proceedings wednesday 13th april
DESCRIPTION
Proceedings Wednesday 13th April - The 16th North Sea Offshore Crane and Lifting Conference.TRANSCRIPT
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Wednesday 13th April
Table of Contents, Wednesday 13th April
Heavy Lifting in 2,500 m water depth, Henk de Boo van Uijen,Design, construction and commissioning of a heavy lift offshore crane, Arjo van Putten, Flexible load handling solutions for multi purpose vessels, Tønnes Seierstad
Page 3Page 27Page 76
New risk based bolt maintenance procedures – improved reliability/reduced life cost of offshore cranes, Rod Corbett Special engineered bolts for critical joints in the lifting industry, Ragnar SandveLifting and handling remote monitoring and diagnostic solutions, Aaron J. Spak W A RFID inspection system the new Crosby Quic ‐ Check, inspection and identification system , Frédéric CrynenTemporary lifting facilities for the BP Magnus crane replacement, Gordon Mccombie
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Mob‐boat handling with offshore cranes – combination of design parameterTor RaknestangenTraining & competence in crane transfer operations; the importance of being prepared, David BrittanLifting persons with carriers suspended from offshore cranes application of European commission guidance document, Gunnar Matre
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Reception given by the municipality of Stavanger in the Stavanger Maritime Museum Local beer tasting program with small tapas
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Program part oneWednesday 13th April
Morning session Chair: Stephen WerhleHeadline: Heavy Lifting08:30 Heavy Lifting in 2,500 m water depth, Henk de Boo van Uijen,09:00 Design, construction and commissioning of a heavy lift offshore crane,
Arjo van Putten09:30 Flexible load handling solutions for multi purpose vessels, Tønnes SeierstadHeadline: Operational Maintenance & Inspection10:00 New risk based bolt maintenance procedures – improved reliability/reduced
life cost of offshore cranes, Rod Corbett 10:30 Coffee / CraneExpo11:00 Special engineered bolts for critical joints in the lifting industry, Ragnar Sandve11:30 Lifting and handling remote monitoring and diagnostic solutions, Aaron J. Spak W
12:00 Lunch / crane expo
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Speaker
Henk de Boo van Uijen,Jumbo Offshore, NLLecture: Heavy Lifting in 2,500 m water depth‐ Cascade & Chinook FSHR Installation
Background:He has a bachelor degree in Mechanical Engineering and has more than 20 years experience in the marine heavy lift, transport and installation industry. Prepared preliminary, principal and detailed engineering for all kinds of lifting
operations, raised method statements, risk assessments etc
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13 April 2011 – Stavanger
Heavy lifting in 2,500 m water depth -Cascade & Chinook FSHR Installation
Henk de Boo van Uijen – Manager Offshore Engineering Jumbo Offshore
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13 April 2011 – Stavanger
• Jumbo Offshore
• Cascade & Chinook project details
• Project execution phase:– Mobilisation– Loading and transportation– Offshore operations
• Project specific challenges
Cascade & Chinook TSFK presentation
Heavy lifting in 2,500 m water depth – Cascade & Chinook FSHR installation
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13 April 2011 – Stavanger
Jumbo Offshore
• Jumbo is a privately owned company
• Jumbo employs over 450 people worldwide
• Jumbo operates a fleet of 13 Heavy Lift Vessels
• Jumbo has > 40 years of experience in heavy lift shipping
• In-house new building department
• Evolution lift capacity from 100 Te to 1.800 Te
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13 April 2011 – Stavanger
Jumbo Offshore - vessels
• Huisman Mast Cranes 900 Te at 25 m
• Dual crane configuration
• Re-reeving to various configurations
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13 April 2011 – Stavanger
Jumbo Offshore - vessels
A new patented Deepwater Deployment System, installed September 2009: 1000 t at 1000 m Depth
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13 April 2011 – Stavanger
Cascade & Chinook Project - General
FSHR
Water Depth : 2515 – 2744 m
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13 April 2011 – Stavanger
Cascade & Chinook Project - General
• Client: Technip Houston, USA– (main contractor)
• Ultimate Client:Petrobras Americas, USA
• Mobilise Project Equipment in Rotterdam (The Netherlands)
• Load 5 B-Cans in Pori (Finland)
• Set-up in field
• Construction of Riser by Deep Blue
• Hand-over 410 Te riser to Fairplayer
• Dual crane shift 350 Te B-Can and connect to Riser
• Lift B-Can/Riser Assembly (760 Te) and lower to 200 m water depth
• Connection to bottom anchor at -2500 m by Technip
• Demobilise in Pascagoula
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13 April 2011 – Stavanger
• Provision of vessel related engineering:– Vessel Stability and Motion Analysis– Assistance with design of Hang-Off Frame– Engineering for loading, shipment &
overboarding of BC’s– Subsea installation engineering by Technip
• Lifting Operations– Overboard B-Can/Riser assembly, up-end B-
Can and lower assembly to - 200 m water depth
Pull in of Riser at - 2500 m by Technip
Cascade & Chinook Project – Jumbo Scope
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13 April 2011 – Stavanger
• Install Hang-Off Frame
• Re-reeve cranes to 14-fall configuration (800 Te SWL each) with Deepwater Deployment System
• Install and test 2 Deepwater Winches
• Install accommodation + facilities for additional crew
• Install anti twist system
• Install Crane Tip Monitoring System
• Misc. Installation Aids
Mobilisation Rotterdam
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13 April 2011 – Stavanger
Loading Buoyancy Cans – Finland
• Loading 5 B-Cans at Technip yard in Pori, Finland
• 350 Te, 6.4 m dia, 38 m length
• Fibre grommets were used for lifting(same as for Offshore use)
• 2 B-Cans in the lower hold + 3 on deck
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13 April 2011 – Stavanger
Transport Buoyancy Cans
Transport from Pori (Finland) to offshore location Gulf of Mexico (18 days)
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13 April 2011 – Stavanger
Construction of Riser
Technip Deep Blue – deepwater construction vessel
410 Te riser through moonpool
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13 April 2011 – Stavanger
Wet Handshake of Riser
With forward crane of Fairplayer
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13 April 2011 – Stavanger
Wet Handshake of Riser and hang off
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13 April 2011 – Stavanger
Connect Riser to Buoyancy Can
Connection made on deck Fairplayer
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13 April 2011 – Stavanger
Lift and Overboard B-Can + Riser
Lifting and overboarding of the complete system (B-Can + Riser)
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13 April 2011 – Stavanger
Lift and Overboard B-Can + Riser
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13 April 2011 – Stavanger
Lift and Overboard B-Can + Riser
Upending of the Buoyancy Can, load transfer from forward crane to aft crane
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13 April 2011 – Stavanger
Lift and Overboard B-Can + Riser
Lowering through splashzone and completion of upending
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13 April 2011 – Stavanger
Lowering B-Can + Riser
• Connect orientation rigging, disconnect forward crane
• Lowering by Jumbo’s Crane – subsea operations performed by Technip’s Offshore Construction Vessel Deep Pioneer
• Connection of Riser to seabed by Deep Pioneer
• Once connected, Jumbo’s crane block disconnected from the B-Can by Technip ROV
• Final Pull-Down by Deep Pioneer
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13 April 2011 – Stavanger
Cascade & Chinook project movie
Jumbo Cascade project movie - 2 mins
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13 April 2011 – Stavanger
Project Specific Challenges
• First time usage of Deepwater Deployment System• 760 tonnes offshore dual crane lift with Jumbo vessel• Hang-off frame design• Subsea hand over 5 long Risers• Lifting B-Cans from the HLV hold to launching position on deck• Predicting the full dynamic loading of Jumbo’s cranes with the
2300m FSHR suspended subsea. • Planning and designing the systems with sufficient redundancy to
cope with the lengthy operations and limited available weather windows.
• SIMOPS: Accurate positioning of the Heavy Lift vessel as well as working closely to Technips installation vessels during the installation at 2,500m water depth and in close proximity to subsea infrastructure.
• Integrating strengths of two offshore contractors to make the project to a success.
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13 April 2011 – Stavanger
Cascade & Chinook Project
THANK YOU FOR YOUR ATTENTION
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Speaker
Arjo van Putten, GustoMSC, NLLecture: The design, construction and commissioning of a heavy lift
offshore craneBackground: Graduated at Delft University in 1998 at Mechanical
Engineering. Employed at GustoMSC in Schiedam (Netherlands) since April 2007.
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The design, construction and commissioning of a heavy lift offshore crane
Stavanger, 13 March 2011
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Presentation
page 2
1. Introduction offshore crane
2. 5000 T Crane characteristics
3. Engineering - Boom
4. Fabrication - Main hook
5. Installation - A-frame
6. Commissioning and testing
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Introduction offshore crane
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Introduction offshore crane
page 4
1. Tubcollar
3. Slewing platform
A-frame
Boom
Main block
2. Bogie system
Vessel fixed
Revolving
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Introduction offshore crane
page 5
Diameter: 28 meter, weight: ~ 600 ton including part of tub
Toothrack basis for revolving, upper rail for bogies
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Introduction offshore crane
page 6
Front bogie wheels: 2 x 8
Aft bogie wheels: 2 x 4
Counter bogie wheels: 2 x 4
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Introduction offshore crane
Front bogie wheels: 2 x 8
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Introduction offshore crane
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Fully electric 360 deg revolving crane
Main hoist SWL of 5000t and Auxiliary hoist 1 of 800t
Simultaneous use of main hoist and auxiliary 1 for tilting jackets
COG of crane in slewing center with empty boom at 60⁰
To pass Bosporus bridge; lowering A-frame
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5000 T crane characteristics
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5000 T crane characteristics
Lifting height Main Hoist: ~ 100 m
Lifting height Whip Hoist: ~ 135 m
Short minimum radius on aft side
Maximum radius: 110 t @ 118 m with whip hoist
With auxiliary 1 hoist 500 t @ 114 m
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5000 T crane characteristics
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Ship
Designed by GustoMSC
Special hull shape for dual draft
transit speed / stability
DP3
Length: 183 m
Width: 47 m
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5000 T crane characteristics
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GustoMSC building
12 floors high
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1. Tubcollar
3. Slewing platform
A-frame
Boom
Main block
2. Bogie system
Vessel fixed
Revolving
page 13
Crane design – Y-shaped boom
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Crane design – Y-shaped boom
page 14
Main aspects:
Reduce weight
Reduce complexity
Trolley hoist integration
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Crane design – Y-shaped boom
page 15
Difference mainly in the lower part:
4 chords instead of 8
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Crane design – Y-shaped boom
page 16
Y-shaped boom versus A-shaped boom:
Weight reduction
No support structure for trolley hoist, 5th chord!
Reduced number of joints, less complex
Top part similar
Y-shape not traditional for lattice tubular boom
BUT:
Strength?
(Lateral) stiffness?
Dynamic behaviour?
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Crane design – Y-shaped boom
page 17
Strength lattice structure
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Crane design – Y-shaped boom
Strength boom head
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CRANE DESIGN – Y SHAPED BOOM
Eigen modes
Natural frequency below minimum wave period
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Crane design – Y-shaped boom
Dynamic behavior – superposition eigen modes
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Y-shape boom at construction yard
Crane design – Y-shaped boom
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Main aspects:
Size and weight
Capable fabricators in EU
Extensive fabrication process
Fabrication – Main hook
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Fabrication – Main hook
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Complete main lower block
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Starting points:
Four prong hook
5000 T in 2 prongs @ 45 deg
Up to 2x250 mm slings on each prong
Fabrication :
Weight 37 ton
Size 3.6 m x 3.6 m x 2.0 m
Casting
Fabrication period: > 4 months
Fabrication – Main hook
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Monitoring temperature
Monitor steel composition – adding elements
Fabrication – Main hook
Steel out-of furnace into transport can
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Pouring steel from transport can in cast
Fabrication – Main hook
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After cool-down:
Heat treatment to achieve mechanical properties
Material testing
Machining
Fabrication – Main hook
Cool down - 1 month
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Fabrication – Main hook
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Installation – A-frame
Main aspects:
Double hinged structure
Lifting height
Aft leg in two parts
Tolerances
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A-frame terminology
Installation – A-frame
Front leg
Upper part aft leg
Lower part aft legs
Top hinge
Aft leg hinge
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Installation – A-frame
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Commissioning and testing
Commissioning of all systems:
Winches
PLC system / HMI interface / LMS system
Slewing drives
HVAC
Pneumatic and hydraulic systems
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Commissioning and testing
(Overload)Testing of the crane:
Tuggerwinches
All hoist winches at the maxima of the load curves
Calibration of LMS
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Commissioning and testing
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550t @114m overload test auxiliary 1
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Commissioning and testing
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5000t @ 32m test of main
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Commissioning and testing
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Commissioning and testing
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Your partner
www.GustoMSC.com
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Speaker
Tønnes Seierstad, National Oilwell Varco, NO
Lecture: Flexible load handling solutions for multi purpose vesselsBackground: He joined NOV (former Hydralift) as a Project Engineer in 1996 after
working in the offshore industry since receiving his B.Sc. in Mechanical Engineering/Marine Technology from University of Agder, Norway in 1988.
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One company … unlimited solutions
Lifting and Handling Solutions
Flexible load handling solutions for
multi purpose vessels
The 16th North Sea OFFSHORE CRANES
& LIFTING CONFERENCETønnes Seierstad
Sales Manager Cranes & WinchesNational Oilwell Varco
76460355
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One company … unlimited solutions
Lifting and Handling
NOV - Company Overview
Company at a Glance
•NYSE NOV
•Employees 40,000
•Market Capitalization $ 33.1 B
•Revenue 2009 $ 12.1 B
•Countries represented: 50+
•# of facilities: 700+
•# of service personnel 1700+
•# of engineers 3500+
National Oilwell Varco is a worldwide leader in the design, manufacture and sale of equipment and components used in oil and gas drilling and production, the provision of oilfield inspection and other services, and supply chain integration services to the upstream oil and gas industry.
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One company … unlimited solutions
Lifting and Handling
Drillships and Semi-submersibles delivered from Korean Yards with NOV Equipment
Are you ready to assist?
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One company … unlimited solutions
Lifting and Handling
Flexibility?
Versatile system
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One company … unlimited solutions
Lifting and Handling
How to be flexible? Prepare:For Newbuilds and major upgrades: Cooperation Operator, Designer and Supplier Prepare for the future – think ahead Examples:
SWL and operatingdepth spare capacity
Full hoisting height with AHC on both winches
2 pcs AHC Cranes Multiple Winches (under deck)
– alternative routing / tandem lift Knuckle Boom Special Lift Mode Fiber Rope Extension System
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One company … unlimited solutions
Lifting and Handling
Offshore Subsea Cranes and Winches – Active Heave Compensation (AHC) Heavylift cranes and shipboard deck cranes Fiber Rope Extension Systems Deep Water Lowering Systems A-Frames Electric Anchor Handling Winches
with Loadlim™- AHC options Electric Secondary Winches
Well Intervention Systems
Cable Lay Equipment
Pipe Lay Systems
How to be flexible? Mix these:
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One company … unlimited solutions
Lifting and Handling
Photo: www.valderhaug.no
Aker Wayfarer –400t & 50t NOV AHC Cranes
Flexible solutions
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One company … unlimited solutions
Lifting and Handling
Far Samson –250t NOV AHC Crane–315t / 250t AHC Winches
Photo: www.valderhaug.no
Flexible solutions
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One company … unlimited solutions
Lifting and Handling
Flexible solutionsWell Intervention Vessels Well Intervention Tower with all required equipment Main lifting system with AHC Guide-/Podline system with AHC Auxiliary Winches Pipehandling systems Top drive
(top hole drilling) Moonpool systems Skidding systems AHC Crane Integrated HPU for
Tower equipment and AHC Crane
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One company … unlimited solutions
Lifting and Handling
Skandi Aker–400t NOV AHC Crane & 450t Well Intervention System
Flexible solutions
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One company … unlimited solutions
Lifting and Handling
Flexible solutionsLarger Anchor Handling Vessels Electric Anchor Handling Winch with Loadlim(Pat)
- Reduced CO2 emission and vessel fuel consumption Turning your AHTS vessel into a construction vessel
- Winch approved for lifting with AHC- Regeneration of energy in AHC operation- Reduced installed power requirement (peak power)
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One company … unlimited solutions
Lifting and Handling
Flexible solutions
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One company … unlimited solutions
Lifting and Handling
Flexible solutionsPipe / Cable lay systems Deck-mounted add-on systems
for existing OCV’s Complete systems:
Under-deck or above-deck Carousels / reels
Tensioners Over-boarding systems Ramps & towers Aligners A&R Winches Plough handling systems
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One company … unlimited solutions
Lifting and Handling
Flexible solutions – NOV FRES
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One company … unlimited solutions
Lifting and Handling
NOV Main Crane 3000T Post
Crane
NOV FRES 800T – 3000m
NOV AHC Winch 800T – 1000m
Flexible solutions – 800mT DWLS
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One company … unlimited solutions
Lifting and Handling
Flexible solutions – Triple crane
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One company … unlimited solutions
Lifting and Handling
Flexibility on existing equipmentExtend the operational capacities of your existing equipment: Fiber Rope Extension Systems (FRES) Active Heave Compensation New winch with more wire / higher SWL Upgrade Hydraulic Power Unit – Higher speed Upgrade Crane Control System
- ASOPS (Automatic Subsea Overload Protection System)- Splash Zone Mode- Logging System-Wire Wear Estimator (WWE)
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One company … unlimited solutions
Lifting and Handling Solutions
Thank you for your attention!Questions?
One company … unlimited solutions
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Speaker
Rod Corbett, RotaBolt Ltd, UK
Lecture: New risk based bolt maintenance procedures – improved reliability/reduced life cost of offshore cranes
Background: He is a fastener specialist and metallurgist having worked in the ‘Bolt’ business for the majority of his career. Experience covers manufacturing,
design, application engineering and tightening of bolts and joints. This experience has been gained initially in aerospace, automotive, motor sport and defence and then for the last twenty years in power generation, petrochemical, mining, oil and
gas industries.
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Mandatory Bolt CheckingCost Effective Options
The 16th North Sea Offshore Cranes &Lifting Conference
KRANTEKNISK FORENINGNORWEGIAN SOCIETY OF LIFTING TECHNOLOGY
Rod CorbettRotaBolt
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Mandatory Bolt Checks
Slew bearing
Boom
A Frame
Fatigue Corrosion
Loosening Re-tightening
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Bolted Joint Reliability
DesignComponent Quality
Installed Bolt TensionJoint compression
Maintenance Free
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Fatigue on bolt ±σa
WorkingLoad
FA
Design TensionFMmin
Design Tension versus fatigue
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Friction Grip
Design tension versus transverse shake
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Bolt Checks
20-50%Up to 5 years
10-20% per annum
Bolt removal
Tightness ?? retighten Tensioner Break out
TensionMeasure
NDT crack detect
Corrosionvisual
TechnologyDriven Corrosion ??
Local Surveyor
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Anomalies/mismatch
Design
Bolt Spec
Installation
Corrosion Protection
Corrosion Check
Crack Detect
DesignTension
Elastic Strength
Tension Control
TighteningFeasibility
?
?
?
?
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A
A
B B
ELONGATIONELONGATION
LOAD LOAD
0.2% 0.2%
A = Elastic LimitB = 0.2% Yield Stress
A = Elastic LimitB = 0.2% Yield Stress
UTS 1030 MPa
0.2%PS 940
EL 830
ISO 898 10.9 Tensile Capacity
Bolt 658
HT O/Load 846
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Hydraulic Tensioners
Bolt Load = Pressure x area
Load Transfer Relaxation
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O v e r lo a d F a c to r in r e la t io n to B o l t D im e n s io n s
1
1 .0 5
1 .1
1 .1 5
1 .2
1 .2 5
1 .3
1 .3 5
1 .4
1 .4 5
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3
L e n g t h : D ia m e t e r R a t io
Ove
rloa
d Fa
ctor
Hydraulic Overload
Load Transfer Compensation
Residual Design TensionBased on estimate
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Tensioner Accuracy Research
90 2.1/4 x 29 in 4340 studs
Overload to 79% yield
Effective overload 1.09 – 1.76
HT O/Load 846
Bolt 658
O/Load 1.28
A
A
B B
ELONGATIONELONGATION
LOAD LOAD
0.2% 0.2%
A = Elastic LimitB = 0.2% Yield Stress
A = Elastic LimitB = 0.2% Yield Stress
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Slew Ring Bearing bolt design VDI 2230
FMmin = (1- ∅)FA + FKreq + FZ
FMmax = FMmin x aa
Hydraulic Tensioner Mind Set1.2
Actual1.6
Mind Set1.6
aa
1.1
Torque Actual2.0
Tension Control
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Advanced Tension Control System
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Corrosion Galvanic Protection
Carbon
Gold
Silver
Titanium
Nickel alloy
St Steels
Steel
Aluminium
Zinc/Cadmium
Sacrificial
Noble
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PTFE
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PTFE Poor Adhesion
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PTFE Coating 2 years
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New Coatings
Xylar 1
Zinc Nickel EP
AL Ceramic520C, 20 micron
Zinc Nickel EP25 micron plus
Un ProvenU/size Bolt
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DeltaTone Zinc Flake
Automotive30 years
Wind Turbines10 years
1000 hrsSalt Spray
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Electroless Nickel
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Galvanic Series
Carbon
Gold
Silver
Titanium
Nickel alloy
St Steels
Steel
Aluminium
Zinc/Cadmium
Sacrificial
Noble
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Electroless Nickel
12-17 yrs Drilling Rigs Shell Brent Subsea Clamps
Coastal RefineriesHigh TemperatureNo Corrosion
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Design Tension
Corrosionprotection
No FatigueNo loosening
No corrosion long term
Future Cost EffectiveBolt Checking
Bolt removalx
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Speaker
Speaker: Ragnar Sandve, Bolt Norge as, NO Lecture: Special engineered bolts for critical joints in the lifting
industryBackground: Degree as an Aeronautical Engineer
Extended with Aviation Maintenance Management program and various positions within Aviation Maintenance management and Marketing & Sales
Maintenance Management within oil service companiesManaging Director of Bolt Norge AS
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Special engineered bolts for criticaljoints in the lifting industry
Ragnar Sandve, CEO Bolt NorgeArne Aarre, Co-author, inventor & founder
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Scedule: Who we are: Challenges in joint design: What did we do?: Film: Why do they still engineer the same
problem?: 3D-animations: What is Bondura?: Summary: Questions
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Who we are
: Bolt Norge established 1986
: Developed and patented Bondura pin
: Engineering and production in Bryne
: Production in the US
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Challenge
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Challenge
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Result
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Solution
Fill the gap!
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What did we do?
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Film
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Why do they still design/engineer in the same problems today?
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Technology is not known widely enough!
: Bondura becoming the new industry standard for critical joints.
- Heavy loads- High precision
Our goal:
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3D-animations
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“….trialed these expandable coned pins on the G1 PHM pivot arms back in 2003”
“…. would wear out in a few years and require frequent weld and machining repairs”
“…. to the G1 in late 2008 I inspected this common wear connection and found “
“…. the bondura bolts to be as tight as the day it left the shop in 2003.”
Dean Young Program Manager - Top Drive & PipehandlingTransocean
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Summary: Problem is introduced during design: Becomes a safety issue over time: Is it worth it?: There is a solution: Use it for your safety: New industry standard
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Bilde sluttsekvens film
Questions!
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Speaker
Speaker: Aaron J Spak, Impact‐RLW Systems
Lecture: Lifting and handling remote monitoring and diagnostic solutions
Background: Mr. Spak has been managing hardware, software, and system development programs at Impact‐RLW for the past 6 years and holds a B.S. and M.S. in Mechanical
Engineering from Bucknell University in Lewisburg, PA USA.
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www.impact-rlw.com © 2011, Impact-RLW Systems, Inc. – All Rights Reserved 1
Lifting and Handling Remote Monitoring Solutions
Aaron J. Spak, Manager, Technology Deployment13 April 201116th Annual North Sea Offshore Cranes and Lifting Conference, Stavanger, Norway
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www.impact-rlw.com 2© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Agenda
2
• Impact-RLW Systems Introduction
• Condition Based Maintenance
• Monitoring Technologies as Part of a Comprehensive CBM Strategy
• Remote Monitoring Design Considerations
Objectives
1) Present overall approach for implementing remote monitoring systems as part of an overall Health Management system.
2) Share case study of implementation on Lifting and Handling equipment.
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www.impact-rlw.com 3© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
What Does Impact Do?• Engineer and implement advanced health management solutions that
monitor, detect, isolate, and predict equipment performance and readiness • Software solutions, smart sensors and hardware solutions, full system designs• Development, test and evaluation, integration, and deployment expertise
• Integrate with operator, maintenance, and logistics systems to minimize life cycle costs while maximizing system availability
Impact Technologies
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www.impact-rlw.com 4© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Impact Core Business Areas
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www.impact-rlw.com 5© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Condition Monitoring Terminology
• Condition Based Maintenance (CBM): A philosophy of maintaining equipment based on an estimation of its condition and maintenance logistics. Enhanced application of CBM is through the prediction (prognosis) of the equipment remaining useful life or time to service need.
• Prognostics and Health Management (PHM): A health management approach to reduce or eliminate inspections and time-based maintenance through accurate monitoring, incipient fault detection, and prediction of impending failure.
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www.impact-rlw.com 6© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
CBM/PHM Cost Benefit
6
Cost Chart Adapted from “Machinery Oil Analysis - Methods, Automation & Benefits”, Larry Toms, p. 23, 1995.
Number of Faiure Events
Cos
t
ConditionBased
Preventive Corrective
Total Cost
Maintenance
Cost
Operating or
Performance
Cost
Number of Failure Events
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www.impact-rlw.com 7© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
• Optimize maintenance based on objective evidence• Real-time visibility into asset operations/utilization• Facilitate long-range re-capitalization planning
Condition Based Maintenance Benefit
Run to FailureSchedule/Time-based PM
Usage-based PMCondition Based Maintenance
Prognostics Health Management
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www.impact-rlw.com 8© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Establish Basis of Implementation
• Begin with the end in mind, and the overall implementation constraints
• Asset coverage – definition of system boundary• Asset Management Strategy• Cost
• It’s easy to collect data – but how do you know you are looking in the right place?
• Understand component relationships and system vulnerabilities through design and experience
• Maintenance history• Legislated inspection criterion• Failure Modes, Effects, and Criticality Analysis (FMECA)• Reliability Centered Maintenance (RCM) Analysis• Physics-of-Failure modeling
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Monitoring Systems Enables Upstream Analysis
Monitor
Diagnostics and PrognosticsDetect
Maintenance Reasoning
• Monitor: Acquire, process, and deliver Objective Quality Evidence (OQE)
• Detection: Monitored parameter(s) has departed its normal operating envelope
• Diagnosis: Identify, localize, and determine severity of an evolving (incipient fault through functional failure) condition
• Prognosis: Reliably and accurately forecast remaining operational time to end of useful life, future condition, or risk to complete planned operations – “mission readiness”
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www.impact-rlw.com 10© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Case Study – US Navy Shipyard Cranes• Customer has 28 portal cranes at 4 remote sites• No objective evidence of asset utilization• No automated workflow – pure schedule based
maintenance.• Program Goals
• Provide ability to monitor shipyard capital assets, facilities and equipment in support of performing maintenance based on objective evidence of need -- Condition Based Maintenance (CBM) IAW OPNAVINST 4790.16a
• Develop, install and accredit secure wireless network• Enable shipyard business processes and applications (e.g.,
IBM Maximo)
Improve Asset Availability – Decrease Maintenance Costs
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System Key Characteristics
• Function usage data collected for bridge and portal cranes at one Shipyard. • In this case, usage is the first assessment of condition.
• Introduce at-the-hook load monitoring technology.• Provide data on asset usage to EAM application • Complete Certification and Accreditation (data security)
process to ensure integrity of wireless transmission.• Use Open Systems and a modular architecture to support
future applications.
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Open Platform for Condition Monitoring
• Open systems approach permits easy installation.
• A modular approach permits hierarchical implementation.
• Embedded processing reduces bandwidth needs and increases overall system robustness.
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www.impact-rlw.com 13© 2011, Impact-RLW Systems, Inc. – All Rights Reserved 13
SNAP2 - Technical Basis
SNAP2
XML Interfaces [S2NAP® XML Schema]
8 Sensor Channels Tachometer Input 2 Analog Output Channels 1 Relay Contact Output 2 EIA-232 Serial Ports. (Optional
EIA 422/485) Dual Processor Architecture Wi-Fi (IEEE 802.11b) Wireless
Network – FIPS 140-2 Mil-Qualified
Shipboard
Shipyard
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End-to-End Infrastructure
SNAP2
SNAP2
System
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System Enhancement – Direct Load Measurement
• Customer cranes had no reliable load measurement systems.• System installed on sister cranes operated for tandem lifts.• Developed and implemented as risk mitigation for portal cranes.• Developed with leading industry partner.
Reference Load Cell [lbs]
GL112 Hand Held
Display [lbs] Error
15,180 15,370 ‐1.30%30,235 29,760 1.60%45,307 46,050 ‐1.60%60,571 60,650 ‐0.10%70,614 71,450 ‐1.20%
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Enhancement Extended to Portal Cranes
Whip Hoist AssemblyModified main hook trunion
• At-the-hook load monitoring provides high accuracy load-moment indication on whip and main hoist.
• Safe Load Indication capability• Data output compatible with enterprise monitoring system.
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www.impact-rlw.com 17© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Portal Crane System Key Features
• Main Hook = 0.5% accuracy• Whip Hoist = 0.1% accuracy• Selectable Load Chart• Single point zero from the cab• Handheld displays for personnel on the ground• Secure data transmission for storage in SQL
database• 6 month calculated battery life• Design flexibility for future cranes depending
on required accuracy
• Usage = How Much• Adding Load = How Hard
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Web-based Data Display
• Dashboard display of summary status and cumulative usage data.
• Displays each lift profile as an individual event.
• Data summarized in reports of usage over user-defined time intervals.
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www.impact-rlw.com 19© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Lifting and Handling BenefitsManage, Engineer, and Maintainer
Feature Benefit
In-line measurement Eliminates line rider induced rope wearout
High-accuracy Eliminates dyno/excess geareMail Alerts Faster incident/breakdown response
EAM Connectivity OQE Generation to enable CBM
Automatic work order generation
Expandability Low-cost integration of additional monitoring (e.g. oil sensing)
Cab Display Fast operator response – overloadavoidance
Stored Data Incident reconstruction/resolution, life analyses
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Implementation Lessons - IT System Integration• Remote monitoring systems must preserve data
integrity• Bandwidth is expensive – embedded processing
reduces data quantity• Introduction of Operational Technology (OT) vice
Information Technology (IT) presents technical and administrative challenges• Certification/Accreditation of Applications• Integration with enterprise apps desirable from a
security perspective
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www.impact-rlw.com 21© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Future Applications - SmartMon-OilAn Embedded Monitoring Sensor• Multi-sensor fluid quality monitor
• Broadband Impedance Spectroscopy, RH, Temperature measurements
• Uses patented broadband measurement technique• Measure more fluid parameters => trend more fluid
degradation modes• Much faster than traditional EIS measurements
• Onboard processing• Smart sensor converts measurements to meaningful
information• Impedance and feature calculations• Diagnostic and prognostic algorithms
• Small form factor / lightweight design• Digital communications interfaces
• CAN – J1939• RS-485/422 - Modbus
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www.impact-rlw.com 22© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Design Considerations – Integrating with the Enterprise• Use of Open Standards
• Open Systems Architecture – Condition Based Maintenance / Enterprise Asset Integration (OSA-CBM/EAI)
• Enterprise Asset Management Integration• Data enables workflow automation• Faults/incipient failures can be routed to the right person at the right
time• Enables Performance Based Logistics
• Hierarchical Components • Modules arranged in a hierarchical relationship that mirrors the
functional organization of the machine component, and the functional organization of the system
• Component level processing permits straightforward interpretation of the interaction between components
• Distributed processing increases system robustness
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www.impact-rlw.com 23© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Conclusions
• Begin with the end in mind – design and apply asset monitoring technologies to enable an overall strategy. The data is only useful if analyzed in context.
• Early collaboration between engineering and IT to assist in the application of OT.
• Components that employ local processing and can be applied in a hierarchical, open system anticipate future needs and evolving analysis capabilities and enterprise planning needs.
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www.impact-rlw.com 24© 2011, Impact-RLW Systems, Inc. – All Rights Reserved
Any Questions?
Thank you.
Aaron J. [email protected]
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Program part twoWednesday 13th April
Operational Maintenance & Inspection continuous Chair: Stephen Werhle
13:00 A RFID inspection system the new Crosby Quic ‐ Check, inspection and identification system , Frédéric Crynen
13:45 Temporary lifting facilities for the BP Magnus crane replacement, Gordon Mccombie
14:30 Coffee / CraneExpo
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Speaker
Speaker: Frédéric Crynen, Crosby Europe, UKLecture: A RFID inspection system The new Crosby QUIC – CHECK,
inspection and identification systemBackground: He has been working for Crosby Europe N.V. since January 2006. He is born in Antwerp, Belgium, on the 21st of June 1981 and graduated from Antwerp University in
2004 with a degree in Economic Sciences.
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Crosby is a world leading manufacturer of lifting & rigging equipment with production units in the USA, Canada, Belgium, France, Holland and the UK.
Different products have type approval such as DNV, API, ABS,…
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Crosby is an innovative company with different tools to support our distributors & end users.- Interactive website www.thecrosbygroup.com
- Complete catalogue (including user & warning instructions, videos,…)
- 2D-drawings
- VerificationPro
- Crosby Knowledge Center (online self-study)
- Different calculators & configurators
- Apps for Iphone & Ipad
- Training seminars- LEEA approved seminar
- Heavy Lift seminar
- Block Clinic
- Quic-Check RFID software
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Quic-Check
Radio Frequency Identification
(RFID)
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Crosby has developed an electronic inspection software that incorporates the technology of RFID, to provide a tool for our business partners that provides many benefits.
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Types of RFID record keeping systems:PC Based
Inspections are completed on handheld unitHandheld must be manually synchronized to user
databaseOnly data for single location viewable
Web BasedInspections are completed on handheld unitHandheld is synchronized to user database
simultaneouslyData can be viewed from anywhere with web
access and a security code
RFID and the identification of products to inspect
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The process
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McKissickBlocks
CrosbyShackles
25t & larger
CrosbyIPPlate Clamps
CrosbyHoist Rings
EliminatorChain Fittings
Crosby “RFID equiped” products:
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Points to consider…– Do you conduct onsite inspections?– How many hours are spent throughout the
entire inspection process?– How accurate are the inspection reports?– Are your inspection reports typed &
formatted?– Can you currently pick up any product to
inspect and quickly determine when it was last inspected, as well as the inspection status?
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Different types of RFID– Active (long range, battery powered, finite life
span)– Passive (no battery, powered on by reader,
infinite life span)– Standards
• Low, High, Ultra high frequency
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Components of an RFID assisted electronicinspection system:
1. Tag or chips2. Reader (pda & pen)3. Software
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The basics:RFID simply assiociates the “globally unique” number of the RFID tag with the unique serial number assigned to your product (shackle, chain sling, snatch block,…)
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Benefits– Accuracy of inspection reports– Timelines of reports– Inspection history– Product tracking– Improved employee efficiency– In field validation of inspections– Reduced liability
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Benefits
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
Eliminates handwritten information
Eliminates need to re-type inspection reports
No misread or incorrectly recorded tags
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BenefitsLess manual entry… means less proofreading…which more timely reports
Report can be issued same day as inspection was conducted
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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Benefits“Cradle to grave” service history available
Ability to view each inspection performed on the product since it was first placed into service
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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BenefitsAs a minimum, the location of the last inspection is recorded.
Additional product information may be recorded and tracked
Date of inspection
Noted defects (if found)
Applicable comments
Status of the product after inspection
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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BenefitsReduces potential downtime associated with the inspection process by as much as 65%
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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BenefitsUtilize reader for instant identification of critical or retired slings
Should be able to read tag in the field to quickly to quickly determine if the product is within specification.
Status of sling
Last inspection date
Date of next inspection
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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BenefitsInspection records are kept up-to-date and maintained electronically.
Provides a proper audit trail of a product’s safety history, including repairs, pull tests and visual inspections.
Provides accurate, extremely detailed inspection reports in case of a safety audit or workplace incident.
Accuracy of inspection reports
Timelines of reports
Inspection history
Product tracking
Improved employee efficiency
In field validation of inspections
Reduced liability
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1. Start software & discuss homepage1. Contacts2. Products3. Inspections
2. Contacts1. Distributor2. End user (add new)3. Manufacturer
3. Products1. Product type
1. Existing products already in the system2. Create new category + product
4. Create new product5. Inspect products6. Reporting
RFID demo
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Speaker
Gordon Mccombie, Sparrows group, UKLecture: Temporary lifting facilities for the BP Magnus crane
replacementBackground: Gordon McCombie is a well‐known figure within the oil and gas industry, having represented Sparrows’ wide range of products and services for over 26 years. Gordon has played an integral role in the growth and development of Sparrows since the early 80’s, responsible for expanding the machining services division and promoting lifting engineering
and design services within the engineering, marine and drilling sectors.
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Temporary Lifting Facilities.16TH North Sea Offshore Cranes & Lifting Conference BP Magnus
Life Extension Project – 2010 / 11
Presented by: Gordon McCombie
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Introduction
“BP Magnus Life Extension Project”
– Survey– Crane upgrade or crane
replacement– Opportunity for lifting
operations improvement – The challenges– Methodology
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Survey
Survey objectives;– Define / identify all key plant locations– Define key lift weights & description– Confirm short/medium/long term lifts for each crane for life of field– Platform management to specify all major projects over next 10 years– Determine power requirements prime mover for new cranes (diesel / electric)– Identify all lay down areas– Confirm location of all existing blind lifts– Confirm pedestal strength / overturning moment
• Inspection reports• Any defects• Any limiting factors
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Crane upgrade or crane replacement?
Analysis;
1. Crane replacement (new cranes)2. Offshore upgrade of existing Stothert & Pitt cranes3. Onshore upgrade of existing Stothert & Pitt cranes
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Replacement / Upgrade Justification
• OEM recommended life • HSE integrity inspections• Single point failures (winches)• Fatigue (all major components)• Known boom defects• Capacity –future coiled tubing lifts on platform• Hoist speed – for boat lifts• Pump spares obsolescence• Motor spares obsolescence• Increasing maintenance costs
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Pros / Cons - Crane Replacement
• Pros‐ Latest generation cranes‐ Less maintenance down time‐ Increased boom Length‐ Increased capacity @ 35m (for coil tubing lifts
‐ Increased spares for ‘B’ crane
• Cons– Greater initial cost– Long lead time– Possible boom rest & other
modifications
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Pros / Cons – Offshore Upgrade
• Pros– Cheapest option– Shortest overall project
completion– Increased life of existing crane
• Cons– Limited scale of upgrade– Extensive platform disruption
• Crane downtime• Loss of lay down area• Loss of access to large portion of
pipe deck
– Increased exposure to un‐foreseen delays
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Pros / Cons - Onshore Upgrade
• Pros– Delivery of a more
comprehensive overhaul/ upgrade compared with the offshore option i.e.
• Chassis overhaul / upgrade• “A” frame overhaul / upgrade• Cranes fully tested prior to re –
installation– Minimised disruption to sea
lifting cranes– Less platform disruption than
offshore upgrade option
• Cons– Higher upgrade cost compared
with offshore upgrade option– Longest project timescale of all
three options
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Crane upgrade or crane replacement summary
• Stothert &Pitt OS200 ‐Upgrade considerations– Obsolete systems / design features– Single point failures– Age – Lifting performance limitations– Increasing maintenance costs– Upgrading work performed on or off the installation
• Kenz‐Figee B.V.DHC 70/3500 OS Ex. (Proposed replacements)– Pedestal height increased with installation of a new adaptor attached to
existing pedestal flanges– EN13852‐1 standard / compliant– Increase in lifting performance – Good for remaining life of platform– Existing OEM support
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Opportunity for lifting operations improvement
• Improvements / benefits;– Elimination of obsolete systems & design features– Meets with EN13852‐1 standard– Physical increase in crane pedestal height– Elimination of blind lifting conditions – Improved visibility during deck & sea lifting operations– Improved/ increased lifting speeds– Overall safer deck & sea lifting operations
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The challenges
• Overcoming requirement for temporary crane access to service both “a”& “c” cranes without re assembling the elevated skid structure.– Design /supply R.M.D (Kwikform) support structure.
• Overcoming the inadequate strength of the existing pedestal flange connection.– OEM design / supply purpose built segmented clamps creating a retaining ring
around pedestal.• Overcoming machining existing flanges to a pre determined size.
– Design & manufacture special purpose insitu machining equipment
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Methodology
Temporary Crane & elevated skid structure
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MethodologyInventor modelling image
“C” crane
Temporary crane
“A” crane
Elevated skid track
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Methodology
• Inventor modelling image
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Methodology
• RMD elevated towers
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Methodology
• RMD elevated towers
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Bridging member assembly
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Temporary crane installation
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Temporary crane installation / boom assembly
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Temporary crane commissioning & skidding
Final assembly at position No 1 Hydraulic skidding to position No 2
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Pedestal flange machining
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New adaptor installation
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Adaptor & pedestal flange clamp ring assembly
Fem analysis of flange joint
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Assembled joint
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Crane Installation
Rotating machinery bed installed
View of deck taken from drill derrick
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Machinery house installation
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Cab Installation
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Winch Installation
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New “C” crane assembled complete
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Progress to second crane position
New “C” crane installed at position 1. Temporary crane skidded to position 2.
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Project summary
• New / replacement cranes: EN13852‐1 standard compliant • Methodology employing modularised B.E. Mk60 temporary crane • Elevated RMD towers / skid track structure facilitated temporary crane skidding• Increased crane height via new adaptor eliminated many operator lifting issues• New adaptor / existing pedestal flange strengthened using segmented ring /
clamps• Overcome pedestal flange dimensional control issues by machining underside of
flange insitu.• Bp now decided to replace the third B” crane with a new machine during 2013
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The Sparrows Family of Brands
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Acknowledgments
• Sparrows Group acknowledge with thanks to all BP Magnus on / offshore personnel who assisted / participated in this project.
• We also acknowledge with thanks the assistance & support received from Kenz / Figee B.V. and all our other contracting partners in the successful delivery of this project.
Thank you all for your attention
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Program part threeWednesday 13th April
Late afternoon session Chair: John MorrisonHeadline: Personnel Transfer and Evacuation15:00 Mob‐boat handling with offshore cranes – combination of design parameter
Tor Raknestangen
15:40 Training & competence in crane transfer operations; the importance of beingprepared, David Brittan
16:15 Lifting persons with carriers suspended from offshore cranes application of European commission guidance document, Gunnar Matre
17:00 End of day 2 with closing remarks, questions and reflections
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Speaker
Tor Raknestangen,National Oilwell Varco Norway AS, NOLecture: MOB – Boat handling with offshore cranes
Background: He joined NOV (formerly AS Stålprodukter) as a Project Engineer in 1997, he received his Bachelors in Telematics the same year. He has been working as a Project Manager since 1998, the projects spanning from new deliveries, large
modifications and development projects. Since 2009 he has been working as Product responsible for lattice boom cranes for the European market.
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One company … unlimited solutions
Lifting and Handling Solutions
Launch and recovery of MOB boat with offshore cranes
Selection of crane design parameters
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One company … unlimited solutions
Lifting and Handling
NOV - Company Overview
Company at a Glance
•NYSE NOV
•Employees 40,000
•Market Capitalization $33.1B
•Revenue 2009 $12.1B
•Countries represented: 50+
•# of facilities: 700+
•# of service personnel 1700+
•# of engineers 3500+
National Oilwell Varco is a worldwide leader in the design, manufacture and sale of equipment and components used in oil and gas drilling and production, the provision of oilfield inspection and other services, and supply chain integration services to the upstream oil and gas industry.
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One company … unlimited solutions
Lifting and Handling
Loading and unloading of supply vessels
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One company … unlimited solutions
Lifting and Handling
MOB Training
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o EN 13852-1
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o NMD 854o NMD 853
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o NORSOK S-001 Technical safety
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o NORSOK R-002 (preliminary edition)
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o NORSOK R-003
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o FEM 1.001 / EN 13001
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One company … unlimited solutions
Lifting and Handling
Relevant standardsNorwegian sector North sea
o DNVo ABSo Lloydso Germanischer Lloyds
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One company … unlimited solutions
Lifting and Handling
EN13852
Prel. R002
API 2 C DNV 2.22
ABS( N)
ABS(API)
Reduced SWL SWL2
2 SWL3
SWL3
SWL2
SWL2
SWL3
Increased Structural SF Indir. 1,5 Indir. Indir Indir. Indir.
Increased Rope SF Indir. Indir. /1,5 10 8 Indir. 10
Soft sling / damper requirement
No Yes No No No No
MOB dynamic limit No Yes No No No No
Control system barriers Yes Yes No Yes Yes No
Secondary means of rescue Yes Yes No Yes Yes No
Secondary brake requirement
Yes Yes No Yes Yes No
Operational limits (training)
10 m/sSW 2m
Yes, Both for NLS and LS
No 10 m/sSW 2m
Yes No
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One company … unlimited solutions
Lifting and Handling
Example of a typical crane for fixed installation North Sea
Crane design parameters: 50 tonnes on 3 fall / 15 tonnes on 1 fall Approx 50 meter
operational radius. MOB weight ≤3 ton No impact MOB weight >3 and ≤ 7,5 -10 ton, gradually impacting crane
design. MOB 10 ton+ will be governing for crane design/size
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One company … unlimited solutions
Lifting and Handling
Consistency
Ea standard / class rule is written to be used as a standalone standard, and is deemed to give the right level of safety of its own.
Combining standards are off course possible, but it is imperative to have a deep knowledge within the standards to be able to get what you are after.
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One company … unlimited solutions
Lifting and Handling
Lifting on a “rainy day”
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One company … unlimited solutions
Lifting and Handling
Conventional pennant
0
5
10
15
20
25
30
35
Boat weight 2000 3000 4000 5000 6000 7000 8000 9000 10000
Weight lower end of pennant vs MOB weight
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One company … unlimited solutions
Lifting and Handling
Summary
The offshore crane still is the best way to launch and recover MOB boats and will continue to be.
When designing Cranes intended for MOB handling the main issue will be to balance the “Normal“ lifting requirement against the regulatory requirements for emergency preparedness.
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One company … unlimited solutions
Lifting and Handling
MOB Rescue situation
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Speaker
David Brittan, Reflex Marine Ltd, UKLecture: Training & competence in crane transfer operations; The importance of
being prepared!Background: David graduated in mechanical engineering from Sheffield
University (1986) and holds an MBA from Cranfield Business School (1999). He began his career as a well engineer with BP and later pursued an international
career with a number of operators. He has held a several senior positions, including head of Well Engineering at BG. David was appointed to the Board of Reflex Marine
in 2008.
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Training & competence in crane transfer operations
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Reflex Marine
10Years
1Million
500Units
54Countries
Units Operating Across 5
Continents
Passenger Transfers Performed Each Year
Operating worldwide in Tropical to Arctic
Conditions
Leading the Way in
Safer Access Solutions
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Contents
The changing role of the personnel carrierLevers to reducing transfer riskThe competence of users and owners of SCE?Inspection and Maintenance schedulesTraining OptionsServicing Centre competenceCase history of mass transport by crane transferSummary
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THE ROLE OF CRANE TRANSFER CARRIERS
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Personnel Carrier Roles – Work Rate
Emergency Ad‐Hoc Complimentary Mass Transport
2 Transfers per
week
10Transfers per
week
30Transfers per
week
50+Transfers per
week
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Personnel Carrier Roles – Work Environment
Arctic Standard Tropical
‐40 Deg C ‐20 Deg C +40 Deg C
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Personnel Carrier Opportunities
Helicopter at operating limits – Temperature– Distance– Effective Pax transfer rateHelicopter integrity concerns– Monopoly markets – Local standardsLimited Operating budgets– Economic evaluations on logistical support– Marine / Heliport support bases
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Carriers are changing to meet these requirements
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Changing Carriers – Changing Systems?
Traditional rope baskets– Visual check & disposal strategy
Modern Personnel Carriers– Long field life– Suspension system maintenance– Replaceable parts– Ensure “Carrier Integrity”
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REDUCING TRANSFER RISK
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Factors affecting crane transfers
A large number of factors that affect the safe conduct of all marine personnel transfers, including :‐
Met‐ocean conditionsLanding areaVessel station keeping capability and response to sea conditionsVisibility and line of sightCrew skill and experienceHuman factors
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Crane Transfer Risk reduction through...Good design– High safety factor, protected,
single point failures
Good inspection– Right frequency, right quality
Preventative maintenance– Comprehensive manuals and procedures
Good materials– Original and replacement
Good people– Skills and experience – Competence
Good record keeping– Service records, parts used, reminders for inspection or test
80% of all incidentshave a root cause inhuman factors
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Design Central column load path
Single central load column – difficult to damage
Design Safety Factor in excess of 10
Units Load Tested to 2* Maximum Gross Mass
Sling Assembly load tested to 2* SWL
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Design No Welding on Critical Load Path
Simpler low cost field inspection (no skilled weld inspector)
Eliminates the risk of weld related fatigue induced cracking
Critical components replaced by simple mechanical change out
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OperationalIntegrity
I & M
Risk awareness
Procedures
Vessels, Cranes & Transfer
equipment
Training &briefings
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Top 10 issues with offshore lifting
Top Ten Issues Issue No. Rank
Competence of crane operator E2 22
Competence of banksmen/slingers E1 21
Man riding using winches D3 20
Planning g of lifting operations E6 19
Analysis of lifting accidents F1 19
Static and dynamic crane rating B4 18
Hook snagging on the supply boat B1 17
Competence of maintenance staff E3 17
Supervision of lifting operations E5 17
Inadequate maintenance E7 17
Courtesy of International Regulators Forum 2004
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COMPETENCY in PERSONNEL CARRIERS
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Who needs to be Competent?
Daily checks... performed by?– Vessel or platform Decks Crews /
Foreman– Crane Operators
Formal Inspections... performed by?– Vessel or platform foremen ?– Crane Operators or Vessel captains– Independent lifting authority.
Examinations and Load tests... performed by?– Onsite maintenance crews– Third party service providers (assurance/accreditation)
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INSPECTION AND MAINTENANCE
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Objectives of inspection & maintenance
Return equipment to as new conditionHighlight any damage from operationsEstablish design weaknessesEnsure no intrinsic hazards – i.e. dropped objectEnsure it is safe to operate for the next period
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Inspection categories
Four TYPES of inspections– Check– Inspection– Examination– Proof load test
Templates provided by RML
Operators to develop or embed recommended inspection templates into their inspection management system (Maximo etc.)
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Maintenance & inspection schedule
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Recommended Inspection scheme
Pre‐operation check – prior to every use
Formal inspection – at least every 6 months (in accordance with LOLER)
Examination (and test) – at least every 12 months
But... more frequent with higher use– Current users range from <5 to over 5,000 transfers per year
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Recommended Maintenance scheme
Sling Assembly Maintenance – Sling assemblies are critical AND vulnerable – New Slings at least every 12 months, possibly changed EVERY 3 months
Critical Parts Maintenance– New Critical Parts AT LEAST every 36 months, normallyevery 12 months
Spare Parts Maintenance– As required according to inspection
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Critical Parts & Kits
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Typical Maintenance Parts
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TRAINING OPTIONS
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Personnel Carrier Training Model
RML Trainer
1 day Advanced Familiarisation
Course
1 ½ day Inspection and Maintenance
Course
EQUIPMENT
CertifiedTrainer
CertifiedTrainer Certified
I&MCertifiedI&M
USERS
½ DayFamiliarisation
Course
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Training objectives
ContentClassroom ContentDesktop ExercisesPractical SessionsTest and Evaluation
“To equip with the theory and practical knowledge to effectively Use, Inspect and Maintain Personnel Transfer Equipment”.
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Available support material
User manuals (website download)Maintenance and Inspection Manuals Inspection templates (Word and Excel web downloads)Operational User Briefing videoCrane Transfer Golden Rules videoReference Documentation
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Maintenance Manuals
Step by Step Guide (100 photo pages)
Including:– Inspection Set up– Critical Parts change out– Sliding Sleeve Inspection– Spring Change Out– Feet replacement– Sling Inspection– Load Testing
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Inspection templates
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Crane Transfer – The GOLDEN RULES1. Understand your risks: Each operation is unique, individual
risk assessments required
2. Be familiar with your conditions; Check prevailing weather and met‐ocean conditions
3. Know your vessels Station‐keeping and stability, availability of a large clear landing area
4. Know your cranes Limitations, Maintenance, Certification, location, lift height, emergency lowering, hoist speed
5. Know your transfer device Select equipment suitable for your operating envelope and risk levels
6. Be familiar with your crews Training and competence
7. Plan your lift Swing Factor, weather, collision, snagging
8. If in doubt – STOP Perform dry runs
9. Recognize complex operations Where appropriate seek expert advice
10.Emergency planning Integrate crane transfers into emergency planning and perform drills, confirm capabilities
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SERVICING CENTRE COMPETENCE
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Accredited Service Centres
Quality of servicing on SCE is essential.
Training of service centre maintenance personnel
Now establishing a world‐wide Accredited Service Centre Program
– Audit schedule of QMS– Assured training – Assured facilities– Customer and unit record tracking
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Examples of good inspection reports
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CASE HISTORY of MASS TRANSPORTATION BY CRANE TRANSFER
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CASE HISTORY – FROG 9’s in BAKU
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Frog 9 History
2007 – Frog 9 developed with Seacor Marine LLC2008 – 2 Frog 9’s in Angola– 2 years service– 600 people per week– zero incidents2009 – 7 Frog 9’s to Azerbaijan– Helicopter replacement strategy– Risk based selection– 1+ year service history– 2 Fast crew vessels, large landing deck area2011 – Frog 9’s to Nigeria, Trinidad and Sakhalin
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Transfer Times Analysis
2935
53
69
0
20
40
60
80
100
120
FROG‐3 Rope Basket(Benchmark)
FROG‐6 FROG‐9 FROG‐9(Dual Use)
TORO 4
Passen
ger T
ransfer R
ates per hou
r (on
e way)
Transfer Rates (pax/hour)
See appendix 1 for detailed calculations & assumptions
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Baku, Azerbaijan
Helicopters not used since 20092 FAST crew vessels and 7 Frog 9’s mobilised in Dec 200957,000 transfers in first 12 months60 pax per hour avg.120 pax per tripNo incidents Vessel transit time 3‐4 hrsVery minor sickness complaints
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Very High Use Maintenance Schedule
Rotational schedule– 2 operational, 2 ready for use ,2 in maintenance, 1 spare
3 monthly Service Interval– After circa 1,500 lifts– Formal inspection conducted – Sling Assembly replaced6 monthly Service Interval – After circa 3,000 lifts– Examination and critical parts replaced– Load Test– Sling Assembly replaced
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Mass Transportation Preparations
Passenger handling at portPassenger induction videoLuggage handling proceduresInspection and maintenance trainingLocal spare parts
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SUMMARY
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Concluding MessagesTransfer equipment is important – ensure it is well designed and suitable for the intended duty Ensure an appropriate inspection frequency – understand your usage rate (past and future)The competence requirements of personnel who use, check, operate and maintain such equipment are different.Crane transfer carriers need comprehensive I&M regimes, as part of SCE register.Training for users and I&M personnel can only enhance the transfer system safety.Accredited Service Centres for peace of mind on servicing quality.
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THANK YOU FOR YOUR ATTENTIONLET’S STRIVE FOR SAFER TRANSFERS
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Speaker
Gunnar Matre, DNV, NOLecture: Lifting persons with carriers suspended from offshore cranes Application of
European commission guidance document
Background: Gunnar Matre (born 1970) joined DNV in 1996 and has worked in section Cranes & Machinery in Bergen the last 13 years. Currently Group Leader
with service responsibility for verification services within the section.
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Gunnar Matre13 April 2011
Lifting persons with carriers suspended from offshore cranes
Application of European commission guidance document
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Lifting persons with carriers suspended from offshore cranes
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What is a CARRIER?
DEFINITON IN MACHINERY DIRECTIVE 2006/42/EC:
‘Carrier’ means a part of the machinery on or in which persons and/or goods are supported in order to be lifted.
Annex I Section 4.1.1 (g)
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Carriers used with offshore cranes
SUSPENDED WORK PLATFORM (”BASKET”)
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Lifting persons with carriers suspended from offshore cranes
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Carriers used with offshore cranes
PERSONNEL TRANSFER CARRIERS
Source: www.reflexmarine.com
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Lifting persons with carriers suspended from offshore cranes
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Carriers used with offshore cranes
RESCUE BOATS (”MOB” BOATS)
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Lifting persons with carriers suspended from offshore cranes
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European Commission guidance document, Dec. 2009Clarifies status of 2 categories of equipment:
1. Interchangeable equipment assembled with lifting machinery for the purpose of lifting persons Subject to Directive 2006/42/EC
2. Equipment used for the purpose of lifting persons with machinery designed for goods Not subject to Directive 2006/42/EC
First revision drafted in 2005 by Machinery Working Group, with ref. to 98/37/EC
Used as reference in the Guide to 2006/42/EC, comments to Annex IV item 17
http://ec.europa.eu/enterprise/sectors/mechanical/documents/guidance/machinery/index_en.htm
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Lifting persons with carriers suspended from offshore cranes
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Cat. 1: Interchangeable equipment
Equipment (carriers) assembled withlifting machinery in order to modify its function for the purpose of lifting persons
'...is assembled with...' means that the equipment is fitted to the lifting machinery by the user so that the assembly functions as an integral whole.
Included in the scope of the Machinery Directive, and requires:- CE-marking- EC Declaration of Conformity- Notified Body involvement, e.g. EC Type-
examination (Annex IV machinery).
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Lifting persons with carriers suspended from offshore cranes
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Cat. 2: Equipment used with machinery designed for lifting goods
Carriers intended to be lifted with lifting machinery designed for lifting goods only, e.g. - cranes- fork lift trucks
Category based on Directive 2009/104/EC (”use of work equipment”)
Annex II, Section 3.1.2:”PERSONS MAY BE LIFTED ONLY BY MEANS OF WORK EQUIPMENT AND ACCESSORIES PROVIDED FOR THAT PURPOSE”
Exception:“(…) EXCEPTIONALLY, WORK EQUIPMENT WHICH IS NOT SPECIFICALLY DESIGNED FOR THE PURPOSE OF LIFTING PERSONS MAY BE USED FOR THAT PURPOSE, PROVIDED APROPRIATE ACTION HAS BEEN TAKEN TO ENSURE SAFETY IN ACCORDANCE WITH NATIONAL LEGISLATION AND/OR PRACTICE PROVIDING FOR APPROPRIATE SUPERVISION (…)”
Purpose of guidance document to exclude equipment for exceptional use from the scope of the machinery directive
Also excluded from the Machinery Directive (2006/42/EC) by the directive itself, by 7th recital
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Lifting persons with carriers suspended from offshore cranes
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Categories and CE-marking Category 1 – Interchangeable equipment:
- To be CE-marked- May be used for both planned operations and in exceptional circumstances
Category 2 – Equipment used with machinery not designed for lifting persons:- Not to be CE-marked- CE-marking prohibited- May only be used in exceptional circumstances, in accordance with national legislation
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Lifting persons with carriers suspended from offshore cranes
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Carriers used with offshore cranes – WHAT CATEGORY?1. Interchangeable equipment?
OR
2. Equipment used with machinery designed for lifting goods (not persons)?
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Cat. 2: Equipment used with machinery for lifting goods?Exeptional use?
Launching/recovery of rescue boat:- training of rescue crew is performed regularly - rescue operations are exceptional, but, nevertheless, PLANNED operations
Access to work places with suspended work platform:- may be both PLANNED and UNPLANNED (exceptional) operations
Personnel transfer:- REGULAR operation in connection with crew shifts/transfers- an alternative means of medical transport (e.g. injured personell), exceptional, but,
nevertheless, a PLANNED operation - an alternative operation in case of weather conditions prohibiting helicopter transport
Crane designed for lifting goods only?
Offshore cranes in accordance with EN 13852-1 may be designed for lifting persons
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Cat. 2: Carriers used with offshore cranes? Operations may be both exceptional and
planned/regular
Most offshore cranes are designed for lifting persons as well as goods
CE-marked carriers are desired
Category 2 not appropriate for carriers suspended from offshore cranes
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Lifting persons with carriers suspended from offshore cranes
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Cat. 1: Interchangeable equipment (IE)?CONCEPT:
Definition, 2006/42/EC, Article 2 (b):- ‘interchangeable equipment’ means a device which, after the putting into service of
machinery or of a tractor, is assembled with that machinery or tractor by the operator himself in order to change its function or attribute a new function, in so far as this equipment is not a tool
IE canges the function of, or attributes a new function to existing machinery
IE does not have to fit the strict definition of machinery
IE may be put on the marked separately, by another manufacturer
IE follows the same formal procedures for CE-marking, as machinery
Manufacturer of IE takes responsibility for the combination machinery + IE
User manual for IE must inform which machinery the IE can be assembled with
End user may assemble IE with machinery. Does not need to consider if the combination is complying with the machinery directive.
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Cat. 1: Interchangeable equipment (IE)?REQUIREMENTS AND CONSTRAINTS IN GUIDANCE DOCUMENT:
IE ”assembled with” lifting machinery- requires a certain integration between the carrier and the lifting machinery- to what extent?
”Equipment placed on (…) the hook of a crane is not considered interchangeable equipment (…)”- technical constraint to carriers suspended from the hook of an offshore crane, based on a
political decision- excludes carriers used with offshore cranes from the definition of IE
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Lifting persons with carriers suspended from offshore cranes
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Guidance document – Problems Does not address the need for CE-marking of carriers to be suspended from
offshore cranes
Conflicts with harmonised standard for offshore cranes, EN 13852-1- Harmonised under 98/37/EC- Currently under revision, expected to be harmonised with 2006/42/EC- Contains technical requirements for lifting persons- No requirements to the carrier, but the carrier is intended to be suspended from the hook
Manufacturer of IE is responsible for the safety of the assembly of crane + carrier.- safety is depending on crane design- only the crane manufacturer is able to evaluate the safety of the assembly crane + carrier
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Need for clarification
May carriers suspended from the hook of an offshore crane be regarded as interchangeable equipement, when the offshore crane complies with EN 13852-1?
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Lifting persons with carriers suspended from offshore cranes
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Alternative approach – Lifting accessories Carriers suspended from offshore cranes = Lifting Accessories
Definition, 2006/42/EC Article 2 (d):- ‘lifting accessory’ means a component or equipment not attached to the lifting
machinery, allowing the load to be held, which is placed between the machinery and the load or on the load itself, or which is intended to constitute an integral part of the load and which is independently placed on the market; slings and their components are also regarded as lifting accessories
The term ”load” may be understood as both ”goods” and ”persons”, ref. definition of ”lifting operation”, 2006/42/EC, Annex I sec. 4.1.1.(a):- ‘Lifting operation’ means a movement of unit loads consisting of goods and/or
persons necessitating, at a given moment, a change of level.
A carrier suspended from the hook of an offshore crane will therefore in most cases fit the definition of ”lifting accessories”.
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Lifting accessories – Annex IV machines? Categories of machinery to which one of the procedures referred to in Article
12(3) and (4) must be applied
List of machinery categories which require involvement of a Notified Body when machinery is not manufactured in accordance with a harmonised standard.
The term ”machinery” in the heading of Annex IV must be understood as machinery both in the strict sense and in the broad sense.- Ref. Guide to application of Directive 2006/42/EC – 2nd Edition – June 2010, §33
Item 17: Devices for the lifting of persons or of persons and goods (…)
The term “Devices” is universal, i.e. it can be:- machinery in the strict sense, e.g. a crane- lifting accessories- interchangeable equipment
Annex IV includes lifting accessories for lifting persons.
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Lifting Accessories – ProblemGUIDANCE DOCUMENT, Category 2:
”(…) Such equipment is not used to attach the load to the machinery: therefore it is not a lifting accessory (although such equipment may be attached to the machinery by means of a lifting accessory such as a sling). Such equipment is to be considered as a part of the load. It is thus not in the scope of the Machinery Directive and shall not bear the CE-marking in relation to that Directive (…)”
May lead to the understanding that carriers suspended from offshore cranes are not lifting accessories.
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To summarise
HOW DO WE CATEGORISE CARRIERS SUSPENDED FROM OFFSHORE CRANES IN TERMS OF THE GUIDANCE DOCUMENT?
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Lifting persons with carriers suspended from offshore cranes
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Categorisation according to guidance documentINTERCHANGEABLE EQUIPMENT?
EQIUPMENT USED WITH MACHINERY FOR LIFTING GOODS ONLY?
LIFTING ACCESSORIES?
NO
YES/NO
NO
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Application of user directive 2009/104/EC Annex II, 3.1.2 ? Offshore cranes are already designed for lifting persons
Lifting persons with offshore cranes are NOT exceptional operations, but planned or regular operations
Application of national legislation does not necessarily give any further risk reduction compared to application of MD
Application of national legislation introduces a barrier to trade and impedes the freedom of movement of goods.
Application of user directive not appropriate.
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Offshore crane carriers – interchangeable equipment?BY DEFINITION, NO:
Suspending a carrier from the hook does not change the function or introduce any new function on the crane, the functions are already there.
FROM MANUFACTURERS VIEW:
Manufacturer of carrier, takes responsibility for the assembled combination.
Requires in depth knowledge of the crane.
Crane types must be listed in the user manual and declaration of conformity for the carrier.
BY POLITICAL DECISION, YES:
Only minor changes to the guidance document needed to define them as IE.
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Recommended solution
Condition: User manual for carrier must explicitly state that it is only intended for lifting with offshore cranes designed and manufatured for lifting persons in accordance with Machinery Directive
Modification of the guidance document is necessary
This solution will be an acceptance of EN 13852-1 as representing state of the art for lifting persons with offshore cranes, and enable conformity assessment of crane and carrier as separate objects.
CARRIER INTERCHANGEABLE EQUIPMENT
LIFTING ACCESSORY
OTHER
(national legislation)
Suspended work platform
No Yes No
Personnel transfer carrier
No Yes No
Rescue boat
(Elastic pennant)
No
(No)
No
(Yes)
Yes
(No)
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Safeguarding life, property and the environment
www.dnv.com
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Social program Wednesday 13th April
18:30 Bus to reception19:00 Reception given by the municipality of Stavanger in the
Stavanger Maritime Museum Local beer tasting program with small tapas
Remember to check our web site www.liftingoffshore.com
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Wednesday 13th April, Reception given by the municipality of Stavanger in the Stavanger Maritime Museum and with a local beer tasting program with small tapas
Chairman Eriksson Deputy Mayor Bjørg Tysdal Moe gave a good introduction to Stavanger region
Local beer from LervigMorten Robberstad from Lervig brewery gave a introduction to their products