Lindstrand HiFlyer

SITE PREPARATION GUIDE

SURFACE MOUNT WINCH OPTION

Lindstrand Technologies Ltd

Maesbury Road
Oswestry
Shropshire
SY10 8GA
UK

TEL: +44 1691 671 888

FAX: +44 1691 679 991
www.lindstrandtech.com
email:sales@lindstrandtech.com

All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means,
electronic, or mechanical, including photocopy, recording, or any information storage and retrieval system, without
permission in writing from Lindstrand Technologies Ltd, Maesbury Road, Oswestry, Shropshire, SY10 8GA, England.

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Contents
1.

INTRODUCTION..................................................................................................................... 6

2.

PERMITS TO OPERATE ........................................................................................................ 6

3.

SITE REQUIREMENTS .......................................................................................................... 6

3.1

Site Profile ..............................................................................................................................................................................6

3.2 Conflicts ..................................................................................................................................................................................7

3.2.1
Surface Obstructions.......................................................................................................................................................7
3.3

Services ...................................................................................................................................................................................8

4.

SHIPPING REQUIREMENTS ................................................................................................. 8

4.1 Transportation .......................................................................................................................................................................8

4.1.1
Container 1 .....................................................................................................................................................................8
4.1.2
Container 2 .....................................................................................................................................................................9
4.1.3
Customs arrangements ....................................................................................................................................................9
4.1.4
Transportation insurance ..............................................................................................................................................10

5.

SITE PREPARATION ........................................................................................................... 10

5.1 Scope of work .......................................................................................................................................................................10

5.1.1
Extra equipment............................................................................................................................................................11
5.2 Concrete and Building .........................................................................................................................................................11
5.2.1
Landing Platform ..........................................................................................................................................................11
5.2.2
Gimbal Sheave Support Fabrication .............................................................................................................................12
5.2.3
Gimbal Sheave Ring Fabrication ..................................................................................................................................12
5.2.4
Cover Panels .................................................................................................................................................................12
5.2.5
Main Winch Housing Base ...........................................................................................................................................13
5.2.6
Centralising Guide Rollers ...........................................................................................................................................14
5.2.7
Cable Channel ..............................................................................................................................................................14
5.2.8
Inner Mooring Winch Hard Points 16 off ..................................................................................................................14
5.2.9
Outer Mooring Hard Points 16 off.............................................................................................................................14
5.2.10 Winch House ................................................................................................................................................................15
5.3 Installation ............................................................................................................................................................................16
5.3.2. Gimbal sheave installation ............................................................................................................................................18
5.3.4. Location and Mounting of the Mooring Winches .........................................................................................................19
5.4 Electrical ...............................................................................................................................................................................20
5.4.1. Power Supply................................................................................................................................................................20
5.4.2. Main Power Supply ......................................................................................................................................................20
5.4.3. Single Phase Power ......................................................................................................................................................20
5.4.4. Auxiliary Power Supply from Generator ......................................................................................................................20
5.4.5. Mooring Winches x 20 (size 1.5 kW) ...........................................................................................................................21
5.4.6. Other controls ...............................................................................................................................................................27

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6.

INFLATION ........................................................................................................................... 27

6.1 General Requirements .........................................................................................................................................................27

6.1.1
Training ........................................................................................................................................................................27
6.1.2
Hotel Accommodation ..................................................................................................................................................27
6.1.3
Telephone / Fax/ Email & Internet ...............................................................................................................................28
6.1.4
VHF Radios ..................................................................................................................................................................28
6.1.5
Vehicle Access to Site ..................................................................................................................................................28
6.1.6
Storage ..........................................................................................................................................................................28
6.1.8. Site Office.....................................................................................................................................................................28
6.2 Envelope Inflation Checklist ...............................................................................................................................................29
6.2.1
Power ............................................................................................................................................................................29
6.2.2
Helium ..........................................................................................................................................................................29
6.2.3
Crane ............................................................................................................................................................................30
6.2.4
Lights ............................................................................................................................................................................30
6.2.5
Crew .............................................................................................................................................................................30
6.2.6
Weather forecasts .........................................................................................................................................................30
6.2.7
Amenities ......................................................................................................................................................................31
6.3

Penalty fee .............................................................................................................................................................................31

DRAWINGS ................................................................................................................................. 32
DRAWING FI-GW-054 SURFACE MOUNT WINCH FORCES ................................................. 33
DRAWING GW-002-A-001 SURFACE MOUNT SITE LAYOUT ............................................... 34
DRAWING FI-GW-038 GENERAL ARRANGEMENT OF INFLATION HOSES ....................... 35
DRAWING FI-GW-039 CRANE REQUIREMENTS FOR INSTALLATION OF HIFLYER
SYSTEM ...................................................................................................................................... 36
DRAWING FI-GW-045 SHT 1 MOORING WINCH BLOCK...................................................... 37
DRAWING FI-GW-045 SHT 2 WINCH OUTER MOORING BLOCK ........................................ 38
DRAWING WI-003-A-307 GIMBAL PIT EQUIPMENT ............................................................. 39
DRAWING GW-003-A-011 SURFACE WINCH INSTLLATION ................................................ 40
DRAWING GW-002-A-004 SURFACE WINCH HOUSE ARRANGEMENT.............................. 41
DRAWING WI-001-A-060 CONTROL CABINET ...................................................................... 42
APPENDIX A INSTALLATION AND INFLATION GUIDE ALL TIMINGS ARE
APPROXIMATE ........................................................................................................................... 43
APPENDIX B - HELIUM PROCUREMENT FOR HIFLYERS ...................................................... 48
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Record of Amendments

No.

Date

Affected Pages

Incorporated By

19.02.2010

All

Liam Hope

Amendments:
This manual is kept up to date by amendments consisting of loose-leaf pages, required to add
new information or amend existing information. The pages affected by an amendment and the
effective date are shown above. The pages themselves are identified by a change of the issue
number at the bottom of each page. The number after the point in the issue number represents
the amendment level of that page, e.g. a page marked Issue 1.4 is at Level 1 modified by
Amendment 4. The checklist of pages indicates the issue level of all pages included in this Site
Preparation Guide.

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Page No.

Issue

1. INTRODUCTION
This document outlines the site preparation, logistics and documentation
which needs to be in place before inflation can take place. The customer
should budget for the extra costs and time associated with site preparation
when planning the project.
It should be pointed out that this document is only intended as a guide
to clients preparing the site for the installation of the Lindstrand HiFlyer.
It may need adapting depending on the local requirements at each site.

2. PERMITS TO OPERATE
There are various permissions to have in place prior to being able to operate
the HiFlyer.
These will vary from country to country, but will usually include:
Airspace permissions
Planning permission
Operations permission
Insurance
Some local authorities may impose restrictions on operating hours, operating
height, lighting, etc. It is important that these are resolved out for a specific
site before time and money is invested in actual site preparations.

3. SITE REQUIREMENTS
When looking at specific sites the following issues should be taken into
account.
It is important that you advise Lindstrand Technologies (LTL) of the elevation
of your site, i.e. altitude above sea level.
3.1 Site Profile
The site needs to be 50 metres in diameter to accommodate the full low
mooring system, which protects the balloon during high winds. This can be
varied quite considerably and can be tailored to the requirements of the site,
but geometry does have to be considered carefully. Contact LTL for further
guidance. See GW-002-A-001.
The landing platform must be located on level ground. If the local slope is
greater than this, then the area within a 6 metre radius of the cable exit point
must be levelled by earthmoving.

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3.2 Conflicts
3.2.1 Surface Obstructions
The site should be clear of buildings, trees, electricity pylons and other
surface obstructions within a 25m (82ft) radius of the landing platform. Short
bushes and plants are acceptable but must not obstruct the landing platform,
mooring points or passenger entry/exit routes. A 70 o cone of airspace from
the winch cable centre position must be clear of all obstructions to
accommodate the flight envelope of the balloon.

Cone of airspace
0

Note: 35 at 120 metres = 84 metres (275.6 feet)

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3.3 Services
The following services will be required on site:
Electrical (refer to section 5.4) - Lindstrand Technologies must be
informed of the electrical voltage and frequency supplied to your site.
Drainage for sewerage and surface water.
Vehicle access for helium supply, crane, emergency vehicles, etc.
Water
Telephone/Fax/ Email/ Internet

4. SHIPPING REQUIREMENTS
Lindstrand Technologies deliver the HiFlyer System Ex-Works. Therefore
the responsibility for insurance of the system and shipping the system to the
installation site is the clients responsibility.
Lindstrand Technologies are able to arrange all freight issues and pass the
costs onto the client. However, if you wish to make separate shipping
arrangements, the following procedural description is intended to assist you in
ensuring all issues are covered and that the quotations received are as
representative as possible:
4.1 Transportation
There are two loads to be packaged and shipped to site:
-

Container 1 is a 40ft sea container

Container 2 is a 40ft open top container

4.1.1 Container 1
From: Lindstrand Technologies Ltd, Oswestry
The package will include the envelope, net, gondola, auxiliary generator,
gimbal ring, and one crate for the mooring winches. The shipment will be
made in an ISO 12.2m (40ft) container.
Approximate weight: 5,000 kg

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4.1.2 Container 2
The package will include the main winch, assembly, control cabinet, resistor
cabinet, and one crate for the mooring winches.
Note: inform shipping agent that container is open topped as special
arrangements are required for sea shipping.
Approximate weight:

15,000 kg

4.1.3 Customs arrangements

Irrespective of who takes care of the shipping arrangements, the customs
liaison must be undertaken by the client. The best way of achieving smooth
importation is to retain the services of a clearing agent in the destination
country.
The clearing agent is then shown as the consignee on all the shipping
documentation.
All importation duties are the responsibility of the client.
Containers will not be loaded until payment has been received as per the
contractual arrangements.
Loading will only take place:
Monday Friday

08:00 17:00

At the time of shipping, Lindstrand Technologies Ltd will provide a shipping

list and invoice for customs declaration.
A copy of the Airway Bill or a Bill of Loading will be provided if Lindstrand
Technologies Ltd is arranging transportation. Your shipping agent will provide
you with this information if you are arranging your own shipping.

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4.1.4 Transportation insurance

Whilst title for the HiFlyer passes to the customer on receipt of payment (i.e.
on handover after installation), risk in the equipment passes to the customer
on delivery (i.e. ex-works - refer to section 4.3 of LTL HiFlyer contract).
It is essential that insurance is obtained by the customer ex-works and LTL
will seek proof of such cover.

5. SITE PREPARATION
All civil and electrical work should comply with local regulations
The exact details of the civil work required are site dependent
(soil/climate/water table/local regulations, etc). The customer must contract a
local consulting civil engineer and architects to arrange details.
5.1 Scope of work
The basic order of site preparation is as follows:
Concrete and Building
- Winch housing concrete base
- Gimbal sheave concrete fabrication
- Landing platform
- Centralising guide rollers concrete base
- Cable channel base and walls
- 16 inner mooring winch hard points
- 16 outer mooring hard points
- Winch house
Installation - phase 2
- Main Winch
- 20 mooring winches + isolator boxes
- Gimbal sheave
- Centralising guide rollers
Electrics
(Refer to Section 5.4)
Further consideration should also be given to the following and their
implications to ground works:

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5.1.1 Extra equipment

The following is not supplied with the HiFlyer system, but will be necessary for
the installation:
Electrical cable (Refer to Section 5.4)
Cable lengths will vary depending on individual site layouts
Main 3-phase power supply
Single phase power supply
3-phase back-up generator supply
Mooring winch power supply and control cables
Lighting
3 socket outlets equally sited around the platform (for battery chargers,
ground fan, etc).
M16 x 75mm anchor bolts for mooring winches and centralising sheave
Chemical fixing resin for winch locating bolts
Mounting brackets for ground station and R/C aerial
2 metre 5-step ladder to access the ballonet, through the ballonet flap
Lockable key cabinet
Hand held radios two way (balloon to ground)
Rechargeable torch for winch housing
Binoculars (7 x 50) for balloon inspection
Diesel fuel for generator
Battery charger 12 volts auto-regulated for generator
Battery 12 volt for generator starter
Winch touch up paint, yellow RAL 1021
Hard standing for back-up generator
Emergency recovery access
Ticketing booth
On-site storage
Telephone / fax line/ email & Internet access

Toilet facilities
Crew welfare
Helium storage area (top up)
Passenger access
Access for wheelchairs

5.2 Concrete and Building

Concrete structures will need to be laid with load bearing reinforcement to
support the ground equipment and to restrain the balloon as follows:
See drawing FI-GW-054
5.2.1 Landing Platform
The landing platform is centred around the winch cable exit from the gimbal
sheave (site centre). The platform provides a landing stage for the gondola
with room for passengers around the outside. It also incorporates the gimbal
sheave in a pit and a channel for the cable to the gimbal sheave. See
drawing FI-GW-054
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5.2.2 Gimbal Sheave Support Fabrication

The gimbal sheave support fabrication must be concreted into the gimbal
sheave pit incorporated in the landing platform.
As the gimbal sheave carries the full lifting force of the balloon it is a critical
load bearing component and must be fully contained by the entire platform
concrete and reinforcing steel network.
The configuration of the gimbal sheave pit is shown in drawing WI-003-A-307
and the location in drawing WI-003-A-011.
After the gimbal sheave is secured to the support fabrication it will be
subjected to a pull test of 8 tonnes (17,600 lbs).
5.2.3 Gimbal Sheave Ring Fabrication
The gimbal sheave ring is finally secured after the gimbal sheave is installed
onto its support. However, it is advisable to pre-locate the ring at the
concreting stage to ensure that it will fit correctly. The ring and its location are
shown in drawing WI-003-A-307.
5.2.4 Cover Panels
The gimbal pit and cable channel will be covered by 25 mm (1 inch) thick floor
panel.
To accommodate these panels a rebate 50 mm (2 inches) wide and 27 mm (1
1/16 inches) deep will be required around the gimbal pit and along the cable
channel. The rebate should be cast in at the concreting stage.

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5.2.5 Main Winch Housing Base

To unload the winch onto the site a crane will be needed, capable of lifting 10
tonnes (22,000 lbs) and lowering it under control onto the concrete base. See
drawing FI-GW-039.
Once the winch is located onto the concrete base, it is secured by 16 x M24
bolts supplied.
The concrete base should be suitable for drilling and resin anchoring a
quantity of 16 x M24 studs. The hole diameter and depth should be in
accordance with resin manufacturers recommendations (the customer should
liaise with the consulting civil engineer and architects).
NOTE:

The manufacturers recommended curing time for the concrete

must not be compromised. These bolts must be anchored with
resin. (Epoxy resin which can be obtained from any good local
building suppliers). The following type of Epoxy resin is
recommended:
HILTI - internet: www.hilti.com (for international distributors).

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5.2.6 Centralising Guide Rollers

The guide roller concrete base is located in the cable channel between the
winch base and landing platform.
The location and dimensions are shown in drawing WI-003-A-011. The base
will be drilled for retaining bolts for the guide rollers.
If fitted the intermediate sheave should be subjected to a pull test of 2 tonnes
(4,400 lbs).
5.2.7 Cable Channel
A channel to enclose the winch cable will run from the winch base to the
landing platform. The channel will consist of a floor with a vertical wall on
each side raised to the level of the top of the landing platform. The top of the
wall should be rebated for cover panels. See drawing WI-003-A-011.
Hard wood blocks 100 x 100 mm (4 inches x 4 inches) section should be laid
across the bottom of the channel as cable supports when it is slack.
5.2.8 Inner Mooring Winch Hard Points 16 off
Sixteen inner mooring winches and isolator boxes are installed around the
balloon on a 23m (75ft) diameter circle. Each winch is mounted on a
concrete block. These winches are used for mooring the balloon.
Mooring winch blocks should be 500mm (20) above ground level or at
ground level. It is ideal for all of them to be at the same level for operational
purposes, with 700mm (30 inches) buried into the ground or fully submerged.
See drawing FI-GW-045 Sheet 1.
Anchor hoops should be cast into the concrete of the 16 inner mooring blocks
and should be capable of withstanding the test load of 2,000 kg (4,400lbs).
5.2.9 Outer Mooring Hard Points 16 off
To further stabilise the balloon, ropes are led to 16 outer mooring blocks.
Four of these are for the outer mooring winches located on a 50m (164ft)
circle equispaced between the inner moorings. All 16 concrete blocks should
have anchor hoops cast into the top.
The anchor hoops should be capable of withstanding the test load of 2,000 kg
(4,400lbs). See drawing FI-GW-045 Sheet 2.

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5.2.10 Winch House

The winch house will cover the winch to protect it from the weather, and
secure it against unauthorised access. The house will be erected on the main
winch concrete base with the same outside plan dimensions and a minimum
internal height of 2.4 meters (94 inches). See drawing GW-002-A-004.
The structural design of the house is the responsibility of the customer. Local
planning approval of the appearance may be required.
The house cannot be finally erected until after the winch is installed. It is
therefore necessary to assemble the building with the minimum of on-site
construction, dust and debris around the winch.
Balloon operation cannot proceed until the building is completed.
To reduce construction and save time the building may be prefabricated, and
preferably trial erected before the winch arrives on site.
The following features should be included in the construction:
Footings onto the winch base concrete
Insulation to prevent overheating (glasshouse effect)
Windows (double glazed) for light and crew observation (the winch is also
a visitor attraction)
Heavy duty extraction fan in end wall, inlet vent in opposite wall to remove
heat from resistor bank
Slot for winch cable passage with brush seal
Rubbing surface (hardwood) on lower lip of slot
Inlet ports for electric cables to control cabinet
Secure, lockable double door for crew and equipment access
For suggested layout see drawing GW-002-A-004.

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5.3 Installation
Installation will take place after the Lindstrand Technologies crew and all
components are on site.
5.3.1. Installation of the main winch
NOTE:

The installation of the main winch will be supervised by LTL and

will require 4-5 days depending on weather.

The installation requires a crane capable of lifting 10 tonnes (22,000 lbs) and
lowering it under control at a radius of approx. 14m (46ft). Note the ground
may have been disturbed during the site civil works, and care should be taken
when positioning the crane outriggers.
At least 2 people will be required to assist in the positioning of the winch as it
is lowered down.
Locate the winch as follows:
a)

the transverse (shaft) centre line of the fleeting sheave is 4000 mm

(158 inches) from the transverse (shaft) centre line of the
centralising sheave in the cable channel. See drawing WI-003-A011.

b)

The longitudinal (groove) centre line of the fleeting sheave in mid

travel lines up with the longitudinal (groove) centre line of the
tension sheave and gimbal sheave. See drawing WI-003-A-011.

Once the winch has been located, the 16 foundation bolt positions should be
identified and marked using a pen or spray. See figure 1.
Remove the winch from the concrete base and check that all holes can be
located. If this is difficult, they should be re-marked.
The M24 studding and nuts are supplied with the system, but the chemical
anchoring resin should be bought locally under the instruction of the
consulting engineer.
Drill the holes to the clearance size specified by the resin manufacturer.
Note: If the chemical resin is not applied in the correct manner, it will
not sustain the pull of the foundation bolts and the whole of the
above process will have to be repeated. It is the contractors
responsibility to use the resin in accordance with the
manufacturers instructions.

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Locate mounting bolts in holes and fix

using resin.

Lift winch back out of pit and drill holes in

concrete.

Lower the winch back into pit guiding it

onto the bolts. Tighten nuts to specified
torque and trim down bolt excess.

When resin is cured and has been tested (see

text), protect the bolts with 25 mm id plastic
tube.

Figure 1 Installation of the main winch

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Once the resin (not supplied) has been allowed to set for the recommended
period, a physical pull test up to 1 tonne (2,200 lbs) should be made using the
crane on-site, to ensure the resin has set. If the pull test is successful, the
winch can be located onto the 16 studs using plastic sheathing tubes as
guides.
Note: Care should be taken not to damage the threads on the stud
bolts as the winch is being located.

Once the winch has been located, the crane can be disconnected, and using
the nuts and washers supplied, the frame can be tightened down.

Figure 2 - Bolting down sequence for main winch

Due to the large area of the winch system and the significant compressive
force of the M24 bolts, the pattern shown above should be used when
tightening down the nuts. Once the nuts have started to pull, move to each
bolt in turn and tighten down one at a time. See Figure 2.
5.3.2. Gimbal sheave installation
The gimbal sheave is mounted on the bolts fixed into the gimbal sheave
support fabrication. The base of the sheave bracket is secured with lock nuts
or plain nuts centre peened to lock them.
The sheave swing must be limited by cushioned stop brackets mounted either
side.

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The gimbal ring is mounted on top of the gimbal pit. See drawing WI-003-A307.
After installation the gimbal sheave will be tested by a pull of 8 tonnes (17,600
lbs) on the winch cable.
5.3.3. Centralising Guide Rollers Installation
The centralising guide roller is mounted to bolts set into the base with resin,
the bolt size and spacing to match the base of the sheave mounting
fabrication.
5.3.4. Location and Mounting of the Mooring Winches
The 20 mooring winches are bolted to the concrete bases in alignment with
the centre of the winch cable exit. They are secured with a quantity of 4 x M16
anchor bolts (not supplied) set into each block.
The holes for the anchor bolts can be marked-off and drilled to match the
base of the mooring winch, or a template made from drawing WI-002-A-904
(a drawing will be supplied with the mooring winches).
The anchor bolts can be HILTI expansion type or studs installed with chemical
resin. In either case the holes must be sized to the recommended clearance.
The 4 anchor bolts, when correctly fitted, must be capable of sustaining the
full 2,000kg (4,400 lbs) tension, which will be pull tested by the crane.
Due to differing site layouts and electrical regulations, the mooring winch
isolator boxes are supplied loose, and will require a suitable mounting
position. It is recommended that local electrical regulations are consulted
regarding the location of the isolator boxes.
Note: The mountings should be arranged to ensure that the mooring
ropes cannot be trapped or snagged on the box or the mountings.

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5.4 Electrical
All electrical work should be carried out by a qualified electrician and is the
sole responsibility of the client.
No attempt should be made to power up the system until an LTL
representative is on site.
5.4.1. Power Supply
A mains electricity supply is required to power the system.
5.4.2. Main Power Supply
Typical cable size: 50 mm depending on length cross sectional area to
conform to local regulations.
1 x 4 core, 3-phase + earth mains (380 440 volts, 100A).
Supply should be fed from 100A rated breaker in sub-station, the cable size
will depend on the length of the cable run. The supply should be connected
to the main isolator on the right hand door of the control panel.
It will be necessary to drill a suitable hole at the base of the cabinet and fit a
gland. The cable should then be routed up to the isolator and connected
using suitable crimped terminations. The cable should be buried at least
600mm (2ft). (Warning tape should be laid 200mm above the cables to
conform to local regulations).
5.4.3. Single Phase Power
Single phase + earth (35A) at 240 V 50 HZ or 110 V 60 HZ.
This extra power supply is necessary for lights, sump pump (not supplied by
LTL), battery charger, and internal illumination (if ordered). The supply must
be able to be isolated from the main system. It is the responsibility of the
customer to provide the socket outlets.
5.4.4. Auxiliary Power Supply from Generator
Typical size cable: 6mm cross sectional area to conform to local regulations.
1 x 4 core, 3-phase + earth for generator (20 kVA)
Size of generator: 170 cm L x 120 cm H x 70 cm W
Weight of generator: 650 kg
The 3-phase supply should be fed from the generator to terminals L4, L5 and
L6 at the base of the control panel. It will be necessary to drill a suitable hole

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at the base of the cabinet and fit a gland. The cable should then be routed up
to the terminals and connected using suitable crimped terminations.
The cable size will depend on the length of the cable run.
The generator must be mounted on a concrete base and covered for weather
protection. It should be located to provide a short cable run to the winch
control cabinet entry port. See drawing GW-002-A-004 and WI-001-A-060
Issue 3.
5.4.5. Mooring Winches x 20 (size 1.5 kW)
Each mooring winch needs a 3 phase power supply and 3 control wires which
are all fed from the control cabinet in the winch housing. The cables should
be laid and connected as per Figure 3 by a qualified electrician and is the
sole responsibility of the client to arrange.
It will be necessary to drill 40 holes in the winch control box and 8 at the
winches for the glands.
1 x 4 Core power cable minimum 2.5 mm, cross sectional area to conform
with local regulations.
1 x 3 core signal cable minimum 1.5 mm, maximum 2.5 mm cross sectional
area to conform to local regulations.
Preferably use multicore steel wire armoured PVC coated copper conductors.
Metal glands should be used to terminate the cables in the winch control box
so all armoured cables are grounded. Plastic glands can be used on the
winch isolator boxes. All terminators should be crimped and a suitable colour
coding or numbering system should be used throughout the installation

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ISSUE 2.0

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Figure 3 recommended layout for electrical cabling

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22

Mooring Winch Panel Connections

The wiring connections to the mooring winches are as follows:
Three phase power supply

Control supply

Inner
Mooring
winch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

phase 1

phase 2

phase 3

Earth

common 1 common 2 return

U1
U2
U3
U4
U5
U6
U7
U8
U9
U10
U11
U12
U13
U14
U15
U16

V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16

W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16

Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth
Earth

50
50
50
50
50
50
50
50
50
50
50
50
50
50
50
50

Outer
Mooring
winch
17
18
19
20

phase 1

phase 2

phase 3

Earth

common 1 common 2 return

U17
U18
U19
U20

V17
V18
V19
V20

W17
W18
W19
W20

Earth
Earth
Earth
Earth

48
48
48
48

51
51
51
51
51
51
51
51
51
51
51
51
51
51
51
51

52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82

49
49
49
49

84
86
88
90

The pre-run wires can now be connected into the mooring winch isolator
boxes. The 3-phase supply should be connected into the isolator terminals
and the control wires connected into the push button. A link should then be
wired from the isolator box to the motor terminal box. It is prudent to follow a
set pattern when connecting the 3-phase supply as this will ensure that phase
rotation is the same on each winch. The mooring panel can be wired-in as
the mooring winches are being connected, with the main 3-phase supply
wires connected into the terminal rail at the top of the main panel - i.e. winch
1 wires are connected to U1, V1, W1 and winch 2 to U2, V2, W2 etc.

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The common control wires (51 & 52) are connected to the terminal rail which
runs vertically up the right hand side of the panel, and the control return wires
are connected to the relevant terminal on the same rail (52, 54, 56, 58
through to 82), see figure 4.
The outer mooring winches are connected in a similar system but with
common control wires (48 & 49) and control return terminals (84 through 90),
see figure 5.

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WIRING FOR 16 INNER MOORING WINCHES

1.5kW
INDIVIDUAL MOORING
WINCH MOTORS

EARTH
3
U1 V1

W1

INDIVIDUAL MOORING WINCH

ISOLATOR BOXES

50 (MOOR ALL)
51 (MOOR ONE)
1

NC
2

NO
3

SWITCH ON
FRONT COVER

LINK WIRE

EARTH WIRE FROM MOTOR IS

CONNECTED TO EARTH WIRE ON
4 CORE POWER CABLE FROM
WINCH CABINET

U1
U2
U3
U4

V1
V2
V3
V4

W1
W2
W3
W4

52
54
56
58
+

U1 V1
U2 V2
U3 V3
U4 V4

W1
W2
W3
W4

ISOLATOR

MOORING WINCH No1

MOORING WINCH No2
MOORING WINCH No3
MOORING WINCH No4
etc

MOORING WINCH PANEL

MOORING WINCH No1

MOORING WINCH No2
MOORING WINCH No3
MOORING WINCH No4
etc

50

51

MOORING WINCH No1

MOORING WINCH No2
MOORING WINCH No3
MOORING WINCH No4
etc

52
54
56
58

Figure 4 - power supply and controls wiring for 16 inner mooring winches

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WIRING FOR 4 OUTER MOORING WINCHES

1.5 kW
INDIVIDUAL MOORING
WINCH MOTORS

EARTH
3
U1 V1

W1

INDIVIDUAL MOORING WINCH

ISOLATOR BOXES

48 (MOOR ALL)
49 (MOOR ONE)
1

NC
2

NO
3

SWITCH ON
FRONT COVER

LINK WIRE

EARTH WIRE FROM MOTOR IS

CONNECTED TO EARTH WIRE ON
4 CORE POWER CABLE FROM
WINCH CABINET

U17
U18
U19
U20

V17
V18
V19
V20

W17
W18
W19
W20

84
86
88
90

U17
U18
U19
U20

V17
V18
V19
V20

W17
W18
W19
W20

ISOLATOR

MOORING WINCH No17

MOORING WINCH No18
MOORING WINCH No19
MOORING WINCH No20

MOORING WINCH PANEL

48
MOORING WINCH No17
MOORING WINCH No18
MOORING WINCH No19
MOORING WINCH No20

49

MOORING WINCH No17

MOORING WINCH No18
MOORING WINCH No19
MOORING WINCH No20

84
86
88
90

Figure 5 - power supply and controls wiring for 4 outer mooring winches

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5.4.6. Other controls

Ground station
Mooring winch wand
R/C aerial
These are pre-wired in the factory, but the mounting of them is the
responsibility of the customer.

6. INFLATION
NOTE:

The inflation procedure will be supervised by LTL.

Once the installation has been completed and the mooring system has been
tested for correct functionality, Lindstrand Technologies Ltd will commence
with the inflation, which will be subject to the weather. The inflation normally
takes place during calm or near calm conditions.
6.1 General Requirements
6.1.1 Training
Lindstrand Technologies will undertake all staff training to a competent level
for your crew for safe operation of the system.
There is the need to
undertake a written test for all operators. There are two levels level 1 and
level 2. A certificate is issued at the end of successful training.
A training manual will be issued for both Level 1 and Level 2 operators.
6.1.2 Hotel Accommodation
Single rooms for 4 people should be arranged in a hotel (4* standard or
equivalent) near to the site, preferably within walking distance. If the hotel is
located more than 10 minutes walking from the site then transport must be
arranged for the installation team, i.e. hire cars or minibus.

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Anticipated duration on site (subject to weather and progress on site)

Lindstrand Technologies
1 Launch master
1 Site Engineer
1 Site Electrical Engineer
1 Staff Trainer

10 days
10 days
10 days
30 days

These times are approximate.

6.1.3 Telephone / Fax/ Email & Internet
A telephone line should be installed on site for use by the installation crew,
with fax and telephone available.
6.1.4 VHF Radios
We recommend the use of VHF radios during installation / inflation of winch
and envelope, as well as for the operation of the balloon rides.
6.1.5 Vehicle Access to Site
Access will be required for the helium tanker and crane. See drawings FIGW-038 and FI-GW-039.
6.1.6 Storage
A lockable storage facility for tools and equipment must be available on site.
6.1.8. Site Office
There should be onsite conveniences, i.e. toilets, for crew welfare, as well as
a suitable office. This is required for communication services, storage of
equipment and personal belongings while working on site, and for meal/
refreshment breaks.

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6.2 Envelope Inflation Checklist

The following must be available on site prior to inflation:
6.2.1 Power
It is imperative that the local electricity supply company has the mains
electrical power connected on site before the arrival of the winch and
envelope installation team, in order to avoid any unnecessary costs or delays.
See paragraph 5.4.2 Main Power Supply.
6.2.2 Helium
6,500 cubic metres (229,580 cu.ft.) of high purity Helium (99.9%) in the form
of compressed gas is required on site for the duration of the inflation. If liquid
Helium is to be used, extra equipment will be required this is usually
supplied by the Helium provider, and is the responsibility of the client.
Lindstrand Technologies is not responsible for this.
Please inform Lindstrand Technologies at least three weeks before the
inflation date, of whether the Helium will be delivered in compressed gas or
liquid form.
We will also need to know the type of hose fitting on the Helium tanker. We
generally use one of the following:
7/8 inch POL female right-hand
Linde Gas 5/8 inch BSP bull nose right-hand
inch male NPT right-hand
Air Products BS3 right-hand
Iwatani Japan PT special adapter
inch JIC male connections
Flow rate required from Helium tankers is 1500 cubic meters per hour
minimum.
There will be a regular requirement for 'top up' of Helium. It is advisable to
arrange a supply of compressed gas cylinders at this stage. We recommend
keeping 160 cubic metres (7,000 cu ft) on site for this purpose. This is
equivalent to a titan of Helium.
Refer to Appendix B - Helium procurement.

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6.2.3 Crane
An "all terrain" type crane with a main boom length of at least 35 metres (115
ft) and maximum radius of at least 25 metres (82ft) is essential. The crane
should be supplied with a man cage and driver for the duration of the inflation
(minimum 24hrs).
The crane needs to be capable of lifting a 10 tonne (22,000 lbs) winch at 14
metre (46ft) radius. See diagram FI-GW-039.
The crane needs to load test the gimbal sheave mounting to 8 tonnes (17,600
lbs) and all mooring winches to 2 tonnes (4,400 lbs) each.
6.2.4 Lights
Portable lighting (usually in the form of a self-contained light with generator
unit) will be required for overnight inflation. A minimum of 6 x 500W halogen
lights are required.
6.2.5 Crew
In addition to LTL personnel, 8 extra people will be required for the duration
(12 - 14 hours). It should be noted that these people must be motivated and
physically fit to actively participate in the inflation.
We would recommend your balloon operators attend the inflation as it is a
useful training / familiarity exercise.
6.2.6 Weather forecasts
A detailed daily local meteorological report will be required to identity the
inflation weather window when appropriate. Lindstrand Technologies also
require detailed weather history along with the microclimate data on the area
around the HiFlyer site.
We recommend met reports be faxed or e-mailed over to us one week before
our on site visit. This will help to familiarise us with local weather patterns.
The installation of a local weather station is recommended for recording of
wind speed, direction, peak gusts, temperature, barometric pressure, rainfall,
sunshine duration and humidity. The weather station can be obtained
through Lindstrand Technologies.

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30

6.2.7 Amenities
Due to the lengthy nature of the balloon inflation, and the importance of
keeping personnel on site for the duration, it is beneficial for food and drink to
be readily available.
It will be advantageous to have easy access to toilets, i.e. arrange portable
ones to be on site or obtain permission to use a local hotel facility.
When all these factors are in place, Lindstrand Technologies can
proceed with inflation (subject to the weather), commissioning and
training.
6.3 Penalty fee
Please note the LTL purchase contract (clause 8.6) provides provision for a
daily penalty fee of 2,000 to be paid by the customer for each and every day
the Lindstrand crew cannot work on site for reasons beyond their control
(excluding reasons of force majeure or weather).

NOTE:

LTL / TASPGSM

IF IN DOUBT, PLEASE ASK BEFORE LTL ARRIVE ON SITE

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31

DRAWINGS
FI-GW-054

Surface Mount Winch Forces

GW-002-A-001

Surface Mount Site Layout

FI-GW-038

General Arrangement of Inflation Hoses

FI-GW-039

Crane Requirements for Installation of

HiFlyer System

FI-GW-045 SHT 1

Mooring Winch Block

FI-GW-045 SHT 2

Winch Outer Mooring Block

WI-003-A-307

Gimbal Pit Equipment

WI-003-A-011

Surface Winch Installation

GW-002-A-004

Surface Winch House Arrangement

W1-001-A-060

Control Cabinet

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Drawing FI-GW-054 Surface Mount Winch Forces

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Drawing GW-002-A-001 Surface Mount Site Layout

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Drawing FI-GW-038 General Arrangement of Inflation Hoses

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Drawing FI-GW-039 Crane Requirements for Installation of HiFlyer System

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Drawing FI-GW-045 SHT 1 Mooring Winch Block

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Drawing FI-GW-045 SHT 2 Winch Outer Mooring Block

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Drawing WI-003-A-307 Gimbal Pit Equipment

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Drawing WI-003-A-011 Surface Winch Installation

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Drawing GW-002-A-004 Surface Winch House Arrangement

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Drawing WI-001-A-060 Control Cabinet

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APPENDIX A INSTALLATION AND INFLATION GUIDE All timings are approximate

Day

Day 1

Activity

Who

Note: Crane required all day

Container 1 arrives:
Unload container
Container 2 arrives:
Unload container
Crane must be on site ready to unload containers and lower
winch onto concrete pad
Unpack winch
Lower winch onto concrete pad and locate position
accurately
Mark off holes for winch bolts
Remove winch from base
Drill winch bolt holes
Start to assemble gondola.
Epoxy resin bolts into place.
Position mooring winches
Position generator on base
Weather update and forecast
Lower winch onto pad with crane and bolt down.
Start on electrical supply to main winch and mooring
winches.
Wire up auxiliary generator.
Generator will be wired prior to arrival
Wire generator to control panel

LTL / TASPGSM

ISSUE 2.0

Crane operator/ Lindstrand

Crane operator/ Lindstrand
Crane operator/ Lindstrand
Lindstrand
Crane operator under Lindstrand supervision
Lindstrand to mark. Crane operator to remove
winch
Site contractor
Lindstrand
Site contractor
Lindstrand/ contractor
Site contractor/ LTL
Lindstrand/ client
Crane operator & Lindstrand.
Site electrician under Lindstrand supervision

Site electrician
Site electrician /Lindstrand supervision

43

Day 2

Note: Crane required for morning

Drill off mooring winches and isolator boxes (supplied by
LTL).
Winch house assembly
Locate control cabinet and resistor bank adjacent to winch,
and secure

Contractor
Lindstrand/ contractor/ site electrician

Bolt down gimbal sheave assembly, securely lock all nuts.

Check side travel stops

Lindstrand

Fit centre ring and closing panels above gimbal sheave

Lindstrand/ contractor

Bolt down centralising sheave, securely lock all nuts

Lindstrand

Weather update and forecast

Lindstrand/ client

Fix 20 mooring winches to concrete blocks and 20 mooring

winch control boxes.
Mark location
Drill holes
Fasten bolts
Start on electrical supply to mooring winches.
Electric feed to mooring posts completed to junction
box prior to or at arrival.
Connection to mooring winch

Lindstrand
Site contractor
Site contractor
Site electrician

Site electrician/Lindstrand
Lindstrand
Lindstrand/ client

Gondola assembly
Weather update and forecast

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Lindstrand / Site contractor

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Day 3

Day 4

Finish electrical supply to mooring winches and test

Check main winch wiring is completed and test
Check back up generator and test
Fit winch cable from gimbal to drum, wind on and secure
end

Site electrician/ Lindstrand to test

Lindstrand
Lindstrand
Lindstrand

Test gondola control box and valves

Weather update and forecast

Lindstrand
Lindstrand

Crane with man bucket required from 16.00 hours

Helium tankers on site, test purity

Lindstrand

Test main winch cable to 8 tonne using crane/load cell

Lindstrand & crane operator
Test all 20 mooring winches, 12 outer mooring points and Lindstrand & crane operator
centralising sheave to 2 tonne each
Safety briefing for inflation team and crew
Weather update (8 crew plus LTL staff)
Layout plastic ground sheets
Position envelope with crane on platform
Spread out envelope on platform
Fit helium valve to envelope
Attach artwork banners if applicable
Attach fill hoses to Monsun valves from helium tanker
supply
Elevate net with crane
Lower net into position over envelope
Attach Helium valve to net and attach sling
Elevate Helium valve slightly with crane
LTL / TASPGSM

ISSUE 2.0

Lindstrand and crew.

Lindstrand + crew of 8
Lindstrand & crane operator
Lindstrand + crew of 8
Lindstrand
Lindstrand
Lindstrand
Lindstrand/crane
Lindstrand/crane + crew of 8
Lindstrand
Lindstrand/crane
45

Day 4 contd.

LTL / TASPGSM

Attach net to all mooring winches/ outer mooring positions

Attach electrical wiring loom to net
Connect control box and test helium valve
Purge helium through fill hoses and connect to Monsun
valves
Purge helium through envelope, close Helium valve
Ready to inflate refreshment break
Gas on weather permitting
Elevate valve with crane as necessary during inflation
Release crane as appropriate and continue fill
Continue to attach loom to net throughout the inflation
Allow balloon to rise on mooring winches to fit PRV/ fan/ top
up hose
Connect electrical loom to ballonet fan

Lindstrand + crew of 8
Lindstrand
Lindstrand
Lindstrand

Stop the fill and leave Helium hoses connected

Elevate envelope
Remove plastic ground sheets
Move gondola into position underneath envelope
Attach gondola ring to envelope and main winch
Low moor balloon
Connect loom to gondola and control box
Complete top up and remove helium fill hoses
Install lighting system if applicable
Check helium purity and test for leaks around helium valve
area
Install lightning rod and anemometer
Check balloon is secure
Test systems
Inflation complete

Lindstrand
Lindstrand/crane
Lindstrand + crew of 8
Lindstrand + crew of 8
Lindstrand
Lindstrand
Lindstrand
Lindstrand
Lindstrand + crane fitted with man basket
Lindstrand

ISSUE 2.0

Lindstrand
Lindstrand
Lindstrand
Lindstrand/ crane
Lindstrand/crane
Lindstrand
Lindstrand
Lindstrand

Lindstrand
Lindstrand
Lindstrand
Lindstrand
46

DAY 5
DAY 6
DAY 7
DAY 8
DAY 9

High moor balloon, tidy up electrical loom and make general

checks of system
Commissioning checks (weather permitting)
Commissioning & training
Commissioning & training
Commissioning & training, final checks and handover

Lindstrand
Lindstrand
Lindstrand
Lindstrand
Lindstrand

NOTE: The above schedule for inflation is approximate and heavily dependent on favourable weather conditions and the
correct flow rate of helium supplied.

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APPENDIX B - HELIUM PROCUREMENT FOR HIFLYERS

INTRODUCTION
It is of assistance to provide HiFlyer clients with as much information as
possible about Helium for the HiFlyers. This is to help them negotiate with
Helium supply companies for the purchase of the initial Helium fill and for
subsequent top-up.
1.

Quantity

We specify that a minimum of 6,500 m3 (229,580 cu.ft.) is available for the

initial fill of the HiFlyer. This can be supplied in a variety of different cylinder
types, but normally for this quantity, it will be contained within long high
pressure cylinders mounted on articulated lorry trailers. Two trailers are
normally necessary, but sometimes three trailers are required. It is important
that the type of cylinders used are established and that this information is
available during the inflation (see Flow Rate Measurement).
Another consideration is over-supply. It is rare to find a supplier who can
provide exactly 6,500 m3 to the site for inflation. Consequently, more Helium
is shipped to the site than is necessary. It is best to negotiate a sale or
return policy with the gas supplier, so that unused Helium is returned and not
charged for.
2.

Measurement of Helium Quantity

To comply with the sale or return conditions it is necessary to calculate the

volume of Helium extracted from the cylinders.
This is derived from Boyles Law which states that for constant temperature,
gas volume is inversely proportional to pressure. This is expressed by the
formula:
P1V1 = P2V2
Where:

LTL / TASPGSM

P1
V1
P2
V2

=
=
=
=

Gas pressure in high pressure cylinders

Volume of the high pressure cylinders
Atmospheric pressure
Free gas volume

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(Standard Atmospheric Pressure at Sea Level is 1 bar (14.7 psi) but

local pressure taken on site should be measured and used for pressure P 2).
For example, if one gas cylinder has a volume of 10 m and the gas is at a
pressure of 200 bar, then when this gas is released its free volume will be:
P1

200 bar

P2

1 bar (atmospheric pressure)

Free Volume

V2 =

V1

P1 V1
P2

V2 =

10 m

200 x 10
= 2000 m 3
1

When the Helium arrives on site it is important to record the volume and
pressure of gas in each cylinder. This procedure should be undertaken with
the helium suppliers representative and the delivered amounts agreed.
Similarly, once the inflation has been completed, the same procedure should
be followed to establish how much helium is to be returned. The used volume
is the difference between the delivered and returned volumes and this is what
the client will be charged for.
It should be noted that this procedure should be followed for initial fill or for
subsequent top-ups.
For the initial inflation, Lindstrand staff will be making the above calculations
and will pass this information to the client.
3.

Helium Quality

Helium is available commercially to many different levels of purity. The higher

the purity the greater the cost. The recommended purity level is 99.9% pure
helium. This is sometimes called four 9-5 helium, which refers to four nines
in the number. Using less pure gas reduces the free lift of the balloon. This
will have an adverse effect on the maximum number of passengers that may
be carried.
Be careful when discussing helium quality with suppliers, because one of the
commercial helium grades is called balloon gas. This is normally only 98%
pure and is used for filling toy latex/ Mylar balloons.
One percent of purity = 50 kg loss of lift
4.

Flow Rate

We require a minimum flow rate of helium of 1,500 m per hour. This results
in an inflation time (gas on period) of approximately four hours. If the helium
is being supplied as a high pressure gas, then this is not a problem (see Type
of Helium).
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If lower flow rates are to be considered, then Lindstrand Technologies must

be consulted in advance. Slow flow rates increase the inflation time when the
balloon is most vulnerable to deteriorating weather.
5.

Type of Helium

Helium is stored and delivered in two options:

a) Gaseous Helium in high pressure cylinders.
system.

This is the preferred

b) Liquid Helium in super-cooled Dewars. Conversion of liquid helium

into gas extracts considerable heat from the atmosphere, requiring
large heat exchangers which limit the flow rate. The low gas
temperature can also cause problems by embrittling the delivery hoses
and balloon fabric.
6.

Helium Connection

Lindstrand Technologies requires written confirmation, preferably with a

drawing, of the type of connection that the gas supplier will require on the end
of the high pressure hoses. Lindstrand Technologies will be supplying all
required expansion chambers and low pressure filling hoses which attach to
the balloon. The preferred connections are either a JIC M, or a right hand
thread bullnose connector with a 7/8 F BSP thread.
7.

Personnel on Site

It is necessary to have a technical representative from the gas supplier on-site

for the beginning and end of the inflation. This is to confirm the measurement
of helium used. Lindstrand staff control the flow of high pressure helium
during the inflation.
If liquid helium is to be supplied, then the supplier will have to provide staff to
set up and operate the heat exchanger equipment. In this case, the supplier
should be informed that the inflation will take approximately 14 hours.
If there are any specific local operating permits or licences necessary to
operate high pressure gas equipment, the supplier must provide suitably
qualified staff for the initial inflation. However, if this is the case, the client
should establish whether it is in their own best interests to obtain such
permission for themselves, since there will be a continuing requirement for
topping-up with helium during the operational life of the balloon, which they
will want to control.

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8.

Period of Notice

The minimum period of notice should be discussed with the supplier. This is
important to establish because it will dictate how long in advance of inflation
the weather forecast must be obtained and planned upon.
In most countries, weather forecasts which are longer than 72 hours only
have a 50% reliability level. This means that alternative arrangements would
have to be made, such as positioning the helium on site prior to an inflation
date being decided upon.
9.

Site Access and Planning

On some sites with restricted access through security fencing, the order of
events needs to be considered. If two articulated lorries cannot gain access
at the same time through the gate, it is important that the other required
equipment is introduced into the site before the helium tankers arrive, e.g.
cranes, cherry pickers, balloon system delivery, etc. Normally, we find that
the Helium trailers block the entrance to the site, effectively trapping
everything in the site.

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