VOL. | - 4. INSTALLATION Quay TABLE OF CONTENTS Maritime Pusnes AS 4. INSTALLATION.. 4.1. Fairlead, 500 ARF .. 4.2. Guide Roller With Load Cell 4.3. Mooring Winch 450 HW+ 140 TU (Traction type). 4.3.1. Installation traction unit... 4.3.2. Mounting TU- calipers 4.4. Power Sheave Unit 4.8. Bow Roller Retractable 4.8. Cardan Suspension, BLC 20 4.7. Guide Roller For Hose Handling Winch.. 4.8. Hose Handling Winch, 400 HW.... 4.9. Accumulator Rac! 4.10. Hydraulic Power Uni 4.14. Inboard Valve With Actuator. 4.12. Hydraulic installation. 4.13, Instructions for pipe installations (Instr. 8101) 1. Generally about the pipe installation and flushing 4.13.2. Select pipes for hydraulic system. .... 4.13.3. Determine the lay-out of the pipe lines 4.13.4, Make pipes to correct shape... 4.13.5. Prepare pipes for connection ... 4.13.6, Grind and sandblast the pipe piece. 4.13.7. Clean the pipes 4.13.8. Protect pipe against contamination... 4.13.9, Install the pipes. 4.13.10. Connect the pipes 4.13.11. Check the pipe system 4.13.12, Flush the pipe system ue 4.13.13, Check the cleanliness of the pipe systemvPusnes' approval. 4.13.14. — Pressure testing Peeeelrtel eset 4.13.15, Starting up... 7 4.14. Instructions for flushing of pipe system (Instr. #102, 4.14.1, Flushing the pipe system (general notes) .. peta 4.14.2. Recommended flushing procedure 4.14.3. Specifications/recommendations. Main criteria for proper flushing... ao Filters and the separation of solid i patil. scene Verification of cleanliness level... Verification of turbulence Special recommendations... 4.18. Instruction for starting up systems (Instr. 8103 4.15.1, General notes 41 Procedure: 4 Sketches... 36 BLS Samsung HN 1408 1 of 37 LaProsjehti03 OLMI750 Samsung BLS HN1408\13 Dokumentasjon\Instruksjonsbok\vol_1104_installation.docGao Maritime Pusnes 4. INSTALLATION 4.1, Fairlead, 500 ARF Drawing: No [ Weight *] 171396 (Volume 2, chpt. 1) 16,2 tonnes When installing the 500 ARF it is important to study the drawing of the unit, as well as the deck arrangement drawings provided by Maritime Pusnes. The 500 ARF should be located in accordance with these drawings. Always fit the fairlead first. The fairlead must be welded to the deck as shown on the arrangement drawing showing the 500 ARF. Make sure that the weld sizes are in accordance with the drawing. Alter the fairlead is welded to the deck, the cylinder bracket can be bolted to the fairlead. Then weld the cylinder bracket to the deck as shown on the drawing. During welding, make sure to protect the hydraulic cylinder and the flexible hoses from heat and sparks. Finally, connect the hydraulic cylinder to the roller in the fairlead. Wiiren Make sure that the hydraulic connections are blinded at all times, in order to avoid ] ingress of dirt in the hydraulic syste! 4.2. Guide Roller With Load Cell Drawing Ne 213363 (volume 2, chpt. 3) | Weight [0,71 tonnes The guide roller is welded to platform deck with a fillet weld a8, and shall be placed in front of the mooring winch. The centre height is adapted by cutting the side plates. BLS Samsung HN 1408 2 of 37 LAProsjektio3 OL11750 Samsung BLS HN1408\13 Dokumentasjon\instruksjonsbokivel_1104 installation doeVOL. 1-4. INSTALLATION 4,3 Mooring Winch 450 HW+ 140 TU (Traction type) Maritime Pusnes AS Mooring ae 450 HW+ 140 TU (Traction type) i 111397 (Volume 2, chpt. 4) 17,0 tonnes | weight The winch is a mooring winch with a traction unit for mooring purposes. Installation of the winch is done in two steps. Step 1 «Lift onboard the gear case with the bearing bracket. * Position the gear case correctly on the foundation and tighten the foundation slightly. Use this as a master when aligning the main shaft through the bearing bracket, * Position the bearing bracket. Be sure that the main shaft is resting properly in the bearing. Adjustment is done by the adjustment screws in the foundation, Tolerance on clearance is #/- 0,1 mm. ‘+ Tighten the foundation bolts slightly when in position. Step 2: Lift onboard the traction unit with disc brake, and position it on its foundation. Adjust the centre height with the adjustment screws. Rotate the drums so that the clutch can be engaged. Place the callipers on their foundation. Release the disc brake with the hand pump to be able to rotate the drums. The hand pump is placed on the ball valve cabinet. Grind off the paint on 3 or 4 spots on both couplings. Align the traction unit main shaft by using a straight rod. Check that the disc brake calipers is aligned with the foundation. BLS Samsung HN 1408 He 3 of 37 LAProsjokti03 OL11750 Samsung BLS HN1408\13 DokumentasjontinstruksjonsbokIvol_1104 installation docVOL. | - 4. INSTALLATION qa 4.3 Mooring Winch 450 HW+ 140 TU (Traction type) Maritime Pusnes AS Check that the foundation bolts slip easily through all bolt holes. The winch can now be moulded with chockfast or adapted by steel liners, and foundation bolts tightened. * Put on the disc brake protection cover. + All hydraulic connections must be made after the winch is tightened to the specified torque. + Allpipe connections are described on drawing 111397. Please note the importance of that the pipes is proper adapted and does not create any force on the equipment it is connected to. BLS Samsung HN 1408 4 of 37 \\146,224.222.141dokument\Prosiekt03 OLI1750 Samsung BLS HN408\13 Dokumentasjon\inetruksjonsbokivol_ 1104 instalation docVOL. | - 4, INSTALLATION Gay 4.3 Mooring Winch 450 HW+ 140 TU (Traction type) 7 Maritime Pusnes AS 4.3.1. Installation traction unit BLS Samsung HN 1408 \\146.224.222.14\dokumentProsjektid3 OL11750 Samsung BLS HN1408\13, Dokumentasjoniinstruksjonsbokival_ 110d _installation.doc 5 of 376 of 37VOL. 1 - 4. INSTALLATION Gory 4.4 Power Sheave Unit eZ Maritime Pusnes AS 4.4. Power Sheave Unit [ Drawing: No. ~~ 1.213366 (Volume 2, chpt.6) [Weight ” 1,2 tonnes: The PSU provides the traction winch with necessary back tension and guides the rope down in a storage unit. The PSU has to be mounted on the foundation over the top deck with bolts. A hole under the rope guide has to be maked, We recommend to place this unit a little over the deck, on some U-profiles. This PSU will start automatically when the pump station is started, and has to be secured with signs, which tells that this PSU starts automatically. 4.5. Bow Roller Retractable “1 117400 (Volume 2, chpt. 6) 0,42 tonnes The bow roller retractable is bolted to the ARF 500 with 8 M24 bolts and welded to hull structure on port side of the ARF 500. It is equipped with two locking bolts to ensure that the roller is kept in desired position. It is important that the bushings for the locking bolts that are to be welded in the hull structure, is positioned correctly. Ensure that the cylinder is in extreme outer and inner position when the bushings are positioned. 4.6. Cardan Suspension, BLC 20” Drawing No | 111398 (Volume 2, chpt. 7) Welght — 6,4 tonnes The cardan suspension is located below the platform deck, and is hanging in two bearing brackets. Make sure that the bearing brackets are aligned properly, before mounting the cardan suspension. The bearing brackets are to be moulded with chockfast to the foundation. The foundation for the stow cylinder should be on the same level as the bearing brackets The inboard ball valve can be moved to a new position by fitting a spool piece between the swivel and the inboard valve. The flanges are 20", 150 Ibs ANSI B-16-5, raised face. Make Sure that the pipe fitted to the swivel has correct alignment, to avoid bending moment on the swivel. Alter final pipe welding and lining up of cardan suspension, the bolts on the swivel flange facing the fixed piping should always be loosened for control. No misalignment or gap over 2- 3 mm should be allowed. BLS Samsung HN 1408 7 of 37 \\148.224.222.44\dokumentProsjekt03 OL\I750 Samsung BLS HN408\13, Dokumentasjoniinstruksjonsbokivol_ 1104 Installation docVOL. 1-4. INSTALLATION Gay 4.7 Guide Roller For Hose Handling Winch __ Maritime Pusnes AS 4.7. Guide Roller For Hose Handling Winch Drawing. No. “| 318098 (volume 2, chpt. 8) Weight ‘| 0.88 tonnes The guide roller shall be mounted to the yard-supplied foundation behind the cardan suspension. 6 M30 bolts shall be used. 4.8. Hose Handling Winch, 400 HW Drawing. No. | 213364 (Volume 2, chpt. 6) 5,6 tonnes — * Lift onboard the hose handling winch. * Position the winch correctly on the foundation and tighten the foundation bolts slightly, * Be sure that the main shaft is resting properly in the bearing. + Adjustment is done by the adjustment screws in the foundation. Tolerance on clearance is + 0.1mm. * Place the brake support in accordance with the foundation and check that the brake fits properly around the brake drum and check that the link to the foundation has the correct vertical orientation. Please note that the foundation for the band brake are 30mm lower than the winch foundation, ‘* Check that the foundation bolts slip easily through all bolt holes. + The winch can now be moulded with chock fast or steel liners, and foundation bolts tightened, 4.9. Accumulator Rack Drawing. No. ~ 77319095 (volume 2, chpt. 15) | Weight | 04 tonnes | The accumulators for emergency hydraulic power are assembled on a rack. This rack is to be bolted to a frame, with 4 M20 bolts. Please note the free space of min. 500mm above the accumulators for service purposes. The rack has space and clamps for a spare N2 bottle for filing purposes. BLS Samsung HN 1408. if 8 of 37 \\146.224.222.14\cokumontiProsjokti03 OL\1750 Samsung BLS HN1400\t3 Dokumentasjontinstruksjonsbokivol_1104 installation. doeVOL. I- 4. INSTALLATION 4.10 Hydraulic Power Unit 4.10. Hydraul | Drawing. No. Weight References: See vol. 3 Power Unit 1111394 (see volume 3) | 2,4 tonnes 4.11. Inboard Valve With Actuator {tis recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and orientate the actuator accordingly. Be restricted by undersize Pipe or fittings, these could throttle the flow thus reducing the hydraulic pressure at the actuator and causing intermittent motion. All Rotork actuators are tested prior to despatch and copies of test certificates are available on request. Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the cylinder to the centerline of the associated pipework. When the actuator has been bolted to the valve flange or adaptor and keys inserted, the Position of the stop bolts should be checked to ensure full opening and closing of the valve If these end positions are not suitable, the stop bolts 21 may be adjusted by first loosening the jam nut 22 and screwing the bolts in or out until the desired position is obtained. Stroke the yoke away from the stop bolt when adjusting, then return it to check position. When the Cortect positioning is obtained, retighten the jam nut. Certain vaives incorporate their own stops. In these cases, it is recommended that the actuator stop boit positions coincide with the valve stop positions. Relocate the yoke cover so that the white bar lies parallel to the pipeline when the valve is open. This is the visual position indicator. ‘Once in position, the actuator should operate the valve with a smooth continuous action. If Jerky operation occurs, the hydraulic supply should be checked for correct pressure and volume flow. For greased filled units, all moving surfaces should be liberally packed with grease (Schaffer #221 Moly Ultra 800 EP). The speed of operation can be adjusted by varying the hydraulic supply. A needle valve in the supply or exhaust line will reduce flow and hence increase operating time BLS Samsung HN 1408 9 of 37 |LAProsjekti0s OL\1750 Samsung BLS HN1408\13 Dokumentasjoninstruksjonsbokivol_1104_installation doeVOL. 1 - 4. INSTALLATION Qa 4.12 Hydraulic installation 7 Maritime Pusnes AS 4.12. Hydraulic installation Se Note! The "Instructions/recommendations for installation and starting up PUSNES HYDRAULIC SYSTEMS" is enclosed as a guideline and reference for future repair and maintenance of the hydraulic system. BLS Samsung HN 1408 10 of 37 \\146.224.222.14\dokumentiProsjekti02 OLI1750 Samsung BLS HN1408113 Dokumentasjoniinstruksjonsbokivol_1\04 installation deeVOL. I - 4, INSTALLATION f PUSNES | 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13. Instructions for pipe installations (Instr. 8101) Important This instruction should be read by designers and pipe fitters before installation of hydraulic pipes onboard the vessel. This is extremely important in order to achieve trouble free operation of the hydraulic equipment when the complete system is started up. Please observe that if the hydraulic pipe installation is not in accordance with these instructions, the guarantee will not come into effect! For normal periods of guarantee se "Pusnes conditions for supply of deck machinery", Rev. D. Do not hesitate to contact Pusnes in questions conceming installation of the hydraulic system. BLS Samsung HN 1408 11 of 37 \\146.224,222.14idokumentiProsjekti03 OLIY750 Samsung BLS HN1408\19. Dokumentasjoniinsiruksjonsbokivol_1\04 installation decVOL. | - 4, INSTALLATION Gur 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.1. Generally about the pipe installation and flushing The following are instructions for planning, making and mounting hydraulic pipe installations for connection with Pusnes hydraulic equipment. The pipe installation should be carried out in same succession as described. For each operation are also mentioned recommended or not approved production methods, materials etc 'tis of greatest importance that the installation of the hydraulic pipes is carried out according to the following instructions. Especially the cleaning of pipes must be paid the greatest attention, as cleanliness is the main requirement for troublefree operation of any hydraulic system. Please note that when starting up the complete system, any impurities will have to pass through pumps, motors, valves etc. and possibly cause damage to these Parts. Therefore it is most important that the complete pipe system is thoroughly cleaned before starting up. The pipe system is the section where most of the impurities can enter the circuit, The rough particles cause deep scratches while the minute ones work like grinding paste causing a rapid wear and tear of pumps, valves ete. Also, the impurities can jam hydraulic valves and put the system out of function 'n order to assure that the impurities in the system are reduced to an acceptable level, the pipe system will have to be flushed properly. Generally we recommend that flushing is done with separate flushing pumps and with special flushing filters (see instructions/ recommendations). The hydraulic systems built by Pusnes are normally equipped with fitters, which mainly are meant for removing particles being generated in the system during operation. These filters should normally not be used for flushing, however, if by any reason it should be required to use the working pumps for flushing; this will have to be cartied out strictly in accordance with special instructions given separately on request. BLS Samsung HN 1408 12 of 37 \\146.224.222.14idokumentiProsjokti03 OLI1750 Samsung BLS HN1408119, Dokumentasjoniinstruksjonsbokivol_1\04 installation docime Pusnes AS 4.13.2. Select pipes for hydraulic system. The correct type and size of pipes should be selected according to Pusnes requirements and as required by the classification society Quality, Material Pressure lines Quality: Seamless steel precision tubes, cold drawn or cold rolled, DIN 2391-C, NBK. Phosphated and oil impregnated. Material: St. 35,4, DIN 1629/4 or better. Return lines, 0 - 10 bar: Quality: We recommend steel tubes similar to the pressure lines, or according to DIN 2448. Material: St. 35, DIN 1629/3 or better. Note! For pipes with outside diameter less than 18 mm we recommend acid resistant material. [Not approved: Copper pipes are not recommended. L Galvanized pipes and accessories must not be used. Dimensions Pipe dimensions should be as recommended certified in Pusnes drawings of the pipe system. If the pipe line should be extremely long, Pusnes should always be contacted in case special modification should be required. Install flexible rubber hoses where indicated The wall thickness must comply with the rules of the classification society. Note inside and outside additions for corrosion, the latter depending on mounting arrangements. BLS Samsung HN 1408 7 13 of 37 \\146.224.222.14\dokument\Prosjekti0S OLI1750 Samsung BLS HN1408\13 Dokumentasjoninstruksjonsbokivol_ 1104 installation docVOL. I - 4. INSTALLATION Gua 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.3. Determine the lay-out of the pipe lines The pipe lines should be well arranged and easy to survey. Itis also important that the various components of the system are of easy access for checking and adjusting, or removal for repair. See also chapters "Connect the pipe" and “Check the pipe system' for fastening of pipes and pipe connections. Expansion compensation In a hydraulic system the temperature can vary considerably. Under certain conditions the temperature in the pipes varies from -30°C at stand still in the winter to +80°C in service at summer time. This gives a 110°C possible temperature difference, which again means a length variation for steel tubes of about 1,2 mm per meter. The pipe lengths and temperature differences must be given special attention when installing the pipes. If, for example, pipes are to be fitted between two fixed Points there have to be flexible parts somewhere to take care of the length variations. Noise damping To keep the noise level at a minimum following instructions should be followed: * All pipe connections to the power pack/pump station must be made by flexible rubber hoses, length 0,5 m to 1,0 m. All components should be mounted to solid foundations that cause a minimum of vibrations. * Make sure the pipe lines are fastened to well stiffened deck plating, bulkheads etc. * The use of bulkhead penetrations and pipe bends (elbows) should be kept at a minimum. * In accommodation areas; use pipe clips and bulkhead penetrations with noise dampers Recommended arrangements The pipeline should be laid up the shortest way between the power pack and the consumer (winch). The pipes should be well protected from extemal forces by mounting them below deck, in pipe tracks etc. where possible Make sure the distance between the pipes if sufficient for easy access of Couplings. Bends and couplings should be kept at a minimum to prevent unnecessary pressure drops. BLS Samsung HN 1408 14 of 37 \\146.224.222.141dokumentiProsjekti03 OLIT750 Samsung BLS HN‘408\19 Dokumentasjoniinstruksjonsbokvol_1\04 instalation doeVOL. 1-4. INSTALLATION aay 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS The illustrations beneath show correct pipe fitting by use of length compensators. ioe So ae TG OT ay = a3 a , ar Pe 7 or wes Pie ine works a8 aang Fig. 44 BLS Samsung HN 1408 \\146,224.222.141dokumentiProsjokti03 OLI1750 Samsung BLS HN1408\13 Dokumentasjoniinstruksjonsbokivol_1\04. instalation doc 15 of 37VOL. 1-4, INSTALLATION Gur 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.4. Make pipes to correct shape 'tis important that the tubes are made to correct length and shape in order to avoid statical forces and leaks caused by inaccurate pipe pieces being forced into position assembled. By assembling it should be possible to connect the pipes and components without bending and twisting. Methods of cutting For cutting tubes, crosscut saws are recommended. Smalll size pipes with outside diameter less than 25 mm may also be cut by pipe cutters. After cutting, clean off the burrs. This should aiso be done when flanges are to be welded to the pipe. Note! Pipe must not be cut by flame cutting or any other method, which will heat the pipe. Pipe bending The steel tubes should be bent without heating. It is important to use the correct bending device for the actual pipe diameter. In order to maintain strength and to Prevent unnecessary pressure drop, the cross section of the pipe must remain circular after bending. The bend radius should be as large as practical possible. Minimum bend radius guidance is following: Up to 18 mm dia. - 3 x pipe dia. 20 mm dia. and over - 4 x pipe dia. Check that the pipe is open and free from impurities before bending, Se Note! Do not use sand or heat when bending. BLS Samsung HN 1408 i 16 of 37 \1146,226.222.141dokument\Prosjekt#03 OLII750 Samsung BLS HN1408\13 DokumentasjoniinstruksjonsbokWvol_1104_installation.docVOL. | - 4. INSTALLATION y PUSNES J 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.5. Prepare pipes for connection All welding of flanges to the pipes must be done before the pipes are cleaned and mounted. No welding must be done where mechanical cleaning is not possible. Threads for threaded connections should also be made before the pipe is cleaned. After cutting threads, clean off the burrs. High and low pressure lines with outside dia, 25 mm or more must be connected by welding flanges. Use solid flanges designed for high pressure lines and with required number of bolt holes. The flanges should comply with the rules of the classification society. Check that one of the flanges for each connection is equipped with groove for O-ring or other satisfactory sealing. Welding of flanges Before welding check that all burrs from cutting of the pipes are removed. When welding the flange to the pipe make sure the weld penetrates completely. Checking of accuracy Make sure the flanges are welded in the correct angle to the pipe. The flanges of two adjacent pipes must be absolutely parallel when connected. Adjust if necessary. Fig. 4-2 BLS Samsung HN 1408 i 17 of 37 \\146.224.222. 14idokumentiProsjekti03 OLI1750 Samsung BLS HN‘408113 Dokumentasjoniinstruksjonsbokivol_1104 installation doeVOL. I - 4. INSTALLATION 4.13 Instructions for pipe instal ns (Instr. 8101) 4.13.6. Grind and sandblast the Pipe piece Slag, burrs and other contamination from welding and cutting should be mechanically removed. Special attention should be paid to the inside of the pipe. Outside slag and corrosion should be removed by sandblasting, Required grinding Edges of pipe ends should be well grinded when pipes are connected by threaded connections or compression type couplings. Grind the inside of the pipe where welded. ge Note! Check also that there are no welds where grinding is not accessible. Lo an Grinding required Fig. 4-3 BLS Samsung HN 1408 18 of 37 \"146.224.222.14\dokument\Prosjokt}03 OL\1750 Samsung BLS HN1408\13 PokumentasjeniinstruksjonsbokWol_1104 installation. doeVOL. I - 4. INSTALLATION Gary 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.7. Clean the pipes The complete pipe piece should be thoroughly cleaned before mounting. No pipe must be mounted unless they have been treated by the cleaning methods described below. Methods of cleaning 1. All pipes must be degreased. * Clean mechanically the pipe from visual impurities, + Then wash the inside of the pipe with white spirit, trichloroethylene or some other solvent. * Blow the pipe dry by using dry, filtered, compressed air or nitrogen. Pipes not fitted with welding flanges should be inspected for corrosion, Pull a Nap-free piece of clothing through the pipe (twist must not be used). If no Corrosion is observed inside, the pipe may be mounted without being acid washed. Blow through the pipe with compressed air before mounting. 2. Pipes which have been exposed to heat (welding of flanges) and pipes with sign of corrosion must also be chemically cleaned (acid washed). See recommended methods. oe jote! Note that all pipes must be degreased before acid washing. Chemical cleaning The pipes should be acid washed and then neutralized, or they should be washed in combined cleaning/neutralizing chemicals. 1. Combined cleaning/neutralizing chemicals There are chemicals on the market, which are cleaning (acid washing) and neutralizing with water. Usually on the basis of phosphoric acid. Degreasing before the acid washing is required in this case too. Working period is about 2- 4 hours dependent on the acid density, the degree of pollution and the temperature, Check the result and repeat the treatment if necessary. 2. Acid washing Acid bath 1 part 36 % hydrochloric acid 3 parts of water ge Warmingiii Hydrochloric acid to be poured into the water; never the opposite way. BLS Samsung HN 1408 19 of 37 146,224.222.14\dokument!Prosjekti03 OL11750 Samsung BLS HN1400119. Dokumentasjoniinstruksjonsbokivol_ 1104 installation. doeVOL. 1-4. INSTALLATION y PUSNES J 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS The part to be cleaned should stay in the bath for 6 - 8 hours dependent on temperature and the amount of impurities. By temperature above 20° C the bath Period can be reduced. Ifthe solution is filled into the tube, it must be completely filled. Check that no air is left inside. Neutralization The hydrochloric acid solution to be removed. The tube to be scoured welll with water. Neutralizing liquid: 1 part anhydrous sodium carbonate 1 part of water All the sodium carbonate must be dissolved in the water (to be fully agitated), Hot water accelerates the dissolving. The part should ‘Stay in the bath for 6 hours, As the sodium carbonate crystallizes at low temperatures, the bath should be kept at 18-20° C. Scour the part well with water Check that the result is satisfactory, repeat process if necessary Se Note! Ensure that the pipes are completely dry. impregnate the pipes immediately after cleaning. BLS Samsung HN 1408 20 of 37 \\146.224.222.14idokument\Prosjokt03 OLI1750 Samsung BLS HN1408\13 Dokumentasjon\InstruksjonsbokWwol_1104 installation doeVOL. I - 4. INSTALLATION aoe 4:13 Instructions for pipe installations (Instr. 8101) __ Maritime Pusnes AS 4.13.8. Protect pipe against contamination Immediately after cleaning, the inside of the pipe must be impregnated because itis strongly disposed to corrosion, especially after being acid washed. Make sure no foreign particles can enter the cleaned pipe. The extemal part of the pipes should be coated with primer, especially if the Pipes are to be stored before installation. Impregnation against corrosion The inside of the pipes should be completely covered with an impregnation fluid which will protect the pipes against corrosion in the time from cleaning until the system is filled with hydraulic oil The actual quality of the impregnation fluid depends on the time the pipes are expected to be stored. Choose an impregnation fluid which covers the pipe inside well, gives required protection and does not flow towards the bottom of pipe when stored. ge Note! Make sure the impregnation fluid will not harm the hydraulic oil when the system is taken into use. Check with the suppliers of impregnation and hydraulic oil. : Ste Plugging of pipes When the pipes are impregnated, the pipe ends should be properly closed against contamination. This is important as impurities, which enter the tube, will stick to the impregnation fluid. Use plastic plugs to close the pipes. The plugs should remain inserted in the pipe ends at all time during storage, transport etc. They should not be removed until the pipe is being mounted. Plastic Plug Fig. 4-4 BLS Samsung HN 1408 21 of 37 \\146.224.222.14\dokument\Prosjokti03 OL\1760 Samsung BLS HN1408\13, DokumentasjoniinstruksjonsbokWvol_1\04 installation docVOL. I - 4, INSTALLATION 4.13 Instructions for pips installations (Instr. 8101) 4.13.9. Install the pipes Mounting devices for the hydraulic pipe system should be spaced adequately and have Sutticient strength to absorb statical and dynamical influences on pipes (Weight of Pipe line and components fitted to them, as well as the ships motion in the sea), ge Note One should notice that a pipe coupling is a pipe assembling device and not suitable as support for components. Fastening of pipes Some recommendations for fastening of pipes: * A pipe clip must have sufficient mechanical strength to keep the pipe in place. * It must not prevent the pipe from expanding (axial load) * A pipe clip should be made from a wear resistant material in order to minimise wear and tear by axial movement. * It should be made from corrosion resistant material or protected against corrosion. * The pipe clip should also be made from a noise damping material. Where extra noise damping is required (accommodation areas) use pipe clips with built-in noise dampers. * Several pipes in a common pipe alip should have the possibilty to be removed one by one, There are no fixed rules for calculating the distance between the pipe clips. Recommended distance: Recommencied spacing for clamps Max. tightening torque in Nm. (ace. To ASTM 1241.4) Pipe OS. | Spacing Vato |—Paiy—] Payamide | Mamata inn nim) ope propane | ba aL Seri Ga ear [Stender a = 0 z 159-225 ae —5 6 Ba Dowie TST yg 2 iz q siasaT Gis 8 3 = a3 38 [ae iz 20 a 203. 48 [Mi 2 20 30 7 Hea 3s “ani ~5 25 35 365 6s] we ES a0 35 To16 736 35 35 i] tas es_} w29 % 80 | a0. Hig TE 180} a0 —} 350 1082 ios_[ M90 250 S00 | 00 2ig.t SED 350, 00 [-—a50 7 ws Waa 390] s00 [as wa [3556 2 BLS Samsung HN 1408, 22 of 37 \M146,.224.222.14\dokumont!Prosjekti0S OL\1750 Samsung BLS HNT408\3. Dokumentasjoniinstruksjonsbokivol_ 104 installation.deeVOL. | - 4. INSTALLATION 4.13 Instructions for pipe installations (Instr. 8101) Plastic clips are recommended [Availabte on the market in most of the actual dimensions. Reducing the transfer of noise and vibrations. Allows for axial movement. any Maritime Pusnes AS when noise reduction is very important. Special arrangement of clips supported by vibration dampers. To be used Fig. 4-7 Fig. 48 [Not recommended! Flat steel clips with The lead lining is compressed by the Wear and tear of pipes and clips, as well as transfer of noise and vibrations are considerable pulsations of the pipe and is getting loose. | lead lining ] | Fig. 4-9 BLS Samsung HN 1408, \\146.224.222.14\dokumentProsjekti03 OLI1750 Samsung BLS HN1406\13 BokumentasjoniinstruksjonsbokWol_1\04 installation doc 23 of 37VOL. 1-4. INSTALLATION y PUSNES J 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS Bulkhead penetrations oad ‘Standard bulkhead penetrations can be used. Note! Note that the bulkhead penetration is a fixed point in respect of expansion. 'n accommodation areas bulkhead penetrations with noise dampers should be used. Rubber compressed in a steel casing eventually vulcanized, Necessary when noise damping is very important ‘The weight of the pipe must not act as an extra load on the noise damping bulkhead penetrat tion. Check that the pipe line is well supported on each side of the bulkhead, BLS Samsung HN 1408 \W148.224.222.14\dokument\Prosjekt03 OL\1750 Samsung BLS HN1408\13. Dokumentasjoniinstruksjonsbokivol_1\04_installation doc 24 of 37VOL. | - 4. INSTALLATION Gay 4.13 Instructions for pipe installations (Instr. 8101) Maritime Pusnes AS 4.13.10. Connect the pipes Before connecting the pipes, check that all parts are properly prepared and Cleaned as described in the foregoing chapters. Bonded seal/o-ring should be covered with grease when fitted. This helps keeping them in position in the groove of the flange when the pipes are being mounted, S Note! Do not forget to remove the plastic plugs! eee Plasticplugss Couplings Only couplings approved by the classification society may be used, No pipe must be connected by welding only; scale and slag from the welding is impossible to remove, (Ae (Ale ~ pproved coupt ing 1 Ie Fig. 4-11 One of the following coupling types should be used dependent on pipe size and pressure: 1. Flange connection All high and low pressure lines with outside diameter 25 mm or more must be connected by welding flanges. See also chapter "Prepare pipes for connection" for welding of flanges. For sealing of the flange connections use bonded seal/o-ring mounted in a groove in one of the flanges. Size and finish of the grooves should be in accordance with the recommendations from the sealing makers. Drain lines may be connected by couplings designed for low pressure lines (0.9. flanges for steam lines) BLS Samsung HN 1408 25 of 37 \\146.224.222.14\dokumentiProsjekti0s OL!1750 Samsung BLS HN400\13, Bokumentasjoniinstruksjonsbokivol_ 1104 installation docVOL. 1-4, INSTALLATION PUSNES J 4.13 Instructions for pipe installations (Inst e 1e Pusnes AS 101) Ma 2. Compression type couplings Follow the instructions given by the various makers. Check that the precision Steel tubes have the required tolerances for use of this type of coupling 3 Threaded connections Generally only to use when the two coupling types above are not suitable. Properly sealing must be assured, e.g. by means of O-rings, bonded seals, hardening sealing liquids (Lactite) etc. Follow the makers’ instructions, Note! Hemp and Teflon tape is not recommended. Accuracy of work * Check that pipe fines are not exposed to external load by being forced into position when connected. * Cheek that coupling flanges are absolutely parallel and that connection bolts are evenly tightened, + Check that compression couplings are properly tightened. 4.13.11. Check the pipe system The complete pipe system should be thoroughly checked for cleanliness and leakage. Normally flushing of the system will be necessary. 4.13.12. Flush the pipe system fuses recommendations for flushing and cleanliness approval (acceptance figures) are given separately (see instr. 8102) 4.13.13. _ Check the cleanliness of the pipe system/Pusnes* approval The installation should be checked and approved by Pusnes’ representative before starting up. Pusnes' representative is entitled to order pars of the pipe system dismantled for inspection, IF not satisfactory, the complete system may be ordered flushed once more, or dismantled for proper cleaning, eS Note! The life time of the components are closely connected to the cleanliness of the system when starting up, and maintenance on _board later on, Bee BLS Samsung HN 1408 26 of 37 \\146,224.222.14\dokument\Prosjekti03 OL\1750 Samsung BLS HN1408\13 Ookumentasjontinstruksjonstokivol_ 104 instalation docVOL. I - 4. INSTALLATION 4.13 Instructions for pipe installations (Instr. 8101) 4.13.14. Pressure testing [ PUSNES | Maritime Pusnes AS Pressure testing of the pipe system is the responsibility of the yard. Pressure {esting should preferably be carried out with a special pump before connecting Pusnes equipment to the pipe system. Testing pressure should be in accordance with the requirements of classification Society. The calculation of test pressure should be based on max. working pressures specified for the actual hydraulic system. jh BY any reason, pressure testing should need to be carried out after connecting Pusnes' equipment, this should be done as a part of the starting up procedure. Ip such case Pusnes’ representative should be present for careful evaluation of method and precautions against damages. ge Warningi Protect Pusnes' equipment from abnormal pressure! Extensive damage can occur! 4.13.15, Starting up ae Starting up must be carried out in accordance with instructions/recommendations given separately See instr. 8103, Pusnes' representative should preferably be present. BLS Samsung HN 1408 \\148.224.222.14\dokument\Prosjekt!03 OLLI750 Samsung BLS HN1408\13 Dokumentasjon\instruksjonsbokWwol_1104 installation. doc 27 of 37VOL. | - 4. INSTALLATION Gary 4.14 Instructions for flushing of pipe system (Instr. 8102) Maritime Pusnes AS 4.14. Instructions for flushing of pipe system (Instr. 8102) 4.14.1, Flushing the pipe system (general notes) In the instruction/recommendations for hydraulic pipe-installations we have given information which is considered as important for ensuring an acceptable pipe installation, A system which is property cleaned and free from particles will safeguard the components and ensure the best possible operation of the equipment, as well as. long lifetime, “Note! ‘Read this instruction carefully! 4.14.2. Recommended flushing procedure 1. Check that all connections on the lines are free from leakage. This may be done by applying compressed air (recommended pressure 6 kg/em*) and test the connections with ‘soap water. If no bubbles are observed, the lines are acceptable and the flushing can be prepared. 2. Provide necessary equipment (separate flushing station, filters as recommended, and hoses). 3. Connect the hoses for by-passing the equipment as indicated in the sketch. 4. Make sure that the filter, placed in the retum line of the system is suitable. 5. Fill up the pipe system with suitable flushing oil. 6. Close the valves for leak oil pipe (on deck) and start the flushing through P- and T lines, 7. Check that the flushing is acceptable according to recommendations in chapter "Specification/Recommendation", paragraph “Main criteria for proper flushing” Notel a Check all lines carefully! 8. Run the pump about 20 - 30 min. and check the filter. Clean or change the filter according to which type (paper or gauze) is used. Repeat the flushing until the filter seems to be completely free from particles BLS Samsung HN 1408 28 of 37 \146,224,222.14\dokument\Prosjekti03 OL11750 Samsung BLS HN1408113, ‘Bokumontasjoniinstruksjonsbok\vol_1\04_ Installation doeVOL. 1-4. INSTALLATION Gur 4.14 Instructions for flushing of pipe system (Instr. 8102) Maritime Pusnes AS 8. Open valves for leak oil pipe (on deck). Close the valve for T-pipe and start the flushing through P and L lines. Repeat the flushing until the filter soams to be free from particles. 10.Check that the cleanliness of the system is acceptable according to NAS 1638 class 7, or ISO 4406 class 16/13. Oil sample to be taken from the system before the filter. Follow instructions. 11.lf special flushing oil is used, or if by any reason the oll is not acceptable, drain the complete system and fill ol of correct quality through filing filters (5 microns is recommended) 12.Disconnect flushing station and hoses above deck. 18.Connect the permanent pump stations and hydraulic equipment to the lines. 14.Follow the instructions for starting up hydraulic systems (see instr. 8103), 4.14.3. Specifications/recommendations Main criteria for proper flushing A flushing procedure should be adapted to the practical condition. Certain main criteria shall, however, be fulfilled to obtain sufficient results. The reservoir of a portable pump station shall be cleaned to the level required of the system, The system js filled through a filter. Air should not be brought into the system when filling. 1f necessary, top the system and bleed. BLS Samsung HN 1408 29 of 37 \W146.224.222,t4\dokument\Prosjekt03 OLI1750 Samsung BLS HN1406\13 Dokumentasjon\instruksjonsbokWvol_1\04 installation deVOL. 1-4. INSTALLATION 4 Instructions for flushing of pipe system (Instr. 8102) Maritime Pusnes AS Gury condition the | To prevent mi | With Reynolds number larger than 3000 there will be a turbulent fl fluid wipes the surfaces with high energy and tears off the contaminants, | ore contaminants to be wiped off during working operation the Reynolds flow. Having this number by flushing has to be at least 25% higher than the maximum achievable | Reynolds number when the system is in operation. | The Reynolds number may be calculated as follows: j |where | pe = 2120-0 Re vd vis viscosity Itis often difficult to obtain a Reynolds nui recommended to i Increase the fluid flow, q. This may be both unpractical and ex; Ldis internal tube diameter in mm is flow in Yimin in mm */s (centistokes) increase the Reynolds number: flushing pump and larger power unit Reduction of viscosity, v. In most cases this is the best way reduction may be obtained by increasing the temperature, thus lower t using a flushing fluid with lower viscosity, If @ special flushin used in operation. ‘The use of vibration, high frequent sound, chan contribute to a fast imber large enough. The following methods are ‘pensive as it requires a larger y to achieve the required Re .The he viscosity, or by 17 fluid is used, it shall be compatible with the system oil, which is to be The only general recommendation is to use the same type of fluid, Possible with a lower viscosity, ter removal of particles. This is, however, a supplem alternative to the right Reynolds number. ging flow directions or gas injections would lent and not an To ensure transportation of the contaminants from the system to the filters, i is very important ~ in all parts of the system - to have m/s of the flushi ing fluid, both turbulent flow and a velocity of minimum BLS Samsung HN 1408 \\146.224.222 t4\dokumentProg Dokumentasjoniinetruksjonsbe jekt109 OLI1750 Samsung BLS HN40813 kivol_1104 installation doc 30 of 37VOL. 1-4. INSTALLATION Gag 4.14 Instructions for flushing of pipe system (Instr. 8102) Ma Filters and the separation of solid Particles. {The filers used for flushing are quite decisive for two essential conditions. The filters decide the final cleanliness level which can be expected, and how fast this level can be reached, The choies of an optimal fitration ratio is important. When using fiters with a too poor {ilration ration, situations may arise where the specttiod cleanliness is not achieved or is achieved after an unnecessary long flushing time. ‘The flushing filters should be provided with alarm or visual indicator. Sizing of external flushing filters. It's generally good economy to use large flushing fiers. The smallest flushing fitter which Should be accepted has a pressure drop through a clean element of 5 % of the opening pressure i the bypass valve or the indicator sotting , calculated at the relevant flushing viscosity. Selection of filtration performance. Filtration performance is measured according to ISO 4572. 'SO 4572 defines Beta ratio (fitration ratio) as the relationship between the number of Haricles greater than a given size upstream of the filter, and the number of patticles greater shan the same size downstream ofthe fier. If there are 20 times as many particles greater than Sum in the oil upstream of the filter compared to downstream of the fit, the Bata ratio for § um equals 20. This may be presented as; is = 20. Filters with s-values, considerably higher than 1, should be used. Recommended minimum value is: Until filters seem to be free from particles, Bs > 20 “Thereafter, until satisfactory cleanliness lever is reached fs > 75 External flushing filter lis recommended to use extemal fiters during flushing. The system filters normally are Selected with a certain dirt capacity to keep the system on a recommended cleanliness level, {Kis Rot economical to use system fitors as flushing fiters, The selected flushing filtration ratio very often deviates from that of the system filters of the system. BLS Samsung HN 1408 31 of 37 \\148.224.222.14\dokument\Prosjekti93 OL\1750 Samsung BLS HNI408\13 Dokumentasjon\instruksjonsbokvol_1104 installation. docVOL. I - 4, INSTALLATION Qu 4.14 Instructions for flushing of pipe system (Instr. 8102) Maritime Pusnes AS Minimum flushing time <@__The fushing time depends on the system capacity and its complexity Even if samples from the system indicate that the specified cleanliness level is reached after a short time, the flushing shall Continue for a total of at least three hours at turbulent flow. - The probability of removing particles sticking hard to the tube walls therefore increases, Verification of cleanliness level. The obtained cleanliness level shall be documented before a flushing operation may be considered as finalised. Use particle counting or comparison membrane. Particle counting The use of an automatic particle counter is the fastest method for particle counting ina flushing fluid sample, See ISO 4402 for calibration. Particles may alternatively be separated on a membrane filter and counted by using a microscope. See ISO 5884. When required cleanliness level is specified according to ISO 4406 , itis sufficient to count particles larger than 5 and 15 um Comparsion membrane ‘The equipment for microscopic particle counting may also be used by applying comparison membrane. The procedure is the same except for the counting. Instead of counting particles, {he relevant test membrane is compared to a reference membrane by using a microscope. For a trained operator it is easy to ascertain that the sample is equal to or better than the reference. The reference membrane should be made for the relevant type of system, and it shall represent the cleanliness level required, Se Note! The membranes shall be compared using a microscope only. Dye pigment and other substances, which create colour nuances, may give completely misleading results. Samples should be verified by counting of particles. BLS Samsung HN 1408 32 of 37 \\148.224.222.4idokument\Prosjokti03 OL\1750 Samsung BLS HN1A06\13 Dokumentasjoniinstruksjonsboklvol_ 1104 installation docVOL. 1-4. INSTALLATION Gay 4.14 Instructions for flushing of pipe system (Instr, 8102) Maritime Pusnes AS Verification of turbulence 'n cold environment the flushing of pipe systems may suffer from loss of heat. To verify that the Reynolds number is larger than 3000, the temperature shall be checked at the estimated Coldest spot of the system. The flushing is only real when the lowest temperature gives a Reynolds number larger than 3000. See data for the viscosity and temperature of the relevant flushing fluid. Especially cold environments Under especially cold conditions, the pipe system etc. should be insulated to keep the temperature above the necessary minimum level. Special recommendations Max. flushing pressure must not exceed the “design pressure” for the actual pipes. d ‘Temperature of flushing oil should not exceed +70°C BLS Samsung HN 1408 33 of 37 \W146.224.222.14\dokument\Prosjekti02 OL11750 Samsung BLS HN1406\13 Dokumentasjon\instruksjonsbokWvol_ 1104 instalation docVOL. | - 4. INSTALLATION 4.14 Instructions for flushing of pipe system (Ins Nomogram for oil velocity FLOW RATE NOMOGRAM (English and Metriey r y / Veli Pt see 8 3 pitts ui) § Babes ys 8 Flow Reto—Gallon ai, s Pps Bore— neh Fw Rate—Lites ai, fio eae a Fig, 4-42 BLS Samsung HN 1408 34 of 37 \\48.224.222.14\dokument\Prosjekt03 OL\1750 Samsung BLS HN1408\13 okumentasjoniinstruksjonsbokivol_1\04 installation docVOL. |- 4. INSTALLATION 4.15 Instruction for starting up systems (Instr. 8103) 4.15. — Instruction for Starting up systems (Instr. 8103) 4.15.1. General notes * We recommend to install filters with filtration ratio [is » 75 during the ‘Starting up period. + Ensure that starting up procedures and instruction books for all units are available * Follow these procedures strictly 4.15.2. Procedure: 1. Start up pump station/power pack (see instruction books!) 2. Connect to the pipe system 3. Air bleed properly the complete system 4. Check all units and adjust the pressures as described in instruction books and “Valve adjustments" 5. Function test all units 7 Se Note! “VALVE ADJUSTMENTS" is normally attached to the equipment when despatched from Pusnes. A copy is also normally inserted in the instruction books. Extra copies may be ordered from Pusnes, BLS Samsung HN 1408 35 of 37 18148 224.222.14\dokument\Prosjekti03 OL\1780 Samsung BLS HN140013. Dokumentasjon\instruksjonsbokWvol_ 1104 instalation docGary Maritime Pusnes AS VOL. |- 4, INSTALLATION 4.15 instruction for starting up systems (Instr. 8103) 4.15.3. Sketches = By- passing/interconnection for flushing Pump motor system Deck Permanent filter [Punpstatial, -—— oR, lpower pack® “> Fig. 4.13 Ring main system | Dh temas winch inen co losstmment Lit Le Permanent filter statioge po NS q F pack f-—\_S Fig. 4.14 36 of 37 BLS Samsung HN 1408 \M46 224 222.14\dokument\Prosjekti03 OL\1750 Samsung BLS HNTAOE3 Dokumentasjontinstruksjonstokivol_ 104 installation dec4.15 Instruction for starting up systems (Instr. 8103) VOL. 1-4. INSTALLATION Fig. 4-15 |__BATPA worsonpox sarwcard an “eatea. nesaonboa a aanesaad tr | jeer ae | Gsop ahs) a atyeonn jHieecee EeePC co 1H | (reuPrs azery) 1 s24e0 eq I OATPA FetqOR oarisnoda (ret 02) enrea toxques exssosz i a A __[(cdoranypentes textos d2rseazg/ [eaten Fertez omaseagr— PATA Toriuos arnssazz] “" aoatas eieavaad” 407, | aoazoua | EO nes | ZIT SWELI 20} ea AGP, | F°ON MEquO seNsna’— ed “wotTOs *pEBORUS aR. waaw 37 of 37 installation. doc sektl03 OLI1750 Samsung BLS HN1408113 Pokumentasjoniinstruksjonsbokivol_ 1104 BLS Samsung HN 1408 \\146,224.222.14\dokument\Pros;