TJ-583-03A Davit Hydrographic Survey Launch (HSL).pdf

Technical User Manual Operation and maintenance

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-TM-91534-35 26.10.2016 00 1 of 96

Technical user manual for operation and maintenance Davit HN-9003

No.:

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

Page:

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

Table of Contents

1. Introduction to technical manual

1.1 General information

1.2 Symbols used in manual

1.3 Abbreviations

1.4 Restrictions in use

1.5 Main connections and requirements for connected system

2. Technical data

2.1 Davit

2.2 Winch

2.3 Hydraulic power unit

2.4 Heat exchange data

2.5 List of drawings

2.6 Reference documents

3. Design and Function

3.1 Design temperature

3.2 Davit functions and overview

3.3 Winches

3.4 Hydraulic power unit system

Hydraulic power unit

Control equipment

3.5 Constant tensioning system

3.6 Accumulators

3.7 Shock absorber

3.8 Cylinders

3.9 Emergency system

3.10 Wire puller

4. Operation and control

4.1 General

Securing the boat

4.2 Health, Safety and Environment in operation process

4.3 Start and check procedure

Check points before start:

mailto:post@vestdavit.no http://www.vestdavit.no/

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Starting

Start and stop of HPU from different positions during normal operation

Start-up of system from terminal during normal operation

4.4 Control system

Manual operation by control levers;

Turn on the hand-held remote control

General info about the control system

Explanations of functions on the terminal

Alarms on the terminal

General about the control system

4.5 Description of the operator panel in CC1

Winch settings

Cylinders settings

HPU settings

Regulator settings

Trending of temperature

Trending of hydraulic pressure

Driving pattern for “via railing” mode

Alarm viewer

Other functions

4.6 Safety functions

Absolute encoder, common sensor for several safety functions

Slow stop

End stop

Monitoring of communication between the PLC and the base unit

Amplifier cards for proportional valves

4.7 Normal operation procedures

Launching of boat with davit

Retrieving of boat

Manual operation by levers

4.8 Re-charging of accumulator bottles in use

4.9 Emergency operations procedures

Back-up power with remote control operation

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Emergency ball valves for swing out and lower

Re-charge accumulator bottles with hand pump

4.10 Tension function and interlocks

4.11 Setting 0-position/end stop on winch

4.12 Automatic shutdown of system

4.13 Interlock in terminal

4.14 Stop of system and parking position

4.15 Stop of system from remote control

5. Maintenance and inspections

5.1 General

5.2 Health, Safety and Environment in the maintenance process

5.3 Inspection routines

Maintenance of surface on davit system

5.4 Maintenance of hydraulic power unit

Maintenance of control system

5.5 Maintenance of piston rods

5.6 Maintenance of wire puller

5.7 Pressurized hydraulic hoses and injuries

5.8 Hydraulic oil, grease and other lubricants

Oil types

Greasing of davit parts

Miscellaneous lubricants and fillings

Grease tape

Hydraulic oil in hydraulic power unit

Oil filling plugs and drain connections for winch

Lubrication points and greasing nipples

5.9 Wire rope

Threading of wire rope

5.10 Accumulator bottles

Charging of accumulator

Procedure for safe depressurizing of emergency accumulator

5.11 Table for refilling nitrogen in accumulator on shock absorber

5.12 Instruction for activating shock absorber on HN-davit system

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Procedure for safe de-pressurizing of the shock absorber

5.13 Yearly and five yearly inspection

Re-certification of davit-five yearly inspection

5.14 Storage and parking

5.15 Troubleshooting

VDT-MCL Maintenance check list

Bladder accumulator, service and table for record of pressure

VDT-Tag/label List

VDT-DWG List of drawings for davit HN-9003

VDT-CERT List of certificates for davit HN-9003

List of miscellaneous documents for davit HN-9003

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

1. Introduction to technical manual

1.1 General information

This manual gives the user instructions and information about the davit system and how to operate and maintain the davit system. It is vital that the manual is read and understood by all who is operating and maintaining the davit system. All installation work shall be done by trained and authorized service personnel.

Any questions regarding this 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-TM-91534-35

Rev.:

Date:

26.10.2016

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

1.2 Symbols used in manual

Note

Warning

Important

Attention

Information

1.3 Abbreviations

HPU - Hydraulic power unit LS – Load sense PLC - Programmable logical controller Base unit - Cable remote control, receiver Terminal – Cable remote control, transmitter (portable unit) RIO – Remote IO on profibus communication CC1 - Control cabinet 1 with PLC and starters JB1 - Junction box on HPU with RIO JB2A- Junction box on control station with RIO, starboard side JB2B - Junction box on control station with RIO, port side Operator panel – Graphic touch panel for HMI HMI – Human machine interface

VD - VESTDAVIT AS

SWL - Safe working load

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

1.4 Restrictions in use

The launched or recovered boat and its capacity shall never exceed SWL for the davit system.

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

The davit is only to be used in launching or recovering operations of mob-boat or life-boat connected correctly in the lifting wire rope.

Only original spare parts from Vestdavit AS are allowed.

Use oil specified in hydraulic oil chapter in maintenance part.

Vestdavit AS takes no responsibility for electric 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.

It is not allowed to disassemble the winch or do any modifications on our delivered system without contacting Vestdavit AS.

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

We recommend that personnel assigned to use the davit are trained and familiar with the davit system.

Any violation to these restrictions will invalidate the warranty conditions.

1.5 Main connections and requirements for connected system

If the davit hydraulic system is connected to external hydraulic, supply, i.e. constant pressure system, load sensing system and so on, hook up valve arrangements should be stated in the hydraulic diagram. If not, contact Vestdavit AS.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

2. Technical data

More information can be found in the drawings.

2.1 Davit

Davit type HN-9003

Maximum load, SWL 9000 Kg

2.2 Winch

Winch type C-394-7-V-S-Dual

Wire rope Ø 24mm, L= 24m

Maximum hoisting speed 40 m/min (+/-10%)

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

2.3 Hydraulic power unit

Electric motor 2x99kW 480V, 60Hz

Oil type, recommended

Note what is really used on-board:

Panolin Atlantis N 32 or similar, see §Hydraulic oil

Maximum operation temperature 65° C

2.4 Heat exchange data

From hydraulic power unit Standby pressure 50Bar: 1,25kW for each pump.

Full operation: 9,6kW for each pump.

From electrical cabinets CC1 300W during operation.

From junction box JB1 5W during operation.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

2.5 List of drawings

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 Starboard side 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

2.6 Reference documents

Description / title Document number

Installation manual VDT-IM-91534-35

Spare parts list VDT-SPARE-91534-35

Maintenance check list VDT-MCL-91534-35

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

3. Design and Function

3.1 Design temperature

The davit is designed and built for an outside temperature of -15° Celsius to +45° Celsius, with materials that correspond with this temperature range.

The steel in davit structure, winch and cylinders are chosen according to the specifications DNVGL has set for such design temperature. Same goes for seal-kit for cylinders and bladder in accumulator.

3.2 Davit functions and overview

HN-davit is a hydraulic operated twin-suspension davit designed for safe lowering/hoisting of life-/working boat. All operations of the davit are hydraulic driven which benefits control of the boat position at all stages during the operation and, in contrast to a gravity davit, gives the opportunity to bring the boat back on-board in any position required at any time.

The davit system is equipped with dual winches and the system has automatic synchronic hoist/lower function, with one joystick for both winches on the remote control panel. The system is also equipped with individual levers for each winch, which is helpful for recovering the boat in rough sea conditions.

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

Embarkation of the boat can take place in parked position or in parked position on ship side at deck level. The davit is operated by one person with the control station or the remote control, and the operator shall have a clear view to the boat when launching.

Launching of the boat is done by swinging the davit from parked position to a position where it is free of the ship side, and then lowered by means of the winch. This two-step operation makes it possible to move the davit backwards after lowering the boat below deck level, allowing it to rest along the ship side and prevent it from excessive movements in rough weather conditions, or to park the boat along the ship side for embarkation or disembarkation.

The shock absorbers are fully automatic/passive hydraulic devices, and ensure smooth lowering and hoisting of the boat.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Figure 1 Remote control

Overview of the system

1. Davit

2. Winch

3. Hydraulic power unit

4. Control system

5. Accumulator

6. Shock absorber

7. Cylinder

8. Emergency system

9. Wire puller

10. Control cabinet

VDT-TM-91534-35

Rev.:

Date:

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

Figure 2 Overview of davit

JB2/proportional control valves shall be placed behind the davit.

VDT-TM-91534-35

Rev.:

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

3.3 Winches

The winches consist of;

Frame with wire drum The wire drum is connected directly to the gear shaft and the winch frame is mounted to the davit by 4 bolts.

Gear Planetary flanged reduction gear.

Mechanical brake Between gear and motor there is an automatic spring-loaded disc brake functioning as parking brake and a mechanical brake. The brake is released by hydraulic pressure.

Hydraulic motor The motor is an axial piston motor connected to a hydraulic pump in open circuit.

Hydraulic control unit (Valve block) The hydraulic control unit controls the hydraulic brake and dynamic stop of the winch. It functions as an automatic controller of the disk brake, hydraulic brake and the maximum speed.

Note the bleeding plug/ tube on gear, tube and fittings for access and fill of gear oil must be over oil level and oriented to air out pressure in all conditions. For more information check the hydraulic diagram.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

3.4 Hydraulic power unit system

The hydraulic system operates:

Hydraulic double acting cylinders for swing out/in.

Shock absorbers to smooth lowering and hoisting.

Accumulators to ensure complete pressure during emergency launching and refilling oil on the shock absorbers.

Hydraulic power unit

The hydraulic power unit is a power system for davits that is reliable, easy to maintain and compact. Hydraulic power unit consists of carbon steel oil tank with hydraulic and electric equipment assembled with water/oil cooler on carbon steel frame. The main element is the power pack which consists of marine execution electric motor and piston pump with changeable control: load sense and pressure cut-off, and with check valves to eliminate unwanted backflows. Hydraulic system is protected against overloading by pressure relief valve. The set value on the safety valve is set above the working pressure to avoid constantly open safety valve. Hydraulic power unit is equipped with oil cooler to provide correct temperature of hydraulic oil. Temperature and level measurement for oil is done by sensor which will shut off the system when temperature rises to 70°C or when oil level gets too low.

Breather filter protect tank against inside pressure rise and enable system filling, filters out moisture and particles from incoming air. Return filter provide correct filtering of oil returning from hydraulic system.

The hydraulic power unit consists of a closed reservoir and following equipment:

An electric motor drives a load-sensing axial piston pump through a flexible coupling.

A hydraulic pressure filter for oils flowing from the power unit.

A hydraulic return filter with clogging indicator for oils flowing from the davit.

Air breathers filter for preventing dirt and dust to enter the tank and vapours to leave.

An oil level gauge and temperature sensor.

Water/Oil cooler.

Control valves and fittings including safety devices.

A manual hand pump for emergency operation of the davit.

The emergency stored power system consists of 5 bladder accumulators and 3 ball valves. Ref. hydraulic diagram.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Figure 3 Overview hydraulic power unit

VDT-TM-91534-35

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

Cabinets

Control cabinet 1 (CC1) with operator panel and starter.

Junction box 1 (JB1) is placed on the hydraulic power unit.

Junction boxes 2 (JB2A) & (JB2B) with cable connection to the remote control and emergency stop button. To be placed in no more than an arm length away from the proportional control lever stand.

Figure 4 Overview cabinets

VDT-TM-91534-35

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

Figure 5 Control equipment

Control equipment

The davit is controlled by a remote control. The levers on the proportional control valve is meant for service, or a back-up in emergency if the remote control is lost . The control stand should be installed at a location so the operator has complete view of the operation.

The ball valves, needed for emergency operation, are locateted close to the control stand.

Pressure gauges for monitoring pressure in the hydraulic system are located close to the control stand.

An emergency button is located close to the control stand.

The remote control is equipped with an emergency stop button on the side.

VDT-TM-91534-35

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Date:

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

3.5 Constant tensioning system

Constant-tension system is a wave compensator system that is only to be used when the boat is sea born. This is a system based on hydraulic which gives the system a unique and reliable operation. With the constant tensioning system activated (by manoeuvre lever on control station) the Winch will automatically spool in and out the lifting wire thus letting the boat ride the waves up and down.

3.6 Accumulators

A bladder accumulator consists of a fluid section and a gas section with the bladder acting as the gas-proof screen. The fluid around the bladder is connected to the hydraulic circuit so that the bladder accumulator draws in fluid when the pressure increases and the gas are compressed.

When the pressure drops, the compressed gas expands and forces the stored fluid into the circuit.

An accumulator is used in emergency operation and shock absorption, and shall always be pre-charged with nitrogen.

Figure 6 Accumulator, illustration only

VDT-TM-91534-35

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

3.7 Shock absorber

A shock absorber is a fully automatic/passive hydraulic device that will ensure smooth lowering and hoisting operation of the boat.

The system is an oiled filled cylinder with a nitrogen filled accumulator.

The device absorbs sudden acceleration during vertical hoist/lowering.

The wire is guided through the cylinder via a wire sheave.

The nitrogen pressure inside the accumulator acts as a spring and prevents the hydraulic cylinder from moving under load.

Essential component for man safety and boat structure protection.

Figure 7 Shock absorber, illustration only

VDT-TM-91534-35

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

Figure 8 Cylinders, illustration only

3.8 Cylinders

The hydraulic cylinder gets its power from pressurized hydraulic oil. The cylinder consists of a cylinder barrel in which a piston connected to a piston rod moves back and forth and lets the davit move out.

Here is some off the cylinder’s main parts:

Bronze bearing (spherical).

Piston rod, stainless rod with welded rod ear.

Stuffing box.

Cylinder body, barrel with welded bottom ear.

Seals.

Piston.

VDT-TM-91534-35

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

Figure 9 overview of cylinders

VDT-TM-91534-35

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

Figure 10 overview of emergency system, illustration

3.9 Emergency system

The emergency system is based on stored energy and gravity. Oil pressure from the preloaded accumulator connected to hydraulic circuit, is used for pivoting the davit outwards. To achieve this, a ball valve must be opened before using the manual control station. The oil pressure of the accumulator will when fully loaded be the same as the system pressure. The brake release pump is used to open the parking brake and activating the lowering speed control. With help of this power and gravity, the boat can be lowered to the water.

For hoisting in an emergency situation, use the accumulator system. If the pressure in the accumulator has been used to launch the boat, use the hand pump to raise the pressure in the accumulators. To hoist the boat completely, the accumulator must be pressurized several times.

Launching from the boat can be done by pulling the emergency lowering drum.

VDT-TM-91534-35

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

3.10 Wire puller

Device recommended for avoiding bird nesting of the wire during launching and recovering of the boat.

A hydraulic system linked to the winch motor.

A rubber wheel is pressed against the lifting wire rope by two springs.

A hydraulic motor drives the wheel to pay out the wire with a constant load No load required for spooling out the wire.

Figure 11 Wire puller, illustration only

VDT-TM-91534-35

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

4. Operation and control

4.1 General

Follow the instruction given in the signs, and the descriptions in this chapter for safe operations. The valves are set in correctly set with no more basic adjustments required, and the settings on the adjustable valves can be found in the hydraulic diagram.

Important:

If the davit-winch is operated without any weight in the wire rope it might result in bird nesting of the wire rope. If this happens, the wire rope must be re-spooled correctly onto the drum. Keep an eye on the davit when operating the davit system, notice if the noise levels increase. This can be a sign of an error in the system.

Securing the boat

Use lashings to secure the boat when it is parked and not in use.

VDT-TM-91534-35

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4.2 Health, Safety and Environment in operation process

Attention/Wakefulness:

Be awake and alert, do a visual check of the davit system before operation. Keep attention to the surroundings for unexpected situations. Always check the pressure gauges to ensure that the pressures are kept within their normal values.

Operator:

The operator must be trained in the davit system, and have a good understanding of the processes around the davit and the operation procedures, and shall know where the emergency stop buttons are located.

The operator has to be aware of the people that are going into the boat (and make sure that the safe working load is not exceeded). It is important that the operator focuses on the boat during lowering and hoisting, and keeps in mind that the perception of depth may be inaccurate.

Emergency:

Follow the emergency procedures for emergency launching and emergency recovering. It is important that the operator has knowledge and training on how emergency procedure works.

Emergency stop:

It is located one emergency stop on the hand hold remote control and one on the starter cabinet.

Protective Equipment:

Follow the yard or vessel internal requirements regarding protective equipment.

Foundation:

If oil spill is found, then locate the source, clean up all oil spill and repair if required.

Warning! Be aware that every operating situation has the potential for personnel injury, equipment damage or even death. In order to minimize the risk, it is important to read this manual and familiarize yourself with the operation of the davit before using it. Operation of the davit should normally take place by instructed personnel.

VDT-TM-91534-35

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26.10.2016

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

4.3 Start and check procedure

Check points before start:

1. Oil level in tank.

2. Ball valves to be closed according to the signs on the valves (normally open, normally closed) and with reference in hydraulic diagram.

3. Accumulators to be pressurized according to hydraulic diagram.

Starting

1. Start the hydraulic power unit from the remote control, or from the JB cabinet close to the proportional control levers, and wait around 10 seconds for the pump to circulate the oil and stabilize.

2. Release the lashings that are securing the boat, (if applicable).

3. Do a visual check of the equipment before operating the remote control joysticks.

Observe the sound from the hydraulic power unit and the winch when operating the davit system.

4. Take notice of unusual sounds from the hydraulic power unit and winch during operation.

VDT-TM-91534-35

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

Figure 12 CC1

Start and stop of HPU from different positions during normal operation

The HPU can be started from 3 different positions, by choosing with a switch at the door front of the CC1:

0- [OFF] – System turned off 1- [LOCAL] – Local start. Only available from buttons in front of starter cabinet.

2- [OPER.STATION] – Start from local box on deck by Davit (JB2A or JB2B), meant for use if remote control fails, and operation from proportional valves are wanted.

3- [REMOTE] – Start from terminal.

To choose between these four options, turn the switch to desired position.

It is not possible to start the HPU from more than one position at a time. For normal operation with the terminal, choose 3-[REMOTE]

VDT-TM-91534-35

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Start-up of system from terminal during normal operation

1. Be sure that power is available.

2. Turn the Terminal on (1).

3. See that the corresponding status LED light is lit, and that the alarm LED light (13) is off.

4. Set the mode selector switch (12) to desired position.

5. Press the Start button (3). Both hydraulic pumps will now start. Check that the corresponding green LED light is lit.

6. The hydraulic pumps are now running

Note: Do not start to operate the joysticks before the motors are finished with the starting sequence, and the LED is lit (not flashing).

Figure 13 Remote control

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4.4 Control system

Manual operation by control levers;

For normal operation, use the handhold remote control. The proportional control valve is a backup in case of emergency operation, and is located on a pedestal close to the davit.

Proportional control levers for manual operation of davit, only intended for service or emergency:

[WINCH A IN / OUT]

[WINCH B IN / OUT]

[DAVIT CYL IN / DAVIT CYL OUT]

[TENSION W1]

[TENSION W2]

Handles for ball valves used in emergency operation, see chapter for emergency operation, marked [2] & [3] & [4] are normally closed.

Pressure gauges for monitoring hydraulic pressure are located close to the control levers pedestal, reference to hydraulic diagram.

Turn on the hand-held remote control

1. On the starter cabinet; Switch the button from 1-Local to 3-Remote.

2. Find the start button/switch on the remote control and turn on. Connect remote with cable to the junction box on the hydraulic power unit.

3. Release emergency stop button on the hand-held remote control.

Figure 14 Select button on CC1

VDT-TM-91534-35

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Figure 15 overview of remote control

General info about the control system

The control system contains the following parts:

Terminal (portable unit) Base unit, mounted inside CC1.

CC1 – Control cabinet with PLC and starters JB1 – Junction box on HPU JB2A - Junction box on control stand with RIO, starboard side JB2B - Junction box on control stand with RIO, port side

The terminal is the operators HMI; a mean to control the davit during normal operation. The terminal shall be fastened to the waist with the provided waist strap. This ensures that the operator’s arms are unrestricted and there is no need to carry the terminal by hand.

The terminal is an only cable solution (no radio communication), so there is no need for a battery to power the terminal.

All information regarding control of the davit is available from the terminal.

This system is also equipped with an operator panel, mounted in the door front of CC1. If the alarm on the terminal goes off, walk to the operator panel mounted in CC1 and view the alarm list, before any further operation takes place.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Explanations of functions on the terminal

The terminal is equipped with several buttons, joysticks and LEDs for operator use and information. Following is a description of each item on the remote.

1- On/Off switch for the terminal. The switch needs to be on in order to operate the remote.

2- Stop button for stopping the HPU. The HPU stops automatically if this button is pushed, or the remote control is turned off (1).

3- Start button for starting the HPU.

4- Light – background light in display 5- Tension - gives constant tension to the winch. One button for each winch. If the corresponding light is constant lit, it indicates that the tension is working. IF the light is flashing, it indicated that the load in the hook is above the limit to be safe to activate tension.

6- Cable connection.

7- Emergency stop button 8- Status Led – lit when communicating with base unit 9- Display change – button for switching screens on LCD Display, for more info.

10- Synchro winch joystick. For operation of both winches simultaneous with auto leveling function.

11- Davit in/out joystick, for operation of Davit in/out 12- Control mode switch for MANUAL, VIA RAILING and ALL OUT mode 13- Alarm LED. Blinking = warning, Steady light=Auto stop alarm 14- Winch A joystick, for lower and hoist of winch A separately 15- Winch B joystick, for lower and hoist of winch B separately 16- LCD display – contains several variables such as pump pressure, oil temperature, oil level and winch positions

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Explanations of screen information on remote control:

Figure 16 Initial Screen; winch position, virtual position and oil temp

The terminal is equipped with a LCD display. Different kind of information is available. By pushing the button “DISPLAY CHANGE” on the terminal, 3 different screens can be chosen.

This is only for information to the operator.

The “VirtSetP” shown on the screen above, is an average of the 2 winch positions. This value is used by the PLC to control the synchronization of the two winches.

Alarms on the terminal

The alarm handling is done by the PLC, and the operator panel in door front of CC1 is monitoring the alarms. If the alarm LED on the terminal is activated:

-If the alarm led is flashing, it is a warning -If the alarm LED is lit solid, the result is automatic shutdown of the system.

General about the control system

The davit system is equipped with a PLC, mounted inside CC1. RIO is mounted inside several of the junction boxes in the installation. IO signals to the PLC are communicated over Profibus.

The motor starters are fed from separate feeders. If one feeder is down, it will still be possible to start the other motor.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

4.5 Description of the operator panel in CC1

This chapter describes the functions of the operator panel

The CC1 shall be mounted in lower deck area. The operator panel is of a so called standard model, that is not suitable for outdoor use.

The operator panel has the following functions:

1. Giving detailed information about alarms to the operator.

2. Viewing status of the HPU and davit for the operator

3. Access point for service personnel, for adjustment of parameters and settings.

4. A connection point, for automation engineer to connect a laptop to the system during commissioning and possibly later updates of software or changes.

In the door front of CC1, there is a mounted a touch panel (operator panel) with a colour screen (see picture below).

Figure 17 Initial screen of operator panel

On the initial screen, the operator can access different pictures.

Available screens are; ALARMS, WINCH, CYLINDERS, HPU and REGULATORS. On this initial screen it is also possible to log into a higher security level, to access the SETTINGS screen.

This screen is only applicable for specially trained service personnel.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Winch settings

The winch settings screen is viewing info to the operator:

-WINCH POSITION: actual winch position for the winches -RESET WINCH POSITION: resetting of winch position -DISABLE TENSION: when pushing the button, the tension function is disabled

(disabling of the tension function is normally not necessary).

-Hydraulic pressure in shock absorbers

Figure 18 Winch setting screen

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Cylinders settings

The cylinder settings screen is viewing info to the operator:

-ZT1: Position of main cylinder on each davit.

Press MAIN MENU button to go back to the initial screen.

Figure 19 Cylinder settings screen

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

HPU settings

The HPU settings screen is viewing info to the operator:

-PRESSURE PUMP: hydraulic pressure from HPU pumps -LS PRESSURE: hydraulic pressure in proportional valve -RUNNING HOUR MOTOR 1 & 2: running hours for motors -OIL TEMPERATURE: Oil temperature in reservoir -OIL LEVEL: oil level in reservoir -LOAD SENSE SETTINGS: Adjustment of minimum pump pressure, and max pump pressure, depending on signal from PT4 (load sense pressure transmitter).

Figure 20 HPU settings

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Regulator settings

The regulator settings menu is only to be operated by service personnel from Vestdavit, and is therefore password protected. From this menu, it is possible to adjust regulators for both winch.

Figure 21 Regulator settings

VDT-TM-91534-35

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

Trending of temperature

This screen is to monitor the oil temperature in the reservoir over time.

Figure 22 screen with temperature trend

VDT-TM-91534-35

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Date:

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

Trending of hydraulic pressure

This screen is to monitor the hydraulic pressure from each of the pumps, and the hydraulic LS pressure from PT4. The trending can be used to adjust pump pressure in accordance with the LS pressure

Figure 23 Screen with hydraulic pressure trend

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Driving pattern for “via railing” mode

This screen is for adjustment of the pattern the davit will operate after. In each curve, there is a position entered, where the cylinder and the winch shall be, on its way to the launching position.

Note: Adjustment of the settings, are done by specially trained service personnel, and this menu is password protected.

Figure 24 Screen with adjustment of “via railing” mode

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Alarm viewer

On the alarm viewer screen, time and date for alarms are being displayed here.

Figure 25 Alarm viewer screen on operator panel

On the ALARM VIEWER screen, the operator can see current alarms and historical alarms.

What time and date they went off is also possible to see. On the right side of the list, there are buttons for acknowledge of single alarms or all alarms. It is also possible to clear the whole list, after e.g. testing of alarms during commissioning and service.

In the below table is an overview of the alarms:

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Figure 26 Alarm list

Other functions

Light on davit: The davits are equipped with flood light. The lights are turned on and off from the JB2A and JB2B boxes.

Heaters in cabinet and boxes: Junction boxes on deck are equipped with heater and thermostat. From the door of CC1 the heaters can be turned on and off. Normally this switch can be set to On.

Connection of terminal: The terminal can be connected to both JB2A (starboard side) and JB2B (port side)

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

4.6 Safety functions

The davit is controlled by a PLC located in CC1. The PLC is programmed with software according to the standard IEC 61131. The development of the specific software for this system is a result of many applications and development during the last 10 years. Most of the software has been used on earlier applications, and have been thoroughly tested.

In the following, the different safety functions are described.

Absolute encoder, common sensor for several safety functions

An absolute encoder is mounted on the winch. This sensor monitors the position of the winch, and are used for end stop and automatic slow down. The absolute encoder is communicating with the PLC over Profibus DP. The encoder has a resolution of 8192 positions per rotation of the winch, and 4096 rotations. The inside of the encoder is made of optical glass plates, giving a unique bit-pattern for each position. In a situation where the power is lost to the encoder, and the winch is turned, the encoder will still know its position when the power is back again. The need for resetting the encoder after a power loss, is therefore eliminated. The only situation for resetting the encoder is after replacing the wire.

Slow stop

The encoder on the winch gives accurate position during hoisting and lowering. The allowed speed at different positions is stored in the PLC software, and tuned during commissioning.

During hoisting, the allowed speed will reduce. When the boat enters the retardation area, the winch will go into slow speed for the last meters of hoisting.

The area where retardation of the hoisting and lowering speed is entered, is adjusted by Vestdavit during commissioning of the davit.

End stop

The encoder on the winch gives an accurate position during hoisting and lowering.

The end stop at hoisting is always set to 0cm. This is the value from the encoder sent to the PLC over profibus. Even if the operator tries to hoist over this position with the remote control, the PLC will not give any output to the proportional valve, operating the winch. The profibus communication is continuously monitored and a fault in the communication will set an alarm both on the portable terminal, and on the operator panel in LCP1.

During lowering, the end stop is set to Xm of wire. This might be adjusted during commissioning. These values are adjusted from the HMI and are password protected.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Monitoring of communication between the PLC and the base unit

The PLC and the base unit communicates via Profibus DP. The communication is monitored with a watchdog in both units. Any fault will result in a stop of the pump.

If communication between terminal and base unit is faulty, the base units’ watchdog will set a fault to the PLC, and the PLC will automatically stop the Hydraulic pump, and set output to proportional valves to 0. Communication between the base unit and the terminal uses advanced parameters containing start and stop bits, specific serial number in the telegrams to ensure that no other equipment can cause unintended activity. Worst case scenario is that the hydraulic pump stops, due to loss of communication.

Amplifier cards for proportional valves

The control system contains amplifier cards to give current to the solenoids on the proportional valves. These cards are located in JB2A and JB2B. The PLC sends a 4..20mA signal to the amplifier cards, and the amplifier cards sends a 250..600mA signal to the solenoids.

Both input to the card from the PLC, and output to the solenoid from the amp.card is monitored by the amp.card. Any cable break will result in no output from the card (0 mA), and will stop the movement.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

4.7 Normal operation procedures

Launching of boat with davit

Requires:

That the HPU is running and the remote control is on, see chapter 4.3.4 That the selector switch (12) is set to [MANUAL] position

When the davit is in start position (all the way in, and cylinders approximately 0 mm, the system is ready for launching from stowed position to launching/lowering position.

1. Check that the painter line is connected to the boat.

2. Release the lashings.

3. Hoist the boat to the top position by operating the joystick (10) [SYNCRO WINCH] towards [HOIST]. The hoisting will stop automatically as soon as the winches have met the 0-point/end position. Watch the position on the LCD display (16)

4. Now bring the davit out to the launching position, by operating the joystick (11) towards [DAVIT OUT]. The cylinders will now bring the davit and the boat towards the launching position.

5. When the boat is all the way out, release the joystick.

6. When the boat is steady and in the launching position, operate the joystick (10)

[WINCH] towards [LOWER].

7. When the boat is sea-born, and the crew in the boat have released the hook, hoist the winch, so the hook is kept in a safe position.

NOTE: It is possible to operate the davit in 3 different modes with selector switch [CONTROL MODE] (12). By using the modes [VIA RAILING] and [ALL OUT], the davit in/out joystick operates also the winch in a semi-automatic manner to simplify operation.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Retrieving of boat

Requires:

HPU is running and the remote is on, see chapter 4.3.4 Boat in position for retrieving Davit in launching position (see chapter 4.7.1) ready for retrieving

1. Operate the davit outward far enough to give the boat the best position when hoisting with joystick [DAVIT IN/OUT].

2. When the Boat is in position for retrieving, pay out the wire with the joystick (10)

[SYNHCRO WINCH] towards [LOWER] until the crew can hook on the wires, and there is a good slack in the wire. Alternatively, use the individual joysticks. Fasten painter line (if applicable).

3. When the Boat is hooked onto the wire, apply tension by activate the [TENSION]

2) button (5).

4. Let the tension work until the boat is alongside, and steady.

5. At a wave top, activate the joystick (10) [SYNHCRO WINCH] towards [HOIST], and hoist the boat all the way up, until the hoisting stops automatically at the 0-position.3)

6. Next, bring the boat and the davit in to stowed position by operating the joystick

(11) towards [DAVIT IN].

7. When the davit is all the way in, gently lower the boat into the keel support by operating the joystick [SYNHCRO WINCH] towards [LOWER]

8. Secure the boat with lashings or similar, and turn off the hydraulic power unit.

2) If the Led over the “Tension” button (5) is blinking when activating the button, there is already too much load in the wire. For safety reasons, the software is monitoring the load in the hook (by monitoring the hydraulic pressure from PT3A and PT3B). This is to prevent unwanted drop of boat into the water and/or crashing the boat in the mothership.

3) The tension function is automatically turned off if any of the joysticks (10), (14) or (15) are operated

The hoisting operation with tension allows the boat to be lifted gently off the waves without any hard and bumpy falls on the waves. The constant tension method should be practised as often as possible for operation improvement and training.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Manual operation by levers

Requires that the HPU is running, see section 4.3.4

Manual operation is only to be used during maintenance or any other situation where the automatic function does not work. This situation could occur if the terminal is lost over board or damaged. This way of operating the davit is not to be used in emergency situation.

For emergency operation, see chapter 4.8

Please note that during manual operations, the automatic controls which prevent the boat from crashing into the deck, davit or other structures, is deactivated! The operator is in complete control of the operation!

To operate the davit manually, perform the following steps:

1. Set selector switch on CC1 to [OPERATOR STATION]

2. Push start button on JB2A or JB2B depending on what side to launch from, and wait until green running light is lit (not flashing)

3. The Davit consists of 1 cylinder pairs and 2 winches. To operate the cylinder, move

Davit in/Davit out valve towards the cylinder movement that is required. The winch and tension is also possible to activate from the proportional valves.

4. To be able to activate tension both Winch and Tension valves must be activated at the same time.

NOTE: Manual operations of the tension valve shall not be performed unless the boat is in water or in close proximity to it. Unintended operation of the tension valve can result in drop of the boat and possible damage of boat and injury of persons on-board. All interlocks are disabled!

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

4.8 Re-charging of accumulator bottles in use

With HPU running;

1. Ensure that ball valves are in normal position.

2. Start the Hydraulic Power Unit.

3. If davit is in parked position – Pull joystick: [DAVIT IN] and hold until full pressure is reached.

If davit is in outer position – push joystick: [DAVIT OUT] and hold until full pressure is reached.

Warning: Do not carry out this procedure if the boat is hanging in the wire rope, (except during emergency procedure). Ensure that the boat is secure on the keel supports before carrying out this function.

With hand pump;

1. Ensure that all ball valves are in normal position.

2. Operate the emergency hand pump until max. Pressure is obtained in accumulator.

The accumulator pressure can now be used for lifting the boat.

4.9 Emergency operations procedures

Back-up power with remote control operation

This is only applicable if normal power (480V) is lost

When normal power is lost, there is one way to operate the davit.

Operation by stored power from hydraulic accumulators. Please read separate chapter describing how to open valves for stored power. The PLC system is fed from a UPS inside CC1. 24V DC UPS power is available in a 30-minute period from when other power is lost.

The terminal will be operational even if the 230V is lost. Operate the davit in the same manner as if the power were available. See chapter 4.7.1 for launching of boat. There will not be enough power to hoist the boat out of the water and all the way up to the davit. Only launching.

Figure 27 Hand pump

VDT-TM-91534-35

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Date:

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

Figure 28 Emergency davit out handle

Emergency ball valves for swing out and lower

Launching from deck

1. Release boat lashings.

2. Open the ball valve marked [3] on the deck.

3. Bring the Emergency-Lowering-Drum onto deck with sufficient slack on wire.

4. Open the ball valve marked [4] close to winch.

5. Lift boat just out of keel support with [Winch Hoist]-lever on control station.

6. Swing davit out by operating [Davit Out]-lever on control station.

7. Lower boat by operating [Winch Lower]-lever on Control Station or by pulling

[Emergency Winch Lower] with the Emergency-Lowering-Drum.

Launching from inside boat

1. Release boat lashings.

2. Open the ball valve marked [3] on the deck.

3. Open the ball valve marked [4] close to the winch.

3. Climb into the boat with the Emergency-Lowering-Drum.

4. Swing the davit out by pulling the wire marked [Emergency Davit Out].

5. Lower the boat by pulling [Emergency Winch Lower] with the Emergency-Lowering-

Drum.

VDT-TM-91534-35

Rev.:

Date:

26.10.2016

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

Re-charge accumulator bottles with hand pump

Hoisting and recovering

In a dead ship situation, the boat can be lifted by using the stored hydraulic power in the accumulators, along with the emergency hand pump on the HPU for re-pressurizing.

Charging of accumulator with hand pump;

The ball valves marked [2], [3] and [4] to be closed as normal.

Operate the emergency hand pump until maximum pressure is obtained in accumulator.

1. Fasten boat lifting ring to hook.

2. Pull lever [WINCH HOIST] and hold.

3. Open ball valve marked [2] – winch will operate until pressure drops.

4. When winch stops, close ball valve [2] and return handle to neutral position.

5. Re-charge accumulator with hand pump.

Repeat steps 2-5 until boat is hoisted.

6. Pull lever [DAVIT IN] and hold.

7. Open ball valve marked [2] – davit will swing inboard until pressure drops.

8. When davit stops, close ball valve [2] and return lever to neutral position.

9. Re-charge accumulator with hand pump.

Repeat steps 6-9…