DY-591-01 Trawling Winch Engineering (047).pdf

FRV40-224-048-010

DESCRIPTION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Trawling and Scientific Winch System Engineering Manual

Model: PTS Pentagon

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-224-048-010

DESCRIPTION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Trawling and Scientific Winch System Engineering Manual

Model: PTS Pentagon

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

30 SEPTEMBER 2003

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-224-048-010

TITLE OF MANUAL: Trawling and Scientific Winch System Engineering Manual

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-224 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-224-048-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

VL LOGISTICS

Ocean Springs, MS 39564

CAGE CODE: 1JA28

VALIDATION PERFORMANCE

Title of Publication

Trawling and Scientific Winch System Engineering Manual

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc. VL Logistics, Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-224 Trawling and Scientific Winch System. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to perform maintenance on and troubleshooting of the Trawling and Scientific Winch System. The text is broken down as follows:

Section 1- List of Sections Order Confirmation

Section 2- Hydraulic System Drawings and Specification

Section 3- Electric System Cable Drawings

Section 4- Electric System Detail Drawings

Section 5- Hydraulic Components Dimension Drawings

Section 6- Electric Components Dimension Drawings

Section 7- Oil Selection Lubrication Charts

Section 8- Installation Instruction

Section 9- Winches W/Drive Units Installation on Board Alignments Checks

Section 10- Mechanical Dimension Drawings for the Winches

EN-IM Mechanical Installation

INSTALLATION OF

DECK MACHINERY

2 (6) - INSTALLATION OF DECK MACHINERY -

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Depreservation and preparation for installation

Requirements to foundations

Installation procedures

Control of installation

- INSTALLATION OF DECK MACHINERY - 3 (6)

Depreservation and preparation for installation Deck machinery and hydraulic equipment shall be preserved and packed at the manufacturer’s to provide guaranteed time of storage, provided that the buyer fulfills storage instructions.

Depreservation of external and internal surfaces of equipment shall be allowed just before installation, connection to hydraulic system etc.

Winch supporting surfaces shall be depreserved just before installation of the winch on the foundation. Depreservation to be made by scraping bright supporting surface and sponging it with cleaning cloth moistened in solvent.

Screws and levelwind shall be depreserved just before trial run of the winch. Depreservation shall be made by removing surplus preservative. The screw and working surfaces of the levelwind carriage shall be oiled with thin layer of lubricant.

Prior to installation of deck machinery, proper foundations for winches shall be ready in accordance with requirements of this document.

By the time of installation the shipyard shall prepared oil and grease for gearboxes and spooling arrangement, ropes of required type and size and device for rope winding.

Requirements to foundations Deck machinery (winches) and power packs shall be installed on foundations.

Dimensional drawings for the winches the following characteristics are given:

• weight;

• dimensions;

• service areas;

• drawing of support surface;

• diameters, strength class and number of fastening bolts;

• max. pull on the 1-st layer of drum;

• angles of rope (chain) run-down;

• stops availability for the winches;

• flatness of support surface;

Strength and quality of foundations shall meet requirements of the Ship Classification Rules.

4 (6) - INSTALLATION OF DECK MACHINERY -

Installation procedures Winches shall be installed on foundations in accordance with the diagram, fig. 1, and procedure of installation below.

• Place unmachined shims of thickness 20-25 mm on the surfaces of the deck foundation.

Two shims on each side.

• Move the winch into position on the deck foundation and make sure that all shims are bearing.

• Fit the hold-down bolts. Tighten the bolts lightly.

• Check the drum for easy rotation.

• Now machine new shims of thickness according to exact measurement of the space between the foundation parts on each screw position.

• Remove the hold-down bolts and unmachined shims.

Fig. 1.

- INSTALLATION OF DECK MACHINERY - 5 (6)

• Fit the new machined shims under the hold-down bolts and make sure that each of the shims is located to the right place in relation to the measurement.

• Check clearance between shim and support surface of the winch and between shim and foundation. The clearance gauge 0.06 mm thick shall not pass by 2/3 of the support surface.

• Fit the hold-down bolts. Tighten the bolts with prescribed tightening torque, shown on dimensional drawing for the winch..

• Check the drum for easy rotation. If the drums do not rotate as freely as they did before tightening, the foundation has been racked.

• Loosen bolts, check shims and repeat procedure until all bolts are tight and drums are free.

For each winch shall be filled out form with results of installation control.

Note! Installation procedure for gear drive winches is described in separate instruction.

Control of installation Results of the control of deck machinery installation shall be presented to the representative of the Rapp Hydema A/S.

This documentation shall present following parameters.

1. For deck machinery:

• clearances on connections to the support surfaces;

• parameters of fastening bolts tightness;

• coordinates for the first block (wire guides) position.

2. For oil and grease selection:

• type/brand of oil/grease;

• certificates for oil quality;

• oil analyses results.

Note! One copy of above documentation shall be submitted to the representative of Rapp Hydema A/S.

6 (6) - INSTALLATION OF DECK MACHINERY -

Item Description Check point Remarks Accepted date / sign.

1 Winches A No mechanical defects

B Fundation type, accepted

C Fundation stoppers mounted according dim. sketches

D Correct distance to first block

E Block mounted in center line of drum

F Service distances correct

G Support of connection pipes

H

2 Gear winches

A Installed according to RAPP instructions

B Run out tolerances checked after installation

C Pull test for foundation stiffness

D Correct type of gear oil filled

E

3 Servicing A Future servicing of all components possible

B

EN-IM Safety Precautions

SAFETY

PRECAUTIONS

2 (4) - SAFETY PRECAUTIONS -

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Safety of personnel

Protection of equipment

- SAFETY PRECAUTIONS - 3 (4)

All works connected with mounting and installation of the Rapp Hydema’s equipment shall be fulfilled according to delivery documentation for the system

Negligence of instructions and limitations can cause failure of equipment, damage of property or injury of personnel.

Present document contain only those safety rules, which are not specified in standards and are related to particular equipment.

Safety of personnel Winches and pump units shall be shipped in accordance with recommendations for attaching slings to the load and instructions of the supplier.

During tests of hydraulic system it is important to mind that maximum operating pressure in the system can reach 250 bar.

All pipes installed shall be tested for required pressure.

Sources of danger for personnel during operation of winches are as follows: rotation of drums, levelwind screws, warping heads and lifters of anchor/mooring winches, as well as tension of ropes and high voltage in electric and high pressure in hydraulic equipment.

Due to this the following precaution measures shall be observed:

1. To avoid coming up close to rotating parts of the winch and to the rope; to avoid ingress of clothes into the dangerous zones.

2. To prevent oil leakage from connections of hydraulic system; it is forbidden to tight connections when hydraulic pumps of the system are running.

3. All electric equipment shall be reliably grounded to foundations according to instructions contained in delivery documentation. Electric safety before equipment start-up shall be provided by the test of insulation resistance and grounding.

4. Remote control panels of winches shall be located in a place safe for operator. The button for emergency stop of the winch shall be in operator’s accessible range.

5. Pump room is zone with high level of noise. Inside pump room is necessary to use ear protection.

6. During wire spooling protection glasses must be used.

7. Qualified personnel, acquainted with relevant documentation and safety instructions in required volume, can operate Rapp Hydema’s deck machinery.

4 (4) - SAFETY PRECAUTIONS -

Protection of equipment Containers with equipment shall be opened in the presence of the supplier’s representative.

Electric equipment and controls shall be stored in a dry heated room.

It is unacceptable to keep equipment opened and not connected to hydraulic system for more than 15 days.

Production, flushing, tests and installation of pipes of hydraulic system shall be in strict conformity with Rapp Hydema’s instructions for Installation of Hydraulic System.

The class of the system purity shall be in accordance with filtration level of the system filters - 10 µm and particle level 16/13 (ISO-4406).

Ingress of off-grade oils inside hydraulic equipment of the supplier shall be avoided. For filling of hydraulic system, gearboxes and junction boxes use grades of oils and their equivalents, recommended by Rapp Hydema A/S.

Before initial start-up it is forbidden to adjust hydraulic and electric components or carriages of levelwind and brake controls, set by the manufacturer.

Prior to connection of hydraulic system to hydraulic equipment of the supplier, the representative of the supplier shall be provided with documentation, confirming quality of tests for strength, tightness and purity of hydraulic system.

Before initial start-up of hydraulic system the representative of the supplier shall be provided with all documentation for installation of equipment, including tables of installation control, filled in by the shipyard.

Test programs used by shipyard shall be preliminary agreed upon with the Rapp Hydema A/S.

EN-IM Installation of Hydraulic System

INSTALLATION

OF HYDRAULIC SYSTEM

2 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

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Depreservation and preparation for installation

Hydraulic installation

Climatic requirements

Requirements to pipe lines

Requirements to installation tubing and hoses

General requirements

Bending the tube

Tube expansion due to air temperature changes

Tube clamps / brackets

Trough-hole connections

Pressure testing of welded tubing

Hoses installation

Protection of tubing and valves during installation

Requirements to arrangement of pump room

Oil tank

Oil cooler

Hydraulic pumps

Filters

Temperature transmitter

Valves

Requirements to cleanliness

Tube treatment and cleaning

Requirements for achieving a desired cleanliness level

Cleaning and internal treatment of tubes

Preparation to the filling oil tank

Control of hydraulic installation

- INSTALLATION OF HYDRAULIC SYSTEM - 3 (23)

Depreservation and preparation for installation After the equipment is received following things need to be done.

The parts shall carefully be taken out of the container and preservation material removed.

Check all items in the shipment for damage and compare the contents with the packing list, enclosed with the shipment. Inform the Rapp Hydema A/S as soon as possible if you notice any damaged or missing components.

All equipment to be installed indoors, shall be stored in dry and warm environment. Storage longer than 6 months requires special protection against corrosion. All primed components shall be treated with anti corrosion oil/paint.

During installation all plugs and protection for pumps and hydraulic valves shall not be removed before the pipe or hose is connected.

It is strictly forbidden to connect hydraulic equipment to hydraulic system, until piping system and hydraulic tank are accepted after flushing. Due to this the proper adapters shall be made prior to the start of installation.

Hydraulic installation Today�s high pressure hydraulic systems demand a high level of cleanliness in order to operate satisfactory.

Valves, pumps and motors have fine tolerances that prohibit pollutants. It is commonly agreed upon within the field of hydraulics that pollutants in the hydraulic fluid cause 8 out of 10 problems in hydraulic systems.

Based on this it is imperative that all components, that at one or another time is in contact with the hydraulic fluid, is free of pollutants.

Polluted hydraulic fluid causes:

• excessive wear - reduced life-time;

• frequent change of filter elements - high cost;

• seized or clogged valves - stop in operation/down-time/lost income.

The installation instructions below must be complied with in order to avoid unpleasant surprises during trial-run and regular operation.

Note! The yard is responsible for the hydraulic installation being in accordance with specifications supplied by Rapp Hydema A/S.

Climatic requirements

The winches are installed on the open deck and are intended for installation on ships of unlimited area of operation.

4 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Electric equipment to be installed on winches is placed in junction boxes filled with oil.

All other equipment with electric components shall be installed in dry warm room. Operating conditions must be such as to exclude ingress of water or other liquids.

In case of special requirements to components, protection class (IP) to be indicated on dimensional drawings.

Requirements to pipe lines

Hydraulic diagrams of the supplier show required diameter and thickness of pipes in accordance with standards DIN 2391C (NS 2503) for pressure lines -seamless, cold-treated precision steel tubing and DIN 2448 (NS 583) for return and suction lines - steel tubing. Above standards specify certain ratio between diameter, thickness and pressure of working fluid.

In system design Rapp Hydema A/S using following pipe sizes:

Nominal size - ∅∅∅∅ x thickness, mm

Internal ∅∅∅∅ , mm

St. 52.4 – max.

Working pressure, bar

12 x 1.5 9 304

15 x 1.5 12 239

20 x 2 16 256

25 x 2 21 202

25 x 3 19 335

30 x 2 26 167

30 x 3 24 275

38 x 3 33 214

38 x 4 30 300

50 x 3 44 167

50 x 5 40 290

60 x 3 54 138

60 x 5 50 239

75 x 3 DN65/70 76

80 x 10 60 384

90 x 3.5 DN80 154

100 x 4 DN100 113

115 x 4 DN100 97

140 x 4.5 DN125 91

On diagrams minimum allowable sizes of pipes are indicated.

Ensure that the wall thickness of pipes you have chosen is enough to withstand pressure in the system considering required safety coefficient and test pressure.

- INSTALLATION OF HYDRAULIC SYSTEM - 5 (23)

Note! The shipyard takes responsibility for the choice of fittings for pipes, laid outside the package delivery.

For pipe connections the supplier uses fittings approved for max. pressure:

• Parker Triple Lock 37 deg. non collar;

• Ermeto;

• GS-Hydro.

Note! Parts from different types/brands of fittings shall not be mixed or interchanged.

For installation of return pipe lines PN16 flanges shall be used.

Diameter and thickness of tubes to be installed by the shipyard shall correspond to those specified on drawings because for each outer connection adapter (see fig.) will be supplied suitable for the tube size.

Material of adapter corresponds to the group of weldability of steels.

Connections of this type exclude ingress of the welding scale into the system and does not require special flaring equipment for pipes.

Tubing dimensions for components not supplied by Rapp Hydema A/S, but connected to the same system, must given by the individual supplier.

Note! Rapp Hydema A/S is not responsible for tube connections to components they do not supply. Each individual supplier shall in this case be consulted.

Requirements to installation tubing and hoses

In order to get a �silent and soundless� system it is imperative that the number of bends are kept at a minimum, and that necessary bends are as �slack� as possible (2�3 of outside pipe diameter). This is particularly important with suction lines to the pumps.

General requirements

• Choice of flanges and fittings must be approved by Rapp Hydema A/S.

• All tubing shall be rinsed inside as described in the installation instruction.

• Use TIC welding.

6 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

• All welded tubing must be pressure tested prior to installation on board.

• Welded tubing shall be pickled and post treated.

• Outside and inside cuttings shall be removed from the cut ends of the tubing.

• All components shall be completely rid of pollutants prior to installation.

• The number of angle fittings for the complete system must be kept at a minimum.

Bending the tube All tubing must be cold when bent, do never use heat.

Use pipe bending machines for bending. Thus you will avoid reduction of the tube inner diameter at the bend.

Tube expansion due to air temperature changes Hydraulic deck arrangements are exposed to extensive temperature variations.

On our latitudes the temperature may vary from -40°C on a winter day to +75°C during operation in summer. This means a temperature difference of 115°C.

As the coefficient of expansion for steel is approx. (12 x 10 6K1) a temperature difference of 115°C will give a longitudinal expansion of 1,4 mm per meter tubing.

To calculate steel pipe expansion follow next diagram:

Choose first point on the left graph as pipe length. Chose second point on the right graph as temperature difference. Draw line between those points and find out value of pipe expansion from intersection point on the mid graph.

Pipe length, m

Pipe expansion, mm

Temperature difference, °C

- INSTALLATION OF HYDRAULIC SYSTEM - 7 (23)

Long lines must have an expansion �bend� along the line, to avoid problem.

Tube bends for length compensation must, however, not be �locked�.

T P C l

T o

I m

T c s correct correct wrong correct wrong wrong correct, this part acts as a length compensator If space permits, the length compensator placed in the corner as indicated ube clamps / brackets roper clamping is important. Careful consideration must be taken when choosing type of clamps.

orrect use of these must be closely observed. Next figure shows some examples of clamp types:

he tube clamp shall prevent cross line vibrations and at the same time allow for a certain ongitudinal movement.

he clamp must be mechanically strong enough to absorb all forces from the tubing., i.e. the weight f the tubing, reactions from pressure shocks and forces due to longitudinal changes in the tubing.

t must not wear on the tubing and not be worn by the tube movements. Use of sound absorbing aterial in the clamp is an advantage.

he clamp must be easy to install, and allow for adjustments due to difference in distance between enters in tubing where several parallel tube lines are located. The clamp must also allow for eparate removal of the tubing.

8 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Only elastic clamps may be used (plastic or rubber type).

The distance between the clamps will vary, depending on the stress normally imposed on the tubing (pressure, oil velocity, vibration) as well as the tube dimensions.

Normally a distance between the clamps equal to 25...50 times the outside tube diameter is sufficient.

Trough-hole connections All through-hole connections for tubing diameter 30 inc. and above must be elastic (see fig.).

The type of through-hole connection used must be approved by Rapp Hydema A/S.

Pressure testing of welded tubing It is permitted to use on the return and suction lines welded tubes. All welded tubes must be pressure tested prior connection to the system.

Testing pressure is 1.5 times from nominal working pressure. Maximum testing pressure is 70 bar.

Hoses installation Different types of hydraulic hoses using in the system for connection of equipment staying on rubber legs (such as pump units).

Check pressure ratio indicated on the hose prior connection. For pressure lines only high pressure hoses shall be used.

Rapp Hydema A/S supplied standard length suction hoses, which are not permitted to cut. During installation of suction hoses good alignments of the connected ends must be considered. This is important to avoid leaking. Use bend-type of clumps. For more secure tightness use two clumps on each end of hose.

During installation

As a �rule-of-thumb� for minimum bending radius of the hose the following may be used:

Outside hose diameter - D, mm 0�25 25�40 40�55 55�>

Minimum bending radius, mm 6 x D 7 x D 8 x D 9 x D

- INSTALLATION OF HYDRAULIC SYSTEM - 9 (23)

Correct Acceptable Wrong

Correct Correct ,but the hose is too short Wrong

Correct, side view Correct, front view Wrong, side view

Correct, А � min. 2 x bending radius

Wrong, bending torque increases with vibration

Correct Wrong, avoid twisting the hose

Correct Wrong, bend too close to coupling

10 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Protection of tubing and valves during installation

During installation ensure that tube ends, filter openings, valves, etc. remain closed until you are ready to complete the installation and fill the tank.

USE PLASTIC PLUGS OR CAPS - NOT RAGS OR PAPER PLUGS

Note! Remember to remove plugs before final hook-up!

Requirements to arrangement of pump room

Installation of equipment in the pump room shall be made in strict conformity with hydraulic diagram and specifications from the supplier.

Arrangement of the pump room shall provide access to equipment for adjustment and repair.

Oil tank If oil tank is not part of Rapp Hydema A/S delivery, but other supplier or manufactured by yard, writing acceptance of tank drawing is required. In this case order from Rapp Hydema A/S mounting equipment for oil tank � parts for connection of oil level switch, return filters etc.

Hydraulic oil tank must be made from stainless steel or painted inside with oil resistance paint.

Hydraulic oil tank shall be installed as follows:

It is important that the tank is situated as close as possible to the hydraulic oil pumps. The minimum distance between tank bottom and center of the pumps to be 200 mm (vertically).

The oil tank must not be positioned direct connected to the side of the ship or close to the cooling tanks room, stable temperature reduces risk for condensations inside the oil tank.

Service and inspection through the manholes must be possible.

Oil cooler Service distance as indicated on dimensional sketch to get access for service of oil cooler. To avoid extra oil drop during servicing all ball and check valves to be installed as close to the cooler as possible.

The water IN end shall be positioned so as �UP STREAM� cooling is achieved.

Normally every cooler has its own separate pump for cooling water supply. If otherwise is the case the supplier shall be contacted for approval.

Also ensure that the cooling water pump has sufficient capacity.

- INSTALLATION OF HYDRAULIC SYSTEM - 11 (23)

Hydraulic pumps All el. motors shall be installed on �rubber legs�/rubber elements or other highly elastic surfaces.

These are normally NOT supplied.

The electric motors can be positioned horizontal or vertical, to better use space in the hydraulic room. During installation pay special attention to the future servicing, as per dimensional sketches..

For connection of hydraulic pumps to the system use hydraulic hoses. This to avoid extra vibration forces from the pumps to the pipe lines.

Do not use 90° fittings direct mounted on the pumps outlets. Most types of hydraulic pumps allowed to turn their sections (both pressure and suction sections) against each other. Use this future to optimize pipe lay out from the pumps.

Filters Service distance and accessibility for filter replacement shall be provided.

It must be easy to inspect the filter indicators.

Pipe length from the pump to the filter to be as short as possible.

12 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Temperature transmitter The temperature transmitter shall be positioned before the oil cooler and assembled with the temperature detector directly in contact with the main flow. See fig. below:

If diameter of pipe is not big enough for this type of installation, use one of the 90° bends in the return line.

Valves The hydraulic and electro/magnetic valves shall be easy available for service, testing and adjustment.

Electro hydraulic valves without watertight protection shall be installed in dry environment correspondent to the IP class.

Requirements to cleanliness

This Part is based on NS 5910 - �Cleaning of hydraulic pipe systems�.

The objective of this standard is to ensure that hydraulic system has a proper initial cleanliness level to ensure that desired reliability and expected life can be obtained

The standard can be a supplement to, but cannot replace the recommendations of the supplier of the components and the customers requirements, especially when their requirements are higher than those of the standard.

Tube treatment and cleaning All tubes must be 100% clean before the installation starts.

Precision steel tubing is normally without solid pollutants (except shaving from cutting). Pull a clean cloth rag (not polishing yarn or paper) through the tube, then oil it before plugging the ends.

- INSTALLATION OF HYDRAULIC SYSTEM - 13 (23)

Other kinds of tubing must be cleaned with a suitable solvent such as white spirit, trichlorethylene or similar, before being pickled in an acid solution.

Welding connections at flanges, bends, branch-outs must be made completely mechanically clean from particles before cleaning and pickling.

When cutting the tubing, the tubing must be carefully rinsed and inspected.

Any sandblasting must be carried out with special care, as the sand tend to settle in corners, bends, etc. inside the tubing.

During any sandblasting ensure that all open hydraulic connecting points are sealed.

Requirements for achieving a desired cleanliness level Flushing the system The main purpose of flushing is to achieve the cleanliness level specified by the supplier of the system or the components.

The level of particles content (ISO 4406 max.: 16/13).

Actions to achieve a satisfactory cleanliness level in a hydraulic system comprise:

1) cleaning and internal surface treatment of tubes;

2) drying of fitted piping system;

3) flushing;

4) verification of cleanliness level.

Presupposition for retaining a high cleanliness level after flushing are the selection of suitable and properly located system filters, and that oil filling is done through a system filter or another suitable filter.

In the design phase it is important to plan for system flushing.

Circuits shall be connected in series, when flushing. Areas without circulation shall not exist.

Flushing units capacity shall be calculated to ensure high oil flow for efficient cleaning of the internal surfaces of the system pipes .

Components which may prevent high flow velocity or which may be damaged in high flow velocity or high particle content shall be disconnected from the circuit.

It shall be possible to flush all connections of the piping.

All equipment supplied by Rapp Hydema A/S is cleaned, flushed and ready for operation. If the shipyard uses assemblies or components which turned out to be uncleaned, they shall be flushed separately. This is also valid where space does not allow flushing of installed piping system.

It is important that a representative flushing fluid sample can be taken.

14 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Components cleanliness level Components and assemblies are often connected to the pipe system after flushing. The cleanliness of these components and assemblies should be at least as good as the desired cleanliness of the main system.

The component suppliers should be able to give information about the cleanliness level of the components.

Note! If the components contain anticorrosion agents which are not compatible with the system fluid, the components shall be flushed using system fluid with 5-10% degreasing agents added. The degreasing agent shall not influence component seals.

Cleaning and internal treatment of tubes

Mechanical cleaning of tubes Welded tubes shall be mechanically cleaned internally to grade St. 2 according to SIS 05 59 00.

Grinding or brushing is recommended. Sand-blasting shall not take place.

Note! After mechanical cleaning, tube and tube flanges shall be smooth and free from slag, welding beads, baking, pores and foreign particles.

Chemical cleaning of tubes Tubes with scale and/or corrosion shall be treated according to the following procedure:

• Alkaline degreasing;

• Water rinsing;

• Pickling;

• Water rinsing;

• Neutralization;

• Water rinsing;

• Drying.

The current guidelines from the Directorate of Labor Inspection and the National Pollution Control Authority are to be followed.

Alkaline degreasing The tubes shall be cleaned with an approved degreasing agent.

Note! Oil and grease reduce the effect of the pickling process. An alkaline bath which removes most of the organic dirt (lacquer, oil, fat) may consist of 10% NaOH (caustic soda) and 90% water. Treatment time is approximately one hour at 90°C. Certain types of fat are not removed by this procedure.

Water rinsing The tubes shall be thoroughly washed with fresh water.

- INSTALLATION OF HYDRAULIC SYSTEM - 15 (23)

Pickling Pickling by the sulphuric acid

The tubes are preferably pickled in a sulphuric acid bath consisting of 10-25% H2SO4 (sulphuric acid) in water, 1-2 ml/l inhibitor (hexamine).

Maximum bath temperature 80°C. Alternatively the tubes are filled completely with pickling fluid.

Note! Always pour acid concentrates into water, not vice versa. The acids must be treated carefully as they are highly corrosive. Protect skin and eyes and follow the recommendations of the acid supplier.

Alternative pickling Hydrochloric acid pickling

50% hydrochloric acid in water (hydrochloric acid in 35-38% concentration, non-arsenic) 1-2 ml/l inhibitor (hexamine).

Maximum bath temperature 35°C.

Pickling time 10-60 min.

Hydrochloric acid is very reactive and leads to immediate corrosion if neutralization measures are not taken immediately after the pickling. Also pickling in hydrochloric acid may lead to hydrogen embrittlement in the steel if the inhibitor is not effective enough.

Phosphoric acid pickling

Phosphoric acid pickling gives a small amount of corrosion and normally requires neutralization.

Water rinsing The tubes shall be washed thoroughly with fresh water immediately after the acid pickling.

Neutralization The tubes shall be washed with an adequate neutralizing liquid.

Note! An adequate neutralizing liquid may consist of 2% Na3PO4 (triosodiumphosphate) in water. Bath temperature 80-90°C. Treatment time 1-2 minutes.

Water rinsing The tubes shall be washed thoroughly with fresh water to remove the neutralizing liquid.

Drying The tubes shall be dried with warm, dry air within 30 minutes after rinsing.

Surface treatment To maintain the obtained cleanliness until installation, the tubes shall be treated with a suitable protection liquid. The liquid used should give corrosion protection for at least five months and shall not alter the properties of the flushing fluid or the system fluid.

16 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Storing of tubes and tube parts Cleaned and surface treated tubes and fittings shall be capped immediately and should be stored in a dry place.

Drying of piping systems Before the piping system is connected to machines, panels, pump stations etc. all tubes shall be thoroughly blown through with dry, filtered compressed air or nitrogen. Dew point is to be 45°C at normal atmospheric pressure.

Sizing of external flushing filters It is a generally good economy to use large flushing filter; the smallest flushing filter which should be accepted has a pressure drop through a clean element of 5% of the opening pressure of the bypass valve or the indicator setting, calculated at the relevant flushing fluid viscosity.

Criteria for proper flushing A flushing procedure should be adapted to the practical conditions. Certain main criteria shall, however, be fulfilled to obtain a satisfactory result (see level of cleanliness).

The reservoir of a flushing unit shall be cleaned to the level required of the system.

The system shall be filled through a suitable filter. Air should not be brought into the system when filling. If necessary, top up and bleed the system.

Removing particles from internal surfaces To remove contaminants effectively from internal surfaces, the main requirement is that the flushing fluid has a turbulent flow. This condition is fulfilled when the Reynolds number is larger than 3000.

If the flushing is done with Reynolds number smaller than 3000, there will be different degrees of laminar flow within the tubes. In the area close to the tube wall, where the particles are situated, the fluid velocity is approximately zero. This stationary fluid does not possess the ability to remove particles from tube and component walls.

With Reynolds number larger than 3000 there will be a turbulent flow. Having this condition the fluid wipes the surfaces with high energy and tears off the contaminants effectively.

The Reynolds number may be calculated as follows:

Re= 21200.Q

v. d where

Q is flow in l/min.

v is viscosity in mm 2/S (centistokes) d is internal tube diameter in mm.

It is often difficult to obtain a Reynolds number larger than 3000. The following methods are recommended to increase the Reynolds number:

Increasing the fluid flow �Q�.

This may not be practically acceptable and this is expensive as it requires a larger flushing power unit.

- INSTALLATION OF HYDRAULIC SYSTEM - 17 (23)

Reduction of the viscosity �v�

In most cases this is the best way to achieve a turbulent flow. The reduction may be obtained by increasing the temperature, thus lowering the viscosity.

If a special flushing fluid is used, it shall be compatible with the system oil which is to be used in operation. The only general recommendation is to use the same type of fluid, possibly with a lower viscosity.

Note! When studying the equation for the Reynolds number, it may look as if a reduction of the tube diameter may contribute to increase Reynolds number. The pressure drop through a tube, however inversely proportionally with the inside tube diameter to the 5th power. Narrow tubes are therefore very difficult to flush because the flow resistance becomes too high.

The use of vibration, high frequency sound or changing flow direction, will contribute to a faster removal of particles. This is, however, a supplement and no an alternative to turbulent flow.

A turbulent fluid flow will also ensure transportation of the contaminants from the system to the filters.

Selection of filtration performance The filters used for flushing are quite decisive for two essential reasons. They gives the final cleanliness level which can be expected and how fast this level can be reached.

The choice of an optimum filtration ratio is important. Using filters with a poor filtration ratio, situations may arise where the specified cleanliness level is not achieved, or is achieved after a very long flushing time.

Filtration performance is measured according to ISO 4572.

ISO 4572 defines Beta ratio (filtration ratio) as the relationship between the number of particles greater than a given size upstream of the filter, and the number of particles greater than the same size downstream of the filter. If there are 20 times as many particles greater than 5 µm in the oil upstream of the filter compared to downstream of the filter, the Beta ration for µm equals 20. This may be presented as: Beta-5 = 20.

Filters with Beta-5 values considerably higher than 1 should be used.

Recommended minimum value is Beta-5 equal to 20.

External flushing filters In several cases external filters are used during flushing.

The reason for this may be that the selected filter rating deviates from that of the system filters, or it may be for economical reasons.

Minimum flushing time The flushing time depends on the system capacity and its complexity. Even if samples from the system indicate that the specified cleanliness level is reached after a short time, the flushing shall continue for at least three hours at turbulent flow. The probability of removing particles sticking hard to the tube walls therefore increase.

18 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Verification of the cleanliness level The obtained cleanliness level shall be documented before flushing operation may be considered as finalized. Use particle counting or comparison membrane.

Particle counting

The use of an automatic particle counting is the fastest method for particle counting in a flushing fluid sample. See ISO 4402.

When required cleanliness level is specified according to ISO 4406, it is sufficient to count particles larger than 5 and 15 µm.

Particles may alternatively be separated on a membrane filter and counted by using a microscope.

See ISO 5884.

Comparison membrane

The equipment for microscopic particle counting may also be used by applying comparison membrane. The procedure is the same except for the counting.

Instead of counting particles, the relevant test membrane is compared to a reference membrane by using a microscope. For a trained operator it is easy to ascertain that the sample is equal to or better than the reference. The reference membrane should be made for the relevant type of system, and it shall represent the cleanliness level required.

Note! The membranes shall be compared using a microscope only. Dye pigment and other substances which create color nuances may give completely misleading results. Samples should be verified by counting of particles.

Cleanliness level (only for particles counting) defined in other standards shall be corresponded to ISO 4406 level 16/13:

ISO 4406 NAS 1638 SAE 749

16/13 7 4

Especially cold environment

In cold environment the flushing of pipe systems may suffer from loss of heat. To verify that the Reynolds number is larger than 3000, the temperature shall be checked at the estimated coldest spot of the system. The flushing is only real when the lowest temperature gives a Reynolds number larger than 3000. See data for the viscosity and temperature of the relevant flushing fluid.

Under specially cold conditions, the pipe system etc. should be insulated to keep the temperature above the necessary minimum level.

- INSTALLATION OF HYDRAULIC SYSTEM - 19 (23)

Preparation to the filling oil tank

Check again cleanliness of the oil tank and suction lines. This is very important in case suction filters are not used in the system.

Before first filling of oil tank it must be inspected and approved be representative of Rapp Hydema A/S.

Use only oil recommended by Rapp Hydema A/S, see �Oil and Lubricant Requirements�.

Inspect the oil drums to see if they are properly sealed. Let drums rest for 1�2 hours by the oil tank to separate water or other contaminants.

Ensure that oil pump, hoses, other relevant equipment are clean and have not been used for pumping motor oil or such.

Always use filter 10µм between drum and tank, new oil is not clean. It is possible to use one of the system return filter.

There may be water/contaminants even in new, sealed oil drums. Therefore it is a good rule to leave last 5-6 cm oil in the drum.

It is necessary to have spare amount of oil for filling up oil tank after pumps starts and oil came to the system pipelines. Volume of the system pipes can be up to 20% of the oil tank volume. Spare oil also used for compensate drop of oil during trouble shouting servicing of hydraulic system.

20 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Control of hydraulic installation

Item Description Check point Remarks Accepted date / sign.

1. Oil tank A Made by yard Made by Rapp Hydema

B Painted inside with oil resistance paint (type)

C Cleanliness checked

D Suction pipe ends min. 100 mm and cut 45°

E �Long� circulation from filter to suction (dividing plates)

F Return line filters correct placed

G Correct service distance for return line filters

H Manholes correct placed

I Oil tank is not part of ship side

J Breather cap correct mounted

K Well placed in relation to pumps

L One suction to each pump

M Level switch correct

N Oil level glasses

O Thermal switch correct

P Gate valves of accepted type

Q Gate valves well placed

R Volume

S

- INSTALLATION OF HYDRAULIC SYSTEM - 21 (23)

Control of hydraulic installation (continued)

Item Description Check point Remarks Accepted date / sign.

2 Suction pipes

A Cleanliness checked

B Dimensions according to hydraulic diagram

C No air traps

D Suction hoses correct mounted

E Used correct type of the clamps

F Suction hose length checked

G

3 Pumps A Type of pump according

B Mounted vertically (V) or horizontally (H)

C Rotation directions of all pumps checked

D Line up of pumps checked

E Pumps mounted by shipyard - others

F No 90° bends of pressure lines directly on pumps

G Plastic plugs removed

H No mechanical forces from pipes

I Hoses correct

J All pumps mounted below oil level (min 300 mm)

K All pumps protected by relief valves

L

22 (23) - INSTALLATION OF HYDRAULIC SYSTEM -

Item Description Check point Remarks Accepted date / sign.

4 Pressure / return /

A Dimensions according drain lines B Piped up according to hydraulic diagram.

C Cleanliness

D Fittings / flanges of acceptable type

E Pipes / tubes of acceptable quality

F Well bended, numbers of bends kept at minimum

G Well clamped, elastic clamps of acceptable type

H Elastic trough hole connections

I Length compensators

J

5 Pressure filters

A Type according to hydraulic specification

B Filter indicators correct

C Service distance

D Correct elements installed

K Filtration ratio, µm

6 Check valves

A All check valves according

B Direction

7 Relief

A All relief valves according

B Relief to the tank trough oil cooler and return filters

- INSTALLATION OF HYDRAULIC SYSTEM - 23 (23)

Item Description Check point Remarks Accepted date / sign.

8 El./hydr.

valves

A Piped according hydraulic diagram

B Service distances as specified

9 Oil cooler

B Mounted according to

C Mounted vertically (V)

D Cooling water upstream to oil

E Water supply described capacity (l/min)

F Service distance

10 Return line manifold

A Placed according to

11 Valve panels

A According to specification No defects

B Piped according

12 Servicing A Future servicing of

EN-IM Installation of Electric System

INSTALLATION OF

ELECTRIC SYSTEM

2 (5) - МОНТАЖ ЭЛЕКТРООБОРУДОВАНИЯ -

C:\WORK\DOCUMENTATION\EN-IM INSTALLATION OF ELECTRIC SYSTEM.DOC

Depreservation and preparation of installation

Electric installation

Climatic requirements

Foundations and shock-absorbers

Protection of electric cables

Separate laying of cables

Sealing

Grounding

Control of installation

- МОНТАЖ ЭЛЕКТРООБОРУДОВАНИЯ - 3 (5)

Depreservation and preparation of installation Before installation electric equipment shall be carefully taken out of container and preservation material removed.

Check all items in the shipment for damage and compare the contents with the packing list, enclosed with the shipment. Inform the Rapp Hydema A/S as soon as possible if you notice any damaged or missing components.

Remove out plugs of the cable input holes. Make sure that ventilation holes of electric motors for input and outlet of cooling air are not plugged.

Electric installation All cables used for connection of el. equipment shall not have broken cores or damages of insulation, and cables connected to junction boxes filled with oil shall have oil-resistant insulation.

Climatic requirements

Electric motors, control panels and magnetic starters shall be installed in spaces having temperature from +1°C to +45°C and relative humidity 70% at max. humidity 98% and temperature +35°C.

Operational conditions shall be such as to exclude ingress of water, oil and other liquids, as well as impurities onto above electric equipment.

Foundations and shock-absorbers

Foundations for control panels shall be reliable and provide their proper operation in different sailing conditions. Rigid fastening of panels to supporting surfaces is acceptable, but shock-absorbers can be also used. Maximum allowed movemed from foundation surfaces is 0.5 mm.

Protection of electric cables

All cables for connection of electric equipment shall be laid inside the pipes or have other protection against mechanical damage.

Separate laying of cables

Cables for control system to be laid separately from power supply cables.

Sealing

After connection of cables all cable inputs of el. equipment shall be waterproof sealed. Junction boxes mounted by the shipyard shall be waterproof.

4 (5) - МОНТАЖ ЭЛЕКТРООБОРУДОВАНИЯ -

Grounding

All electric equipment with metal housings shall be properly grounded. For connection of electric equipment to the ground mat grounded terminals to be used.

Do not use grounding of 24VDC solenoid valves.

Control of installation After completion of installation make sure that wires and terminals are marked properly as per diagrams, all grounding jumpers are available and contact connections are reliable; then check resistance of electric circuits insulation which should be not lower than 1 MOhm.

Insulation resistance of circuits operated at 24 V shall be checked with 100 V megohmmeter, other circuits - with 500 V megohmmeter.

- МОНТАЖ ЭЛЕКТРООБОРУДОВАНИЯ - 5 (5)

1 Electric motors

A Mounted on rubber legs

B Voltage / frequency

C Motor heating Environment acc. to IP class

D Mounted vertically (V)

E Overload setting correct

F Rotated according to the pump working direction

2 Electric components

A Cables dimensions as specified on cable diagrams

B All power supplies as specified

C Relay cabinets vertically placed

D All electric components in dry conditions

E Additional junction boxes

F Polarity and voltage checked

G Grounding as specified

H Breakers as specified on cable diagram

I El. cable support / protection

3 El./hydr.

A Installed in dry conditions, sealed

B Voltage checked, no grounding on coils

C Diodes installed for 24VDC ON/OFF valves

D PG inputs are sealed

E Valve boxes are filled with hydraulic oil

F

4 Servicing A Future servicing of

EN-IM Oil Requirements

OIL AND LUBRICANT

REQUIREMENTS

2 (7) - OIL AND LABRICANT REQUIREMENTS -

I:\TEKNISK\INSTRUKS\PDF-INSTRUCTIONS\ORIGINALS\EN-IM OIL REQUIREMENTS.DOC

Последние изменения: 15.06.01

Hydraulic oil

Type of oil

Checking of oil conditions

Storage of oil

Working conditions

Changing of oil

Gear oil

Type of oil

Checking of oil conditions

Change of oil

Lubricant

Oil Table

- OIL AND LABRICANT REQUIREMENTS - 3 (7)

We recommend using of oil and lubricant from reputable Oil Company with a worldwide spread-out distribution network.

If it is any doubts in choose of oil/lubricant or if it is choose from several brands, contact Rapp Hydema A/S for writing confirmation.

It is prohibited to mix oil of different quality/brands.

Hydraulic oil Oil for Rapp Hydema’s hydraulic system should be corresponded to the following specification:

Kinematic viscosity cSt at 40°C 46 at 50°C 30 at 100°C 9,1 at -20°C 5000 Flash point, °C 175 Solidification temperature °C, not higher than -48 In compliance with DIN-52524 (2) type: H-LP Anti wear quality IP 281 <<<< 20 mg Gear test FZG ≥≥≥≥ 11 Viscosity index >>>> 175

Type of oil

We recommend to use hydraulic oil Shell Tellus Oil “T” or other brands approved by Rapp Hydema A/S (see Oil Table).

Checking of oil conditions

Use daily visual checking of oil color (in oil tank level glasses). Gray color of hydraulic oil indicated that water came in to the system. It is strictly prohibited to use hydraulic oil mixed with seawater.

First time laboratory test of oil sample to be made after system flushing. Oil samples from running system to be taken 3-4 times per year and the following have to be checked:

• Spectrometric;

• Water content;

• Particle counting (ISO-norm);

• Viscosity;

• TAN.

4 (7) - OIL AND LABRICANT REQUIREMENTS -

Check of oil sample should pass the following limitations:

Particle level (ISO-4406) max.: 16/13 Optimal working viscosity (cSt) 46 Minimum working viscosity (cSt) min.: 40 Water content < 0,1% Filter element rating (Absolute) min.: 12 µm

During warranty period copy of results from sample check to be sent to Rapp Hydema A/S.

Note! If the specified viscosity level during use of the system, drop more than 5%, heavier hydraulic oil have to be added to the system to maintain the specified level.

Storage of oil

Always keep reserve amount of oil for hydraulic system.

Hydraulic oil shall be supplied in sealed drums. In this drums oil must be stored indoors in dry, dust clean environment with close to constant temperature.

If special storage tank to be used, this tank and filling system to the main tank to be approved by Rapp Hydema A/S in writing.

Note: Long storage at low temperature cause deposits.

Working conditions

Normal working temperature for hydraulic oil +40°C. This is nominal temperature, which used for calculation of working parameters of equipment. Maximum oil temperature during operation can go up to +70°C, but should never exceed +80°C.

Nominal working viscosity of hydraulic oil about 46 cSt. Oil viscosity during operation can changing in interval 30 – 100 cSt, depending of working temperature. Minimum allowed viscosity – 10 cSt (for working temperature approx. +75°C). Maximum allowed viscosity for starting hydraulic pumps – 2000 cSt (for working temperature approx.