UTS 35 Pioneer Rd Postal Adress: untae Jurong Point Post Oca ‘Singapore 628503, PO Box 205 Tel: +05 68618006, ceczan34 ‘Singapore 916407 Fax +85 68632885 E-mail enquiries @underwatertechnologyservices.cam UNDERWATER TECHNOLOGY SERVICES (S) Pte Ltd SAT-04 HRC DAVIT HPP Manual Underwater Technology ServicesUnderwater Technology Services (S) Pte Ltd SAT-04 HRC DAVIT HPP Manual CONTENTS 1.0 Introduction 2.0 Technical Information 3.0. Hydraulic Schematic of System 4.0 Ball-valve location Drawing 5.0 Electrical Schematic of System 5.0 Set up Procedure of System 7.0 Operating Manual for Davit HPP 8.0 General Maintenance Information 8.0 Hydraulic Power Pack Start Up Check ListUnderwater Technology Services (S) Pte Ltd ( SAT-04 HRC DAVIT HPP Manual 1.0 Introduction HRC Davit hydraulic power pack is designed to operate the HRC Davit for emergency purposes and to launch the divers into the sea in a hyperbaric chamber. This power pack is not used for primary operation of the saturation diving system but rather for @ short period for launching and periodic testing. The objective is to provide a falisafe power pack. The power pack consists of the following item: = Electric Motor + Hydraulic Fluid Immersed Pump © Reservoir Tank * Hand Pumps ‘+ Hydraulic Bladder Accumulator ‘© Directional Control ValveUnderwater Technology Services (S) Pte Ltd ~~ (UTS SAT-04 HRC DAVIT HPP Manual 2.0 Technical Information Electrical Supply: 440V 634 5O/60Hz Dimension 2500 x 1450 x 2450 Weight: 157 Reservoir Capacity 400 Litres Hydra Oi SPC Hito HD 68 Pump Variable Piston Pump(Oil Immersed) (atovso71) Electric Motor Electric Motor 3PH/S80-415V 50Hz Pressure Relief Valve 240 Bar Control Valve ‘Open Centre Valve Block Accumuators 50 L Cylinders @ 300Bar WPUnderwater Technology Services (S) Pte Ltd s ‘SAT-04 HRC DAVIT HPP Manual The Sat system Davit hydraulic power pack supplies power to the davit for extending hydraulic cylinders and winches for raising and lowering the HRC into the sea. A stand alone power pack connected to the Davit at al times provides the hydraulic power for launching the HRC at any moment. The launching of the HRC is controlled from the power pack with hoses interconnected between the power pack and the davit. In its as delivered configuration, submerged pump delivers to the control block and the 4 accumulators. It extends and retracts the hydraulic cylinders and operates the winches up and down. A back up will be the hand pump to pressure up the accumulators in case of power failure. And the hydraulics will be operated from the accumulators, The hydraulic pump has no cooling system as it is not used on timely basios but rather for emergency and therefore does not require cooling. There will be periodic function test to ensure the equipment is working however the pump must not run for long duration during the function test. The cross line relief valves fitted on Supply & Return lines protect the system from over pressure. When the Supply line is the pressure line it will dump hydraulic oil back into the Retum line in case of overpressure. This ensures that the closed loop system is not starved of oil. The cross line relief valves are set at 210bar. 10 micron low pressure spin on element filters are fitted to the main pump suction line and the hand pump suction lines Hydraulic oil used is SPC Hito HD 68 however there are many compatible hydraulic oils available. Reservoir Tank holds 400L of hydraulic oil. The accumulators will use up 2001. of hydraulic oil. ‘Therefore during operation, hydraulic tank only has half of the hydraulic oil Figure 1: Pump Layout 1 Electric Motor 380/415V. S0/60Hz. 2 Fixed displacement axial piston open circuit pump; WP 200bar; Flow 100lpm @ 4500 rpm Relief valve set at 210bar Hydraulic Pump suction filter Suction strainer aneTL anouisy9s maps oe lenueW ddH LIAVG UH ¥0-LVS SL PY 81d (S) seo1,1eg ABojouyse seyeMepun,wORBDEyNUDPT ATE A TIPE OF lenueW ddH LIAVG O¥H P0-LVS SL P¥1 8d (S) Seales ABojouyde! JeyeMUepUuN,Streaiaqs Teoma O'S Jenuey ddH LIAVG DUH bO-LvS 4 Pr eld (s) seaiaiag ABojouyo4 1oyeMuopuNUnderwater Technology Services (S) Pte Ltd SAT-04 HRC DAVIT HPP Manual 6.0 Set up Procedure of System Connect all flexible hoses between the power pack and davit based on drawing Connect main and essential electrical supply cable to operate electrical motor. See Fig 2 Fill up hydraulic tank with hydraulic oll to the maximum. See Fig 3 Follow operating instructions for the power pack to charge the accumulators. Connect hose from Nitrogen cylinder to accumulator to maintain bladder pressure of 60Bar Ensure accumulators are always charged up to 200Bar Figure 3 Level Gauge for ReservoirUnderwater Technology Services (S) Pte Ltd UTS SAT-04 HRC DAVIT HPP Manual 7.0 Operating Manual for Davit HPP Primary Hydraulic Power System 1,_ Pre start up checklist Ball Valve | _ Status Closed Closed Closed Closed Closed Towards Fi Towards G1 Towards H1 Towards Id Towards J1 ‘Towards Ki Closed Closed Closed zlz|e|xl-|-|zla/a|m|ola|m|> 2, Start up hycraulic power pack by pressing the start button. (There are two power supplies to the power pack. Switch between main power supply or back up supply on the panel before turning on the power pack) 3. Ensure accumulators are fully charged up to 200bar before commencing periodic testing to censure operational readiness. See Charging Procedure to charge accumulators in the operations manual 4. Operate HRC Davit using the control valves shown inthe below picture, 5. Push Davit Arm lever towards OUT position to extend hydraulic cylinders for the HRC to launch from the DDC2 Chamber. ( Ensure clamps ‘connecting HRC to DDC2 have been opened fully before launch) 6. Push Winch 1 & 2 lever towards PAY OUT position to lower the HRC into the sea. 7. Lower till there is no tension on the wire ropes to operate the release hooks. At this stage the HRC has reached the buoyancy level in the water. NOTE: All flow control valves are preset for controlled operating ofthe launch of the HRC. ‘They should not be adjusted by inexperienced personnel.Underwater Technology Services (S) Pte Ltd ‘SAT-04 HRC DAVIT HPP Manual Secondary Hydraulic Power System (No Power Supply to HPU) 1. When there is no power supply to the Hydraulic power pack, the accumulators have to be used to drive the hydraulic cylinders. Open ball valves (Nx) to supply pressure from the accumulators to the ball valves for launching, Ensure pressure in the accumulators is in the range of 190-200Bar. See Back-up HPU procedure if there is no pressure in the accumulators, extending the hydraulic cylinders, close ball valve (B). Lower the HRC by operating the winches. ‘Open ball valve (B) and switch ball valve from (M1012) and (1 t0 12). 2. Ensure all ball valves are positioned as specified below prior to operation, Ball Valve Status A Closed 8 Closed Valves 1 & Tare used to supply hydraulic power c Closed _ to the winches D Closed iz Gosed 5. Ifthe winches stop lowering haf way, the pressure E Towards Fl . the a en to — GS Towards G1 lot the HRC lower on its own weight. Close ball | Towards Ha valve (E), open ball valves (C & D) and open ball T Towards 11 valves (L & M) located on the davit arms J Towards J1 kK | Towards ka | L Closed M Closed 3, To launch the HRC from DDC2 chamber, open ball valve (B) and tur ball valve G from (G1 to Gy.Underwater Technology Services (S) Pte Ltd SAT-04 HRC DAVIT HPP Manual arr Alternative method to lower the HRC 1. [releasing the brakes on accumulator power to Jower the HRC using its own weight does not ‘work, an aerative method is to use the 2"*hand pump to reease the brak Close ball valve € and turn ball valve (31 te 32) and (K1 to K2). 2. Push the directional lever of the hand pump to the right and operate the hand Pump 2. Underwater Technology Services (S) Pte Ltd ‘SAT-04 HRC DAVIT HPP Manual Back-Up Hydraulic Power System (No Power & Accumulator Supply to HRC Davit) 1, If there is no power supply to the HPU and no pressure in the accumulator. The system comes With a hand pamp (Pump 1) to charge up the accumulator and a hand pump (Pump 2) to release the brakes on the winch for lowering. pen ball valves (Nad) to commence charging of accumulators. sure all ball valves ate positioned as specified below prior to operation. Ball Valve | _ Status A Closed Closed Closed Closed Closed Towards Fi Towards G1 Towards Hi Towards 11 Towards J1 Towards KL Closed Closed zle|x/-|-|z|o)_|mlolol= 2. Charge the accumulators using the hand pump to 200 bar. Push the directional lever on the hand ‘pump to the left and operate the hand pump, - Commence launching of the HRC using the Secondary operating method ~ launching on the accumulators Charging and Discharging of Accumulators |. To charge the accumulators by the hydraulic pump ensure all ball valves are positioned as specified in the previous table. Open ball valve (Nxd). Switch on the HPU and turn ball valve (FI to F2). This will charge the accumulators to 200Bar that is required for secondary operation. ‘Tum ball valve (F2 to FI) to operate the HPU using the electric motor. To discharge the accumulators ensure the hydraulic tank is at the 1/4 height of the level ‘gauge. This will not overflow the hydraulic tanke when the accumulators are discharged. Open ball valve (A) to drain the accumulatorsUnderwater Technology Services (S) Pte Ltd SAT-04 HRC DAVIT HPP Manual 8.0 General Maintenance Information Refer to the system preventative maintenance schedule for detailed maintenance information, Electrical Motors and Components The electrical motors and electrical components will be inspected and tasted every six months as described in IMCA D018 Section 11. “Visual examination, function test of unit (including protective devices} plus continuity and resistance testing of any cables”. Thus this will satisfy electrical systems maintenance and compliance with IMCA requirements, Hydraulic System ‘Due to the low expected running hours and the safety critical nature of the services provided by the hydraulic system, maintenance will be based periodical rather than running hours. During caily walk around inspections the general condition of the hydraulic system must be visually checkec. Check for leaks, loose bolts & fittings, corrasion hydraulic oll level During rormal operation of the hydraulic system listen for uncharacteristic noises and monitor the pressure gauges for changes in operating pressures, either high or low. Functions test all valves monthly. Hydraulic Oi! The hydraulic oil will be visually inspected monthly for contamination particularly by water and particuletes from the hydraulic system which might indicate degradation of any of the hydraulic components. This can be achieved by draining a sample from the reservoirs. Repiace the oil and clean the tanks annually, Hydraulic Filters After commissioning the system, change the inline fiters after one month of operation. Subsequently filters wil be changed every 6 months, unless monthly visual inspection of the hydraulic oil indicates that there may be cause to change more often, Replaced filters will be cut open and visually inspected for contaminants, If there is visually recognizable contaminants and investigate into the cause will be initiated, Hydraulic Pumps ‘The flexble coupling and hardware will be visually inspected every 6 months for integrity Every 6 years, the pumps will be removed for inspection and overhaul. Relief Valves Relief valves will be maintained as prescribed by IMCA D018 Sect 24.3. They will be visually inspected at least every 6 months and tested to verify that they are working at the correct relief pressure every 12 months. Cooling System Monitor she temperature of the hydraulic oil daily. (Open the heat exchanger end caps every 6 months and inspect for marine growth which will restrict the cooling capacity of the heat exchanger. If the hydraulic oil operating temperature starts to rise during normal operations, inspect the cooler for marine growth. Inspect the stainless steel piping in the region of the cooler both internal and external, for corrosion. If there are signs of corrosion, conduct a more thorough inspection.Underwater Technology Services (S) Pte Ltd UTS SAT-04 HRC DAVIT HPP Manual Hydraulic Hoses & Fittings Conduct a thorough visual inspection of the flexible hoses monthly. Check for damage or deterioration. Check all quick connects are securely tightened. Test to 1.25 x working pressure annually. Manual Operation of the winches and Davit Frame The winches and Davit frame are normally operated from the control block in the HPP. However in case of failure of the electro hydraulic. control system, operate the systems by manual control. Follow operating manual for the instructions. Hydraulic Motors ‘There is no specific maintenance for the hydraulic motors other than described in general above. Both winches operate from the same HPP. They have to be tested periodically so that there is assurance that the motors are in good working order should it be required during emergency. Gauges and other indicators Visual examination for physical condition and function test throughout normal operating range every 6 months. This includes digital and other indicators/alarms.Underwater Technology Services (S) Pte Ltd (UTs SAT-04 HRC DAVIT HPP Manual Power Pack Start Up Check List Action Notes & Comments 4.0 Check the oil level in the hydraulic oll tanks 2.0 | Check that the hydraulic connects on the power pack are connected tight! - — 30 | Start Power Pack at the local panel and check the Pressure Reading = bar ‘gauge to determine that the pump is circulating ol. 40 | Charge the Accumulators up to 200 Bar and check __| there is no discharge of pressure. 50 | During operation, periodically check the oil temperature inthe tanks.