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LAWSON ENGINEERS LTD

Mechanical & Structural Engineers Carlisle, England, +44 (0) 1228 711470

OPERATION & MAINTENANCE MANUAL

Transmark Subsea Standard Winch TO SUIT 29.2 mm DIAMETER UMBILICAL CABLE

EQUIPMENT REFERENCES SERIAL No.: KA1850

LAWSON ENGINEERS Ltd Issue Date 11.10.2012 Serial No. KA1850

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CONTENTS

1 GENERAL DESCRIPTION .............................................................................................. 1 1.1 DESCRIPTION.......................................................................................................... 1 1.2 LEADING PARTICULARS ..................................................................................... 2

1.2.1 WINCH .................................................................................................................. 2 1.3 PHOTOGRAPHS ...................................................................................................... 3

2 HANDLING ...................................................................................................................... 9 2.1 LIFTING & TRANSPORTING ................................................................................ 9 2.2 LIFTING PRECAUTIONS ....................................................................................... 9

3 INSTALLATION, ASSEMBLY & DISASSEMBLY .................................................... 10 3.1 INSTALLATION .................................................................................................... 10 3.2 ASSEMBLY & DISASSEMBLY ........................................................................... 10

3.2.1 DRUM FITMENT ............................................................................................... 10 3.2.2 COILING GEAR FITMENT ............................................................................... 11

4 WINCH OPERATION .................................................................................................... 12 4.1 OPERATION ........................................................................................................... 12

5 MAINTENANCE ............................................................................................................ 14 5.1 LUBRICATION ...................................................................................................... 14

5.1.1 LUBRICATION SCHEDULE............................................................................. 14 5.1.2 RECOMMENDED LUBRICANTS .................................................................... 14 5.1.3 GEARBOX OIL CHANGES ............................................................................... 14 5.1.4 GENERAL PRECAUTIONS .............................................................................. 15

5.2 MECHANICAL MAINTENANCE PROCEDURES.............................................. 15 5.2.1 PAINTWORK...................................................................................................... 15 5.2.2 FASTENERS ....................................................................................................... 15

6 STORAGE PROCEDURES ............................................................................................ 17 6.1 MONTHLY STORAGE MAINTENANCE PROCEDURES ................................. 17 6.2 START-UP AFTER STORAGE. ............................................................................ 17

7 RECOMMENDED SPARE PARTS ............................................................................... 18 8 PROPRIETRY INFORMATION .................................................................................... 19 9 PARTS LISTS & DRAWINGS ....................................................................................... 20


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1 GENERAL DESCRIPTION 1.1 DESCRIPTION Refer to drawing KA1843-0001 Winch Assembly & General Arrangement See also photos on pages following. This Lawson Standard marine umbilical winch is used for lifting and lowering a cable and end-attachment (camera, sensors, vehicle, mass, etc) from a ship of convenience, platform or drilling rig. It is hydraulically driven from an external HPU (by others) or ship ring-main (by others). It can be operated either locally or remotely. A remote switch is provided on the winch for connection the customers system. The drum is of fabricated steel construction and is supported on a centrally mounted slew-ring bearing. This arrangement gives much better access to the slip-ring and rotating junction box (if these are fitted) than would be available on a conventional winch with a bearing at each end of the drum. The winch is driven by a hydraulic motor through a 54.4:1 ratio gearbox. The motor and gearbox are mounted on the end frame, which also supports the bearing and the gearbox protrudes into the drum thereby reducing the overall width of the winch. The gearbox is fitted with a spring applied, fail-safe brake. Automatic coiling gear is fitted to the winch to ensure even spooling of the umbilical cable. This is hydraulically driven, and works by sensing the movement of the cable as it traverses the drum. Where required the coiler can be switched into manual operation mode. The coiler can be fixed in seven positions allowing an off-lead angle over the top of the drum between zero and sixty degrees from horizontal. The drum is plain, hence by definition the first layer of cable must be properly laid onto the drum as this acts as the The winch can be operated locally via a hydraulic DCV, or remotely using a proportional joystick. All electrical equipment on the winch is suitable for operation in a zone 1 hazardous environment. All four sides of the frame are guarded with a cut-out in the drive side guard for access to the local controls. Four lifting points are provided on the winch frame. Although the winch has some Zone 2 components (Fixed Junction Box, electrics, gearbox, etc) it is not Certified for use in a Hazardous area (reason: on this project we weren’t asked to provide it). SHOULD YOU WISH TO USE IT IN A ZONE 2 ENVIRONMENT PLEASE CONTACT LAWSON ENGINEERS for confirmation that this winch is actually suitable for that area and the relevant certification.


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1.2 LEADING PARTICULARS 1.2.1 WINCH Safe Working Load (Bottom Layer) 2500 kg It pulls less from the top layer: depends on the cable length stored Maximum Drum Speed 10.7 rpm Coiling Speed (Top Layer) 0 to 45 m/min Winch speed depends on the oil flow available from the customer ring-main or HPU Drum Diameter 1020 mm Flange Diameter 1530 mm Drum Width 714 mm Drive (Hydraulic) Single Geared Motor c/w brake Gearbox Ratio 54.4:1 Maximum Operating Pressure 200-bar Length of Cable Coiled 600 m on 8-layers Umbilical Cable Diameter 30.2 +/-1mm (actual size 28.2) Mass of Umbilical (in air) 954 kg/m Mass of Umbilical in sea water 219 kg/m Mass of Winch empty 2200 kg Mass of Winch with Umbilical Cable 2800 kg (estimated) Recommended Hydraulic oil Tellus 32 or 46 or equivalent, or near offer Test Loads Dynamic test 1.25x SWL (from the bare drum) Brake Test 1.5x SWL (from the bare drum)


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1.3 PHOTOGRAPHS

Figure 1: Winch Controls

Figure 2: Winch Drive Side


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Figure 3: Winch Front


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Figure 4: Winch Non-Drive Side

Figure 5: Winch Rotating Junction Box Arrangement


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Figure 6: Hydraulic Bulkheads & Emergency Stop Valve


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Figure 7: Coiler pivot top


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Figure 8: Coiler pivot bottom


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2 HANDLING 2.1 LIFTING & TRANSPORTING The winch is fitted with a protective bump frame, at the top corners of which are four lifting padeyes. The winch should always be lifted on four slings or chains. Overall Mass of Winch & Umbilical 4500 kg (this the heaviest allowed) Transport Dimensions, Length 1800 mm Width 1359 mm Height 1660 mm 2.2 LIFTING PRECAUTIONS

1. Lifting of the system should be carried out only by experienced & competent personnel.

2. Personnel involved should be issued with suitable protective clothing including helmets and protective footwear.

3. Check that all connections are secure before lifting commences.

4. Ensure that the electrical supply cable and all hydraulic hoses, fitted to the bulkheads in the base, have been disconnected prior to lifting.

5. All personnel should stand well clear when lifting heavy equipment. On no account should anyone stand underneath the system while it is being lifted.

6. It is strongly advised that lifting equipment be thoroughly examined at least once every six months. This is a legal requirement in the U.K.


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3 INSTALLATION, ASSEMBLY & DISASSEMBLY Refer to drawings KA1843-0001 Winch Assembly & General Arrangement KA1843-0002 Hydraulic Schematic KA1843-0002 Electrical Layout Drawing KA1988-0007 Electrical Schematic 3.1 INSTALLATION The winch is secured to the deck using four M20 bolts, one at each corner of the frame. The bolts should be of grade 8.8 minimum with grade 8 nuts. It is recommended that the frame be packed up from the deck at the four corners to avoid putting an induced load into the frame when the bolts are tightened - as the deck is unlikely to be perfectly flat. A rail is provided adjacent to the hydraulic bulkhead plate for fitment of a clamp to support the deck cable. . Mesh guards are fitted on four sides of the winch. These may be removed to assist installation of the winch as well as for maintenance but they must be replaced before the winch is actually run. 3.2 ASSEMBLY & DISASSEMBLY The following is a recommended assembly sequence for the major components of the winch. Disassembly sequences are simply a reversal of assembly procedures. Numbers in parentheses refer to the reference numbers on Parts List KA1850-0001PL. 3.2.1 DRUM FITMENT 1. Bolt bearing ring (3) to mounting face on frame (1) 2. Lift drum (2) into frame by passing the drum through the side of the frame, tipping the

drum at an angle. 3. Chock drum to support it on an axis along the centreline of the drive, but pushing the

drum as close to the frame as possible. 4. Fit the drive motor /gearbox assembly (4) to the frame (1). Bolt in place and torque bolts

to recommended value. 5. Insert a threaded rod through the boss in the drum into the threaded hole in the end of the

gearbox shaft. 6. Carefully jack the drum onto the gearbox shaft until contact is made between the bearing

ring and the mounting face on the drum. Bolt together


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7. Torque the bearing ring bolts (47) and (48) to the recommended values. Access to bolts (47) is through 3-off holes in the centre plate of the drum, to gain access all bolts the drum must be rotated. On completion these 3- holes must be sealed.

3.2.2 COILING GEAR FITMENT Refer to drawing KA1850-0001 Winch Assembly & General Arrangement The coiling gear can be fitted in one of seven different positions to accommodate an off-lead to the first sheave, over the top of the drum, between zero and sixty degrees from horizontal. The coiler is positioned by bolting it to the appropriate set of holes on the winch frame coiler supports. This is illustrated on drawing number KA1850-0001. What follows is the procedure for assembling the coiling gear and is relevant regardless of the required position. 1. With the drum installed into the frame fit the junction box side coiler box support (45) in

place 2. Assuming the coiler box is ready assembled, pass the coiler guide bars (12) through the

bushed bores in the coiler box (29) and the coiler drive shaft (20) through the remaining bore, inserting this shaft into the coiler nut (26) which fits into a pocket between the coiler box side plates.

3. Fit the coiler shaft thrust washers (24) and coiler shaft spacers (25) 4. Approximately align the shoulders on the coiler guide bars and coiler shaft and fit the

coiler box ( J B side) bracket (6) and coiler box (motor side) bracket (7). Fit the coiler guide bar nuts (15). There should be minimal end float to the coiler guide shaft.

5. Fit the coiler motor drive shaft bearing (18) and the coiler drive shaft bearing (19) to the

coiler drive shaft. 6. Fit the coiler motor torque arm (46) to the coiler box motor side bracket. 7. Fit the coiler torque bolt (8) to the coiler nut 8. The drive motor is fitted with a mounting plate (28) and a Drive coupling (23), these are

mounted on the end of the coiler drive shaft, ensure the M5 grub screws are tight. 9. This assembly can now be fitted to the coiler supports (45 & 1) and the hydraulic hoses

connected to the coiler bulkhead plate (34).


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4 WINCH OPERATION 4.1 OPERATION There are 2 hydraulic valves and 1 electrical switch (item 9, drg. No. KA1843-0003) to control the winch. These are mounted at the same side as the drive motor. The electrical switch can be set to local or remote. If set to remote the coiler select valve must be set to auto. The winch can then be operated to pay in or out and the coiler will operate automatically. If the winch is to be operated locally, the electrical switch is set to local, the coiler select valve can be set to auto or manual and the winch can then be operated to pay in or out using the control valve levers. In an emergency situation the winch can be stopped by using the Emergency Stop Ball Valve (item 34, drg No KA1843-0002). This is situated below the controls, to the right of the hydraulic bulkheads. See figure 6. SAFETY PRECAUTIONS 1. This equipment must be operated in accordance with this manual, by experienced and

competent personnel. 2. Do not lift more than the safe working load. (As shown in Leading Particulars). 3. Do not operate outside environmental design conditions (See Leading Particulars). 4. Stand clear of the umbilical cable during hoist / lower operations. 5. The guards on the winch must be in place while the equipment is being operated. 6. The umbilical termination must be inspected regularly, and not allowed to become worn

or corroded. 7. Do not use any device to hold or wedge the control levers in position. 8. Ensure the equipment is maintained regularly in accordance with the maintenance

instructions. 9. Only one person should use the controls at any one time. 10. Prior to operating equipment check all communication links are operating correctly. 11. Ensure equipment movement paths are clear of all obstructions, tools, timbers, etc. 12. Beware of nip points.


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13. Ensure that the junction box is isolated before carrying out any electrical work on the equipment.

14. Avoid physical contact with oils and greases - use barrier cream. A safety data sheet is

included overleaf for the rust inhibitant 'Tectacote 205' which was smeared on all exposed metal surfaces during assembly.

If in doubt, ask: Lawson Engineers Limited Barras Lane Industrial Estate Dalston CARLISLE Cumbria CA5 7ND ENGLAND (U.K.) Tel: +44 (0)1228 711470 Fax: +44 (0)1228 711255 email :

[email protected] [email protected]

mailto:[email protected]



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5 MAINTENANCE 5.1 LUBRICATION 5.1.1 LUBRICATION SCHEDULE Part Number Description Method Application

Frequency (hours)

Drain/Flush Refill (hours)

Lube Ref.

KA1850-0001/3 Winch Drum Bearing Grease Gun Monthly 1 KA1850-0001/18 Coiler Drive Shaft

Brg Grease Gun Monthly 1

KA1850-0001/19 Coiler Drive Shaft Brg

Grease Monthly 1

KA1850-0001/4 Gearbox See below See below 2 KA1850-0001/4 Brake See below See below 3 KA1850-0001/26 Coiler Nut Grease Gun Monthly 4 KA1850-0001/20 Coiler Drive Shaft Brush Monthly 4 KA1850-0001/12 Coiler Guide Bars Brush Monthly 4 5.1.2 RECOMMENDED LUBRICANTS 1. Shell Alvania EPLF2 2. Autogear W (Gannon oils) 3. Shell Tellus 37 4. Rocol Tufflube Allweather Grease . 5.1.3 GEARBOX OIL CHANGES The winch drive gearbox (Part No KA1843-0001/4) is fitted with drain, filler and level plugs the locations of which are shown in the relevant proprietary information (Section 8).These are located adjacent to the gearbox mounting face The brake (Part No KA1843-0001/4) is fitted with drain, filler and level plugs the locations of which are shown in the relevant proprietary information (Section 8) .These are located adjacent to the drive motor mounting face Extreme care must be taken that these points are not transposed and the wrong lubricants used. The gearbox and brake oils should be changed after the first 50/100 hours of use. Subsequently, they should be changed every 1000-hours or annually, whichever comes first. A drip tray is provided beneath the motor/gearbox unit, into which the oil can be drained. This has a drain plug fitted so that the oil can then be drained off into a suitable container for disposal.


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Once the oil has been drained the gearbox case should be flushed with a suitable flushing fluid. To units should be filled until oil is sighted through the window on the level plug. 5.1.4 GENERAL PRECAUTIONS The following precautions regarding lubrication are advised : 1. During oil changes it is recommended that the inside of the casing be flushed out with a

suitable flushing fluid. 2. The oil should be changed when hot in order to prevent any build up of sludge deposit. 3. The oil level should be checked on a weekly basis when in use. 4. If more than 10% of the total capacity has to be added over a month check the casing for

oil leaks. 5. It is recommended that only the specified lubricant be used. Never mix synthetic and

mineral oils. An equivalent lubricant may be used, provided that the manufacturer can guarantee that it is an entirely suitable equivalent in every respect, and that responsibility for satisfactory operation is accepted by them.

TIPS ON HYDRAULICS See Danfoss Hydraulics Publication 5.2 MECHANICAL MAINTENANCE PROCEDURES 5.2.1 PAINTWORK The condition of the paintwork should be checked monthly and touched up when bare metal is exposed, to prevent corrosion. 5.2.2 FASTENERS Regularly check all bolts to ensure that they are secure and that locking devices are in place. Approximate torque values are tabulated below. Bolts should also be checked regularly to ensure that they remain in good condition and have not deteriorated due to corrosion. It is recommended that fasteners are coated in Tectacote 205 rust inhibitant.


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Table 5.2.2 Approximate Bolt Torque values (Nm)

Metric ISO Thread Strength Class DIN/ISO 898 DIN 13 8.8 10.9 12.9

M5 5.5 8 9.3 M6 9.3 13.9 16.2 M8 22.5 33 38 M10 45 67 78 M12 78 117 135 M14 126 184 216 M16 193 279 333 M18 270 387 459 M20 387 558 648 M22 522 747 873


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6 STORAGE PROCEDURES 6.1 MONTHLY STORAGE MAINTENANCE PROCEDURES 1. Check condition of paintwork ensuring that there is no bare metal and touch up where

necessary. 2. Check condition of rust inhibiting gel applied to hydraulic fittings and fasteners. Renew if

necessary 3. Grease all lubrication points as laid out in the lubrication schedule. 4. Drain off any water in the drip tray by removing drain plug in the rear of the winch frame. 5. Grease all exposed parts, (especially the coiler drive shaft). 6. Connect the winch to a hydraulic power pack and drive the winch backwards and

forwards for 15 minutes. 6.2 START-UP AFTER STORAGE. 1. Ensure system is fully greased, i.e. by carrying out the lubrication schedule. 2. Inspect all electrical junction boxes for possible water / condensation build-up. 3. Inspect all hydraulic hoses for inadvertent damage. 4. Inspect structure for inadvertent damage. 5. Ensure all bolted connections are secure.


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7 RECOMMENDED SPARE PARTS There follows overleaf a list of recommended spare parts. Lawson Engineers Ltd advise that the owners of the equipment keep in stock at all times in order to reduce downtime in the event of a breakdown. Lawson Engineers do not keep a stock of spares (there’s too many variants to allow us to do this) hence, it takes time to receive the items (worst case is a gearbox at 12-weeks approx). Prices are deliberately omitted from the list as they only remain current for a short time. Should a list of current prices be required for some or all of the items listed then please use the following procedure: 1. Remove the list from the manual, photocopy it and replace it. 2. Place a tick in the empty item box for the spares you require. An empty page has also been provided so that you can use this form to enquire about non-recommended spares (The details of which can be found in the parts lists - Section 9). 3. Post/Fax/scan and send the form with a covering letter/page to Lawson Engineers at the address/ number below. Lawson Engineers Limited Barras Lane Industrial Estate Dalston CARLISLE Cumbria CA5 7ND ENGLAND Tel: +44 (0)1228 711470 Fax: +44 (0)1228 711255 email :

[email protected]



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8 PROPRIETRY INFORMATION Information regarding equipment supplied to Lawson Engineers Ltd is included in this section to aid maintenance and repairs to the equipment. This information is listed in part number order (see parts lists in section 9).


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9 PARTS LISTS & DRAWINGS The listed drawings and their parts lists (where relevant) can be found on the pages following Winch Assembly & General Arrangement KA1843-0001 Hydraulic Schematic KA1843-0002 Electrical Schematic KA1988-0007

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