MECHANICAL INSTALLATION INSTRUCTIONS

2016-04-11 BTI/FNA

MECHANICAL INSTALLATION INSTRUCTIONS

FOR

SIWERTELL SHIP UNLOADER M-TYPE

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MECHANICAL INSTALLATION INSTRUCTIONS
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1.0 DELIVERY.
The different units are pre-assembled at the factory as far as the transportation and
other practical circumstances permit. The ship unloader is normally delivered in units
as shown on page 4. However, reference shall be made to packing lists for further
details of equipment to be handled and assembled

Parts that have not been pre-mounted at the factory and other miscellaneous items
are delivered in separate boxes or in a container, such as:

- Platforms (partly). - Slewing gear ring

- Ladders.
- Railings (partly).
- Hydraulic cylinders.
- Cables and cable trays (ways)
- Electrical equipment & Cable reel
equipment
- Shafts & Hinge details
- Hydraulic- and lubrication equipment
(partly).
- Logotypes & warning signs
- Chutes & Discharge Arrangement
- Conveyor machineries
- Dust filter & Aux. Hoist equipment
- Compressor equipment
- Hydraulic- and Electrical containers
- Gantry conveyor
- Travelling- and slewing machineries
- Storm lock arrangements

Generally upon delivery, the vertical conveyor has been pre-assembled onto the
vertical arm steel structure. The horizontal conveyor has been pre-assembled onto
the horizontal arm steel structure. Some other equipment has also pre-assembled
onto the vertical- and horizontal arms, e.g. some platforms and hydraulic equipment.
Bogie/wheel packages has been pre-assembled except machineries and some hinge
details. All other parts and equipment of the ship unloader shall be assembled during
this final installation.

2.0 ERECTION PROCEDURE.

The design of the ship unloader has in some cases to be somewhat altered to fit the
application where it is going to be operating. The manuals show in principal how
different parts are to be mounted. Exactly how and in which order, is to be carried out
according to the set of drawings supplied with each machine and according to the
instructions given by the Siwertell Erection Supervisor at site.

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NOTE.
REGARDING “PRE-ERECTION” MENTIONED BELOW; MOUNT AND
INSTALL AS MUCH AS IS PRACTICALLY POSSIBLE WHILE THE
UNITS IN QUESTION STILL ARE ON THE GROUND.

NOTE.
THE FOLLOWING INSTRUCTIONS ARE GENERAL. THE SEQUENCE
IN WHICH DIFFERENT PARTS ARE MOUNTED CAN BE CHANGED
AT SITE DUE TO PRACTICAL CIRCUMSTANCES. ALSO DESIGN
MAY DIFFER FROM PICTURES AND INSTRUCTIONS HEREIN
AFFECTING THE PROCEDURE OF THE ERECTION.

NOTE
NOT MENTIONED IN THIS TYPICAL INSTALLATION MANUAL IS
THE ASSEMBLY OF ELECTRICAL COMPONENTS & PARTS. THIS
WORK IS ALSO INCLUDED IN THE INSTALLATION.

IMPORTANT
The horizontal arm, vertical arm, machinery and counter weight elements must be
assembled in a specific sequence. Failure to do so can cause serious accidents. The
unloader is balanced by the counterweight and at certain stages without following the
sequence, the load holding valves or cylinders are overloaded or the steel structure
itself can be overstressed. The sequence is individual and calculated with every
machine Siwertell supplies.

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3.0 MAIN UNITS OF A SIWERTELL SHIP UNLOADER.

1. Inlet feeder 9. Hydraulic unit 17. Pendulum leg

2. Vertical arm and conveyor 10. Counterweight beam and blocks 18. Land side end carriage
3. Pendulum cylinder 11. Upper turret (Slewing ring) 19. Rail clamp
4. Vertical machinery and inlet machinery 12. Lower turret (vertical chute, not shown) 20. Power & Signal cable reel
5. Horizontal arm 13. Electric container 21. Automatic grease system
6. Horizontal conveyor 14. Gantry conveyor 22. Sea side end carriage
7. Luffing cylinder 15. Main beam 23. Stormlock
8. Auxiliary hoist 16. Belt lifter and Dust filter 24. Operator’s cabin & arm

4 5 6 7 8 9 10

11 13 14 15 16
4
24 12
2

1
20
17
21
18
22
19
23

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4.0 ASSEMBLY OF THE BOGIES AND THE ENDCARRIAGE SEASIDE.

1. Place the seaside bogies and balances on rail.

2. Adjust the bogies so that the flanges on the wheels are pressed against one
side of the rail. This to ensure that the wheels are really in line with the rail.
3. Level the bogies and weld support.
4. Place the endcarriage on the bogies and mount the shafts.
5. Level the carriage and weld supports.
6. Prepare the fixed leg and the endcarriage for welding.
7. Place the fixed leg on top of the endcarriage, check that it is level and tack-
weld.
8. Mark the centre of the carriage.
9. Transfer, with laser or other method, the centreline over to the landside rail,
mark and place the landside bogie on rail.
10. Adjust the bogie so that the flanges on the wheels are pressed on the same
side of the rail as it is on seaside.
11. The weld between the endcarriage and the fixed leg has to be carried out by a
licensed welder and tested by an authorised inspector. Use welding rods
according to Siwertell instructions.

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5.0 PRE-ERECTION OF MAIN BEAM.

 Place the main beam on supports 40 – 100 cm above ground.

 Install the ladders, railings and platforms that are necessary to give easy access
to the main beam and to ensure a safe working place.
 Mount cable trays.
 Mount supports/consoles for dust filter, gantry conveyor, electric container, cable
reels, etc.

6.0 LIFT AND ASSEMBLY OF MAIN BEAM AND PENDULUM LEG.

Mount the pendulum leg horizontally on the main beam. With two cranes, lift the main
beam with the pendulum leg while the lower part of the pendulum leg is kept from
touching the ground by either a forklift or a chain block attached to the main beam
(see picture).

Hinges for
Pendulum Main Chain block
leg Beam

Pendulum Sea side

leg endcarriage

TheLand
mainside
beam has to be landed on the fixed leg horizontally without leaning. In
order to adjust,
endcarriage attach chain blocks between the cranes and the main beam. Check
by cross measuring that there are no angle deviation between the fixed and the
pendulum leg. Check with a water level that the flange for the lower turret is
horizontal. Tack-weld the main beam to the fixed leg and mount the shaft between
the pendulum leg and the landside bogie. The weld between the fixed leg and the
main beam has to be carried out by a licensed welder and tested by an authorised
inspector. Use welding rods according to Siwertell instructions.

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7.0 LIFT AND ASSEMBLY OF LOWER TURRET AND ELECTRIC CONTAINER.

 Prepare for grouting with Epocast 36 between flanges se Siwertell instruction 731,
 Install the lower turret and grout. (The lower turret has been pre-assembled with
platforms, handrails and chutes, among other items).
 Put in the bolts and tight with the torque stated on the drawings.
 Install the ladders and platforms that have not been installed on the ground.
 Install the electric container, transformer and other equipment.

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8.0 ASSEMBLY OF THE GANTRY CONVEYOR AND VERTICAL CHUTE.

 Install the gantry conveyor temporarily.

 Check the measurements versus the belt lifter or the installation made at shore.
 If necessary, adjust the thickness of the insert plates by machining.
 Install the gantry conveyor permanently and drill the holes for gantry conveyor.
 Install the vertical chute.
 Install the lower vertical chute inside lower turret
 Install the platform inside lower turret.

Upper turret

Lower turret

Vertical chute
In turret

Gantry
conveyor

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9.0 PRE-ASSEMBLY OF UPPER TURRET AND CABIN ARM.

 Put the slewing ring on the ground. Put the upper turret on support over the
slewing ring.
Lift up the slewing ring to the upper turret, put in the bolts and tighten with the
torque stated on the drawing.
 The slewing gear ring is positioned on the upper turret with the “S-mark” for the
inner ring oriented 90 degrees to the hydraulic piston rod bracket. The “S-mark”
on the outer ring must be oriented, when mounted to the lower turret, in such a
way that when the ship unloader is in working position the two “S-marks” are 180
degrees to each other and parallel to the quay.
 Mount the slewing machineries, lubrication equipment, cable trays, cover for
slewing ring etc onto the upper turret.
 Mount parts of inner hinge, if applicable at this stage.
 Mount the transfer hopper
 Mount cabin, handrails and cable tray to the cabin arm while on ground.
 Mount the cabin arm to upper turret and tighten with torque according to actual
drawings while these parts are on the ground.
 Mount the leather cuff before lifting
 Place the upper turret on the lower turret.
 Put in the bolts and tighten with the torque stated on the drawing.

Upper turret and

Slewing
machineries

Slewing gear ring

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10.0 PRE-ASSEMBLY OF THE HORIZONTAL ARM.

Mount the following:

 Counterweight support (hinged) to horizontal arm.
 The counter weight beam with rubber and weld supports for the beam (the
concrete counterweight elements are not assembled before the lift. These are
lifted / assembled in later stage).
 Platforms, railings, ladders, stairs incl their supports not earlier assembled and
which are not obstructing lifting equipment when making the later assembly lift.
 Support, platform, railings for the hoist, hoist, supports for wire, hook, overload
guard.
 Hydraulic cabinet and hydraulic hoses.
 Luffing- and pendulum cylinders with attachments.
 Lubrication hoses.
 Drive units for horizontal conveyor (and feeding conveyor, if applicable)
 Other equipment for horizontal (belt) conveyor and feeding conveyor), if
applicable
 Cable trays (ways) and cables (many cables incl. big ones). Other electrical
equipment.
 Filling of oil in hydraulic tank.
Oil type: Hydraulic oil with specified viscosity. Must contain wear additives. See other instructions
supplied which oil to be used.

Horizontal
arm

Upper Assembly
Turret shaft

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11.0 LIFT AND ASSEMBLY OF THE HORIZONTAL ARM.

 Prepare the transfer hopper flange and bearings

 Prepare the outlet flange and bearings.
 Hook up one crane at the lifting lug at the front end
 Hook up one crane with a soft sling around the shaft. To ensure that the arm is
lifted without tilting sideways, attach a chain block to the balance lug at point
 Lift the horizontal arm into place.
 Mount the caps for the inner hinge.
 Tightening the bolts with torque stated to the drawings
 Evacuate the air from the luffing cylinder according to the following:
o Open the hydraulic valves on the luffing cylinder lines.
o Start the back-up motor.
o Run the piston in and out until the air is evacuated.
o Fill in more hydraulic oil in the tank, if necessary.
 Run the luffing cylinder piston so that the head lines up with the lugs on the
upper turret. Mount the cylinder shaft.
 Tightening to torque stated on the drawings
 Start the back-up motor and lift the horizontal arm and let the luffing cylinder
take up the load of the horizontal arm.

Horizontal
arm

Inner
Hinge

Upper
turret

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Press tools for inner hinge assembly:

12.0 PRE-ASSEMBLY OF THE VERTICAL ARM.

 Install floodlight.
 Prepare the outlet flange.
 Assemble the support for laser.
 Assemble the platforms.

Detachable
liftlug

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13.0 ERECTION OF THE VERTICAL ARM AND COUNTER WEIGHT ELEMENTS.

The vertical arm and counter weight elements are mounted in sequence. The
sequence is made to individually suit each Siwertell unloader.
 Mount the number of counter weight elements stated in the instructions.
 With two cranes lift the vertical arm into vertical position.
 With one crane lift the arm in place and mount the top of the bearing holders.
 Tightening the bolt to torque stated on drawings.
 Mount the rest of the counter weight elements according to instructions.
 Mount the bolts for the counter weights.

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14.0 INSTALLATION OF AUXILLERY EQUIPMENT.

 Stairway, ladders and platforms are to be completed.

 Air system to be completed.
 Limit switch with brackets to be installed.
 Filling of oil in all gearboxes with the recommended oils.
 Greasing of all manual grease points and to make sure that all grease line
hoses are full of grease.
 Touch up painting and protection of all unpainted parts.
 Dust filter system to be completed.
 Lubrication system to be completed.
 All chutes and flexible joints to be aligned and completed.
 Belt lifter to be completed.
 Cable reels to be completed
 Electrical equipment assembly to be completed.
 Water equipment for 4S system to be installed and completed.
 To assist the electricians with any extra brackets or work they require.
 Mechanical commissioning including verifying all installations being correct,
tightening bolts, making adjustments etc.

Start of the commissioning

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