HYDRAULIC WINCH-MS1059 - Operation & Maintenance Manual Rev A

7/25/2019 HYDRAULIC WINCH-MS1059 - Operation & Maintenance Manual Rev A

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motiveoffshoreMARINE EQUIPMENT SPECIALISTS

OPERATION & MAINTENANCE MANUAL

Revision Generatedby:

Date: Checked by: Date: Approved by: Date:

B J Turner 11/04/2014 D Acton 11/04/2014

5Te SWL CONSTANT TENSION WINCH

c/w SPOOLING GEAR

ID: MS1059


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Manual Operation & Maintenance Manual

Page i of iii MOS-MA-EM-02 Rev A

PREFACE

Motive Offshore was developed in order to provide the market with high quality marine equipment andassociated services. The directors of the company have many years operational experience in hire andmanufacturing specialised marine equipment such as, winches, HPUs, compressors and generators.

The companysfirst priority is to its staff. We believe with the appropriate level of staff experience, training and

management, the company can offer a superior service. We aim to offer the highest level of equipment reliabilityand customer service available in the market.

This manual contains the safety and technical information which is necessary for the installation, commissioning,operation and maintenance of the equipment. This document is revised periodically. Enquiries concerningclarification or interpretation of this manual should be directed to Motive Offshore.

IMPORTANT:

This manual forms part of the product and as such should be kept for the duration of the products life span. Anyamendments made during this time should be incorporated into this manual and should also be passed onto anynew owner and / or end user.

This manual provides important information with regards to the safe installation, operation and maintenance ofthis product.


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Page ii of iii MOS-MA-EM-02 Rev A

DEFINITIONS:

1. Factory Acceptance TestingFAT2. Personal Protective EquipmentPPE3. Scheduled Maintenancemaintenance at a prescribed regular time4. Preventative Maintenancemaintenance required on a piece of equipment to keep it in good working

order5. Corrective Maintenancerequired when a piece of equipment or component has failed or is worn out,

to bring it back to working order6. User Maintenancemaintenance that the owner / operator can carry out7.

8.

9. Guide on Gear - GOG

WARNING

CAUTIONARY NOTE


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Page iii of iii MOS-MA-EM-02 Rev A

HEALTH & SAFETY INFORMATION

HAZARDS

This equipment requires the use of chemicals, and or lubricants which may become hazardous to healthunless appropriate precautions are taken. MSDS sheets are made available in section 12 of this manual.

This equipment contains features that require the use of fluids under high pressure which may pose ahazard unless suitable precautions are taken.

This equipment contains moving parts which have been protected by the provision of guarding. Allprovided guards must be utilised when the equipment is operational.

Suitable precautions are to be taken to protect personnel from the effects of the sudden release ofstored energy if under emergency conditions there is a breakage of wire.

This manual provides important information and guidance on the control of hazards listed above and should beread in its entirety prior to attempting to operate the equipment.

PRECAUTIONS

This equipment may have been drained of fluids for transportation purposes. Quantities and types of lubricants required are clearly marked on the equipment and further detailed in

this document. Hydraulic pipework has been colour coded for ease of reference and connection. The manufacturer recommends that only suitably trained and authorised personnel operate and

maintain this product. Supporting structures for the winch installation shall be capable of supporting the winch, the payload

and any reaction forces encountered during winching operations. Load attaching devices used in conjunction with this winch must be capable of supporting the rated load

and any additional dynamic loading effects of the work environment such as drag buoyancy etc. Prior to each operation the winch should be checked for signs of wear, general deterioration and / or

damage. Details of suggested routine checks are contained in this document. The winch should only be used to operate within the specified working limits. The winch shall not be used for lifting, supporting, or transporting personnel. Never permit personnel under any raised load. Never leave a load suspended if the winch is unattended or not in use. Do not permit grease or other lubricants to the brake friction material. Personal Protective Equipment should be worn to suit the activity. Always keep hands, loose clothing etc. away from moving parts and pinch points.

After use, or when not in operation, the winch should be secured from unauthorised and unwarranted use.


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MOS-MA-EM-02 Rev A

CONTENTS

PagePreface iDefinitions iiHealth & Safety Information iii

1.0 General Product Information 2

1.1 Unpacking 2

2.0 Services 2

3.0 Installation & Set Up 3

3.1 Commissioning 3

4.0 Operating Information 5

4.1 General Operating Information 5

4.2 Pre-operational checks 5

4.3 Operating Instructions 5

4.4 Treatment of Malfunctions 6

5.0 Maintenance Instructions 7

5.1 Scheduled Maintenance 7

5.2 Preventative Maintenance 7

5.3 Corrective Maintenance 7

6.0 Maintenance Schedule 8

6.1 Recommended Oils & Lubricants 8

7.0 Parts 9

7.1 Recommended Spare Parts 9

7.2 Ordering Spare Parts 9

8.0 Storage, Handling & Shipping 9

8.1 Preservation 9

8.2 Packaging 10

8.3 Labelling & Handling 10

8.4 Shipping 10

8.5 Storage 10

9.0 Modifications 11

10.0 Disposal 11

11.0 Technical Data 12

11.1 Equipment Specification 12

11.2 Performance Data 13

11.3 Drawings and Schematics 14

11.4 Table of Values 15

12.0 HSE Literature 16

12.1 Risk Assessment 16

Appendices:

1.Motor2.Main Control Valve


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Page 2 of 20 MOS-MA-EM-02 Rev A

1.0 GENERAL PRODUCT INFORMATION

The drum winch has been designed and built forpulling and lifting applications and should providemany years of trouble free service providing thatthe instructions set out in the manual are adheredto. This equipment is not designed for lifting orconveying personnel.

The equipment has been built with dueconsideration to the often harsh environmentsencountered in marine and similar applications,

suitable protective measure have been incorporatedas Motive standard.

All Motive Offshore winches are designed and builtto perform within specific parameters details of thespecific performance characteristics can be found inthe technical data section of this manual.

The following figures depict the main componentsand elements of the winch to enable equipmentfamiliarisation.

Figure 1

a) Base frame b) Chain drive guardc) Pad eyes d) Guarde) Drum f) Guide on gear

Figure 2

g) Scroll shaft h) Guide bari) GOG carriage j) Knife

Figure 3

k) Spreader beaml) Brake cylinderm) Hydraulic motorn) Control valve

1.1 Unpacking

On receipt the winch package should be checkedagainst the delivery manifest ensuring that all itemslisted are in fact present and there are no obviousindications of transportation damage.

If there are any anomalies consult the manufacturerat the earliest opportunity.

All protective and preservative packaging should be

removed and safely disposed of in a controlledmanner in accordance with local regulations.

2.0 SERVICES

Motive power to the winch may be supplied from anindependent hydraulic power unit (HPU) or from asuitable hydraulic service ring main system. Details

of the services required are given in the technicaldata section of this manual.

WARNING:

Hydraulic component failure may give rise to fluidloss e.g. hydraulic fluid, diesel fuel, lubricating oilsand coolants this may in turn present a slip hazard

to personnel and may also pose an environmentalhazard. Due consideration should be given to thepositioning of the spooling winch and associatedservices to minimise the risks.

a

b

c

d

e

f

g

i

j

h

k

l

m

n


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3.0 INSTALLATION & SET UP

The following information is provided to assist theuser in the installation of the winch. The use ofgeneral hand tools may be required. Mechanicalaids may also be required to facilitate positioning.

Due consideration should be given duringequipment positioning to the ergonomicrequirements for servicing, operations, maintenanceand or repair.

It is essential to ensure when mounting the winchthat the foundation or supporting structure iscompatible with the fastening arrangements.Where bolts are used as a means of securing theequipment it is essential that the correct tensilegrade of bolt is employed and correctly tightened tothe values given in section 11 of this manual. Thebelow figure depicts the footprint details of thewinch base-frame.

Figure 4

CAUTIONARY NOTE:

Timber bearers should never be used assupport.

The winch drum should be positioned such that it isperpendicular to the line of pull. If it is intendedthat the wire rope will pass over a change ofdirection sheave or similar device, this will result inan angled pull as the rope feeds on and off of the

drum. This angle is known as the flee angle. Themaximum fleet angle for grooved drums should notexceed 2.5 and for plain drums should not exceed1.5. (See figure 5 below).

Figure 5

During installation it is essential to maintain overallgeometric flatness of the winch base. This is toprevent bearing overload due to distortion of thewinch frame.

Post installation, if the drum does not turn freelycheck the foundation and the winch base forgeometric flatness and rectify by shimming asrequired. Re-tighten and torque any retainingfasteners to the values given in section 11 of thismanual.

The winch framework should be electricallygrounded. Earth bosses are provided on theframework for this purpose.

Until such times the spooling winch is ready foroperation it should be protected from detrimentalenvironmental effects such as;

Water ingress into critical parts Contamination of oil Moisture ingress into electrical controls

CAUTIONARY NOTE:

Certain electrical devices are sensitive tothe high energies involved in weldingoperations. Where fitted these devicesmay require additional isolation prior toany welding taking place. If in doubtconsult the manufacturer.

3.1 Commissioning

All winch service connections should be made asper the appropriate hydraulic schematic at section11 of this manual. The below figure depicts thelocation of the bulkhead panel that houses allumbilical / termination points.

Figure 6


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For ease of reference the winch hydraulicconnections are labelled appropriately and colourcoded.

The umbilical / termination points are colour codedas below:

Pressure RedTank BlueDrain 1 GreenDrain 2 GreenPilot P RedPilot T BluePilot A BlackPilot B WhiteLoad Sense YellowBrake GreyPressure Control BrownBoost pressure Purple

Carry out an inspection of fluid levels and replenishas necessary. New hydraulic fluid is not clean and

should be filtered prior to use. Fluid types,quantities and lubrication points are as depicted onthe lubrication plan at section 11 and in table 3 ofthis manual.

The winch was subject to thorough FactoryAcceptance Testing (FAT) prior to despatch toconfirm its operational conformance. Results of thetest carried out can be found in the certificationpackage supplied.

Before the winch is placed into service the followingpost installation checks should be performed;

a)

Service connections are secure and correct todrawing requirements

b) Required lubrication has been carried outc) Fluid levels in gearbox and hydraulic reservoir

are at the required levels (where fitted)d) Pilot lines are bled of trapped aire) Winch direction of operations checked and as

indicatedf) Limit switches are operational (where fitted)g) Slipping clutch functions correctly (where fitted)h) Brake operates effectivelyi) Load test to required tonnage (if required)

j) Check for leaksk) Ensure all supplied guarding is in place

The recording that the above checks have beencarried out should be recorded using the postinstallation check form, which is maintained withinthe equipment data book.


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4.0 OPERATING INFORMATION

4.1 General Operating Information

Local regulations may require documented riskassessment or Job Safety Analysis to be carried outprior to the use of this equipment.

With regards to PPE the manufacturer recommendsthat as a minimum coverall, protective footwear andgloves but reference should be made to locallyconducted risk assessment for any additionalrequirements. Motive generic risk assessment iscontained within section 12 for your reference.

It is vital that good visual contact andcommunication with all personnel involved inspooling activities is maintained at all times.

4.2 Pre-operational checks

Prior to each use it is essential that the following

pre-operational checks are carried out;a) Service connections are secure and correctto drawing requirements

b) Required lubrication has been carried outc) Fluid levels in gearbox and hydraulic

reservoir are at the required levels (wherefitted)

d) Pilot lines are bled of trapped aire) Winch direction of operations checked and

as indicatedf) Limit switches are operational (where fitted)g) Slipping clutch functions correctly (where

fitted)

h) Brake operates effectively

i)

Check for leaksj) Ensure all supplied guarding is in place

4.3 Operating Instructions

The main operating controls for the winch may beone or a combination of the following:

Directional control valve fitted directly ontothe winch itself

A stand-alone control unit A chest mounted or hand held remote

control unit which may be either hardwired or radio operated

Refer to the technical data section for details of thespecific control arrangement supplied.

The brakes fitted to the winch release automaticallywhen the controls are operated and are configuredto fail to safe if for any reason the operatingcontrol is released.

Operators should familiarise themselves with thelocation and operation of emergency stop devices.

A winch may operate in one or more operatingmodes i.e. manual, remote, active heave, active

tension and constant tension. Refer to thetechnical data section for specific winch operatingmode. Refer to figure 7 for operating instructions.

The emergency stop may be activated at any pointin time ceasing all operations.

Connect winch to power unit.

Carry out pre-operation checks.

Apply power.

Operate winch control (pay out / haul in).

Release control for operations to cease.

Switch power until off.


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Operating Instructions in Constant Tension Mode

To operate the winch in Constant Tension mode thefollowing procedure should be used:

Image 1

Image 2

Image 3

Connect winch to power unit.

Carry out pre-operation checks.

Apply power.

Fully back out pressure control

(Turn full CCW)

Operate winch control full heave

Image 2.

Observe brake cylinder fully extend

Close isolating ball valve on brake

cylinderImage 4.

Adjust press control (C.W.) to

desired tension.

NOTE:To operate winch in standard mode

configuration, open the brake isolation valve

and screw in the press control full (C.W.)

Image 4


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4.4 Treatment of Malfunctions

This section aims to provide the user with guidance for the detection, correction and reporting of anymalfunction with the equipment.

The table below details the symptoms, probable causes and corrective actions.

SYMPTOM CAUSE CORRECTIVE ACTION

Winch does not operate No oil supply to winch

Winch is overloaded

Brakes not released

Check oil supply line connections

Reduce load to within rated

capacity

Check brake opening pressure

Load continues to move when

winch is stopped

Winch overloaded

Winch motor controls sticking

Brake not applying

Reduce load to rated capacity

Check control levers return to

neutral when released

Adjust brake band

Winch does not lift the rated load Insufficient oil supply

Brake not releasing

Motors may be damaged

Verify oil supply pressure and

volume is as specified

Inspect oil filters for

contaminationConsult the manufacturer

Control lever moves but winch does

not operate

Insufficient oil supply

Oil leak

Motor may have been damaged

Ensure oil supply is according to

specification

Repair any leaks, retesting as

necessary.

Contact the manufacturer

Winch runs slowly Brakes not fully released

Motor may be damaged

Check the brake operating

pressure

Contact the manufacturer

Motor runs hot or makes excessive

noise during operation

Contamination in oil

Motor or valve may be

damaged

Check oil contamination, drain &

refill with recommended oil and

replace filters as necessaryOperate winch with no load

slowly in both directions. If

noise still exists or motor

overheats then contact

manufacturer

Scroll shaft not sliding smoothly Scroll shaft knife may be

damaged

Chain or sprocket may be

damaged

Remove the scroll shaft knife

and replace if damaged

Check the chains and sprockets

and replace if damaged

Table 1

If any of the suggested corrective actions does not resolve the equipment malfunction, the manufacturer shouldbe consulted for supported.


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5.0 MAINTENANCE INSTRUCTIONS

To achieve optimum operating safety and servicelife, it is vital that the winch is maintained at regularintervals.

The following maintenance instructions will ensurethe integrity of the winch and avoid unnecessarydown time and or damage.

WARNING:

The winch must be released of all loads andbe isolated during maintenance works.Maintenance should only be carried out bysuitable trained and authorised persons.

5.1 Scheduled Maintenance

Scheduled maintenance is based on winch usage of810 hours per shift. Details of what is requiredat any given point are given in table 2.

5.2 Preventative Maintenance

This type of maintenance is intended to ensure thatif the winch is not in regular use that it ismaintained in good order in readiness for use whenrequired.

If the winch is expected to be out of service formore than three months;

Protect the hydraulic system against rustwith hydraulic oil that has rust preventingadditives.

If the winch is still out of service within a year thewinch should be run at intervals so as to maintain aprotective film on the internal surfaces ofcomponents and oil lines, thus protecting againstcorrosion.

CAUTIONARY NOTE:

If any of the parts of the system aredisconnected, open fittings must beprotected by plugs or covers to preventingress of any dirt particles.

5.3 Corrective Maintenance

In the event of breakdown in the first instance referto the malfunction table 1, however if that does notresolve the issue consult the manufacturer foradvice and assistance.

Brake

The brake is fitted with a wear indicator dial whichis a simple vision device that may be used as ageneral guide as to the brake conditions.

Figure 8

5.4 Corrective Maintenance

In the event of breakdown in the first instance referto the malfunction table 1, however if that does notresolve the issue consult the manufacturer foradvice and assistance.

5.5 User Maintenance

Replacement of brake band:

The brake lining is worn out and the completebrake band must be exchanged when themeasurement, band plus lining, is as shown in thefigure below:

Figure 9

Because they must be run, the FK measurementwith new brake bands must be 127mm (5.00 in).Check the FK measurement after approximately 10brake operations and adjust it to 117mm (4.61 in).

Figure 10


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Brake Adjustment:

Without braking torque adjust when the indicatorsshow red.

1. Remove locking devices on adjustmentscrews.

2. Stretch the bands with the adjustmentscrews when the pressure is applied to thebrake cylinder. Drain the brake cylinder,check the measurement FK and adjust to117mm. The scale indicators, sign 2,should then show green.

3. Replace the locking devices on theadjustment screws.

Figure 11

With braking torque scale not valid. The value ofthe braking torque must be used when checking theadjustment. Refer to figure 16 if adjustment isnecessary. Carry out steps 13 as above.

Example: a line force F of 100 000 N and a linedrum of radius r = 0.5 metres, the braking torque isMb = 50 000Nm. The brake is to be adjusted if theFK measurement is less than 77mm. Adjust FK to91mm.

WARNING:

Adjustment-check of brakes with brakingtorque is only to be performed when thebrakes cannot be relieved of braking torque.

Brake Assembly Lubrication Points:

Figure 12

All maintenance activities should be recordedin the maintenance record in the equipmentdata book.


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6.0 MAINTENANCE SCHEDULE

Item PRE-USE 1 month 6 months 12 months

Motor Iensure correctdirection of rotation

I - oil

Brake Iensure correctoperation

Las per fig12 of thismanual

Control Valve Ivisually check forproper function

Base Frame Iensure base frame isfitted to foundationstructure appropriately

Lift Point Ivisuallyinspection liftpoints, re-stampname plate and re-certify *

Bearing Lgrease as perlubrication drawing

Drum Iinspect for damage

and report as necessaryHoses & Fittings Iensure there is noevidence of cracks ordamage, replace ifnecessary

Guards Iensure all guards arein place

Iensure thereis no damage,repair asnecessary

Paintwork Atouch uppaintwork asrequired

Labelling Iensure allwarnings, weight

data etc. is visibleControls Iensure all controls

are functioning and ingood working order

Level wind L - grease chain, guidebar & scroll shaft pre &post use

Table 2Key:

(I) Inspection(R) Replacement(A) Adjustment(L) Lubricate* To be carried out by trained and competent personnel

6.1 Recommended oils & lubricants:

ITEM FLUID TYPE CAPACITY

Motor ISO 46normal temperature 40L, fill as required

ISO 68tropical temperature

Bearings EP2 Grease Grease gunas required

Table 3

Notes:Aggressive detergents may damage the seals of the hydraulic motor and cause them to age faster.Never use a high pressure cleaner near hydraulic components.Oil on the brake linings reduces the braking torque.


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7.0 PARTS

7.1 Recommended Spare Parts & Tooling

The following is a list of recommended spare parts:

Set of dowty seals and Orings Grease cartridges Brake band

The following is a list of recommended toolsrequired for installing, commissioning, operatingand maintaining a winch:

Lubricating grease and gun Basic tool kit

7.2 Ordering Spare Parts

When ordering spare parts, quote the followinginformation:

a) Company nameb) Addressc) Equipment IDd) Description of part requirede) Serial number (if available)

8.0 STORAGE, HANDLING & SHIPPING

If at any time the winch is to be put into storage,the following guidelines should be followed toensure that the winch is maintained in good order.

8.1 Preservation

Measures should be put in place to provide

adequate protection of the product against damage,deterioration and corrosion.

With regards to metallic materials the below tableprovides the basic requirements for the corrosionprotection of metallic parts.

Material Corrosion Protection

Low Alloy Steel

12% Chromium Steels

Corrosion Preventive Oil + Polythene film over wrap

VCI paper / film + Polythene film over wrap

VCI paper / film + Non-absorbent container

Austenitic Stainless Steels

Nickel or Cobalt Base Alloys

Titanium Alloys

No preservation required + Polythene film over wrap

No preservation required + Non-absorbent container

Aluminium Alloys

Copper Alloys

Corrosion Preventive Oil (unpainted surfaces) + Polythene film over

wrap

Corrosion Preventive Oil (unpainted surfaces) + Non-absorbent

container

Magnesium Alloys Corrosion Preventive Oil (unpainted surfaces) + Polythene film over

wrap

Corrosion Preventive Oil (unpainted surfaces) + Non-absorbent

container

VCI Paper (Volatile Corrosion Inhibitor)Reference

Note 1:VCI treated paper / film shall not be used with any of the following alloys or platings: magnesium, copper, lead, lead-

indium, silver, zinc, tin based, cadmium, or nickel-cadmium. VCI treated paper / film is acceptable for use with non-ferrous

material except magnesium, lead, or lead indium.

Note 2:Application of preservative materials shall be preceded by thorough cleaning of parts to remove foreign objects from

processing and handling, i.e., metal chips, abrasives, blasting grit, metal finishing compounds, fluxes, cutting fluids, lubricants,

test fluids, moisture, fingerprints etc.

Table 4

All connection points to be appropriately closed off with protective caps, covers and plugs.


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8.2 Packaging

The winch and any ancillary equipment should bepacked in manner that will permit removal from thepackaging without any damage.

Primary packaging is the first level of packagingapplied to the product and is designed to come intodirect contact with the product, however anadditional level of primary packaging can beincluded with any protective materials (dunnage)where required to ensure that the primarypackaging is robust enough to protect the part fromdamage, deterioration, corrosion, tampering andother risks during storage or transportation.

It is important that all materials used for packagingwill not contaminate the goods enclosed. In somecircumstances dunnage shall be used to provideadequate support, bracing and protection of partsduring shipment i.e. padding in a shipping containerto prevent unnecessary movement of load. It is

important that all dunnage material is wrapped upso that it is not in direct contact with the product.Loose form materials such as polystyrene chips orshredded paper shall not be used.

All ancillary equipment should be palletised andsecured. All pallets and bases should be in goodcondition with no loose broken boards, noprotruding nails etc. The pallet should be suitableto carry the product load during shipment andstorage.

8.3 Labelling & Handling

It is important that each package is clearlyidentified. Appropriate despatch and / or storagelabelling should be firmly and securely attached.

Any special instructions with regards to handlingand storage of delicate equipment such as electricalinstrumentation and fluids should be clearly madevisible. Recognised International symbols may beused.

Handling of large, heavy, and or cumbersomeequipment should be carried out by means ofappropriate lifting equipment such as sling setsconnected to certified lifting points.

Extreme care should be taken to determine thecentre of gravity of the device during any lift or anylifting operation as the unit may be weight biased.Refer to the loading and transportation drawing insection 11.

8.4 Shipping

It is essential that all tools, supplies and servicesrequired for shipping are made available at therequired time. This may include slings, forklift,crane, etc. Advice should be sought from the

haulage company.

It is also essential that all delivery paperwork isprepared and compiled with all relevant details such

as weights and dimensions of the winch.Compilation of the documentation will aid incatering for any movement restrictions or specialtransportation considerations.

8.5 Storage

In permanent installations, when not in use thewinch must be left in a safe position that neitherthe winch nor associated rigging gear presents ahazard. It may be found that pulley blocks, hooksetc. need to be raised to the highest level to avoiddanger of collision with persons or passing vehicles,however in some cases they may need to beremoved.

In temporary installations, when not in use thewinch and associated equipment should be returnedto a suitable storage facility. The storageconditions should meet the following requirements:

Storage areas must be dry, free frominjurious pollution and not subject toextreme temperatures. All parts withexposed threads or machined bearingsurfaces should be protected and handledwith care. If the winch has been returnedto stores wet or subject to othersubstances liable to cause deteriorationadditional treatment may be necessary. Itshould be remembered that weak acidsbecome strong acids when in directcontact with metal products.

Pulley blocks and detachable items

normally used in association with thewinch should be removed and storedseparately.

All functions of the winch should bechecked prior to storage, in particular theoperation of the clutch and brakes.

All hoses and cables should be checked toensure that there is no damage. Wherepractical cables, hoses and handles shouldbe removed from the winch and storedseparately.

Prior to storage the winch should belubricated.

Hydraulic motors and pump casings shouldbe fully filled with oil.

When being handled care should be takento ensure that the winch and accessoriesare not dropped or thrown down and thatrope, hoses or cables are not draggedacross the floor.

During transportation additional protectionmay be required to prevent the ingress ofmoisture, dust or foreign particles.


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9.0 MODIFICATIONS

At no time should this spooling winch be modifiedwithout prior consultation with the manufacturer.No liability whatsoever will be accepted forconsequential loss or injury as a consequence ofunauthorised modification.

Authorised modification shall be documented andrevisions incorporated into future publications ofthis manual.

Since manufacture the following modification havebeen made to this winch;

Addition of level wind (details arecontained through the manual)

10.0 DISPOSAL

For end of life product advice please consult withthe manufacturer.


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11.0 TECHNICAL SPECIFICATION

11.1 Equipment Specification

Equipment ID

Motive reference: MS1059

Client reference (if used): n/a

Weight & Dimensions

Length: 1925mm

2006mm with level wind

Width: 991mm,

1396mm with level wind

Height: 1438mm

Weight: 3,725Kg Tare, 6,000Kg Gross

Lifting: Fitted with forklift pockets & 2 point lifting spreader

beam

Design Temperature: -10 - +40

Guarding All moving parts guarded

Drum

Core dia: 508mm

Flange dia: 930mm

Inside width: 1025mm

Wire capacity: 650m of 19mm Wire

Level Wind: Fitted to suit 19mm diameter wire

Drive

Control Valve: Hydranor6MB

Motor: HagglundsViking

Motor type: 64 Series

Gear: Not fitted

Clutch: Not fitted

Brake

Type: Hagglunds BA 63 brake assembly c/w BCIM brake

cylinder

Parking brake: Hydraulic failsafe brakes fitted to hydraulic motor

Operating Controls

Type: Control panel mounted on winch

Controls: Hydraulic main system pressure gauge

Directional control

Emergency stop

Surface Coating:

Stage 1: Shotblasted to SA2.5

Stage 2: Single coat of two-pack Jotamastic 80 high build

marine primer, colour - Grey

Stage 3: Single coat of a two-pack Hardtop AS marine grade

paint, colourRAL 5018 (Teal)


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Rules & Regulations:

The Machinery Directive2006/42/EC

The Pressure Equipment Directive97/23/EC

The ATEX Directive94/9/EC

PUWER

LOLER

BS EN 13414

CE Marked

IP 56 rated

Table 5

11.2 Performance Data

Based on hydraulic system power at winch control valve as follows:

Flow: 176L/minPressure: 230Bar (cross port pressure)Power Required: 71kWWire Rope Diameter: 19mm

LIFTING SPECIFICATION

Wire RopeLayer

Layer Diameter

(mm)

Length of Wire /Layer(mtr)

Line Pull

(Tonne)

Line Speed

(m/min)

Brake HoldingForce

(Tonne)

1 527 89 6.9 52.0 10.4

2 565 185 6.4 55.8 9.6

3 603 287 6.0 59.5 9.0

4 641 395 5.6 63.3 8.4

5 679 510 5.3 67.0 7.9

6 717 650 5.0 70.8 7.5

CONSTANT TENSION SPECIFICATION

Wire RopeLayer

Layer Diameter

(mm)

Length of Wire /Layer(mtr)

Line Pull

(Tonne)

Line Speed

(m/min)

Brake HoldingForce

(Tonne)

1 527 89 5.0 70.0 13.3

2 565 185 5.0 70.0 12.4

3 603 287 5.0 70.0 11.7

4 641 395 5.0 70.0 11.1

5 679 510 5.0 70.0 10.4

6 717 650 5.0 70.0 9.9Table 6


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11.3 Drawings & Schematics


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FRONT VIEW ( 1:25 )

SIDE VIEW ( 1:25 )SIDE VIEW ( 1:

ISOMETRIC VIE

UNDERNEATH VIEW ( 1:25 )(FOOTPRINT)

motive

INSIDE : 0.50 MM UNO

OUTSIDE : 0.65 MM UNO

MACHINED CORNER RADS.

GENERAL TOLERANCES

: 0.25 MM UNO

: 0.05 MM UNO

: 0.5 UNO

STEEL FABRICATIONS : 3.00 MM UNO

ANGULARCONCENTRICMACHINING

REFERNCE DRAWING

B 07/05/14 AR RM DL DA AS BUILT

A 29/11/13 AR DA DA ISSUED FOR INFORMATION

0 29/11/13 AR DA DA ISSUED FOR COMMENT

REV DATE BY CHK'D APPD APPD COMMENT

29

6

42

9

19

FIRST LAYER

TOP LAYER

4 OFF GREASEPOINTS, GREAS

DAILY

WIRE ROPE EXIT

92061

1384

=


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11.4 Table of Values

Torque ValueBolt / Nuts

These figures below are for greased bolts only, notvalid for greased containing copper or EP additives.

Torque in NmTensile Strength

Bolt/NutSize

4.6 8.8 10.9 12.9 SS

M8 8 20 27 33 21

M10 15 39 54 64 41

M12 27 69 94 112 64

M16 67 171 232 278 158

M20 130 333 452 543 233

M24 224 575 784 939 408

M30 443 1143 1558 2240 -

1 Nm = 8.851 lbin = 0.738 lbft = 0.102 kgm

IP Ratings

Protection provided by enclosures for electricalequipment is indicated by the IP codes twocharacteristic numerals.

Protectionagainstsolidobjects

Protectionagainst;

Protectionagainstliquids

Protectionagainst

X Untested X Untested

0 Notprotected

0 Notprotected

1 Solid objects

over 50mm(e.g.accidentaltouch byhand)

1 Falling drops

of water

2 Solid objectsover 12mm(e.g.fingers)

2 Direct spraysup to 15from thevertical

3 Solid objectsover 2.5mm(e.g. toolsand wires)

3 Sprays up to60 from thevertical

4 Solid objectsover 1mm

(e.g. tools,wires andsmall wires)

4 Sprays fromall directions

limitedingresspermitted

5 Dust limitedingress (noharmfuldeposit)

5 Lowpressure jetsif water fromall directions limitedingresspermitted

6 Strong jetsof water

7 Effects oftemporaryimmersion

between15cm & 1m.

8 Long periodsof immersionunderpressure

Hydraulic cleanliness

NAS Classification:

NAS 1638 standard comprised of fluid cleanlinessclasses, each class defined in terms of maximumallowed particle counts for designated particle sizeranges:

ClassMaximum No. of particles / 100ml

5-15 15-25 25-50 50-100

>100

00 125 22 4 1 0

0 250 44 8 3 0

1 500 89 16 6 1

2 1000 178 32 11 1

3 2000 356 63 22 2

4 4000 712 126 45 4

5 8000 1425 253 90 8

6 16000 2850 506 180 16

7 32000 5700 1012 360 32

8 64000 11400 2025 720 164

9 128000 22800 4-50 1440 128

10 256000 45600 8100 2800 256

11 512000 91200 16200 2880 512

12 1024000 182400 32400 5760 1024

ISO 4406:

ISO 4406 classified by a two number code as belowtable:

Range Number No. of Particles per ml

More than Up to andincluding

24 80 000 160 000

23 40 000 80 000

22 20 000 40 000

21 10 000 20 000

20 5 000 10 000

19 2 500 5 000

18 1 300 2 500

17 640 1 300

16 320 640

15 160 320

14 80 160

13 40 80

12 20 40

11 10 20

10 5 10

9 2.5 5

8 1.3 2.5

7 0.64 1.3

6 0.32 0.64


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12.0

HSE LITERATURE

12.1 Risk Assessment

Ref: RA-01 Title: Winch & EHPU Operations

HAZARDSEXISTING RISK

CONTROL

MEASURESRISK AFTER CONTROL MEASURES

Hazard Description People at riskHazard severity

(H)

Likelihood of

Occurrence (L)

Risk

RatingRisk

Details of existing

controls

Hazard Severity

(H)

Likelihood of

Occurrence (L)

Risk

RatingRisk

Describe all hazards identified

and their effects of each task

Detail who is at

risk. Include all

people who may

be affected

Slightharm=

1

Harmful=

2

Extremeharm=

3

Highlyunlikely=

1

Unlikely=

2

Likely=

3

(H) x

(L)

Tolerable,

Moderate,

Substantial,

Intolerable

(refer to

table)

Consider hierarch of risk

controls and describe fully

all controls applicable for

each hazard e.g. if PPE is

used as control, it must be

specified. All controls must

reduce severity, likelihood

or both.Slightharm=

1

Harmful=

2

Extremeharm=

3

Highlyunlikely=

1

Unlikely=

2

Likely=

3

(H) x

(L)

Tolerable,

Moderate,

Substantial,

Intolerable

(refer to

table)

Slip, Trip and Falls

Winch Operator

and others in

vicinity of

equipment.

2 2 4 Moderate

Make all personnel aware of

the operation, all non-

essentials to stay clear,

housekeeping to continually

kept to a high standard.

Erect barriers and signs

warning of danger areas.

Wear correct PPE. Be

aware of simultaneous

operations in the

equipment vicinity.

2 1 2 Tolerable

Pinch Points

Winch Operator

and others in

vicinity of

equipment.

2 2 4 Moderate

Wear correct PPE, keep

hands/limbs away from

moving parts. Take care

and fully understand task

before starting.

2 1 2 Tolerable


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Caught in rotating machinery

Winch Operator

and others in

vicinity of

equipment.

3 2 6 Substantial

Stay clear of moving parts,

ensure moving parts where

possible are guarded.

Barrier off area around

winch while in operation.

Operator to be fully trained

and component in winching

operations.

3 1 3 Moderate

High pressure fluid release

Winch Operator

and others in

vicinity of

equipment.

3 2 6 Substantial

Ensure hoses are correctly

fitted by a trained

competent technician. All

hoses, valves and

connections to be check

and confirmed fit forpurpose. Where possible

stay clear of pressure lines.

3 1 3 Moderate

Electric Shock Winch Operator 3 2 6 Substantial

Electrical work to be carried

out by a trained competent

technician. Ensure all

cables and free from

damage and correctly

terminated. If defects are

found during operation

isolate supply before

starting maintenance.

3 1 3 Moderate

Contact with oils and lubricants Winch Operator 2 2 4 Moderate

Wear correct PPE. If skin

contact occurs wash off

immediately.

2 1 2 Tolerable

Winch wire failure All on site 3 2 6 Substantial

Ensure wire is terminated

correctly, is free from

defect and certified.Perform a SWL test on

winch/wire before

commencing operation. If

wire gets damaged during

operation, stop the job and

replace wire.

2 1 2 Tolerable


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Loss of communication

Winch Operator

and others in

vicinity of

equipment.

3 2 6 Substantial

Check radios prior to use.

Have hand signals defined

for emergency backup.

Hold TBT prior to starting

operation.

3 1 3 Moderate

Assessor: Dave Acton Date: 15/01/2014

HSEQ Dept. Reviewed by: Valene Morrison Date: 16/01/2014


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MOS-MA-EM-02 Rev A

APPENDICIES:


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MOS-MA-EM-02 Rev A

1. Motor:


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MOS-MA-EM-02 Rev A

2. Control ValveMain (6MB)

The control unit is ideal for the controlling of hydraulic driven winches and has the following improvedcharacteristics:

Extremely compact design All valves integrated into one unit

Designed to withstand marine surroundings Pressure compensated flow control system, giving excellent metering Prepared to fit directly to motor flanges by an adapter Hand lever with 39 control movement in each direction Wide range of options Extremely wide capacity range

Modular Code Data

6MB Directional control valve

Counterbalance valve in A

Free flow check valve

Pressure relief valve A to B

Anti-cavitation valve to B

Pressure compensator flow control

Max operating pressure 315 bar650 Rated flow Q = 650 l/min

37B Manually / remote operated with brake release 4BA3

2C Spool Type


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MOS-MA-EM-02 Rev A

Hydraulic Schematic:

Item Description

1 Main block

2 Directional control valve 4/3This is a three position directional spool valve with hand lever. When activating the directional valvehandle, the operator controls the direction and drive speed of the drum. Throttling grooves in the mainspool open progressively for flow either to A or B port. The spool has adjustable end stoppers in bothend covers for limiting of the spool stroke. A shorter travel of the spool will result in an increase of the

pressure drop through the spool and an increase of maximum flow through the valve.C Counterbalance valveA to T

The counterbalance valve keeps the load under control during lowering operation. Throttling groves inthe counter balance spool opens progressively for flow from A-T port, thus gives a smooth loweringoperation and low pressure rise with full flow. The counterbalance spool opens by a pilot pressure takenfrom line B.Factory pre-set to 40 bar

Q Adjustable throttlingThrottling for the counter balance pilot channel.Factory pre-set to turn counter clockwise (ccw) from closed position.

CA Check-valve free flowP to ABypassing the counter balance valve in Heave

D Pressure relief valveA to BThis pilot operated pressure relief valve will in some application be used as a mooring valve, to keep aconstant tension on the drum, or freewheeling of the hydraulic motor. Tension pressure can either beadjusted by a hand wheel (option MAM) or remote controlled by the port MX.The pressure relief valve is set to its minimum.

DA Anti-cavitation check valveBoosting from T to B


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MOS-MA-EM-02 Rev A

GeneralMeasures must be taken to ensure that cavitation cannot occur in a hydraulic system.Therefore, a certain flow must be applied to A or B to replace internal leakage. It is important toprevent boosting oil from running out of the boosting system. A check valve with opening pressure of 2-3 bar in T will usually satisfy this. As far as possible, internal leakage from the hydraulic motor shouldbe connected before the check valve in T. Remember to check max motor casing return pressureagainst system return pressure.Standard Boosting 6MBhas internal boosting from T to B as standard. Also a certain flow will leakthrough nozzle PB, and shuttle valve PC to either A or B.Generally about the pressure compensator systemThis is a load independent system, which meansthat a fixed spool stroke on the directional valve will give equal flow independent of the load at themotor / drum. The main directional spool (2) in conjunction with pressure compensator flow A (Heaverotation) or B (Lower rotation) by sensing the pressure either in A or B line through the shuttle valve(PC). When operating direction valve (2), the spool will open progressively to A or B. Pressurecompensation element will maintain equal p across the directional valve. Maximum flow over the maindirectional valve is depending on the force induced on the pressure compensator element (P). Thisforce is made up of a spring force in the compensator pilot valve (PA) and the load pressure sensing in Aor B via (PC). When setting is altered on the compensator pilot valve (PA), the flow will change. Whenadjusting pressure relief valve PA, the p through the directional valve will alter, and thus maximumflow to the hydraulic motor.

PC Shuttle Valve for the pressure compensatorPort V can be used for load sensing or in some application for a hydraulically operated brake releasevalve.

P Pressure compensator elementNormally opens the modulating element, which acts as a pressure compensator to maintain a constantpressure drop across the directional valve (together with PC, PB, PA and Z).

Z Adjustable throttlingAdjustable throttle for the pressure compensator element, if the element is fluctuating.

PB NozzleMaintain flow to compensator pilot valve PA.

PA Compensator pilot valveThe spring on the compensator is rather weak. Therefore, pressure created by an adjustable pressurerelief valve is added to the spring force.

Port dimension for brake release valve 4BA3: 3/8 BSPP


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MOS-MA-EM-02 Rev A

Hydranor control valve dimensions:

Pressure drop:


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Description Symbol Unit Value

Flow (p 32 bar) Q max l/min 450-650

Max operating pressure in ports P, A and B P max Bar 315

Recommended max. pressure in port T. (See Notebelow)

T max Bar 20

Directional valve pilot pressure P Bar 5-20

Weight basic version m Kg 96Hydraulic fluid Mineral oils for hydraulic system

Viscosity range v m/s 10 to 350 (cST)

Viscosity index VI >120

Filtration, recommended filter with 20 100 Class 9 according to NAS 1638,18/15 according to ISO 4406

Fluid temperature range T -20C to +70C

Ambient temperature range T -20C to +50C

Standard body material EN-GJS-400-15(GGG40)

Standard O-rings Nitrile shore 70

Note: Be aware that pressure on the tank port T is direct additive to valve setting for pressure relief valve itemD, counterbalance valve item C. Pressure peaks in T port can influence the stability of the system, particularproportional remote control of main directional valve.

Interfaces:

Connections

Ports Dimensions

P, A and B 1 SAE 6000

T 2 SAE 3000

MX, V, X, Y, TA, TB 3/8 BSPP

E BSPP

L (When having adapter for direct motor mounting) BSPP

TPP, TPT, TPA and TPB BSPP

Mounting Screws 4 of M12 (thread depth 17mm)

HYDRAULIC WINCH-MS1059 - Operation & Maintenance Manual Rev A

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Transcript of HYDRAULIC WINCH-MS1059 - Operation & Maintenance Manual Rev A