CAVIDYNE CaviBlaster 1030-ROV Manual

CAVIDYNETM, LLC
5077 Fruitville Rd., Suite
109-157 Sarasota, FL 34232
Phone: [phone]
Operation &
Maintenance
Manual
Model 1030-ROV

CAVIDYNE LLC is not responsible for damages or injuries
resulting from a failure to comply with instructions in this
manual. Please read and study the entire manual
carefully before use.
The CaviBlaster® 1030-ROV must only be operated and
maintained by trained personnel.
This equipment generates high pressure water and is
intended for underwater use only. Serious personal
in ury or death and equipment / property damage may
result from improper use.
For more information please email [email protected] or call 1-[phone]
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TABLE OF CONTENTS
1.0 UNIT SPECIFICATIONS.............................................................................................5
2.0 GENERAL DESCRIPTION..........................................................................................6
2.1 Using this Manual.....................................................................................................8
2.2 Conventions.............................................................................................................8
2.3 Scope.......................................................................................................................8
2.4 Terms and Abbreviations.........................................................................................8
3.0 SAFETY INFORMATION............................................................................................9
3.1 Personal Safety........................................................................................................9
3.2 Personal Protective Equipment..............................................................................10
3.3 Modification to the Equipment................................................................................11
4. 0 INSTALLATION........................................................................................................12
4.1 Uncrating and Lifting..............................................................................................12
4.2 Initial Set-Up...........................................................................................................13
5.0 OPERATION..............................................................................................................14
5.1 Preparing the CaviBlaster® for Operation..............................................................14
5.2 Startup of the CaviBlaster®.....................................................................................15
5.3 Normal Operation...................................................................................................15
5.4 Adjusting the CaviBlaster® for Maximum Performance..........................................16
5.5 Recommendations for Effective Results................................................................19
6.0 MAINTENANCE........................................................................................................21
6.1 Basic Preventive Maintenance Recommendations...............................................22
6.2 Pump Service.........................................................................................................22
6.3 Inspection/Cleaning of Water Inlet Strainer...........................................................22
7.0 TROUBLESHOOTING..............................................................................................23
8.0 REPLACEMENT PARTS..........................................................................................24
APPENDIX - COMPONENT LITERATURE....................................................................25
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LIST OF FIGURES & TABLES
Figure 1.1 – CaviBlaster 1030-ROV Especifications ……………………………..……...05
Figure 2.1 - CaviBlaster 1030-ROV General Features…………………………………...07
Figure 4.1 – Lifting Guidelines ……………………………………………………………...12
Figure 5.1 – Hydraulic Connections ………………………………………………………..17
Figure 5.2 – Lance Pressure Calibration …………………………………………………..18
Figure 5.3 – Lance Position for Best Cleaning Results …………………………………..19
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1.0 UNIT SPECIFICATIONS
The CaviBlaster® 1030-ROV power unit consists of a 28HP 19 kW) Cross hydraulic
gear motor power-pack and a UDOR GSC34/15 triplex plunger pump. Detailed
performance and specifications are listed below:
CaviBlaster® 1030-ROV Specifications
Nominal Pump Flow 10 GPM 38 LPM)
Nozzle Operating Pressure 3,000-PSI 207 BAR)
Driver 28 HP Hydraulic Gear Motor
Installation Environment Submersible
Hydraulic Oil Flow Requirements *See below.
Overall Unit Dimensions L x W x H) 23-1/4” x 20” x 9-1/2” 59 cm x 50.8 cm x 23.1 cm)
Maximum Pressure Hose Length 300 LF 100 meters) of 1/2” 1.3 cm) diameter
Power Unit Weight Dry) 131 LBS 54.5 KG)
*Hydra lic Power Unit m st be capable of operating the water press re p mp at 1450 rpm and 21 HP.
Cons lt CaviDyne regarding yo r existing Hydra lic Power Unit capabilities.
Fig re 1. 1 – CaviBlaster® 1030-ROV Specifications
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2.0 GENERAL DESCRIPTION
The CaviBlaster® 1030-ROV high-pressure water power unit allows the operator to use
the water flow and pressure to generate cavitation at the end of the proprietary nozzle.
The CaviBlaster® cleans the surface of any underwater structure using the energy
released by the implosion of the bubbles during the cavitation process. When directed
at the surface being cleaned, the energy released by the collapsing bubbles causes
marine growth to be removed from the surface.
The system consists of a portable high-pressure pumping unit designed for submersible
ROV use and a high pressure cavitation lance connected to ROV manipulator) with
connecting high pressure hose.
The system is normally supplied with an integral pressure compensator, pressure
compensation can also be achieved using the ROV onboard pressure system, consult
with CaviDyne LLC for acceptable pressure compensations options.
The CaviBlaster® 1030-ROV power unit is a complete “plug and play” system built on a
supporting platform that allows quick deployment and/or installation of the unit. Water is
supplied directly from the unit operating environment.
The unit is equipped with many features to maintain safety while operating at pressures
of 3,000-psi 207 bar).
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Fig re 2.1 – CaviBlaster ® 1030-ROV General Feat res
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2.1 Using this Manual
Every attempt has been made to ensure that this documentation is complete and
accurate at the time of publication. It is imperative; however, that anyone
attempting to use this manual must have good comprehension of how this
equipment operates. Further, this manual can in no way replace the common
sense of an individual. If at any time this manual seems to contradict itself, or
common sense, discontinue the procedure, re-read the section, and seek
assistance from CaviDyneTM or other personnel familiar with the operation of this
equipment.
2.2 Conventions
The first time a component is mentioned, it is typically followed by a figure
reference; e.g., Emergency Stop button See Figure 2.1). Figure numbers and
section numbers are always coincident.
When other sections are referenced the SECTION NAME will appear in italic
caps. The electronic version allows users to click on the section name or figure
reference to jump to that section. The words “This space intentionally left
blank” will appear where there is more than 3 inches of white space.
(EOS) will appear above the page number on the last page of each section.
2.3 Scope
This manual covers installation, operation, and maintenance of the CaviBlaster®
1030-ROV. It is essential that personnel who will operate and/or service this
equipment familiarize themselves with this manual. Standard components, such
as the unit engine and pump, are covered by the manufacturer’s literature found
in the Appendix.
2.4 Terms and Abbreviations
CCW Counterclockwise
CW Clockwise
EOS End of Section
GPM Gallons Per Minute
HP Horsepower
LPM Liters Per Minute
PPE Personal Protective Equipment
PSI Pounds Per Square Inch without suffix, assumed to be gauge pressure).
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3.0 SAFETY INFORMATION
The CaviBlaster® 1030-ROV power unit is an inherently powerful and potentially
dangerous piece of equipment; however, with proper care and training it can be
operated safely. The 1030-ROV must only be operated by personnel that have read and
understand this manual. It is intended to reinforce and review safety techniques to
prevent personal injuries and property damage.
Users must comply with all local, state, and national laws concerning high-pressure
water jetting equipment as well as all underwater work regulations.
It is strongly recommended that this entire manual be reviewed in-depth before
operating or servicing this equipment. Service work should only be performed by
individuals who are proficient in using this equipment. Refer to the applicable section in
this manual for the correct procedures prior to any installation, setup, or maintenance
work.
Note that the oil pressure compensator is not a pressurized component and therefore
not a safety hazard. It is open at one end and connected to the pressure pump oil
chamber at the other end. Its purpose is simply to balance the oil pressure in the water
pressure pump with the unit’s surrounding environmental pressure to prevent damage
to the water pressure pump.
3.1 Personal Safety
Operation of the CaviBlaster® 1030-ROV underwater submersible ROV-mounted
cleaning system must only be operated by personnel who have been trained in
its use. Operation of the system without the proper training can result in property
damage and damage to the CaviBlaster® unit.
CaviDyne LLC is not responsible for damages resulting
from a failure to comply with instructions in this manual.
Please read carefully before use.
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If maintenance or repair of the CaviBlaster® is being conducted out of the
water, remember that the unit generates a high pressure water jet stream.
Never direct the jet stream at a person or animal. Never direct the jet
stream toward power lines or other high voltage equipment.
Ensure that there is a safe area to work while operating
or maintaining the CaviBlaster® 1030-ROV.
Seek immediate medical attention if the operator suffers
an injury as the result of contact with the high-pressure
water stream. Serious personal in ury can result
from an untreated water in ection wound.
3.2 Personal Protective Equipment
Always wear appropriate Personal Protective Equipment PPE) when performing
maintenance or calibration on this equipment.
Personnel operating or working in the vicinity of the power unit should wear
appropriate hearing protection when the CaviBlaster® during maintenance or
calibration procedures.
Personnel performing maintenance or calibration procedures on the CaviBlaster®
1030-ROV system should always wear neoprene or heavy rubber gloves to
provide protection to the hands and, in particular, to the nails. The gloves will
absorb most of the energy produced by bursting cavitation bubbles and prevent
the cavitation bubbles from contacting the operators’ hands. The gloves will also
protect operators’ hands from the initial shockwave when the lance is activated.
Failure to wear appropriate PPE may result in personal
injury.
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3.3 Modification to the Equipment
Do not make any unauthorized modifications or repairs to this equipment.
Components used throughout this assembly were specifically designed or
selected to safely meet the unique high-pressure requirements. Only replace
parts with those recommended by or supplied by CaviDyneTM. Any unapproved
modifications will void the equipment warranty. Unauthorized modification or part
substitution can result in serious personal injury or property damage.
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Unauthorized replacement of any part may lead to
catastrophic equipment failure and serious personal
injury.

4. 0 INSTALLATION
The CaviBlaster® 1030-ROV must be securely attached to the ROV using the vibration
mounts supplied or other secure fastening mechanism.
4.1 Uncrating and Lifting
Unpack the equipment and inspect for damage. If damage is found, immediately
contact CaviDyneTM and the shipping company. If the nit will not be installed
immediately, provide adeq ate indoor storage to protect against damage.
The CaviBlaster® power unit should be lifted from underneath. Do not use
components of the CaviBlaster® to lift the entire unit.
Fig re 4. 1 – Lifting G idelines
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4.2 Initial Set-Up
After first receiving the CaviBlaster® power unit, the following must be completed:
See Figure 2.1 for item locations.
1. Remove hose between pump and oil pressure compensator.
2. Add oil to pump by completely filling pump to top of fill port.
3. Reconnect hose to pump only.
4. Stand unit on end with pump at top, hold hose upright to prevent leakage.
5. Remove oil pressure compensator fill port cap.
6. Fill oil pressure compensator and hose with oil.
7. Reconnect hose to oil pressure compensator and allow unit to sit for
several minutes to allow any trapped air to escape.
8. Top off oil pressure compensator as required.
9. Replace oil pressure compensator fill port cap.
10.Set unit back down on vibration mounts.
11.Connect hydraulic power unit hoses.
12.Connect water pressure hose.
The CaviBlaster® 1030-ROV can be used with seawater but must be flushed and
rinsed with fresh water after every use in seawater. Failure to flush and rinse the
power unit after use in seawater will result in increased wear and tear on components
and can cause the pump valve s) to stick in the open position. This will prevent the
system from producing the correct operating pressure.
(EOS)
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Pump fluids may have been removed for shipment. Check
ALL fluid levels prior to starting.

5.0 OPERATION
The CaviBlaster® 1030-ROV should only be operated by properly
trained personnel who are familiar with the contents of the manual.
Review the safety requirements found in Section 3 before operating.
5.1 Preparing the CaviBlaster® for Operation
The following checklist should be completed in advance, so that the unit is
always ready for immediate use. This should be completed after each use.
1) Inspect the CaviBlaster® power unit, hoses, JIC fittings and lance for any
signs of damage.
2) Inspect the water inlet strainer to ensure that it is not clogged See Figure
2.1). Clean if necessary.
3) Check for proper pressure pump oil level See pump Owner’s Manual found
in the Appendix). Add oil SAE 30 non-detergent) if necessary. PUMP MUST
BE COMPLETELY FILLED.
Incorrect oils should not be used as they may damage the
equipment.
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5.2 Startup of the CaviBlaster®
Before starting the CaviBlaster® 1030-ROV unit, review all safety requirements
found in Section 3.0 SAFETY INFORMATION. This equipment should only be
operated by individuals who have read and understand the CaviBlaster®
Operation and Maintenance Manual.
1) Verify that the unit has been properly prepared for operation as described
in Section 4.
2) Verify that the lance is properly connected to the CaviBlaster® and the
ROV.
3) Run the ROV hydraulic system to verify that the CaviBlaster® hydraulic
motor and pressure pump are functioning correctly.
5.3 Normal Operation
Normal operation of the CaviBlaster® system is defined as user control of water
flow via the lance. In the absence of a diver, control of the power unit is
accomplished by the ROV manipulator. Should a problem develop with the
control valve, discontinue using the CaviBlaster® until fixed.
Review the safety requirements for PPE and safe
operation before proceeding.
1) The ROV hydraulic system needs to be operating at a capacity that
matches the water pressure pump requirements for the CaviBlaster® 1030-
ROV to function correctly. Unlike gasoline or diesel engines, a hydraulic
motor will run as fast as the oil supply it receives, which means that the
hydraulic oil supply must be adjusted to match the water pressure pump
requirements. Consult with CaviDyne LLC to determine if your high
pressure oil supply unit is suitable for the CaviBlaster® 1030-ROV.
Please see flow requirements in spec sheet attached at the appendix of this manual.)
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2) Activate the cleaning cavitation stream by turning ON the hydraulic power
unit.
Although the CaviBlaster® system is safe to use when submerged in water,
the system generates a high-pressure up to 3,000-psi [207 bar]) water
stream, which can cause injury when the lance is out of the water. ALWAYS
keep the lance submerged when the pressure pump is engaged.
5.4 Ad usting the CaviBlaster® for Maximum Performance
The pressure at the nozzle of the lance has to be maintained within certain limits
to achieve cavitation and for best performance results. If using a calibration
pressure gauge situated between the pressure hose and the CaviBlaster® lance,
the water pressure should be 3,000-psi 207 bar) with the lance submerged and
the hydraulic power unit operating. For best results, repeat this calibration
procedure if cleaning performance degrades, or every 3 months at a maximum.
To calibrate the pressure at the lance, follow the procedure below:
-Stop the hydraulic power unit to discharge any residual pressure in the hose
lines.
-Disconnect the lance from the main hose line.
-Attach the calibration gauge between the main hose line and the lance and
tighten the JIC connections. See figure 5.1)
-Submerge the lance. Because of the danger of the operator coming in contact
the water stream from the cavitating nozzle, CaviDyne does NOT recommend
calibrating the lance out of the water. Use extra care to avoid the water
stream if doing so.
-Ensure that the cavitation nozzle is pointed away from the diver’s or
operator’s hands, arms and body.
-Start the hydraulic power unit.
-Hold the lance tight and observe the calibration gauge.
- Turn the knob on top of the pressure regulating valve See figure 5.1) until
pressure reads 3,000-psi 207 bar) on the calibration gauge. Turning the knob
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A CALIBRATION GAUGE IS RECOMMENDED WITH EVERY UNIT.
CONNECT BETWEAN THE END OF THE HOSE AND THE LANCE.

clockwise will increase the pressure and turning it counter clockwise will
decrease the pressure.
Fig re 5. 1 – Hydra lic Connections
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DO NOT ADJUST THE PRESSURE AT THE LANCE TO MORE THAN
3,000-PSI 207 BAR). HIGHER PRESSURE WILL NOT IMPROVE
PEFORMANCE AND COULD RESULT IN SERIOUS DAMAGE TO THE
PUMP.
Hydraulic Motor
Inlet and Outlet
Ports
Turn Knob to regulate
Pressure

Fig re 5. 2 – Lance Press re Calibration
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HOSES ARE RATED FOR 4,000-PSI 272 BAR) PRESSURES ABOVE
4,000-PSI 272 BAR) COULD RESULT IN HOSE FAILURE.

5.5 Recommendations for Effective Results
When the ROV operator is ready to commence cleaning operations, verify that
the lance is securely attached to the manipulator.
Once the hydraulic power unit is operational and the water jet stream is flowing
from the lance, the ROV operator has to find the most effective distance between
the lance nozzle and the surface being cleaned. See Figure 5.3)
1. Engage the ROV’s hydraulic power unit to activate the CaviBlaster® unit.
2. The most efficient operating technique is to hold the nozzle 2-5 inches 5-12
cm) away from the surface to be cleaned and at a 25 to 45 degree angle to
the surface being cleaned See Figure 5.3). The ROV operator needs to
observe the shape of the cavitating jet cone. At greater depths, the higher
ambient pressure will cause the jet cone to be shorter. The widest zone of the
cone is the most efficient part of the cavitating jet. Placing the nozzle closer
than 2 inches 5 cm) from the surface being cleaned will not allow for efficient
cavitation performance and will degrade the cleaning capability of the
CaviBlaster® system.
3. Follow all safety regulations that may be applicable to the work being
performed.
Fig re 5. 3 – Lance Position for Best Cleaning Res lts
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5.6 Shutting Down the CaviBlaster® 1030-ROV.
1. Shut down the ROV hydraulic power unit, this will turn off the pressure pump
and relieve pressure in the system.
2. It is now safe to remove the lance from the water.
3. Flush the system and rinse the power unit with fresh water at the end of the
day or work shift.
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