MacGregor Pusnes Academy
Pusnes Bow Loading System (BLS)
Training Course for
Operators & Maintenance Personnel
©2015 MacGregor Pusnes AS: This document and contents remain the company’s exclusive property; they shall not be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Table of Contents
1. MacGregor Pusnes AS2. Safety Manual3. Offshore Loading4. Fairlead5. Chain Stopper (QRS 83)6. Traction Winch7. Guide rollers & Hose handling bow roller8. Rope pulling unit PSU & SU9. Hose Handling Winch10. Cardan Suspension with coupler valve11. Valve Unit Skid & Accumulators12. Hydraulic Power Unit (HPU)13. Control System14. Emergency System15. Spare Parts16. Pusnes Lifecycle Services17. Attachment
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel MacGregor Pusnes AS
Chapter: Table of Contents Rev. 03
Welcome to
MacGregor Pusnes
A brief company introduction
Pusnes Academy
Pusnes Bow Loading Systems – Training Course for Operators & Maintenance
Personnel
Employees: 374
Revenue : 1,100 MNK
2012
2
This is Cargotec
Cargotec shapes the cargo
handling industry for the benefit of
its customers and shareholders.
Our products are present in every
major cargo hub worldwide.
They are used in ships, ports,
terminals, distribution centres,
heavy industry and in on-road
load handling globally.
Operations in more than 100
countries
3
Employees: ~11 000
Sales: EUR 3,4 bn
Nasdaq OMX Helsinki
Revenues and profits are in euro and approximates
for 2014.
Cargotec and
MacGregor in
brief
4
Merchant/ Offshore Load Handling Terminal Merchant / Offshore Terminal
MacGregor, Kalmar and Hiab are recognised market leaders in their fields.
Improve efficiency for offshore
and merchant vessels by
delivering innovative solutions
The world's leading brand of
engineering solutions and
services for offshore mooring,
crude oil loading and handling
of marine cargoes and
offshore loads
Built on more than 140 years
of industrial tradition
This is MacGregor
5
Employees: 2 700
Sales: EUR 1 bn
100 % owned by Cargotec
Revenues and profits are in euro and approximates
for 2014.
MacGregor solutions for Merchant Ship &
Offshore segments
Hatch covers, container lashings
Cranes RoRo access
equipment Port and terminal
solutions Marine
selfunloaders
Offshore load handling
Marine loading arms
Deck machinery Steering gear Mooring Systems
Offloading systems Bow loading
systems
6
MacGregor’s journey with key milestones
until today
2005
MacGregor acquired
All Set Lashings
1937
MacGregor & Company formed
1957 Navire company formed
1983
MacGregor merged with
Navire to form
MacGREGOR-Navire and
became part of Kone
1993 Incentive acquired
MacGREGOR-Navire.
Hägglunds Marine and
MacGREGOR-Navire
were combined to form the
MacGREGOR Group
2005
Kone acquired
MacGregor
International AB
Kone demerged and
Cargotec was listed
1969 Navire Cargo
Gear AB formed
2007
Plimsoll and
Hydramarine
acquired for
entering offshore
business
2013
Acquisition
of Hatlapa
1998
Industri Kapital acquired
the majority of the
MacGREGOR Group
shares from Incentive
1992 MacGREGOR-
Navire acquired
Conver-OSR
2014
Acquisition
of MLS
World wide presence
8
Total MacGregor - team members by country
9
593
463
346
280
197
163 147
87 86 84 64
45 23 21 20 16 15 15 14 13 13 12 11 10 8 7 6 5 4 4 3 2 1
0
50
100
150
200
250
300
350
400
450
500
550
600
Offshore
Mooring systems for fixed floating offshore vessels
Offloading and loading of crude oil, condensate and LNG
Merchant
Deck Machinery and Rotary Steering Gears
Terminals
Loading arms for crude and LNG
This is MacGregor Pusnes
October 2014 10
Employees: 400
Sales: EUR 135 million
100 % owned by Cargotec
Pusnes history
October 2014 11
Shipbuilding 1780 - 1960
Marine equipment 1891 -
Oven foundry 1875 - 1904
Offshore Equipment 1968 -
Equipment supplier to Marine and Offshore industry since 1875
MacGregor Pusnes
Hatch covers, container lashings
Cranes RoRo access
equipment Port and terminal
solutions Marine
selfunloaders
Offshore load handling
Marine loading arms
Deck machinery Steering gear Mooring Systems
Offloading systems Bow loading
systems
26 November, 2015 12
Deck Machinery and Steering Gears
October 2014 13
Hydraulic and Electric Deck Machinery
Emergency Towing System Arctic
Solutions
■ Supplier of Marine equipment to the shipbuilding industry since 1875
■ More than 2000 vessels operating with Pusnes Deck Machinery and Porsgrunn Steering gears
■ Production sites in Polen, Korea and China
Steering Gears
Woodfield Loading Arms
October 2014 14
■ Loading arms
■ Swivels
■ Crygenic and Ambient
Offshore Mooring
October 2014 15
Winches
Floating Drilling Units (Semi’s)
Floating Production Units (FPSO, Spar, Semi)
Ram Winch Drum Winch
Chain handling
Rotation winch
Main Focus:
■ Lightweight, robust and reliable
■ Well Proven technology
■ Low maintenance requirements
Offshore Loading
16
■ Releasable Hawser winch
■ Offloading hose reel
■ Hose end valve
■ FLNG offloading
■ Direct offloading
■ Arctic solutions
Customized / new concepts
Shuttle tankers
FPSOs
■ Bow Loading System
■ Arctic inboard version
Market position, offshore
17
Mooring Loading
Average annual market size
2007-2010 (MNOK)
Average annual market size
2009-2015 (MNOK)
30 % 30 %
FloatingProduction Units
Drilling Semi's
Average annual market size
2009-2015 (MNOK)
30 %
100 %
Offloading(FPSO's)
Loading -Shuttle Tankers
350-400 40-60 400-500 300-400
* *
Differentiators
• Experience
• Safety and reliability
• Know-how on
standards and regulatives
• Technology partner
• Lifecycle network
Customer
Service
Commissioning
Training
Service
Technical
Support
Spare Parts
Overhauls and Upgrades
Global Lifecycle Support
Service
Commissioning
Annual inspections
Pre-docking service
Service work
Maintenance and damage repair
Function testing and adjustments
Recommendation of spareparts
mailto:[email protected]
Commissioning
Checking of supplied equipment
Checking of installation of equipment
Starting up of equipment
Testing of equipment
Annual Inspections
Background Information
We offer annual and pre-docking inspection of
supplied equipment.
The inspections cover all parts of the system
and possible failures or defects are identified.
Inspections performed prior to drydocking will
identify the need for repairs and replacements
of defective parts of the system. This gives a
clear scope of work that can be presented to
yard so that they are prepared for the
forthcoming drydock.
Customer benefits
Potential downtime of system is eliminated
Detailed inspection report is submitted
A quotation for all necessary parts is given so
that spares for drydocking are available
Various technical alternatives and upgrades
are informed
Inspections can include tasks like calibration,
upgrading and adjustments of system
MacGregors service organisation is
class-certified
Pre-docking service
Dry-dock planning
- Qualified assesment of the condition of the equipment
Pre-docking check list
Pre-docking inspection
Recommendation of corrective and maintenance
and repairs
Listing of recommended spares for the docking
Spareparts
Store of most common items with short lead time
Dedicated personnel which gives quick response help
Knowledge in use of parts list and documents
Close co-operation with technical support
Field support from branch offices
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]
Sparepart identification
Spareparts
Equipment
Drawing nr. Example:
Valve units
Pos 235
Pos nr. Pos 240
(Item name)
Quantity
Revision changes, parts changed
Replaced by new
improved sealings
Technical support
24/7 technical support
Troubleshooting
Mail support
Assistance in maintenance
Parts identification help
Project team in assistance with modernisations and conversions
Assistance with rules and regulations
Specifications
Analysis
mailto:[email protected]
Training for crew and personnel
The training courses ensure that operators and maintenance personnel have the necessary know-how to safely and correctly operate and maintain all our equipment.
We offer:
Classroom/ On – site training
Maintenance training
Operator training
QEHS awareness/ best practices
Testing procedures
Trouble shooting
Safety inspections
mailto:[email protected]
Future challenges
28
MacGregor Pusnes will be there!
MacGregor Pusnes
Why acquire Pusnes?
Expand MacGregor offshore market into FPSOs, drilling rigs
Synergy effects:
Highly distributed network of Sales and Service
Technology and products
Manufacturing setup
29
No compromises on Pusnes Offerings, Quality and Dedication!
How to reach MacGregor Pusnes
Main office + 47 37 08 73 00
New Sales:
Auxiliary and Machinery Systems
Offshore Mooring and Loading:
Global Lifecycle support:
24 hours support phone: 00 47 90 05 39 24
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]
OL STANDARD DOCUMENTS Client
MacGregor Pusnes AS
Box 732 - Stoa, N-4808 Arendal,
NORWAY
Tel.: +47 37 08 73 00 [email protected] www.macgregor.com
Client project no. Pusnes project no.
STD OL
Document title
SAFETY MANUAL
Client doc. no. Client rev. Pusnes doc. no. Pusnes rev.
Total pages
AN EXAMPLE FOR BLS COURSE 02 9
Client Tag no. Pusnes product serial no.
Revisions
29.04.15 02 An example for Pusnes Academy, BLS course REK JFi
30.11.07 01 Updated KS SAN OSK
30.09.05 00 Initial issue LAa SAN KS
Rev. Date Reason for issue Prepared Checked Accepted
Acceptance code Date / Signature ………………………………………………………….
Code 1 Code 2 Code 3 Code 4 Code 5
Accepted Accepted with comments incorporated Not accepted, revise and resubmit Issued for information Interface information as clouded is accepted and frozen
©2015 MacGregor Pusnes AS: This document and contents remain the company’s exclusive property; they shall not be copied,
reproduced and/or made available to third parties without the company’s expressed consent.
http://www.macgregor.com/
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
Table of Contents
1 Legend ....................................................................................................................................... 3
2 Hazards , Risks and Safety Equipment ..................................................................................... 4
3 General safety ........................................................................................................................... 5
4 Transportation, Handling And Installation .................................................................................. 5
5 Operation ................................................................................................................................... 6
5.1 Work Area ........................................................................................................................... 6
5.2 Operation ............................................................................................................................ 6
5.3 Special Conditions .............................................................................................................. 7
5.3.1 Ice formation ................................................................................................................ 7
5.3.2 Extreme cold ............................................................................................................... 7
6 Maintenance/inspection safety .................................................................................................. 7
7 Electrical components ................................................................................................................ 8
8 Risk Assessment – Incident Frequency and Consequences ..................................................... 8
9 Need assistance? ...................................................................................................................... 9
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 2 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
1 Legend Standardised symbols related to hazards / risks and safety equipment. Combination of the symbols identified below may be found on the shipment, machinery and instructions. Symbol Interpretation
General danger / hazard / risk
Risk of crushing / shearing / cutting / stabbing / puncture entanglement / drawn-in
Risk of live parts / electrical shocks
Risk of high pressure fluid ejection / oil spill
Lifting operations - Risk of falling objects
Moving operations - risk of loss of stability / overturning.
Risk of falling or flying objects
Risk of spill / slippery surface
Hard hat
Eye protection
Ear protection
Safety gloves
Safety boots
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 3 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
2 Hazards, Risks and Safety Equipment Synopsis of hazard-identification related to specified phases, and recommended safety equipment hereto.
Phase Combined hazards and risks Recommended safety equipment
Transportation
Lifting, moving and handling of items and packages
Installation
Lifting and assemble items
Commissioning / start-up
Operation – Mooring and Anchoring
Additional risk-increasing factors: • Wrong operation of equipment • Unskilled personnel • Lack of maintenance • Handling of wire/soft rope • Wire/soft rope breakage • Breakage • Operations at low temperature
(below – 20OC)
Maintenance
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 4 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
3 General safety Handling, installation, commissioning, operation and maintenance of Bow Loading-,Off-Loading and Deck Machinery equipment are to be considered as high-risk operations. Involved personnel should have the relevant knowledge and proper training according to the onboard safety regulations, the user manual and this document. This will contribute to safe handling and operation. This manual is supplemental to the general safety manual onboard.
Keep first aid kit available at all times. Recommendations: Booklet: “Effective Mooring” ISBN 948691 88 3. Might be ordered through internet or bookshop. www.ocimf.com CD as: “Mooring”, CD #63, Computer Based Training, see www.sgull.com
4 Transportation, Handling And Installation
Phase Combined hazards and risks Recommended safety equipment
Transportation
Lifting, moving and handling of items and packages
Installation
Lifting and assemble items
Commissioning / start-up
• Reference documents and drawings must be studied closely in order to obtain satisfactory installation and future safe operation.
• A safe work environment and work practice must be adapted. • Study Appendix 1. “Lifting, Handling and Transportation”.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 5 of 9
http://www.sgull.com/
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
5 Operation
Phase Combined hazards and risks Recommended safety equipment
Operation
Additional risk-increasing factors: • Wrong operation of equipment • Unskilled personnel • Lack of maintenance • Handling of wire/soft rope • Wire/soft rope breakage • Breakage • Operations at low temperature
(below – 20OC)
5.1 Work Area
1. Plan and organise your work program before starting. Always read and follow operating instructions.
2. Stay well clear of the wire and soft rope at all time. 3. Do not work or stand too close to the winch drum. 4. Never place any foreign object onto the equipment. 5. Have a first aid kit available for use.
5.2 Operation
1. Be aware of the ambient condition e.g. wind, waves, tide etc. 2. Stop operation immediately if any safety device fails. 3. Never leave the control station in a running mode. 4. When finished, secure the equipment. 5. If you are in doubt about operations or the condition of the
equipment - report it.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 6 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
5.3 Special Conditions 5.3.1 Ice formation
Ice must be removed in order to secure emergency release when required. This is also required for visual/manual control of equipment both before and after normal operation.
5.3.2 Extreme cold Any operation below design temperature will increase the risk of equipment failure. If any operation is required, this must be performed with care and caution. Remember that some of the components will be more fragile with decreasing temperature. Check the equipment extremely carefully both before and after any operation below –20°C.
6 Maintenance/inspection safety
Phase Combined hazards and risks Recommended safety equipment
Maintenance
Ref.: “Maintenance” and “Troubleshooting” chapters in user manual. For lubrication, study Pusnes’ recommended lubrication charts in user manual.
1. Follow Pusnes maintenance programme. It is important to perform periodic and regular inspection as stated in the user manual.
2. If abnormal situations occur check the “Trouble shooting” chapter in the user manual.
3. If any oil leakage is observed, this must be repaired as soon as possible.
4. Never attempt to clean, oil or perform any maintenance on the equipment with power on.
5. If you are in doubt about operations or the condition of the equipment - report it.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 7 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
7 Electrical components
DANGER Contact with live equipment may result in death or injury.
1. Carefully study the onboard safety procedures regarding electrical equipment.
2. If personnel are in contact with live equipment, do NOT touch the person or anything he or she is touching if there's a chance the person may still be in contact with the source of the electricity. Turn off the electrical source and call for assistance immediately!
8 Risk Assessment – Incident Frequency and Consequences
Consequence (of an incident after it has occurred) Frequency (probability of how often an incident may occur)
HUMAN ENVIRONMENT EQUIPMENT /
MACHINERY
G
r
a
d
e
1 time per 100
year or less (1)
1 time per 10
years
(2)
1 time per year
(3)
10 times
per year or
more (4)
First aid Insignificant Less than 10’ $ 1 Low risk Low risk Medium risk Medium
risk
Medical treatment Minor More than 10’ $ 2 Low risk Medium risk Medium risk High risk
Serious w/possible
disabling Moderate More than 50’ $ 3
Medium risk Medium risk High risk High risk
Death Large More than 100’ $ 4 Medium risk High risk High risk High risk
Risk assessments are performed in relation to the individual equipment in separate construction evaluations. The risk assessment incident frequency are based on actual statistics, but when statistics are not available, conclusions are based on presumptions.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 8 of 9
Project: OL STANDARD DOCUMENTS
MacGregor Pusnes AS Client Doc No: Rev:
Pusnes Doc No: AN EXAMPLE FOR BLS COURSE Rev: 02
Title: SAFETY MANUAL
9 Need assistance?
MacGregor Pusnes AS, P.O Box 732,Stoa NO-4808 Arendal, Norway MacGregor Pusnes AS
Switchboard: +47 37 08 73 00 Mail: [email protected] Service enquieries: [email protected] Spare Parts department:
Technical support enquiries: [email protected]
Warranty enquiries: [email protected]
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 9 of 9
http://www.cargotec.com/en-global/macgregor/solutions/mooring-and-loading-systems/Pages/default.aspxmailto:[email protected]:[email protected]:[email protected]:[email protected]
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
BLS Overview
Fig 1: BLS Side view
Fig 2: BLS Front view
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 1 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Operation Preparation for mooring
The following procedure describes the operation of the mooring and loading system. The crude oil hose valve is equipped with a swivelling lifting ring, to which a two-legged wire sling (hose bridle) is connected. Shackles to the mooring line further connect this. Before the vessel approaches the offloading unit, the following must be prepared: Start the pumps on the hydraulic power unit with the pressure selector switch in "standby" mode. Note! Always start the pumps in accordance with the HPU instruction manual. In cold climate, let the HPU run for at least 30 minutes before any of the equipment is operated. Remove any ice from the equipment. When starting operation, push the pressure selector switch to Work pressure.
Fig 3: HPU control menu
Accumulator pressure
HPU pressure selection
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 2 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Check pressure in the accumulators. Open the chain stopper by pressing the pushbutton for “Chain stopper open” at the local control stand. The placement of this local control box is shown on Fig 12. The chain stopper can also be operated from the bridge control console.
Fig 4: Chain stopper locking bolt located in the cylinder lug
The forerunner rope (min 2” dia.) from the stowing tank has been pre-laid through (Mooring deck equipment) as illustrated in figure below:
Fig 5: Pre-laid forerunner rope from Traction Winch
1. Power Sheave Unit (PSU) (pos. 06) 2. Guide Roller for PSU (pos. 09) 3. Traction Winch (pos. 05) 4. Guide Roller with Load Cell (pos. 04) 5. Chain Stopper, QRS83 (pos. 03) 6. Adjustable Roller Fairlead, 500ARF (pos. 02)
Locking bolt
WARNING: Locking bolts must be in cylinder lugs when opening/closing the QRS.
Cylinder lug
Pre-laid forerunner rope
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 3 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Remote Control Post, RCPH/E
Fig 6: Remote Control Post Hydraulic/Electric, RCPH/E
Fig 7: RCP Layout, electrical control
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 4 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Clutch for Hose Handling Drum When engaging the drum for hose handling, special attention must be paid to ensure that the dog clutch is properly engaged. Before high tension is applied to the drum, ensure that the dog clutch is in correct contact with the drum.
Greenline On the bridge control console the complete loading operation can be monitored. Select the “Greenline” mode and monitor the operation. The steps must be completed in sequence, when one step is completed a green light for this step will be given, see Fig 8 and 9. When all the steps are completed, there will be a line of green lights, from the chain stopper to the Loading Ready signal. When the Greenline is complete, the pumping permitted YES can be activated, and a signal is given to the telemetry system that the pumps can start. The telemetry system (not AP supply) will then send a signal to the loading terminal, that the shuttle tanker is ready to receive oil and the pumping can start. The following functions can be controlled from the Greenline interface in the bridge control console at the bridge (see Fig 8): Chain stopper OPEN / CLOSE Inboard valve OPEN / CLOSE Coupler valve OPEN / CLOSE Pumping permitted YES / NO The following can be monitored: Hawser tension Hose tension Crude oil pressure See chapter 5 for more detailed information on the bridge control console.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 5 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Fig 8: Full Greenline, ready for loading
Fig 9: Auxiliary conditions, these form a single point in Greenline
Greenline
Selecting “Info” shows the following screen with other functions required to build a full Greenline
Controllable functions
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 6 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Single Point Mooring (SPM)
Introduction When the shuttle tanker is approaching the offloading unit, the bow door is opened, coupler claws opened, chain stopper opened and the ARF fully forward/out.
When the tanker is positioned near the buoy, the following procedure is to be followed: A stand-by vessel is transferring the messenger line for the mooring line from the offloading unit to the shuttle tanker. The forerunner from the shuttle tanker is lowered into the sea level and the messenger line and the forerunner is connected on the stand-by vessel (or by shooting line).
Fig 10: Messenger line connected to chafing chain
When the connection is made, the shuttle tanker is pulling over the mooring lines from the offloading unit by means of the traction winch. Begin with the traction winch in "high speed" mode. Select lower speed steps, as the tension in messenger/mooring line increases, while the offloading unit is paying out the mooring lines.
When the chafing chain which is the outer part of the mooring line (between messenger- and hawser) has reached the chain stopper, this has to be locked. Preferably the chain stopper shall be locked on link No. 2, alternatively link No. 3, depending on which way the chain enters.
Messenger line
Chafing chain
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 7 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
When positioned, activate the local pushbutton for "Chain stopper Close". We recommend that this operation is done locally (not from the bridge).
Fig 11: Chain Stopper operation (locally)
Check with the indication lamp that the function is performed.
Fig 12: The Chafing Chain/Mooring Hawser is now locked in the Chain Stopper
Important: Check that the locking bolts are placed in the cylinder lugs on the chain stopper before closing the chain stopper.
When the chain stopper is closed, the locking bolts must be removed from the cylinder lugs on the chain stopper due to the quick release function.
WARNING: During mooring/loading locking bolts should be removed due to the quick release function.
Disconnect the messenger line from the chafing chain to prepare for emergency release.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 8 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Fig 13: Chafing Chain disconnected from Messenger Line
SPM loading connection The following procedure describes the SPM operation of the loading system.
The Shuttle Tanker is now safely moored to the offloading unit, and a auxiliary line from the Hose Winch shall be pulled over the Guide Roller for Hose Handling (pos. 18) and over roller on Hose Handling Bow Roller (HHBR pos. 08). The line shall then be dragged outboard and into the ARF as illustrated in fig. below.
Fig 14: Pre-laid auxiliary rope/wire for hose handling
Disconnect the hose handling rope from the chafing chain and connect it to the pre-laid auxiliary rope/wire from the hose winch. By means of the hose handling winch pull in the hose handling rope and disconnect the suspension rope as illustrated below.
Chaffing chain Messenger line
Pre-laid auxiliary rope/wire from the hose winch
Hose
Suspension Rope
Hose handling Rope
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 9 of 18
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 3 – BLS Overview Rev. 02
Fig 15: Disconnection of suspension rope
Then pull in the hose messenger and bridle until the hose end valve is positioned 0,5 m below coupler valve flange. The hose handling bow roller and the cardan suspension stow actuator should be operated until the coupler valve is centered inside the bridle as illustrated below.
Fig 16: Hose end valve positioned 0,5m below the coupler valve flange
HHBR ARF
Hose messenger
Hose handling rope Suspension rope
Suspension rope
Bridle
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Chapter: 3 – BLS Overview Rev. 02
Make sure coupler claws are fully open and pull in slowly with the hose winch until the hose valve is in full contact flange/flange inside coupler valve guide pins. Use stow actuator (transverse actuator if needed) for proper alignment, meaning the surfaces of the coupler flange and the valve flange are to be parallel. After ensuring that these surfaces are parallel, the coupler claws can be closed The coupler claws will pull the hose valve to a connected position with the ship coupling. The entire weight of the hose valve and loading hose will be transferred through the coupler claws for the duration of the loading operation.
Fig 17: Hose valve connected to Coupler valve
The Cardan stow and transverse actuator to be set in "free wheeling" mode by opening the two separate by-pass valves in the RCPH/E, see Fig 18.
Fig 18: Free wheeling valves in RCPH/E
Hose handling shackle
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Chapter: 3 – BLS Overview Rev. 02
Slack off the hose handling winch and disconnect the bridle from the hose messenger line. The bridle is pushed outside the coupler valve and secured by a soft rope for retrieval.
Fig 19: The hose prepared for emergency disconnection
When the coupler claws are closed, the inboard valve and the coupler valve can be opened. Green line established and loading start.
Hose handling rope Soft rope
Hose Bridle
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Chapter: 3 – BLS Overview Rev. 02
SPM Greenline A fully connected Greenline in SPM mode should look as shown below:
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Chapter: 3 – BLS Overview Rev. 02
Shut down and disconnection, SPM mode When loading is finished and the tanker is ready for dispatching, this procedure is to be followed:
1. Start HPU and turn set the pressure to “work”. This can be done both at the starter cabinet and at the bridge control console.
2. Disable the signal "Pumping permitted" from the bridge control console.
3. Close the coupler valve (ship and hose valve).
4. Flush the ship coupling thoroughly with water.
5. Close the inboard ball valve.
6. Move the ARF forward (OUT).
7. Reconnect the hose rope bridle, and haul in the rope-slack until the winch
takes the weight of the hose.
8. Release the coupler claws.
9. Pay out the entire length of the hose messenger, and reconnect suspension rope. Reconnect hose handling rope to chafing chain.
10. Reconnect the messenger line to the chafing chain and open the chain
stopper. Pay out the hawser using the traction winch.
When the disconnection procedure is completed, the loading system has to be stowed by using the following procedure:
1. Close the free wheeling valves.
2. Stow the cardan by operating the stow actuator to inner stowed position (in).
3. Close the coupler claws.
4. Heave in the forerunner using the traction winch and close the bow door.
5. Stop the HPU. This can be done both from the starter cabinet and the
bridge control console.
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Chapter: 3 – BLS Overview Rev. 02
Offshore Loading System (OLS):
Introduction This system is based on offshore bow loading without any use of a mooring buoy. The only connection is through the crude oil hose or sometimes a riser.
In this case, the loading hose is stowed in a submerged position. All the remaining loading equipment is installed on the seabed, or kept in a submerged position.
A shuttle tanker loading from this system is kept in position by means of a dynamic positioning (DP) system. The loading hose is equipped with a hose valve and a spooling piece in one end to which a two-legged wire sling is connected. This wire sling is further shackle-connected to a messenger line with a forerunner. Connection and disconnection of hose and hose valve to the vessel will be done without any manual handling. (Not using the hose-handling winch.)
OLS Loading connection
Select OLS from the Mode select area found in the bottom right corner of the Greenline interface, this will change the layout of the interface to correspond to a loading operation in OLS mode.
Fig 20: Mode select
The forerunner rope (min 2” diameter) from the stowing tank has been pre-laid through the PSU, Guide Roller, Traction Winch, Guide Roller, QRS and ARF. Before the vessel approaches the offloading unit, the following must be prepared: Start the pumps on the hydraulic power unit with the pressure selector switch in "standby" mode. Note! Always start the pumps in accordance with the HPU instruction manual. In cold climate, let the HPU run for at least 30 minutes before any of the equipment is operated. Remove any ice from the equipment. Set the HPU to "work" pressure on the starter cabinet or from the bridge control console.
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Chapter: 3 – BLS Overview Rev. 02
1. In the OLS mode the chain stopper shall remain fully open during the whole loading operation. The messenger line will pass through the chain stopper.
2. Check that the coupler claws are open. 3. Check that the coupler valve is in completely stowed (in) position. 4. Before starting to pull in the messenger forerunner, the ARF (pos. 02) roller
must be moved to fully forward (out) position.
Fig 21: Prepared for loading connection
Chain stopper fully open
ARF moved to fully outer position
Coupler valve in stowed position
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Chapter: 3 – BLS Overview Rev. 02
5. By means of the traction winch the shuttle tanker is pulling in the hose messenger rope and hose bridle.
6. Stop hauling when the hose end spool piece is approx. 2 - 3 m from the
coupler flange
7. Pull in the hose slowly until positioned 0,5 m below coupler flange.
8. Move the ARF roller aftward (IN) and swing out the stow actuator until the coupler valve is centred inside the bridle.
9. Pull in slowly with the traction winch by the "creep speed" control on the RCP
until there is contact flange/flange.
10. The cardan stow and transverse actuators are put in "free wheeling" mode by opening the two separate by-pass valves in RCPH, see Fig. 18.
11. Close the coupler claws. This completes the connection phase.
12. Move the ARF forward (OUT).
13. Disconnect the traction winch from the gear box by dog clutch. (Check the
indication lamps).
14. Open the crude oil valves. First open the inboard ball valve, then open the internal valve in the ship coupling. When opening this valve, the hose valve will automatically be opened. Both valves are controlled from the main control console.
When the coupler valves indicate "open", the lamp "ready for loading" will light up. The ship is now ready for loading, and the operator can, by means of a push-button, transfer this signal to the telemetry system. As long as this signal is kept steady, the crude oil can be pumped onboard the tanker. Set the HPU pressure to “standby” and stop the HPU, this can be done both at the starter cabinet and at the bridge control console.
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Chapter: 3 – BLS Overview Rev. 02
OLS Greenline A fully connected Greenline in OLS mode should look as shown below:
Fig 22: Full Greenline in OLS mode
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Chapter: 4 – Fairlead Rev. 02
MacGregor Pusnes Bow Loading System Components Adjustable Roller Fairlead (500 ARF)
A welded construction Hydraulic movable roller Design force is 5.000 kN in 90° off the ship’s centreline and ±30
degrees in the vertical plane Internal stainless coating to avoid sparks in contact with the chafing
chain Cylinder stroke is 1.200mm The mooring system is used to receive and connect a mooring line at
the bow of the shuttle tanker. The picture shows the bow fairlead where the mooring line initially
enters. A messenger line and chafing chain from the offloading vessel is
received via a pickup line, pulled through the fairlead until the chain part is locked in the chain stopper.
The messenger line continues over a traction winch, through a rope pulling unit and into a storage unit or a storage bin.
Hard wood on top Roller bearings in roller
Cylinder bearings
Roller bearing
Stainless steel surface
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Chapter: 4 – Fairlead Rev. 02
Adjustable Roller Fairlead (500ARF) Before and after each loading Check stainless steel coating for damage and sharp edges. Check stainless steel coating on roller for damage and sharp edges. Check wooden lining for damage. Check hydraulic cylinder and hoses for leaks. Check piston rod seal for damage. Check roller bearings for abnormal noise/slack.
Once each 3 month or after every 4th loading whichever comes first Grease all 4 lubrication nipples. Check weld between fairlead and hull structure / deck. Check hydraulic hoses for damage – replace if necessary.
ARF lubrication nipples
Cylinder bearings
Roller bearings
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Chapter: 5 – Chain Stopper (QRS 83) Rev. 02
Pusnes Bow Loading System Components Chain Stopper (QRS 83)
”Over center” principle 83 med mer (3 ¼ inches) chain diameter Hydraulically operated Releasable at full tension 5000 kN Buildt in loadcell for tension monitoring Sutitable for ø76mm chain for ETS and SPM purpose Closing time will not exceed 30s Redused pressure in closing direction The QRS secures the mooring line during loading operation Bolts to be taken out during loading (Quick release)
Load Cell Hydraulic Release mechanism
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Chapter: 5 – Chain Stopper (QRS 83) Rev. 02
Quick Release Chain Stopper (QRS 83)
Before each loading operation: Visually inspect the chain stopper
Once each 3 month or after every 4th loading whichever comes first Apply grease through all lubrication nipples Grease the three sliding grooves Inspect the flexible hoses and the cylinders - check for leaks and
damages Once each year: Control the load cell Check for wear of stopper surface
After emergency release: The complete chain stopper must be thoroughly inspected after an emergency release
QRS 83
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Chapter: 5 – Chain Stopper (QRS 83) Rev. 02
Control of the Chain Stopper, QRS 83 load cell
The control device is a tool for easy control of the load cell for the Chain stopper, Guide Roller and Cardan Suspension. By use of MacGregor Pusnes supplied load cell control device. Note: Hydraulic manometer to be calibrated once a year.
To prevent personnel injury and damage to equipment, the control must be performed by trained personnel only.
In addition the following items should be considered and followed: Observers should be wearing proper personnel safety equipment. The equipment is operated with high-pressure oil.
Equipment on drawing 324739 and 395353.10100 must be available. All the parts are stored in the control device box (drawing 324235). The maximum control load is 400kN. Equipment to be mounted as illustrated below. Control is preferably done without chain in the stopper. If chain is present, make sure it has no tension that can disturb the control measure results.
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Chapter: 6 – Traction winch Rev. 02
Pusnes Bow Loading System Components Traction Winch (TW)
The mooring winch is of a twin drum traction type designed for a 120 mm diameter synthetic fibre rope.
Capacities: Pulling force : 700 kN at 7 m/min Medium force : 350 kN at 14 m/min Slack rope : 70 kN at 50 m/min Brake : 900 kN
The brake is equipped with a hand pump in order to release the brake in the event of hydraulic failure. The winch is equipped with a fail safe disc brake system suitable for doing an automatic emergency release of the OLS at a speed of 1-2 m/s. Traction winch can be combined with the hose winch.
Open gear
Disk brake
Roller
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Chapter: 6 – Traction winch Rev. 02
Traction Winch maintenance. Routine inspection Routine inspection of the winch unit is a very important form of preventive maintenance. Establishing a good practice, checking at regular intervals will result in considerable savings by detecting any major trouble that might develop and following up the necessary repairs to be made on a planned or normal shut down time. The following is a guide to some of the key points, which should be observed during routine inspections. The frequency at which the inspection should be made is depending on the time and conditions the winch have been in operation, however, it is recommended that the intervals listed below to be considered as a minimum for optimum performance from the winch.
It is also recommended that the inspection of the winch is made more frequently in the first period after the winch has been started up for the first time.
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Chapter: 6 – Traction winch Rev. 02
Maintenance procedure After each mooring operation Check the oil level in the gear box. Grease all plain bearings. Grease the open gear wheel on the twin drum unit + roller bearings in
the two groove drums. Grease all lubricate nipples on both clutches. Grease all lubricate nipples on the disc brake calipers. Check the brake linings.
During Operation Listen to transmission for abnormal gear wheel noise. Listen to bearings for abnormal noise and check for overheating.
Once each 3 month or after every 4th loading whichever comes first Check the oil level in the gear box and in the grooved drums. Drain off any accumulated water. Check that the coupling is working properly. Check proper tightening of the hydraulic motor fastening bolts. Grease the open gear wheel on the twin drum unit. Check all bolts and nuts for proper tightness. Check brake pads for wear. Check hand pump function.
Once each year Renew or settle gear box oil within the first 12 months of service. Check the bearing clearances. Check the endstoppers and see that the winch is not moving. Check the condition of the complete winch.
Adjust disc brake if hydraulic motors can overcome brake capacity in low speed mode. When each brake lining is worn 15 mm it is time to renew it. At this stage 4 mm lining is left to the edge of the steel brake shoe.
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Chapter: 6 – Traction winch Rev. 02
Traction winch brake.
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Chapter: 7 – Guide rollers & Hose handling bow roller Rev. 02
Pusnes Bow Loading System Components Guide rollers & Hose handling bow roller.
Guide roller for traction winch
Hydraulic cylinder for HHBR
Placed between the chain
stopper and the mooring winch Built-in load cell is for
continuous monitoring of the mooring winch tension
Tension shown on bridge
Hydraulic cylinder placed on
top deck.
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Chapter: 7 – Guide rollers & Hose handling bow roller Rev. 02
Maintenance procedure Hose Handling bow roller. Before and after each loading Check hydraulic cylinder and hoses for leaks. Check roller for abnormal noise in the bearings.
Once each 3rd month after every 4th loading whichever comes first Grease all lubrication nipples. Check weld between bow roller and hull structure / deck. Check hydraulic hoses for damage – replace if necessary.
Hose handling bow roller
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Chapter: 7 – Guide rollers & Hose handling bow roller Rev. 02
Guide rollers Before and after each loading Check roller for damage and abnormal noise in the bearings.
Once each 3rd month after every 4th loading whichever comes first Grease all lubrication nipples. Check foundation bolts for proper tightening.
Guide rollers
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Pusnes Bow Loading System Components Rope Pulling Unit (PSU&SU)
Power sheave unit (PSU) Installed immediately after the traction winch and above the stowing tank Provides the necassery back tension for the traction winch Adjustable back tension 0-4 kN Hydraulically automatically operated and does not require attendance or an
operator. Protection covers of all rotating parts are provided.
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Storage unit (SU) The Storage unit coils up the messenger line / rope as it passes through
the traction Winch. Hydraulic parts are basic equal either used on PSU or SU unit. STORAGE UNIT STARTS AUTOMATICALLY WHEN HYDRAULIC POWER PACK STARTS AND GIVE PRESSURE TO HYDRAULIC SYSTEM.
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Maintenance procedure Power Sheave unit Storage unit Before and after every loading operation: Grease all bearings Once every 3rd month: Check proper tightening of the Hydraulic motor fastening bolts. Once every year: Check bearing clearances Check foundation bolts for proper tightness Check condition of the complete winch Check adjustment of hydraulic valve
Powersheave Valve Unit, front view The PSU to be locked by a solid rope for avoid turning. Start the Power Pack and run in "Working pressure". Adjust safety valve pos. 263 to approx. 270 bar by open anticlockwise
till “blowing”. Close (clockwise) till stop ”blowing” + 1 turn.
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Powersheave Valve Unit, side view
Put the manual valve pos. 272 in "lower" direction. Close pos. 266 (clockwise). Attach a manometer in "Minimess" connection on valve 267. Adjust valve pos. 267 to 100 bar on manometer.
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Powersheave Valve Unit, top view
Adjust valve pos. 266 until the sheave starts to rotate slowly. Adjust valve pos. 267 to 60 bar on manometer connected to pos. 267. The sheave will now stop rotating. Secure the adjusting screws and adjustment is finished.
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
Procedure for hydraulically adjustment of Storage Unit (SU) or
Power Shave Unit (PSU)
This procedure is based on that personnel’s executing the adjustment has a fear understanding and skill regarding hydraulic machinery of such kind.
1 Preparations • Make sure that a shut off valve on the unit’s P – line (P-line valve) is fitted and work
proper. Close the valve. • Start the subject Hydraulic Power Unit (HPU) and select pressure the unit will
normally be exposed for. • Tie a solid rope between unit and traction winch preventing the unit rotate haul in haul
in direction. The unit’s pulling capacity is approx. 1 ton. • Make sure the manual lever is properly spring set to haul in direction. • Make sure by-pass valve pos. 270 is closed. • Make sure no pilot pressure from traction winch via SA connection is present (“crack
open” fitting for check).
2 Adjustment of main relief valve Pos. 263 : 1. Start HPU and select the pressure step unit normally working under (normally highest
mode 240 bar). Gently open P- line valve and observe the unit stall against the rope in haul in direction (don’t touch the manual lever!).
2. If PSU: Adjust the reduction valve Pos. XXX maximum pressure setting. 3. Lower pressure setting, by turn the adjusting screw anti clock-wise till high pressure
oil is heard to “blow” trough the valve. Set the pressure by turn adjusting screw clock-wise till oil stop “blow” and continue ½ turn. The relief valve is now holding a set point of approx. 20 bar above normal working pressure (adjustment finish, “lock off” adjusting screw).
4. If PSU: Adjust the reduction valve Pos. XXX to a setting giving the tension in rope required (normally 200 bar).
3 Adjustment of reduction valve Pos. 267: Caution: The unit might now turn in pay out direction so ropes etc. to be prepared for such or removed and precautions taken for avoid of injures of personnel and equipment.
• Fit a pressure gauge (0 – 150 bar) in “M” port on reduction valve Pos. 267. • Close P- line valve, start HPU and fix the manual lever in pay out direction. • Close fully the relief valve Pos. 266 (clock-wise). • Gently open P-line valve fully and register pressure on gauge fitted. Unit shall in
principal not turn in pay out direction now, but due to various internal leakage, motor might turn very slowly.
• Adjust pressure setting on reduction valve Pos. 267 till gauge indicate 50 bar. • Open the relief valve Pos. 266 till unit is rotating normal in pay out mode. Relief valve
Pos. 266 has now a setting of 50 bar (adjustment finish, “lock off”).
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Chapter: 8 – Rope Pulling Unit (PSU & SU) Rev. 02
• Adjust/decrease pressure setting on reduction valve Pos. 267 till gauge indicate 30 bar. Unit will now stop rotate. Reduction valve Pos. 267 has now a setting of 30 bar (adjustment finish, “lock off”).
• Release the manual lever and make sure it is spring set to haul in direction.
4 Adjustment of emergency release supply valve Pos. 265:
• Setting to be of approx. 30 bar. Such is obtained fully turn the adjusting screw anti clock-wise and then close (clock-wise) 3 turns.
• However, setting of this valve might depend on various forces and speed the unit is exposed for during ESD II emergency release of loading hose. Hence a confirmation of proper setting is registered by observe proper behaviour of rope between traction winch and unit during a full scale emergency release sequence of loading hose. Hint: Too slack rope: increase pressure set point. Too tight rope and struggling of motor to turn: decrease pressure set point.
5 Test of unit after adjustments • Arrange rope normally between storage unit and traction winch. Open P- line fully. • Operate the traction winch under all-different speed, modes and directions. • Especially register that the unit (SU or PSU) do not pay out faster than the traction
winch under the absolute lowest possible speed and develop a slack on rope between unit and traction winch. If such happen, try other settings of valves Pos.266 and Pos. 267, but always maintain a different of 20 bar on their settings. Old and worn valves/motor might cause that it is impossible to obtain a “slow enough” pay out speed on the storage unit. In such case components to be considered changed.
• Pay out rope from real / bin by not use of traction winch: Move manual lever to pay out direction. Open gently bypass valve Pos. 270 and unreal rope. The speed and direction can now be controlled by manual lever BUT be extremely careful.
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Chapter: 9 – Hose Handling Winch (HHW) Rev. 02
Pusnes Bow Loading System Components Hose Handling winch (HHW)
• The hose handling system is used to connect the hose end to the bow coupler of the shuttle tanker.
• Hose Handling Winch pulls the hose up to mate with the flange of the bow coupler (typically 25 – 40 tonne pulling force).
• The hose winch and traction winch can be combined as one unit. • Hydraulic fail safe brake.
- Pulling force : 400 kN at first layer
- Brake capacity : 600 kN at first layer, adjustable
- Maximum speed : 10 m/min
When engaging the drum for hose handling, special attention must be given that the dog clutch is properly engaged. Before high tension is applied to the drum, ensure that the dog clutch is in correct contact with the drum.
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Chapter: 9 – Hose Handling Winch (HHW) Rev. 02
Hose Handling winch maintenance. See chapter 6 Traction winch maintenance for details regarding maintenance procedure. Adjustment – hydraulic parts
Valve Unit Main Block Check once a year that the speed of the winch is in accordance with the specifications and adjust the flow if necessary. The max flow through the valve is adjusted by regulating the pilot, PA. Remove the cap and loosen the counter nut on the adjusting screw. Turn the screw clockwise to increase the speed. Safety relief valve, D. Raise system pressure to 270 bars. Apply brake to prevent the drums rotating. Pull the handle to heave position and verify the relief valve opens. Remove the cap and loosen the counter nut on the adjusting screw and turn the screw clockwise to increase setting.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 2 of 3
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 9 – Hose Handling Winch (HHW) Rev. 02
Counter Balance Valve Ref: Drawing 193981, C. The valve should be adjusted if the winch has a tendency to erratic running when lowering a load or paying out wire under tension.
Note! Never operate the winch with the throttle completely closed. This may cause damage to the hydraulic parts.
Connect a pressure gauge to the minimess in the TPB connection. Move handle to the lower position. Adjust counter balance valve to a pilot pressure of approx. 40 bar. Turn the screw clockwise to increase the pilot pressure, adjust satisfactory functions.
If the counter balance valve is unstable, adjust the dampening screw, Q, on the pilot pressure line. Clockwise rotation decreases the pilot flow. Most application gets a satisfactory result when first turn the adjusting screw complete clockwise, then turn ¾ in opposite direction. When adjusting dampening, the reaction time of counter balance valve will alter.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 3 of 3
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 10 – Cardan Suspension with couper valve Rev. 02
Pusnes Bow Loading System Components 20” Cardan Suspension
The 4th generation coupler was developed in 1991 Bow Coupler with so-called ”moment-free” suspension, that allows the
connected hose to move more freely. Opening of coupler and hose valves is intergrated into the PLC control
system. The connection is closed and locked by three coupler claws in the bow
coupler itself. The cardan suspension system ensures that loads up to 100 tonnes can be
handled with only a practical limitation on the angle of the incomming hose. The coupler can follow hose movements covering 45 degrees in both port
and starboard directions, 60 degrees forward and 45 degrees aft.
Load Cell Coupler
claws
Swivel
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 1 of 5
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 10 – Cardan Suspension with couper valve Rev. 02
Pusnes Bow Loading System Components Coupler valve
Approaching Claws engaged Valves open Pictures illustrate sections of the single pass coupler system.
A winch pulls the hose termination piece into reach of the coupler claws.
The claws hydraulically clamp the connection.
The hydraulic “plunger” in the coupler valve pushes the “spring-loaded” hose
piece open. Due to an interlock system and several proximity switches, the coupler claws
are prevented from releasing the hose before the valves have closed. As the two discs are mated at all times, there is no volume between them.
When the valves are closed, and the coupler claws release the hose, there is
no oil spill.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 2 of 5
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 10 – Cardan Suspension with couper valve Rev. 02
• The unit is of cast non corrosion steel and machined to optimal size and
shape. • The unit contains several internal functions and hydraulic oil passages are
arranged in drilled channels.
• Hydraulic units such as relief valves and check valves are bolted directly on the coupler.
• The three connecting claws are capable of safe holding a load of 100 tonnes.
• Coupler can handle a crude oil flow of 9000 m³ with a minimum of turbulence.
• Coupler is of Dry Break Type.
• No spill when disconnecting.
• Protecting and guiding cover not shown.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 3 of 5
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 10 – Cardan Suspension with couper valve Rev. 02
Maintenance procedure Before/after/during each loading. Grease all bearings when in motion. Check for leakages in the swivels and flange connections, renew leaking
seals.
Once each 3 month or after every 4th loading whichever comes first Check that the swivels are working properly, and listen to the bearing for
abnormal noise. Check all bolts and nuts for proper tightness.
Once each year Check bearing clearances. Check foundation bolts for proper tightening. Check condition of complete unit. Check adjustment of hydraulic valves, pressure setting according to dwg.
193980 Check set pressure on safety valve pos 222 dwg.193980 set pressure =240 bar. Check set pressure on safety valve pos 224 dwg.193980 set pressure
=240 bar. Check closing time for valve on pos. 219 dwg.193980. Control the load cell.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 4 of 5
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 10 – Cardan Suspension with couper valve Rev. 02
Loadcell test
Loadcell test device to be connected and adjusted in accordance with procedures and drawings see chapter 17. Attachement
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 5 of 5
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Pusnes Bow Loading System Components Valve Unit Skid & Accumulators.
The Hydraulic Plant consists of various high pressure (250 bars) components. Valve skid is a steel frame construction that holds all the Electro-Hydraulic valve units. The electrical signals from operator’s console/computer are transferred from electric to hydraulic signals on this skid. Skid is also equipped with filter, transducers, connection blocks and junction box. The hydraulic connections for all units are on a common connection plate Components placed in groups, for easy identification.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 1 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Maintenance procedure Valve unit, Coupler.
Every 3rd month (Closing time): Closing time of "inboard valve" and coupler valve is adjusted by means of flow
control valves pos. 218 and 219. Other settings see Hydraulic system Bow loading.
Note! Pos. 225 and 226 are accumulator drain valves. Every 12th month: Pressure reducing valve (pos.206) and Pressure relief valves (pos.212, 213)
should be checked / adjusted for correct adjustment. Pressure setting should be in accordance with Hydraulic System Bow loading drawing.
Adjustment of Pressure relief valve (pos.206): Unscrew the plug marked "M" on the hydraulic valve (minimess) and connect
a pressure gauge. If the pressure does not correspond with the system drawing, the pressure
should be adjusted by means of adjusting screw.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 2 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Valve unit, Chain Stopper.
Every 12th month: Pressure reducing valve (pos.230) and Pressure relief valve (pos.245) should
be checked / adjusted for correct adjustment. Pressure setting should be in accordance with Hydraulic System drawing.
Note! Pos. 243 are accumulator drain valve.
Adjustment of Pressure relief valve (pos. 245): Start HPU and charge accumulator till 250 bar. Stop HPU. Adjust pos. 245 anticlockwise till “blow”. Adjust pos. 245 clockwise till “stop blow”. Turn ¼ turn clockwise.
Tight counter nut
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 3 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Valve Unit, Winch / PSU
Every 12th month: Pressure reducing valves (pos.220, 221, 224), should be checked / adjusted
for correct adjustment. Pressure setting should be in accordance with Hydraulic System drawing. Valve unit, Disc brake.
Every 12th month: Pressure reducing valve (pos.234), should be checked / adjusted for correct
adjustment. Pressure setting should be in accordance with Hydraulic System drawing.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 4 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Valve unit, Emergency release
Valves pos. 254 and 255 are controlling the emergency release of Disc Brakes on Traction Winch
Every 12th month: Pressure reducing valve (pos.255), should be checked / adjusted for correct
adjustment. Pressure setting should be in accordance with Hydraulic System Bow loading drawing.
Valve unit, Emergency release PSU.
Valves pos. 238 and 239 are controlling the release of PSU during emergency release in OLS mode.
Every 12th month: Pressure reducing valve (pos.239), should be checked / adjusted for correct
adjustment. Pressure setting should be in accordance with Hydraulic System drawing.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 5 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Oil filter
Use wrench here to dismount filter housing.
Clogging sensor.
Element in filter (pos. 306) should be changed every 12 months. If clogged alarm occurs during normal winch operation, the filter element has
to be renewed when operation is finished. If the filter is completely blocked by impurities, the built in pressure relief valve
will open at a pressure of approx. 3.3bar. The excess oil will by-pass the filter element, and the system is without filtration.
General hydraulic maintenance
Oil change After first 500 hours operation. After 2000 hours operation. Once a year or when the oil quality sample is not approved by the oil supplier.
Testing for water It is utmost importance to test the water level in the hydraulic oil. Even smaller amounts may cause the filter element to swell. This will increase the filter pressure drop and then the filter element is by-passed. This will cause the system to operate with no filtration.
Send oil sample to oil supplier for examination. Every 2.nd year, empty oil reservoir and inspect tank bottom.
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 6 of 7
Course title:
MacGregor Pusnes Academy
Pusnes Bow Loading System –
Training Course for Operators & Maintenance Personnel
MacGregor Pusnes AS
Chapter: 11 – Valve Unit Skid & Accumulators Rev. 02
Accumulators
The accumulators’ major purpose is to be able to store high pressurized hydraulic oil in case of loss of energy from regular source. Capacity in the accumulators is sufficient to safety execute an emergency release of hawser and loading hose. Regular check of the nitrogen pressure is of extremely high importance, we recommend before every loading. Pre-charged to 80 bars with Nitrogen.
Test kit
©2015 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
Page 7 of 7
OL STANDARD DOCUMENTS Client
MacGregor Pusnes AS
Box 732 - Stoa, N-4808 Arendal,