Lifting Appliances
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1 Standards d for Certification Lifting Appliances Ole-Henrik Andressen and Åge Mikkelsen 29th of April 2009 Rules for Certification of Lifting Appliances 1994 Standard dadfor Certification Cet cato 2.22 Lifting Appliances Slide 2
2 Standard for Certification 2.22 Lifting Appliances Slide 3 Standard for Certification Lifting Appliances Main topics Content _ Validity _ Main issues _ DNV Certification process _ Design _ Safety and Safety Systems _ Sub-sea handling _ Personnel handling _ Testing of Lifting Appliances _ Slide 4
3 Content Systems and Features covered: All load-carrying structural members and components Cargo hooks, blocks, sheaves, lifting beams, ropes and loose gear Structural integrity of grabs or other load transferring components Winches Slewing bearing system Power systems Safety equipment Protection against fire Seating and fasteners for prime movers, winches and for bearings of power transmitting components. Instrumentation and automation Electrical installation Slide 5 Validity Date of validity: 15th of November 2008 ILO 152 Date of contract between Yard and Manufacturer Class notation CRANE/Crane Vessel Date of contract between Yard and Ship Owner - After 1st Jan Slide 6
4 Standard for Certification Lifting Appliances Slide 7 Main issues Direct references to DNV Rules for Ships (web shop) Materials: Pt.2, Ch.2 Systems: Pt.4, Ch.9 Control and Monitoring Systems Pt.4, Ch.8 Electrical Installations Certification of offshore crane safety systems Cranes with Brains Functional requirements Verification sheets Slide 8
5 Standards for Certification Lifting Appliances Slide 9 DNV Certification process Design approval Manufacturing survey Witness testing Slide 10
6 DNV Certification process Slide 11 DNV Certification process Documentation A consistent overview of what to be submitted. Document requirements. Slide 12
7 Standards for Certification Lifting Appliances Slide 13 Design Design Temperature Slide 14
8 Design - Materials Rolled Structural Steel for Welding The categorisation of normal strength steel, high strength steel and extra high strength steel has the following yield stress categories: -Corresponding with DNV's Ship Rules - normal strength steel: up to 265 MPa yield strength - high strength steel : MPa yield strength - extra high strength steel : MPa yield strength The requirement to Chemical properties and Mechanical properties are as given in the DNV Ship Rules DNV Ship Rules gives the requirements to Charpy V notch energy, which exceeds the max 42 J The requirements to test temperatures are maintained Steel with specified minimum strength above 750 MPa shall be especially agreed Slide 15 Design Materials Requirements EN (3.1 / 3.2) DNV Ship Rules Std.for Cert 2.22 Certification X Mechanical properties X Design temp., Td X Test temp. X Slide 16
9 Design STRUCTURAL DESIGN AND STRENGTH Design Loads: For derating purpose, the modulus of elasticity it for wire ropes shall now be as specified as a un-used wire rope The design dynamic factor for hose handling cranes shall not be lower than 1.3 Relative velocity between load and hook is changed Slide 17 Design STRUCTURAL DESIGN AND STRENGTH Design Loads: For grab duty, the design dynamic factors shall be increased New method for calculating relative velocities for cranes on barge and bulk carriers unloading from another barge or bulk carrier Slide 18
10 Design STRUCTURAL DESIGN AND STRENGTH Design and Strength of Particular Components : The required safety factor for the slewing bearing ultimate carrying capacity is lowered from 1.7 to 1.5 The effective length of slewing ring bolts shall be at least 4.5 times the bolt diameter Slide 19 Design WINCHES Winch brakes for offshore crane applications shall remain off when the operator releases the operating device in Constant Tension and Active Heave Compensation modus For Lebus grooved drums, the C-value in the equation for calculation of hoop stress shall be increased to 3.0 for 5 layers and more (lower factors may nevertheless be applied if thoroughly documented) Specific method/specification to strength calculations for brake components Safety factor for Luffing ropes equal to hoisting Specific requirements to chains Slide 20
11 Design Electrical Installations Electrical equipment and systems for offshore cranes shall be categorised and treated as essential according to DNV s Ship Rules Pt4 Ch8.. Specific requirements for: - Service description - System design - Equipment - Cables - Installation Slide 21 Design Hydraulic, Pneumatic, Instrumentation, Automation and Wireless remote Control Systems More detailed specifications of hydraulic and pneumatic systems Specified requirements to hydraulic cylinders with respect to strength, materials and approval. Described in DNV Standard for certification No 2.9 Hydraulic cylinders Guidelines to wireless remote control systems are introduced Instrumentation and automation components for offshore cranes shall be categorised and treated as essential according to DNV s Ship Rules Pt4 Ch9. For cranes covered by CRANE or Crane Vessel, testing at Manufacturer s works and issuance of product certificate will be required Slide 22
12 Design Certification Requirement, System Type of cranes Certification scheme Design review Survey & testingti DNV Product Certificate t ILO 152 Ship board CRANE class X X X Offshore ILO 152 CRANE class X X X X Slide 23 Standard for Certification Lifting Appliances Slide 24
13 Safety and Safety Systems Generic safety requirements based on a standard offshore crane are specified If the crane in question deviates from generic ( standard crane ), a risk-based approach is introduced; d opening for specific and modified safety requirements for the specific crane It is specified that it is up to the customer to select the technological l platform for the safety functions A new verification method by means of verification sheets is introduced Slide 25 Safety and Safety Systems The method is to: Identify the risk contributors Then identify the risk control measures (Safety functions) APPENDIX G VERIFICATION GUIDELINE FOR SAFETY FUNCTIONS To be used in connection with Sec.6 Safety function requirements for offshore cranes Introduce a new method for verification by means of verification sheets to be filled out by Crane Maker, verifying that the generic safety requirements are met and documented Slide 26
14 Safety and Safety Systems Slide 27 Safety and Safety Systems APPENDIX G VERIFICATION GUIDELINE FOR SAFETY FUNCTIONS Slide 28
15 Safety and Safety Systems APPENDIX G VERIFICATION GUIDELINE FOR SAFETY FUNCTIONS Slide 29 Safety and Safety Systems For generic/standard offshore cranes, the following new requirements are significant: Automatic Overload Protection (AOPS) will be required for cranes operating in areas with a short-wave characteristics A boom tip camera shall be provided Two brakes with independent load paths will be required for hoisting and luffing winches where a gear box is positioned between the winch drum and the brake. For multiple gear applications, the number of gear and brake sets shall be at least 30% above required Facilities for emergency operation in case of blackout/shutdown Slide 30
16 Standards for Certification Lifting Appliances Slide 31 Sub-sea handling Characteristics : Additional dynamic factor for the pedestal/slewing ring (minimum 2.0) will be required for subsea handling cranes also Other and higher C-factor for calculation of drum and flanges for Lebus grooved drums De-rating chart based on dynamic factor will now be required Overload protection by means of stopping the luffing-out movement AOPS not required Special considerations for off lead- and side lead Slide 32
17 Personnel handling Characteristics: Intended for lifting of persons with ordinary crane arrangement, not for man-riding winches Rated capacity below 50% of ordinary SWL Operational independent secondary brakes Manual key selection switch (mode) for lifting of persons Operational limitations with respect to wind, wave height and visibility Minimum SF for loose gear at 8 Slide 33 Standard for Certification Lifting Appliances Slide 34
18 Testing of Lifting Appliances Main characteristics: Limited testing may be carried out at the final testing, based on tests carried out at Manufacturer s location For subsea handling cranes, the interpretation of the functional test requirements will be that the crane shall be tested with the load submerged at full depth Slide 35 COMING DNV is launching a new class notation later in 2009 Equipment E i t and service notation ti CRANE (N) - DNV classed vessels and offshore installations This notation shall document compliance with obligations related to operation on the Norwegian Continental Shelf (NCS) Slide 36
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