crane load testing and monitoring.pdf
TRANSCRIPT
www.waterweightsinc.com
History
Established in 1979 - Water Weights was
the originator of the water-filled load bag,
used in proof load testing of cranes and
lifting equipment.
What are Water Weights?
Water Weights proof load test bags are
used for suspended or deck loads using
any number of bags for loads up to 1500
tons.
• empty bags weigh >2% of achievable load
• savings in transportation, labor, and downtime of
equipment under test
• minimum floor loading during staging of weights
• load measured accurately with certified load cell or flow
meter
• wide range of bags for all sorts of testing parameters
• different weight capacities achieved with single rigging
using manifold and valve systems.
Typical 100 ton test transport and labor savings
Performed with
conventional weights
requires 5 tractor trailer
Loads and 5 men on site
Performed with
Water Weights ™
Requires 1 pickup truck
with trailer
and 2 men on site
ISO 9001:2008
FS 96689
Water Weights bags are fully
certified and tested in accordance
with government requirements and
regulations.
How are they tested?
ISO 9001:2008
FS 96689
ISO 9001:2008
FS 96689
After every job….
After every job….
Environmental Responsibility
We fulfill this commitment by:
Lowering the carbon footprint when crane testing compared to traditional methods
Invasive species mitigation and prevention
Conducting operations in an environmentally sound manner
without disturbing local ecosystems during testing
Promoting environmental responsibility among our employees
Pursuing continuous improvement in our environmental performance
• Global supplier of monitoring /measurement solutions
• Load, force, torque and strain
• Asset management
Applications include:
•Above the hook (sheaves, drums. trolleys)
•Below the hook (links, shackles, canisters, beams)
•In the hook block (trunnion, sheave pin, hook)
•Rope dead end (A2B, wedge socket, clamp-on, line rider)
•Cabled or wireless telemetry
Standard Below-the-hook Product Range LE Series Wireless Load Link SL Series Wireless Load Shackles GL112 Wireless Handheld Load Indicator
www.waterweightsinc.com
NORTHWEST HYDROELECTRIC
ASSOCIATION
Technical Seminar
Hood River, Oregon
May 23 & 24, 2013
Maximising Remaining Useful
Life of Lifting Assets
Jim Bentley
Vice President, Imes Inc
My Glossary of Terms
• Design Life – Original life of asset based
on the as designed (specified)condition
(design code used, loads to be carried, for
how long and in what environment etc).
• Life Extension – Operation under the as
designed criteria for extended period.
• Change of use – Alteration to one or
more of the original design criteria (loads
to be carried, frequency of lift, environment
etc).
Change in Methodology
• Traditional approach based on prescriptive test and inspection.
This approach has in generally served us well but tends to manage assets on a day to day, week to week basis.
• Risk Based approach based on design condition, actual service loadings and degradation with sights set on required life of asset. This approach produces an “organic” maintenance plan based on results of each inspection/maintenance cycle.
Limitations of Prescriptive Testing
Overload Testing
Potentially More Harm
Than Good
Lack of Flexibility
Unable to Benefit From
Experience
IN SERVICE DATA
INSPECTION DATABASE
TESTING
DEFECT REPORTS
DATA MINING
& ANALYSIS TOOL
DESIGN DATA
MANUFACTURING DATA
STRUCTURAL ANALYSIS
LOAD TESTING
BASELINE NDE SAFETY CASE
STATISTICAL DATABASES
RISK RISK BASED
INSPECTION
SCHEDULE
Evaluation of Current Condition
Risk Based - Objectives
• Continued safe, cost effective operation and management of mechanical handling assets through programmed life.
– Compliance with relevant legislation and corporate requirements
– Risk based system to target inspection and mitigation measures
– Provide an auditable trail
– Traceability for all decisions made
– Manage information interfaces
– Effective control of costs and resources
– Reduce Life Cycle Cost
– Added value
Crane Condition Monitor (CCM)
Software Hook Height
Telemetry
Motor Temp.
Motor Current
Load
Cross Travel
Long Travel
Block Diagram
Future expansion...
Software
• Displays assets current status
• Allows viewing of all recorded historical data – Allows detailed analysis of the
assets usage
– Can be used for incident investigation
• Data can be viewed from any location on corporate network – Remote access possible using
VPN technology
Crane Example
• Installed Crane
– 1989 i.e current 24 years of service
– Design Life 25 years to CMAA 70
– Regular use intermittent operation 100K to
500K cycles
– Mean Effective Load Factor 0.671 to 0.85
• Customer desire to operate crane until
2040 as a hard target with stretched
targets of 2060 and 2080.
• At 2080 crane would be 90 years old.
Life Extension Approach
• Establish current condition
– Review design code and any legislation changes
– Visual inspection
– Instrumented load test (AE/Strain gauges etc)
– Review existing or develop Finite Element Model
– Apply current inspection conditions to model
– Review current inspection, test and maintenance
activity
• Complete risk assessment of design and
operational use past, present and future.
Life Extension Cont.
• Against identified risks map current
inspection, test and maintenance activity
to give level of mitigation
• Continue doing activity that underpins risk
mitigation
• Stop doing activity that does not
contribute
• Start doing activity that reduces risk to
acceptable level – ALARP/ALARA
Life Extension Cont.
• Collect usage data (fatigue) and apply to
design calculations.
• Establish where crane lies on “fatigue
clock”
• Use fatigue history to establish when in
future crane will exceed maximum mean
effective load factor – end of life date
• Use information to plan re-capitalization of
asset
Mean Effective Load Factor
Hook Load
(lbs)
Recorded lifts
during lifetime 24
years
(288 months)
Load/Rated
Capacity
W
W3
Est. lifts/total lifts, P
k3 = W3P
<1000 2493 0.1 0.001 0.4003 0.0004
<2000 540 0.2 0.008 0.0867 0.0007
<3000 1080 0.3 0.027 0.1734 0.0047
<4000 189 0.4 0.064 0.0303 0.0019
<5000 9 0.5 0.125 0.0014 0.0002
<6000 315 0.6 0.216 0.0506 0.0109
<7000 387 0.7 0.343 0.0621 0.0213
<8000 9 0.8 0.512 0.0014 0.0007
<9000 639 0.9 0.729 0.1026 0.0748
<10000 504 1.0 1.000 0.0809 0.0809
≥10000 63 1.25 1.953 0.0101 0.0197
Totals 6228 - - 1.0000 0.2225
Estimated value of k = 3√0.2225 = 0.6082
For a Service Class D (Heavy Service) crane, Load Class L3 and N2 load cycles k =
0.671 to 0.85 (ref. CMAA#70 Table 2.8-1)
Hence the crane usage to date is within the mean effective load derived from the
load spectrum
Projected Life
• For the crane the mean effective load
factor k = 0.85 max.
• Hence k3 = 0.6141 compared with 0.2225
at present.
• Hence, for the same load distribution the
crane life will be (0.6141/0.2225) x 24 =
66.24 years.
• If the installation date was at the beginning
of 1989, the max mean load factor will be
met in the year 2055.
And Finally……………. • In all you do just remember that when faced
by a strong challenge an appropriately strong
response is needed………