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Operation Instruction No. :


Date :

Operating instructions manual for Jack-up & Lube oil unit

Hydraulic - System

for

Jack-up high pressure and Lube oil unit


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Operation Instruction No. :
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Contents

1. General instructions

1.1 General operating instructions

2. Technical data

2.1 Technical data of the hydraulic system

3. Safety

3.1 Proper utilisation

3.2 Safety instructions for the operator

3.3 Consequences of unauthorised modification

4. Installation

4.1 General instructions

4.2 Installation conditions

4.3 Installation of the pipelines

4.4 Installation of the electrical connections

5. Commissioning

5.1 Description of the commissioning procedure

5.1.1 Filling the hydraulic system

5.1.2 Instructions for switching on the electric motor

5.1.3 Venting of the pump

5.1.4 Venting of the hydraulic system

5.1.5 Purging the hydraulic system


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6. Maintenance and repairs

6.1 Maintenance and inspection

6.1.1 General instructions

6.1.2 Maintenance after commissioning

6.1.3 Maintenance in mormal operation

6.2 Repairs and dismantling of the hydraulic system

7. Annex

7.1 Genearal assembly (Jack-up unit)

7.2 Genearal assembly (Lube oil unit)

7.3 Piping and Instrument Diagram (Jack-up unit)

7.4 Piping and Instrument Diagram (Lube oil unit)


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1. General instructions

1.1 General operating instructions

This hydraulic system can entail unavoidable residual hazards for persons and
material objects.
Therefore every person involved in work with this machine and concerned with
transport, installation, operation, maintenance and repair of the hydraulic unit
must be duly instructed and aware of the possible dangers.
For this purpose the operating instructions manual and, in particular, the safety
instructions must be read attentively and understood.

2. Technical data

2.1 Technical data of the hydraulic system

drive side 14.0 [l/min]


Lube unit
Flow rating : non-drive 6.0 [l/min]
Jack-up unit 1.0 [l/min]
Lube unit 1.0~1.8 [bar]
Operating pressure :
Jack-up unit 46.0~60.0 [bar]
drive side 1.5[kW]1720[rpm]440[V]60[Hz]
Lube unit
Electric motor : non-drive 0.75[kW]1695[rpm]440[V]60[Hz]
Jack-up unit 0.75[kW]1695[rpm]440[V]60[Hz]
drive side 4.1[kW] average dT=17.71℃
Cooling power : Lube unit
non-drive 2.16[kW] average dT=18.48℃
Ambient temperature : 10 - 50℃
Control voltage : 24[V] ■ DC □ AC
Operating medium : ISO VG 68
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□ The hydraulic system was designed and projected for the technical data
specified above.

3. Safety

3.1 Proper utilisation

□ The hydraulic system has been designed and constructed according to the
state of technology and the approved safety and technical regulations.
Nevertheless, utilisation of this hydraulic system can entail dangers for life
and limb of the operator and / or other persons, or damage of the hydraulic
system and other objects, especially if the instructions and regulations in
this operating instructions manual are not obeyed.

□ This hydraulic system is designed exclusively for the application specified by


the contract giver and may be operated only when in technically perfect
condition, for the intended purpose and with due awareness of the safety
requirements and hazards, thereby observing the contents of this operating
instructions manual.

3.2 Safety instructions for the operator

□ All pipeline, hoseline and valve connections as well as screw fittings must be
checked for leakage and externally recognisable damage.

□ Damage must be repaired immediately.

□ Squirting out oil can cause injuries and fire.

□ The warning instructions contained in this manual for maintenance and repair
tasks on the hydraulic system must be observed.

Caution !

The hydraulic fluid can cause skin rash and other health damage. Avoid prolonged skin
contact. After contact, wash thoroughly. Always observe the safety and handling
instructions provided by the hydraulic fluid supplier.
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Warning

Hydraulic systems are operated under high pressure. If dismantled improperly they
can explode and thereby cause severe accidents. To reduce this risk of explosion,
it is essential to depressurise the systems before dismantling them.

3.3 Consequences of unauthorised modification

□ Unauthorised modifications of or additions to hydraulic systems are


forbidden for safety reasons. The manufacturer is not liable for damage
caused by such unauthorised actions, for which the user alone is responsible.

□ No modifications of the hydraulic system are permitted without the approval


of the manufacturer

4. Installation

4.1 General instructions

□ Commissioning, maintenance and repairs may be carried out only by trained


or duly instructed personnel with special knowledge of and experience with
hydraulic systems.

□ Work on the electrical system and electric connections of the solenoid valves
may be carried out only by trained or duly instructed personnel with special
knowledge of and experience with electrical systems.

4.2 Installation conditions

□ Before installation on site, make sure that the foundation or mounting surface
is flat and firm in order to avoid mechanical distortion and / or vibrations.

□ Use the provided screw threads and mounting bores for attaching the hydraulic
unit to the foundation.
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4.3 Installation of the pipelines

□ The hydraulic pipelines to the consumer devices must be absolutely free from
rust and dirt particles internally, and without burr at the pipe ends.
No further welding or brazing is permittes after installation.

□ The pipelines and fittings must conform to the pressure classification for
which the hydraulic system is designed.

□ The dimensions must correspond to the specification on the circuit diagram.


Utilisation of pipes with too small internal diameter, unnecessary length of
pipelines and too many angle screw fittings lead to pressure losses impairing
the overall performance of the hydraulic system.

□ Pipelines must be installed with care and without stress. They must be held
in exactly fitting pipe clamps which exert no unnecessary loading pressure.

□ The connentions of the hydraulic pipelines to the units must be made


according to the circuit diagram.

□ Remove the closing plugs which we have fitted on the hydraulic connections
of the unit in factory, and the coverplates, only immediately before connecting
the corresponding pipelines.
This helps to avoid unnecessary contamination.

□ We recommend the installation of measuring screw fittings at the highest


points of pipelines for venting.

4.4 Installation of the electrical connections

□ Before connecting the electric motor and the control lines, check that the
electrical ratings on the type spcification plate of the electric motor and on the
terminal connections plan are identical to the ratings of the local mains power
supply and of the eletrical control system.

□ The electrical cable connections must be established according to the circuit


diagram and the terminal connections plan.
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5. Commissioning

5.1 Description of the commissioning procedure

5.1.1 Filling the hydraulic system

□ Always use a filter system for filling the hydraulic system, to ensure that the
hydraulic fluid comes into the tank conforming to the specified cleanliness class.
This also applies to filling from new barrels.

5.1.2 Instructions for switching on the electric motor

□ When switching on the electric motor for the first time, let it run for only a
short time to check the rotation direction.
Clockwise rotation of the pump corresponds to anticlockwise rotation of the
electric motor.

5.1.3 Venting of the pump

□ When the electric motor is running in the specified rotation direction, the pump
must be vented according to the instructions of the pump manufacturer.
If any problems are encountered, please get in touch with Dae Dong Entec

5.1.4 Venting of the hydraulic system

□ The hydraulic system must be vented thoroughly before adjusting the operating
pressure. This should be done at a pressure with which the load devices can
just be moved.

□ The venting must be made at the highest point of each hydraulic pipeline and
continued unit foam-free medium is coming out.

5.1.5 Purging the hydraulic system

□ In every new hydraulic system from the factory, however carefully constructed,
there are dirt particles in the pipeline system. Hydraulic systems with
particularly dirt-sensitive devices (proportional and servo control valves) must
therefore be purged thoroughly before running them with full working pressure
and speed.
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□ For the purging process, bypass the connections directly at the load devices
with hoseline connections and replace particularly sensitive valves with purging
plates. It may be possible to accelerate the purging process by fitting by filters
in the hoseline connections.

□ When purging make sure that cleaning filters are not in the subsidiary stream.
Insert new filter elements after purging.

6. Maintenance and repairs

6.1 Maintenance and inspection

6.1.1 General instructions

□ The personnel deployed for commissioning, maintenance and repair tasks


must have read this operating instructions manual before commencing work.

□ This operating instructions manual must always be available at the operating


location of the machine.

□ Commissioning, maintenance and repair tasks may be carried out only by


trained or duly instructed personnel with special knowledge of and experience
with hydraulic system.

□ Work on the electrical system and elentrical connections of the solenoid valves
may be carried out by trained or duly instructed personnel with special
knowledge of and experience with electrical/ electronic system.

6.1.2 Maintenance after commissioning

□ During the first two months after commissioning the maintenance tasks must
be carried out at shorter intervals. The following points must be checked daily
during the first week, and daily to weekly as from the second week.

● Hydraulic lines and connections, tank lid and any oil troughs or leaks.

● Tank fill level and temperature of the medium.

● Quiet running of pumps and motors.

● Settings of pressure valves and switches.

□ Leaks and fill level deficiencies must be remedied immediately. In the case
of problems which cannot be solved by the maintenance personnel of the
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operator, Dae Dong Entec must be informed immediately.

□ Contaminated filter cartridges must be replaced immediately.

□ After the first week and then monthly, check all operationally and safety relevant
screw fittings for firm seating, and retighten them if necessary.

6.1.3 Maintenance in normal operation

□ Hydraulic screw fittings and couplings must be checked weekly for any leaks.
Leaks must be sealed and escaped hydraulic fluid must be cleaned up.

□ Make sure that fill level deficiencies in the hydraulic tank are corrected
immedeately, and that contaminated filter elements are replaced immediately.
Depending on the environmental conditions, the venting filter, too, must be
replaced once or twice each year.

□ Check at montly intervals for any damage to the unit, control blocks of the
pipelines, pipeline fixing elements, valves, pressure operated switches,
solenoids and electrical connections.
Detected damage must be remedied immediately.

□ Get a specialist to check whether the hydraulic hoselines are in proper working
condition. The following criteria must be inspected;

● Externally visible damage, such as cracks, kinks, detachments, worn


locations, brittleness. etc.

● Torsion/deformation of the hoselines in the depressurised and pressurised


state.

● Leaks between the hose and the fitting. Is the hoseline wandering off the fitting?

Damaged hoselines must be replaced immediately.

Caution !

The hydraulic fluid can cause skin rash and other damage to health . Therefore avoid
prolonged skin contact. Wash thoroughly after contact, It is essential to obey the safety
and handling instructions provided by the hydraulic fluid supplier.
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6.2 Repairs and dismantling of the hydraulic system

□ Depressurise the hydraulic system before commencing repair work or


dismantling it. For this purpose switch off the electric control system at the main
switch and, if possible, remove the key to prevent unintended start up of the
hydraulic system.

□ Before commencing repair work or dismantling, check on the pressure


gauge for the "pump pressure" to make sure that the hydraulic system
is depressurised.

Warning

Hydraulic systems are operated under pressure. They can explode, causing severe
accidents, If dismantled improperly. To reduce this explosion risk, it is essential
to depressurise the systems before dismantling them.

□ Load devices which could drop down or move in uncontrolled manner when
dismantling the hydraulic system must be supported and secured before
commencing the tasks.

□ Clean up small quantities of hydraulic fluid of hydraulic fluid with rags. Scatter
binding agent on larger quantities and fence off to prevent access. Rags
and binding agents soaked with hydraulic fluid must be disposed of separately.
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7.
7.1 Genearal assembly (Jack-up unit)

No Part List Q'ty Description


1 Motor 1 0.75kw 1695rpm 440V/60Hz
2 Rotex coupling 1 Spidex A19.19H7-N1 Alu
3 Gear pump 1 1LQ3-3DE10R
4 Pressure relief valve 1 RDBA-LAN
5 Flow control valve 1 NDVE-08-1A
6 Pressure transducer 1 UPA51(250bar, 4~20mA)
7 Pressure gauge 1 ¢63, 250bar
8 Double switch filter 1 HDD.30.10VG.30EP-G3-AE40
9 Flow switch 1 BFS30-L-G1/2-MS-WE-ST
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7.2 Genearal assembly (Lube oil unit)

No Part List Q'ty Description


1 Motor 1 1.5KW / 0.75KW 440V 60Hz
2 Rotex coupling 1 Spidex A19.24.24H7-N1 Alu
3 Gear pump 1 1L16DC23R / 1L9DC23R
4 Check valve 1 CXBA-XCN
5 Flow control valve 1 NDVE-DN08-1A
6 Pressure relief valve 1 RPGE-LEV
7 Pressure switch(low) 1 MBC5100-2431-1CB04.1~10bar
8 Pressure switch(high) 1 MBC5100-2431-1CB04.1~10bar
9 Double switch filter 1 DU63.25VG30.E.P.G.4.S1.AE.40
10 Oil cooler 1 4.1KW / 2.16KW
11 Check valve 1 RV-DIN16-G3/4-1-4.5bar
12 Water control valve 1 AVTA-20-003N3162
13 Thermometer 1 0~100℃
14 Flow switch 1 BFS30-N-G1-MS-WE-ST
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7.3 Piping and Instrument Diagram (Jack-up unit)

No Part List Q'ty Description


1 Motor 1 0.75kw 1695rpm 440V/60Hz
1.1 Rotex coupling 1 Spidex a19.19H7-N1
1.3 Gear pump 1 1LQ3-3DE10R
4.1 Pressure relief valve 1 RDBA-LAN
4.2 Flow control valve 1 NDVE-08-1A
5.1 Pressure transducer 1 UPA51(250bar, 4~20mA)
5.3 Pressure gauge 1 ¢63, 250bar
6 Double switch filter 1 HDD.30.10VG.30EP-G3-AE40
7 Flow switch 1 BFS30-L-G1/2-MS-WE-ST
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7.4 Piping and Instrument Diagram (Lube oil unit)

No Part List Q'ty Description


1 Motor 1 1.5KW / 0.75KW 440V 60Hz
2 Rotex coupling 1 Spidex A19.24.24H7-N1 Alu
3 Gear pump 1 1L16DC23R / 1L9DC23R
7.1 Check valve 1 CXBA-XCN
9.1 Flow control valve 1 NDVE-DN08-1A
9.2 Pressure relief valve 1 RPGE-LEV
10.1 Pressure switch(low) 1 MBC5100-2431-1CB04.1~10bar
10.2 Pressure switch(high) 1 MBC5100-2431-1CB04.1~10bar
11.0 Double switch filter 1 DU63.25VG30.E.P.G.4.S1.AE.40
12 Oil cooler 1 4.1KW / 2.16KW
12.1 Check valve 1 RV-DIN16-G3/4-1-4.5bar
13 Water control valve 1 AVTA-20-003N3162
14.1 Thermometer 1 0~100℃
15 Flow switch 1 BFS30-N-G1-MS-WE-ST