2004 9000 0A 0740 - CPP Crane Maintenance Guideline - Rev1

Cuu Long Joint Operating Company
Su Tu Field Development – Su Tu Vang
STV COMPETENCY TRAINING
CRANE MAINTENANCE GUIDELINE
2004-9000-0A-0740
0 APPROVED 4/2008 DWG

A IDC 8-Dec-07 L A Hao GWI
Rev. Description Date Prepared Checked Approved
/conversion/tmp/activity_task_scratch/678203842.doc
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Document No. : 2004-9000-0A-
STV-CPP CRANE MAINTENANCE GUIDELINE 0740
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TABLE OF CONTENT
DISTRIBUTION LIST............................................................................................................
DEFINITION OF TERMS......................................................................................................
1 PURPOSE....................................................................................................................
2 SCOPE.........................................................................................................................
3 REFERENCES...........................................................................................................
4 DEFINITION..............................................................................................................
5 SAFETY AND / OR ENVIRONMENTAL REQUIREMENTS............................
6 GUIDELINE...............................................................................................................
6.1 RESPONSIBILITIES.....................................................................................................
6.2 GENERAL...................................................................................................................
6.3 CRANE OPERATING INSTRUCTION...............................................................
6.4 CRANE DRIVEN ENGINE....................................................................................
6.4.1 Engine Starting...........................................................................................................
6.4.2 Engine Stopping.........................................................................................................
6.4.3 Battery........................................................................................................................
6.5 ANNUNCIATOR...........................................................................................................
6.5.1 Product Description...................................................................................................
6.5.2 Display Head..............................................................................................................
6.5.3 Power and Control Inputs/Outputs..........................................................................
6.5.4 Display........................................................................................................................
6.6 CRANE LOAD INDICATOR SYSTEM.........................................................................
6.6.1 General Description of the Operation Limit Monitor.............................................
6.6.2 Technical Description of the Main Parts..................................................................
6.6.3 Operating Instruction................................................................................................
6.6.4 Maintenance...............................................................................................................
6.7 CCTV........................................................................................................................
6.7.1 Description..................................................................................................................
6.7.2 10” LCD Colour Uni..................................................................................................
6.6.3 Camera........................................................................................................................
6.8 METEOROLOGICAL SYSTEM....................................................................................
6.9 RADIO......................................................................................................................
6.9.1 General Information..................................................................................................
6.9.2 Operation....................................................................................................................
6.10 AIR CONDITIONER....................................................................................................
6.11 CALIBRATION SAFE LOAD INDICATOR.....................................................................
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DEFINITION OF TERMS
TERM DEFINITION
ESD Emergency Shutdown – Will cause a complete surface shutdown
of the processing facility (ESD-3), along with closure of Surface
Controlled Sub-Surface Safety Valves (SCSSV) and automatic
depressurisation of hydrocarbon process equipment through
blowdown. (ESD-2). For ESD-1a/1b and PAF, pls. refer to doc
2004-4006-4H-0001 “STV Detail Engineering CPP Control,
Automation and Shutdown Philosophy” for more detail.
HWP Hot Work Permit
LEL Lower Explosive Limit, the minimum concentration of Methane
gas in air to support combustion (5% x Vol)
PSD/ ESD-3 Process Shutdown – Will cause a complete surface shutdown of
the processing facility. However Surface Controlled Sub-Surface
Safety Valves (SCSSV) will still be open and any utility system
will remain operational.
PTW Permit to Work.
SEMS CLJOC Safety and Environment Management System.
CPP Su Tu Vang Central Processing Platform
FPSO Floating production and Storage & Offloading Facilites
WHP-A Well Heat Platform A
MCC Motor Control Centre
CCR Central Control Room
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1. PURPOSE
To detail the method for operating and maintenance the Crane System during operate on
the STV-CPP. This guideline is applicable to developments in STV-CPP.
2. SCOPE
This guideline applies to the Crane System on the STV-CPP which will be used to install,
operate and maintain the system.
3. REFERENCES
Vendor Manual:
Refer to the latest revision of the SEATRAX O&M Crane System Manual, Drawings:
Refer to the latest revisions of the following P&ID:
Document/Drawing Number Document/Drawing Title

PFDs
Control Drawings
R2837-004015-D8-0001 Pneumatic Schematic
R2837-004015-D13-0001 Electrical Single Line Diagram
R2837-004015-D16-0001 Electrical Schematic
R2837-004015-D37-0001 Hydraulic Schematic
Process Calculations
Control System Documents

2004-4098-1L-0001 Platform Crane Specification
R2837-004015-T1-0001 Crane O&M Manual
Datasheets
2004-4098-1M-0001 Pedestal Crane ZZZ-9800 A/B
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4. DEFINITIONS
FCS Facility Control System

CCTV Closed Circuit Television
PTT Press To Talk
5. SAFETY AND / OR ENVIRONMENTAL REQUIREMENTS

Components on any machine are subject to wear, deterioration, or damage, which limit
their useful life. When new, all parts have built-in reserve strength against unknown
conditions and reasonable loss of strength due to gradual deterioration. However, if
maintenance and lubrication are neglected, these parts can eventually reach a condition
where they become a safety hazard. Failure to maintain correct adjustments of the various
mechanisms to assure proper performance of the crane can also be a safety hazard.
Hydraulic relief valve settings should never exceed specified pressure without the consent
of the manufacturer. Re-adjustment, when necessary, should be performed by a competent
and qualified person. Since the manufacturer has no direct control over field inspection and
maintenance, safety in this area is the responsibility of the user and his operating personnel.
6. GUIDELINE
6.1 RESPONSIBILITIES
The E/I Supervisor is responsible for the correct implementation of this procedure.
6.2 GENERAL
Two (2) units of Diesel Engine Driven Hydraulically Operated Pedestal Crane Assembly
are installed
on STV-CPP
The following shall be the minimum Scope of Supply for each crane assembly:
 Diesel Engine Driven Hydraulic Power Packs and Hydraulic System, complete with
Air starting system, back-up hydraulic start system, gearbox, pumps, reservoir,
filtration, relief valves and all ancillaries
 Lifting and Luffing System Hydraulically Operated Winch Assembly, Wire Rope,
Load Blocks, Brakes, etc.
 Crane Swing System complete with all necessary Drive and Braking Facility
 Boom Flood Light System, Cabin and Machinery compartment lighting, etc.
 Aviation Warning Light System meeting CAP 437 / ICAO requirement
 Illuminated Wind Sock, mounted on Crane Structure conforming to Certifying
Authority Regulations.
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 Lightning Protection System

 Anti-two block system
 Emergency Load Lowering System for Main Load Line
 Emergency Load Lowering System for the Fast Line (Auxiliary Line)
 Emergency Slewing System
 Crane Safety Systems, which shall include Gross Overload Protection System, Safe
Load/Moment Indication System, Emergency Stops, MIPEG OLM system for Slew
limits (No Go area), Limit Switches together with Alarms and Automatic Cut-outs
for Travel of Hoist, Boom, etc.
 Insulation for Personnel Protection on the Diesel Engine
 Boom tip CCTV
6.3 CRANE OPRATING INSTRUCTION
Primary Motion Controls

 This crane is equipped with low pressure, hydraulic remote Control Levers
(Joysticks) mounted in the armrests of the Operator’s chair.
 These controllers are spring loaded to the neutral (center) position and provide
independent, proportional, infinitely variable speed control for all of the primary
crane motions.
 When performing simultaneous operations involving two or more of the primary
motions, the diesel engine should be operated at a constant speed between 1,800
and 2,200 rpm. Individual joysticks should be used to independently control the
speed of the various crane motions.
 The “Left Hand” controller is a dual axis “Joystick” and controls the Swing (slew)
and Boom Hoist (luff) motions.
 The “Right Hand” controller has two independent single axis “Joysticks.” The
inside Control Lever controls the Auxiliary Hoist. The outside Control Lever
controls the Main Hoist.
Swing (slew) Motion

 The Left Hand Joystick is moved to the left of center to “Swing Left”
(counterclockwise), or moved to the right of center to “Swing Right” (clockwise).
 Speed of rotation is proportional to the amount of Control Lever movement from
the center position.
 Start and stop swing motion as slowly and smoothly as possible to avoid possible
damage to equipment or injury to personnel from a wildly swinging load.
 The crane is free to swing or drift when the joystick is in the center position,
provided the swing brake pedal, free slew valve is activated and swing lock lever
are not engaged.
Boom Hoist (Luff) Motion
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 The Left Hand Joystick is “pulled” back to Raise the Boom (reduce the radius) or
“pushed” forward to Lower the Boom (increase the radius).
 Boom Hoist motion is always under the control of the hydraulic system and cannot
overrun or freewheel in the lowering mode.
 The speed of movement, in both directions, is proportional to the engine speed and
amount of Control Lever movement from the center position.
 The Boom Hoist brake(s) automatically set and lock the boom in position when the
Control Lever is centered.
 Simultaneous operation of both above motions is accomplished by moving the left
hand joystick diagonally. Speed of operation of both motions is independently
proportional to the displacement of the Control Lever from the center position. For
example, it is possible to raise the boom at maximum speed while the crane swings
very slowly to the left.
Main and Auxiliary Hoist Motions

 The appropriate Right Hand Joystick is “pulled” back to Raise the Main or Whip
Line (take in cable) or “pushed” forward to Lower the Main or Whip Line (pay out
cable).
 Hoist motion is always under the control of the hydraulic system and cannot
overrun or freewheel in the lowering mode.
 The speed of movement, in both directions, is directly proportional to the amount
of Control Lever movement from the center position.
 Hoist brakes automatically set and lock Drums when the joysticks are centered. In
case of a mechanical failure, releasing the controls will set the brakes and stop
drum rotation.
Swing (slew) Brake(s)

 Dynamic braking is accomplished by “Cross Controlling” the Left Hand Joystick.
For example; if the crane is swinging to the left at high speed and the joystick is
then centered, the crane will continue to “coast” to the left. Moving the joystick
away from center to the right will apply a ‘braking torque’ to the crane motion,
hence stopping rotation more quickly.
 The crane and its associated Swing System machinery are protected from damage
during this operation by means of a torque limiting hydraulic valves. These valves
will limit the amount of swing torque available during acceleration and
deceleration of the crane. However, it is strongly recommended that swing motion
should start and stop as slowly and smoothly as possible to avoid possible damage
to equipment or injury to personnel from a wildly swinging load.
 The crane and load can be held in position against the wind by means of the Foot
Pedal Brake (if equipped) or centering of the joystick, when equipped with the
hydrostatic drive. “Cross controlling”, as described above, is the preferred method
for stopping rotation.
 The crane may be locked in position indefinitely by means of the Swing Lock
Brake Lever mounted in the control console. When this lever is in the “Engaged”
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position, the crane is locked against rotation. Any attempt to rotate the crane by
means of the swing control lever, while the lock is engaged, will result in the
hydraulic swing motor being stalled against the lock. This is not harmful and will
not damage any portion of the Swing Machinery.
Console Mounted Instruments and Controls

 The “Air Pressure” gauge indicates accessories.
 The “Pilot Circuit Pressure” gauge displays hydraulic pressure in the Control
Circuit.
 The “Swing Motor Pressure” gauge shows hydraulic pressure in the Swing Circuit.
 The “Boom Hoist Pressure” gauge shows hydraulic pressure in the Boom Hoist
Circuit.
 The “Load Hoist Pressure” gauge shows hydraulic pressure in the Main or
Auxiliary hoist circuit depending on which is in use.
 The “Swing Lock” Brake lever is used to engage and release the slew shaft brake.
This lever should be placed in the “engaged” position whenever the operator leaves
the cab. This lever must be placed in the “released” position to rotate the crane.
 The “Hydraulic Controls knob disables the hydraulic controls. The Hydraulic
control should be disengaged when crane operations cease to prevent accidental use
of the main/auxiliary controls and the boom/swing controls. To immobilize the
controls, simply pull up on the Hydraulic Control knob.
 The Hydraulic Gauge denotes the level of hydraulic oil in the reservoir.
 The “Fuel Gauge” shows the amount of diesel available to fuel the prime mover.
 The Upper Wiper control valve is used to start and stop the upper pneumatic
windshield wiper on the upper window (option).
 The Lower Wiper control valve is used to start and stop the lower pneumatic
windshield wiper on the main window.
 When the black “Horn” button is depressed, the horn, mounted below the cab, will
sound.
 The ‘Hyd. Oil Temp.” gauge shows temperature of the hydraulic oil in the suction
pipes.
 The “Water Temp.” gauge displays diesel engine coolant temperature.
 The “Oil Pressure” gauge shows diesel engine lubricating oil pressure.
 The Alarm Reset Control silences the diesel engine low oil pressure alarm. The
latch must be reset immediately after the engine is shut down to prevent the horn
from sounding as oil pressure subsides.
 The green Engine “Start” Button energizes the pneumatic starting motor for the
diesel engine. The button is pressed to start the engine.
 The “Tachometer” indicates diesel engine rpm.
 The “Boom Lock” is used to engage the locking pawl against the ratchet wheel of
the boom hoist drum. The pawl is engaged whenever the “T handle” is pushed in
(cable style), when the knob on the console is turned (pneumatic style) or manual
latch is activated at the hoist. The Boom Lock is designed to lock the boom hoist
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drum during maintenance and repairs to the Boom Hoist gearbox and brake
assemblies. DO NOT engage the boom lock while booming down! DO NOT use
the boom lock to test luffing pressure. Damage to the lock, gearbox, and shaft could
occur as well as damage to the boom. Injury to personnel is also possible!
 The Emergency Stop Handle shuts down intake airflow to the diesel engine turbo
charger(s), thus choking the engine. This will render all of the Primary Control
Levers inoperative and lock all Hoist Brakes. The Emergency Stop Handle should
only be used in the event of an emergency. Pull the handle to apply. Reset turbo(s)
after use.
 The Engine Stop Handle is used to stop the diesel engine. When pulled out, this
prevents fuel from flowing to the intake system properly stopping the engine and
disengaging the hydraulic controls. Return handle to its original position after
engine has stopped.
Foot Operated Secondary Controls

• The Right Side Foot Operated Throttle Pedal controls the speed of the diesel engine.
Sealrax recommends an engine speed between 1.800 and 2,200 rpm while performing
simultaneous operation of the primary crane motions.
6.4 CRANE ENGINE

6.4.1 Engine Starting
Starting the Engine
1. Place the manual stop control in the RUN position. Turn the ignition switch to the
RUN position. Advance the throttle in order to supply fuel to the engine.
2. Turn the ignition switch to the START position in order to crank the engine.
3. Allow the ignition switch to return to the RUN position as soon as the engine
starts.
4. Move the throttle to approximatoly one quarter of the engine rpm.
5. Allow the engine to idle for three to five minutes, or allow the engine to idle until
the water temperature indicator begins to rise. The engine should run at low idle
smoothly until speed is gradually increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation. Increase the rpm until the
engine speed reaches 1200 rpm. Return the engine to low idle rpm.
6. Operate the engine at low load until all systems reach operating temperature.
Check the gauges during the warm-up period.
Air Starting
For good life of the air starting motor, the air supply must be free from dirt and water.
1. Open the drain valve and close the drain valve in order to drain condensation and
oil carryover. This drain valve is located on the bottom of the air tank.
2. Check the air supply pressure. The air starting motor requires a minimum of 690
kPa (100 psi) air pressure to operate properly. The maximum air pressure must not
exceed 1550 kPa (225 psi). The normal operating air pressure will be 758 to 965
kPa (110 to 140 psi).
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3. Check the oil level in lubricator bowl (2). Keep the bowl at least half full and add
lubricant, if
necessary.
4. Press air valve (1) or press the start button for the engine in order to crank the
engine, After the engine starts, release the air valve or release the start button.
6.4.2 Engine Stopping

Emergency Stopping
NOTICE :Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use
emergency shutoff devices or controls for normal stopping procedure.
Ensure that any components for the external system that support the engine operation are
secured after the engine is stopped.
Emergency Stop Button
The emergency stop button is in the OUT position for normal engine operation. Push the
emergency stop button. The engine will not start when the button is locked. Turn the
button clockwise in order to reset.
Manual Stop Procedure
A manual shutoff shaft will override the governor control. The shaft will move the fuel
control linkage to the FUEL OFF position.
Hold the lever at the FUEL OFF position until the engine stops.
Some engines are equipped with an air shutoff. The air shutoff is located between the
aftercooler and the turbocharger. If the engine is equipped with an air shutoff lever, move
the lever to the OFF position.
Note: Individual applications will have different control systems. Ensure that the shutoff
procedures are understood. Use the following general guidelines in order to stop the
engine.
1. Reduce the engine speed (rpm) to low idle. Remove the load.
2. Increase the engine speed (rpm) to no more than one-half of the rated speed (rpm).
Perform this procedure for three to five minutes in order to cool the engine. Reduce
the engine speed (rpm) to low idle.
3. After the cool down period, turn the start switch to the OFF position
6.4.3 Battery
Battery - Replace
1. Turn the key start switch to the OFF position. Remove the key and all electrical
loads.
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2. Turn OFF the battery charger. Disconnect the charger.

3. The NEGATIVE -“ cable connects the NEGATIVE battery terminal to the ground
plane. Disconnect the cable from the NEGATIVE battery terminal.
4. The POSITIVE “+“ cable connects the POSITIVE “+“ battery terminal to the
starting motor. Disconnect the cable from the POSITIVE “÷“ battery terminal.
5. Remove the used battery.
6. Install the new battery.
7. Note: Before the cables are connected, ensure that the key start switch is OFF.
8. Connect the cable from the starting motor to the POSITIVE “÷“ battery terminal.
9. Connect the cable from the ground plane to the NEGATIVE “-“ battery terminal.
Battery Electrolyte Level Check
When the engine is not run for long periods of time or when the engine is run for short
periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent
the battery from freezing. If batteries are properly charged, ammeter reading should be
very near zero.
1. Remove the filler caps. Maintain the electrolyte level to the “FULL’ mark on the
battery.
If the addition of water is necessary, use distilled water. If distilled water is not
available use clean water that is low in minerals. Do not use artificially softened water.
2. Check the condition of the electrolyte with the 1U-7298 Coolant/Battery Tester
(°C) or the 1 U -7297 Coolant/Battery Tester (°F).
3. Keep the batteries clean.
Clean the battery case with one of the following cleaning solutions:
• A mixture of 0.1 L (0.11 qt) of baking soda and 1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the
items until the surfaces are bright or shiny. DO NOT remove material excessively.
Excessive removal of material can cause the clamps to not fit properly. Coat the
clamps and the terminals with 5N-5561 Silicone Lubricant, petroleum jelly or
MPGM grease.
Battery or Battery Cable - Disconnect
1. Turn the start switch to the OFF position. Turn the ignition switch to the OFF
position and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the battery that goes to the start switch.
Ensure that the cable cannot contact the terminal. When four 12 volt batteries are
involved, the negative side of two batteries must be disconnected
3. Tape the leads in order to help prevent accidental starting.
4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all
of the cables.
Checking Before Start-Up
Check the battery charger for proper operation. If the batteries are properly charged, the
needle of the ammeter will register near “0” (zero).
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The battery charger must not produce excessive current during start-up. Alternatively, the
charger must be automatically disconnected for start-up. If the engine has an alternator, the
charger must be automatically disconnected during start-up and during engine operation.
Charging the Battery
WARNING :Never disconnect any charging unit circuit or battery circuit cable trom the
battery when the charging unit is operated. A spark can cause an explosion from the
flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte
through the battery outlets. Injury to personnel can be the result.
Perform the following procedure to charge the battery:
1. Ensure that the charger is turned OFF
2. Adjust the voltage of the charger in order to match the voltage of the battery.
3. Connect the POSITIVE “+“ lead of the charger to the POSITIVE ‘÷“ battery
terminal Connect the NEGATIVE -“ lead of the charger to the NEGATIVE “-“
battery terminal.
4. Turn ON the battery charger.
Overcharging of Batteries
Overcharging reduces the service life of batteries. Use a battery charger that will not
overcharge the battery. DO NOT charge the battery if the meter of the battery charger is in
the RED zone.
Overcharging is indicated by the following symptoms:
• The battery is very warm to the touch.
• A strong odor of acid is present.
• The battery emits smoke or a dense vapor (gas).
Perform one of the following procedures if the battery shows symptoms of overcharging:
• Reduce the rate of charging by a significant amount. Complete the charging at the
reduced rate.
• Turn OFF the charger
6.5 ANNUCIATOR
6.5.1 Product Description
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The TTDT Annunciator System is comprised of two separate components, the Display
Head unit and Control Inputs/Outputs mounted on a Plug-In Power Supply. The TTD
product is a solid-state fault annunciator and shutdown control system designed to protect
engines, compressors and their associated equipment.
The TTD model will accept 48 sensor inputs from normally open and/or normally closed
sensors. Each of the 48 Inputs can be configured for “Shutdown” or “Alarm Only”. Any
input can be locked out by one of the two Start-Run timers, or configured as Class C, ESD
or Ignore. The annunciator provides for both closing of a fuel valve and grounding of an
ignition after a time delay.
Incorporated in the TTD annunciator’s non-volatile memory:
• Run HourslElapsed Time Meter
• Last 10 Shutdowns with associated run hours
• Last 4 Alarms with associated run hours
• Selectable RS232/RS485 serial communications
• Selectable baud rates running hours
• Running hours
Optional Features:
• Pre/Post lube timed functionality
• Tachometer w/ Overspeed and Underspeed setpoints
• No-Flow Switch Detection
6.5.2 Display Head

The Display Head displays operational and configuration data. Configuration parameters
are entered via keypad or download from MConfig software The operator interface will
accept digital inputs directly on the back of the unit. Power is provided to the Display
Head via a direct Phoenix connector or a cable connecting to a remote mounted power
supply. The display head contains the microprocessor, the Liquid Crystal Display (LCD),
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the membrane keys for configuring the sensors inputs and the sensor inpuL terminal
blocks.
The TTD liquid crystal display annunciates any fault from the sensor inputs, displays
engine speed, and elapsed time. Other features for the TTD model are: built-in Test Mode
to test the sensor circuits without shutting down, Pre-lubrication and Post-lubrication
timers, and onboard backup battery to retain the fault display after shutdown on ignition
powered units.
6.5.3 Power and Control Inputs/Outputs

The Power Input and Control Output Terminals are mounted on the Plug-in Power Supply
(PSU-2) and include an RS485/RS232 serial communication port (Modbus RTU slave) to
interface with micro-controllers. PC’S, PLC’s, and/or communication and control systems.
The serial communication provides read and write register capability and selectable Baud
rate up to 38,400 bps.
The Power Supply is reverse polarity protected and can be powered by 10-32vdc or 90-
400vdc negative ground CD ignition. The TTD is fully operable with the internal battery;
the external DC power enables communications support (Modbus slave) and turns on the
display backlight.
6.5.4 Display
The TTD annunciator features a static LCD display with backlight (external DC is
required). The operating temperature is between -40° to 85°C. The applicable Icon and
number will be displayed to clarify the display readings or alert the operator to an
operating condition.
• RUN-run mode
• RPM - screen value
• HOURS - screen value
• TYPE - channel type configuration
• LOW BATT - low battery warning (displayed if the condition exists)
• HISTORY - alarm or shutdown history
• TEST - test mode
• LUBE - pre-lubncation timer
• POSTLUBE - post-lubrication timer
• SHUTDOWN - stop mode
• ALARM - alarm(s) warning (displayed if the condition exists)
• SETPOINT - edit set-point value
• SETUP - setup menu(s)
6.6 CRANE LOAD INDICATOR SYSTEM

6.6.1 General Description of the Operation Limit Monitor
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The Operation Limit Monitor (OLM) system, utilise the same computer as the Mipeg
2000. In addition, it comprises a sensor (absolute encoder) fitted on the slew system and a
display unit in the drivers cabin.
The OLM system monitors the movement of the crane rotation and indicates the slew
position in degrees on the digital display. It will also indicate how much the crane is
allowed to turn in each direction.
An audible buzzer, inside the display unit, will sound when the crane reaches the slew
warning limit When the crane reach the slew alarm limit, the OLM system will activate an
output relay and stop the crane from turning The slew warning and slew alarm may be
cancelled by pressing the ACK button on the OLM display ancilor the ACK switch.
In addition to the standard Mipeg 2000 system, the OLM system compnses the following
main parts:
- OLM Display Unit
- Slew Sensor ( Absolute Encoder)
6.6.2 Technical Description of the main parts

MIPEG 2000 in standard version comprises the following main parts :
-Computer Cabinet
-Drivers Display Unit
-Sensors (load and boom angle)
In addition comprises the OLM the following parts:
-Aux Display
-Slew sensor (Absolute Encoder)
A- Computer Cabinet
The Computer Cabinet houses the Mipeg computer, relays and terminal rows for external
cable connection.
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
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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 cranes 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, 1 2V
• level detection circuits on logic (5V) and input (24V) power,
• power protection circuits
• fuse: 1A/250V - 5*20mm
SIP2 Card
The SIP2 card, containing extended interface logic is mounted on the top of the Master II
card. There is a ribbon cable between the cards. Power is distributed on this system bus, as
well as logic signals. Interconnections between the cards are made by the use of cord edge
jumper cables.
The SIP2 card contains the following electronics:
• parallel 10 circuits with optical isolation and converter circuits.
• analogue output circuits
• analogue input circuits
• tacho inputs
• keyboard and display interfaces
• galvanic isolated power circuits 5V, 1 5V
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.
Battery Replacement
Due to the RSI function this system has a battery to keep the RSI parameters. The battery
is located on the Master II card in the Computer Cabinet and must be unsoldered to be
replaced.
Battery type: Tadlran TL-21 50 , size 1/2 AA
Nom. voltage: 3.6 V
Nom. current: 10 microamps (when Mipeg is unpowered)
When the battery voltage goes below 3.0 V, there will be a warning, Error 10, on the
display. Press the ACK button to continue operation. Replace the battery as soon as
possible.
B- Driver’s Display Unit
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).
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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.
C- Sensors
MIPEG 2000 sensors are used to measure the following:
• Loads in the hoisting lines, main and whip
• Boom inclination relatively to horizontal plane
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)
To verify correctlundamaged 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.
Pin sensors with temperature sensor included have an extra wire for the temperature
resistor. The Ssensor and the temperature sensor use a common ground wire. The
resistance in the temperature sensor shall be approximately 2200 ohms.
The load hoist sensor(s) has to be replaced as a complete unit.
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 l2Vdc (BAR+). The Inclinometer has a typical resolution of
30-35 mV/degree boom angle. The sensor is not damaged by shorts or open circuits.
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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.
The output from the sensor can be read by means of a PTU function.
D- Mipeg Aux Display
The Mipeg OLM Dispiay is a microprocessor controlled unit, located in tne driver’s cabin.
Information is presented by use of 20 characters x 4 lines liquid crystal display. There are
four push buttons available on the display front.
The unit has a four two wire powerlsignal connection. Non,nal voltage; 24 Vdc
The display unit is sealed to IP54,
E- Slew Sensor
The slew sensor is used to measure the crane’s slew position. This absolute encoder is
mounted on the crane slew system. The encoder is connected into the Mipeg system via a
DEI (Dual Encoder Interface) module to the Master II card, connector J12.
The absolute encoder has 24 bits resolution:
• 12 bits, 4096 counts per revolution and 12 bits, 4096 revolutions.
• Totally number of counts: 16 millions.
The standard Mipeg system reads number of studs on a pulley wheel or drum. When an
encoder is used, the frequency from the encoder has to be divided by four.
I.E. the number of studs’ has to be set to 1024 * gear ratio in the system.
6.6.3 Operating Instruction
A- 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.
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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.
MIPEG 2000 Interfaces with the crane and prohibits some functions under dangerous
conditions. 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
B- Information presented on the Mipeg 2000 display
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 vanes. 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.
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.
Push Buttons on the Display :
The PUSH BUTTONS have normally the following functions:
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 tight intensity. Release the buttons between
each setting.
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 bourn radius, crane curve and operating
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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
C- 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.
D- 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/l000Lbs. * number of falls
calculated from the last zero calibration. The tare function will not change the zero
frequency in the system.
E- In formation presented on the Digital Display
The Mipeg Digital Display is a microprocessor controlled unit located in the driver’s
cabin. Information is presented by use of a 20 characters x 4 lines liquid crystal display.
The unit also incorporates four push buttons.
Information presented on the display:

Text
Bar graph The bar graph will show dots when the crane is slewirig. This line is
also used to give alarm messages.
Slew Angle Slew angle in degrees from set-up (zero point)
BoomAngle Angle of the boom
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BA_LowLim Boom angle low limit setting

Push-button
ACK Press to acknowledge alarm and to reset the system after a spurious
error
FALLS Not used. Falls selected on Mipeg 2000
TEST Press to test display and buzzer
RESET LENGTH Not used.
F- Mipeg OLM - Offline Mode
The Mipeg Digital display is also used to set up and calibrate the system. Press the TEST
button and then the ACK button within two seconds to obtain the offline function, The
four push buttons are then used according to the text on the display
Several crane parameters are required to initiate the system. The parameters are adjusted
using the FALLS button (increment value) or RESET LENGTH button (decrement value)
Keeping the FALLS or RESET buttons depressed gives increasing stepping (+/-10). Press
ACK when the required value is displayed and the next parameter will follow.
The following crane parameters have to be set:
• Zero Point -zero degrees, the midpoint of the slew
• Rotation Direction - rotation direction of the slew encoder
• Teeth Encoder - number of teeth on the encoder shaft
• Teeth Crane - number of teeth on the slew shaft (gear ratio
encoder)
• Number of Sectors - number of slew inhibit sectors (max. 10)
• Sector Left - sector limit in degrees from zero point
• Sector Right - sector limit in degrees from zero point
• Bang Low - sector low angle limit for Sector
• Bang Hgh - sector high angle limit for Sector
• Sector Load - load limit within sector limits
• Boom Angle Low Limit - minimum boom angle
• Boom Angle High Limit - maximum boom angle
• Warn Margin Slew - no. of degrees for warning prior to alarm (slew
angle)
• Warn Margin Up/Down - no. of degrees for warning prior to alarm (boom
angle)
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The computer will store all calibration data in its memory. The program is permanently
stored on integrated circuits No program or memory contents are lost due to power loss.
When slewing into the sector in a clockwise direction, the message Alarm:Slew/Boom
Warn will be displayed and the buzzer will sound. The text and the buzzer will go off if
the ACK button on the OLM display is pressed Continuing stewing, the message
Alarm:Slew CCW will be displayed on the OLM display, the buzzer will sound and the
Relay outputs Stop Boom Up & Stop Slew CW will be activated This message tells you to
move the boom to get out of the sector .
When slewing into the sector in counter-clockwise direction, the message
Alarm:Slew/Boom Warn will be displayed and the buzzer will sound The text and the
buzzer will go off if the ACK button on the OLM display is pressed. Continuing slewing,
the message Alarm:Slew CW will be displayed on the OLM display, the buzzer will sound
and the Relay outputs: Stop Boom Up & Stop Slew CCW will be activated. This message
tells you to move the boom to get out of the sector
6.6.4 Maintenance
A- Introduction
This section describes the maintenance procedures for MIPEG 2000 system. It is divided
into two parts:
- Scheduled maintenance
- Unscheduled maintenance
B- 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
Prior to Each
Verification of system operation Crane driver
shift
Check calibration of toad sensors Crane supervisor /
3 Monthly
and inchnon,eter Maintenance engineer
Check integnly of crane operation Crane supervisor 1

Inhibit relays. Maintenance engineer
Crane supervisor! Maintenance
6 Monthly Check crane curves
engineer
Crane supervisor /
As required Catibration of pulley compensation
Maintenance engineer
1. Calibration of Sensors
The sensors of Mipeg 2000 are carefully checked during instalIation 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 arid changes
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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:
- 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 y MIPEG. while the actual quantity. i.e. weight or angle, is
keyed in on the Display’s push buttons.
- 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.
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: 40-80% of full load
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%.
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
• 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.
• Make a record In the calibration protocol.
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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 Lest loads or a calibrated dynamometer to measure the test
loads.
The calibration procedure for the load hoist sensor(s) is as follows:
• Boom in/out to the radius that gives a boom angle
• Lower the empty hook to just above deck level.
• 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.
2. Checking of Crane Operation Inhibit Relays

Checking of the crane operation rihibit 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 oveiload
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 Nonoc,erational
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.
3. 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
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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 loadradius 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 loadradius
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.
C- Unscheduled Maintenance
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. If all checks are passed the full system software is
initialised and starts it’s normal execution.
Different checks arp continuously performed during normal system execution:
• Sensor data limit checks
• Processing data evaluation
• Processing time control (swatch 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.
2. Faults Indicated on Driver’s Display
Fault recognised by the Mipeg 2000 system during runtime, 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 or the cabling to the display may be
damaged both of which will display a normal error indication.
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The error code will assist the maintenance engineer in locating the fault. When fault
tracing, reference should be made Into the technical description where further details may
found
6.7 CCTV
6.7.1 Description
This system is designed to operate on a crane with a safe cab and an hazardous boom and
gives the operator a bird-eye-view of the load on the hook and the area around the load
and the hook. Extra compact cameras can be fitted optionally to also overview the winches
or other areas around the crane that are of interest.
HAZARDOUS BOOM:
The camera is put inside a pressurized, explosion-proof enclosure with oil damped
pendicular bracket and is designed to meet the rigorous requirements of explosion-proof
and dust-ignition-proof electrical equipment for installation and use in hazardous
locations.
SAFE CAB:
The other components: LCD display, junction box, keyboard, cameraswitcher and
compact cameras are industrial components, suitable to be fitted in the safe area. The
compact cameras and the cameraswitcher are waterresistant and can be put outside the cab.
The other components LCD Display, juntion box and keyboard are not waterresistant and
should be put inside the cab.
6.7.2 10” LCD Colour Uni

Type: TFT (thin film transistor) color active matrix LCD, CCFT backlight
Anti glare and hard coated 3H, 6 bit color 262.144
Size: 10,4” diagonal display, active area contains 800 x 600 pixels
(RGB dots 0.264x0.264). Wide viewing angle (H140°-V110°)
TV System: PAL CVBS video-input
Luminance: High luminance: max. 350 Cd/m2
Contrast ratio: 300:1
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Housing: High Pressure Moulded Aluminum (AISI 12D), Anodized. Rugged

finish.
Weight: 3,5 kg
Protection IP51 following DIN/IEC 529
Power input: +12...32V/DC, 20W, protection integrated on loaddump,
overvoltage, undervoltage, polarity
Oper. temp: -35°C to +70°C,temperature sensor will (de)activate the LCD
at -10°C & +65°C
Approvals: CE EMC EG/2004/104
Settings: All settings are controlled by software menu structure such as:
contrast, brightness, colour, electronic distance markers, mirror
image etc.
Software: menu contains English, German, French and Dutch languages.
Operator functions
This section describes the basic LCD monitor operation using the frontpanel buttons. all
settings made on the frontpanel can also be adjusted in the service menu.
Operator menu operation:
Press the enter button once to open the operator menu. The following keys are used to
navigate through the menus :
minus Go to the next menu option
plus Go to the previous menu option
enter Select or activate the highlighted option
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option Return to the previous menu

• Camera selection
Press the camera button once.
The camera LED will now blink, indicating that the manual camera override is active. Use
the plus and minus buttons to select the camera. It is possible to use the other controls
(brightness, contrast, etc) as long as manual camera selection is active. Press camera once
more to leave manual camera selection mode. The manual camera selection function can
be disabled in the service settings menu.
• Brightness adjustment
Press brightness once to enter brightness adjustement mode. Now use the plus and minus
buttons to select the image brightness.
The camera image settings function can be disabled in the service settings menu.
• Contrast adjustment
Press contrast once to enter contrast adjustement mode.
Now use the plus and minus buttons to select the image contrast.
Note: The camera image settings function can be disabled in the service settings menu.
• Saturation adjustment
Press brightness and contrast at the same time to enter saturation adjustement mode. Now
use the plus and minus buttons to select the imagesaturation. The camera image settings
function can be disabled in the service settings menu.
• Backlight compensation / zero-lux control
Press backlight once to enter backlight compensation / zero-lux mode. Press the plus
button to toggle backlight compensation between on and off, press the minus button to
toggle zero-lux between on and off, This option is only available when an autofocus
camera is connected to the LCD Part number ( 02065030) and when the monitor is
configured to use an autofocus camera on this input.
Standby
This option switches the LCD monitor to standby mode. Press the enter button to switch to
power on.
Info
This option shows the Orlaco LCD monitor.
6.7.2 Camera
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-Autofocus
-Zoom camera PAL 8OAFEX Hard Wired (Explosion proof)
-Model Camera 0103970 VIA
-Green led is activated when heating is on
-Red led is activated when camera receives a correct power supply
6.8 METEOROLOGICAL SYSTEM

The Meteorological System provided for this project comprises of:
• Wind monitor
• Marine wind tracker
The purpose of the Meteorological System is to monitor wind speed and direction
Wind monitor
These Wind Monitors measure horizontal wind speed and direction. Originally developed
for ocean data buoy use, they are rugged and corrosion resistant yet accurate and
lightweight.
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The main housing, nose cone, propeller, and other internal parts are injection moulded
UV- stabilised plastic. Both the propeller and vertical shafts use stainless steel precision
grade ball bearings. The bearings have light contacting Teflon seals and are filled with a
low torque wide temperature range grease to help exclude contamination and moisture. The
‘marine’ version, model 05106, is specially made for use in marine and other harsh
environments. Model 05103LM has a built-in 4-20mA line driver.
Wind Monitors can be used directly with the Wind Tracker display unit to give a
convenient immediate display of wind speed and direction.
Marine Wind Tracker
The Wind Tracker is an extremely versatile instrument, allowing a continuous display of

current and maximum wind speed in a variety of units, and the setting up of various alarm
conditions. Changes can be easily made using the readily accessible button on the front of
the unit
6.9 RADIO
6.9.1 General Information
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The STANDARD HORIZON VLH-3000 is a marine Loud Hailer that operates as a

multifunction unit. It has three modes:
• Hail/ListenBack
• Intercom
• Automatic Signauing
In the Hail/Listen-Back mode, the Loud Hailer can send amplified audio signals to a PA
horn and then listen bad for signals coming in from the PA horn.
In the Intercom mode, the Load Hailer can have private conversations with up to two
MLS-300i intercom stations.
In the Automatic Signaling mode, the Loud Hailer can send different kinds of signals used
mostly to alert nearby vessels to the presence and appcoximate position, and to indicate
the vessels status or maneuverability hmitation.
Your Loud Hailer requires 13.8 VDC (±20 %) power input The VLH-3000 maximum PA
speaker output is 30W.
6.9.2 Operation
A- Switching Power On/Off

1. Rotate the LISTEN/PWR knob clockwise to turn on the VLH-3000
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2. To turn the VLH-3000 off, turn the LISTEN/PWR knob fully counter-clockwise.
B- Hail/Listen-Back
1. Press the PA button to activate the PA horn, then select the output PA horn by
pressing the FWD, BOTH, or AFT button.
2. Adjust the LISTEN/PWR knob to approximately 10 o’clock position, if necessary
turn clockwise to increase the internal (or external speaker when connected)
speaker volume.
3. Adjust the PA knob to approximately 10 o’clock position.
4. Press the microphone PTT button then speak clearly with your mouth about one
inch (2.5 cm) from the microphone. Rotate the PA knob with the PTT button
pressed to adjust the PA horn output level The PA horn output level can be set
from 0 to 30 watts
5. Release the microphone PTT button. The PA horn will automatically act as a
microphone and the incoming audio signal will be heard from the built-in or
external VLH-3000 speaker. This is called Listen-Back.
6. Rotate the IC knob to increase or decrease the Listen-Back volume.
C- Intercom
To use the Intercom feature of the VLH-3000 optional Intercom Speaker are necessary.
The following are available from your Dealer:
• MLS-300i - Intercom Speaker with PTA (Push To Alert)
1. To activate the Intercom Speaker(s) press the following keys:
• IC1 to activate intercom Speaker 1
• 1C2 - to activate Intercom Speaker 2
2. Make sure the VLH-3000 is in the HAIL mode, and press the microphone PTT
button. Speak clearly with your mouth about one inch (25 cm) from the
microphone.
3. To use the LISTEN-BACK mode, release the microphone PTT button. The
activated Intercom Speaker will automatically act BS a microphone and the
incoming audio signal will be heard from the built-in/external VLH-3000 speaker
4. Rotate the IC knob to increase or decrease the Listen-Back volume,
5. PTA (Push To Alert) feature: If the VLH-3000 In any other mode the Intercom
Speakers can alert the VLIl-3000 by pressing the PTA button on the MLS.3001
The VLH.3000 will produce a beep to indicate a call from Intercom Station 1 of 2.
At same time, “1’ or “2” icon will blink Press the corresponding intercom key to
activate the intercom Speaker. If the calling intercom speaker is already activated,
the icon will light continuously
6. Adjust the volume of the internal/external speaker by rotating the LIS- TEN/PWR
knob.
D- Automatic Signaling
Automatic Signaling is typically transmitted through the PA horn but the VLH-3000 can
also send these signals to the intercom speaker(s)
1. Select the PA horn to be used by pressing the FWD BOTH. or AFT button
2. Press the one of the AUTOMATIC SIGNALING button to send the desired signal
to the selected PA horn:
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Procedure
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Fog Horn Signaling

UNWY (Underway) Sends one 5-second blasts ever 2 minutes
STOP Sends two 5-second blasts (separated by 2 seconds) ever 2
minutes.
SAIL Sends one 5-second blasts followed by two 1-see- arid blasts
(separated by 2 seconds) ever 2 minutes.
TOW Sends one 5—second blasts followed by three 1-second
blasts (separated by 2 seconds) ever 2 minutes.
ANCH (Anchor) Sends one 5-second rings every 1 minute.
AGND (Aground) Sends one 11-second rings every 1 minute.
Passing signals
SIREN Sends a varying pitch (yelping) tone while pressing
the microphone PTT button.
HORN Sends a passing signal while pressing the micro phone PTT
button
3. Rotate the PA knob to adjust the AF output level, The AF output level can be set
from 0 to 30 watts,
When the Fog signal or Siren and Horn signals are not transmitted to the PA horn,
turn the LISTEN/PWR knob to increase or decrease the listen back volume from,
the PA horn
4. Press the PA button to disable the Automatic Signaling feature,
6.10 AIR CONDITIONER

To start unit
If your air conditioner is installed and plugged into a properly grounded receptacle, it is
ready to operate.
Mode control
This dial allows you to select cooling at three different speeds, as well as Fan Only.
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Procedure
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Off - turns the unit off.

Hi Cool - for quick cooling.
Med Cool - to maintain a desired temperature.
Lo Cool - when demand is low.
Sleep Setting - for night time use, or when demand is low.
Fan Only - will circulate air in the room without the compressor coming on.
This setting can also be used with the EXHAUST air setting to remove stale air or smoke
from the room; or it can be used with the FRESH AIR setting to bring outside air into the
room. This is especially useful in the spring and fall when cooling may not be necessary.
The FRESH AIR and EXHAUST controls are in the upper air discharge area. The center
position of this control is the normal, or closed position, which recirculates air for
maximum performance in the cooling mode.
Temperature control
This dial is the thermostat. Turn it clockwise for cooler temperature and counterclockwise
for warmer.
Money Saver® switch
This rocker switch can be depressed to either Yes or No. The Yes position provide the
most economical operation. Both the fan and compressor will cycle on and off together,
maintaining the selected temperature at a more constant level and reducing the humidity
more efficiently. This control will only operate when the unit is in a Cool mode. in the No
position, the fan will run constantly as long as the unit is in the cooling mode.
Page 35 of 67
Procedure
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6.10 Calibration Safe Load Indicator

General information:-
This document refers to two Appendixes located in the project specific Mipeg 2000 Operation
& maintenance Manual.
Appendix G is the crane boom angle versus hook radius relationship. This is required to obtain
the correct boom angle of the crane for boom angle calibration. This document shows the
distance measured from the centre of rotation (centre of the pedestal/kingpost) to the crane
hook which is required to be measured to establish the required boom angle. If this distance is
measured out on the deck and the crane hook is lowered down to this spot, the correct boom
angle/inclination is established. This has to be done if the mechanical angle pendulum is not
fitted to the crane or cannot be trusted.
Appendix F, the Calibration Protocol Form, shows the specific indexes or addresses used for
calibration of the system:-
The boom angle sensor or Inclinometer will always use indexes 1-4.
The whip (aux) line will always use indexes 5-10 (if the crane has a whip/aux winch fitted)
The main line will always start from index 11 onwards;
The lowest combination of falls/parts of line will always use indexes 11- 16.
If the crane can be used in other falls combination, the second lowest fall combination will be
allocated to index 17- 22. The full specification will be stated in Appendix F.
The text OFF in the right hand window in the step-by-step procedure below is an indication
that the MIPEG system is switched to an OFFline mode, accepting calibration.
Page 36 of 67
Procedure
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Revision : 0
Calibration of the Mipeg Boom Angle Sensor, Inclinometer.
6.43
01
Boom out or in to a boom inclination of 30 degrees boom angle. (Refer to appendix G of the
project specific Mipeg Operation and Maintenance Manual to find the corresponding radius
for your selected crane model)
To select “offline mode”; press the TEST and CURVE buttons at the same time. This will
turn the system into offline mode to accept the calibration parameters. (Please remember the
“safe guard switch” in the computer cabinet). This switch has to be opened. The Mipeg 2000
NR operators display has above typical layout. The system will start in Index 1.
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Procedure
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6.43
01
7.85
With the boom in this position;

Index 1 is the start index/address for the boom angle sensor, the Inclinometer.
Keep the green AUX button depressed and while depressed, press the TEST button. The
output signal from the boom angle is now read automatically by the computer and displayed
in the bottom window. (New value window)
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Procedure
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7.85
01
7.85
No changes to the calibration are yet done. Press the green AUX button which “enters” the
value into the system. This is verified by the bottom window displayed value being copied to
the top window (Calibration Value Window).
Page 39 of 67
Procedure
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23.0
02
30.0
Press CURVE button once to move to the Next index, Index 2 (If the CURVE button is kept
depressed too long, the index number may scroll through 2 to index 3, 4 ….) Verify that the
Index window shows index 2. To scroll backwards to the previous index number, use the
TARE/FALLS button.
The actual boom inclination is now to be programmed in by altering the existing calibration
value to conform with the current boom inclination, ie 30 degrees. If the Calibration Value is
to be changed, use the ACK button to increase and the TEST button to decrease the value. The
value is changed in the bottom window (New value window)
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Procedure
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30.0
02
30.0
When the correct value is reached in the bottom window, confirm the value by pressing the
AUX button which enters this value into the top window (Calibration Value)
The first calibration point is now completed which has combined one output value from the
sensor to the programmed boom angle. Next required point is done as described in the next
few pages.
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Procedure
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5.03
03
Boom up to minimum radius, eg boom angle 80 degrees. (Refer to appendix G to find the
corresponding radius for your selected crane model)
Use the CURVE button to scroll to index number 3, and verify that the index window shows
3. The existing Calibration Value is displayed in the top window.
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Procedure
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5.03
03
4.34
output signal from the boom angle is now read automatically by the computer and displayed
in the bottom window. (New value window)
Page 43 of 67
Procedure
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4.34
03
4.34
the top window (Calibration Value Window)
Page 44 of 67
Procedure
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90.0
04
80.0
TARE/FALLS button.
The actual boom inclination is now to be programmed in by altering the existing calibration
value to conform to the current boom inclination, ie 80 degrees. If the Calibration Value is to
be changed, use the ACK button to increase and the TEST button to decrease the value. The
Page 45 of 67
Procedure
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80.0
04
80.0
AUX button, which enters this value into the top window (Calibration Value)
The second calibration point is now completed which has combined the output value from the
sensor to the programmed boom angle. This also completes the calibration for the Inclinometer,
the boom angle sensor.
Please go back on line (press the AUX and ACK buttons at the same time) to verify the
correct calibration by booming in/out and check against known radii. The display will show
the boom radius measured from the centre of the rotation to the crane hook in use.
Page 46 of 67
Procedure
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Calibration of the WHIP (AUX) hoist sensor:-
6.43
01
Boom out/in to the boom is at approximately 45 degrees. (Refer to appendix G of the project
specific Mipeg Operation and Maintenance Manual to find the corresponding radius for your
selected crane model)
Lower the empty hook to just above deck/ground level.
Select the Whip line Sensor system before you go offline by keeping the green AUX button
depressed and scroll through the pre-programmed alternatives, typically these are displayed as
U1, 2,4 etc where U1 is the whip line, 2 & 4 is the main line in 2 (4) falls (parts of line).
“safe guard switch” in the computer cabinet. This switch has to be opened. The Mipeg 2000
Page 47 of 67
Procedure
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450.0
05
446.8
Press CURVE button several times to move to the Next index, Index 5 (If the CURVE button
is kept depressed too long, the index number may scroll through 5 to index 6, 7 ….) Verify
that the Index window shows index 5. To scroll backwards to the previous index number, use
the TARE/FALLS button.
Index 5 is the start index/address for the whip hoist (Aux) sensor.
output signal from the whip hoist sensor is now read automatically by the computer and
displayed in the bottom window. (New value window)
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Procedure
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446.8
05
446.8
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Procedure
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0.4
06
0.0
TARE/FALLS button.
The actual load seen by the crane hook is now to be programmed by altering the existing
calibration value to conform with the current load, ie 0 as the hook is empty. If the Calibration
Value is to be changed, use the ACK button to increase and the TEST button to decrease the
value. The value is changed in the bottom window (New value window)
Page 50 of 67
Procedure
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0.0
06
0.0
sensor to the programmed load value. Next required point is done as described in the next few
pages.
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Procedure
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350.0
07
With the boom still at approx. 45 degrees, lift a known weight or pull against a strong point
on the deck using a calibrated load cell. A loading of at least 70-80% of the capacity of the
line in use is required to do a calibration.
Use the CURVE button to scroll to index number 7, and verify that the index window shows
7. The existing Calibration Value is displayed in the top window.
Page 52 of 67
Procedure
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350.0
07
385.1
Keep the green AUX button depressed and while depressed, press the TEST button. The output
signal from whip hoist sensor is now read automatically by the computer and displayed in the
bottom window. (New value window)
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Procedure
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385.1
07
385.1
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Procedure
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13300
08
10500
TARE/FALLS button.
The actual load is now to be programmed by altering the existing calibration value to conform
with the current load seen by the crane hook, eg 10500 LBS. If the Calibration Value is to be
changed, use the ACK button to increase and the TEST button to decrease the value. The
Page 55 of 67
Procedure
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10500
08
10500
AUX which enters this value into the top window (Calibration Value)
sensor to the programmed load seen by the crane hook. This also completes the calibration for
the Whip (Aux) hoist load sensor. (NOTE 1)
correct calibration by lifting known loads.
NOTE 1:- If the third “mid point calibration point” is proven to be required, please refer to the
last page of this procedure.
Page 56 of 67
Procedure
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Calibration of the MAIN hoist sensor:-
6.43
01
Boom out/in to the boom is at approximately 45 degrees. (Refer to appendix G of the project
specific Mipeg Operation and Maintenance Manual to find the corresponding radius for your
selected crane model)
Lower the empty hook to just above deck/ground level.
Select the Main hoist line Sensor system in correct number of falls/parts of line before you go
offline by keeping the green AUX button depressed and scroll through the pre-programmed
alternatives, typically these are displayed as U1, 2, 3, 4, etc where U1 is the whip line, 2, 3 &
4 is the main line in 2 (3/4) falls (parts of line).
“safe guard switch” in the computer cabinet. This switch has to be opened. The Mipeg 2000
Page 57 of 67
Procedure
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443.2
17
448.8
Press CURVE button several times to move to the index 17 (not 11 as previous guideline)
(If the CURVE button is kept depressed too long, the index number may scroll through 11 to
index 12, 13 ….) Verify that the Index window shows index 11. To scroll backwards to the
previous index number, use the TARE/FALLS button.
Index 17 (not 11 as previous guideline) is the start index/address for the main hoist
sensor. (Please refer to Appendix F in your project specific Mipeg Operation &
Maintenance Manual)
output signal from the Main hoist sensor is now read automatically by the computer and
displayed in the bottom window. (New value window)
Page 58 of 67
Procedure
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448.8
17
448.8
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Procedure
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0.2
18
0.0
Press CURVE button once to move to the Next index, Index 18 (not 12 as previous
guideline) (If the CURVE button is kept depressed too long, the index number may scroll
through 12 to index 13, 14 ….) Verify that the Index window shows index 18(not 12 as
previous guideline). To scroll backwards to the previous index number, use the TARE/FALLS
button.
The actual load seen by the crane hook is now to be programmed by altering the existing
calibration value to conform with the current load, ie 0 as the hook is empty. If the Calibration
Value is to be changed, use the ACK button to increase and the TEST button to decrease the
value. The value is changed in the bottom window (New value window)
Page 60 of 67
Procedure
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Revision : 0
0.0
18
0.0
sensor to the programmed load value. Next required point is done as described in the next few
pages.
Page 61 of 67
Procedure
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Revision : 0
367.8
19
With the boom still at approx. 45 degrees, lift a known weight or pull against a strong point
on the deck using a calibrated load cell. A loading of at least 70-80% of the capacity of the
line in use is required to do a calibration.
Use the CURVE button to scroll to index number 19(not 13 as previous guideline), and
verify that the index window shows 19 (not 13 as previous guideline). The existing
Calibration Value is displayed in the top window.
Page 62 of 67
Procedure
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367.8
19
355.8
Keep the green AUX button depressed and while depressed, press the TEST button. The output
signal from whip hoist sensor is now read automatically by the computer and displayed in the
bottom window. (New value window)
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Procedure
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355.8
19
355.8
Page 64 of 67
Procedure
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25600
20
30000
Press CURVE button once to move to the Next index, Index 20 (If the CURVE button is
kept depressed too long, the index number may scroll through 20 to index 21, 22 ….) Verify
that the Index window shows index 20. To scroll backwards to the previous index number,
use the TARE/FALLS button.
The actual load is now to be programmed by altering the existing calibration value to conform
with the current load seen by the crane hook, eg 30000 LBS. If the Calibration Value is to be
changed, use the ACK button to increase and the TEST button to decrease the value. The
Page 65 of 67
Procedure
Document No. : 2004-9000-0A-
Revision : 0
30000
20
30000
AUX button which “enters” this value into the top window (Calibration Value)
sensor to the programmed load seen by the crane hook. This also completes the calibration for
the Main hoist load sensor in the first or lowest capacity reeving . (NOTE 1)
correct calibration by lifting known loads.
If the crane can be operated in other #falls/parts of line, index numbers will be referred to in
Appendix F. Each #falls/parts of line requires a calibration. The calibration sequence is the
repeat of the above “Calibration of the Main hoist sensor” procedure, only using other index
numbers.
NOTE 1:- If the third “mid point calibration point” is proven to be required, please refer to the
last page of this procedure.
Page 66 of 67
Procedure
Document No. : 2004-9000-0A-
Revision : 0
NOTE 1:
The Mipeg load hoist sensors (Whip and Main hoist) are linear sensors. This means that only
two calibration points are required and the computer uses a straight line as a calibration
relationship. The required steps are already explained in detail in this document.
An additional calibration point, calibration point 2 or a “mid point calibration” is available. If

this is introduced, the computer “creates a best match through three points”, a curve.
If the “mid point calibration point” is to be introduced, the same procedure can be followed as
already described but the following indexes should be used:-
“Mid point” calibration or the calibration point 2
- the whip (aux) line:
Index 9 is the “read output” index from the sensor when the whip line is selected and a “mid
range load” is lifted by the hook. The load value lifted is entered into index 10.
- the main line:
Index 15 is the “read output” index from the sensor when the main line is selected and a “mid
range load” is lifted by the hook. The load value lifted is entered into index 16.
If other combinations on the Main line is used, the used mid point indexes will be 21&22 /
27&28 etc. Please refer to appendix F for the project specific details.
If the mid point or calibration point 2 is to be deleted, the content of the two indexes should
be put to zero by using the ACK or TEST buttons to increase/decrease the values to zero and
enter these into the system.
Page 67 of 67

2004 9000 0A 0740 - CPP Crane Maintenance Guideline - Rev1

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STV COMPETENCY TRAINING

CRANE MAINTENANCE GUIDELINE

0 APPROVED 4/2008 DWG

Rev. Description Date Prepared Checked Approved

5 SAFETY AND / OR ENVIRONMENTAL REQUIREMENTS............................

Document/Drawing Number Document/Drawing Title

Control System Documents

FCS Facility Control System

5. SAFETY AND / OR ENVIRONMENTAL REQUIREMENTS

 Lightning Protection System

6.3 CRANE OPRATING INSTRUCTION

Primary Motion Controls

Swing (slew) Motion

Boom Hoist (Luff) Motion

Main and Auxiliary Hoist Motions

Swing (slew) Brake(s)

Console Mounted Instruments and Controls

Foot Operated Secondary Controls

6.4 CRANE ENGINE

6.4.2 Engine Stopping

2. Turn OFF the battery charger. Disconnect the charger.

6.5.2 Display Head

6.5.3 Power and Control Inputs/Outputs

6.6 CRANE LOAD INDICATOR SYSTEM

6.6.2 Technical Description of the main parts

Information to be visualised on the display is transmitted from the computer on a serial

6.6.3 Operating Instruction

A- Brief Description of MIPEG 2000 Operation

Information presented on the display:

BA_LowLim Boom angle low limit setting

Calibration of Load Hoist Sensors:

2. Checking of Crane Operation Inhibit Relays

6.7.2 10” LCD Colour Uni

Housing: High Pressure Moulded Aluminum (AISI 12D), Anodized. Rugged

option Return to the previous menu

6.8 METEOROLOGICAL SYSTEM

The Wind Tracker is an extremely versatile instrument, allowing a continuous display of

The STANDARD HORIZON VLH-3000 is a marine Loud Hailer that operates as a

A- Switching Power On/Off

Fog Horn Signaling

6.10 AIR CONDITIONER

Off - turns the unit off.

6.10 Calibration Safe Load Indicator

Calibration of the Mipeg Boom Angle Sensor, Inclinometer.

With the boom in this position;

Calibration of the WHIP (AUX) hoist sensor:-

Lower the empty hook to just above deck/ground level.

Calibration of the MAIN hoist sensor:-

Lower the empty hook to just above deck/ground level.

An additional calibration point, calibration point 2 or a “mid point calibration” is available. If

“Mid point” calibration or the calibration point 2

- the whip (aux) line:

- the main line:

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