VDT-IM-91534-35 User manual for installation of davit HN-9003 POEA-133M-15CN-0139MOA2-11(14) rev.00..pdf

User Manual

Installation and Preparation

VestDavit type HN-9003

Winch type C-394-7-V-S-Dual Customer PO : EA-133M-15-CN-0139 /MOA2-11(14) Customer : NOAA Ship name : Thomas Jefferson Vestdavit project number : 91534 & 91535

Prep.by Appr.by Doc.no Date Rev.no Page

IAB TO VDT-IM-91534-35 10.10.2016 00 1 of 36

Installation and Preparation HN-9003

No.:

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Page:

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Table of Contents

1. HSE Procedure

1.1 Health, safety and environment in the installation process

2. Installation and preparation

2.1 General

2.2 Procedures for storage and unpacking of davit

2.3 Lifting points

2.4 Guidelines for use of a shore-side crane

2.5 Step by step installation

2.6 Welding information

2.7 Control equipment

2.8 Hydraulic power unit

2.9 Cabinets

2.10 How to mount 4mm wire rope for emergency lowering

2.11 Hydraulic system on ship

2.12 Hydraulic oil, grease and other lubricants

2.12.1 Oil types

2.12.2 Greasing of davit parts

2.12.3 Miscellaneous lubricants and fillings

2.13 Starting the system

2.13.1 Preparation before starting

2.13.2 Starting

2.14 Functions test

2.15 Charging of accumulator

2.16 Instruction for activating shock absorber on HN-davit system

2.17 Table for refilling nitrogen in accumulator on shock absorber

2.18 Procedure for touch up paint and grease

2.19 Test procedures

Yards checklist: pre commissioning installation

List of drawings for davit HN-9003 mailto:post@vestdavit.no http://www.vestdavit.no/

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Any questions regarding the manual or the davit system should be directed to:

Vestdavit AS Damsgårdsveien 143

5160 Laksevåg, Norway

Telephone: 47 55 54 92 00 Telefax : 47 55 34 24 04 E-mail: post@vestdavit.no

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

1. HSE Procedure

1.1 Health, safety and environment in the installation process Always follow the regulations and HSE procedures for the yard, vessel and assigned contractor.

Cold weather;

Ensure there is no ice or snow on the foundation to avoid difficulties and accidents when mounting davit.

Use warm clothes and protect yourself from frost bites.

Spilling and contact with hydraulic oil;

Remove oil spill at once to avoid accidents or pollution of the environment.

Work in surroundings;

Ensure there is no work carried out in the area around the davit to avoid unexpected dangerous situations.

It is recommended to install the davit in day light to ensure the best view to the surroundings and the installation process.

Personal protecting equipment during installation;

For safety, always use personal protective equipment like safety helmet, safety shoes, hearing protection, working gloves and safety glasses during the installation process.

Use breathing mask if there is any oil fog in the area.

Attention/ wakefulness;

Ensure that everyone working with the installation has had enough sleep and food so they are awake and can be aware of unexpected situation around the davit installation.

If components are transported with crane;

Be aware of components and similar transported in the area with a crane.

Lifted parcels can be heavy and swing uncontrolled.

Stay in the safety zone when the crane is used.

Follow instructions given by the internal rules.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2. Installation and preparation

2.1 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 e-mail.

Before starting the installation, check that no part of the system or any components have been damaged during transportation. If any damages have occurred; contact immediately Vestdavit for replacements.

The davit is complete for installation on board. The davit system consists of following components:

Davit arm with winch.

Davit and cylinder pillars Proportional Control valve.

Emergency system.

Hydraulic cylinders.

Shock Absorbers.

Hydraulic Power Unit.

Remote control unit.

Electric motor soft starter. Starter and HPU should be placed close and in the same area, if possible.

Emergency backup accumulators and hand pump.

Emergency stop button. This should be close to the operator, and no longer than an arm length from the proportional control valve.

IMPORTANT: NO WELDING IS PERMITTED ON THE DAVIT WITHOUT PRE APPROVAL

FROM VESTDAVIT AS.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.2 Procedures for storage and unpacking of davit

For acceptance check at yard, be aware of following points;

Take picture of the shipment at arrival.

Check the packing list and control that the delivery is complete.

Check for any transport damages.

If any damages have occurred; contact immediately Vestdavit AS for replacement.

Preservation and packing information:

Preservation of the davit system and equipment shall be done in such a way that it can withstand a saline atmosphere.

The davit in this delivery is preserved for transportation. The wire rope is greased for transport, and all lubrication points are greased.

All electric cabinets and boxes are internally protected by use of “vapour corrosion inhibitors tape” (VCII) which release a layer of mist on the internal surface to protect the electro components so they are not exposed for corrosion during transport, storage and operation.

Unpacking - checking:

Davit shall be handled by means of soft lifting on lifting points or lifting lugs on structure if present. Follow the internal safety regulations and the signs placed on the davit system.

Remove all lashings used for transport.

The davit system shall, when received at yard, be cleaned, and checked thoroughly for transport damages or other issues. If wrapped in transport film/ shrink plastic, remove it to uncover any issues.

Loose items delivered in wooden crates or similar shall when received at yard be inspected, labelled properly and stored indoors in a dry environment. Crates to be used: ISPM 15 type (compliance with “international standards for phytosanitary measures”-revision 15)

All electric equipment needs to be stored indoors in a dry environment before installation.

Storing - installation:

Clean off dust and dirt; inspect for any damages, cover up to avoid dust from sandblasting or similar pollution.

Before starting the installation, check that no part of the system or any components have been damaged during transportation or storing. If any damages have occurred;

contact immediately Vestdavit AS for replacement

Correct installation is prerequisite for safe operation. If any questions arise during the installation, contact Vestdavit AS supervisor at site or contact a Vestdavit AS engineer.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Preserve the equipment before storage longer than 4 months:

Clean, remove corrosion and touch up paint work.

The wire rope to be lubricated in its total length.

Protect moveable parts that will not be moved during storage, especially limit switch valve, with extra grease.

All cylinders and shock absorber shall be totally retracted, piston rods and dust ring to be covered with teflon lubricant or grease, and bushings in cylinder hinges must be extra greased.

The hydraulic power unit to be topped up with hydraulic oil (arctic oil if low temperature during storing time).

The gear and brake to be topped up with oil, ref. hydraulic oil section in manual.

All grease nipples on the davit to be lubricated.

Check that valves on valve block are properly grease taped.

The davit system shall be covered with tarpaulin or similar to avoid dust and pollutions from sandblasting, welding or similar.

For cabinets stored more than 3 months before commissioning, connect power for heaters, and turn space heaters on to prevent humidity and corrosion. (Applies for storing in varied temperature and humidity, not for storing in-house in a temperate and ventilated room). For cabinets delivered without heaters, use “vapour corrosion inhibitor tape”.

Systems delivered with a UPS system and stored more than 3 months: Connect power to ensure charging of UPS batteries. Batteries needs to be fully charged minimum every 6 months to maintain warranty.

The system shall not be started before the oil level is drained to correct amount, signs should be put up to avoid that.

The equipment shall be inspected every second month or so to control that the requirements above are met. If any type of work including welding is performed close to the davit system, there shall be set up covers/walls or similar to protect the davit.

Loose items should be stored indoor, clearly labelled that it belongs to the davit system.

Vestdavit AS shall perform a new commissioning if the davit is stored for 12 months or more. Any corrosion shown on the davit system and components at time of re-commissioning will be yard responsibility.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

To bring the equipment out of preserved state and ready for commissioning:

Wash and clean the equipment for dust and dirt.

Touch up paint work, if necessary.

Check all moveable parts are still moveable as supposed to, and that they are greased.

Drain the brake and gear for oil to achieve correct amount of oil.* Clean the cylinder rods for dirt to avoid any harm to the sealing during operation.

Check that no valves have corroded, and that they are properly grease taped.

Drain oil from the hydraulic power unit to the correct amount.* Note; when the system is installed, the total oil level in the hydraulic power unit also has to include the oil from the accumulators. When the oil in the accumulators is drained to tank it is important that the tank has space for this oil included.

Replace filters, if necessary.

*Before start-up, take an oil sample to verify the quality of the oil.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.3 Lifting points

Use only soft slings for lifting the davit, please see pictures below. Shackles can be used in the lifting holes. Be aware of hydraulic tubes that could be in disturbance with the lifting slings.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.4 Guidelines for use of a shore-side crane

When to support or lift a davit to or from deck mountings with vessel afloat.

When a heavy crane is used to support or lift a davit from deck, the hydraulic circuits must be configured to allow free flow of oil between the two sides of all load bearing cylinders until:

a) The davit is free from its mounting points or

b) Maintenance operations are complete.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.5 Step by step installation

Clean off all transport and storage protection preservation.

The installation procedure; step by step:

Lift the davit in position on board the ship as described in GA drawing, and follow procedures below.

1. Mount and tack weld davit pillars according to foot prints given in GA drawing.

2. Mount and tack weld cylinder pillars according to foot prints given in GA drawing

3. Remove the davit from hinges and complete welding of the hinges.

4. Check that the pillars and hinges do not twist whilst welding, and that all the hinge bolts are moveable after welding.

5. Install davit to hinges with bolts.

6. Mounting of main cylinder into deck hinge with bolt.

7. Installation of proportional control valve.

8. Install hydraulic power unit according to specified location.

9. Install hydraulic tubes on deck.

10. Install cables for remote cabinet and starter cabinet.

11. Flushing of system.

12. Filling of system oil.

13. Charging of accumulators. Achieve the preloaded pressure in hydraulic diagram.

14. Starting of system.

15. Bleed the system.

16. Touch up paint and grease.

17. Functions tests.

18. Load test.

Check that the hoses are moveable after the installation.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.6 Welding information

All surfaces have to be clean, primer and paint to be removed before welding starts.

Make sure the surface (deck) is flat to avoid imbalances on davit.

Hinges must be mounted on a flat surface. There must be no gap between deck and hinge. Avoid twisting in hinges during welding operation.

Properly protection of the davit is required to avoid damages to the surface during welding process.

Davit and cylinder hinges need to be chamfered.

Control footprints according to GA drawing before brackets for hinges are welded to deck.

IMPORTANT: All reinforcements under the deck in the footprint zone must be welded before davit and cylinder hinges are welded to the deck. This is the shipyard's responsibility.

The brackets are delivered to fit the hinges, and shall be correctly levered before welding. Use shims if needed to compensate any skewness. Check that the hinges do not twist during welding, and that all the hinge bolts are “floating/ moveable” after welding.

Welding should be done according to applicable standards and regulations, and the yards internal welding procedure specification.

Painting after welding has to be done.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.7 Control equipment

Proportional control valve should be located in agreed position according to GA drawing 141144 and 141145.

Proportional control valve should be placed so the levers comes in a natural operation position and the hydraulic couplings shall not be on the operater side.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.8 Hydraulic power unit

The hydraulic power units (HPU) to be installed on agreed location, ref. GA drawing. For effective isolation of vibration and noise, there are mounted vibration dampers on the HPU.

After installation user is obligated to check the neutral grounding correctness.

The hydraulic power unit should be fastened to well stiffen deck plating (yard responsibility).

The power pack should be grounded (yard responsibility).

Use flexible hoses to connect HPU with piping installation (yard responsibility). See chapter for § Hydraulic system, for more information regarding hydraulic, tubing and hoses.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.9 Cabinets

Control cabinet 1 (CC1) with operator panel and starter mounted, shall be located indoor and mounted to the floor with bolts.

Junction box 1 (JB2A) is pre-mounted on the hydraulic power unit.

Junction box 2 (JB2B) with cable connection to the remote control, shall be mounted on deck near davits and proportional control valves.

See GA and single line arrangement for details.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.10 How to mount 4mm wire rope for emergency lowering

Thread the 4mm wire rope from the start marked [1] to points marked [2]- [3]-[4] and [5] and put the emergency lowering drum on hooks placed on leg and hang the handle for emergency davit swing out close. Both handles shall be reachable from back of the boat.

The davit frame has eyebolt, shackle and wire block with swivel eye for the wire.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.11 Hydraulic system on ship

General:

The installation should be in accordance with the system diagram. It is recommended to use suitable protective caps to avoid damaging connection elements, and to avoid dirt entering the tubes. The system is designed for minimum pressure loss. Tube sizes as shown on system drawings are based on distance maximum 10m between davit and control valve. Cover the stainless steel tubes when welding close to the davit.

Tubes:

On long distance tube lines, the velocity must be reduced by increasing the tube diameter.

Pressure head loss and oil velocities must be kept to a minimum in tube lines for oil leakage from pumps and motors. These tube lines should go direct to the tank, and not be connected to the return line. Forming the tube lines, bends must be achieved by cold bending without sand- or lead filling. If welding cannot be avoided, the joining should be placed easy accessible for maintenance.

NOTE! Choose of tubes/pipes shall be stainless steel tubes acc. to ASTM A269/A213

– AISI 316 or equivalent.

Make sure that the correct dimension hydraulic tubes / pipes are installed on the ship for connecting with the davit hydraulic tube system. Fitting elbows 90˚ shall not be used to avoid unnecessary pressure drop and leaking points.

Fittings:

In hydraulic installations, non-welded couplings are preferable. For external diameters up to 42 mm, EO-fitting system may be used. For preparation of the tubes; cut and remove burrs thoroughly external and internal from the tubes before assembly with fittings.

Fittings are to be assembled according to the manufacturer specification. The tubes must be properly adjusted/ fitted prior to installation. It is recommended to use Parker’s catalogue for industrial tube fittings for more information regarding fitting system.

NOTE! It is not recommended to paint unpainted tubes. Grease tape is more recommendable.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Threaded connections:

Use Castrol Optimol Paste White T or Parker assembly oil on threaded connections. Do not use thread tape.

Cleaning of tubes:

All tubes must be cleaned when the assembly is finished. This is important. They must be free of fixed and loose grit, welding slag and splatter, remove any traces of paper or rags.

Cleanliness is necessary

Arrangement of tubes:

The distance between pump, valves and motors should be kept to a minimum. It is preferable to use formed tubes rather than elbows due to loss of efficiency.

Clamping:

The clamps shall prevent the tubes from vibrating and at the same time allow longitudinal movements. The clamps should be lined with plastic or rubber to prevent wear of the tube and reduce the noise level. Normal distance between clamps is 25-50 times outer diameter of the tube.

Longitudinal expansion:

Tube 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 system functioning as shock absorbers and elongation compensators.

No metallic contact between tubes and clamps.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Flushing of the system:

Prior to assembly of the main components the tube system fitted on deck shall be flushed.

The main components as the davit, hydraulic power unit and even the proportional control valve shall be by-passed when flushing. The flushing 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 tube 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 is to be achieved. The oil used for flushing shall be of the same type as that used under operation.

NOTE! Flushing of the system needs to be carried out for the warranty to be valid!

Pressure testing:

Pressure testing of the tubes must be achieved prior to starting operation of the system. The power pack and other hydraulic components are not to be tested, or to be used in the pressure testing of tubes.

Hydraulic hoses for all pressure lines shall be pressure tested to 1.5 times the maximum working pressure for the system, limited to 70 Bar above the maximum working pressure.

Piping and tube fittings according to above mention combination of industrial tube fittings and cold formed tube ends may be excluded from pressure testing. The manufacturer of the lifting appliance shall however perform a one-time prototype test of each tube dimension. The documented results shall be available on request.

Piping and tube fittings other than above mention combination of industrial tube fittings and cold formed tube ends shall be pressure tested to 1.5 times the maximum working pressure of the system; limited to 70 Bar above the maximum working pressure.

Hydraulic hoses and tube fittings for the return lines and drain lines shall be excluded from pressure testing.

NOTE! Pumps, motors, cylinders and valves are normally factory tested.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Hydraulic hose and tubes installation example:

Hydraulic tubes; use only seamless precision steel tubes and follow specifications in hydraulic diagram. During installation of tubing, try to keep the run as straight as possible and securly clamped. Avoid too many 90deg bends to avoid leaks, but if necessary, bends is to be kept tidy and follow corners and steps in a way that do not interupt other installations or tubes.

Allow expansion and contraction. Do not hamper expansion and contraction near by tube bends.

Vibration has to be eliminated near by the connectors.

Tube lines have to be supported in certain distances: ref table for distance from tube manufacturer.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Keep tube lines away from components that require regular maintenance.

Right-angeled-parallel-clear.

Have a neat appearance that keep repair, troubleshooting and miantenance easy .

Do not use tube lines to support other tubes.

Always fix tubes onto a rigid point with tube clamps.

Do not use cable channels to support tubes.

Use appropriate tube clamps.

Avoid eccessive strainon joint: a strained joint will eventually leak.

Allow for expansion effects.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Hydraulic hoses; to be handled with care to prevent excessive bending, twisting and kinking.

Never step on, stand on or pull the hose. Flexible hoses should be installed according to specifications on the hydraulic diagram.

When routing installation is straight, be assured that there is enough slack in the hose to allow for changes when pressure is applied, but not too much slack for risk of snagging on other equipment.

Avoid twisting and ample bend radius, direct surface contact that will cause abrasive wearing on the outer cover of the hose.

No sharp bends below minimum bending radii, use correct fittings to avoid straining the hose. Tables for minimum bending radii can be found in manufactures’ catalogue.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Fluid injection injuries shall be treated without dely and shall not be treated as a simple cut.

Fluid under pressure can cause serious injury. It can be almost invisible escaping from a pinhole, and it can pierce the skin into the body

Do not touch a pressurized hydraulic hose assembly with any part of your body.

If a fluid-injection accident occurs, medical treatment by a doctor shall be sought immediately.

Stay out of hazardous areas while testing hose assemblies under pressure. Use proper safety protection

Remember; Safety first!!

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.12 Hydraulic oil, grease and other lubricants

Be sure to fill or lubricate with correct oil or lubricate-type according to manufacture specification on tank, pump, proportional control valve, gear, break and motor. The tables in this chapter list different types of hydraulic oil, grease and cleaner that Vestdavit AS recommend. Other types not mentioned here can be used if the product characteristics are similar to our recommendation.

It is recommended to use an external filter for filling of hydraulic oil to the system, due to cleanliness of hydraulic oil in the system.

Note that gear and brake mounted on winch shall not use same type of oil. If there is a secondary brake, note that it shall not be refilled with oil. Do not mix oils of different types even if it is the same brand.

2.12.1 Oil types

For the davit system to functional optimal; be ensured that the hydraulic oil used in the davit system has a correct viscosity at all times, and at all temperature conditions.

Use NAS CLASS 7 or better.

Filling of hydraulic oil;

The following table indicates the temperature range for the viscosity during start-up and operation.

Viscosity 22 is recommended with ambient temperature from +5°C to -10°C.

Viscosity grade @40°C

Start up 860 cSt

Start up 220 cSt

Start up 110 cSt

Running 54 cSt max.

Running 13 cSt min.

22 cSt -22°C -5°C 8°C 18°C 55°C

32 cSt -12°C 6°C 14°C 27°C 62°C

46 cSt -6°C 12°C 22°C 34°C 71°C

68 cSt 0°C 19°C 29°C 42°C 81°C

Arctic conditions;

Use Panolin Atlantis 15 low temperature oil or equal for the davit and EP 80W/90 or equal for the gear box.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Operation temperature;

For continuous operation the temperature should not exceed 65°C anywhere in the system.

Normally the best results are achieved at 55°C.

Table of oil for hydraulic oil system and brake;

Brand Hydraulic oil system and brake

Panolin Atlantis N 32

Table of oil for gear oil;

Brand Gear OIL ISO VG 150 Higher quality GEAR OIL (Recommended) ISO VG 150

Shell Omala S2 G 150 Omala S4 GX 150

Exxon Esso Spartan EP 150 Spartan S EP 150

Exxon Mobil Mobilgear XMP 150 Mobilgear SHC XMP 150

Castrol Alpha SP 150 Alphasyn EP 150

Total Carter EP 150 Carter SH 150

Optimol Optigear BM 150 Optigear Synthetic X 150

BP Energol GR-XP 150 Enersyn EP-XF 150

2.12.2 Greasing of davit parts

Table for nipple lubrication (davit, cylinder);

Brand Nipple Lubrication (davit, cylinder)

Shell Gadus S2 V220

Exxon Mobil Mobilux EP

Castrol LM Grease

Total Ceran WR

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Table for wire rope grease;

Brand Wire grease

Lanopro Condor Lube 50-70G

Statoil Statoil wire grease

Shell Shell Gadus S3 wirerope A

2.12.3 Miscellaneous lubricants and fillings

Table for cylinder rod cleaner and protection (similar products can be used);

Brand Lubricant Function

CRC CRC 2000 Cleaner

Loctite Loctite 8032 Teflon spray for protection

Table for nitrogen filling;

For preloading and refilling of bladder accumulator with nitrogen, please check the hydraulic drawing for amount.

Gas Equipment

Nitrogen Bladder accumulator

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.13 Starting the system

A service engineer from Vestdavit AS should be present for initial start-up.

2.13.1 Preparation before starting

1. After oil filling, check the following:

2. Correct oil level and type in tank.

3. Main and control voltages.

4. Check that all hydraulic connections are according to hydraulic diagram.

5. Check all valves are positioned as per drawing and local indication (marked with normally open to be open, and normally closed to be closed).

6. All tube couplings to be securely tightened.

7. The accumulators must be pre-charged with Nitrogen to specified pressures. (The bladder will be damaged if it is not charged with Nitrogen before the system is pressurised).

2.13.2 Starting

1. On initial start-up, check the turning direction of the pump, if wrong way, stop the system and get qualified electrician to re-connect. (The pump has to be started in order to check if it is turned the right way, the pump/motor can be destroyed if it is run the wrong way more than 20 seconds).

2. Check for leaks and abnormal sounds when the motor runs idle.

3. Operate winch hoist and lower lever, and check that the winch motor rotates well.

4. Slowly move the cylinders out and in, - slowly in order to bleed the system.

5. After the system is bled, raise the pressure maximum by pulling lever [DAVIT IN] and hold the pressure for 10 seconds, and check for any leaks. Do not exceed 250bar.

6. Run all functions several times in order to bleed the system.

7. Bleed the shock absorber (see § instruction for activating shock absorber).

2.14 Functions test

Turn on the hydraulic power unit, check that the main pressure is increasing.

Check that the directional control valve is moving freely.

Check that the remote, if applicable, is activated by moving a joystick.

Run the system and check if there are any oil leakages.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.15 Charging of accumulator

Charging and testing unit (charging kit) consist of;

Valve body Spindle [A] Check valve [B] Release valve [C] Pressure gauge [D] Charging hose Adapter for bladder accumulators

Safety instructions:

Prior to each testing, topping up or recharging of nitrogen, the hydraulic accumulator must be isolated from the pressurised system by means of a shut-off valve and the fluid released.

Preparation:

Unscrew protective cap and sealing cap, remove the O-ring. Slightly loosen the adjusting screw on adapter in an anti-clockwise direction and screw the adapter onto the accumulator gas valve.

Screw the connector by hand to the adapter on accumulator bottle.

Unscrew spindle [A] all out, connect the adapter for bladder accumulator.

Connect the charging and testing unit onto the gas valve of the hydraulic accumulator and connect via a hose to a commercial nitrogen bottle. If the nitrogen pressure is only to be checked or reduced, the charging hose does not need to be connected.

Be careful not to turn the spindle all the way in (downwards) due to avoid damaging the needle.

Testing:

Firmly close the release valve [C] on the testing unit.

Turn spindle [A] in a clockwise direction (inwards) to open the gas valve in the accumulator.

Turn spindle [A] until the needle of the gauge begins to move.

The pressure gauge now indicates the gas pre-charge pressure inside the accumulator.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Reducing the pre-charge pressure:

Open release valve [C] to bleed pressure.

Charging:

Turn spindle [A] in a clockwise direction to open the gas valve insert in the accumulator until the needle of the gauge begins to move.

Open the shut-off valve on the nitrogen bottle and release nitrogen into the accumulator at a moderate speed.

Interrupt the charging process from time to time and check the pre-charge pressure reached. Repeat this process until the required gas pre-charge pressure is achieved.

The given pressure to be found in the hydraulic diagram.

After temperature equalisation has taken place, re-check the pre-charge pressure and adjust if necessary.

Completion and dismantling:

Turn spindle [A] in an anti-clockwise direction to close the gas valve insert in the accumulator.

Release pressure from the charging and testing unit using the release valve [C].

Remove the unit from the accumulator by unscrewing connector, replace the O-ring and screw the sealing cap onto the accumulator gas valve and tighten firmly. Put on the protective cap.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.16 Instruction for activating shock absorber on HN-davit system Item description:

1. Minimess coupling.

2. Ball valve.

3. Accumulator.

4. Shock absorber.

5. Minimess hose.

6. Charging kit.

Description:

The absorbing element consists mainly of a single acting cylinder which is connected to a preloaded accumulator. Make sure that the accumulator is preloaded with nitrogen (N2) before any hydraulic oil pressure is added and is in parked position so the minimess is on the highest point.

Activating:

1. Connect the minimess hose (5) to the minimess coupling (1), and insert the open end of the hose to a bucket or bottle suitable for oil spill. Open the ball valve (2).

2. Start the system. Push control lever gentle towards lowering. The cylinder will now be activated; air and oil will flow through the minimess hose.

Warning! The cylinder will eject at high speed and be able to inflict damage on personnel standing in front of the cylinder. Move to a safe area.

3. When the cylinder is fully activated, let go of the lever and close the ball valve. Unscrew the minimess hose.

The shock absorber is now ready to use.

Filling up accumulator:

The N2 pressure is calculated according to the weight to be suspended in the davit. If the pressure is too low or too high, it can be adjusted by using the nitrogen charging kit (6) delivered with the davit.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.17 Table for refilling nitrogen in accumulator on shock absorber

For refilling nitrogen on shock absorber accumulator we recommend using filling and checking equipment. This equipment was delivered with the davit system.

Important! The accumulator must be preloaded with nitrogen (N2) before any hydraulic oil pressure is added.

Operational weight is boat weight +3 crew members.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.18 Procedure for touch up paint and grease

Check after installation is done that painted areas are still covered with protecting paint, and touch up paint work on surfaces that has been harmed or worked on. All surfaces shall be protected, and grease, grease tape, Teflon spray or similar like Dinitrol, to be used to protect the davit structure and other surfaces.

Note! Do not paint the grease nipples.

After the installation it is required to go over the complete davit system and inspect for damages in the paint. If there are damages, it will be necessary to touch up paint. If grease tape is removed or damaged it is required to add new grease tape. The complete davit system shall be cleaned with soap and water. We recommend to add Dinitrol or similar to protect the davit structure.

Touch up paint of scratches in the paint “top coat”;

1. Wash the surface with soap and water (de-greasing).

2. Add top coat according to specifications.

Touch up paint of scratches down to the steel structure;

1. Wash the surface with soap and water (de-greasing).

2. Use a fine sandpaper to get it even.

3. Add Jotun- Jotacote Universal,

4. Add top coat according to specifications.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

2.19 Test procedures

Tests performed at Vestdavit AS production site:

SWL=Safe working load, please check the certificate for davit.

Overload test (davit frame), static proof load of SWL x 2.2.

Static brake test winch (only done during FAT), test of brake, SWL x 1.5.

Dynamic brake test winch, SWL x 1.1.

Performance test of winch, emergency stop to be activated to shut down power during lowering, SWL x 1.1.

Emergency function test, SWL x 1.0.

FAT test according to specifications. Tension function to be tested, if fitted.

NDT test, carried out after overload test.

Tests performed at the yard:

Load test are done by use of a “water bag weight” or similar in the hook. For the guaranty to be valid, these tests must be performed by the service engineer from Vestdavit AS.

Dynamic brake test; water bag weight to be loaded with SWL x 1.1. Load to be lowered at full speed with the hydraulic power unit running, and stopped abruptly three times during lowering sequence.

Simple lowering test, weight of boat with normal equipment and hydraulic power unit running. The load placed in stored position, swing out the load and lower it.

Maximum lowering speed = 40m/min (+/- 10%).

Functional test, test that all functions work normally with normal SWL at normal speed.

NDT test of the welded hinges on deck, to be checked after the dynamic brake test.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Test of emergency procedures

Emergency launching when “dead ship”.

Basic: The boat in stored position, hydraulic power unit off.

Load: Similar weight as to the fully loaded boat. No people shall be used, only test weights.

Perform the emergency lowering according to instructions given on the emergency procedure signs.

Charge accumulators according to emergency procedure signs.

Emergency hoisting when “dead ship”.

Maximum weight for this operation is equipped boat without persons.

Perform the emergency hoisting according to instructions given on the emergency procedure signs.

Recovery when “dead ship”.

Perform the emergency hoisting according to instructions given on the emergency procedure signs.

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

Yards checklist: pre commissioning installation.

Vessel name: Thomas Jefferson Davit type: HN-9003

Vessel owner: NOAA Davit serial no: 91534 & 91535

Vestdavit project no: 91534 & 91535 Winch serial no: 91534 & 91535

Vessel IMO no: Date of installation check:

Check points to be completed before commissioning;

1. Check that davit installation is ready for commissioning. □

2. Check that all welding of davit to deck is done. □

3. Check that all welding is NDT tested. □

4. Check that all hydraulic pipes and hoses between davit and proportional control valve is connected according hydraulic diagram. □

5. Check that the system is flushed and pressure tested. □

6. Check that all electrical connection is connected according electrical diagram. □

Parts and equipment to be on site before commissioning;

1. Oil for HPU, ref Davit Installation Manual. □

2. Nitrogen bottles for charging of accumulators. □

3. Loose parts according to packing list. □

4. Test weights according to classification. □

5. Test weights of 1.1 of SWL. □

6. Test weights of 1.0 of SWL. □

Go through list and sign off all points, if OK. Please sign and return to Vestdavit.

Date Signature

VDT-IM-91534-35

Rev.:

Date:

10.10.2016

Damsgårdsvn. 143, 5160 Laksevåg, NORWAY | Tel.: +47 55 54 92 00 | E-mail: post@vestdavit.no| www.vestdavit.no

List of drawings for davit HN-9003

Projects 91534 and 91535

Reference Description / title Drawing number

Davit Starboard side General Arrangement 141144

Davit Port side General Arrangement 141145

Davit Starboard side Hydraulic Diagram A-15165

Davit Port side Hydraulic Diagram A-15167

Deck Hydraulic Diagram A-15229

Overview Hydraulic Diagram A-15143

Winch Hydraulic Diagram A-15166

Shock absorber Hydraulic Diagram A-15202

Wire puller Hydraulic Diagram A-14825

Hydraulic Power Unit General Arrangement 1585366

Cabinets GA & single line Diagram 1594682

Cabinets Wiring diagram 1599353

List of drawings for davit HN-9003