SP2552-2-15-1 IOM 12 T Crane
SP2552-2-15-1 IOM 12 T Crane
SP2552-2-15-1 IOM 12 T Crane
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1. Introduction
The purpose of this procedure is to:
1. Ensure that all components are handled / lifted in a safe and correct way to avoid any injury or damage
to personnel or equipment.
2. Ensure up to 2 years’ storage with no deterioration in function and/or quality that could reduce the
working performance or service life of the unit.
3. Ensure that installation and initial start up are performed in a safe and correct way.
3. Crane Preservation
See separate document: T0011 – Handling, Preservation & Storage Procedures page 3.
• Deck structure must be free from cracks, rust, oil and other elements that could inhibit bolting/welding
of the pedestal to the sub-foundation.
• The crane is delivered as agreed.
• Be sure that no dust or other contaminants enter the hydraulic system.
• Be sure that the vessel’s foundation sub-structure is dimensioned to bear the weight of the specific
crane and the forces it will exert.
5. Initial Start-up
It is important to check that valves and controls are in the correct position before attempting to start the crane.
As a final check before starting, check the rotation of the electric motors. Motors must rotate in a clockwise
direction as seen from the motor’s fan end. If a motor rotates in the wrong direction, swap two phases and check
again for clockwise rotation.
The main HPU motors are bolted just below the slew bearing on the underside of the king bottom plate. Access
is through a door in the pedestal.
A hydraulic pump must not be allowed to run in the wrong direction for any length of time, as this will
reduce the service life of the pump.
Upon completion of the initial test run, check the oil level in the oil tank, and top up if necessary.
The first time the system is started there may be air in the system. Run the power pack for a couple of minutes at
low pressure. The winch and the slew will automatically vent air from the system when operated.
This is done by lowering and raising the full length of wire a minimum of three times while maintaining a
tension equivalent to 10%-20% SWL.
2 MACGREGOR NORWAY AS
User Manual for Crane
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4 MACGREGOR NORWAY AS
PROJECT DOCUMENT
This document and all information and data herein or herewith is the confidential and proprietary property of
MacGregor Norway AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without
the written confirmation from MacGregor Norway AS.
© MacGregor Norway AS
www.macgregor-group.com
Equipment:
Offshore Products
- -
- MacGregor Norway AS
Andøyfaret 15, N-4623 Kristiansand
NORWAY
1 GENERAL ............................................................................................................. 3
1.1 References ...................................................................................................................................3
3 LIFTING ................................................................................................................. 3
3.1 Safety Note ...................................................................................................................................3
4 TRANSPORT ........................................................................................................ 4
4.1 Packing .........................................................................................................................................4
5 STORAGE ............................................................................................................. 5
5.1 Preparation ...................................................................................................................................5
6 PRESERVATION .................................................................................................. 6
6.1 Inspection of equipment on Receipt .........................................................................................6
1 GENERAL
The purpose of this procedure is to ensure proper storage, safe lifting and transport of
MacGregor Norway Offshore Products
1.1 References
HM Doc. No. Doc. Title
SPxxx-XXXX-GXX [300T Main….]
SPxxx-XXXX-…. [Spooling….]
SPxxx- XXX-…… [Control…..]
2 PRECEDING ACTIVITIES
2.1 Preparation
The following actions shall be done prior to lifting and transport operations of MacGregor
Norway products. A “Tilt Watch” may be placed on the items to check if the transport and
lifting has been done in a proper way.
• Wire rope to be fully spooled onto the drum with tension. The free end to be
fastened properly.
• Wooden pads (4 off) are to be fitted underneath the feet of the foundations on
small parts without transport cradle.
• Ensure that all movable parts are properly fastened to prevent them from any
uncontrolled movements.
• Ensure that end of interface electric cables and hydraulic hoses are disconnected
and their loose end are fastened and protected properly. Make sure that all ends
are marked properly to avoid any problems during reconnection of the
equipment.
• The opened hydraulic connections to be protected against impurity with caps.
• Lifting and handling of the equipment to be prepared according to relevant lifting
drawing.
• Length and capacity of loose lifting gear to be in accordance to relevant lifting
drawing.
• Loose lifting gear to be inspected for defects.
• Loose lifting gear certificates to be present.
3 LIFTING
4 TRANSPORT
The equipment may be transported by ship or truck to final destination.
For more detailed information about overall dimension weights and COG locations
individually for each unit, refer to section 3 in this document and/or corresponding GA
drawing, transport drawing, and or relevant packing list.
4.1 Packing
Belonging equipment to the product may be packed in standard 20` container and on
deck of transport vessel. Preparations described in 2.1 shall be performed. Make sure
there remains no loose component in the container. All the modules shall be properly
strapped to container.
Smaller items may be packed in VCI bags for transport
4.2 Unpacking
The unpacking shall be done short time prior to installation. If unpacking is done earlier,
follow instruction given in section 5.
Check that equipment has not moved inside container, and there are no damages or
elements missing before unloading. If any damages are found, take pictures when
equipment still is inside container, or on transport vessel. Carefully loosen the securing of
each element.
Unpacking from open top container is done by using lifting sets/sling mounting on the
equipment. Follow lifting instructions given in section 3. Fork truck is used for unpacking
equipment without lifting sets.
5 STORAGE
5.1 Preparation
• Prepare sufficient area for storing: The equipment shall be stored in areas free of
contamination from welding, grinding or other activity containing hot metal
particles.
• It is recommended to choose sheltered place, if storing the equipment outdoors.
• All the disconnected interface electrical and hydraulic joints are to be protected, no
loose items left.
• Carbon steel surfaces which are not painted to be preserved as described in
attached tables of preservative
• Touch up painting if paint has been damaged.
• If the equipment is contaminated by salt, dirt or particles which may damage the
equipment, the equipment shall be washed with fresh water prior to storage.
5.2 Storage
The product and loose components should be stored in their natural position. They should
rest on wooden pads to isolate the equipment from the ground. Unpainted/exposed steel
shall rest on a rubber layer with wooden pads below. The equipment cannot be stacked
up on top of each other. The equipment is to be protected during storing, and also after
installation onboard against dust, damages, humidity, painting etc. (see chapter 6)
NOTE:
If the equipment is stored for more than three months, the standard periodic maintenance
activities (lubrication) are to be done to the equipment according to the maintenance
schedule. For details refer to corresponding documents. Re-preservation is solely the
responsibility of the buyer or the buyers appointed as described in chapter 6.7 Project
Cycle for Preservation.
Title: Handling Preservation & Storage Procedure
Proj.No.:
Doc.No.: T0011
6 PRESERVATION
Preservation work in all stages of the project may involve usage of solvent that may be
harmful to human. Personal performing this type of work, should be wearing personal
protection equipment.
When purchasing preservatives, data sheet must be required as a part of the delivery.
These sheets must be received and correct action taken according to listing on data sheet
before preservation can be carried out.
All yellowcromated materials, as well as valve spindles are covered with Densotape to
avoid corrosion.
Shafts on rotating equipments, which are not locked, shall be rotated 1 ¼ turn in the
rotation direction to avoid brinelling of the bearing. Make sure that new shaft positions
vary from one turn to the other.
Connect heaters to all motors that are specified in the check record to be heated. Check
the heaters to be effective after power hook up by using an Ampere meter, or hand feel
the temperature outside the motor.
HM has topped up all gearboxes with gear oil. Vertical gear box with the pinion facing
down, are topped when they are in operation as well as during storage. These gearboxes
are filled with oil and can go right into operation provided that the storage time is limited.
Horizontal gearboxes are also topped with oil. Horizontal gearboxes must be drained to
correct level prior to use of the boxes. However, heavy-duty gearboxes have been
drained for gear oil, and the gear oil is replaced with preservation oil to specified
level. See check record for correct oil and level. Gear boxes topped with oil shall be
marked with labels as shown in chapter 6.6.
All air bottles or accumulators are put under pressure using dried Nitrogen. The pressure
is normally between 2 and 3 bars. Inspect air bottles or accumulators for positive Nitrogen
pressure. If the pressure is below 1.5 bars, re-pressurize with Nitrogen of dew point –
30deg.
All electrical and electric boxes or cabinets exposed to humidity shall be protected with
desiccants inside. Place a sticker on the outside of the cabinet showing the date when the
desiccant was put in.
Title: Handling Preservation & Storage Procedure
Proj.No.:
Doc.No.: T0011
Shafts on electrical motors and the mechanical seal at the front bearing shall be protected
with grease of type described in preservation record.
All non terminated cable ends shall be fitted with shrinking shroud.
All space heaters on motors, generators, panels etc. shall be energized for storage.
Paint system in
3 3 All painting to be undamaged. If not, repair painting
HM…….
Tectyl506/
4 3 Chain linkages which can be exposed to rust to be protected
CortecVpCI369
Tectyl506
5 3 Stainless steel sign to be protected
Decordyn 350
HDG Bolt or
6 3 Open holes unused treaded opening in carbon steel to be sealed of
plastic plug
Texaco
7 3 Door / Hatch hinges to be greased
Multifak EP2
Comments:
Comments:
Inspect internals for corrosion and moisture – if so, dry up and repair, add
3 3
desiccant and ensure tight sealing’s
All spare cable entrances in panels and boxes plugged. If not vertical installed
4 3
with drain plug down – seal drain plug.
5 3 Open nipples and glands in panels and junction boxes to be sealed off.
Comments:
Paint system in
3 3 All painting to be undamaged. If not, repair painting
HM…….
Tectyl506/
4 3 Chain linkages which can be exposed to rust to be protected
Cotec369
Tectyl506
5 3 Stainless steel sign to be protected
Decordyn 350
Texaco
7 3 Door / hatch hinges to be greased
Multifak EP2
Tectyl506 on bolt
9 3 Bondura Bolts, for assembly use Kluberpaste 46 MR 401 ends and creviced
area.
Check air bottles or accumulators for Nitrogen pressure. Pressure between 1,5
2 3
to3 barg or VCI protection. See list of preservatives
3 3 Gear box topped up with specified gear oil according to list of preservative.
Open end nozzles plugged or capped properly. Nozzle face coated with Tectyl 506
5 3
preservatives. Flange protected with flange protectors. Decordyn 350
Densotape
6 3 Extended cylinder rods coated with preservative an protected with wood
Wood
Shafts on rotating equipment, wich are not locked, shall be rotated 1 ¼ turn in
8 3 rotating direction. New shafts pos. from one turn to another. Bearings with
lub.oil, check oil level before turning.
Comments:
All cabinets, panels and boxes exposed to humidity protected with desiccant.
3 3
Replace desiccant if necessary.
Inspect internals for corrosion and moisture – if so, dry up and repair, add
4 3
desiccant and ensure tight sealing’s
All spare cable entrances in panels and boxes plugged. If not vertical installed
5 3
with drain plug down – seal drain plug.
6 3 Open nipples and glands in panels and junction boxes to be sealed off.
Comments:
Inspect the space heater is effective using an ampere meter or handfeel the
12 1
unit. Ensure that indication light on temp heating distribution panel is working
For space heaters that are not temporarily energized, measure insulation
13 3 resistance phase to phase and phase to earth. Attached form EP 02 to be filled
in.
14 3 Batteries for PLC and CPU fully charged and isolated from consumer.
17 3 Cabin to be heated.
18
3 Cabin AC Unit to be protected by a tarpaulin
Comments:
Paint system in
3 3 All painting to be undamaged. If not, repair painting
HM…….
Tectyl506/
4 3 Chain linkages which can be exposed to rust to be protected
Cotec369
Tectyl506
5 3 Stainless steel sign to be protected
Decordyn 350
HDG Bolt or
6 3 Open holes unused treaded opening in carbon steel to be sealed of
plastic plug
Tectyl506 on
7 3 Bondura Bolts, For assembly use Kluberpaste46 MR401 bolt ends and
creviced area.
Rando oil
8 1 Cylinders shall be full of hydraulic oil
HD46
Texaco
10 3 Nylatron sliding pads (crane booms)
Multifak EP2
Texaco
11 3 Wire sheaves to be turned 1 ¼ turn and greased ( central lub. system )
Multifak EP2
Comments:
Check air bottles or accumulators for Nitrogen pressure. Pressure between 1,5
1 3
to3 barg or VCI protection. See list of preservatives
Open end nozzles plugged or capped properly. Nozzle face coated with Tectyl 506
3 3
preservatives. Flange protected with flange protectors. Decordyn 350
Densotape
4 3 Extended cylinder rods coated with preservative an protected with wood
Wood
Comments:
All cabinets, panels and boxes exposed to humidity protected with desiccant.
3 3
Replace desiccant if necessary.
Inspect internals for corrosion and moisture – if so, dry up and repair, add
4 3
desiccant and ensure tight sealing’s
All spare cable entrances in panels and boxes plugged. If not vertical installed
5 3
with drain plug down – seal drain plug.
6 3 Open nipples and glands in panels and junction boxes to be sealed off.
Comments:
Inspect the space heater is effective using an ampere meter or handfeel the
11 3
unit. Ensure that indication light on temp heating distribution panel is working
For space heaters that are not temporarily energized, measure insulation
12 3 resistance phase to phase and phase to earth. Attached form EP 02 to be filled
in.
Comments:
Paint system in
3 3 All painting to be undamaged. If not, repair painting
HM…….
Tectyl506/
4 3 Chain linkages which can be exposed to rust to be protected
Cotec369
Tectyl506
5 3 Stainless steel sign to be protected
Decordyn 350
Comments:
Open end nozzles plugged or capped properly. Nozzle face coated with Tectyl 506
3 3
preservatives. Flange protected with flange protectors. Decordyn 350
Densotape
4 3 Extended cylinder rods coated with preservative an protected with wood
Wood
Comments:
All cabinets, panels and boxes exposed to humidity protected with desiccant.
3 3
Replace desiccant if necessary.
Inspect internals for corrosion and moisture – if so, dry up and repair, add
4 3
desiccant and ensure tight sealing’s
All spare cable entrances in panels and boxes plugged. If not vertical installed
5 3
with drain plug down – seal drain plug.
6 3 Open nipples and glands in panels and junction boxes to be sealed off.
Comments:
Comments:
6.3 De – Preservation
Effort has been made to minimize the need of de-preservation. Preservatives may be left
on the products when going into operation provided that these will contribute to extended
life of the product and not harmful to the product in any way.
The preparation checking and functional activities must be performed in the same phase,
but the operational activities may be performed in a later phase than the functional
activities depending on installation completion.
If commissioning is performed during multiples phases, the equipment shall be preserved
when functional activities are completed. Subsequently, de-preservation must be
performed prior to commissioning operational activities.
MAINTENANCE
Signature Date
PRESERVATION
CARRIED OUT
HM PROJECTNO.: _____________
SERIAL NO.:__________________
INTERVALS:__________________
DATE_________ SIGN_________
Title.:
Proj.No.:
Doc.No.:
Date________ Sign._________
Title.:
Proj.No.:
Doc.No.:
1. Decordyn 350
Exposed/Machined carbon steel 2. Tectyl 122A with overlap towards
painted surfaces
Other accepted products:
Cortec VpCI 368HB
1. Bridon Brilube 70
Wire 2. Cortec VpCI368 on dry wire
3. Wire grease outside
Wires are pre-greased.
Cabin AC unit Protect outside unit from rain and dust with a
tarpaulin.
De-preservation where
Required in Procedure
User Manual for Crane
5 Operation
Table of Contents
1. Safety ..............................................................................................................................................1
1.1. Safety features ..........................................................................................................................1
1.2. Safety Instructions .....................................................................................................................3
1.3. General Handling Considerations ..............................................................................................4
1.3.1. Weather and Sea State .......................................................................................................4
1.3.2. Derating ..............................................................................................................................4
1.3.3. Parking................................................................................................................................4
1.3.4. Welding ...............................................................................................................................4
2. Modes of Operation .........................................................................................................................5
2.1. Normal.......................................................................................................................................5
2.2. Constant Tension (CT) ..............................................................................................................5
3. Crane Controls Overview .................................................................................................................6
3.1. General .....................................................................................................................................6
3.2. Cabin Equipment .......................................................................................................................7
3.2.1. Operating Panel OP-105 .....................................................................................................7
3.2.2. Operator Panel OP-103 (Chair Left Armrest).......................................................................8
3.2.3. Operator Panel OP-104 (Chair Right Armrest) ....................................................................8
3.2.4. Control Cabinet CC-100 ......................................................................................................9
3.2.5. Control Screen ....................................................................................................................9
4. Crane System Start and Stop.........................................................................................................17
4.1. Pre-Start Preparations .............................................................................................................17
4.1.1. Planning ............................................................................................................................17
4.1.2. Equipment Check ..............................................................................................................17
4.1.3. Control System On / Off Switch .........................................................................................17
4.1.4. System Checks (In / From Cabin) .....................................................................................18
4.1.5. Check HPU Status ............................................................................................................18
4.2. Normal Start ............................................................................................................................19
4.2.1. Motor Start-Up ..................................................................................................................19
4.2.2. Cold Weather ....................................................................................................................19
4.2.3. After Start..........................................................................................................................19
4.3. Normal Shutdown ....................................................................................................................20
4.4. HPU Control ............................................................................................................................20
4.4.1. General .............................................................................................................................20
4.4.2. Local / Remote Pump Control ...........................................................................................20
5 Operation
MACGREGOR NORWAY AS
User Manual for Crane
5 Operation
MACGREGOR NORWAY AS
User Manual for Crane
5 Operation
MACGREGOR NORWAY AS 3
User Manual for Crane
1. Safety
1.1. Safety features
General The equipment delivered by MacGregor Norway AS under this contract has been
designed in accordance with current HSE regulations and standards.
Emergency stop An emergency stop button is located on the right-hand operating panel on the
operator’s seat inside the cabin. Pressing this button cuts off the crane’s hydraulic
pressure. At least one emergency stop button is also located inside the king.
Spring-centred control All control levers, both two-way and joystick type, are spring-centred. When released,
levers they all return to centre, and whatever motion is active stops.
Overload protection All crane motions are protected against overload by hydraulic relief valves and by the
control system. If a particular motion is attempted which exceeds the crane’s design
capabilities, the relevant relief valve for the particular motion will feed the hydraulic
oil back into the hydraulic oil tank, preventing the motion.
Hook stop systems There are two hook stop systems. The software hook stop is based on wire payout
information from rotational encoders on the winch drums and implemented by the
PLC software. The hardware hook stop is based on a switching device suspended
from the tip of the knuckle jib. When the hook touches this device, twin switches send
a double signal to the control system, which stops the winch before the hook is pulled
into the sheave.
Luffing cylinder The jib luffing cylinders are fitted with mechanical stroke limiters which allow luffing
limitation to take place at full speed.
Load holding valves The main jib luffing cylinders are fitted with pilot-operated load-holding valves.
These valves are connected directly to the cylinder ports and have a dual function:
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Failsafe brakes The winch and slew gearboxes all have failsafe, oil-bath, multidisc hydraulic brakes. In
case of hydraulic pressure loss due to hose/pipe failure, the brake actuates automatically
and halts further motion.
Aircraft warning Red aircraft warning lights are mounted atop the main winch and the main jib outer end
lights to mark the crane during conditions of darkness.
Emergency If the main system power should fail, the winch and other crane functions may be
power supplied by the emergency power system which provides a direct connection to the
ship’s power supply. The AHC system will not be available for operation in emergency
mode, however.
Load / Radius A jib angle sensor system provides data to the control system for calculating the
control system working radius. Load cells in sheave hubs on the knuckle jib register the actual load
suspended from the crane. When a lift is close to the allowable radius/capacity, a
warning is displayed on the operator screen. When the maximum permissible radius is
exceeded, the control system halts jib out movement. The only manoeuvre then allowed
by the control system is movement towards a shorter radius.
Tugger The crane operator must ensure that ANY and ALL operations in which a tugger winch
Winches physically holds the main hook away from the whip winch working area are under
precise control. The tugger winch must always be in constant tension mode. This will
allow the tugger winch to pay out wire if the load on the main hook increases. This may
be due to movement of the crane or accidental movement of the main winch. If there is
a power failure or the crane has been switched off, the tugger winch must be reset to
constant tension mode. MacGregor Norway AS also recommends the use of a “weak-
link” connecting sling equivalent to the tugger winch SWL with an extra safety sling
instead of connecting the tugger hook directly to the main hook.
AOPS is inaccessible when the jib tip is over deck, and is automatically made accessible
when the jib tip is over water.
If the wire is caught on another vessel or the seabed and the crane and/or vessel is
disabled, there is a risk of exposing the crane to higher loads than it is designed for as
the vessel drifts. Should this occur, the operator can activate the MOPS by pressing the
yellow button for the appropriate winch on operating panel OP-104 (next to right
joystick). The system will then pay out wire while maintaining a retaining force of
approx. 10-20% of maximum rated winch capacity.
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Risk of collision Pay attention to the risk of collision with the superstructure when slewing and jibbing.
Auto Tension with Never activate Auto Tension Mode while a load is hanging from the hook. This can put
load in the hook the load into free fall and cause major damage to vessel or other structure.
Lifting gear Never use lifting gear with cracks deformations etc. that can reduce the original
strength. All lifting gear must also have the required lifting capacity for the actual load.
Always pay Respect the alarms and information given on the screen.
attention to the
crane control system
Override Mode Do not operate the crane in override mode unless the situation requires this. Override
mode supersedes all interlocks of crane
Operator To operate the crane, the operator must be familiar with the crane and crane user
manual. The crane operator must also fulfil the requirements given by the vessels flag
authorities.
Single wire parts The crane must never be operated if the information on the screen is not correct
compared to actual block in use.
Wire tension – Operational restriction on main winch, please refer to Annex B - "Safety Bulletin 2010-
retrieval operations SB03".
5 Operation
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User Manual for Crane
A crane can operate under a wide range of conditions, but a few key parameters are critical to operational
planning. These include wind speed and direction, heave (wave height and period), list and trim conditions,
offlead angles and the type of lift (i.e. internal, external or ship-to-ship – also treated as an environmental
factor).
Obviously, where relative movements are concerned (external and ship-to-ship lifts), sea state and weather are
important factors that must be taken into account in all planning and operations.
1.3.2. Derating
Operators and users of MacGregor HMC offshore cranes need to understand the basics of crane load limitations
under the different operating modes to avoid putting too much strain on the crane under varying conditions.
Incorrect crane operation can lead to dangerous situations, damage to equipment or to the vessel, and serious
personal injury or worse.
A crane always has its own individual ratings, which describe exactly what capacity the crane can lift at a given
radius under given conditions. As the radius increases or as conditions deteriorate, the allowed rating decreases;
this is referred to as derating. Load diagrams apply to internal, subsea (external) and ship-to-ship lifting
situations.
1.3.3. Parking
The crane must be properly parked after use: knuckle jib folded in, main jib down, slew angle at park and both
knuckle jib and hook(s) in their cradles, if present. This achieves three important purposes:
1. With the cylinder rods fully retracted, their bare metal surfaces are protected from the corrosive marine
environment.
2. Releasing system pressure eliminates strain on system components and extends the life of seals on
cylinders, valves and connections.
3. Securing idle equipment is an important safety measure on board a ship.
1.3.4. Welding
Sensitive electronic components are easily damaged by the stray electrical charges that welding currents can
produce. Therefore, if any electric welding is to be done on the crane, the control system must first be isolated
by turning off the main control system circuit-breaker, F15, located in ES400 in the king.
5 Operation
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2. Modes of Operation
2.1. Normal
Normal crane operation allows the crane operator to carry out most lifting operations with the crane such as
slewing, luffing, ordinary lifting and lowering with any winch, and parking.
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Cabin ventilation The operator cabin is equipped with two heaters and an air conditioner. The heaters
are located under the operator chair and are controlled by an on/off switch located
on the control panel on the left wall. Temperature is thermostat-controlled.
The air conditioning unit is located on the rear wall of the cabin and has individual
controls for cooling and fan speed on the front of the unit.
Radio w/ CD player The operator cabin is equipped with an RDS radio/CD player and a set of speakers
mounted on the side walls on either side of the operator.
VHF/UHF radio The operator cabin is equipped with a VHF radio and a UHF radio mounted on the
wall panel. The top switch on the right joystick is used for push to talk (PTT), and a
switch below the radios is used to select which radio to operate.
Window wiper and The left, right, front (central) and rooftop windows are fitted with a wiper/washer
washer system. The window wiper and washer switches are located on the wall mounted
utility panel at the operators left side.
Window wipers and The front top window, front bottom window, roof window and both side windows of
washers the cabin are all equipped with wipers and washers.
Cabin heater These switches control the cabin heating and defrosting.
Radio/CD player Stereo system with speakers on left and right walls
5 Operation
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Four-way joystick The spring-centred four-way joystick with thumb wheel and front switches controls
the crane slew and main jib luffing functions.
FUNCTION COMMENTS
Joystick X- • Crane slew Clock Wise (CW)
positive
Joystick X- • Crane slew Counter Clock Wise
negative (CCW).
Joystick Y- • Main jib down
positive
Joystick Y- • Main jib up
negative
Front switch • Alarm Acknowledge
Front switch • Front washer
Front switch • Front wiper
Thumb wheel • Tugger 1 in/out, tension +/-
MOPS Main winch The MOPS Main winch button has a cover to protect it from being pressed
accidentally. Lift cover to operate. Push once to activate MOPS mode, and once more
(Manual Overload to deactivate. More information in the Main Winch section.
protection system)
Four-way joystick The four-way spring-centred joystick with thumb wheel and front switches controls
the main/whip winches and knuckle jib functions.
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FUNCTION COMMENTS
Joystick X-positive • Crane knuckle jib out
Joystick X-negative • Crane knuckle jib in
Joystick Y-positive • Winch down
Joystick Y-negative • Winch up
Front switch • Signal horn
Front switch • Main/whip winch selection
Front switch • PTT (UHF/VHF)
Thumb wheel • Tugger 1 in/out, tension +/-
Note: To prevent accidents, always set in ‘Off’ position when leaving the operator
chair or when the crane is not being operated!
Emergency stop The ES button locks in stop position when activated. To release turn the button CCW.
button
When this switch is turned Off, the emergency stop loop is de-energized, meaning that no pumps or crane
functions can be activated. This switch is always turned off to ensure that the crane cannot be operated while
service is being performed. System off is also indicated by an alarm on the control screen. This switch may be
locked in the Off position.
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Main functions
1. Alarm Banner (always on top) displays the last incoming alarm. This alarm is acknowledged on the
alarm screen or by pressing the yellow top switch on the left joystick. Described in further detail in the
alarm section.
2. Alarm Status Banner (always on top) displays the alarm status for different groups. Described in further
detail in alarm section.
3. Equipment and Functions Status Banner (always on top) displays the status of equipment and functions
by using different colours. Described in more detail below.
4. Field displaying the name of the active screen
5. Time and date field
6. Load indicator:
o Green area: Load range for the selected crane derating. This range can change according to
mode, wave-height and dynamic factor.
o Yellow area: Dynamic forces are acceptable. This range can change according to mode, wave-
height and dynamic factor.
o Red area: Load exceeds 100% of maximum SWL for Internal Hs=0 in current mode
7. Menu button (menu presented next page).
8. Relative Knuckle Jib Angle Information. Press Rel. Knuckle Jib button for pop-up dialog box (ill. Next
page).
1 3 5
4 2
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Bringing up displays
The following screens are defined and can be selected by touching the MENU button at the
bottom and selecting the desired screen from the menu (shown at right):
• Previous
• Setup
• Alarm
• Misc
• MW Lineup
• HPU
• Trend
• Main
The menu also has a Previous button at the top which will return the previous screen.
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The items in the equipment and function status banner are presented here.
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Examples of screen objects are ‘bar graphs’. All bar graphs in the front screen application have the same design
and share the same basic functionality. Other examples are numeric output fields etc.
Common functionality improves recognition, accelerates the learning curve and simplifies the application. It is
very important that the user is familiar with the different properties of the screen objects.
General buttons
Buttons in the HMI screen application are activated by touching them on the touch screen. Some buttons, when
touched, will produce a pop-up dialogue that prompts the user for input. The various pop-up dialogues will now
be presented in brief.
Background is The associated function is active (the Main Winch mode-selection buttons are typical
Blinking examples). After pressing Confirm, but before AHC is ready, the button blinks.
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Bar Graphs
Bar graphs are a vital part of the front screen application. These are used to show system
parameters both in analogue and numeric format.
The bar graphs used in the HMI screen application have a set of features associated with
them.
Bar graph scaling enables the operator to adjust the scale to suit the values expected in the
coming operation, or to zoom in to specific signal ranges. Touch the bar graph that is to be
adjusted. A pop-up dialogue with several options is displayed on the screen. Use the
selections to set a new maximum or minimum, for example, and then close the pop-up.
The bar graph will now show the new settings.
A max/min marker function is included to help visualise the range of a signal. When this
function is active, two light blue lines are used to continuously show the lowest and
highest value shown by the bar graph. For example, if this mode is active and the highest
value ever shown is 7.0, the “high” marker is next to the 7.0 point on the scale. If the bar
graph value exceeds this value, for example to 8.0, the “high” marker is pushed up to the
8.0 point. Note that the low/high markers for all bar graphs can be reset by touching the
Set Markers button on the bar graph pop-up that appears when the bar graph is touched.
A reference marker function is included as a help to the user. When this function is active,
a yellow line is “frozen” on the screen to display a reference that the user can adjust as
needed. This feature is useful for observing variations.
Numeric output fields are used to display any real time value. The
output field states the name of the signal and the unit of measure.
All output fields have a light grey background and black numbers.
Input fields
Numeric input fields are used to enter new values. The input field consists of the name of the signal, and the unit
of measure, if relevant.
All input fields have a white background and black text/numbers. After touching the white area, a pop-up
dialogue appears in which the user enters the appropriate input.
Status indicators
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Radio buttons
Click inside the circle beside the item to be selected. If the selection is approved by
the control system, a black dot is showed inside the circle indicating that the selection
has been carried out.
Valve objects
Two types of valves are used in the HMI screen application: valves which the operator can open/close directly,
and valves which the operator cannot open/close (operated by the control system).
When the operator touches a valve object with direct control capabilities, a pop-up dialogue will appear
prompting to confirm a start or stop command.
The colour coding below is used to show the various modes of operation for all valve objects with direct control
functionality.
Steady white fill The valve has been closed by the PLC
Flashing white and green Flashes while the valve is closing or opening
Steady green fill The valve has been opened by the PLC
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Pump objects
The pumps are presented with colour codes indicating pump status.
Filter objects
The various filters are presented on the front screen with colour coding indicating filter status.
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• Check that lifting gear / loose gear is in good order and approved for the purpose by a visual inspection
of equipment and certificates.
• Visually inspect crane, wires, wire sheaves, machine room with pumps, hoses, oil tank level and valves
(visible leaks/defects).
• Check that emergency stop buttons in king are not activated.
• Check that the crane is fit for the operation and rigged for the job in question: winch selection, reeving,
hook height above deck, working radius etc.
• Communication with bridge
Warning: If the key is in OFF position, always check whether any service operations are being performed
on the crane before switching ON and starting up.
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Check that the Ctrl Enable switch on OP-104 (right operating panel) is Off.
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• Check that oil level and temperature are acceptable, that all colour codes on the HPU screen are normal
(green motors, grey filters), and there are no critical alarms on the alarm banner.
• Pay attention to the crane control system and respect the warnings and alarms it gives.
• Is communication with the slinger / banksman satisfactory?
• Is communication with the bridge in order?
Once the HPU has started and system checks are complete, the crane is ready for operation.
The Ctrl Enable switch on OP-103 (left operating panel) remains Off if any mode is to be selected or derating
performed. Always turn this switch off before leaving (or entering) the operator’s seat.
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Park crane Park crane before initiating shutdown: knuckle jib folded in, main jib down, slew
angle at park and both knuckle jib and hook(s) in their cradles, if present.
Controls on/off Check that the Ctrl On/Off switch on operating panel OP-104 (right) is turned OFF.
Shut down The main pumps can now be stopped by touching the motor symbols on the HPU
screen to select them, and then touching the Stop button in the motor pop-up to stop
them.
The circulation pump will continue to run 5 minutes after the last main pump has
stopped. The circulation pump will stop automatically if it is set in “Auto” mode. The
CJC filter pump is left to run continually, even when the crane is not in use.
To return pump control to the control system, the local/remote switches on the starter panel in the king must be
set to Remote, indicated in the control system by a grey frame around the motor symbols.
4.4.3. Sensors
Level and temperature sensors and switches on the oil reservoir send information to the control system.
Pressure sensor switches on all system filters send signals to the control system when clogged.
Analogue indications are given in the king (thermometer, sight glass, warning lights).
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8
5
6
2 10
9
The following table below lists the main functions on this screen.
No. Description
1 Main pump status (1-4)
2 Circulation pump status
3 Filter symbol (red when clogged)
4 Pressure reading main pressure
5 Oil Temperature
6 Oil Tank Level in %
7 High temp alarm lamp
8 High and low level indication lamps and bar graph
9 Buttons for choosing the HPU, main winch or whip winch lineup screens
10 CJC filter pump status
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These screens display information about the valves in the hydraulic control system as well as various pressure
readings. They also provide oil cooler fan motor control.
The buttons along the bottom right provide easy access between the three HPU system screens.
Analogue Sensors
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Filter Status
All hydraulic system filters have built-in pressure switches that signal the PLC when the filter is clogged. When
a pressure switch is activated, an alarm is generated in the control system and displayed on the HMI screen, as
described in earlier chapters.
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Mode Description
Manual Manual mode is set by touching MAN in the Oil cooler motor operation pop-up. This must be done
for each cooler. Each cooler can then be started and stopped by touching the OFF and ON buttons.
Note: The oil cooler will not start automatically when in manual mode, which may lead to
overheating, especially during AHC operations.
Automatic Automatic mode is set by touching AUTO in the Oil cooler motor operation pop-up. When automatic
(recommended) mode is selected, the coolers start at the following temperatures:
Cooler 1: > 45 degrees C
Cooler 2: > 50 degrees C
Cooler 3: > 55 degrees C
Cooler 4: > 60 degrees C
Cooler 5: > 65 degrees C
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All motor/pump units are started from the operator’s touch-screen in the cabin. Check that the HPU is running at
an idle pressure of approx. 40 bar. Check that the circulation pump has started automatically. Make sure that the
oil coolers are set Auto to maintain proper temperature control during operation.
Note: When planning to operate more than one crane function at a time, ALL pumps must be running.
Loads are always lifted off the deck by using the winch. Any of the main jib, knuckle jib and slew functions
may then be used once the crane is carrying the load.
During crane operations, relevant information and controls are found in the Main screen on the operator’s
terminal. All items on these screens will be briefly presented in the sections on the winch, the details on pop-ups
and so on will be presented in subsequent sections as their functions are presented.
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A rotational encoder is installed on the main winch for keeping track of hook position and wire payout. The
encoder registers nothing but the length of wire paid out. Since the hook position follows the jib tip, and the jib
tip’s position varies with the main and knuckle jib angles without affecting wire payout, the control system PLC
must continuously use real-time crane geometry parameters to calculate the hook’s true position.
The main winch has two upper hook stops and one lower hook stop
The upper (software) hook stop is activated by the control system when the calculated hook position is less than
the initialized zero meters. When upper hook stop is reached, the knuckle jib in and main jib down movements
stop.
The lower hook stop (end stop) is activated by the control system when three turns are left on the winch drum.
Payout stops, preventing the entire length of wire from being run out. An alarm is given when the calculated
wire payout is less than 50 metres from the end stop.
It is recommended that a verification of this function is included in the crane operator’s daily check list.
A dual bridge load cell fitted to the upper sheave hub on the knuckle jib measures the main winch load. The
load can be monitored on the HMI display in the cabin. Refer to MacGregor Hydramarine AS load charts for an
overview of crane derating according to radius and sea state.
Maximum Load
The maximum permissible load for the current crane derating and radius is displayed inside the dial on the main
screen.
An alarm is generated on the control screen and the cabin buzzer is activated when 90 % of max load is reached.
At 100 % of maximum load the horn outside the cabin will sound and an alarm will be generated on the operator
display.
When the load reaches 100% of allowed maximum load, the main- and knuckle jib will only be allowed to
move to a smaller radius.
Crane Radius
The radius is the calculated distance from jib tip to centre of crane king. Crane radius is calculated from the
main jib angle and knuckle jib angle registered by the jib angle encoders.
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Interlocks
Derating
Derating comprises a range of parameters in specific situations, and is dealt with in the following section.
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Modes
This is the process called derating, which implements a reduction in crane capacity reflecting the higher
dynamic forces acting on the crane and load under certain conditions.
The Significant Wave Height input box is used in Ship To Ship and Ship to Ship Connected modes for
derating the crane according to the sea state.
Dynamic factor
In Subsea Lift mode, a hydrodynamic analysis based on the specific geometry of a load must be performed to
obtain the dynamic factor for each specific subsea lift.
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When the main winch has been selected on the operator’s control terminal, the Main Winch Screen appears on
the display:
11
12
10
8 9
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This pop-up gives the operator information on various pressure measurements and status items relevant to other
crane functions.
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5.5. Slew
The left joystick’s x-axis (left control panel OP-103) controls crane slew. Pushing the joystick left slews the
crane to the left (counter clockwise), and pushing the joystick right slews the crane to the right (clockwise).
Centring the joystick as the crane is slewing will cause the control system to ramp down the slew speed to zero,
bringing crane slew to a smooth, controlled stop.
The displayed slew angle range is from zero to 360 degrees, where zero indicates the crane pointing straight
forward relative to the vessel. Angle value increases in right (clockwise) direction. Crane slew is unlimited in
both directions.
Interlocks
The position of the main jib is measured by an angle sensor, with the angle increasing as the jib moves up. Zero
degrees is when the main jib is at its lower end stop. Main jib angle is displayed on the operator’s terminal.
Main jib down movement is stopped if the active winch’s hook stop is reached (indicated by alarms). The active
winch’s wire must then be paid out in order to continue the main jib’s down movement.
Interlocks
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The position of the knuckle jib is measured by an angle sensor, with the angle increasing as the jib swings out.
The angle of the knuckle jib is relative to the main jib. Zero degree is when the knuckle jib is perpendicular to
the main jib. Knuckle jib angle is displayed on the operator’s terminal.
Knuckle jib in movement is stopped if the active winch’s hook stop is reached (indicated by alarms). The active
winch’s wire must then be paid out in order to continue the knuckle jib’s in movement.
Knuckle jib out movement is stopped if the maximum hook load is exceeded.
Interlocks
• Main winch Hook load > 100% of max allowed load and increasing radius
• End stop reached
• Knuckle jib angle encoder error.
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6. Derating
6.1. Derating overview
To prevent peak loads and dynamic forces from exceeding a crane’s design limits, it is necessary to restrict hook
load and operating radius in heavy seas (high significant wave height). A calm sea creates little need for
regulating maximum allowed hook load, and a crane can operate at full rated capacity. But rough seas and a
swaying crane subject the crane to considerable dynamic forces, and capacity must be reduced through a
procedure called derating. Each crane is supplied with its own load/derating curves which roughly indicate load
limits relative to radius in defined operating modes:
• Ship to Ship lift – This applies to a pickup or landing point defined by another vessel which is moving
independently. The derated capacity is based on an increase in the dynamic amplification factor
resulting from the higher relative velocities of the jib tip and the other vessel.
• OnBoard / OffBoard – This applies to a pickup or landing point defined inside the vessel, or to
shallow water always in conditions that heave is less than 0.5m.
• Higher forces acting on the crane as a result of increased crane base motion.
• Very high peak loads caused by high relative motion between the jib tip and the sea surface or the load
at rest.
If derating is required, the operator must open the Crane Rating pop-up and select the appropriate lifting mode
and enter the wave height (or dynamic factor). The control system then imposes reduced load/radius limits
automatically. But the load charts are based on analysis of normal operating practices and relevant standards,
and cannot cover all possible crane manoeuvres. The operator is therefore still responsible for careful
assessment, planning and execution of each lift and for a correct response to unforeseen situations.
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7. Emergency Procedures
7.1. Emergency Stop
When activated: All HPU pumps will shut down and all crane functions will stop. All valves are de-energized.
Note: An emergency stop will not de-energize all components in the system, and the control system will still be
powered up.
Emergency stop buttons Turn emergency stop button counter clockwise to release.
must be reset Check emergency stop buttons in king (2) and in cabin (1).
Execute start procedure Resetting the emergency stop button will not start the system.
from HMI touch-screen
AOPS is inaccessible when the jib tip is over deck, and is automatically made accessible when the jib tip is over
water.
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When the MOPS button is pressed, the winch will pay out wire while the system maintains a retaining force of
approximately 10-20% of maximum rated winch capacity. MOPS works independently of the control system
and is powered by batteries.
Both emergency release functions are inaccessible to winches operating in personnel-lift mode.
When needed, the motor is connected to the ship’s normal or emergency power system by means of a jumper
cable and started from the emergency starter panel on cabinet ES-404 inside the king.
In the event of HPU or power failure, the crane can be operated from the cabin in the normal way using the
control system. If the control system has failed, the crane is operated from the emergency control unit stored
inside the king.
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8. Alarms
8.1. Responsibility of the User
The alarm system is a vital part of the operator’s ability to understand the overall situation, safety information
and environment at all times. Every effort has been made to implement a safe and simple system that presents
all alarms, but which helps the important ones stand out rather than blend in with the range of other alarm
messages.
The alarm system will only work as intended if the user has set it up to give the expected response.
It is important that the crane operator inform other users whenever alarms are acknowledged but not corrected,
or whenever the alarm buzzer is silenced (for trouble-shooting for example), whenever such actions may present
a safety hazard or affect trouble-shooting.
• A new alarm is always displayed in the alarm banner in the top menu bar and in the alarm list. Alarms
are automatically associated with an alarm group for sorting and grouping
• All defined alarms require operator acknowledgement
• If an alarm is acknowledged and the alarm condition resolved, the alarm message will automatically be
removed from the display
• If an alarm condition is resolved (returned alarm), but the alarm is not acknowledged, the alarm
message will turn green and remain showing until acknowledged by the operator
When an inappropriate condition exists for a preset amount of time, an alarm is generated in the PLC CPU and
stored in temporary memory. The HMI continuously reads the memory, grouping and sorting alarms according
to the crane systems (main winch, whip winch etc.) The HMI time-stamps the alarms and displays any new
alarm in both the alarm banner and in the alarms list (the most recent unacknowledged alarm is always
displayed on the alarm banner).
The alarm display will be continuously updated with new incoming and returned alarms. All alarms are logged
for two weeks within the control system (newer systems).
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• A red frame around the shortcut button indicates an active (standing) alarm within the alarm group
• A blinking red frame indicates a new (and not acknowledged) alarm within the alarm group
Clicking on an alarm group shortcut will open the alarms page with the alarms for that group sorted by date and
time.
Note that the Status Banner is further described in other parts of the user manual.
8.3.3. General
Alarms are sorted by date and time according to when they were read by the operator terminal system. They are
always displayed with the most recent on top. Thus, as alarms are acknowledged, the display goes backward
through the list (newest to oldest).
The user may acknowledge alarms with the dedicated Alarm Acknowledge button in the left joystick, or via the
buttons on the alarms screen.
To list all alarms, the operator can call up a separate alarms screen via the alarm button on the main menu. On
the alarms screen, the alarms list presents alarms according to the alarm query setting. The most recent alarm is
always shown on top. Alarms are displayed in rows with alarm information in columns as follows:
• "Date" is when the alarm was received and stamped by the control system
• "Time" is the time the alarm was received and stamped by the control system
• "Priority" shows alarm priority - however this feature is irrelevant to crane operation
• "Group" defines the alarm group the alarm is associated with. Groups are as follows:
HPU Hydraulic power unit alarms
CR Crane alarms
MW Main winch alarms
AHC Active heave compensation alarms
MISC Miscellaneous alarms
• "Name" is the actual name used by the control system for the alarm. This will usually correspond to the
tag name used by the PLC
• "Comment" shows the alarm description
• "Value" shows the status of the alarm when it was received
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The alarm status screen shown above is accessed by pressing "Alarm" from the "Menu" button.
• Alarm Status: the current alarm situation is displayed. Only non-acknowledged alarms (whether they
are standing or returned) are listed. Alarms are sorted by time
• Alarm History: all alarms (since the last HMI reboot) for the selected group are displayed. The list is
sorted by time
The active display mode is shown in the upper left corner of the alarm display. Alarm status is the default view.
The "New Query" button allows the operator to filter alarms in greater detail. This function is described in
greater detail later in this section.
The "Long Term History" button allows access to a list of all alarms from the past 2 weeks (can be filtered by
date/time, but not sorted) as seen in the following image.
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This screen shows the alarm history displayed in "Long Term History" mode. Here, the operator is able to
display alarms from the following periods:
• Last 15 minutes
• Last hour
• Last day
• Last week
• Last 2 weeks
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From the alarm display, alarms can be acknowledged individually or by groups. To acknowledge an alarm, click
on the alarm in the display. Press and hold on the touch screen, and repeat to select several alarms. Click “Ack
Selected” to acknowledge the selected alarm/s, or click “Ack ALL” to acknowledge all alarms in the alarm
group.
The alarm system is divided into simple, intuitive alarm groups. Each of these groups typically pertains to a
part or aspect of the crane. Each alarm group may consist of further subgroups which are available by selecting
and performing a new alarm query. The alarm display shows alarms for selected alarm groups according to the
last alarm query.
• Click on the group symbol in the status banner. The alarm status display will appear with an alarm
query for the selected group
• In the alarm status display a new alarm query can be selected with the “New Query” button. A menu for
the query selection will appear
Click on “Alarm Query” to bring up the alarm query popup which will appear over the lower buttons in the
alarm display.
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The following list presents the main operational alarms of the system. The alarms are presented with Tag info,
alarm text, alarm group and alarm description.
General system
Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
2.0 CR_EmergencySto Emergency Stop CR Any emergency stop activated
p Activated
2.1 CR_EmergencySto Emergency stop CR Emergency stop activated –ES400
p_S0 on/off
2.2 CR_EmergencySto Emergency stop CR Emergency stop activated –ES404
p_S04 on/off
2.3 CR_ServiceMode Emergency Stop - CR Service mode switch activated – crane lock out
Service Mode
2.4 CR_IntLockOverrid Interlock Override CR Interlock button override – all interlocks disabled
e_STA
2.5 CR_JS_Right_X_E Joystick Right - CR Error with joystick directional switch or
RR Switch Error X Axis potentiometer. Calibration needed.
2.6 CR_JS_Right_Y_E Joystick Right - CR Error with joystick directional switch or
RR Switch Error Y Axis potentiometer. Calibration needed.
2.7 CR_JS_Right_ERR Right Joystick error - COM Right Joystick - Profibus communication error
DP19
2.8 CR_JS_Left_X_ER Joystick Left - CR Error with joystick directional switch or
R Switch Error X Axis potentiometer. Calibration needed.
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
2.18 CR_MOPS_Battery MOPS Battery NOT CR MOPS Battery NOT ready
_Fault2 ready
2.19 CR_MOPS_Battery MOPS Battery < CR MOPS Battery < 85% charged
_LOW 85% charged
2.20 MISC_RollAngle_ Roll Angle High MISC MRU roll ≥ 6,0 degree.
H
2.21 MISC_MRU_ERR MRU - Signal Error MISC MRU error – analog outputs from MRU not OK.
2.22 IC300_ERR CC-300 - Remote IO COM CC-300 – Profibus communication error
Error - DP3
2.23 IC400_ERR ES-400 - Remote IO COM ES-400 - Profibus communication error
Error - DP4
2.24 Encoder_MW_ERR Main Winch Encoder COM Main Winch Encoder - Profibus communication
IO Error - DP11 error
2.25 Encoder_MJ_A_ER Main Jib Encoder A COM Main Jib Encoder A Profibus communication error
R IO Error - DP13
2.26 Encoder_MJ_B_ER Main Jib Encoder B COM Main Jib Encoder B - Profibus communication error
R IO Error - DP14
2.27 Encoder_WW_ER Whip Winch Encoder COM Whip Winch Encoder - Profibus communication
R IO Error - DP12 error
2.28 Encoder_KJ_A_ER Knuckle Jib Encoder COM Knuckle Jib Encoder - Profibus communication
R A IO Error - DP16 error
2.29 Encoder_KJ_B_ER Knuckle Jib Encoder COM Knuckle Jib Encoder - Profibus communication
R B IO Error - DP17 error
2.30 Encoder_Slew_ER Slew Encoder IO COM Slew Encoder - Profibus communication error
R Error - DP10
2.31 Encoder_WW_Spo Whip Winch COM Whip Winc Spooling Encoder - Profibus
olPos_ERR Spooling Encoder IO communication error
Error - DP15
2.32 CR_OverloadM55 Grease Pump M55 CR Grease Pump M55 for crane functions is overloaded
overloaded and not moving
2.33 CR_GreasePumpM Grease Pump M55 CR Grease pump for crane functions disabled.
55Disabled disabled
2.34 CR_OverloadM56 Grease Pump M56 CR Grease Pump M56 for Main Winch is overloaded
overloaded and not moving
2.35 CR_GreasePumpM Grease Pump M56 CR Grease pump for Main Winch disabled.
56Disabled disabled
2.36 CR_LubeMon1NoF No grease flow - CR No grease flow detected by the lubrication monitor 1
lowM55 Lubrication Monitor on –M55
1 on -M55
2.37 CR_LubeMon2NoF No grease flow - CR No grease flow detected by the lubrication monitor 2
lowM55 Lubrication Monitor on –M55
2 on -M55
2.38 CR_LubeMon3NoF No grease flow - CR No grease flow detected by the lubrication monitor3
lowM56 Lubrication Monitor on –M56
3 on -M56
2.39 Software_ERR Software error CR Error in PLC software
2.40 Module_ERR I/O-Access error CR PLC I/O access error
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
3.0 HPU_TankLevel_ERR HPU Reservoir Level HPU Cable break or faulty sensor.
- Signal Error
3.1 HPU_Tank1LevelSwitc Oil Tank 1 Level HPU HPU oil level sensor fault. Cable break or faulty
h_ERR Switch - Sensor Fault sensor.
3.2 HPU_TankLevel_L HPU Reservoir Level HPU HPU oil tank level less than 55 %
- Low Alarm
3.3 HPU_TankLevel_LL HPU Reservoir Level HPU HPU oil tank level less than 50 %
- Low Low Alarm
3.4 HPU_TankLevel_H HPU Reservoir Level HPU HPU oil tank level above 95 %
- High Alarm
3.5 HPU_TankLevel_HH HPU Reservoir Level HPU HPU oil tank level above 100 %
- High High Alarm
3.6 HPU_Tank1TempSwitc Oil Tank 1 HPU HPU oil temperature sensor fault. Cable break or
h_ERR Temperature Switch - faulty sensor.
Sensor Fault
3.7 HPU_TankTemp_H HPU Tank HPU HPU reservoir - high temperature
Temperature - High
Alarm
3.8 HPU_TankTemp_HH HPU Tank HPU HPU reservoir - high high temperature
Temperature - High
High Alarm
3.9 HPU_MP1_TRP HPU M1 - Main HPU Motor start/stop tripped
Pump 1 - Tripped
3.10 HPU_MP2_TRP HPU M2 - Main HPU Motor start/stop tripped
Pump 2 - Tripped
3.11 HPU_MP3_TRP HPU M3 - Main HPU Motor start/stop tripped
Pump 3 - Tripped
3.12 HPU_MP4_TRP HPU M4 - Main HPU Motor start/stop tripped
Pump 4 - Tripped
3.13 HPU_CircPump_TRP HPU M10 - Circ HPU Motor start/stop tripped
Pump - Tripped
3.14 HPU_CJCPump_TRP HPU M11 - CJC HPU Motor start/stop tripped
Pump - Tripped
3.15 HPU_Cooler1_TRP HPU M20 - Cooler 1 HPU Motor start/stop tripped
- Tripped
3.16 HPU_Cooler2_TRP HPU M21 - Cooler 2 HPU Motor start/stop tripped
- Tripped
3.17 HPU_Cooler3_TRP HPU M22 - Cooler 3 HPU Motor start/stop tripped
- Tripped
3.18 HPU_Cooler4_TRP HPU M23 - Cooler 4 HPU Motor start/stop tripped
- Tripped
3.19 HPU_Cooler5_TRP HPU M24 - Cooler 5 HPU Motor start/stop tripped
- Tripped
3.20 HPU_Cooler6_TRP HPU M25 - Cooler 6 HPU Motor start/stop tripped
- Tripped
3.21 HPU_Cooler7_TRP HPU M26 - Cooler 7 HPU Motor start/stop tripped
- Tripped
3.22 HPU_EmPump_TRP Emergency Pump HPU Motor start/stop tripped
M31 tripped
3.23 HPU_CoolingFan_TRP HPU M61 - Cooling HPU Motor start/stop tripped
Fan - Tripped
5 Operation
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
3.24 HPU_MP1_PowerMissi Main Pump 1 - HPU Main motors, power missing. Check supply and
ng Power Missing fuses.
3.25 HPU_MP2_PowerMissi Main Pump 2 - HPU Main motors, power missing. Check supply and
ng Power Missing fuses.
3.26 HPU_MP3_PowerMissi Main Pump 3 - HPU Main motors, power missing. Check supply and
ng Power Missing fuses.
3.27 HPU_MP4_PowerMissi Main Pump 4 - HPU Main motors, power missing. Check supply and
ng Power Missing fuses.
3.28 HPU_Circ_PowerMissi Circulation Pump - HPU Circulation Pump power missing. Check supply
ng Power Missing and fuses.
3.29 HPU_CJC_PowerMissi CJC Pumps - Power HPU CJC Pump power missing. Check supply and
ng Missing fuses.
3.30 HPU_Cooler1_PowerMi Cooler 1 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.31 HPU_Cooler2_PowerMi Cooler 2 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.32 HPU_Cooler3_PowerMi Cooler 3 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.33 HPU_Cooler4_PowerMi Cooler 4 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.34 HPU_Cooler5_PowerMi Cooler 5 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.35 HPU_Cooler6_PowerMi Cooler 6 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.36 HPU_Cooler7_PowerMi Cooler 7 - Power HPU Cooler motor power missing. Check supply and
ssing Missing fuses.
3.37 HPU_DrainFilter Main pump drain HPU Clogged oil filter. Replace filter element.
filter pressure switch
3.38 HPU_WinchDrainFilter Winch motor Drain HPU Clogged oil filter. Replace filter element.
Filter
3.39 HPU_ReturnFilter1 Return filter 1 HPU Clogged oil filter. Replace filter element.
pressure switch
3.40 HPU_ReturnFilter2 Return filter 2 HPU Clogged oil filter. Replace filter element.
pressure switch
3.41 HPU_ReturnFilter3 Return filter 3 HPU Clogged oil filter. Replace filter element.
pressure switch
3.42 HPU_ReturnFilter4 Return filter 4 HPU Clogged oil filter. Replace filter element.
pressure switch
3.43 HPU_CJCFilter CJC Filter pressure HPU Clogged oil filter. Replace filter element.
switch
3.44 HPU_MainFilter1A Main filter 1A HPU Clogged oil filter. Replace filter element.
pressure switch
3.45 HPU_MainFilter1B Main filter 1B HPU Clogged oil filter. Replace filter element.
pressure switch
3.46 HPU_MainFilter2 Main filter 2 pressure HPU Clogged oil filter. Replace filter element.
switch
3.47 HPU_MainFilter2 Main filter 2 pressure HPU Clogged oil filter. Replace filter element.
switch
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
3.48 HPU_MainFilter3 Main filter 3 pressure HPU Clogged oil filter. Replace filter element.
switch
3.49 HPU_MainFilter3B Main filter 3B HPU Clogged oil filter. Replace filter element.
pressure switch
3.50 HPU_MainFilter4 Main filter 4 pressure HPU Clogged oil filter. Replace filter element.
switch
3.51 HPU_MainFilter4B Main filter 4B HPU Clogged oil filter. Replace filter element.
pressure switch
3.52 HPU_KingDrainFilter Slew / Tugger Drain HPU Clogged oil filter. Replace filter element.
Filter
3.53 HPU_OilRecoveryFilter Oil Recovery Filter HPU Clogged oil filter. Replace filter element.
pressure switch
3.54 HPU_DrainTankLevel_ Level switch oil drain HPU Oil leakage detected in drain tank/king.
H tank
3.55 HPU_MainPress_L Main Pressure - Low HPU Main pressure below 50 bar.
Alarm
3.56 HPU_MainPress_H Main Pressure - High HPU Main pressure above 350 bar.
Alarm
3.57 HPU_EmPump_RUN Emergency Pump HPU Emergency pump running.
M31
3.58 HPU_LS_Press_A_ERR LS pressure A HPU Cable break or faulty sensor.
(PT219A) - Sensor
Fault
3.59 HPU_LS_Press_B_ERR LS pressure B - HPU Cable break or faulty sensor.
Sensor Fault
3.60 HPU_LS_Press_DEV LS pressure - HPU Deviation between sensor A and B.
Deviation Error
3.61 CR_PowerReqM1_Faile Power request for M1 HPU Request sent from crane to ship’s PMS but no
d failed confirmation within 90 seconds.
3.62 CR_PowerReqM2_Faile Power request for M2 HPU Request sent from crane to ship’s PMS but no
d failed confirmation within 90 seconds.
3.63 CR_PowerReqM3_Faile Power request for M3 HPU Request sent from crane to ship’s PMS but no
d failed confirmation within 90 seconds.
3.64 CR_PowerReqM4_Faile Power request for M4 HPU Request sent from crane to ship’s PMS but no
d failed confirmation within 90 seconds.
3.65 HPU_MainPress_ERR Main Pressure - HPU Cable break or faulty sensor.
Signal Error
3.66 HPU_AuxSupEarthFault Aux Supply (230V) - HPU Earth fault detected on 230V supply to control
Earth Fault system.
3.67 HPU_MainSup1EarthFa Main Supply 1 (A) - HPU Earth fault detected on 690V main supply 1.
ult Earth Fault
3.68 HPU_MainSup2EarthFa Main Supply 2 (B) - HPU Earth fault detected on 690V main supply 2.
ult Earth Fault
3.69 HPU_MainSup3EarthFa Main Supply 3 (C) - HPU Earth fault detected on 690V main supply 3.
ult Earth Fault
3.70 HPU_MainSup4EarthFa Main Supply 4 (D) - HPU Earth fault detected on 690V main supply 4.
ult Earth Fault
3.71 HPU_TankTemp_ERR HPU Tank HPU Cable break or faulty temperature sensor.
Temperature - Signal (TT201)
Error
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
3.72 HPU_TankTemp_L HPU Tank HPU HPU tank temperature below 10 degrees Celsius.
Temperature Too Main pumps start inhibited to prevent damage.
Low To Start Main
Pumps
Slew system
Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
4.0 CR_SlewAccuPress_ Slew accu. pressure - CR Cable break or faulty sensor.
ERR Sensor Fault
4.1 CR_SlewPosDeviatio Slew Position CR Measured slew position deviates from preset slew
n Deviation position
Jib system
Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
5.0 CR_MainJibMoving_ Main Jib Moving CR Main jib moving without joystick command.
ERR Error
5.1 CR_MJ_Enc_DEV Main Jib Encoders - CR Deviation between sensor A and B.
Deviation Error
5.2 CR_KJ_Enc_DEV Knuckle Jib Encoders CR Deviation between sensor A and B.
- Deviation Error
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
6.0 WW_Load_H Whip Winch Load > WW Whip winch load > 90% of allowed load.
90%
6.1 WW_Load_HH Whip Winch Load > WW Whip winch load > 110% of allowed load.
110%
6.2 WW_Load_HHH Whip Winch Load > WW Whip winch load > 125% of allowed load.
125%
6.3 WW_LoadCell_DEV Whip Winch Load WW Deviation between WW load cell channels.
Cell - Deviation
Error
6.4 WW_AOPS_ERR Whip Winch AOPS - WW AOPS disabled due to deviation between WW load
Disabled Due To cell channels.
Sensor Fault
6.5 WW_AOPS Whip Winch AOPS - WW WW AOPS activated by control system.
Active
6.6 WW_MOPS Whip Winch MOPS - WW WW MOPS activated by operator.
Active
6.7 WW_HookStop Whip Winch Hook WW WW hook stop activated either by mechanical hook
Stop stop sensor or by the hook position measurement.
6.8 WW_MechanicalHoo Whip Winch WW WW hook stop activated by mechanical hook stop
kStop Mechanical Hook sensors.
Stop
6.9 WW_HookPos_H Whip Winch Position WW WW hook position close to lower hook stop (end
High stop).
6.10 WW_LowerHookSto Whip Winch Lower WW WW lower hook stop active (end stop).
p Hook Stop
6.13 WW_PersonnelLift_ Load Too High To WW Load too high to activate personnel lift.
NAvail Activate Personnel
Lift
6.14 WW_BrakeOff WW Brake Off - WW Whip winch brake off without joystick command.
Alarm
6.16 WW_AHC_PosDev_ WW AHC Position AHC Position deviation more than 0.5 meters of hook
H Deviation High relative to the seabed in AHC.
6.17 WW_AHC_PosDev_ WW AHC Position AHC Position deviation more than 1.5 meters of hook
HH Deviation High High relative to the seabed in AHC.
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
6.18 WW_MOPS_AccuPr Whipline Winch AHC Cable break or faulty sensor.
ess_ERR MOPS Accumulator
Pressure - Signal
Error
6.19 WW_AHC_ControlV WW AHC Control AHC Deviation between commanded and read signal.
alve_DEV Valve Deviation
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
7.0 MW_Load_H Main Winch Load > MW Main winch load > 90% of allowed load.
90%
7.1 MW_Load_HH Main Winch Load > MW Main winch load > 110% of allowed load.
110%
7.2 MW_Load_HHH Main Winch Load > MW Main winch load > 125% of allowed load.
125%
7.3 MW_LoadCell_DEV Main Winch Load MW Deviation between MW load cell channels.
Cell - Deviation Error
7.6 MW_AOPS_ERR Main Winch AOPS - MW AOPS disabled due to deviation between MW load
Disabled Due To cell channels.
Sensor Fault
7.10 MW_MechanicalHoo Main Winch MW MW hook stop activated by the mechanical hook
kStop Mechanical Hook stop sensors
Stop
7.11 MW_HookPos_H Main Winch Position MW MW hook position close to lower hook stop (end
High stop).
7.12 MW_LowerHookSto Main Winch Lower MW MW lower hook stop active (end stop).
p Hook Stop
7.13 MW_HookStop_ER Main Winch Hook MW Only signal from one of the proximity switches in
R Stop - Sensor Fault the mechanical hook stop sensor.
7.14 MW_Speed_H Main Winch Speed - MW MW hook speed higher than specified.
High Alarm
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
Alarm
7.16 MW_MOPS_AccuPr Main Winch MOPS MW MW MOPS accumulator pressure 2 LOW.
ess2_L Accumulator
Pressure 2- Low
Alarm
7.17 MW_PersonnelLift_ Personnel Lift active MW MW personnel lift activated by key switch.
Active (Recovery Mode)
7.18 MW_PersonnelLift_ Wrong mode or Load MW Wrong mode or Load too high to activate personnel
NAvail Too High To lift.
Activate Personnel
Lift
7.19 MW_BrakeOff Main Winch Brake MW MW brake off without joystick command.
OFF Alarm
7.20 AHC_WrongMode AHC - Wrong Mode AHC Load too high for AHC/AT High Speed Mode.
According To Load Switch to AHC/AT Normal Mode.
7.21 AHC_HeaveVelocity Heave Velocity > 2,0 AHC True heave velocity in crane tip higher than 2 m/s or
_H m/s (120 m/min) 1m/s in double part.
7.22 AHC_PosDev_H AHC Position AHC AHC position deviation. More than 0,5 meters
Deviation High deviation between hook and set point relative to the
seabed.
7.23 AHC_PosDev_HH AHC Position AHC AHC position deviation. More than 1,5 meters
Deviation High High deviation between hook and set point relative to the
seabed.
7.24 MW_AHC_ControlV Main AHC Control AHC Deviation between commanded and read signal.
alve1_DEV Valve 1 - Deviation
Error
7.25 MW_AHC_ControlV Main AHC Control AHC Deviation between commanded and read signal.
alve2_DEV Valve 2 - Deviation
Error
7.26 MW_AHC_ControlV Main AHC Control AHC Deviation between commanded and read signal.
alve3_DEV Valve 3 - Deviation
Error
7.27 MW_AHC_ControlV Main AHC Control AHC Deviation between commanded and read signal.
alve4_DEV Valve 4 - Deviation
Error
7.28 MW_MOPS_AccuPr Main Winch MOPS AHC Cable break or faulty sensor.
ess1_ERR Accumulator
Pressure 1 - Signal
Error
7.29 MW_MOPS_AccuPr Main Winch MOPS AHC Cable break or faulty sensor.
ess2_ERR Accumulator
Pressure 2 - Signal
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Item TAG info (HMI) Alarm text (HMI) Group Alarm description
(HMI)
Error
7.30 MW_BrakePress1_E Main Winch Brake MW Cable break or faulty sensor.
RR Pressure 1 - Signal
Error
7.31 MW_BrakePress2_E Main Winch Brake MW Cable break or faulty sensor.
RR Pressure 2 - Signal
Error
7.32 MW_DoublePartDet Main Winch Double MW Double part sensor active but mode not selected.
Part Detected (not
selected)
7.33 MW_DoublePartSel Main Winch Double MW Double part selected but not detected by double part
Part Selected (not proximity switch.
detected)
7.34 MW_MotorDisp1_D Main Winch Motor MW Deviation between commanded and read signal.
EV Disp. 1 - Deviation
Error
7.35 MW_MotorDisp2_D Main Winch Motor MW Deviation between commanded and read signal.
EV Disp. 2 - Deviation
Error
7.36 MW_MotorDispPres Main Winch Motor MW Deviation between sensor A and B.
s_DEV Disp. Pressure
Sensors - Deviation
+CC100
7.37 MW_MotorDispPres Main Winch Motor MW Cable break or faulty sensor.
s1_ERR Disp. Pressure 1 -
Signal Error
7.38 MW_MotorDispPres Main Winch Motor MW Cable break or faulty sensor.
s2_ERR Disp. Pressure 2 -
Signal Error
7.39 MW_AHC_Stopped AHC stop condition AHC AHC stop conditions:
active on Main Emergency stop active, NOT MW On selected, no
Winch main pumps running, MOPS/AOPS active, hook
pos < 5 meters, AHC deviation > 1,5 meters, MRU
error or load cell sensor error (only in AT).
AHC/AT has to be enabled to generate this alarm.
7.40 AHC_MW_ModeSpe AHC Main Winch Speed too high for normal AHC/AT mode. Select
ed_H Mode – High Speed High Speed Mode.
7.41 AHC_MainPress_L AHC - Main Pressure MW Main pressure below 220 bar.
Low
7.42 MW_OutsideWorkin Main Winch outside MW Main Winch outside working area
gArea working area
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The Trend display can show both real time and historical data, and can show up to 6 simultaneous plots.
2
1
Display functions
The large trend chart (1) shows historical or real-time trends colour-coded for the various parameters that may
be displayed.
To select a parameter for display, click inside the trend chart. The Historical Trend Setup popup now opens
(next page, bottom), displaying a list of parameters and a range of fields for defining the chart.
The left side of the chart shows the chart’s vertical scale (2) (in either metric or oilfield units), and the top shows
the time scale.
At the bottom of the display, trend-related controls enable the user to set range, zoom and other chart properties.
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Mode It is possible to show both real-time data and historical data. The historical data is
stored in the computer for 28 days.
While in real time, the right side of the trend is always ‘now’. In historic mode, the
right side of the trend is not necessarily ‘now’.
Pan time Pan time is only available in Historical Mode. It is used to pan forward or backward in
time to display the desired time period.
Vertical range The vertical scale (2) is actually a bar graph showing the magnitude of the selected
parameter. The colour of the scale lines indicates which parameter it applies to.
Horizontal range The standard horizontal range is 30 minutes, but this can be changed with the “Zoom
Time” buttons.
Zoom Time (Zoom The horizontal scale is adjusted using the “Zoom Time” buttons. This is a real-time
horizontal) trend factor that can be scaled from one second up to approximately 20 hours.
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2 5
1. Information button to access a screen showing details regarding the Profibus network.
2. Information button to access a screen showing details regarding Digital Inputs and Outputs to the PLC
system.
3. Information button to access a screen showing details regarding Analogue Inputs and Outputs to the
PLC system.
4. Radio buttons used for globally changing the units between Metric and Oilfield. (If implemented – this
may be an option)
5. Button for setting and resetting the Main Interlock override function. When activated, the button turns
yellow, and the IntLock Override icon in the status banner at the top of the screen is activated.
Note: When interlock override is active, all safety features in the crane and control system are
deactivated. We recommend that a report is prepared stating the reason for activating this function each
time it is used.
6. Counter for the Interlock override, increases by one each time the override function is activated.
7. Buttons for turning jib floodlights and other lights on. These buttons turn yellow when the lights are on.
8. Activation button for operating the remote control. Button will turn yellow while remote control is
active.
9. Hour counter
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If a node on the network is not communicating with the PLC, this is indicated by a red light. When the node is
“healthy” and connected, the light is green.
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The menu is password protected, so only authorized personel can enter the menu. Password is 1000.
1. Radio buttons for selecting which of each set of dual sensors is used as system reference. Analogue
information fields to the right display reference and realtime values.
2. Menu buttons to access encoder, lubrication and joystick calibration, setup and reset screens.
3. Button for shutting down front screen HMI software application.
4. Button for reinitializing I/O values.
5. Button for starting uninitiated I/O conversations.
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It is of utmost importance to follow the directions below when resetting encoders or position measuring devices.
Incorrect position settings can cause serious damage or personal injury. The interlock override may be used if
neccesary to reach the required reset position.
With the device in the desired position, press the relevant S button on the encoder reset screen (below) to reset
the device’s “null point”.
Encoder Instructions
Main winch position Place hook in desired upper position (about 1.5 metres from sheaves), knuckle jib
fully in, main jib fully down, when resetting main winch position encoder.
Whip winch position Place hook in desired upper position (about 1.5 meter from sheaves), knuckle jib
fully in, main jib fully down, when resetting whip winch position encoder.
Slew angle The crane must be parked, with the knuckle jib resting in the parking cradle.
Knuckle Jib angle The knuckle jib encoders are to be reset with the knuckle jib folded all the way in.
Main Jib angle The main jib encoders are to be reset with the main jib lowered completely.
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2 3
1. Indicators for whether or not the direction switches for the joystick axes are active.
2. Potentiometer X axis force reading.
3. Potentiometer Y axis force reading.
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14. Troubleshooting
Although the Control System is designed for a long and trouble-free service life, problems may occur with the
equipment.
Trouble-shooting then becomes necessary. Technicians must have drawings, descriptions and component data
sheets as their primary aids. These will normally be sufficient for 90% of the problems occurring on systems
that have been operative for some time.
By experience, the PLC system, software and input/output modules are very rarely the cause of failure!
Note that all software changes should be done subsequent to filling out a Software Change Request form
(contact MacGregor service for request form). This is required to ensure that all parties have an updated base of
system features, as well as to ensure that the built-in safety and functions are not jeopardised.
For detailed information on the components used, refer to the component data sheet section of this manual.
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What to do Select “Setup” from the menu sidebar on the touch screen terminal. The setup menu is
password protected.
Password: 1000.
Press S next to Slew Angle sensor, then R (Reset) in the Slew Angle popup.\
Comments The AOPS system will not be operational if the crane slew angle is not initialised.
What to do Select Setup from the menu sidebar on the touch-screen terminal. The Setup menu is
password-protected.
Password: 1000.
Park the crane and run the main winch hook to the correct hook-stop position relative
to the jib tip.
Press S next to Main/Whip Winch Hook Position, then R (Reset) in the popup.
Comments It is not possible to run the hook past the position set when the winch was last
initialised. To set a new “final hook-stop” the PLC has to be restarted.
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What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.
Password: 1000.
Lower the Main Jib until it reaches its mechanical end stop.
Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.
What to do Select Setup from the menu sidebar on the touch-screen terminal. This menu is
password protected.
Password: 1000.
Retract the knuckle jib until it reaches its mechanical end stop.
Comments An incorrect setting on this encoder will affect hook load calculations, winch position
calculations and the AOPS system.
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LED Meaning
SF DC5V FRCE RUN STOP
D D D D D CPU power supply missing
D L X D L CPU is in STOP mode
Start the CPU
L L X D L CPU is in STOP mode as result of error
X L X D F CPU requesting memory reset
(0,5Hz)
X L X D F CPU executing memory reset
(2Hz)
X L X F L CPU is in startup mode
(2 Hz)
X L X F L CPU was halted by a programmed break point
(0,5Hz
L L X X X Hardware or software error
X X L X X User enabled the force function
X X F X X Node flashing test was activated
(2 Hz)
F F F F F CPU has an internal system error.
Proceed is as follows:
Set mode selector switch to STOP
Perform POWER ON/OFF
Read diagnostics buffer, see STEP 7
Contact your local SIEMENS partner
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LED Meaning
SF 5VDC BF BF1 BF2
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Fault Description
SF Some i/o modules have the ability to indicate group-error.
Remedy: check fuses and/or replace module (when power is switched off).
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Fault Description
SF Some i/o modules have the ability to indicate group-error.
Remedy: check fuses and/or replace module (when power is switched off).
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17.4. PLCs
PLC modules may only be replaced by modules with the exact same part number. The part number is printed on
the lower left corner of the module front. If another PLC module is to be used, it may only be replaced by
qualified MacGregor Marine Service personnel.
Note that all accumulated data is stored in the Micro Memory Card on the PLC module so no data will be lost.
This may include data such as motor run time, wire usage and similar integrated information.
1. Hook the new module of the same type on and swivel it downward.
2. Screw the module on.
3. Connect all connectors.
4. Set the PLC mode switch to STOP.
5. Insert the micro memory card.
6. Set the power supply module’s Standby switch up (output voltages at rated values).
7. Set the PLC mode switch to RUN.
8. Close the cover.
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1. You cannot replace analogue and digital modules while in RUN mode. Therefore, switch the Standby
switch on the power supply down.
2. Loosen the front connector’s mounting screw and pull it off.
3. Loosen the module mounting screw.
4. Swivel the module out.
Before fitting the front connector, you must remove (break off) the front part of the coding key, because this
part is already fitted in the wired front connector.
If, for example, you insert a front connector for a digital module in an analogue module, the module may be
damaged.
Modules are only to be operated with their complete front connector-coding key.
1. For analogue modules make sure that the measurement type-coding key on the side of the new module
matches that of the old module. If in doubt refer to the loop diagrams for further information.
2. Hook the new module of the same type on at the appropriate slot and swivel it downward.
3. Screw the module on with the mounting screw.
4. Fit the front connector.
5. Switch the power supply Standby switch up.
6. After fitting, each programmable module will be reinitialised by the PLC with parameters.
1. Set the power supply Standby switch down and switch off all load power supplies for the module.
2. Loosen the front connector screw and pull it off.
3. Remove the labels from the front connector and insert them into the new front connector.
4. Wire the new front connector.
5. Insert the front connector in the module.
6. Screw the front connector on.
7. Switch on the load voltage and set the power supply Standby switch up.
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Winches with AHC/AT mode, and winches with Constant Tension (CT) mode and >1000
metres of hook travel are also fitted with mechanical hook stops.
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Blank page.
5 Operation
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EMERGENCY Project: SP2552-2.
OPERATION Page 1 of 2.
PROCEDURE PART 1:
1. Main power supply Normal operation. Emergency operation from cabin with
(440 V), FAULT emergency pump.
2. PLC &230 Voltage
supply, RUNNING/OK
A. CONNECT THE MAIN
EMERGENCY POWER
SUPPLY CABLE
Jumper cable to be
connected to RED
Socket in cabinet
ECC1.
B. CONTROL CABINET
ES400
Switch to emergency
mode on.
C. OPEN SUCTION
VALVE FOR
EMERGENCY PUMP
( MH 03.2)
IT IS RECOMMENDED THAT
THIS VALVE IS OPEN, AT ALL
TIME.
D. OPEN EMERGENCY
PUMP “SUPPLY”
SHUT OFF VALVE FOR
EMERGENCY
OPERATION OF
CRANE FUNCTIONS
( MH60)
E. OPEN EMERGENCY
PUMP “LS” SHUT OFF
VALVE FOR
EMERGENCY
OPERATION OF
CRANE FUNCTIONS
( MH63.2 )
H. START EMERGENCY
PUMP FROM
OPERATOR SCREEN.
Operate crane from
cabin.
EMERGENCY OPERATION Project: SP2552-2.
PROCEDURE PART 2: Page 1 of 2.
1. Main power supply (440 V), Normal operation. Emergency operation with emergency
FAULT panel and pump.
2. PLC &230 Voltage supply,
FAULT
A. CONNECT THE MAIN
EMERGENCY POWER SUPPLY
CABLE
Jumper cable to be connected to
RED Socket in cabinet ECC1.
CONNECT EMERGENCY PANEL OP-
206 CABLE
A. ACTIVATE EMERGENCY
PANEL
6 Maintenance
Table of Contents
1. General Maintenance Instructions ....................................................................................................1
2. General Inspection Instructions ........................................................................................................2
3. Periodic Maintenance.......................................................................................................................4
3.1. Interpreting the Periodic Maintenance Program Matrix ..............................................................5
3.2. Maintenance Program ...............................................................................................................6
4. MOPS Function Test ......................................................................................................................15
5. Annexes .........................................................................................................................................16
6 Maintenance
MACGREGOR NORWAY AS
User Manual for Crane
6 Maintenance
MACGREGOR NORWAY AS 1
User Manual for Crane
• Prevent accidents and maintain safe operation of your MacGregor equipment through inspections and
operator training.
• Avoid unnecessary interruptions in up-time.
• Ensure peak efficiency throughout your crane's long life.
• Address potential problems before they become more costly or inconvenient.
• Reduce overhead costs associated with parts, lubricants and tools.
• Reduce downtime by scheduling when production will not be interrupted.
In addition to the periodic maintenance program, it is recommended to perform daily / pre-start inspections:
• Visual check for hydraulic oil leaks on the crane, both internal and external.
• Visual check of the hydraulic reservoir fluid level.
• Visual check of the oil coolers.
• Visual check of the aircraft warning light as required.
• Visual check of the crane hook latch.
• Visual check of wire sheaves and spooling.
• Visual check of wire rope for evident deterioration and damage or improper reeving.
• Visually check for loose, missing or corroded bolts, pins, keepers or locking wire.
• Visually check loose gear to be used, such as slings, sling hooks and shackles.
• Ensure the correct load-rating chart for the configuration in use is visible to the crane operator.
• Perform a “walk-around” visual examination of the crane structure to ensure that no damage exists.
• Visually check that the crane can rotate freely in its working area.
• Verify mechanical hook function.
• Check control system alarm log.
• Lubricate components and correct deficiencies as required based on the results of these inspections.
National and recertification requirements by classification bodies like: DnV, Lloyds Register of Shipping,
Germanischer Lloyd, Bureau Veritas and American Bureau of Shipping include yearly and five yearly safety
inspections and retesting. These inspections have to be made by the original equipment manufacturer (OEM) or
OEM certified service companies.
Inspections on your advanced MacGregor Active Heave Compensated Offshore Cranes produce neutral reports
on equipment condition and provide recommendations for necessary actions when required. The main purpose
of an inspection is to assess and maintain the condition of the equipment. Our experience and high standards of
design and manufacturing of your advanced crane is the basis for all inspections.
A proactive approach can help to avoid catastrophic breakdowns, downtime and off hire situations. MacGregor,
the original equipment manufacturer (OEM), have the resources of personnel that provide the skill and
experience necessary to guide a proactive approach, helping you as our customer to focus on and to predict the
most effective maintenance needs.
6 Maintenance
2 MACGREGOR NORWAY AS
User Manual for Crane
The inspection of advanced cranes rely on equipment specific inspection programs, where MacGregor advanced
cranes are looked at not only with respect to mandatory standards but also to specified technical and operational
requirements.
The final inspection report is a document that complies with industrial and mandatory requirements. The full
report includes two documents; an ”Inspection summary report” which is a evaluation of the overall equipment
condition in terms of safety and operation, based on what the inspection reveals, and the second document is a
”Service report” in which you will get recommendations for actions and spare parts when needed.
6 Maintenance
MACGREGOR NORWAY AS 3
User Manual for Crane
3. Periodic Maintenance
Maintenance of the crane is organized in different time intervals. The intervals are specified as follows:
• xx Weeks: xxW
• xx Months: xxM
• xx Years: xxY
• xx Hours: xxH (operating hours)
Examples:
• 3 months interval: 3M
• 2 years interval : 2Y
• 1 Week interval: 1W
• 2 months / 200 hours: 2 M / 200 h
Maintenance Log
During the warranty period, either the enclosed maintenance log or the
vessel’s own maintenance log should be used to document crane
maintenance, as this will be called upon should a warranty issue occur.
All necessary inspection points are identified in the periodic maintenance program tables.
As a general recommendation all hydraulic motor bearings should be replaced after 15000 operating hours.
To prevent corrosion of the main and knuckle jib cylinder rods, the crane should not be parked with the cylinder
rods left exposed.
In longer periods of inactivity, to avoid shortening of the main and knuckle jib cylinder’s service life, repeatedly
extend and retract the cylinders to maintain internal lubrication and tightness.
6 Maintenance
4 MACGREGOR NORWAY AS
User Manual for Crane
Where referred to, please find the applicable annex in section 6.6 – Annexes.
6 Maintenance
MACGREGOR NORWAY AS 5
User Manual for Crane
6 Maintenance
MACGREGOR NORWAY AS 6
User Manual for Crane
6 Maintenance
MACGREGOR NORWAY AS 7
User Manual for Crane
6 Maintenance
8 MACGREGOR NORWAY AS
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6 Maintenance
MACGREGOR NORWAY AS 9
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6 Maintenance
10 MACGREGOR NORWAY AS
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6 Maintenance
MACGREGOR NORWAY AS 11
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6 Maintenance
12 MACGREGOR NORWAY AS
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14 MACGREGOR NORWAY AS
User Manual for Crane
The MOPS controls are located in the operator cabin as indicated in the picture to the right (yellow buttons with
safety guard).
Safety measures:
Observe:
6 Maintenance
MACGREGOR NORWAY AS 15
User Manual for Crane
5. Annexes
The following annexes are provided at the end of this chapter:
6 Maintenance
16 MACGREGOR NORWAY AS
User Manual for Crane
Annex A -
Lubrication Standard Specifications (LSS)
6 Maintenance - Annex A
MACGREGOR NORWAY AS A1
User Manual for Crane
Blank page.
6 Maintenance - Annex A
A2 MACGREGOR NORWAY AS
Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-01 nipples.doc 02 / 28.04.09 1 of 1
Specification no. :
LSS-01
Lubrication equipment:
GREASE NIPPLES IN GENERAL
General Instruction:
Comments / notes :
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Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-02 wire.doc 03 / 28.04.09 1 of 1
Specification no. :
LSS- 02
Lubrication equipment:
DIN 51502
ISO 6743-09
Comments / notes :
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Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-03 slew gear BRE.doc 03 / 28.04.09 1 of 3
Specification no. :
LSS- 03 BRE
Lubrication equipment:
Comments / notes :
Lubricating Instruction:
General
- All gears for vertical mounting: completely fill with oil.
Check the table next page for correct plug positions. For vertical mounting an
header oil tank can be supplied.
Continuous working temperature must not exceed 90° C.
OIL CHANGES.
Oil intervals may be modified, depending on actual operating conditions. During
oil change, we recommend that the inside of the gear case is flushed out with
flushing fluid recommended by lubricant manufacturer. Oil should be changed
when hot to prevent build up of sludge deposit. It is advisable to check oil level at
least once per month. If more than 10 % of total oil capacity has to be added,
check for oil leaks. Do not mix oils of different types even of the same make.
Never mix mineral and synthetic oils. Pay attention to oil and gear temperature
during oil change, to avoid the risk of scalding. Be conscious of the pollution
hazard due to the oil.
The main bearing (nearest to the output pinion) from the series
065/150/250/400 and 600 is grease lubricated. Take care to fill the bearing
compartment with grease before starting. This is done by pumping grease into the
grease-nipple until the grease comes out of the main bearing which is protected by a
so called “NILOS” ring. Grease should be completely exchanged every 1000
hours or six months, whatever occurs first.
Lubricating Instruction:
Specification no. :
LSS- 04 BRE
Lubrication equipment:
Comments / notes :
Lubricating Instruction:
General
Check the table next page for correct plug positions. Check oil filling carefully in all cases.
Extension pipes may be installed to facilitate checking of oil level.
Continuous working temperature must not exceed 90° C.
OIL CHANGES.
Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing fluid
recommended by lubricant manufacturer. Oil should be changed when hot to prevent
build up of sludge deposit. It is advisable to check oil level at least once per month. If
more than 10 % of total oil capacity has to be added, check for oil leaks. Do not mix oils
of different types even of the same make. Never mix mineral and synthetic oils. Pay
attention to oil and gear temperature during oil change, to avoid the risk of scalding. Be
conscious of the pollution hazard due to the oil.
The main bearing (nearest to the output pinion) from the series 065/150/250/400 and 600
is grease lubricated. Take care to fill the bearing compartment with grease before
starting. This is done by pumping grease into the grease-nipple until the grease comes
out of the main bearing which is protected by a so called “NILOS” ring. Grease should be
completely exchanged every 1000 hours or six months, whatever occurs first.
Lubricating Instruction:
NOTE:
• The gearbox filling/breather port is fitted with a pressure relief breather valve. Inspect and
replace if necessary before refitting.
• The gear section lower plugs are equipped with magnetic tips. At oil change intervals check
for metal particles. Thoroughly clean plug before refitting.
• Each individual gear housing will be slightly rotated compared to each other due to the
eccentric mounting. Therefore indentify the plug nearest to the gear centreline when checking
oil levels in the chambers.
• After removing centreline plug for oil level checks and no oil is visible through port, make a
simple dipstick from a plastic strip or equal to verify oil level.
Blank page.
Maintenance system for MacGregor Hydramarine
products.
Specification no. :
General Lubrication Specification Gear oil: General Lubrication Specification Brake oil:
Comments / notes :
-
Maintenance system for MacGregor Hydramarine
products.
Lubricating Instruction:
General
Check the next pages for plug positions.
Continuous working temperature must not exceed 90° C.
OIL CHANGES.
• Oil intervals may be modified, depending on actual operating conditions. During oil
change, we recommend that the inside of the gear case is flushed out with flushing
fluid recommended by lubricant manufacturer. Oil should be changed when hot to
prevent build up of sludge deposit. It is advisable to check oil level at least once per
month. If more than 10 % of total oil capacity has to be added, check for oil leaks. Do
not mix oils of different types even of the same make. Never mix mineral and synthetic
oils. Pay attention to oil and gear temperature during oil change, to avoid the risk of
scalding. Be conscious of the oil pollution hazard.
• The gear section oil plugs are equipped with magnetic tips. At oil change intervals
check for metal particles. Thoroughly clean plug before refitting.
Specification no. :
LSS- 05
Lubrication equipment:
Comments / notes :
**) For low temperature operation below ÷20 °C, special arctic oil is
recommended. Please contact relevant supplier for exact specification.
Ex.:
Statoil: HYDRAULIC OIL 131 For temp >÷40 °C < +65 °C
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Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-08 Drive 05 / 30.04.2009 1 of 1
pinion.doc
Specification no. :
LSS-08
Lubrication equipment:
General Instruction:
Use a brush to apply grease to all tooth flanks of pinions and gear ring.
For location of pinions, refer to the lubrication chart for the product in
question.
Typical properties:
Consistency: NLGI 2
Recommended temperatures: –30→110 °C (for Kluberplex AG 11-462)
Recommended temperatures: –3→150 °C (for Omega 73)
Recommended temperatures: –10→60 °C (for Texclad 2)
Comments / notes:
* : Not to be used in automatic grease pump system
The colour of AG 11-462 is white. Omega73 and Texclad 2 is black
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Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-11 Heavy duty 01 / 29.04.2009 1 of 1
grease.doc
Specification no. :
LSS-11
Lubricating equipment:
General Instruction:
Typical properties:
Method
Soap type: Calcium
Consistency: 2 NLGI
Oil type: Mineral
Base oil viscosity at 40 °C: 1300 mm²/s ISO 12058*
Base oil viscosity at 100 °C: 106 mm²/s ISO 12058*
Recommended temperatures: –20→120 °C
Long polymer (“tacky”) additives: Yes
Extreme pressure (EP) additives: Yes
Solid lubricants: No
*) Base oil viscosity applies to the final mixed oil including long polymer additives.
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Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-20 Winch with gear 03 / 29.04.2009 1 of 2
rim.doc
Specification no. :
LSS-20
Lubrication equipment:
General Instruction:
The winch has the following main components which need lubrication:
• A set of gearboxes
• Main bearings
• Wire rope
Comments / notes :
Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-20 Winch with gear 03 / 29.04.2009 2 of 2
rim.doc
Lubrication Instruction:
Specification no. :
LSS-21
Lubrication equipment:
General Instruction:
• Bearing
(winch with one gearbox only)
• Wire rope
Comments / notes :
Maintenance system for MacGREGOR Hydramarine
products
Doc. ID. : Rev. / date : Page:
LSS-21 HM Winch 01 / 29.11.2006 2 of 2
without gear rim.doc
Lubrication Instruction:
Specification no:
LSS- 22
Lubrication equipment:
ELECTRIC MOTORS
50 / 60 Hz
General Instruction:
On Lønne motors the bearings should be relubricated every 3 years. This is due to ageing and
irrespective of operation hours. Motors operating under special conditions, such as frequent
operation at maximum speed (n max), heavy vibration, sudden load changes and frequent
reversing operation, the relubrication should be performed at a considerably shorter interval than
at the intervals stated below.
Supplie Manufactu Type Delivery Temp (0C) Mount. Interval Type / Amount Notes Notes
r rer with Ambient / Pos. (h) comp.
grease bearing for vert.
mount.
Lønne Marelli B5M355L Yes 20/50 Vertical 8000 ESSO UNIREX Temperature Information regarding
4 V36 30/60 (V3/V6) 4000 N3 increased by 15 bearing / greasing
45/80 First time greasing deg C, regreasing intervals are noted on a
2000
200 gr. interval halved plate on the motors
55/90 1000
Relubrication 50
gr.
Lønne MEZ 14BG1802 Yes 40 Vertical 4000 ESSO UNIREX Temperature Information regarding
80 V36 50 (V3/V6) 2000 N3 increased by 10K, bearing / greasing
regreasing interval intervals are noted on a
60 1000
Relubrication 20- halved plate on the motors with
30 gr. 40C and in standard
horizontally mounting
Lønne MEZ 14BG315 Yes 40 Vertical 3000 ESSO UNIREX Temperature Information regarding
V36 50 (V3/V6) 1500 N3 increased by 10K, bearing / greasing
60 regreasing interval intervals are noted on a
750
Relubrication 30 - halved plate on the motors with
40C and in standard
40 gr.
horizontally mounting
ABB ABB M3BP355 Yes 25 Vertical 2000 ESSO UNIREX Temperature Information regarding
V36 40 (V3/V6) 1000 N3 increased by 15 bearing / greasing
Relubrication 70 deg C, regreasing intervals are noted on a
gr. interval halved plate on the motors
Lønne MEZ 7AA/BA Yes 40 Vertical 4000 ESSO UNIREX Temperature
160 V36 50 (V3/V6) 2000 N3 increased by 10K,
60 1000 Relubrication 20- regreasing interval
30 gr. halved
Tp HUALI Y3- Yes 40 Horizo 4000 ESSO UNIREX Temperature Information
nordic 280M2-4 ntal N3 increased by 10- reg.bearing/greasing
15 deg.c, interval are noted on a
Relubrication 30- regreasing interval plate on the motor with
40 gr. halved. 40c and in standard
horiz.mount.
Comments / notes :
Only relubricate bearings when the motor has a speed of at least n >300 rpm.
Lubrication intervals are compensated for vertical mounting.
Smaller electrical motors normally have closed bearings. Relubrication may not
be required.
User Manual for Crane
1. General
The crane is fitted with an automatic lubrication system .The purpose of lubrication is to promote longer service
life for the equipment. The advantage of a automatic lubrication system is that it releases “a little grease
frequently”, as opposed to “too much grease infrequently”, which is often the case with manual lubrication.
2. System Overview
The system will efficiently provide lubrication for all bearings on king/main jib and knuckle jib. Grease is
stored in two container/pump units, and pumped/distributed out via several distribution blocks to each
individual lubrication point on the jib assembly among others. See picture 2 for typical installation of
container/pump unit.
The system itself is fairly simple and comprises a pump with a lubricant reservoir. The pump has 1-3 outlets,
which lead to progressive distributors (”distribution blocks”). These have one inlet port and several outlet ports.
The grease is distributed from the progressive distributor to the various lubrication points or to a new
distribution block on the crane. These distribution blocks are mechanical blocks that have been designed
according to the desired dosage. See pump unit M55 and M56 in Drawing, Vol. 2: 2.10 Lubrication Charts.
6 Maintenance - Annex B
MACGREGOR NORWAY AS B1
User Manual for Crane
In order for the adjustable element to receive the correct dose of lubricant, it is also important to set the pump
sequence. The adjustment screws are located behind a red cap at the front of the pump where the one set screw
is for setting the number of pump revolutions and the other is for setting the frequency of pump actuation. If the
pump setting is 30 revolutions and 30 minutes it means that the pump shall run 30 revolutions every 30 minutes
the pump has current.
The crane automatic lubrication system will also provide lubrication for the main winch bearings and main
winch drive pinions/gear wheel.
Safety valve.
(Do not cover)
Pump elements
6 Maintenance - Annex B
B2 MACGREGOR NORWAY AS
User Manual for Crane
If the pump has no integrated timer / logics, it is controlled by the crane’s PLC.
Typical setup see picture 3. If the alarm is released frequently and no grease are released through the safety
valve, set Overload Time Before Alarm higher than 7 sec. The alarm can also be released when the Lubrication
monitor are mounted away from the pump unit.
6 Maintenance - Annex B
MACGREGOR NORWAY AS B3
User Manual for Crane
• Blockage in the progressive distributor due to a jammed slide/piston in an element can occur because of
contamination in the lubricant or because the element has been under counter pressure and unused for a
long time.
Action: Disconnect the outlet connections, start the pump and observe if lubricant is released trough the
safety valve. If not: replace the progressive distributor. If lubricant is released: replace the connectors
and check the next distributor or the element.
• High counter pressure due to long tubes/hoses. Install a check valve on the pump element outlet.
• Breakage/damage of a tube/hose. Lubricant leaking on a damaged hose or a pipe can occur without
realising the alarm. In consequence one or more lubricant points are not receiving lubricant. Inspect the
hoses regularly (3M).
7. Lubricant
It is important that the grease is pump-able in the system, even at low temperatures. The system has been
designed to use NLGI class 2 grease.
6 Maintenance - Annex B
B4 MACGREGOR NORWAY AS
User Manual for Crane
filling socket
for grease coupling box
filling press
Filling the pump units (See Picture 4.) demands a high cleanliness level. Avoid any particles. Even the
slightest dirt can block the piston in the distributor blocks.
6 Maintenance - Annex B
MACGREGOR NORWAY AS B5
User Manual for Crane
10003724 M 06 LL NUT 10
6 Maintenance - Annex B
B6 MACGREGOR NORWAY AS
User Manual for Crane
1. General
The automatic lubrication system (if applicable) delivers lubrication to nearly all critical rotation points.
Most of the manual lubrication points serve preservation purposes and not lubrication of a rotation bolt. Use
LSS-01. See Manual Lubrication Grease Nipples Chart in Vol. 2 of the user manual.
2. Preservation Points
According to the Periodic Maintenance Program (“preservation points”) lubricate the following points:
6 Maintenance - Annex C
MACGREGOR NORWAY AS C1
User Manual for Crane
3. Rotation Points
According to the Periodic Maintenance Program (“rotation points”) lubricate the following points:
Lubrication of hinges
Lubricate door hinges and other non critical lubrication points.
6 Maintenance - Annex C
C2 MACGREGOR NORWAY AS
User Manual for Crane
1. Lift Wires
1.1. General
MacGregor HM offshore cranes uses the following
wire rope type(s):
1.2. Inspection
In order to keep wire ropes in a good working condition, routine inspections and periodic maintenance is
necessary. On wire ropes frequently used in AHC operations, particular attention must be paid at the areas
where they pass over a wire sheave as the wire rope strands have a tendency to open slightly and thus making it
possible for the inspector to get a better view of the wire rope core.
As a minimum, the wire ropes should be inspected monthly. However, lift wires in continuous service should
be observed during normal operation and visually inspected on a weekly basis.
The purpose of the inspection is to reveal dryness, abrasion, internal/external corrosion, core or strand
protrusion/distortion, wire breaks, wear, kinks etc. before the wire rope becomes unsafe to work with (see
illustrations on the following page of unwanted situations).
Note: Any deterioration leading to a suspected loss of original rope strength should be carefully examined and
the Discard criteria provided in ISO 4309 applied in determining whether to remove the rope from service.
6 Maintenance - Annex D
MACGREGOR NORWAY AS D1
User Manual for Crane
Wire protrusion.
External corrosion.
Kinked wire.
Local increase in rope diameter due to core distortion.
6 Maintenance - Annex D
D2 MACGREGOR NORWAY AS
User Manual for Crane
1.3. Lubrication
Over time, the factory lubrication of the wire ropes will wear off due to the environment and usage. Periodic
maintenance is therefore a necessity.
Manual lubrication with the aid of brushes, rags, gloves, or by other means is costly, risky, and ineffective. The
lubricant forms a film on the surface which water vapour can penetrate, thus becoming trapped. Temperature
changes cause condensation and rust then begins to form from the inside. This will lead to severe corrosion
which promotes premature fatigue failures in the wires and strands.
A high pressure wire lubrication system (e.g. Masto lubrication system) will be able to maintain good
lubrication of the wire rope, penetrating through to its core which is absolutely necessary to keep friction low
and corrosion away.
How often the wire ropes need to be re-lubricated depends on the environment in which the wire ropes operate
along with the usage and the result of the routine inspections. Generally, if the wire rope show signs of dryness,
lubrication should be initiated, ideally before. As a minimum, check every 3 month if the wire rope show signs
of lubrication deterioration.
6 Maintenance - Annex D
MACGREGOR NORWAY AS D3
User Manual for Crane
2. Lifting Hooks
2.1. Inspection
Every 4 years, the hook and hook nut are to be dismantled, inspected and retested (proof loaded). Particular
attention to be paid to the following:
• Wear in hook, centre pin, becket and threads in hook and nut.
• Play in sheave bushes or bearings.
• Spacer bolts, nuts and lynch pins.
• Check for cracks in welds.
• Condition of safety catch and grease nipples.
• Wear to holes in side plates and becket.
2.2. Lubrication
Lubrication of the hooks is normally to be done once a week (each week for frequently used hooks/blocks,
monthly for infrequently used equipment or each time it is used). Refer to the periodic maintenance table.
6 Maintenance - Annex D
D4 MACGREGOR NORWAY AS
User Manual for Crane
4. Hazards
• Avoid skin contact with hydraulic oils by use of gloves.
• Be wary of any cuts that may be caused by running a hand carelessly across damaged wire. Use gloves.
• Ensure winch has been stopped before inspecting wire.
• When laying down the double part block on its side for lubrication, ensure the block is completely
secure as there can be a risk of it falling over.
6 Maintenance - Annex D
MACGREGOR NORWAY AS D5
User Manual for Crane
1. General
Inspection and replacement intervals should be done according to chapter 6.2 Periodic Maintenance.
Hydraulic hose manufacturers estimate that 80% of hose failures are attributable to external physical damage
through pulling, kinking, crushing or abrasion of the hose.
Hydraulic hose can and will age whether it is in normal service conditions or unused in storage. Hose failure is
not an indication of poor product performance, but rather natural degradation. After a while a hydraulic hose
will show sign of wear that include cracking, blisters and bubbles.
The operating conditions that a correctly installed hydraulic hose is subjected to will ultimately determine its
service life. Extremes in temperature, e.g. high daytime operating temperatures and very cold conditions when
the machine is standing at night, accelerates aging of the hose's rubber tube and cover.
• Environmental conditions.
• Ultraviolet light.
• Salt water.
• Air pollutants.
• Extreme temperatures.
• Ozone.
• Chemicals.
• Electricity.
• Abrasion damage.
6 Maintenance - Annex E
MACGREGOR NORWAY AS E1
User Manual for Crane
Abrasion caused by hoses rubbing against each other or surrounding surfaces is the most common type of
damage. Replace the hoses and avoid new abrasion and external damage, ensure all clamps are kept secure, pay
careful attention to routing whenever a replacement hose is installed and if necessary, apply inexpensive
polyethylene spiral wrap, zip tie, sleeves and guards to protect hydraulic hoses from abrasion (see photo below).
6 Maintenance - Annex E
E2 MACGREGOR NORWAY AS
User Manual for Crane
2. Replacement
MacGregor recommend to replace hoses at the following intervals:
Replacement of denso tape on hose connections after reinstallation is recommended to avoid corrosion.
Installation of a replaced hose at less than the minimum recommended bend radius may significantly reduce the
lifetime of the hose (see illustrations below). Particular attention must be given to prevent sharp bends at the
hose connection to the fitting (photo above).
Proper physical installation of the hose assembly requires a correctly installed port connection ensuring that no
twist or torque is transferred to the hose when the fittings are being tightened.
Bending a hydraulic hose in more than one plane results in twisting of its wire reinforcement. A twist of five
degrees can reduce the service life of a high-pressure hydraulic hose by as much as 70% and a seven degree
twist can result in a 90% reduction in service life.
6 Maintenance - Annex E
MACGREGOR NORWAY AS E3
User Manual for Crane
4. Hazards
• Ensure both the system and the specific damaged hose are devoid of pressure before attempting any
replacement. Removing hoses or tampering with damaged hoses while the system is under pressure can
result in a high pressure release of hydraulic oil.
• Clean the maintenance area before and after maintenance to avoid slippery surfaces and any
contamination.
• Remember to dispose of any damaged or unusable components in the correct manner, by taking them to
a recycling center that deals with the components in question.
6 Maintenance - Annex E
E4 MACGREGOR NORWAY AS
User Manual for Crane
1. General
1.1. Before Disassembly
Prior to replacement of the hydraulic filters (for action intervals,
see section 6.2 - "Periodic Maintenance Program"), it is important
to make sure that the oil level in the tank is below the return filters
mounted on the tank top. These filters have contamination
retainers which might contain some particles. Lower the level in
the tank by lifting the main jib and the knuckle jib. This action
must be taken to reduce the risk of mixing unfiltered “dirty” oil
with the clean oil in the tank.
Then, shut down the HPU for at least 15 minutes. This will release
the pressure and drain oil to the tank. When applicable, press the
emergency (local) stop button.
Make sure you have the correct filters and sealings. MacGregor Return filter with
recommends to replace the O-rings each time the filters are replaced. contamination retainer(circled)
Most of the filters are located on the HPU (inside the king). However, they can also be placed outside on the
king platform or mounted on the winches. Normally, all filters (apart from the air breathers and emergency
supply filter) have clogged filter indicators (lights) and an alarm indication in the crane control system.
6 Maintenance - Annex F
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6 Maintenance - Annex F
F2 MACGREGOR NORWAY AS
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2. Breather Filters
Breather filters prevent contamination from the surroundings from entering
the system in connection with fluctuations of the oil level in the tank (tank
breathing).
Some filters are delivered as one unit but most commend are filters with
separate elements.
6 Maintenance - Annex F
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3. Offline Filter
Offline oil filtration systems with integrated circulating pumps are
ideal for controlling oil contamination levels for particles, water
and degradation products (oxidation resin/sludge, varnish). The
filters are normally mounted at the bottom of the tank and
circulates the oil in the tank.
6 Maintenance - Annex F
F4 MACGREGOR NORWAY AS
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Stop the CJC filter Close valve on the oil Close valve on the oil Automatic air vent: No Open oil drain valve.
pump inlet filter outlet action Drain according to
Air vent screw: Open environmental
screw precautions
When the filter housing Lift off the filter housing Unscrew the spring nut Remove the spring and Remove the used filter
is drained, unscrew the the spring guide inserts. Depose of
top nut according to regulations
Clean the filter bottom Put the new CJC filter Insert type B, BLA or Mount the spring guide Tighten the spring nut Replace both O-rings Replace O-ring for the Tighten the top nut with Automatic air vent: No Be aware that oil
inserts in place BLAT, use insert guide carefully - make sure by hand until contact top nut a torque of 90Nm action. spillage is a serious
between the filter there is no contact with spring guide. Then Air vent screw: Replace safety risk - keep clean!
elements between the O-ring and tighten the spring nut 4 usit ring for air vent
the thread turns per filter insert screw, and tighten with
torque of 10 Nm
6 Maintenance - Annex F
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6 Maintenance - Annex F
F6 MACGREGOR NORWAY AS
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4. Return Filters
These filters are normally low pressure filters.
The location are typically at the top of the
tank, but they can also be mounted as in-line
filters outside on the king platform or on the
winch itself.
1. Moisten the sealing surfaces and thread on the cover plate and housing, as well as the O-ring on the
cover plate and element, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Fit the contamination retainer onto the new or cleaned filter element by turning clockwise (only for type
1.0).
4. Place the filter element(s) carefully onto the element location spigot.
5. Screw on the cover plate fully. Then unscrew by one quarter-turn.
6. Screw in the oil drain screw(s); tighten the vent screw(s).
7. Switch on the hydraulic system and vent filter at an appropriate point in the system.
8. Check the filter for leakage.
6 Maintenance - Annex F
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Drain valve
4.3. Hazards
• Avoid skin exposure to hydraulic oil.
• Clean area before and after maintenance to
avoid slippery surfaces or contamination.
• Dispose of old filter appropriately by taking it to a recycling centre.
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5. Pressure Filters
High-pressure filters are installed after the pumps and other prime movers to protect critical hydraulic
components such as cylinders, motors and valves.
1. Close the inlet and the outlet valve (if present). Ref. Hydraulic flow diagram.
2. Remove oil drain plug at the bottom of the bowl, collect oil in a container.
3. Unscrew bowl. (Collect fluid in a suitable container and dispose of it in accordance with environmental
regulations).
4. Remove filter element from element location spigot (examine surface of element for dirt residue and
larger particles; these can indicate damage to the components).
5. Clean bowl by using white sprite or similar.
6. Examine filter, especially sealing surfaces and threads, for mechanical damage.
7. Replace O–rings.
1. Moisten thread and sealing surfaces on the filter bowl and head, as well as the O–ring on the bowl and
element if necessary, with clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Place filter element carefully onto the element location spigot.
4. Screw in filter bowl fully.
5. Screw in oil drain plug.
6. Unscrew filter bowl by one quarter–turn.
7. IMPORTANT: Open Inlet and outlet valve
8. Clean/dry the outside of the filter bowl. After start-up of the hydraulic system again, check for any
leaks.
6 Maintenance - Annex F
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5.3. Hazards
• Clean area before and after maintenance to avoid slippery surfaces or contamination.
• Ensure valves are closed and system depressurised before performing any maintenance. If valves are
opened while the system is pressurised, high pressure hydraulic oil will be released.
6 Maintenance - Annex F
6. Drain Filters
The drain filters are normally located at the top of the tank, but can also be mounted outside on the platform or
on the winches. Three different drain filter types can occur:
1. Loosen cover plate bolts, turn and 1. Moisten sealing surfaces and thread on
remove the cover plate. the cover plate and housing, as well as
2. Remove filter element carefully from the O-rings on the cover plate and
element spigot. Examine element element, with clean hydraulic fluid.
surface for dirt residue and larger 2. When fitting a new element, check that
particles; these can indicate damage to the designation corresponds to that of the
the system components. old element.
3. Remove contamination retainer (if 3. Fit the contamination retainer (if present)
present) by turning anti-clockwise onto the new filter element by turning it
(bayonet fitting). clockwise.
4. Clean cover plate, housing and 4. Place filter element(s) carefully onto the
contamination retainer; pay particular element location spigot.
attention to the threads. 5. Re-fit cover plate and tighten cover plate
5. Examine filter, especially sealing bolts.
surfaces and thread, for mechanical 6. Switch on hydraulic system and Check
damage. filter for leakage.
6. Replace O-rings.
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6.3. Hazards
• Avoid skin exposure to hydraulic oil.
• Clean area before and after maintenance to
avoid slippery surfaces or contamination.
• Dispose of old filter appropriately by taking it to a recycling centre.
6 Maintenance - Annex F
1. Verify that the HPU is not running. 1. Use clean hydraulic fluid to moisten
2. Close the inlet valves to the sealing surfaces and threads on the cover
replenishment pumps, normally located plate and housing, as well as the O-rings
on the tank wall. on the cover plate and element.
3. Close the outlet valve (if present). 2. When fitting a new element, check that
the designation corresponds to that of the
4. Open the air bleed plug on the top of the old element.
filter to make it easier to drain the oil.
3. Place filters element(s) carefully onto the
5. Drain the replenishment pump filters element location spigot.
with the valves at the bottom of the filter
houses. 4. Screw on cover plate fully and then
unscrew by one quarter-turn.
6. Unscrew top covers.
5. Close the drain valve and air bleed plug.
7. Remove filter element(s) from element
spigot. Examine element surface for dirt 6. IMPORTANT: Open the inlet and outlet
residue and larger particles; these can valves.
indicate damage to system components.
8. Clean cover plate and housing; pay Vent the filters:
particular attention to the threads.
1. Start the HPU and let the replenishment
9. Examine filter, especially sealing pump run for one minute.
surfaces and threads, for mechanical
2. Stop the HPU
damage.
3. Release carefully air bleed plug on top of
10. Replace O-rings and check seals.
the replenishment filter and bleed of all
air.
4. Close the air plug when the oil is floating
and no more air is bleeding.
5. Clean up, start HPU and check filters for
leakages
Replenishment filters
6 Maintenance - Annex F
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Blank page.
6 Maintenance - Annex F
1. General
According to section 6.2 - "Periodic
Maintenance", the health of the hydraulic oil
in the system needs to be tested at a regular
basis. This is to be done by taking an oil
sample from the reservoir.
2. Bottle Cleanliness
Because of the extreme oil cleanliness levels, even the slightest dirt originating in a sample bottle can have an
adverse effect on the precision of the particle count. It is common to represent bottle contamination levels as the
number of particles greater than ten microns per millilitre (0.01 mm).
6 Maintenance - Annex G
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3. How to Sample
1. The system should have normal operating temperature and flow conditions when taking an oil sample.
MacGregor recommends to operate the system for at least 30 minutes with actuators cycling prior to
talking samples. (If not possible to sample when the equipment is operating, sample as soon as safely
possible after shutdown to prevent the settling of contaminants).
2. Open the sampling valve and let at least one litre pass the ball valve tube. Collect the flushed fluid in a
container.
3. Use a 100 % clean standard analysis bottle (typical 500 ml) provided by a bottle supplier. Open the
sample bottle cap, taking care not to contaminate. Hold the cap in hand or place on a clean surface, face
down.
4. Fill the sample bottle about halfway, cap and shake well to flush the internal surface. Discard the fluid.
5. Fill the sample bottle again until the fluid level is about 1 cm (½”) from the top.
6. Cap the bottle immediately and then close the sampling valve.
7. Label the sample bottle with sample details, fill out the sample form and enclose both in the supplied
plastic container for transport.
4. Visual Analysis
Looking and smelling at hydraulic fluid is the simplest way to determine the fluid's condition. Clean fluid is
amber in color. A milky, dark, or otherwise abnormal color may indicate the presence of one or more
contaminants. A milky appearance implies contamination by water. If the fluid looks milky, take immediate
action to avoid severe damage to your hydraulic system.
A marked change in the smell of the hydraulic fluid can indicate a chemical breakdown. If a distinct change in
the smell of hydraulic fluid is detected, have it chemically analyzed by a commercial lab.
5. Type of Analysis
A minimum recommendation from MacGregor is to perform a particle and water analysis every 6 months,
whether you are conducting onsite particle counting, or relying on a commercial lab. A full oil analysis are
recommending to be done once a year. The analysis may include particle counter, water content, viscosity,
oxidation, iron, silicon and copper content.
6 Maintenance - Annex G
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7. Hazards
• Avoid skin exposure to hydraulic oil. If exposed wash area with water and soap.
• Clean area before and after sample to avoid slippery surfaces or contamination of sample.
• Ensure bottle top of sample is secure.
6 Maintenance - Annex G
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6 Maintenance - Annex G
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1. General
Instructions for pre-charging of both bladder and piston accumulators via an accumulator test and filling kit is
provided in this section. When checking or re-charging accumulator pressure, the test and filling kit provided by
MacGregor Norway AS must be used.
Note: When the accumulator is installed in a system, reduce the system pressure to 0.
12T Winch
WH-11.1, 12.1, 13.1, 14.1, 11.2, 12.2, 13.2, SP2552-2-L-XA-005 50 bar
14.2
Slew System
SH11, 12, 13, 14 SP2552-2-L-XA-004 6 bar
6 Maintenance - Annex I
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2. Charging Procedures
2.1. Bladder Accumulator
• Attach the hexagonal connector (1) to the nitrogen bottle.
• Remove the gas valve protective caps from the accumulator. Secure the swivel connector (2) on the gas
valve and tighten sufficiently to prevent gas leakage. (Use adapter (5) on the accumulator for
installation of swivel connector on gas valve). Screw the bar handle (3) in a clockwise direction to open
the accumulator gas valve.
2 1
• Slowly open the nitrogen bottle valve until the expanding bladder closes the poppet valve. Check this
closure prior to charging to desired pressure.
• Close the nitrogen bottle valve. Wait for 5 minutes, before checking the pre-charge pressure. To lower
the pressure, open the air bleed valve (4).
• The Pre-charge pressure will drop slightly when the compressed gas cools off. Therefore, pre-charge to
20% above required pressure.
• Screw the bar handle (3) in a counter clockwise direction to close the gas valve. Use the air bleed valve
(4) to expel all gas from the pre-charging assembly. Remove the swivel connector (2) . (Remove the
adapter (5) if this has been used). Carefully test the gas connections for leakage by applying soapy
water or using leak detector in and around the gas valve area when the pre-charging is complete.
• Fit the gas valve protective caps.
• Remove the hexagonal connector (1) from the nitrogen bottle.
• Check the pre-charge after one, two and three weeks to ensure that no leakage has occurred. Further
pre-charge checks should be made every six months.
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Note: Use nitrogen only! Compressed air and oxygen involve risk of explosion!
6 Maintenance - Annex I
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2.4. Hazards
• Filling accumulators involves dealing with pressurised nitrogen which if handled incorrectly can result
in explosion. Experience personnel recommended.
• Check for damaged hoses, as working with damaged hoses can lead to release of pressurised gas.
• Ensure hose connections are secure.
6 Maintenance - Annex I
I4 MACGREGOR NORWAY AS
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1. General
• Bolt inspection critical areas: Elongation, threads, cracks and tension.
• Inspect all slew ring bolts / nuts (bolts / nuts in place): 1 M / 500 H
• Perform “knock-test” of all slew ring bolts: 6 M / 500 H
• Initial re-tensioning of all bolts: 1 M after crane delivery
• Periodic re-tensioning of all bolts: 6 M / 500 H
• Removal and examination of individual bolts: 20 % of bolts annually*
* 20% of the bolts shall be removed and examined. The first 20% shall be taken in the most loaded sector of the
crane. If any significant defects are found during this examination another 20% are drawn. If any of this second
set is found to be defective then all bolts shall be drawn. If the first 20% are found to be acceptable the bolts can
be re-used and the next 20 % can be drawn the following year.
When refitting, all bolts shall be tensioned according to: HM doc. No: T0001.
1.1. Knock-Test
It is recommended to use a ball peen hammer and do a “knock test” on each bolt. In the event that a nut should
have become loose, the lack of tension in the bolt will generate a different sound during the knock test as
compared to the fully tensioned bolts. Loose nuts indicate that bolt must be re-tensioned according to HM doc.
no: T0001.
Note: At the 6’th month interval, the knock-test and re-tensioning can be performed every other time.
T0001 – Tightening Torques & Bolt Tensioning Forces: See the following pages.
6 Maintenance - Annex K
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3. Hazards
• A safety harness is recommended if a ladder or lift is being used for re-tensioning.
6 Maintenance - Annex K
K2 MACGREGOR NORWAY AS
TECHNICAL REQUIREMENTS
This document and all information and data herein or herewith is the confidential and proprietary property of
MacGregor Norway AS and is not to be used, reproduced or disclosed in whole or in part by or to anyone without
the written confirmation from MacGregor Norway AS.
© MacGregor Norway AS
T0001 - 5
T:\Technical Requirements\
Title: BOLT SELECTION / TIGHTENING TORQUES / BOLT TENSIONING FORCES
Doc. No.: T0001
1 Applicability
The bolt selection in this document refers to how to select bolts and bolt quality in general
applications (e.g. winch assembly, gearbox assembly, etc.) and special applications (e.g. slew
ring bolts and nuts)
The tightening torques in this document applies to critical bolts specifically identified by the
drawing, technical specification/requirement or other document. See section 3.
The bolt tensioning forces (hydraulic tensioning) apply to all crane slewing ring bolts with
thread diameter M33 or larger. See section 4.
The tightening torques (section 3) are valid for standard, full-section, uncoated carbon steel (not
stainless) fasteners lubricated with anti-seize compound, such as Loctite 8009. These tightening torques
are also generally used for hot dip zinc coated fasteners, although such fasteners would require a
somewhat higher torque to achieve maximum clamping force. Source: Tingstad table T-18, lower left-
hand section.
2 Bolt/nut Selection
Selection of bolts/nuts for different assemblies and applications is normally done according to
material specification list on the relevant assembly drawing. Here the bolt size, type and quality
and number are specified. In addition to this, all bolts shall conform with and be tested in
accordance with a recognised standard e.g. pertinent part of ISO 898.
In general bolts are to be delivered according to DNV “Standard for certification of lifting
appliances Oct 2008, Ch. 2, Sec. 2, D400
Bolt connections are normally divided into three different groups; secondary, primary and
essential.
1. Secondary bolts are bolts in platforms, stairs, ladders, railings, installation of cabins and
cabinets etc. Bolts in this category are to be delivered with 2.2 works certificate and it is
T:\Technical Requirements\ Page 2 of 5
Title: BOLT SELECTION / TIGHTENING TORQUES / BOLT TENSIONING FORCES
Doc. No.: T0001
no requirement to charpy tests. Bolts smaller than M12 to be stainless steel A4 quality.
Bolts from M12 and up to be hot dip galvanised 8.8 quality.
2. Primary bolts are transferring structural loads and are elements in the primary load
carrying structure. Bolts in this category are to be delivered with 2.2 works certificates
and there it is no requirements to charpy tests. Bolts smaller than M12 to be stainless
steel A4 quality. Bolts from M12 and up to be hot dip galvanised 8.8 quality. If the
structural calculations show that an increased strength is required, 10.9 qualities may be
used.
3. Essential bolts are part of a non-redundant load path and a breakage may result in a
collapse or a serious mal-function. Bolts used in slew bearings are also considered as
essential. Bolts in this category are to be delivered with 3.1 certificates. If installed in a
slew bearing for offshore cranes, 3.2 certificates is required. Normally 8.8 or 10.9
qualities are used in this category. No higher than 10.9 quality is allowed. The
requirements to charpy test are given in DNV “Standard for certification of lifting
appliances Oct 2008, Ch. 2, Sec. 2, Table D4. Bolts with diameter less than Ø25mm has
no charpy test requirements. The requirements for bolts from Ø25mm are 42J for
offshore applications and 25J for other applications Test temperature (Td) is normally -
20 degC for offshore cranes and -10 degC for other cranes.
3 Tightening torques
Bolt tension forces including tolerances for "large-clearance metric thread" – DIN 2510 –
Sheet 2 – using hydraulic tension cylinders.
Preload the bolts with the advisable care crosswise to the specified values. It is possible to
calculate with a tightening factor of αA of 1.2 to 1.6, depending on the tightening method, and to
use the yield point of the bolt up to 90%.
The preload of the bolt tightened first is influenced by the tightening of the other bolts so that a
minimum of two passes is required.
This will at the same time compensate for the settling produced by the smoothing out of the
unloaded mating surface during preloading (thread and nut contact surface).
As the tension force applied in this method will not only cause elongation in the shaft but also in
the thread, it is important to choose the correct thread series or thread tolerances acc. to
DIN 2510. An inadequate thread clearance may cause jamming of the nut, when the bolt is
elongated. Taking into account the nut height, consultation with the bolts manufacturer is
absolutely necessary.
The bolts should be long enough to leave at least 1 · d above the nuts free for positioning the
tension cylinder.
6 Maintenance - Annex L
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6 Maintenance - Annex L
L2 MACGREGOR NORWAY AS
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In order to have comparable measurements it is important that the measurements are done in the exact same
slew positions each year and with the jibs in the same geometric position. The operator panel in the crane cabin
shows both jib and slew positions. These positions can be used for future reference.
The following table is to be used for recording measurements every 6 months following the initial
measurement. The accuracy of the measuring instrument is to be minimum ±0.01mm.
Depth micrometer
6 Maintenance - Annex L
MACGREGOR NORWAY AS L3
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The photo below shows measurement at one of the four measurement points on the crane pedestal. The
maximum allowable deviation is:
If the wear is found to have increased significantly, the time intervals between measurements should be
shortened. If the wear exceeds the given limit, consult MacGregor Marine Service.
*Deviations in flatness are measured in accordance with DIN EN ISO 1101 on the contact surfaces
**The value for increase in slack is a measurement of how much the hardened layers of the bearing are worn
6 Maintenance - Annex L
L4 MACGREGOR NORWAY AS
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2 0
3 0
4 0
2 90
3 90
4 90
2 180
3 180
4 180
2 270
3 270
4 270
6 Maintenance - Annex L
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Grease sampling:
6 Maintenance - Annex L
L6 MACGREGOR NORWAY AS
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Tester:
Signature:
Date:
Grease
sample
result
6 Maintenance - Annex L
MACGREGOR NORWAY AS L7
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2. Hazards
• In order to measure correctly paint may need to be removed.
• For any necessary paint removal for correct measurements, use a paint removal chemical or paint
removal sand paper.
• Ensure adequate protection is used for working with paint removal.
• Use Tectyl rust preventative after measuring to prevent rust.
6 Maintenance - Annex L
L8 MACGREGOR NORWAY AS
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Note: From early 2011, some cranes were equipped with tempered steel sheaves. For these cranes, the wire
sheave groove wear measurement is not applicable.
Obtaining good measurements of wire sheave groove wear will help the crane owner to apply appropriate
sheave maintenance actions in addition to providing relevant input to the crane maintenance schedule.
The wire sheave grooves include a two to three mm induction hardened layer beyond which the hardness
gradually decreases. The abrasion that the grooves are subject to can be monitored and understood by use of a
sliding gauge for measuring the depth of the groove. Measurements are taken to a tenth of a millimeter. Based
on the original inspection date, wear measurement trend analysis can be used to influence the measuring
schedule itself so that it continues to accurately indicate the health and future useful lifetime of the sheaves.
Groove Measuring
There are normally eight wire sheaves to be measured
(four for the main winch and four for the whip winch
wire). The measurement shall be taken at the same
reference position on the wire sheave every time. This is
to avoid "false" wear indications. The reference position
is normally marked on the wire sheave flange by means
of a sign plate (shown here by an arrow).
Operate the crane (rotate wire sheaves) to make the measuring point indicators on the wire
1
sheaves clearly visible and accessible.
Locate the mark (photo at previous page) which exactly indicates where the measurement should
2
be taken.
Perform depth measurement by means of a steel rule and a sliding gauge (or equivalent) to
3
measure the distance from top of flange to bottom of groove (photo below).
Record the measurement/deviation in the "wire sheaves log", an example of which is provided on
4
next page.
5 Repeat procedure for all wire sheaves.
Scheduled Maintenance
Due to the characteristics of wire sheave groove wear, it is recommended that the measuring frequency is set to
once every six months initially for a period of one year. Thereafter it will be at the crane owner's discretion to
adjust the maintenance schedule based on the previous depth measurements and the crane owner's inherent
technical experience and expertise.
6 Maintenance - Annex M
M2 MACGREGOR NORWAY AS
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*Note: The table provided in this page is standardized. The amount of sheaves may differ from crane to crane.
The initial measurement value in the table above is the value for the first measurement taken for each individual wire sheave. If, upon receipt of this procedure,
the values are not already stated measurements should be carried out and logged in conjunction with the cranes’ Harbor Acceptance Test or equivalent.
6 Maintenance - Annex M
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6 Maintenance - Annex M
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6 Maintenance - Annex M
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2. Hazards
• Ensure to clean the area before measuring to achieve accurate results.
• If a lift or ladder is used it is advised to use a safety harness.
6 Maintenance - Annex M
M2 MACGREGOR NORWAY AS
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• Open and check that the doors gaskets are in good condition (apply Vaseline, silicone, or similar if dry).
• Check regularly for water ingress, corrosion, damage, loose glands, and ambient conditions in excess of
the specifications.
Tighten all cable terminal Tighten all cabinet Check and clean the
connections and fuses bushings drain plug (if applicable)
VCI device
plate at JB
(see photo
Tighten all cable
below)
terminal connections
and fuses
6 Maintenance - Annex N
MACGREGOR NORWAY AS N1
User Manual for Crane
3. Hazards
• Ensure power is turned off before accessing electrical cabinet or junction box. This is in order to avoid
electrocution. Working with live wires is extremely dangerous.
6 Maintenance - Annex N
N2 MACGREGOR NORWAY AS
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1. Inspection
1.1. General
The pressure transmitters have been calibrated to a certain pressure range, and sends a 4-20 mA signal,
corresponding to the calibrated range to an analogue input channel in the PLC system.
However, to secure correct pressure readings, an inspection of the most "essential" pressure transmitters must to
be done. MacGregor Norway recommend to do this at least every two years to verify accuracy and followed up
by a recalibration (often replacement) if needed.
The transmitters on active boost cranes which must be checked is listed in the table below, while those for semi-
active cranes are listed on the following page. In the tables, the name of the transmitter, its tag number and
maximum allowed deviation is provided.
Active Boost
For active boost cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:
Main winch motor displacement pressure 2 -PT204B (or -PT205) 0.5 bar
6 Maintenance - Annex P
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Semi-Active
For semi-active cranes, the following pressure transmitters are evaluated to be "essential" and must be checked
frequently:
* Whip winch displacement pressure (* if whip winch AHC) -PT260 0.5 bar
Other:
Replenishment pressure -PT203 2.0 bar
Recommended tools:
• Hand pump.
• T-joint (2x).
• Calibrated pressure transmitter (0-60 bar).
• Calibrated pressure transmitter (0-400 bar).
• Calibrated pressure transmitter (0-460 bar) for main pump transmitters.
• Portable data recorder / measurement device.
6 Maintenance - Annex P
P2 MACGREGOR NORWAY AS
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After the transmitter is unplugged from the crane, testing is done in the following order:
Note: The pressure should be applied step by step between 5-10 bar. If the deviation exceeds the maximum
allowed value, the transmitter must be changed. The consequence of having too high deviation will differ from
transmitter to transmitter. Please contact MacGregor Norway for advice!
Transmitter to be tested
6 Maintenance - Annex P
MACGREGOR NORWAY AS P3
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2. Replacement
Replacement of pressure transmitters is done in the following order:
Required tools:
• Wrench/spanner - 27 mm.
4. Hazards
• Ensure system is depressurised.
• Clean area after maintenance to avoid slippery surfaces.
• Use drip tray.
6 Maintenance - Annex P
P4 MACGREGOR NORWAY AS
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Annex Q - Encoders
1. General
All pulse encoders must be inspected and checked for proper
function, damage and corrosion every 3M/500H, whichever
occur first. They are located the following places:
6 Maintenance - Annex Q
MACGREGOR NORWAY AS Q1
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2. Inspection
Inspection of a pulse encoder is done in the following order:
Required tools:
6 Maintenance - Annex Q
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User Manual for Crane
3. Replacement
If a pulse encoder is damaged, it must be replaced. Replacement is a simple procedure which may be undertaken
by an electrician.
Required tools:
6 Maintenance - Annex Q
MACGREGOR NORWAY AS Q3
User Manual for Crane
Blank page.
6 Maintenance - Annex Q
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User Manual for Crane
System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
1
2
HYDRAULIC
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
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User Manual for Crane
System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
20
MECHANICAL
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
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User Manual for Crane
System Maintenance Date Comments Sign. Date Comments Sign. Date Comments Sign
Action
39
ELECTRICAL
40
41
42
43
44
45
46
47
48
49
6 Maintenance - Annex Z
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