CRANE LOAD

INDICATOR
Engineering Forum – Conoco Philips
CONTENT

04

03
Crane Load 05
Indicator
Crane Load Function and
Indicator Principle
Crane Load Indicator
02 Concept. Component 06
Common
Test & Inspection
Root
Cause.

01 Crane Trouble Shooting 07

Accident.
Sample
text
 Crane Accident –
Common Root Cause

www.superkrane.com 3
 1st Accident by overload, Underestimating the wind
2nd Accident (this picture) load on “light loads with
due to improper repair large sail areas”

Crane out of service, wind from the

front, excessive damage,

Unknown load, outrigger forces

The Netherlands, wind on
exceed ground bearing capacity
load, boom pushed back,
damages
 Crane Accident

LMI setting wrong, damage only

 Traveling at
night on soft
ground,
Derrick
Ballast
grounded,
crane pulled
over,

4 Cranes lifting one load, CoG

unclear,

… is such incident avoidable by

advanced controls systems?

Proper Repair and Maintenance

LMI setting wrong, 1 fatality
Chart Common Root Cause
LMI Wrong
LMI Bypass Setting
Crane Accident SUPERKRANE 9

Types/Frequency
Top Four Accident Types and Causes

www.superkrane.com
Human Intervention
SUPERKRANE 10

www.superkrane.com
 Crane Load Indicator
Concept
• Regulation
• Safety Integrity Level
• Functionality & Principle
• Crane Load Indicator Component
• Configuration Matrix of Alarm and
Indicator
• Bypass or Override System

www.superkrane.com 11
Regulation

Permenaker ISO EN ISO ASME

No. 5/1985 4301:2016 13000:2014 102451:1994 B.30.5

4.2.6.3.2 Rated
capacity limiter
All mobile cranes
having a rated
capacity of not less
than 1 000 kg or an
overturning moment
of not less than
40 000 Nm shall be
fitted with a rated
capacity limiter.
 Crane Safety Integrity Level
ERP Procedure Emergency
Mitigation

Event Accident

Safety Instrument Safety Layer Protection

Trip/Cut Off
Layer

Operator Intervention Alarm Process Shutdown

Preventif

Crane Control System

Loop System Crane Control

Process Value Crane Design

Crane Load Indicator Functionality
A device like internal computer or microprocessor with various which is installed on cranes to
alert the operator if the lift is exceeding the safe operating range of the machinery.
The function of load indicator are to set boom angle, boom length, hook block type used, limit
of load capacity, slewing angle, Jib length & offset angle, outrigger extension, wing
measurement and additional ground bearing calculation,
Type Name Crane Load Indicator in Market: Common Sensor & Component:
• Rate Capacity Limiter/Safe Load Indicator • Angle detector, Wind detector
• Integrated Control System (LICONN- Liebherr) • Overhoist limit switch/ATB
• Automation Control System (ACS-Kato) • Transducer (Load detector)
• Load Detector System (Kobelco) • Boom, slewing, backstop limit switch
• Rate Limit Control (RTC – Terex) • Outrigger stroke sensor
• Automatic Moment Limiter (Tadano) • Camera (CCTV)
• Engine Level Control

Liebherr Kobelco KATO Tadano

Crane Load Indicator Principle
• All information provided by the indicators and displays shall be visible from the control positions,
including remote controls, where that information is required.
• The response of indicators and displays shall follow the corresponding motion with a suitable
precision (e. g. ± 5 %) and speed, so that they always show the current situation.
• All mobile cranes having a rated capacity of not less than 1 000 kg or an overturning moment of
not less than 40 000 Nm shall be fitted with a rated capacity limiter.
• The rated capacity limiter shall operate, with lowest possible working speed, between 100 % and
110 % of the rated capacity. The rated capacity indicator shall warn:
a. The crane operator both visually and audibly of the approach to the rated capacity;
b. The crane operator both visually and audibly and persons in the danger zone of the crane
audibly so that they can take heed of the warning when the rated capacity limiter is
activated;
c. Persons in the danger zone of the crane visually and audibly when the rated capacity
limiter has been overridden.
• The rated capacity indicator shall give a warning of approach to the rated capacity starting
between 90 % and 97,5 % of the rated capacity of the crane.
Crane Load Indicator Principle (Con’t)
• Crane level indicator, Mobile cranes supported by outriggers shall have in addition a crane level indicator. The
crane level indicator shall have an accuracy better than ± 0,1 of a degree.
• Hoisting limiter, All cranes shall be fitted with a hoisting limiter to stop all motions which can cause the hook block
to make contact with the jib/jib head and cause damage.
• Lowering limiter, All cranes shall be fitted with a lowering limiter. As a minimum the lowering limiter shall ensure
three turns of rope on the drum.
• Additional mandatory indicators, the following indications shall be given for the current configuration and position
of the crane under the following conditions:
a. Continuous display during crane operation:
 Utilisation of rated capacity, Rated Capacity and working Load.
b. Selected display (to be selected manually by the crane operator):
• Radius, Jib Angle, wind speed, slew range, jib length, jib lock, axle lock, slew position, travelling (audible
warning).
• Additional Mandatory Limiter,
a. Maximum and minimum jib angle
b. Telescoping
c. Slewing
d. Control station position
e. A-frame position
Crane Load Indicator Load Monitor
Wind Detector

Component
Over Hoist Limit
switch

Load Detector
(Tranducer)
Back stop limit switch

CCTV for Back Crane

Exp. CLI Component
Exp.: Kato SR 700 Exp.: Kobelco 7250s
Exp. CLI Component
Exp.: Liebherr 100 T Process Flow
Display Indicator 1

3
1

2
Display Indicator
 Configuration Matrix of Alarm
and Indicator

www.superkrane.com 22
 Automation Stop Principle

www.superkrane.com 23
 Setting Work limit Area
SUPERKRANE 24

ln case of work requiring area limitations, the work area limiting function can be utilized for upper and lower boom
angles, maximum load, maximum work radius, and maximum height. (Work area limiting function) Items which
can be set by area limit are boom upper and lower angle, maximum load, maximum work radius and maximum
height.

www.superkrane.com 24
 SUPERKRANE 25

Bypass or Override System

Override Can processed if (EN.13000:2010): Override Key
- Overload system is failure Provision override key for purpose test, emergency
- Emergency Situation or in assy/de-assy crane situation and assembling Crane.

www.superkrane.com 25
Crane Load Indicator
Test -Inspection & Troubleshoot

www.superkrane.com 26
Test & Inspection
SUPERKRANE 27

Inspection Overhoist Limit

Inspection Type After Daily Annual
Assy Operation
Function & Error Test X X

Control Test/Visual Inspection X X

Calibration X

General Procedure
1. Conduct function test to over hoist limit, boom limit, ect. Till
alarm and cut off system has operate.
Inspection Boom Limit
2. Know accurate radius and load with measure of actual radius
and load manifest who has to know.
3. Read manual operation about load indicator.
4. Attention to display monitor if occur error code.
5. Record inspection and report if any problem occur.
6. For calibration, consider to manufacture recommendation and
maintain schedule and conduct load testing with load cell.

www.superkrane.com 27
Troubleshoot
SUPERKRANE 28

• When abnormal occur, message column in Load Indicator will

give message with code. When the error code appears the
buzzer sounds.

• By pushing error code in display detail failure can be

displayed.
• Some brand have different way, so read manual operation or
call contact centre of manufacture.

www.superkrane.com 28
 SUPERKRANE 29

www.superkrane.com 29