Gold level Training: Hydrohammer®

Revision 1: 14-09-2018
 Types of training. 2

1. Bronze level
- Basic knowledge about the Hydro Hammer
- Aware of the danger and safety
- Knows how to operate the Hydro Hammer
- Bronze level for a rental period up to 4 weeks

2. Silver level
- Good knowledge about the Hydro Hammer
- Learns how to find faults in the system
- Learns how to do proper maintenance
- Silver level for a rental period from 4 weeks up to 1 year

3. Gold level
- Expert knowledge about the Hydro Hammer
- Learns how to find faults in the system
- Learns how to repair failures in the system
- Gold level for working with the Hydro Hammer on a daily base

Intelligent equipment
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 Main page - Index
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3. Introduction. 17. Hammer individual parts – main valve.

4. Operating Markets. 18. Hammer individual parts – A/B sensor.
5. Hammer layout. 19. Hammer individual parts – Accumulator.
6. Hammer layout. 20. Control equipment C-34 – Exterior
7. Hydraulic system. 21. Control equipment C-34 – Interior.
8. Hammer cycle. 22. Hammer malfunctions – Valves elec.
9. Hammer cycle. 23. Hammer malfunctions – Valves elec.
10. Hammer cycle. 24. Hammer malfunctions – A/B Sensor.
11. Hammer cycle. 25. Hammer maintenance – Draining.
12. Hammer cycle. 26. Hammer maintenance – Preservation.
13. Hammer cycle. 27. Sleeve – General.
14. Hydraulic system - animation. 28. Recommended piling
15. Hydraulic system - main valves. 29. Refusal criteria
16. Hydraulic system - pilot valve. 30. Trips and Alarms
31. End page

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 Introduction
4

• Started in 1984 +/- 10 employees

• +/- 350 employees
Locations;
• The Netherlands, Main office and workshop
• Singapore, Australia, China Regions office / Service
Center
USA, France, Germany
• UK Engineering office

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 Operating Markets
5

Natural Coastal & Renewable

Oil & Gas Civil Energy

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 Hammer Safety – Be Aware
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1. Hydraulic Pressure up to 350 bar

2. Accumulator Nitrogen Pressure up
to 170bar
3. Cap Nitrogen Pressure
4. Dropped Objects - Loose Bolts and
loose rigging.
5. Exclusion Zone under Hammer -
Always maintained when the
hammer is in use.
6. High Noise Levels From both
Engine and Hammer operation -
Wear Double Hearing Protection.
7. Trip and Slips on hoses moving,
maintain clear path to Power Pack
at all times
8. Pinch Points – be aware of heavy
items and avoid any pinch points.
Use mechanical aid where possible.

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 Hammer Internal Working Parts
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1. Cap
2. Piston head
3. Accumulator
12. 10. 8. 6. 13. 4. 2. 1.
4. Bearing
5. Upper ring
6. Ram housing
7. Ram weight
8. Lower bearing
9. Shock absorbers
10. Sleeve
11. Connecting Ring
12. Anvil
13. Pile
14. A/B Sensor

11. 9. 7. 5. 3.

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 Hammer layout
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1. Pressure accumulator

2. Pressure valve

3. Upper ring

4. Piston head

5. Cap

6. Nitrogen or air in Cap

7. Return valve

8. Return accumulator

9. Suppletion valve

10. Ram weight

11. A / B sensor set

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 Hydraulic system
9

350 BAR
“A” Valve

380 BAR 90 BAR

Back Pressure
valve

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 Hammer Cycle – Rest position
10

• Ram weight in lowest position.

• A – B Sensors off.
• P-valve opened (N/O).
• R-valve opened (N/O).
• Anvil on lowest position in Sleeve

350 bar

380 bar 90 bar

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 Hammer Cycle – Hammer on pile
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• Ram weight in A-B sensor position.

• A – B Sensors on.
• P-valve opened (N/O).
• R-valve opened (N/O).
• Suppletion valve closed
• Anvil on Highest position in Sleeve.

350 bar

380 bar 90 bar

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 Hammer Cycle – Start Hammer
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• Ram weight moves up.

• A – B Sensors off.
• P-valve opened (N/O).
• R-valve closed (activated).
• Suppletion valve closed.
• Anvil on Highest position in Sleeve.

350 bar

380 bar 90 bar

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 Hammer Cycle – Upper Dead Point
13

UDP (Upper Dead Point T2):

• Ram weight in high position.
• A – B Sensors off.
• P-valve closed (activated).
• R-valve closed (activated).
• Suppletion valve closed.
• Anvil on Highest position in Sleeve.

350 bar

380 bar 90 bar

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 Hammer Cycle - Stroke
14

Stroke
• Ram weight in A-B sensor position.
• A – B Sensors on.
• P-valve closed (activated).
• R-valve opened (N/O).
• Suppletion valve closed.
• Anvil on Highest position in Sleeve.

350 bar

380 bar 90 bar

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 Hammer Cycle – Lower Dead Point
15

LDP (Lower Dead Point T3):

• Ram weight in A-B sensor position.
• A – B Sensors on.
• P-valve closed (activated).
• R-valve closed (activated).
• Suppletion valve opened.
• Anvil on Highest position in Sleeve.

350 bar

380 bar 90 bar

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 • Note

Hydraulic system Animation A/B sensor not on correct position in movie

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 Hydraulic system – Main valves
17

Detailed valve lay-out

Air valve

Pressure line

Return line
To cylinder

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 Hammer individual parts – Pilot Valve
18

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 Hammer individual parts – Main valve
19

Note!
Valve depth need
to be measured
and adjusted
according to list.

Only applies for:

S-70 & S-90

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 Hammer individual parts – A/B sensor
20

Note!
Drill hole is
calibrated and
can’t be adjusted.

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 Hammer individual parts - Accumulator
21

Transfer accumulator

Non transfer accumulator

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 Control equipment C34 – Basic
Connection 22

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 C-34 Control Unit
23

1. Display variable
2. Display energy
3. Selector buttons
4. Reset button 1 2
5. Trip indicator
6. kJ / ft.lbs 4 5 6
7. AB / CD lights
S1. Emergency stop 3a/b 7
S2. Flow / rpm
S3. Engine RPM Selector
S4. Piling/Vibro/Extract selector
S5. Reset/Stop/Start switch
S6. Back pressure switch S1 S2 S3 S4 S5 S6 R1
R1. Energy selector.

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 Control equipment C34 – Interieur
24

C-34 parts

F1 Main fuse
D5 EPROM
A A-valve switch
P P-valve switch
R R-valve switch
S7 Timer selector
B1 Power 24V
Ct Counter
X7 Jumper config (see lid)
X8 Jumper config (see lid)

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 Hammer malfunctions – Valve elec.
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Connections C34
1 C-34 12 13 14 15

12 P-valve 24v - Cable

12 13 14 15
13 P-valve 24v + plug
14 R-valve 24v -
15 R-valve 24v +

Cable AMP
AMP
2 plug 5 6 7 8
5 P-valve 24v -
6 P-valve 24v +
7 R-valve 24v -
8 R-valve 24v +

3 P R

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 Hammer malfunctions – Valve elec.
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Cable C-34 plug

12 P-valve 24v - Cable

12 13 14 15
13 P-valve 24v + 1 plug
14 R-valve 24v -
15 R-valve 24v +

Cable AMP
14 – 20
14 / 20 AMP
Ohm Ohm 2 plug 5 6 7 8
5 P-valve 24v -
6 P-valve 24v +
7 R-valve 24v -
8 R-valve 24v +
P P R

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 Hammer malfunctions – A/B sensor
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Connections C34
1 C-34 2 3 4 5

2 A-sensor 24v + Cable

2 3 4 5
3 A-sensor 24v - plug
4 B-sensor 24v +
5 B-sensor 24v -

Connections Hammer AMP

AMP
1 A-sensor 24v - 2 plug 1 3 2 4

3 A-sensor 24v +
2 B-sensor 24v -
4 B-sensor 24v +

Note!
If (jumper) connection is made, “A” or A B
“B” light will go off!!

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 C34 Basic Use
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Stop
Normal Change Increase Start
Hammer
Starting Engine flow and piling.
if any
Position to Auto energy
issues or
RPM dial to a Check manual complete
minimum if backpressure
is needed piling.
setting

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 Hammer maintenance - Connection
29

• Depressurize the upper ring

• Connect pressure hose
• Connect return hose
• Connect control cable
• Remove locking pins / install blind covers
• Check pressure and return accumulators.
• Check Cap pressure
• Visual inspect for any strange conditions
on complete hammer spread.
• Close by-pass valve
on power pack

• Hammer accumulator connection

• Low pressure clock. to be closed when measuring high pressure +40bar
• Pressure relief
• Air bottle connection open / closed
• Air bottle connection

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 Hammer maintenance - Draining
30

S-30 up to S-90 S-120 up to S-4000 S-30 up to S-4000

1. Upper Ring and SC hammers All ram weight-housings
2. Spindle have one or more drain
1. Plug points for vertically and
3. Plug with hose
2. Spindle horizontal draining.
4. Non-return valve ball

Drain point

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 Hammer maintenance - Preservation
31

Preservation points
• Ram weight housing.
• Lower piece.
• Ram weight (open bottom).
• Cap (when depressurized).

Note!
Only use
Total Osyris DWY 6000.

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 Sleeve – General Requirements on Pile
32

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 Sleeve – Installation sleeve to hammer
33

• Remove pre-tension ring (only for S-90 series)

From S-120 and up shock absorber set is pre-tensioned in lower
housing
• Alignment of sleeve to hammer
• Lift sleeve against hammer
• Assembly of sleeve – shock absorber set – O-ring –
lower piece hammer.

The shock absorber set is pre-tensioned between lower housing Shock absorber in lower housing

and sleeve. S-90 series.

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 Recommended piling procedure.
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For the best hammer performance and durability there has been a guideline created.

In this guide line we talk about:

- blows/min
- blows/25cm
- energy at blows/25cm

For constant speed of penetrating the pile during piling

IHC IQIP recommends to keep a constant of 30 to 50 Blows per 25cm

During the first few meters of piling.

We start with a low energy. When the resistance of the pile increases we increase the energy.
The lower the energy the higher the Blows/min can be.
The higher the energy becomes the more the blows/min will decrease

The best performance for the hammer is

30 > 50 blows per 25cm
If the blows per 25cm exceeds 50blows. Slowly increase energy again to maintain 30>50 Blows per
25cm.
If the blows go under 30blows per 25cm. Decrease energy again to maintain 30>50 blows per 25cm.

Depending on the energy. Determinate your blows/min

Maximum energy with maximum blows/min can be found in the hammer manual

Example for S-90

Operating data
• Maximum net energy/blow 90 kJ
• Minimum net energy/blow 9 kJ
• Blow rate 46 bl/min
• (at maximum energy and recommended oil flow)

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 Refusal Criteria.
35

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 Trips and Alarms
36

Trip 01 – Emergency stop > Check al emergency stops

Trip 02 – > Switch S4 (Piling/Extract) during operation switched over.
Trip 03 – Ram to high > Exceeded maximum? Pot meter R1 to high
> Cap pressure to low
> Electric failure
Trip 04 – Ram to low > Pile drop fall
> Hammer not correct on pile
> Electric failure
Trip 05 – Energy to high > Exceeding 6% over the hammer maximum ( example S-90 = 100% 90Kj – 106% = 95,4 kJ )
Trip 06 – power failure 24v > battery power is low > check voltage and if the dynamo is still charging the batteries
> Can also occur when starting the engine. 24v drops down when the engine starter is being used. When
engine runs, use the reset switch and continue operation.
Trip 07 – Oil pressure to high > Something is blocked inside the complete oil circuit, this made the pressure rise above normal
Restart power pack again. Occurs again? Call IHC IQIP service team.
Trip 08 – Filter clogged > Return filter inside Power pack is dirty and gives to much resistance for the oil flow
Trip 09 – Hydraulic oil > Something is wrong with the hydraulic oil > temperature is to high > Oil level low
Check Power pack information screen
Trip 10 – Engine alarm > Something is wrong with the engine. Coolant temperature to high > check engine and information screen
Trip 11 – Hammer not correct on pile
> Ram weight is not in its starting position > Hammer correct on the pile ?
> A/B sensor failure ?
> Cap pressure to high ?
Trip 12 – Water to high > Can occur when piling with the L-34 control box for underwater piling
> Can occur when piling with the single water electrode installed
Trip 14 – Overload P-valve > Short-cut with in the wires to the pressure valve solenoid or a defective solenoid
Trip 15 – Overload R-valve > Short-cut with in the wires to the return valve solenoid or a defective solenoid
Trip 18 – Hammer low > Only possible when using the Rock breaker. Rock breaker has reached its max. penetration depth
Trip 20 – Program failure > C-34 program is damaged > call IQIP Service team
Trip 22 – Ram in top > Only for SC-hammers. Will occur when starting while sensor C sees steel ( This trip priors over trip 11)
Trip 24 – System failure > This trip can only occur when switching on the power supply. An error has been detected by the build-in
Check of the adjustable parameters.
Before handling on any of the more difficult trips. Always Contact the IHC IQIP
service team before taking any actions
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 Thanks for your attention…
37

End of course.
• Certificate of competence.
• Well Done.

Course extensions.
• Underwater operations

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