Winch Brake Rendering Test Kit
Our Code: BTK030, BTK050
BTK Series – Mooring Winch Brake Test Kit
The BTK Series is a specialized hydraulic testing system designed for marine applications to verify and certify the brake holding capacity of mooring winches on vessels. It enables onboard testing to ensure compliance with classification society requirements and international maritime safety standards.
Primary Function
Measurement and verification of mooring winch brake capacity equivalent to 60% of the Ship Line Design Minimum Breaking Load (MBL).
Model: BTK030 (30 Metric Tons)
System Parameters
| Parameter | Specification |
|---|---|
| Max. Testing Capacity | 30 Metric Tons (30,000 kgf) |
| Max. Hydraulic Pressure | 350 bar (5,000 psi) |
| Pump Type | Manual Hand Pump |
| Operating Medium | Hydraulic Oil No. 15 |
Oil Jack Specifications (FCY-30150)
| Specification | Value |
|---|---|
| Capacity | 30T |
| Maximum Stroke | 150 mm |
| Collapsed Height | 211 mm |
| Extended Height | 361 mm |
| Connection Type | NPT/BSP Hydraulic Fitting |
Model: BTK050 (50 Metric Tons)
System Parameters
| Parameter | Specification |
|---|---|
| Max. Testing Capacity | 50 Metric Tons (50,000 kgf) |
| Max. Hydraulic Pressure | 500 bar (7,250 psi) |
| Pump Type | Manual Hand Pump (Heavy-Duty) |
| Operating Medium | Hydraulic Oil No. 15 |
Oil Jack Specifications (FCY-50150 / FCY-50200)
| Specification | Value |
|---|---|
| Capacity | 50T |
| Maximum Stroke | 150 mm / 200 mm (Optional) |
| Collapsed Height | ~240 mm |
| Extended Height | ~390 mm / ~440 mm |
| Connection Type | NPT/BSP Hydraulic Fitting |
* BTK050 specifications are standard configurations. Contact us for customized stroke lengths and pressure ratings.
Standard Components & Materials
Each BTK Series test kit ships as a complete, ready-to-use system. The following components are included for both BTK030 and BTK050 models:
| Item | Description | Qty | Material |
|---|---|---|---|
| 1 | Hydraulic Oil Jack | 1 Set | Alloy Steel |
| 2 | Manual Hand Pump | 1 Set | Steel / Brass |
| 3 | Triangle Link Plate Assembly | 1 Set | High-Strength Steel |
| 4 | Support Fork End | 1 Pc | Hardened Steel |
| 5 | Jack Base | 1 Set | Steel |
| 6 | High-Pressure Rubber Hose | 1 Pc | Synthetic Rubber |
| 7 | Connection Pins with Nuts & Washers | 3 Pcs | Alloy Steel |
| 8 | Pressure Gauge | 1 Pc | Stainless Steel |
Calculation Methodology
Brake Capacity Formula
Target Brake Load (F):
F = 60% × Ship Line Design MBL
Where:
F = Brake Capacity (metric tons, mt)
MBL = Minimum Breaking Load of mooring line
Required Hydraulic Pressure (P)
P = [ F × (r + d/2) × 1000 ] / (A × L) = [ F × (D + d) × 500 ] / (A × L)
Where:
P = Hydraulic Pressure (kg/cm²)
F = Brake Capacity (mt)
A = Jack Pressure Area = 78.5 cm² (for 30T jack)
L = Distance between Jack and Drum center (cm)
r = Radius of Drum (cm); D = Diameter of Drum (cm) = 2r
d = Diameter of Rope (cm)
Pressure-Tonnage Conversion (BTK030)
For 30T Oil Jack with P700-02 Hand Pump:
| Pressure Gauge (MPa) | Pressure Gauge (BAR) | Oil Jack Capacity |
|---|---|---|
| 15 | 150 | — |
| 20 | 200 | — |
| 25 | 250 | — |
| 30 | 300 | — |
Operating Procedure
Preparation
- Rotate drum and adjust link plates to ensure fork end face is vertical to main deck.
- Align jack base to level line using integrated leveling indicators.
- Engage winch brake by adjusting brake screw mechanism.
Testing Sequence
- Connect hydraulic hoses between hand pump and oil jack.
- Mount the triangle link plate assembly between drum flange and jack fork end using supplied pins.
- Jack up gradually using hand pump to reach calculated test pressure (see Calculation Methodology).
- Hold Period: Maintain pressure for 3–5 minutes to evaluate brake capacity condition.
- Acceptance Criteria: If pressure holds steady, brake capacity is satisfactory. If pressure drops, adjust brake and retest until pressure maintains constant.
Application & Scope
Suitable for:
- Single drum mooring winches
- Split-flange drum designs
- Wire rope diameters: Compatible with standard mooring lines (d ≤ drum grooves)
- Drum diameters: Universal fit via adjustable link plate geometry
Vessel Compatibility:
- Container vessels
- Bulk carriers
- Tankers
- Offshore supply vessels
- Cruise ships and ferries
Packing & Shipping
- Shipping Case: Wooden crate with metal reinforcements
- Standard Supply: Complete test kit (Items 1–8), instruction manual (English), calibration certificate for pressure gauge, test record sheets (16-winch vessel layout template)
- Service: Annual calibration and component replacement available
Safety Notes
⚠️ WARNING:
- Ensure all connections are secure before pressurizing.
- Never exceed maximum rated pressure of 350 bar (BTK030) / 500 bar (BTK050).
- Keep clear of load path during testing.
- Use only trained personnel for testing procedures.
- Verify all pins and retaining hardware are properly installed.
- Inspect hydraulic hoses for damage before each use.
Compliance & Standards
- IMO: International Maritime Organization guidelines for mooring equipment
- ISO: ISO 3730 (Shipbuilding – Mooring winches)
Manufacturer: NINGBO YINXUN MECHANICAL & CHEMICAL CO.,LTD.
Technical specifications subject to change without notice.
