Container Crane
Presentation
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Customer Benefits
Port Operators / Port Authorities
❖ Impact on Direct maintenance costs
❖ Impact on Indirect maintenance costs
❖ Safety
❖ Time losses and delay in shipment
❖ Loss of Contribution
❖ Unplanned vs. planned breakdowns
❖ Penalties
❖ Port charges
❖ Return on investment
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Equipment on Container Crane
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Machine Room
Main Hoist
Trolley Drive
Boom Hoist
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Main Hoist – up & down movement
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Trolley Drive – horizontal movement
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Boom Hoist - extension
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Motor
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Case Study
Container Crane online condition monitoring system
Technical application description
MSC Home Terminal
Antwerpen Belgium
March 2009
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MSC Home Terminal Antwerp, Belgium
MSC Home Terminal is a joint venture between Mediterranean Shipping
Company (MSC) and Hesse-Noord Natie NV, a subsidiary of the PSA Group.
The container terminal is a busy terminal and has a quay length of 2.9
km.
The total capacity of the terminal is 4.1 million tons.
The containers are moved to and from the vessels by 22 quay cranes.
Delwaide dock
(north side of the Port of Antwerp)
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Objectives
Crane application
”One of the most challenging machine condition monitoring applications
you can imagine is probably the hoisting winch and trolley drive in a
crane.”
The weight of the container, the hoist direction and hoisting speed will
have an influence in the running condition of the crane.
All of these variables need to be controlled during the machine condition
measurements to get stable, meaningful and trendable readings.
Trend graph with unfiltered data
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Objectives
Customer
The MSC Home Terminal company wants to have full control over the
availability of the Quay cranes to serve their customers to the highest
standards and to avoid unplanned downtime and secondary damage.
To reach this goal, all Kalmar cranes should be equipped with a machine
condition monitoring system. The evaluated machine condition
information from the system should be available for the Siemens Sicma
Crane management system as status coded in green, yellow or red
condition.
In March 2008, as a trial, SPM installed the Intellinova system on Quay
Crane No. 16 in the Hoisting winch of MSC Home Terminal, Antwerp in
Belgium. After more than 9 months of studying and fine tuning the
system, the Intellinova system was proven to be successful in managing
and controlling the operating condition of the cranes.
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Hoisting winch
Machine layout
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Hoisting winch
Measuring point positions -2
RPM
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Main Hoist Gearbox – Kumira, Finland
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Trolley Drive
(Future installation)
RPM
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Boom hoist
Machine layout (no plans yet)
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Crane specifications
Operating speeds and acceleration
Max. hoisting speeds
• with 80 tonnes on the ropes: 90 m/min – 2 sec. / 0.75 m/s2
• with 23 tonnes on the ropes: 180 m/min – 4 sec. / 0.75 m/s2
Max. trolley travel speed: 240 m/min – 4 sec. / 1.00 m/
s2
Max. crane travel speed: 45 m/min – 8 sec. / 0.10 m/
s2
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Crane specifications
Machine speed Hoisting winch
Electromotor speed: 0 – 1992 rpm
Load vs RPM
15 T – 1992
28 T – 1590
40 T – 1380
43 T – 1330
45 T – 1280
60 T – 1150
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Hoisting winch
Trial installation MSC Crane no. 16
In this trial installation, the equipment monitored is the Hoisting Winch,
comprising the 2 electric motor drives and the gearbox. The SPM Commander
Unit is equipped with two Bearing Monitoring Modules, one Vibration Monitoring
Module and one Analogue Input module.
To ensure the repeatability of the measurements, two condition parameters
(Load and Hoisting direction) are determined and measured. The triggered
condition for machine speed (RPM) is used to start the measurement whenever
the machine speed passes the trigger level.
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Hoisting winch
Gearbox Kumera type LD-3600-16-E1 (Bearing types)
23160 22336 22330 22320
23160 22336 22330 22320
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Installation of measuring points, load direction
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Installation of measuring points
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Hoisting winch
Electromotor Wölfer type ODRKF 400L-6T (Bearing types)
6224
6322
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Hoisting winch
Pictures / transducer installation
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Measuring techniques used
• Shock Pulse Method, for Bearing condition severity.
• SPM Spectrum, for Bearing spectrum analysis & evaluation.
• 9 EVAM Condition parameters for symptoms condition trending.
• Vibration severity.
• Vibration FFT spectrum analysis & evaluation (Acceleration,
Velocity and Enveloping).
• Analogue input signal 0-10V for container weight/load
measurement.
• Digital input signal for hoisting direction.
• RPM for machine speed measurement.
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Transducers used
Vibration & Shock Pulse
Accelerometer type SLD 144b
100 mV/g , 2-10.000 Hz
Piëzo electric compression type sensor for
vibration measurements in industrial
applications.
Shock pulse transducer type 42.000
with built-in TMU (transducer matching unit)
converts the shock pulses emitted by the bearing
into an electrical signal.
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Transducer used
Machine speed measurement
Inductive proximity switch
Generates pulses (V) when the teeths
of the gearwheel passing the probetip.
Intellinova suitable for 4 Tacho inputs
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Cabling & connections
Electrical
cabinets
Multi core cable
Crane operation
overview
Intellinova Rack module, Connection box, SPM, VIB, RPM
Load, Ethernet etc.
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Measuring Logic Parameters for monitoring
“Splash Animation”
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Intellilogic sequence, Container Crane
1. Measuring interval, check
2. Triggers, check
3. Conditions (Weight & Lifting), check
4. RPM stability, check
5. RPM within range, check
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Intellilogic sequence
1. Trigger preparation
1. Prepare the system prior to data aquisition
1. Bias Power on, (Settling time)
2. Stabilaising filters on the CU, fix amplification settings
3. Make sure that the ”Settling time” is completed
2. Waiting for Trigger event to happend during ”Max trigger
window.
2. Check Conditions (less then 1 ms)
1. Only measure when lifting
2. Check if load is within range
3. Check RPM Stability
4. Check Bias voltage
5. Store value in Database if RPM is
within RPM levels (By Linx)
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Trigger window (Tw)
Time to wait for the RPM to pass the Trigger level
RPM
Trigger Level
eg. 1000 rpm
3 sec 20 sec Time
Tw
Max. Tw
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Trigger window (Tw)
Sometimes the Trigger Level is not reached
RPM
Trigger
Level, eg. 1000
Time
Max. Tw 20 sec
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Retry Trigger Interval, how long time to wait before you restart the
Trigger window
RPM
Trigger
Leve, eg. 1000
Time
Tw Tw Tw Tw
Retry Trigger Interval
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Retry Logic for Vibration & SPM Spectrum data acquisition
The time between VIB measurement retries depends on the RPM slope and maximum allowed deviation
Start measurement
Deviation exceeded, stop
Retry counter (Initialized to for example 30)
Selected allowed RPM deviation
RPM
Trigger
Level
Time
30
29
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SUCCESS!
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26
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Retry Logic for Vibration & SPM Spectrum data acquisition
The time between measurement retries depends on the RPM slope and maximum allowed deviation
Start measurement
Stop
Retry counter (Initialized to for example 30)
Selected allowed RPM deviation
RPM
Trigger
Level
Time
3
30 2
29 1 Failed last try, measurement skipped
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26, 25, 24 …
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Trigger when RPM passes 1000 RPM
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Lifting Up
DI1=Lifting
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RPM vs. load
Speed
(RPM)
2200
1650 Load Range
1100
550
0
Load (t)
0 10 20 30 40 50 60 70 80
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Lifting load is checked every second,
range 30-80 ton
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Condition check
If not fullfilled, then Retry Trigger Interval is used as measuring interval.
If Conditions is fullfilled, then check RPM stability.
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Intellilogic
Difference between with and without Intellilogic
Without Intellilogic
With Intellilogic
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Intellinova system architecture
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Intellinova System Configuration
SQL Data
Base
CRANE
Communication from/ to
Crane management system
Service Laptop
OPC
Field LINX Server
OPC Client
Link between
Support the Database and Data Access
Software The Commander OPC
LINX
(FSS) Units Client OPC Server
Ethernet/SD Network connection
card
Crane 16 Commander Unit Crane no xx Commander Unit Crane no xx Commander Unit
Unit (out)
Vibration
Vibration
Vibration
Vibration
Bearing
Unit (in)
Bearing
Bearing
Bearing
Analog
Analog
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Unit
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Intellilogic
Data Flow and Alarms
Alarm Logic
-Absolute level SQL DB
-Alarm delay
-Alarm filter Storing Logic
-Trend -Time based
-Criteria based (standard/flexible) -Value level
-Band Value -Value change
-When alarm
LINX
Local Alarm Logic
-Absolute level
Vibration
Vibration
Vibration
Bearing
Unit (in)
Measuring Logic
Bearing
Bearing
Bearing
Analog
Unit
-Time based
Unit
Unit
Unit
Unit
Unit
Unit
-Conditional
-Triggered
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Intellicheck
No Measurement
SQL DB -Measuring results not received
Data buffers
-In case of communication failure
Data Buffer
Delayed Measurements
-The most delayed measurement
LINX task is reported
Vibration
Vibration
Vibration
Bearing
Unit (in)
Bearing
Bearing
Bearing
Analog
Unit
Unit
Unit
Unit
Unit
Unit
Unit
Data Buffer Data Buffer
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Configuration
Sequence files and buffered data via SD card
• Initial configuration like:
-IP address
-Choice of dynamic or static IP address
-Commander unit name
-Server name for LINX
-Etc
Can be done either via a directly connected PC (crossed LAN cable)
or via the SD card. FSS is used in both cases.
• A sequence file can be loaded to the Commander Unit from LINX via
the SD card.
• Buffered measurements can be downloaded to LINX via the SD card.
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Unique Features of
❖ Commander Unit
❖ Vibration & Shock Pulse Monitoring Unit
❖ Analog Input and Output Unit
❖ Condmaster Nova Software
❖ LinX Software
❖ Field Service Software
❖ OPC Data Access
❖ Web Access and SMS
❖ LAN or Wireless Ethernet
❖ Buffered Measurement via SD card
❖ Intellilogic:
✓ Intellicheck
✓ Measuring logic
✓ Storing Logic
✓ Alarm Logic
✓ Analysis Logic
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Condmaster Software
Overview Crane condition
Condmaster Nova
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Crane condition monitoring
Overview Crane condition
Condmaster Nova
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Crane condition monitoring
Overview gearbox measurements
Condmaster Nova
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Fault Symptoms
Machine faults definitions
The SPM online monitoring system automaticaly evaluates
the machine specific problems.
Pre-defined machine fault symptoms:
Bearing defect frequencies: BPFO, BPFI, BSF and FTF
Gear damage frequencies
Unbalance
Shaft misalignment
Loosseness
Electrical problems on Electric motors
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Symptoms
Gear damage – FFT Analysis
The FFT spectrum shows Input shaft Gearwheel damage markers
The amplitude and quantity of the side band frequency components
are indicators for damage development.
1x Gear Mesh Frequency (28x rpm)
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Symptoms
Gear damage – Trend graph
For every defined fault symptom like Gear damage in this case,
we calculate the sum value of the matching frequencies for trending for each
measurement.
Trend graph of Gear damage Z1 vibration components from FFT Spectrum
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Symptoms
Bearing damage – Trend graph
Trend graph of bearing with damage development
Trend graph of bearing in good condition
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Container Crane online condition monitoring system
Project Considerations
Supplier / Client
MSC Home Terminal
Antwerpen Belgium
March 2009
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Project Considerations
• Project planning - who will take care of:
network connection
brackets for tacho probe, junction box and Intellinova system
location of Intellinova system
power supply
• Project planning – time table
• Define the Objective to achieve
• Database set-up and fine tuning of the system
• Training for different types of users:
management, maintenance and operation
• Support - service level agreement
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Technical information
• Average vibration level
• Average dBc, lubrication
condition
• Per equipment
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Statistics
• Distribution green-yellow-red
• Per measuring technique
• Per machine type
• Per manufacturer
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Economics
• Direct maintenance costs
• Indirect maintenance costs
• Time losses
• loss of contribution
• Unplanned vs. planned
breakdowns
• Penalties
• Port charges
• Return on investment
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At your service . . .
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