VD-TM-91721 incl drawings (OM) Manual.pdf

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

TO HG VD-TM-91721 30.11.2018 00 1 of 47

TECHNICAL USER MANUAL

OPERATION & MAINTENANCE

VESTDAVIT TYPE F-10000

WINCH TYPE A-470-4-D-V-S

Customer PO :13PDX 118663

Customer :Vigor LCC

Ship name :Yaquina

VESTDAVIT AS project number :91721

Doc.no Date Rev.no Page

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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 List of drawings

2.5 Reference documents

3 Design and functions

3.1 Design temperature

3.2 Davit functions

3.2.1 Overview of the davit system

4. Operation and control

4.1 General about operation chapter

4.1.1 Securing the boat

4.1.2 Lifting ring

4.1.3 Health, safety and environment in operation process

4.2 Start and check procedure

4.2.1 Check points before start

4.2.2 Starting

4.3 Launching operations

4.4 Recovery operation by tension – and guiding arms

4.5 Re-charging of accumulator bottles in use

4.6 Emergency operation procedure

4.7 Stop of system and parking position

5 Maintenance and inspections

5.1 General information

5.1.1 Health, safety and environment in the maintenance process

5.1.2 Maintenance of surface on davit system

5.1.3 Inspection routines

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5.2 Hydraulic oil, grease and other lubricants

5.2.1 Oil types

5.1.3 Greasing of davit parts

5.1.4 Miscellaneous lubricants and fillings

5.1.5 Grease tape

5.1.6 Hydraulic oil in hydraulic power unit

5.1.7 Pressurized hydraulic hoses and injuries

5.1.8 Lubrication points and greasing nipples on the davit system

5.2 Winch

5.2.1 Oil filling plugs and drain connections for winch

5.3 Wire rope

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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

1.2 Symbols used in manual

Note

Warning

Important

Attention

Information mailto:post@vestdavit.no

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1.3 Abbreviations

HPU - Hydraulic power unit

PCV - Proportional control valve

SC1 - Starter cabinet 1

LCP1 - Local control panel 1

Operator panel – Graphic touch panel for HMI

HMI – Human machine interface

VD - Vestdavit AS

SWL - Safe working load

LS mode – Load sense mode

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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.

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2 Technical data

More information can be found in the drawings

2.1 Davit

Davit type F-10000, reference to general drawing

Maximum load, SWL 10000 kg

2.2 Winch

Winch type A-470-4-D-V-S, reference to general drawing

Wire rope Ø=18mm, L=64m

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

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

2.3 Hydraulic power unit

Electric motor 118kW, 440V, 60Hz reference to HPU drawing

Oil type, recommended

Note what is really used on-board ->

Shell Tellus S2 V 32 or similar, see chapter

Hydraulic oil

Maximum operation temperature 65°C

2.4 List of drawings

Drawing Rev. Title/ description

102960 01 Davit, General arrangement

103130 01 Winch, General arrangement

A-15374 1.1 Winch, Hydraulic diagram

A-15372 2.1 Davit, Hydraulic diagram

A-15373 1 Deck, Hydraulic diagram

A-15202 00 Shock absorber, Hydraulic diagram

A-15116 01 Limit switch, Hydraulic diagram

A-15275 00 Wire puller, Hydraulic diagram

1795013 A2 Hydraulic power unit, General arrangement

1787552 A2 Cabinet, Starter / Electric diagram

VD-IP-F-10000 N/A Installation procedure Davit parts

2.5 Reference documents

Document number Title/ description

VD-IM-91721 Installation manual

VD-SPL-91721 Technical specification, Spare part list

VD-MCL-91721 Maintenance check list

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3 Design and functions

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

F-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.

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.

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Limit switch: When limit switch is deactivated, counterweight will create force stronger then spring. In activation mode wire clamp (position can be adjusted) will pull up the counterweight which is hanging on wires. After this spring will have enough force to pull the limit switch arm back and activate valve.

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3.2.1 Overview of the davit system

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4. Operation and control

4.1 General about operation chapter

Instructions given in sign on the control equipment and the davit, and instructions given in the procedures in this chapter should be followed for safe operations.

The valves are correctly set with no more basic adjustments required, the settings on the adjustable valves can be found in the hydraulic diagram.

If the davit-winch is operated without any weight in the wire rope it might result in bird nesting of the wire rope. (rarely happens with wirepuller).

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.

The hydraulic power unit is equipped with a thermometer, it is necessary to keep an eye on the temperature of the oil. The temperature should not exceed 65°C.

4.1.1 Securing the boat

Use lashings to secure the boat when it is parked in stowed position.

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4.1.2 Lifting ring

Before use, check for any damages on the lifting ring.

The lifting ring is designed to be safe and easy to operate, and with handles that provide a good grip.

The handles shall not be used as a securing point for any safety chains.

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4.1.3 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 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 must 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.

Protective Equipment:

Follow the yard or vessel internal requirements regarding protective equipment.

Foundation:

If oil spill is detected, locate the source and 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.

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4.2 Start and check procedure

4.2.1 Check points before start

1) Oil level in tank.

2) Ball valves to be closed accordingly to the sign on the valves (normally open, normally closed) and with reference to hydraulic diagram.

3) Accumulators to be pressurized according to hydraulic diagram.

4.2.2 Starting

1) Start the hydraulic power unit and wait around 10 seconds for the pump to circulate the oil and to stabilize.

2) Release the lashing that are securing the boat.

3) Do a visual check of the equipment before operating the control station levers

4) Observe the sound, and take notice of unusual sounds from the hydraulic power unit and winch when operating the system

Control equipment

The control station has levers for:

[WINCH HOIST]

[WINCH LOWER]

[DAVIT IN/OUT]

[GUIDING IN/OUT]

[TENSION]

Pressure gauges for monitoring hydraulic pressure and emergency stop button are located on the control station, reference to deck hydraulic diagram, A-15373.

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4.3 Launching operations

1) Check that the painter-line is connected to the boat (if applicable).

2) Start the hydraulic power unit.

3) Release the boat lashings.

4) Gently hoist the boat free of keel support with [WINCH HOIST].

5) Keep the boat steady with guiding arms by lever [GUIDING IN/OUT] (do not allow the full weight of the boat to rest on the guiding arms).

6) Operate davit out with lever [DAVIT OUT].

7) Launch boat with lever [WINCH LOWER].

4.4 Recovery operation by tension – and guiding arms

1) Operate the davit and the hydraulic guiding arms outward with lever [DAVIT

IN/OUT] and [GUIDING IN/OUT]. (Aim to give the boat the best position when hoisting).

2) Lower the wire rope in position for the boat with [WINCH LOWER].

3) Fasten first the painter line (if applicable), and then fasten the lifting hook into the rope.

4) Activate tension by first pulling lever [TENSION ON] and hold, and then activate lever/joystick [WINCH HOIST]. The boat will follow the movements of the waves so keep holding the levers.

5) Release [TENSION ON] when the boat is moving upwards towards a wave top.

6) Limit switch will stop the hoisting, but keep in mind that hoisting must stop before spelter socket reaches wire sheave.

7) Keep the boat steady with guiding arms, use [GUIDING IN/OUT].

8) Operate the davit in with lever/joystick [DAVIT IN] and [GUIDING IN]. (Do not allow the full boat weight to rest against the guiding arm).

9) Gently lower the boat to the keel support with [WINCH LOWER].

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

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.

Activated tension is not to be used with empty hook.

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4.5 Re-charging of accumulator bottles in use

With hydraulic power unit running:

1) Ensure that the ball valves are in normal position.

2) Start the hydraulic power unit.

3) If davit is in parked position; -Pull lever: [DAVIT IN] and hold until full pressure is reached.

If davit is in outer position; -Pull lever: [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.

Hand pump

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4.6 Emergency operation procedure

For launching and lowering in a dead ship situation:

1) Release boat lashings.

2) Open ball valves marked [2] and [3].

3) Remove safety pin from brake release pump.

4) Go into the boat with the emergency lowering drum and the handle for for “davit swing out”.

5) In the boat, Skriv resten ut fra skiltene

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4.7 Stop of system and parking position

➢ Check that lashings are tightened and that the boat is resting correctly on the keel support.

➢ Turn off the hydraulic power unit. The hydraulic power unit has to be turned off due to heat build-up in the oil during long idle mode.

➢ Check the condition of davit before leaving.

Important! Always turn off the hydraulic power unit after parking the davit, or when the davit is not being used. The oil in the HPU tank should not exceed 60-65˚C as a general rule. The lubricating property of the oil is directly related to the temperature of the oil - At high temperature the oil will lose its lubricating properties.

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5 Maintenance and inspections

5.1 General information

Inspections shall take place according to relevant Authorities' Regulations.

Always follow internal HSE routines, especially regarding pressurized equipment, and HSE routines in this manual.

Observe if the following should occur:

➢ Increase in noise level.

➢ Vibration in winch.

➢ Functional faults.

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

Vestdavit if necessary.

If painting of hydraulic tubes and connections;

Vestdavit recommend that; if hydraulic tubes and connections of steel are to be painted, that fittings and tubes are thoroughly examined for corrosions, damages etc. before paint are applied. Note that paint can make it difficult to examine the fittings/tubes for corrosion afterwards. Small valves are recommended covered with grease tape, avoid painting if possible.

Replacements;

After replacement of hydraulic parts, wire rope or similar, it is recommended to test the system with SWL x 1.1.

Routine inspections;

The inspection and maintenance guide in this manual is the manufacturer recommendation.

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

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5.1.1 Health, safety and environment in the maintenance process

Important! Be ensured that when maintenance is ongoing, that the system is not running or pressurized.

Attention/Wakefulness:

Be awake and alert, do a visual check on the davit system before operation and be attentive to the surroundings of unexpected situations like oil spill, loose parts or abnormal noise.

Work in surroundings:

Make sure that no work is ongoing in the area around the davit; this can cause unexpected dangerous situations. Make sure that there is no strong heat generated around the davit system.

Components transported with crane:

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

Lifted parcels can have a heavy weight, and might swing uncontrolled. Make sure that you always are in a safety zone when the crane is used. Follow instructions given by the internal rules.

Foundation:

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

Protective equipment during maintenance:

Follow the yard or vessel internal requirements regarding protective equipment.

Dissemblance of parts:

It is not allowed to touch inside the electrical cabinet without contacting Vestdavit. You can have a look inside, but it is not allowed to begin disassemble parts inside the cabinets.

You have to follow maintenance procedure to ensure that you only do the maintenance that you are allowed to do. If any questions, please contact Vestdavit for guidance.

Hydraulic hoses

Please follow chapter for hydraulic hoses and be aware that pressurized system should be handled according to internal, and this manual, routines.

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5.1.2 Maintenance of surface on davit system

It is very important to maintain a cleaning and coating schedule:

➢ Once a month; the davit system should be cleaned thoroughly with fresh water (use low pressure to avoid damages on the surfaces), make sure to remove all dust, sand and salt.

➢ Once a month: Remove all used and dirty grease, and apply new high quality grease.

➢ Once a month; the davit should be inspected for possible visible defects and corrosion. Repaint where necessary.

➢ Check the “procedure for touch up paint and grease” in installation manual for details for coating thickness and RAL code.

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5.1.3 Inspection routines

Weekly inspections;

➢ Check the oil level on the hydraulic power unit. Check the chapter for hydraulic oil, the chapter for maintenance of hydraulic power unit and hydraulic drawings before topping up the oil level.

➢ Check that there are no hydraulic leakages on the system.

➢ Check that the control levers are operating freely. Lubricate with aerosol lubricant.

➢ Inspect wire rope and lifting ring/hook for damage or rust. If damaged it shall be replaced. More information in chapter for wire rope.

➢ Check oil pressure in accumulators. See hydraulic diagram for information about the pressure.

Always ensure that standby pressure in auto refill unit is at least 15 bar minimum before

[dead ship] launching, normally the pressure should be between 40-60 bar.

Operate the davit to check that it is running smoothly and there is no abnormal noise from the system.

➢ Check that the wire sheaves are rotating freely.

Monthly inspections;

➢ Inspect the lifting wire and wedge/spelter lock for damages, lubricate with grease.

See chapter for hydraulic oil and grease.

➢ Lubricate with grease: pin for davit arm, cylinders and sheaves.

➢ Lubricate the emergency ball valves marked [2-3], check that they are moveable by open and close when the boat is secured in the keel support and has no load in the wire rope. After this test the accumulator needs to be re-charged if pressure is below normal pressure.

➢ Check that the 4 mm emergency wire rope is greased.

➢ Check the hydraulic hoses and tubes/fittings for damages.

➢ Check for any oil leakage on winch, and on deck around davit.

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

➢ All parts must be checked for rust, in case of rust please re-paint or refit with grease tape. Dry grease tape must be replaced.

➢ Clean piston rods on hydraulic cylinders and shock absorber, and apply a thin layer of Teflon spray or grease for protection of seal. See more information in chapter for piston rods.

Six-monthly inspections;

The oil is to be tested each 6 months. See chapter about hydraulic oil.

The Nitrogen pressure in accumulator to be checked each 6 months. See chapter for charging of accumulator and table for filling nitrogen.

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Annually inspections;

Refer to relevant requirements from authorities.

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

➢ Gear oil to be renewed as required.

➢ Brake oil to be renewed as required.

➢ Return filter on oil tank to be replaced as required. If indicator is mounted, replace filter when indicator is red.

➢ Pressure filter on oil tank to be replaced when indicator turns red. If mounted

➢ Check and tighten all fittings on davit.

Do not loosen or tighten any hydraulic fitting while the system is pressurized.

Hydraulic fluid under pressure is a risk to personnel and equipment if operated incorrect. Ensure that hydraulic pressure is completely released from the system and hydraulic accumulators before opening hydraulic fittings.

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5.2 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.

5.2.1 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

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Arctic conditions;

Use Shell Tellus Ultra-low temperature oil or equal for the davit and EP 80W/90 or equal for the gearbox

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

Shell Tellus S2 V 32

Shell

(Ultra-low temperature)

Tellus S4 VX 32

Castrol Hyspin AWH M 32

Exxon Mobil DTE 10 Excel 32

Exxon Mobil / Esso Artic Condition Univis HVI 26

Chevron AW Hydraulic HD 32

Texaco Rando HDZ 32

Table of oil for gear oil;

Brand Gear OIL ISO VG 150 Higher quality GEAR OIL

(Recommended) ISO VG

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

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5.1.3 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

Table for wire rope grease;

Brand Wire grease

Lanopro Condor Lube 50-70G

Statoil Statoil wire grease

Shell Shell Gadus S3 wire rope A

5.1.4 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

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5.1.5 Grease tape

General;

Grease tape is an anti-corrosion and sealing tape that is non-cracking and non-hardening.

It is used for protection of exposed tubes, valves and metal fittings from corrosion. Used for moulding around irregular profiles such as flanges, valves and couplings, that provides a suitable contour for wrapping with tape. To protect the metal structure from the environment, the tape must cover the entire surface.

The grease tape shall be replaced when it is dry.

First aid measures;

Grease resistant gloves may be worn to reduce skin contact. Avoid contact with face and arms etc. Wash thoroughly after use with soap and water to remove compound from the skin. Change and clean soiled clothing. If contact with the eyes should happen, wash thoroughly with plenty of water. If irritation persists, seek medical advice. If ingestion, seek medical advice.

Application;

The grease tape has to be applied when it is dry and above 1°C in the air. Prepare the surface first before apply grease tape by removing dirt, grease, oil and other moistures like frost etc. Remove weld splatter, sharp points and sharp edges, if any. Surface must be clean and dry, remove all rust, scale and flaking coating by scraping, brushing or other cleaning.

To apply the grease tape, work with the grease tape so it can be warm enough to mould around the surface. It should not be possible to drag it off when it is fastened properly.

The tape should look like one mass when it is applied properly. Make sure that there are no particles, water or similar under the tape.

To protect the metal structure from the environment the tape must cover the entire surface. Ensure that the entire surface is covered with no gaps or air pockets.

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5.1.6 Hydraulic oil in hydraulic power unit

Control of oil level:

Sign marked with max and min indicates if there is enough or too much oil.

Ensure that oil from accumulator is drained to the hydraulic power unit before reading the oil level. If you fill oil on the tank before the oil from accumulator is drained, it is possible that the tank will become completely full and overflow.

Testing the hydraulic oil for water (each 6 months);

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

Undesirable water in hydraulic oil;

➢ Water is undesirable in mineral hydraulic oil.

➢ Different hydraulic oils have different saturation levels and % saturation (%SAT) is the best and most practical measurement.

➢ These results can be converted to PPM (parts per million) if the oil type saturation/temperature characteristic is known.

➢ Mineral oil usually has a water content of 50-300 ppm which it can support without adverse consequences (temperature related).

➢ Once the water content exceeds 100% SAT the oil starts to appear hazy (free water).

➢ Free water accumulating in the system can lead to corrosion and accelerated wear.

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➢ Also below the saturation point water can be a problem, because it changes the characteristics and electrical conductivity of the oil.

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To get the sea water out of the system;

This is especially important for sub-merged hydraulic power unit systems.

➢ Draining oil from HPU & Davit (if davit is used when there is water in the oil).

➢ Flush clear oil through the system; use an external HPU that has a water removal filter and an option to test the oil along the way.

➢ The electrical motor has to be checked (isolation).

➢ The oil tank has to be cleaned.

➢ All filters have to be changed.

➢ The hydraulic pump has to be cleaned.

➢ The source for the water has to be located and removed.

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5.1.7 Pressurized hydraulic hoses and injuries

Hydraulic injuries could occur when a jet of fluid under pressure penetrates the skin due to a leak in pressurized equipment, e.g. pinhole in hydraulic hoses. Never touch a pressurized hose with your hand, the system must be de-pressurized and de-energized before performing any sort of service, or when hoses and fittings shall be controlled. If a fluid injection accident occurs, medical treatment by an emergency doctor shall be sought immediately.

Follow safe practice, HSE procedures given in manual and the vessels internally procedure when checking for pinhole leaks, and when repairing or replacing hose assemblies. Stay out of hazardous areas while testing hydraulic assemblies, and always when the system is under pressure. No part of the body should ever come in close proximity to fluid power components

(hoses and fittings especially) when the system is pressurized.

Never paint hydraulic hoses or use a hydraulic component that could be defect or have visible wear. The chemistry in paint destroys the hoses and leads to leaks, and makes the control of hoses more difficult.

Important; if an injection injury has occurred, contact medical emergency care at once. Even if only suspicion of an injury has occurred.

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5.1.8 Lubrication points and greasing nipples on the davit system

List of equipment and frequency

Equipment Grease point Location Frequency

Guiding arms See sketch on next page Davit Monthly

Guiding cylinder See sketch on next page Davit Monthly

Main cylinder See sketch on next page Davit Monthly

Davit hinges See sketch on next page Davit Monthly

Wire sheave Greasing stations Davit + Shock absorber

Monthly

Wire rope Greasing stations Wire sheave Six-monthly

Grease table

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5.1.9 Lubrication chart

Greasing station

Greasing station

Greasing points

Greasing point

Greasing points

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5.2 Winch

The winch consists 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.

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5.2.1 Oil filling plugs and drain connections for winch

➢ Use the Illustration below to locate where the drain, oil level, breather and filling plugs are.

➢ Use oil specified in chapter for hydraulic oil.

To fill oil in gear and brake, use filling connections to get the oil level correct. Check the oil level by open the oil level plug; it could take some time before the oil level is stabilized after filling. To change out the oil, open the drain plug and filling connection. Recommended schedule for oil change, see service intervals.

Some of the plugs are magnetic to catch small metal chips due to wear (normal). If bigger parts are found it could give an indication that something is wrong, those plugs should be cleaned at every oil change or inspection.

Note! Do not paint the bleeding plugs on brake and gear. Do not fill oil in the secondary brake.

Amount of oil to be filled depends on the position of the plug, fill so the level is 50% full. If the filling point is not level, tilt the davit so the drain plug point downwards and oil level plug is in correct level and easy to use.

Breather filler plugs on gear and brake shall be replaced once a year. There is one for each.

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5.3 Wire rope

The wire rope is one of the most important components on the davit and therefore effective planned maintenance will improve performance and rope life. Weekly inspections for damages of the wire rope, cleaned and grease re-applied consequently are highly recommended.

” Subsequently the wire rope shall be cleaned where necessary, and the rope dressing re-applied at regular intervals and before the rope shows signs of dryness or corrosion, particularly on the lengths which pass over sheaves. A shorter working life of the rope will result from lack of maintenance” Ref. ISO 4309 §3.3

If the diameter on the wire rope becomes larger or smaller, the rope has to be inspected more thoroughly. It is difficult to see if there has been a fraction in the inner layers of the rope or if there is any corrosion. If the difference on the diameter is one centimetre the wire rope should be replaced at once

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Factors that have an influence of the life of the wire:

➢ Maintenance of wire (greasing).

➢ Sheave diameter (bending fatigue).

➢ Sheave condition (a worn sheave will damage the wire faster).

➢ Multi-layer of wire (more than one layer will have an impact).

➢ The usage of wire (how many cycles).

➢ How much is the wire load against MBL (Minimum Breaking Load).

NOTE! We recommend that the wire rope is replaced every fourth year or more often if required, but must be changed every fifth year! # Falls used in launching shall be inspected periodically, with special regard for areas passing through sheaves, and renewed when necessary due to deterioration of the falls or the intervals of not more than 5 years, whichever is the earlier. #

Reference to MSC.1/Circ.1206

Careful and critical inspections once a month:

➢ Check for splinters.

➢ Check the diameter.

➢ Check for corrosion/rust.

➢ Grease the wire. Remember to check the inner layer as well.

Detailed examination by competent and trained person to:

➢ Establish the condition of a rope.

➢ To assess whether or not it is fit (i.e. safe) to remain in service.

➢ To ensure that the rope is removed from service, whilst still in a safe condition.

Greasing of wire rope

The lubrication that a new wire rope receives during manufacturing is adequate for initial storage and the early stages of the wire 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. Look after the wire rope, the more care, the longer life it gives.

Regular dressing of the rope with an approved lubricant will also lengthen the rope life, and proper lubrication is important to the service life of the rope. The lubrication serves both as protection against corrosion and as factor to reduce the friction between wire 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 viscosity that enables it to penetrate into the rope.

The rope must be clean before the lubricant is applied.

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Wire rope sleeve or cable grips:

A wire rope sleeve is used to pull on the new wire rope with the old wire rope. Control the sleeve before each use for mechanical wear.

Spool out the old wire; attach the wire rope sleeve to its end with a pulling rope attached to the sleeve. Use the wire rope sleeve/ pulling rope to thread the new wire onto the davit, and attach it to the wire drum with the wedge.

You need to maintain tension between the wire rope and the wire rope sleeve to maintain the grip.

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Inspection of wire sheaves:

➢ Rope running through sheave: Wear/wire breaks/corrosion.

➢ Ability of sheave to freely rotate.

➢ Suitability of groove profile.

➢ Evidence of any rope contact with surrounding steelwork: indicating rope has been off sheave.

Handling of wire rope

➢ Correct installation of the wire rope will have an effect on the wire rope performance.

➢ It is important to apply tension to the rope during installation.

➢ This should be approximately 2% of the minimum breaking load of the rope.

When installing or replacing wire rope it is important to do like in the first picture given, you have to be sure that the wire does not get damaged. Check that the wire has not turned between the wire layers.

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