12th North Sea Offshore Cranes &

Lifting Conference 2007

Maintenance, Inspection, Temporary
Cranes & Crane upgrades
Part 1
Part 2
Part 3
Part 4
Part 5

Maintainability of Cranes, Access to Components,

Standardisation of Component Interfaces
Condition Monitoring, Lubricant Analysis,
Oil Flow Monitoring
Data Logging/Recording/Monitoring
Analysis and Value of Recorded Data
Temporary/Mobile Cranes
What has to be considered?
Crane Upgrades
A real example

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Version 1.0, dd. 17.04.07

Part1 Maintainability of Cranes

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.
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Part1 Maintainability of Cranes

Standardise interfaces of components

I.e. Standardised instrumentation via Can-Bus of diesel engine one
plug only. Access to main components by maintenance crane allows
replacement without another crane.

Un-park
maintenance crane

Slew gearbox
replacement
Engine
replacement

Remove radiator
and hood

Lift engine to deck

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Part1 Maintainability of Cranes

Standardise interfaces of components

Simplified 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.

Remove bolted diagonals

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Remove pins from winch

flange

Replace winch
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Part2 Condition Monitoring

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.
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Part2 Condition Monitoring

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) a
database of the leak oil development is created.
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Part2 Condition Monitoring

In Line Oil Flow Monitoring

The 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.
Principle Layout for a hydraulic flow monitoring system.

Le ak Oil Me asure me nt
(leak oil pe r minute wit h 100 bar sys tem pres sur e)
Amoun t in Li tres Per Unit

Date o f
Runni ng
Insp ection Hours
Date o f
Runni ng
Insp ection Hours

DESCRIPTI ON

Type

DESCRIPTI ON

Type

aux. hoist motor no. 1

aux. hoist motor no. 2
main hoist motor no. 1
main hoist motor no. 2
luff ing mot or
sle win g ge ar motor no . 1
sle win g ge ar motor no . 2

A2F80

8
7,5
7
6,5
6
5,5
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0

DESCRIP TION

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A2F125
A2F90
A2F45
A2F45

Ident. No. Max . Allow able Actu al Diffe rence

Leak Oil (max .) Leak Oil
in %
Ident. No. Max . Allow able Actu al Diffe rence
Leak Oil (max .) Leak Oil
in %
510229614
2,00
0, 00% acc ep table
2,00
0, 00% acc ep table
510229714
3,00
0, 00% acc ep table
3,00
0, 00% acc ep table
2,50
0, 00% acc ep table
510229514
1,50
0, 00% acc ep table
1,50
0, 00% acc ep table

Leak Oil (max.)

aux. hoist
aux . hois t
moto r no. 1 motor no. 2

Leak Oil

main hoi s t main hois t luf fing motor slew ing gear s lew ing gear
moto r no. 1 mot or no. 2
motor no. 1 moto r no. 2

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Part3 Data Logger

Existing Data Logger

Limited information such as time, average weight of lift is
recorded. The information content is very limited.

date

load cycle

time start

time end

cycle time

TT.MM.JJ
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998
24.03.1998

No.
0
1
2
3
4
5
6
7
8
9
10

hh:mm:ss
09:38:13
09:41:46
09:44:24
09:48:03
09:55:59
09:59:25
10:01:45
10:04:12
10:07:33
10:10:42
10:13:52

hh:mm:ss
09:39:55
09:42:41
09:45:36
09:48:23
09:57:08
10:00:35
10:02:44
10:06:02
10:09:03
10:12:03
10:14:40

hh:mm:ss
00:05:15
00:03:33
00:04:51
00:08:16
00:04:35
00:03:30
00:03:26
00:05:11
00:04:39
00:04:31
00:07:35

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average load

(t)
18,7
7,9
13,7
4,8
10,6
5,9
7,8
17,7
7,3
14,2
5,9

average load
max load plus dead weight utilization
22t

(t)
50
40,4
43,2
33,6
44,8
47,2
45,1
49
51,9
44
38,6

(t)
40,7
29,9
35,7
26,8
32,6
27,9
29,8
39,7
29,3
36,2
27,9

(%)
115,6
93,2
99,8
77,7
103,5
109,1
104,1
113,1
120
101,6
89,2

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Part3 Machine Data Recorder

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.
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Part3 Machine Data Recorder

Data recorded via existing instrumentation

Master
CPU

Ethernet/RS232

CAN 1...4

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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

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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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
utilization MDE [%]
start time
31.05.2001
15:54:28
stop 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 values
of recorded process variable

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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.
monitored
summed up
process variable
time shares

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Part3 Machine Data Recorder

Possible use of MDR data, results

Classification
according to FEM
Recorded Stress
Cycles
Stress Cycle
Spectrum
Expected Rest
Life Time of
Component
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Part3 Machine Data Recorder

Results from recorded data:

Power Spectrum per Speed

Power Spectrum

Speed Spectrum

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Part3 Machine Data Recorder

Results from recorded data:

Slewing angle versus load

Multi Dimensional
Analyses
Exact details about
Load Spectrum
Preventive
maintenance based
on real and actual
utilization/usage of
each installed
component

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Part3 Machine Data Recorder

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 according
to 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

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Part4 Temporary Cranes

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.
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
speed not

- AOPS/MOPS not installed, hoisting

sufficient

- Big cabins with specific access

requirements

- Small cabins used, required exits and

access size not according to offshore
rules

- Emergency lowering required

- Emergency Lowering not installed

- Dynamic load charts considering

offshore wind speeds, off- and side
leads and heel/trim considered

- Land based load charts only

- Emission standards

- New machines will fulfil required

emission 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/owners
specification/scope of work
Crane survey (if required)

Example:
Crane Model:
Capacity:

Monarch 6032
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 winch
rotation indicators)
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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

New Winch

Existing Winch
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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 circuit
New 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

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Thank you for your attention.

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