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Deck Machinery
Deck Machinery
Deck Machinery
Three forms of power are currently in use: steam, hydraulic and electric,
Each is described with its advantages and disadvantages for particular duties or locations
With a steam powering and control system the steam pipelines are run along the deck to
the various machines. Steam is admitted first to a directional valve and then to the steam
admission valve. Double-acting steam engines, usually with two cylinders, are used to drive
the machinery. Additional back pressure valves are used with mooring winches to control
tension when the machine is stalled or brought to a stop by the load. Arrangements must
also be made, often associated with the back pressure valve, to counteract the fluctuations
in main steam line pressure as a result of other users of steam.
The steam-powered system was widely used currently in the steam ship, large tankers since
it presented no fire or explosion risk, but the lengths of deck pipe work and the steam
engines themselves presented considerable maintenance tasks which have generally
resulted in their replacement by hydraulically powered equipment.
The steam engine efficiency is low, huge structure, laying on the deck for a long pipeline
heat loss, deck steam engine cylinder pressure is generally not more than 0.8MPa,
operation management problems, in winter when the weather is cold, before use to fully
warm engine, to discharge the residual water are some of the disadvantages of this system.
The open-loop circuit takes oil from the tank and pumps it into the hydraulic motor. A
control valve is positioned in parallel with the motor. When it is open the motor is
stationary; when it is throttled or closed the motor will operate. The exhaust oil returns to
the tank. This method can provide stepless control, i.e. smooth changes in motor speed.
The live-line circuit, on the contrary, maintains a high pressure from which the control valve
draws pressurised oil to the hydraulic motor (in series with it), as and when required.
In the closed-loop circuit the exhaust oil is returned direct to the pump suction. Since the oil
does not enter an open tank, the system is considered closed.
Low-pressure systems use the open-loop circuit and are simple in design as well as reliable.
The equipment is, however, large, inefficient in operation and overheats after prolonged
use.
Medium-pressure systems are favoured for marine applications, using either the open or
closed circuit. Smaller installations are of the open-loop type. Where considerable amounts
of hydraulic machinery are fitted the live-circuit, supplied by a centralised hydraulic power
system, would be most economical.
Hydraulic windlass mainly rely on hydraulic device to carry out and control the action.
Hydraulic windlass uses hydraulic energy from motor driven oil pump device is also known
as electric hydraulic windlass. It has the following characteristics:
(1) Good speed control performance of the DC motor.
(2) Usually uses the low speed high torque hydraulic motor, low speed, large output torque,
no longer need to set up a huge mechanical reducer, can directly drive a chain wheel.
(3) Hydraulic drive with self -brake dynamic performance, work safety and reliability.
(4) Compact structure, small weight and size of unit power. .
(5) Easy to operate, maintenance is simple.
(6) Easy remote control and automation
For large, high degree automation ship, the use of hydraulic windlass on the ship's
economy, reliability is more favorable. Hydraulic windlass can also be driven by high speed
oil motor. High speed oil motor is commonly used in the structure of the bending shaft type
axial plunger oil motor and the radial piston (or steel ball) type oil motor or vane type oil
motor. Oil motor itself is small, need to set up a larger gear reducer.
Early installations used d.c. supply with resistances in series to provide speed control. This
inefficient power-wasting method was one possibility with d.c, but a better method was the
use of Ward Leonard control. The high cost of all the equipment involved in Ward Leonard
control and its maintenance is, however, a considerable disadvantage.
Machines now operated on an a.c. supply require a means of speed control with either
pole-changing or slip-ring motors being used. Slip-ring motors require low starting currents
but waste power at less than full speed and require regular maintenance. Pole-changing
motors are of squirrel cage construction, providing for perhaps three different speeds. They
require large starting currents, although maintenance is negligible. All electric drives have
difficulty with heavy continuous overloads.
Apart from the advantages and disadvantages for each of the drive and control methods,
Each system has its advocates and careful design and choice of associated equipment can
provide a satisfactory installation.
Hatch covers
Hatch covers are used to close off the hatch opening and make it watertight. Wooden hatch
covers, consisting of beams and boards over the opening and covered with tarpaulins, were
once used but are no longer fitted. Steel hatch covers, comprising a number of linked steel
covers, are now fitted universally. Various designs exist for particular applications, but most
offer simple and quick opening and closing, which speed up the cargo handling operation.
A MacGregor single-pull weather-deck hatch cover is shown in Figure 10.5. The hatch
covers are arranged to move on rollers along a track on top of the hatch coaming. The
individual covers are linked together by chains and ride up and tip onto a stowage rack at the
hatch end. A hydraulic power unit, operated from a control box at the hatch end, is
used to open and close the hatch cover. It is possible to open and close the covers with a
single wire pull from a crane or winch. Water tightness of the closed covers is achieved by
pulling them down on to a compressible jointing strip. This is done by the use of cleats which
may be hand-operated or automatically engaged as the hatch closes. Hatch covers below the
weather decks are arranged flush with the deck, as shown in Figure 10.6. In the arrangement
shown a self-contained hydraulic power pack with reservoir pump and motor is mounted into
a pair of hatch covers. This power pack serves the operating cylinder for the pair of covers.
Control is from a nearby point and hydraulic piping is reduced to a minimum.
Maintenance requirements for this equipment are usually minimal but regular inspection and
servicing should be undertaken. Most hatch covers can, if necessary, be removed manually.
Correct operation of the mooring equipment onboard is indeed important for the
overall safe operation of a vessel in port. Mooring, being such a critical operation,
reminds us of the fact that any unforeseen event could prove dangerous and
sometimes fatal.In order to implement safety and avoiding lives to be at risk, it’s
imperative for ship’s personnel to maintain high standards of integrity of the mooring
equipment. A better way will be to incorporate all the parts of the mooring equipment
into the ship’s planned maintenance system.
Keep Oil Warm: Before the deck machinery is to be actually used, start the Hydraulic
Pumps at least 15 minutes in advance and allow at least one winch to run idling at slow
speed. This will keep the oil warm by circulating.
Cooling of oil is required when the system is run for long periods and oil needs to be
cooled by air/sea water or fresh water to maintain correct operating temperature of the
oil and efficient operation of the full hydraulic system.
Where the weight is taken on the anchor when Anchor is down and when it is up??
The figure shows a hydraulic accumulator which consists of a fixed vertical cylinder containing
a sliding ram. A heavy weight is placed on the ram. The inlet of the cylinder is connected to the
pump, which continuously supplies water or the hydraulic fluid under pressure to the cylinder.
The outlet of the cylinder is connected to the machine (which may be a lift or a crane).
The ram is at its lower most position in the beginning. The pump supplies hydraulic fluid under
pressure continuously. If the hydraulic fluid under pressure is not required by the machine, it
will be stored in the cylinder. This will raise the ram on which a heavy weight is placed. When
the ram is at its upper most position, the cylinder is full of hydraulic fluid and the accumulator
has stored the maximum amount of pressure energy. When the machine (the crane or the lift),
requires a large amount of energy, the accumulator will supply this energy and the ram starts to
move down.
A special, high speed version of the rotary vane actuator is available for stroking speeds as fast
as 250 milliseconds for full 90° rotation
Advantages:
Only one moving part allows for a 50 year design life with minimal maintenance.
Double vane design will not produce any side loading forces on the valve stem or actuator
bearings.
Balanced and constant torque is applied directly to the valve stem, without any internal
power loss, throughout the complete stroke.
The most compact and efficient actuator design available.
APPLICATIONS
Quarter-turn valve applications on natural gas pipelines, utilizing gas over oil power
pressure for the actuator.
o Emergency shutdown
o Line break protection
Valve control on product pipelines where the actuator is powered hydraulically or by
nitrogen storage vessels.
The actuator's concentric shape and balance is perfect for high vibration applications.
Compact design is ideal for platform applications and subsea applications.
High pressure construction and compact design allows for subsea applications to depths
of 750 meters without pressure compensation devices.
High speed applications with stroking times as fast as 250 milliseconds.
RAM TYPE HYDRAULIC CYLINDER
Ram type hydraulic cylinders
Ram type of hydraulic cylinder is considered as simplest type of hydraulic actuator. A ram type of
hydraulic cylinder will have a piston within its cylindrical housing. Cross sectional area of piston
rod will be more than ½ of cross-section area of piston head. There are other design variations in
ram type of hydraulic cylinder, where cross sectional area of piston rod and piston head will be
similar.
Ram type of hydraulic cylinders is generally used for providing the vertical motion such as lifting
the load in vertical direction. Such type of hydraulic cylinder is also used in providing the motion in
horizontal direction but need attention and suitable guides in order to guide the motion.
Usually ram type of hydraulic cylinders are widely used for pushing action. Hydraulic jacks are the
best example of ram type of hydraulic actuators. However ram type of hydraulic cylinders could
also be used for pulling action such as in case of hollow hydraulic jack. Hollow hydraulic jack is
used for pulling the pin from any assembly and we must note it here that hollow hydraulic jack
could also be used for pushing action.
Types of ram type of hydraulic actuators
Ram type of hydraulic actuator is basically classified in to three types as mentioned here
1. Single acting ram-type of hydraulic cylinder
2. Double acting ram-type of hydraulic cylinder
3. Telescopic ram type hydraulic cylinder
4. Following figure displayed here indicates the single acting ram type of hydraulic cylinder,
and as it indicates single acting ram type of hydraulic cylinder hence such type actuator will
have one port i.e. cap end port and will be operated hydraulically in one direction only.
5. Following figure displayed here indicates the double acting ram type of hydraulic
cylinder, where there will be two ports i.e. cap end port and rod end port. Double
acting ram type hydraulic cylinder, as name indicates, will be operated hydraulically
in both direction i.e. forward direction and return direction.
6. Ram types of hydraulic cylinders are basically used in hydraulic jacks, automobile
hoist and elevators.
The three maintenance procedures that have the greatest effect on system life,
performance and efficiency are:
1. Maintaining an adequate quantity of clean and proper hydraulic fluid with the correct
viscosity
2. Periodic cleaning and changing of all filters and strainers
3. Keeping air out of the system by ensuring tight connections.
A vast majority of the problems encountered in hydraulic systems have been traced to the
hydraulic fluid, which makes frequent sampling and testing of the fluid, a vital necessity.
Properties such as viscosity, specific gravity, acidity, water content, contaminant level
require to be tested periodically. Another area of vital importance is the training imparted to
maintenance personnel to recognize early symptoms of failure. Records should also be
maintained of past failures and the maintenance action initiated along with data containing
details such as oil tests, oil changes, filter replacements, etc.
Oxidation and corrosion are phenomena which seriously hamper the functioning of the
hydraulic fluid. Oxidation which is caused by a chemical reaction between the oxygen
present in the air and the particles present in the fluid, can end up reducing the life of the
fluid quite substantially. A majority of the products of oxidation are acidic in nature and also
soluble in the fluid, thereby causing the various components to corrode.
Although rust and corrosion are two distinct phenomena, they both contribute a great deal
to contamination and wear. Rust, which is a chemical reaction between iron and oxygen,
occurs on account of the presence of moisture-carrying oxygen. Corrosion on the other
hand is a chemical reaction between a metal and acid. Corrosion and rust have a tendency
to eat away the hydraulic component material, causing malfunctioning and excessive
leakage.
Heat kills hydraulic systems. That’s why hydraulic oil coolers are widely used to remove
excess heat generated by energy losses in a system.
Maintaining the correct temperature keeps oil at its recommended viscosity, ensuring
mechanical components are properly lubricated and hydraulic devices run at peak
efficiency. Letting oil temperature rise beyond recommended limits can reduce the life
of a system due to poor lubrication, higher internal leakage, a higher risk of cavitation,
and damaged components.
Keeping temperatures down also helps ensure the oil and other components last
longer. Excess heat can degrade hydraulic oil, form harmful varnish on component
surfaces, and deteriorate rubber and elastomeric seals.
Finally, with more machine uptime and fewer shutdowns, it reduces service and repair
costs.
Considering the benefits coolers offer, it’s apparent that accurately sizing them is a
paramount concern for design engineers. Undersizing obviously allows higher-than-
recommended oil temperatures. But over sizing hurts system efficiency as well, by
reducing temperatures below the recommended range and increasing costs with a
larger-than-necessary purchase.
With cooler weather on the way, you may not be too worried about rising oil
temperatures, but the fact is, any industrial hydraulic system running higher than 140
degrees is too hot. Consider that for every 18-degree increase in temperature above
140 degrees, the life of the oil is cut in half. Systems that operate at high temperatures
can produce sludge and varnish, which result in the sticking of valve spools. Pumps
and hydraulic motors bypass more oil at high temperatures, causing the machine to
operate at a slower speed. In some cases, high oil temperatures can waste electrical
energy by making the pump drive motor pull more current to operate the system. O-
rings also harden at higher temperatures, leading to more leaks in the system.