LINDSTRAND HiFlyer, Training Manual

Page 1: ...hire SY10 8HA UK Tel 44 0 1691 671 888 Fax 44 0 1691 679 991 www 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 8HA Eng...

Page 2: ...ue 1 modified by Amendment 4 The checklist of pages indicates the issue level of all pages included in this Training Manual Amendments are issued to all relevant operators of the Lindstrand Balloon Ltd Hi Flyer System on a free of charge basis provided that the Inclusion Check Sheet is signed and returned to Lindstrand Balloons Ltd for each issued amendment Change of Ownership If the ownership of ...

Page 3: ... No Issue i ii iii iv v 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 4 0 4 2 4 2 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0 25 26 27 28 29 30 31 32 33 34 4 0 4 0 4 0 4 0 4 2 4 1 4 1 4 2 4 1 4 2 ...

Page 4: ...LTL TATM LTL Vol 1 Issue 1 0 iv Manual Supplements Supplement No Title Tick if Applicable ...

Page 5: ...pex Mooring 10 3 4 High Mooring from flying 10 3 5 Low Mooring 12 3 6 High Mooring from Low Mooring Position 16 3 7 Flying from High Mooring Position 17 4 CONTROLS 19 4 1 Control panel 19 4 2 Winch Controls 20 5 NORMAL PROCEDURES 21 5 1 Pre flight 21 6 SAFETY 25 6 1 Rope Safety 25 6 2 High Pressure Gases 25 6 3 Fire 27 6 4 Site Safety 27 7 EMERGENCY PROCEDURES 28 ...

Page 6: ...ift to support all the equipment and passenger weights A gondola which provides a safe carrying structure for the occupants A winch system which secures the balloon and controls the ascent and descent 3 Mooring and Un mooring The mooring and un mooring of the HiFlyer are two of the most important tasks to be undertaken by the operator The envelope is over 22 metres in diameter which means that a l...

Page 7: ...R BOTH HIGH and LOW MOOR 2 5 TONNE RATCHET STRAP Outer mooring winch option Used for both High and Low Moor MOORING WINCH DRUM Lower apex mooring The lower apex of the envelope has 8 load patches fixed to it Straps are fastened to these load patches and anchored to hard points set into the concrete base supporting alternate mooring winches LOW MOOR ONLY 2 5 TONNE RATCHET STRAP The HiFlyer is able ...

Page 8: ...r up Feed out the strap until there is only 300mm of the free end of the strap through the handle Operate the ratchet mechanism a few times to secure the strap then close the handle to lock the ratchet b Using a karabiner connect the looped end of the strap up to the highest loop of the mooring line that can be reached ...

Page 9: ...hown d Open the ratchet handle out again and pull the loose end of the strap through to take up the slack It is important to take up all of the slack if too much slack is left when the ratchet is tightened the volume of strap wrapped around the spool will jam the mechanism ...

Page 10: ...echanism with the other until the strap and mooring line are fully tensioned Make sure that the strap is not twisted or out of alignment otherwise this will cause premature wear f There should be no sag in the mooring line when correctly tensioned Close the ratchet handle to finally lock the mechanism ...

Page 11: ...LTL TATM LTL Vol 1 Issue 1 0 7 g Route the free end of the strap back through the handle of the ratchet Coil up the loose mooring line and tie it off to the strap to prevent it dragging on the ground ...

Page 12: ... not tangled or knotted Set the mooring winch control pendant to LOWER and MOOR ONE a Pass the sewn in loop back through itself to form a slipping loop b Place the slipping loop around the mooring winch drum and pull it tight Make sure that the sewn in loop is positioned so that the free rope locks back around to secure the rope onto the drum ...

Page 13: ...nto the drum SAFETY Make sure that fingers loose clothing jewellery etc cannot be snagged or trapped around moving parts of the winch d Take up an equal amount of slack on each winch If the rope is too tight the motor may back drive It is best to one person judge the tension for all 16 ropes before continuing ...

Page 14: ...ng winch support block As there are only 8 lower apex mooring points the ratchet mechanisms should be fixed to each alternate winch hard point situated on the winch motor NOTE The strap and extension should be routed over the top of the gondola mooring ring This is to ensure that the load applied to the patches on the envelope is aligned in tension and will not cause a peel load 3 4 High Mooring f...

Page 15: ...dicular to the wind direction Fig 3 These will steady any sideways motion which should make it easier to connect the remaining ropes Place the karabiner through the first loop at the end of the outer mooring ropes When all outer mooring lines are secured at the end loop starting with the perpendicular move the karabiners progressively up to the highest loop possible on each rope and tighten Refer ...

Page 16: ...to MOOR ALL and LOWER The operator in charge of Low Mooring should stand where the control panel in the gondola is visible The HELIUM VALVE switch on the control panel should be set to MANUAL to prevent pressure from opening the valve Other personnel should stand clear of the mooring winches but in a position where as many of them are visible as possible Before depressing the button to commence Lo...

Page 17: ...m the mooring ring re fasten the outer mooring lines to take up the tension again on the outer mooring ropes In moderate to strong winds it may be prudent to attach the lower apex mooring lines whilst the balloon is in this position This will prevent the envelope from straying towards the mooring ring and damaging the fan assembly at the bottom of the balloon The operator can now lower the envelop...

Page 18: ...LTL TATM LTL Vol 1 Issue 1 0 14 The gondola should now be secured to the decking using the ratchet straps 2 5T The balloon is now in the Low Moored Position ...

Page 19: ...he ground fan must be disconnected before the balloon is flown or raised to the high mooring position 3 5 1 1 Ground Fan Installation Locate fan on the platform outside the gondola Lead the duct over the top of the gondola and under the mooring ring Couple the duct up to the connection under the ballonet fan using the four over centre catches Mains lead plug in to mains or generator supply socket ...

Page 20: ...ore depressing the button to commence High Mooring the operator should indicate to other personnel that the winches are about to work by shouting WINCHES Other personnel should return this call to indicate that they are aware that the winches are about to be used Once the operator is satisfied that all personnel are clear the mooring button should be depressed The operator should watch the load as...

Page 21: ... should indicate to other personnel that the winches are about to work by shouting WINCHES Other personnel should return this call to indicate that they are aware that the winches are about to be used Once the operator is satisfied that all personnel are clear the mooring button should be depressed The remaining ground crew should watch the winches for any sign of malfunction or problems If anyone...

Page 22: ...e 1 0 18 Switch the mooring winch control pendant to LOWER and MOOR ONE The balloon is now in the flying position record un laden grounded freelift helium pressure ballonet pressure helium temperature and ambient temperature ...

Page 23: ...VE PWR EM PEAK DOORS LIGHTS NAV TEMP WARNING DOORS EM PWR AMB TEMP C He TEMP C RESET LIFT FREE VOLTS CHECK ON OFF FAN ON PANEL LIGHTS OFF ON OFF NAV HELIUM VALVE STROBE OFF AUTO ON PUSH TO TEST AUTO MAN CLOSE OFF OPEN He PRESSURE WARNING VALVE OPEN ON OFF The control panel is mounted on the gondola All controls readouts circuit breakers etc relating to the envelope and gondola are contained within...

Page 24: ...MANUAL REFERENCE SECTION 1 4 2 8 1 Remote Control unit The remote control is incorporated in the gondola control panel 4 2 2 Auxiliary Control Panel OPERATIONS MANUAL REFERENCE SECTION 1 4 2 8 2 Auxiliary Control panel The platform mounted operator control station can override the remote control unit in the balloon gondola the key switch must be changed from gondola to ground Lights indicate mains...

Page 25: ... require maintenance or repair The balloon should not be allowed to operate until faults have been repaired The Master Minimum Equipment List MMEL in Appendix 1 identifies certain types of faults on some parts and sub systems where operations are allowed to continue Procedures must be followed to repair the fault within the specified time A section of the Tech Log provides a record of inspection a...

Page 26: ...ata can be used to estimate the volume purity of helium This should be monitored carefully as it will highlight any increased helium loss through valve leakage envelope damage etc The battery voltage must be between the limits specified in the Operations Manual 5 2 2 Monitoring During the test flight the pilot should be monitoring the control panel the gondola netting and envelope for any abnormal...

Page 27: ...round controllers OPERATIONS MANUAL REFERENCE SECTION 3 4 2 2 Radio procedures 5 3 1 The Gondola The gondola is the passenger carrying component of the HiFlyer A full description is contained in the operations manual 5 3 2 The Gondola door mechanism The gondola operator is be positioned in the triangle area formed between the two open doors in front of the control panel a b The doors are held open...

Page 28: ...fully into its locating hole It is then pushed down to lock it Into position e f Both doors are to be fully locked When both independent door locks are in position the central over lock can be rotated into position g When all three locks are in position The control panel indicator light should be off ...

Page 29: ...l also be ropes on the ground and this has the potential to wrap around feet Never wrap the ropes around any part of the body When the ropes are being taken from their storage bags it is important to ensure that they are not left in a tangle as this can cause injury if they swing around When the first ropes are being attached to the winch drum there is a risk of crushing a hand as there is still m...

Page 30: ... It is advisable to wear gloves when dealing with helium cylinders This sort of situation can occur if a valve is left cracked open or a valve failure develops 6 2 1 Storage of Cylinders When the helium top up cylinders are delivered they will usually be single cylinders as opposed to the way the helium arrives for the inflation Sometimes however the helium will be delivered as a titan ie 16 cylin...

Page 31: ... to be affected by the leaking gas and is therefore best to evacuate the people concerned until all of the helium has dissipated If the cylinder cannot be removed to outside and nobody is able to enter the room then contact the fire brigade who have the correct equipment Do not allow anybody to re enter the evacuated area until it is safe to do so 6 3 Fire If there is a fire the gas in the cylinde...

Page 32: ...the shift supervisor Passengers should be kept calm and re assured The shift supervisor should carry out regular practice drills to make sure that crew are familiar with emergency procedures The winch emergency recovery procedure as shown in this manual should be copied laminated and displayed on the front of the winch control cabinet ...

Page 33: ...8 WHEN PROBLEM FIXED ZERO RIDE HEIGHT 9 E STOP OUT 10 PRESS RESET MAIN MOTOR DISABLED AUXILIARY MOTOR ON MAINS RECOVERY 1 E STOP IN 2 ENGAGE AUXILIARY GEAR COUPLING 3 CLOSE GEAR COVER 4 OPERATION MODE KEYSWITCH TO EMERGENCY 5 ALL E STOPS OUT 6 PRESS RESET 7 AUXILIARY COUPLING ENGAGED INDICATOR ON 8 AUXILIARY MOTOR CLEAR TO RUN INDICATOR ON 9 PRESS AUXILIARY START 10 PRESS AUXILIARY STOP WHEN DISC ...

Page 34: ...ERATOR 7 ALL E STOPS OUT 8 RESET 9 AUXILIARY COUPLING ENGAGED INDICATOR ON 10 AUXILIARY MOTOR CLEAR TO RUN INDICATOR ON 11 AUXILIARY START 12 AUXILIARY STOP WHEN DISC REACHES NORMAL CUT OUT LEVEL 13 E STOP IN 14 GENERATOR OFF STOP 15 DISENGAGE GEAR COUPLING 16 CLOSE GEAR COVER 17 OPERATION MODE KEYSWITCH TO NORMAL 18 SUPPLY KEYSWITCH TO MAINS 19 WHEN POWER IS RETURNED ZERO RIDE HEIGHT 20 PRESS RES...

Page 35: ...harger to maintain power Record unladen freelift temperatures and pressures Turn panel key to UNLOCK Ballonet fan switch to AUTO Manual Helium Valve Operation OBSERVER TO COUNTDOWN OPEN TIME AND MONITOR FREELIFT OPERATOR TO CONTROL HELIUM VALVE SWITCHES PRESS TO TEST HELIUM VALVE INDICATOR LIGHTS L H HELIUM SWITCH UP TO MANUAL R H HELIUM SWITCH UP TO OPEN RED INDICATOR LIGHT ON COUNTDOWN 6 SECONDS...

Page 36: ...ALLONET REPEAT VENTING PROCEDURE UNTIL TARGET FREELIFT ACHIEVED LOW MOOR BALLOON MEASURE INCREASED BALLONET HEIGHT AND RECORD EMERGENCY VALVE CLOSURE IF VALVE DOES NOT CLOSE RED INDICATOR REMAINS ON ARM EMERGENCY BOX ON TOP OF CONTROL BOX SWITCH ARMING SWITCH UP TO ON PUSH RED CLOSE BUTTON This bypasses the control box systems CONFIRM RED VALVE OPEN INDICATOR OFF ...

Page 37: ...206 Hardener Bostikure D 200 Mixture 4 hardener Application Clean area with alcohol wipes Brush on 1 coat to both surfaces Wait until tack dry Brush on second coat to both SURFACES Wait until tack dry Apply patch with hand pressure working out from centre Allow at least 10 minutes for curing Sealing cover cut from self adhesives vinyl sheet Allow 3 8 10mm overlap around patch Peel off backing and ...