manual da instalação

Installation manual
Eisa Estaleiro Ilha S.A

Drawings of
Deck equipment
Hydraulic system
Electrical system

General installation manual

 GENERAL
INSTALLATION
MANUAL

21.05.2003
 2

1 CONTENTS

1 CONTENTS....................................................................................................................... 2
2 INTRODUCTION ............................................................................................................. 3
2.1 RESPONSIBILITY.............................................................................................................. 4
3 PIPEWORK ....................................................................................................................... 5
3.1 BENDING THE TUBE........................................................................................................ 5
3.2 PRESSURE TESTING WELDED TUBING .................................................................... 5
3.3 TUBE CLAMPS / BRACKETS.......................................................................................... 7
3.4 PICKLING ........................................................................................................................... 8
3.5 ANTI – CORROSION TREATMENT .............................................................................. 9
4 CLEANLINESS............................................................................................................... 10
5 HYDRAULIC TANK....................................................................................................... 11
6 INSTALLATION OF HYDR. PUMPS........................................................................... 12
6.1 LINE-UP ............................................................................................................................. 12
6.2 INSTALLATION OF THE PUMP .................................................................................. 12
6.3 CONNECTION OF PIPELINES TO THE PUMP......................................................... 12
6.4 DIRECTION OF PUMP SHAFT ROTATION .............................................................. 13
6.5 STARTING AND VENTING ........................................................................................... 13
7 DIV EQUIPMENT.......................................................................................................... 14
7.1 ACCUMULATORS........................................................................................................... 14
7.2 OIL COOLER.................................................................................................................... 14
7.3 OIL FILTER ...................................................................................................................... 14
7.4 PRESSURE RELIEF VALVE.......................................................................................... 14
8 PREPARATION FOR START-UP................................................................................. 15
8.1 OIL FILLING PROCEDURE .......................................................................................... 15
8.2 INITIAL STARTING ........................................................................................................ 16
9 ELECTRICAL INSTALLATIONS................................................................................. 18
10 PERIODIC MAINTENANCE .................................................................................... 19
11 TROUBLE SHOOTING ............................................................................................. 20
 3

2 INTRODUCTION
This manual gives some general advice for the installation of KARM deck machinery.

Correct installation, and preventive maintenance of the hydraulic system prolong the
lifetime of the equipment and ensure uninterrupted operation and unnecessary down
time.

We therefore recommend that the following instructions are closely followed during
installation and start-up.
These guidelines are general for our systems.
Information regarding specific service details will be given as required.

Both during installation and start-up of the machinery, as well as during possible
inspections, cleanliness is of outmost importance. Winches and valves are closely
examined before leaving our facilities, but we still recommend that you examine it at
arrival as transportation damage and transportation dirt is quite common. In case
something is not satisfactory, please contact us before you start the installation.
This is to your advantage as we are not responsible for costs related to cleaning and
replacing parts damaged by foreign matters and/or dirt as the cause of the presence of
such can hardly be determined after the installation has commenced.

CLEANLINESS IS A "MUST" FOR TROUBLE-FREE OPERATION.

Under other conditions, such as a higher or lower ambient temperature, humid or dusty
atmosphere or other special conditions, we recommend you to contact our service
department for consultation, or you may ask for assistance by one of our service
engineers.

Warranty: This manual gives only general advice. The system must be installed by
skilled workers.
Warranty.

Warranty on equipment supplied by Karmøy Winch A/S is valid only if the following
instructions are complied with.

If you are stuck or in doubt, contact Karmøy Winch A/S:

Telephone: 52 856800
Fax: 52 856802
E Mail: post@karmoy-winch.no
 4

2.1 RESPONSIBILITY
The yard is responsible for the hydraulic installation being in accordance with
specification supplied by Karmøy Winch A/S.

Tubing dimensions are given in minimum.

The individual supplier must give tubing dimensions for components not supplied by
Karmøy Winch A/S, but connected to the same system. Tubing dimensions in this
case indicated on Karmøy Winch A/S drawings must be considered only as
suggestions.

Karmøy Winch A/S is not responsible for tube connections to components not
supplied by Karmøy Winch A/S. Each individual supplier must in this case be
consulted
 5

3 PIPEWORK

The installation should be made in accordance with the existing system diagram, see
hydraulic drawing.

Particular attention should be paid to the pipe work. No pipe lines are allowed to
transmit mechanical forces (stress) to components or to the power unit. The pipe lines
should be safely supported to avoid vibrations or movements, and mounted to obtain
an attractive appearance.

Choose fittings and hoses of a good quality, and use pipes which can be cold bended in
a bending machine. Please remember that fittings are assembly elements, not pipe
supporters.

Flexible hoses should be installed according to specifications on the diagram. The

hoses cannot stand sharp bends or torsion’s. The bending radius must be checked to
make sure that it is sufficient and that the hose is long enough to be moved freely.

As a rule of thumb for the minimum bending radius of the hose the following may be
used:

Outside diameter, D mm 0-25, 25-40, 40-55, 55 and larger

Smallest bending radius, mm 6xD, 7 x D, 8 x D, 9 x D

Before power unit and valve panels are connected with the rest of the system, an
examination must be made to make sure that the pipe work between power unit and
actuators is carefully cleaned.

3.1 BENDING THE TUBE

All tubing must be cold when bent, never use heat.
Use pipe bending machines for bending. Thus you will avoid reduction of the tube's
inner diameter at the bend.

3.2 PRESSURE TESTING OF WELDED TUBING

All welded tubing must be pressure tested prior to installation onboard.

The testing pressure should be 70 bar (115 psi) above the normal system operating
pressure.
 6

SECTION FROM DIN 2391C, ST35,4

Outside diam. x Wall thickness Max. working pressure

10 x 2,0 mm 571 bar
12 x 1,5 mm 333 bar
12 x 2,0 mm 461 bar
14 x 2,0 mm 387 bar
15 x 1,5 mm 261 bar
15 x 2,0 mm 358 bar
18 x 1,5 mm 214 bar
18 x 2,0 mm 292 bar
20 x 2,0 mm 261 bar
20 x 3,0 mm 409 bar
22 x 1,5 mm 173 bar
22 x 2,0 mm 235 bar
25 x 2,0 mm 205 bar
25 x 3,0 mm 261 bar
28 x 2,0 mm 318 bar
28 x 2,5 mm 230 bar
30 x 2,0 mm 170 bar
30 x 2,5 mm 214 bar
30 x 3,0 mm 332 bar
35 x 2,0 mm 143 bar
35 x 2,5 mm 181 bar
35 x 3,0 mm 221 bar
38 x 2,5 mm 166 bar
38 x 3,0 mm 202 bar
38 x 4,0 mm 276 bar
42 x 2,0 mm 118 bar
42 x 3,0 mm 181 bar

St,52.4
50 x 5 mm 301 bar
60 x 5 mm 248 bar
80 x 10 mm 400 bar

Note!
Dimensions given on the Karmøy Winch A/S diagrams are all minimum sizes.
Make sure that steel quality and fittings are designed for max. pressure in the system.
 7

3.3 TUBE CLAMPS / BRACKETS

Proper clamping is important. Careful consideration must be taken when choosing
type of clamps. Correct use of these must be closely observed.

The tube clamp shall prevent cross line vibrations and at the same time allow for a
certain longitudinal movement. The clamp must be mechanically strong enough to
absorb all forces from the tubing i.e. the weight of tubing, reactions from pressure
shocks and forces due to longitudinal changes in the tubing.
It must not wear on the tubing and not be worn by the tube movements. Use of sound
absorbing material in the clamp is an advantage.

The clamp must be easy to install, and allow for adjustments due to difference in
distance between centers in tubing where several parallel tube lines are located. The
clamp must also allow for separate removal of the tubing.

Only elastic clamps may be used (plastic or rubber type).

The distance between the clamps will vary, depending on the stress normally imposed
on the tubing (pressure, oil velocity, vibration) as well as the tube dimensions.
Normally a distance between the clamps equal to 25 – 50 times the outside tubes
diameter is sufficient.
However, the distance may at times be as much as 1 meter. It is important to position
the clamps such that they prevent uncontrolled movements of the tubing.
Tighter clamp ring may be needed when the tubing has many bends.
Tube bends for length compensation must, however, not be "locked".
 8

3.4 PICKLING
Note:
Pickling must be done with caution.
The solution is caustic and is very harmful to eyes, skin and clothing.

1. Degreasing.
This must be done, as most acids do not dissolve grease.
Normally an alkaline solution is used.

2. Rinse carefully in water.

3. Now pickle the tubing.

Note:
It is advisable to make test in advance to ensure that the chosen combination of
ACID SOLUTION/TEMPERATURE/TIME is sufficient to properly clean the
tubing.

- example of pickling bath:

One part HYDROCHLORIC ACID (HCC) – 35% to be purred into 3 parts of

water.

Note:
DO ALWAYS PURE THE ACID INTO THE WATER – NOT THE OTHER
WAY AROUND.

4. Rinse carefully in running water – the water must not contain chlorine (Ch).
Make Ph-value tests to ensure that all acid remains are gone.

5. Neutralization.
The tubing is neutralised by a solution giving a Ph-value of approximately 9
(nine).

Bath temperature: 60 – 8 ºC.

As neutralising solution you may use a 2% phosphoric acid solution or

ammonium chloride alcohol.

6. Rinse in boiling water not containing chlorine.

This last rinsing process is often skipped. However, if it is done, make sure the
water is so hot that it quickly evaporates from the surfaces during drying.
 9

3.5 ANTI – CORROSION TREATMENT

Pickled parts should be oil treated before installation.
If days pass before the tubing is in touch with the system oil, the tubing should be oil
treated to avoid surface corrosion. Preferably it should be treated with system oil or
hydraulic fluid.

If long time storage is necessary, heavier oil like ISOVG68 or 100 may be used. The
oil is thus heated and pumped through the tubing.

The treatment oil must be filtered through a filter micron (absolute extreme).

If the storage time is not of significant length you must avoid using anti-corrosion
protections containing wax. These contain additives that normally break down the
anti-foaming qualities and the oxidisation suppressing additives in the hydraulic fluid.
 10

4 CLEANLINESS
Today's high pressure pumps, motors and valves have very fine tolerance and a high
level of efficiency.
In order to prolong the life-time and maintain the high level of efficiency it is
important to observe close attention to cleanliness throughout the installation.

Normally, the components are pump is sealed with plastic plugs from the
manufacturer.
Circumstances considered the sealing may have to be further improved on
( welding deposits will melt the plastic plugs and enter the pump.)
 11

5 HYDRAULIC TANK
The hydraulic tank must be constructed to have the sufficient capacity of oil. A general
rule is 2-3 times the total pump capacity of the pumps installed on the tank,

The tank must be surface treated and cleaned before use.

- It must not have much vibration. This can make foam into the oil.
- The return pipe end must be under the oil level This to prevent air generation into
the tank.
- The suction pipes must always be under the oil level.
- There must be installed draining point for water on tanks lowest point.
- Installation of hatch to easy inspection and cleaning of tank.
- Installation of devices to prevent oil movement. (swash plates)

1. The oil tank must be positioned as close to the pumps as possible.

The suction lines must run directly down to the pumps in order to prevent
possible "trapped air".

2. Each pump must have separate suction line from the tank. If common suction
line must be used for two or more pumps, consult with Karmøy Winch A/S in
each and every case for approval of the arrangement.

The end of the return flow pipe must lie at least 50 mm beneath the lowest possible oil
level to prevent foaming.

The tank should be designed with suction and return flow pipes well spaced apart to
ensure adequate separation of air from the oil.
 12

6 INSTALLATION OF HYDR. PUMPS

6.1 LINE-UP
The line-up of pumps, motors, cylinders and similar units should be inspected.
El. motors and pumps that are properly lined up from the factory may easily be
warped during transportation or installation.
Use the following when inspecting the line-up.

Chain couplings: Max. 0,5degrees Max. 0,25 mm

Spline couplings Max. 2,0 degrees Max. 0,4 mm

Perfect line-up prolongs life-time for couplings, pumps and el. motors. Therefore
we recommend that line-up's are performed with finer tolerances than the given
max. value.

6.2 INSTALLATION OF THE PUMP

The direction of rotation of the drive component has first to be established. The
direction of rotation of the pump must be the same. This is shown by an arrow marked
"Rotation" either on the housing or on the type plate.

Interpolation of a compensating coupling (e.g., flexible or arc coupling) is

recommended. Any form of force, such as impact or pressing, is to be avoided when
fitting the coupling.

Exposure of the drive shaft to lateral or longitudinal forces must be limited. This
necessitates exact centring of the pump shaft and the drive component connection.
Axial bracing of the pump is to be avoided at all costs.

Prior to installation or commissioning, fill the pump from suction and pressure sides
with oil.

6.3 CONNECTION OF PIPELINES TO THE PUMP

Suction side:
When operating with mineral oils, the pump intake pressure measured as an absolute
pressure must lie between 0,8 and 2 bar. In the start-up phase, an under-pressure of up
to 0.6 bar (absolute) is temporarily permissible.
 13

6.4 DIRECTION OF PUMP SHAFT ROTATION

Check that the direction of the rotation correspond with the arrow showing the
direction. The arrow should correspond with the model code of the pump.
The standard for vane pumps are for right-hand (clockwise) operation seen
from the shaft end. Left-hand turn is usually indicated by a "L" of "LH" added
to the Model code.

6.5 STARTING AND VENTING

Different types of vane pumps require different ways of starting.
Regarding angle axial piston pumps, PF, PV and PVA, we recommend you to
contact our service department for assistance in the starting procedure.

An incorrect starting procedure can destroy or damage the pump in a few

seconds. Therefore the following instructions should be followed.
 14

7 EQUIPMENT
7.1 ACCUMULATORS
The accumulators on the gas-side should be pre-charged with nitrogen (N2) only.
Pre-charge to the stated pressure on the diagram, and check at regular intervals that the
pressure does not fall. An accumulator does not work satisfactory if the pre-charge
pressure is wrong. Please remember that systems with an accumulator are able to
work after the current has been cut off. Therefore, at stops and inspections the oil
should always be drained off the accumulator, so that no damages on personnel or
material may occur during unskilled operations.

Note: The accumulators have to bee installed with the oil connection down to prevent
reduced effect.

7.2 OIL COOLER

The oil cooler should be positioned horizontally.

The water IN end must be positioned such as UP STREAM" cooling is achieved.

Normally every cooler has it's own separate pump for cooling water supply. If
otherwise is the case, Karmøy Winch A/S must be contacted for approval.
Also ensure that the cooling water pump has sufficient capacity. If the flow have to
bee reduced, the valve have to bee placed 1 m before the cooler.

7.3 OIL FILTER

Of primary importance for the trouble-free operation of hydraulic plant is the perfect
filtering of the hydraulic fluid. The trapping of even the smallest particles in the filter
elements will ensure greater plant reliability and will prevent premature wear.

Clean filter elements regularly (screen filters with ultrasonic cleaning equipment,
paper filters to be exchanged).

7.4 PRESSURE RELIEF VALVE

Setting of the pressure relief valve should be such that the maximum permissible
pump pressure is not exceeded ( see type plate on pump housing). The pressure relief
valve should be located between the pump and directional control valve to permit any
inadmissible pressure peaks from arising when switching over valves with shut-off
position.
 15

8 PREPARATION FOR START-UP

8.1 OIL FILLING PROCEDURE

1. Inspect the oil drums to see if they are properly sealed/not leaking and that they
are contain the correct type of oil for the system.
Let the drum/drums for 1 – 2 hrs. by the oil tank (this to separate water, contaminants).

2. Ensure that the filler pump, hoses, other relevant equipment are clean and have not
been used for pumping motor oil or such.

3. Always use filter (10 microns) between drum and tank. New oil is not "clean".
Experience proves that oil straight from the drum may contain more contaminants than
what is tolerated in today's high-pressure systems.

4. If the tank has been opened and cleaned make sure it is dry and clean.

5. Connect the filler pump and fill the tank to normal working level.

6. "Top" the tank if necessary after starting the system pump/pumps.

Note!
There may be water/contaminants even in new, sealed oil drums.
Therefore it is a good rule to leave the last 5 – 6 cm in the drum.
If several drums are used pour the remains into one drum so that
the water/mud, etc. may settle on the bottom. This may take several
days, depending a bit on the oil temperature.

7. Filling of oil
We recommend to use a combined filtering and filling unit, which can be delivered by
Karmøy Winch. The strainer in the oil filler should never be removed. Filling should
only take place when the cylinder pistons are in their inner position. If fluid level falls
during starting or when bleeding off trapped air, refill to normal oil level. Standard oil
reservoirs contain their normal oil volume at upper oil level. Maximum volume,
which can be taken out is about 35% of the nominal oil volume.
 16

8.2 INITIAL STARTING

Cleanliness
As mentioned under chapter 2 we guarantee that the delivered components and
actuators are carefully cleaned. Therefore please check that no damages have occurred
during transport and contaminants coming into components. Also check that dust-cap
covers, air breather etc., which may have been dismounted during the installation,
have been correctly fitted again.

Alignment
Mechanical alignment of pumps, motors, cylinders and so on should be checked.
The electric motor and pump, which have been carefully aligned at the factory, may
have got out of alignment during transport when mounted on the foundation.
Alignment should be checked as follows:

Chain couplings max. 0,5 degrees max. 0,25 mm

Tooted coupling max. 2 degrees max. 0,4 mm

A careful alignment gives long life of coupling, pump and electric motor.
Therefore we recommend a lower figure than the above stated.

Electrical equipment.
Please check that voltage and frequency correspond with all electro hydraulic
components and electric motors.

Hydraulic oil.
Operate all cylinders and motors one by one bleed air where it is necessary. Check the
oil level in the tank. Before a hydraulic system can be used all air must be removed.
If this is not done the trimming is made difficult or may be impossible. In small
systems, bleeding of air usually can be made by operating the cylinders with full
stroke once or twice and making a stop of 2-3 seconds in the end position.

Piston pumps.
Fill the pump house with oil. Be shore that the valve on the suction line is open.

If the pump has a variable displacement, it should be set on at least half the
displacement.

Pumps with booster

Pumps with booster pump should usually be started with a special procedure
depending on the system.

Filters and strainers.

Filters and strainers should be cleaned frequently during the first running period, and
thereafter at intervals dictated by experience from this very system.
 17

Temperature.
While the system is run, approx. 6 – 8 hours under normal working condition,
bearings, stuffing boxes, oil, electric motors, solenoid etc. should be checked so not
overheated.

As most power-losses in a hydraulic system will heat the oil. It is natural for a
hydraulic system to be warm. Therefore the oil is not overheated until the temperature
exceeds 65 degrees C (150 degrees F). Special hydraulic systems can be designed for
higher operation temperatures.

Pressure setting.
The pressure is adjusted by the relief valve of the system or by some other pressure-
limiting device. The pressure must never exceed the maximum pressures indicated on
the piping diagram. When setting the pressure by means of a pilot operated relief
valve care must be taken to adjust the pressure a little higher than the necessary
working pressure of the system.
 18

9 ELECTRICAL INSTALLATIONS
A) Electro motors
The Electro motor is normally supplied for horizontal installation. When
vertical installation is necessary Karmøy Winch A/S must be contacted.

The el. motor must be mounted on a solid base.

The base must be able to withstand any forces created by short circuits. It must
also be dimensioned so that no vibration due to resonance is developed.

The el. motor must be placed on a level surface and have good supply of air for
cooling. The cable must have easy access for servicing. If running in exposed
areas, a shield must protect the cable. The motor must be mounted on elastic
vibration dampers.

The pump must be installed in such a way that it gives easy access for
inspection/service/maintenance.
Also, consider space needed for disassembly of pump and section flange.
The Electro motor must be placed in an environment for which it is approved.

B) Starter cabinet.
-The starter cabinet must be installed vertically because of the starter relay.
-Contact Karmøy Winch A/S if "extras" are to be installed in the starter
cabinet.
-It must be installed in a dry environment.
-The starter cabinet should be installed close to the el. motor.

C) Electrical installation in general.

Ensure that voltage and frequency on all el. hydraulic components as well as
El.-motors and relays match those in your area available, and that they are in
accordance with the el. diagram.

Note!
All electrical components must be installed in dry environment.
 19

10 PERIODIC MAINTENANCE
After some time in operation all hydraulic components should be subject to a thorough
overhaul. Depending on the type of system and local conditions of operation the time
interval between such overhauls can vary between 1 and 5 years, but both shorter and
longer periods can necessary.

The oil should be checked for possible deterioration and contamination and changed if
necessary. A dark coloured, cloudy oil with sediments most likely needs a change.
Depending on conditions, a good hydraulic oil can be used between 5000 to 25000
hours. Clean air-, oil-, and magnet filters and also the tanks, pipes, pumps and valves.
Take care that no dirt is enter into the system during the overhaul. Seals and damaged
or worn parts should be replaced when necessary. Inspect pipe hangers and fittings
and replace if necessary.

If practically and economically possible, large repairs should be done by using spare
components, while the originals are sent to Karmøy Winch for repair.

To benefit fully from maintenance experiences, a good report system is essential.

Such reports should include:
1. A description of the system and the date they were detected.
2. Description of the preliminary investigation and its results.
3. Explanation of corrective actions taken, replacement parts required,
date when the repairs were made and length of shut-off time.
4. A report when fluid is added or changed, filter cartridges replaced or strainer
elements cleaned.

Those reports, if analyzed frequently, will indicate areas which require special
attention as well as frequently troubles, which may be anticipated and corrected before
the breakdown occurs.
 20

11 TROUBLE SHOOTING

If a hydraulic system has been correctly designed to meet the requirements and if it
has been correctly installed and started, it will give long life and trouble free
operations. However, when troubles occur, it is important to find the cause and to
rectify this as soon as possible.

No pressure.
1. Low oil level.
2. Pump drive reserved or not running.
3. Pump shaft broken.
4. Relief valve stuck open.
5. Pumps full volume by-passing through faulty valve or cylinder.

Actuator fails to move.

Faulty pump operation (see noisy pump)
Directional control not shifting.
1. Electrical failure, solenoid, limit switches etc.
2. Insufficient pilot pressure.
3. Interlock device not actuated.

Mechanical bind.
Operating pressure too low.
Worn or damaged cylinder or hydraulic motor.

Slow erratic operation.

1. Air in fluid.
2. Low fluid level.
3. Viscosity of fluid too high.
4. Internal leakage through actuators or valves.
5. Worn pump.
6. Pump drive speed too low.

Erratic feed rates.

1. Sticking not parallel or binding slide-ways.
2. Air in fluid.
3. Faulty or dirty flow control valve.

Overheating of the system.

Water shut off or clogged oil-cooler.
Continuos operation at relief valve setting.
1. Stalling under load etc.
2. Fluid viscosity too high.

Excessive internal leakage.

1. Check stalled leakage through motors and cylinders.
2. Fluid viscosity too low.