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    © All Rights Reserved
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    18 views201 pages

    Davit 60 Ton Manual

    Uploaded by

    ES Rouza

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    I. GENERAL DESCRIPTION A. INTRODUCTION (By DAVIT SPECIFICATIONS Il, OPERATING PROCEDURES A, BOOM UP OPERATION BOOM DOWN OPERATION . WINCH UP OPERATION WINCH DOWN OPERATION SIMULTANEOUS DAVIT OPERATION MAXIMUM LOAD LIMITING CIRCUIT INTENANCE GENERAL TROUBLESHOOTING SETTINGS AND ADJUSTMENTS PARTS -- HYDRAULIC PARTS -- MECHANICAL PARIS -- ELECTRICAL Tis I, GENERAL DESCRIPTION A, INTRODUCTION é cnuk The HSMC Pipe Laying Davit System is comprised of five 60 ton ee: Stationary, and one 60 ton swivel pipe handling devices controlled from either individual or master control stations. The system is designed to handle pipe from the side of a pipe laying barge as used by the offshore pipe laying industry. The Davits are hydraulically operated, electrically controlled devices using electrically operated solenoid valving for the distribution of hydraulic power. By virtue of the control system, the Davits may be used individually either at the local or master control station for raising, lowering or : positioning loads, suchas the stinger, or loads requiring the use of < a single Davit. The Davits may be used simultaneously from the master control station for raising and lowering a continuous length of pipe. | Succeeding sections of this manual describe in greater detail the individual components which mak® up the HSMC Pipe Laying Davit System, including operational and maintenance procedures. A draw- ings section. aeplatiog the equipment and an appendix providing comp- onent details are also included. a2 ole r I The 60 Ton Stationary and 60 Ton Swivel Davits are composed of welded steel rectangular shaped pedestals, welded steel booms, fe and intebrally mounted hydraulic power units with hydraulic cylinders to raise and‘lower the boom, The fixed and swivel davit construction is basically the same, Dio However, the swivel Davit has a base construction to house a swivel 227s. bearing and power means to permit the davit to swivel under load. The boom is pin connected to the pedestal base at its lower end. The hydraulic cylinder is pin connected at its rod end to the upper end of the boom, and at its blind end to the top of the rectangular pedestal. The hydraulic power unit is mounted to the base of the pedestal on its left-hand side when viewing the Davit from the rear. The unique feature of this device is the boom winching system. This is a gearmatic roto-versal winch system containing automatic braking features. The winch system has two hoisting speed selection. Each speed selection gives a constant hoisting speed for that selection. The local control station is mounted to the right-hand side of the Davit for use of individual localized loads. The Davit power unit must be started and its load lifting capability set at the master control station. ae The operator may then position the boom, operate the winching system, Btn monitor the load and,shut down the power unit from the local control station. When the Davits are controlled from the master control station, they may be operated either individually or simultaneously. Each Davit's power unit is started and its load capability set individually. By proper positioning of the selector switches, the operator may then position the boom, operate the winching system, monitor the load, and_shut down Bee ieiielsidividually or simultancously.. The following eon tosen are located on the Master Console: (1) EMERGENCY STOP - When depressed will de-energize motor starter circuits and stop all electric motors. (2) NO LOAD, AND FULL LOAD selector switch - Energizes solenoid valves, which determines speed and load conditions. (3) LOCAL MANUAL, MASTER IND. AND MASTER SIM. selector switch - Allows Davits to be controlled individually frorg local station or individually at Master Console, or simultaneously at Master Console, Station.A'.controls are used for "Master Simul- taneous Operation. " (4) ON = OFF - Switch - These switches are used to isolate power on each Davit. ® (6) BOOM. - switches - Used only to control the boom operation. Station 'A' Boom stick is used to boom all Davits simultaneously + when in "Simultaneous Operation. " Es (7) SWINGER SWITCH - Activates the swivel (swinger) control on Ga the swivel Davit. NOTE: The davit can be rotated only from the local control panel at the davit. (8) RUN lights Indicates when run stage of motor starter circuit is energized. (9) WINCH SWITCHES - (Joysticks) - -- Activates the wireline winch to raise or lower the load. Station "A"' winch stick is used to operate all davits simultaneously when in "Simultaneous Operation." (10) LOAD INDICATOR switch - These switches are ysed to set in- dividual Davit loads by adjusting electrical contacts on dial to the desired maximum load on each Davit. (11) OVERLOAD - light - These lights indicate when LOAD INDICATOR switch’ has reached its load setting. (12) BOOM-WINCH - This switch selects the boom or winch mode. (13) METERS OF HOOK TRAVEL-These dials indicate the meters of travel of the wireline block. An overhead panel, located over the Master Console, contains the 1 y Martin-Decker Load Gauges. These gauges indicate winch load in kilograms. i @ B, DAVIT SPECIFICATIONS Maximum Load Boom Swivel Range Services Required Maximum Hydraulic Fluid Temperature Maximum Hook Speed 54,500Kg 359° Max, Swivel Davit Only 460 VAC, 3 phase, 60 cycle 110 VAG, 60 cycle Cooling Water Supply ee Ly 165° F in Reservoir 180° F at Case Drains Pane 10 FPM -- Full Load 20 FPM -- No. Load \ g.tm/on, = 1025/4 ql we Ise IL OPERATING PROCEDURES (Reference Drawing D-11614 & 11436), ‘The following describes Davit hydraulic circuit operation under six basic headings: v -- Boom Up -- Boom Down -- Winch Up Vv v == Winch Down -- Simultaneous Davit Operation ~ Serene Maximum Load Limiting Circuit“ A. BOOM UP OPERATION ‘The following circuit description is based on operation from the Master Control Console in the "Master Individual" Mode: (1) Select mode of operation desired; in this case, place in "Master Individual. "' (2) Blace ON - OFF switch in ON position for Davits that will be used. (3) Push START button (on lgcal control panel) to start motor. (4) Put Boom -_Winch switch in BOOM. position, (5) Push BOOM joystick to UP Position. BOOM joystick energizes solenoids "1" & "3" simultaneously. Solenoid '"1" brings vane pump (item 3) up to pressure and solenoid "3" (Valve #7) directs pumps output to rod end of Davit cylinder through free flow side of pilot check valve (Item 8). Fluid from ram end of cylinder is then directed to tank through solenoid controlled four-way valve (Item 7). BOOM DOWN OPERATION Follow steps (1)(2)(3) & (4). as described in Section A. This will give mode of operation, power on, and electric motor started. ‘With these steps completed, place BOOM joystick in DOWN position. —— ee This will energize solenoids! and 2 simultaneously. Solenoid ''1"" pressures up vane pump (Item 3) as described in Section A, Solenoid Por rienced ised, will ahite epool tn foureway watva Citeea 7) Bs direct fluid to ram end of cylinder. Fluid in rod end of cylinder is trapped by pilot check valve (Item 8) until pilot pressure from ram side builds up to open overcenter valve (Item 8). When fluid passes through overcenter valve (Item 8), it is directed back to tank through solenoid controlled four-way valve (Item 7). WINCH UP OPERATION WINCH UP operation is divided into two groups: NO LOAD, and FULL LOAD, We will consider WINCH UP -- FULL LOAD fi keeping in mind that we are still working from the Master Console. (1) Place selector switch in "Master Individual." (2) Place load selector switch in FULL LOAD, (3) Place Boom-Winch switch in WINCH position, (4) Power is ON_and Davit electric motors are running. Push individual winch switch to"UP" position. This will activate solenoid and ''6" which will direct the fluid flow from the low volume side of the double pump (Item 3) to the "UP" side of the winch motor, The return flow from the winch motor is then returned through the heat exchanger and to the reservoir, The winch contains an automatic braking system which locks the winch until hydraulic pressure builds up to a predetermined setting. Thus the winch will drive (either up or down) only at the rate corresponding to the fluid supply rate. When in FULL LOAD mode the hydraulic fluid flow from the high volume section of the pump (Item 3) ie being returned to tank at no pressure through valve #11, WINCH UP operation in NO LOAD is similar to full load except solenoid A and solenoid £6 are activated. This allows the flow from the high volume side of the pump to flow to the winch motar. When in the NO LOAD condition the circuit pressure is limited to 127 Kg/Cm? by the relief valve (Item 11), WINCH DOWN OPERATION is functionally the same as WINCH UP, except for directional control, In winch down conditions solenoid 5 Waive 12) is activated instead of solenoid 6 (Valve 12). Thereby causing the winch motor to turn the opposite direction and play out line instead of pull in line, SIMULTANEOUS DAVIT OPERATION Be athe The SIMULTANEOUS Davit operation is carried out at the Master Console using controls for Davit 'A', When booming up or down in SIMULTANEOUS, the hydraulic circuit aids : 7 Feacts the same as in "Master Individual" function, When Davit 'A! Joystick is placed either in up or down position, an electrical interlock energizes all selected boom circuits and boom directional valves simultaneously. This will let the Davit arms carry a load in or out at the same rate, When winching up or down, the hydraulic circuit will react the same as in "Master Individual." When Davit 'A' joystick is placed either in UP er DOWN position, an electric interlock energizes all selected winch circuits and winch directional valves simultaneously, This will cause each Davit winch to play out or take up line at the same rate. MAXIMUM LOAD LIMITING CIRCUIT An electrical interlock circuit is provided to limit maximum loads that can be placed on individual Davits. This is performed by the Murphy Pressure switches located in the upper section of the Master Console. When "Raising" a load simultaneously, one Davit may tend to outrun the others. When this happens, the faster Davit will steal load from the other Davits and will result in reaching maximum load setting of the Murphy switches, At this time, the Murphy switch electrical contacts will "make", which will de-energize the activated solenoids which will by-pass or deactivate the hydraulic circuit and allow the winch or boom to take the hold or static position, thus over-riding the "UP" position of the joystick. This will occur on Davit A, B, C, D) E or F, which- ever is overloaded, causing this Davit load to stop moving up and allow eoe RT the other Davits to regain their shear of the load, At this time, contacts in the Murphy switch will open, allowing the joystick to take over and the \ Davit load to proceed to be raised in the normal manner. When "lowering" a load simultancously, the "slower" Davit will tend to steal the load, causing its Murphy switch contacts to "Make, " which will de-energize the "faster" Davits solenoids. This will cause the "faster"! Davits' winch drives to stop momentarily, allowing the one "slower! Davit to catch up and reduce its load. The other four Davits that are hay momentarily stopped will resume normal operation, anys a NN Il, MAINTENANCE A. GENERAL This section contains information on normal scheduled maintenance procedures for the 60 Ton Davit System, Personnel are cautioned not to perform corrective (unscheduled) main- tenance on equipment that is operating satisfactorily. %. Before attempting any repairs, study the hydraulic schematic and the electrical schematic and the "Operating Procedures"! to become familiar with component configurations. When a hydraulic component must be removed for repair or replacement, the open lines must be capped to prevent Ghee ate of the fluid. Always insure that Sure TS Zerg before attempting any removal or repair procedure, Never torque fittings or connections while lines are pressurized as this may rupture lines and result in injury to personnel. Set the appropriate circuit breaker to OFF and tag with a notice requiring open circuit condition to prevent accidental application of power to the Fa bo system while maintenance procedures are being performed. Inadvertent starting of the equipment during maintenance procedures may result in injury to personnel. iio t WARNING Only personnel qualified to work on hydraulic systems shall perform corrective maintenance on the hydraulic portions of the system, Only personnel qualified to work on electrical systems shall perform corrective maintenance on the electrical portions of the system, Hydraulic systems require very little maintenance. - The primary A aire ‘ 445 tres maintenance factors encountered in any hydraulic system are related to maintaining proper cleanliness and condition of the hydraulic fluid, cleaning or replacing strainer or filter elements, and lubricating * motor bearings. ‘The hydraulic components of the Davit System are lubricated by the j hydraulic fluid. System reliability is primarily dependent upon keeping _ the hydraulic fluid clean, and on maintaining the lines leaktight at system operating pressyres. Loose fittings will allow air to enter the lines. This & Ry can result in erratic, noisy operation and in pump cavitation, with conse- quent degradation of system operability. Keeping hydraulic systems operable is primarily dependent upon keeping the fluid clean and on maintaining it at the proper temperature, The moving parts of pumps and valves are lubricated by the hydraulic fluid. Fluid contaminated with dirt, metal particles, aa or other foreign 30. b matter will damage the fine tolerances of these components. Therefore, ation control is of prime importance in maintaining system Because lubricity and viscosity of fluid is a function of 22 temperature range for proper system operation, excessive temperature creates changes in the chemical structure of hydraulic fluid. For instance, acids are formed which attack O-Rings, seals and so forth, with consequent degradation of performance. System operating temperature should be held ew ene 130° - 180° F. ‘ betwe: Before opening a drum of hydraulic oil, when adding fluid to the system, clean the top of the drum, using particular care to clean the area sur- rounding the closure. Use clean, Lint-free wiping cloths, Use only transfer containers and hoses which have been cleaned and flushed with a recommended flushing oil prior to use. All hydraulic fluid introduced into the reservoir 7 Never strain fluid through cloth.’ Lint thus introduced into the system , | can clog small drilled passages in the valves and change the hydraulic bal+ ance, causing erratic operation or rendering these components inoperative.” i When storing the reserve supply of fluid, observe the following precaution: (1) Store drums of new fluid on sides rather than upright, (2) Store drums out of the weather in a clean area, (3) Keep containers tightly closed to avoid condensation of moisture inside and to prevent the entry of contaminants. O-Rings, Seals and Gaskets O-Rings, seals and gaskets are selected on the basis of their compatibility ia ; * ; ye with the hydraulic fluid. Replacement parts must be of the same material as new parts. O-Rings must be removed and replaced with care to avoid damage. Replace any O-ring that has been nicked, cut or deformed, Filtration ‘The strainers and filters incorporated in the hydraulic system trap | contaminants and extract them from the circulating fluid. Unless these filters and strainers are kept clean, fluid flow is reduced and speed of operation is affected adversly. All filters and strainers must be cleaned or replaced by a scheduled periodic maintenance, -14- ————= PERIODIC MAINTENANCE AND INSPECTION HYDRAULIC AND MECHANICAL SYSTEM ¢ PART LOCATION MAINTENANCE FUNCTION PERIOD Hydraulic Fluid Reservoir Observe fluid level in sight gauges; Prior to each replenish when level reaches start-up and lower gauge. periodically while running Reservoir Drain off accumulated sludge and Six Months water from reservoir tank bottoms Reservoir Collect oil samples for analysis Yearly Suction Reservoir Inspect; clean as required £00 operating Strainers earl Filters Power Unit Inspect; replace element as required Three Months Electric Motor Coupling System Piping Tubing and Connections Pressure Gaug Load Gauges, & Temperature Indicator Gearmatic Winch & Roto- Versal Gear Boxes Power Unit Throughout System Control Panels & Reservoir Base Check motor-pump coupling align- Yearly ment Inspect for damage and leaks;repair Daily when as required operating Calibrate Yearly Final Drive assembly-Drain and re- Yearly place with SAE 90 to the level of the filler plug. Primary drive assembly- Drain and replace with same oil as is used in the Hydraulic system. aise -16- oo oe ====—= PERIODIC MAINTENANCE AND INSPECTION —— PART Electric Motor Electric Motor Electric Motor Electric Motor Insulation & » ELECTRICAL SYSTEM LOCATION Power Unit Power Unit Power Unit Power Unit Wiring MAINTENANCE FUNCTION Visual inspection: General Check outside temperature of motor against data,plate on mptor Listen for motor bearing noise Check current of each leg of motor winding Check insulation to ground 2176 PERIOD Weekly when operating Weekly when operating. Weekly when operating Yearly Yearly B. TROUBLESHOOTING The Davit System is composed of rugged, trouble-free operating units, If the recommended preventive maintenance procedures are followed, * little corrective maintenance should be required, The basic reasons for hydraulic system failure are electrical mal- fanctions and hydraulic malfunctions. In general, it is preferable to eliminate possible electrical causes first, since these can be corrected without opening the hydraulic lines and exposing the system to contami- nants. Also, it should be noted that often, what appears to be a mal- function is often due to improper adjustment of a component, thus whenever possible, adjustments should also be checked prior to opening the hydraulic lines. When a hydraulic component must be removed for repair or replace- ment, the open lines must be capped to prevent contamination of the hydraulic fluid. Study the system troubleshooting chart to become familiar with typical indications of abnormal system functions, and study the circuit schematics and the "Operating Procedures" before attempting to make any repairs. : Sige, ve === GENERAL HYDRAULIC TROUBLESHOOTING CHART =———= SYMPTOM. Excessive pump noise or erratic operation PROBABLE CAUSE Pump cavitation because of: a 2. 10, a. aes Clogged suction filter element Fluid too cold Formation of vapor Fluid aerated due to low level Suction line joint or pump shaft seal allowing air to enter line Lines not bled Local restrictions in suction line; such as, partly closed valve or damaged pipe Faulty alignment or loose coupling Worn pump Pump shaft seal allowing entry of air 2 Broken pump shaft or rotor Pump case not filled Sts a3 10. ue ee REMEDY __* Remove, clean or replace Heat fluid to operating temperature Cool fluid to operating temperature Add fluid Test by pouring oil on suspected areas while running and listen for change in sound; Repai Bleed system and add fluid as needed Open valve, repair, or replace valve Re-align or refit Repair Replace shaft seals Repair Fill SYMPTOM ( “sdequate pressure, pressure or Flow Pulsations 4. oe PROBABLE CAUSE Pump not primed Pump running hot due to wear or damage Relief valve set low Relief valve not operating because of dirt or defect Directional valve not shifting electrical failure, dirt, or defect Incorrect electrical terminatien-pump reversed Air pockets in system caus- ing erratic and spongy pres- sure Leak in hydraulic control system a REMEDY. See steps 4,5, & 6 on page 21 Repair pump Adjust setting Clean and repair or replace Locate defective valve clean, adjust or replace Correct wiring Bleed air from system Repair Oil excessively hot (above 180°F) Relief valve set too low Relief valve malfunction Pump running hot due to wear or damage Oil not being passed thru oil cooler, ” eeo= Adjust settings Clean or repair as required Repair pump Open valves to pass oil thru cooler. : ee SYMPTOM PROBABLE CAUSE REMEDY Power Unit will not 1, 440 volt supply dead 1, Check breaker in ( ort control room 2, 110 volt control dead 2. Check fuses in con- troller box, replace as necessary 3. Defective relay . Replace relay Power Unit will not Pressure relief valve mal- 1. Reset pressure setting Develop Pressure adjusted 2, Pressure relief valve stuck 2, Clean or repair as open because of dirt required 3, Solenoid operated vent valve. 3. Repair or replace failure 4. Insufficient fluid in reser- 4, Add fluid voir > “External leakage past pump shaft Shaft packing worn aie Replace packing per vendor's instructions Fer “=== GENERAL ELECTRICAL TROUBLESHOOTING CHART — ? SYMPTOM PROBABLE CAUSE REMEDY S Electric Motors will 1, No electric power 1, Check power source not start 2, Tripped breaker 2. Reset circuit breaker Motor will not pull in 1. Overloads kicked out 1, Allow time to cool, Check for binding,. | Check current load on wmotor, disconnect coupling to motor; if current drops tc normal overhaul pump, Faulty or no pilot 1. No electric power I< Check aouree ? light indication(s) 2, Burned out fuse 2. Replace i 3. Loose connection 3. Correct 4, Burned out bulb, 4. Replace 5. Switch malfunction 5. Correct eae SETTINGS AND ADJUSTMENTS ‘This portion of the manual should be considered as important as the °perational section. If the numerous pressure control valves in thie circuit are not properly kept in adjustment, a waste of horsepower, malfunction of valves, and wear of equipment can result, There are three different adjustments to make in the hydraulic circuit, All adjustments can be made at the Puming Unit mounted on the Davit base. Hem 5 - To adjust this solenoid controlled relief, have electric motor running. Screw relief valve handle all the way out, manually activate solenoid #1 with a welding rod, and slowly screw handle of relief valve down until gauge reads 176 2. Lock adjustment 2%60 P3/, handle in this position by the lock nut, Valve should be set. Hem 11 - To adjust this solenoid controlled relief, have electric motor running. Screw relief valve handle out, Manually activate solenoid #4 with a welding rod, and slowly screw handle of relief Valve should be set, eae £70 T Jo0yg NI aazmoMnY anyouioads sy Lag asoamna ANY 401 YO ONIIRIOVINNYW. 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