12 maintenance inspection
TRANSCRIPT
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12th North Sea Offshore Cranes &
Lifting Conference 2007
Maintenance, Inspection, Temporary
Cranes & Crane upgrades
Part 1 Maintainability of Cranes, Access to Components,
Standardisation of Component InterfacesPart 2 Condition Monitoring, Lubricant Analysis,
Oil Flow Monitoring
Part 3 Data Logging/Recording/Monitoring
Analysis and Value of Recorded Data
Part 4 Temporary/Mobile Cranes
What has to be considered?Part 5 Crane Upgrades
A real example
Version 1.0, dd. 17.04.07
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Maintainability
Due to more stringent rules (i.e. exhaust emissions),
increased maintenance intervals, decreased size etc.,
installed components to cranes become more and more
complex. Maintenance and repair to the component on
site has become more difficult. Special tools and specific
knowledge is required and in most cases the environment
needed can not be achieved offshore. In addition, down
time of the crane shall be kept at a minimum.
New philosophies in regards to maintainability have
therefore to be considered for the latest generation of cranes.
Part1 Maintainability of Cranes
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Standardise interfaces of componentsI.e. Standardised instrumentation via Can-Bus of diesel engine one
plug only. Access to main components by maintenance crane allows
replacement without another crane.
Part1 Maintainability of Cranes
Un-park
maintenance crane
Lift engine to deck
Remove radiator
and hoodEnginereplacement
Slew gearbox
replacement
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Standardise interfaces of componentsSimplified and standardised interfaces allow a quick and
problem free replacement of the whole component.
I.e. Standardised winch flanges with four pins. No special
tensioning equipment required. Winch is installed to allow
exchange without major lifting equipment.
Part1 Maintainability of Cranes
Remove bolted diagonals Replace winchRemove pins from winch
flange
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Condition Monitoring
Mainly external measuring equipment like vibration
analyses, noise analyses or oil sampling are considered
as condition monitoring.
All this monitoring is prone to failure, oil samples might be
taken from the wrong port or are not taken at all.
However, they are a tool for evaluating the condition of
any component and in some cases the only option for a in
situ evaluation.
It is therefore important to implement in line monitoring
without any interaction of the operator/user.
Part2 Condition Monitoring
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Lubricant Analyses
Lubricant analyses are a good and simple measure for
condition monitoring but when not carefully taken a
completely wrong result can be created.
The latest control systems are offering monitoring without
any interaction of the operator/user assuring the exact
same measurement/sampling method.
I.e. In line flow monitoring, allows constant monitoring
of all hydraulic components. Together with a machine
data recorder (refer to part 3 of this presentation) adatabase of the leak oil development is created.
Part2 Condition Monitoring
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In Line Oil Flow MonitoringThe leak oil is a direct indication of wear which gives a
good and reliable indication of the current condition of all
installed hydraulic motors and pumps. No additional
measurements are required.
Part2 Condition Monitoring
Principle Layout for a hydraulic flow monitoring system.
00,5
1
1,52
2,53
3,54
4,55
5,56
6,57
7,58
D ES C RI P TI O N a u x. h o is t
m o t o r n o . 1
a u x . h o ist
m o t o r n o . 2
m a i n h o i s t
m o t o r n o . 1
mai n h o i s t
m o t o r n o . 2
l u f f i n g m o t o r s l e w i n g g e a r
m o t o r n o . 1
s l e w i n g g e a r
m o t o r n o . 2
L e a k O il ( m a x . ) L e a k Oil
L e a k O i lM e a s u r e me n t( l e a k o i l p e r m in u t e w it h 1 0 0 b a r s y s t e m p r e s s u r e )
A m o u n t i n L i t re s P e r U n it
D at e o f R un ni n g D ES CR IP T IO N T yp e I de nt . No . M a x. A ll ow a bl e A ct u al D if fe re nc e
In sp ec ti on H ou rs Le ak Oil (m ax . ) Le ak Oil in %D at e o f R un ni n g D ES CR IP T IO N T yp e I de nt . No . M a x. A ll ow a bl e A ct u al D if fe re nc e
In sp ec ti on H ou rs Le ak Oil (m ax . ) Le ak Oil in %
a ux . h oi st mo to r n o. 1 A 2F 80 5 102 29 614 2 ,0 0 0 ,0 0% a cc ep ta bl e
au x . h ois t m o to r n o . 2 2,00 0, 00% acc ep ta bl e
m ai n h oi st m ot or no . 1 A 2F 12 5 5 102 29 714 3 ,0 0 0 ,0 0% a c ce pt ab le
m ain ho i s t m o tor no . 2 3,00 0, 00% acc ep ta bl eluf f ing m ot or A 2F 90 2,50 0, 00% acc ep ta bl e
s le wi ng g ea rm ot or no . 1 A 2F 45 5 102 29 514 1 ,5 0 0 ,0 0% a cc ep ta bl e
s le win g ge ar mo to rno .2 A 2F 45 1, 50 0, 00% ac cep ta bl e
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Existing Data Logger Limited information such as time, average weight of lift is
recorded. The information content is very limited.
Part3 Data Logger
date load cycle time start time end
TT.MM.JJ No. hh:mm:ss hh:mm:ss
24.03.1998 0 09:38:13 09:39:55
24.03.1998 1 09:41:46 09:42:41
24.03.1998 2 09:44:24 09:45:36
24.03.1998 3 09:48:03 09:48:23
24.03.1998 4 09:55:59 09:57:08
24.03.1998 5 09:59:25 10:00:35
24.03.1998 6 10:01:45 10:02:44
24.03.1998 7 10:04:12 10:06:0224.03.1998 8 10:07:33 10:09:03
24.03.1998 9 10:10:42 10:12:03
24.03.1998 10 10:13:52 10:14:40
cy cle time average load max load
average load
plus dead weight
22t
utilization
hh:mm:ss (t) (t) (t) (%)
00:05:15 18,7 50 40,7 115,6
00:03:33 7,9 40,4 29,9 93,2
00:04:51 13,7 43,2 35,7 99,8
00:08:16 4,8 33,6 26,8 77,7
00:04:35 10,6 44,8 32,6 103,5
00:03:30 5,9 47,2 27,9 109,1
00:03:26 7,8 45,1 29,8 104,1
00:05:11 17,7 49 39,7 113,100:04:39 7,3 51,9 29,3 120
00:04:31 14,2 44 36,2 101,6
00:07:35 5,9 38,6 27,9 89,2
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Machine Data Recorder (MDR)
What is a MDR?
MDR is the permanent measurement and recording of
machinery conditions using the existing instrumentation.
The recording contains loading spectrum and maximum
values for main components of the crane.
Unlimited information which can be used for
maintenance, condition monitoring without guessing and
assumptions.
Gives data for all installed components.
Part3 Machine Data Recorder
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Data recorded via existing instrumentation
- All rights reserved - E. & O. E -
Master
CPU
Ethernet/RS232
CAN 1...4
Part3 Machine Data Recorder
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Maximum Value Recorder 10 maximum values inclusive of date and time are
recorded.
At the same time when maximum value arises, also
additional parameters will be recorded to describe the
environmental field
Load Spectrum Recorder The monitored process variable (i.e. load) is subdivided
into categories.
During operation the process variable usually passes
through several categories in which the time of stay will
be summed up.
Part3 Machine Data Recorder
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utilization MDE [%]
start time 31.05.2001 15:54:28stop time 30.08.2001 08:44:54
date time utilization MDE [%] outreach LML [m] operation mode load l.m.l. [to] slewing angle [°]
%MD1.73 %MD1.24 %MD1.8 %MD1.18 %MD4.18
MDutilizationMde MDoutreachLML MDoperationMode MDloadLML SDVslewingAngle
31.07.2001 10:26:01 106.81 38.70 8 55.00 131.54
05.07.2001 20:47:58 106.59 36.55 8 59.25 72.45
07.08.2001 04:43:10 106.36 42.99 8 47.48 79.97
05.07.2001 21:32:02 105.64 38.64 8 54.51 73.44
30.07.2001 09:19:53 105.49 38.96 8 53.80 64.67
26.08.2001 09:19:00 104.98 40.62 8 50.61 49.10
20.06.2001 03:29:21 104.95 38.34 8 54.74 44.33
20.06.2001 03:10:29 104.26 37.05 8 56.82 48.51
08.07.2001 00:02:42 104.14 36.95 8 56.99 96.21
09.07.2001 03:46:11 103.02 38.98 8 52.50 144.86
10 maximum valuesof recorded process variable
Part3 Machine Data Recorder
Maximum Value Recorder 10 maximum values inclusive of date and time are
recorded.
At the same time when maximum value arises, also
additional parameters will be recorded to describe the
environmental field
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monitored
process variable
summed up
time shares
Part3 Machine Data Recorder
Load Spectrum Recorder The monitored process variable (i.e. load) is subdivided
into categories. During operation the process variable usually passes
through several categories in which the time of stay will
be summed up.
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Possible use of MDR data, results
Recorded Stress
Cycles
Stress Cycle
Spectrum
Expected RestLife Time of
Component
Classification
according to FEM
Part3 Machine Data Recorder
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Results from recorded data:
Power Spectrum
Part3 Machine Data Recorder
Power Spectrum per Speed
Speed Spectrum
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Ø Multi Dimensional
Analyses
Ø Exact details about
Load Spectrum
Ø Preventive
maintenance based
on real and actual
utilization/usage of
each installed
component
Part3 Machine Data Recorder
Results from recorded data:
Slewing angle versus loadSlewing angle versus load
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Summary of Machine Data Recording:
The machine data recording is permanently recording data of the
condition of the crane. The data recorded and analysed will be
supportive for the evaluation of the condition, utilisation and theoretical
calculated remaining life time of components.
The data recorded supports and is used for
establishing major maintenance and service intervals accordingto FEM, DIN, BS or equivalent standards
establishing of strategic and preventative maintenance
remaining life time calculations
analyses of crane data, i.e. heavy load and overload situations
- All rights reserved - E. & O. E -
Part3 Machine Data Recorder
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Temporary/Mobile Cranes used offshore! What has to be considered?
In the recent past, we have been approached more and more to use mobile/crawler
cranes as temporary lifting aids offshore.
Part4 Temporary Cranes
However there is a big
difference between such a
standardised land based
machine compared with an
offshore crane.
Since the offshore standards
have become more and more
stringent, many points have to
be considered before such a
crane can be used offshore.
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Part4 Temporary Cranes
Rough comparison
Offshore Cranes Land based mobile/crawler crane
- Certified material and welding - Material certification not traceable
- Failure Mode Charts required - Free standing machine not connected
to platform structure
- AOPS/MOPS required - AOPS/MOPS not installed, hoisting
speed not sufficient
- Big cabins with specific access - Small cabins used, required exits and
requirements access size not according to offshorerules
- Emergency lowering required - Emergency Lowering not installed
- Dynamic load charts considering - Land based load charts only
offshore wind speeds, off- and side
leads and heel/trim considered
- Emission standards - New machines will fulfil requiredemission standards, but certification
is generally not available
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Part4 Temporary Cranes
Other issues
The maximum allowed deck loads to be considered, crawlers
and other free standing machines are generally quite heavy
(counter weight). Edge loads implemented to the deck are
therefore quite high which requires a heavy structure
distributing the forces to the deck.
Cabin is positioned very low which causes many blind lifts.
For cranes designed for an onshore environment, corrosion
protection has to be specifically checked (i.e. slew pinions
outside).
Conclusion
Based on the above, a lot of effort is required to allow using
a crawler/mobile crane for an offshore application (off site
lifts), still requiring a lot of compromises. In many cases it is
more practical to use an offshore crane on a suitable frame
or a temporary pedestal as a temporary solution.
The minimum component weight for the installation has been
found to be similar for both offshore and crawler/mobile
cranes.
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Part5 Crane upgrade
Why to upgrade an existing crane:
Changes of requirements
Higher reliability Unavailability of spare parts (obsolete)
Shorter delivery time as a new crane
Difficulties replacing entire machine (restricted lifting aids, access, etc.)
It is more cost efficient (existing crane in very good condition, crane is very big, etc.)
Possible upgrades:
Power pack
Control system
Load Indicator / Moment Limiter
Increase of Lifting Capacity
Upgrade of man riding capability
Upgrade to suite new rules
Boom extension
More speed
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Part5 Crane upgrade
Basis of such a Project:
Review/Availability of Crane Documentation
Review of requirements/ownersspecification/scope of work
Crane survey (if required)
Example:
Crane Model: Monarch 6032
Capacity: 21,8to at 8m, 2-fall operation
Requirements:
Replace of existing winches with wet running
drive splines and additional brakes
Install a new hydraulic open loop system
Install a new LML/SLI (Mipeg 2000 Type)
Install new electrics as required (Including winchrotation indicators)
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Existing Winch
New Winch
Part5 Crane upgrade
Requirements:
Replace hoisting and luffing winch against new winch
New winch with
wet running drive splines
additional brakes (suitable for man riding)
winch frame
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Part5 Crane upgrade
Requirements:
Install a new hydraulic open loop system for hoisting and luffing circuit and a separate
closed loop for the slewing circuitNew pumps and hydraulic motors
New radiator and filtration system
New Joysticks
Use existing tank and under floor piping from tank to pumps
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Part5 Crane upgrade
Requirements:
Install a new LML/SLI
Mipeg 2000 recording
New load cell and angle sensor
New rope sheave to suite new load cell
Install new electrics
Winch rotation indicators
Control panel