crane presentationfinal sal(rev5)

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Folie 1

Structural Assessment of Crane on Heavy Lift Ship with Load Check and Fatigue Life Calculation check and fatigue life calculation

Rostock, Feburary 1/ 2017Udit Sood EMship cohort: September 2016 February 2017 Supervisors: Prof. Dr.Eng./Hiroshima Univ. Patrick Kaeding, University of Rostock Dr.-Ing. Thomas Lindemann, University of RostockInternship Supervisor:Mr. Helge Rathje, SAL Heavy Lift GmbH, Hamburg, GermanyReviewer:Prof. Maciej Taczala, University of Szczecin

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Major Goals Achieved 2Structural Assesment of Crane

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Crane StructureCrane BoomCrane wiresWire ConnectionSlewing BearingCrane HousingPedestalOpeningsSlew Ring BoltsWire ConnectionsMaterial & StiffnessPin Bearing

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

3Structural Assesment of Crane

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Cranes: 2 x 1,000 mtons SWL, combinable up to 2,000 mtons.Safe Working Load: 1,000 MT @ 16m outreach800 MT @ 25m outreach500 MT @ 38m outreach

Slewing: 360 degree with hydraulicmotor drive Luffing : 18.17 degree to 84.35 degree Hoisting: Maximum boom tip height of 37.3 metersOperating:Conditions5.4 degree inclination(5 degree Heel and 2 degree trim.)Wind Speed: 20m/sec

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

183 Ship CranesStructural Assesment of Crane

Fd=Duty factor Lg=dead loadFh=Live loadLl=Hoisting factorLh1=Horizontal component due to the heel.Lh2=The next most unfavourable horizontal load.Lh3= The horizontal component due to trim. Lw=The most unfavourable wind loadLoad case Type 1Load case Type 2Load case Type 3the crane is considered in the stowed positionIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Lloyds Register Rules and Guidelines 5Structural Assesment of Crane

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Crane LoadsSpecial LoadsIrregular LoadsRegular LoadsIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

DNV-GL rules and guidelines for lifting appliances6Structural Assesment of Crane

Design FEM

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Matching the model with the actual crane material properties7Structural Assesment of Crane

Manufacturer FEM

7Currently, the lowering to the seabed is performed through a so-called wet handshake with an achor handling tug. (an area that K-Line will also be investing in). The cargo is lowered with the vessels own cranes via a winch and then released into the splash zone to a depth of about 200 to 300mt. Here the anchor handling tug takes over.

StudyMFG FEMDesign FEMDeflection:350.4mm350.3mmModel Wt:152 tons151.7 tonsMaterial 940KN/mm^2,102KN/mm^2 940KN/mm2,102KN/mm2

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Validation of result with manufacturer Data

MFG FEMDesign FEM61.3mm46.9mm157 tons156.7 tonsSteel S-355 Steel S-355

8Currently, the lowering to the seabed is performed through a so-called wet handshake with an achor handling tug. (an area that K-Line will also be investing in). The cargo is lowered with the vessels own cranes via a winch and then released into the splash zone to a depth of about 200 to 300mt. Here the anchor handling tug takes over.

Wind conditions at 20m/secList of ship 2 degreeTrim of ship 5 degreeShip speed zero during cargo operationTemperature less than 150 degreeMaterial of structure steel S355Wire stiffness and material properties matched with real craneNo influence of waves

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Load Case S.No.Boom angle.(degrees)load (tons)OutreachWeight of Boom(t)Total WeightForce P(KN)169.741000 (SWL)16152115211301.12254.04800 (SWL)251529529339.12318.17500 (SWL)381526526396.12454.04500251526526396.12569.74500161526526396.12618.17350381525024924.62754.04350251525024924.62818.17250381524023943.62

Physical conditions considered:

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Analysing the Load CasesStructural Assesment of Crane

StudyLoad Case 1Load Case 2Load Case 3Load Case 4Max Stress20KN/cm220KN/cm210KN/cm211KN/cm2Load1000 tons800 tons500 tons500 tonsBoom Ang69.74 degree54.04 degree18.17 degree54.04 degree

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Stress History of Boom with inclination 5.4 deg

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StudyLoad Case 1Load Case 2Load Case 3Load Case 4Max Stress13.30KN/cm212.2KN/cm221.0KN/cm211.7KN/cm2Load1000 tons800 tons500 tons500 tonsBoom Ang69.74 degree54.04 degree18.17 degree54.04 degree

IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Stress History of Housing with Inclination 5.4 degree

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IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Hot Spot Locations all Load Cases

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Analyze Crane LoadsReview cargo conditionsGenerate load radius curveCount cargo operations for 1.8 years Finite element modelling of craneCalculate stress tensors at nodes for all load casesDetermine hot spots and generate stress historyCalculate Fatigue using stress data.Sum up data and calculate damageBeginCalculate fatigue life of craneIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

13Structural Assesment of Crane

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Plate AnalysisWeld AnalysisCarried out to check failure of plateNotch case of 120 to 160 usedAnalysed by coarse grid stressesMATLAB program used for analysisCarried out to check failure of weldsNotch case of 80 to 120 usedAnalysed by special fatigue finite element module More elaborate approach used for analysisIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

14Structural Assesment of Crane

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Maximum damage given by manufacturerDamage difference=0.71-0.663=0.047IntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Maximum damage calculated on welds :=~ 0.711.00Locating Maximum Fatigue Damage15Structural Assesment of Crane

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Plate fatigue determinationGrid stresses obtainedPlate joining locatedNotch case of 120 to 160 Damage found at each grid point Cumulative damage found by summing the results of 8 load casesIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

16Structural Assesment of Crane

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Maximum boom outreach (38mts) is the limiting load case Housing deflections are maximum (46.9mm)Horizontal bearing forces are maximum

Maximum fatigue damage is found to occur on the boom tip after 25 years of lifetimeStructure welds are more prone to fatigue failure compared to the platingThe housing bottom plating and the foundation shape is critical for analysis and hot spot point of viewWindows on the housings need to be optimized with regard to minimum area and clear visibilityIntroductionScopeComparisonAnalysisSimulationFatigue Calc.Conclusion

Important Findings17Structural Assesment of Crane

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18Structural Assesment of CraneStructural Assessment and Fatigue Life Determination Tool in Order to Simplify the Inspection Task Onboard

18With oil and gas resources becoming increasingly scarce around the world offshore drilling has become more and more prevalent. SAL has responded to this trend by designing new vessels that cannot only provide transportation services but also installation and construction services.