Quick guide Hydraulic Winches English 2 nd Edition 2010
Introduction The intention with this Quick Guide for TM deck machinery is to help prevent equipment damage caused by incorrect operation of the ships mooring winches. It also contains useful reminders about preparations and basic maintenance requirements. This booklet is not a replacement for the Maintenance or Instruction Manual, both of which the operator should be completely familiar with. It should be considered as an additional handy resource that can be kept in a pocket and available when needed. ONLY trained personal should perform anchoring and mooring operations. This to reduce equipment damage and hazardous situations, leading to serious injuries or loss of life. Read the Instruction Manual thoroughly so you are familiarised with the equipment. Always wear personal protective equipment!
1 of 18 Table of contents Before starting an Anchoring operation... 2 Inspect the Hydraulic Power Unit - HPU... 3 On deck preparations... 4 Anchor Winch operation... 5 Lower/ Walking Out the anchor with the winch motor... 6 Heave-in operation / adjustment of chain length... 7 After completion of heave-in operations... 11 Emergency release of anchor chain... 12 Mooring operation... 13 Before operation... 13 Inspect the Hydraulic Power Unit.... 14 Manual mooring operation... 14 Warping end.... 15 Automatic Mooring operation... 17 Testing of mooring drum brakes... 18 How to order Spare Parts?... 18 Abbreviations: HPU SOG Cable lifter Shackle, Shot Hydraulic Power Unit Speed Over Ground Chain handling part of windlass 27.5 m of anchor chain References: Effective mooring Anchoring Systems and Procedures for Large Tankers Both published by OCIMF - Oil Companies International Maritime Forum.
2 of 18 Before starting an Anchoring operation Be aware of the equipments limitations / design criteria. Keep in mind: Maximum pulling force for the anchor windlass is less than 10% of the chain breaking load. The windlass is not able to haul the vessel against wind and current or break-out an embedded anchor.. The windlass is only designed for heaving a free hanging anchor from a depth of 80 100 m. With the windlass motor engaged, especially when heaving, the hydraulic motor is the weak link in the transmission system. Note the following: Max anchoring depth: 3 to 4 shackles (approx. 80 100 m). Speed over ground (SOG) not to exceed 0.3 knots (9 m/min) astern. Weather condition: Wind, current, waves and swell. NOTE! Waves and swells can induce hazardous dynamic forces into the anchoring system. Make sure you have communication equipment so you can have direct contact with the bridge at all times. Check the anchoring equipment s condition before operation. The most frequent failures for an anchor windlass are due to a lack of maintenance, especially adjustment for wear of the band brake linings and lack of lubrication.
3 of 18 Poorly adjusted windlass brakes or lack of maintenance can result in loss of anchor and chain, as the brake no longer will have sufficient holding power. Inspect the Hydraulic Power Unit - HPU Oil leakage. Reservoir oil level. Tank close-off valves need to be fully open (suction and pressure lines). Cooling water/air supply fully open/available. Alarms; Check the lamps by pressing the Lamp Test.
4 of 18 On deck preparations Correct: Check the brake lining thickness and the brake adjustments! Getting Critical Set indicator to marking (Hydraulic brake only) α always to be bigger than 0 degree Check the adjustment of the Stripper Bar Remove all lashings and coverings from chain stopper, hawse pipe and spurling pipe. Grease all lubrication points and the open gears. Remove and secure the chain stopper locking bolt and locking pin if there is one.
5 of 18 Anchor Winch operation General: Start HPU and select Stand-By High mode. Make sure that the vessel is not drifting off with a speed over ground (SOG) higher than 0.3 knots (9m/min) astern. Anchor Drop using the cable lifter brake; RECOMMENDED NOTE! Apply the cable lifter brake every time there is a stop in the anchoring operation. Engage the cable lifter unit to the winch and than insert the clutch locking pin if it is not a hydraulically operated clutch. Rotate the shaft in heave direction to take-up the slack in the transmission system. Release the cable lifter brake. Open the chain stopper dog/guillotine bar. Lower the chain till the anchor is at sea level. Apply the cable lifter brake and disengage the cable lifter unit from the anchor winch and insert locking pin, if it is not a hydraulically operated clutch. Open and close the cable lifter brake, dropping the anchor IN CONTROLLED STEPS. WARNING ABSOLUTELY AVOID too higher speed during anchor drop.
6 of 18 When the required chain length is paid out, apply the cable lifter brake, close the chain stopper dog/guillotine bar and insert the locking bolt and the securing pin if there is one. Forgot the locking bolt? Lower/ Walking Out the anchor with the winch motor Engage the cable lifter unit to the winch and insert the clutch locking pin, if it is not a hydraulically operated clutch. Rotate the shaft in heave direction to take-up the slack in the transmission system. Release the cable lifter brake. Open the chain stopper dog/guillotine bar. Lower the anchor by control of the winch motor in low speed only apply the cable lifter brake at all stops. Make sure the vessel is not drifting with a SOG higher than 0.3 knots astern. If required use the main engine to counteract.
7 of 18 When the required chain length is paid out, apply the cable lifter brake, close the chain stopper dog/guillotine bar and insert the locking bolt and the securing pin if there is one. Disengage the cable lifter from the anchor winch and insert the clutch locking pin, if it is not a hydraulically operated clutch. Manual clutch with locking pin Heave-in operation / adjustment of chain length If the paid out length of the chain has to be adjusted, or when the anchor heave-in operation has to be started, ensure minimum tension in the chain. Avoid high tension in chain when heaving.
8 of 18 The windlass is not designed for breaking out an embedded anchor or hauling the vessel as the motor is the weak link in the anchoring system. To break out the anchor, lock the chain in the chain stopper and use the vessels main engine. Potential damage of equipment when overloaded. Start the HPU and select Work Pressure mode. Engage the cable lifter unit to the anchor winch and insert the clutch locking pin if it is not a hydraulically operated clutch. Rotate the shaft in heave direction to take-up the slack in the transmission system. Release the cable lifter brake.
9 of 18 Too high tension in chain. Heave up position. No tension in chain. Break out an embedded anchor with main engine and chain locked in the chain stopper. Remove and secure the chain stopper locking bolt and locking pin if there is one. Open the chain stopper dog/guillotine bar.
10 of 18 Start to haul in the anchor in Low Speed mode. Remember the vessel should be manoeuvring towards the anchor, not the winch pulling it! Use the anchor chain washing system and observe the condition of the chain links and length markings. Reduce the speed before the anchor reaches the hawse pipe. When the anchor and flukes are properly stowed, stall the hydraulic motor while applying the band brake. Release the control lever once the cable lifter brake is fully applied. Close the chain stopper dog/guillotine bar and restore the locking bolt and securing pin if there is one. Disengage the winch clutch and insert the clutch locking pin, if it is not a hydraulically operated clutch. Shut down the HPU (Inspect alarms prior to shutdown). Switch HPU to "Stand-By Low" pressure for long waiting periods to avoid overheating the hydraulic oil. Stop the pumps when the work is completed. Overheating of the oil will stop the HPU automatically.
11 of 18 After completion of heave-in operations Lash the anchor with the lashing equipment and make sure that the anchor is fully secured in its "housed position". In case of hydraulically operated band brakes, check the brake setting according to the drawing below. Adjust if required with the hand wheel to set the marking to correspond with the indicator, see view X. For full details see the Instruction Manual. Check the brake lining thickness and the brake adjustment. Replace all covers and weather protections etc. on spurling and hawser pipes Grease all lubrication points and the open gears. Check condition and movement of the couplings/clutches. Notify the appropriate officer of any issues or observations made during the operation of the equipment.
12 of 18 Emergency release of anchor chain In case of black-out or lack of power, the anchor has to be dropped manually by using the windlass brake only. Remove lashing and all covers from spurling and hawse pipe. Check that the winch coupling is disconnected and clutch locking pin inserted if it is not a hydraulically operated clutch. Release/open the chain stopper, use a crowbar if necessary. Carefully release the cable lifter brake by turning the brake wheel counter clockwise. Control the speed manually in steps with the brake wheel. When sufficient chain is paid out, tighten the cable lifter brake. Close the chain stopper dog/guillotine bar and insert the locking bolt and securing pin if there is one. WARNING AVOID too higher speed during anchor drop.
13 of 18 Mooring operation WARNING The winch gear and motor is NOT designed to stop the vessel s motion at quay approach! Before operation Inspect the condition of the winches and grease all lubrication points, especially the mooring drum bearings, preferably have the shaft rotating and the drums disconnected. Check the condition of band brake lining and that it is correct adjusted. Check condition of the other items of mooring equipment.
14 of 18 Inspect the Hydraulic Power Unit. Oil leakage. Reservoir oil level. Tank close-off valves need to be fully open (suction and pressure lines). Cooling water/air supply is fully open/available. Alarms: Check the lamps by pressing the Lamp Test. Manual mooring operation. Start HPU and select Work Pressure mode. Engage the drum coupling and secure the coupling lever with the locking pin if it is not a hydraulically operated clutch. Rotate the main shaft in heave direction to take-up the slack in the gear transmission before releasing the brake. Coupling arm with locking pin Manual operated drum brake Hydraulic spring applied drum brake
15 of 18 Select Low Speed when tensioning the rope and High Speed or Auto Speed for slack rope operations. Switch HPU to "Stand-By Low" mode for long waiting periods to avoid overheating the hydraulic oil. Stop the pumps when the work is completed. Warping end. Never allow more then 3 to 4 turns on the warping end. WARNING! Never use high modulus synthetic fibre ropes under tension on the warping end due to the low friction coefficient in the rope. Avoid operating the warping end when there is tension in the mooring lines. Frequently use of warping end during mooring operation requires intermittent greasing of the mooring drum bearings. Never use the warping end for continuous mooring. To fairlead To fairlead Incorrect Correct Note! Always fix the line on a bollard in front of the warping end.
16 of 18 Too many layers on tension part and rope stored on the warping end Winch nominal pull, speed and brake holding load refers normally to the FIRST LAYER on drum. Use the split flange opening when changing from the storage to the tension part of the drum. When the winch operation is completed, engage the mooring drum brakes. Release the tension in the clutch and disengage the drum coupling. When adjusting tension, engage the clutch fully and rotate the shaft in heave direction to take-up the slack in the transmission system before releasing the mooring drum brake. Once the mooring operation is completed, shut down the HPU.
17 of 18 Automatic Mooring operation When automatic mooring is to be used the mooring plan has to take following precautions into consideration: Winches operating in the auto-mooring mode will have a recovery load about 0.55 times and a rendering load about 1.5 1.7 times the nominal pulling load. One drum only to be connected to the winch gear. If two drums on the same winch are used in auto mooring mode, the resulting load must be equal to the total load for one drum! However, the individual tension in the two ropes will be unknown. Winches with multiple drums: One drum connected to winch gear, the remaining drums to be disengaged. Alternatively the mooring lines to be set on drum brake. Winches with multiple drums: Grease the drum bearings before operation. Intermittent greasing is necessary for long time operation! If bad weather, wind and current: Use the mooring drum brakes for the lines heading in to the wind and current. The remaining lines to be set in automatic mode; ONE LINE EACH WINCH! Never put all spring lines in automatic mooring mode, minimum one line to be kept on the drum brake. With both spring lines in automatic mode the vessels can start to walk along the quay.
18 of 18 Warping ends are not subject to automatic mooring activities. When berthing is completed, select which winches to be set in automatic mooring mode: Let only one pump run on the HPU to avoid overheated oil. Switch the hydraulic pressure to Stand-By High mode. Speed selection valve to be set to Low Speed. Lock the manoeuvring handle in Heave position. Check that the vessel is not drifting out of position. Testing of mooring drum brakes. When testing of the holding load for the mooring drum brakes is required, follow the instructions and procedures given in the Instruction Manual. How to order Spare Parts? For ordering spar parts, detailed instructions are given in the Spare Parts chapter of the Instruction Manual.
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