system is designed so that the accumulator is automatically loaded when the maneuvering lever is held in “cylinder in” position. To obtain full pressure in the accumulator, make sure that cylinder is completely inwards. Then keep the maneuvering lever in the ”cylinder in” position until you observe full system pressure indication on the gauge located on the maneuvering valve.
Procedure for emergency push out: (The HPU to should be turned off) 1.
Release lashings.
2.
Open the ball valve marked 2.
3.
Move maneuvering lever to position ”cylinder out”.
4.
Keep “cylinder out” until boat is clear of deck side.
IMPORTANT! The lever must not be placed in position ”cylinder in”, because all oil from the accumulator will flow directly to tank.
Procedure for emergency lowering: 5. 6.
Lower boat to embarking position. Lower boat to sea level
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Page 28 of 40
User Manual TDB-3602
5.7
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 29 of 40
Emergency hoisting operation (see Hydraulic diagram)
In a dead ship situation using the emergency hand pump can lift the boat. The accumulator is pressurized by using the emergency hand pump. The operation will require 2 men.
Charging of accumulator. accumulator. The davit in ou outer ter position. The valves marked 2 must be closed. Push the maneuvering handle to "Cyl. out" position and hold. Operate the hand pump until max. pressure is obtained in the accumulators. The accumulator pressure can now be used for lifting the boat.
Lifting the boat (The accumulators loaded) One person operates maneuvering valve to ” winch hoist ” position, and then the ball valve marked 2 is opened. The boat will be lifted. When the winch has stopped, close the ball valve and put the handle in neutral position. Load the accumulator once more and repeat until the boat is hoisted.
Recovery of davit arm (The accumulator loaded) One person operates maneuvering valve to ”CYL. IN” position and then the ball valve marked 2 can be opened, and the boat will move in.
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Page 29 of 40
User Manual TDB-3602
5.6
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 30 of 40
Charging of accumulator
Instructions for filling / checking of Nitrogen pressure
Figure 10 Charging of accumulator
1
Ensure that accumulator is shut off from the circuit and decompressed on the liquid side.
2
Valve E to be unscrewed. Valve B to be closed. Attach the charging valve with its appropriate connector on the accumulator using the knurled nut F. Then tighten it fully after positioning the pressure gauge in the required position.
3.
Turn clockwise the adjustment knob E carefully. Check the pressure in the pressure gauge.
4.
If the charging pressure is too high, slowly open the general bleed valve B until the required pressure is obtained.
5.
To increase the pressure, connect the hose to the nitrogen supply and feed in slowly the pressurized gas.
ATTENTION: In all cases, wait until the thermal exchange caused by the changes of pressure has stabilized before checking / adjusting the charge. DISMANTLING: 1.
Unscrew the knob E completely.
2.
Bleed off with bleed valve B.
3.
Undo the nut F, and screw home the protection cap(s). Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
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Page 30 of 40
User Manual TDB-3602
Part VI 6.1
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 31 of 40
INSPECTION INSPECT ION AND MAINTENANCE
General
Inspections shall take place according Observe if the following should occur: to relevant Authorities’ Regulations. - Increase in noise level - Vibration in winch - Functional faults If faults should occur, repair action must be taken immediately. Contact VESTDAVIT if necessary. The inspection and maintenance guide below is the manufacturer recommendation. However, the operation conditions for the davit, or the Authorities, may require more frequently or extended routines. 6.2
Inspection routines
Monthly 1.
Hinge bolts for cylinders and sheaves shall be lubricated with grease. Check that maneuvering valve is moving freely and grease if necessary.
2.
Check oil pressure on accumulator, ref. manometer.
3.
The davit wire must be checked for splinters. The wire should be greased with special oil.
4
The hydraulic oil level must be checked and the tank filled up if necessary. Oil identical to the oil in the tank must be used. Change of oil may be necessary after 1500 hours of operation or annually.
5.
Check oil level in gear and fill up if necessary.
6.
Check oil level in brake and fill up if necessary.
7.
Return filter element on oil tank must be checked and replaced if required. Normal interval for replacement: 500 hours of operation. Min. once a year.
8.
The piston rods for hydraulic cylinders must be kept clean and oiled to avoid seal damages.
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Page 31 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 32 of 40
The Nitrogen pressure in accumulators to be checked each 6 months.
YEARLY INSPECTIONS Ref. relevant requirements from authorities. 1.
Change of oil in the systems should normally be done after 1500 hours of operation or annually.
2.
Gear oil to be renewed if necessary.
3.
Brake oil to be renewed if necessary.
4.
Return filter on oil tank to be replaced as required. Normal interval for replacement: 500 operation. Min. hours once aofyear.
5.
Once a year perform a visual inspection of the cylinder and seals. Drive the davit out and check the cylinder rod for pitting and the seals for leakage. Replace if necessary.
After two years 1. Replace seals according to serv service ice interval desc described ribed in the technical manual . If pitting on the rod is evident, replace rod when replacing seals..
After ten years 1. Replace cylinder. If the davit arrangement when in use is exposed to a worst case scenario with 20deg inward heel and 10deg trim, replacement of the cylinder is needed. The used cylinder will then be sent to the manufacture for service and refurbishing given that the cylinder has not been in service for more than 10 years.
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Page 32 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 33 of 40
WARNING Do not loosen or tighten any hydraulic fitting while system is energized. Hydraulic Hydraul ic fluid under pressure is a risk to personnel and equipment. Ensure hydraulic pressure is bleed from hydraulic accumulators before “breaking” hydraulic fittings.
Greasing of wire The lubrication new wire ropes receive during manufacture is adequate for initial storage and the early stages of the ropes working life. It must however be supplemented at regular intervals. The frequency of this re-lubrication depends on the frequency of usage. When the wire appears ”dry”, it needs re-lubrication. Proper lubrication is important to the service life of the rope. The lubrication serves both as protection against corrosion and as a factor to reduce the friction between wires and strands in the rope. Lubricants should be free from acid and with no pernicious influence either on the wires or on the core. The lubricant must have a consistency that enables it to penetrate into the rope. The rope must be clean before the lubricant is applied.
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Page 33 of 40
No.: Rev.: Date: Page:
User Manual TDB-3602
6.3
VDT-UMT-8050 00 0-JUL-09 34 of 40
Disturbance of operations.
DEFECT
POSSIBLE CAUSE
REMEDIAL ACTION
A. The winch will not hoist/lower.
1. Safety valve opens too early.
Measure the pressure with the drum locked. If the pressure is too low, the safety valve should be ad justed until until the p pressure ressure gaug gauge e shows correct pressure.
2. Throttle valve on hoist line is closed.
Check the valve.
3. The safety valve can be partly open due to particles between seat and valve. The winch will run slower than normal due to reduced oil supply to winch motor.
Clean safety valve.
4. Insufficient amount of oil in the hydraulic oil tank. Suction line can be obstructed or have an air leakage. The pump will then give a squealing sound.
5. Having checked the above points and found the winch pressure to be as specified without achieving the specified pulling force, the fault might be in the winch.
B. Substantial speed reduction.
1. Ref. A.2.
Check oil level on hydraulic oil tank. Check pump suction line.
Contact VESTDAVIT.
Ref. A.2
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Page 34 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 35 of 40
DEFECT
POSSIBLE CAUSE
REMEDIAL ACTION
B Substantial speed reduction.
2. Ref. A.3.
Ref. A.3.
3. Ref. A.4.
Ref. A.4
4. If the speed reduction has developed gradually, the cause might be worn hydraulic pump or winch motor.
Check hydraulic pump. If the pump is in order, the motor m otor in the winch must be overhauled or replaced. INVESTIGATE FIRST IF REPLACEMENT UNIT CAN BE DELIVERED.
C. Lowering speed is slower than hoisting speed
1. The control valve can reduce slide movement.
Check that coil movement in the control valve is equal in both directions.
2. Ref. A.1.
Ref. A
3. Ref. A.2.
Ref. A
4. The oil might be too thick and cause the safety valve to open.
D The brake releases when the control handle is returned to neutral after hoisting with load.
5. Gasket in the winch might be defect.
Can be controlled by checking the amount of oil from the driver side.
1. Wrong type of control valv valve. e. Correct valve shall have all gates to tank open when the handle is in neutral position.
Remove hoses or pipes from control valve. With handle in neutral position it shall be possible to blow air from gate "A" and "B" to tank gate. If not, a correct valve type must be provided provided..
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Page 35 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 36 of 40
DEFECT
POSSIBLE CAUSE
REMEDIAL ACTION
D
2. Too high back pressure in the winch reverse the gate. Too high pressure on return line. Too small pipe dimensions or obstructions.
Check the pressure close behind the winch. Run the pump with maximum number of revolutions and read the pressure when the handle is in the neutral position. If the pressure is higher than 0,4kg/cm 2 the return line should be investigated for possible obstructions, obstructio ns, or be re-placed to greater dimensions.
3. Throttle valve on brake line is too tight.
Replace the valve.
4. Load control valve defect.
Check the valve.
5. Dirt in change valve.
Check, clean or replace the valve.
6. Dirt in return filter.
Replace filter element.
E. The brakes do not work at lowering
1. Ref. D1, D2, D3, D4 and D5.
Ref. D1/D2.
operation.
2. The winch may be over loaded.
Measure the pressure with locked drum. If the pressure is higher than the specified maximum for the winch winch,, it must be reduced. r educed.
3. After the above points have been checked and found satisfactory, the Contact VESTDAVIT. error is probably located in the winch.
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Page 36 of 40
User Manual TDB-3602
6.4
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 37 of 40
Long term stop and new start
For long term stop in operation the oil tank must be completely filled to underside of tank (if separate power unit). This is to prevent condensation and internal corrosion. For the same reason it is recommended to run the system at regular intervals in order to lubricate all the moving parts. New restart should be performed in the same manner as the first starting operation.
Additionally, do the following: 1.
Drain oil from the tank bottom and check that the oil is free from water and dirt. If necessary, filtrate or replace oil before starting the pump.
2.
Check oil level.
3.
Check filter, clean all parts or replace if necessary.
4.
Check that maneuvering valve is moving freely and grease if necessary.
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
[email protected] [email protected] http://www.vestdav http://www.vestdavit.no it.no
Page 37 of 40
No.: Rev.: Date: Page:
User Manual TDB-3602
PART VII
VDT-UMT-8050 00 0-JUL-09 38 of 40
SPARE PARTS
Item no.
Item name
1
Filter cartridge
Recom. qty. per davit 1
Vestdavit part no. 11242
Prime manuf. id.
Del. time
TTF230 TXW-5-10
1 week
Item 1 is recommended to store onboard.
2
Seal kit for maneuvering valve
1
10810
HPV-O-77M19041C80
2 weeks
3
Seal kit for hydraulic cylinder.
1
11309
HMT2-V-D100/90x70/40x370
2 weeks
4
Seal kit for shock absorber
1
11359
CP4G 80 x 400
2 weeks
5
Wire ø18mm
29m
10674
35x7 W/Spelter soc.
1 week
Item 2 – 5 are spare parts recommended for the first 5 years. 6
Hydraulic Cylinder
1
11200
HMT2-V-D100/90x70/40x3 700-S-R-SP
4 weeks
How to order When ordering spare parts to davit, please provide the following information:
Davit type
:
TDB - 3602
Davit serial no.
:
8050
Vestdavit Project No.
:
8050
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Page 38 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 39 of 40
APPENDIX A - DRAWINGS DRAWINGS A-14539
Davit arrangement
A-32137
Hydraulic diagram
A-14585
Hydraulic Winch
13540-1A
Hydraulic Power Unit
20613
Starter
612-33A
Shock absorber
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Page 39 of 40
User Manual TDB-3602
No.: Rev.: Date: Page:
VDT-UMT-8050 00 0-JUL-09 40 of 40
APPENDIX B - CERTIFICATES Davit Winch Wire Ring Electric Motor Hoses
Damsgårdsvn. 143, 5160 Laksevåg, NORWAY Tel.: +47 55 54 92 00 E-mail:
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Page 40 of 40
