ITEM 108 - VESTDAVIT_MAINTENANCE_INSPECTIONS_MANUAL.pdf

USER MANUAL

Maintenance & Inspections

VESTDAVIT TYPE HN-9002

WINCH TYPE A-320-1D

Customer : NOAA

Purchase order : AB133M-11RP-0140

Vestdavit project no. : 91134-37

Delivery Year : 2012

Prepared by Approved by Doc. No. Rev.No. Date Page

H.Laupsa H. Gravdal VDT-UMH-91134 01 01.10.12 1 of 32

HN-9002

No.: VDT-UMH-91134 Rev.: 01 Date: 01-OCT-2012 Page: 2 of 32

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

TABLE OF CONTENTS

List of illustration Part I INTRODUCTION Part II MAIN DATA

2.1 Restrictions in use

2.2 Technical Data

2.3 Main connections and requirements for connected systems

PART III Design and functions

3.1 Davit functions

3.2 Winch

3.3 Hydraulic system

3.4 Maneuver valve

3.5 Hydraulic power unit

3.6 Self-tension system

3.7 Shockabsorber

3.8 Wirepuller

3.9 Cylinders

Part IV INSPECTION AND MAINTENANCE

4.1 General

4.2 INSPECTION ROUTINES

4.3 Filling of hydraulic oil

4.3.1 Checking oil level in hydraulic power unit

4.4 Threading of wire

4.5 Lubrication oil and drain connections for winch

4.6 Greasing of wire

4.7 Maintenance of piston rods

4.8 Instructions for refilling nitrogen on shock absorber accumulator

4.9 Charging of accumulator

4.10 Long term stop and new start

4.11 Disturbance of operations

PART IV SPARE PARTS

APPENDIX A DRAWINGS

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List of illustration

Figur 1 Winch Figur 2 Manouver valve Figur 3 Hydraulic power unit (HPU) Figur 4 Shockabsorber Figur 5 Wirepuller Figur 6 Cylinder Figur 7 Indicator Figur 8 oil level Figur 9 The wrong way to do it Figur 10 Threading of wire Figur 11 Threading of wire Figure 12 Even layers Figur 13 Winch illustration Figur 14 Cylinder Figur 15 Pressure - Load graph Figur 16 Charging of accumulator

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Part I INTRODUCTION

This manual contains description of all necessary details needed for maintenance of the davit.

The manual consist of the following parts:

PART I Introduction

PART II Main data

PART III Design and funtions

PART IV Inspection and maintenance

PART V Spare parts

APPENDIX A Drawings

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

Vestdavit A/S Damsgårdsveien 143

5160 Laksevåg, Norway

Telephone: 47 55 54 92 00 Telefax : 47 55 34 24 04

E-mail: post@vestdavit.no

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Part II MAIN DATA

2.1 Restrictions in use

1 The hoisted/lowered boat shall never exceed SWL for the davit arrangement.

2 The davit is not to be used as a crane, i. e. cargo net or similar is not allowed.

3 The davit is only to be used in lowering/hoisting operation of work/mob boat connected correctly in lifting wire.

4 Only original spare parts from Vestdavit AS are allowed.

5 Use oil specified in filling of hydraulic oil chapter in the user manual.

6 Vestdavit AS takes no responsibility for electrical wiring and circuit breaker (Fuses) must be installed prior to the electrical starter to protect the system. Electrical installation must be done according to drawings and accepted international standards.

7 It’s not allowed to disassemble the winch, or do any modification on our delivered system without contacting Vestdavit AS.

8 Maintenance has to be carried out as Vestdavit AS has described in the user manual.

Any violation to these restrictions will invalidate the warranty conditions.

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2.2 Technical Data

DAVIT

Davit type Vestdavit HN-9002 Max. Load, SWL 9000 Kg Test load in work shop 19800 Kg Wire Ø20mm, L=60 m Hydraulic cylinder davit 2 X CD10MS 125/70 x 2700 Shock Absorber 2 X CP4BG 80x400 SD

WINCH

Winch type Vestvinsj A-320-1D Max. Wire pull 2. Layer 9000 kg Drum dim. Ø320 mm Max. Hoisting speed 22 m/min (+/-10%) Max. Lowering speed 22 m/min (+/-10%) Max. Oil pressure 200 bar Required oil flow 145 l/min Hydraulic motor, type H2V 226 Gear, type Brevini ED 2255 /FL760 Gear reduction 1: 28

CONTROL EQUIPMENT

Control valve PSL 6H/245-5 Accumulator for emergency swing 10 liter

HYDRAULIC POWER UNIT

Electric Motor Bevi 55Kw, 440V, 60Hz Oil Reservoir 450 Liter Pump T7DS-B28-1R00-A100 Oil Flow 145 l/min at 200 bar Oil type Shell Tellus T32 or similar Return Filter TXW5-10B Operation temp. max. 55º C

2.3 Main connections and requirements for connected systems.

If the davit hydraulic system is connected to external hydraulic supply, i.e. constant pressure system, load-sensing etc., hook up valve arrangements should be stated in hydraulic diagram. If not, contact Vestdavit A/S.

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PART III Design and functions

3.1 Davit functions

VESTDAVIT Type HN is a hydraulic operated twin- suspension davit designed for safe lowering/hoisting of life-/working boats.

All operations of the davit are hydraulic driven which benefits control of the boat position at all stages during the operation, and gives the opportunity to bring the boat back onboard in any position required at any time.

The davit arms are hinged on the deck nearly under the centreline of the boat. With hydraulic cylinders the davit arms are swung out or inboard, so the boat can be lowered along the ship’s side.

In parked position the boat is normally resting on keel supports and sides, secured by two or more lashings.

Embarkation of the boat can take place in parked position or in parked position on ships side in deck level.

The davit is operated by one person from the operator's console and should have a location that gives a clear view to the boat launching.

Launching of the boat is done by swinging the davit from its parked position to a position where the boat is free of ship’s side, and then lowered by means of the winch.

This two-step operation makes it possible to swing the davit backwards after lowering the lifeboat below deck, allowing the boat to rest along the ships side, preventing it from excessive movements in rough weather conditions, or to park the lifeboat along the ship side for embarkation/disembarkation.

The davit is fitted with a mechanical end stop on hoisting that will work in parallel with the release valve.

The Shock absorber is a fully automatic/passive hydraulic device that ensure smooth lowering and hoisting of the boat.

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3.2 Winch

Figur 1 Winch

The winch is constructed with four main elements:

1) Wire drum and winch foundation with bearing brackets.

The drum is at drive end directly connected to the gear and gear bearings, and in the other end roller bearing on the winch bracket. The drum is divided in two separate sections, each grooved. The wire is entered in the middle between the drums.

2) Gear.

The reduction gear is a planetary gear flanged directly to the frame.

Transmission from motor to gear is made by a splined flange coupling.

3) Between gear and hydraulic motor there is a automatic spring-loaded disc brake working as a parking brake and a mechanical brake. The brake is released by hydraulic pressure.

4) Hydraulic motor:

Standard. The motor is an axial piston motor, fixed displacement.

Self Tension (if fitted, extra equipment) Hydraulic motor. The motor is an axial variable piston motor, with hydraulic control to maximum or minimum displacement.

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3.3 Hydraulic system

The winch system consists of hydraulic motor, valve block flanged to the hydraulic motor, the Self Tension System and a hydraulic operated brake.

Hydraulic double acting cylinder for swing out/in, with throttle-check valves.

Hydraulic double acting cylinder for swing out/in of grid, with throttle-check valves.

Hydraulic shock absorber for smooth lowering and hoisting.

The Maneuvering unit is a lever operated directional valve. Spring centered 3 spools valve. First bank closed center for operating grid cylinders, center bank closed center for operating davit cylinders and third bank open center for winch motor.

3.4 Maneuver valve

PSL 6HY/245-5

Figur 2 Manouver valve

Winch Davit Tension

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3.5 Hydraulic power unit

The hydraulic power unit supplies pressurized hydraulic oil to hydraulic components like cylinders, motors and accumulators.

Figur 3 Hydraulic power unit (HPU)

3.6 Self-tension system

Self-tension system is a wave compensator system that is only to be used when the boat is sea born. The system is based on a only hydraulic operated system without use of any sensors, which gives the system a unique and reliable operation.

Return

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3.7 Shockabsorber

Figur 4 Shockabsorber

Device required to take away peakloads during launching and retrieving of the boats.

Essential components for man safety and boat structure protection.

Shockabsorbers

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3.8 Wirepuller

Figur 5 Wirepuller

Devise recommended to avoid any bird-nesting of the line during launching and retrieving of the boats.

This components replaces smartly the Drum-Press used now days, because it allows to run davit empty of boat.

Wirepuller

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3.9 Cylinders

Poston rods exposed to salt and marine enviroment may cause failure on the chrome layers on the piston rods. If the chrome layer get pitting/cratering the sealings inside the cylinder will fail, and a leakage may occur.

All cylinders have projection of the piston rod. To prevent damage on the chrome layer the davit must be in parked position when it’s not in use. This means all cylinders on the davit all in.

Figur 6 Cylinder

Projection (Exposed all time)

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Part IV INSPECTION AND MAINTENANCE

4.1 General

Inspections shall take place according to relevant Authorities’ Regulations.

Observe if the following should occur:

o Increase in noise level o Vibration in winch o Functional faults

If faults should occur, repair action must be taken immediately.

Contact VESTDAVIT if necessary.

The inspection and maintenance guide below is the manufacturer recommendation.

However, the operation conditions for the davit, or the Authorities, may require more frequently or extended routines.

Please use our maintenance checklist that are included.

4.2 INSPECTION ROUTINES

Weekly:

Inspect wire for damages Clean piston rods on cylinders

Monthly:

Warning! Always ensure that oil level in gravity-tank is at least ½ full, or that standby pressure in auto refill unit is at least 15 BAR minimum before “dead ship” Launching.

1. Hinge bolts for davit arm, cylinders and sheaves shall be lubricated with grease.

2. Check that maneuvering valve is moving freely and grease if necessary.

3. Check oil pressure on accumulators, ref. Pressure gauge. See hydraulic diagram for information about the pressure.

4. The davit wire must be checked for splinters. The wire should be greased with special oil.

See spare parts and chapter for wire.

5. Check if any oil leakage on winch.

6. Check pressure gauge on refill unit (accumulator) See hydraulic diagram for the correct pressure.

7. Check oil level in emergency lowering pump and fill up if necessary.

8. The tank must be full, or the brake will not open in case of emergency.

9. The piston rod for hydraulic cylinders to be kept clean and oiled with a thin layer of acid free Vaseline or grease to avoid seal damages. See more information in chapter for piston rods.

10. All parts must be checked for rust, in case of rust please re-paint or refit with denso tape.

Dry denso tape must be changed to new one.

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½ YEAR INSPECTION:

The oil is to be tested each half year.

The Nitrogen pressure in accumulator to be checked each 6 months.

YEARLY INSPECTIONS:

Ref. relevant requirements from authorities.

1. Change of oil in the systems should normally be done after 1500 hours of operation or annually.

2. Gear oil to be renewed if necessary.

3. Brake oil to be renewed if necessary.

4. Return filter on oil tank to be replaced as required. See indicator (as picture under shows.

When this is red you should replace it.

Figur 7 Indicator

5. Pressure filter on oil tank to be replaced when indicator turns red.

WARNING:

Do not loosen or tighten any hydraulic fitting while system is pressurized. Hydraulic fluid under pressure is a risk to personnel and equipment. Ensure hydraulic pressure is bleed from hydraulic accumulators before opening hydraulic fittings.

Special Tool

The Nitrogen Charging Set is the only special tool needed.

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4.3 Filling of hydraulic oil

Tanks, pumps, manoeuvre valve, gears, breaks and motors must be filled with correct type of oil according to manufacture specifications.

Oil types To have an optimal functional davit system is it important that the hydraulic oil has a correct viscosity at all times, and at all temperature conditions.

Oil with viscosity grade 22-68 cSt at 40ºC, running 13-54 cSt

Use NAS CLASS 7 or better

The following table indicates the temperature extremes between which the viscosity grades can be used to remain within start-up and running viscosity range recommendations.

Viscosity 22 is recommended with ambient temperature from +5 to -10ºC

Viscosity Grade @ 40 ºC

Start up 860 cSt

Start up 220 cSt

Start up 110 cSt

Running 54 cSt Max.

Running 13 cSt Min

22cSt -22 ºC -5 ºC 8 ºC 18 ºC 55 ºC 32 cSt -12 ºC 6 ºC 14 ºC 27 ºC 62 ºC 46 cSt -6 ºC 12 ºC 22 ºC 34 ºC 71 ºC 68 cSt 0 ºC 19 ºC 29 ºC 42 ºC 81 ºC

Arctic conditions:

In special arctic conditions is the use of synthetic oil recommended. Shell Tellarctic Oil or equal.

The gearbox should use gear oil EP 80W/90 or equal.

Operation temperature:

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

Normally the best results are achieved at 55 ºC.

Under is a table of oil to choose for Hydraulic oil System and brake:

BRAND Hydraulic oil

System and brake Shell Tellus 32 Castrol Hyspin AWH M 32 Mobil DTE 10 excel 32 Chevron AW Hydraulic HD 32 Texaco Rando HDZ 32

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Under is a table of oil to choose for gear oil:

BRAND GEAR OIL ISO VG 150 Higher Quality GEAR OIL

(Recommended) ISO VG 150

SHELL Omala 150 Omala HD 150 ESSO Spartan EP 150 Spartan S EP 150 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 syntethetic X 150 BP Energol GR-XP 150 Enersyn EP-XF 150

Under is at table for Nipple Lubrication (davit, cylinder):

BRAND

Nipple Lubrication (Davit,cylinder)

SHELL ALVANA EP

MOBIL MOBILUX EP

CASTROL LM Grease

FINA MARSON

BRAND

Wire grease

LanoPro Condor Lube 50-70G Statoil Statoil wire grease

Warnings:

Do not mix oils of different types even of same brand.

Testing your fluid for water (each 6 months):

A simple ‘crackle test’ will tell you if there is free water in your fluid.

Simply take a metal dish or spoon with a small amount of fluid.

Apply a flame under the container to heat the content.

If bubbles rise and ‘crackle’ from the point of applied heat, you have free water.

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4.3.1 Checking oil level in hydraulic power unit

Push in button A and B, at the same time to check the oil level.

NB! Ensure that oil from accumulators is drained to hydraulic power unit tank, before reading the oil level. If you fill oil on the tank before the oil from accumulators is drained, it is possible that you are going to spill oil, and that the tank gets completely full.

Figur 8 oil level

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4.4 Threading of wire

Handling of wire When you are going to change the wire is it important that you don’t do it like in the picture under, you have to be sure that the wire don’t gets any violation.

Figur 9 The wrong way to do it

Check that the wire has not turned between the wire layers.

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Figur 10 Threading of wire

1. Mark the centre of the wire.

2. Thread wire through guide pipe in centre of winch drum, pos. 1. Tighten bolt pos.

5, to prevent wire from moving in winch drum.

3. Thread wire part pos. 3 through pos. 2 located in winch frame.

4. Spool wire on winch drum.

5. Unspool wire, and adjust height of wedge locks so they fit boat hooks for/aft.

Boat is used for this purpose. Adjustment of the centre point of wire may be necessary.

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Figur 11 Threading of wire

Figure 12 Even layers

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4.5 Lubrication oil and drain connections for winch

VESTWINCH

Figur 13 Winch illustration

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4.6 Greasing of wire

The lubrication new wire ropes receive during manufacture is adequate for initial storage and the early stages of the ropes working life. It must however be supplemented at regular intervals. The frequency of this re-lubrication depends on the frequency of usage. When the wire appears ”dry”, it needs re-lubrication.

Proper lubrication is important to the service life of the rope. The lubrication serves both as protection against corrosion and as a factor to reduce the friction between wires and strands in the rope.

Lubricants should be free from acid and with no pernicious influence either on the wires or on the core. The lubricant must have a consistency that enables it to penetrate into the rope. The rope must be clean before the lubricant is applied.

See spare part for wire grease.

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4.7 Maintenance of piston rods

Piston rods exposed to salt and marine environment may cause failure on the chrome layers on the piston rods.

If the chrome layer get pitting/cratering the sealings inside the cylinder will fail, and a leakage may occur.

All cylinders have projection of the piston rod. (See pictures) This area to be cleaned once a week.

This area will always be exposed to salt and marine environment.

Figur 14 Cylinder

Projection (Exposed all time)

To prevent damage on the chrome layer the davit must be in parked position when it’s not in use. This means all cylinders on the davit all in.

If some of the cylinders must be in out position for some days, the piston rod must be cleaned also then once a week.

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4.8 Instructions for refilling nitrogen on shock absorber accumulator

For refilling nitrogen on shock absorber accumulator we recommend using a filling and checking equipment. This charge equipment can be obtained from You can find the pressures to the accumulators in the hydraulic diagram.

Vestdavit A/S.

Operational weight is boat weight + 3 crew members.

216 bar

151,5 ton 1 2 3 4 5 6 7

PRESSURE-LOAD GRAPH Ø80

SHOCKABSORBER

STATIC LOAD

PRELOADING ACCUMULATOR

IN BAR/ TON

Figur 15 Pressure - Load graph

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4.9 Charging of accumulator

Instructions for filling/ checking of nitrogen.

Figur 16 Charging of accumulator

1 Ensure that accumulator is shut off from the circuit and decompressed on the liquid side.

2 Valve E to be unscrewed. Valve B to be closed. Attach the charging valve with its appropriate connector on the accumulator using the knurled nut F. Tighten it fully after positioning the pressure gauge in the required position.

3. Turn the adjustment knob E carefully clockwise. Check the pressure in the pressure gauge.

4. If the charging pressure is too high, slowly open the general bleed valve B until the required pressure is obtained.

5. To increase the pressure, connect the hose to the nitrogen supply and feed in the pressurized gas slowly.

ATTENTION: In all cases, wait until the thermal exchange caused by the changes of pressure has stabilized before checking / adjusting the charge.

DISMANTLING:

1. Unscrew the knob E completely.

2. Bleed off with bleed valve B.

3. Undo the nut F, and attach the protection caps.

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4.10 Long term stop and new start

For long term stop in operation the oil tank must be completely filled to underside of tank (if separate power unit). This is to prevent condensation and internal corrosion.

For the same reason it is recommended to run the system at regular intervals in order to lubricate all the moving parts.

New restart should be performed in the same manner as the first starting operation.

Additionally, do the following:

1. Drain oil from the tank bottom and check that the oil is free from water and dirt.

Take a oil sample and have it analyzed.

If necessary, filtrate or replace oil before starting the pump.

2. Check oil level.

3. Check filter, clean all parts or replace if necessary.

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4.11 Disturbance of operations

DEFECT POSSIBLE CAUSE REMEDIAL ACTION

A.

The winch will not hoist/lower.

1. Safety valve opens too early.

2. The safety valve can be partly open due to particles between seat and valve. The winch will run slower than normal due to reduced oil supply to winch motor.

3. Insufficient amount of oil in the hydraulic oil tank. Suction line can be obstructed or have an air leakage. The pump will then give a squealing sound.

4. Having checked the above points and found the winch pressure to be as specified with-out achieving the specified pulling force, the fault might be in the winch.

Measure the pressure with the drum locked.

If the pressure is too low, the safety valve should be ad-justed until the pressure gauge shows correct pressure.

Clean safety valve.

Check oil level on hydraulic oil tank. Check pump suction line.

Contact VESTDAVIT.

B.

Substantial speed reduction.

1. Ref. A.2.

Ref. A.2

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B Substantial speed reduction.

2. Ref. A.3.

3. If the speed reduction has developed gradually, the cause might be worn hydraulic pump or winch motor.

Ref. A.3.

Check hydraulic pump. If the pump is in order, the motor in the winch must be overhauled or replaced.

INVESTIGATE FIRST IF

REPLACEMENT UNIT CAN

BE DELIVERED.

C.

Hoisting speed is slower than lowering speed

1. The control valve can reduce slide movement.

2. Ref. A.1.

Check that coil movement in the control valve is equal in both directions.

Ref. A.1.

D The brake releases when the control handle is returned to neutral after hoisting with load.

1. Wrong type of control valve.

Correct valve shall have all gates to tank open when the handle is in neutral position.

Remove hoses or pipes from control valve.

With handle in neutral position it shall be possible to blow air from gate "A" and "B" to tank gate.

If not, a correct valve type must be provided.

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D

2. Too high back pressure in the winch reverse the gate.

Too high pressure on return line.

Too small pipe dimensions or obstructions.

3. Throttle valve on brake line is too tight.

4. Load control valve defect.

5. Dirt in change valve.

6. Dirt in return filter.

Check the pressure close behind the winch. Run the pump with maximum number of revolutions and read the pressure when the handle is in the neutral position. If the pressure is higher than 0,4kg/cm2 the return line should be investigated for possible obstructions, or be re-placed to greater dimensions.

Replace the valve.

Check the valve.

Check, clean or replace the valve.

Replace filter element.

E.

The brakes do not work at lowering operation.

1. Ref. D1, D2, D3, D4 and D5.

2. The winch may be over loaded.

3. After the above points have been checked and found satisfactory, the error is probably located in the winch.

Ref. D1/D2.

Measure the pressure with locked drum. If the pressure is higher than the specified maximum for the winch, it must be reduced.

Contact VESTDAVIT.

No.: VDT-UMH-91134 Rev.: 01

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

PART IV SPARE PARTS

Item no.

Item name Recom. qty.

per davit

Vestdavit part no.

Prime manuf. id.

Return Filter cartridge 1 11242

TXW5-10B

2 Seal kit maneuvering valve 1 PSL 6H/245-5 3 sections 3 Seal kit handpump 1 10007 HPT25M 4 Seal kit 1 10963 HPT25 / Tank seal 5 Seal kit for hydraulic cylinder. 2 10428 CD20MS 125/70 6 Seal kit hydraulic cylinder.

Shock absorber 1 11359 CP4BG 80x400

7 Wire, non rotating

1 10363 ø20mm, 60 m, SWL 6000, non rotation

8 Pressure Gauge, Back 1 10254 0-400 bar, back

Pressure Gauge, Back 1 10251 0-100 bar, back

10 Wire grease 5 KG 12840 Condor Lube 50-70G

How to order When ordering spare parts to davit, please provide the following information:

Davit type: HN-9002

Davit serial no: 91134, 91135, 91136 and 91137

Vestdavit Project No: 91134-37

No.: VDT-UMH-91134 Rev.: 01

Page: 32 of 32

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

APPENDIX A DRAWINGS

General Arrangement

Hydraulic Diagram davit

Hydraulic Diagram deck

HPU GA

HPU Hydraulic circuit

Soft starter