PUSNES Deck Machinery Installation Procedure

Title: Doc. No.: DM06001 Installation Procedure, Deck Machinery

Rev No: 05 Date: 08.07.10

Pusnes TM deck machinery Page 1 of 18

Installation Procedure, Deck Machinery

08.07. 10 05 Tables added in 5.2.3 and 5.2.4 KH - SEl 09.10.07 04 Chapter 5.3 Added, Logo Changed ThB 13.11.06 03 Figure 1.3 And Appendix Added ThB TS KH 13.09.06 02 Alignment Of Gear Case (EW) ThB - TS 18.05.06 01 Generally Updated ThB JHP KH 12.05.06 0 Initial Issue ThB TS KH

Date Rev Remarks Prep. Check Appr.


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Table of contents: 1 INSTALLATION PROCEDURE FOR DECK MACHINERY ...........................3

1.1 General .................................................................................................................3 1.2 Deck Machinery, General information for installation........................................3

2 ANCHOR- MOORING WINCH.............................................................................6 2.1 Alignment of Anchor and Mooring Winch..........................................................6

3.0 WINCH BAND BRAKE........................................................................................7 3.1 Adjustment to Brake Drum..................................................................................7 3.3 Brake Band Support .............................................................................................7

4 CABLE LIFTER UNIT (CU) ..................................................................................8 4.1 Alignment of Cable Lifter Unit............................................................................8

5 WINCH AND CABLE LIFTER UNIT COMBINATION....................................8 5.1 Alignment of Windlass ........................................................................................8 5.2 Angular deviation.................................................................................................9 5.3 Engagement of Claw Couplings ........................................................................12

6 TIGHTENING TORQUE AND FINAL CHECK ...............................................13

7 ENDSTOPPERS .....................................................................................................13

8 HYDRAULIC PIPING...........................................................................................14

9 ELECTRIC INSTALLATIONS............................................................................14

10 APPENDIX............................................................................................................14 10.1 Record Sheet Winch ........................................................................................15 10.2 Record Sheet Windlass ....................................................................................16 10.3 Gear Contact Record Sheet I/II........................................................................17 10.4 Gear Contact Record Sheet II/II ......................................................................18


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1 Installation procedure for Deck Machinery

1.1 General 1.1.1 Purpose of this Document This document covers the installation procedure for winches and cable lifter units of Aker Kvrner Pusnes AS Deck Machinery. This document combined with Working (Certified) drawings for actual project give instructions, guidelines and how to prepare and erect foundations, and also specifies how to install the actual units. 1.1.2 Referenced Documents Ref. Title/ Description 1 General Information, Deck Machinery 2 Working (Certified) Drawings for the actual project 3 Instruction for Lifting, Handling and Transportation, Deck Machinery

) IMPORTANT! This installation procedure together with the Working (Certified) drawings of each unit holds the guidelines and tolerances necessary for a safe installation of hydraulic and electric driven deck machinery. However, this procedure can be superseded by other procedures, which ensure the integrity of the below instructions.

1.2 Deck Machinery, General information for installation 1.2.1 The anchor/ mooring winches and cable lifter unit (CU) can be installed on

deck with an inclination of maximum 5 in any direction. 1.2.2 The winch and CU foundations have to be welded to the deck structure

keeping the top level of the foundation within a flatness tolerance of +/- 5,0 mm in any direction. Check by means of a levelling telescope, laser level, alignment plate or a piano wire. An accurate top level on foundation regarding flatness would reduce the alignment process, especially for the steel liners.

1.2.3 The top of steel liners and/ or plastic compound should be within flatness tolerance of +/- 1,0 mm.

Steel liners should be made in one part, this to avoid/ limit crevice corrosion between several plate layers. Steel liners are required for all CUs as plastic compound will crack and crumble away due to heavy vibrations when dropping the anchor.

1.2.4 Before lifting the winches and CU units onboard, check that the borehole pattern of all units and foundations are within the tolerance of +/- 1,5mm, see fig.1. Check also that the centrelines for the holes in length and transverse direction are perpendicular to each other.

1.2.5 Place the winches and CU units on the foundations resting on their adjustment screws. Allowance for liner thickness is to be taken into consideration, in


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general a maximum thickness of 30mm.

) Note! The thickness of the liner compounds to be in accordance with makers recommendation.

1.2.6 When positioned on the foundation, check that the foundation bolts slip easily through the bolt holes.

Fig 1.1 Geometrical tolerances for foundations Given geometrical tolerances are applicable for foundation top level with belonging hole patterns for Winch and Cable lifter Unit, combined/ or not.

1.2.7 Gear contacts between pinions and wheels for all gear types to be kept at a

minimum of 80% over the gear tooth length. 1.2.8 For electric driven winches special conditions needs to be considered;

Adjust height of gearbox in motor end with jack bolt on motor side (see fig. 1.2). Adjust jack bolt opposite from motor to 0.2 - 0.3mm clearance. Tighten foundation bolt opposite side of motor until the jack bolt with clearance is pressed against foundation. Tighten foundation bolt on motor side finger tight (~2Nm). Check the gear tooth contact. It should be minimum 80 % tooth surface contact (Use blueprint). If gear contact is less than 80 % adjust again with larger or smaller clearance on jack bolt opposite of motor. On the rest of the gearboxes, start with the final clearance from previous winch and adjust to get required gear contact. After pouring and hardening of chock fast, tighten securing nuts as usual. Make sure required gear contact is achieved. (Record data in enclosed Gear Contact Record Sheet II/II).


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Fig 1.2 Alignment of Gear Case, Electrical driven winches. For electric driven winches special conditions due to weight of motor needs to be considered, see1.2.8

Fig 1.3 Gear tooth contact. Specified requirements given in 1.2.7 and 1.2.8 are applicable for both open gears (Cable Lifter Unit) and closed gears (Hydraulic and Electrical Winches).


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Fig 2. Flatness requirements for foundation

2 Anchor- Mooring Winch

2.1 Alignment of Anchor and Mooring Winch Following has to be taken into consideration when aligning these units: 2.2 Adjust the jacking bolts on the gear case and the outermost bearing bracket to

correspond with the thickness of the liner compound/ steel liners to be used. For two or three drum winches check that the centre-bearing brackets are hanging loose.

2.3 When the main shaft is resting properly in both the gear case and the outermost bearing bracket, i.e. in 6 oclock position, tighten the foundation bolts in the gear case slightly. For electric driven winches special conditions needs to be considered, see details 1.2.8.

2.4 Check that the couplings will operate properly. 2.5 It is essential that the bearing bushings are parallel to the main shaft. There are

several methods to check this: 2.5.1 If no access from outside, remove the top cover of the split bearing and check

the gap each side is equal by using a feeler gauge. Tolerance: +/- 0.1 mm. 2.5.2 Use a feeler gauge to check the axial clearance between the bearing bracket

and the distance ring to be equal all way around the shaft within a tolerance of +/- 0.1 mm.

2.5.3 When finished, tighten the foundation bolts slightly and set back the top cover of bearing housing.


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Pusnes TM deck machinery

Fig 3. Radial clearing shaft/ bearing 2.6 Position the centre-bearing bracket(s).

As the bearing bracket is hanging loose turn the jacking bolts clockwise until the lower part of the bearing reaches the main shaft. This to be checked by positioning a dial gauge at the outermost bearing bracket. When the pointer shows a reaction, the bearing bracket is in position.

For positioning of dial gauge, see fig.1.1. 2.7 As for the outermost bearing bracket it is essential that the bearing bushing is

parallel to the main shaft. If no access from outside remove the top cover of the bearing housing and check the gap on each side and both ends of bearing. Tolerance: +/-0,1 mm. Then tighten the foundation bolts slightly and reinstall the top cover.

2.8 Gear contacts between pinions and wheels for all gear types to be kept at a minimum of 80% over the gear tooth length. This to be checked with blue paint or lead thread. For electric driven winches, see 1.2.8.

2.9 If adjustment is necessary to obtain specified gear contact, repetition of above alignment procedure to given requirements is obtained.

2.10 Coupling/ Clutches supported by the bearing bracket(s) to be adjusted to operate fully engaged/ completely free. When in correct position holes for the locking pin has to be drilled, one in engaged position and one in completely free position. Diameter holes, 14mm.

3.0 Winch band brake

Fig 4.1 Brake Anchor

3.1 Adjustment to Brake Drum Place the brake support in accordance with the foundation and check/do following: 3.1.1 The brake fits properly around the brake drum. 3.1.2 The brake is vertically correct and in centre of machined brake drum. 3.1.3 Tighten brake. 3.2 Fastening Brake Anchor 3.2.1 Tack weld the brake anchor to the foundation. 3.2.2 Check that the brake is in correct position according to above criterias. When placement is satisfactory,

Page 7 of 18 Fig 4.2 Brake Band Support

complete the welding. 3.2.3 Check the alignment.

3.3 Brake Band Support 3.3.1 When the brake is fully applied, check the gap between brake band and supporting bolt(s). Gap = 1-2mm (min-max), adjust if necessary.


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4 Cable Lifter Unit (CU)

4.1 Alignment of Cable Lifter Unit The cable lifter unit should be aligned separately. Following has to be taken into consideration when aligning this unit: 4.2 Position the cable lifter unit on its four jack bolts. Adjust the height to

compensate for the thickness of the steel liners, refer to 1.2.3. 4.3 Check that the position of the chain pipe is in accordance with the

specification given on the installation drawing for the unit. 4.4 Driving shaft and driving shaft bearings:

The driving shaft has to rest in the bearings at about 6 oclock position and to be parallel with the inside of the bearing bushings. This to be checked by using a feeler gauge directly into the bearings and checking the gap to be equals both sides. Remove top cover of bearing housings to check the gap if no access from outside is possible. Tolerance: +/- 0,1 mm.

4.5 Driving shaft equipped with a mooring drum: Start with adjusting the jack bolts to compensate for liner thickness. Adjust the jack bolts clockwise until the shaft is resting at the 6 oclock position in the bearing bracket. In correct position, the shaft shall rest with equal spacing in all three bearings. This to be checked by using a feeler gauge in the two bearings on cable lifter unit. Remove top cover of bearing housings to check the gap if no access from outside is possible. Tolerance: +/- 0,1 mm.

4.6 Gear contact between the main wheel and pinion to be checked with blue paints or lead thread.

5 Winch and Cable lifter unit combination

5.1 Alignment of Windlass The cable lifter driving shaft and the anchor winch main shaft are to be aligned as follows: 5.1.1 Start with aligning the cable lifter unit and continue with the anchor winch, see

section 4, 2 and 3 for instructions. 5.1.2 The horizontal offset tolerance between the two shafts is +/- 0.1 mm. 5.1.3 The main shaft of anchor winch should preferably be 0,2 - 0,3 mm higher than

the driving shaft of the cable lifter unit. This due to the fact that the windlass driving shaft will be lifted up and come into contact with the upper part of the bearing when the cable lifter is under tension.


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5.1.4 Above demands can be checked by using a dial gauge. Check points, four positions 3-6-9 and12 oclock around the outside of the two couplings.

Fig 5. Vertical offset, Winch and cable lifter combination

) Note! Excepted are cable lifter units of CUO type (driving shaft placed at the opposite side). For these units the shafts to be in line.

5.2 Angular deviation 5.2.1 The angular deviation between the Winch main shaft and the driving shaft of

the Cable Lifter Unit is to be kept within a tolerance of 0,1 degrees.

Fig 6. Angular deviation between CU and Winch (horizontal and vertical) 5.2.2 There are several methods to check this: 5.2.3 With use of a feeler gauge. Measure gap between the shaft ends of the shafts/couplings. Guideline for the checking:

0,1 degrees deviation make 0,175 mm over 100 mm.

Measure the diameter (D mm) for shaft or coupling and use this formula to calculate the maximum gap or use the table below:

.100175,0 mminGapD =


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Shaft / Coupling diameter

(mm)

GAP (mm)


(mm)

GAP (mm)


(mm)

GAP (mm)

100 0,175 260 0,455 420 0,735 110 0,193 270 0,473 430 0,753 120 0,210 280 0,490 440 0,770 130 0,228 290 0,508 450 0,788 140 0,245 300 0,525 460 0,805 150 0,263 310 0,543 470 0,823 160 0,280 320 0,560 480 0,840 170 0,298 330 0,578 490 0,858 180 0,315 340 0,595 500 0,875 190 0,339 350 0,613 510 0,893 200 0,350 360 0,630 520 0,910 210 0,368 370 0,648 530 0,928 220 0,385 380 0,665 540 0,945 230 0,403 390 0,683 550 0,963 240 0,420 400 0,700 560 0,980 250 0,438 410 0,718 570 0,998

5.2.4 An alternative is to place a ruler on one of the couplings and measure the gap

between ruler and shaft at two points with a distance of l . To obtain certain accuracy, l should be at least 200mm.

Max allowable deviation to be calculated for a distance l by using the below formulae or the table values:

.100175,0 mminDeviationl =

l (mm)

Deviation (mm)

l (mm)

Deviation (mm)

l (mm)

Deviation (mm)

200 0,350 310 0,543 410 0,718 210 0,368 320 0,560 420 0,735 220 0,385 330 0,578 430 0,753 230 0,403 340 0,595 440 0,770 240 0,420 350 0,613 450 0,788 250 0,438 360 0,630 460 0,805 260 0,455 370 0,648 470 0,823 270 0,473 380 0,665 480 0,840 280 0,490 390 0,683 490 0,858 290 0,508 400 0,700 500 0,875 300 0,525


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5.2.5 With use of a dial gauge. Attach a dial gauge to the cable lifter driving shaft, see fig. 7. By measuring the offset on the winch driving shaft at two points with distance , alignment and angular deviation is given. )100(min mml

Instructions: Rotate the cable lifter driving shaft and measure the offset on the main shaft of the winch.

Allowable offset, vertical, 1.posv : +0,2-0,3mm (12 and 6 oclock) Allowable offset, horizontal, :1.posh 0,1mm (3 and 9 oclock)

Move the measuring point ( l ) to Pos 2 figure 7.

Allowable offset vertical, 2.posv : lv pos 100175,0

1. (12 and 6 oclock)

Allowable offset horizontal, :2.posh lhpos 100175,0

1. (3 and 9 oclock)

Fig 7. Alignment of windlass with use of dial gauge 5.2.6 When dial gauge is placed on claw coupling, use a wedge lock to avoid radial

movement between claw coupling and shaft, see fig.8. To avoid damage on shaft and claw coupling, use a wedge lock made of brass

or copper.


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Fig 8. Radial locking of claw coupling 5.2.7 Use of two dial gauges at pos1. and pos.2 simultaneously would simplify the

aligning process.

5.3 Engagement of Claw Couplings 5.3.1 Inaccuracy in alignment of main shaft and driving shaft would lead to a radial

force acting on one claw face, instead of the desired torque transmission (force equally distributed on two claw faces). If the radial force acting on only one claw face it could result in overload and severe damage of claw face, shaft and bearing bushings.

5.3.2 Control claw contact with a feeler gauge or marking colour. Turn driving shaft

(CU) in pull in direction to obtain pressure against contact face (area of engagement) on claw coupling (main shaft on the anchor winch). Measure and note gap at A and B.

5.3.3 Since there is two possible ways of engagement of claw couplings in each rotating direction, rotate the driving shafts (CU) 180 degrees, and make new engagement. Repeat procedure in 5.3.2.

5.3.4 If there have been gaps more than 0,8 mm between the claw couplings contact areas in 5.3.2 and 5.3.3 improve the coaxial alignment between the shafts and repeat procedure in 5.3.


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6 Tightening torque and final check The winches and cable lifter units are now ready for moulding the liner compound (winches) or making the final steel liners (cable lifter units).

) Note! All hydraulic pipe connections to be made after the compound is properly hardened and the foundation bolts tightened to the specified torque.

6.1 When moulding, make sure that the jack bolts are not fastened in the liner

compound. This can be done by covering or greasing the treaded part of the jack bolt in the moulding area.

6.2 After the liner compound is completely hardened and/or the steel liners are finished, loosen the jack bolts slightly so the entire weight rests on the foundation.

The foundation bolts shall be tightened according to specified torque, see specification in the Working (Certified) Drawings.

6.3 As a final check of the alignment, all winches have to be run for 15 minutes in each direction at varying speed, with the bearing temperature monitored.

6.4 After running the test of the Cable Lifter Unit: Control/ adjust brake band support according to point 3.3.

7 Endstoppers 7.1.1 Endstoppers should be fitted in accordance to the Working (Certified)

Arrangement Drawings. Different arrangements can be used. Pusnes recommend one of the alternatives shown in fig.9.

7.1.2 The endstoppers should be fitted with a clearance to the thrust edge. The clearance must be wide enough to allow welding all around. Make wedges for each endstopper to fit clearance. One edge being chamfered to leave room for welding. Weld endstoppers to the foundation, drive the wedge home and tack weld together.


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Fig 9. Alternative arrangement of endstoppers

) Note! 1. Bolt, wedges, steel- or compound liners and endstoppers: Yards supply. 2. The fastening bolts may be mounted with head up or down.

8 Hydraulic Piping Pipe dimensions and arrangement should be according to Working (Certified) drawing: Pipe Diagram. For further information see Pusnes instructions for hydraulic pipe installations.

9 Electric Installations For installation of control columns, electric connections etc., refer to electric drawings and instructions included in the Working (Certified) drawings.

10 Appendix

10.1 Record Sheet Winch

10.2 Record Sheet Windlass

10.3 Gear Contact Record Sheet I/II

10.4 Gear Contact Record Sheet II/II

1 Installation procedure for Deck Machinery1.1 General1.2 Deck Machinery, General information for installation

2 Anchor- Mooring Winch2.1 Alignment of Anchor and Mooring Winch

3.0 Winch band brake3.1 Adjustment to Brake Drum3.3 Brake Band Support

4 Cable Lifter Unit (CU)4.1 Alignment of Cable Lifter Unit

5 Winch and Cable lifter unit combination5.1 Alignment of Windlass5.2 Angular deviation5.3 Engagement of Claw Couplings

6 Tightening torque and final check7 Endstoppers8 Hydraulic Piping9 Electric Installations10 Appendix 10.1 Record Sheet Winch10.2 Record Sheet Windlass10.3 Gear Contact Record Sheet I/II10.4 Gear Contact Record Sheet II/II

PUSNES Deck Machinery Installation Procedure

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