Manual - NoreqFender Customer: Kristiansund Taubåtservice AS Project name: Our project no.: 10-1092 Your P.O. no: Description: 2 pcs PF2555CTN Delivery: March 3 rd ---------------------------------------------------------------- CONTACT: NoreqFender A/S PHONE NO.: + 47 53 46 47 40 P.O. Box 144 FAX NO.: + 47 53 46 47 51 5480 Husnes E-Mail: noreq@noreqfender.no NORWAY Web page: www.noreqfender.no
CONTENTS 1. INTRODUCTION----------------------------------------------------------------------------3 2. SPECIAL PRECAUTION--------------------------------------------------------------------3 3. PERFORMANCE 2-1. Pneumatic 50 fender size and performance requirements--------------------------- 4 2-2. Pneumatic 80 fender size and performance requirements--------------------------- 4 4. CONSTRUCTION 3-1. NET TYPE--------------------------------------------------------------------------------5 3-2. SLING TYPE-----------------------------------------------------------------------------7 3-3. BODY ONLY TYPE-----------------------------------------------------------------------8 3-4. FENDER WITH STANDARD CHAIN NET------------------------------------------------9 5. INFLATION--------------------------------------------------------------------------------10 6. UNPACKING 5-1. PACKED AND DEFLATED--------------------------------------------------------------10 5-2. CONTAINERIZED AND DEFLATED-----------------------------------------------------10 7. INSTALLATION 6-1. FOR A PEAR / JETTY-------------------------------------------------------------------11 6-2. FOR A SHIP----------------------------------------------------------------------------11 6-3. INSTALLATION OF NET TYPE PNEUMATIC RUBBER FENDER------------------------12 6-4. INSTALLATION OF SLING TYPE PNEUMATIC RUBBER FENDER----------------------13 8. PRECAUTIONS----------------------------------------------------------------------------13 9. INSPECTION AND MAINTENACE-------------------------------------------------------14 10. REPLACEMENT----------------------------------------------------------------------------14 11. SAFETY VALVE----------------------------------------------------------------------------14 12. REPAIR-------------------------------------------------------------------------------------14 13. GUARANTEE-------------------------------------------------------------------------------16 2
1 INTRODUCTION This manual has been prepared to familiarize you with the specifications and procedures for operation, installation, maintenance, inspection, testing and repair of NOREQ Pneumatic Rubber Fenders, We hope that the manual will be useful and convenient so that you can use our fenders safely and satisfactorily. The main features of NOREQ Pneumatic Rubber Fenders are; 1) High energy absorption and low reaction force and surface pressure. 2) No decline in the rate of energy absorption when obliquely compressed, under normal circumstances, and uniform surface pressure for any contact area. 3) Low reaction force to prevent damage from repeated impacts against the hull of a ship, jetty, or a mooring rope. 4) Ability to float and thus rise and fall with the ebb and flow of tides and the movements of a ship. 5) Easy installation. 6) High standard of uniform quality in compression performance with no deterioration of the rubber. 2 SPECIAL PRECAUTION This product is containing compressed air inside. If the product bursts, energy of the compressed air could cause damage to people or environment. Therefore, 1) Make sure that air pressure is not more than specified pressure, as there is a possibility of burst if the air pressure is higher than the specified pressure. 2) Make sure that there are no damage on the product as the damage will weaken pressure resistance strength of the product and make the product burst. 3) Use within the maximum energy absorption specification in Table 3-1/3-2 to avoid rupturing the fender. 4) Avoid allowing the fender to come in contact with surface protrusions or sharp-edged implements at anytime. 5) Cut or exposed reinforcement cords might result in damage to the fender. 6) The fender must be lifted at its designated lifting points. Failure to do so could result in damage to the fender. 3
3 PERFORMANCE 3-1. Pneumatic 50 fender size and performance requirements Nominal size Diameter x length Initial internal pressure Guaranteed energy absorption Reaction force at GEA deflection Hull pressure (internal pressure) at GEA deflection P Reference value GEA R Minimum value at Tolerance deflection mm kpa 60±5% ±10% KJ KN kpa 300 x 600 50 0,5 24 134 500 x 1,000 50 6,3 67 134 800 x 1,500 50 23,7 158 132 1,000 x 1,500 50 35,5 189 126 1,000 x 2,000 50 50,1 267 134 1,200 x 2,000 50 69,4 308 129 1,350 x 2,500 50 111 439 130 1,500 x 2,500 50 135 479 128 1,500 x 3,000 50 168 596 133 1,500 x 4,000 50 229 815 136 1,700 x 3,000 50 210 658 129 2,000 x 3,000 50 282 752 126 2,000 x 3,500 50 336 896 128 2,500 x 4,000 50 660 1,409 141 2,500 x 5,500 50 961 2,051 149 3,000 x 5,000 50 1,136 2,021 135 3,300 x 4,500 50 1,118 1,921 130 3,300 x 6,500 50 1,915 3,097 145 3,300 x 10,600 50 3,338 5,398 155 4,500 x 9,000 50 4,960 5,883 146 4,500 x 12,000 50 6,987 8,284 154 Notes: 1. Each reaction force and energy absorption are measured under static condition. 2. Special sizes are available upon request. 3-2 Pneumatic 80 fender size and performance requirements Nominal size Diameter x length Initial internal pressure Guaranteed energy absorption Reaction force at GEA deflection Hull pressure (internal pressure) at GEA deflection P Reference value GEA R Minimum value at Tolerance deflection mm kpa 60±5% ±10% KJ KN kpa 300 x 600 80 0,6 31 173 500 x 1,000 80 8,2 87 168 800 x 1,500 80 30,6 204 170 1,000 x 1,500 80 45,7 244 163 1,000 x 2,000 80 64,7 345 173 1,200 x 2,000 80 89,5 398 166 1,500 x 2,500 80 174 620 166 1,500 x 3,000 80 218 776 173 1,500 x 4,000 80 296 1,053 176 1,700 x 3,000 80 272 853 168 2,000 x 3,000 80 386 1,030 172 2,000 x 3,500 80 440 1,174 168 2,500 x 4,000 80 931 1,831 184 2,500 x 5,500 80 1,353 2,659 194 3,000 x 5,000 80 1,593 2,608 174 3,300 x 4,500 80 1,673 2,491 168 3,300 x 6,500 80 2,707 4,029 188 3,300 x 10,600 80 4,677 6,959 199 4,500 x 9,000 80 6,948 7,581 188 4,500 x 12,000 80 9,667 10,548 196 4
Notes: 1. Each reaction force and energy absorption are measured under static condition. 2. Special sizes are available upon request. 4 CONSTRUCTION 4-1. Net Type Fig. 4-1 5
Fig. 4-2 Fig. 4-3 6
4-2. Sling Type Fig. 4-4 Fig. 4-5 7
4-3 Body Only Type Fig. 4-6 8
4-4. Fender with Standard Chain Net(ø4500x9000L) Fig. 4-7 9
5 INFLATION CAUTION: Overinflating is very dangerous, Therefore, Please follow the procedures below very closely. 1) Remove the cap from the air valve at the flange opening and press the top of the air chuck at the end of the pressure gauge onto the valve of the fender to measure the air pressure and to see if additional air is necessary. 2) Connect the air hose to the compressor. 3) Turn on the compressor and open the compressor valve. The pressure of the compressor should be between 4 to 7 Kgf/cm 2. 4) Press the air chuck at the end of the air hose onto the valve and air will automatically fill the fender. 5) Before reaching the specified pressure, periodically check the air pressure in the fender to avoid overinflating. To make these checks remove the air chuck being used for inflation and apply the air chuck of the pressure gauge in the same manner as described in the above 1). 6) Stop inflating the fender at the specified air pressure plus an additional 0.05 Kgf/cm 2. 7) Close the compressor valve. 8) Use soapy water to check for leaks from the valve or the flange opening. 9) Air from the compressor will have a high temperature but will decrease in temperature after inflating the fender. Therefore, check the pressure again one hour after inflating the fender. Lastly, check the pressure again once the fender is floating on the water. 10) If the pressure is too high, release the air by pushing the head of the valve core. 11) Finally, close the valve cap firmly. Store the air hose without folding it tightly. 6 UNPACKING 6-1. Packed and deflated Unpack the fender and inflate it. 1) Cut all wire ropes or steel bands wrapped around the fender. CAUTION: The ropes or bands may recoil with great force when cut. 2) Inflate the fender after clearing the area in order that the surface of the fender is not damaged with sharp protrusions or points. Inflate the fender slowly to avoid tangling the net. 6-2. Containerized and deflated Unpack the fender and inflate it. 1) Life the fender from the container using a bar. 2) Place the fender on the desired surface area in the same condition as it was loaded in the container. 3) Cut the wire ropes surrounding the fender. CAUTION: The wires may recoil with great force when cut. 4) Before inflating the fender, make sure that the flange opening, the ends of the fender, and the net are in the correct position, so that the net will not slip during inflation. 5) Remove all cut wires, and inflate the fender slowly to prevent tangling of the net. 10
7 INSTALLATION 7-1. For a Pier / jetty Refer to Fig. 6-1 and 6-2 and the following points. 1) Remove all protrusions such as frame books and steel framework to make the pier wall as flat and smooth as possible. 2) Construct the pier wall as flat as possible to avoid deforming the fender (unreasonably). If special characteristics of the pier prevent this, please contact us for proper installation. 3) At both dolphins and ordinary piers/jetties, it is desirable to put the mooring position(anchor position) more than three meters away from the fender. 4) The guy rope or chain securing the fender should have some play to accommodate the ebb and flow of the tide. 5) When installing a fender at an ordinary pier/jetty, at least two fenders must come in contact with the parallel body of the ship, one at each end of the parallel section. 7-2. For a ship 1) When the fender is floating, the guy rope or chain should be long enough to avoid sudden stress on the guy ropes or chains. 2) Attach the guy ropes to a secure part of the ship such as a bollard. Avoid weaker parts such as handrails etc. 3) It is desirable to use a crane, derrick or davit to hang the fenders. For information about NoreqFender Davit, please see www.noreqfender.no or contact us. 4) Install the fenders away from scuppers and other protrusions. 5) When two ships are moored side by side, at least two fenders must come in contact with the parallel bodies of each ship, one at each end. 6) When waves are high or the contact area cannot be fixed, avoid rigging in a continuous string. Instead, place them at individual points along the ship s hull. 7) The guy lines should be sufficiently long to allow for tidal variations. Fig. 7-1 11
7-3. Installation of Net Type Pneumatic Rubber Fender DWG. No. 1 2 3 4 Part Shackle (SB) Swivel Rope (JIS- G3525) Chain (SBC50) Anchor Unit mm mm mm mm mm Initial Pressure 0.5 0.8 0.5 0.8 0.5 0.8 0.5 0.8 0.5 0.8 Kgf/cm 2 500 x 1000 22 22 19 19 16 16 16 16 25 25 600 x 1000 22 22 19 19 16 16 16 16 25 25 700 x 1500 22 22 19 19 16 16 16 16 25 25 1000 x 1500 22 22 19 19 16 16 16 16 25 25 1000 x 2000 22 22 19 19 16 18 16 16 25 25 1200 x 2000 24 24 22 22 18 18 16 16 25 25 1350 x 2500 24 24 22 22 18 20 16 19 25 25 1500 x 3000 24 24 25 25 20 24 19 20 32 32 1700 x 3000 24 24 25 25 22 24 19 20 32 32 2000 x 3500 26 28 28 28 24 28 22 24 32 36 2500 x 4000 32 34 32 38 30 32 26 30 42 42 2500 x 5500 34 40 38 44 34 40 32 36 44 50 3300 x 4500 36 40 38 44 34 38 30 34 44 50 3300 x 6500 44 48 44 50 42 46 38 42 55 60 3300 x 10600 44 48 60 70 52 60 48 54 75 75 4500 x 9000 46 52 65 72 54 65 50 58 75 75 4500 x 12000 46 52 65 90 56 75 58 68 80 85 Fig. 7-2 12
7-4. Installation of Sling Type Pneumatic Rubber Fender DWG. No. 1 2 3 4 Part Shackle (SB) Swivel Rope (JIS- G3525) Chain (SBC50) Anchor Unit mm mm mm mm mm Initial Pressure 0.5 0.8 0.5 0.8 0.5 0.8 0.5 0.8 0.5 0.8 Kgf/cm 2 500 x 1000 22 22 19 19 16 16 16 16 25 25 600 x 1000 22 22 19 19 16 16 16 16 25 25 700 x 1500 22 22 19 19 16 16 16 16 25 25 1000 x 1500 22 22 19 19 16 16 16 16 25 25 1000 x 2000 22 22 19 19 16 18 16 16 25 25 1200 x 2000 24 24 22 22 18 18 16 16 25 25 1350 x 2500 24 24 22 22 18 20 16 19 25 25 1500 x 3000 24 24 25 25 20 24 19 20 32 32 1700 x 3000 24 24 25 25 22 24 19 20 32 32 2000 x 3500 26 28 28 28 24 28 22 24 32 36 2500 x 4000 32 34 32 38 30 32 26 30 42 42 2500 x 5500 34 40 38 44 34 40 32 36 44 50 3300 x 4500 36 40 38 44 34 38 30 34 44 50 3300 x 6500 44 48 44 50 42 46 38 42 55 60 3300 x 10600 44 48 60 70 52 60 48 54 75 75 8 PRECAUTIONS 1) Make sure the fender s air pressure is correct. 2) Keep within the fender s maximum energy absorption limits (ref. 3-1/3-2). The energy the fender must absorb depends on the speed of the vessel approaching for berthing and its weight. Please observe these factors when berthing in order to utilize the maximum energy absorption characteristics of the fender. 3) It is advisable to adopt specific berthing procedures for each type of vessel and port in order not to exceed the fender s maximum energy absorption limits. 4) Avoid contact with sharp protrusions when berthing. 5) When the vessel is mooring, do not drop anything sharp edge or pointed object onto the fender. 6) Special care should be taken in berthing for a ship having smaller free board than the top of the fender. 7) Avoid securing the ship s hawsers too tightly during offloading to prevent the fenders from rolling up the face of the pier. Loosen the ropes to ensure that the fenders are floating. 8) When two or more fenders are used, periodical rotation of the fender is recommended to lengthen their service life. 9) When mooring, make sure that the parallel body of the ship s hull comes in contact with at least two fenders. 10) Oblique compression to the fenders should be limited max. ten degree when 13
berthing. 11) Avoid moving the ship while the fenders are under strong compression. 12) Do not use fenders in extremely rough water. 9 INSPECTION AND MAINTENANCE 1) Check the air pressure of each fender at least once a year and, if possible, more frequently. If you make a spot check with your hand and the pressure seems less than normal, perform a gauge check referring to the description in 4-1 of this manual. If additional air is needed, fill the fender according the specifications show in Table 2-1. If the pressure is low, even considering the temperature factor, air might be leaking from the fender. In this case, check for leaks around the flange openings using soapy water. An air-leakage test should be done by making a gauge check of the specified pressure and repeating the check twenty-four hours later to determine if the pressure has dropped or not. 2) If there is a cut or worn part on the fender s surface, repair according to the procedures given in Section 10 of this manual. 3) When the metal fittings on the fender become rusty, remove the rust and coat the fittings with rustproof paint. 4) Check the net and guys for rust and wear. Check the shackles for loss of pins, and the swivels to see if they are properly greased. Repair or replace accordingly. 5) Remove all protrusions from the pier-jetty wall and check periodically for any new protrusions that might appear. 6) Check all anchors for wear and tear, and repair when necessary. 7) Remove all sea moss or other marine life that has attached itself to the fender. 8) To ensure proper rotation of the swivels, apply grease when necessary. 9) Inspect and clean the safety valve every second year. 10 REPLACEMENT If one of the following conditions applies to your fenders, have them replaced. 1) If over ten years have passed since the date of purchase. 2) If the reinforcement cord layers are damaged beyond repair. 3) If the metal fittings are deformed beyond repair. 4) If further use of the fender appears to be dangerous. 11 SAFETY VALVE The safety valve for the pneumatic rubber fender is specially designed to function in emergencies. If the internal air pressure of the fender goes up too rapidly, the safety valve will release the pressure and prevent the fender from bursting. Although the fender has a safety valve, this does not mean that it is safe to compress the fender beyond its maximum energy absorption capability. 12 REPAIR The materials and instruments in the accessory box are available only for temporary repair of a fender. The best method for complete repair is vulcanization by a rubber company. The NoreqFender Repair Kit contains the following: Pressure gauge, hose, nipple and rubber sheet. Adhesive is not included in repair kits. 14
Please obtain TIP TOP SC2000 locally for adhesive. 1) If a fender s surface rubber is cut or peeled enough to expose the reinforcement cord layer use the following five steps to repair it. a) Buff the damaged rubber and a 100mm radius area around it immediately with sandpaper. Do not buff the exposed reinforcement cord. Please clean the exposed rubber, the buffed area and the exposed reinforcement cord with a solvent such as gasoline. b) Mix TIP TOP Cement SC2000 and 10% RF hardener, and apply one coat of the mixture onto buffed area. Allow this coat to dry completely until no longer tacky on back of finger. c) After that, apply a second coat of the cement to the same area. d) Cut a rubber patch roughly the same size of the buffed area and taper the edges. When the second application of cement has dried sufficiently, apply the patch over it. e) Use the hand roller provided in order to roll the patch onto the prepared surface, beginning from the center of the patch and working toward the edges to ensure that no air is between the patch and the surface rubber. 2) If the fender appears to be leaking, use the following steps to find and repair the leak. a) Check the point of the leak by applying soapy water to the surface of the fender. b) Buff a 100-150mm radius area immediately around the hole with sandpaper, and clean the area with a solvent such as gasoline. c) Mix TIP TOP Cement SC2000 and 10% RF hardener together thoroughly. d) Hole the rubber plug with the jig as shown in the following figure, and after dipping the plug into the mixed cement, insert it into the hole. e) Pull out the jig, leaving only the plug in the hole. Check the leak again, and if it is still leaking air, insert one or more plugs into the hole until the leaking stops. f) After the leak has been plugged completely, cut the plug(s) flush with the top of the surface rubber layer of the fender. g) Wash the buffed area with a solvent again, and apply the cement mixture. 15
h) When it has dried sufficiently, apply another coat of cement to the same area. i) Cut a rubber patch 100mm x 100mm with tapered edges, and when the second coat of cement has dried sufficiently, apply the patch over the plugged hole. j) Use the roller to roll on the patch, beginning from the center of the patch and working toward the edges to ensure that no air is between the patch and the surface rubber. 3) If the reinforcement cord layer is damaged, the best way to repair it is vulcanization by a rubber company. However please contact us for an evaluation and assistance. 4) It is structurally impossible to repair a cut within the area of approximately 300mm of the flange opening. 13 GUARANTEE We guarantee the quality of NOREQ Pneumatic Rubber Fenders for one(1) year from the date of installation or one(1) year and three(3) months from the date of shipment, whichever is the earlier. The guarantee shall cover any and all defects in materials, quality and workmanship caused in manufacturing. It shall not cover any damage which results from accidents or from failure to comply with the articles of this manual. 16