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Leslie L Moyo
______________________________________________________________________________________________
Leslie L Moyo
(061140947)
DECLARATION
I Leslie L Moyo confirm that this work submitted for assessment is my own and is
expressed in my own words. Any uses made within it of the works of other authors in
any form (e.g. ideas, equations, figures, text, tables, programmes) are properly
acknowledged at the point of their use. A full list of the references employed has been
included.
Signed: .
Date: 28-Jul-09
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Table of Contents
Contents
Table of Contents __________________________________________________iii
List of Tables _____________________________________________________iv
List of Figures _____________________________________________________iv
Acknowledgements _________________________________________________ v
Abstract __________________________________________________________vi
Glossary of Terms _________________________________________________ vii
Nomenclature ____________________________________________________viii
Project Planning Documents __________________________________________ix
Chapter 1 Introduction_____________________________________________ 1
Chapter 2 Literature review: Design Requirements for Offshore Hoist Drums _ 3
Chapter 3 Hoist Drum Structural Strength Requirements _________________ 23
Chapter 4 Case Study: Auxiliary Hoist Drum on Ruston Bucyrus Crane _____ 32
Chapter 5 Probability of Failure of Hoist Drum ________________________ 41
Chapter 6 Discussion of Results ____________________________________ 65
Chapter 7 Conclusions and Recommendations _________________________ 67
Chapter 8 Suggestions for future work _______________________________ 68
References _______________________________________________________ 71
Appendices ______________________________________________________ 73
Appendix A: MIPEG Rated Capacity Indicators _________________________ 74
Appendix B: MIPEG Data from Ruston Bucyrus Crane ___________________ 77
Appendix C: Project GANTT Chart ___________________________________ 86
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List of Tables
Table 1 Failure Mode & Effects Analysis___________________________________ 31
Table 2 Material Properties______________________________________________ 38
Table 3 FORM Results Flange Failure ___________________________________ 58
Table 4 FORM Results Fatigue Failure ___________________________________ 60
Table 5 MIPEG Data___________________________________________________ 85
List of Figures
Figure 1 Diagram showing rope forces on flange for Method 1 (3) ________________ 5
Figure 2 Diagram showing rope forces for Method 2 (3) ________________________ 6
Figure 3 Relationship between P & P (3) ___________________________________ 7
Figure 4 Load Cell Positions on Drum Flange (2) _____________________________ 9
Figure 5 Flange Design Curves (2) ________________________________________ 10
Figure 6 Variation of Flange Force with Number of layers (3) __________________ 11
Figure 7 Asymmetric Deformation of Drum Flange (13)_______________________ 12
Figure 8 T-joint _______________________________________________________ 14
Figure 9 Hoist Drum Requirements according to API 2C (23) __________________ 19
Figure 10 Drum Forces _________________________________________________ 24
Figure 11 Drum Forces _________________________________________________ 25
Figure 12 Flange Loading (33) ___________________________________________ 28
Figure 13 Schematic of the Ruston Bucyrus Crane (34)________________________ 33
Figure 14 Failed Original Drum (34) ______________________________________ 34
Figure 15 Close-up of Failed Flange on Original Drum (34) ____________________ 35
Figure 16 Failed Replacement Drum (34) __________________________________ 36
Figure 17 Close-up of Failed Flange on Replacement Drum (34) ________________ 37
Figure 18 Schematic of Proposed Replacement Drum (34) _____________________ 38
Figure 19 Visual Basic Subroutine for the Monte Carlo Simulation of Flange Failure 63
Figure 20 Results of Monte Carlo Simulation for Flange Failure ________________ 63
Figure 21 Visual Basic Subroutine for the Monte Carlo Simulation of Fatigue Failure 64
Figure 22 Results of Monte Carlo Simulation of Fatigue Failure_________________ 64
Figure 23 Calculation of Flange Force using Roark (33) _______________________ 70
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Acknowledgements
I wish to thank Dr Dimitry Val for his assistance and guidance during this project. I
would also like to thank Dr Phil Clark for his kind assistance and guidance in selecting
an appropriate project. I would also like to thank Lloyd's Register staff in Aberdeen,
namely Mr Manoj Tripathi, Mr Peter Davies and Mr Rubik Allhaverdi for their
assistance in researching some parts of this document. I am also grateful to Mr Ian
Cumming of Specialist Maintenance Services for his assistance in obtaining information
about the hoist drum failures considered in this project. I would like to dedicate this
project to my darling Anna without whose support this project would never have been
completed.
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Abstract
Most hoist drums consist of a drum to wind the rope and where a number of layers are
required, end plates (flanges) are fitted. Whilst the effects of rope pressure on the drum
itself are well researched and understood, the effect of flange forces in hoist drums is
constantly underestimated resulting in the catastrophic failure of the drum. In addition
flanges are also sometimes subjected to forces from band brakes, clutches or both.
These additional forces further complicate hoist drum design, and clear guidance on
how the drum flange is to be designed is not readily available. The difficulty lies in
determining the magnitude and pattern of loading of the drum flange. Once the flange
force has been determined, the stresses can be evaluated.
From the research undertaken during this project, it was found that the magnitude of the
flange force varies significantly depending on various hoist characteristics such as rope
type, drum grooving, rope tension, number of layers and the fleet angle. It was also
found that despite significant research and experiments undertaken on the subject, the
findings are yet to be incorporated into most design standards. It appears that even
though hoist drum design is a complex subject, it is considered trivial by most design
standards. Most design codes and standards do not even specify any requirements for
the drum flange, leaving the designer to decide the best way to proceed based on their
knowledge and experience.
This project looks at the requirements for the design of hoist drums from various design
codes and carries out a literature review on the subject. A case study is considered
where the hoist drum flange failed twice due to poor design, and the reliability of the
proposed replacement drum is evaluated. The reliability of the hoist drum is calculated
based on the probability of failure of a proposed replacement drum using various
methods.
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Glossary of Terms
Fleet Angle Angle at which the rope approaches the drum to the drum centre
line
Langs Lay The rope is constructed such that the direction of twist of the
wires in the strand is in the same direction to that of the strands in
the rope.
LeBus Winding system on the drum
Ordinary Lay The rope is constructed such that the direction of twist of the
wires in the strand is opposite to that of the strands in the rope.
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Nomenclature
DNV Det Norske Veritas
FC Fibre Core
FEM Federation Europeenne de la Manutention
IWRC Independent Wire Rope Core
OEM Original Equipment Manufacturer
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Chapter 1 Introduction
1.1 General
Crane safety is of critical importance today, especially if the HSE are going to achieve
their target of reducing lifting equipment related accidents by 10% by 2012 in the North
Sea(BAE Systems, 2002). The integrity of individual crane elements therefore is critical
as it affects the overall crane safety. Crane design criteria will determine the likelihood
of crane failure and crane approval standards are central in determining the reliability of
the crane and by extension, its mechanisms. There are a number of Standards and
Design Rules for Offshore Cranes with differing requirements. In general, however,
they all leave the determination of the drum strength to good engineering practise.
Hoist drums are single line components whose failure will result in the failure of the
hoisting system. This project looks at the various methods used in industry to determine
hoist drum strength along with the design equations for each failure mode and where
possible the probability of failure associated with each method is calculated. A case
study of the failure of two auxiliary hoist drums of an MK35 AD Ruston Bucyrus
Pedestal Crane is used as an example.
1.2 Scope
A typical hoisting system consists of various components that include the mounting
frame, bolts, shafts, bearings, the drum, the hoist rope, the drive system that will include
a motor (usually hydraulic) and may include a gearing system and the braking system.
This research is limited to the hoist drum which is essentially a component of the
hoisting system.
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1.3 Aims
To assess the different methods used to determine the structural strength of a hoist drum
and establish how the effect of flange forces is considered in hoist drum design. Based
on a Case Study, the probability of failure associated with the effect of the flange forces
will then be determined using various methods. This is then used as an indicator of the
criticality of considering flange forces during hoist drum design.
1.4 Objectives
To achieve the above aims, the following objectives were set;
Review of crane hoist design standards mainly FEM, BS2573, API2C, AS1418,
DNV and Lloyds Register Code of Lifting Appliances in a Marine
Environment.
Literature review on hoist drum design.
Outline of hoist drum design criteria in use.
Strength analysis of hoist drum using a selected method.
Determine the structural reliability of a hoist drum by calculating the design
probability of failure using various methods.
1.5 Method
A literature review on the subject of hoist drum flange forces is undertaken. The
requirements to design a hoist drum flange from various design codes available are then
outlined and a method selected from the most comprehensive design code. The hoist
drum strength is then assessed based on the selected code and MIPEG data for an
auxiliary hoist drum is then used to calculate the probability of failure of the drum
which is used as an indicator of the hoist drum reliability.
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1. High rope tensions causing the internal compressive hoop stress in the drum
barrel to exceed the ultimate limit strength of the drum material.
2. The pressure on the wound rope on the drum flanges causes a high stress
concentration at the root or fillet of the flanges. This causes the flange to part
from the drum barrel.
As stated previously, the first mode of failure does not present a novel problem as the
methods for calculating the strength are well researched and understood. It is generally
accepted that the second mode of failure is not well understood. A number of studies
have found that hoist drums failed as a result of poorly designed drums due to a lack of
understanding of the effects of the rope pressure on the flange(Bellamy NW, 1969).
Additionally, as the drum and flange is a single unit, failure of the drum will in some
cases affect the flange as well. An instance has been recorded where the drum hoop
stress exceeded the yield stress at the centre of the drum causing the flanges to deflect
inwards. One of the flanges was geared and the deflection caused the gear teeth to
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The literature review looks at published material relating to the strength of drum flanges
as well as design standards that are currently in use. The most common design standards
are;
1. Federation Europeenne de la Manutention commonly referred to as FEM
2. BS2573
3. API2C
4. AS1418
5. Lloyd's Register Code of Lifting Appliances in a Marine Environment
6. DNV Rules for Certification of Lifting Appliances
Waters reported that flange thickness was a function of rope tension and the depth of the
winding. Using two methods, he derived formulae to calculate the total pressure acting
on the flange of a grooved drum with a given initial tension and depth. Two other
formulae were then deduced, which related total pressure to the flange thickness and the
maximum allowable tensile and shearing stress in the material. The second formula
presented by Waters took into account the effect of friction between adjacent layers of
rope and between the rope and drum, as well as the flattening of the rope coils which
relieves the rope of some of the tension and resulting in a reduction in the pressure
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Figure 1 Diagram showing rope forces on flange for Method 1(Waters, 1920)
lb
Where;
N Total axial thrust
m No. of layers
P Rope tension
Angle as shown in the Figure above
He found this formula to give excessive values of the flange thrust as it did not take into
account rope friction, reduction in rope tension due to rope compression and the cross-
over of the rope.
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lb
Where;
N Total axial thrust
p No. of coils between a and b
coefficient of friction between rope layers
Angle as shown in the Figure above
P Rope tension in coil
P Tension loss in coil
The relationship between P and P is given in the table below;
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He found that the two equations gave significantly different results particularly for a
large number of layers. To simplify the formulae he derived, Waters made the following
assumptions;
The shear at the surface of the flange is zero,
The slope of the deflected flange is zero at the shoulder (i.e. a rigid connection
between the flange and the drum),
The deflection of the flange at the edge is maximum,
The flange is of constant thickness.
He then considered the flange as a short cantilever beam with a depth equal to the flange
thickness and a length equal to the circumference at the surface of the drum. The
cantilever is loaded with a uniformly distributed load N (Flange axial thrust). Other
loads, such as brake or clutch forces may also be included. The maximum radial stress
(tension or compression) which acts at the shoulder of the flange is then given by;
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lb/in2
Where and;
ri Drum outer radius
ro Outer rope layer radius
ti Flange thickness
N Flange thrust as calculated
lb/in2
From the experiments he carried out, Waters found that flange pressure increased in
direct ratio to the number of layers (i.e. a straight line relationship), contrary to the
formulae he had presented. He accounted for this by pointing out that the formulae took
into account several variables that may not have been present in the experiment.
In 1957, Dolan(Dolan, 1957) carried out experiments similar to those carried out by
Waters and he demonstrated that the approach proposed by Waters results in too thin a
shell. Dolan presented a second paper(Dolan, 1963) where he investigated various drum
failures and proposed formulae to be used to determine the strength of the drum for
design purposes. In 1958, Egawa & Taneda(Egawa, et al., 1958) also presented a paper
with experimental backing on the determination of flange forces. However, their work
as was the work of Dolan, Broughton(Broughton, 1928, Revised 1948) and
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Torrance(Torrance, 1965) was largely concerned with stresses in drum barrels and did
not present significant findings on flange forces.
In 1966, Atkinson & Taylor(Atkinson LTJ, 1966) also presented a series of papers on
the analysis and design of fabricated drums for mine winders. They found that a number
of drums designed using Waters approach had failed. They also found that some drums
which theoretically would have failed under Dolans criteria were still operational and
drums which were well below the design limit had failed. They presented a number of
formulae to determine the drum strength taking into account dynamic effects of the rope
under load(Atkinson LTJ, 1967).
Further Research
In 1968, Bellamy& Philips(Bellamy NW, 1969) also carried out a series of experiments
based on Waters experiments to investigate the forces acting on a winch drum during
multi-layered rope winding. They considered the effects of rope construction, rope
tension and the spooling arrangement. Four different types of rope were used and the
test drum was of welded construction made from mild steel and had load cells placed in
the flange to measure exact pressures. The load cells were positioned as shown below;
For an identical rope tension, different types of rope constructions were found to exert
significantly different forces on the flange. For example, the force exerted by an 18 x 7
Fibre Core Langs lay rope was more than twice that of a 6 x 37 Independent Wire Rope
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Core rope with all other parameters constant. When the results were processed to give
graphs of average pressure exerted by rope on the flange, it was noted that the average
pressure on the flange became constant with an approximately uniform distribution after
a few layers. However, the 18 x 7 Fibre Core Langs lay rope had a higher flange
pressure. Ropes with an independent wire rope core were found to present lower flange
forces and fillet strains. From their findings, they presented a series of design curves as
shown below;
Where;
Rope A Type 6 x 37 Fibre Core, Langs Lay
Rope B Type 6 x 37 Independent Wire Rope Core, Langs Lay
Rope C Type 18 x 7 Fibre Core Ordinary Lay
Rope D Type 18 x 7 Fibre Core, Langs Lay
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They stated that they found it impossible to present an empirical formula for the failure
of drum flanges due to the diverse forms of flanges in existence. They also found that
flange forces were mainly dependent on three main variables;
a) Type of rope construction,
b) Rope tension,
c) Type of spooling.
Other factors they found to be important included rope size, rope lubrication, LeBus
spacing, drum grooving, settling time and variable rope tensions. The curves presented
in Figure 5 above are applicable for the rope constructions specified. To use the curves,
the rope winding stress is calculated from the rope tension and cross-section; then the
flange pressure is obtained for the particular type of rope construction and spooling. A
graph showing the variation of flange pressure with the number of layers is given
below;
In 1979; Song, Rao & Childers(Song, et al., 1979) investigated winch drum design in
mooring applications offshore. The drums are generally larger than the hoist drum
found on cranes for instance, as mooring applications generally require ropes of larger
diameter (up to 89mm diameter rope was found, normal hoisting applications on
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average require diameters up to 20mm). They found that flange splitting was the most
common structural failure in the large wire rope mooring winch drums. One of the
reasons they gave for the failures was that designers were using formulae derived for
use with smaller hoist drums. Their study is of interest as it shows that hoist drum
design is a complex area that is affected by a number of variables.
Recent Research
The University of Clausthal in Germany has also done a significant amount of work
under the leadership of Dr Peter Dietz(Dietz, 1972), who presented the principle that
tension reduction occurs due to the flattening of the wire and the radial deflection of the
layer on which the successive layers are wrapped. In 2002, Otto, Mupende &
Dietz(Otto, et al., 2002) using experimental methods and Finite Element Analysis found
that LeBus spooling resulted in asymmetric pressure distribution over the flange.
Conventional methods for determining the strength of a drum flange have assumed a
symmetric load distribution. The effect of this is shown in the picture of a failed drum
shown below;
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2.3.1 Bolting
It is essential that the loading on the flange is modelled correctly so that the required
strength of the bolts can be determined accurately. The maximum force that a bolt is
capable of supporting is basically given by the product of the bolts yield or ultimate
stress and the bolts stress area. The bolts stress area is dependent on the thread pitch
diameter. It is commonly accepted that a minimum Grade of 8.8 for the bolt according
to ISO 898/1 will be used for structural purposes. Black bolts (i.e. bolts of a Grade
below 8.8) are normally not accepted for structural purposes.
Where a bolt is supporting a flange, the point of application of the force is not normally
coincident with the location of the bolts. This is because the force on the flange due to
rope pressure is considered to be a uniformly distributed load as described by Waters,
and the bolts are usually fitted around the drums circumference. This will therefore
give rise to a moment that will tend pry the flange from the barrel.
Fatigue is also significant in this case as the loading will be cyclic i.e. the load will vary
as the rope is wound and unwound onto the drum.
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2.3.2 Welding
A welded drum-flange structure, however intricate its shape, is usually composed from
a number of fundamental joint types. Since in most circumstances, the flange and the
drum are at right angles to each other, they are normally joined using a T-joint as shown
below (Hicks, 1999);
Figure 8 T-joint
The basic strength of a butt weld is normally taken as equal to that of the parent
material. A perfect butt weld joint, when subjected to an external force, provides a
distribution of stress throughout its volume which is not significantly greater than that
within the parent metal. This is achieved as long as the following features apply(Oberg,
2008):
Welds should consist of solid metal throughout a cross section at least equal to
that of the parent metal.
All parts of a weld should be fully fused to the parent metal.
Welds should have smoothly blended surfaces.
If any of these requirements are not fulfilled then the weld is imperfect and the stress
distribution through the joint is disrupted.
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resulting from the eccentricity of the weld metal relative to the parts joined or from
secondary moments. A partial-penetration weld welded from one side only shall not be
subjected to any loading that would cause the root of the weld to be in tension if failure
due to such tension would be liable to be progressive and to lead to structural collapse
unless it can be demonstrated that proper attention has been paid to the detailed design
of the joint and testing and operational experience has shown this detail to be
satisfactory. Partial penetration welds have a weld root which acts as a stress
concentration point(Maddox, 1969). Based on this, full penetration welds are therefore
recommended for drum-flange joints.
The weld strength in the case of a partial penetration weld is given by the length of the
weld multiplied by the weld throat. The throat thickness of a partial-penetration butt
weld welded from one side only shall be taken as the depth of penetration and the
adverse effect of the eccentricity of the weld metal relative to the parts joined shall also
be allowed for when calculating the strength.
Several methods have been proposed to mitigate the failure of welded members due to
fatigue. One such approach is ultrasonic peening(Jinu, et al., 2009), which was found to
increase fatigue life by up to 35% at 250 Mpa of applied stress.
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Basis of Design
The design of power operated mechanisms is based on the following;
1. Strength basis.
2. Life basis based on wear or fatigue (finite or infinite).
Details of the structural strength requirements according to AS1418 are covered in the
next section as they are quite detailed. The calculation of stresses is based on the
approach by Dr Helmut Ernst and Peter Dietz who published detailed papers on the
strength of crane hoist drums. The standard has comprehensive requirements for the
drum barrel but has limited requirements relating directly to the drum flange.
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Basis of Design
The drum is required to provide a minimum first layer rope pitch of 18 times the
nominal rope diameter. This is more onerous than the requirements of FEM and
BS2573-2 where the requirement is 16 times.
API 2C also requires that the flange extend a minimum distance of 2.5 times the wire
rope diameter over the top layer of the rope unless an additional means of keeping the
rope on the drum is provided e.g. keeper plates, rope guards or kicker rings. A minimum
of 5 wraps of the rope are also required to remain on the drum in the operating
condition. This would prevent the rope anchor failure as cases have been documented
where the rope has detached from the rope anchor(Piskoty, et al., 2009). The standard
does not specify particular requirements relating to the drum flange and leaves it to the
designer.
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In addition, the maximum rope tension is considered taking into account dynamic
loading conditions, friction effects and any environmental effects as well as the stalling
force corresponding to the maximum line load attainable due to an overload condition
such as may occur in the event of snagging of the lifting hook or attached load.
The capacity of the drum should normally be designed to accommodate the rope on a
maximum of three layers of rope. Where a greater number of rope layers are required,
suitable spooling arrangements are to be provided. A single layer of rope is acceptable
provided the rope ends are adequately secured to anchor points. A minimum of three
complete turns of rope is to remain on the rope drum at all times during normal
operation. This is less than the API 2C requirement of a minimum of 5 turns of rope.
There are no specific requirements for the drum flange in the code.
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The drum barrel is to be designed to withstand the surface pressure acting on it due to
the maximum number of windings with the rope spooled under maximum uniform rope
tension. The DNV Code also requires that drums are checked with respect to their
overall equilibrium situation and beam action, with the maximum rope tension acting in
the most unfavourable position. The effect of the support forces, overall bending, shear
and torsion is to be considered at the maximum rope tension including any amplification
factors. However, if more unfavourable the situation with forces directly dependent on
motor or brake action is to be considered. The structural requirements for hoist drums
according to DNV are outlined in the next section. There is evidence that DNV Rules
are likely to be revised in future to include methods for estimating target
reliability(Ruud, et al., 2007). The code states that the pressure acting on the flange
varies linearly from zero at the outer layer to a maximum near the barrel surface. A
formula is given to determine the magnitude of the flange pressure.
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2.5 Conclusion
It is clear from the literature review that methods for determining drum barrel strength
are readily available and the mechanism of failure is well understood. Research also
indicates that flange failure is the most common mode of drum failure and as a result
the reliability of the hoist drum will be based on an assessment of the flanges structural
strength.
It can be seen from the literature review that the most comprehensive standard is the
DNV Rules for Lifting Equipment when it comes to hoist drum design. The code
considers the effects of flange forces, and outlines formulae to be used. The evaluation
of the drum flange structural strength will therefore be based on the DNV approach.
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CS
hoop =
p t av
where;
C- amplification factor (1.75 for more than one layer).
S- rope tension under spooling
P- pitch of rope grooving
tav - average drum thickness
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Pr
hoop =
t
where;
P- external pressure
r- radius of drum
t- drum shell thickness
The line tension F gives rise to the external pressure acting on the drum shell and can be
expressed as;
F = hoop b t
where;
b- width
therefore;
F
hoop =
bt
and therefore;
F
P=
r b
This method then assumes that each of the succeeding layers will add to the pressure
acting on the drum. However, the outside layers will tend to force the preceding layers
into a smaller diameter, reducing their tension and hence the pressure. Therefore, only
the effect of the outer two layers is considered;
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pT = p n + p n +1
The minimum thickness of the drum that prevents failure due to buckling is then
determined using the formula below;
E t3
p cr =
4(1 2 )r 3
Where;
Pcr - Critical Pressure acting on barrel and resulting in buckling
E - Youngs Modulus for the material (Modulus of elasticity)
t - Barrel thickness
r - Barrel inner radius
- Poissons ratio
4 Pcr (1 2 ) r 3
t min = 3
E
This method calculates the minimum required drum barrel thickness to prevent drum
buckling. As outlined above it is similar to the Lloyds Register approach. The method is
sometimes used by manufacturers to determine the minimum barrel thickness even
though it only considers failure due to buckling only.
However, from analysis, it has been found that the minimum drum barrel thickness
determined using this method is inadequate to resist the hoop stress as calculated using
the DNV Hoop Stress formula and is much less than the minimum thickness calculated
using the approach presented in the Australian Standard AS1418. This approach is
therefore to be used with caution and its limitations must be fully understood by the
designer.
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Tmin = (T 2
DB + TDB TDC + TDC
2
)
where;
TDB - is the minimum theoretical thickness of the drum shell allowing only for
the beam bending stresses given by;
M
TDB = 1250
D Fb
2
DM
TDC - is the minimum theoretical thickness of the drum shell allowing only for
the compressive stresses given by;
1000 K RL PRS
TDC =
p Fc
M- is the bending moment due to beam action of unfactored (static) rope
load (PRS)
Fb - is the permissible bending stress in MPa (67% of yield stress)
DDM - is the mean diameter of the drum shell in mm.(DDN-Tmin)
DDN - is the nominal diameter of the drum shell
KRL - is the rope layer factor and rigidity constant for the drum shell (1.6 for
more than three layers)
p- is the pitch of the rope coils
d- is the nominal diameter of the rope
Fc - is the permissible compressive stress in MPa.
PRS - is the maximum unfactored rope load in kN
It can be seen from the formulae presented above that the minimum theoretical
thickness as calculated will take into account the effect of bending, buckling and the
compressive stress.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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where;
CS
hoop =
p t av
and;
D- outer diameter of barrel
p- wire rope pitch
C,S are defined in the previous section
then;
2C S
pf =
3 p D
The maximum force on the flange is then given by the product of the pressure and the
area over which the force acts. This is the area of the flange covered by the rope layers
and is given by;
(DOuterlayer
2
D2 )
A flange =
4
C S (Douterlayer
2
D2 )
or simply; Fflange =
6 p D
The force in the flange Fflange shall not be greater than the allowable force in the flange
as determined from the allowable stress multiplied by the area of the flange covered by
the rope layers.
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Buckling,
Cracking,
Fatigue.
Elastic failure,
Cracking,
Fatigue.
Elastic failure
Elastic failure,
Cracking,
Fatigue.
The results of a Failure Mode and Effects Analysis are shown in the Table overleaf.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Description of unit Description of failure Effects of failure Failure Severity Risk Reducing
Comments
Component Failure Mode Failure Mechanism on System Function Rate Ranking Measures
Drum Flange Elastic failure Bending Dropped load High Inspection Design information, Crane
Collapse history/records, NDE inspection
records, End of life assessment
Drum Flange Excessive deflection Overload Damaged wire rope High Inspection Fatigue failure in parent metal,
Dropped load Repair weld or connection could result in
Replacement a sudden failure leading
Maintenance to collapse and dropped load/jib.
Drum flange Plastic Collapse Bending Damaged wire rope High Inspection
Dropped load Replacement
Drum flange Brittle fracture Stress concentration Damaged wire rope High Inspection
Dropped load Repair
Drum Barrel Elastic failure Bending Damaged wire rope High Inspection
Dropped load Repair
Drum Barrel Buckling Overload Damaged wire rope High Inspection
Dropped load Repair
Drum weld Elastic failure Overload Damaged wire rope High Inspection
Dropped load Repair
Drum weld Fatigue Cracking Damaged wire rope High Inspection
Dropped load Repair
Drum weld Buckling Overload Damaged wire rope High Inspection
Dropped load Repair
Drum weld Brittle fracture Stress concentration Damaged wire rope High Inspection
Dropped load Repair
Bolts Elastic failure Shearing Damaged wire rope High Inspection
Dropped load Repair
It is clear from the above analysis that a lot is left to the discretion of the designer. For instance, none of the design codes specify requirements relating to fatigue,
even though it is a significant mode of failure. In this instance, failure of a single component of the hoist drum unit is considered as failure of the whole system.
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below;
Figure 13 Schematic of the Ruston Bucyrus Crane(Specialist Maintenance Solutions, 2008)
The crane was supplied with the platform circa 1975. The crane is fitted with MIPEG
2000 (Sparrows Offshore) data instrument which monitors and records the loading data
over time (See Appendix A).
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The flange failure is shown in the picture above, and other than the part of the flange
that broke off, cracks were also observed on the flange.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The darker areas that can be observed from the picture above where the cracks would
have initiated. The mode of failure for the drum would therefore quite likely have been
fatigue, with the machined rope groove acting as a stress concentration point.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The drum flange can be observed to have parted from the drum at the top of the picture.
From the investigation, it was determined that failure occurred due to the flange bolts
shearing.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The parting of the flange from the drum resulted in significant damage to the wire rope
as can be observed from the picture above. Had the failure gone unnoticed, which is
possible as the hoist drum is positioned above the crane operators cabin, this may have
resulted in an uncontrolled lowering of the load.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The position of the hoist drum as well as the hoist drum specification is as shown
below;
Material
Properties used in making up drum are presented in Table below
Material Standard Min. Yield UTS (N/mm2)
(N/mm2)
Plate BSEN 10025 345 490
Barrel API 5LX52 345 490
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Therefore;
1.75 45126
hoop = = 115.5 N / mm2
19 36
For the barrel to be acceptable, the hoop stress has to be less than 85% of the yield
stress.
hoop = 0.85 * 345 = 293.3N / mm2
C S (Douterlayer
2
D2 )
F flange = = 1047659 N
6 p D
Where the yield stress is 345 N/mm2 and the weld area is 22368 mm2. Therefore;
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Introduction
The structural strength of the hoist drum replacement has been calculated using various
approaches in the previous section. It can be seen from the results that according to the
various code requirements, the hoist drum should be suitable for service. In this section,
the probability of failure of the hoist drum is calculated using the First Order Second
Moment Method (FOSM), the First Order Reliability Method (FORM) and the Monte
Carlo Method. The methods require a limit state function which is formulated in the
next section.
From the Case Study, it can be seen that the means of attaching the flange to the drum is
critical and this would be the area that is considered most likely to fail. The assessment
of the means of attachment also takes into consideration the strength of the barrel and
flange and the probability of failure of the means of attachment will be a good indicator
of barrel and flange strength.
Assumptions
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The Limit State function will also have a Normal Distribution with ;
G = C D and G2 = C2 + D2
where:
respectively.
G ,C , D - Standard deviation of G(x), Capability and Demand function
respectively.
and the probability of failure Pf is given by;
Pf = G
G
G
Where the value of is given in Normal Distribution Tables. is also known as the
G
Safety or Reliability Index.
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Let;
Aweld weld area given by the product of weld throat(h) and weld length (lweld)
y flange material yield stress
FAllowable allowable force in weld
The weld strength is given by the allowable force in the weld. The length of the weld is
given by the circumference of the barrel in this case and is equal to;
l weld = D
therefore;
FAllowable = h D y
If the applied force in the weld area is F, then the limit state function can be stated as;
G ( x) = h D y F
Where F is the force acting on the flange and is dependent on the pressure due to the
rope force and is given by Fflange as defined in the previous section;
C S ( Douterlayer
2
D2 )
F flange =
6 p D
C S ( Douterlayer
2
D2 )
G ( x) = h D y
6 pD
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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where;
C amplification factor (1.75 for more than one layer).
S rope tension under spooling
p pitch of rope grooving
D outer diameter of barrel
However, the expected number of cycles for the life of the hoist drum (which is taken as
25 years) is approximately 25000 (based on 1000 cycles per year). The maximum load
distribution is assumed to be Extreme Value Distribution and will be approximated by a
normal distribution. Therefore, the mean and variance for the maximum loading
throughout the life of the hoist drum is then given by;
n 25 000
And;
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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0.577216
Y = y + un + y = 21127 + 3.962 + * 8058 = 54086.4 N
n
n 4.5
2 y 2 2 * 80582
Y 2
= = = 5274459.9
6 n
2
n
6 * 4.52
Y = 2296.6 N
n
The rope tension distribution for the 25000 expected load cycles will be described as
below.
2
+ 2
= 345 = e 2
+ = ln(345) = 5.844
y therefore 2
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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And;
2
2 = e2 + 2 2 = 17.252
Therefore;
2 + 2 2 = ln(17.252 + 3452 ) = 11.69
Using the two equations obtained above, we get;
= 0.05 and = 5.842
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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This will vary with material thickness and with welding errors. In this case however it
can be considered a random variable with a Normal distribution.
Parameter Mean (mm) Coefficient of Variation
h 20 0.05
mathematical constant
For Layer 3;
G( x) = 1118.41 y h 7.289CS
For Layer 4;
G( x) = 1118.41 y h 10.166CS
For Layer 5;
G( x) = 1118.41 y h 13.267CS
For Layer 6;
G( x) = 1118.41 y h 16.59CS
For Layer 7;
G( x) = 1118.41 y h 20.138CS
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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Where n is the expected number of cycles and A and m are the material parameters and
S is the stress range.
The Limit State Function is then given by;
1
G ( x ) = Dcr E ( n ) E ( S m )
A
The expected number of cycles E(n) is 25000 as stated in the previous section. Since the
distributions are lognormal, the parameters to and s are calculated as below;
For Dcr;
1
to = = = 0.959
1 + [0.3]
2 2
1+
Therefore;
ln(to ) = 0.042
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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And;
2
s = ln 1 + = ln(1 + 0.32 ) = 0.294
For A;
1.0 E13
to = = = 8.65E12
1 + [0.58]
2 2
1+
Therefore;
ln(to ) = 29.79
And;
2
s = ln 1 + = ln(1 + 0.582 ) = 0.539
Stress Range S
Assuming the flange does not bend, the weld is primarily under a direct stress due to the
drum flange force. This stress has a minimum of zero when there is no force acting on
the flange and the maximum stress in the weld is given by;
F flange
max =
Weld _ Area
The weld area is given by the weld throat multiplied by the length of the weld. These
parameters were detailed in the previous section. Therefore;
Aweld = Dh = 22368.14mm2
The flange force (with 5 rope layers) is given by;
C S ( Douterlayer
2
D2 )
Fflange =
6 p D
Therefore;
C S ( Douterlayer
2
D2 )
max = N / mm2
6 p D h 2
The stress varies from zero (when there is no loading) to the maximum value given by
[ ]
the formula. The expected value E S m is obtained using Appendix B of the JCSS
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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2
S ( Douterlayer D2 )
max = = 32.1
C 6 p D2 h
C ( Douterlayer
2
D2 )
max = = 0.001
S 6 p D2 h
1122.7
max = 2 = 2.8
h h
2
n
2
= max E[( xi i ) 2 ] = 32.12 * 0.3632 + 0.0012 * 2296.62 + (2.8) 2 *12
i =1 xi
max
Therefore;
max
= 12.2 N / mm2
[ ] m
E S m = ( 2 max 2 ) m where m = 3 as described above, then;
2
[ ]
E S 3 = (2 *12.2 * 2 )3 *
3
where =
2 2 2
[ ]
Therefore; E S 3 = 36528.6
The Limit State Function is therefore;
1 9.1E 08
G ( x ) = Dcr E ( n ) E ( S m ) = Dcr
A A
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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2
n
G ( x )
=
2
G E[( xi i ) ]
2
i =1 xi
G
5. The Safety or Reliability Index is then calculated from .
G
6. The probability of failure is then obtained from Normal Distribution Tables.
In this case, the limit state function and the variables have been defined in the preceding
section. The calculation steps continue below with the evaluation of the mean value of
the limit state function.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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C S ( Douterlayer
2
D2 )
G ( x) = h D y
6 p D
The values for the variables are given in the table below;
Parameter Mean Value Standard Deviation
y 345 17.25
C 1.75 0.363
S 54086.4 2296.6
h 20 1
C S ( Douterlayer
2
D2 )
G = G ( ) = h D y
6 p D
Therefore;
G = 6461321.5
Next, differentiating the Limit State function with respect to each variable;
G( x)
= hD = 22368.14
y
and;
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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G ( x) C ( Douterlayer D )
2 2
= = 23.22
S 6 pD
G ( x)
= D y = 385850.4
h
And;
G ( x) S ( Douterlayer D )
2 2
= = 717535.2
C 6 pD
n 2
G ( x)
G2 =
i =1
x i
2 2 2 2 2 2 2
E[( xi i ) ] = 22368 * 17.25 + 23.22 * 2296.6 + 717535.2 * 0.363 + 385850.4^ 2 * 1^ 2
Therefore;
G = 604654.2
G 6461321 .5
= = = 10.7
G 468578.3
and the probability of failure from Normal Distribution Tables is given by;
p f = ( ) = 5.09 E 27
The hoist drum flange fillet therefore has a very low chance of failure with 5 layers
according to the FOSM method.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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1 9.1E 08
G ( x ) = Dcr E ( n ) E ( S m ) = Dcr
A A
9.1E 08
G = G ( ) = 1 = 0.9999
1.0 E13
Therefore; G = 0.9999
Next, differentiating the Limit State function with respect to each variable;
G ( x) G ( x) 9.1E 08
= 1 and; =
Dcr A A2
2 2
n
G ( x) 9.1E 08
=
2
G E[( xi i ) ] = 1 * 0.3 +
2 2 2
2
* 5.8 E12 2
i =1 xi 1E13
Therefore; G = 0.3
G 0.9999
= = = 3.333
G 0 .3
and the probability of failure from Normal Distribution Tables is given by;
p f = ( ) = 0.00043
The hoist drum therefore has 0.043% chance of failure with 5 layers from weld fatigue
according to the FOSM method.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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xi i
xi' =
i
Any variable that is not normally distributed must be converted to the equivalent
Normal variable using the Normal Tail Approximation.
3. The starting values of the standardised normal variates are selected as 0, i.e. the
origin in the standard Normal space.
4. The partial derivatives of the limit state function G(x) at the current value of x '
are calculated.
5. The direction cosines i are then calculated using the formula below;
G ( x)
'
i = xi x '*
2
G ( x)
'
i =1, n xi x '*
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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2
G ( x ' )
l =
i =1, n xi
'
x '*
= x '* i
i =1, n
9. New values of x ' are then computed using the equation below;
G( x( m) ) x '
x(' m +1) = ( m ) ( m ) + (m)
l
10. Steps 4 through to 9 are then repeated until convergence is achieved or G(x) is
equal to or close to zero.
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C S ( Douterlayer
2
D2 )
G ( x) = h D y
6 pD
G( x) = 1118.4h y 13.3CS
y C C h h S S
y' = y
, C'= , h' = and S ' =
y
C h S
Therefore;
y = 17.25 y' + 345 , C = 1.75C ' + 0.363 , h = h ' + 20 and S = 54086 .4 S ' + 2296 .6
And;
G ( x ' ) = 1118.4(345 + 17.25 y' )(20 + h' ) 13.3(54086.4 + 2296.6S ' )(1.74 + 0.363C ' )
G ( x ' )
= 1118.4 *17.25 * (20 + h' ) ,
y'
G ( x ' ) G ( x ' )
= 1118.4(345 + 17.25 y' ) = 13.3 * 2296.6 * (1.75 + 0.363C ' )
h' S '
And;
G ( x ' )
= 13.3 * 0.363 * (54086.4 + 2296.6 * S ' )
C '
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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As stated the starting point is chosen as the origin where the variables equal zero. The iterative calculations are then computed in an Excel
spreadsheet inserted below;
Variable Iteration 1 Iteration 2 Iteration 3 Iteration 4 Iteration 5 Iteration 6 Iteration 7 Iteration 8 Iteration 9
y_1 (Sig_y) 0.0000 -6.7666 -6.8635 -6.3465 -6.3960 -6.3966 -6.3971 -6.3970 -6.3970
y_2 (h) 0.0000 -6.7665 -6.8634 -6.3464 -6.3959 -6.3965 -6.3970 -6.3969 -6.3969
y_3 (C) 0.0000 4.5677 7.2801 7.2956 7.2245 7.2251 7.2241 7.2244 7.2243
y_4 (S) 0.0000 0.9350 2.7914 3.3514 3.2539 3.2468 3.2474 3.2472 3.2472
(dg(y)/dy_1) 385851.4500 255307.5271 253439.5807 263412.2840 262457.6213 262446.0075 262437.2333 262439.1574 262438.5978
(dg(y)/dy_2) 385848.0000 255304.0771 253435.5253 263407.9695 262453.2535 262441.6072 262432.8175 262434.7343 262434.1713
(dg(y)/dy_3) -260465.0312 -270806.3305 -291337.8303 -297531.3130 -296452.0163 -296374.3976 -296380.5063 -296377.9960 -296378.7261
(dg(y)/dy_4) -53318.5259 -103836.5551 -133834.9628 -134006.0374 -133219.8133 -133227.0906 -133215.3940 -133218.4711 -133217.5731
l 606996.6378 463120.0752 480885.3452 495229.5327 493352.8452 493295.7990 493286.9660 493288.3322 493287.9311
alpha_1 0.6357 0.5513 0.5270 0.5319 0.5320 0.5320 0.5320 0.5320 0.5320
alpha_2 0.6357 0.5513 0.5270 0.5319 0.5320 0.5320 0.5320 0.5320 0.5320
alpha_3 -0.4291 -0.5847 -0.6058 -0.6008 -0.6009 -0.6008 -0.6008 -0.6008 -0.6008
alpha_4 -0.0878 -0.2242 -0.2783 -0.2706 -0.2700 -0.2701 -0.2701 -0.2701 -0.2701
beta 0.0000 10.6448 12.4501 12.0422 12.0249 12.0240 12.0240 12.0240 12.0240
g(y) 6461343.5878 836078.7710 -196171.1257 -8553.5341 -424.4711 -0.9624 -0.0283 -0.0019 -0.0003
Probability of failure 5.000E-01 9.221E-27 6.984E-36 1.067E-33 1.315E-33 1.329E-33 1.329E-33 1.329E-33 1.329E-33
The probability of failure is therefore taken when the value of G(x`) approaches zero. The probability of failure with 5 rope layers according to
the FORM method is therefore very low.
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1 9.1E 08
G ( x ) = Dcr E ( n ) E ( S m ) = Dcr
A A
9.1E 08
G ( x) = Dcr
A
y A A
y' = y
and A' =
y
A
Therefore;
And;
9.1E 08
G ( x ' ) = 0.3Dcr' + 1
5.8E12 A' + 1E13
As stated the starting point is chosen as the origin where the variables equal zero. The
iterative calculations are then computed in an Excel spreadsheet inserted below;
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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The probability of failure is therefore taken when the value of G(x`) approaches zero.
The probability of failure with 5 rope layers according to the FORM method is therefore
0.043%.
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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1. Once the mean and standard deviation as well as the type of distribution of the
parameters have been determined, the initial values to be used in the analysis are
determined as follows;
x1 = x + x 2 ln(u1 ) cos(2u2 )
And;
x2 = x + x 2 ln(u1 ) sin(2u2 )
And;
Since the Extreme Value Distribution is used for the rope tension, the initial
value is calculated from the Asymptotic distribution;
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Structural Reliability Assessment of a Winch Drum for an Offshore Crane
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x1 x 1
= n ln( ln(u ))
x n
2. The generated values are then substituted into the Limit State Function G(x) and
the value calculated.
3. The number of trials nf for which G(x) 0 are then counted. The estimate of the
probability of failure is then given by;
nf
pf =
N
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Start simulation
Probability of failure 0
COV_Pf
The probability of failure of the flange fillet according to the Monte Carlo Method is
0% with 5 layers of rope.
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Start simulation
Probability of failure 0
COV_Pf
The probability of failure due to weld fatigue according to the Monte Carlo Method is
0% with 5 layers of rope.
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The results obtained from the previous are summarised in the Table below;
The results indicate that the probability of failure of the hoist drum flange is very low,
which implies a very high reliability of the hoist drum. However, the probability of
failure of the hoist drum is higher for the fatigue limit state using FOSM and FORM but
the Monte Carlo Simulation did not indicate any failures for weld fatigue failure, even
after the number of trials was increased to 1million.
It is possible that the hoist drum has been over designed since the probability of failure
is quite low. However, the previous failures of the drum indicate that failure is possible
and it is therefore quite possible that the formulae used do not model the flange loading
accurately. It is quite clear from the research that the drum flange forces are critical to
the reliability of the hoist drum, given the failures reported by Song & Rao which
further reinforces the possibility that the formulae used in determining the strength of
the drum flange do not give a true indication of the drum flange loading model.
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Unfortunately, there is no clear guidance on how the flange forces are to be evaluated,
and it appears that most design standards consider the issue of hoist drum design to be
trivial. Further work will need to be done to develop formulae that will model the drum
flange loading accurately.
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The reliability of a hoist drum is subject to many factors and the results only give an
indicator of the probability of failure of the hoist drum assuming all other variables are
acceptable. Due to the large number of failures associated with the drum flange, the
flange strength has been selected as the most critical in this instance. However, the
results obtained seem to indicate that the failure of the hoist drum flange is unlikely in
this instance. It would have been worthwhile to apply the same approach to the failed
hoist drums with a view of verifying the accuracy of the formulae. The results therefore
are not conclusive, but indicate that further work needs to be done to come up with
substantive conclusions.
The differences in the pattern of loading are also quite significant. Waters suggests a
uniform loading of the flange, whereas DNV propose that the flange force increases
linearly from zero at the outer layer to a maximum near the barrel surface. Song & Rao
found that the flange thrust increased with the number of layers and Bellamy & Phillips
found that the flange force increased linearly with the number of layers but observed
non-linearity for one type of rope. Bellamy & Philips also observed that LeBus spooling
only had an effect on flange force for certain types of ropes, whilst the effect was
negligible for others.
Unfortunately, it appears as if none of the design standards have taken the work and
findings of the researched authors into account. It is accepted that the results from the
experiments carried out may now be out of date as the stiffness of steel wire ropes has
changed significantly(Lange, 2007) over the years. However, the research can be used
as a basis for future study on the subject.
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A similar study can be undertaken taking into consideration the failed drums to verify
the accuracy of the design code formulae. The magnitude of the flange forces as
calculated using approaches can also be compared. The project outlined the challenge
facing the hoist drum designer. Whilst the drum barrel can be designed based on clear
procedures and guidelines, the same is not true for the drum flange. The difficulty lies in
determining the magnitude and pattern of loading of the drum flange. Once the flange
force has been determined, the evaluation of the flange stresses is relatively straight
forward.
The approach proposed by Waters, the graphs presented by Bellamy and the DNV
formula can be compared to come up with a clear, verified procedure for determining
drum flange forces. Song & Rao also found significant variations in the flange forces
for small drums compared to large drums and it would be helpful to clarify these
variations. A common design code covering the design of winch drums can then be
developed. A considerable amount of research has been carried out on the subject of
drum flange forces, but unfortunately it does not appear as if any of the work has been
used in any of the design standards reviewed.
The University of Clausthal in Germany has also carried out a number of experiments to
determine the strength of drums in recent years. Unfortunately the papers they have
published are in German and the author did not have the resources to translate the
documents. It would be useful in future if the work was translated to English and the
findings combined with other research findings.
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Plate thickness t= 40 mm
2
C2 = 0.12965 = 0.25 * (1 - [b / a] * [1 + 2 * ln{a / b}]) [Eqn. 2]
2 2
C3 = 0.02073 = (b / [4 * a]) * ([{b / a} + 1] * ln[a / b] + [b / a] - 1) [Eqn. 3]
2
C6 = 0.09583 = (b / [4 * a]) * ([b / a] - 1 + 2 * ln[a / b]) [Eqn. 5]
2
C9 = 0.29736 = (b / a) * (0.5 * [1 + ] * ln[a / b] + 0.25 * [1 - ] * [1 - {b / a} ]) [Eqn. 7]
2 2
L3 = 0.01124 = (r0 / [4 * a]) * ([{r0 / a} + 1] * ln[a / r0 ] + [r0 / a] - 1) [Eqn. 8]
2
L6 = 0.06876 = (r0 / [4 * a]) * ([r0 / a] - 1 + 2 * ln[a / r0 ]) [Eqn. 9]
2
L9 = 0.28114 = (r0 / a) * (0.5 * [1 + ] * ln[a / r0 ] + 0.25 * [1 - ] * [1 - {r0 / a} ]) [Eqn. 10]
Therefore;
3
ya = -1.0112 = - (w * a ) / D * ([C2 / C8 ] * [r0 * C9 / b - L9 ] - [r0 * C3 / b] + L3 ) [Eqn. 13]
2
a= -0.0023 = - (w * a / D) * ([C5 / C8 ] * [r0 * C9 / b - L9 ] - [r0 * C6 / b] + L6 ) [Eqn. 14]
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References
API Specification for Offshore Pedestal Mounted Cranes [Book]. - Washington : API,
2004. - API 2C.
Atkinson LTJ Taylor GL The Analysis and Design of Fabricated Steel Cylindrical
Drums for Mine Winding Engines [Article] // Colliery Engineering. - January - August
1967. - pp. 44-45,32,79,115,201,236,315.
Atkinson LTJ Taylor GL The Analysis and Design of Fabricated Steel Cylindrical
Drums for Mine Winding Engines [Article] // Colliery Engineering. - December 1966. -
pp. 43,524.
Australian Standards Cranes, Hoists and Winches [Book]. - Sydney : Standards
Australia, 2002. - AS1418-1.
BAE Systems Beyond Lifetime Criteria of Offshore Cranes [Report]. - Norwich : HSE
Books, 2002.
Bellamy NW Phillips BDA An Investigation into Flange Forces in Winch Drums
[Journal] // IMechE. - 1969. - Vol. 183 Pt 1 No. 27. - pp. 579-590.
Blodgett Omer W. Design of Weldments [Book]. - Cleveland : James F. Lincoln Arc
Foundation, 1976.
British Standards Rules for the Design of Cranes - Part 1 [Book]. - [s.l.] : British
Standards, 1983. - BS2573-1.
British Standards Rules for the Design of Cranes - Part 2 [Book]. - 1980. - BS2573-2.
Broughton H. H. Electric Winders - A Manual on the Design, Construction,
Application and Operation of Winding Engines and Mine Hoists [Book]. - London :
Spon, 1928, Revised 1948.
Crawford WR Design of Colliery Machinery and Equipment [Article] // Colliery
Engineering. - July & September 1949. - pp. 261, 319.
Dietz Peter A Method for Calculating a Single & Multi-Layered Winch Drum
[Journal]. - [s.l.] : Journal of the Societyof German Engineers, July 1972. - 13 : Vol.
12. - pp. 34-344.
DNV Rules for Lifting Appliances [Book]. - Hovik : Det Norske Veritas, 2007.
Dolan J Winding Drums, Shell Loading due to Successive Layers of Stressed ropes
[Journal]. - [s.l.] : South African Institute of Mechanical Engineers, 1957.
Dolan John Winder Drum Tread Design Investigation [Article] // The South African
Mechanical Engineer. - 1963.
Egawa T and Taneda M External Pressure produced by Multi-Layers of rope wound
about a Hoisting Drum [Journal]. - [s.l.] : Japanese Society of Mechanical Engineers,
1958. - Vol. 1. - p. 133.
FEM FEM Booklet 1 & 2 [Book]. - London : European Handling Federation, 1998. -
Vol. 1 : 9.
Gagg Colin R and Lewis Peter R In-service Fatigue Failure of Engineered Products
and Structures - Case Study Review [Article] // Engineering Failure Analysis. - 2009. -
pp. 1775-1793.
Hicks John Welded Joint Design [Book]. - New York : Industrial Press, 1999.
Imanishi Estujiro, Nanjo Takao and Kobayashi Takahiro Dynamic Simulation of
Wire Rope with Contact [Journal] // Journal of Mechanical Science and Technology. -
2009. - pp. 1083-1088.
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IMCA Winch Drum Failure - Deep Water Operations [Article] // IMCA Safety Flash. -
February 2009.
Jinu GR, Ravichandran G and Rathinam A Investigation of the Fatigue Behaviour of
Butt-Welded Joint treated by Ultrasonic Peening Process and compared with Fatigue
Life Assessment Standards [Journal] // Int J Adv Manuf Technol. - 2009. - Vol. 40. - pp.
74 - 83.
Joint Committee of Structural Safety JCSS Probabilistic Model Code Part3:
Resistance Models; Part 3.12 Fatigue Models for Metallic Structures [Book] = JCSS. -
2006. - Third Draft.
Lange Walter Design of Hoist Winches with Multi-Layer Spooling. - [s.l.] : Liebherr
Cranes, 2007. - Presentation.
Lloyds Register Code for Lifting Appliances in a Marine Environment [Book]. -
London : Lloyds Register, 2008.
Maddox SJ Fatigue Strength of Welded Structures [Book]. - Cambridge : Woodhead
Publishing Ltd, 1969.
Oberg Erik Machinery Handbook [Book]. - New York : Industrial Press, 2008.
Otto S, Mupende I and Dietz P Influence of the Hoisting Drum Winding System on
the End Plate Loads [Conference] // International Design Conference. - Dubrovnik :
International Design Conference, 2002.
Perry John F and Smith D M Mechanical Braking and its Influence on Winding
Equipment [Journal]. - [s.l.] : Institute of Mechanical Engineers, 1932. - pp. 537-620.
Piskoty G [et al.] Structural Failures of Rope Based Systems [Journal] // Engineering
Failure Analysis. - 2009. - pp. 1929-1939.
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[Journal] // Reliability Engineering and System Safety. - 2007. - pp. 1369-1376.
Shapiro Howard, Shapiro Jay and Shapiro Lawrence Cranes and Derricks [Book]. -
New York : Mcgraw-Hill, 1991.
Song KK, Rao GP and Childers Mark A Large Wire Rope Mooring Winch Drum
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pp. 2737-2746.
Sparrows Offshore MIPEG Systems [Online]. - 24 September 2008. -
http://www.sparrowsoffshore.com/MIPEG_Load_Monitoring_Systems.html.
Specialist Maintenance Solutions Design Review for MK35 Whip Hoist Welded
Drum / compl. Cumming Ian. - 2008.
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[Book]. - New York : Mcgraw-Hill, 2002.
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Appendices
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MIPEG has been a world wide market leader for decades. The MIPEG 2000 crane
monitoring system brings not only enhanced standards of safety to crane operation, but
also records historical lift information to support more cost efficient crane maintenance
planning and slewing replacement deferral.
Load sensors at the boom tip measure both the static load and the peak load during each
lift and pass the information to the central computer. Both main and auxiliary hoists
have load sensors fitted so that lift information is recorded regardless of which hook is
used.
The moment sensor on the A-frame measures the crane over turning moment - the
stresses on the bearing and the pedestal - with this parameter also being passed to the
central computer. Simultaneously, the Inclinometer at the boom foot measures boom
angle and translates this into operating radius before feeding this data to the computer.
This allows the computer to constantly monitor the safe working load (SWL) at any
given radius.
Figure A.1
Outputs from the computer are fed directly to the in-cab display and audio warnings.
The operator's display can also be mounted remotely from the crane where no cab
exists. The outputs can interface fully to the crane's gross overload protection system,
activating cut outs as required, typically boom out inhibit.
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All this data, which is used in real time to protect the crane, its operator and all those
within the vicinity of the lifting operation, can be recorded for subsequent download to
a standard laptop. These records provide complete analysis (for each individual lift and
cumulatively over the life of the crane) of the dynamic and static hook loads, over
turning moments, radius, number of rope falls set, sea condition, lift duration and many
other parameters. This information is invaluable in planning cost effective crane
maintenance, based on actual crane utilisation and also in gathering information to
guide upgrade or replacement strategies later in the crane's life.
The MIPEG range also includes a rope speed indicator (RSI) which assists the operator
when making 'blind lifts'. The unit displays rope speed visually, with a bar graph, and
audibly, using a buzzer, and has a reset button for zeroing height/depth display. The unit
can also be configured such that outputs can control rope paid out and anti two block
position.
Source: http://www.sparrowsoffshore.com/MIPEG_Load_Monitoring_Systems.html
Date: 24/09/08
Figure A.2
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