125001-B316-1006 - Rev.0 - Operation and Maintenance Manual

Operating and
Maintenance Manual
Keppel Fels Hull NO. B 316
Traction - Storage Winch Combination

TSW-325
83mm – 2020 kN
SFI No.:
432-M1 (Winches)
Maschinenfabrik Bröhl GmbH & Co oHG

Koblenzerstr. 42
D-56656 Brohl -Lützing
0 First edition 06.06.11 K.Bous

Revision Changes Date Name
Translation by Jasen Richards
125001-D-B316-1006 24.04.06 K.Bous
Document No.: Date Name
BRÖHL GmbH & Co. oHG Tel. : +49 02633 291 0
Koblenzer Str. 42 Fax : +49 02633 291 32
D-56656 Brohl-Lützing Internet : http:\\ www.Broehl.de
Germany e-mail : info@broehl.de
TABLE of CONTENTS
A. INTRODUCTION 5
1. GENERAL DESCRIPTION 8
1.1 General................................................................................................ 8
2. TECHNICAL DATA TRACTION WINCH 9
3. DESCRIPTION DOUBLE TRACTION WINCH 11

3.1 Gear Box with drive ........................................................................... 11
3.1.1 Dynamic Brake (water cooled) ................................................. 13
3.1.1.1Cooling System for the Dynamic Brake ................................. 14
3.1.2 Gear Brake ............................................................................... 16
3.1.3 Gear shifting ............................................................................. 17
3.1.4 Electrical Drive with Variable Frequency Drive ........................ 18
3.2 Traction Winch................................................................................... 21
3.3 Drum.................................................................................................. 22
3.3.1 Band brake ............................................................................... 22
3.3.2 Brake cylinder........................................................................... 23
3.3.3 Dog clutch ................................................................................ 24
3.3.4 Interlocking device ................................................................... 26
3.3.5 Load measuring device ............................................................ 28
3.3.6 Air pressure system ................................................................. 30
3.3.6.1Pressure air valves and electric cabinet at the traction winch 32
3.3.6.2Pressure air valves and electric cabinet at the gear box ....... 35
4. TECHNICAL DATA STORAGE WINCH 36
5. DESCRIPTION STORAGE WINCH 38

5.1 Gear Box with drive ........................................................................... 38
5.1.1 Clutch / Dynamic brake (water cooled) .................................... 39
5.1.1.1Cooling System for the Clutch / Dynamic Brake .................... 40
5.1.2 Electrical Drive with Variable Frequency Drive ........................ 42
5.2 Drum and Band brake ....................................................................... 47
5.2.1 Drum......................................................................................... 47
5.2.2 Band brake ............................................................................... 47
5.2.3 Brake Cylinder.......................................................................... 48
5.2.4 Air Pressure System ................................................................ 51
5.2.4.1Pressure air valves and electric cabinet at the Storage winch53
5.3 Measuring Devices ............................................................................ 55
5.3.1 Length measuring and speed monitoring................................. 55
Traction-Storage Winch TSW 3253 -2020 kN Page: 2

5.3.2 Bitter End Switch ...................................................................... 56
5.3.3 Over Speed Protection............................................................. 56
5.3.4 Load measuring ....................................................................... 57
5.3.5 Slack Rope Switch ................................................................... 58
6. LOCAL CONTROL STAND LCS 59
7. CENTRAL MONITORING PANEL CMP 62
8. COMMISIONING 64
8.1 Lifting ................................................................................................. 64
8.2 Transportation ................................................................................... 66
8.3 Storage .............................................................................................. 67
8.4 Assembly ........................................................................................... 67
8.5 Commissioning .................................................................................. 71
9. OPERATION 72
9.1 Operating Devices ............................................................................. 72
9.2 Motor Mode ....................................................................................... 74
9.3 Drag Mode......................................................................................... 75
9.4 Emergency Brake Release................................................................ 80
10. MAINTENANCE AT TRACTION WINCH 81

10.1 General.............................................................................................. 81
10.2 Gear Box ........................................................................................... 82
10.3 Greasing points ................................................................................. 82
10.4 Piping / Pressure Tank .................................................................... 887
10.5 Coolant Lines with Drag brake ........................................................ 888
10.6 Band Brake........................................................................................ 90
10.7 Gear Brake ........................................................................................ 91
10.8 Curved Tooth Coupling ..................................................................... 92
10.9 Electrical Drive................................................................................... 93
10.10 Local Control Stand (LCS) ................................................................ 94
10.11 Coating .............................................................................................. 94
11. MAINTENANCE AT STORAGE WINCH 95

11.1 General.............................................................................................. 95
11.2 Gear Box ........................................................................................... 95
11.3 Maintenance and Grease Fittings ..................................................... 96
11.4 Piping / Pressure Tank at Storage Winch ....................................... 103
11.5 Coolant Lines with dynamic Brake / Clutch..................................... 104
11.6 Band Brake...................................................................................... 106
11.7 Spooling device with adjustment Gear ............................................ 108
11.8 Electrical Drive................................................................................. 110
11.9 Switch cabinet with air conditioning................................................. 111
11.10 Coating ............................................................................................ 112
12. SPARE PARTS 113

12.1 Traction Winch................................................................................. 113
12.2 Storage Winch ................................................................................. 115
13. PARTS LIST 117

A. INTRODUCTION
Introduction
This operating and maintenance manual contains information regarding the
installation, commissioning, maintenance and spare parts of the winch.
The rules of safety covered in this document are to be followed to the letter.
Notes on Safety
BRÖHL products are made according the latest technology available. That
said dangerous situations, situations that are hazardous to both the health and
life of individuals, are commonplace in the offshore setting.
In addition there is also the possibility of the winch being damaged.
This symbol is used when a potential

danger threatens both the life and
health of the personal
This symbol is used when a potential

danger could damage the winch
When this symbol is displayed pay

special attention to the accompanying
comment.
Case for case the following difficulties can arise:

• if personal with insufficient training were to manipulate the winch
installation;
• if the winch equipment were to be installed improperly; ran or
maintained improperly;
• if the winch equipment were to be used for anything other than its
intended purpose.

All individuals that operate or maintain the winch equipment must
observe the following:
the section “Safety Notes” page 4, must be read and understood.
at the very least the operator must be familiar with the part of the operating
manual that covers the activity he is carrying out and the associated
dangers there with.
The operator must be familiar with procedures for shutting the equipment
down like “Emergency Stop”.
the operator must have specific knowledge about the winches performance.
The operating and maintenance personal must have a sufficient technical
qualification and be authorised to execute relevant activities on the
equipment.
The operating and maintenance personal are not to operate the winch in a
manner that could lead to damage to the equipment or harm to individuals.
a report is to be made on all damages discovered during the operation of
the product such as e.g. abnormal noises while running.
the winch equipment must be kept in a clean and operationally reliable
condition.
the winch equipment is only to be run provided it is in a operationally sound
condition.
the winch equipment is only to be used for its intended purpose.
The general accident prevention regulations must be observed.
Guarantee Obligation
BRÖHL will not honour guarantee obligations for claims deriving from the
following circumstances:
if the winch equipment were to be opened or modified without our consent.
in the event that the instructions outlined in this manual are not followed
if replacement parts or accessories were to be built on or into the equipment
that were not provided or approved by BRÖHL.
if the winch equipment was not properly aligned.
if the specified technical particulars are exceeded or as the case may be
fallen short of.
if the winch equipment was not properly operated.
if the winch equipment has been manipulated

We reserve the right to carry out technical alterations for the purpose of
product improvement.
The photos and data, presented in this manual can slightly differ from the
actual design.
If nothing else is stated in the contract, Bröhl will handle guarantee claims
according to the “General Supply and Service Terms” valid during the point of
time when the contract was signed.
Right to Reproduce
We reserve the right to copy drawings.

A drawing is only to be used for the purpose for which the receiver claims.
Drawings are not to be passed on to a third party without our specific written
permission.
Reproducing drawings in any form, as a whole or a partial reproduction, is not
permitted. Infringements will be legally pursued.
Right to Reproduce
We reserve the right to copy drawings

1. GENERAL DESCRIPTION
1.1 General
The Semisubmersible drilling tender is equipped with an 8 point rope anchor

mooring system.
The Winch system is a traction- storage winch system.
At each corner of the vessel a double traction winch is placed on the deck.
Inside each column two storage winches are installed and outside each
column two underwater swivel fairleads.
Each traction/storage winch system has its own electrical control cabinet
and operation panel (Local control stand) located on the same level as the
traction winch.
The operational data of the 4 double traction winches and 8 storage winches
are monitored on a central panel which is positioned in a separate room.
Traction Winch
Local
control
stand
Fairleader
Storage Winch
Fig. 1 – Traction – Storage Winch System TSW 325 on SSDT 3600 E

2. TECHNICAL DATA TRACTION WINCH
General
Wire Rope Diameter: 3 1/4” (83mm)
Nominal Pull: 2,020 kN
Overload: 2400 kN (max. 20 min)
(Stalling Pull)
Nominal Speed: 0-10 m/min. @ 2020 kN
Gear Ratio "Low Gear" 10-20 m/min. @ 2020-1010 kN
Gear Ration “High Gear" 0-20 m/min. @ 1010 kN
20-40 m/min. @ 1010-505 kN
Brake Holding Force 6200 kN = MBL
(minimum breaking load)
Dynamic Brake Capacity: 1500 kW
Max. Speed with the Dynamic Brake: 120 m/min.
Max. Braking Force with 900 kN
the dynamic Brake
Drive:
Frequency Control. Squirrel Cage Motor:
Power: 415 kW
RPM: 0–1200 1/min (Constant Torque)
1000–2000 1/min (Constant Power)
Rated Voltage: 480 V
Frequency: 0–100 Hz
Variable Frequency Drive:

Regenerative Type
Make: ABB
Type: ASC-800-17
Power: 630 kW

Gear Box:
Transmission Gear Ratio i= 440
Oil Contents: app. 840 ltr.
The indicated oil quantities are recommendations.

The oil level should always be between the two marks
on the dipstick.
Air Pressure System:

Max.Pressure: 8 bar
Coolant System (Fresh Water):

Coolant Consumption: 900 liter / min.
without Antifreeze
1300 liter/min.
with Antifreeze
Required Pressure Difference: at least 2,5 bar
for the brake
Maximum Water Pressure 4,2 bar
Weight of the Main Components:

Winch (complete): 57 t
Gear Box (complete): 17 t
Weight of the Individual Components:

Each Drum 9,6 t
Electrical Drive: 3,2 t
Dynamic Brake (Drag Brake) 2,5 t
Gear Brake 0,15 t
Band Brake Complete (each) 0,75 t
Bow Tooth Coupling 2t
Axle for Drums 0,9 t /each

3. DESCRIPTION DOUBLE TRACTION WINCH
Fig. 2 –Double Traction winch
3.1 Gear Box with drive
The gearbox, consists of an enclosed housing with pinions and gears made
from highly alloyed steel (some parts also hardened) that run on roller
bearings.
These are lubricated by means of both sump and splash lubrication.
The gearbox is a 2-step transmission. This can be switched pneumatically
from the local control stand as well as manual by hand in high gear, low
gear and neutral position.
The housing has been fitted with inspection covers to allow for easy checks.
A special aspirator takes care that sea water can not enter the gearbox
housing while keeping it properly ventilated.
A pneumatically actuated and water cooled disc brake attached to the side
of the gearbox housing is fixed to the first pinion shaft. This serves as a
dynamic brake for the winch during the operation where the Anchor is
pulled out from the vessel with the tug boat.
A pneumatically operated disk brake on the opposite site of the electric
motor serves as a parking brake.

A movable curved tooth coupling located between the gearbox housing and
the winch serves as a power transmitter. This can compensate a limited
amount of angular misalignment that may have arisen from the separate
foundation frames.
Aeration Oil Dipstick Flashing light
Motor
Fig. 3 –Gear box with motor

Dynamic Brake
On top of the gear box a flashing light is mounted which lights up when the
winch is in operation.
The aeration of the housing is ensured by means of a spring operated valve
on the cover of the gear box.

Dynamic Brake (water cooled)
The pinion shaft has been fitted with a three disc-type brake system type
336 from WPT. The brake is pneumatically actuated.
The brake is used to control the speed of the rope while the anchor is
being taken out by the tugs (drag mode).
The brake torque and therewith the brake resistance while being pulled
out is generated pneumatically. The braking force can be controlled from
0% to 100% over a potentiometer on the local control panel.
The control valves have been grouped together to form one unit. They are
located in water tight, stainless steel switch cabinet located on the front
side of the gear housing.
The brake does not have a "Fail Safe" design meaning when the pressure
drops off the brake force will drop off as well. The springs will open the
brake as soon as there is no more pressure.
The brake linings are made of a special material which provides both a
good friction coefficient with low wear. Copper lined cooling jackets are
used in order to quickly dissipate the heat. The cooling feature allows the
brake to absorb a huge amount of energy (1689 kW) during continuous
operation.
For further information and technical data see the WPT manual provided
in the sub suplier folder.
Water Outlet
Hoses
Pressure Air Inlet
Drag Brake
Water
Outlet
interface Water Intlet
Interface
Water Intlet
Hoses
Fig. 4 –Dynamic Brake; pneumatically operated and water cooled

3.1.1.1 Cooling System for the Dynamic Brake
The brake will be cooled with continually flowing fresh water.
The coolant is provided from the on board fresh water system.
The pressure of the coolant is limited by means of a combined pressure
regulating – shut of valve. The valve is located in the inlet pipe for the
coolant for the brake. The maximum pressure should not exeet 2.7 bar
to secure the copper cooling plates of the drag brake.
NOTE: Do not close the shut of valve of the outgoing pipeline.
A dammage of the copper plates inside the brake can be caused!
A temperature gauge and a flow sensor monitors the temperature and
the volume flow of the coolant. A temperature sensor in the coolants
exiting pipe measures the temperature and transmits the data to the
PLC.
Will 65°C are exceeded the temperture sensor gives a signal to the PLC
and as result the brakes wil be closed completely. So the tug boat is
braked and an overheating and damage of the dynamic brake is
avoided.
The automatic closing of the band and gear brake as a

reaction to the over heated coolant could be hazardous
to the tug boat that is pulling out the wire rope.
Continual feed back between the operation personal and
the tug is necessary to safeguard against damage.
The consumption rate for the dynamic brake is 900 l/min. when using
fresh water and 1200 l/min when using a water-glycol mixture.
If the temperature exceeds the maximum temperature, the temper-ature
gauge will send an alarm. If their is no coolant flow a monitor will
prevent the operation of the winch in the drag mode.
Flow meter
Pressure
Regulating
Valve
Backflow
Pipeline
Fig. 5 –Cooling line equipment

The pressure difference between the inlet and outlet should not exeed 2.7 bar.
In order to protect the brake from contamination a filter has been built into the
coolant line that should be checked and cleaned in regular periods.
Cooling Pipeline
with Strainer
Backflow Pipeline
Fig. 6 –Dynamic Brake; pneumatically operated and water cooled
Closing the recirculation line to the pump is prohibited. A

pressure surge could be cause if the outlet line were to be
closed while the inlet were still opened which in turn could
damage the brake.
As a basic principal the outlet line is always to be opened
before the inlet line!
Bröhl recommends that the outlet valve be secured in the
open position!
If subject to the danger of frost the system should be purged

of any untreated water in order to avoid any damage to the
brake or the coolant system.
Or: mix the water with 40% glycol.
Danger of being Burnt!

The outlet pipe fort he dynamic brake can get very hot!
Cooling with sea water is prohibited!
No Water pressure in the outletline should increase 1 bar!

Gear Brake
Attached to the drive shaft for the winch and opposite the E-motor, is a
pneumatically operated air cooled multiple-disc brake from WPT type 314
LI.
The brake works in sinc. with the winch motor. It will open only after the
motor has enough torque to hold the load.
In the drive mode the brake is used to hold the load when the motor is not
moving.
The brake has a „fail-safe“feature. A loss of pressure will allow springs to
uncoil and close the brake. The brake will remain closed during a loss of
pressure.
The control valves have been grouped together to form one unit. This is
mounted in a water-tight stainless steel cabinet on the front of the gear
box housing.
A pressure in the line monitors the air lines to assure that sufficient air
pressure is being supplied. The winch will not be able to be run if the
pressure is too low.
The pressed air will be supplied by the rig air system. The minimum
pressure is 6 bar. For information on the pneumatic air quality see chap.
XXXXXXX
The static breaking torque amounts to 6100 Nm.
Air Terminal
Fig. 7 – Air Operated Gear Brake

Gear shifting
The gearbox is a 2-step design. Two opposing pneumatic cylinders wich

are switched by means of solenoid valves, shift the 2-step (high/low)
gearbox into three different positions. Limit switches monitor the setting of
the gearbox by means of a cam disk. (high / neutral / low) .
The operation is from the local control stand.
The gear ratio, high / low is 2:1. In the high gear the winch is twice as fast
with half the pull.
If there is a loss of air pressure, the gear shifting can also be carried out
by means of a hand wheel. The hand wheel is located near both cylinders.
Blow off any residual pressure in the pressure tank before using the
handwheel.
Hand Wheel Cam Disk Pneumatic Cylinder
Limit Switch
Fig. 8 – Gear shifting by means of cylinders or Hand wheel (image similar)

Electrical Drive with Variable Frequency Drive
Motor
The winch is driven by a external fan cooled squirrel cage type ABB motor
with a effective power of 415 kW.
The motor is designed with a variable frequency drive (VFD) with a range
of 0 Hz to 100 Hz. This allows for precise alterations in the motor speed to
suit the conditions at hand.
The motor is controlled by a PLC that sends signals to the frequency
converter over the Profibus.
The motor has been fitted with an encoder to monitor the RPM´s.
Three temperature sensors type PT100 (one for each coil) and three
spare sensors monitors the coil temperature. If the temperature were to
exceed 135°C an alarm will be sent to the operator. It will not be possible
to operate the motor if the temperature were to continue to raise and
exceed 145°C.
An anti-condensation heater will be active if the winch motor is not in
operation.
An elastic shock absorbing coupling (drip-proof) has been installed
between the motor and gearbox.
Fig. 9 – Motor assembled at the Gear box

Fig. 10 – Motor Data sheet

Variable Frequency drive(VFD)
The winch motor is feed by a variable frequency drive (VFD) make ABB type
ASC 800-17. It is a cabinet build drive, located in a air conditioned MCC room.
The air cooled drive is regerative type that means the regenerative enregy is
return to the network and will not be wasted as heat.
A emergency stop is equiped as well as a remote control panel.
The VFD makes it possible to variably choose the RPM between
0-2000 1/min, which in turn translates to a cable speed of 0-20 m/min in low
gear and 0-40 in high gear.
Fig. 11 – VFD cabinet for one winch
Remote Control
Panel
Measuring
Display
Emergency Stop
Main Switch
Fig. 12 – Front view of the VFD

3.2 Traction Winch
The winch is a welded steel construction with two solidly built pedestals
arranged to the side. This arrangement transfers the cable forces to the
vessel´s foundation.
Braking of the winch is by means of two sling band brakes which serves as
holding brakes.
A manual operated interlocking wheel at the seaside drum is lateraly
arranged to lock the drum for maintenance purpose.
At the oposite side of the band brake a spur wheel is located which is driven
by means of a pinion between both tration drums.
The winch is furnished with load measuring equipment situated under the
foundation feet. This equipment makes it possible to monitor the cable
loads
Interlocking Wheel Band Brakes
Spur Wheel
(covered)
Pedestal
Pneumatic /
Electric Valve
Cabinet
Guiding Rollers
Air Reciever
Brake Cylinder
Fig. 13 - Winch with attached Parts
Load cells

3.3 Drum
Traction drums with 7 grooves for steel wire 3 ¼” Ø, material S355J2G3,
grooves hardened (hardness min. 40 HRC), with laterally arranged spur wheel
and brake ring (one drum with interlocking sheet), spur wheel with protec-tion
cover, grease lubricated.
Spur Wheel
Drum with Grooves
Brake Ring
Fig. 14 Rope drum with attached Parts (without interlocking sheet)
Band brake
Every traction winch is fitted with two band brakes that work independently
from one another. Each band brake has been designed to hold 50% of the
rope braking force, and together 100% of the MBL of 620 metric tons. This
was a requirement oft the classification society.
Brake cylinder
Brake Band
Ring
Fig.15 Band brake with brake cylinder

A high-grade asbestos free brake lining has been attached to the steel brake
ring.
All bolts used on the band brake are made of stainless steel.
Brake re-adjustment when necessary should be carried out as described in
chapter XXXX
Brake cylinder
The band brake is released by means of a pneumatic cylinder.
Disk springs inside of the pneumatic cylinder, provide the force necessary
to close the brake. Additional pressure air increases the brake force with
50%.
The disks are running in a oil bath to avoid corrosion. During moving of
the piston the oil is flowing to the oil reservoir and back to the cylinder.
The oil reservoir is pressure free and ventilated with a goose neck.
The brake cylinder is equiped with a visual wear indication as well as a
wear indication by means of proximity limit switch. A alarm message is
occurred on the screen in the local control stand when the break lining is
weared.
Release Hose
Goose Neck
(Ventilation)
Oil Reservoir
Booster Hose
Wear Adjustment
Spindle
Visual Wear
Indikation
Proximity Switch
Fig. 16 Band brake with brake cylinder
The brakes „fail-safe“design assures that it is fully engaged in the case of

loss of pressure. The brake holding force will be also generated even in
case the brake linings are worn.

Brake Brake Brake worn
released engaged out
Fig. 17 Crossection brake cylinder in different positions
The necessary pneumatic pressure is supplied by air reciever which is

feed from the ships system.
mounted in a water-tight stainless steel cabinet at the side of the winch
frame( see chapter XXX).
In case of dead ship conditions – the air reciever has been designed to
provide enough pressure to open the brakes at least 3-times, enabling a
brake release under emergency conditions.
The winches pre-designed brake holding force can only be achieved when
the brakes are properly adjusted. When the brake is engaged the indicator
on the brake cylinder must be in the red area to assure for a proper
running of the system If not, adjustments are necessary.
Dog clutch
The spline clutch which is attached to the transmission shaft allows for the
engaging and disengaging of the two traction winches.
The clutch is operated by means of a pneumatic cylinder. The control
valves have been grouped together with the brake controls to form a
hydraulic block located in a stainless steel cabinet at the winch (see
drawing 120220-102, fig.6). (see drawing 120220-102, fig.6)
The end position of the clutch is monitored by a limit switch and can be
seen on the touch screen at the local control stand.

The clutching operation runs automatically. If the cylinder is unable to put the
two parts together due to their relative (to each other) positioning. The motor
will automatically move one of the pieces and retry till it has found an opening.
Fig.18.1 – Dog clutch (disengaged) Fig.18.2 – Dog clutch (engaged)
The end positions of the clutch is interlocked by means of a pneumatic

cylinder which blocks the shifting lever of the clutch. Both engaged and
relased position are monitored with inductivity limit switches.The operation of
the winch is interlocked when the end positions are not reached.
In the case of loss of power the clutch can be switched with a hand lever
which should be fixed at the switching lever.
Extension
for Hand
Lever
Fig.19.1 – Cylinder with Limit Switch Fig.19.2 – Hand Lever

The automatic clutching process can last up to
90 sec. The RPM´s and torque will adapt
accordingly.
It is prohibited to execute other procedures
during the clutching process .
The coupling must always either be completely

engaged or completely disengaged.
These positions will be displayed when they
are reached. Operating the winch when the end
position has not been reached is prohibited.
This can cause damage to the clutch!
Interlocking device
The winch has been fitted with a manually operated mechanically

interlocking device which allows for maintenance or repair work (without
the band brake) while the winch is under load. Both end positions
(completely open-closed) fort he interlocking device are monitored by
means of two proximity switches.
Once the locked position is recognized, the system will automatically limit
the motor in the “lowering” direction in both RPM and torque assuring that
the equipment is "softly" set in position.
The hand wheel (1) connected to the threaded spindle (2) is used to
position the pawl (3).
In order to engage the pawl the hand wheel (1) must be turned in the
clockwise direction till its end point and the spindle (2) can no longer be
turned.
This will cause the pawl to (3) to slip into the next available slot in the
interlocking wheel (4). If the position of the pawl don’t fit with the gap in
the interlocking wheel a loaded spring on the pulling rod (5) will push the
pawl into position with the next movement of the wildcat.
To release the interlocking device the hand wheel must be turned in the
“counter clock-wise” direction until it stops. The spring on the pulling rod
will be enable uncoil relieving the system of tension and the pawl (due to
gravity) will fall back into place.
If the pawl cannot be completely released (gets stuck), it can be “helped”
into its resting position by "hoisting". If the winch is then briefly ran in the
“hoisting” direction the pawl will brake free.

Interlocking
Wheel (4)
Hand Wheel
for Actuation
Fig.20 – Interlocking sheet with handwheel
Interlocking
Wheel (4)
Pulling Rod (5)

with Spring
Threaded Spindle(2)
Interlocking
Pawl (3)
Hand Wheel (1)
for Actuation
Fig.21 – Interlocking sheet with handwheel

Load measuring device
The pulling force of the winch is monitored by two stainless steel, load
cells, mounted between winch frame and foundation feet of the windlass
frame. The measured value in the loadcell is always a constant
percentage of the complete load. A recalculation takes place in the PLC
which then displays the true (end) value at both the local and the central
control desks.
Measuring Range: 0 – 300 t

Max. Load: 450 t
Breaking Load: 900 t
Supply Voltage: 10 V DC
Output Signal: 4-20 mA
Accuracy: 1% of measuring value
For detailed information on load measuring bolts refer to the information

provided by the sub supplier.
Junction Box
Fig.22.1 – Loadcell Fig.22.2 – Loadcell mounted between

foundation feet and frame
cable output

Replace of the Load cell:
Fig.23 – Loadcell replacement sketch
To replace the loadcell pls. follow the following steps:
1. Disconnect the cable from the junction box (fig. XXX)

2. loose nut “A”
3. remove screw “B”
4. lift up the winch frame “F” for approx. 1mm and remove the thrust piece “C”
5. open screw “D” until its not fastened in foundation feet
6. loose the load cell with e.g. a screwdriver
To install the new loadcell handle in the counterwise procedure.

After installation grease the contact surface between loadcell and thrust piece
through grease nipple “G”

Air pressure system
Various parts of the winch are driven and controlled using pneumatics.
The pressure supplied by the on-board system must have at least 7 bar.
The air must be free of water and solids.
The pressurized air goes through a coarse filter before it is pumped into
the 500 liter tank. The underside of the tank has been fitted with a manual
condensation bleeder valve. A safety valve set at 10 bar ensures that
overpressure is blown out of the system.
Safety Valve=10 bar
Shut Off Valve

to the Cabinet
Check Valve
and Filter
Condensate
Condensation
Drain
drain off valve
Fig. 24 – Air reciever tank 500 l
For more information on how to conduct maintenance on the equipment

read chapter XXX pneumatic lines and pressure tank.
Quality Requirements on the Pneumatic Air Supply
Air quality
Depending on the geographic and climatic conditions the quality of the
atmospheric air, which is used as a medium in compressed form, will differ.
Today’s requirements on lifetime and operation safety of appliances as well as
the environmental requirements aim to a permanent high quality of
compressed air – independent from climate and surroundings.

The air covers not only water but also dust, aerosol, chemicals, organism etc.
which are sucked-off the compressor. This mixture must be conditioned in
relation to its application and the selected appliances.
Contamination materials and their state of aggregation are listed in the ISO
8573-1. This standard defines quality grades and their limits.
Solid matters
Solid matters appear in form of dust of different size and shape (amorph,
crystalline). They cause wear of the sealing elements and running surfaces.
The width of the pores of the mechanic filters limits the particle size of the solid
matters; at same time the pressure drop at the filter cartridge is increased in
relation to its fineness.
Moisture and water content

Depending on its temperature to pressure relationship water will exist in a
liquid or gaseous form.
It can contribute to corrosion of structural parts or could wash-off the grease in
the appliances.
By drying the air these consequences could be avoided.
Oils
Residual oil from the compressor or sucked-off oil aerosol do not have any
positive effect on the greasing. They could cause damages of the structural
parts and lead to wear. However precautions can be taken by using suitable
filters.
Synoptical table of classification according to ISO 8573-1
Class Solids Moisture - Water content Oil content

Max. numbers Particle size Numbers of Pressure dew Amount of water Amount of oil
of particles particles point*
per m3
1<d≤5µm [µm] [mg /m3] [ °C] [g/ m3 ] [mg /m3]
0 ** ** - **
1 0 - - ≤ -70 - ≤ 0,01
2 10 - - ≤ -40 - ≤ 0,1
3 500 - - ≤ -20 - ≤1
4 1000 - - ≤ +3 - ≤5
5 20000 - - ≤ +7 - -
6 - ≤5 ≤5 ≤ +10 - -
7 - ≤ 40 ≤ 10 - 0,5 ≤ m ≤ 5 -
8 - - - - ≤5 -
9 - - - - ≤5 -
* The pressure dew point should be lie at ** to be stipulated

least 15°C below the ambient temperature.
Fig. 25 – classification table

Pressure air P&I
Fig. 26 – Pressure Air P&I diagram (refer to Drwg. 125001-101)
The air recievers at each traction winch are connected to each other so that in
case one fails the other can provide pressure air for both traction winches. The
possibility to open the brake several times during loss of pressur in case of
EBR is limited then.
3.3.1.1 Pressure air valves and electric cabinet at the traction winch
The switching of the bandbrake, the dog clutch as well as the
interlocking for the dog clutch will be executed by solenoid valves which
are located in a stainless steel cabinet beside the traction winch. The
cabinet contains as well PLC modules and electric equipment in a
separate part.

The following elements are housed in the valve part of the cabinet:
A filter with a condensation draining device for filtering the pressured air
and separating the remaining water.
A proportional valve for regulating the braking force of the drag brake.
A solenoid-operated 5/2 way valve for opening and closing the gear brake.
Two solenoid-operated 5/2 way valves for switching in high and low gear.
A pressure switch for monitoring the pressure in the line for the drag brake.
A pressure switch in the main line for monitoring the pressure in the air
supply system.
The noise caused by exiting pressurized air is muffled using an appropriate

muffler.
Clutch
IN / OUT
Filter
Clutch
Interlocking
Condensate Band Brake

Drain Release
Condensa
te drain
Pressure
Switches
Pressure
reducer Pressure
Boost for Band
Brake
Mufflers
Fig. 27 – Pressure Air valves cabinet at traction winch

The following parts are housed in the electronic part of the cabinet:
Several I/O modules for transmitting the measured data in the PLC
A standstill heater to prevent condensation
Electrical conectors
Fiber optic cable connection
I/O modules
fiber optic
cable
connection
Fig. 28 – Pressure Air electric cabinet at traction winch
Heater

3.3.1.2 Pressure air valves and electric cabinet at the gear box
The switching of the gear brake, the drag brake and the gear shifting
will be executed by solenoid valves which are located in a stainless
steel cabinet in front of the gear box. The cabinet contains as well PLC
modules and electric equipment in a separate part.
A filter with a condensation draining device for filtering the pressured

air and separating the remaining water.
A proportional valve for regulating the braking force of the drag brake.
A solenoid-operated 5/2 way valve for opening and closing the ger
brake.
Two solenoid-operated 5/2 way valves for switching in high and low
gear.
A pressure switch for monitoring the pressure in the line for the drag
brake.
A pressure switch in the main line for monitoring the pressure in the
air supply system.
Cylinder for
Proportional Valve Gear Shifting Pressure Measuring
Filter
Pressure
Switches
Silencer
Gear
Brake
Fig. 29 – Pressure Air valve cabinet at gear box

4. TECHNICAL DATA STORAGE WINCH
General
Nominal Pull: 50 kN
Nominal Speed: 0-40 m/min in all layers
Storage capacity: 1342 mm in 13 layers
Band Brake Holding Force: 120 kN
Dynamic Brake Force: 100 kN
Max. Speed with the Dynamic Brake: 120 m/min.
Wire Rope Diameter: 3 1/4” (83mm)
Drive:
Frequency Control. Squirrel Cage Motor

Power: 48 kW
RPM: 0–703 1/min (Constant Torque)
703–1636 1/min (Constant Power)
Rated Voltage: 480 V

Frequency: 0–100 Hz
Variable Frequency Drive:
Regenerative Type
Make: ABB
Type: ASC-800-11
Power: 90 kW

Gear Box:
Transmission Gear Ratio i= 19
Oil Contents: app. 90 ltr.
The indicated oil quantities are recommendations.

The oil level should always be between the two
marks on the dipstick.
Air Pressure System:

Max.Pressure: 8 bar
Coolant System (Fresh Water):
Coolant Consumption: 80 std. liter / min.

without Antifreeze
100 std. liter/ min.
with Antifreeze
Required Pressure Difference: at least 2,5 bar
for the brake
Maximum Water Pressure 4,2 bar
Weight of the Main Components:

Winch (complete) 24 t
Weight of the Individual Components:

Each Drum: 9,5 t (10,8 t complete)
Electrical Drive: 725 kg
Dynamic Brake / Clutch 540 kg
Band Brake Complete (each) 240 kg
Axle for Drums 540 kg

5. DESCRIPTION STORAGE WINCH
Chain Drive
(covered)
Drum Box
Pinion Motor
Gear Box Pinion

Measuring Device
Clutch/Brake
(covered)
Adjustment Gear
Spooling
Adjustment
Buttons
Spooling device
Fig. 30 - Storage winch
5.1 Gear Box with drive

The gearbox, consists of an enclosed housing with pinions and gears made
from highly alloyed steel that run on roller bearings.
These are lubricated by means of both sump and splash lubrication.
The housing has been fitted with a inspection cover to allow for easy
checks. A special aspirator takes care that sea water can not enter the
gearbox housing while keeping it properly ventilated.
A pneumatically actuated and water cooled clutch / brake attached to the
side of the gearbox housing is fixed to the pinion shaft. This serves as a
dynamic brake for the winch during the operation where the Anchor is pulled
out from the vessel with the tug boat (Drag mode).
A trip movable curved tooth coupling located between the gearbox housing
and the winch serves as a power transmitter. This can compensate a
limited amount of angular misalignment that may have arisen from the
separate foundation frames.

Clutch / Dynamic brake (water cooled)
The pinion shaft has been fitted with a disc-type brake system type 336
from WPT. The brake is pneumatically actuated.
It will be used in two operation modes:
1. In motor mode it works as a clutch. Friction disks and steel disk doesn’t
slip. The force will be created by means of springs. No cooling water
and pressure air is neccesary.
2. In drag mode it worked as a sliping brake and controls the speed of the
outgoing rope while the anchor is being taken out by the tugs. The
brake is slipping and the heated brake disks will be cooled by means of
fresh water. Temperature of the cooling water is monitored
Water
Pressure Air Inlet
Water
Outlet
Fig. 31- Clutch /Dynamic brake with triple passage rotary coupling
The brake torque and therewith the brake resistance while being pulled
out is generated pneumatically. The braking force can be controlled from
0% to 100% over a potentiometer on the local control panel. Both, the
traction and the storage winch will be controled with one potentiometer in
the same time.
The control valves have been grouped together to form one unit. They are
located in water tight, stainless steel switch cabinet located at the side of
the storage winch.

The brake has a „fail-safe“feature. A loss of pressure will allow springs to
uncoil and close the brake. The brake will remain closed during a loss of
pressure. The brake is working then as a engaged clutch.
The brake linings are made of a special material which provides both a good
friction coefficient with low wear. Copper lined cooling jackets are used in
order to quickly dissipate the heat. The cooling feature allows the brake to
absorb a huge amount of energy (1689 kW) during continuous operation.
For further information and technical data see the WPT manual provided in
the sub suplier folder.
5.1.1.1 Cooling System for the Clutch / Dynamic Brake

The brake will be cooled with continually flowing fresh water. The coolant is
provided from the on board fresh water system.
The pressure of the coolant is limited by means of a pressure regulating
valve. The valve is located in the inlet pipe for the coolant for the brake.
The maximum pressure should not exeet 3.1 bar static

(4.5 bar dynamic) to secure the copper cooling plates
of the brake. A damage of the copper plates will be
occurred.
NOTE: Do not close the shut of valve of the outgoing pipeline.

A dammage of the copper plates inside the brake can be caused!
A temperature gauge and a flow sensor monitors the temperature and the
volume flow of the coolant. A temperature sensor in the coolants outlet
pipe measures the temperature and transmits the data to the PLC.
Will 65°C are exceeded the temperture sensor gives a signal to the PLC
and as result the brakes wil be closed completely. So the tug boat is
braked and an overheating and damage of the dynamic brake is avoided.
The automatic closing of the band and gear brake as a

reaction to the over heated coolant could be hazardous
to the tug boat that is pulling out the wire rope.
Continual feed back between the operation personal
and the tug is necessary to safeguard against damage.
The consumption rate for the dynamic brake is 900 l/min. when using fresh
water and 1200 l/min when using a water-glycol mixture.
If the temperature exceeds the maximum temperature, the temperature
gauge will send an alarm. If their is no coolant flow a monitor will prevent
the operation of the winch in the drag mode.

Pressure
Water regulating
inlet pipe valve
Thermometer
Flow meter
Water
outgoing pipe
Open – close
valve
Strainer
Fig. 32 –Cooling line equipment storage winch

The pressure difference between the inlet and outlet should be not exeet
3,1 bar.
In order to protect the brake from contamination a filter has been built
into the coolant line that should be checked and cleaned in regular
periods.
Closing the recirculation line to the pump is prohibited. A

pressure surge could be cause if the outlet line were to be
closed while the inlet were still opened which in turn could
damage the brake.
As a basic principal the outlet line is always to be opened
before the inlet line!
Bröhl recommends that the outlet valve be secured in the
open position!
If subject to the danger of frost the system should be urged

of any untreated water in order to avoid any damage to the
brake or the coolant system.
Or:
Mix the water with 40% glycol.

Electrical Drive with Variable Frequency Drive
Motor
The winch is driven by a external fan cooled squirrel cage type ABB motor
with a effective power of 48 kW.
The motor is designed with a variable frequency drive (VFD) with a range of
0 Hz to 100 Hz. This allows for precise alterations in the motor speed to suit
the conditions at hand.
The motor is controlled by a PLC that sends signals to the frequency
converter over the Profibus.
The motor has been fitted with an encoder to monitor the RPM´s.
Three temperature sensors type PT100 (one for each coil) and three spare
sensors monitors the coil temperature. If the temperature were to exceed
135°C an alarm will be sent to the operator. It will not be possible to operate
the motor if the temperature were to continue to raise and exceed 145°C.
An anti-condensation heater will be active if the winch motor is not in
operation.
An elastic shock absorbing coupling (drip-proof) has been installed between
the motor and gearbox.
Fig. 33 – Motor assembled at the Gear box

Fig. 34 – Motor data sheet

Variable Frequency drive(VFD) and switch cabinet
The winch motor is feed by a variable frequency drive (VFD) make ABB type
ASC 800-11. It is a wall mounted drive drive, placed in a air conditioned switch
cabinet near the storage winch.
The air cooled drive is regerative type that means the regenerative enregy is
return to the network and will not be wasted as heat.
Two VFD’s for two storage winches are installed in one switch cabinet.
The VFD makes it possible to variably choose the RPM between
0-1636 1/min, which in turn translates to a cable speed of 0-40 m/min.
The switch cabinet contain fuses, connectors, I/O modules for the PLC and
monitoring devices as well. At the front door are displays for current and voltage
as well as a main switch, a emergency stop button and the remote control for
the VFD.
The complete switch cabinet is cooled by a lateral installed aircon.
Aircon
Remote Control Panel

for VFD
Emergency Stop
Main Switch
Fig. 35 – Switch cabinet with build in VFD

Safety Relais
VFD for Storage Winch 2
VFD for Storage Winch 1
Fig. 36 - VFD’s inside the switch cabinet
Spooling device
The winch has been equipped with a cable spooling device which
guarantees for the proper spooling of the rope over multiple layers.
Guiding sheave
Spooling
Arm
Spooling head
Cross
threaded
Fig. 37 – Spooling device Spindle

The special design including a spooling arm with guiding sheave is designed to
absorb and transfer high rope forces. The cross threated spindle serves as a
guide for the spooling arm.
The cross threated spindle gets its drive from the drum over a roller chain. The
spooling device can be manually re-adjusted by means of a special motor
gearing to compensate for any “fore-drifting” or “slow” rope against the rope
drum.
The readjustment can be done from both, the local contol stand and directly at
spooling adjustment buttons at the storage winch.
Pls. check the direction of the adjustment via CCTV

camera in regard of the mirror immage builded winches.
Gear Motor
Fig. 38 – Adjustment gearing
Spooling Adjustment Buttons
Fig. 39.1 – Spooling adjustment at winch Fig. 39.2 – Spooling adjustment at LCS

5.2 Drum and Band brake
Drum
Storage winch with capacity of 1342m of 3 ¼” (83mm) rope in 15
windings and 13 layers.
The drum is fitted with guiding bars welded at the drum to ensure proper
spooling of the rope.
Drive is by means of a 2” roller chain from the outgoing shaft of the gear
box to the chain wheel fixed at the drum.
Roller Chain Drum with Guiding

Bars
Outgoing Shaft of
the Gear Box
Fig. 40 Rope drum with drive
Band brake
Each storage winch is fitted with a sling band brake. It was operated by
means of a pneumatik cylinder. Brake holding force is 12 tons.
Fig. 41 – Band Brake attached at drum

A high-grade asbestos free brake lining has been attached to the steel brake
ring.
All bolts used on the band brake are made of stainless steel.
Brake re-adjustment when necessary should be carried out as described in
chapter XXXX
Fig. 42 – Band Brake with Brake cylinder
Brake Cylinder
The band brake is released by means of a pneumatic cylinder.
Disk springs inside of the pneumatic cylinder, provide the force necessary
to close the brake. Additional pressure air increases the brake force with
50%.
The disks are running in a oil bath to avoid corrosion. During moving of
the piston the oil is flowing to the oil reservoir and back to the cylinder.
The oil reservoir is pressure free and ventilated with a goose neck.
The brake cylinder is equiped with a visual wear indication as well as a
wear indication by means of proximity limit switch. A alarm message is
occurred on the screen in the local control stand when the break lining is
weared.

limit switch
“released” ;
limit switch for

wearing
Fig. 43 - Brake cylinder
The brakes „fail-safe“design assures that it is fully engaged in the case of loss
of pressure. The brake holding force will be also generated even in case the
brake linings are worn.
BRAKE
ENGAGED
A: triggered
B: not triggered
BRAKE
RELEASED
A: triggered
B: triggered
BRAKE WORN OUT

A: not triggered
B: not triggered
Fig. 44 - Brake cylinder in different possitions

The necessary pneumatic pressure is supplied by air reciever which is feed
from the ships system.
mounted in a water-tight stainless steel cabinet at the side of the winch frame(
see chapter XXX).
PLC I/O Modules Flow Indication
Proportional
Valve
Pressure
Switch
Pressure
Switch
Fig. 45 - Pneumatic and electronic switch cabinet
Filter
provide enough pressure to open the brakes at least 3-times, enabling a brake
release under emergency conditions.
The winches pre-designed brake holding force can only be achieved when the
brakes are properly adjusted. When the brake is engaged the indicator on the
brake cylinder must be in the red area to assure for a proper running of the
system If not, adjustments are necessary.

Air Pressure System
Various parts of the winch are driven and controlled using pneumatics.
The pressure supplied by the on-board system must have at least 7 bar.
The air must be free of water and solids.
The pressurized air goes through a coarse filter before it is pumped into
the 60 liter tank. The underside of the tank has been fitted with a manual
condensation bleeder valve. A safety valve set at 10 bar ensures that
overpressure is blown out of the system.
Shut off valve to the

cabinet
Check valve and

filter
Condensate
drain
Safety
Valve=10 bar
Fig. 46 – Air reciever tank 60 l
For more information on how to conduct maintenance on the equipment

read chapter XXX pneumatic lines and pressure tank.
Quality Requirements on the Pneumatic Air Supply

Air quality
Depending on the geographic and climatic conditions the quality of the
atmospheric air, which is used as a medium in compressed form, will differ.
Today’s requirements on lifetime and operation safety of appliances as well
as the environmental requirements aim to a permanent high quality of
compressed air – independent from climate and surroundings.
The air covers not only water but also dust, aerosol, chemicals, organism etc.
which are sucked-off the compressor. This mixture must be conditioned in
relation to its application and the selected appliances.
Contamination materials and their state of aggregation are listed in the ISO
8573-1. This standard defines quality grades and their limits.

Solid matters
Solid matters appear in form of dust of different size and shape (amorph,
crystalline). They cause wear of the sealing elements and running surfaces.
The width of the pores of the mechanic filters limits the particle size of the solid
matters; at same time the pressure drop at the filter cartridge is increased in
relation to its fineness.
Moisture and water content

Depending on its temperature to pressure relationship water will exist in a
liquid or gaseous form.
It can contribute to corrosion of structural parts or could wash-off the grease in
the appliances.
By drying the air these consequences could be avoided.
Oils
Residual oil from the compressor or sucked-off oil aerosol do not have any
positive effect on the greasing. They could cause damages of the structural
parts and lead to wear. However precautions can be taken by using suitable
filters.
Synoptical table of classification according to ISO 8573-1
Class Solids Moisture - Water content Oil content
Max. numbers Particle size Numbers of Pressure dew point Amount of water Amount of oil
of particles particles *
per m3
1<d≤5µm [µm] [mg /m3] [ °C] [g/ m3 ] [mg /m3]

0 ** ** **
-
1 0 - - ≤-70 - ≤0,01
2 10 - - ≤-40 - ≤0,1
3 500 - - ≤-20 - ≤1
4 1000 - - ≤+3 - ≤5
5 20000 - - ≤+7 - -
6 - ≤5 ≤5 ≤+10 - -
7 - ≤40 ≤10 - 0,5 ≤m ≤5 -
8 - - - - ≤5 -
9 - - - - ≤5 -
* The pressure dew point should be lie at ** to be stipulated

least 15°C below the ambient temperature.
Fig. 47 – classification table

Pressure air P&I
Fig. 48 – Pressure Air P&I diagram (refer to Drwg. 125013-101)
The air recievers at each storage winch are connected to each other so that in
case one fails the other can provide pressure air for both traction winches. The
possibility to open the brake several times during loss of pressur in case of
EBR is limited then.
5.2.1.1 Pressure air valves and electric cabinet at the Storage winch
The switching of the bandbrake and the dynamic brake / clutch will be
executed by solenoid valves which are located in a stainless steel
cabinet beside the traction winch. The cabinet contains as well PLC
modules and electric equipment in a separate part.
mounted in a water-tight stainless steel cabinet at the side of the winch
frame( see chapter XXX).

A filter with a condensation draining device for filtering the pressured

air and separating the remaining water.
A proportional valve for regulating the braking force of the dynamic
brake.
A solenoid-operated 5/2 way valve for opening and closing the band
brake.
A pressure switch for monitoring the pressure in the line for the
dynamic brake.
A pressure switch for monitoring the pressure in the line for the band
brake.
The noise caused by exiting pressurized air is muffled using an appropriate

muffler.
PLC I/O Modules power supplies brakes
Proportional
Valve
Pressure
Switch
Pressure
Switch
Fig. 49 - Pneumatic and electronic switch cabinet at Storage winch
Filter
provide enough pressure to open the brakes at least 3-times, enabling a brake
release under emergency conditions.
The winches pre-designed brake holding force can only be achieved when the
brakes are properly adjusted. When the brake is engaged
The following parts are housed in the electronic part of the cabinet:

5.3 Measuring Devices
Length measuring and speed monitoring
An encoder positioned at the end of the outgoing shaft of the gear box
monitors both the speed and length of the paid-out rope.
The measuring system is based on 4096 signals per rotation. In this way a
high degree of accuracy is provided.
The PLC housed in the switch cabinet uses the steps to calculate the time
/ rotation, the speed and the chain length.
For detailed information on load measuring bolts refer to the manual
provided by the subsupplier.
Even in the case of a loss of power, the actual length of rope can still be
determined due to the encoder’s optical measuring concept.
As soon as the power supply is functioning again the correct value for the
current length of the line will be displayed.
Gear Limit Switch

Encoder (Bitter End)
Fig. 50 – Location of measuring devices (without cableing)

Bitter End Switch
To monitor the bitter end at the storage winch, a mechanical gear limit
switch has been installed that is likewise driven by the outgoing shaft of
the gear box.
The limit switch will send a signal to the PLC app. 20m before the bitter
end is reached that will prohibit the further letting out of the rope. If for
whatever reason the software in the PLC does not send a signal, an
additional safety feature has been integrated into the system which is
directly wired to the frequency inverter which in turn will shut it down if
contact were to occur.
This safety feature will trigger several meters after the length where the
software switch should be actuated.
Over Speed Protection
A monitor has been installed at the guid sheave of the spooling arm to
assure that the rope speed during the Emergency Brake Release does not
exceed a certain limit (120m/min predefined).
Two inductive proximity switches receive signals from a segmented disc.
The disk is fixed at the sheave.
The signals from the proximity switches are sent using safety relays. The
relay is forwarded to an adjustable switch for the Emergency Brake Valve.
The band brake will close for a short time reducing the rope speed. When
the rope has been slowed down to a predefined speed the brake will
receive a signal to re-open.
Inductive
proximity Spooling arm
Segmented
Fig. 51 – Over Speed Protection

Load measuring
A load measuring pin is placed in a lever connected with the axle of the
guide sheave of the spooling arm.
The load pin is prespanned by using disk springs. A damage of the pin
because of overload will be avoided by means of a safety bolt. This blocks
the load when it increase 125%.
The range of the load pin is 10 kN. The lever system reduces the actual load
in the sheave and forward it to the pin. The outgoing signal will be increased
with a measuring amplifier and recalculated in the PLC.
The actual load is displayed at the local control stand and the central
monitoring panel.
To replace the load pin pls. read chapter XXX
Measuring amplifier Lever
Safety Bolt
Load pin
Fig. 52 – Load measuring

Guide sheave Disk springs
Axle

Slack Rope Switch
A slack rope switch monitors if the rope between traction and storage winch
is under tension. It is placed on top of the spooling arm near the guiding
roller.
When there is a tension of more than approx. 2 tons the spooling arm will be
lifted up for some milimeters until the guiding roller is blocked by the rolling
track. The distance is reduced and the switch is triggered.
The switch is a inductive proximity switch type.
Rope switch
Guiding
roller
Fig. 53 – rope switch location
Rolling track
Switch low tension

EBR
1.1
Spooling arm
Fig. 54 – rope switch location Guide sheave axle

6. LOCAL CONTROL STAND LCS
At each corner of the rig, in front of the traction winch a local control stand is
placed to operate the related winch system.
The housing is made from stainless steel. A pressure air cooling system
avoids the overheating of the electronic parts inside the stand.
The closed stand is protection class IP 56.
The LCS is dedigned wether to operate winch 1(rope 1) or winch 2 (rope 2)
of the system. The selection is by pressing the related button on the panel.
The winch operation is by means of a joystick (Motor mode) or brake
potentiometer (Drag mode).
A 15 inch TFT monitor allows to display all the relevant datas of the related
winch as well as alarm messages and service funktions.
CCTV
TFT Monitor
Monitor
Operating
panel
Fig. 55 – Local control stand with opened flap

The following elements are placed on the operators panel:
A Information area for winch operation in general:

• Control lamps for “Ready”, “Failure”
A Motor Mode operation area with operating equipment:

• Push button for “On” / “Off”
• Push buttons for Gear selection “high gear” / ”neutral” / ”low gear”
• Control lamp for “Enable”
• Joystick for winch operating “Pay out” / “Haul in”
A Drag Brake operation area with operating equipment:

• Push button for “On” / “Off”
• Control lamp for “Enable”, “Valve open”, Water flow”, High Temperature”
• Potentiometer knob for brake force “0% - 100%”
Fig. 56 – Operators panel in LCS
A Spooling adjustment area for rope 1 and rope 2 with operating equipment:
• Push buttons for “Left”, “Right”
• Control lamp for “Failure”
A selection area for rope 1 and rope 2 with operating equipment:

• Push button for “Clutch in” / “Clutch out”
• Push button for “Start”
• Control lamp for “Band brake Traction winch”, “Band Brake Storage Winch”,
• Control lamps “Pawl in”; “Pawl out”

An Area for Alarm and lamp test:
• Push button “Alarm reset”,
• Push button “Lamp test”
An Area for Emergency brake release:

• Key switch to arm the buttons
• Covered push buttons to release the brakes
A Buzzer for alarm indication:
A “Emergency Stop” push button
A switch to switchover CCTV camera between Rope 1 and Rope 2
CCTV monitoring
The spooling of the wire into the storage winch in the column is monitored by a
CCTV camera below deck. A 19” TFT monitor shows the moving spooling
shaft of the storage winch. A adjustment of the spooling device can be
monitored in an easy way.
The camera system is a switching system with two cameras and one monitor.
The switchover between the two cameras should be done by a switch below
the monitor.
Fig. 57 – CCTV watching spooling of storage winch

7. CENTRAL MONITORING PANEL CMP
A central monitoring panel is located on the bridge. From here it is possible to

monitor the main datas of all 8 ropes as well as the alarm messages. The
alarms can be confirmed at the screen and the beeper can be switched of.
The tension alarm can be adjusted at the CMP as well. special service page is
provided.
A operation of the winches expect of emergency brake release is not possible
Fig. 58 – Central monitoring Panel CMP
The following elements are located on the CMP:

Touchscreen to monitor the rope data’s
For each wire rope a covered EBR button for a fast payout of rope in
emergency case
For the forward located winches (STB FWD / PS FWD) a covered
EBR button for a fast pay out of rope in emergency case
A key switch for arm the EBR buttons
An emergency stop button for shut down of the winches. The
emergency stop works on all 4 winches simultaneously.
A main switch at the side of the CMP

The touch screen, which is completely independent from the winch controls,
will be activated as soon as the main switch at the side of the panel is
switched on.
This assures that all technical data relevant to the anchor chain is continually
monitored.
The screed protector will activate after 1 minutes. A wipe with the finger will
reactivate it.

8. COMMISIONING
8.1 Lifting
Traction Winch
The following drawing demonstrates how best to lift the traction winch.
Fig. 59 – Lifting the traction winch
The winch weights app. 57 metric tons.

Gear Box for Traction Winch
The following drawing demonstrates how best to lift the gear box of the
traction winch.
4 suspension holes have been machined into the gear box for lifting:
Fig. 59 – Lifting the Gear Box
The gear box weighs app. 17 metric tons.
Storage Winch
Fig. 60 – Lifting the Storage winch

8.2 Transportation
Traction winch
The winch has been broken down to its main components and packed for
shipping
Caution: Observe safety regulations while lifting heavy

weights!
The described procedures should be used as a guideline when moving a

previously assembled winch:
Attention! The winch can not be lifted as an entire unit!
Before transportation the winch needs to be separated into
its main components. (2x traction winch + 1 gear box).
1. The two traction winches and the gear box are connected by a curved
tooth coupling and the E-motor console. The curved tooth coupling has
to be demounted before transportation. (See instruction manual
provided by the supplier) Once demounted the coupling is to be dealt
with as a single unit.
2. The E-Motor is to be demounted from its console and the bolts
connecting the console to the anchor construction are to be removed.
Fig. 61 – Top view of the entire winch

Storage Winch
The storage winch can be transported as a comlete unit.
Pls. take care on the mounted cooling water pipeline.
For lifting the winch see chapter 8
8.3 Storage
If a winch is not to be commissioned within 4 weeks of arrival preparation
steps must be taken for long term storage.
• The packaging around the curved teeth coupling attached to the
windlass needs to be taken off. The coupling is then to be covered in a
thick coat of grease. These parts need to be kept out of the rain
• All parts are to be kept dry and free of dust
• The following positions need to be fitted with a moisture absorbing
medium (Silica Gel) and followed up on.
Pneumatic and electric switch cabinets (on the windlass and gear
box of traction and storage winch).
The switch cabinet in the local control stand
The local control Stand
The central control console
The switch cabinets for storage winch
The VFD cabinets for Traction winch
The control stands will have to be protected from dust. (We recommend that
the control stand is shrink-wrapped)
If the winch is to be stored for more than 6 months consult the supplier.
8.4 Assembly
The foundation for the winch needs to be properly prepared before setting
the winch in place.
The height differences between the foundations for the windlasss and the
gearbox will have to be checked using a leveling device. A maximum
tolerance of ± 1,0 mm is to be withheld. Equalize height differences using
distance plates or chockfast.
The preparations for mounting the winch can begin as soon as the
foundation has been drilled or when the bolts M36 are be set.
The fixing of the foundation feet is by means of bolts M36 – 8.8. These bolts
are not included in the scope of supply.
Height adjustment can be done by means of the screws M30 x 150.
Caution: The foundation foot and the load cell are loose fitted
togethert with a strip and a bolt for transportation.
Take care not to damage it during setting of the winch.

Load cell Adjustment Screws
Fig. 62 – Foundation proper fixed
The adjustment screws make it possible to position individual components

vertically.
To assist the setting of the components in the vertical position a hydraulic-
jack will be needed. The cylinder must have a capacity of at least 30t and
be able to be positioned directly under the vertical plates on the windlass.
Fig. 63 – Height Adjustment of the Winch
The positioning of the gear box is done exactly like the windlass.
Broehl recommend the positioning of the windlass and the gear box with a
laser alignment device.
Attention! We recommend that a Bröhl technician supervise this stage of the
commissioning.

Caution: A winch system that has not been
properly aligned can lead to high wear or damage.
The foundation feet can be bolted down only after the alignment of the entire
system has been completed. Torque Specifications for the Foundation Bolts:
Gear Box: M30 – 1215 Nm

Traction winch: M36 – 2125 Nm
After all of the foundation feet have been bolted down they can be cast in
shockfast.
Mounting the Motor

Use the suspension holes to position the motor.
Care needs to be takes that the motor is properly positioned. This is done with
the help of fixing plates. Fixing plates are included in the shipment and need to
be with the motor.
The exact positioning of the motor, Clutch and driveshaft must be done with a
laser alignment device. In addition refer to the alignment instructions provided
by the clutch manufacturer.

Mounting the Curved Tooth Coupling
The curved tooth coupling can be installed only after the entire system has
been properly aligned. The couplings main function is to transmit the torque
from the gear box to the traction winch and between both traction winches
Additionally the coupling is designed to compensate small angular
displacements.
The inner coupling must be filled with grease. The bolts are to be tightened to
the (specified by the manufacturer) pre-defined torque.
For further information see the manufacturer’s documentation.
Traction winch
Gear
Box
Fig. 64 - Curved tooth coupling between gear box and traction winch before
alignement
Fig. 65 - Curved tooth coupling between both traction winches

8.5 Commissioning
The commissioning of the winch is to be carried out by a Bröhl technician.
The document 120220-B280-1060 contains details, procedure order, etc.
for the commissioning process
After successfully going through the first commissioning, which includes a
functionb test, load test and operational tests, the winch is to be given over
to the customer. The official transfer of responsibility for the winch, in written
form, is kept in document 125001-B316-1060.
Re-Commissioning after a longer operational brake is to be carried out as
described.
The following points, critical to the problem free running

of the winch, are to be checked before re-commissioning.
Is the oil level in the gear box o.k.?

Have all grease points been greased?
No leakage from the pressure air pipes?
Have all of the electrical cables been properly connected?
Have all of the pneumatic and electrical components been run through
function checks?
Is the wire rope properly maintained ?
Is their ample supply of compressed air, electricity and coolant?
Is it possible to operate the winch from the Local control?
If one of the points listed above is defective , it can not

be guaranteed that the winch will run trouble free.

9. OPERATION
9.1 Operating Devices
Fig. 66 – Local Control Panel (LCP) at Traction winch
General functions:
Pressing an emergency stop button on LCP or

any other location of the winch will slow down the
movement off the winch as fast as possible
(approx. 3 sec) to zero speed. After a delay time
of approx. 5 sec after pressing the button all
brakes will be closed.
Fig. 67 – LCP emergency stop button
Locations of emergency stop buttons for one winch
• Local Control Panel

• Switchboard storage winches
• Gearbox terminal box traction winch
• Terminal box traction winch 1 & 2
• Traction winch 1 AFT side
• Traction winch 2 FWD side
• Terminal box storage winch 1 & 2
The emergency stop system has to be tested before every operation by

pressing at least all push buttons once and reset again.

In section main ignition lamp “Failure” shows
that at least one alarm is active or not
acknowledged.
The “ready” ignition lamp shows that all power
supplies are switched on.
Fig. 68 – LCP main section on the left side
The push button “lamp test” should be used to test

the function of all ignition lamps on the LCP. To
reset the sleep mode (all ignition lamps OFF) is also
resettable by this button.
Fig. 69 – LCP main section on the right side
The push button “Alarm reset” can be used to acknowledge an active alarm.
After pressing the button all active alarms are marked as acknowledged
and all alarms which are no longer active will be deleted from the alarm
list. The function is the same as the touch button on the Touch panel.
This section is built in twice.

One on the left side for traction winch 1
(rope 1,3,5 or 7) and one on the right side for
traction winch 2 (rope 2,4,6 or 8)
Fig. 69 – LCP Spooling adjusting
The ignition lamp “failure” shows all alarms of the spooling device of the
regarding winch.
Pressing the push button “right” or “left” starts the spooling adjusting motor
forward or reverse. The direction of position change of the spooling device
depends on the layer. Every second layer the movement of the spooling
device is inverse to the motor direction.

9.2 Motor Mode
In section “Motor Operation” all general parts

for Motor mode are combined. The operation
must follow the sequence below. For example
isn’t it possible to select low or high gear
without a stable lamp “ON / OFF”.
Fig. 69 – LCP Motor Operation
Operation sequence to start Motor Mode:
Step Action Requirement Result

1 start motor mode with Ignition lamp (IL) IL "ON / OFF" starts flashing. Main circuit
push button (PB) "Enable" is ON no breakers for VFD_M and VFD_SW will be
"ON / OFF" Alarm active (see closed and all VFD´s will start up. IL "ON /
description fault OFF" will shine stable if all VFD´s are ready
messages) for operation.
2 select PB "low gear" or IL "ON / OFF" is ON - gear brake will be engaged (see TP)
"high gear" - valves for selected gear will be energized
- IL of selected gear starts flashing
- IL will shine stable when the gear shifting
end position is reached.
- if the end position is not
reached after 3 seconds the main motor
is started and turns with 5 RPM.
- after reaching end position motor stops
and gear brake will be disengaged.
3 selection of “Low speed - Joy stick in zero - maximum rope changes to 40 m/min
or high speed” on TP position - maximum motor speed is 2000 RPM
- motor speed is
Zero
- tension of rope
below 100t

Operation sequence to stop Motor Mode:

1 select PB "neutral gear" Both traction - gear brake will be engaged (see TP)
winches are in - valves for selected gear will be energized
clutched OUT - IL of neutral gear starts flashing
position and the IL - IL will shine stable when the gear shifting
“Clutch OUT” shines end position is reached.
stabile - if the end position is not reached after 3
seconds the main motor is started and
turns with 5 RPM.
- after reaching end position motor stops
and gear brake will be disengaged.
2 stop motor mode with Ignition lamp (IL) IL "ON / OFF" will be switched off. Main
push button (PB) "neutral gear" is ON circuit breaker for VFD_M is shut off and
"ON / OFF" VFD_SW will be shut off after 3 minutes.
(cooling time VFD´s)
Fig. 69 – LCP operation section of traction part 1 (rope 1)
Operation sequence to start traction winch 1 or 2:

1 press PB "clutch IN" - IL “low gear” or - IL “Clutch IN” starts flashing
“high gear” is ON - the automatic Clutch IN procedure will be
- opposite traction winch started. (see below)
is in clutched OUT - IL will shine stable when the Clutch IN
position and the IL and interlocked position is reached
“Clutch OUT” shines
stabile
2 press PB “Start” - IL “Bandbrake - Valves for bandbrakes (valve –
Storage winch” is ON V8.a and –Y9.a) will be energized
- IL “Ready” is ON - IL “Bandbrakes Traction winch” is ON if
pressure switches are actuated.
- IL “Start” is ON
3 Operation in PAY IL “Ready” is ON Winch runs in paying out or hauling in
OUT or HAUL IN mode.
direction with joy IL “Ready” is flashing storage winch is regulating the tension
stick in Motor Mode between traction & storage winch
section
Operation sequence to shut off traction winch 1 or 2:

1 Joy Stick in Motor Winches stops running.
Mode section in zero
position
2 press PB “Start” actual motor speed is - IL “Start” is OFF
zero - bandbrakes will be disengaged
3 press PB "clutch pressure switch - IL “Clutch OUT” starts flashing
OUT" bandbrake traction - IL “Ready” is OFF
winch is deactivated - the automatic Clutch OUT procedure will
be started. (see below)
- IL will shine stable when the Clutch OUT
and interlocked position is reached
Automatic Clutch IN procedure traction winch 1 or 2:

1 Valve -Y12.a will be Interlocking cylinder moves in
energized unlocked position
2 Valve –Y11.b will be position switch –B9 clutch cylinder moves Clutch to
energized “clutch unlocked” is IN-Position
actuated
3 After delay time of 5 see motor speed on TP
seconds:
- gear brake engages
- main motor starts
running with 20 RPM
4 gear brake disengages position switch –B5 Clutch is in IN-Position
main motor stops “Clutch IN” is actuated
and motor torque is more
than 20% of max. Torque
(see Setpoints on TP)
5 VFD for associated Clutch is in IN-Position VFD – Run indication on TP changes
storage winch is started to green
6 Bandbrake Storage VFD storage winch is in - IL “Bandbrake storage winch” is ON
winch will be engaged RUN – Mode - IL “Ready” starts flashing
7 Storage winch starts position switch –B2 IL “Ready” starts flashing
regulating tension “brake open” at storage
between traction and winch is actuated
storage winch
8 IL “Ready” is stabile Tension is 5t (setpoint in Traction winch is ready for start
ON TP) +- 0,5t command

Automatic Clutch OUT procedure traction winch 1 or 2:

1 Bandbrake Storage - IL “Bandbrake storage winch” is OFF
winch will be - IL “Ready” is OFF
deactivated
2 Valve -Y12.a (unlock pressure switch - Interlocking cylinder moves in
Clutch) will be bandbrake traction winch unlocked position
energized & position switch –B2 - IL “Bandbrake traction winch” is OFF
“brake open” storage - IL “Bandbrake storage winch” is OFF
winch is deactivated - IL “Ready” is OFF
3 Valve –Y11.a (Clutch position switch –B9 clutch cylinder moves Clutch to
out) will be energized “clutch unlocked” is OUT- position
actuated
4 - gear brake engages see motor speed on TP
- main motor starts
running with -10 RPM
5 gear brake disengages position switch –B5 Clutch is in OUT-Position
main motor stops “Clutch OUT” is actuated
6 Valve -Y12.a (unlock position switch –B8 IL “Clutch OUT” is ON
Clutch) will be “clutch locked” is actuated
deenergized
7 VFD for associated Clutch is in OUT-Position VFD – Run indication on TP changes
storage winch is to white
stopped

9.3 Drag Mode
In section “Drag Brake Operation” all general parts

for Drag mode are combined. The operation must
follow the sequence below.
Fig. 70 – LCP Drag Brake Operation
Operation sequence to start Drag Mode:

1 start drag mode with Ignition lamp (IL) - IL "ON / OFF" starts flashing.
push button (PB) "Enable" is ON no alarm - booster pump is started
"ON / OFF" active (see description - cooling water valves on traction &
fault messages) storage winch will be opened
2 All water flows are ok - IL "ON / OFF" in ON.
3 select PB "Clutch - IL "Water Flow" is ON - Main circuit breaker for VFD_M will be
IN" of traction part 1 - no high temperature closed and VFD_M will be started up.
or 2 Alarm is active - IL "ON / OFF" motor mode will shine
stable if the VFD is ready for operation
- low gear will switched on (see IL & TP)
- the automatic Clutch IN procedure will be
started. (as described above)
- IL will shine stable when the Clutch IN
- motor stops and gear brake will be
disengaged.
- VFD_M will be stopped
- Main circuit breaker for VFD_M will be
opened.
- bandbrake of storage winch will be
engaged.
- pressure control regulator for clutch is
activated to control the tension between
traction & storage winch on set point.

4 - adjust poti. for drag - IL “Bandbrake - Valves for bandbrakes (valve –
mode to 100% Storage winch” is ON V8.a and –Y9.a) will be energized
- press PB “Start” - IL “Ready” is ON - IL “Bandbrakes Traction winch” is ON if
pressure switches are actuated.
5 adjust poti. to lower - clear direct - the winch starts paying out
set points communication to tug - control the rope speed by adjusting
boat captain slowly the poti.
- min. tension of 25t on - reacting time after set point changes is
the rope approximately 2-3 sec.
6 - adjust poti. for drag - drag brake will be fully disengaged

mode to 100% - rope speed slows down to zero
Operation sequence to stop Drag Mode:

1 - adjust poti. for drag - drag brake will be fully disengaged
mode to 100% - rope speed slows down to zero
2 - press PB “Start” - rope speed is zero - bandbrake of storage winch will be
deactivated.
- pressure control regulator for clutch will
be switched OFF
- Valves for bandbrakes (valve –
V8.a and –Y9.a) will be deactivated
- IL “Bandbrakes Traction winch” is OFF
3 select PB "Clutch - bandbrakes are closed - Main circuit breaker for VFD_M will be
OUT" closed and VFD_M will be started up.
- IL "ON / OFF" motor mode will shine
stable if the VFD is ready for operation
- low gear will switched on (see IL & TP)
- the automatic Clutch OUT procedure will
be started. (as described above)
- IL will shine stable when the Clutch OUT
- motor stops and gear brake will be
disengaged.
- VFD_M will be stopped
- Main circuit breaker for VFD_M will be
opened.
4 stop drag mode with IL "Clutch OUT" for, - IL "ON / OFF" is OFF.
PB "ON / OFF" traction part 1 & 2 is ON - booster pump is stopped after delay a of
5 min.
- cooling water valves on traction &
storage winch will be closed

9.4 Emergency Brake Release
Fig. 70 – LCP Drag Brake Operation
Operation sequence for emergency brake release:

1 turn key switch to Clutch is in OUT-position EBR is activated alarm message is
ON – Position generated
2 Open safty cover Clutch is in OUT-position
from push button
3 push the button Clutch is in OUT-position - bandbrakes of traction part and
associated storage winch will be opened.
- clutch off storage winch will be engaged
- rope starts paying out
- rope speed is related to the rope tension
4 low tension switch bandbrakes of storage winch will be closed
between traction and until tension comes up again
storage is activated
5 safty device detects - bandbrakes of traction part and
overspeed associated storage winch will be closed
until is below max. speed setpoint
6 release the button - all bandbrakes will close
- clutch will be disengaged
- rope movement will be stopped
7 Close safty cover
from push button
8 turn key switch to reset alarm message on TP
OFF – Position

10. MAINTENANCE AT TRACTION WINCH
10.1 General
Maintenance only from specialized personal.

Before starting with winch maintenance, the winch will need to
be electrically disconnected. Additionally measures must be
taken to assure that it cannot be reconnected.
Separate heater lines are also to be shut off!
In order to obtain and test the readiness of the winch, the follo-
wing work is to be carried out every 3 months.
With declutched winchs let the transmission run for 15 min.
This can be done in the menu „Service“ (login before) – „Motor
& VFD Data“ – „VFD Hand“. The motor is possible to run now
without the necessity to be in the motor mode. Oil is splashing
now on all gear wheels.
The coolant inlet must be opened.
Attention! First open the coolant backflow line, then the
coolant inlet.
Check to make sure that nothing is obstructing the coolant flow.
The coolant valve must be checked. This can be done in the
operational menu "Service" – „Coolingwater Valve“ – “Hand” –
“Open-Close”
If nothing to the contrary has been stated all bolt up connections are to be
tightened to the torque values found in the chart below:
SIZE Grade 10.9 Bolts Grade 8.8 Bolts

Metric Nm Kgm Lb.ft Lb.in Nm Kgm Lb.ft Lb.in
M8 32,5 3,3 24,0 287,6 22,0 2,2 16,2 194,7
M10 63,2 6,4 46,6 559,3 43,0 4,4 31,7 380,5
M12 110,7 11,3 81,6 979,6 75,2 7,7 55,5 665,5
M14 175,5 17,7 129,4 1553,0 119,7 12,2 88,3 1059,3
M16 271,8 27,7 200,4 2405,2 185,4 18,9 136,7 1640,6
M20 532,8 54,3 392,9 4714,9 373,5 38,1 275,4 3305,2
M22 682,0 69,5 503,0 6035,2 485,0 49,4 357,7 4291,9
M24 915,3 93,3 675,0 8099,7 642,6 65,5 473,9 5686,5
M27 1260,0 128,4 929,2 11150,0 891,0 90,8 657,1 7884,7
M30 1710,0 174,3 1261,1 15132,2 1215,0 123,9 896,0 10751,8
M33 2330,0 237,5 1718,3 20618,7 1830,0 186,5 1349,6 16194,1
M36 2988,0 304,6 2203,6 26441,5 2125,0 216,6 1567,1 18804,6
Fig. 66 – Bolt Torque Table

10.2 Gear Box
The first oil change after 500 operational hours or 12 months.

Further oil changes after every 2000 operational hours or 2 years.
Gear Box filling Quantity app. 840l (use the dipstick as a reference)
The position of the drain plug, oil fill and dipstick are displayed in the
overview drawing. or refer to chapter
The oil level is to be checked every three month (the

level must be between the two marks on the dipstick).
The oil needs to be regularly checked against condensation build up.

Excessive water may make an early oil change necessary.
Use an oil with an EP additive according to DIV 51519 220cSt at 40°C.
10.3 Greasing points

These places are open gears / threads and have to be greased as soon as
bare metal spots are noticed. The grease can be applied with a brush.
These places are to maintain / grease ever 4 months.
These places are maintenance free
Recommended grease to be applied while the winch is running without

load.
Recommended Grease
Location of Viscosity
SHELL EXXON MOBIL CALTEX
Grease Fitting or Type
Meropa 220 cst
Close Gear Box Omala 220 Mobilgear 632
LUB 20 40°C
Mobiltac 375
Open Gears Malleus OGH Crater EP0
NC
Multifak
Grease Nipples Alvania EP2 Mobilux EP2
EP2
Tellus Oil T ISO VG
Hydraulic Oil UNIVIS N 56
46 46 HV
Fig. 67 – Grease Recommodation Table

Greasing Points at Traction winch
The spots to be lubricated are shown in the following drawings.
Fig. 68 – Grease points Traction winch mainshaft and drums

Fig. 69 – Grease Points Curved Tooth Coupling
Fig. 70 – Grease Points Guiding Roller

Fig. 71 – Grease Points Interlocking sheet

Fig. 72 – Grease Points Band Brake
Fig. 73 – Grease Points Dog clutch

10.4 Piping / Pressure Tank
The pneumatic lines must be checked in regular intervals. The general

condition of the lines is to be checked taking special care that the winch is
not operated till lines found which have been heavily corroded have been
replaced.
Pneumatic Lines Air Tank
Filter (fine particle) for

Compressed Air Filter (primary) for
Compressed Air
Drain Line for

Condensate Automatic drain
Fig.74.1 – Compressed Air Filter in cabinet Fig.74.2 – Compressed Air Filter at reciever
The primary and fine filters for the compressed air, located in front of the
valve block grouping are to be checked after every 25 operational hours
against build up.
If necessary the filter element should be cleaned or swapped out.
The automatic drain of valve is to remove condensation from the air
reciever.
The fine filter also needs to be checked against condensation build up
before every use.

10.5 Coolant Lines with Drag brake
Coolant Outlet Hoses
Coolant Inlet Hoses

Fig. 75 – Coolant Lines
The hoses connected to the brake are to be checked at least 1x per year
against leakage and flexibility.
If the hoses are damaged or worn they are to be replaced.
As a rule ruber hoses regardless of their condition are to be replaced every
5 years.
For further information (e.g. testing the wear on the disks) please refer to
the manufactures documentation that is a separate part of the
documentation.
For safety purposed a Strainer has been installed in the coolant line.
The Strainer is to be cleaned after every 50 operational hours.
Fig. 76 – Strainer

The condition and the setting of the pressure regulating valve needs to be
checked. Never let increase the input pressure of more than 2.7 bar. A
damage of the copper plates inside the drag brake will be occurred.
Pressure Gauge Pressure Regulating Screw Pressure Regulating Valve
Flowmeter
Fig. 77 – Pressure regulating valve and Flowmeter
Never increase the inlet pressure to the drag brake

more than 2,7 bar. A damage of the copper plates
will be occurred.
During drag brake modus check the volume flow of the coolant. It should be
approx. 800 l/min (48 m³/h). If the flow isn’t sufficient check the status of the
hand valve between booster pump and traction winch as well as the
pressure of the coolant.
A thermo sensor is installed in the coolant collector pipe. These cables also
need to be checked that they have been properly fit, against corrosion and
leakage.

10.6 Band Brake
The band brake will have to be adjusted as soon as the indicator (2) is in the
area of the upper ring.
An alarm will also show on the screen of the local control as soon as this
condition is recognized.
The following steps describe how to adjust the band brake:
1. The pneumatic brake cylinder (1) is to be activated in order to release the
brake band. (see chapter XXX – Service Menu)
2. Loose the clamp screw (3)
3. Turn the spindle (3) to adjust the band brake. Turn the spindle clockwise
to tighten and counter clockwise to loosen.
4. The brake can now be closed. The next step is to check if the indicator (2)
is now in the area of the lower ring. If this isn’t the case a readjustment is
necessary. When the adjustment is finished the anti twist protection will
need to be reinstalled.
5. The proximity switch (5) has to be installed so that the indicator (2) leaves
the active part of the switch in the upper ring. This adjustment has to take
place when the brake is closed. This work is to be done after repair or
during the commissioning phase.
The proximity switch doses not serve as a position indicator for the
band brake but instead as a wear indicator.
Fig. 78 – Adjusting brake lining wear out

The brake lining will need to be replaced when it reaches a thickness of
8,5mm or less.
The first step in changing the brake lining is to dismantle the brake band. The
brake linings are attached to the brake band using both adhesive and bolts.
The worn brake lining can be stripped off the band after the bolts have been
taken off.
It is important that all reminisces of the old lining be stripped off before the new
lining is attached to the band.
10.7 Gear Brake

The condition of the brake lines is to be checked against leaks and corrosion
after 1 years time.
The hoses connected to the gear brake are to be checked at least 1x per year
against leakage and flexibility.
If the hose is damaged or worn it is to be replaced.
As a rule hydraulic hoses regardless of their condition are to be replaced every
5 years.
The Friction of the linings can be checked in regard to the clearance between
airtube holding plate (8) and Ring (1). Clearance should be between 3,18mm
- 4,76mm.
For further information please refer to the manufactures documentation that is
a separate part of the documentation.
Clearance 3.18mm – 4.76mm
Fig. 79 – Gear brake cross section

10.8 Curved Tooth Coupling
Regularly control at least 2x per year.
Check minimum the following:
All connection bolts must be properly tightened (1215 Nm).
Check for corrosion on the bolts and nuts.
Check for leakage of the grease filling.
Is the coupling running without strange noise? Check for vibrations and
temperature.
Maintenance:
The coupling should be disassembled and inspected every 8000 working
hours. At least every 2 years.
Before moving the sleeves, clean the hub surface near the
O-rings of dust and dirt.
Remove bolts and O-ring
Inspect gearing and sealing. remove grease from gearing.
Assemble in counterwise sequence.
Fill in new grease
Recommended Lubricants
SHELL EXXON MOBIL NGLI type
0 (-20°C-30°C)
Albania-EP Beacon-EP Mobiltemp 78
1 (30°C-70°C)
Gear Box Curved tooth coupling Traction winch
Fig. 80 – Traction winch with tooth couplings

10.9 Electrical Drive
Before starting with the maintenance, the winch will

need to be electrically disconnected. Separate heater
lines are also to be shut off!

1. All cable connections for the winches motor are properly seated?
2. Is the free motor ventilation ensured. External Fan are able to run?
3. Is the motor properly fixed? Check of corrosion for all screws nuts
and fastenings(A). The fastenings of the connection between motor
frame and gear box must be checked as well (B).
4. Check the condition of the shaft seals.
5. Is the motor running without strange noise? Check for vibrations
and bearing temperature.
6. Check the coupling between motor and gear box. The fastening
ring has to be in the middle of the coupling. The plastic buffers
should be in proper condition and not dammaged.
A B
Fig. 81.1 – Motor foundation Fig.81.2 – Motor coupling
For further information please refer to the manufactures documentation of

motor manufacturer ABB, Motor Type M3BP 400L and coupling
manufacturer Tschan flexible coupling Type BH 350.
Theese are separate parts of the documentation.

10.10 Local Control Stand (LCS)

need to be electrically disconnected. !
The air conditioning needs to be run at all times,

when the rig is located in warmer regions where the
average temperature is over 25°C.
The following maintenance work is to be carried out on the local control

cabin:
Maintenance steps to the air conditioning unit indicated by the
manufacturer are to be carried out.
The switch cabinet in the local control cabin is to undergo a
visual inspection. Check in regular intervals to assure that the
heater for the switch cabinet is working. The temperature is to
be set at 25°C.
10.11 Coating
The winch has been coated according to the following specification:
a.)Sandblasting: according to DIN 55928 Part 4 Quality SA ½

b.)Primer Coat: Interzink 72 2-Component-Zink-Epoxy
50 - 60 µ
c.) Second Coat: Ikosit EG1 2-Component-epoxy-resin-iron-mica
150 - 180 µ
d.)Final Coat: Ikosit EG5 2-Component Polyurethane RAL5015 (Grey)
50 - 60 µ
Total: at least 250µ
If touch up work is to be done, be sure that the type and layer thickness
matches the table above.

11. MAINTENANCE AT STORAGE WINCH
11.1 General
Maintenance only from specialized personal.

Before starting with winch maintenance, the winch will need
to be electrically disconnected. Additionally measures must
be taken to assure that it cannot be reconnected.
Separate heater lines are also to be shut off!
In order to obtain and test the readiness of the winch, the

following work is to be carried out every 3 months.
The coolant inlet must be opened. Attention! First open the
coolant backflow line, then the coolant inlet. Check to make
sure that nothing is obstructing the coolant flow. The coolant
valve must be checked. This can be done in the operational
menu "Service" – „Coolingwater Valve“ – “Hand” – “Open-
Close”
If nothing to the contrary has been stated all bolt up connections are to be
tightened to the torque values found in chapter 10.1
11.2 Gear Box

The first oil change after 500 operational hours or 12 months.
Further oil changes after every 2000 operational hours or 2 years.
Gear Box filling Quantity app. 90l (use the dipstick as a reference)
Dipstick
Oil drain
Fig. 82 –Gear box Storage winch

The oil level is to be checked every three month (the
level must be between the two marks on the dipstick).
The oil needs to be regularly checked against condensation build up.

Excessive water may make an early oil change necessary.
Use an oil with an EP additive according to DIV 51519 220cSt at 40°C.
11.3 Maintenance and Grease Fittings

These places are open gears / threads and have to be greased as soon as
bare metal spots are noticed. The grease can be applied with a brush.
These places are to maintain / grease ever 4 months.
These places are maintenance free (new grease filling after 5 years)
Recommended grease to be applied while the winch is running without

load.
Recommented grease types are shown in chapter 10.3

Greasing points at Storage winch
The spots to be lubricated are shown in the following drawings..
Fig. 83 –Grease Points Gear box

Fig. 84 –Grease Points measuring devices
Fig. 85 – Grease Points Band Brake
Fig. 86 – Grease Points guiding roller

Fig. 87 – Grease Points guiding roller
Fig. 88 – Grease Points chain tensioner

Fig. 89 – Grease Points Chain
Fig. 90 – Grease Points cross threat spindle

Fig. 91 –Grease Points spooling arm guiding roller
Fig. 92 – Grease Points rope adjusting gear

Fig. 93 – Grease Points sheaves

11.4 Piping / Pressure Tank at Storage Winch
The pneumatic lines must be checked in regular intervals. The general

condition of the lines is to be checked taking special care that the winch is not
operated till lines found which have been heavily corroded have been
replaced.
Pneumatic Lines Filter (primary) for

compressed air
Filter (fine particle)

for compressed air
Air reciever
Drain line for

condensation
Fig. 94.1 – Compressed Air Filter in cabinet Fig. 94.2 – Compressed Air Filter at reciever
The primary and fine filters for the compressed air, located in front of the
valve block grouping are to be checked after every 25 operational hours
against build up. If necessary the filter element should be cleaned or
swapped out.
The automatic drain of valve is to remove condensation from the air
reciever.
The fine filter also needs to be checked against condensation build up
before every use.

11.5 Coolant Lines with dynamic Brake / Clutch
Coolant Outlet Hoses

Coolant Inlet Hoses
Pressure air inlet

hoses
Fig. 95 – Coolant Lines
The hoses connected to the brake/clutch are to be checked at least 1x per

year against leakage and flexibility.
If the hoses are damaged or worn they are to be replaced.
As a rule ruber hoses regardless of their condition are to be replaced every
5 years.
For further information (e.g. testing the wear on the disks and linings)
please refer to the manufactures documentation that is a separate part of
the documentation.
For safety purposed a Strainer has been installed in the coolant line.
The Strainer is to be cleaned after every 50 operational hours.
Fig. 96 – Strainer

The condition and the setting of the pressure regulating valve needs to be
checked. Never let increase the input pressure of more than 3,0 bar. A
damage of the copper plates inside the drag brake will be occurred.
Limit switch
Pressure Regulating Pressure Gauge
Screw
Flowmeter
Fig. 97.1 – Pressure regulating valve Fig. 97.2- Flowmeter
Never increase the inlet pressure to the brake/clutch to

more than 3.0 bar. A damage of the copper plates will
be occurred.
During drag brake modus check the volume flow of the coolant. It should be
approx. 90l/min. If the flow isn’t sufficient check the status of the hand valve
between booster pump and traction winch as well as the pressure of the
coolant.
A thermosensor is installed in the coolant collector pipe. These cable and
plug also need to be checked that they have been properly fit, against
corrosion and leakage.
Coolant inlet
Line Coolant outlet
Line
Fig. 98 – Thermosensor

11.6 Band Brake
The band brake will have to be adjusted as soon as the end of the indicator
(2) is in the area of the lower ring (see Fig. XXX).
An alarm will also show on the screen of the local control as soon as this
condition is recognized.
The following steps describe how to adjust the band brake:

1. The pneumatik brake cylinder (1) is to be activated in order to
release the brake band. (see chapter XXX – Service Menu)
2. Loose the clamp screw (3)
3. Turn the spindle (4) to adjust the band brake. Turn the spindle
clockwise to tighten and counter clockwise to loosen.
4. The brake can now be closed. The next step is to check if the
indicator (2) is now in the area of the upper ring (see Fig. XXX). If
this isn’t the case a readjustment is necessary. When the adjustment
is finished the anti twist protection will need to be reinstalled.
The proximity switch doses not serve as a position indicator

for the band brake but instead as a wear indicator.
Fig. 99 – Adjusting brake lining wear out

BRAKE
ENGAGED
A: triggered
B: not triggered
BRAKE
RELEASED
A: triggered
B: triggered
BRAKE
WORN OUT
A: not triggered
B: not triggered
Fig. 100 – Brake cylinder in different possitions
The proximity switches (A and B) has to be installed in a way that A is

triggered and B not triggered when the brake is engaged.
When the brake in relased both A and B are triggered.
When the brake lining is worn out both switches are not triggered in the
engaged position. A lining adjustment with the spindle (see page 104) is
needed.
This adjustment of the proximity switches has to take place when the brake is
closed. This work is to be done after repair, after brake lining replacement or
during the commissioning phase.
The brake lining will need to be replaced when it reaches a thickness of
8,5mm or less.

The first step in changing the brake lining is to dismantle the brake band. The
brake linings are attached to the brake band using both adhesive and bolts.
The worn brake lining can be stripped off the band after the bolts have been
taken off.
It is important that all reminisces of the old lining be stripped off before the new
lining is attached to the band.
11.7 Spooling device with adjustment Gear

The cross threaded spindle of the spooling device must be properly greased
that no areas without grease will be occurred.
A not proper greased cross threaded spindle will be

corroded very fast!
Inside the spooling head a sliding block made from gunmetal bronze
ensures a smooth running of the head. The block must be spanned by a
adjustment screw.
For spanning turn the screw inside until it is blocked and then turn back ¼
revolution.
After that fix it with counter nut and cover with cap nut.
Fig. 101 –Spooling head
Check the spanning twice per year.

The oil filling of the adjustment gearing must be checked twice per year.
Oil filling socket
Gear motor
Oil Sight
Glas
Fig. 102–adjustment gearing
The oil sight glas is opposite of the oil filling socket. The oil level should be
seen in the oil sight glas.
The drive of the adjustment gearing is my means of a gear motor make SEW.
For maintenance of the gear motor see the manufactures documentation of
SEW Type RF 57 which is attached in a separate part.
Gearing Chain wheel Gear motor Gearing Chain wheel
Fig.103.1 –adjustment gearing side view Fig.103.2 –adjustment gearing front view
For greasing the gearing and the chain wheels the covers have an
turnable flap for an easy axcess.

11.8 Electrical Drive

need to be electrically disconnected. Separate heater
lines are also to be shut off!

All cable connections for the winches motor are properly seated?
Is the free motor ventilation ensured? External Fan are able to
run?
Is the motor properly fixed? Check of corrosion for all screws nuts
and fastenings.
Check the condition of the shaft seals.
Is the motor running without strange noise? Check for vibrations
and bearing temperature.
Check the coupling between motor and gear box on corrosion.
The plastic buffers should be in proper condition and not
dammaged.
Fig. 104 –Motor for storage winch Coupling
For further information please refer to the manufactures

documentation of motor manufacturer ABB, Motor Type M3BP 400L
and coupling manufacturer Tschan flexible coupling Type BH 350.
That is a separate part of the documentation.

11.9 Switch cabinet with air conditioning
Before starting with the maintenance, the switch cabinet will

need to be electrically disconnected. Air contitioning lines are
also to be shut off!

Is the switch cabinet damaged or corroded?
Are both remote controls fixed in the seat at the front of the
door?
Is the aircon working?
All cable entrys from bottom side tight and properly seated?
Are the oppenings between cabinet and aircon free from dust
and dirt?
All electrical components working?
Remote
control
Aircon
Fig.105 – Switch cabinet Storage winch
For further information regarding the air conditon please refer to the manu-
factures documentation of aircon manufacturer Pfannenberg, Type DTI/DTS
9841 which is attached in a separate part.

11.10 Coating
refer to chapter 10.11

12. SPARE PARTS
12.1 Traction Winch

Recommended standard collection of spare parts for 2 years.

12.2 Storage Winch
Recommended standard collection of spare parts for 2 years.

13. PARTS LIST
Service / After Sales
Spare parts must meet the technical requirements stipulated by Bröhl.
Original spare parts supplied by Bröhl always meet these demands.
Please submit your spare parts orders in writing. In urgent cases, the
order can also be placed by phone, E-mail or fax.
These orders however will have to be confirmed at a later point in
writing.
Please send your spare parts orders to:
Maschinenfabrik Bröhl GmbH&Co.OHG

PO Box 84
D- 56654 Brohl - Lützing
Telephone: 02633/2910
Fax : 02633/29132
E-mail info@broehl.de
Internet: http:\\ www.Broehl.de
When ordering you will need to specify the following:
− Part
− Serial Number
− Serial Number (when applicable)
− Bröhl Commissioning No.
− Year Built
− Spare Part Ordering No. (included in the parts list)
− Drawing Number
− Required Quantity
− Type of Shipment Desired (e.g. express, freight, airfreight)

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Operating and

Keppel Fels Hull NO. B 316

Traction - Storage Winch Combination

Maschinenfabrik Bröhl GmbH & Co oHG

0 First edition 06.06.11 K.Bous

2. TECHNICAL DATA TRACTION WINCH 9

3. DESCRIPTION DOUBLE TRACTION WINCH 11

4. TECHNICAL DATA STORAGE WINCH 36

5. DESCRIPTION STORAGE WINCH 38

Traction-Storage Winch TSW 3253 -2020 kN Page: 2

6. LOCAL CONTROL STAND LCS 59

7. CENTRAL MONITORING PANEL CMP 62

10. MAINTENANCE AT TRACTION WINCH 81

11. MAINTENANCE AT STORAGE WINCH 95

12. SPARE PARTS 113

13. PARTS LIST 117

Traction-Storage Winch TSW 3253 -2020 kN Page: 4

This symbol is used when a potential

This symbol is used when a potential

When this symbol is displayed pay

Case for case the following difficulties can arise:

Traction-Storage Winch TSW 3253 -2020 kN Page: 5

Traction-Storage Winch TSW 3253 -2020 kN Page: 6

We reserve the right to copy drawings.

We reserve the right to copy drawings

Traction-Storage Winch TSW 3253 -2020 kN Page: 7

The Semisubmersible drilling tender is equipped with an 8 point rope anchor

Fig. 1 – Traction – Storage Winch System TSW 325 on SSDT 3600 E

Traction-Storage Winch TSW 3253 -2020 kN Page: 8

Variable Frequency Drive:

Traction-Storage Winch TSW 3253 -2020 kN Page: 9

The indicated oil quantities are recommendations.

Air Pressure System:

Coolant System (Fresh Water):

Weight of the Main Components:

Weight of the Individual Components:

Traction-Storage Winch TSW 3253 -2020 kN Page: 10

Fig. 2 –Double Traction winch

3.1 Gear Box with drive

Traction-Storage Winch TSW 3253 -2020 kN Page: 11

Aeration Oil Dipstick Flashing light

Fig. 3 –Gear box with motor

Traction-Storage Winch TSW 3253 -2020 kN Page: 12

Traction-Storage Winch TSW 3253 -2020 kN Page: 13

The automatic closing of the band and gear brake as a

Fig. 5 –Cooling line equipment

Traction-Storage Winch TSW 3253 -2020 kN Page: 14

Fig. 6 –Dynamic Brake; pneumatically operated and water cooled

Closing the recirculation line to the pump is prohibited. A

If subject to the danger of frost the system should be purged

Danger of being Burnt!

Cooling with sea water is prohibited!

No Water pressure in the outletline should increase 1 bar!

Traction-Storage Winch TSW 3253 -2020 kN Page: 15

Fig. 7 – Air Operated Gear Brake

Traction-Storage Winch TSW 3253 -2020 kN Page: 16

The gearbox is a 2-step design. Two opposing pneumatic cylinders wich

Hand Wheel Cam Disk Pneumatic Cylinder

Fig. 8 – Gear shifting by means of cylinders or Hand wheel (image similar)

Traction-Storage Winch TSW 3253 -2020 kN Page: 17

Fig. 9 – Motor assembled at the Gear box

Traction-Storage Winch TSW 3253 -2020 kN Page: 18

Traction-Storage Winch TSW 3253 -2020 kN Page: 19