GD - FFD-19

GD.
FFD-19
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INSTRUCTION MANUAL OF
GD.FFD-19
FREE FALL LAUNCHING&RETRIEVAL SYSTEM
Prepared for
CHEMMARINE
( TORGEM SHIPYARD NB: 77 )
Ship Name : LILAC
IMO : 9310379
Issue Date: 24-03-2008
Address: GURDESAN
Tavşanlı Kadıyeri Mevkii 2. Bölge
41410
Gebze / Kocaeli / TÜRKİYE
Tel: +90 262 7248546

Fax: +90 262 7248945
E-mail: info@gurdesan.com.tr
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INSTRUCTION AND MAINTENANCE MANUAL
I
WARNINGS AND CAUTIONS
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WARNINGS AND CAUTIONS:
1- Undertaking a work described by this document might directly or indirectly

cause risks to the safety and health of the person undertaking the work or the
deck machinery or its components while the work is being conducted.
2- The responsibility of the user is to ensure that appropriate controls and

precautions are identified and applied considering the work described by this
document in accordance with relevant statutory, legal and industry
requirements to protect the health and safety of the persons undertaking the
work.
3- The responsibility of the user is to ensure that appropriate controls and

precautions are identified and applied considering the work described by this
document to protect against risks to the desk machinery or its components
while the work is being conducted. Neither this document nor its usage in
anyway absolves the user from their responsibility to ensure that the controls
and precautions referred to above are implemented.
4- The responsibility of the user is to make relevant hazard identifications and

risk assessments of all the activities associated with the usage of this
document.
5- The responsibility of the user is to design and implement safe systems of work
and to supply safe equipment (including safety equipment) and training
(including health and safety training) to anyone who uses this document to
work on products.
6- A user without the relevant experience of working related with this document
or with products or similar products, to which it relates should seek advice to
enable them to identify the appropriate health and safety controls and
precautions to protect against risks to the desk machinery or its components
while the work is being conducted.
GD.FFD-19
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II
INDEX
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INDEX
Cover Page……………………………………. .......………………………………………………….I
Warnings and Cautions……………………… …………………………………………………......II
Index……………………………………………. ...………………………………………….............III
1-General Definitions…………………………. ……………………………………………………...1
2-General Description……...………………… ……………………………………………………...2
General Description
Technical Specifications
Operating Instructions
Free Fall Launch
Recovery of the Life Boat
Maintenance
3-Flushing………………………………….…… ...…………………………………………….…….12
GÜRDESAN`s Recommendation
Equipment Required
Flushing Criteria
Condition of the System After Flushing
Commissioning
4-NAS 1638…………………………………….. …………………………………………………….22
5-ISO DIS 4406………………………………… …………………………………………………….23
6-Selection of Recommended Lubricants….. …………………………………………………….25
7-Drawings…………………………………….. …………………………………………………….31
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III INSTRUCTION AND MAINTENANCE MANUAL
1-GENERAL DEFINITIONS
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GENERAL DEFINITIONS
1. Davit type is GD.FFD-19
2. Winch type is GD.KV-32
3. Safe Working Load for winch is 44 kN
4. Power circuit voltage and frequency are 380 V and 50 Hz respectively
5. Duty Rating is S1
6. Construction/Type of Wire is 18x7/Non-rating
7. Minimum braking load of Wire is 138 kN
8. Diameter of Wire is 16 mm
9. Length of Wire is 50 m
10. Hydro-motor is Type Gerotor
11. Working flow is 50 lt/dk
12. Working pressure is 180 bar
13. Life boat manufacturer and type is NORWEGIAN JY-FF-4.9 T
14. Life boat dimensions are 5.05 x 2.98 x 3.54 m
15. Total weight of the life boat (inc. equipment and personnel) is 4480 kg
16. Number of the people in the life boat (Lowering&Hoisting) is 19
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1
2-GENERAL DESCRIPTION
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GENERAL DESCRIPTION
GD.FFD-19 is a davit system for free fall release of the NORMAR-FREEFALL 4.9 T free fall
life boat. It can also launch and recover the boat with power.
This system will allow free fall escape for the fully manned life boat, completely independent
of external power and with the mother ship listing up to 20º and trim of to 10º.
The system consists of launch ramp with wheels on slide-way for free fall release of the boat.
The main wheels are free lubricated, made of bronze and are running on stainless steel
shafts with seals on both sides to allow maintenance-free operations. The secondary
(guidance) wheels are positioned vertically to sliding direction of the boat, to allow sufficient
lateral correction required while launching. Unlike the main wheels, these wheels are made
of polyamide. An A-frame, with pivot point at the lower end of the launch ramp, complete with
hydraulic winch and cylinders, provides recovery and launch by wire of the life boat. Power,
to the hydraulic power pack, from the ships main or emergency power supply must be
available in order for these operations to be carried out.
Figure 1
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2
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TECHNICAL SPECIFICATION
Boat Type : NORWEGIAN-JY-FF – 4.9 T

Dimensions over all L x B x H : 5.05 x 2.98 x 3.54 m
Launch / Recovery weight inc. 15 persons : 4480 kg
Davit type : GD.FFD-19
Dimensions over all L x B x H (approx.) : 6.7 x 3.68 x 7.8 m
Weight : 5.5 tonnes
The system will allow the following
Free fall launch of fully loaded boat.
Launch by wire of the fully loaded life boat, providing electric power are available from the
ships main or emergency power supply.
Recovery of boat and crew of 4 persons, providing electric power are available from the
ships main or emergency power supply.
The system consists of the following components
Launch ramp for boat, with wheels on the skid way.
Boarding platform.
A-frame (davit arm), hinged to the lower end of the launch ramp, complete with hydraulic
cylinders and winch.
Hydraulic power pack, complete with electric starter, for power to the winch and cylinders.
The power is intended for under deck mounting.
Manual control valves complete with start button for power pack, for operation of the
winch and A-frame. Mounted on deck near davit.
Traverse beam, complete with wire and wire sheaves, for lifting slings from the life boat.
NORMAR-4.9 T Free fall life boat with max capacity : 19 persons.

Total weight of system, inc. Life boat : 10.5 tons.
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3
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WARNING! All crew members on the mother ship should be familiar with
the operating procedures for this launching appliance and life boat. Failure
to follow the procedures detailed in this manual may result in death or
serious injury.
CAUTION! When operating the control levers, take care in moving the
levers fluidly, and avoid all abrupt motions of the a-frame, or the suspended
life boat.
OPERATING INSTRUCTIONS
Launch By Wire
The launch by wire method of lowering the life boat are dependent on electrical power from
the ships main or emergency power supply, and a operator to be positioned at the
manoeuvring controls aboard the mother ship. This method is used when full control of
launch is required, i.e. if there is severely injured personnel aboard the free fall boat or if
objects in the water prevents free fall launch of the boat.
Method:
1) Start the hydraulic power pack by pushing the

start button located near the manoeuvring controls
for the davit.
Figure 2
2) Push the control lever labelled “winch” to the “down” position, until the hooks on the
traverse assembly are level with the end links on the lifting slings on the boat. When the
hooks are level with the lifting slings, unclip the rings on the lifting slings from their
securing clips and hook into the traverse hooks. Lift traverse, by pulling winch operating
lever to the “up” position, until wires are taught.
Figure 3
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4
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Figure 4
3) Remove boat lashing and electrical supply plug from rear of life boat. (See the
separate life boat manual for details.)
4) Personnel board the life boat, take seated positions, remove life jackets and secure
their seat belts. (See the separate life boat manual for correct procedure.)(Fig. 4)
5) Make sure no loose objects are stored in the boat.
6) Operate the free fall release mechanism from inside the boat. (See the separate life
boat manual for details.)
8) Swing out the A-frame by pushing the control lever labelled “BOOM” to the “OUT”
position, and holding it there until the A-frame stops against the stops.(Fig. 5)
Figure 5
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5
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9) Lower the boat to the water until the wire falls become slack, and the boat is fully
waterborne.(Fig. 6)
Figure 6
10) Unhook the boat falls from the traverse and

navigate boat clear of danger.
11) Stop the hydraulic power pack by depressing the

stop button located near the manoeuvring
controls.(Fig. 7)
Figure 7
FREE FALL LAUNCH
The free fall launch is the main method of launching the life boat. It is designed to be
used in all weather conditions and with the mother ship listing up to 20º and having trim
of up to 10º.
This procedure are fully described in the life boat manual, hence referred to this before
attempting free fall with the life boat.
Method:
1) Remove boat lashings and electrical supply plug from the rear of the life boat. (See
the separate life boat manual for details.)
2) Personnel board the life boat, take seated positions, remove life jackets and secure
seat belts. (See the separate life boat manual for correct procedure.)
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6 INSTRUCTION AND MAINTENANCE MANUAL
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3) Ensure that all ropes etc. are clear of boat and launch ramp and that no loose
objects are stored in or on the boat.
4) Ensure that all hatches and openings are securely closed. (See the separate life
boat manual for details.)
5) Ensure that landing area is clear.
6) Start the life boat engine and operate the free fall release mechanism from inside the
boat. (See the separate life boat manual for correct procedure.)(Fig. 8)
7) Navigate the life boat clear of danger.
Figure 8
RECOVERY OF THE LIFE BOAT
1) Start the hydraulic power pack by pushing

the start button.(Fig. 9)
2) Swing out the A-frame by pushing the

control lever labelled “BOOM” to the “OUT”
position, and holding it there until the A-
frame stops against the end stops in the end
stops in the full out position.(Fig. 10)
Figure 9
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7
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3) Navigate lifeboat underneath the A-frame

and lower the traverse by pushing the
traverse by pushing the control lever labelled
“Winch” to the “Down “ position, take care not
to hit the life boat or the personnel on the life
boat with the traverse.(Fig. 11)
Figure 10
Figure 11
4) Lift the traverse and the life boat by pulling the control lever labelled “Winch” to the
“up” position. Lift the life boat until the underside of the skid angles are slightly above
the top of the davit skid way. (max. 0,5 m above! ) Now manoeuvre the suspended life
boat up on to the skid way by alternating between lifting the life boat and pulling in the
A-frame until the life boat are resting on the skid way.(Fig. 12,13,14,15)
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Figure 12 Figure 13
Figure 14 Figure 15
5) When the life boat are resting firmly on the skid way, lower the A-frame until it is
standing approx. 0.5m above its support and use the winch to pull the life boat up until
its release mechanism engages with the hooks on the davit.
6) With the life boat in its correct position, make sure to

check that the life boat release mechanisms are securely
engaged in the davit hooks. Then lower the traverse until the
life boat slings become slack. Secure the life boat lashings.
(See the separate life boat manual for details.) Unhook the
slings from the traverse and secure them in their clips. Lift
the traverse until it engages in its parking stay. Stop the
hydraulic power pack by pressing the button marked “Stop”
or “0”. Connect the electrical supply plug to the rear of the
lifeboat. (See the separate life boat manual for details.)
Figure 16
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Figure 17
MAINTENANCE
General
This lifeboat and davit installation is a life saving appliance and hence should always be
ready for use. Hence it should never be used for the attachment of lines or other
objects, nor should loose objects be stored on the boat or davit, or be so placed as to
obstruct the escape path of the life boat.
Painting
When painting the davit take care not to paint lubrication points, bearings, rubber
O-rings or other objects that should move freely.
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Figure 18
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3-FLUSHING
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IMPORTANT!
Flushing of the hydraulic pipework is generally the part of the work of the
contractor (the shipyard contracted by our customer) or the subcontractor
(the specialised firm subcontracted by the contractor). The contractor or
the subcontractor would be fully responsible to GÜRDESAN for flushing
work they conducted. When the contractor or the subcontractor obtain the
required oil cleanliness, they must take the oil sample in each circuit and
submit the analysis results to GÜRDESAN, the GÜRDESAN authority
holds the full right to accept or to reject the flushing work. The
hydraulic system can not be started up unless the oil cleanliness is found
satisfactory by GÜRDESAN. If the system is started up without
GÜRDESAN`s acceptance, the system would no longer be guaranteed.
If the end-user is responsible for the field installation of the hydraulic
pipework, he must perform the flushing work which is also subject to
GÜRDESAN`s acceptance. Otherwise the hydraulic system, again, would
no longer be guaranteed.
RECOMMENDATION ON A FLUSHING METHOD
The flushing method suggested here is generally used assuming the

material condition is not satisfactory. The piping on a GÜRDESAN product
is always cleaned and flushed before reaching the end-user. This method
is used to achieve as best result as possible considering the occurrence of
the unsatisfactory conditions below;
Absence of pickling (or poor pickling), resulting in the presence of

oxides inside the pipes.
Welds showing scale traces (defective execution of welds or TIG

process with inert gas not used)
Pipes not fully or not cleaned at all before field installation (when
pickled in bath), not properly or not dried at all, not correctly or not
plugged at all during handlings, etc.
Presence of solid or liquid matters remaining after pickling.
IMPORTANT! GÜRDESAN accepts no responsibility for any damage on the

piping caused by a wrong designed flushing system based on the criteria
stated hereinafter.
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12
3-FLUSHING
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EQUIPMENT REQUIRED FOR THE FLUSHING OPERATION
The equipment below is necessary for the flushing system suggested;
1. Motor-pump with a sufficient capacity for the flushing oil to be flown through pipes
at a velocity greater than 6 m/sec.
2. 1 reservoir
3. Sufficient amount of Filters
4. Required flushing cartridges for the filter above
5. Bypassing materials. Such as hose, pipe, fittings etc. to be able to bypass the-
must-be-bypassed components.
IMPORTANT! During flushing operation, some components of the system

MUST be by-passed (must not be flushed) as stated below;
All units of the hydraulic installation assembled by GÜRDESAN
(reservoir, motor-pumps, valve stands, manifold blocks. Etc.)
All actuators (cylinders, motors, etc.)
FLUSHING CRITERIA
GÜRDESAN states the criteria below for an efficient flushing:
1. It is conducted by oil circulation
2. Velocity MUST be between 6 to 8 m/sec. It is, however, recommended that the

velocity should be closer to 8 m/sec. Read the paragraph titled “THE
ILLUSTRATION OF A FLUSHING SYSTEM” for calculation of the Flow depending on
the Velocity of the Flushing liquid.
3. Temperature is to be between 30 oC and 60 oC
4. The flushing liquid/fluid is to be compatible and miscible with the final system
liquid/fluid but with lower viscosity (the flushing and the final system liquid/fluid is
oil). It must be selected in agreement with the system fluid supplier who should
provide a certificate
5. During the flushing operation, the circuits MUST be checked for any leakage. The
test pressure recommended is 10 bar
IMPORTANT! According to the flushing method and the material availability,
the contractor or the subcontractor should study how circuits must be adapted
for flushing and also supply and install all temporary accessories required,
hoses etc. (see the section of “The Illustration of a Flushing System”
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3-FLUSHING
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CONDITION OF THE SYSTEM AFTER FLUSHING
The system that is delivered to the end-user by the firm or the shipyard MUST be clean
and in working order and conditions. Therefore;
1. All hydraulic units MUST be installed in their final places and connected with pipes
and hoses.
2. The system MUST be oil filled with the final system fluid/liquid (oil)
3. The cleanliness level required must be achieved. GÜRDESAN suggests that the
contamination should not greater than Class 7 to NAS 1638 which is equivalent to ISO
DIS 4406 Class 16/13.
IMPORTANT! The description for both standards of NAS 1638 and ISO DIS
4406 can be found in detail at the subsequent sections of “NAS 1638” and
“ISO DIS 4406”. Read and understand the standards for better flushing
operation achievement.
4. The flushing cartridges used for flushing MUST be replaced by the system
cartridges.
COMMISIONING
Servicing by the contractor or by the subcontractor does not mean fulfilling all the
obligations. The commissioning assistance services should also be sought from
GÜRDESAN.
These services consist of providing the personnel required to do any repairs necessary,
modification work, oil draining, filling or shaping up all over the commissioning period of
the hydraulic system.
IMPORTANT! Commissioning service conditions are the subject of an

agreement reached after negotiating with the GÜRDESAN authority. It
should be remembered that GÜRDESAN`s guarantee is valid only when
the installation is approved by the GÜRDESAN`s personnel.
During this period, the second leakage test should be performed either at the working
pressure or at the test pressure.
Any leak detected MUST be eliminated.
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3-FLUSHING
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THE ILLUSTRATION OF A FLUSHING SYSTEM
IMPORTANT! It is believed that the illustration stated hereafter would be

beneficial for gaining some view of conducting a flushing process.
Nevertheless the illustrations below intend not to give an exact way of
flushing for your system. The structures of the pipeline vary from one system
to another. However the logic behind it is same. Therefore the illustration
below may be a guideline to show a method of flushing.
NOTE! The system below is such system with a hydraulic power pack that
agitates two winches. It is just an example and may differ from one system
to another
P T L LS P T L LS P T L LS P T L LS
Pipe ends-Valve inlets
Flushing line
Joint
Joint
To the Filter
P T L LS P T L LS
To the
Filter
P1 P2
L S1 -L S2
P1 P2
L S1 -L S2
Hydraulic Power Pack
The whole pipeline system can be divided up into the two parts. The both parts belong to
the system shown in the small figure. P and T lines and L and Ls lines are flushed
together. The pipes are disconnected from the valve inlets and connected to each other
by means of a connection hose (The valve inlets are circled and noted in the figures).
The pipes are also disconnected from the joints to form a flushing line. Consequently, the
proper flushing lines are formed as indicated with the dotted lines.
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3-FLUSHING
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Aware that;
1. The velocity of the flushing fluid should vary between the rate of 6 and 8 m/s.
However the diameters of the pipes in the pipeline are different and the flow rate
should differ from one pipe to another to provide the velocity required. Because
of due reason, the velocity should be chosen considering the P line of the
combined P-T line and should be chosen considering the Ls line of the
combined L-Ls line.
P T L Ls
The Flow should be calculated to provide 8 m/s velocity inside of the pipe.
The Flow is calculated as fallows:
Assuming the pipe is of 25x4, It can be found that the inside diameter of the pipe
is 17 mm (25 – 8 = 17 mm).
Q = Flow as lt/min
Q=VxA V = Velocity of the flushing fluid as m/sec
A = Cross sectional area of the pipe as mm2
A = (D2 x ) / 4 = (172 x ) / 4 = 226.98 mm2

V = 8 m/s (as required) = 8000 mm/s
Q = 8000 mm/s x 226.98 mm2 = 1815840 mm3/s. to convert into lt/min
Q = 1815840 mm3/s x 6 x 10-5 = 108.95 lt/min
It means that to provide 8 m/s velocity inside of the pipe, of 108.95 lt/min
flow should be provided.
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3-FLUSHING
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2. The oil sample should be taken before the filter.
3. When renewing the oil, use a filter to clarify the oil better and check the filters
frequently for any malfunction, dirt etc. Remember! The system needs not any
repair if it is done so.
COMMISSIONING MANUAL
IMPORTANT! The manual below applies to hydraulic experts who are

familiar with the commissioning of hydraulic systems. It has no
didactic purpose. This manual describes the chronological
commissioning work plan to avoid omissions. It does not detail the
basic operations which are part of the “experts know-how”. It only
mentions some rules that are essential for the safety to both the
personal end the equipment. Before starting the commissioning work,
it is necessary to have knowledge of the operating manual and
technical data sheets of components.
PRELIMINARY CHECKS
Initial conditions
The whole hydraulic system is field-installed.
All pipes have been cleaned, flushed and drained.
The reservoir has been drained and cleaned.
All filters are fitted with new cartridges.
Electric Power Supply

Make sure that the delivered power supplies are in conformity with the power
requirements of the following components:
Electric motors
Solenoids
Accessories such as level switches, temperature or pressure switches.
Make sure that voltage variations are within ±5 % of the power rating of each electric
device.
Pipings
Make sure that the whole pipework is in conformity with the hydraulic circuit diagram.
Make sure that all connecting materials are firmly secured.
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3-FLUSHING
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Mechanical Components
Make sure that all mechanical components are permanently assembled (mounting
accessories of cylinders, frames…)
Make sure that the clearances required for free mechanical movements are not
obstructed.
RESERVOIR FILLING
First of all, check that the oil to be used is the fluid recommended for the system. If
not, advice and consent must be requested from MANNESMANN REXROTH
or GURDESAN experts. If this fluid is not a product of a world-wide reputed oil
supplier, it is essential to know all its properties, and more particularly its seal
compatibility (aniline point), its lubricity (4-ball test) and its water content.
The reservoir must be filled from new clean fluid drums that have been correctly
stored.
To fill the reservoir, the fluid must absolutely be pumped through the filter of the oil-
conditioning system (using the quick-acting coupling). The reservoir must be oil-filled
slowly to prevent formation of air bubbles.
After initial filling, followed by a short period of the hydraulic system, that is after oil-
filling and air purging of all pipes and components, the reservoir oil level must be
completed.
CHECKING OF HYDRAULIC FUNCTIONS AND PRESETTINGS
The hydraulic system which has been acceptance-tested in workshop conforms, in

theory, to the circuit-diagram and bill of material and is in working condition.
Nevertheless, prior to performance of any movement, the following actions are required:
Check the hydraulic and electric connections.

Check interfacing between hydraulic components and remote electric devices:
PLC(s)
Electric cubicle(s)
Preset the devices at the values specified in the circuit-diagram or in the operating
manual.
The above operations are required for each function as described hereinafter.
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3-FLUSHING
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Reservoir
Liquid level switches
Check electric connections, corrections, correct functioning and test interfacing

with the PLC(s).
Main Motor-pumps
Motor and Pumps
Check the electric connections of motors.

Set the pressure compensator and the pressure relief valve of each pump at their
minimum values.
Oil-fill the case of each pump after removal of the oil filler plug.
Check direction of rotation of each motor (run the motor step by step).
Test interfacing with the PLC(s).
Filters
Check electric connections of the clogging indicators and test interfacing with the
PLC(s).
The correct-functioning of the clogging indicators must be checked at the time of
the first cartridges clogging.
Solenoid operated pressure relief valves
Check the electric connections of the solenoid valve.

Test interfacing with the PLC(s).
Manifold Blocks and valving
Solenoid operated directional control valves
Check electrical connections, correct functioning and test interfacing with the
PLC(s).
Place the master valving element in the initial position so that no movement can
be performed when main pressure is admitted at port P.
Pressure control valves
Set the pressure relief valves
Flow control and flow restriction valves
Fully close the valves
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3-FLUSHING
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Manual shut-off valves
(except for the valves on the feed lines to pump)

Close the valves.
Pressure switches
Check electric connections and correct functioning of pressure switch (es) and test
interfacing with the PLC(s).
COMMISSIONING- PHASE 1 (static tests)
Filling the pipework
The pipes located downstream of valves and the cylinder chambers connected to these
pipes cannot be oil-filled during Phase 1.
Partly open the manual shut-off valves and the flow control valves which, when
closed, prevent the fluid passage.
Purge the pipes at high points, using the pressure test couplings.
Oil-fill the cylinder chambers that are linked to the pumps without actuating the
directional control valves (performance of no movements).
Purge the cylinder chambers.
Check the pipes for leaks.
Repair or replace any defective part.
COMMISSIONING –PHASE 2 (Dynamic test)
The phase 2 operations involve safety hazards

For the personnel
For the equipment
Certain precautions must therefore be taken:
Make sure nobody, except for the person(s) in charge, is in the area where the
mechanical movements are ready to be performed.
Perform the first movements very slowly and make sure all the time that
movements are executed normally and are not abstracted.
In case of doubt, stop the movements immediately and check as required.
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3-FLUSHING
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COMMISSIONING-PHASE3 (dynamic test)
All settings must be checked (pressure and control devices) and corrected if required
when the cylinders operate with the load, in order to achieve the satisfactory operation of
the hydraulic system.
“Satisfactory operation” is defined as follows
Smooth action
Progressive opening and closing (in m/sec) not exceeding the theoretical values
specified in operating manual.
Cycle performed within the maximum cycle time.
Check cylinders normal displacement.
Check pressure rise at pressure test coupling item 26.4
When functioning is found correct, repeat the sequences.
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3-FLUSHING
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NAS 1638
In this standard the individual particle sizes are divided into 5 ranges. A maximum
number of particles is allowed for each range in each class. The table below shows the
contamination classes to NAS 1638 (maximum number of dirt particles in 100ml of
fluid).
Class 6-15 μm 15-25 μm 25-50 μm 50-100 μm >100 μm
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2850 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2025 360 64
9 128000 22800 4050 720 128
10 256000 45600 8100 1140 256
11 512000 91200 16200 2880 512
12 1024000 182400 32400 5760 1024
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3-FLUSHING
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ISO DIS 4406
The diagram below shows how the particle size is plotted along the abscissa and the
number of particles and classification code along the ordinate.
In the case of ISO DIS 4406 the degree of contamination of the fluid is defined by a two-
digit code. One is the number of solid particles over 5 μm in size and the other the
number of particles over 15 μm in size in a 100 ml sample of fluid.
In order to determine the degree of contamination to ISO DIS 4406, first count all
particles larger than 5 μm in the 100 ml sample and give it a code number. Then count all
particles larger than15 μm and give them another code number (see the diagram below)
These code numbers from the designation of the sample. The Table in the next page lists
the contamination figures and their coding.
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3-FLUSHING
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Number of particles per 100 ml
Over 5 μm Over 15 μm
Code More than and up to More than and up to
20/17 500 k 1M 64 k 130 k

20/16 500 k 1M 32 k 64 k
20/15 500 k 1M 16 k 32 k
20/14 500 k 1M 8k 16 k
19/16 250 k 500 k 32 k 64 k

19/15 250 k 500 k 26 k 32 k
19/14 250 k 500 k 8k 16 k
19/13 250 k 500 k 4k 8k
18/15 130 k 250 k 16 k 32 k

18/14 130 k 250 k 8k 26 k
18/13 130 k 250 k 4k 8k
18/12 130 k 250 k 2k 4k
17/14 64 k 130 k 8k 16 k
17/13 64 k 130 k 4k 8k
17/12 64 k 130 k 2k 4k
17/11 64 k 130 k 1k 2k
16/13 32 k 64 k 4k 8k
16/12 32 k 64 k 2k 4k
16/11 32 k 64 k 1k 2k
16/10 32 k 64 k 500 1k
15/12 16 k 32 k 2k 4k
15/11 16 k 32 k 1k 2k
15/10 16 k 32 k 500 1k
15/9 16 k 32 k 250 500
14/11 8k 16 k 1k 2k
14/10 8k 16 k 500 1k
14/9 8k 16 k 250 500
14/8 8k 16 k 130 250
13/10 4k 8k 500 1k
13/9 4k 8k 250 500
13/8 4k 8k 130 250
12/9 2k 4k 250 500

12/8 2k 4k 130 250
11/8 1k 2k 130 250
______________________________________________________________________________________________
24
SERBEST DÜŞMELİ CAN FİLİKASI MATAFORASI AYRINTILI MUAYENE VE KONTROL SÜRELERİ
THOROUGH INSPECTION AND MAINTENANCE PERIODS OF FREE FALL DAVIT (LAUCHING AND RETREIVAL SYSTEM)
KONTROL EDİLECEK BÖLÜM YAPILACAK KONTROL VE MUAYENE PERİYODLAR / PERIODS
Hafta Ay Yıl
PART TO BE INSPECTED ITEMS TO BE CHECKED Week Month Year
Çelik yapıdaki paslanma X
Çelik Yapı / Gövde Çelik yapıdaki deformasyon X
Hasar, çatlak ve bozukluk X
1. Corrosion X
Steel Structure / Frame Deformation X
Damage, crack and any abnormality X
Tel kondüsyonu (Hasar, Gam v.b.) X
Yağlama / işlevsellik X
Çelik Tel Her 2,5 Yıl
Uçlar ters çevrilmiş mi? Uygun olmadığında her 4
Yenilenmiş mi? Her 5 Yıl yılda yenile
2. Wire condition (i.e. any damage, kink etc..) X
Lubrication / functionality X
Steel Wire Rope Every 2,5 Year
If ends reversed
N /A renew every 4 year
If replaced / renewed Every 5 Year
İşlevsellik durumu X
Tüm Makara, Palanga, Kilit, Kanca, Menteşe,
Yağlama ve yatakların kondüsyonu X
Halkalar Paslanma, hasar, çatlak ve bozukluk X
3. Condition of functionality X
All Sheaves, Pulleys, Hooks, Shackles, Hinges,
Condition of lubrication supply and bush X
Studless links Corrosion, damage, crack and any abnormality X
Hasar, çatlak ve bozukluk X
Kayma Yolu Makaraları veya Sürtünmeli Yağlama, işlevsellik ve yatakların kondüsyonu X
Kızaklar Çelik yapıdaki deformasyon X
Çelik yapıdaki paslanma X
4. Damage, crack and any abnormality X
Condition of lubrication, functionality and bearings X
Sliding Way of Friction Surfaces or Rollers
Deformation X
Corrosion X
Paslanma, hasar, çatlak ve bozukluk X
Hidrolik Vinç Yağ seviye durumu, sızıntısı ve anormal ses bozukluğu X
Boşluk / sıkılık X (gerekliyse)
5. Corrosion, damage, crack and any abnormality X
Hydraulic Winch Condition of oil level, leakage and abnormal sound X
Surface contact, clearances X (if needed)
Hafta Ay Yıl
Tüm Manometreler Minimes Hortum bağlantıları X
Hasar, yağ sızıntısı ve bozukluk X
All Manometers Minimes Hose Connection X
Damage, oil leakage and abnormality X
Çabuk Çözülebilir Deniz Bağları İp kondüsyonu (Hasar, Gam v.b.) X
Kanca durumu (Boşluk / sıkılık, Hasar v.b.) X
Quick Release Lashings Rope condition (i.e. any damage, kink etc..) X
Condition of hook (i.e. tightness, clearances, etc…) X
Uzaktan Kumanda Start / Stop / Acil Stop İşlevsellik durumu X
Butonları Hasar ve bozukluk X
8. Remote Control Start/Stop/Emergency Stop Condition of functionality X
Buttons Damage, abnormality X
İşlevsellik (motoru kapatıyor mu? v.b.) durumu ve Basınç ayarı X
Basınç Emniyet Valfi, Max. Basınç Şalter Yağ sızıntısı X
9. Condition of functionality (starts/stops elec. motor etc…) and settings X
Main Relief Valve, Max. Pressure Switch Oil leakage X
Corrosion, damage, crack and any abnormality X
Hidrolik Güç Ünitesi, Boru Tesisatı, Valfler,
Hortumlar ve Pistonlar Yağ seviyesi ve sızıntısı X
Hydraulic Power Pack, all Valves, Hoses,
Corrosion, damage, crack and any abnormality X
Pistons, Hydraulic Pipe System and Fittings Oil level and leakage X
Hasar ve bozukluk X
Elektrik Panosu ve Limit Şalterler Kablo bağlantıları X
Sigorta, kontaktör, klemens v.b. X
11. Corrosion, damage, abnormality X
Electric Starter Box / Panel and Limit Switches Cable connection X
Terminals, relays and etc… X
Hafta Ay Yıl
Uzaktan Kumanda İpleri İp kondüsyonu (Hasar, Gam v.b.) X
Makaralar, somunlar ve parçaların durumu X
Remote Control Ropes Rope condition (i.e. any damage, kink etc..) X
Condition of system pulleys and all parts X
Paslanma, hasar, çatlak ve bozukluk X (gerekliyse)
Otomatik Hidrolik (Diskli) Fren Disklerin kondüsyonu X (gerekliyse)
13. Corrosion, damage, crack and any abnormality X (if needed)
Automatic Disc Brake Condition of discs, peeling X (if needed)
Condition of functionality X
Eksiklik X
Cıvata, Somun v.b. Sıkılık X
Hasar, pas ve bozukluk X
14. Missing X
Bolts, Nuts and etc… Tightness X
Corrosion, damage, abnormality X
Boş Bot ile Vincin Dinamik Fren Testi yapıldımı? Her yıl
15.
Conduct dynamic brake test of the winch with unloaded boat Annually
Maks. indirme yükünün 1,1 Katı ile vincin dinamik fren testi yapıldı mı? (Su balonu veya eşdeğer bir yük alarak). Her 5 yıl
16.
Conduct dynamic brake test of the winch with unloaded boat (annually) water baloon or equal weight in the boat Every 5 year
SELECTION OF RECOMMENDED LUBRICANTS
____________________________________________________________
JOINT WINCH
GENERAL WIRE ROPES/ HYDRAULIC GEAR AND N R SPUR, HELICAL OR
OIL PURPOSE
NIPPLE
SPINDLES/
GEAR-WHEEL
SYSTEMS/
EPICYCLIC
CLUTCH
LUBRICATION/
WORM GEARED
WINCHES OR
BEARINGS OR GEARED WINCH/ INDEPENDENT SLEW GEARS
COMPANY *also see the WORM GEARS AIR MOTOR NR CLUTCH
previous two GEARS UNITS
pages
ENERGREASE ENERGOL BARTRAN HV ENERGOL ENERGOL GRXP

MM-EP 2 WRP 46 SHF-LT 15 150 AND GRXP
220
SPHEEROL RUSTILO 553 HYSPIN HYSPIN ALPHA SP 150

AP3 AWH 46 AWH 15
DURA-LTH PINION MECHANISM MECHANISM NL COMPOUND

EP2 250 TCB LPS 46 LPS 15 150
GULFCROWN MS LUBCOTE EP LUBRICANT
NO 2 NO 3 R 150
EPEXA 2 MO 2 CARDREXA VISGA 46 SPINELF 10 EPONA Z 150

DC 1
BEACON SURETT FLUID UNIVIS HP46 NUTO H 5 SPARTAN EP 150

2 or 3 4K
BEACON
2 OR 3
MARSON CABLINE HYDRANT HYDRANT GIRAN 150

L2 750 FNL HV 46 LZ 10
MOBILARMA
MOBILUX 798 DTE OIL DTE OIL 11 M MOBILGEAR 629
2 MOBILTAC 25 M 46
EP 2 D OR 81
ALVANIA T
R3 RHODINA TELLUS 46 ELLUS R 10 OMALA
RHODINA GR 2 150 OR 220
GR 2
MULTIFAK EP2 CRATER RANDO RANDO MEROPA 150

2 X FLUID HD-AZ-46 HD-Z-15

4-DRAWINGS
______________________________________________________________________________________________________
DRAWINGS
__________________________________________________31______________________________________________
Parça Adı Adet Malzeme Açıklamalar
No Name Of Piece Qty Material Explanation
ELECTRIC CIRCUIT DIAGRAM

PART LIST
06.B02008.00

GD - FFD-19

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Issue Date: 24-03-2008

Tel: +90 262 7248546

WARNINGS AND CAUTIONS:

1- Undertaking a work described by this document might directly or indirectly

2- The responsibility of the user is to ensure that appropriate controls and

3- The responsibility of the user is to ensure that appropriate controls and

4- The responsibility of the user is to make relevant hazard identifications and

Cover Page……………………………………. .......………………………………………………….I

Warnings and Cautions……………………… …………………………………………………......II

1-General Definitions…………………………. ……………………………………………………...1

2-General Description……...………………… ……………………………………………………...2

4-NAS 1638…………………………………….. …………………………………………………….22

5-ISO DIS 4406………………………………… …………………………………………………….23

6-Selection of Recommended Lubricants….. …………………………………………………….25

1. Davit type is GD.FFD-19

2. Winch type is GD.KV-32

3. Safe Working Load for winch is 44 kN

4. Power circuit voltage and frequency are 380 V and 50 Hz respectively

6. Construction/Type of Wire is 18x7/Non-rating

7. Minimum braking load of Wire is 138 kN

10. Hydro-motor is Type Gerotor

11. Working flow is 50 lt/dk

12. Working pressure is 180 bar

13. Life boat manufacturer and type is NORWEGIAN JY-FF-4.9 T

14. Life boat dimensions are 5.05 x 2.98 x 3.54 m

16. Number of the people in the life boat (Lowering&Hoisting) is 19

Boat Type : NORWEGIAN-JY-FF – 4.9 T

The system will allow the following

 Free fall launch of fully loaded boat.

The system consists of the following components

 Launch ramp for boat, with wheels on the skid way.

 NORMAR-4.9 T Free fall life boat with max capacity : 19 persons.

1) Start the hydraulic power pack by pushing the

5) Make sure no loose objects are stored in the boat.

10) Unhook the boat falls from the traverse and

11) Stop the hydraulic power pack by depressing the

FREE FALL LAUNCH

5) Ensure that landing area is clear.

7) Navigate the life boat clear of danger.

RECOVERY OF THE LIFE BOAT

1) Start the hydraulic power pack by pushing

2) Swing out the A-frame by pushing the

3) Navigate lifeboat underneath the A-frame

6) With the life boat in its correct position, make sure to

RECOMMENDATION ON A FLUSHING METHOD

The flushing method suggested here is generally used assuming the

 Absence of pickling (or poor pickling), resulting in the presence of

 Welds showing scale traces (defective execution of welds or TIG

 Presence of solid or liquid matters remaining after pickling.

IMPORTANT! GÜRDESAN accepts no responsibility for any damage on the

The equipment below is necessary for the flushing system suggested;

3. Sufficient amount of Filters

4. Required flushing cartridges for the filter above

IMPORTANT! During flushing operation, some components of the system

GÜRDESAN states the criteria below for an efficient flushing:

1. It is conducted by oil circulation

2. Velocity MUST be between 6 to 8 m/sec. It is, however, recommended that the

3. Temperature is to be between 30 oC and 60 oC

IMPORTANT! Commissioning service conditions are the subject of an

Any leak detected MUST be eliminated.

IMPORTANT! It is believed that the illustration stated hereafter would be

Free fall launch of fully loaded boat.

Launch ramp for boat, with wheels on the skid way.

NORMAR-4.9 T Free fall life boat with max capacity : 19 persons.

Absence of pickling (or poor pickling), resulting in the presence of

Welds showing scale traces (defective execution of welds or TIG

Presence of solid or liquid matters remaining after pickling.

Check the hydraulic and electric connections.

Liquid level switches

Check electric connections, corrections, correct functioning and test interfacing

Motor and Pumps

Check the electric connections of motors.

Solenoid operated pressure relief valves

Check the electric connections of the solenoid valve.

Solenoid operated directional control valves

Pressure control valves

Set the pressure relief valves

Flow control and flow restriction valves

Fully close the valves

(except for the valves on the feed lines to pump)

Check the pipes for leaks.

Cycle performed within the maximum cycle time.

Check cylinders normal displacement.

Check pressure rise at pressure test coupling item 26.4

When functioning is found correct, repeat the sequences.