motive offshore

MARINE EQUIPMENT SPECIALISTS

OPERATION & MAINTENANCE MANUAL

5Te SWL CONSTANT TENSION WINCH

c/w SPOOLING GEAR
ID: MS1059

Revision Generated Date: Checked by: Date: Approved by: Date:

by:
B J Turner 11/04/2014 D Acton 11/04/2014
Manual Operation & Maintenance Manual

PREFACE

Motive Offshore was developed in order to provide the market with high quality marine equipment and
associated services. The directors of the company have many years operational experience in hire and
manufacturing specialised marine equipment such as, winches, HPUs, compressors and generators.

The companys first priority is to its staff. We believe with the appropriate level of staff experience, training and
management, the company can offer a superior service. We aim to offer the highest level of equipment reliability
and customer service available in the market.

This manual contains the safety and technical information which is necessary for the installation, commissioning,
operation and maintenance of the equipment. This document is revised periodically. Enquiries concerning
clarification or interpretation of this manual should be directed to Motive Offshore.

IMPORTANT:

This manual forms part of the product and as such should be kept for the duration of the products life span. Any
amendments made during this time should be incorporated into this manual and should also be passed onto any
new owner and / or end user.

This manual provides important information with regards to the safe installation, operation and maintenance of
this product.

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Manual Operation & Maintenance Manual

DEFINITIONS:

1. Factory Acceptance Testing FAT

2. Personal Protective Equipment PPE
3. Scheduled Maintenance maintenance at a prescribed regular time
4. Preventative Maintenance maintenance required on a piece of equipment to keep it in good working
order
5. Corrective Maintenance required when a piece of equipment or component has failed or is worn out,
to bring it back to working order
6. User Maintenance maintenance that the owner / operator can carry out
7.
WARNING

8. CAUTIONARY NOTE

9. Guide on Gear - GOG

Page ii of iii MOS-MA-EM-02 Rev A

Manual Operation & Maintenance Manual

HEALTH & SAFETY INFORMATION

HAZARDS

This equipment requires the use of chemicals, and or lubricants which may become hazardous to health
unless appropriate precautions are taken. MSDS sheets are made available in section 12 of this manual.
This equipment contains features that require the use of fluids under high pressure which may pose a
hazard unless suitable precautions are taken.
This equipment contains moving parts which have been protected by the provision of guarding. All
provided guards must be utilised when the equipment is operational.
Suitable precautions are to be taken to protect personnel from the effects of the sudden release of
stored energy if under emergency conditions there is a breakage of wire.

This manual provides important information and guidance on the control of hazards listed above and should be
read in its entirety prior to attempting to operate the equipment.

PRECAUTIONS

This equipment may have been drained of fluids for transportation purposes.
Quantities and types of lubricants required are clearly marked on the equipment and further detailed in
this document.
Hydraulic pipework has been colour coded for ease of reference and connection.
The manufacturer recommends that only suitably trained and authorised personnel operate and
maintain this product.
Supporting structures for the winch installation shall be capable of supporting the winch, the payload
and any reaction forces encountered during winching operations.
Load attaching devices used in conjunction with this winch must be capable of supporting the rated load
and any additional dynamic loading effects of the work environment such as drag buoyancy etc.
Prior to each operation the winch should be checked for signs of wear, general deterioration and / or
damage. Details of suggested routine checks are contained in this document.
The winch should only be used to operate within the specified working limits.
The winch shall not be used for lifting, supporting, or transporting personnel.
Never permit personnel under any raised load.
Never leave a load suspended if the winch is unattended or not in use.
Do not permit grease or other lubricants to the brake friction material.
Personal Protective Equipment should be worn to suit the activity.
Always keep hands, loose clothing etc. away from moving parts and pinch points.

After use, or when not in operation, the winch should be secured from unauthorised and unwarranted use.

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Manual Operation & Maintenance Manual

CONTENTS

Page
Preface i
Definitions ii
Health & Safety Information iii
1.0 General Product Information 2
1.1 Unpacking 2
2.0 Services 2
3.0 Installation & Set Up 3
3.1 Commissioning 3
4.0 Operating Information 5
4.1 General Operating Information 5
4.2 Pre-operational checks 5
4.3 Operating Instructions 5
4.4 Treatment of Malfunctions 6
5.0 Maintenance Instructions 7
5.1 Scheduled Maintenance 7
5.2 Preventative Maintenance 7
5.3 Corrective Maintenance 7
6.0 Maintenance Schedule 8
6.1 Recommended Oils & Lubricants 8
7.0 Parts 9
7.1 Recommended Spare Parts 9
7.2 Ordering Spare Parts 9
8.0 Storage, Handling & Shipping 9
8.1 Preservation 9
8.2 Packaging 10
8.3 Labelling & Handling 10
8.4 Shipping 10
8.5 Storage 10
9.0 Modifications 11
10.0 Disposal 11
11.0 Technical Data 12
11.1 Equipment Specification 12
11.2 Performance Data 13
11.3 Drawings and Schematics 14
11.4 Table of Values 15
12.0 HSE Literature 16
12.1 Risk Assessment 16
Appendices:
1. Motor
2. Main Control Valve

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Manual Operation & Maintenance Manual

1.0 GENERAL PRODUCT INFORMATION
The drum winch has been designed and built for
pulling and lifting applications and should provide
many years of trouble free service providing that
the instructions set out in the manual are adhered
to. This equipment is not designed for lifting or
conveying personnel.
The equipment has been built with due
consideration to the often harsh environments
encountered in marine and similar applications,
suitable protective measure have been incorporated
as Motive standard.
All Motive Offshore winches are designed and built
to perform within specific parameters details of the
specific performance characteristics can be found in
the technical data section of this manual.
The following figures depict the main components
and elements of the winch to enable equipment
familiarisation.

c k

e
m
n

b
l

Figure 1 Figure 3
k) Spreader beam
a) Base frame b) Chain drive guard l) Brake cylinder
c) Pad eyes d) Guard m) Hydraulic motor
e) Drum f) Guide on gear n) Control valve

1.1 Unpacking

On receipt the winch package should be checked

against the delivery manifest ensuring that all items
listed are in fact present and there are no obvious
g j indications of transportation damage.

If there are any anomalies consult the manufacturer

at the earliest opportunity.
i
h
All protective and preservative packaging should be
removed and safely disposed of in a controlled
manner in accordance with local regulations.

Figure 2
g) Scroll shaft h) Guide bar
i) GOG carriage j) Knife
WARNING:
2.0 SERVICES

Motive power to the winch may be supplied from an
independent hydraulic power unit (HPU) or from a
suitable hydraulic service ring main system. Details
of the services required are given in the technical
data section of this manual.
Hydraulic component failure may give rise to fluid
loss e.g. hydraulic fluid, diesel fuel, lubricating oils
and coolants this may in turn present a slip hazard
to personnel and may also pose an environmental
hazard. Due consideration should be given to the
positioning of the spooling winch and associated
services to minimise the risks.

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Manual
3.0 INSTALLATION & SET UP
The following information is provided to assist the
user in the installation of the winch. The use of
general hand tools may be required. Mechanical
aids may also be required to facilitate positioning.
Due consideration should be given during
equipment positioning to the ergonomic
requirements for servicing, operations, maintenance
and or repair.
It is essential to ensure when mounting the winch
that the foundation or supporting structure is
compatible with the fastening arrangements.
Where bolts are used as a means of securing the
equipment it is essential that the correct tensile
grade of bolt is employed and correctly tightened to
the values given in section 11 of this manual. The
below figure depicts the footprint details of the
winch base-frame.
Figure 4
CAUTIONARY NOTE:
Timber bearers should never be used as
support.
The winch drum should be positioned such that it is
perpendicular to the line of pull. If it is intended
that the wire rope will pass over a change of
direction sheave or similar device, this will result in
an angled pull as the rope feeds on and off of the
drum. This angle is known as the flee angle. The
maximum fleet angle for grooved drums should not
exceed 2.5 and for plain drums should not exceed
1.5. (See figure 5 below).
Figure 5
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Operation & Maintenance Manual
During installation it is essential to maintain overall
geometric flatness of the winch base. This is to
prevent bearing overload due to distortion of the
winch frame.
Post installation, if the drum does not turn freely
check the foundation and the winch base for
geometric flatness and rectify by shimming as
required. Re-tighten and torque any retaining
fasteners to the values given in section 11 of this
manual.
The winch framework should be electrically
grounded. Earth bosses are provided on the
framework for this purpose.
Until such times the spooling winch is ready for
operation it should be protected from detrimental
environmental effects such as;
Water ingress into critical parts
Contamination of oil
Moisture ingress into electrical controls
CAUTIONARY NOTE:
Certain electrical devices are sensitive to
the high energies involved in welding
operations. Where fitted these devices
may require additional isolation prior to
any welding taking place. If in doubt
consult the manufacturer.
3.1 Commissioning
All winch service connections should be made as
per the appropriate hydraulic schematic at section
11 of this manual. The below figure depicts the
location of the bulkhead panel that houses all
umbilical / termination points.
Figure 6
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Manual Operation & Maintenance Manual

For ease of reference the winch hydraulic

connections are labelled appropriately and colour
coded.

The umbilical / termination points are colour coded

as below:

Pressure Red
Tank Blue
Drain 1 Green
Drain 2 Green
Pilot P Red
Pilot T Blue
Pilot A Black
Pilot B White
Load Sense Yellow
Brake Grey
Pressure Control Brown
Boost pressure Purple

Carry out an inspection of fluid levels and replenish

as necessary. New hydraulic fluid is not clean and
should be filtered prior to use. Fluid types,
quantities and lubrication points are as depicted on
the lubrication plan at section 11 and in table 3 of
this manual.

The winch was subject to thorough Factory

Acceptance Testing (FAT) prior to despatch to
confirm its operational conformance. Results of the
test carried out can be found in the certification
package supplied.

Before the winch is placed into service the following

post installation checks should be performed;

a) Service connections are secure and correct to

drawing requirements
b) Required lubrication has been carried out
c) Fluid levels in gearbox and hydraulic reservoir
are at the required levels (where fitted)
d) Pilot lines are bled of trapped air
e) Winch direction of operations checked and as
indicated
f) Limit switches are operational (where fitted)
g) Slipping clutch functions correctly (where fitted)
h) Brake operates effectively
i) Load test to required tonnage (if required)
j) Check for leaks
k) Ensure all supplied guarding is in place

The recording that the above checks have been

carried out should be recorded using the post
installation check form, which is maintained within
the equipment data book.

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Manual Operation & Maintenance Manual

4.0 OPERATING INFORMATION

4.1 General Operating Information

Local regulations may require documented risk The emergency stop may be activated at any point
assessment or Job Safety Analysis to be carried out in time ceasing all operations.
prior to the use of this equipment.

With regards to PPE the manufacturer recommends

that as a minimum coverall, protective footwear and
gloves but reference should be made to locally
conducted risk assessment for any additional
requirements. Motive generic risk assessment is
contained within section 12 for your reference. Connect winch to power unit.

It is vital that good visual contact and

communication with all personnel involved in
spooling activities is maintained at all times. Carry out pre-operation checks.

4.2 Pre-operational checks

Prior to each use it is essential that the following Apply power.

pre-operational checks are carried out;
a) Service connections are secure and correct
to drawing requirements
b) Required lubrication has been carried out Operate winch control (pay out / haul in).
c) Fluid levels in gearbox and hydraulic
reservoir are at the required levels (where
fitted)
d) Pilot lines are bled of trapped air
e) Winch direction of operations checked and Release control for operations to cease.
as indicated
f) Limit switches are operational (where fitted)
g) Slipping clutch functions correctly (where
fitted) Switch power until off.
h) Brake operates effectively
i) Check for leaks
j) Ensure all supplied guarding is in place

4.3 Operating Instructions

The main operating controls for the winch may be

one or a combination of the following:

Directional control valve fitted directly onto

the winch itself
A stand-alone control unit
A chest mounted or hand held remote
control unit which may be either hard
wired or radio operated

Refer to the technical data section for details of the

specific control arrangement supplied.

The brakes fitted to the winch release automatically

when the controls are operated and are configured
to fail to safe if for any reason the operating
control is released.

Operators should familiarise themselves with the

location and operation of emergency stop devices.

A winch may operate in one or more operating

modes i.e. manual, remote, active heave, active
tension and constant tension. Refer to the
technical data section for specific winch operating
mode. Refer to figure 7 for operating instructions.

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Manual Operation & Maintenance Manual

Operating Instructions in Constant Tension Mode

To operate the winch in Constant Tension mode the

following procedure should be used:

Connect winch to power unit.

Carry out pre-operation checks.

Image 1

Apply power.

Fully back out pressure control

(Turn full CCW)

Operate winch control full heave

Image 2.
Image 2

Observe brake cylinder fully extend

Close isolating ball valve on brake

cylinder Image 4.

Adjust press control (C.W.) to

desired tension.

Image 3

NOTE: To operate winch in standard mode

configuration, open the brake isolation valve
and screw in the press control full (C.W.)

Image 4

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Manual
4.4 Treatment of Malfunctions
This section aims to provide the user with guidance for the detection, correction and reporting of any
malfunction with the equipment.
The table below details the symptoms, probable causes and corrective actions.
SYMPTOM
Winch does not operate
Load continues to move when
winch is stopped
Winch does not lift the rated load
Control lever moves but winch does
not operate
Winch runs slowly
Motor runs hot or makes excessive
noise during operation
Scroll shaft not sliding smoothly
If any of the suggested corrective actions does not resolve the equipment malfunction, the manufacturer should
be consulted for supported.
CAUSE
No oil supply to winch
Winch is overloaded
Brakes not released
Winch overloaded
Winch motor controls sticking
Brake not applying
Insufficient oil supply
Brake not releasing
Motors may be damaged
Insufficient oil supply
Oil leak
Motor may have been damaged
Brakes not fully released
Motor may be damaged
Contamination in oil
Motor or valve may
damaged
Scroll shaft knife may
damaged
Chain or sprocket may
damaged
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Operation & Maintenance Manual
CORRECTIVE ACTION
Check oil supply line connections
Reduce load to within rated
capacity
Check brake opening pressure
Reduce load to rated capacity
Check control levers return to
neutral when released
Adjust brake band
Verify oil supply pressure and
volume is as specified
Inspect oil filters for
contamination
Consult the manufacturer
Ensure oil supply is according to
specification
Repair any leaks, retesting as
necessary.
Contact the manufacturer
Check the brake operating
pressure
Contact the manufacturer
Check oil contamination, drain &
refill with recommended oil and
replace filters as necessary
be Operate winch with no load
slowly in both directions. If
noise still exists or motor
overheats then contact
manufacturer
be Remove the scroll shaft knife
and replace if damaged
be Check the chains and sprockets
and replace if damaged
Table 1
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Manual Operation & Maintenance Manual

5.0 MAINTENANCE INSTRUCTIONS CAUTIONARY NOTE:

To achieve optimum operating safety and service
life, it is vital that the winch is maintained at regular
intervals.
The following maintenance instructions will ensure
the integrity of the winch and avoid unnecessary
down time and or damage.
WARNING:
The winch must be released of all loads and
be isolated during maintenance works.
Maintenance should only be carried out by
suitable trained and authorised persons.
If any of the parts of the system are
disconnected, open fittings must be
protected by plugs or covers to prevent
ingress of any dirt particles.
5.3 Corrective Maintenance
In the event of breakdown in the first instance refer
to the malfunction table 1, however if that does not
resolve the issue consult the manufacturer for
advice and assistance.
Brake

5.1 Scheduled Maintenance
Scheduled maintenance is based on winch usage of
8 10 hours per shift. Details of what is required
at any given point are given in table 2.
The brake is fitted with a wear indicator dial which
is a simple vision device that may be used as a
general guide as to the brake conditions.

5.2 Preventative Maintenance

This type of maintenance is intended to ensure that

if the winch is not in regular use that it is
maintained in good order in readiness for use when
required.

If the winch is expected to be out of service for

Figure 8
more than three months;

Protect the hydraulic system against rust

5.4 Corrective Maintenance
with hydraulic oil that has rust preventing
additives.
In the event of breakdown in the first instance refer
to the malfunction table 1, however if that does not
If the winch is still out of service within a year the
resolve the issue consult the manufacturer for
winch should be run at intervals so as to maintain a
advice and assistance.
protective film on the internal surfaces of
components and oil lines, thus protecting against
corrosion.

5.5 User Maintenance

Replacement of brake band:

The brake lining is worn out and the complete Because they must be run, the FK measurement
brake band must be exchanged when the with new brake bands must be 127mm (5.00 in).
measurement, band plus lining, is as shown in the Check the FK measurement after approximately 10
figure below: brake operations and adjust it to 117mm (4.61 in).

Figure 10

Figure 9

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Manual Operation & Maintenance Manual

Brake Adjustment: Brake Assembly Lubrication Points:

Without braking torque adjust when the indicators

show red.
1. Remove locking devices on adjustment
screws.
2. Stretch the bands with the adjustment
screws when the pressure is applied to the
brake cylinder. Drain the brake cylinder,
check the measurement FK and adjust to
117mm. The scale indicators, sign 2,
should then show green.
3. Replace the locking devices on the
adjustment screws.

Figure 12

All maintenance activities should be recorded

in the maintenance record in the equipment
data book.

Figure 11

With braking torque scale not valid. The value of

the braking torque must be used when checking the
adjustment. Refer to figure 16 if adjustment is
necessary. Carry out steps 1 3 as above.

Example: a line force F of 100 000 N and a line

drum of radius r = 0.5 metres, the braking torque is
Mb = 50 000Nm. The brake is to be adjusted if the
FK measurement is less than 77mm. Adjust FK to
91mm.

WARNING:

Adjustment-check of brakes with braking

torque is only to be performed when the
brakes cannot be relieved of braking torque.

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 Manual Operation & Maintenance Manual

6.0 MAINTENANCE SCHEDULE

Item PRE-USE 1 month 6 months 12 months

Motor I ensure correct I - oil
direction of rotation
Brake I ensure correct L as per fig
operation 12 of this
manual
Control Valve I visually check for
proper function
Base Frame I ensure base frame is
fitted to foundation
structure appropriately
Lift Point I visually
inspection lift
points, re-stamp
name plate and re-
certify *
Bearing L grease as per
lubrication drawing
Drum I inspect for damage
and report as necessary
Hoses & Fittings I ensure there is no
evidence of cracks or
damage, replace if
necessary
Guards I ensure all guards are I ensure there
in place is no damage,
repair as
necessary
Paintwork A touch up
paintwork as
required
Labelling I ensure all
warnings, weight
data etc. is visible
Controls I ensure all controls
are functioning and in
good working order
Level wind L - grease chain, guide
bar & scroll shaft pre &
post use
Table 2
Key:
(I) Inspection
(R) Replacement
(A) Adjustment
(L) Lubricate
* To be carried out by trained and competent personnel

6.1 Recommended oils & lubricants:

ITEM FLUID TYPE CAPACITY

Motor ISO 46 normal temperature 40L, fill as required
ISO 68 tropical temperature
Bearings EP2 Grease Grease gun as required

Table 3

Notes:
Aggressive detergents may damage the seals of the hydraulic motor and cause them to age faster.
Never use a high pressure cleaner near hydraulic components.
Oil on the brake linings reduces the braking torque.

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Manual Operation & Maintenance Manual

7.0 PARTS

7.1 Recommended Spare Parts & Tooling 7.2 Ordering Spare Parts

The following is a list of recommended spare parts: When ordering spare parts, quote the following
information:
Set of dowty seals and Orings a) Company name
Grease cartridges b) Address
Brake band c) Equipment ID
d) Description of part required
The following is a list of recommended tools e) Serial number (if available)
required for installing, commissioning, operating
and maintaining a winch:
8.0 STORAGE, HANDLING & SHIPPING
Lubricating grease and gun
Basic tool kit If at any time the winch is to be put into storage,
the following guidelines should be followed to
ensure that the winch is maintained in good order.

8.1 Preservation

Measures should be put in place to provide

adequate protection of the product against damage,
deterioration and corrosion.

With regards to metallic materials the below table

provides the basic requirements for the corrosion
protection of metallic parts.

Material Corrosion Protection

Low Alloy Steel Corrosion Preventive Oil + Polythene film over wrap

12% Chromium Steels VCI paper / film + Polythene film over wrap

VCI paper / film + Non-absorbent container

Austenitic Stainless Steels No preservation required + Polythene film over wrap

Nickel or Cobalt Base Alloys

No preservation required + Non-absorbent container
Titanium Alloys

Aluminium Alloys Corrosion Preventive Oil (unpainted surfaces) + Polythene film over
wrap
Copper Alloys Corrosion Preventive Oil (unpainted surfaces) + Non-absorbent
container

Magnesium Alloys Corrosion Preventive Oil (unpainted surfaces) + Polythene film over
wrap

Corrosion Preventive Oil (unpainted surfaces) + Non-absorbent

container
VCI Paper (Volatile Corrosion Inhibitor) Reference
Note 1: VCI treated paper / film shall not be used with any of the following alloys or platings: magnesium, copper, lead, lead-
indium, silver, zinc, tin based, cadmium, or nickel-cadmium. VCI treated paper / film is acceptable for use with non-ferrous
material except magnesium, lead, or lead indium.
Note 2: Application of preservative materials shall be preceded by thorough cleaning of parts to remove foreign objects from
processing and handling, i.e., metal chips, abrasives, blasting grit, metal finishing compounds, fluxes, cutting fluids, lubricants,
test fluids, moisture, fingerprints etc.
Table 4

All connection points to be appropriately closed off with protective caps, covers and plugs.

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Manual
8.2 Packaging
The winch and any ancillary equipment should be
packed in manner that will permit removal from the
packaging without any damage.
Primary packaging is the first level of packaging
applied to the product and is designed to come into
direct contact with the product, however an
additional level of primary packaging can be
included with any protective materials (dunnage)
where required to ensure that the primary
packaging is robust enough to protect the part from
damage, deterioration, corrosion, tampering and
other risks during storage or transportation.
It is important that all materials used for packaging
will not contaminate the goods enclosed. In some
circumstances dunnage shall be used to provide
adequate support, bracing and protection of parts
during shipment i.e. padding in a shipping container
to prevent unnecessary movement of load. It is
important that all dunnage material is wrapped up
so that it is not in direct contact with the product.
Loose form materials such as polystyrene chips or
shredded paper shall not be used.
All ancillary equipment should be palletised and
secured. All pallets and bases should be in good
condition with no loose broken boards, no
protruding nails etc. The pallet should be suitable
to carry the product load during shipment and
storage.
8.3 Labelling & Handling
It is important that each package is clearly
identified. Appropriate despatch and / or storage
labelling should be firmly and securely attached.
Any special instructions with regards to handling
and storage of delicate equipment such as electrical
instrumentation and fluids should be clearly made
visible. Recognised International symbols may be
used.
Handling of large, heavy, and or cumbersome
equipment should be carried out by means of
appropriate lifting equipment such as sling sets
connected to certified lifting points.
Extreme care should be taken to determine the
centre of gravity of the device during any lift or any
lifting operation as the unit may be weight biased.
Refer to the loading and transportation drawing in
section 11.
8.4 Shipping
It is essential that all tools, supplies and services
required for shipping are made available at the
required time. This may include slings, forklift,
crane, etc. Advice should be sought from the
haulage company.
It is also essential that all delivery paperwork is
prepared and compiled with all relevant details such
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Operation & Maintenance Manual
as weights and dimensions of the winch.
Compilation of the documentation will aid in
catering for any movement restrictions or special
transportation considerations.
8.5 Storage
In permanent installations, when not in use the
winch must be left in a safe position that neither
the winch nor associated rigging gear presents a
hazard. It may be found that pulley blocks, hooks
etc. need to be raised to the highest level to avoid
danger of collision with persons or passing vehicles,
however in some cases they may need to be
removed.
In temporary installations, when not in use the
winch and associated equipment should be returned
to a suitable storage facility. The storage
conditions should meet the following requirements:
Storage areas must be dry, free from
injurious pollution and not subject to
extreme temperatures. All parts with
exposed threads or machined bearing
surfaces should be protected and handled
with care. If the winch has been returned
to stores wet or subject to other
substances liable to cause deterioration
additional treatment may be necessary. It
should be remembered that weak acids
become strong acids when in direct
contact with metal products.
Pulley blocks and detachable items
normally used in association with the
winch should be removed and stored
separately.
All functions of the winch should be
checked prior to storage, in particular the
operation of the clutch and brakes.
All hoses and cables should be checked to
ensure that there is no damage. Where
practical cables, hoses and handles should
be removed from the winch and stored
separately.
Prior to storage the winch should be
lubricated.
Hydraulic motors and pump casings should
be fully filled with oil.
When being handled care should be taken
to ensure that the winch and accessories
are not dropped or thrown down and that
rope, hoses or cables are not dragged
across the floor.
During transportation additional protection
may be required to prevent the ingress of
moisture, dust or foreign particles.
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Manual Operation & Maintenance Manual

9.0 MODIFICATIONS

At no time should this spooling winch be modified

without prior consultation with the manufacturer.
No liability whatsoever will be accepted for
consequential loss or injury as a consequence of
unauthorised modification.

Authorised modification shall be documented and

revisions incorporated into future publications of
this manual.

Since manufacture the following modification have

been made to this winch;
Addition of level wind (details are
contained through the manual)

10.0 DISPOSAL

For end of life product advice please consult with

the manufacturer.

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11.0 TECHNICAL SPECIFICATION

11.1 Equipment Specification

Equipment ID
Motive reference: MS1059
Client reference (if used): n/a
Weight & Dimensions
Length: 1925mm
2006mm with level wind
Width: 991mm,
1396mm with level wind
Height: 1438mm
Weight: 3,725Kg Tare, 6,000Kg Gross
Lifting: Fitted with forklift pockets & 2 point lifting spreader
beam
Design Temperature: -10 - +40
Guarding All moving parts guarded
Drum
Core dia: 508mm
Flange dia: 930mm
Inside width: 1025mm
Wire capacity: 650m of 19mm Wire
Level Wind: Fitted to suit 19mm diameter wire
Drive
Control Valve: Hydranor 6MB
Motor: Hagglunds Viking
Motor type: 64 Series
Gear: Not fitted
Clutch: Not fitted
Brake
Type: Hagglunds BA 63 brake assembly c/w BCIM brake
cylinder
Parking brake: Hydraulic failsafe brakes fitted to hydraulic motor
Operating Controls
Type: Control panel mounted on winch
Controls: Hydraulic main system pressure gauge
Directional control
Emergency stop
Surface Coating:
Stage 1: Shotblasted to SA2.5
Stage 2: Single coat of two-pack Jotamastic 80 high build
marine primer, colour - Grey
Stage 3: Single coat of a two-pack Hardtop AS marine grade
paint, colour RAL 5018 (Teal)

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Rules & Regulations:

The Machinery Directive 2006/42/EC
The Pressure Equipment Directive 97/23/EC
The ATEX Directive 94/9/EC
PUWER
LOLER
BS EN 13414
CE Marked
IP 56 rated
Table 5

11.2 Performance Data

Based on hydraulic system power at winch control valve as follows:

Flow: 176L/min
Pressure: 230Bar (cross port pressure)
Power Required: 71kW
Wire Rope Diameter: 19mm

LIFTING SPECIFICATION
Wire Rope Layer Diameter Length of Wire / Line Pull Line Speed Brake Holding
Layer Layer Force
(mm) (mtr) (Tonne) (m/min) (Tonne)
1 527 89 6.9 52.0 10.4
2 565 185 6.4 55.8 9.6
3 603 287 6.0 59.5 9.0
4 641 395 5.6 63.3 8.4
5 679 510 5.3 67.0 7.9
6 717 650 5.0 70.8 7.5

CONSTANT TENSION SPECIFICATION

Wire Rope Layer Diameter Length of Wire / Line Pull Line Speed Brake Holding
Layer Layer Force
(mm) (mtr) (Tonne) (m/min) (Tonne)
1 527 89 5.0 70.0 13.3
2 565 185 5.0 70.0 12.4
3 603 287 5.0 70.0 11.7
4 641 395 5.0 70.0 11.1
5 679 510 5.0 70.0 10.4
6 717 650 5.0 70.0 9.9
Table 6

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11.3 Drawings & Schematics

Page 16 of 20 MOS-MA-EM-02 Rev A

 MATERIALS LIST
ISOMETRIC VIEW ( 1:25 )
ITEM No. QTY MATERIAL GRADE DESCRIPTION

FRONT VIEW ( 1:25 )

MASTER LINK

2 LEG WIRE ROPE SLING

SET, HARD EYES BOTH ENDS

2 OFF
=<4 SHACKLES
5

CONTROL VALVE
SIDE VIEW ( 1:25 ) 1025
2 OFF SIDE VIEW ( 1:25 )
PADYES 1035 NOTES
1. ALL DIMENSION IN MILLIMETRES
2. ESTIMATED WEIGHT OF ASSEMBLY AS SHOWN : 3600 kg (WITHOUT WIRE)
3. MAX SLING ANGLE =<45
4. SLING SET TO BSEN 12079

n930 FLANGE
HYDRAULIC
GREASE CHAIN FIRST LAYER
BULKHEAD
BEFORE USE
PANEL

CORE
508
TOP LAYER
1368

19
WIRE ROPE EXIT
572

296
429
521 4 OFF GREASE
399 1000 399 POINTS, GREASE
61 920 DAILY
1798

1384
2035

UNDERNEATH VIEW ( 1:25 )

(FOOTPRINT)
40
193 130

203 x 203 x 86 UC
193

18 OFF
n26 THRU
130 193

THIS DRAWING IS COPYRIGHT AND IS

40

THE PROPERTY OF MOTIVE OFFSHORE LTD

AND MUST NOT BE REPRODUCED
40 430 430 430 430 40 OR USED WITHOUT THE EXPRESS
PERMISSION OF
THIRD ANGLE PROJECTION MOTIVE OFFSHORE LTD

GENERAL TOLERANCES TITLE

STEEL FABRICATIONS : 3.00 MM UNO

OCEAN RIG 5T WINCHES
MACHINING
CONCENTRIC
: 0.25 MM UNO
: 0.05 MM UNO MS1059, MS1060, MS1061 AND
ANGULAR : 0.5 UNO

B 07/05/14 AR RM DL DA AS BUILT
motive offshore MS1062 UNDERSPOOLING
A 29/11/13 AR DA DA ISSUED FOR INFORMATION
MACHINED CORNER RADS.
INSIDE : 0.50 MM UNO
GENERAL ARRANGEMENT
0 29/11/13 AR DA DA ISSUED FOR COMMENT SCALE DRAWING No. SHT. REV.
OUTSIDE : 0.65 MM UNO
REFERNCE DRAWING REV DATE BY CHK'D APPD APPD COMMENT 1:25 011-118 1 OF 1 B
Manual Operation & Maintenance Manual

11.4 Table of Values

Torque Value Bolt / Nuts Hydraulic cleanliness

These figures below are for greased bolts only, not NAS Classification:
valid for greased containing copper or EP additives.
NAS 1638 standard comprised of fluid cleanliness
Torque in Nm classes, each class defined in terms of maximum
Tensile Strength allowed particle counts for designated particle size
Bolt/Nut 4.6 8.8 10.9 12.9 SS ranges:
Size
Maximum No. of particles / 100ml
M8 8 20 27 33 21 Class 5-15 15-25 25-50 50- >100
M10 15 39 54 64 41 100
M12 27 69 94 112 64 00 125 22 4 1 0
M16 67 171 232 278 158
0 250 44 8 3 0
M20 130 333 452 543 233
M24 224 575 784 939 408 1 500 89 16 6 1
M30 443 1143 1558 2240 - 2 1000 178 32 11 1
3 2000 356 63 22 2
1 Nm = 8.851 lbin = 0.738 lbft = 0.102 kgm
4 4000 712 126 45 4
IP Ratings 5 8000 1425 253 90 8
6 16000 2850 506 180 16
Protection provided by enclosures for electrical
equipment is indicated by the IP codes two 7 32000 5700 1012 360 32
characteristic numerals. 8 64000 11400 2025 720 164
9 128000 22800 4-50 1440 128
Protection Protection Protection Protection
against against; against against 10 256000 45600 8100 2800 256
solid liquids
11 512000 91200 16200 2880 512
objects
X Untested X Untested 12 1024000 182400 32400 5760 1024
0 Not 0 Not
protected protected
1 Solid objects 1 Falling drops ISO 4406:
over 50mm of water
(e.g. ISO 4406 classified by a two number code as below
accidental table:
touch by
hand) Range Number No. of Particles per ml
2 Solid objects 2 Direct sprays More than Up to and
over 12mm up to 15 including
(e.g. from the 24 80 000 160 000
fingers) vertical
3 Solid objects 3 Sprays up to 23 40 000 80 000
over 2.5mm 60 from the 22 20 000 40 000
(e.g. tools vertical
and wires) 21 10 000 20 000
4 Solid objects 4 Sprays from 20 5 000 10 000
over 1mm all directions
(e.g. tools, limited 19 2 500 5 000
wires and ingress 18 1 300 2 500
small wires) permitted
5 Dust 5 Low 17 640 1 300
limited pressure jets 16 320 640
ingress (no if water from
harmful all directions 15 160 320
deposit) limited 14 80 160
ingress
permitted 13 40 80
6 Strong jets 12 20 40
of water
7 Effects of 11 10 20
temporary 10 5 10
immersion
between 9 2.5 5
15cm & 1m. 8 1.3 2.5
8 Long periods
of immersion 7 0.64 1.3
under 6 0.32 0.64
pressure

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12.0 HSE LITERATURE

12.1 Risk Assessment

Ref: RA-01 Title: Winch & EHPU Operations

CONTROL
EXISTING RISK RISK AFTER CONTROL MEASURES
HAZARDS MEASURES

Hazard severity Likelihood of Risk Details of existing Hazard Severity Likelihood of Risk
Hazard Description People at risk Risk Risk
(H) Occurrence (L) Rating controls (H) Occurrence (L) Rating

Consider hierarch of risk

Tolerable, controls and describe fully Tolerable,
Detail who is at Moderate, all controls applicable for Moderate,

Highly unlikely = 1

Highly unlikely = 1
Extreme harm = 3

Extreme harm = 3
Describe all hazards identified risk. Include all (H) x Substantial, each hazard e.g. if PPE is (H) x Substantial,
Slight harm = 1

Slight harm = 1
and their effects of each task people who may Harmful = 2 (L) Intolerable used as control, it must be (L) Intolerable

Harmful = 2
Unlikely = 2

Unlikely = 2
be affected (refer to specified. All controls must (refer to

Likely = 3

Likely = 3
table) reduce severity, likelihood table)
or both.

Make all personnel aware of

the operation, all non-
essentials to stay clear,
housekeeping to continually
Winch Operator
kept to a high standard.
and others in
Slip, Trip and Falls 2 2 4 Moderate Erect barriers and signs 2 1 2 Tolerable
vicinity of
warning of danger areas.
equipment.
Wear correct PPE. Be
aware of simultaneous
operations in the
equipment vicinity.

Wear correct PPE, keep

Winch Operator
hands/limbs away from
and others in
Pinch Points 2 2 4 Moderate moving parts. Take care 2 1 2 Tolerable
vicinity of
and fully understand task
equipment.
before starting.

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Stay clear of moving parts,

ensure moving parts where
Winch Operator possible are guarded.
and others in Barrier off area around
Caught in rotating machinery 3 2 6 Substantial 3 1 3 Moderate
vicinity of winch while in operation.
equipment. Operator to be fully trained
and component in winching
operations.

Ensure hoses are correctly

fitted by a trained
Winch Operator competent technician. All
and others in hoses, valves and
High pressure fluid release 3 2 6 Substantial 3 1 3 Moderate
vicinity of connections to be check
equipment. and confirmed fit for
purpose. Where possible
stay clear of pressure lines.

Electrical work to be carried

out by a trained competent
technician. Ensure all
cables and free from
Electric Shock Winch Operator 3 2 6 Substantial damage and correctly 3 1 3 Moderate
terminated. If defects are
found during operation
isolate supply before
starting maintenance.

Wear correct PPE. If skin

Contact with oils and lubricants Winch Operator 2 2 4 Moderate contact occurs wash off 2 1 2 Tolerable
immediately.

Ensure wire is terminated

correctly, is free from
defect and certified.
Perform a SWL test on
Winch wire failure All on site 3 2 6 Substantial winch/wire before 2 1 2 Tolerable
commencing operation. If
wire gets damaged during
operation, stop the job and
replace wire.

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Check radios prior to use.

Winch Operator
Have hand signals defined
and others in
Loss of communication 3 2 6 Substantial for emergency backup. 3 1 3 Moderate
vicinity of
Hold TBT prior to starting
equipment.
operation.

Assessor: Dave Acton Date: 15/01/2014

HSEQ Dept. Reviewed by: Valene Morrison Date: 16/01/2014

Page 20 of 20 MOS-MA-EM-02 Rev A

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APPENDICIES:

MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

1. Motor:

MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

2. Control Valve Main (6MB)

The control unit is ideal for the controlling of hydraulic driven winches and has the following improved
characteristics:

Extremely compact design

All valves integrated into one unit
Designed to withstand marine surroundings
Pressure compensated flow control system, giving excellent metering
Prepared to fit directly to motor flanges by an adapter
Hand lever with 39 control movement in each direction
Wide range of options
Extremely wide capacity range

Modular Code Data

6MB Directional control valve
Counterbalance valve in A
Free flow check valve
Pressure relief valve A to B
Anti-cavitation valve to B
Pressure compensator flow control
Max operating pressure 315 bar
650 Rated flow Q = 650 l/min
37B Manually / remote operated with brake release 4BA3
2C Spool Type

MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

Hydraulic Schematic:

Item Description
1 Main block
2 Directional control valve 4/3
This is a three position directional spool valve with hand lever. When activating the directional valve
handle, the operator controls the direction and drive speed of the drum. Throttling grooves in the main
spool open progressively for flow either to A or B port. The spool has adjustable end stoppers in both
end covers for limiting of the spool stroke. A shorter travel of the spool will result in an increase of the
pressure drop through the spool and an increase of maximum flow through the valve.
C Counterbalance valve A to T
The counterbalance valve keeps the load under control during lowering operation. Throttling groves in
the counter balance spool opens progressively for flow from A-T port, thus gives a smooth lowering
operation and low pressure rise with full flow. The counterbalance spool opens by a pilot pressure taken
from line B.
Factory pre-set to 40 bar
Q Adjustable throttling
Throttling for the counter balance pilot channel.
Factory pre-set to turn counter clockwise (ccw) from closed position.
CA Check-valve free flow P to A
Bypassing the counter balance valve in Heave
D Pressure relief valve A to B
This pilot operated pressure relief valve will in some application be used as a mooring valve, to keep a
constant tension on the drum, or freewheeling of the hydraulic motor. Tension pressure can either be
adjusted by a hand wheel (option MAM) or remote controlled by the port MX.
The pressure relief valve is set to its minimum.
DA Anti-cavitation check valve
Boosting from T to B
MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

General Measures must be taken to ensure that cavitation cannot occur in a hydraulic system.
Therefore, a certain flow must be applied to A or B to replace internal leakage. It is important to
prevent boosting oil from running out of the boosting system. A check valve with opening pressure of 2-
3 bar in T will usually satisfy this. As far as possible, internal leakage from the hydraulic motor should
be connected before the check valve in T. Remember to check max motor casing return pressure
against system return pressure.
Standard Boosting 6MB has internal boosting from T to B as standard. Also a certain flow will leak
through nozzle PB, and shuttle valve PC to either A or B.
Generally about the pressure compensator system This is a load independent system, which means
that a fixed spool stroke on the directional valve will give equal flow independent of the load at the
motor / drum. The main directional spool (2) in conjunction with pressure compensator flow A (Heave
rotation) or B (Lower rotation) by sensing the pressure either in A or B line through the shuttle valve
(PC). When operating direction valve (2), the spool will open progressively to A or B. Pressure
compensation element will maintain equal p across the directional valve. Maximum flow over the main
directional valve is depending on the force induced on the pressure compensator element (P). This
force is made up of a spring force in the compensator pilot valve (PA) and the load pressure sensing in A
or B via (PC). When setting is altered on the compensator pilot valve (PA), the flow will change. When
adjusting pressure relief valve PA, the p through the directional valve will alter, and thus maximum
flow to the hydraulic motor.
PC Shuttle Valve for the pressure compensator
Port V can be used for load sensing or in some application for a hydraulically operated brake release
valve.
P Pressure compensator element
Normally opens the modulating element, which acts as a pressure compensator to maintain a constant
pressure drop across the directional valve (together with PC, PB, PA and Z).
Z Adjustable throttling
Adjustable throttle for the pressure compensator element, if the element is fluctuating.
PB Nozzle
Maintain flow to compensator pilot valve PA.
PA Compensator pilot valve
The spring on the compensator is rather weak. Therefore, pressure created by an adjustable pressure
relief valve is added to the spring force.

Port dimension for brake release valve 4BA3: 3/8 BSPP

MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

Hydranor control valve dimensions:

Pressure drop:

MOS-MA-EM-02 Rev A
Manual Operation & Maintenance Manual

Description Symbol Unit Value

Flow (p 32 bar) Q max l/min 450-650
Max operating pressure in ports P, A and B P max Bar 315
Recommended max. pressure in port T. (See Note T max Bar 20
below)
Directional valve pilot pressure P Bar 5-20
Weight basic version m Kg 96
Hydraulic fluid Mineral oils for hydraulic system
Viscosity range v m/s 10 to 350 (cST)
Viscosity index VI >120
Filtration, recommended filter with 20 100 Class 9 according to NAS 1638,
18/15 according to ISO 4406
Fluid temperature range T -20C to +70C
Ambient temperature range T -20C to +50C
Standard body material EN-GJS-400-15
(GGG40)
Standard O-rings Nitrile shore 70

Note: Be aware that pressure on the tank port T is direct additive to valve setting for pressure relief valve item
D, counterbalance valve item C. Pressure peaks in T port can influence the stability of the system, particular
proportional remote control of main directional valve.

Interfaces:

Connections
Ports Dimensions
P, A and B 1 SAE 6000
T 2 SAE 3000
MX, V, X, Y, TA, TB 3/8 BSPP
E BSPP
L (When having adapter for direct motor mounting) BSPP
TPP, TPT, TPA and TPB BSPP
Mounting Screws 4 of M12 (thread depth 17mm)

MOS-MA-EM-02 Rev A