ttd hmc 3568 lko 250-32 1000-15 3000m ahc revg€¦ · no. ttd hmc 3568 lko 250-32 _1000-15_3000m...

PROJECT DOCUMENT of 19

No. TTD HMC 3568 LKO 250-32

_1000-15_3000m AHC RevG

Form-ID-Document-201011

Customer Romas

Supplier MacGregor Norway AS Andøyveien 23 NO-4623 Kristiansand NORWAY [email protected]

Project number, supplier 1126xxx Project name, customer Unknown

P.O. number, customer

Technical Tender

Equipment: MacGregor Offshore Knuckle Jib Crane

Type: HMC 3568 LKO 250-32 (1000-15) 3000 m AHC

Active heave compensated 100t offshore knuckle jib crane with main winch on crane.

Revision Description Date Author Checked by

A Issued for Information 29.10.2012 LMA RGO

B Issued for IDC as Standard TTD 18.04.2013 LMA

C Revised Ch.6: Test and installation 05.06.13 LMA

D Re-issued for Information 17.01.2014 RGO

E Re-issued for Information 31.01.2014 RGO

F Revised according to customer requirements 06.08.2014 LAH

G Revised to include 15 t whip line winch 13.08.2014 LAH

This document and all information and data herein or herewith is the confidential and proprietary property of MacGregor Norway AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without the written confirmation from MacGregor Norway AS. © MacGregor Norway AS www.macgregor.com



_1000-15_3000m AHC RevG

CHANGE DESCRIPTION HISTORY

Revision Change Description

A Initial version

B Issued for IDC as Standard TTD

C Revised Ch 6

D Logo updated

E Classification according to FEM added

F Revised according to customer requirements

G Revised to include 15 t whip line winch



_1000-15_3000m AHC RevG

CONTENTS

1 SCOPE OF SUPPLY ............................................................................................................... 5

1.1 Project Management ......................................................................................................... 5

1.2 Engineering ...................................................................................................................... 5

1.3 Procurement ..................................................................................................................... 5

1.4 Manufacturing ................................................................................................................... 5

1.5 Testing and Commissioning .............................................................................................. 5

1.6 Installation ........................................................................................................................ 5

2 LIST OF ABBREVIATIONS ...................................................................................................... 6

3 TECHNICAL DESCRIPTION ................................................................................................... 7

3.1 100t AHC Offshore Knuckle Jib Crane .............................................................................. 7

3.2 Electro Hydraulic Power Unit (HPU) .................................................................................. 8

3.3 Active Heave Compensation System, (AHC/AT) ............................................................... 8

3.4 Dual Sensor System (Important Safety Function) ............................................................. 8

3.5 Operator Cabin ................................................................................................................. 9

3.6 Fully Integrated Automatic Grease Lubrication System ................................................... 10

3.7 Emergency Power System, EPS ..................................................................................... 10

3.8 Main Hook ...................................................................................................................... 10

3.9 Flood Lights .................................................................................................................... 10

3.10 Helicopter Warning Lights ............................................................................................... 10

3.11 Winch Camera Monitoring System .................................................................................. 10

3.12 SPM Nipples in Main Electric Motors .............................................................................. 10

3.13 Spare Slip Rings ............................................................................................................. 10

3.14 Remote Diagnostic Control system ................................................................................. 10

3.15 FMEA. ............................................................................................................................ 10

4 EQUIPMENT DATA SHEET .................................................................................................. 12

4.1 Performance Data ........................................................................................................... 12

4.1.1 Main Hook Lifting Capacity, Shipboard Mode .......................................................... 12

4.1.2 Main Hook Lifting Capacity, Offshore Mode ............................................................. 12

4.1.3 Remaining Hook Pull Force vs. Depth ..................................................................... 12

4.1.4 Active Heave Compensation System, (AHC/AT) ...................................................... 13



_1000-15_3000m AHC RevG

4.2 Technical Specification ................................................................................................... 14

4.2.1 Design Data ............................................................................................................. 14

4.2.2 Approximate Weights ............................................................................................... 14

4.2.3 Power Consumption ................................................................................................ 14

4.2.4 Main Crane Data ...................................................................................................... 14

4.2.5 Main Winch Data ..................................................................................................... 15

4.2.6 Surface Treatment ................................................................................................... 15

4.2.7 Hydraulic Oil Piping ................................................................................................. 15

5 OPTIONS .............................................................................................................................. 16

5.1 List of Options ................................................................................................................. 16

5.2 Description of Options ..................................................................................................... 17

5.2.1 Whip Winch, ............................................................................................................ 17

5.2.2 Camera at Boom Tip ................................................................................................ 17

5.2.3 Power Management System .................................................................................... 17

5.2.4 Bridge Monitor ......................................................................................................... 17

5.2.5 DNV Certification for Large Cranes .......................................................................... 17

5.2.6 Tugger Winches ....................................................................................................... 18

5.2.7 Personnel Lift ........................................................................................................... 18

5.2.8 Water Cooling, Pedestal .......................................................................................... 18

6 TESTING AND INSTALLATION ............................................................................................. 18

6.1 Testing and Commissioning at Designated Ship Yard ..................................................... 18

7 MISCELLANEOUS INFORMATION ....................................................................................... 19



_1000-15_3000m AHC RevG

1 SCOPE OF SUPPLY

One active heave compensated offshore crane with main winch on crane. The work to be performed includes

all project management, engineering, supervision, equipment and materials necessary to perform the work

outlined below.

All images/pictures are for illustration purposes only. The actual equipment may vary.

1.1 Project Management

• Project management and planning to ensure delivery of the product in accordance with the

customer’s requirements.

• Project reporting forecasting completion of the product to the customer.

• Project completion and close out with customer.

1.2 Engineering

• Determine and confirm the final detailed design.

• Produce detailed manufacturing procedures.

• Prepare the user and operating manuals as well as the data book.

• Update As built documentation.

1.3 Procurement

• Purchase all material and components necessary to complete and deliver the product as per customer

requirements.

1.4 Manufacturing

• Manufacturing and assembly of the equipment/structure and all ancillary components.

• Manufacturing supervision by MacGregor personnel and any required third party .i.e. classification

society.

1.5 Testing and Commissioning

• FAT - Factory Acceptance Test at MacGregor’s test facilities.

• HAT - Harbour Acceptance Test at MacGregor’s facilities or other designated location

• SAT - Sea Acceptance Test at MacGregor’s facilities or other designated location.

(See chapter 6 for reference to work scope)

1.6 Installation

• Installation of the crane on the vessel at MacGregor’s facilities or other designated location

(See chapter 6 for reference to work scope)



_1000-15_3000m AHC RevG

2 LIST OF ABBREVIATIONS

AHC - Active Heave Compensation

AHC/AT - Active Heave Compensation/ Auto Tension

CT - Constant Tension

DAF - Dynamic Amplification Factor

EPS - Emergency Power System

FAT - Factory Acceptance Test

GA - General Arrangement

HAT - Harbour Acceptance Test

HPU - Hydraulic Power Unit

HSE - Health Safety Environment

LK - Luffing Knuckle Jib Crane

LKO - Luffing Knuckle Jib Offshore Crane

m - Metres

MW - Main Winch

SAT - Sea Acceptance Test

SWL - Safe Working Load

t - Metric Tonnes

UDLS - Ultra Deep Lifting System

WW - Whip Winch

WUD - Winch Under Deck



_1000-15_3000m AHC RevG

3 TECHNICAL DESCRIPTION

3.1 100t AHC Offshore Knuckle Jib Crane

A complete Active Heave Compensated electro-hydraulically operated MacGregor crane designed for

efficient and safe load handling, offshore lifting operations and subsea load handling. Other features include

ship to ship mode and personnel lift all depending on which options are declared upon purchase.

This crane is delivered and mounted on a circular foundation which, depending upon design, can be welded

or bolted to the vessel’s crane foundation. All main operational functions i.e. hydraulic luffing cylinders,

slew drive system, main, auxiliary and tugger winches are all controlled from a spacious fully equipped

operator cabin with good operating views to the vessels’ main deck and lifting zones.

Knuckle jib cranes were originally designed to keep the jib end, including the load, as low as possible to

reduce the pendulum motion caused by movement of the vessel. However, when these cranes are used to lift

the large and heavy objects, it is at times necessary to have more free-hook height to provide increased space

for lifting arrangements, slings etc.

MacGregor knuckle boom cranes.

All our knuckle jib cranes are designed to lift the high loads with an extended knuckle jib. This includes

strengthen structure and cylinder system to deal with these forces. This feature provides operators with a

great flexibility during the planning of lifting operations.

When the crane is in the over-side working position, with the active heave-compensation (AHC) activated

and with the crane hook in the water, it is still possible to operate the jib and slew crane functions. This

makes load positioning possible and optimizes other crane functions without shutting down the AHC mode

or moving the vessel.



_1000-15_3000m AHC RevG

On all larger MacGregor cranes the slew drive system components, including drive gears and motors, are

located inside the crane’s king. This simplifies the maintenance and inspections throughout the entire

lifetime of the crane and protects the components from the harsh environment/surroundings.

3.2 Electro Hydraulic Power Unit (HPU)

Complete electro hydraulic power unit for all the crane’s hydraulic functions. The HPU is a totally enclosed

unit mounted in the crane king. The hydraulic oil tank is built-in in the crane king structure. The oil pumps

are submerged in the oil reservoir. El.powered air fan coolers of sufficient capacity are supplied to avoid

overheating of the hydraulic oil.

3.3 Active Heave Compensation System, (AHC/AT)

By using the finest and most reliable motion sensors, position sensors and control system components,

MacGregor cranes provide the best possible active heave compensation performance on the market.

Accuracy measured to a few centimetres is achievable even under extreme heave conditions.

3.4 Dual Sensor System (Important Safety Function)

In our expert opinion, regulation sensors used in AHC/AT mode are of critical importance and are therefore

specifically focused on during the product design stage. A fail-safe sensor system with dual sensors has been

developed, tested and implemented in our products. This system with auto-takeover ensures unique winch

function reliability when operating in AHC/AT mode. The load cell is one of these sensors which have a

dual output (two channels). This enables the AHC/AT to continue (without stop) in case of a failure in one of

these channels. Another sensor is the winch position encoder which is original a Profibus sensor, while a

secondary independent analogue sensor operates without the Profibus system. If a failure in the default

sensor occurs, the secondary sensor takes over immediately, without shutting down AHC/AT mode. These

new features significantly increase the system reliability. The crane jib system is also equipped with dual-

sensors giving important feedback to the system in AHC/AT mode. The control system will automatically

switch to the second sensor if there is a failure in the primary one. All dual sensors will generate alarms if

there is deviation between them. This is to warn the operator at an early stage that one of the sensors is not

sending a correct value. The operator can easily switch between the sensors, unless one of them has totally

failed.



_1000-15_3000m AHC RevG

3.5 Operator Cabin

The crane is equipped with a spacious operator cabin presenting a comfortable work place for the crane

operator. The operator cabin is equipped with an ergonomic and shock absorbed operator chair providing all

main crane operations via joysticks located on armrests either side of the operator’s chair.

Full operational status of the crane can be monitored and operational modes changed via the operators

control touch screen. The display shows various critical operational information such as: load in hook, load

vs. radius, operating temperatures, alarms etc.

The cabin is also fully sound insulated and equipped with an air conditioning system, close circuit TV

monitors (from main and aux winches) window wipers, signal horn, window sun-blinds, FM radio/CD

player, VHF / UHF radio and general instrumentation.

The standard cabin design provides a comfortable and user friendly environment to allow all types of lifts to

be performed in a safe and proper manner. The cabin can be upgraded according to customer’s requirements.

Typical interior of an offshore operator cabin with touch screen display



_1000-15_3000m AHC RevG

3.6 Fully Integrated Automatic Grease Lubrication System

A fully automatic grease lubrication system supplies necessary and correct lubrication to various points on

the crane. This system significantly simplifies the maintenance of the crane. The advantage of the central

lubrication system is that it provides grease to points on the crane that may have difficult access and requires

additional equipment i.e. lift hire and working at height trained personnel. It also ensures that it releases “a

little grease frequently” as opposed to “too much grease infrequently”.

3.7 Emergency Power System, EPS

An emergency power system, consisting of a totally-independent pump/motor system with a separate remote

control panel, ensures a safe operation of the crane, even if the main power supply (and aux. 230V power

supply) fails. All crane and winch functions (not AHC/AT mode) can be operated at full load at reduced

speed.

3.8 Main Hook

Subsea swivel hook for single line lift.

3.9 Flood Lights

2 x Pendulum suspended 400W marine floodlight protected for marine environments. The lights are fitted on

both sides of the jib end.

3.10 Helicopter Warning Lights

2 x helicopter warning lights in marine enclosures. One mounted on top of the king/main winch and one in

front on the main jib.

3.11 Winch Camera Monitoring System

Complete camera monitoring system for all crane winches. LCD flat screen monitor mounted in the crane

cabin.

3.12 SPM Nipples in Main Electric Motors

All main electric motors are fitted with SPM nipples for condition monitoring.

3.13 Spare Slip Rings

6 available single rings for signal.

3.14 Remote Diagnostic Control system

Satellite communication based remote control system that gives service personnel immediate access to the

crane control system anywhere in the world. The remote diagnostic control system is free of charge in the

warranty period. After that, a yearly fee will apply.

3.15 FMEA.

An FMEA analysis will also be provided as part of the final documentation



_1000-15_3000m AHC RevG



_1000-15_3000m AHC RevG

4 EQUIPMENT DATA SHEET

4.1 Performance Data

4.1.1 Main Hook Lifting Capacity, Shipboard Mode

Crane lifting capacity is an automatic stepless function of the crane outreach. (Lifting capacity on outer

layer, full drum)

Lifting capacity, single line arrangement SWL 250 kN (25 t) at 32 m outreach


4.1.2 Main Hook Lifting Capacity, Offshore Mode

Crane lifting capacity is an automatic step less function of the crane outreach. (Lifting capacity on outer

layer, full drum)



Ship to ship capacity Derating curves will be issued

Subsea lift capacity Reduce SWL described above with the weight of

submerged rope and DAF due to hydrodynamic

forces and add buoyancy of the load.

Auto tension system (AT) High speed auto-tension function included

Auto tension force setting 0-100t, set from operator’s cabin

Emergency pay out function MOPS and AOPS

4.1.3 Remaining Hook Pull Force vs. Depth

Depth (m) Remaining hook lifting

capacity (t)

Estimated deployment

capacity (dry t)

0 100 100

500 91 100

1000 82 93

1500 74 83

2000 65 73

2500 56 64

3000 48 54

Hydrodynamic forces etc. are not considered in this table.

Data used in table above:

Max hook pull, single line 100 t

Wire diameter TBC 64 mm

Wire weight dry/wet 19.9/17.29 kg/m

Density of seawater 1025 Kg/m3



_1000-15_3000m AHC RevG

Remaining hook lifting capacity is the SWL in air from deck which is reduced by the weight of the paid

out wire at the operational depth. No buoyancy effect acting on the lifted object is included.

Estimated deployment capacity (EDC) is the remaining hook lifting capacity with the buoyancy of the

lifted object included. The lifted object is estimated to have a density of 7.85t/m3, therefore by using the

following formula we can calculate the estimated deployment capacity (or dry weight of the lifted object).

4.1.4 Active Heave Compensation System, (AHC/AT)

Max top wire tension, during AHC operation 1000 kN (100 t single line)

Reference system MRU in crane control system

Performance case AHC/AT, 0-50% of max SWL

Heave period 10 sec.

Nominal displacement +/- 3.2 m (6.4 m total motion)

Max compensation speed 120 m/min (2.0 m/s)

Performance case AHC/AT, 0-100% of max SWL

Heave period 12 sec.

Nominal displacement +/-1.9 m (3.8 m total motion)

Max compensation speed 60 m/min (1.0 m/s)

Re-generation of power to the electric system: (Active system only)

Estimated re-generated power NA

The electrical systems onboard should have the ability to withstand possible re-generated power from main

motors. The estimated re-generated power is calculated as an approximate max. value that occurs during the

lowering of max. load, and as a peak value in AHC/AT at max. load and speed.



_1000-15_3000m AHC RevG

4.2 Technical Specification

4.2.1 Design Data

1. Type of operation General load handling up to 100t in harbour and

offshore.

Subsea load handling, both deployment and

retrieval.

2. Area classification Safe zone

3. Environment Harsh environment / Temperate

4. Wind speed in boom stored/out of service 44 m/s

5. Wind speed operational 25 m/s

6. Design temperature (°Celsius) -20 °C to + 45 °C

7. List + Trim 5° + 2°

8. Design life FEM – Rules for the design of Hoisting

Appliances, (1.001, 3rd

edition 1998, 10.01.)

9. Appliance group Crane as a whole-

SWL < 250t:

A3

Crane as a whole-

SWL ≥250t:

A2

10. Class of utilization U3 U2

11. Load spectrum class Q2 Q2

12. Safety devices - Emergency stop

- Spring centred control valves

- Overload protection

- Hook stop system

- Luffing cylinder limitation

- Load holding brakes

- Fail safe brakes

13. Design code DNV Standard for Certification No.2.22, Lifting

Appliances, October 2011

14. Additional rules EN13852-1 Applied as practical as possible

15. Certifying authority DNV or customer specification 4.2.2 Approximate Weights

1. Total weight, incl. wire 270t 4.2.3 Power Consumption

1. Power supply connection location To terminals inside pedestal 2. Main power supply 690V/60Hz/3ph,

3. Required power, main motors 3x300 kW + 1 x 550 kW S1-100%

4. Required power, aux motors 30 kW S1-100%

5. Required power, emergency system 45 kW S1-100%

6. Secondary power supply 230V/60Hz/1ph

7. Required power, control system, lights etc. 5 kW 4.2.4 Main Crane Data

1. Max reach, main hook 32 m from centre of pedestal

2. Max reach, whip line 33 m from centre of pedestal



_1000-15_3000m AHC RevG

3. Min reach 6.0 m from centre of pedestal

4. Pedestal height 5.0 m

5. Slewing speed 0-1rpm (Rmin-15m), 0-0.5 rpm (20m-Rmax)

6. Slewing angle 360 degrees- endless

7. Dynamic factor ψ = 1,3 for working load (WL) 10 kN<WL<2 500

kN

For the slew system/foundation an extra safety

factor (SF1) is required when the operator cabin is

attached above the slew bearing.

SF1 = 1,3 for WL < 2 500 kN

SF1 is a global safety factor which shall be applied

to all load components. 4.2.5 Main Winch Data

1. Hook travel distance, single line 3000 meters

2. Wire type and dimension OD Ø64mm, galvanized, non rotating type

3. Normal mode, single line, 0-33t Max speed = 0-60 m/min, step less variable

4. Normal mode, single line, 0-66t Max speed = 0-60-30 m/min, step less variable 5. Normal mode, single line, 0-100t Max speed = 0-30-20 m/min, step less variable 4.2.6 Surface Treatment

1.

Surface treatment The external surfaces are sandblasted to Sa 2,5

• International Interspec System 1, or equivalent for general purpose.

• International Interspec System 6, for application on non-ferrous metals.

• International Interspec for Hydraulic Tank, for oil reservoir on the inside.

2. Colour White (RAL 9010) 4.2.7 Hydraulic Oil Piping

1. Pipes ISO 8434-1 (DIN 2353) standards

2. Pipes, Nuts and Locking Rings Stainless steel AISI 316

3. External pipe material: OD up to Ø50mm AISI 316 stainless steel

4. External pipe material: OD above Ø50mm Mild steel

5. Fittings ISO 8434-1 (DIN 2353) el. zinc coated steel

6. Fitting system <Ø38mm pipes Walform

DIN 2353

Body- yellow chromate steel

7. Fitting system >Ø38mm pipes Flange syst.

SAE J518 and ISO 6164

Yellow chromate steel

8. Hoses EN 856 (SAR R13/12)/EN 857 (SAE R2T)

9. Hose couplings Regular steel coated with ”Tuff Coat”

10. Non corrosive protection for couplings, fittings Denso tape



_1000-15_3000m AHC RevG

5 OPTIONS

5.1 List of Options

NUMBER CODE/TYPE OPTION INCLUDED NOT

INCLUDED

1. AO815T1500 Whip winch X

2. AO9.1 Camera at boom tip X

3. AO11.1 Power management system X

4. AO12.2 Bridge monitor X

5. AO14.3 DNV certification for large cranes X

6. AO15.1 2 x Tugger winch (4t) X

7. AO15.2 2 x Tugger winch (10t) X

8. AO17.1 Personnel lift whip winch X

9. AO19.2 Water cooling, pedestal X



_1000-15_3000m AHC RevG

5.2 Description of Options

5.2.1 Whip Winch,

A complete whip line winch mounted on the main jib. Separate wire sheave bracket on the knuckle jib.

Whip winch type AO815T1500

Safe working load (SWL) 150 kN (15 t)

Hook travel 1500 m

Hoisting speed 80 m/min

Weight, incl. wire sheaves and wire 18 t (approximately)

Spooling device N/A

Personnel lift Option

Max top wire tension, during AHC operation N/A

Reference system N/A

5.2.2 Camera at Boom Tip

Code: AO9.1

The crane is equipped with a camera system on a pendulum beam at the boom tip.

5.2.3 Power Management System

Code: AO11.1

A crane control system with interface for control of power management.

5.2.4 Bridge Monitor

Code: AO12.2

Includes 17” slave monitor with a repeater.

5.2.5 DNV Certification for Large Cranes

Code: AO14.3

The crane is designed, manufactured and tested according to DNV requirements for offshore cranes. As

option a third party certification by DNV can be included. This includes complete DNV design

review/approval, manufacturing control, FAT test attendance and a final product certificate.



_1000-15_3000m AHC RevG

5.2.6 Tugger Winches

Code: AO15.1

2 x 4t hydraulic tugger winches, side-tiltable +/- 15 degrees. Both winches are foot operated from crane

cabin. Winches are located on side of crane king, just below main jib cylinders. The feature of constant

tension is included and adjustable range is 0-4t.

Code: AO15.2

2 x 10t hydraulic tugger winches, side-tiltable +/- 15 degrees. Both winches are foot operated from crane

cabin. Winches are located on side of crane king, just below main jib cylinders. The feature of constant

tension is included and adjustable range is 0-10t.

5.2.7 Personnel Lift

Code: AO17.1

The crane and control system is designed for personnel lifting. Personnel lift mode ensures two means of

braking: lift safety factor of 10, deadhip retrieval and blocking of AHC/AT and emergency release functions.

5.2.8 Water Cooling, Pedestal

Code: AO19.2

The crane is equipped with a water cooler in pedestal. Customer to provide ice water.

6 TESTING AND INSTALLATION

6.1 Testing and Commissioning at Designated Ship Yard

See Appendix: TTD Inst and comm_Designated Ship Yard.docx



_1000-15_3000m AHC RevG

7 MISCELLANEOUS INFORMATION

The delivery of the crane includes:

DNV approval of crane pedestal:

Design review and manufacturing control of the crane pedestal.

FAT:

FAT test carried out at MacGregor’s facilities. FAT invitation to be sent to the customer.

Documentation:

Crane load diagrams:

Full set of load diagrams covering normal offshore operation modes. The diagrams cover internal lifting on

the vessel, ship to ship operation and ship to sea bed operations.

The diagrams will be calculated and included in the user manual. The diagrams will also be used as a basis

for programming the crane computer in the cabin.

Derating table; Ship to ship operation:

Derating table for ship to ship lifting is included in scope. The table specifies the crane’s capacity during the

loading/offloading operations between a mother vessel and another vessel in a specified sea state condition.

The key element in these calculations is the expected max relative speed between the crane hook and the

load at time of pick up.

User Manual

A part of the delivery is a standard documentation package (User Manual). Contains all required user

information such as installation, first start up, operation, maintenance and preservation, including all required

drawings, diagrams and certificates.

Language: English

Copies: Three hard copies.

For additional documents or copies contact the sales department.

ttd hmc 3568 lko 250-32 1000-15 3000m ahc revg€¦ · no. ttd hmc 3568 lko 250-32 _1000-15_3000m...

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