Mipeg Safe Load Indicator Sagar Kiran Manual m2000nr

Aanderaa Data Instruments Document W-130 H00 623, Date 26.06.06, of 34

MIPEG

COMPUTERISED CRANE MONITORING SYSTEMS

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�� Safe Load Indicator System Operating & Maintenance Manual

SeaTrax Model 4228 - Offshore Pedestal Crane

Sagar Kiran ANCHOR ONGC SVR INTERNATIONAL

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Contents Page

SAFETY NOTES ............................................................................................................................. 4

General Description............................................................................................................................ 5

Operating Instructions ....................................................................................................................... 7

3.1 Brief Description of MIPEG 2000 Operation ....................................................................... 7 3.1.1 Verification of Driver's Display Unit......................................................................................................... 7

3.2 Information presented on the Mipeg 2000 display............................................................... 9 3.2.1 Push Buttons on the Display..................................................................................................................... 9 3.2.2 Alarms .................................................................................................................................................... 10

3.3 Error handling...................................................................................................................... 10

3.4 Tare Function ....................................................................................................................... 10

Offline Instructions for Driver’s Display Unit (DDU).................................................................... 11

4.1 Introduction ........................................................................................................................... 11 4.1.1 Push Buttons in Offline Mode ................................................................................................................ 12

4.2 Calibration of Sensors........................................................................................................... 13 4.2.1 Direct calibration of Sensors................................................................................................................... 14 4.2.1.1 Calibration of sensors.......................................................................................................................... 14

Maintenance ..................................................................................................................................... 15

5.1 Introduction ........................................................................................................................... 15

5.2 Scheduled Maintenance ........................................................................................................ 15 5.2.1 Calibration of Sensors............................................................................................................................. 16 5.2.1.1 Calibration of Boom Angle Sensor ....................................................................................................... 17 5.2.1.2 Calibration of Load Hoist Sensors ........................................................................................................ 17 5.2.2 Check and calibration of Pulley Compensation ...................................................................................... 18 5.2.3 Set-up of Angle Limits (optional)........................................................................................................... 19 5.2.4 Checking of Crane Operation Inhibit Relays .......................................................................................... 20 5.2.5 Checking Crane Curves .......................................................................................................................... 20

5.3 Unscheduled Maintenance.................................................................................................... 21 5.3.1 Built In Test Equipment.......................................................................................................................... 21 5.3.2 Faults Indicated on Driver's Display....................................................................................................... 21 5.3.3 Faults Not Indicated on Driver's Display................................................................................................ 22

Technical description of the main parts .......................................................................................... 23

6.1 Computer Cabinet................................................................................................................. 23 6.1.1 Master II Card......................................................................................................................................... 24 6.1.1.1 Replacement of the Master II card ....................................................................................................... 24 6.1.1.2 Set-up of a new Master II card............................................................................................................. 24 6.1.1.3 Strap J5 for Safe or Ex i ....................................................................................................................... 24 6.1.2 Power Converter Unit ............................................................................................................................. 24

6.2 Driver's Display Unit ............................................................................................................ 25 6.2.1 Introduction............................................................................................................................................. 25 6.2.2 Mipeg 2000 Driver’s Display Characteristics......................................................................................... 25

6.3 Sensors.................................................................................................................................... 26 6.3.1 Load Hoist Sensor................................................................................................................................... 26 6.3.2 Boom Angle Sensor ................................................................................................................................ 26


APPENDICES Page APPENDIX A: MIPEG 2000 ERROR MESSAGES................................................................................................ 27 APPENDIX B: MIPEG SPARE PARTS LISTING ................................................................................................... 28 APPENDIX C : MIPEG DOCUMENTATION LISTING .......................................................................................... 28 APPENDIX D : MIPEG CERTIFICATE REFERENCE LIST ................................................................................. 28 APPENDIX E: NECESSARY TEST LOADS / DATA FOR CALIBRATION ........................................................ 29 APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM ................................................................ 30 APPENDIX G: BOOM ANGLE / CRANE RADIUS RELATIONSHIP................................................................... 32 APPENDIX H: PROJECT SPECIFICATION ........................................................................................................... 33 APPENDIX I : WIRING DIAGRAM ........................................................................................................................... 34

FIGURES Page Figure 2.1: MIPEG 2000 System Configuration ....................................................................................................... 6 Figure 3.1: MIPEG 2000 Driver's Display Unit.......................................................................................................... 8 Figure 3.2: PUSH BUTTONS on Display Unit ....................................................................................................... 12 Figure 3.3: Addressing table for parameters. ........................................................................................................ 13

This document is the property of Aanderaa Data Instruments A.S.

It must not be traced, copied, or exhibited to any third party without permission in writing.


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SAFETY NOTES

1. Check and if necessary calibrate the boom angle sensor (Inclinometer) prior to calibration of the load sensors.

2. Care should be taken when removing the sensor cover to gain access to the

sensor unit and its wiring. The sensor cover should be supported at all times when the socket head retaining screws are removed. The sensor covers are heavy and if their weight is allowed to hang on the internal wiring damage to the wires and sensor could occur. On reassembly it is essential to use the correct torque figure for the cover retaining screws.


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General Description

The MIPEG 2000 crane load indicator system, comprise sensors fitted to the crane, a computer cabinet and a display located in the crane cabin. Figure 2.1 shows a block diagram of the MIPEG 2000 system.

The load sensors provide frequency modulated electrical signals that are proportional to the developed loads in the load hoist rope systems of the crane. An inclinometer provides boom angle information that is used for calculation of the hook radius. In operation the actual load lifted by the crane are automatically compared with corresponding data related to the maximum permissible crane loading. The permissible and actual loads, together with the actual, expressed as a percentage of permissible are displayed. If this percentage exceeds a pre-set value, alarms and safety functions are activated. The computer stores the required load-radius curves. These fixed crane parameters are stored in the main computer's memory while the calibration of the crane is performed using known loads and boom angle, or known calibration factors. This information is tabulated into the main computer memory via push buttons on the Display unit.

MIPEG 2000 in standard version comprises the following main parts:

- Computer Cabinet (6.1) - Driver's Display (6.2) - Sensors (load and boom angle) (6.3)

A technical description of these main parts is given in Section 6. The numbers in parenthesis are references to paragraphs for these descriptions.


Figure 2.1: MIPEG 2000 System Configuration


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Operating Instructions

3.1 Brief Description of MIPEG 2000 Operation

MIPEG 2000 is a computerised crane safety system. It measures load and radius and indicates safe or hazardous conditions. It has three main parts; the computer cabinet, the driver's display unit and the sensors. The driver's display unit is located in the crane driver's cabin, and its layout is shown in Figure 3.1. MIPEG 2000 interfaces with the crane and prohibits some functions under dangerous conditions. These crane operation relays and their functions are described in Appendix H. In addition, alarms are given for loads exceeding the alarm limits of the safe working load. It is recommended MIPEG 2000 to be constantly powered if possible, even during periods of time when the crane is not in operation. No warm up time for the system is required, but the load sensors will need 5-10 minutes after power on to achieve maximum accuracy and stability.

3.1.1 Verification of Driver's Display Unit

Before using the crane: Check that the LEDs back lighting the driver’s display panel are illuminated to show that MIPEG 2000 is powered up.

The back lightning can be adjusted if one keep the AUX button depressed and use the TEST button to toggle the light intensity. Release the buttons between each setting.

Press the TEST button on the Drivers Display unit and confirm: • Operation of the analogue display of percentage safe working load by allowing the needle to

make at least one complete revolution. • Integrity of the WARNING (Yellow) and ALARM (Red) lamps on DDU - will light continuously. • Operation of display digits. Each segment of each window will show a figure eight with decimal

points being visible between each digit. • If everything is satisfactory proceed, otherwise call maintenance.

Press the 'AUX' button and confirm that the hoisting line is correct for the operating configuration of the crane. • Confirm that the hoisting line is correct for the operating configuration of the crane. If

not, select correct hosting line by pressing the ‘AUX’ and 'FALLS' buttons. Verify that the correct 'Crane curve' is displayed. • If not, select correct crane curve by pressing the ‘CURVE’ button.


Figure 3.1: MIPEG 2000 Driver's Display Unit


3.2 Information presented on the Mipeg 2000 display STANDARD LAYOUT

The outer circular analogue scale shows percentage safe working load (%SWL).

The scale is divided into three parts, coloured: • green - for the range 0 - 85/95% SWL, • yellow - for the range 85/95 - 110% SWL, and • red - for the range >110% SWL.

The top Window shows the Hook Load.

• This load will vary slightly as the amount of rope paid out varies. It also varies depending on how the load is lifted; the smoother the lift the less the resultant fluctuation.

The left Window displays the Crane curve selected. See Appendix H for details The right Window shows the Hook Radius. The lower Window shows the Safe Working Load that is related to:

• operating configuration of the crane • crane curve selected • radius of operation.

ALTERNATIVE INFORMATION

Window Information presented with AUX button depressed Top Boom angle Left Not used Right Number of hoist falls registered in MIPEG Lower Not used

3.2.1 Push Buttons on the Display

The PUSH BUTTONS have normally the following functions: BUTTON FUNCTION ACK Press this button to reset the Mipeg.

Spurious error will be disabled and satisfactory operation will continue. Pressing this button when an overload will also stop the flashing light on the display.

TEST Press this button to check the function of the needle and LCD's. AUX Press this button to activate the alternative information on the display. CURVE Press this button to toggle between the different crane curves (sea curves). AUX+FALLS Pressing these buttons will change the number of falls in the system. AUX+TEST The back lighting can be adjusted if one keep the AUX button pressed and use the

TEST button to change the light intensity. Release the buttons between each setting.


3.2.2 Alarms

The visual and audible alarms warn of approaching danger. The WARNING (Yellow) light on Drivers Display will flash and the buzzer inside the computer cabinet will sound when the load raised reaches the warning limit at boom radius, crane curve and operating configuration of the crane. This means that although a load may have been lifted at a given radius the alarm may come on as the crane is boomed out beyond that radius and the crane capacity reduces. To acknowledge an alarm, press the ACK button; the WARNING light will remain constantly lit until the overload situation has decreased below the warning threshold. The ALARM (Red) light on Drivers Display will flash when the load raised reaches the alarm. When the ACK button is pressed; the ALARM light will remain constantly lit until the overload situation has decreased below the alarm threshold and the WARNING light will remain constantly lit until the overload situation has decreased below the warning threshold.

3.3 Error handling

If a detectable error occurs the MIPEG 2000 clears the operators display, and blinks an error message 'ERxx' in top window; "xx" is two digits identifying the error. Operator should press 'ACK’ on the Display Unit that then resets MIPEG. If it was a spurious error, satisfactory operation will continue, otherwise call for maintenance. See Appendix A for Mipeg 2000 error messages. The two digit error codes have an error explanation with fault sources and references.

3.4 Tare Function

The zero setting of the hook load may vary due to length of rope payed out or weight of the slings in use. A tare function has been implemented in the Mipeg 2000 to set the hook load read-out to zero, prior to lifting operations. The load read-out may be 'tared' by pressing the 'FALLS' button once. Another push on this button will deactivate the tare function. The tare function will only work below +/- 0.5Tonne/1000Lbs. * number of falls calculated from the last zero calibration. The tare function will not change the zero frequency in the system.


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Offline Instructions for Driver’s Display Unit (DDU)

4.1 Introduction

The push buttons on the Display Unit are used to select the Offline Mode. When the TEST and CURVE buttons are pressed simultaneously, the following data is displayed: (Note: This Mode is disabled by a switch in the computer cabinet).

Window Data Top Presented value of displayed parameter (Calibration value). Left Parameter no. which contents presently displayed in upper window. Each parameter

to be displayed/changed in setting mode is tabulated and given a number according to its position in the table. When change of parameter is required, the number is found in the table given in figure 3.3 or in the calibration protocol, Appendix F.

Right Off (Offline) Lower Frequency value read from sensor (for calibration).


4.1.1 Push Buttons in Offline Mode

When calibration or inspection of calibration data is required, the offline mode is selected by pressing TEST and CURVE push buttons simultaneously. The push buttons then get a new function, shown in Figure 3.2. The PUSH BUTTONS have the following functions in the Offline Mode: Button Offline Mode UP Pressing this button will increase the last digit on the displayed parameter by one. (ACK) Keeping the button continuously pressed will give a fast change in value. All

alterations are done in the bottom window. The new value will also be displayed in the top window when accepted.

DOWN Pressing this button will decrease the last digit on the displayed parameter by one. (TEST) (Details as above) ENTER Pressing this button will put the changed parameter value into the system. (AUX) NEXT Pressing this button will give a step to the next parameter in the table. Its value and (CURVE) no. are displayed in the upper and left window respectively. When one comes to the

end of the table, the system returns to the first entry, which also is the starting point when entering offline mode.

READ Pressing these buttons, AUX and then TEST, will read the frequency from the (AUX+TEST) appropriate sensor and display it in the lower window. This value can then be set in

the system as a calibration value by pressing AUX. PREVIOUS Pressing this button will give a step to the previous parameter in the table. It’s value (FALLS) and no. are displayed in the upper and left window respectively.

Return to normal operation by pressing ACK and AUX simultaneously.

Figure 3.2: PUSH BUTTONS on Display Unit


4.2 Calibration of Sensors

Calibration of the system is performed in the following steps: • Use the TEST and CURVE push buttons to select ”Offline Mode”. • The first parameter is now displayed in the left window and the present value/frequency are

displayed in upper window.

• The parameters are organised as follows. See Appendix F for details. Index number Parameter

1-4 Inclinometer 5-10 Whip Load Sensor 11-34 Main Load Sensor 39-40 Pulley Compensation, Main 41-42 Pulley Compensation, Whip 43-46 Angle limits Figure 3.3: Addressing table for parameters.

• Press the UP (ACK) or DOWN (TEST) button to increase or decrease the last digit on the display by

one. • Press ENTER (AUX) button to set the value in the computer.

• Press NEXT (CURVE) or PREVIOUS (FALLS) button to go to another parameter. Ref. the

calibration protocol, Appendix F.

• Repeat until all parameters are set as required.

• Update all values in the calibration protocol form, Appendix F.

• Return to normal mode by use of ACK and AUX push buttons.


4.2.1 Direct calibration of Sensors

The calibration points are organised as follows:

Cal. Point Load Sensors Inclinometer 0 Empty hook (0) 30° 1 100% SWL 80° 2 40-60% SWL N/A

Point 2 is the value for the second order calibration and should only be used when required. The second order calibration is not activated if point 2 is set to zero.

4.2.1.1 Calibration of sensors To calibrate a Sensor, one must know which Index to use, see Appendix F Cal. Point 0 - The Zero calibration is done as follows:

• Use TEST & CURVE buttons for Offline Mode. • Press CURVE to select the correct Index (see Appendix F). • Press AUX & TEST to read new value from Sensor. Wait. • Press AUX to confirm new calibration. • Press CURVE to go to next Index. • Use ACK (UP) or TEST (DOWN), enter the Y-value (see Appendix E for details):

• 0 Tonns/Lbs. for Load. • normally 30 degrees for Inclinometer.

• Press AUX to confirm new calibration. • The calibration values will be updated. • Press AUX & ACK to go back Online.

Cal. Point 1 - The maximum point (100%) calibration is done as follows:


• Load lifted in Tonns/Lbs. • normally 80 degrees for Inclinometer.

• Press AUX to confirm new calibration. • The calibration values will be updated. • Press AUX & ACK to go back Online.

Cal. Point 2 - The Midpoint (40-60%) calibration is done as follows:


• Load lifted in Tonns/Lbs. • Press AUX to confirm new calibration. • The calibration values will be updated. • Press AUX & ACK to go back Online.

When the calibration is completed, one should write all calibration values into the Mipeg Calibration Protocol, Appendix F.


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Maintenance

5.1 Introduction

This section describes the maintenance procedures for MIPEG 2000 system. It is divided into two parts: - scheduled maintenance (5.2) - unscheduled maintenance (5.3) It is recommended that all repair work is performed by Aanderaa Data Instruments A.S, Bergen, for the aspects of warranty related requirements.

5.2 Scheduled Maintenance �

The maintenance schedule and instructions below should be followed rigorously to ensure correct operation of the MIPEG 2000 system.

FREQUENCY

TASK

PERFORMED BY

INSTRUCTIONS

Prior to Each shift

Verification of system operation

Crane driver

Perform check detailed in Section 3, 'Operating instructions for crane driver

3 Monthly

Check calibration of load sensors and inclinometer

Crane supervisor / Maintenance engineer

See paragraph 5.2.1. below

Check integrity of crane operation inhibit relays.



6 Monthly

Check crane curves



As required

Calibration of pulley compensation


See paragraph 5.2.1.3. below


5.2.1 Calibration of Sensors

The sensors of Mipeg 2000 are carefully checked during installation and their initial calibration constants are semi-permanently kept in the Mipeg 2000 non-volatile memory. Their output might vary within certain limits due to temperature drift, ageing and changes in environmental conditions. If the variation is too large, malfunction may occur, and a calibration must be performed. The zero point drift of the load hoist sensor(s), i.e. the deviation from zero on the display reading with empty hook is considered to be the most important factor to monitor. It must be kept in mind that the zero point for this sensor(s) has been defined at 45 degrees boom angle and hook at deck level. Deviation from zero in a no load condition might be caused by different length of hoisting rope payed out. The calibration constants could be set up in two different ways: 1. Normally one would use calibrated test loads or dynamometers for the force sensors and crane

radius marks on the deck for the inclinometer. The frequency is read from the sensor by MIPEG, while the actual quantity, i.e. weight or angle, is keyed in on the Display’s push buttons, as described in paragraph 4.2.1.

2. It is also possible to enter both the frequency and the actual quantity from the Display’s push

buttons. This method is used to enter old calibration constants; giving calibration values to MIPEG which already are recorded in the calibration protocol, Appendix F. See paragraph 4.2.1.

A compensation for variation caused by an unlinear load sensor arrangement is included in the MIPEG system. Calibration point 2 is set by the Display Unit buttons during calibration, in the same way as point 0 and 1. If the compensation is not required, point 2 should be set to zero.

Cal. point 0: Empty hook / No load Cal. point 1: 100% load Cal. point 2: 40-60% of full load

The calibration protocol given in Appendix F should be followed whenever possible. Ensure that the calibration points of the boom angle sensor are checked, and if necessary, calibrated before any other sensor is calibrated.


5.2.1.1 Calibration of Boom Angle Sensor

Calibration of the boom angle sensor is recommended if the deviation between the real and the indicated crane radius is greater than one metre. It is recommended that two permanent calibration points are used, one at minimum radius using the boom's end stop, the other point at approximately 30 degrees boom angle, i.e. 87% of maximum radius. The two points must be marked on the deck as radius in metre. As Mipeg 2000 always measures boom angle above horizontal, a calibration point at maximum working radius is not recommended as a small inaccuracy in the radius can cause a significant inaccuracy in the angle reading. This is because changes in boom angle in the range 0 to 20 degrees will give a small change in radius of approximately 7%. Radius/angle relationships for calibration purposes are given in Appendix G.

The calibration procedure for the boom angle sensor is given as follows:

• Boom out to the outer radius mark on the deck. • With the hook on this mark, do a calibration of point zero as described in paragraph 4.2.1. • Type in the boom angle according to the table in Appendix G, or according to earlier recorded

data in the calibration protocol. • Boom in to the inner radius mark on the deck. • With the hook on this mark, do a calibration of point one similar to point zero. • Set MIPEG in Online state and check the two calibration points. • If not ok, go back to point a) and/or d) and make adjustments of point zero and/or point one. • If ok, go Offline and read back the new calibration data, see paragraph 4.2. • Make a record in the calibration protocol.

5.2.1.2 Calibration of Load Hoist Sensors

Calibration of the load hoist sensor(s) is recommended if the hook load reading in a no load condition, i.e. boom angle at 45 degrees and hook at deck level, is outside the following limits: Whip line: +/- 1Tonne/2000Lbs. (Optional) Main line, Plural Falls: +/- 2Tonnes/4000Lbs.

Calibration requires calibrated test loads or a calibrated dynamometer to measure the test loads. Recommended sizes of the test loads are given in Appendix E. The calibration procedure for the load hoist sensor(s) is as follows: • Boom in/out to the radius that gives a boom angle given in Appendix E. See Appendix G for

radius/angel conversion. • Lower the empty hook to just above deck level. • Do a calibration of point zero as described in paragraph 4.2.1, function 'Calibration of Sensors'. • Type in zero as hook load. • Put on the test load and hoist it just above the deck level. • Do a calibration of point one similar to point zero. • Go back online and check the two calibration points. Test with approximately 50% of SWL and verify if the Mipeg readout is acceptable. If not calibration point 2 should be activated. • Do a calibration of point two as above. • Repeat the load test. • If the calibration is acceptable without point 2, the frequency and value for point 2 should be set to

zero.


5.2.2 Check and calibration of Pulley Compensation The weight of the pulley on the load hoist sensors could cause a varying output from the load sensors as the boom angle varies. A compensation for this is implemented on MIPEG. The parameters for this compensation are stored as calibration parameters according to the following table. HOIST LINE Index no. PARAMETER Main 39 Weight parameter

40 Angle for maximum load value Whip (Optional) 41 Weight parameter

42 Angle for maximum load value The check of the pulley compensation is done as follows:

• Set the values in index 39-42 to zero as described below. • Select Main hoist line first and repeat for Whip hoist line. • With the boom at maximum radius, position the empty hook just above the deck level. Keep

this hoisting line position during this test. • Boom in and note the displayed hook load values for every 5 Metre/15 Foot from maximum to

minimum radius. • Check the variations of the hook load values. If the variation exceeds 0.5Tonne/1000Lbs. for

whip line and 1Tonne/2000Lbs. for main line, a calibration as described above is required. To disable the pulley compensation, set the Parameters to zero as follows:

• Use TEST & CURVE buttons for Offline Mode. • Press CURVE several times to go to the Index 39 • Use ACK (UP) or TEST (DOWN) to set to zero • Press AUX to confirm. • Press CURVE to go to Index 40, 41 and 42 and set all to zero • Press AUX & ACK to go back Online.

The calibration of the pulley compensation is done as follows:

The compensation are set in degrees of boom angle and weight of the pulley. Theses values could be changed from the display unit as described below.

• Use TEST & CURVE buttons for Offline Mode. • Press CURVE several times to go to the Index 39 • Use ACK (UP) or TEST (DOWN) to adjust the weight parameter values, Index 39 for Main

(and Index 41 for Whip) according to the following formula: Adjustment = (Variation / No. of falls) / (1 - cos(A)), where: A=Boom angle difference for variation readout

• Press AUX to confirm. • Press CURVE to go to Index 40 • Use ACK (UP) or TEST (DOWN) to set Index 40 for Main (Index 42 for Whip) to the angle

where the highest load value was during the test. • Press AUX to confirm. • Use TEST & CURVE buttons to return to Offline Mode. Repeat the test above and if necessary adjust the weight parameter values (Index 39 & 40) until acceptable read-outs are achieved.


5.2.3 Set-up of Angle Limits (optional) 'Mipeg 2000 will activate a buzzer and/or output relays if the boom is outside the set angle limits. See Appendix H for project details. The parameters for these limits are stored as calibration parameters according to the following table: LIMIT INDEX NO. Parameter High Angle-1 43 High limit on 44 Low limit off Low Angle-1 45 High limit on

46 Low limit off These limits are set in degrees of boom angle and could be set from the display unit as follows: Set-up of the High Angle Limits:

• Use TEST & CURVE buttons for Offline Mode. • Press CURVE several times to go to the Index 43 • Use ACK (UP) or TEST (DOWN) to select the high angle limit, 'on value' • Press AUX to confirm. • Press CURVE to go to Index 44 • Use ACK (UP) or TEST (DOWN) to select the high angle limit, 'off value' • Press AUX to confirm. • Press AUX & ACK to go back online.

Set-up of the Low Angle Limits: • Use TEST & CURVE buttons for Offline Mode. • Press CURVE several times to go to select the Index 45 • Use ACK (UP) or TEST (DOWN) to select the low angle limit, 'on value' • Press AUX to confirm. • Press CURVE to go to Index 46 • Use ACK (UP) or TEST (DOWN) to select the low angle limit, 'off value' • Press AUX to confirm. • Press AUX & ACK to go back online.


5.2.4 Checking of Crane Operation Inhibit Relays

Checking of the crane operation inhibit relays are recommended to be performed by the crane supervisor every third month.

To test the overload outputs, one needs a hook load sufficient to create an overload condition. In order to use a smallest possible load, one can set MIPEG in the highest sea condition. Pick a load size according to the crane curves. With this load available, the check are done in the following steps: • Lift the load off the ground. • While watching the %SWL readings on the driver's display, boom out until it reaches the warning

limit. The yellow light should be activated. Boom out until it reaches the alarm limit. The red light and the relay output(s) should now be activated.

• Boom in and put the load down. In addition to this, the output relays may be tested as follows: MIPEG Nonoperational Turn MIPEG power off. The horn and overload relays should be activated. MIPEG Error Simulate an error condition on MIPEG. The horn and overload relays should now be activated.

5.2.5 Checking Crane Curves

The tables of safe working loads (SWL) are permanently stored in the Mipeg 2000 memory and are called crane curves. These are thoroughly tested during the commissioning of the crane. One should therefore not expect any problems with the crane curves during operation, but it is recommended that the crane supervisor checks the crane curves installed in Mipeg 2000 against the load- radius tables available in the crane cabin twice a year.

The crane curve checking is done in the following steps:

• With no load in the hook, hoist the boom to top position. • Set number of falls to the lowest implemented value. • Set curve to the lowest implemented value. • While reading radius and SWL from driver's display and comparing the readings with the

load-radius tables, lower the boom to maximum radius. • Change the curve to next lowest value and perform point d) while hoisting the boom to top

position. • Go through all crane curves for this number of falls, then change to next number of falls and go

through all curves, and so on until all combinations are checked. • If possibilities for more boom lengths are implemented, change to next boom length, and repeat. • After the checking of the crane curves is finished, set the parameter values for boom length,

number of falls and curve back to the correct values.


5.3 Unscheduled Maintenance �

5.3.1 Built In Test Equipment.

The computer will start to execute once the logic supply (5V) reaches it's working level after power is turned on to the system.

If the bus or timer checks fails, the program will signalise the fault condition and indicate an error message on the display, see Appendix A. If all checks are passed the full system software is initialised and starts it’s normal execution.

Different checks are continuously performed during normal system execution:

• Sensor data limit checks • Processing data evaluation • Processing time control ("watch dog" function) • Evaluation of the crane's parameter set

These tasks are all contained in the software package called the Online BIT-functions. If any of the checks fail this will lead to an immediate shut down of the system by use of the normal error exit and indication, see paragraph 5.3.2.

5.3.2 Faults Indicated on Driver's Display

Fault recognised by the Mipeg 2000 system during run-time, will be indicated on the driver's display by a flashing light in the WARNING and ALARM lamps and an error code in the upper window. The horn will blow for 10 seconds and overload alarm will be activated. When the crane driver acknowledges the fault, the fault indications on the driver's display will disappear and the overload function will be deactivated. If, however, the fault is of a permanent nature, the same indications will appear over again. The fault may of course be located in the computer (and be of a major kind, ref. paragraph 5.3.1 above) or the cabling to the display may be damaged both of which will display a normal error indication. The error code will assist the maintenance engineer in locating the fault. Appendix A gives a list of error codes with the probable fault source(s). When fault tracing, reference should be made into the technical description where further details may found.


5.3.3 Faults Not Indicated on Driver's Display Prior to faultfinding on this level, the Mipeg 2000 system should be given a power reset by turning power off/on. These faults normally fall into the following categories: FAULT "Dead system", a typical power supply problem Faults located in the Driver's Display prohibiting normal error indication Erratic behaviour, where parts of the system do not operate properly or as specified. The system does not follow the input switches Horn or other outputs not functioning

FAULT SOURCE : Trace the input power through fuses on TR1. If 24V dc present, check fuse located on the Master II card. If the error is strictly located to the display unit, error indication by the use of the horn will still be maintained. If not, reference to paragraph 5.3.1 should be made. If a malfunction is established and no fault found in the cabling a replacement of the display or cards may be necessary, see paragraph 6.1. Check the cabling of the switch or eventually replace the Master II card, see paragraph 6.1 Check the cabling of the item or eventually replace the Master II card, see paragraph 6.1


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Technical description of the main parts

MIPEG 2000 in standard version comprises the following main parts:

Computer Cabinet (6.1) Driver's Display Unit (6.2) Sensors (load and boom angle) (6.3)

A technical description of these main parts is given in this section.

6.1 Computer Cabinet �

The Computer Cabinet houses the Mipeg computer, zener barriers (EEx nC only), relays and terminal rows for external cable connection. EEx nC Certificated systems: The cabinet is certified EEx nC and sealed to IP66. Dimensions: 380*380*210 mm. Weight: approximately 30 kgs. The computer cabinet has been found to comply with the IEC 79-15 1987 standard and has successfully met the type verification and test requirements of this standard.

Systems in safe areas: The cabinet is sealed to IP66. Dimensions: 380*300*210 mm. Weight: approximately 15 kg. The computer cabinet has been found to comply with the IEC 79-15 1987 standard and has successfully met the type verification and test requirements of this standard.

There are three fuses in the system:

Supply Location Fuse type

24 Vs Master II Card 1.0 A / 250V - 5*20 mm 24 Vs TR1 - no. 3 3.15 A / 250V - 5*20 mm 85-240 V ac TR1 - no. 1 2.0 A / 250V - 5*20 mm (in safe area) 85-240 V ac TR1 - no. 1 8.0 A / 250V - 5*20 mm (certificated systems)

WARNING:

FOR CONTINUED PROTECTION AGAINST FIRE REPLACE WITH SAME TYPE AND RATING OF FUSES


6.1.1 Master II Card

The computer is built in microprocessor technology located on the Master II card. The Master II card also contains power, sensor and interface logic. The cards are connected to the terminal rail through connectors on the cards. These connectors can be split to make a quick replacement of cards.

The Master II card contains the following electronics: • microprocessor with program memory • volatile memory used to store the crane's parameter set • timing circuits • interface for three S-sensors • interface for the inclinometer • DC/DC converter for generation of the galvanic isolated power supply 5V, 12V • level detection circuits on logic (5V) and input (24V) power, • power protection circuits • fuse: 1A/250V - 5*20mm

6.1.1.1 Replacement of the Master II card When replacement of the Master II card is found to be necessary one should always continue with the same program unless this circuit (EPROM) is proven damaged. The EPROM containing the program is found in socket U37. To remove this socket inserted component, gentle insert a small screwdriver under the component and twist until component is free. Insert carefully onto spare Master II card.

6.1.1.2 Set-up of a new Master II card Prior to operation of the Mipeg 2000 system, a new Master II card has to be reset with default values from the system program and old calibration values should be entered: • Reset the Prom parameters (please contact Aanderaa Data Instruments for this procedure) • Enter old calibration values from the Calibration protocol, ref. paragraph 4.2.

6.1.1.3 Strap J5 for Safe or Ex i Due to the use of Zener barriers for Exi systems, the strap J5 on the Master II card has to be set in different positions for a safe or Ex i. • SAFE: strap J5 in position towards the crystal • Ex i : strap J5 in position towards J14

6.1.2 Power Converter Unit �

The Power Converter Unit is included inside the computer cabinet. The unit is a switching power supply, coping with input voltage from 85 - 264 Vac. The output from the power unit to the Mipeg 2000 Master II card is nominal 24 Vdc. The unit is in accordance with UL,CSA, TUV and VDE (IEC950). Noise terminal voltage is conforming to FCC class B and VDE0871 class B. Proof pressure AC 3000V.


6.2 Driver's Display Unit �

6.2.1 Introduction.

The Mipeg 2000 Driver's Display is a microprocessor controlled display designed for use in harsh environment.

Information is presented by four LCDs and by an analogue needle. All LCDs and the display facia are backlit by LEDs. The unit incorporates two alarm indicators (LEDs). Information to be visualised on the display is transmitted from the computer on a serial interface line. The Display Unit consists of three major parts all housed in an enclosure supplied with a cable entry through a gland and terminal row: • A printed circuit board including the front plate and electronic components of the display. • A push-button panel mounted on the front plate. This panel consists of five push-buttons. • A connector for the PTU connection mounted on the bottom plate of the enclosure.

The back-light can be adjusted if one keep the AUX button pressed and use the TEST button to change the light intensity. Release the buttons between each setting.

The display is mounted on a bracket fitting which enables the unit to be tilted in both the vertical and horizontal planes. ‘Selica Gel’ should be included inside the enclosure to prevent condensation of water on the display front glass. It is recommended that the Driver's Display is serviced by Aanderaa Data Instruments personnel.

6.2.2 Mipeg 2000 Driver’s Display Characteristics.

Physical characteristics Outer size: 225 x 200 x 60 millimetre Overall weight: Approximately 3 kgs Housing material: Aluminium given an epoxy resin finish. Electrical characteristics Supply Voltage: Nom. 7.5 Vdc Supply current: Nom. 152 mA External connections Two pairs connected to a terminal row. • DC supply: DD+/-. • Serial communications line to/ from display: RS485 A/B Environmental characteristics Operating/Storage temperature: -20, +40 C Sealing: to IP65


6.3 Sensors

MIPEG 2000 sensors are used to measure the following:

• Loads in the hoisting lines, main and whip (optional) • Boom inclination relatively to horizontal plane

A technical description of each of the sensors is given in the following paragraphs.

6.3.1 Load Hoist Sensor

The load hoist primary sensor(s) is of S-band type. This primary sensor is MIG-welded to a suspension part that also carries a pulley for the load sensing. The sensor measures the material stress in the suspension part, which is proportional to the line load.

The output from the sensor is a frequency signal in the range 350-450 Hz. The resolution is typically 5Hz/tonne for one fall configuration. The sensor has two wire power/signal connection and is not damaged by short or open circuits. The primary sensor may be overloaded 5-10 times the nominal working range. This is far above the yield strength of the material. The primary sensor is temperature compensated. The primary sensor is sealed hermetically to SEN431614-k (MIL-STD-883A). The sensor cover is sealed to protection index IP67. The sensor has been examined against the requirements of the CENELEC standards EN50 014 and EN50 018 for flameproof enclosures and has been approved for use in hazardous areas and to bear the marking EEx d IIB T6. The sensor cover mounted on the sensor with four socket screws. These are tightened with a torque wrench to a torque of 5 Nm. The flame gap area must be filled with an 'EExd' approved protection matter/grease, e.g. of mark PBC. To verify correct/undamaged cabling and sensor, a resistance measurement from the terminal row in the computer cabinet can be done. Between disconnected cores, the resistance shall be approximately 6 ohms (3 ohms in sensor plus cable). There shall be open circuits between cores and drain, and between drain and chassis earth. The load hoist sensor(s) has to be replaced as a complete unit.

6.3.2 Boom Angle Sensor

The Boom Angle Sensor is an inclinometer mounted in an EX d enclosure at the boom foot. The inclinometer gives a voltage output in proportion to the boom angle (BAS+). Voltage supply to the unit is 12Vdc (BAR+). The Inclinometer has a typical resolution of 30-35 mV/degree boom angle. The sensor is not damaged by shorts or open circuits. The unit is manually set to give approximately 4 Volt dc at zero degree boom angle if the unit is installed facing towards the left hand side of the crane. At minimum radius the voltage will then be approximately 7 Volts. If the unit is installed facing towards the right hand side of the crane, it should manually be set to give approximately 7 Vdc at zero degree boom angle. At minimum radius the voltage would then be approximately 4 Volts.


APPENDIX A: MIPEG 2000 ERROR MESSAGES CODE

Error Explanation, (fault sources & references)

19

Sensor fault, Moment sensor out of range. (Cabling, sensor, Master II card).

20

Sensor fault, Whip hoist sensor out of range. (Cabling, sensor, Master II card)

21

Sensor fault, Main Hoist sensor out of range. (Cabling, sensor, Master II card).

23

Sensor fault, Inclinometer out of range. (Cabling, sensor, Master II card).

25

Computer fault, Initializing error. (Master II card).

28

Computer fault, SWL-parameter error. (Master II card).

30

Computer fault, EEPROM/RTC read/write error (Master II Card)

31

Computer fault, EEPROM overflow (Master II Card)

50

Crane identity does not correspond to parameter set.

51

Both or none of the Main and Whip inputs selected.

9509 Or 0210

No communication between the computer cabinet and the display. (Cabling, Display, Master II Card)

Datainstrument document W-130 H00 623, Date 26.06.06 of 34

APPENDIX B: MIPEG SPARE PARTS LISTING Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran Part Name Part no. COMPUTER CABINET Master II Card DI-130 P01 001 MIPEG 2000 DRIVER'S DISPLAY Display Box/Front DI-130 P02 000 Mounting Bracket DI-130 P02 005 SENSORS Main Hoist Sensor DI-112 P05 239 Whip Hoist Sensor DI-112 P01 225 Boom Angle Sensor DI-130 P05 003 APPENDIX C : MIPEG DOCUMENTATION LISTING COMPUTER CABINET S - 123 B01 002 Block Schematic, Master II card DISPLAY A-130 M02 000 General Assembly, Mipeg 2000 Driver's Display SENSORS I - 112 M05 239 General Assembly, Main Hoist Sensor I - 112 M01 225 General Assembly, Whip Hoist Sensor I - 130 M05 005 General Assembly, Inclinometer APPENDIX D : MIPEG CERTIFICATE REFERENCE LIST MIPEG Part Marking Certificate no. Main Load Sensor Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 304 Whip Load Sensor Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 302X Inclinometer Ex II 2 GD EEx d IIB T6 NEMKO 03 ATEX 303X


APPENDIX E: NECESSARY TEST LOADS / DATA FOR CALIBRATION Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran The following test loads/data are recommended for calibration: �

�

�

� Sensor

Number of Falls

Calibration

Point

Cal. at

Degrees

Test value

Inclinometer

-

0 1

30 80

No test load

Whip Hoist

1

0 1

45

0 Lbs 11 800 Lbs

Main Hoist

2

0 1

50

0 Lbs 27 000 Lbs

Main Hoist

4

0 1

75

0 Lbs 56 000 Lbs

Main Hoist

6

0 1

80

0 Lbs 85 000 Lbs


APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM page 1 of 2 Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran CRANE: ______________________________ Calibrated - Date/Sign. : _________________________

SENSOR

No. of Falls

Cal.

Point

Index

no.

Calibration Parameters

Frequency / value

0

1

Volt

INCLINOMETER

-

0

2

Degrees

1

3

Volt

1

4

Degrees

0

5

Hz

0

6

Lbs

LOAD HOIST,

1

7

Hz

Whip

1 1

8

Lbs

2

9

Hz

2

10

Lbs

0

11

Hz

0

12

Lbs

LOAD HOIST,

1

13

Hz

Main

2 1

14

Lbs

2

15

Hz

2

16

Lbs

0

17

Hz

0

18

Lbs

LOAD HOIST,

1

19

Hz

Main

4 1

20

Lbs

2

21

Hz

2

22

Lbs

0

23

Hz

0

24

Lbs

LOAD HOIST,

1

25

Hz

Main

6 1

26

Lbs

2

27

Hz

2

28

Lbs


APPENDIX F: MIPEG 2000NR CALIBRATION PROTOCOL FORM page 2 of 2 Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran CRANE: ______________________________ Calibrated - Date/Sign. : _________________________

PULLEY COMP.

-

0

39

Lbs

( Main )

0

40

Degrees

PULLEY COMP.

-

0

41

Lbs

( Whip )

0

42

Degrees

ANGLE LIMITS

-

0

43

Degrees

( High Angle-1 )

0

44

Degrees

ANGLE LIMITS

-

0

45

Degrees

(Low Angle-1 )

0

46

Degrees


APPENDIX G: BOOM ANGLE / CRANE RADIUS RELATIONSHIP

Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran

RADIUS = Distance from Centre of Pedestal to Jib Pin (+ Sheave radius for 1 Fall)

+ Boom Length * cos(@) + Offset Centerline * sin(@) RADIUS for Whip line = 3.75 + 0.60 + 122.32 * cos(@) + 3.52 * sin(@) RADIUS for Main line = 3.75 + 118.80 * cos(@) + 1.50 * sin(@) ��

�

Boom lengths:

Whip 1 fall

122.32

Main 2or> falls

118.8

Angle Radius Radius

0 126.7 122.6

5 126.5 122.2

10 125.4 121

15 123.4 118.9

20 120.5 115.9

25 116.7 112.1

30 112 107.4

35 106.6 101.9

40 100.3 95.7

45 93.3 88.8

50 85.7 81.3

55 77.4 73.1

60 68.6 64.4

65 59.2 55.3

70 49.5 45.8

75 39.4 35.9

80 29.1 25.9

85 18.5 15.6

90 7.9 5.2

�

��


APPENDIX H: PROJECT SPECIFICATION

Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran

Crane specification BOOM LENGTH: 118.80 Feet LOAD SENSORS: Whip Line – 1 Fall Main Line – 2, 4 & 6 Falls

MIPEG 2000 Non Recording System LOAD CURVES: PLF(Static) & SEA(Dynamic) WARNING LIMIT: 95% SWL UNITS: Lbs / Ft COMPUTER CABINET: Rittal AE1030, Safe area. POWER SUPPLY: 85 - 240V ac

DIGITAL INPUT SIGNALS to MASTER II CARD J13-2 INP#a : ON / OFFLINE SWITCH (in TR1) J13-1 INP#b : spare

DIGITAL OUTPUT SIGNALS from MASTER II CARD J13-3 OUT#10 : 95% SWL & Angle Limits - BUZZER J13-4 OUT#11 : 110% SWL – Horn & BOI - R1 J15-6 OUT#12 : High Boom Angle - R2 J15-7 OUT#13 : Low Boom Angle - R3


APPENDIX I : WIRING DIAGRAM Cranes: SeaTrax Model 4228 : ONGC – Sagar Kiran

Mipeg Safe Load Indicator Sagar Kiran Manual m2000nr

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