Ports Solution

Cranes and moving machines

Tran Duy Hoai

 Main cranes types – Ports

◼ Ship-to-Shore Gantry cranes or Container cranes

◼ Bulk Handling cranes

◼ Container Yard Cranes

 Main cranes types – Industrial

◼ Mainly overhead crane, also known as a bridge crane

Main cranes types – Mines & Others

◼ Drag Lines and Trawler cranes

1. A common problematics
Components monitoring

◼ For the all the cranes types, the monitoring of their components can be
divided in 3 categories:

▪ Hoist

▪ Trolley

▪ Propulsion: wheels, tracks or shoes

1. Our Solution
Cranes specificities

A large range of crane type

• Versatile solution
• Cost effective solution

A process with many variables

• Speed variations
• Load variations
• Short acquisition windows

Large sites and moving machines

• Local monitoring and display
• Remote analysis and database server
• Wireless communication

Low speed
• Dedicated analysis tools
Cranes key points

◼ Variable speed
▪ Reduced acquisition time required
◼ Limited time for acquisition
▪ No go for scanning system
▪ No go for standard systems
◼ Variable conditions
▪ No go for fix alarm levels
◼ Far and moving
▪ Acquisition must be onboard
▪ Wireless solution

MVX is the only dedicated solution on the market

▪ Parallel acquisition
▪ Automatic measurement set selection
▪ Low speed analysis
 OneProd MVX Key features
The right vibration
measurements at the
right time
Monitoring of complex &
non stationary machines.
Permanent monitoring of the
operating conditions of the
machines
Synchronous
acquisitions of all
channels

Embedded
processing
capabilities

Local indicators processing Ethernet, Internet & RS485

for Diagnosis & local communication
surveillance

Sharing data with local

The right features for a & remote environment

pertinent monitoring
 OneProd MVX Key features
Ethernet, RS485
 OneproD MVX achieves :
 Permanent monitoring of the
machine running conditions
 Synchronous measurements
of all channels
 Local processing of specific
indicators

 To get :
 The right measurements at
the right time
 Coherent overview of each
machine
 Local and autonomous
RPM
monitoring
 Advanced measurements &
key indicators
Measurement set automatic selection

◼ Machine running condition

Signals Speed
- Vibration
- Oil Direction
- Electrical Power
◼ Short acquisition time
Speed Usually about 3 s
Direction (optional)
◼ Measurement done when the
Power (optional)
machine is in the same
running condition

Comparable measurements
Meaningful measurements : spectrums, overall levels, time
waveforms, envelopes, etc…
Measurement set automatic selection Load

Speed

Power

Measurement set selection

•Overall levels
•Spectrums
•Envelopes
•Time wave forms
•Kinematics frequencies

•Alarm set points

•Bandwidth
•Periodicity
•Etc…
 Technical benefits

▪ OneProd MVX triggers the data acquisition according to the operating

conditions
- acquires comparable data
▪ OneProd MVX performs synchronous measurements
- short acquisition time
▪ The acquisition strategy based on the machine running conditions
- avoids false alarms
- transforms the crane in a simple machine easy to analyze

+
+
+
+

+ +
+ +
Trend without operating conditions Trend with operating conditions allow
to compare data

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 Measurement examples
(Australia)

Measurement according
machine running conditions

3s acquisition

Gearbox defect

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Communication

◼ On board processing
➔ low bandwidth required
➔ all wired or wireless technologies possible
◼ Connection to the PLC possible (and recommended)
 STS

Cranes Monitoring
 Benefits

◼ Detected failures :
▪ Gears defects: Wear, cracked/broken teeth, gear eccentricity, backlash, loose
bearing fit
▪ Bearings defects: Wear, cracks, pitting, lubrication defects, corrosion
▪ Coupling defects between gearbox and motor
▪ Motor unbalance
▪ Motor rotor defects (cracked rotor bar, rotor eccentricity)
▪ Mechanical looseness
▪ Structural resonances, etc…

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1. Customers
 SLEWING GANTRY CRANE

▪ Shanghai Zhenhua Heavy Industry Co., Ltd. (ZPMC) is one of the biggest heavy-
duty equipment manufacturer specialize in port and marine cranes
▪ ZPMC was looking for a solution to propose a condition monitoring option to all of
their customers. MVX was selected.
▪ More than 150 MVX have been installed on brand new ZPMC cranes before
delivery to the end users.

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SLEWING GANTRY CRANE

Fieldbus
TCP/IP Modbus Converter
Modbus Master
RS485 Modbus Fieldbus Slave

Motor Acceleration
Velocity
DEF

TCP/IP Fieldbus

Gearbox

Hoist

PLC
Architecture for Slewing Ring

Machine conditions
Alarms
• • Modbus
4/20mA
• • Relays
Modbus
• DC

Dedicated
Real
Vibrationtimemonitoring
monitoring
tools for low for
•speed
Baseanalysis:
Full
Automatic
proximity on conditions:
data transfer to the server
analysis
probes
• Speed(tuning period)
FFT
Direct
• DC components
ShockFinder (SFI) = Smart Denoising
• Load Wifi, satellite, etc…
Timewaves
GSM,
• Real Time Alarms
Filtering
• Angle,
OVL etc…
etc…
• Autocorrelation, Kurtosis, etc…
Detection WITH SFI

 

SHOCKS HIDDEN BY VIBRATIONS FILTERING AND IDENTIFICATION

OF HIGH-SPEED SHAFTS OF SHOCKS
ONBOARD TOOTH
BROKEN
PROCESSING
ON PLANETARY GEAR
 (WIND TURBINE)

Defect Detection

SIMPLE AND EFFICIENT RESULT

IN XPR AND SUPERVISION
Diagnostic WITH ShockFinder

 

TIME WAVE FORM DISPLAY SHOCKFINDER DENOISING

IDENTIFICATION OF THE DEFECT

China: ZPMC

1 motor + gearbox
Hoisting
4 points
Power house 3 motors + gearboxes
- Hoisting
Trolley - Trolley movement
- Arm rotation
12 points
Australia : Port Adelaide

▪ The 3 container cranes of port Adelaide are equipped with 2 MVX system each
▪ The data are sent to a cloud server based in Melbourne for analysis and
periodical reporting.
Australia : Port Adelaide - Details of application

◼ Industry: Shipping
◼ Customer: Flinders Adelaide Container Terminal
◼ Monitored Equipment:
▪ Container Loading Cranes – 2x Liebherr, 1x ZPMC
◼ Products used:
▪ 3x MVX 32 Channel, 3x MVX 16 Channel
Australia : Port Adelaide - Details (1/3) - Context

◼ Flinders Ports is a major marine services company. Flinders Adelaide

Container Terminal (FACT) is the South Australian ship loading facility.

◼ The customer did not use any Condition Monitoring in the

past.

Main Hoist
◼ The main problem is availability of the Cranes for 24/7 (continuous)
operation, very expensive down time and unnecessary over-maintaining of
the cranes.

Boom Lift Trolley

◼ Three segments of the crane are monitored:
▪ Main Hoist, Boom Lift & Cross Travel Trolley.
Australia : Port Adelaide - Details (1/3) – Context
continued

◼ Machine is very hard to monitor due to changing operating conditions.

Detailed study of the process info was required to determine the optimal
parameters for data acquisition.
▪ Speed, Load and Direction were monitored for several hours of operation
▪ Operating conditions were determined based on stability of data
▪ Time available for data acquisition was determined to enable accurate setting of parameters.

Stable speed with full

load and same direction.
Australia : Port Adelaide- Details (1/3) – Context
continued

◼ The fine-tuning of operating conditions

transformed the variable speed
machine into a “fixed speed” like
machine allowing:
▪ Meaningful trending and alarm setting
Without condition

▪ Easy comparison of spectra

Optimal condition set-up

Trends with and without condition strategy.

Australia : Port Adelaide - Details (2/3)
The Solution
◼ 6 MVX systems were installed to monitor 9 individual
PLC
components at 3 cranes.
▪ 3x MVX 32 channel for Main Hoist and Boom Lift on each crane PLC Trigger Inputs
▪ 3x MVX 16 channel for Cross Travel Trolley on each crane

◼ PLC inputs are fed into the MVX’s via Modbus and data is
acquired at specified operating conditions for each
assembly.
▪ Defined values for Speed, Load and Direction
MVX 16ch MVX 32ch
◼ Data is collected on condition and sent to a cloud server
Internet Switch
◼ SWB Plus can access the data remotely for analysis and
Data Data
reporting
◼ Individual reports are issued on change in condition Cloud Server

◼ Monthly report is created to summarise condition of all

equipment
Report

SWB Plus Analyst Customer access

Australia : Port Adelaide- Details (2/3)
The Solution continued
◼Affordable cost of the system compared to
potential benefits.
◼ Customer access to data (supervision module).
◼Email and/or SMS notification options in case of
alarms.
◼Continuous monitoring and monthly reporting by
SWB Plus.
◼ …
Australia : Port Adelaide - Details (3/3)
Happy customer
◼ It is an early stage however a fault has been
detected on one of the Boom Lift assemblies.
▪ It is currently classified as unsatisfactory and monitored
closely by SWB Plus.
▪ Improved lubrication schedule caused the deterioration rate
to slow down, potentially avoiding a premature failure of the
bearing.
◼ Fault details:
▪ Elevated DEF levels were observed on Crane 2 Boom Lift
Motor DE.
▪ Spectral data were checked and frequency train of 168Hz
was evident in all spectra.
▪ Enveloped spectrum showed a clear harmonic train of
168Hz.
▪ Customer was notified and lubrication schedule was
revised.
▪ The fault level is currently stable and monitored closely.
 Brazil : Arcelor Mittal Tubarão, cranes

▪ The Arcelor Mittal plant of Tubarão located in Vitoria has selected OneProd MVX
to monitor 2 huge cranes of 450 tons capacity.
▪ For each crane, a 32-channel OneProd MVX is used to monitor vibration, gear oil
TAN and oil temperature, according to the operating conditions of the crane.
▪ To integrate the permanent displacements of the crane, the data is transferred to
OneProd XPR conditional maintenance software in Wireless communication
mode.

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 Republic of South Africa : Transnet, Iron Ore Bulk Shipping
Terminal
▪ Transnet’s Saldanha Bulk Shipping Terminal at Saldanha port is a vast iron-ore
shipping terminal on the west coast of South Africa.
▪ The iron-ore handling machines at the terminal including stacker/reclaimers,
tipplers, stationary and mobile conveyors and ship-loaders, operate on a very
tight schedule to insure meeting the international demand on the South African
iron-ore.
▪ The first phase of implementation includes 15 MVX units,

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