DNV Standard 2-22 Rules for Lifting Appliances

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DET NORSKE VERITAS STANDARD FOR CERTIFICATION No. 2.22 LIFTING APPLIANCES OCTOBER 2008 This Standard for Certification includes all amendments and corrections up to April 2009.

Transcript of DNV Standard 2-22 Rules for Lifting Appliances

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STANDARD FOR CERTIFICATION

DET NORSKE VERITAS

No. 2.22

LIFTING APPLIANCES

OCTOBER 2008

This Standard for Certification includes all amendments and corrections up to April 2009.

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FOREWORD

DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, prop-erty and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancyservices relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out researchin relation to these functions.

Standards for CertificationStandards for Certification (previously Certification Notes) are publications that contain principles, acceptance criteria and prac-tical information related to the Society's consideration of objects, personnel, organisations, services and operations. Standardsfor Certification also apply as the basis for the issue of certificates and/or declarations that may not necessarily be related to clas-sification.

A list of Standards for Certification is found in the latest edition of Pt.0 Ch.1 of the ”Rules for Classification of Ships” and the”Rules for Classification of High Speed, Light Craft and Naval Surface Craft”.

The list of Standards for Certification is also included in the current “Classification Services – Publications” issued by the Society,which is available on request. All publications may be ordered from the Society’s Web site http://webshop.dnv.com/global/.

The Society reserves the exclusive right to interpret, decide equivalence or make exemptions to this Standard for Certification.

Amendments and Corrections This document is valid until superseded by a new revision. Minor amendments and corrections will be published in a separatedocument normally updated twice per year (April and October).

For a complete listing of the changes, see the “Amendments and Corrections” document located at: http://webshop.dnv.com/global/, under category “Standards for Certification”.

The electronic web-versions of the DNV Standards for Certification will be regularly updated to include these amendments andcorrections.

Comments may be sent by e-mail to [email protected] information about DNV and the Society's services is found at the Web site http://www.dnv.com

© Det Norske VeritasComputer Typesetting (Adobe FrameMaker) by Det Norske Veritas

If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation to such personfor his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum compen-sation shall never exceed USD 2 million.In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalf of DetNorske Veritas.

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Standard for Certification of Lifting Appliances, October 2008Page 3

Main changesThis Standard shall replace “Rules for Certification of LiftingAppliances” (January 2007 reprint of the 1994 issue) and willenter into force 15 November 2008.

The main changes are:

— Detailed explanation regarding scope and procedures aswell as necessary documentation/calculations to be sub-mitted for certification, have been added.

— The important material section has been completely re-or-ganized and made shorter. The Classification of ShipRules, often referred to as the "ship rules", are referenced

to a great extent, carefully avoiding repetition of text andtables found therein.

— The fatigue calculations necessary are now based on thepresently valid 1998 edition of the Inter-European CraneStandard (F.E.M), whereas the present "crane rules" arebased on the 1970 edition.

— The requirements for system equipment and system safetyare completely new: More extensive, less prescriptive, andthus leave the designers with a choice of how they will ar-range the safety goals to be met.

— Five new appendices, in addition to the present two, havebeen added to enhance information and support for the us-ers.

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CONTENTS

CH. 1 GENERAL .............................................................9

Sec. 1 General Information .......................................... 11

A. Objectives and Principles ..................................................... 11A 100 Introduction.....................................................................11A 200 Hierarchy of documents ..................................................11A 300 Principles for application of requirements ......................11A 400 Deviation from the requirements ....................................11A 500 Conflicting codes ............................................................11A 600 Date of reference of applied codes..................................11A 700 Organization of this Standard for Certification...............11

B. Application ........................................................................... 11B 100 Application......................................................................11

C. Definitions, Abbreviations, Symbols and References .......... 12C 100 General ............................................................................12

D. Services................................................................................. 14D 100 Objectives........................................................................14D 200 Regulatory basis ..............................................................14D 300 Acceptance by National Authorities ...............................14

E. Parts, Systems and Features covered by the Standard for Certification .......................................................................... 15

E 100 General ............................................................................15E 200 Design assessment...........................................................15E 300 Survey during fabrication and installation ......................15E 400 Testing and marking........................................................15E 500 Extension of scope of work.............................................15E 600 Safe means of access and personnel safety devices ........15E 700 Reduced scope of work ...................................................15

F. Type of Services ................................................................... 16F 100 Basic certification ...........................................................16F 200 Class covered cranes .......................................................16F 300 Assignments completed before installation ....................16F 400 Verifications....................................................................16F 500 Review in accordance with other standards ....................17F 600 Customers who may request certification and

verification ......................................................................17F 700 Written confirmation.......................................................17F 800 Certificate annotations ....................................................17

CH. 2 TECHNICAL REQUIREMENTS.....................19

Sec. 1 Documentation.................................................... 21

A. Documentation and Information to be Submitted.............................................................................. 21

A 100 General ...........................................................................21A 200 Documentation ...............................................................21A 300 Specifications and information .......................................21A 400 Material grades and certificates ......................................21A 500 Components and accessories...........................................21

B. Calculations to be Included in the Documentation............... 23B 100 Necessary calculations ....................................................23

C. Design and Extreme Temperature ........................................ 23C 100 Design temperature .........................................................23C 200 Extreme low temperature ................................................23

D. Design Conditions (environmental, operational) for Machinery and Systems........................................................ 23

D 100 General ............................................................................23

Sec. 2 Materials and Fabrication ................................. 25

A. General.................................................................................. 25A 100 Scope...............................................................................25A 200 Required documentation .................................................25A 300 Steel manufacturing process ...........................................25A 400 Material manufacture survey, certification and

testing procedures ...........................................................25A 500 Retesting..........................................................................25

B. Rolled Structural Steel for Welding ..................................... 25B 100 General ............................................................................25

B 200 Impact test temperatures .................................................26B 300 Testing.............................................................................26

C. Rolled Steel not for Welding ................................................26C 100 General ............................................................................26C 200 Bolts and nuts .................................................................26C 300 Rolled rings .....................................................................26C 400 Shafts and plates..............................................................26

D. Steel Forgings .......................................................................26D 100 General ...........................................................................26D 200 Forgings for general application .....................................27D 300 Forged shackles, cargo hooks, swivels,

sockets and chains...........................................................27D 400 Bolts and nuts..................................................................27D 500 Forged rings for slewing bearings...................................27

E. Steel Castings........................................................................29E 100 General ............................................................................29

F. Iron Castings.........................................................................29F 100 General ............................................................................29

G. Steel Tubes, Pipes and Fittings.............................................29G 100 General ............................................................................29

H. Aluminium Alloy Structures.................................................29H 100 General ............................................................................29

I. Steel Wire Ropes ..................................................................29I 100 General ............................................................................29I 200 Materials..........................................................................29I 300 Construction ....................................................................29I 400 Testing.............................................................................30

J. Crane Manufacturing and Construction................................30J 100 General ............................................................................30J 200 Welding procedure specifications...................................30J 300 Welding consumables .....................................................30J 400 Forming of materials.......................................................30J 500 Welding preparation........................................................31J 600 Welding performance......................................................31J 700 Repair of welds ...............................................................31J 800 Heat-treatment after forming and welding......................31J 900 Production weld tests ......................................................31J 1000 Inspection and testing of welds.......................................31J 1100 NDT-procedures and NDT-operators .............................32J 1200 Weld acceptance criteria .................................................32J 1300 Material protection against corrosion .............................32

Sec. 3 Structural Design and Strength of Cranes ...... 33

A. Group Classification of Lifting Appliances..........................33A 100 General ............................................................................33A 200 Fatigue calculations of cranes and

components applicable to strength calculations..............33

B. Design Loads ........................................................................33B 100 General ...........................................................................33B 200 Principal loads.................................................................34B 300 Vertical Loads due to operational motions .....................34B 400 Horizontal loads due to operational motions ..................35B 500 Loads due to motion of vessel on which

the crane is mounted .......................................................36B 600 Loads due to climatic effects ..........................................36B 700 Miscellaneous loads ........................................................36B 800 Loads for strength analysis of mechanisms ....................36

C. Cases of Loading ..................................................................37C 100 General ............................................................................37C 200 Case I: Crane working without wind ..............................37C 300 Case II: Crane working with wind ..................................37C 400 Case III: Crane subjected to exceptional loadings ..........37

D. Strength Calculations............................................................37D 100 General ............................................................................37D 200 Checking with respect to excessive yielding ..................37D 300 Checking with respect to buckling..................................38D 400 Checking with respect to fatigue.....................................38

E. Design and Strength of Particular Components....................39

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E 100 General............................................................................39E 200 Buckling stability of jibs.................................................39E 300 Slewing bearing for jib cranes ........................................ 39E 400 Flanges ............................................................................40E 500 Pedestal and pedestal adapter for jib cranes ...................41

Sec. 4 Conventional Cargo Gear, Cargo Ramps and movable Cargo Decks.................................. 42

A. General..................................................................................42A 100 Definitions ......................................................................42A 200 Scope...............................................................................42A 300 Classification ..................................................................42A 400 Operational limitations ................................................... 42

B. Basic Requirements ..............................................................42B 100 Materials ........................................................................42B 200 Wire ropes.......................................................................42B 300 Welding and workmanship .............................................42

C. Derrick Systems....................................................................42C 100 Rigging plan and force diagram......................................42C 200 Basic design assumptions ...............................................42C 300 Allowable stresses...........................................................42C 400 Union purchase arrangement ..........................................43C 500 Stayed masts and derrick posts .......................................43C 600 Un-stayed masts and derrick posts..................................44C 700 Derrick booms.................................................................44

D. Cargo Ramps and Movable Cargo Decks.............................45D 100 Structural strength...........................................................45D 200 Mechanism and operational safety ................................. 45

Sec. 5 Machinery and Equipment ................................ 46

A. Basic Requirement................................................................46A 100 Materials ......................................................................... 46A 200 Arrangement and general design of

components and equipment ............................................ 46A 300 Ventilation ......................................................................46A 400 Strength...........................................................................46

B. Components ..........................................................................46B 100 Winches ..........................................................................46B 200 Drums..............................................................................46B 300 Brakes .............................................................................47B 400 Steel wire rope with fittings and anchorages ..................48B 500 Sheaves ...........................................................................48B 600 Anti-breakdown device for slewing mechanism ............49B 700 Lifting gear, including loose gear and grabs...................49B 800 Chains .............................................................................49B 900 Skids ...............................................................................49

C. Power Systems......................................................................49C 100 Prime movers ..................................................................49C 200 Power independency....................................................... 49

D. Electrical Installations, Equipment and Systems..................49D 100 General............................................................................49D 200 Plans and specifications ..................................................50

E. Hydraulic, Pneumatic, Instrumentation, Automation and Wireless Remote Control Systems ................................ 50

E 100 Hydraulic systems...........................................................50E 200 Testing ............................................................................51E 300 Pneumatic systems..........................................................51E 400 Control and monitoring systems .....................................51E 500 Wireless remote control systems ....................................51

Sec. 6 Safety and Safety Equipment ............................ 53

A. Safety ...................................................................................53A 100 Operator's cabin .............................................................. 53A 200 Platforms, access gangways and operator’s cabins ........53A 300 Parking and precautions against wind loads ...................53A 400 Protection and precautions against fire...........................53A 500 Safety functions and equipment, offshore cranes ........... 53A 600 Safety functions and equipment for

ordinary shipboard cranes, industrial cranes and cargo decks/ramps...........................................................57

A 700 Lifting of personnel ....................................................... 58

Sec. 7 Testing and Test Certificates Marking............. 60

A. Functional Testing of Completed Lifting Appliances ..........60A 100 General............................................................................ 60A 200 Prime movers and fluid power systems .......................... 60A 300 Governing and monitoring systems ................................ 60A 400 Electrical installations..................................................... 60A 500 Brakes ............................................................................. 60A 600 Safety equipment ............................................................ 60

B. Load Testing .........................................................................60B 100 General............................................................................ 60B 200 Test weights .................................................................... 60B 300 Test loads ........................................................................ 60B 400 Examination after testing................................................ 61B 500 Certificates...................................................................... 61B 600 Procedure for load testing of a lifting appliance............. 61

C. Testing of Steel Wire Ropes .................................................62C 100 Cross reference ............................................................... 62C 200 Certificates...................................................................... 62

D. Marking and Signboards.......................................................62D 100 General............................................................................ 62D 200 Derrick booms ................................................................ 62D 300 Cranes ............................................................................. 62D 400 Blocks ............................................................................. 62D 500 Slings and lifting tackles................................................. 62

App. A Wind Loads on Cranes....................................... 63

A. Wind Load Calculation.........................................................63A 100 General............................................................................ 63A 200 Wind force on flat surfaces............................................. 63A 300 Wind force on bodies of flat surfaces ............................. 63A 400 Wind force on structural members ................................. 63A 500 Air velocity pressure....................................................... 64

App. B Marking of Single-sheave Blocks ...................... 65

A. General..................................................................................65A 100 Method of marking the safe working load...................... 65

App. C Ship Mounted Cranes without Jib Support in Transit Condition ...................... 66

A. Example on Checking for Compliance with the Structural Strength Requirements of Sec.3.....................66

A 100 General............................................................................ 66A 200 Case of loading to be considered .................................... 66A 300 Calculation of vessel motion .......................................... 66A 400 Calculation of loading due to vessel motion................... 66A 500 Calculation of wind load................................................. 66A 600 Checking with respect to excessive yielding .................. 66A 700 Checking with respect to buckling ................................. 67A 800 Checking with respect to fatigue .................................... 67A 900 Considerations not included in DNV’s approach ........... 67

App. D Examples on Requirements for Documentation for Acceptance of Works Certificates .............................................. 69

A. Winches* for Shipboard Cranes ...........................................69A 100 Case 1. Designed in accordance with applicable,

recognised standard ........................................................ 69

B. Winches* for Shipboard Cranes ...........................................69B 100 Case 2. Designed in accordance with

this Certification Standard .............................................. 69

C. Transmission gears for non-critical application ..................70C 100 Designed in accordance with this

Certification Standard or other recognised standard ...... 70

D. Hydraulic cylinders exempted from DNV certification .......70D 100 Conditions for use........................................................... 70

App. E Examination of Brackets, Skids and Monorails ............................................................. 71

A. Purpose .................................................................................71A 100 Questions related to specific lifting appliances and

fundaments...................................................................... 71

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A 200 Brackets...........................................................................71A 300 Skids................................................................................71A 400 Monorails .......................................................................71A 500 Testing of standard brackets

(lifting lugs, pad eyes) ...................................................72

App. F Register and Certificate Forms ......................... 73

A. List Forms............................................................................. 73A 100 General ............................................................................73A 200 Relevant forms ................................................................73

B. Sample Copies ...................................................................... 73

App. G Verification Guideline for Safety Functions.................................................. 82

A. Application, Scope and Objective ........................................82A 100 Application......................................................................82A 200 Verification .....................................................................82A 300 Scope...............................................................................82A 400 Objective .........................................................................82

B. Verification Procedure .........................................................82B 100 General ............................................................................82B 200 Explanation of the verification

templates elements ..........................................................83B 300 Verification sheet templates............................................83

C. Required Documentation and Information ...........................91C 100 Documentation ................................................................91

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STANDARD FOR CERTIFICATION OFLIFTING APPLIANCES

CHAPTER 1

GENERAL

CONTENTS PAGE

Sec. 1 General Information ................................................................................................................. 11

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Veritasveien 1, NO-1322 Høvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11

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Standard for Certification of Lifting Appliances, October 2008Ch.1 Sec.1 – Page 11

SECTION 1 GENERAL INFORMATION

A. Objectives and Principles

A 100 Introduction

101 This Standard for Certification provides criteria andguidance for certification and verification of the design, mate-rials, fabrication, installation, testing and commissioning oflifting appliances.

A 200 Hierarchy of documents

201 The Standard for Certification consists of a three levelhierarchy of documents.

— Chapter 1 “General” Provides principles and proceduresof DNV classification, certification, verification- and –consultancy services.

— Chapter 2 “Technical Requirements” Provides technicalprovisions and acceptance criteria as well as the technicalbasis for the services stated in Chapter 1.

— Appendices. Provide proven technology and sound engi-neering practice as well as guidance for the higher leveldocuments mentioned in Chapter 1 and Chapter 2.

A 300 Principles for application of requirements

301 The standard selected for the design of a lifting appli-ance should be applied consequently from concept designthrough the final construction, including major modifications.

302 Requirements presented herein are minimum require-ments to be satisfied, but shall take into account available tech-nological and technical improvements at the time ofapplication for certification. Prescriptive requirements are notintended to inhibit application of practical improvements.

303 The requirements of this Standard for Certification maybe supplemented with additional requirements where installa-tion of specific design or assessment shows that higher stand-ards are more appropriate.

A 400 Deviation from the requirements

401 Without prejudice to 302, deviations from the require-ments of this Standard may only be substituted where shownto provide an equivalent or higher level of integrity or saferthan under this standard.

402 At the Society’s discretion it can accept equivalent solu-tions and exemptions from the requirements of this Standard.

A 500 Conflicting codes

501 In case of conflict between requirements of this Stand-ard for Certification and a reference document, the require-ments of this certification standard shall prevail.

A 600 Date of reference of applied codes

601 Where reference is made to codes other than DNV doc-uments, the valid revision shall be taken as the revision whichwas current at the date of issue of this Standard, unless other-wise noted.

A 700 Organization of this Standard for Certification

701 It is a principal object of the certification standard to dis-tinguish clearly between:

— information and description of services— requirements.

Consequently, these two subjects are separated, and the Stand-ard for Certification is divided into three parts:

— Chapter 1: General information, application, definitionsand references. Description of applicable services and re-lations to rules and regulation from institutions other thanDNV.

— Chapter 2: Requirements and technical provisions. — Appendices (included in Ch.2).

B. Application

B 100 Application101 The Standard for Certification applies to:

— shipboard cranes— conventional cargo gear derrick systems and other lifting

appliances (cargo ramps and movable decks) onboard aship or other floating vessel

— offshore cranes— industrial cranes— various types of lifting gear.

102 The application as listed in 101 is to be understood asfollows:

a) Shipboard cranes and conventional cargo gear derricksare:

— Lifting appliances onboard ships and offshore unitsintended for cargo handling in harbours, sheltered wa-ters, within the deck area or below deck (e.g. engineroom cranes).

— Lifting appliances on non-buoyant offshore installa-tions, for cargo handling within the deck area.Guidance note:Hose handling cranes intended for operation outside thedeck area in open sea may normally be categorized as ship-board cranes. However, based on special consideration acategorization as offshore crane may be required.

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b) Offshore cranes are:

— Lifting appliances on offshore installations and shipsintended for loading and discharging of offshore sup-ply vessels, barges etc., or from the sea or seabed.

— Lifting appliances based on a bulk carrier or barge lift-ing from another bulk carrier or barge at open sea.Guidance note:The information in the requirements in Ch.2 Sec.1 B104 dis-tinguishes between lifts from vessels and lifts from the sea/seabed.

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c) Industrial cranes are:

— Lifting appliances onshore or offshore and not be-longing to the categories mentioned in a) or b) above.

103 The Standard also applies to mobile cranes, i.e. cranethat are transported by vehicle or other means from one loca-tion to another, and cranes that can move long distances byroad by means of their own machinery and wheel arrangement.In the latter case the moving machinery and its arrangement aswell as the overturning stability of the mobile crane are notcovered by the certification.

104 The Standard does not apply to cable cranes, personnel

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lifts (elevators), jacks, overhead drilling equipment, fork lifts,portable hoisting gear etc.

105 Personnel lifting with cranes otherwise designed for lift-ing of loads/cargo may be covered upon agreement.

106 Lifting appliances rated to a safe working load of lessthan 10 kN will be especially considered.

C. Definitions, Abbreviations, Symbols and References

C 100 General101 Active cable tensioning system (ACT)

System keeping the tension of the hoisting wire to a given setpoint value.

Guidance note:A supply of external energy is required.

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102 Active heave compensation system (AHC)

System that maintains the position of the load to a given setpoint value.

Guidance note:A supply of external energy is required.

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103 Actual hook load

The static weight of the load attached to the hook; includes theuseful load lifted plus any loose gear used, such as slings, lift-ing beams, etc.

104 Additional Equipment and System Notation

Code used by the classification societies to confirm that a ves-sel possesses certain systems, equipment or features coveredby the classification. (Examples are HELDK, CRANE, E0and F-AMC).

Guidance note:E0 means that the vessel complies with requirements for havingunattended machinery space and F-AMC means that the vesselcomplies with requirements for additional fire protection, in thiscase both for Accommodation, Machinery space and Cargospace.

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105 Additional Service and Type Notation

Code used by the classification societies to define a type ofvessel related to its most typical service. (Tanker for Oil, Pas-senger Vessel and Crane Vessel are typical examples).

106 Automatic overload protection system (AOPS)

A system that automatically safeguards and protects the craneagainst overload and “over-moment” during operation by al-lowing the hook to be pulled away from the crane in order toavoid significant damage.

107 Certificate of Conformity

A document attesting that a product or service is in conformitywith specific standards or technical specifications. (ISO “Cer-tification - Principles and practice.”, 1980).

108 Competent Person/Body

Person or body possessing knowledge and experience requiredfor performing thorough examination and test of lifting appli-ances and loose gear, and who is acceptable to the competentauthority.

109 Crane stiffness

Coefficient defined as the weight attached to the hook neces-

sary to obtain a unit deflection at the hook level.

110 Customer

Signifies the party who has requested the Society’s service.

111 Dead loads

All the loads of constant magnitude and position that act per-manently on the structure or member and that are not subjectedto inertia forces. The working load is not included in the deadload.

112 Designer

Signifies a party who creates documentation submitted to theSociety for approval or information.

113 Design approval

Verifying that a design, represented by a drawing or set ofdrawings, is found to comply with all requirement of a speci-fied standard or regulation.

Guidance note:Only drawings are subject for design approval. Descriptions,specifications, calculations, etc. are not considered for approval.

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Guidance note:In DNV’s business procedures design approvals are valid for oneorder only. One order, however, may include a specified numberof units for specified locations/vessels.

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114 Design approval letter

Written confirmation of a design approval.

115 Design Assessment for Type Approval

Examination and acceptance of a design for Type Approval.The Type Approval will be assigned first after a prototype testalso has been successfully carried out.

116 Design dynamic factor

The dynamic factor applied to the working load for a specificSWL

Guidance note:For an offshore crane the design dynamic factor is normally re-ferred to the still water condition for determining the SWL at stillwater. The design dynamic factor may, however, be defined alsoto refer to a specified significant wave height.

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117 Design Verification Report (DVR)

Formalized report confirming the result of a completed verifi-cation assignment.

118 Dynamic factor

Also named dynamic coefficient. A variable factor represent-ing the dynamic effects that the working load is exposed to.

119 Dynamic load

The working load when subjected to (multiplied with) a dy-namic factor.

120 Dynamic load chart

Diagram or table showing rated capacity depending on seastate and on radius or boom angle.

121 Heavy lift crane

Crane with SWL above 200 tons.

122 Inertia forces

The forces induced by change of velocity.

123 Inspection Release Note (IRN)

Report confirming survey work/results of a provisional phasecompleted. Often used for a component partially completed by

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one manufacturer before it is sent for completion by another.Classification Societies will normally use a Survey Report, butIRNs are sometimes preferred, for example by the offshore in-dustry.

124 Lifting appliance

Machine or appliance used for the purpose of lifting goods andmaterials, or in special modes, personnel.

125 Lifting accessories

As for lifting gear, see below.

126 Lifting equipment

General expression including lifting appliances, lifting gear,loose gear and other lifting attachments; used separately or incombination.

127 Lifting gear

Load carrying accessories used in combination with a liftingappliance, however, that are not necessarily a part of the per-manent arrangement of the lifting appliance, such as:

— attachment rings, shackles, swivels, balls, pins— sheaves, hook-blocks, hooks, load cells— loose gear.

Guidance note:Lifting gear, considered as separate components, shall be de-signed and tested in accordance with the provisions for loosegear.

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128 Load chart

Diagram or table showing rated capacity depending on radiusor boom angle.

129 Loose gear

Loose gear are equipment used to attach the useful load to thehook, such as slings, nets, baskets, chains, links, rings, shack-les, lifting beams and frames, spreaders, grabs, loading pallets,skids, etc., but which do not form a part of the useful load,which is normally not permanently attached to the hook, andwhich may be stored separately from the crane.

130 Man riding winch

Device specially designed for hoisting/lowering of a person.

131 Manual overload protection system (MOPS)

System, activated by the crane operator, protecting the craneagainst overload and “over-moment” by reducing the load-car-rying capacity and allowing the hook to be pulled away fromthe crane.

132 Mean time to failure (MTTF)

The mean value of service time until failure occurs.

133 Overload

Load which exceeds the Safe Working Load (SWL).

134 Over-moment

Load moment which exceeds the maximum load moment(Safe Working Load (SWL) multiplied by radius).

135 Passive cable tensioning system (PCT)

System keeping the tension of the hoisting wire between pre-defined limits, using stored energy.

136 Passive heave compensation system (PHC)

System that maintains the position of the load between prede-fined limits, using stored energy.

137 Probability of failure on demand (PFD)

Probability of failure on demand.

138 Product Certificate (general)

Document issued under the rules of a certification system, in-dicating adequate confidence is provided that a duly identifiedproduct is in conformity with a specified standard or normativedocument.

139 Product Certificate (DNV’s)

Det Norske Veritas Product Certificate is a document signedby a surveyor of the Society stating:

— conformity with rule or certification standard require-ments

— that tests are carried out on the certified product itself— that tests are made on samples taken from the certified

product itself— that tests are performed in presence of the surveyor or in

accordance with special agreements.

140 Purchaser

Company or person who orders the lifting equipment from amanufacturer. This standard does not necessarily require thatthe purchaser will need to have any direct relationship to orcommunication with DNV.

141 Rated capacity

Actual hook load that the crane is designed to lift for a givenoperating condition (e.g. boom configuration, reeving arrange-ment, offlead/sidelead, heel/trim, radius, wave height, etc.)

142 Recognised manufacturer

A manufacturer that DNV’s local survey station accepts ascompetent to produce the product in question. If found neces-sary, DNV’s local survey station may initiate investigation re-garding the manufacturer’s competence and quality controlregime.

143 Risk

Combination of the probability of occurrence (frequency) ofharm and the severity (consequence) of the harm.

144 Risk control measure (RCM)

A means of controlling a single element of risk; typically, riskcontrol is achieved by reducing either the consequence or thefrequencies.

145 Running rigging

Wire ropes passing over rope sheaves of guide rollers, orwound on winches, irrespective of whether or not the ropes aremoved under load.

146 Reference SWL

A theoretically increased SWL used for determining of over-load for load tests. Used when the design dynamic factor (seeabove) exceeds 1.33. (See Ch.2 Sec.7 B301).

147 Safe Working Load (SWL)

Also called rated load or rated capacity. The actual hook loadpermitted for a given operating condition (e.g. configuration,position of load).

148 Significant wave height Hsign

Average height of the highest one third of the individual waveheights in a short-term constant seastate, typically 3 hours.

149 Standing rigging

Ropes that are not turned round or wound on to winches (e.g.guided wires, pendants, stays).

150 Subsea cranes

Cranes intended for handling submerged loads.

151 Type Approval

Approval of conformity with specified requirements on the ba-sis of systematic examination of one or more specimens of aproduct representative of the production.

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152 Verification

A service that signifies a confirmation through the provision ofobjective evidence (analysis, observation, measurement, test,records or other evidence) that specified requirements havebeen met. See also the Note in the introduction to F400.

153 Working load (suspended load)

The static weight of the useful load lifted, plus the weight ofthe lifting gear. The working load is subjected to inertia forces.

D. Services

D 100 Objectives101 The objective is to present an overview of possible com-binations of the different services offered. Furthermore, vari-ous alternatives are described for DNV confirmation of thevarious services. See also Table F1.

102 The purpose of the objectives in 101 is to enable the gen-eral objectives to be met as described in A200.

103 Documentation of Services are shown in Fig.1

Figure 1 Documentation of Services

Alternatives for documentation that may be issued to Custom-ers depending on type and combination of services requested.

D 200 Regulatory basis

201 The Standard for Certification is based on DNV’s under-standing and interpretation of the ILO Convention No.152 of1979.

D 300 Acceptance by National Authorities

301 A number of bodies, such as Port Authorities, MaritimeAuthorities, Shelf Authorities and Municipal or Governmental

Health and Safety Authorities require that lifting appliancesand loose gear shall be certified. Normally, DNV’s certifica-tion in accordance with this certification standard will satisfythe authorities’ requirements.

302 In cases where requirements laid down by the pertinentbody exceeds the DNV requirements described in Ch.2, DNVmay, as a voluntary service, include the additional require-ments in the examination and confirm whether or not they arefound to be fulfilled

303 The conditions for review in accordance with other bod-ies’ requirements are as set out in F500.

SERVICESrequested

DOCUMENTS that may be issued

DESIGN ASSESSMENT

Design Approval Letter

Design Verification

Report

TESTS at the

MANUFACTURER(Optional )

SURVEYOF

INSTALLATIONAT

FINAL LOCATION

FINALTESTS

ManufacturingSurvey Report

” Certificate ofConformity”

or if loose gearDNV Product Certificate

Type CG3

orSurvey Report

confirmingDesign Approval ,

Manufacturing Survey and Tests

DNVProduct Certificate

Type CG2 for Lifting Installations

(complies with ILO )Mandatory if class

coverage is requested

MANUFACTURINGSURVEY

Manufacturing Survey Report

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Standard for Certification of Lifting Appliances, October 2008Ch.1 Sec.1 – Page 15

E. Parts, Systems and Features covered by the Standard for Certification

E 100 General

101 The following parts, components and systems are cov-ered by the Standard of Certification:

— all load-carrying structural members and components ofthe lifting appliance

— cargo hooks, chains, rings, blocks, sheaves, shackles, lift-ing beams, swivels and ropes

— structural integrity of grabs, hydraulic dampers or otherload transferring components

— rope drums— slewing bearing including fasteners— power systems (for hoisting, derricking, slewing and trav-

elling)— brakes and braking systems— safety equipment— protection against fire— seating and fasteners for prime movers, winches and for

bearings of power transmitting components— instrumentation and automation— electrical installation, see Ch.2 Sec.5.

102 The following activities are covered by the Standard forCertification:

— design assessment— survey during fabrication and installation— witness testing and marking.

E 200 Design assessment

201 Load-carrying and other important components of a lift-ing appliance are subject to design assessment with respect tostrength and suitability for its purpose. A design approval isgranted when the design assessment has been concluded with-out detection of non-compliances.

The design assessment may be substituted, partly or complete-ly, by enhanced manufacturing survey and/or testing. In caseswhere the substitutions are applied for by the Customer, agree-ments shall be made between the Customer and the Society re-garding possible reductions of documentation to be submittedfor approval/information.

Upon special agreement, the design assessment may be substi-tuted by a strength evaluation based upon testing until failure.

Strength examination of components related to power supplyand safety equipment is normally not carried out by the Socie-ty.

Guidance note:The Society’s splitting of the certification process in the sequenc-es design approval, manufacturing survey (including installationsurvey) and testing, shall be considered as a part of the Society’sinternal scheme to organize its work.

The Society’s reports covering the separate phases is consideredinternal documents, and information enabling the progress of thecertification project.

The Society’s formal documentation of the certification to theCustomer will be the product certificate CG2 issued upon com-pletion of the project.

An exemption to this principle is the below described Design As-sessment for Type Approval, which is a document completed for,and which will be delivered to, the Customer who has ordered theType Approval.

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202 Each lifting appliance is normally given a separate de-sign approval.

203 The design approval may be obtained either on a case-by-case basis or as a general approval, Type Approval.

The Type Approval means that the design as approved can beapplied for identical units to be fabricated, i.e. requested docu-ments need not be submitted for each unit.

The Type Approval will be based on certain conditions and itsperiod of validity will be limited.

Reference is made to DNV Certification Note No. 1.2 “TypeApproval” December 1996 or later issue.

E 300 Survey during fabrication and installation

301 Normally, a survey during manufacture of each separatelifting appliance shall be carried out by the Society's surveyorin order to ascertain compliance with the approved drawings,other requirements of this certification standard as well as gen-eral good workmanship.

302 As an alternative to survey during manufacture of eachseparate lifting appliance, modified survey procedures and sur-vey arrangements may be accepted provided the manufactureroperates a quality-assurance system approved and certified bythe Society.

303 After a lifting appliance has been installed on its perma-nent foundation, and before testing can take place, it is to besubjected to a survey by a surveyor of the Society.

E 400 Testing and marking

401 Components and each completed lifting appliance shallbe subjected to functional testing and load-testing as specifiedin Ch.2 Sec.7.

E 500 Extension of scope of work

501 Upon request from the Customer, the scope of work maybe extended beyond the subjects and aspects covered in thiscertification standard.

502 Extensions shall be agreed in writing. DNV may, iffound necessary, require that the Customer presents referencedocuments for the extended scope of work, such as authorityregulations, norms and standards.

503 In case of disputes regarding interpretations of require-ments on which extended work is based, the Customer mustcontact the publisher/owner of the requirements and obtaintheir written interpretation.

If the publisher/owner is not willing to interpret the disputedrequirement, or an interpretation for other reasons cannot beacquired, the respective extension of the scope of work must beomitted.

E 600 Safe means of access and personnel safety devices

601 Personnel safety protection devices such as guard rails,shielding, safety of ladders, etc. are not covered by this certifi-cation standard and the scope of work. If the Customer re-quests that such aspects shall be covered, the provisions set outin E 500 shall be followed.

E 700 Reduced scope of work

701 Upon request from and agreement with the Customer,parts of the scope of work, components, systems or specific as-pects or requirements may be excluded from the scope of workspecified in the certification standard. This will be annotated inthe documentary evidence of the completed assignment (certif-icate).

702 DNV will not agree to limit the scope of work or parts ofthe suggested services if they are of the opinion that this maylead to hazards or unacceptable lowering of the safety stand-ard.

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F. Type of Services

F 100 Basic certification

101 The basic requirements presented in Ch.2 are consideredto cover the requirements of the ILO Convention No.152 of1979 specified in D201. Lifting appliance and loose gear foundto comply with these basic requirements are qualified for DNVproduct certification, whereupon the product certificate maybe issued, and the Cargo Gear Register (CG1 if published bythe Society) may be endorsed.

102 The basic requirement covers the three basic types ofcranes a), b) and c) defined in B102 as well as loose gear com-ponents allocated the same types of cranes, as well as person-nel lifting as denoted in B105.

103 Some details of the basic requirements in Ch.2 are dif-ferent for the different types of cranes a), b) and c). Further-more, some specific requirements are stated for cranes alsoused for personnel lifting.

F 200 Class covered cranes

201 On a voluntary basis, cranes installed onboard DNVclassed vessels and offshore installations may be included inthe class. In such cases the vessel/ offshore installation will beassigned the Additional Equipment and System NotationCRANE.

In order to obtain this notation at least one of the cranes on-board must have been certified in accordance with the basic re-quirements of Ch.2 as well as having been assigned the productcertificate CG2.

202 Vessels, barges and offshore installations whose mainpurpose is to support a crane, may be assigned the voluntaryAdditional Service and Type Notation Crane Vessel if thecrane has been certified in accordance with the basic require-ments of Ch.2 and as well as having been assigned the productcertificate CG2.

Guidance note:DNV classed crane units fulfilling the requirements as specifiedin 202 will get the combined class notation:1A1 Crane Vessel.DNV classed crane vessels or crane barges where the crane (ma-jor crane) has not been subjected to DNV certification will havethe Main Character of Class 1A1.For further information regarding e.g. the difference between thenotations 1A1, see DNV’s Rules for Ships Pt.1 Ch.2 .In addition to the requirements specified in Ch.2 for cranes to becertified by DNV, vessels or offshore units having cranes in-stalled will be subjected to a number of obligatory class require-ments. These requirements apply independently of whether ornot the cranes are certified by DNV and whether or not they areincluded in the class. They cover such topics as deck support,foundations (pedestals), boom rests (cradles), electrical and hy-draulic power supply, earthing as well as trim, stability and bal-lasting conditioned by the cranes or their lifting operations.

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203 Some of the requirements in this certification standardhave been extended with additional detail requirements forcranes to be covered by classification.

F 300 Assignments completed before installation

301 Assignments completed at the manufacturers’ premisescan be agreed. Such services are normally to be completedwith monitoring of tests at the manufacturer, (FAT-tests). Ap-plicable reports or certificates may be issued. See also 302.

302 The reason for, or purpose of, such assignments may e.g.be:

— Completed certification of loose gear or components.DNV will normally issue the product certificate CG3 after

completion of the tests.— Provisional certification after FAT-test. For instance, if fi-

nal destination is not decided, or if the manufacturer isproducing for stock. Or the Customer has requested FAT-tests and a documentary confirmation of the Society’sservice rendered until a certain point. A ManufacturingSurvey Report, Certificate of Conformity or Inspection Re-lease Note (often preferred in the offshore industry) maybe assigned.

See also Fig.1.

F 400 Verifications

Guidance note:Verification constitutes a systematic and independent examina-tion of the product itself or its design and/or manufacturing to de-termine whether it is in compliance with some or all of thespecifications. Verification activities are expected to identify er-rors or failures in the work and to contribute to reducing the risksto the operation of the product and to the health and safety of per-sonnel associated with it or in its vicinity or other unwanted sit-uations.

Verification shall be complementary to routine design, construc-tion and operations activities and not a substitute for the work,and the assurance of that work, carried out by the Customer andits contractors, it is inevitable that verification will duplicatesome work that has been carried out previously by other partiesinvolved.

The Society’s verification may be based on risk evaluation. Thisis founded on the premise that the risk of failure can be assessedin relation to a level that is acceptable and that the verificationprocess can be used to manage that risk. The verification processis therefore a tool to maintain the risk below the acceptance limit.Verification based on risk aims to be developed and implementedin such a way as to minimise additional work, and cost, but tomaximise its effectiveness. Society’s verification level will bechosen based on experience combined with engineering judge-ment and the findings from the examination of documents andproduction activities.

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401 The Society may upon request carry out specified exam-ination or combination of separate services referring to the re-quirements in Ch.2 or the related standards and servicesdescribed in D and E and in this item.

402 The depth, thoroughness and completeness of the exam-inations must be agreed upon for each specific verification as-signment, and shall be ambiguously described in the contractand in the documentation of the verification service.

Guidance note:The Society is flexible in agreeing on type of documentation ofverification services performed. Normally, the Society’s propos-al will be to issue a verification report. For instance, for a com-pleted design assessment the Society will suggest issuance of a“Design Verification Report”.

The Society endeavours to find the best solution for issuance ofrequired verification documentation.

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403 Whereas the scope, standards and acceptance criteria fora certification or classification assignment is laid down by theSociety, the scope, standards and acceptance criteria formingthe basis for a verification assignment may, if requested, beadapted to the needs and desires of the Customer. However, theSociety will decline to carry out a commission that may beused, intentionally or unintentionally, to mislead a third partywith regard to the safety of the object.

404 A verification report may be edited in accordance withthe Customer’s needs and requests. The Society is, however,not prepared to omit non-conformances or other negative ob-servations or results detected during the examinations.

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Standard for Certification of Lifting Appliances, October 2008Ch.1 Sec.1 – Page 17

F 500 Review in accordance with other standards501 Upon request, additional requirements, other thanDNV’s own laid down in Ch.2, may be included in the exami-nation work.

Examples on additional standards that have been found appli-cable are:

— EN13852 Offshore Cranes — EU Machinery Directive — EU Machinery Directive Annex 4 — NPD— API 2C.

Applicable combinations of certification/verification assign-ments and review of additional requirements are illustrated inTable F1.

502 It is emphasized that the comparisons are based uponDNV’s understanding and interpretation of the additional re-quirements.

In cases where DNV’s interpretation is questioned or it givesrise to conflicts between involved parties or for other reasonsare considered inappropriate, DNV may refuse to carry out thework based on DNV’s own interpretation of the additional re-quirements. In such cases, the Customer must obtain writteninterpretation from the legislators/standard publishers.

503 Commissions such as described in D302 and F 501 willnormally be limited to the topics and aspects covered in theDNV requirements in Ch.2. Upon request, however, the com-missions may be extended to cover also additional topics.

Such extensions and amendments of scope of work shall be re-flected in written agreements.

504 If it has been agreed to include additional requirementsin the certification work and the additional requirement is notcomplied with, this shall be reported to the Customer in writ-ing.

505 Covering of additional requirements may be limited to;design assessment, manufacturing survey, installation surveyand testing, or to any combinations of these phases.

506 The measures applied to demonstrate compliance withthe additional requirements dealt with in D302 and F501 shallbe documented by the Customer.

F 600 Customers who may request certification and verification

601 Certification may be requested by:

— manufacturer of a complete lifting appliance— manufacturer of components or loose gear— owner/user of a lifting appliance— owner of a ship, mobile offshore unit or offshore installa-

tion, etc.— shipyard or offshore installation fabrication site, etc.

602 Verification services may be requested by persons/bod-ies/institutions/companies possessing legitimate access to thedocumentation forming the basis for the requested verification.

603 Request for certification and verification shall be madein writing as specified in F700.

F 700 Written confirmation

701 Before a certification or verification assignment is com-menced, at least following shall be confirmed in writing:

— Which of the type a), b), or c) in accordance with B102 thelifting appliance or lifting gear belongs to. For type b) itmust also be specified whether the crane is to lift loadsfrom decks of other vessels or only from the sea/seabed.

— Whether the assignment shall be amended to cover re-quirements for lifting of personnel.

— Whether the assignment shall be amended to cover also re-quirements to qualify the lifting appliance for additionalclass notations CRANE or Crane Vessel.

— Whether the assignment shall be amended to cover any ofthe additional requirements listed in D302 or F501.

F 800 Certificate annotations

801 Unless otherwise requested by the Customer, compli-ance with the requirements pertaining to the additional require-ments review as described in D302 or F501 shall be confirmedin writing in the relevant documents.

Applicable combinations of DNV certification and verificationand additional standards assumed especially relevant.

Table F1 Modular Service SchemeLoose gear

Industrialcranes Shipboard cranes Offshore cranes lifting from

sea or from seabedOffshore cranes lifting

from other vesselBasic certification(ILO) X X X X X

Certification extended to cover class(CRANE or Crane Vessel)

X X X

EN 13852(verification) X X

EU Mach. Dir.(verification) X X X X X

EU Mach. Dir.ANNEX 4(verification)

X X X X

NPD Guidelines(verification) X X X X X

API 2C(verification) X X

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Page 19: DNV Standard 2-22 Rules for Lifting Appliances

STANDARD FOR CERTIFICATION OFLIFTING APPLIANCES

CHAPTER 2

TECHNICAL REQUIREMENTS

CONTENTS PAGE

Sec. 1 Documentation ......................................................................................................................... 21Sec. 2 Materials and Fabrication......................................................................................................... 25Sec. 3 Structural Design and Strength of Cranes ................................................................................ 33Sec. 4 Conventional Cargo Gear, Cargo Ramps andmovable Cargo Decks....................................... 42Sec. 5 Machinery and Equipment ....................................................................................................... 46Sec. 6 Safety and Safety Equipment ................................................................................................... 53Sec. 7 Testing and Test Certificates Marking ..................................................................................... 60App. A Wind Loads on Cranes ............................................................................................................. 63App. B Marking of Single-sheave Blocks ............................................................................................ 65App. C Ship Mounted Cranes Without Jib Support in Transit Condition ............................................ 66App. D Examples on Requirements for Documentation for Acceptance of Works Certificates.......... 69App. E Examination of Brackets, Skids and Monorails ....................................................................... 71App. F Register and Certificate Forms................................................................................................. 73App. G Verification Guideline for Safety Functions ............................................................................ 82

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Veritasveien 1, NO-1322 Høvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11

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Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.1 – Page 21

SECTION 1 DOCUMENTATION

A. Documentation and Information to be Submitted

A 100 General 101 The documentation necessary for verification assign-ments will depend on the scope of work agreed. The documen-tation and information requirements stated below arenecessary for design approval and ensuing certification.

A 200 Documentation 201 For cranes to be certified, plans and supplementary doc-umentation (e.g. necessary calculations, see B) giving perti-nent particulars of the technical subjects listed below shall besubmitted in duplicate in ample time before fabrication of thelifting appliance:

— general arrangement of the lifting appliance including anyhazardous area classification

— ratings of the lifting appliance— rigging plan/reeving plan— structural drawings with pertinent calculations— slewing ring and fasteners — ropes, thimbles, shackles, swivels, chains, rings, etc.— hooks and blocks — pins and sheaves— drums and brakes— gears transmitting braking forces— braking systems— schematic diagram of: hydraulic systems, electrical sys-

tems, pneumatic systems and instrumentation/automation— material specifications. See also 400.— safety equipment— fire protection— extent, type and acceptance criteria for non-destructive

testing (NDT)— program for functional testing*. See also Sec.7 A — program for load testing*. See also Sec.7 B— load charts and/or load tables.

* See end of 301.

A 300 Specifications and information301 In addition to the drawings, plans, diagrams and calcula-tions listed in 200, following information and specificationsshall be submitted:

— name and address of crane manufacturer, vendors, craneowner (if known)

— intended location of the crane— type of crane. See definitions of Ch.1 Sec.1 B102— possible request for Additional Equipment and System

Notation CRANE or Additional Service and Type Nota-

tion Crane Vessel— design criteria, including codes and standards etc. applied

for the structure, systems and details. See also B102— limitations of use and design ambient and operational con-

ditions for the lifting appliance— type and make of prime mover or specification of other

main power supply— emergency power supply, if arranged— type of power systems applied for the various operations

and movements— lists with functional description of applied hydraulic, elec-

trical and pneumatic components— possible additional services requested. See Ch.1 Sec.1

E500— possible reduced scope of work requested. See Ch.1 Sec.1

E700— conflicting codes or standards identified. See Ch.1 Sec.1

A500— specific design features such as for instance: lifting with

grab, crane controlled by wireless remote control system,lifting of persons, jib unsupported in transit condition, lo-cated in hazardous areas, etc.

— crane Manual. *)

*) To be presented for acceptance to the Society’s surveyorwho shall monitor and accept the testing at the lifting in-stallation’s final location.

302 In order to implement dynamic amplification of theloads on the structures, dynamic factors are to be specified bythe designer:

— industrial crane— shipboard crane— non-class related offshore crane— crane for lifting of submerged load.

For class-related offshore cranes, the determination of the dy-namic factors when lifting in waves is covered by the designapproval. See B104.

A 400 Material grades and certificates

401 For specification of material grades, see Sec.2 A201.

402 Material certificates shall be presented at the Society’smanufacturing survey and are not to be submitted for designassessment. See also Sec.2 A401.

A 500 Components and accessories

501 General requirements to documentation of componentsand accessories are listed in Table A1. The table is intended aseasy reference only, and shall be interpreted in combinationwith relevant text.

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Standard for Certification of Lifting Appliances, October 2008Page 22 – Ch.2 Sec.1

Indexes for Table A1

1) For Shipboard cranes.

2) For Offshore cranes.

3) Design and strength to comply with recognised standard.

4) A prototype test up to at least the specified breaking loadof the rope used. (Quality control of every rope end termi-nation to be done in accordance with recognised standard.Proof loading to maximum 40% of the minimum breakingload of the rope is recommended.

5) Applicable as basis for certification if carried out by DNV.

6) Certification by other Competent Person/Body (whichmay also be the manufacturer) than DNV may normally beaccepted. In such cases the material certificates shall befiled by the manufacturers and shall be presented upon theSociety’s request.

7) Except for lifting appliances categorised as Offshore craneand/or to be covered by class notations CRANE or CraneVessel, certification by other Competent Person/Bodythan DNV (which may also be the manufacturer) may nor-mally be accepted. In such cases the material certificatesshall be filed by the manufacturers and shall be presentedupon the Society’s request.

8) Except for lifting appliances categorised as Offshore craneand/or to be covered by class notations CRANE or CraneVessel, certification by the manufacturer or anotherCompetent Person/Body than DNV may normally be ac-cepted both for winches and winch gears unless otherwisespecified by the Customer. Components in winch gearswhich are transmitting braking forces shall be included in

the scope of certification. See also Appendix D regardingdocumentation to be submitted.Functional testing required. If certified by the gear manufacturer or other CompetentPerson/Body than DNV, the following shall be compliedwith:

— A Certificate of Conformity or equivalent documentcovering functional test shall be submitted.

— Sectional drawings containing relevant parametersincluding torque capacity shall be submitted for com-pletion of DNV’s files (1 copy).

Transmission gears for non-critical application, as for ex-ample non-hoisting purposes (e.g. slewing units) may nor-mally be accepted providing the following is submitted:

— Gear manufacturer’s product certificate coveringfunctional test. See also Appendix D regarding docu-mentation to be submitted.

— Sectional drawings together with calculations docu-menting necessary torque and available torque forcompletion of DNV’s file (1 copy).

9) Or equivalent if certified by other Certifying Authority/Body than DNV, e.g. ILO Form No.3.

10) Or equivalent if certified by other Certifying Authority/Body than DNV, e.g. ILO Form No.4.

11) Preferably. Survey Report may cover the purpose and maysuffice.

12) For Shipboard cranes not to be covered by class (CRANEor Crane Vessel), and with a load carrying capacity notexceeding 20 tons, DNV inspection and survey report/pro-duction certificate may be omitted.

13) For Shipboard cranes not to be covered by class (CRANEor Crane Vessel), and with a load carrying capacity notexceeding 20 tons, the cylinders may be accepted with themanufacturers’ product certificate on the following condi-tions:

— The manufacturer must be considered a recognisedmanufacturer.

— The cylinder is subject to serial production.— The exception may be agreed on a case-by-case basis

and shall be agreed in advance.— The manufacturer shall apply for such exception in

Table A1 Crane components and accessories - general requirements

Designapprovalrequired

Inspectionrequired

Type ofmaterial

certificates 17)

Load testat

manufacturer’s

Before installation:Required documentation

Surveyreport

Type of DNVcertificates 16)3.1 3.2

Sheaves 6) x 3)5) x 5) x x 5) Sheave axles x x x xHooks, chains, swivels,shackles 6) x 3)5) x 5) x x x 5) CG3 9)Wire end terminations(sockets, swaged lugs, etc.) x 3) x 4)

Hoisting blocks 7) x 3)5) x 5) x x x 5) CG3 9)Ropes (steel wire or fibre) 6) CG4 10)Winches incl. brakes, drum, support 8) x 5) x 5) x x 5) Prod. Cert.

Transmission gears 8) x 5) x 5) x x 5) Prod. Cert.Slewing rings x x 12) 1) 2) x 12) Prod. Cert. 11)12)Slewing ring bolts x x 12) 1) 2) x 12) Prod. Cert 11)12)Hydraulic cylinders 15) x 13)14) x 13) x 13) Prod. Cert. 13)

Hydraulic system: Design/System review.Hydraulic components:

Manufacturers’ pressure test certificate.

Electrical system: Design/System review.Electrical cables and accessories:

In accordance with DNV’s Rules (type approval or case by case).

Electrical motors: DNV certificate in case of class no-tations CRANE or Crane Vessel above 100 kW. Otherwise manufac-turers’ test certificate acceptable.

Diesel engine: To be in accordance with Ship Rules Pt.4 Ch. 2.

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Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.1 – Page 23

due time by submitting one copy of documentation onthe cylinder, including all main dimensions and mate-rial specifications enclosed to the application, ena-bling DNV to carry out an independent reviewcalculation as found appropriate.

— Extent of NDT and pressure testing shall be agreed ineach case.

14) For design approval, see Sec.5 E 115-121.

15) The DNV certification shall be carried out as described inDNV’s Standard for certification No.2.9 “Type ApprovalProgramme 5-778.93 Hydraulic cylinders”, October2002.

— (The lower limit of p · Di = 20 000 given in DNVRules for Ships Pt.4 Ch.6 Sec.5 H301 is not applicablefor cylinders for lifting appliances).

— The DNV product certificate shall, in addition to theitems specified in the above Certification Note, statethe dynamic design loads, the design pressure, andthat the cylinder is certified for use in lifting applianc-es only. The design temperature and/or the minimumacceptable design temperature shall be stated on theproduct certificate.

16) Only to be used for certifications carried out by DNV. Cer-tifications carried out by Manufacturers may be evidencedby Works Certificates replacing DNV’s Product Certifi-cates.

17) Designation references in accordance with EN10204:2004.

B. Calculations to be Included in the Documentation

B 100 Necessary calculations

101 For structural parts and components specified in A200,the drawings shall be supplemented with calculations demon-strating that the structural strength complies with the require-ments of the Sections 3, 4 and 5.

102 A complete listing of structural components and partssubjected to strength calculations shall be submitted. The listshall include information of

— types of failures considered (excessive yielding, buckling,fatigue fracture)

— elastic or plastic analysis performed— permissible stress or limit state method used.

See also Sec.3 D.

103 The calculations will be used as information during thedesign assessment work and will not be approved. They will befiled by DNV. Consequently, only one copy needs to be sub-mitted.

Emphasis is made to determination or calculations document-ing the dynamic coefficients used in the design calculations.

104 For Offshore cranes to be covered by class, the calcula-tions of the dynamic coefficients shall cover:

a) The still-water dynamic factor or specification of a possi-ble increased figure chosen as design dynamic factor. Seedefinition in Ch.1 Sec.1 C.

b) Calculations of the dynamic coefficients for all combina-tions of boom angles and Hsign.

c) The crane-supporting vessel’s heave- and roll velocitiesused in the calculations referred to in b) above, as well asa description of the geometrical location of the crane on

board the vessel.

d) As an alternative to the figures required in c) above, thevertical velocity components at the boom tip caused by thecrane-supporting vessel’s heave and roll.

e) For lifts of submerged loads, the maximum acceptable dy-namic coefficient contribution caused by hydrodynamiceffects shall be specified. This includes also hydrodynam-ic effects occurring when the load is lifted through the seasurface.

C. Design and Extreme Temperature

C 100 Design temperature101 Design temperature is a reference temperature used as acriterion for the selection of steel grades.

102 The design temperature TD for lifting appliances is de-fined as the lowest mean daily temperature. (The average tem-perature during the coldest twenty-four hours of one year.)

103 For lifting appliances installed on vessels or mobile off-shore units classified with the Society, the design temperaturesof the appliances and the vessel/unit shall be compatible.

104 If not otherwise specified design temperature accordingto Table C1 shall be applied.

C 200 Extreme low temperature201 The lowest temperature estimated to appear in an areawith a corresponding specified design temperature. Structurescomplying with the material requirements for a specified de-sign temperature are considered to maintain the necessary re-quired mechanical properties down to the extreme lowtemperature.

Guidance note:Values given in brackets to indicate that they shall be consideredfor information only. It is DNV’s opinion, however, that craneoperations shall not take place at temperatures below the extremelow temperature.

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D. Design Conditions (environmental, operational) for Machinery and Systems

D 100 General101 Machinery and systems for lifting appliances shall bedesigned to operate under the following environmental condi-tions if not otherwise specified in the detail requirements forthe component or system:

— ambient air temperature between the design temperatureand 35°C

— ambient air temperature inside machinery housing or othercompartments containing equipment between 05°C and55°C

Table C1 Design temperature for Lifting Appliances.Type of Lifting Appliance Design

temperatureCorresponding Extreme Low Temperature

Shipboard/Industrial Cranes -10°C (-30°C)

Offshore Cranes -20°C (-40°C)Engine rooms and other similar spaces with con-trolled temp. +10°C (0°C)

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— relative humidity of air up to 96%.

102 Where the certification standard stipulates requirementsto capacity or effect of machinery, these shall normally be de-termined on the basis of the following:

— ambient air temperature: 40°C— relative humidity of air: 50%.

These values will be reconsidered if the crane shall work intropical or sub-tropical areas.

Guidance note:Consideration should be taken to the heat generated by machin-ery or other equipment and also to the heat caused by sun radia-tion on surrounding bulkheads.

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103 The effect of ice on an appliance installed in cold weath-er areas shall be considered for the parked/stowed position.

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SECTION 2 MATERIALS AND FABRICATION

A. General

A 100 Scope

101 This section stipulates requirements for materials for im-portant structural members and equipment for cranes with de-sign temperature TD down to ÷30°C.

Materials for cranes with design temperature below ÷30°C willbe especially considered. For definition of design temperature,see Sec.l C100 of this Certification Standard.

102 Materials with properties deviating from the require-ments in this section may be accepted upon special considera-tion.

103 The following categorisation will be used for structuralmembers:

— Essential where no redundancy and/or no redistribution ofstresses are regarded possible.

— Primary structures are main load-carrying members andcomponents subject to high stresses.

— Secondary structures are structures other than primarystructures and essential members.

The categories shall be agreed with the Society in each case.

See also detailed categorisation for bolt connections in D501.

A 200 Required documentation

201 Specifications of material grades to be used in structuralmembers and important equipment of the crane shall be sub-mitted to the Society for approval.

Material grade designations shall be stated with reference tothe Society's Rules for Ships Pt.2 “Materials and Welding”, orwith reference to recognised standards as EN/ISO or nationalstandards.

A 300 Steel manufacturing process

301 Steel shall be made by the basic oxygen process, openhearth process, electric furnace process, or by other process es-pecially approved by the Society.

A 400 Material manufacture survey, certification and testing procedures

401 Certificates covering specification of the chemical com-position and mechanical properties shall be presented for allmaterials for all load-carrying structures and mechanical com-ponents. The test values shall show conformity with theapproved specification. Test specimens shall be taken from theproducts delivered.

See also the Society’s Rules for Ships Pt.2 Ch.1 “General Re-quirements for Materials”.

Approved steel manufacturer will not be required.

402 Inspection certificate 3.1 will normally be accepted, ex-cept for slewing rings and slewing ring fasteners for offshorecranes in which case DNV inspection certificate 3.2 is re-quired, unless otherwise agreed.

Guidance note:The document designation inspection certificate 3.1 and 3.2 arein accordance with EN 10204: 2004.

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403 DNV inspection certificate 3.2 is a document signed bya surveyor of the Society and accepted by the manufacturer’sauthorized inspection representative, covering the results of

the required tests. It shall certify that the tests have been carriedout by the manufacturer in the presence of the surveyor accord-ing to the Rules or according to special agreement on samplestaken from the delivered products direct.

404 Inspection certificate 3.1 is a document issued by themanufacturer which contains the results of all the requiredtests. It shall certify that the tests have been carried out by themanufacturer on samples taken from the delivered products di-rect.

405 The materials shall be adequately marked for identifi-cation. The marking shall at least comprise name or trade markof the manufacturer, material grade, heat number, and when re-ferred to 3.2 certificates, the stamp of the purchaser’s author-ized representative.

406 Marking and identification of smaller items, e.g. boltsand nuts, shall be especially agreed upon between manufac-turer and the Society, but must at least comply with fastenerproduct standard.

407 Materials without proper identification will be rejectedunless renewed testing verifies compliance with approvedspecifications. The number and type of tests will be decided ineach case.

A 500 Retesting501 Materials that prove unsatisfactory during delivery test-ing may be retested. If the standard, with which the materialsshall comply, gives no directive for retesting, the retestingshall be carried out as given in the Society’s Ship Rules Pt.2Ch.1. Provided the new test results are found to satisfy the pre-scribed specification, the material may be accepted.

B. Rolled Structural Steel for Welding

B 100 General101 In addition to the requirements for structural steels setout in the following, further requirements may be stipulated inspecial cases depending on the material application. Thus, test-ing for fracture mechanics analysis and through thickness duc-tility properties may be required. Fracture mechanics testing inaccordance with an approved procedure will be required formaterials and welded joints when the crane manufacturer can-not document satisfactory experience from previous similarmaterial application.

102 Rolled structural steel for welded constructions may becarbon steel or carbon-manganese steel. The steels are dividedinto three groups dependent on the specified yield strength asfollows:

— Normal strength steels, with specified minimum yieldstress 235 N/mm2.

— High strength steels, with specified minimum yield stressof 265 N/mm2 and up to and including 390 N/mm2.

— Extra high strength steels with specified minimum yieldstress of 420 N/mm2 and up to and including 690 N/mm2.

103 Application of steel with specified minimum yieldstrength above 750 N/mm2 shall be especially agreed.

104 Steels having through thickness ductility (“Z-steel”)may be required for primary members which will be signifi-cantly strained in the thickness direction.

105 The requirements to chemical composition, mechanicalproperties etc., are given in DNV’s Rules for Ships Pt.2 Ch.2

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Sec.1 B for normal strength steels, Pt.2 Ch.2 Sec.1 C for high-strength steels, and Pt.2 Ch.2 Sec.1 D for extra high strengthsteels,

106 As an alternative to 105, materials that comply with na-tional or proprietary specifications may be accepted providedsuch specifications give reasonable equivalence to the require-ments of this section or are approved for a specific application.

B 200 Impact test temperatures201 Required impact test temperatures are dependent on de-sign temperature TD and the material thickness. Impact testtemperatures are given in Table B1 for structural steel for pri-mary and secondary applications. For definition of design tem-perature see Sec.1 C100.

For structural members subjected to compressive and/or lowtensile stresses, modified requirements may be considered, i.e.greater material thicknesses for the test temperatures specified.

202 When welding a thinner plate to a thicker plate, e.g. con-necting a flange to the supporting structure for the flange, in-serted reinforcement rings etc., the following apply providedthe thicker plate does not contain butt welds:

The impact test temperature shall be the lower of the tempera-tures according to Table B1, based on t1 or 0.25·t2 where:

t1 = thickness of the thinner supporting plate

t2 = thickness of the flange.

However, the impact test temperature for the flange (thickerplate) shall not be higher than the required test temperature,based on t2 according to Table B1, plus 30° C.

B 300 Testing

301 Test samplesUnless otherwise required the test samples shall be taken forpositions as specified in the Society’s Rules for Ships Pt.2Ch.1 or other recognised standards. The sample of materialfrom which test specimens are cut shall be treated togetherwith and in the same way as the material presented. Thesamples shall be suitably marked for identification.

302 Test specimensTest specimens shall be as specified in the approved standards.The following additional requirements shall apply:

— For impact testing of thin materials where the thicknessmakes it impossible to use an impact test specimen of 10× 10 mm the largest practicable of the following speci-mens shall be used:

- 10 × 7.5 mm or l0 × 5 mm.By this procedure the required impact values are reducedto 5/6 and 2/3, respectively, of the value of the standard10 x 10 mm test specimen.

C. Rolled Steel not for Welding

C 100 General

101 Rolled steel for essential and primary components otherthan those mentioned in 200 and 300 (e.g. machinery parts)shall be specified with reference to a recognised standard. Thematerial shall be delivered in the following conditions:

— carbon and carbon/manganese steel in normalized condi-tion

— alloy steel in quenched and tempered condition.

For all materials, impact toughness shall be documented byCharpy V-notch impact tests. Test temperatures shall be as re-quired by Table D1 but, in the case of low calculated stresses,e.g. not exceeding 50 N/mm2, a test temperature of 20°C willbe accepted. Required minimum impact energy shall be as re-quired for welded parts, ref B105. For carbon and carbon/man-ganese steel the carbon content shall be less than 0.35%.

C 200 Bolts and nuts

201 Materials for bolts and nuts considered as important forthe structural and operational safety of the assembly in ques-tion, shall comply with the requirements in D400 for bolts andnuts. This includes requirements for chemical composition andmechanical properties.

For definition of important bolted connections, see D401.

C 300 Rolled rings

301 Rolled rings for important components such as slewingrings, toothed wheel rims etc. shall comply with the require-ments for steel forgings, see D500.

C 400 Shafts and plates

401 For un-welded load-carrying members, e.g. shafts and/or plates, an impact test temperature of 20°C may be appliedprovided the calculated stresses are less than 50 N/mm2.

402 In cases where calculated stresses are equal to or exceed-ing 50 N/mm2, the impact test temperature for un-weldedmembers shall be as required by Table D1.

D. Steel Forgings

D 100 General

101 Forgings shall generally be manufactured in accordancewith the requirements of the Society’s Rules for Ships Pt.2Ch.2 Sec.5 “Steel Forgings”.

102 As an alternative to 101, materials that comply with na-tional or proprietary specifications may be accepted providedsuch specifications show reasonable equivalence to the re-quirements in 101 or are especially approved. As a minimumthe following particulars shall be specified: manufacturing

Table B1 Impact test temperatures for welded structural steel

Material thickness t in mm

Impact test temperature in°C 1)

Structural steel for primary members 2) Structural steel for secondary members 2)

Offshore cranes Shipboard cranes/Industrial cranes

Offshore cranes Shipboard cranes/Industrial cranes

6 ≤ t ≤ 12 3) TD + 10 TD + 20 Test not required Test not required12 < t ≤ 25 TD TD + 10 Test not required Test not required25 < t ≤ 50 TD - 20 TD - 10 TD TD + 10

t > 50 TD - 40 TD - 30 TD - 10 TD1) For normal and higher strength C-Mn steels, the test temperature need not be taken lower than ÷40°C. For extra high strength steel, the

test temperature shall not be taken higher than 0°C and not lower than ÷60°C.2) See A103 for definitions.3) For plate thickness less than 6 mm, Charpy V testing will not be required.

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process, chemical composition, heat treatment, mechanicalproperties and non-destructive testing. For machinery compo-nents, see the Society’s Rules for Ships Pt.4 Ch.2 Sec.3.

D 200 Forgings for general application201 Forgings shall be specified with reference to DNV’sRules for Ships Pt.2 Ch.2 Sec.5 “Steel Forgings” or other na-tional or proprietary specification. As a minimum the standardshall require impact testing and mechanical properties as spec-ified in Table D2. Forgings intended for welded constructions shall comply withthe requirements in Table D3. For thicknesses over 100 mm,smaller deviations from the specified mechanical propertiesmay be accepted based on specific approval by the Society. Forforged shackles, cargo hooks, swivels, sockets, chains, bolts/nuts and slewing bearings, the special requirements of 300 –500 apply.

D 300 Forged shackles, cargo hooks, swivels, sockets and chains301 Carbon and carbon-manganese steel forgings shall bemade from killed and fine-grain treated non-ageing steel. Itmay be required that the non-ageing properties are verified bytests. The chemical composition and mechanical properties ofthe material, with the exception of the impact test temperature,shall be as given in 200. Chemical composition and mechanical properties for alloysteels shall be specified with reference to recognised standardand are subject to individual consideration and approval by theSociety. The chemical composition shall be suitable for thethickness in question. Alloy steels shall be delivered inquenched and tempered condition. Requirements to impact testtemperatures are specified in Table D1.

TD = design temperature in °C

D 400 Bolts and nuts401 Bolt connections are considered as important if they be-long to one of the three below defined categories, essential,primary or secondary. A bolt connection is considered

essential

— where the connection is non-redundant and a breakage ofone bolt or nut may result in a collapse or a serious mal-function (lifting not possible, safety functions out of order,etc.)

— or, where a bolt or nut breakage may lead to any other pos-sible dangerous situation

— or, where they are part of a slewing ring connection.

primary

— where the bolts or nuts are transferring structural load— and, are elements of a primary load-carrying structure,

however, not necessarily essential.

secondary

— where the bolts or nuts are transferring structural load ei-ther by tension, by friction or in combination, however,not belonging in the category essential or being part of aprimary structure. Examples are bolts or nuts in driver’s

cabin, platforms, stairs and ladders.

Bolts and nuts for use in essential or primary connections shallconform with and be tested in accordance with a recognisedstandard, e.g. pertinent parts of ISO 898 or other recognisedstandard.

The additional requirements given in 402 - 408 also apply.

Further, additional requirements to testing and inspection ofslewing ring bolts are given in Table D4.

Bolt connections considered as secondary shall be made fromsuitable materials.

402 Nuts may be accepted to be in one strength class lowerthan the bolts of bolt/nut assemblies.

403 Magnetic particle testing shall be carried out at least 48hours after completion of quenching and tempering for boltswith yield strength above 355 N/mm2. Inspection shall be inaccordance with ASTM E 709.

Depth of longitudinal discontinuities shall not exceed 0.03 ofthe nominal diameter. Transverse cracks will not be acceptableirrespective of crack depth and location. Other surface irregu-larities will be considered in each case.

404 Testing of Charpy V-notch impact energy is required forthe following bolt categories:

— for slewing ring bolts, d ≥ 25— for bolts in essential connections, d ≥ 25.

405 The Charpy V requirements to slewing ring bolts arespecified in Table D4.

For bolts in other essential connections the Charpy V energyrequirements shall be as specified in Table D4 at test tempera-tures as specified in Table D1.

406 Bolts and nuts shall be delivered with the followingcertificates as per EN10204, verifying compliance with thematerial requirements and other test requirements:

— DNV Inspection certificate type 3.2 for slewing ring boltsand nuts for offshore cranes.

— Works certificate type 3.1 for load-carrying bolts and nutsin essential connections and for slewing ring bolts andnuts for cranes other than offshore cranes.

— 2.2 test report for bolts and nuts in primary and secondaryconnections.

407 Slewing ring bolts for offshore cranes shall have rolledthreads, and the rolling shall be performed after final quench-ing and tempering of the bolts.

408 Fasteners (bolts, nuts and washers) in marine environ-ment shall normally be hot-dipped galvanized or sherardizedwith coating thickness min. 50 micrometer. If special threadprofiles or narrow tolerances prohibit such coating thickness,bolts/nuts may be supplied electro-plated or black providedproperly coated/painted after installation. Pickling and electro-plating operations shall be followed by immediate hydrogen-relief (degassing) treatment to eliminate embrittling effects.

409 For 8.8 and 10.9 bolts and nuts corrosion protection bygalvanizing is accepted provided the galvanizing is removedfrom the contact surfaces prior to assembling.

Note: Zinc on the contact surfaces will reduce the local com-pression strength of the surfaces and contribute to increase ofthe bolts’ fatigue load.

Unless specific measures are taken against absorbsion of hy-drogen, galvanizing is not accepted for 12.9 bolts.

D 500 Forged rings for slewing bearings501 Specifications of slewing rings essential for the struc-tural and operational safety of the crane are subject to individ-ual approval by the Society. All relevant details shall be

Table D1 Impact test temperature for shackles, cargo hooks, chains, sockets and swivels

Material thickness t in

(mm)

Impact test temperaturein

( º C)t ≤ 10 Impact test not required

10 < t ≤ 50 TD + 20º50 < t ≤ 100 TD + 10º

t > 100 TD

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specified such as chemical composition, mechanical proper-ties, heat treatment, depth and hardness of surface hardenedlayer and surface finish of fillets. Position of test specimensshall be indicated. Method and extent of non-destructive test-ing shall be specified and the testing procedures shall be stated.Detailed information about method of manufacture shall besubmitted.

502 For each new material of which the manufacturer has noprevious experience and for any change in heat treatment of amaterial previously used, a principal material examination

shall be carried out. This means that the Society may imposeadditional requirements not specified in this Standard for Cer-tification. The results shall be submitted to the Society for con-sideration. The programme for such examination shall beagreed with the Society.

503 All test results shall comply with the approved specifi-cations.

504 Steel for slewing rings shall satisfy the requirements ofTable D5.

Table D2 Mechanical properties for steel forgings for general application, unwelded

Steeltype

Tensile strength Rm minimum

(N/mm2)

Yield stress Re minimum (N/mm2)

ElongationA5 minimum (%)

Reduction of area Z mini-mum (%)

Charpy V-notch1) Energy (J)

l ta t l ta t l ta t

C and C-Mn

400 200 26 22 19 50 43 35 - - -

440 220 24 20 18 50 43 35 - - -

480 240 22 19 16 45 38 30 - - -

520 260 21 18 15 45 38 30 - - -

560 280 20 17 14 40 34 27 - - -

600 300 18 15 13 40 34 27 - - -

640 320 17 14 12 40 34 27 - - -680 340 16 14 12 35 30 24 - - -

720 360 15 13 11 35 30 24 - - -760 380 14 12 10 35 30 24 - - -

Alloy

600 360 18 16 14 50 43 35 41 31 24

700 420 16 14 12 45 38 30 32 24 22

800 480 14 12 10 40 34 27 32 24 22

900 630 13 11 9 40 34 27 27 22 18

1000 700 12 10 8 35 30 24 25 19 16

1100 770 11 9 7 35 30 24 21 15 131) Testing shall be carried out at +20°C.l = longitudinal, t = transverse, ta = tangentially

Table D3 Mechanical properties for steel forgings for welded structures

Steel type Tensile strengthRm minimum (N/

mm2)

Yield stress Re minimum (N/mm2)

ElongationA5 minimum (%)

Reduction of area Z minimum (%)

Charpy V-notch1)

Temperature(°C)

Energy(J)

l t l t l t

C and C-Mn

400 200 26 19 50 35 0 27 18

440 220 24 18 50 35 0 27 18480 240 22 16 45 30 0 27 18520 260 21 15 45 30 0 27 18560 280 20 14 40 27 0 27 18600 300 18 13 40 27 0 27 18

Alloy550 350 20 14 50 35 0 32 22600 400 18 13 50 35 0 32 22650 450 17 12 50 35 0 32 22

1) Testing at +20°C may be accepted subject to compliance with a specific minimum average energy of 45 J longitudinal or 30 J transverse for all grades.

l = longitudinal, t = transverse

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E. Steel Castings

E 100 General

101 Steel castings shall generally be manufactured in ac-cordance with the Society’s Rules for Ships Pt.2 Ch.2 Sec.7“Steel Castings”.

102 As an alternative to 101, materials which comply withnational or proprietary specifications may be accepted provid-ed such specifications give reasonable equivalence to the re-quirements in 101 or are approved for each specificapplication. As a minimum the following particulars shall bespecified: manufacturing process, chemical composition, heattreatment, mechanical properties and non-destructive testing.For machinery components, see the Society’s Ship Rules Pt.4Ch.2 Sec.3.

F. Iron Castings

F 100 General

101 Iron castings shall generally be manufactured in accord-ance with the Society’s Rules for Ships Pt.2 Ch.2 Sec.8 “IronCastings”.

102 As an alternative to 101, materials that comply with na-tional or proprietary specifications may be accepted providedsuch specifications give reasonable equivalence to the require-ments in 101 or are approved for each specific application.

G. Steel Tubes, Pipes and Fittings

G 100 General101 Reference is made to the Society’s Rules for Ships Pt.2Ch.2 Sec.4 “Steel Pipes”, or other recognised standard/code.Recognition of other standards shall be evaluated by the Soci-ety.

H. Aluminium Alloy Structures

H 100 General101 Reference is made to the Society’s Rules for Ships Pt.2Ch.2 Sec.9 “Aluminium Alloys”, ECC’s “European Recom-mendations for Aluminium Alloy Structures” (last valid edi-tion), or other equivalent recognised standard.

I. Steel Wire Ropes

I 100 General101 Steel wire ropes and wire locks for cranes shall generallybe manufactured and tested in compliance with the require-ments stipulated in the following, as well as EN 13414-1 “Steelwire rope slings – Safety” and EN 13411-3 “Terminations forsteel wire ropes”, respectively.

I 200 Materials201 Wire for steel wire ropes shall be made by open hearthelectric furnace, LD process, or by other processes especiallyapproved by DNV or other classification society.

Normally, the minimum tensile grade of the wires shall be1 570 N/mm2, 1 770 N/mm2, 1 960 N/mm2 or 2 160N/mm2

I 300 Construction301 The strands shall be made in equal lay construction(stranded in one operation).

302 All wire ropes shall be lubricated and impregnated in themanufacturing process with a suitable compound to thorough-ly protect ropes both internally and externally to minimize cor-rosion until the rope is taken into use.

303 The rope lubricant selected shall have no detrimental ef-fect on the steel wires or any fibres (in the core) and shall re-duce the friction in the rope.

304 Certain wire-lay types shall be avoided (f. ex. 4x29). Se-lection of wire type shall be based on manufacturer’s recom-mendations (or catalogue specifications).

Table D4 Testing and inspection of slewing ring boltsStrength Class,

ISO 898, or equivalent

Diameter d in mm

Ultimate strengthN/mm2

Yield strength.

Minimum.N/mm2

Elonga-tion A5

Required Charpy V en-ergy 1) at test temp. as

required for rings Table D5

Fracture me-chanics testing

(CTOD)

Surface inspection

8.8d < 25

800 - 1000 640 14⎯ ⎯ Visual

d ≥ 25 Offshore cranes: 42 JOther cranes: 25 J ⎯ Visual and magnet-

ic particle (MPI)

10.9d < 25

1000 - 1200 900 12⎯ ⎯ Visual

d ≥ 25 Offshore cranes: 42 JOther cranes: 25 J ⎯ Visual and magnet-

ic particle (MPI)

12.9 (not allowed for off-shore

cranes)

d < 251200 - 1400 1080 12 (10) 2)

Other cranes: 25 J To be document-ed 3) Visual and magnet-

ic particle (MPI)d ≥ 25 Other cranes: 25 J To be tested 3)

1) Average value. Single value accepted to be 30% lower. 2) May be accepted on case-by-case basis.3) Alternatively, a Charpy V notch energy of minimum 55 J at TD may be accepted. If TD is not specified, -10º will be applied.

Table D5 Slewing materials

Heat treatmentOffshore cranes Other cranes

According to approved Spec.Charpy V-notch test temperature TD

Average 42 25Charpy V-notch value

Single min. value

27 20

Elongation A5 14% 14%

Fatigue properties Documentation may be required by type tests on specimen of ring section

Fracture toughness Documentation may be required by type tests on specimen of ring section in question

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I 400 Testing

401 Steel wire ropes shall be tested by pulling a portion ofthe rope to destruction.

The breaking load shall be according to ISO 2408 or otherapproved standard or specification.

The testing of wire and wire locks shall be carried out accord-ing to EN 13414-1 and EN 13411-3.

402 If facilities are not available for pulling the whole ropeto destruction, the breaking load may be determined by testingseparately 10% of all wires from each strand. The breakingstrength of the rope is then considered to be:

P = f t k [kN]f = average breaking strength of one wire in kNt = total number of wiresk = lay factor as given in Table I l or according.

FC = Fibre coreIWRC = Independent wire rope core

403 Individual wire tests shall be performed for every wiredimension represented in the strands. The number of tests foreach wire dimension shall be the same as the number of strandsin the rope. The samples shall be taken from a representativepart of the wire rope.

404 The following individual wire tests shall be performed:

— tensile test— torsion test — reverse bend test— weight and uniformity of zinc coating.

These tests shall be made in accordance with ISO 6892, 7800and 7801 and shall comply with ISO 2232.

The average tensile value shall not exceed the minimum tensilestrength 1570 N/mm2, 1770 N/mm2, 1960N/mm2 or 2160N/mm2 by more than the tolerance values giv-en in the Table I2.

J. Crane Manufacturing and Construction

J 100 General

101 The manufacturer shall organize a system for qualitycontrol involving competent personnel with defined responsi-bilities that shall cover all aspects of quality control.

The materials shall be identifiable during all stages of manu-facturing and construction.

102 Manufacturing and construction shall be in accordancewith the approved drawings and specifications The specifica-tion shall refer to a recognised code, standards or rules relevant

for the structure in question. Supplementary requirementsamending the reference documents may be stipulated.

103 Dimensional tolerances specified in the design analysisof the crane structures shall be complied with during manufac-turing and construction.

104 All defects and deficiencies shall be corrected before thestructural parts and equipment are painted, coated or made in-accessible.

J 200 Welding procedure specifications

201 Reference is made to the Society’s Rules for Ships Pt.2Ch.3 “Fabrication and Testing of Ship Structures”.

202 As alternatives to the requirements stated in 201, the fol-lowing standards may also be accepted:

— AWS D.1.1, or— EN ISO 15614 -1 for steel— EN ISO 15614 -2 for aluminium.

J 300 Welding consumables

301 Welding consumables type approved by DNV or accept-ed based on welding procedure tests shall be used.

Guidance note:Guidance:Welding consumables type approved by the Society are recom-mended. The type approved welding consumables are listed onthe intranet. On intranet: http://exchange.dnv.com/tari underType Approval/Type Examination.

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302 Welding consumables shall be selected such as to pro-duce a weld with mechanical properties at least equal to thatspecified for the structural steel type in question. The weldmetal shall be compatible with the base material regarding heattreatment and corrosion. Only welding consumables specifiedin the qualified welding procedure shall be used, or same grad-ing of different brand.

303 Manual welding of high-strength and extra high-strength steels shall be performed with low hydrogen weldingprocesses.

304 Welding consumables shall be supplied in sealed mois-ture-proof containers or packages. Routines for storage, han-dling and rebaking of consumables as advised by themanufacturer shall be established and followed.

Consumables that have been contaminated by moisture, rust,oil, grease, dirt etc. shall be discarded.

J 400 Forming of materials

401 Forming of plates, structural shapes, tubes etc. shall becarried out according to a specification outlining the succes-sive and controlled steps.

402 If cold-forming results in a permanent deformation ex-ceeding 5% for primary structural members, thermal stress re-lieving is normally required unless the notch ductility in thedeformed and artificially aged condition is verified as accept-able.

403 Hot-forming shall be carried out within the minimumand maximum temperatures advised for post-weld heat treat-ment of the steel in question.

When heat treated steel are hot-formed, the initial heat treat-ment shall be repeated, unless it is demonstrated by suitabletests that the temperature control during hot forming and sub-sequent cooling ensures a treatment equivalent to the initialheat treatment.

The specified mechanical properties shall be attained in the fi-nal worked condition.

Table I1 Lay factor kRope construction Rope with FC Rope with IWRC

6 × 19 group6 × 36 group

0.8600.835

0.8010.775

Non-rotating ropes17/18 × 735/36 × 7

0.7800.750

0.7580.743

Table I2 Plus tolerance on tensile strengthNominal diameter in mm Plus tolerance on min. tensile

strengthN/mm2from to

-0.51

1.52

0.51

1.52-

390350320290260

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J 500 Welding preparation

501 Mill scale, rust etc. shall be removed prior to welding,and the grooves shall be dry and clean. The fit-up shall bechecked before welding. Any misalignment between parallelmembers shall not exceed 10% of the material thickness ormaximum 3 mm. Where materials of different thickness arebutt welded, material tapering shall be in accordance with rec-ognised codes or standards.

J 600 Welding performance601 All welding operations, including tack and seal welding,shall be carried out in accordance with an approved weldingprocedure specification WPS. The WPS may be supported bya welding procedure qualification test, WPQT, ref. DNV’sRules for Classification of Ships Pt.2 Ch.3 Sec.5.

602 Preheating may be required for materials of certainthicknesses and chemical compositions. For welding of extrahigh-strength steel the preheating and interpass temperatureshall be as advised by the steel manufacturer.

603 The weld reinforcement shall have a regular finish andshall merge smoothly into the base material without significantundercutting. The height of weld reinforcement shall not ex-ceed 3 mm for material thickness t ≤ 12.5 mm and max. 4 mmfor greater thickness.

604 Welds which are essentially perpendicular to the direc-tion of applied fluctuating stresses in members important to thestructural integrity, shall normally be full penetration type and,if possible, welded from both sides. Dressing of welds bygrinding may be required. Joint members subjected to highstress in the thickness direction shall be of Z-quality, alterna-tively ultrasonically tested for lamellar tearing before welding.

605 The use of permanent steel backing strips may be ac-cepted when properly accounted for in the design analysis. Ce-ramic and other neutral backing strips may be used when ofapproved type. A test weld for the intended application shall beproduced and subjected to mechanical testing agreed upon ineach case.

606 Temporary cut-outs shall be made of sufficient size al-lowing sound replacement. Corners of cut-outs shall be givenappropriate radius minimizing the local stress concentration.

J 700 Repair of welds701 For every type of repair, a repair welding procedurespecification shall be prepared. In addition to the details men-tioned in 200 the method for removal of defects, preparation ofweld area and subsequent non-destructive testing as well asminimum and maximum repair length/depth shall be specified.

702 Repairs by welding of essential and primary structuralmembers and connections of primary to secondary members,shall be carried out in accordance with approved WPS. Docu-mentation shall be presented prior to commencement of repairwelding.

703 Weld defects may be rectified by grinding, machining orwelding. Welds of insufficient strength, ductility or notchtoughness shall be completely removed prior to repair. Themechanical properties of repair welds shall satisfy the mini-mum specified properties of the steel in question. Repair witharc-air gouging shall be followed by subsequent grinding.

Repair welding in the same area may be carried out twice. Fur-ther repairs are subject to the Society's consent.

704 Repair welding shall be carried out with extra hydrogenwelding consumables applying an appropriate preheating andworking/interpass temperature. Generally the preheating andworking temperature when making shallow and local repairsshall be raised 25°C above level used for production welding,but is not to be less than 100°C . The working temperature shallbe maintained until the repair has been completed ensuresound repair welds. The single repair length shall not be short-

er than approx. 100 mm.

705 When repair welding is carried out on heat-treated steel,reheat treatment may be required. When post heat-treated partsneed repair by welding, the post heat treatment (PWHT) shallnormally be repeated.

J 800 Heat-treatment after forming and welding801 If heat treatment after forming or welding is specified inprocedures or on drawings, a detailed heat treatment procedureshall be submitted to the Society for approval.

802 Thermal stress relieving of cold-worked material, iffound necessary, shall be carried out in accordance with theconditions stated below for post-weld heat treatment.

803 Post-weld heat-treatment of C-steels and C-Mn-steelsshall be performed with a soaking temperature in the range550—600°C, for a time of 2 minutes per mm thickness. Soakingtemperature for low-alloyed steel shall be decided in each case.

804 Post-weld heat-treatment shall, wherever possible, becarried out in an enclosing furnace. Where it is not practical toheat-treat the whole structure in a closed furnace, local heat-treatment may be adopted subject to the Society's consent.

805 The heat-treatment cycle shall be recorded using ther-mocouples equally spaced externally, and whenever possibleinternally, throughout the heated region. Heat-treatmentrecords shall be submitted to the Society for consideration.

J 900 Production weld tests901 Welding Production Test (WPT) may be required to becarried out during the production welding under identical con-dition as that of the production welding in order to verify theproperties of the welds. Number and type of tests will be spec-ified in each case.

902 When a WPT fails to meet the requirements, retestingmay be carried out in accordance with the following.

If the impact test (3 specimens) fails to meet the requirements,3 additional impact test specimens may be prepared and testedprovided that only one of the below mentioned cases occurredin the first test:

— The average value was below the requirement, one valuewas below the average requirement but not below the min-imum requirement for a single value.

— The average value met the requirement. Two values werebelow the average requirement but not below the require-ment for a single value.

— The average met the requirement. Two values were aboveor equal to the average requirement and one value was be-low the requirement for a single value.

The initial 3 impact values and the additional 3 values shallform a new average of six values. If this new average complieswith the requirement and no more than two individual resultsof all six specimens are lower than the required average and nomore than one result is lower than the required value for a sin-gle specimen, the test may be accepted.

903 Upon special request and at the discretion of the Society,welding production tests may replace welding procedure qual-ification tests.

J 1000 Inspection and testing of welds1001 Completed welds shall be subjected to visual inspec-tion and non-destructive testing as manufacturing and con-struction proceeds. For material grade NV 420 and higher,NDT shall not be carried out before 48 hours after completion.When post weld heat treatment is performed, the final non-de-structive testing shall normally to be carried out when the heat-treatment has been carried out/completed.

1002 All welds shall be visually inspected over their fulllength.

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1003 Methods for non-destructive testing (NDT) shall bechosen with due regard to the conditions influencing the sensi-tivity of the methods. Unless otherwise agreed, structuralwelds shall be subjected to non-destructive testing to the extentstipulated in Table J1. The specified percentages refer to thetotal length of weld for each structural assembly in question.The categories of the structural members shall be agreed withthe Society in each case, ref. A103.

1004 The non-destructive testing shall include intersectionof butt-welds, cruciform joints and other areas where the stresslevel is high, as well as start and stop-points of automaticallywelded seams.

1005 If non-destructive testing reveals defects which indi-cate unacceptable weld quality, the Society's surveyor may re-quire increased extent of testing until the specified overallquality level has been re-established. If serious defects (i.e.cracks and other planar defects, excessive slag lines and clusterporosities) occur repeatedly, all welds made with the samewelding procedure during the period in question shall be testedover their full length.

1006 The Society's surveyor shall be the final judge when as-sessing the weld quality.

1007 All non-destructive testing shall be properly docu-mented and identified in such a way that the tested areas maybe easily retraced at a later stage.

J 1100 NDT-procedures and NDT-operators1101 NDT shall be performed according to approved pro-cedures and, if required, qualified for the work. The approvedprocedures shall be in accordance with DNV ClassificationNote No.7 or other recognised standard for the test method.

1102 All testing shall be carried out by qualified andcertified personnel. The NDT operators shall be certified ac-

cording to a recognised certification scheme accepted by theSociety, e.g. EN 473, ISO 9712. The certificate shall clearlystate the qualifications as to which testing method and withinwitch category the operator is certified.

1103 The NDT-operators shall issue reports describing theweld quality. The reports shall clearly distinguish between ac-cepted and rejected welds, and the number of repairs carriedout to meet the specified acceptance standard shall be stated.The inspection reports shall specify the NDT-methods andprocedures used including all NDT-parameters necessary for aproper assessment.

J 1200 Weld acceptance criteria1201 All welds shall show evidence of good workmanship.For visual inspection and NDT the acceptance level shall nor-mally comply with ISO 5817 quality level C, intermediate. Forcritical areas more stringent requirements, such as ISO 5817level B, stringent, may be applied.

J 1300 Material protection against corrosion1301 Steel surfaces exposed to marine atmospheric con-ditions shall be protected by a suitable coating system.

1302 Steel surfaces to which application of coating are notpossible and which are exposed to internal corrosive condi-tions shall be protected by other protective systems such as oil,grease, grouting etc.

1303 Bolts, nuts and associated elements shall be protectedby hot-dip galvanizing according to relevant standards, i.e. BS729 or ASTM A 153-82. Alternatively they may be fully en-capsulated and the open space be filled with inhibited oil,grease etc.

Other protection methods may be accepted upon special con-sideration by the Society.

Table J1 Minimum NDT of structural welds

Category ofmember Type of connection

Test methodVisual in-spection

Magnetic particle 3)

Radiography 1) Ultrasonic

Essential/Non-redundant

Butt weld 100% 100% 100%Cross- and T-joints, full penetration welds 100% 100% - 100%Cross- and T-joints, partly penetration and fillet welds 100% 100% - -

PrimaryButt weld 100% 20% 20%Cross- and T-joints, full penetration welds 100% 20% - 20%Cross- and T-joints, partly penetration and fillet welds 100% 20% - -

SecondaryButt weld 100% spot 2) spot 2)

Cross- and T-joints, full penetration welds 100% spot 2) - spot 2)

Cross- and T-joints, partly penetration and fillet welds 100% spot 2) - -1) May be partly or wholly replaced by ultrasonic testing upon agreement.2) Approximately 2-5%.3) Liquid-penetrant testing to be adopted for non-ferromagnetic materials.4) Ultrasonic testing shall not be used for thickness less than 10 mm.

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SECTION 3 STRUCTURAL DESIGN AND STRENGTH OF CRANES

A. Group Classification of Lifting Appliances

A 100 General101 For the purpose of applying requirements concerningstrength of structural and mechanical components, cranes andcomponents shall be classified into groups according to theduty performed.

The group to which a crane as a whole or a component belongsdepends on the utilisation of the crane or component with re-spect to frequency of use as well as magnitude of loads in rela-tion to maximum load.

102 For the crane as a whole and normally also for several ofthe structural components, the frequency of use may be ex-pressed by the expected (calculated) number of hoist cycles (n)during the planned life (t1). The magnitude of loads in relationto maximum load may be expressed by, for instance, a numberindicating to what extent the crane lifts the maximum load(Safe Working Load), or only a lesser load.

For cranes where the safe working load depends on the allowedmaximum overturning moment or allowed maximum momenton the structure, the group classification may also be based onthe frequency with which the allowed maximum moment canbe expected.

103 For structural components in which the stress variationis significantly different from the hoist load variation, stresscycles shall be considered instead of hoist cycles, and stress tomaximum stress ratios shall be considered instead of the loadto maximum load ratios. Otherwise the method of specifyingutilisation is as given in 102.

104 For mechanisms, the frequency of use may normally beexpressed by assumed average daily operating time (A mech-anism is considered to be in operation during motion).

The utilisation with respect to magnitude of loads may be ex-pressed by a number indicating to what extent the mechanismoperates with maximum load, or only with reduced load.

A 200 Fatigue calculations of cranes and components applicable to strength calculations

201 For fatigue calculations normally the latest edition ofF.E.M. standard (Federation Europeenne de la Manutention)or equivalent national standards for cranes may be referred to.

Guidance note:

If F.E.M. 1.001 3rd edition Rev.1998.10.01. is used, and if nototherwise documented by statistical evidence and/or limitationwith respect to operational performance Table A1 applies asguidance. (terminology as in F.E.M. 1.001 3rd editionRev.1998.10.01. )

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

202 The method of fatigue calculation, for example by usinggroup classification in accordance with F.E.M. 1.001 3rd edi-tion Rev.1998.10.01. on one side and calculation procedureand the specific requirements on the other, shall be consistent.

See also D 400.

203 The crane group chosen for the calculation shall also bespecified in the Crane Manual.

B. Design Loads

B 100 General

101 The loads to be considered in the analysis of structuresare divided into:

a) Principal loads (see 200).

b) Vertical loads due to operational motions (see 300).

c) Horizontal loads due to operational motions (see B 400).

d) Loads due to motion of the vessel on which the crane ismounted (see 500).

e) Loads due to climatic effects (see 600).

f) Miscellaneous loads (see 700).

102 The loads to be considered in the analysis of mecha-nisms are divided into:

Table A1 Group classification of lifting appliances

Definition of crane Particulars concerning nature of use 1)

ApplianceGroup 2)

Cranes for exceptionally low service time, e.g. BOP cranes A2Workshop and similar industrial cranes with hook A4Overhead travelling cranes for maintenance purpose A3Pipe rack cranes hook A3Pipe rack cranes magnet A6-A8Store room cranes A4Jib or gantry cranes for container service A5Dock side and shipyard jib cranes hook A5Dock side and shipyard jib cranes grab or magnet A6-A8Shipboard cranes for cargo-, provision- or hose handling hook A4Shipboard cranes grab or magnet A5Offshore cranes, whip hoist A5Offshore cranes, main hoist A3For cranes with safe working load more than 250 tonnes, the group-classification can normally be set at the lower alternative or one group lower, but at least group A2.

1) Only a few typical cases of use are shown, by way of guidance, in this column.2) See F.E.M. 1.001 3rd edition Rev.1998.10.01. Item 2.1.2.4.

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a) Loads which are directly dependent upon the action of mo-tors or brakes.

b) Loads which are not directly dependent upon motor orbrake action, and which in fact are responses to the loadsa) through f) in 101.

Furthermore, the loads may be considered belonging into twoother groups; those initially specified by the Customer, andthose determined by the designer.

The determination of the loads specified by the designer shallbe documented with enclosed calculations, references tostandards, or other justification.

103 The loads mentioned in 101 and 102 shall be determinedand applied in accordance with 200 through 800. Clearly, formany cranes and components some of the defined loads willnever be present. Note that in the following there is not alwaysa clear distinction between loads and responses to loads. A"load" acting on a component may well be an internal "re-sponse" in the crane as a whole. Accordingly, terms like "loaddue to weight" may be used instead of "weight".

B 200 Principal loads201 The principal loads are:

— the loads due to dead weight of the components (SG)— the loads due to working load (SL)— the loads due to prestressing.

Working load (suspended load) is the static weight of the use-ful load lifted, plus the weight of the accessories (sheaveblocks, hooks, lifting beams, grab, etc.).

Safe working load is the static weight of the load lifted (work-ing load exclusive the weight of accessories plus any liftingbeam).

Loads due to prestressing are loads imposed on structural itemsdue to prestressing of bolts, wire ropes, etc.

202 Except for prestressing, all the principal loads are due toweight which always acts vertically (in the normal sense). Thismeans that if the crane is mounted on an object which can ob-tain inclination (heel and/or trim) in any direction, the princi-pal loads may have "horizontal" components when referred toa practical coordinate system of the crane. These componentsshall be taken into account, and shall be considered as principalloads, also if the angles are due to motions such as rolling andpitching of a vessel. Note that the simultaneous inertia forcesare not considered as principal loads, see 101, item d) and 600.

203 For cranes mounted on floating vessels the horizontalcomponents of SG and SL shall be taken into account as ex-plained in 202. The angles to be considered are the maximumangles expected during lifting operation with no wind andwaves acting. Minimum values to be used, when decisive, aregiven in Table Bl. These values are considered as minimumbut may be especially considered provided statistically evi-dence or separate means/operational conditions proving thatlist and trim could be assessed smaller.

B 300 Vertical loads due to operational motions301 Vertical refers to the coordinate system of the crane. Fora crane onboard a floating unit it is assumed that vertical stateis so defined that it corresponds to physical vertical state in the

ideal position with zero "heel" and "trim" of the "unit" onwhich the crane is mounted.

The vertical loads due to operational motions shall be takeninto account by multiplying the working load by a “dynamicfactor”, ψ.

The dynamic factor covers inertia forces and shock.

302 The dynamic factor can be assessed by

C = geometric stiffness coefficient referred to hook posi-tion (also called "spring constant" defined as force athook to produce unit deflection at hook (kN/m))

g = standard acceleration of gravity= 9.81 m/s2

W = working load (see 201) (kN)VR = relative velocity (m/s) between load and hook at the

time of pick-up.

For the purpose of assessing the C-value, the modulus of elas-ticity of steel wire ropes shall be as specified by the wire man-ufacturer for an un-used wire rope. The crane stiffness (C-value) shall be calculated taking into account all elements fromthe hook to the pedestal support structure.

303 For shipboard cranes and industrial cranes, the dynamicfactor ψ for design purposes need not be greater than:

ψ = 1.3 for jib cranesψ = 1.6 for overhead travelling cranes or cranes of similar

design.

The dynamic coefficient factor shall not be taken less than:

ψ = 1.15 for 10 kN < W ≤ 2 500 kNψ = 1.1 for W > 2 500 kN.

For hose handling cranes intended for operation outside thedeck area in open sea, categorized as shipboard cranes, the dy-namic factor ψ for design purposes shall not be taken less than1.3.

304 For offshore cranes, sea lifts, the dynamic factor ψ fordesign purposes shall not be taken less than:

ψ = 1.3 for 10 kN < W ≤ 2 500 kNψ = 1.1 for W > 5 000 kN.

Linear interpolation shall be used for intermediate values of Wbetween 2 500 kN and 5 000 kN.

When the dynamic factor ψ is calculated by the formula givenin 302, the following shall be taken into account when assess-ing the relative velocity between load and hook at the time oflift-off , VR:

Where the value VL above is less than VH, as given in 305,then VH shall be used instead of VL.

VL = maximum steady hoisting speed (m/s) for the ratedcapacity to be lifted.

Vin = downward velocity (m/s) of the load at the time of liftoff (due to movement of the deck of a supply vesselfrom which the load is lifted.

Vt = velocity (m/s) from motion of the crane jib tip if thecrane is located on a mobile offshore unit or otherfloating unit.

Table B1 Minimum heel and trim angles, still waterType of vessel Heel Trim

Ships and vessels having shipshape hull properties Min. 5° Min 2°

Barges of length less than 4 times breadth, and catamarans Min. 3° Min. 2°

Semi-submersibles Min. 3° Min. 3°Submersibles and jack-ups Min. 1° Min. 1°

gW

CVR ⋅

+= 1ψ

225.0 tinLR VVVV ++⋅=

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Vin is to be determined as a function of sea state and motion pa-rameters (roll, pitch and heave response) of the vessel/offshoreunit or hydrodynamic response of an underwater object to behandled.

305 Unless otherwise agreed to by the purchaser, the hoist-ing speed should normally not be less than

for cranes used for cargo operations towards supply boats.

where

Hsign = Significant wave height (m).

The VL used for calculation of dynamic factors for deratingshall be the actual maximum available hook speed attainable,and shall normally be equal to or larger than VH. For signifi-cant wave heights where the hoisting speed VL is less than VH,the derating chart will be shaded and giving information that itis dependent upon the crane driver’s skill to avoid re-entry ofthe next wave.

306 For cranes located on crane vessels, semi submersiblesunits and bottom supported platforms the following values forVL and Vin may be used for the calculation of the dynamic fac-tor when lifting off loads from a supply vessel.

VL = Available hoisting speed or 0.6 Hsign

whichever is the smaller.

Vin = 0.6 Hsign (m/s) for 0 < Hsign ≤ 3 (m)

or

Vin = [ 1.8 + 0.3 (Hsign – 3) ] (m/s) for Hsign > 3 (m)

307 For offshore jib cranes, where the operator is placedabove the slewing bearing, the dynamic factor ψ to be appliedfor the design of the crane foundation including pedestal andslewing bearing with fasteners shall, for structural strength cal-culations, be taken as minimum 1.3 times the dynamic factorapplied for the design of the crane members, but is not to betaken less than 2 for cranes with a SWL less than 2 500 kN.

For cranes with SWL larger than 5 000 kN the additional factorneed not be taken greater than 1.3 times the dynamic factor ap-plied for the design of the crane members. Between 2 500 kNand 5 000 kN the additional factor may be found by interpola-tion.

308 All offshore cranes shall, at it’s operating stand, havedynamic load charts or tables. For offshore cranes operatingagainst supply boats, barges etc., the charts/tables shall givethe safe working load for boom angles or load radii for the var-ious wave heights. For subsea handling cranes, the charts/ta-bles shall give the safe working load for boom angles or loadradii for various dynamic amplifications.

309 For grab duty the design dynamic factor shall be in-creased by 20% for use of self-closing grabs (closed by liftingwire pull) and with 30% for use of grabs with motor closing.

310 For cranes located on barges or bulk carriers unloadingfrom another barge or bulk carrier, the dynamic factor ψ maybe calculated as in 302. The hoisting speed VL may be taken asgiven in 306.

The relative velocity VR may be calculated in accordance withthe formula in 304, where:

Vin = downward velocity (m/s) of the barge or bulk carrierfrom which the load is unloaded at the moment of pick-up. (It is foreseen that the crane is located on the othervessel involved.)

Vt = velocity (m/s) of the jib tip of the crane located on thebarge or bulk carrier to which the load is brought at themoment of pickup from the other vessel.

Vin is to be documented by calculations, or*) may be taken as1/10 · k · Hsign

Vt is to be documented by calculations, or*) may be taken as 1/6 · k · Hsign

*) The two formulas above are valid only for vessels withDWT between 10 000 and 100 000 tons.

DWT = the deadweight tonnage in metric tons of thebarges or bulk carriers used in the operation.

311 For cranes located on the barges or the bulk carriers fromwhere the load is lifted (picked up), the crane may be consid-ered as a shipboard crane being operated in harbour.

B 400 Horizontal loads due to operational motions

401 Horizontal refers to the coordinate system of the crane.It is assumed that horizontal is so defined that it corresponds tophysical horizontal in the ideal position with zero "heel" and"trim" on which the crane is mounted.

The horizontal loads (SH) due to operational motions are:

1) inertia forces due to acceleration or deceleration of hori-zontal motions (see 402)

2) centrifugal forces (see 403 and 404)

3) forces transverse to rail resulting from reeling and skewmotion (see 405)

4) buffer loads (ST) (see 406).

It should be noted that these horizontal forces act in addition topossible simultaneously acting horizontal components of theprincipal loads, see 202.

402 Forces 1) stated in 401 shall be determined on the basisof the maximum possible acceleration with the given machin-ery, and on the basis of the maximum possible decelerationwith the given brakes. Typically, forces of this type occur bystarting and stopping of travelling-, traversing- and slewingmotions. The inertia due to angular acceleration (deceleration)of rotating machinery components shall be taken into accountwhen this effect is significant.

For travelling cranes (and trolleys) it will normally be suffi-cient to consider horizontal forces corresponding to 15% ofmaximum vertical load on each wheel with brakes, or on eachdriven wheel.

For revolving cranes except offshore cranes a lateral force of

(W/100) · [ 2.5 + 0.1 · r · n ]

may be assumed at the jib head where:

r = load radius (m)(distance from revolving axis to load W)

n = revolution per minute (RPM).

403 Radial force on revolving cranes may be determined onthe basis of maximum angular velocity and radius to the con-sidered mass. Except for offshore cranes radial force equal to(W/1 000) n2 · r may be assumed at the jib head.

404 For offshore cranes the following horizontal force at jibhead should be assumed.

Lateral force (side lead):

(W/100) · [ 2.5 + 0.1 · r · n +Hsign ]

Radial force (off lead):

(W/1 000) n2 · r (when the load is airborne)

or

)1(1.0 +⋅= signH HV k 5.5 DWT20000---------------–=

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which ever is the greater.

However, for subsea handling cranes special considerationsapplies.

L = length of jibHw = distance from jib heel bearing to supply boat deckθ = jib angle to the horizontal.

405 Horizontal forces transverse to rail due to travelling mo-tion occur in two ways, of which the more unfavourable one isto be considered:

— Horizontal inertia forces - to be taken as 10% of the weightof the travelling unit - balanced by lateral wheel reactions(Reeling).

— A lateral force acting on one of the "forward" wheels (orbogies) - to be taken as λ times the wheel load - balancedby other physically possible horizontal wheel reactions(skew motion). λ is to be taken according to Fig.1.

Figure 1 Lateral wheel force

406 The following requirements for determination of buffereffects are based on the assumption that the buffers are capableof absorbing the kinetic energy of the crane (or trolley) at atravelling (or traversing) speed of 0.7 times rated speed. If thesuspended load can swing, the kinetic energy of it need not betaken into account.

Buffer effects need not be taken into account for speeds below0.7 m/sec.

For speeds in excess of 0.7 m/s the resulting loads set up in thestructure are to be calculated on the basis of the deceleration,which in turn shall be based upon the buff characteristics.

If automatic decelerating devices are used, the speed of thecrane after deceleration upon approach to the end of the trackmay be used, instead of the rated speed, in the determination ofbuffer effects. Thus, if the speed is reduced, by the deceleratingdevice, to a value of 0.7 m/sec or less, buffer effects need notbe considered

B 500 Loads due to motion of vessel on which the crane is mounted

501 Inertia forces due to ship motion shall be calculated inaccordance with the Rules for Classification of Ships, Pt.3 Ch.lSec.4 B “Ship Motions and Accelerations”.

The forces shall be combined to 10-8 probability level to cor-respond with safety factors as specified for Load Case III.

502 Horizontal inertia forces due to motion of the mobileoffshore unit (semi-submersibles, self-elevating units in tran-sit, etc.) shall be calculated, but need normally not be takenlarger than 0.5g [m/s2]

B 600 Loads due to climatic effects

601 The possible loads due to climatic effects are

— loads due to wind— loads due to snow and ice — loads due to temperature variations.

602 Loads due to wind shall be calculated in accordance withAppendix A or a recognised code or standard.

603 Snow and ice loads may be neglected in the design cal-culations except for cranes working under exceptional condi-tions, or for cranes of special designs being particularlysensitive to such effects.

604 Loads due to temperature variations shall be consideredonly in special cases, such as when members are not free to ex-pand. In such cases the maximum temperature fluctuation foroutdoor cranes shall normally not be taken less than 65°C. Forindoor cranes possible special sources of heat shall be consid-ered. (Note that the maximum and minimum temperaturesshall always be taken into account when selecting the materi-als).

B 700 Miscellaneous loads

701 Access gangways, driver's cabins and platforms shall bedesigned to carry the following concentrated loads in arbitrary(most unfavourable) position:

— 300 daN for maintenance gangways and platforms wherematerials may be placed

— 30 daN as the horizontal lateral force which may act out-wards or inwards on handrails and toe-boards.

702 The loads given in 701 need not be taken into account inthe strength evaluation of the main structural system of thecrane, except as far as necessary for the connection betweenthis system and the structures mentioned in 701. The deadweight of the latter structures however, shall be included in theprincipal loads, see 201.

B 800 Loads for strength analysis of mechanisms

801 In this Standard for Certification mechanism means thedevices needed to cause or to stop a relative motion betweentwo rigid parts of the crane, between the crane and its foun-dation, or between the crane and the lifted load. Thus motorsbrakes, transmission systems and similar components are de-fined as mechanisms.

802 A mechanism will always have to transmit forces whenit is in motion, i.e. it shall be considered for the most unfavour-able motor or brake action (102, a). The loads of this type arethose associated with:

— vertical displacement of centres of gravity of load andparts moved by the mechanism

— friction between moving parts— acceleration (or braking) of the motion— effect of wind acting on the parts moved by the mecha-

nism.

803 A mechanism may have to transmit forces even when itis stationary. In such a case the function of the mechanism issimilar to that of a structural component. Consequently, theloads to be considered are the same as those to be consideredin the analyses of structures.

ψ W2.5 1.5Hsign+

HW L θsin⋅+------------------------------------ (at lift-off)⋅ ⋅

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C. Cases of Loading

C 100 General101 For the purpose of making the nominal safety dependentupon the probability of occurrence of the loading, three generalcases of loading are defined, for which the required safety mar-gins are different:

Case I: Crane working without wind. (See 200).Case II: Crane working with wind. (See 300).Case III: Crane subjected to exceptional loadings.

(See 400).

102 For the various types of cranes the detailed loading to beconsidered for each case may be different. For instance, CaseIII may include different conditions for stationary cranes, mo-bile cranes and ship-mounted cranes.

C 200 Case I: Crane working without wind201 Case I is the main case of loading and includes the loadsthat necessarily will occur under normal operation:

— The principal loads (SG and SL) according to B200.— The vertical loads due to operational motions according to

B300.— The horizontal loads due to operational motions (SH), ac-

cording to B400. The two most unfavourable effects areused, excluding buffer loads.

By use of symbols Case I may be defined as follows:

202 For cranes mounted on floating vessels horizontal com-ponents of SG and SL shall be taken into account as explainedin B202 and B203.

203 With regard to SH the following should be noted: Maxi-mum two of the effects mentioned in B 401 (excluding bufferloads) need be considered simultaneously. Further, in caseswhere travel motion takes place only for positioning the craneand is not used for moving loads, the effect of this motion shallnot be combined with the effect of other motions.

C 300 Case II: Crane working with wind301 Principally, Case II includes the same loads as Case I,with the addition of loads (SW) due to “working” wind:

SW shall be determined in accordance with B600. The meaningof the other symbols is as given in 201, with the exceptionsgiven in 302.

302 The actual difference between Case I and Case II willdepend on type and use of the crane. For indoor cranes therewill be no difference, meaning the Case II need not be consid-ered. For outdoor, stationary, land cranes the difference is nor-mally SW only. For cranes mounted on floating vessels the“horizontal” components of SG and SL shall be based on in-creased angles compared with Case I. Minimum angles are tobe 1.5 times the values given in Table Bl.

303 “Working” wind acting on the suspended load shall betaken into account if the effect is significant. The wind forceshall be determined by taking into account the largest areawhich can face the wind, taking C=1.2 for containers and sim-ilar shapes, and C=1 for more arbitrary shapes.

C 400 Case III: Crane subjected to exceptional loadings401 Any loading condition where one or more exceptionalloads are included belongs to Case III. The following loads aredefined as exceptional loads:

— Buffer loads, according to B406 (Symbol ST).— Inertia forces due to motion of the vessel on which the

crane is mounted, according to B500 (Symbol SM). For thevessel’s transit condition special attention must be given tohow the crane is secured. See Appendix C which presentsan example on how this may be dealt with.

— Loads due to “out of service” wind according to B600(Symbol SW).

Other forces which necessarily must act together with theabove exceptional loads are included in Case III.

402 Defined by symbols, the following load combinationsare to be considered in Case III:

For land cranes SM will be zero. For indoor cranes combina-tion IIIb is not considered. For cranes mounted on floating ves-sels the horizontal components of SG and SL shall beconsidered for estimated maximum rolling and pitching an-gles, including possible initial heel and trim.

D. Strength Calculations

D 100 General

101 It shall be shown that structures and components havethe required safety against the following types of failure:

— excessive yielding (see 200)— buckling (see 300)— fatigue fracture (see 400).

102 The safety shall be checked for the three cases of loadingdefined in C. For each of these cases and for each member orcross section to be checked, the most unfavourable positionand direction of the forces shall be considered.

103 The strength calculations shall be based on acceptedprinciples of structural strength and strength of materials.When applicable, plastic analysis may be used. If elastic meth-ods are not suitable to verify safety, for instance due to pre-stressing, plastic analysis may be required.

104 The verification of safety may be based on the permissi-ble stresses method or the limit state method. With the factorsgiven in this standard there will be only a formal difference be-tween the two methods. The relation is

Safety Factor = Load Factor times Material Factor.

For structures with nonlinear behaviour, however, significantdifferences may occur. In such cases the limit state methodshall be used, or the safety factor shall refer to load and not tostresses.

D 200 Checking with respect to excessive yielding

201 For members made of structural steel the requirementsfor the various cases of loading are given. With reference tomethod of analysis and method of verification of safety givenin Table Dl, σy is the guaranteed minimum yield strength (or0.2% proof stress). If σy is higher than 0.8 times the ultimatestrength σu use in this connection 0.8·σu instead of σy.

202 When using elastic analysis, the permissible stresses (or therequired safety factors) given in Table Dl refer in cases of com-bined stresses to the equivalent stress according to von Mises.

HLG SSS +⋅+ψ

WHLG SSSS ++⋅+ψ

IIIa:

IIIb:

TLG SSS ++

maxWMG SSS ++

mfFS γγ ⋅=

DET NORSKE VERITAS

Page 38: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 38 – Ch.2 Sec.3

203 For components made of other materials than structuralsteel, and for other special components, refer to E.

204 Joints shall not be weaker than the minimum requiredstrength of the members to be connected. For riveted joints,bolted joints, friction-grip joints, and welded joints refer toF.E.M./I or other recognised codes.

D 300 Checking with respect to buckling301 The guiding principle is that the safety against bucklingshall be the same as the required safety against the yield limitload being exceeded. This principle indicates that the factorsgiven in the second line of Table Dl should represent the nor-mal requirement. However, other values may be required or al-lowed, for instance due to uncertainty in the determination ofthe critical stresses (or load) or due to the post-buckling behav-iour. Required factors are given for various types of structuresand conditions in Table D2.

302 The safety factors given in Table D2 are based on the as-sumption that the critical stresses (or loads) are determined byrecognised methods, taking possible effects of geometrical im-perfections and initial stresses into account. Elastic buckling inTable D2 means that elastic buckling stress does not exceed theyield strength.

303 Calculation methods and corresponding required safetyfactors as specified by other crane standards/codes or otherspecialized literature may also be used.

D 400 Checking with respect to fatigue

401 The fatigue strength, expressed as the critical amplitudeof a fluctuating or alternating stress, shall be determined on thebasis of the following information:

— component group according to A200— the material used and the notch effect at the point being

considered— the fluctuation factor = σmin/σmax— whether the maximum stress is tension or compression.

With the above data given, the critical amplitude is defined asthat which corresponds to 90% probability of survival. Regard-ing detailed procedure for the determination of the criticalstress amplitude, see F.E.M./I or other specialized literature.

402 Fatigue considerations shall be made for Case I for alltypes of cranes. In addition, for ship mounted cranes where thetransit condition may be of considerable duration, it may be re-quired to consider fatigue effect on certain components in CaseIII. The effect of wind need not be taken into account.

403 The calculated maximum stress amplitude shall not ex-ceed the permissible stress for fatigue, which is critical stressamplitude divided by a safety factor of 1.33.

33.1/crcallow σσ =

Table D1 Criteria for the checking with respect to excessive yieldingMethod of verification Load Case I Load Case II Load Case III

Safetyfactor

Elastic analysis 1.50 1.33 1.10Plastic (ult. str.) anal. 1.69 1.51 1.25

Permissi-ble stresses Elastic analysis σy/1.50 σy/1.33 σy/1.10

Limitstatemethod

Load factor 1.30 1.16 0.96Materialfactor

Elastic anal. 1.15 1.15 1.15Plastic anal. 1.30 1.30 1.30

Table D2 Safety factors for the checking with respect to buckling

Type of structure or memberFS or γf · γm

Load Case I Load Case II Load Case IIIBars, frames and stiffening systems of plates and shellsElastic buckling 1.86 1.66 1.38Elastic-plastic buckling 1.69 1.51 1.25Plates, redistribution not possibleElastic buckling 1.86 1.66 1.38Elastic-plastic buckling 1.69 1.51 1.25Plates, redistribution possibleElastic buckling 1.59 1.42 1.18Elastic-plastic buckling 1.45 1.29 1.07Shells, redistribution not possibleElastic buckling 2.20 1.96 1.63Elastic-plastic buckling 1.69 1.51 1.25Shells, redistribution possibleElastic buckling 1.98 1.77 1.46Elastic-plastic buckling 1.52 1.36 1.13

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Page 39: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.3 – Page 39

E. Design and Strength of Particular Components

E 100 General

101 This Standard for Certification does not attempt to makea clear distinction between structural and mechanical compo-nents. A mechanism, as defined in B801 may well containcomponents which could be defined as structural components.Such components shall be checked according to D. The onlydifference from an ordinary structural component is that CasesI and II have to include forces acting on the component whenthe mechanism to which it belongs is in motion, see B802. Theterm “particular components” may mean structural as well asmechanical components.

102 Components that transmit forces, whether “structural”or “mechanical”, and that are not directly or completely cov-ered by this Standard for Certification, shall be designed andcalculated in accordance with applicable recognised codes orstandards. To the extent applicable, FEM/I is advised.

E 200 Buckling stability of jibs

201 The buckling problems of a jib may be solved by deter-mining slenderness ratios and by considering the permissiblestress as a function of these ratios. Hence the determination ofeffective lengths with respect to the possible buckling modesmay become a key problem.

202 The effective length of the jib depends on its support andof whether the jib is of latticed design or battened design.

203 The effective length of the jib – considering support ef-fect at jib head – may e.g. be estimated in accordance with Brit-ish Standard 2573:Part l:1983.

For a rope supported jib the effective length may, with refer-ence to Fig.2, be taken as

Figure 2 Effective length of jib

204 For jibs having solid webs in the considered plane ofbuckling, the above values of leff may be used without correc-tion. Jibs that are latticed or battened in the considered plane ofbuckling leff (or the slenderness ratio) according to 203 shall beincreased due to shear deformation of the jib. recognised, sim-plified methods for this correction may be accepted.

The following correction factor may be used for latticed jibs:

i = radius of gyration, see 205.

205 The overall slenderness ratio leff/i of the jib in each planemay be obtained by dividing the effective length of the jib bythe smallest radius of gyration of the complete cross section ofthe jib. Correction shall be made for tapering off cross sectiontowards jib ends.

206 Stresses arising from axial compression and bendingshall comply with the requirements of recognised combinationformulae.

E 300 Slewing bearing for jib cranes301 For slewing bearings of the ball and roller type the fol-lowing aspects shall be examined:

1) Plastic deformation of rolling elements and raceways(raceway capacities).

2) Bolt capacity.

3) Ultimate carrying capacity of the slewing ring as a whole,based on the capacities of the bolts and cross sections –with due regard to the rigidity of the structures supportingthe (fixed and revolving) rings.

4) Fatigue of critical sections of the outer and inner rings, i.e.the ”nose” for multi-row bearings.

The slewing bearings are specialized components, and the de-sign criteria for a given type shall as far as practicable be basedon tests carried out for the particular type. Item 2), 3) and 4),however, will normally be required to be checked by calcula-tions as indicated/specified in the following.

For design loads see B307.

302 The vertical component of rolling element forces on theraceway (roller element track) is assumed to vary linearlyacross the diameter of the raceway, i.e. a sinuous distributionwith reference to the raceway circumference.

The maximum vertical force per unit length is then

respectively at the front (+) and rear (-) of the crane (front isregarded the side on which the boom is fitted).

Mk = overturning design moment on the slewing bearing.Design dynamic coefficient is included.

Fa = axial design force on the slewing bearing. Design dy-namic coefficient is included.

D = raceway (track) diameter.

303 Slewing ring fasteners (bolts) shall have a yield capacityper bolt (i.e. stress area of bolt, As, times the material yield

⎟⎠⎞

⎜⎝⎛ −=

A

BLleff 2 for lateral buckling

40)/(

3001

2>+

i

lfor

ileff

eff

40≤i

lfor eff1.1

D

F

D

Mq ak

A ππ±=

2

4

DET NORSKE VERITAS

Page 40: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 40 – Ch.2 Sec.3

stress, fy) not less than

pr = degree of permanent pre-stressing related to yield(100% = 1.0)

FA = maximum vertical raceway load per bolt sector at therear of the ring

χ = FR/FAFR = maximum horizontal (radial) load per bolt sector.

a, b and c as per Fig.3.

Figure 3 Slewing ring measures

304 The effective bolt length shall be at least 4.5 times thebolt diameter.

Guidance note:Effective bolt length is the part of the bolt that may be free to beelongated at tension. In other words, it does not include the partof the bolt being constrained by the treads.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

305 Bolt material having yield strength exceeding 940 N/mm2 (10.9 ISO strength class) will normally not be acceptedfor offshore cranes.

306 Slewing ring fasteners shall be pre-stressed according toa written procedure. The degree of permanent prestressingshall be as high as possible without producing yield in bolt ma-terial during prestressing. The degree of permanent prestress-ing shall at least be 65% but normally not more than 80% ofbolt material yield strength. If documented by testing, pro-cedures claiming a degree of permanent prestressing up to 90%of bolt material yield strength may be credited.

307 The holding-down bolts shall - as far as practical - beequally spaced over the 360° circumference.

Guidance note:With equally spaced bolts, FA and FR in 303 becomes

Normally, the following formula applies to the rear “element” ofall the bearing.

where:

β = 0° for “multi-row” bearingsβ = 30° for single-row bearingsβ = 45° for cross roll bearingsm = is number of boltsFr = radial force on the slewing bearing.

(Note that Fr is here assumed to act horizontally in the directionof the jib).

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

308 Yield limit load (capacity) of the slewing bearing shallbe evaluated considering equilibrium between rolling elementforces and the following “reactions” acting on an “element” ofthe ring:

— Bolt forces acting on the considered “element” possibleshear included.

— Possible interface pressure between the considered “ele-ment” and the structure supporting the ring.

— Forces acting in the cross section of the ring (i.e. the “endsurfaces” of the considered "element".

309 The ratio between the ultimate carrying capacity (ringand bolts) and calculated load on the slewing bearing shall notbe less than 1.5.

310 Penetration of aggressive materials into the racewaysmust be prevented. For bearings that are often exposed tosplash and surge water, the use of an adequate seal is recom-mended.

311 The vertical support in the bearings companion structureshould preferably be in the vicinity of the track diameter in theheaviest loaded areas (main tension/compression zones). Ifthis is not the case, DNV will normally require use of bracketplates. DNV may, upon evaluation of each actual bearing andcompanion structure design, ask for detailed calculations ofany deflection of the support surfaces under maximum operat-ing load together with documentation of the permissible limitsas specified by the bearing manufacturer.

See also comments on desired avoidance of brackets in 402.Guidance note:Slewing bearings of the ball or roller type are required to beopened up periodically for inspection.However, for cranes on which a retention device (with minimumcapacity equivalent to the slewing bearing) is arranged, or theslewing bearing has been specially adapted and approved fornon-destructive crack detection, or a procedure for regular clear-ance measurements, grease sampling and fatigue evaluations areadopted in agreement with the crane and slewing bearing manu-facturer, the requirement to opening up may be waived.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

E 400 Flanges401 The thickness of connecting flanges shall be checked lo-cally according to

where

S = required safety factorFx = maximum vertical raceway load per bolt at the rear of

the ring, based on pedestal diameter of the lower flangeor kingpost

rb = bolt circle radius for the flange in questionrx = pedestal radius or kingpost radius measured to middle

of plate dh = bolt hole diameter

⎟⎠⎞

⎜⎝⎛ ++⋅≥

c

cbaF

prF AB

χ75.0)( 2.0

mF

D

MF a

kA

14⎟⎠⎞

⎜⎝⎛ −=

⎥⎦

⎤⎢⎣

⎡⎟⎠⎞

⎜⎝⎛ ++= βtgF

D

MF

mF a

krR

44

1

yh

hxbx

fds

drrFS

t

⎟⎠⎞

⎜⎝⎛ −

⎟⎠⎞

⎜⎝⎛ −−⋅⋅⋅

=

2

12

16

min

DET NORSKE VERITAS

Page 41: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.3 – Page 41

s = centre /centre spacing for boltholesfy = yield strength flange material.

402 For excessive moments (when the raceway diameter dif-fers from the diameter of a cylindrical pedestal/kingpost and/or radial forces act on the rings), supporting brackets may berequired under the flange.

Brackets and their welding attachments “will be felt” by theslewing ring when rotating. Consequently, it is preferable toeliminate the difference of the above mentioned diameters asmuch as possible (vertical load on ball/rollers in line with ped-estal/kingpost plate), thereby minimizing the warping momentand contributing to enable the leaving out of brackets.

403 Normally there shall be a full penetration weld betweenthe pedestal/kingpost shell and the flanges.

404 Flatness of the connecting flange mating surface to theslewing bearing shall comply with the slewing bearing manu-facturer's specification.

No surface levelling compound shall be used in order to obtainrequired flatness.

E 500 Pedestal and pedestal adapter for jib cranes

501 Pedestals and pedestal adapters shall be designed for thesame crane group as that of the crane.

For design loads, see also B307.

502 Fatigue evaluation of pedestal/pedestal adapter shall becarried out in accordance with FEM or other acceptable cranestandard.

DET NORSKE VERITAS

Page 42: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 42 – Ch.2 Sec.4

SECTION 4 CONVENTIONAL CARGO GEAR, CARGO RAMPS AND MOVABLE CARGO

DECKS

A. General

A 100 Definitions101 Conventional cargo gear or derrick systems are liftingappliances comprising:

— mast or derrick posts — shrouds and stays— cargo runners and cargo chains— span tackle (topping wire rope systems)— guys— hooks, sheaves and blocks— fittings (shackles, swivels, eye plates, rings, triangle plates

etc.).

102 Ramps are movable ramps for vehicles onboard ships.

103 Movable cargo decks are decks onboard ships for thetransport of vehicles.

A 200 Scope201 The requirements of this section shall be complied within cases where the issue of Forms listed in Sec.7 B500 is re-quested. See also Appendix F.

A 300 Classification301 The structural strength and support of masts, derrickposts, standing rigging and movable cargo decks are classitems and shall always be approved by the Society for shipsclassified with the Society.

A 400 Operational limitations401 The cargo handling systems are presumed only to be op-erated in harbours or within sheltered waters.

B. Basic Requirements

B 100 Materials 101 Selection of material grades for plates and section shallbe based on material thickness and shall basically comply withSec.2. However, NV-steel grades as given in Table Bl will nor-mally be accepted.

B 200 Wire ropes201 For wire and rope materials and construction steel wireropes, see Sec.2.

For testing of steel wire ropes, see Sec.7.

B 300 Welding and workmanship301 Welding and workmanship shall generally comply withSec.2.

Radiographs shall normally meet the requirement Group Blueaccording to "IIW Collection of Reference Radiographs of

Welds". However, scattered porosity according to GroupGreen may be accepted.

C. Derrick Systems

C 100 Rigging plan and force diagram

101 Lay-out of swinging derricks, heavy lift derricks whereunion purchase system is intended shall be indicated on the rig-ging plan.

102 Arrangement plan of shroud and stays on stayed masts/derrick posts shall be submitted.

103 A diagram of forces for each derrick rig shall be submit-ted containing the following combinations:

— number of derricks working simultaneously on hatch— number of derricks working simultaneously out- board to

one side of the ship— whether one or two pair of derricks where the derricks are

arranged for operation in union purchase.

104 In the ease of union purchase the following shall be in-cluded in the rigging plan:

— minimum headroom below the triangle plate— maximum included angle between the cargo runners.

C 200 Basic design assumptions201 A basic angle of heel of 5° and angle of trim of 2° are as-sumed for the ship. Provided these angles are not exceeded theeffect of heel and trim may in most cases be ignored in thestrength calculations.

For angle of heel and trim exceeding above figures the effectshall be taken into consideration.

202 The cargo handling system shall be designed for theforces exerted in the system from the safe working load, SWL,multiplied by a design coefficient.

k = 1.25 for SWL ≤ 650 kN

k = 1.1 for SWL ≥ 600 kN

For intermediate values of the SWL linear interpolation shallbe applied.

203 The most unfavourable position of derrick booms shallbe considered in the strength evaluation of the cargo handlingsystem.

C 300 Allowable stresses301 The total stress at any particular location in the mast(derrick post) shall not exceed the allowable stress consideringthe following:

— global overturning moment = Σ (k · SWL · ld · cos α)— vertical (axial) forces— bending moments and torsional moments resulting from

cross trees (if fitted) and from offset of the forces.

ld = length of derrick boomα = boom angle to the horizontalk = the design factorΣ = the vector sum of external moments on the mast result-

ing from the SWL and derricks being operated simulta-neously.

Table B1 Plate material gradesThickness in mm Normal strength

structural steelHigher strength structural steel

t ≤ 12 A A12 < t ≤ 25 B A25 < t ≤ 50 D D

t > 50 E E

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Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.4 – Page 43

302 α is the lowest angle - for practical considerations - ofthe boom to the horizontal, but shall not be less than 15° whereSWL ≤ 100 kN or 25° where SWL > 100 kN.

303 For members made of structural steels the safety factorsfor load case I of Tables D 1 and D2 in Sec.3 shall be applied.See also Sec.3 D400.

Stresses according to load case II of Table D1 and D2 in Sec.3may be allowed for SWL > 600 kN provided special detailedcalculations are found acceptable taking into account:

— effect of weight of the various members— effect of heel and trim— eccentricities of forces acting— preload of any stays and means for controlling the tension

in stays are available.

304 The safety factor for steel wire ropes shall not be lessthan

but shall not be less than 3 or need not be taken more than 5.

The SWL (kN) applied in the formula shall be the highest SWLfor which the derrick system is designed.

305 Where not otherwise demonstrated by testing a com-bined allowance for friction and bending of the wire ropesequal to:

— 1.5% for each sheave with ball or roller bearings — 5% for each sheave with plain bearings

shall be considered in the calculation of the load in cargo run-ner, span tackle and slewing guys.

306 The minimum plate thickness of masts and derrick postsis normally 7.5 mm. Masts and posts shall be increased inthickness or additionally stiffened at the deck gooseneck andhounds.

C 400 Union purchase arrangement

401 Where the derricks are arranged for operation in unionpurchase the scantlings and arrangement of the derrick systemshall also be suitable for single slewing derricks.

402 The maximum load in the system shall be determinedbased on:

— minimum operational angle of either derrick but not lessthan 15° to the horizontal

— maximum included angle between the cargo runners notexceeding 120°

— outreach beyond the amidships breadth of the ship. Mini-mum outreach is 4.0 metres

— minimum headroom to the triangle plate from top of hatchor bulwark whichever is the higher - of not less than

- 4 metres where SWL(u) does not exceed 20 kN- 5 metres where SWL(u) exceeds 20 kN.

403 The working range of the rig shall be indicated on a sep-arate plan and be attached to Form No. CG2U.

C 500 Stayed masts and derrick posts

501 The mast (derrick post) and stays will share the load act-ing on the system in the ratio of stiffness of stays, respectivelystiffness of the mast, to the total stiffness of mast and stays.

From the force diagram and/or by calculations the load on themast resulting from the cargo runner, span tackle and derrickboom including the effect of cross trees, if fitted, are to be es-tablished by considering the equilibrium between the elasticelongation of the stays related to the deflection of the mast

caused by the above mentioned forces. The forces in the staysmay be calculated.

Stays or shrouds of wire rope which will be subjected to a"negative" force i.e. compression member, shall be ignored inthe calculations.

The buckling strength of steel members acting as stays wheresubjected to compression shall be checked.

502 The combined stress from bending, compression andshear in each section of the mast shall not exceed the allowablestress.

Further, the overall stability of the mast due to axial compres-sion and bending shall be checked to satisfy:

where

σac = the calculated axial compression stress(σac)allow = the permissible compression stress in axially

loaded compression member i.e. the criticalflexural buckling stress divided by the safetyfactor

σbc = the calculated maximum compressive stress dueto bending

(σbc)allow = the permissible compression stress.

503 The maximum compressive stress due to bending of themast may be assessed by:

Cm = stiffness of mast (N/mm)Δl = total deflection of mast and stays (mm)lm = length of mast from deck or top of mast house to

hounds (mm)H = height of derrick heel above deck or top of mast (mm)Zm = section modulus of mast at the derrick heel fitting

(mm³).

The diameter d0 and the plate thickness t0 of the mast are sup-posed to be maintained from the deck and not less than 1 mabove the derrick heel fitting. Above this level, the diameterand the plate thickness may be gradually reduced to 0.75 d0and 0.75 t0 at the hounds.

The total deflection of mast and stays may be assessed by:

using stiffness of mast,

Em = modulus of elasticity of mast (N/mm2)Im = modulus of inertia of mast (mm4)

Stiffness of wire rope stays/shrouds:

Ew = modulus of elasticity of wire, 7.5 104 N/mm2

G = the smaller of

kSWLSF

1

1910885.0

104

⋅+

=

1)()(

≤+allowbc

bc

allowac

ac

σσ

σσ

( ) ( )2/ mmNZ

HllC

m

mmbc

−Δ=σ

( )mmCC

Pl

wm

H

+⋅

=Δ310

( )mmNI

IEC

m

mmm /

4.23

=

GEC ww ⋅=

DET NORSKE VERITAS

Page 44: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 44 – Ch.2 Sec.4

f = area (mm) equal to minimum breaking load of the wirerope divided by the tensile strength of the wires

a = athwart ship distance in mm from the mast to the deckattachment of shroud in question, see Fig.1

c = longitudinal distance in mm from the mast to the deckattachment of shroud in question, see Fig.1. With ref-erence to a transverse plane through the mast, c is to betaken negative (-) for shrouds fitted on the same side asthe derricks in question and positive (+) for those fittedon the opposite side.

ls = length of shrouds (mm)Σ = summation of:

a) Load functions for derricks simultaneously serv-ing one hatch.

b) Support functions for effective shrouds whenloads are as indicated in a), i.e. all shrouds forwardor aft of the mast whichever is opposite to thehatch in question.

c) Load functions for derricks simultaneously work-ing outboard.

d) Support functions for effective shrouds whenloads are as indicated in c), i.e. all shrouds on oneside of the ship; however, the attachment to thedeck is not to exceed 0.3 B forward or aft of themast.

Figure 1 Arrangement of shrouds

and

ld = length of derrick in mm. Where the working positionof the derrick is such that the angle between the centreline of the derrick and the horizontal always exceeds15°, ld is taken as the greatest horizontal projection ofthe derrick.

504 The maximum axial compression stress in the mast maybe assessed by:

PA = total axial compression force in the mast (kN)Am = cross-sectional area of the mast (mm2).

The total axial compression force in the mast shall be

where

β = angle between the stay and the mastPstay = forces in the stays due to the deflection of mast and

stays (kN).

n = 1, 2, 3 etc. for single, double and treble blocks etc.respectively.

The forces in the stays due to the deflection of mast stays andstays may be assessed by:

using

F = the greater of

505 Where masthead span blocks are attached to riggers, thesection modulus of the mast at the level of the outrigger shallnot be less than:

r = horizontal distance in mm from mast to masthead spanblocks on outrigger.

Σ SWL = total load in kN which may be lifted by derrickson one side of the centre line of ship.

C 600 Un-stayed masts and derrick posts601 Where SWL ≤ 100 kN, and there is no crosstree of ex-ceptional spread, the sectional modulus of un-stayed masts orposts from deck level and to approximately 1 metre above thegooseneck may be assessed by

(SWL (kN), ld (mm) as defined in 503, σy = material yieldstrength in N/mm2.)

C 700 Derrick booms701 The derrick booms shall be designed with due respect to:

— compression and bending stresses— overall stability.

702 The axial thrust in the boom and bending caused by off-set of the forces are to be determined from the force diagramand/or direct calculation. The vector sum of bending momentsshall be taken into account.

703 The maximum compression σN = (T/A) and bending

( )3

2

3

2 7.14/1

ss l

cafand

l

cf +ΣΣ

( )kNHl

lkSWLP

m

dH −

=

m

Aac A

P 310⋅=σ

1cos QPP stayA +Σ= β

( )kNHl

l

n

kSWLkSWLQ

m

d

2

1 1 ⎟⎟⎠

⎞⎜⎜⎝

⎛−

+⋅Σ+⋅Σ=

( )kNlFlEP swstay310−⋅Δ=

( )33

7.1

2

1

ss l

cafand

l

fc +

( )312 mmQrZ =

( )kNHl

l

n

SWLSWLQ

m

d

2

1 ⎟⎟⎠

⎞⎜⎜⎝

⎛−

+Σ+Σ=

Z2.3 10

3⋅σy

--------------------- SWL∑ ld (mm3 )⋅=

DET NORSKE VERITAS

Page 45: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.4 – Page 45

stress σB = (M/Z) shall satisfy the following equation:

T = axial force (N) in the derrick boomM = bending moment at derrick headZ = sectional moment at half length of derrickA = sectional area (mm2) at half length of derrick.

ld = length of derrick boom (mm)i = minimum radius of gyration (mm).

For derricks manufactured from pipes with diameter d (mm)the formulae becomes

704 The formulae in 703 apply to derrick booms with con-stant sectional area. Where the sectional area varies σR shouldbe corrected.

In the case of a boom built up by 3 pipes, the mid pipe being oflength "a" and diameter "d2", the end pipes having diameter"d1", σR in 703 shall be multiplied by a correction factor "m"given in Table Cl.

D. Cargo Ramps and Movable Cargo Decks

D 100 Structural strength101 Requirements to structural strength and design are givenin DNV Rules for Ships Pt.5 Ch.2.

D 200 Mechanism and operational safety201 Requirements to hoisting, fittings, safety devices andtesting are covered by Sec.5, 6 and 7.

12.1

≤+y

B

R

N

σσ

σσ

( )[ ]( )[ ] ( )[ ]

y

d

dy

dyR ilfor

il

il

σσ

σσ 2

10/1410/6.3

10/83

23

23

≤⋅+⋅

⋅−=

( )[ ] ( )[ ]y

d

d

ilforil σ

210/

10/7.1

1 323

>⋅⋅

=

( )[ ]( )[ ] ( )[ ]

y

d

dy

ydyR dlfor

dl

dl

σσ

σσσ 705.0

10/7.110/6.3

10/3

23

23

≤⋅+⋅

⋅⋅−=

Table C1 "m"- factora/ld = 0.4 a/ld = 0.6 a/ld = 0.8

(d1/d2)³ = 0.4(d1/d2)³ = 0.6(d1/d2)³ = 0.8

0.670.820.92

0.850.920.96

0.970.980.98

( )[ ] ( )[ ]y

d

d

dlfordl σ

705.010/

10/5.13

1 323

>⋅⋅

=

DET NORSKE VERITAS

Page 46: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 46 – Ch.2 Sec.5

SECTION 5 MACHINERY AND EQUIPMENT

A. Basic Requirement

A 100 Materials

101 The materials applied shall be in compliance with Sec.2or relevant recognised code or standard.

102 Materials with low heat resistance shall not be appliedwhere a fire may cause unacceptable consequences of damage,such as collapse, outflow of flammable fluids etc.

Non-metallic materials shall be flame-retardant in accordancewith recognised standard.

A 200 Arrangement and general design of components and equipment

201 All components in a system shall be adequately matchedwith regard to strength, capacity and functional performance.

202 Relative movements due to load variations, thermal ex-pansion, misalignment, vibration and interaction from founda-tions shall be allowed to avoid detrimental effects.

203 Bolts and nuts exposed to dynamic forces and vibrationsshall be properly secured or pre-stressed.

204 All operational equipment shall be arranged for easy ac-cess. Components and equipment normally subject to inspec-tion and maintenance shall be installed so as to provide easyaccess.

205 Arrangement for adequate lubrication of bearings andgears shall be provided.

206 All means of access shall be of a permanent nature andhave to be considered in each case with due respect to type ofcrane and its intended service.

207 Protection against rain, sea-spray, snow, ice and sandshall be provided (essential for brakes, clutches etc.). Provi-sions shall be made to prevent accumulation of water in anyconstruction. Rapid drainage is to be ensured.

208 Crane seatings and their supporting structures shall be ofrigid design. As far as relevant tolerances of travelling cranesand gantry cranes and their tracks shall at least comply withFEM/I regulations. Tolerances of mating surfaces of seatingsshall meet the standard required by the manufacturer of theslewing ring and general engineering standards.

209 Cranes shall be arranged with emergency escape in ad-dition to the main access. Portable escape equipment may beaccepted.

A 300 Ventilation

301 Forced ventilation (heating/cooling) shall be provided -when necessary - to ensure inside temperatures within therange required by Sec.l D101.

302 Higher temperatures inside cubicles, desks etc. will beaccepted provided installed equipment is regarded as suitablefor such higher temperature.

303 Verification of temperature and final acceptance shall bebased on loads and operational sequence relevant to the liftingappliance.

Figure 1 Wire rope fleet angles

A 400 Strength

401 The strength of components and equipment shall gene-rally be in compliance with D and E of Sec.3. Specific require-ments for some important components are given in thefollowing. Recognised codes and standards may be applied asa supplement to this Standard for Certification.

402 If acceptable accuracy cannot be obtained by strengthcalculations, special tests may be required for determination ofthe strength of a design.

B. Components

B 100 Winches

101 For design of the support of the winch to its foundation,relevant forces from crane operations are understood to havingbeen evaluated at their maximum.

102 The direction of motion of the operating devices shall besuch that the load is raised by clockwise movement of a hand-wheel or crank handle, or alternatively movement of a hand-le-ver towards the operator.

103 The operating device shall be arranged to return auto-matically to the braking position when the operator releases thecontrol. However, for offshore crane applications – in constanttension and active heave compensation modus – the brake shallremain off when the operator releases the control.

B 200 Drums

201 Drum diameters shall be determined with due respect to:

— type of reeving— state of loading— daily operating time

and shall be suitable for the selected steel wire rope, as directedby the rope manufacturer.

The ratio Dp/d shall normally not be less than 18 where

Dp = pitch diameter of drumd = nominal diameter of steel wire rope.

DET NORSKE VERITAS

Page 47: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.5 – Page 47

202 As far as practicable and suitable for the arrangement,drums shall be designed with a length sufficient to reel up therope in not more than 3 layers.

More than 3 layers may be accepted if the wire rope has an in-dependent wire rope core (IWRC) and one of the followingconditions is complied with:

— spooling device is provided — drum is grooved — fleet angle is restricted to 2° — split drum is arranged — separate traction drum is fitted.

However, when the number of layers exceeds 7, special con-sideration and approval will be required.

203 For all operating conditions, the distance between thecentre of the top layer of the wire rope on the drum and the out-er edge of the drum flanges shall be at least 2.5 times the diam-eter of the wire rope, except in the cases where wire ropeguards are fitted to prevent over spilling of the wire.

Guidance note:It is advised that the drums have grooves to accept the rope.Where a grooved rope drum is used the drum diameter shall bemeasured to the bottom of the rope groove. To avoid climbing ofthe rope on the grooves the angles α1 and α2 shall not exceed 4°,see Fig.1. The groove shall be smooth. Advised radius of grooveis 0.53 d (d = nominal rope diameter) and should be between 0.52d < r < 0.57d.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

204 Drums shall either be fabricated from steel plates or becastings.

Ferritic nodular cast iron with minimum elongation (A5) 10%may be accepted. By special consideration a lower elongationmay be acceptable. Impact testing of ferritic nodular cast ironwill for this application be waived.

205 Drums shall be checked with respect to their overallequilibrium situation and beam action, with the maximum ropetension acting in the most unfavourable position. The effect ofsupport forces, overall bending, shear and torsion shall be con-sidered. The rope tension shall in this case include any ampli-fying coefficient and the dynamic factor ψ. If moreunfavourable however, the situation with forces directly de-pendent upon motor or brake action shall be considered.

206 The drum barrel shall be designed to withstand the sur-face pressure acting on it due to maximum number of wind-ings. The rope is assumed to be spooled under maximumuniform rope tension. Maximum uniform rope tension meansthe tension due to safe working load without taken into accountthe amplification factors and dynamic factor. If the rope ten-sion varies systematically, such as when an object is liftedfrom bottom and out of water, this variation shall be taken intoaccount.

207 Unless comprehensive tests justify a lower value, thehoop stress in the barrel shall not be taken less than

σh = hoop stress in drum barrelS = maximum rope tension under spoolingp = pitch of rope grooving (the distance between ropes,

centre to centre, within one layer)tav = average wall thickness of drum barrelC = 1 for 1 layer

= 1.75 for two layers and above, for non-LeBus grooveddrums

= 1.75 for two layers, linearly increasing to 3.0 for 5 lay-ers and above, for LeBus grooved drums. However,lower factors may be applied provided thoroughly doc-umented.

The calculated hoop stress σh shall not exceed 85% of the ma-terial yield stress.

208 The drum flanges shall be designed for an outward pres-sure corresponding to the necessary support of the windingsnear the drum ends. Unless a lower pressure is justified bytests, the pressure is assumed to be linearly increasing fromzero at the top layer to a maximum value of

near the barrel surface. (The pressure pb acting on the barrelsurface is assumed to be three times this value. D is the outerdiameter of the barrel.)

It is assumed proper spooling, avoiding cutting/burying of thewire rope in the underlying layers. Additional forces due tocutting/burying of the wire rope are not taken into account inthe above specified calculation method. Further, wire ropecrushing is not covered.

B 300 Brakes

301 Automatic braking systems shall be arranged and shallbe activated when the operating device is brought to zero orbraking position However, for offshore crane applications, ref103.

For lifting of persons, see Sec.6 A700.

302 Brake mechanisms shall be so designed that the brakesare activated upon failure of the power drive or the control sys-tem. Means shall, however, be provided for overriding suchsystems at any time.

303 Braking systems shall be such as not to introduce shockloads.

304 Brakes shall preferably act directly on the drum. Wherea brake is arranged in front of a transmission, the componentsin the transmission subjected to loads due to braking shall bedesigned to comply with the requirements to strength of thebrake itself.

Brakes for offshore cranes shall also follow the requirementsas specified in Sec.6 A513, i.e. redundancy in case of breakagein the gear transmission.

305 Brakes shall exert a torque not less than 80% in excessof the maximum torque on the brake caused by the loads beingregarded as static loads. If the dynamic factor exceeds 1.8, thebraking capacity shall be increased accordingly. The lowestexpected coefficient of friction for the brake lining with dueconsideration to service conditions (humidity, grease, etc.)shall be applied in the design calculation of braking torquecapacity, but this coefficient of friction shall not be taken high-er than 0.3.

306 Automatic braking is assumed to be obtained by a springforce (or equivalent) and that the brake is released by hydrau-lic, pneumatic or electric means. The spring force shall be suchthat the braking torque capacity required by 305 will be ob-tained.

Particulars of spring performance shall be submitted.

307 All brake components, except those for slewing brakes,shall be designed for a load of at least 1.6 times the maximumunfactored loads, unless otherwise documented by detailedcalculations. For winches intended for subsea operationswhere the brakes are carrying the submerged dynamic load, thebrake components shall be designed for the full dynamic loadif larger than the unfactored load times 1.6. Brake componentsfor slewing motions shall be designed for a torque of at least1.3 times the maximum unfactored load torque.

308 Brakes shall be designed with due regard to inspection,adjustments and maintenance. Brake surface (e.g. on drum)should not be recessed.

avh tp

SC

⋅⋅=σ

hav

f D

tp σ⋅

⋅⋅

=3

2

DET NORSKE VERITAS

Page 48: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 48 – Ch.2 Sec.5

B 400 Steel wire rope with fittings and anchorages

401 For wire and rope materials and construction of steelwire ropes, see Sec.2.

For testing of steel wire ropes, see Sec.6.

402 Length of wire rope for a lifting appliance shall be suchthat there is not less than 3 turns of wire rope on the drum withthe hook at the lowest position and the boom in the most ad-verse position. Normally the ropes for hoisting and derrickingshall be in one length.

403 Steel wire rope safety factor for running application orforming part of sling and for mast stays, pendants and similarstanding applications shall be the greater of:

Not less than the greater of 3 and

but need not exceed 5.

SF = 2.3 ψψ = design dynamic coefficient for the craneSWL = Safe Working Load (kN).

For cranes with wire rope suspended jibs, the same safety fac-tor will be required for hoisting and luffing.

For subsea operations, where the static submersed load meas-ured at the crane tip (Fsub) exceeds SWL, SWL may be substi-tuted by Fsub.

404 For safety factor of wire ropes used for lifting people ormanned objects see Ch.2 Sec.6 A703.

405 The minimum breaking load B of steel wire ropes shallnot be less than

where S is the maximum load in the rope resulting from the ef-fect of the working load (suspended load) and loads due to anyapplicable dead weights. The number of parts and friction insheaves shall be considered.

406 Where not otherwise demonstrated by testing, a com-bined allowance for friction and bending of the wire ropes, tak-en as

— 1.5% for each sheave with ball or roller bearings— 5% for each sheave with plain bearings

shall be applied for calculation purpose of S in 405.

Above friction and bending loss may be reduced in proportionwith the wire ropes’ angle of contact with the sheave.

407 In wire ropes for running application the number ofwires shall not be less than 114 (6 strands with 19 wires each).

In the case of one part hoist line (whip hoist) non-rotation wireshall be used or ball bearing swivel shall be provided for pre-venting accumulation of twist.

Guidance note:A swivel should always be fitted between the hoist rope and thehook or other lifting attachment, and, except in the case of aship's derrick, the swivel should be fitted with ball- or roller bear-ings that can be lubricated regularly

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

408 For rope anchorage properly designed rope sockets likespelter sockets, ferrule secured-eyes (with thimble only) orself-locking wedge sockets shall preferably be used.

Socketing of wire ropes shall be carried out in accordance with arecognised standard and the socket manufacturer’s instruction.

409 Where wire rope clamps are used, the free length of ropeend shall be at least 5 times the rope diameter and the rope endshall be prevented from fraying. Only properly designed wirerope clamps with two gripping areas shall be used (the U-bolttype is not acceptable). The number of clamps depends on thediameter of the wire rope and shall comply with maker's spec-ification. The number of clamps shall in no case be less than 3.

410 A thimble or loop splice shall have at least five tucks,three tucks with the whole strand of the rope, and two tuckswith one-half of the wires cut out of each strand. The tucksshall be under and over against the lay of the rope. Splices shallbe tightly drawn and neatly made. These requirements will notprevent the use of another form of splice that can be shown tobe as efficient.

411 Where other connections are fitted, the method of splic-ing shall be according to recognised codes and standards.

412 The efficiency of the applicable wire rope terminationshall comply with an EN-or ISO standard or be documented bythe test certificate/report covering the actual wire rope beingused. If the efficiency of the end termination is below 80%, theloss shall be compensated for up to minimum 80% efficiency.

413 Except for offshore cranes taking loads from supply ves-sels and the sea bed, the strength of the anchorage of the hoistrope to the drum shall have strength not less than the smallestof 80% of the breaking load of the hoist wire rope or 2.5 timesthe maximum design tensile force in the rope. The force mayinclude the friction of the turns remaining on the drum, basedon coefficient of friction of 0.1.

414 For offshore cranes taking load from supply vessels andthe sea bed, the load carrying capacity of the fixed hoist ropeanchorage to the drum shall approximately equal the wire ropeline pull. However, including the frictional force being appliedthrough the turns of rope always to remain on the drum, the to-tal capacity of anchorage shall be equal to the breaking load ofthe rope. In order to achieve this frictional force it may be nec-essary to increase the minimum remaining turns on the drumto more than 3.

415 The rope anchorage of the boom rope to the drum shallnot be taken less than the maximum design rope pull. Anchor-age including friction of the remaining turns on the drum whenthe boom is in the lowest allowed position shall withstand thebreaking load of the hoist wire rope. The friction force shall bebased on a coefficient of friction of 0.1.

416 All wire rope anchorages shall be easily accessible forinspection.

B 500 Sheaves

501 Sheaves shall comply with a recognised code orstandard. Normally, the sheave diameter for steel wire ropesshall at least correspond to a ratio Dp/d = 18, where Dp is thepitch diameter of the sheave and d is the wire rope diameter.Further, the sheave groove shall comply with the correspond-ing guidance for grooves in drums as specified in 203.

For non-rotating sheaves (e.g. equaliser sheaves) and similararrangements where the wire is not moving the ratio Dp/d shallbe at least 10.

502 Sheaves shall either be castings, welded or be gas cutand machined from steel plate. However, sheaves made fromnylon castings may be accepted after special considerations.

503 Castings and plates for sheaves shall comply with Sec.2.However, for non-welded sheaves the required impact testingof the material will be waived.

504 All sheaves and blocks shall be so arranged that the wirerope cannot run off the sheave.

1910885.0

104

+⋅=

SWLSF

SSFB ⋅=

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Page 49: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.5 – Page 49

B 600 Anti-breakdown device for slewing mechanism

601 Slewing mechanism shall be so designed that it will notbe damaged by heavy braking or reversal of the motion.

Guidance note:This may be achieved either by designing the drive mechanismto resist the torque imposed by the above conditions or by the in-sertion of a torque limiting device (e.g. a slipping clutch) whichwill protect the mechanism from excessive shock loading. Thetorque limiting device should also allow the brake to slip if thehorizontal load on the boom exceeds the load for which the boomhas been designed.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

B 700 Lifting gear, including loose gear and grabs

701 For definition of lifting gear, including loose gear, seeCh.1 Sec.1 C.

702 Material shall be as specified in the applied codes orstandards. If the codes or standards used do not cover applica-ble material requirements, or a design is not covered by codeor standard, the material requirements given in Sec.2 shall becomplied with.

Where certification by other Competent Persons (for examplethe manufacturer) is accepted, the material certificates shall befiled by the Competent Person and shall be presented upon theSociety’s request.

703 Design and strength of lifting gear shall comply withrecognised codes or standards. Where applicable codes orstandards are not followed, the safety factor for chain as givenin 801 will normally be acceptable.

Lifting and spreader beams/frames will normally be acceptedcalculated as outlined in Sec.3. Load Case II stress acceptancelevel, with dynamic factor not less than the overload test factoras given in Sec.6 shall be satisfied in addition to Load Case Iand applied ψ.

704 Design load for lifting gear as well as grabs shall be thegreater of:

— 0.75 × ψ × SWL , and — SWL

ψ is the dynamic factor for which the crane is designed.

For cranes intended for grab duty the dynamic factor shall in-clude also the additional increase specified in Ch2 Sec3 B310

705 The main and auxiliary hook (whip hoist) for offshorecranes shall at least meet the requirements in DIN 15400 ma-chinery group 1 AM and 2M respectively. However, in caseswhere the design hook load corresponds to that caused by thedynamic response for significant wave heights exceeding 3metres, machinery group 1 AM may also be accepted for theauxiliary hook.

706 Hooks shall be fitted with a safety latch or be so de-signed that the ring or sling cannot fall out.

Irrespective of design, hooks for offshore cranes shall be fittedwith a safety latch.

707 Hook blocks shall have protective plates and shall beeasy to handle from any side.

708 In cases where, upon special agreement, (See Ch1 Sec1E700) the damping effect of a hydraulic damper shall be in-cluded in the approval, the damping effect shall be document-ed by both calculations submitted and practical tests The testprogram shall be submitted by the Customer, accepted byDNV’s approval unit, and monitored by the certifying survey-or to the extent agreed before the tests are initiated.

709 Lifting gear and grabs shall be marked with the safeworking load. The crane manual shall contain information ofnecessary specifications for ordering replacements.

B 800 Chains801 The safety factor for chains, measured against the min-imum specified breaking strength, shall not be less than thegreater of:

— 4 × 0.75 ψ × SWL — 4 × SWL

where ψ is the dynamic factor for which the crane is designed.

802 The material of the chains and/or the grade shall be doc-umented with a certificate, for example an inspectioncertificate of type 3.1, referring to a recognised standard.

803 Before being taken into use for the first time the chainsshall be load tested as for loose gear, and the tests shall be doc-umented by ILO Form No.3 or CG3 certificate.

B 900 Skids901 Skids designed for lifting of varying loads as well asskids designed for a specific load and/or a specific transport as-signment may be certified in accordance with the requirementsin 700, however with observation of the conditions outlined inAppendix E A300.

C. Power Systems

C 100 Prime movers101 Prime movers shall be designed to accept normal loadconditions such as running at load levels characteristic for theexpected use of the crane, and to accept frequent and large loadvariations.

102 The crane prime mover shall be such that the full powerdemands of any loading and speed combinations associatedwith the various motions are compatible with the operationsthat the crane is designed for.

103 For operation within hazardous (gas-dangerous) areas,prime movers and their installation shall meet additional perti-nent requirements.

104 Adequate insulation and shielding shall be provided forthe protection of personnel during performance of their normalduties and to prevent ignition of flammable fluids.

105 The internal combustion engines shall normally not belocated in hazardous areas. The exhaust gas outlet of the en-gines shall have an effective spark arrestor. The outlet shall beled to the atmosphere at a safe distance from any hazardous ar-ea.

C 200 Power independency201 Hoisting and derricking functions shall be independentof travelling and slewing functions.

202 The crane and its load shall be able to remain in un-changed position in the event of power failure, see also B302.

D. Electrical Installations, Equipment and Systems

D 100 General101 For industrial lifting appliances electrical installationshall comply with relevant and recognised codes or standardspertinent to the location of the crane.

102 Electrical installations of lifting appliances onboardships- and offshore units classed by DNV shall comply withthe Society’s Ship Rules Pt.4 Ch.8 “Electrical installations”.

103 For offshore cranes and cranes covered by relevant classnotations; the electrical equipment and systems supporting the

DET NORSKE VERITAS

Page 50: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Page 50 – Ch.2 Sec.5

crane main functions will generically be defined as “essential”according to Society’s Ship Rules Pt.4 Ch.8. Specificallyequipment and systems having impact on the Risk Contribu-tors listed in Sec.6 A502 shall fulfil requirements with respectto essential installations.

104 For offshore cranes onboard mobile offshore units (semisubmersibles, jack-ups, etc.), additional requirements as spec-ified by the governing DNV Offshore Codes shall be appliedas far as relevant.

Guidance note:The following codes and standards are recognised:

- Norwegian Standard NS 5513 - Cranes and Lifting Applianc-es.

- DNV Rules (Ships) Pt.4 Ch.8, “Electrical Installations”.- British Standard BS 5345 - Selection, Installation Mainte-

nance of Electrical Apparatus for use in Potentially ExplosiveAtmospheres.

- NEK 420.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Other codes and standards may after special consideration berecognised by the Society.

D 200 Plans and specifications201 For the electrical system the following shall be submit-ted:

1) Drawings and specification of:

a) switchboard

b) distribution boards

c) control panels.

2) Single line diagram of:

a) power distribution

b) lighting distribution showing full load, cable typesand cross sections make-type-rating of fuse andswitchgear.

3) Schematic diagrams of:

a) control system (with safety system)

b) starting arrangement for engines.

4) Arrangement drawings showing:

a) location of electrical equipment

b) cable run.

E. Hydraulic, Pneumatic, Instrumentation, Automation and Wireless Remote Control

Systems

E 100 Hydraulic systems101 Hydraulic systems and their lay-out shall satisfy recog-nised codes or standards and engineering principles and shallas far as relevant or applicable comply with pertinent rules ofDNV.

102 When designing hydraulic circuits, all aspects of possi-ble methods of failure (including control supply failure) shallbe considered. In each case, components shall be selected, ap-plied, mounted and adjusted so that in the event of a failure,maximum safety to personnel shall be the prime consideration,and damage to equipment minimized. (Fail-safe concept)

103 All parts of the system shall be designed or otherwiseprotected against pressures exceeding the maximum workingpressure of a system or any part of the system or the rated pres-sure of any specific component.

104 Systems shall be designed, constructed and adjusted tominimize surge pressures and intensification pressures. Surgepressure and intensified pressure shall cause no hazards.

105 Loss of pressure or critical drops in pressure as well asmissing hydraulic refilling shall not cause a hazard.

106 Leakage (internal or external) shall not to cause a haz-ard.

107 Whatever type of control or power supply used (e.g.,electrical, hydraulic, etc.), the following actions or occurrences(unexpected or by intention) shall create no hazard:

— switching the supply on or off— supply reduction— supply cut-off or re-establishment.

108 Hydraulic systems and other machinery in connectionwith the hydraulic system shall be designed to protect person-nel from surface temperatures that exceed touchable limits byeither insulating or guarding.

109 To facilitate maintenance, means shall be provided orcomponents so fitted that their removal from the system formaintenance:

— shall minimize the loss of fluid— shall not require draining of the reservoir— shall not necessitate extensive disassembly of adjacent

parts.

110 The fluid reservoir shall be designed with respect to:

— dissipation of heat from the oil— separation of air— settling of contamination in the oil— maintenance work.

Indicators showing the fluid level shall be permanently markedwith system “high” and “low” levels.

Air breathers on vented reservoirs should be provided whichfilter air entering the reservoir to a cleanliness level compatiblewith the system requirements, taking into consideration the en-vironmental conditions in which the system is to be installed.

111 Effective means for filtration and cooling of the fluidshall be incorporated in the system.

A means of obtaining a representative fluid sample shall beprovided to allow for checking fluid cleanliness condition.

Valves for fluid sampling shall be provided with sealing andwith warning signs marked “System under pressure”

112 Flexible hoses and couplings shall be of approved type(Type Approval Certificate issued by DNV is recommended).

113 Flexible hoses shall only be used

— between moving elements— to facilitate the interchange of alternative equipment— to support the transmission of mechanical vibration and/or

noise.

114 Flexible hoses shall be located or protected to minimizeabrasive rubbing of the hose cover.

115 Hydraulic cylinders and accumulators shall be separate-ly approved.

116 Hydraulic cylinders that do not meet the conditions list-ed in index 13 of Table A1 of Sec.1, or with a load carryingcapacity exceeding 20 tonnes or for offshore cranes or forcranes to be included in class (CRANE or Crane Vessel),are subjected to DNV approval and certification.

The documentation to be submitted for approval shall meet theapproval procedure as described in DNV Standard forcertification No. 2.9 “Type Approval Programme 5-778.93Hydraulic cylinders.” October 2002.

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Page 51: DNV Standard 2-22 Rules for Lifting Appliances

Standard for Certification of Lifting Appliances, October 2008Ch.2 Sec.5 – Page 51

See also index 14 -15 of Table A1 of Sec.1.

117 The design calculations submitted for approval shall bebased on the maximum obtainable pressure. Alternatively, ifthe maximum dynamic force applied on the crane is known,this may be used as basis for the design calculations. Differentoutreach positions may have to be evaluated.

118 Based on individual considerations, a buckling safetyfactor down to 2.3 may be accepted

119 Materials shall fulfil the requirements in DNV Standardfor certification No. 2.9.

120 Requirements regarding cylinder wall thickness are de-scribed in the Type Approval Programme mentioned in 116.

Requirements regarding wall thickness of tubes are describedin DNV’s Rules for Ships Pt.4 Ch.6 Sec.6 A Tables A1, A2 andA3.

121 Welds shall normally be full penetration welds. Otherthan full penetration welds may be accepted on a case-to-casebasis provided that acceptable stresses (both with respect to fa-tigue and static) can be documented. This will primarily be ap-plicable for cylinders used for pushing only (e.g. jib cylinders).

122 Hydraulic cylinders for cranes other than those men-tioned in 116 may be accepted based on the manufacturer’sproduct certificate and consequently do not need DNV’s de-sign approval. See also index 13 of Table A1 of Sec.1.

E 200 Testing201 Except for mountings, each component of the systemshall be delivered with a Product Certificate documenting thatit has been pressure tested to 1.3 times the design pressure.

202 The test pressure shall be minimum 70 bar above the de-sign pressure. Consequently the requirement for pressure test-ing of the complete hydraulic system of a crane is notconsidered satisfactorily complied with by the overload testingof the crane.

203 Hydraulic testing of the assembly shall be performed inthe presence of a surveyor, unless otherwise agreed. The testpressure shall be maintained for a time sufficient for check ofleakage. The assembly shall exhibit no sign of defects or leak-age.

E 300 Pneumatic systems301 Air intakes for compressors shall be so located as to min-imize the intake of oil- or water-contaminated air.

302 When designing pneumatic circuits, all aspects of possi-ble methods of failure (including control supply failure) shallbe considered. In each case, components shall be selected, ap-plied, mounted and adjusted so that in the event of a failure,maximum safety to personnel shall be the prime consideration,and damage to equipment minimized. (Fail-safe concept.)

303 Loss of pressure or critical drops in pressure shall causeno hazard.

304 Leakage (internal or external) shall create no hazard.

305 Whatever type of control or power supply used, the fol-lowing actions or occurrences (unexpected or by intention)shall not create a hazard:

— switching the supply on or off— supply reduction— supply cut-off or re-establishment.

306 Air supply to instrumentation equipment shall be freefrom oil, moisture and other contaminants. The dew point shallbe below 5°C for air in pipes located in crane engine room. Inpipes outside the engine room the air shall have a dew point be-low (TD-5)°C.

307 Components requiring extremely clean air shall not beused.

308 Main pipes shall be inclined relative to the horizontal,and drainages are to be arranged.

309 Piping and pressure vessels shall comply with relevantrecognised codes and shall generally comply with DNV Rules.

E 400 Control and monitoring systems

401 For offshore cranes in general and all cranes covered byrelevant class notations; components and installations shallcomply with the Society’s Ship Rules Pt.4 Ch.9 "Control andmonitoring systems". Control and monitoring systems supporting the crane mainfunctions will generically be defined as “essential” accordingto Society’s Ship Rules Pt.4 Ch.9.

Specifically equipment and systems having impact on the RiskContributors listed in Sec.6 A502 shall fulfil requirements withrespect to essential installations.

402 For offshore cranes covered by class notations CRANEor Crane Vessel, testing at manufacturer’s works and issu-ance of product certificate will, as addressed in Society’s ShipRules Pt.4 Ch.9 "Control and monitoring systems", be re-quired.

403 For offshore cranes onboard mobile offshore units (semisubmersibles, jack-ups, etc.), additional requirements as spec-ified by the governing DNV Offshore Codes shall be appliedas far as relevant.

E 500 Wireless remote control systemsGuidance note:The principles for wireless remote control should be:

1) Safe state for the crane and for the wireless remote controloperation should be defined.Normally we will assume that safe state is immediate stop ofall crane movements. The crane brake capacities should besufficient to hold the crane and the cargo at any positionwithin a given response time.(Some cranes are equipped with heave compensation, auto-matic overload protection, emergency operation, etc. Insuch cases safe state may not be complete stop).Furthermore:

- The system should prevent operation if the operatorleaves the normal operating area for the crane.

- The data sent to/from the remote control unit should besubjected to error detection and/or error correction.

- Transmitting of radio data should also be made possibleby “handshaking”.

2) The wireless communication with the crane should not bedisturbed by any other external communication signals, andit should be designed in accordance with accepted standardsfor emission.

3) If it cannot be proven that the frequencies allocated for thewireless communication for a specific crane are unique in allareas where the crane will be operated, and that such com-munication will never be interrupted by external communi-cation signals, some kind of unique cryptation or ID of thewireless communication or similar is strongly recommend-ed. The main concern is that such arrangements should preventother signals from controlling the crane movements.

4) Loss of communication with the unique remote controlshould cause the crane to go into a safe state as outlined initem 1 above.

5) Additionally an emergency stop independent of the wirelessremote control should be installed.Furthermore:

- By starting of the remote control unit a self-check mustbe conducted in order to prevent movements if the con-trol has been left in such mode.

- The lifting unit should also be provided with a hardwiredemergency stop easily accessible.

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- The remote control unit should be provided with a key-switch for closing when not in use.

- When used for lifting of persons, the remote control unitshould also be provided with a “dead man button”.

6) The planned operation should be subjected to an analysis

where special hazards and risks should be identified.For high-risk operations caused by mal-operation or equip-ment failure, the risk and the safety measures should be doc-umented in a detailed analysis.

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SECTION 6 SAFETY AND SAFETY EQUIPMENT

A. Safety

A 100 Operator's cabin101 On offshore and shipboard deck cranes an operator'scabin will normally be required. This may also apply to othertypes of cranes. National authorities may require a cabin oncranes for the protection of the operator against noise andweather.

102 If required or fitted, the cabin shall satisfy the followingoverall requirements:

— Be of adequate size and give adequate protection againstweather and other environmental exposure.

— Give the operator an adequate view of the area of opera-tion including hook and hook position.

— Have windows capable of being readily and safely cleanedinside and outside and to have defrosting and defoggingmeans. Outdoor cranes shall have windscreen wipers.

— Be adequately tempered (heated, cooled) and ventilatedaccording to local conditions.

— Be of fireproof construction, have doors that can be readilyopened from both inside and outside.

— In the case of a derrick crane access/exit shall not be ob-structed by any boom elevation.

— Noise and vibration shall remain within acceptable limits.— Have a comfortable and purpose-designed seat from

which all operations can easily be controlled. Foot restsshall be arranged where necessary.

— Have the crane controls marked and lit to show their re-spective function.

103 Where the operator's cabin is attached to and travels withthe crab, the cabin suspension gear shall be so designed that thecabin cannot fall if the cabin or the crab is accidentally dis-placed from its rails.

A 200 Platforms, access gangways and operator’s cab-ins201 For documentation of satisfactory structural strength,see Sec.3 B700.

A 300 Parking and precautions against wind loads301 Lifting appliances shall be provided with means to se-cure the appliance in the "out of service condition" in a safemanner. The effect of wind and wind gusts and any roll, listand trim shall be considered.

A 400 Protection and precautions against fire401 Necessary protection and precautions against fires andexplosions shall be considered in each case.

The number, capacity and location of fire extinguishers shallbe adequate for the type of crane and its intended service.However, at least one fire extinguisher shall be provided in theoperator's cabin.

402 Air pipes from fuel tanks shall be led to open air.

403 Cofferdams shall be arranged at fuel filling pipe.

404 It shall be possible to stop/close the following compo-nents from a central place outside the crane engine room:

— valves on tanks for flammable fluids — pumps for flammable fluids — flaps (shutters) in air ducts to engine room — fans for ventilation — engines.

A 500 Safety functions and equipment, offshore cranes501 General

All lifting appliances categorised as Offshore cranes shall beprovided with safety functions, reducing the risk connected tocrane operations. The subsequent safety function requirementsare founded on a risk based approach. It is up to the customerto select the technological platform for the safety functions. Inprinciple, all alternatives providing equivalent safe operationwill be accepted.

In the following, the safety function requirements are organ-ised as follows:

— listing of generic (i.e. standard) risk contributors, ref. 502— description of the generic risk contributors and corre-

sponding required generic safety functions, ref. 504-519— monitoring of the safety functions, ref. Table A5— documentation requirements to the safety functions, ref.

520— ranking of the safety functions, ref. 521— verification, ref. 522— handling of deviations and extended risk, ref. 523.

Additional requirements for lifting of personnel are specifiedin 700.

The corresponding documentation- and verification require-ments are specified in the “Verification Guideline for SafetyFunctions, Offshore Cranes”, ref. Appendix G.

502 Generic risk contributors.

The following hazards are identified as generic risk contribu-tors for offshore cranes:

— over-loading (see 504).— crane movements outside operational limitations (over

travel) (see 505)— dangerous lifting gear/cargo movements (see 506)— dangerous crane movements (see 507)— lack of visibility (see 508)— lack of communication (see 509)— slack wire rope at drum (see 510)— failure in control systems (see 511)— failure in safety components/systems (see 512)— lack of braking capacity (see 513)— lack of load holding capacity (see 514)— blackout/shutdown of power (see 515)— unintended activation of safety functions (see 516)— spurious trip of safety functions (see 517)— hazards due to activation of safety functions (see 518)— fire/fire ignition (519).

The maximum consequence assumed for each of the abovelisted generic risk contributors is one fatality, with the excep-tion of “Fire/fire ignition” (519). For lifting appliances wherethe specific risk exceeds one fatality (not including “Fire/fireignition”), or where the specific risk contributors deviates fromthe above, ref. 523 “Handling of deviations/extended risk”.

503 Description of risk contributors and corresponding re-quired generic safety functions

The following description of the generic risk contributors andcorresponding required generic safety functions applies.

For lifting appliances with specific safety functions that devi-ates from the following generic safety functions, ref. 523“Handling of deviations/extended risk”.

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Note:

The below bold/italic number references in parenthesesrefer to applied numbering in the “Text reference” row ofthe tables in Appendix G B300.

504 Over-loading

Generic risk contributors:

Over-loading due to crane hook entangled to the supply boat orother moving objects, due to load sucked to the seabed, due toheave compensation not working properly, or other overloadsituations, may lead to crane structure collapse.

Generic risk control measures:

All offshore cranes shall therefore be provided with overloadprotection. The safety functions for overload protection shallbe implemented by means of an automatic overload protectionsystem (504.a and 504.c) and a manual overload protectionsystem (MOPS) (504.b). The automatic overload protectionshall be implemented by means of an “Overload limiting de-vice” (504.a) and - additional for supply boat and barge han-dling cranes operating in nautical zones with short wavecharacteristics - an AOPS (“Automatic Overload ProtectionSystem”) (504.c).

a) For cranes intended for supply boat/barge operations andfor subsea handling cranes, an “Overload limiting device”,stopping the boom from being luffed further out (504.a)will be required. The “Overload limiting device” shall au-tomatically be activated when the crane is subject to anover-load response close to the crane’s design load (givenby the safe working load times the design dynamic factor).When activated, the luffing in and load lowering/hoistingabilility shall stay intact.

b) MOPS (504.b) will generally be required for all offshorecranes, including subsea operating cranes. The MOPSshall operate under all conditions, including failure in themain power supply and failure in the control system, andshall override all other functions when activated. The sys-tem shall be arranged for manual activation for all reevingconfigurations. The activation switch or handle shall be lo-cated for rapid access at the control station, permanentlymarked with yellow colour, and protected against inad-vertent use.At any time, the system shall be able to be reset by thecrane operator, without causing significant damage to thecrane. The system, when activated, shall maintain a retain-ing force in the hoisting system of approx. 10% - 25% ofthe maximum rated capacity for platform lift. The capacityof the system shall be sufficient for activating/reset for atleast 3 times in succession, and for continuous activationfor at least 5 minutes.

c) The requirement to provision of AOPS (504.c) for supplyboat and barge handling operations will be based on dueconsideration to which nautical zone, with correspondingwave parameters, the crane will operate. Provision ofAOPS will be required for operations in nautical zoneswith a short wave characteristic, for instance the NorthSea, whereas operations in nautical zones with a longwave characteristic will not require AOPS. AOPS willgenerally not be required for subsea handling cranes. TheAOPS, when installed, shall be operational for all reevingconfigurations. The trigger load shall not be less than ratedcapacity for platform lift, giving an appropriate responsetime to avoid significant damage to the crane. Automatic overload protection for lateral boom loads ex-ceeding the design limits for the slew system shall also beprovided (not required for heavy lift cranes). The lateraloverload protection shall be independent of the AOPS.The AOPS - with the exception of the lateral overload sys-tem - shall include sector limitation and height limitation,

preventing system activation when the load is positionedabove the platform. Manual overriding of the AOPS shallnot be possible unless for the purpose of lifting of person-nel. The AOPS shall be designed with respect to responsetime and retaining force in the hoisting rope, protecting thecrane from any structural damage. When the system is activated, the crane shall maintain aretaining force at the hook sufficient to suspend a load cor-responding to the rated capacity for platform lift. If thehook load increases beyond this value, the minimum pay-out hook speed due to the increased actual hook load shallnot be less than the velocity given in the expression (Vin

2 + Vt2)0.5, see Sec.3 B304 (the velocities as indicated

in EN 13852-1 Annex B may be used as a simplified meth-od). When the overload/-moment situation no longer ex-ists, the system shall automatically deactivate. However,due to possible oscillation,, delayed deactivation of theAOPS shall be considered.

d) When subjected to an overload response equal to the acti-vation load for the shut-down device or the trigger load forthe AOPS, an alarm warning all the personnel within theworking area, including all personnel onboard the attend-ing supply vessel, shall automatically be activated.

e) When the AOPS or the MOPS is activated, the end stop atthe winch drum (limiting the residual windings to mini-mum 3) shall be overridden, allowing the wire rope to bespooled completely off the drum.

f) Both the AOPS and MOPS shall have control indicators inthe cabin, i.e. a continuous visual signal to indicate wheth-er the system is operational or not. A different continuousvisual and acoustic signal shall be given when the systemis activated. In addition, an external acoustic alarm givinga sound level of approx. 110 dB (A) measured at 1 m fromthe alarm when the MOPS is activated, shall be provided.

g) A rated capacity indicator and a crane inclinometer (if thecrane is installed on a floating unit), giving continuousinformation to the operator, shall be provided. The load in-dicator shall include a display of the selected crane config-uration and the significant wave height. Further, craneswith a variable rated capacity dependent on the radiusshall be provided with a radius indicator clearly visiblefrom the control station. An audible and visual warning/alarm, giving a continuous warning to the crane operatorwhen the load response exceeds 90% of the crane’s ratedcapacity/overturning moment for platform lift, shall be fit-ted.

505 Crane movements outside operational imitations

Generic risk contributors:

Crane movements outside operational limits may lead to stressbeyond the crane’s structural strength and to operational haz-ards.

Generic risk control measures:

All crane movements are therefore to be kept within safe oper-ational limitations, either by means of limit switches/alarms orphysical layout (505.a). The hoisting and luffing winches shallbe equipped with upper and lower limiters, stopping the winchmovements within safe margins to avoid collision with otherparts of the crane and keeping safe number of retaining wirerope turns on the drum - usually minimum 3. Special consider-ation shall be paid to the crane boom’s upper limit protection(505.b) for wire rope suspended booms, where redundancy bymeans of 2 independent limit switches is required.

Limit switches shall be positively activated and be of failsafetype, i.e. the crane shall go to a defined safe condition in caseof failure (power failure, cable defect, etc.). Activation of limitswitches shall lead to indication in the crane cabin. After acti-vation of a limiting device, movement in the reverse direction- to a more safe position - shall not be prevented. Where more

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than one movement cause over-travel, all limit switches limit-ing such over-travel shall be activated simultaneously (e.g.hoist block over-travel at boom top may be caused either byhoisting or luffing). A manually operated “over-ride” system,provided positive and maintained action combined with indi-cation and alarm, may be fitted.

506 Dangerous lifting gear/cargo movements

Generic risk contributors:

Unintended lifting gear/cargo movements may lead to hazard-ous situations for personnel involved in crane operations.

Generic risk control measures:

a) Means for keeping constant tension in the hoisting wirerope (“constant tension”) when carrying out supply boatoperations, compensating for the relative movement be-tween the lifting gear/cargo and the supply boat, may beprovided (optional) (506.a). The constant tension systemshall, when installed, be designed with due considerationto the retaining force (usually in the area of 2 – 3 tonnes),response time and unintentional activation. It shall not bepossible to activate the system outside a defined zoneclose to the supply boat - neither horizontal nor vertical,and shall not be possible to activate when the crane is load-ed. The winch shall automatically return with soft charac-teristic to normal hoisting, braking or holding conditionwhen the constant tension is disengaged. An indication, in-forming when the constant tension system is active, shallbe present in the cabin.

b) Special consideration shall also be paid to dangerous lift-ing gear movements when lifting or lowering the boom/lifting gear to or from the boom rest/cradle. Only slow mo-tions of the boom shall be possible.

c) An audible warning (horn or similar device) (506.c) towarn or attract the attention of any person within the oper-ational area of the crane, operated by the crane operator,shall be provided.

507 Dangerous crane movements

Generic risk contributors:

Dangerous crane movements or unintentional crane move-ments due to malfunction in the crane’s control system maylead to operational risks.

Generic risk control measure:

A manually operated emergency stop function, leading to shut-down and stop of the crane movements, shall therefore be fit-ted. Simultaneously, the brakes shall be engaged in a progres-sive and safe manner. The emergency stop shall retain itsfunction regardless of any malfunction in the crane’s controlsystem. Emergency stop actuators shall be located at conven-ient locations at control station for immediate use by personnelin the event of a hazardous situation occurring.

The emergency stop shall function as, or stopping by:

— immediate removal of power to the machine actuators, or — mechanical disconnection (declutching) between the haz-

ardous elements and their machine actuators.

The emergency stop shall be so designed that deciding to actu-ate the emergency stop actuator shall not require the operatorto consider the resultant effects (stopping zone, decelerationrate, etc.). The emergency stop command shall over-ride allother commands except the MOPS (ref. 521). The emergencystop function shall not impair the effectiveness of the safety de-vices or devices with safety related functions. Resetting thecontrol device shall only be possible as the result of a manualaction on the control device itself. Resetting the control deviceshall not cause a restart command.

The emergency stop actuators shall be designed for easy actu-

ation. Types of actuators that may be used include:

— mushroom type push button.— wires, ropes, bars.— handles.— in specific applications, foot pedals without protective

cover.

Measures against inadvertent operation shall not impair the ac-cessibility of the emergency stop actuator. The emergency stopactuator shall be coloured red. The background shall be col-oured yellow, as far as practicable. If the emergency stop actu-ator is not located directly on the machine, labels shall beprovided addressing the actuator to the machine. A warning/alarm and an indication in the crane cabin shall inform thecrane operator that the emergency stop has been activated.

508 Lack of visibility

Generic risk contributors:

Lack of visibility due to poor sight or due to crane operationsin the crane driver’s blind zone may lead to operational haz-ards.

Generic risk control measure:

Consequently, a boom tip camera is normally required for alloffshore cranes intended for supply boat or barge handling.The camera and camera installation shall be designed with dueconsideration to environmental factors (wind, salt, moisture,vibrations, etc.) and operational suitability.

509 Lack of communication

Generic risk contributor:

Lack of communication between the crane operator and theother participants in the crane operation may lead to operation-al hazards.

Generic risk control measure:

Two-way communication equipment, enabling the crane oper-ator to communicate with the participants in the crane opera-tion in a safe way, shall be provided. The crane operator shallbe able to operate the communication system without movinghis hands from the main control levers.

510 Slack wire rope at drum

Generic risk contributor:

Slack wire rope at the drum may lead to improper spooling andentangled wire rope.

Generic risk control measure:

The drums - both for the hoisting winch and the luffing winch- shall therefore be equipped with a slack wire rope detectiondevice which will be activated automatically if the wire ropebecomes slack during lowering. The device shall stop thewinch motion until the wire rope is re-tightened, before auto-matically returning to normal operation. When activated, a vis-ual and acoustic signal/indication shall be given in the cranecabin. Where the crane driver has a full view of the drums fromhis normal position, the slack wire rope detection device maybe omitted.

511 Failure in control systems

Generic risk contributor:

Failure in the crane’s control system may result in unintention-al crane response and movements.

Generic risk control measures:

Control system design and components shall therefore be se-lected, applied, mounted and adjusted so that in the event of afailure, maximum safety shall be the prime consideration (fail-safe concept). All aspects of possible methods of failure –including power supply failure - shall be considered. If anyfailure occurs, the control system shall always return to the saf-est condition with respect to stabilising the crane and the load.

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Special consideration shall be paid to the below points if sub-jected to failure in the control system:

— unintended start of machinery shall not be possible— safety devices or devices with safety related functions

shall be impaired to a minimum degree.

An alarm and an indicator revealing any detectable failure inthe control system affecting the operation shall be present inthe crane cabin.

512 Failure in safety components/system

Generic risk contributors:

Failure in safety components and the safety system may resultin hazardous situations due to override of safety limits.

Generic risk control measures:

The safety components/system shall therefore be so designedthat all aspects of failure – including power supply failure –shall lead to indication and alarm in the crane cabin (monitor-ing), or – alternatively – safeguarded by redundancy design.

513 Lack of braking capacity

Generic risk contributor:

Insufficient braking capacity may lead to falling load and un-controlled crane movements (falling boom, etc.).

Generic risk control measures:

All driving mechanisms and winches intended for hoisting andluffing shall be fitted with fail-safe brakes, i.e. failure of thebrake’s control system shall lead to automatic application ofthe brake, ref. Sec.5 B300.

If a single geared transmission is placed between the opera-tional brake and the drum for the load hoisting and boom hoist-ing winches, redundancy in case of breakage in the geartransmission shall be provided by an additional brake with anindependent control loop and load path to the drum, designedfor the braking load as specified in Sec.5 B307. In case of mul-tiple gear transmissions, redundancy shall be provided by in-creasing number of gear and brake sets at least 30% aboverequired.

514 Lack of load holding capacity

Generic risk contributors:

Lack of load holding capacity due to missing hydraulic refill-ing or loss/drop of hydraulic pressure, may lead to falling loador boom.

Generic risk control measures:

The crane’s hydraulic system shall therefore be designed sucha way that missing hydraulic refilling shall not occur. Further,the hydraulic system shall be fitted with safety or load holdingvalves on all main circuits protecting against unintendedmovements in case of hose rupture.

515 Blackout/shutdown of power

Generic risk contributor:

Blackout/shutdown may lead to crane stop with the crane andthe load in unfavourable and unsafe position.

Generic risk control measures:

a) Power failure/blackout or unintended shut-down shall leadto automatic application of the brakes (515.a) and an alarmat the operator’s stand.

b) Facilities for emergency operation (515.b), bringing thecrane and the load to safe condition with respect to hoist-

ing, slewing, luffing down and load lowering, shall be pro-vided by means of an independent standby power unitrated to minimum 30% of the capacity of the primary pow-er unit. The activation switches or handles for emergencyoperation shall be of “hold to run” type and clearly andpermanently marked for their purpose. A mobilisationtime of maximum 30 seconds will be required.

516 Unintended activation of safety functions

Generic risk contributors:

Unintended activation of safety functions may lead to crane re-sponse giving unintentional hazards/risks.

Generic risk control measures:

Handling devices for safety functions shall be protectedagainst inadvertent use and positioned away from ordinary op-erating handles. Interlock devices, preventing inadvertent acti-vation in dangerous zones (water zone only, etc.) shall be fittedwhen possible.

517 Spurious trip of safety functions

Generic risk contributors:

Initiation of a safety functions in no-hazardous situations andwhere there is no true demand for safety activation due to safe-ty- or control system failure, may cause other types of hazards/risks.

Generic risk control measures:

Consideration to spurious trip shall be taken in the design ofthe safety- and control systems. A risk assessment may be re-quired for identification and possible elimination/reduction ofspurious trip and corresponding hazards/risks.

518 Hazards due to activation of safety functions

Generic risk contributors:

Activation of safety functions may lead to secondary effectsthat may be harmful to the crane and/or the load.

Generic risk control measures:

Design of safety systems and components shall be done withconsideration to dangerous secondary effects, even if thecrane/load movements are stopped from full speed and/or fullload. Sector limitations for some safety functions shall be con-sidered.

519 Fire/fire ignition

Generic risk contributors:

Fire/fire ignition may arise from the crane itself or from theship/installation, and thereby lead to disaster.

Generic risk control measures:

Generally, necessary protection and precautions against firesand explosions shall be separately considered in each case,with consideration to the hazardous area classification inwhich the crane or parts of the crane will operate and to the re-quirements to the crane’s emergency preparedness. The appli-cation of fire extinguishers and/or automatic fire fightingsystem shall be considered in each case.

a) An automatic acoustic alarm in case of detection of fire orexplosive atmosphere shall be provided (519.a). Thealarm shall be connected to and initiated by the ship’s orthe installation’s fire/gas detectors and alarm system.

b) Automatic crane shut-down in case of detection may beprovided (519.b), however, the requirement to crane’semergency preparedness shall be considered in each case.

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520 Documentation of the safety functions

Documentation of implemented safety functions shall be sub-mitted for review, documenting fulfilment of functional andtechnical requirements. The “Verification Guideline for SafetyFunctions”, Appendix G, specifies the requirements to the doc-umentation. The general scope of the documentation is else tobe as specified in Sec.1 A herein and as in the respective disci-pline chapters.

521 Ranking of the safety functions

The manual overload protection (MOPS) and the emergencystop function shall be the preferred safety functions and haveequal priority, before other safety devices/limiters.

522 Verification

The verification will be carried out according to the “Verifica-tion Guideline for Safety Functions”, as given in Appendix G.This document enables verification by means of verificationtemplates, leading to effective and time-saving verification.

523 Handling of deviations and extended risks

In cases where the risk deviates from the generic by means of:

— assumed maximum consequence for one hazard/risk con-tributor that will exceeds one fatality (with the exceptionof “fire/fire ignition”), or where the specific risk contribu-tors deviates from the specification in 502,

identification of the specific risk and risk contributors is thecustomer’s responsibility and shall be shown in the verifica-tion templates and submitted documentation.

Further, when the specific safety functions deviates from thegeneric as specified in 504-519, this shall appear from the ver-ification templates, and Customer’s proposal to functional andtechnical requirements to the safety functions shall be submit-ted for review and agreement.

Handling of deviations is also described in Appendix G “Ver-ification Guideline for Safety Functions”, B200.

A 600 Safety functions and equipment for ordinary shipboard cranes, industrial cranes and cargo decks/ramps

601 General

As an alternative to document safety as outlined in 500, ordi-nary shipboard cranes, industrial cranes and cargo decks/ramps will be accepted based on fulfilment of the prescriptiverequirements as set out below.

Monitoring of safety equipment shall be as required in TableA6.

602 List of required functionality

Lifting appliances/cranes shall generally to be provided with:

— safety brakes on all movements (see Sec.5 B300)— overload protection (see 603)— load indicator or load moment indicator (see 604)— limit switches (see 605)— safety valves on all main circuits of the hydraulic system

(see Sec.5 E100)— emergency stop system (see 606)— boom stopper on derrick cranes (see 606)— end stoppers for travelling cranes (see 607)— audible warning alarm (see 608)— slack wire rope detection (see 609)— means for emergency lowering of load (see 610).

603 Overload protection

All cranes/lifting appliances shall be provided with automaticoverload protection, arresting the hoisting movement if over-load is detected.

The overload protection shall be activated if the response of theload being raised or lowered exceeds a predetermined amountwhich shall not be greater than the effect of a static load equalto the safe working load times the dynamic factor for which thelifting appliance has been designed.

When activated, the overload protection shall not prevent theload or crane to be moved to a better position (e.g. lower theload or hoist the boom).

604 Load/load moment indicator

A rated capacity indicator giving continuous information shallbe provided when the working load is 50 kN or greater exceptfor cranes where the allowed maximum rated load is constant(i.e. independent of load radius).

605 Limit switches

As specified for limit switches in 505.

606 Emergency stop system

As specified for emergency stop in 507.

607 End stops

End stoppers shall be fitted to prevent over-running wheremovements are restricted. Shut-down of the power shall be ar-ranged before the end stoppers are activated. The end stoppersor the moving parts shall be fitted with buffers made of timber,rubber, etc. If the nominal speed exceeds 1 m/s, the buffersshall be of spring type or similar energy absorbing type. Ifpracticable, the buffers shall be fitted on the main sill and noton the bogies.

608 Audible warning alarm

Gantry cranes and similar cranes shall be provided with a hornor other audible warning device operated by the crane operatorto warn or attract the attention of any personnel within the op-erational area.

In case of travelling cranes moving at ground level, a continu-ous audible warning shall automatically be given when thecrane is to move/is moving along the track/rails. The warningsignal shall be distinctly different from other audio signals onthe installation.

609 Slack wire rope detection

As specified for slack wire rope detection in 510. However,auto stop for arresting the slack wire rope is not required.

610 Emergency lowering

Cranes shall normally have a device for lowering the load inthe event of power failure. However, if a risk evaluation con-cludes that the risk is acceptable without an emergency lower-ing device, this function may be omitted.

Table A5 Monitoring of safety functionsEvent Ref. Indication Alarm Auto

stopLoad high 504 X X XOverturning moment high 504 X X X

Hook position (upper, lower) 505 X X

Boom/jib position (up-per, lower) 505 X X

Constant tension 506 XEmergency stop 507 X X XSlack wire rope detection 510 X XFailure in control system 511 X XFailure in safety system 512 X XBlackout/shut-down 515 X X

Fire/gas 519 X X

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Guidance note:It is assumed that the risk will increase for cranes mounted onmovable vessels. It is further assumed that the risk will increasefor cranes with significant lifting height. The need for bringingthe load down in a safe manner in order to carry out repair workshould be considered.

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611 Cargo ramps and movable cargo decks

Cargo ramps and movable cargo decks shall be provided with:

— Overload protection of hoisting system.— Means to ensuring that power is not disconnected before

all retractable locks securing the ramp/deck are engaged.— Means to ensure that locks securing a ramp/deck are dis-

engaged before any lowering is possible.— Alarm in the event of failure on a remote control system

for locking or latching.— Automatic stop of movement when the cargo ramp/stern

door has reached the upper position.— Alarm if the inclination of an access ramp in its working

position exceeds a predetermined angle to the horizontal.

612 Mobile cranes

In addition to the requirements in 602, mobile cranes shall beprovided with:

— means to secure stability of the crane in operational condi-tions

— means to enable and control that the crane is level.

A 700 Lifting of personnel

701 General

Cranes intended for lifting or moving of persons shall beequipped with the specific features given in the subsequentparagraphs, in addition to the other requirements of thiscertification standard.

Attention is drawn to the fact that many national shelf author-ities, as well as maritime authorities, have own requirementspertaining to lifting of persons.

The requirements specified below are aiming at lifting personswith ordinary crane arrangements and are not intended for manriding winches (lifting/lowering of one person) and other spe-cialised equipment.

702 Rated capacity

The rated capacity shall not exceed 50% of the rated capacityfor lifting of loads at the actual radius and wave height. Thisinformation shall be given in the instructions, load chart and bythe safe load indicator whenever the mode for lifting of personsis selected.

703 Ropes and chains

Ropes shall have a minimum safety factor of 8 and chains shallhave a minimum safety factor of 6, related to the rated capacityfor the lifting of persons.

704 Secondary brakes

Hoisting and luffing winches shall be equipped with an opera-tional independent secondary brake in addition to normalworking brake.

Means shall be provided for separate testing of the secondarybrake.

The secondary brake shall fulfil the requirements for brakes asgiven in Sec.5 B300 for the rated capacity based on the maxi-mum SWL to be lifted.

Where cylinders are used for luffing, folding or telescopic,they shall be provided with a hydraulic shut-off valve. Alterna-tively each motion shall have two independent cylinders whereeach cylinder is capable of holding the rated capacity for liftingof persons.

705 Mode selection for lifting of persons

The control station shall be equipped with a manual key selec-tion switch for the purpose of lifting persons. The switch shallbe lockable in both positions with a removable key and have anadjacent warning light which continuously shall indicate whenit is activated. The light shall not illuminate unless selection forpersonnel lifting is made. When the mode for personnel lift isselected, the following functions shall be maintained:

— All brakes shall automatically be activated when the con-trols are in neutral position and in cases where the emer-gency stop has been activated.

— Where fitted, automatic overload protection system shallbe overridden; i.e. it shall not be possible that this systemis activated.

— Where fitted, motion compensators; i.e. cable tensioningsystems and heave compensator systems shall be overrid-den.

— Where fitted, emergency release systems shall be overrid-den; i.e. it shall not be activated regardless of the positionof the emergency release switch or handle.

— Manual overload protection system (MOPS) shall be over-ridden; i.e. shall not be possible to activate.

706 Operational limitation

Except for emergency operations, the operational limitationsfor lifting of personnel shall be as follows:

— mean wind velocity: 10 m/s— significant wave height: 2 m— visibility: daylight.

707 Shock absorbers

Where a shock absorber is installed it shall be fail-safe and au-tomatic in operation.

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Table A6 Monitoring of safety equipmentRequired monitoring

(stated by an x)Industrial and shipboard cranes Cargo decks and ramps

Event Indication Alarm Auto stop Indication Alarm Auto stopLoad high or Over-turning moment high (see 603) x

Hook position, upper and lower(see 605)

Boom/jib position, upper and lower

x x

x

Travelling motion, end stops

Warning x

x

Slack wire rope (see 609)

Remote control:

Position of ramp:

— upper— inclination.

Power failure to safety system

x

x x

x

x

x

x

xx

Emergency stop (see 606) x x

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Standard for Certification of Lifting Appliances, October 2008Page 60 – Ch.2 Sec.7

SECTION 7 TESTING AND TEST CERTIFICATES MARKING

A. Functional Testing of Completed Lifting Appliances

A 100 General101 Each completed crane shall be subjected to functionaltesting in the presence of a surveyor to the Society after it hasbeen installed at its permanent location.

If complete functional testing has been documented to havebeen carried out at the test bed at manufacturers’ location, lim-ited functional testing may be carried out after final installa-tion.

In such case, the proposed test plan shall specify the extent ofthe limited functional testing to be done after final installation.

102 The functional testing shall be carried out in accordancewith a detailed programme, which shall be submitted for ap-proval well in advance of the actual testing. The programmeshall specify in detail how the respective functions shall betested and how observations during the test can be ensured.The tests specified below shall be included in the test pro-gramme.

103 A copy of the approved test programme shall be kept inthe crane manual. It shall be completed with final results andendorsed by the "competent person".

104 The significant characteristics of power and braking sys-tems as well as the safety equipment shall be considered. Brak-ing systems and safety equipment shall be checked by functiontesting. Pressure testing of hydraulic components is normallynot required to be witnessed by the surveyor. The tightness ofthe systems shall be checked after the installation of the com-ponents and during functional testing.

A 200 Prime movers and fluid power systems201 Relevant parameters such as power, ambient tem-perature and pressure, exhaust gas temperature etc. shall bemeasured and recorded.

202 Automatic control, remote control and alarm systemsconnected with power systems shall be tested.

203 After the test, the lubricating and/or hydraulic oil filtersshall be checked for solid particles. Other components of ma-chinery may be required opened up by the surveyor.

A 300 Governing and monitoring systems301 It shall be verified that control systems function satisfac-torily during normal load changes.

302 Failure conditions or boundary conditions shall be sim-ulated as realistically as possible, preferably letting the moni-tored parameters pass the alarm safety limits.

A 400 Electrical installations401 Insulation-resistance test shall be carried out for all out-going circuits between all insulated poles and earth and, wherepracticable, between poles. Under normal conditions a mini-mum value of 1 mega ohm shall be obtained. This also appliesto instrumentation and communication circuits with voltagesabove 30 V A.C. o V D.C.

The insulation resistance of a motor shall not be less than:

tested on a clean and dry motor when hot.

402 When found necessary by the surveyor, switchgear shallbe tested on load to verify its suitability and that operating ofover-current release and other protective measures are satisfac-tory. Short circuit tests in order to verify the selectivity mayalso be required.

A 500 Brakes

501 Brakes shall be tested with safe working load applied oncrane by braking each motion from maximum speed to fullstop. In addition, each brake for the hoisting and derrickingmotions shall be tested for three such stops in quick successionduring lowering motion. The test shall also include testing ofthe emergency stop system.

A 600 Safety equipment

601 Safety functions as presented in Table A5 and Table A6in Sec.6 shall be tested.

B. Load Testing

B 100 General

101 Lifting appliance shall be load tested after it has been in-stalled at its operational location:

— before being taken into use the first time— after any substantial alteration or renewal, or after repair of

any stress bearing part— at least once in every five years (preferably at regular five-

yearly intervals after the data on which the appliance wasfirst taken into use).

Above requirements are in compliance with international andnational regulations.

102 Every item of loose gear shall be load tested:

— before being taken into use first time— after substantial alteration or renewal— after repair of any stress bearing part.

B 200 Test weights

201 Movable, certified weights shall be used by initial load-testing and by all load-testing where SWL exceeds 15 tonnes.

202 A mechanical or hydraulic precision dynamometer maybe used:

— in cases of periodical retesting and after repair/renewal ofmechanical parts of lifting appliances with SWL ≤ 15 tonnes.

— in cases where a test that follows repair/renewal of a struc-tural part is carried out.

The accuracy of the dynamometer shall be within +2 per centand the indicated load of such dynamometers under test loadshall remain constant for approximately 5 minutes.

203 Test equipment used for the testing of loose gear, eitherassembled units or components of loose gear, is to have beenchecked for accuracy (calibrated) at least once during the 12months preceding the test.

B 300 Test loads

301 The test load applied to a lifting appliance shall exceed

megaohmskVArated

voltageratedx

1000

3

+

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the safe working load (SWL) of the appliance as follows:

302 For hydraulic cranes where, due to limitation of hydrau-lic oil pressure by the safety valve, it is not possible to lift a testload in accordance with Table Bl, it will suffice to lift thegreatest possible load. Generally this should not be less than 10per cent in excess of the SWL.

303 The test load applied to a cargo or pulley block and toloose gear shall exceed the safe working load (SWL) of theblock and gear as follows:

304 Built-in sheaves and other items permanently attached tothe lifting appliance are not considered loose gear. The test ofthe lifting appliance "as rigged" will be accepted as the loadtest of these items.

305 Where hand-operated blocks are used with pitchedchains and permanently attached rings, hooks, shackles orswivels, the hand-operated blocks, the pitched chains and thepermanently attached rings, hooks, shackles and swivels shallbe tested with a test load 50% in excess of the safe workingload.

B 400 Examination after testing

401 After testing, the lifting appliance including gear acces-sories are to be examined thoroughly to observe whether anypart has been damaged or permanently deformed by the test.Dismantling and/or non-destructive testing may be required if

deemed necessary by the surveyor.

The above also applies to blocks and loose gear.

402 Any overload protection system and automatic safe loadindicators that may have been disconnected during load testingshall be reconnected. Accordingly safety valves and/or electri-cal circuit-breakers shall be adjusted. Set points shall be veri-fied and sealed by the surveyor.

B 500 Certificates501 When a lifting appliance or component to a lifting appli-ance after testing and examination have been found satisfacto-ry the following certificates (CG forms) shall be issued (as faras applicable and relevant):

Form No. CG2: Certificate of test and thoroughexamination of lifting appliances.

Form No. CG2U: Certificate of test and thoroughexamination of derricks used in unionpurchase.

Form No. CG3: Certificate of test and thoroughexamination of loose gear.

Form No. CG4: Certificate of test and thoroughexamination of wire rope.

502 As final documentation (certificate) for a lifting appli-ance installed and to be taken into use for the first time, FormNo. CG1 "Register of Lifting Appliances and Items of LooseGear" shall be presented. See also Appendix F.

Guidance note:The Forms Nos. CG2, CG3 and CG4, as well as Form No. CG2Uwhen relevant, shall be attached to Form No. CG 1 in completedorder.

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B 600 Procedure for load testing of a lifting appliance601 Before load testing, the surveyor shall ensure that:

— support of the lifting appliance is acceptable— for a ship or other vessel, necessary precautions with re-

spect to stability, ballasting or similar conditions havebeen taken

— for a mobile crane, the crane has a sufficient margin of sta-bility against overturning

— required test certificates for blocks and loose gear areavailable and acceptable

— for a new installation, design approval and survey duringfabrication of the lifting appliance are documented.

602 A written test programme acceptable to the surveyorshould preferably be available.

603 The test weights shall be lifted by the lifting machineryused for the regular handling of loads. Testing a lifting appli-ance driven by electrical motor(s) the regular electrical supplyshall be used. For ships, electrical shore connection is accept-able when the power is distributed through the ship's mainswitchboard and distribution panels.

604 For derrick systems, the test load shall be lifted with theship's normal tackle with the derrick at the minimum angle tothe horizontal for which the derrick system was designed (gen-erally 15 degrees), or at such greater angle as may be agreedupon. The angle at which the test was made should be stated inthe test certificate. After the test load has been lifted it shall beswung as far as possible in both directions.

605 For cranes, the test load is to be hoisted, slewed andluffed at slow speed. Gantry and travelling cranes togetherwith their trolleys, where appropriate, shall be traversed andtravelled over the full length of their track.

606 For winches where one single SWL-value is specified,testing is to be carried out on the outer layer and with the ropein 3 different positions on the drum, i.e. the extreme ends and

Table B1Test load for cranes and derrick rigsSafe working load Test load

Up to 20 tonnes 25% in excess of the SWLExceeding 20, but not exceeding 50 tonnes

5 tonnes in excess of the SWL

Above 50 tonnes 10% in excess of the SWLNote:Where the design dynamic factor ψ exceeds 1.33, the reference SWL in the table shall be taken as the greater of:

— 0.75 × ψ × SWL— SWL

Table B2 Test load for loose gear and other accessoriesItem Test load, in tonnes 4)

Chains, hooks, shackles, swivels, etc.:SWL ≤ 25 T 2 · SWLSWL > 25 T (1.22 · SWL) + 20Multi-sheave blocks: 2)

SWL ≤ 25 T 2 · SWL25 T < SWL ≤ 160 T (0.933 · SWL) + 27SWL > 160 T 1.1 · SWLSingle-sheave blocks: 1) 3) 4 · SWLLifting beams, etc.: 5)

SWL ≤ 10 T 2 · SWL10 T < SWL ≤ 160 T (1.04 · SWL) + 9.6SWL > 160 T 1.1 · SWLNotes :

1) For single sheave blocks with or without beckets the SWL shall be tak-en as one half of the resultant load on the head fitting. See also Appen-dix B.

2) The SWL of a multiple sheave block shall be taken as the resultant load on the head fitting.

3) For single sheave blocks with a permissible load at the head fitting ex-ceeding 25 tonnes, the test load may be reduced as permitted for the chains, hooks, shackles, swivels, etc. in the table. In this case the SWL notation shall be the resultant load on the head fitting.

4) Where the design dynamic factor ψ exceeds 1.33: See Note to Table B1.

5) The fittings to a lifting beam or frame such as hooks, rings and chain shall be tested independently before they are fitted to the beam.

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in the middle.

607 For variable load-radius cranes, the tests are generally tobe carried out with the appropriate test load at maximum, min-imum and at an intermediate radius.

C. Testing of Steel Wire Ropes

C 100 Cross reference

101 Steel wire ropes are to be tested as required by Ch2 Sec2I400.

C 200 Certificates

201 After testing of steel wire ropes certificates of type CG4shall be issued.

202 A manufacturer or supplier who has obtained acertificate for a coil of wire rope, shall, when he resells the coilor part of it, issue a certificate to the buyer. The certificate shallbe a copy of the original certificate additionally dated andsigned by the supplier.

D. Marking and Signboards

D 100 General

101 Cranes and derrick booms and all items of fixed andloose gear and accessories shall be marked with their safeworking load (SWL) in a legible and durable way. To preventeffacement of the inscriptions, they shall normally be incised,punched or marked as specified below.

102 All blocks and all items of loose gear and accessoriesshall be marked with an identification mark to enable them tobe readily related to their appropriate test certificates, with thestamp of institution, society, body or manufacturer who carriedout the load test.

103 Derrick booms as well as cranes on board vessels shallbe marked with a reference number to enable them to be relat-ed to their location onboard.

D 200 Derrick booms

201 On derrick booms the markings of reference number,SWL and allowed angles shall be located near the seating(gudgeon pin) by painted letters and numbers in a frame of in-dentations or welding spots, incised on a brass plate or in-scribed on other material sufficiently resistant to defacement,such as plastic of sandwich construction.

The identification numbers and stamp of the Surveyor shall bepunched or incised.

202 Booms shall be marked with SWL with single reevedcargo runner and for 15° boom angle, or for the lowest angleexceeding 15° to which the arrangements on board allows thebooms to be lowered. Example No.3 SWL 5 T 15°.

Booms with alternative rigging shall be marked accordingly.Example No. 4 SWL 5/10 T 15°.

203 Heavy lift booms are to be marked with the minimumangle and the maximum load for which boom, gear and acces-sories are calculated. Example SWL 60 T 30.

204 The maximum allowed boom angles shall be marked forbooms that can be subjected to stalling. Example No. 3 SWL15 T 15 - 60°.

205 Where booms may be used in union purchase the mark-ings shall be made on separate plates which shall be fitted at aconvenient location approximately in the middle between thebooms. Example No. 3 + 4 SWL(U) 2 T.

206 Reference number and SWL shall be marked in lettersand figures of at least 80 mm height and the angle in figures ofat least 60 mm height.

D 300 Cranes

301 The markings of SWL and allowed radii (and the refer-ence number in case of shipboard cranes) be painted in a con-spicuous place on the crane.

The identification numbers and stamp of the Surveyor shall bepunched or incised.

302 Cranes with constant SWL for all radii shall be markedwith possible crane reference number, SWL and minimum andmaximum radii for this load. Example No. 5 SWL 5 T 4 - 14M.

303 Cranes with SWL depending on the jib radius shall bemarked with possible crane reference number and with maxi-mum and minimum SWL and corresponding radii. ExampleNo. 5 SWL 15 T 5 M, SWL 5 T 15 M.

304 Reference numbers and SWL shall be marked in lettersand figures of at least 80 mm height and the radii in letters andfigures of at least 60 mm height.

305 Cranes with dual function, e.g. hook duty and grab duty,shall be marked for both alternatives. Clear instructions/sign-board shall be available for the crane driver.

Guidance note:Self weight of loose gear/grab shall be deducted from cranes'SWL before deciding suitability of lifting gear/grab.

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D 400 Blocks

401 The SWL of blocks together with the identificationnumbers and the Surveyor's/Manufacturer's stamp shall bemarked on one of the plates of the blocks.

For definition of SWL of blocks, see Notes to Table B2.

D 500 Slings and lifting tackles

501 Slings and lifting tackles are considered as "loose gear"and shall comply with Sec.5 B700.

502 Slings and lifting tackles shall be marked with SWL,identification number and the certifying authorities' stamp ona legibly and durably fitted ring or plate.

503 Where wire rope slings are fitted with pressure locks themarkings shall be located on the locks.

504 For wire rope slings the SWL by 0° shall be marked forsingle slings.

The safe working load marked on a multi-legged sling shall be:

— Iin the case of a two-legged sling, the safe working load ofthe sling when the included angle between the legs is 90°.

— In the case of a three-legged sling, the safe working loadof the sling when the included angle between any two ad-jacent legs is 90°.

— In the case of a four-legged sling the safe working load ofthe sling when the included angle between any two diago-nally opposite legs is 90° and the total load is carried by 3of the four legs.

505 Instead of marking of slings as stated in 503 above, dis-played information on use of the slings may be accepted. Thedisplay shall be easily seen and the slings shall be easily iden-tified in accordance with the display.

506 Lifting gear and grabs shall be marked with SWL, ownweight, identification number and the certifying authority'sstamp.

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APPENDIX A WIND LOADS ON CRANES

A. Wind Load Calculation

A 100 General

101 A simplified method of wind load calculation is present-ed below. The method will be acceptable for all normal cranedesigns and applications where the wind loads are of signifi-cant less importance than the other design loads.

102 In the design of cranes the distribution of wind pressureand suction around the structure need not be considered in de-tail, and wind loads may normally be determined in terms ofresulting forces on each of the larger parts of the crane, or oneach «assembly» of smaller members, such as a truss. A basicassumption is that wind pressure and suction will act normal tosurfaces. As a consequence the resulting wind force on a pris-matic member will act normal to the axis of the member, irre-spective of wind direction. This applies to long prismaticmembers and, if the ends are not exposed to wind, also to shortprismatic members.

A 200 Wind force on flat surfaces

201 The wind force normal to a flat surface of area A is takenas:

where:

P = wind force in daN.A = exposed area in m2

q = air velocity pressure = ρv2/2 = v2/16. See 500.C = average «pressure coefficient» for the exposed surface.α = angle between the wind direction and the exposed sur-

faceρ = mass density of the air (1.225 kg/m3)v = wind velocity in m/sec.

A 300 Wind force on bodies of flat surfaces

301 For a body bounded by flat surfaces, such as a machin-ery house or the like, the resulting wind force may be deter-mined as the vector sum of one force acting on each surface,each force being determined according to 201. In general, A, Cand α will be different for the different surfaces, and on the lee-ward surfaces there will be suction. In most practical cases,however, it is more convenient to use values of C which repre-sent the sum of pressure and suction on two opposite sides.

Such values of C are given in Table Al.

A 400 Wind force on structural members

401 For flat-sided structural members, such as rolled sec-tions, the equation in 201 may be used for both of the possiblecomponents normal to the member axis:

Referring to Fig.1, P1 is the total force acting normal to theflanges (resulting from pressure and suction on both flanges)and P2 is the total force acting normal to the web.

Further A1 = l · h1 and A2 = l · h2.

α1 = angle between velocity vector and flange plane and α2 = angle between velocity vector and web plane.

Applicable values of C are given in Table A1. Note that C isused as a common symbol for «pressure coefficient» (pressureor suction) and «force coefficient» (sum of pressure and suc-tion).

Figure 1 Wind force on H-shaped members

aCqAP sin⋅⋅⋅=

1111 sin aCqAP ⋅⋅⋅=

2222 sin aCqAP ⋅⋅⋅=

Table A1 Coefficient C

Type of memberCoefficient C

Pressure Suction TotalFlat-sided section 2.0Tubular member:diameter < 0.3 m 1.2diameter ≥ 0.3 m 0.7Trusses of flat-sided sections 1.8Trusses of tubular members 1.1For leeward truss in case of two trusses behind each other 2/3 of above values

Machinery houses, cabins, counterweights and the like Max:1.0Average:0.7

Max:1.0Average:0.7 1.2

Working load:Containers and similar shapes (0.7) (0.5) 1.2Other shapes 1.0

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402 For members of circular (or nearly circular) cross sec-tion the equation in 201 may be used for the resulting force,taking A = ld, C as force coefficient, and a as angle betweenwind direction (velocity vector) and member axis, see Fig.2.

P acts in the plane defined by the member axis and the velocityvector, in the direction normal to the member axis. For valuesof C, see Table A1.

Figure 2 Wind force on tubular members

A 500 Air velocity pressure

501 The velocity pressure q to be used as design parametershall be based on expected conditions for each particular craneor part of crane. The variation with height above ground (or sealevel) may be taken as:

where

q10 is the velocity pressure 10 metres above ground (or sea lev-el) and H is the considered height in metres. General minimumvalues of q10 are given in Table A2. The corresponding «free-stream» wind velocity v10 (m/sec) is also given.

Table A2 Design velocity pressure in N/m2

Location Crane condition v10 q10Inland and sheltered conditions “Working” ≈ 20 250

Ship in harbour “Out of service” ≈ 36 800Offshore and open areas “Working” ≈ 24 360

Ship at sea “Out of service” ≈ 44 1200

( )Hqq 01.09.010 +=

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Standard for Certification of Lifting Appliances, October 2008Ch.2 App.B – Page 65

APPENDIX B MARKING OF SINGLE-SHEAVE BLOCKS

A. General

A 100 Method of marking the safe working load

101 This Appendix explains the method of marking the safeworking load (SWL) of single-sheave blocks with or without abecket. Experience shows that this subject is frequently dis-cussed and often misunderstood.

102 The text is an excerpt from ILO’s Code of Practice“Safety and health in ports”, 2005, Item 4.4.5 “Blocks”, pub-lished by the International Labour Office, Genova, Switzer-land.

— The safe working load of a single-sheave block is the max-imum load that can be safely lifted by that block when it issuspended by its head fitting and the load is secured to awire rope passing round its sheave (Fig.1 ).

— When a single-sheave block is rigged with the load to belifted secured to its head fitting and the block is suspendedby a wire rope passing around its sheave, it should be per-missible to lift a load twice the safe working load markedon the block (Fig.1 ).

— The safe working load of a multi-sheave block is the max-imum force that may be applied to its head fitting.

— The design of blocks to be used with wire ropes should bebased on a wire rope having a tensile strength of 180 to220 kg/mm2 (1 770 to 2 160 N/mm2).

Load attached to rope passing around the pulley

Load attached directly to the block

P Safe working load of the block

Figure 1 Safe working load of a single-sheave block

1

2

1

2

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Standard for Certification of Lifting Appliances, October 2008Page 66 – Ch.2 App.C

APPENDIX C SHIP MOUNTED CRANES WITHOUT JIB SUPPORT IN TRANSIT CONDITION

A. Example on Checking for Compliance with the Structural Strength Requirements of Sec.3

A 100 General

The requirements to ship mounted cranes with respect to trans-port condition are dealt with on a general bases in Sec.3. Forjib cranes where the jib rests in a cradle in transport condition,the transport condition is generally not critical with respect toexcessive yielding. The contribution to fatigue damage fromthis condition is, for a normal crane design, insignificant com-pared to the crane operating condition. The use of jib cradle isthe most frequently used way of securing the crane in transportcondition.

However, for a jib crane without a jib cradle, the situation isquite another. This document describes how DNV, in general,ensures that the requirement in this Standard is fulfilled whena jib crane in transport condition is secured in the followingway:

— Slewing column rotation is prohibited by applying lockingbolts in the slewing ring.

— The jib is secured by tension in the crane’s hoisting wireand tension in the crane’s luffing cylinders.

Design checks that apply to jib cranes generally are not inclu-ded here, only the special checks that follow from the specialsecuring of the crane in transport condition are covered.

A 200 Case of loading to be considered

The case of loading that shall be considered when accountingfor ship movement, is described in Sec.3 C400:

where:

SG = loads due to dead weight of the componentsSM = inertia forces due to motion of the vessel on

which the crane is mountedSW max = loads due to out-of-service wind.

The procedure followed when calculating the loading is inde-pendent of how the crane is secured in transport condition.However, some explanations to how SM and SWmax are calcu-lated are presented in the items below.

The above load case, denoted IIIb in our Standard, is actuallynot one single load case. The reason is that the inertia forcescaused by the ship motion, in accordance with DNV’s Rulesfor Ships, is dealt with as four different load combinations:

— vertical force alone— vertical and transverse force— vertical and longitudinal force— vertical, transverse and longitudinal force.

For these four load combinations it may be easy to foreseewhat direction of the accelerations will give the highest load-ing, and thereby decide what the four load combinations shalllook like when checking for static strength. When checking forfatigue, however, it is the stress ranges that are of interest. Thecrane must therefore be analysed for both directions of the ac-celerations, giving 8 different load combinations.

In addition to the above, the crane is preferably analysed forboth initial heel/trim and no heel/trim. The total number ofload combinations will therefore be 16.

A 300 Calculation of vessel motionThe vessel motion is calculated in accordance with DNV Rulesfor Ships Pt.3 Ch.1 Sec.4. The ship accelerations thus calculat-ed are extreme values (i.e., probability level = 10-8). Thecrane’s location onboard the ship is accounted for. To be sureto avoid shock loads in the crane, it is important to check thatthe upward vertical acceleration never exceeds 1.0·g. (If theupward vertical acceleration exceeds 1.0·g, special considera-tions must be made regarding requirements to tension in the jibluffing cylinders and redundancy of the same.)

Typical values for the calculated accelerations may, for a ca.180 m ship with 60 000 tonnes displacement and the crane nearthe bow, be:

1) Combined means that the acceleration is a result of all theship motion (surge, sway/yaw, heave, roll and pitch).Gravity is, however, not included.

A 400 Calculation of loading due to vessel motionThe forces acting on the crane due to vessel motion are calcu-lated in accordance with DNV Rules for Ships, Pt.3 Ch.1 Sec.4C501. This means that the forces are based on the extreme re-sponse as calculated above, but are modified to a probabilitylevel of approximately 10-4. The four load case combinationscalculated are:

— vertical force alone:PV = (g0 ± 0.5·aV) · M

— vertical and transverse force:PV = g0 · MPT = ±(0.67·aT) · M

— vertical and longitudinal force:PV = (g0 ± 0.5·aV) · MPL = ±(0.67·aL) · M

— vertical, transverse and longitudinal force:PV = (g0 ± 0.5·aV) · MPT = ±(0.27·aT) · MPL = ±(0.67·aL) · M

where M = total mass of unit.

A 500 Calculation of wind loadThe procedure for calculation of wind load is the same as forthe working condition, except that the wind pressure 10 metresabove the sea level, q10, is increased from 250 N/m2 for work-ing conditions in sheltered locations, to 1 200 N/m2 for ship atopen sea. The critical wind direction will in most cases be nor-mal to the plane spanned by the crane slewing column and thejib.

A 600 Checking with respect to excessive yieldingBy calculating the acting forces in the crane for the above loadcombinations, remembering the special conditions with ten-sion in both luffing cylinders and in the hoisting wire, stresscalculations and check with respect to excessive yielding maybe performed. The requirement to safety factor is given inSec.3 Table D1.

For cranes with a long jib that are designed for small SWL, atransport condition with the jib not supported may tend to be

maxWMG SSS ++

Combined1) vertical acceleration: aV = 0.6·gCombined1) transverse acceleration: aT = 0.7·gCombined1) longitudinal acceleration: aL = 0.3·g

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the critical condition. However, the shorter the jib and thehigher the SWL for which the crane is designed, the less criti-cal the transport condition becomes compared to the workingcondition of the crane. An example; for a typical design of acrane with 26 meter jib and a SWL of 36 tonnes, the lowestsafety factors calculated by applying elastic analysis were ap-proximately 3.0 for both the critical spot in the jib and in thehousing (our requirement is SF ≥ 1.10).

A 700 Checking with respect to bucklingBased on consideration of the static system of the crane intransport condition, the acting forces and the calculated stress-es in the transport condition as compared to the stresses in theworking condition, it may be concluded that the transport con-dition will normally not be critical with respect to buckling.Consequently, it is normally not necessary to perform bucklingcheck.

A 800 Checking with respect to fatigueThe fatigue check is based on the stress ranges found by apply-ing the ± altering of the accelerations as shown in A400. Con-servatively, for each hot spot, the maximum stress ranges fromthe four load combinations may be selected: Δσ0. The Δσ0 val-ue is the stress range (for a particular hot spot) that has a prob-ability of 10-4 of being exceeded (ref. A400). Δσ0 thereforerepresents the maximum stress range within n0=104 cycles.

In the following we will calculate the fatigue damage for a shipservice life of 20 years. We will need to know the number ofcycles within 20 years. By assuming a mean wave period of 6seconds (the mean wave period will vary depending on shel-tered condition, open sea, on which ocean the ship operates,etc., 6 seconds is assumed to be a sufficient good estimate forthe actual purpose) the number of cycles in 20 years may becalculated:

After deciding which SN curve applies to a particular hot spot,an estimate for the fatigue damage in a 20 year period for thegiven hot spot may be calculated by applying a closed form fa-tigue formula:

For Weibull shape parameter h = 1.0 and with a one slope S–N curve, where:

Dtr20 = Accumulated fatigue damage over a 20 year periodfor the actual hot spot, as caused by ship movementonly.

n0 = Number of cycles corresponding to the calculatedΔσ0.

ā = Parameter in S-N curve.SCF = Stress concentration factor (in addition to that in-

cluded in the S-N curve).Δσ0 = Stress range found as explained above.m = Parameter in S-N-curve.Γ = Gamma function.

m = 3.0 Γ = 6.00

m = 3.5 Γ = 11.63

m = 4.0 Γ = 24.00n20 = Number of cycles in a twenty year period.

For the crane’s working condition, the fatigue check is normal-

ly done by comparing the actual stress level with allowed stresslevels in accordance with the FEM standard. This check doesnot account for the special fatigue damage as caused by sup-porting the jib in transport condition without a cradle. It istherefore of interest to calculate how the fatigue check for theworking condition may be performed in such a way that thespecial damage from the transport condition is accounted for.This is done by calculating the factor that the stress level in theworking condition must be reduced by, to still keep the fatiguedamage below the acceptable level (remembering that thisStandard requires for fatigue: σallowed = σcr · ¾):

where:

K = Factor to multiply the allowed fatigue stress forworking condition with to account for both workingcondition and transport condition.

Dtr20 = Fatigue damage from transport condition (withoutaccounting for required safety factor) calculated asshown above

m = Parameter in S-N curve.

The procedure for checking fatigue is then:

1) Select a hot spot.

2) Select applicable S-N curve.3) Calculate possible SCF (only the stress concentration that

comes in addition to the stress concentration built into theSN curve).

4) Calculate the stress range for the transport condition: Δσ0.5) Calculate the fatigue damage for transport condition

(without accounting for the required safety factor on stresslevel of 1.33).

6) Calculate the allowed fatigue stress in working conditionfactor k.

7) Check fatigue for working condition. Multiply the allowedstress as found in accordance with the FEM standard byfactor k.

8) Repeat step 1 to 7 for all actual hot spots.

Example of calculated k values for a typical design of a cranewith 26 meter jib and a SWL of 36 tonnes: The factor k is cal-culated for the most highly stressed area of the housing and jibrespectively. Assuming SCF=1.0 (i.e., no SCF except for thatincluded in the SN curve) and SN curve F, the following valueswere found:

A 900 Considerations not included in DNV’s approachThe above approach to special transport condition support forthe jib covers the safety of the crane in transport condition andcontributes to the overall fatigue damage of the crane. Sometypical items that are not covered are:

— Increased abrasion on part of the crane system. The hy-draulic luffing cylinders are a typical example of parts thatmay be exposed to increased abrasion. As part of a normalship crane, the hydraulic cylinders are exposed to 2·105

load cycles in the crane’s working condition. As the hy-draulic cylinders are part of the system supporting the jibin transport condition, they are exposed to additionally 108

0.8sec

sec

20 10/6

/3600/24/36520=

⋅⋅⋅=

cycleonds

hoursonds

dayhours

yeardaysyears

n

( )( )

( )0

20

0

0020 1

ln n

nm

n

SCF

a

nD

m

m

tr ⋅+Γ⋅Δ⋅

⋅=σ

Jib: k = 0.96Housing, tension side: k = 0.93Housing, compression side: k = 0.89

mm

trDk

1

20 3

41

⎥⎥⎦

⎢⎢⎣

⎡⎟⎠⎞

⎜⎝⎛⋅−=

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load cycles due to ship movement. Even if the loading intransport condition is smaller than those in working condi-tion, the transport condition may, due to the large amountof cycles (500 times more cycles than that for workingcondition) be of significance when considering the expect-ed life duration of the cylinders.

— The design check of a crane does not cover investigationswhether the crane interferes with other equipment onboardthe ship. For example, if the jib points along the ships lon-gitudinal axis, the transverse displacement of the jib tip ina storm may be significant. The ship buyer/owner should,when ordering cranes, ensure (or ask the crane manufac-turer to assure him) that the cranes do not interfere witheach other or other equipment, not only for working con-dition, but also for transport condition.

Calculation of natural-frequencies and Eigenmodes is normal-ly not covered. The natural period of the jib is quite differentwhen the jib rests in a cradle compared to when it is supported

by hoisting wire and luffing cylinders. If, for instance, the shipmovement has the same period as a natural period for the jib,quite a dynamic amplification of the displacements in the jibmay occur. Additional securing systems for the jib may be re-quired if the in-service experience of the crane shows that largevibrations may occur under transport condition.

Guidance note:Most S-N curves for air environment are presented as two-slopeS-N curves. The presented closed form fatigue equation will, forthe present purpose, give a reasonable estimate while used to-gether with the part of the S-N curve that is to the left of 107 cy-cles.

Alternatively, the damage may be calculated by a more direct in-tegration of fatigue damage using the actual S-N curves.

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APPENDIX D EXAMPLES ON REQUIREMENTS FOR DOCUMENTATION FOR ACCEPT-

ANCE OF WORKS CERTIFICATES

A. Winches* for Shipboard Cranes

* Components of the winches delivered by sub-vendors (e.g.brakes or gears) shall be documented as for the winch.

A 100 Case 1. Designed in accordance with applicable, recognised standard101 The following to be confirmed:

General

— name of manufacturer— type designation— serial number— marking— type of marking (e.g. chiselled, painted or on attached

plate) and place on the component on which the mark is at-tached.

Testing

— date and place of functional testing— special observations made or remarks to be made to the

functional testing.

General design

— Design standard applied including information on CraneAppliance Group** or equivalent.(**used for fatigue calculations in accordance with theFEM Standard).

— Structural standard applied in combination with the designstandard (in cases where the design standard does not stateacceptable structural design utilization).

— Material types used in all primary load-carrying parts.— Maximum static and dynamic pull and torque accounted

for in the design.— Wire diameter(s) considered in the design.— If available, the breaking strength of the most heavily loaded

steel wire rope allowed attached to the winch (for designcapacity of attachment to foundation) to be specified.

— If available, the type and dimension of holding-down boltsto be specified.

Brake design

— Type and description of braking systems and brake(s).— Confirmation that the following requirements are com-

plied with (or comments), see Sec.5 B301 – B306 (to beseparately confirmed for each item).

— Maximum torque on brake caused by the load that is re-garded as static by automatic braking (see Sec.5 B305).

— Maximum torque which can be exerted by the brake by au-tomatic braking (see Sec.5 B305).

— Maximum coefficient of friction applied in the brakingcalculation for automatic braking (Sec.5 B305).

102 The following drawings and documents shall be at-tached:

— arrangement and sectional drawings including materialdenotations.

103 Signatures and qualifications:

— date and place of issuance of documentation— name in printed letters and signature of person responsible

for the certification (preferably a person related to quality

assurance work and who is in a unit unrelated to produc-tion).

B. Winches* for Shipboard Cranes

* Components of the winches delivered by sub-vendors(e.g. brakes or gears) shall be documented as for thewinch.

B 100 Case 2. Designed in accordance with this Certifi-cation Standard101 The following shall be confirmed:

General

— name of manufacturer— type designation— serial number— marking— type of marking (e.g. chiselled, painted or on attached

plate) and place on the component on which the mark is at-tached.

Testing

— date and place of functional testing— special observations made or remarks to be made to the

functional testing.

General design

— Possible structural steel standard applied in combinationwith DNV’s Rules (in cases where it has been found thatcomplementary specifications were needed) includinginformation on Crane Appliance Group** or equivalent(**used for fatigue calculations in accordance with theFEM Standard).

— Confirmation that the following requirements are com-plied with (or comments), see Sec.5 B100 and B200 (to beseparately confirmed for each item).

— Material types used in all primary load-carrying parts.— Maximum static and dynamic pull and torque accounted

for in the design.— Wire diameter(s) considered in the design.— If available, breaking strength of the most heavily loaded

steel wire rope allowed attached to the winch (for designcapacity of attachment to foundation) to be specified.

— If available, type and dimension of holding-down bolts tobe specified.

Brake design

— Type and description of braking systems and brake(s).— Confirmation that the following requirements are com-

plied with (or comments), see Sec.5 B 301-B306 (to beseparately confirmed for each item).

— Maximum torque on brake caused by load regarded asstatic load by automatic braking (see Sec5 B305).

— Maximum torque which can be exerted by the brake by au-tomatic braking (see Sec.5 B305).

— Maximum coefficient of friction applied in the brakingcalculation for automatic braking (see Sec.5 B305).

102 The following drawings and documents shall be at-tached:

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— arrangement and sectional drawings including materialdenotations.

103 Signatures and qualifications:

— date and place of issuance of documentation— name in printed letters and signature of person responsible

for the certification (preferably a person related to qualityassurance work and who is in a unit unrelated to produc-tion).

C. Transmission gears for non-critical application

(For example non-hoisting purposes (e.g. slewing unit)

C 100 Designed in accordance with this Certification Standard or other recognised standard101 The following shall be confirmed:

General

— name of manufacturer— type designation— serial number— marking— type of marking (e.g. chiselled, painted or on attached

plate) and place on the component on which the mark is at-tached.

Testing

— date and place of functional testing— special observations made or remarks to be made to the

functional testing.

General design

— applied standard.

102 The following drawings and documents shall be at-tached:

— sectional drawings— calculations documenting necessary and available torque

capacity.

103 Signatures and qualifications:

— date and place of issuance of documentation— name in printed letters and signature of person responsible for

the certification (preferably a person related to quality assur-ance work and who is in a unit unrelated to production).

D. Hydraulic cylinders exempted from DNV certification

D 100 Conditions for use

101 May be used provided the following three conditions aremet:

— For shipboard cranes not to be covered by class (CRANEor Crane Vessel) and with load-carrying capacity notexceeding 20 tonnes.

— The manufacturer is considered a recognised manufactur-er.

— The cylinder is subject to serial production.

102 The following shall be confirmed:

General

— name of manufacturer— type designation— serial number— marking— type of marking (e.g. chiselled, painted or on attached

plate) and place on the component on which the mark is at-tached.

Agreement for exception

— date of application for exception— the following submitted as attachments to the application:

- One copy of documentation on the cylinder, includingall main dimensions and material specifications (yes orno).

- Suggested extent of NDT and pressure testing proce-dure (yes or no).

— date when the extent of NDT and pressure testing wasagreed

— DNV unit that agreed on extent of NDT and pressure test-ing.

— date when the exception was granted— DNV unit that granted the exception.

Testing

— date and place of pressure testing— special observations made or remarks to be made to the

pressure testing— date of acceptance of NDT.

General design

— design standard applied— structural standard applied in combination with the design

standard (in cases where the design standard does not stateacceptable structural design utilization)

— material used in all primary load-carrying parts— dynamic design load— design pressure— design temperature— the cylinder is accepted for pushing only (yes or no)— the cylinder is certified for use in lifting appliances only

(yes or no).

103 Signatures and qualification:

— date and place of issuance of documentation— name in printed letters and signature of person responsible

for the certification (preferably a person related to qualityassurance work and who is in a unit unrelated to produc-tion).

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APPENDIX E EXAMINATION OF BRACKETS, SKIDS AND MONORAILS

A. Purpose

A 100 Questions related to specific lifting appliances and fundaments

101 This Appendix aims to present clarifications to somefrequently addressed questions related to a few specific liftingappliances and fundaments.

A 200 Brackets

201 The Society is frequently requested to “certify” brackets(pad-eyes, lifting lugs, etc.). Such items are normally weldedto their supporting structure, and are therefore, by DNV, con-sidered as a fundament for other equipment (for example lift-ing equipment like movable blocks or hoists). As such, thebrackets are normally not applicable to separate certification.See also 206.

202 Brackets fitted on the structure of DNV classified shipsor offshore installations are categorized as fundaments. Assuch, they are included in the classification.

The brackets and the fixation to their support, as well as thesupporting structures’ ability to support them are examined atthe design approval of the hull structure on which it is fitted.

Furthermore, the manufacturing survey of the supportingstructure will also cover the brackets together with other ap-pendages.

203 For brackets other than fitted on class covered struc-tures, however, DNV is prepared to carry out verification, nor-mally based on:

— design approval of the bracket and its fixation to its sup-port

— manufacturing survey including examination of materialcertificates and NDT

— monitoring of load testing (if agreed)— check of marking.

204 The design of brackets is preferably to be based on anapplicable recognised standard for brackets.

Design drawings shall be submitted for examination. Unlessthe details comply completely with a standard referred to,structural strength calculations shall be submitted for DNV’sdesign assessment.

205 Although not subject to certification, DNV will basepossible necessary design assessment on the structural require-ment of this Certification Standard. The customer may, how-ever, choose another applicable structural strength standard asbasis.

206 The verification will be documented with reports. Cer-tificates will normally not be issued. However, since Norwe-gian Maritime Directorate has introduced requirements forcertificates (NIS/NOR Circular no.1/2006), DNV has decidedto offer issuance of certificates upon specific request.

207 When used as foundation for a lifting appliance, thebrackets will be required to be tested according to relevant flagstate requirements, generally in confirmation with ILO 152 re-quirements. As proof of such testing marking of allowable loadis recommended.

Often a number of such brackets exist on a ship. When stand-ardized brackets are used, testing of different sizes may be ac-cepted to follow the guide as outlined at the end of thisAppendix, provided in agreement with flag state requirements.

A 300 Skids301 Both skids designed for transport of different varyingloads as well as skids designed for a specific load may becertified by DNV. For special offshore services one shouldconsider whether certification as offshore portable unit mightbe an alternative to certification as loose gear. Reference ismade to DNV’s Certification Note. 2.7-3 “Portble OffshoreUnits”.

302 If certification as loose gear is requested, the skid will,in principle, be certified in accordance with the ILO Conven-tion. By DNV this implies that this Certification Standard willform the basis for certification. The certification work will bedocumented by DNV’s certificate CG3.

303 The certification work will include the same four stepsas listed in 203. The load test will be mandatory in the case ofcertification.

304 Any limiting design conditions for the operation of theskid shall be defined and annotated on the CG3 and will nor-mally also be required to be included in the marking. This may,in addition to the SWL, include such details as limitations forthe centre of gravity of the load and angles of the lifting slingsthat may be attached.

305 DNV receives requests to certify separately only the padeyes on the top corner of the skids where the lifting slings areconnected.

This is not considered feasible. Certification of skids must in-clude the complete structure.

It is possible, however, to request a separate verification limit-ed only to the pad eyes, in line with the principles for verifica-tion as stated in 200.

306 DNV is frequently requested to certify skids designedfor one specific load, sometimes for one specific transport op-eration only – and sometimes for a skid on which the load(piece of equipment, motor, etc.) shall be permanently in-stalled. Such commissions are accepted according to the pro-cedures set out above. In most such cases, however,verification of the design will suffice.

307 For offshore lifting operations it is advisable (care shallbe taken) to ascertain that the load stipulations include neces-sary reserves for dynamic amplifications that follow from lift-ing in waves. The same applies in cases of general certificationfor issuing of CG3, as well as for verification.

Reference is made to Sec.5 B704.

For verification assignment of a one-off operation it might bepossible to specify the exact necessary dynamic amplificationfactor. Where, for example, the deck crane to be used is knownit will be possible to retrieve the dynamic amplification fromthe crane’s dynamic derating table. Such tables are required forall deck cranes for offshore operations certified by classifica-tion societies. Derating tables are also required by most shelflegislators and maritime authorities.

A 400 Monorails 401 DNV is frequently requested to clarify the scope andpossible structural borderline for certification of cranes travel-ling on rails. Various designs are represented, and differenttype designations are used, such as travelling cranes, travellingbeams, fly-beams, monorails, etc.

Our basic policy is, as mentioned before in this Appendix, thatsupporting structure welded (or otherwise fixed attached; bolt-ed, riveted, etc.) to the hull structure shall be considered as afundament.

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For DNV classified ships and mobile offshore units, the funda-ment’s structural integrity, its fixation and the capacity of thesupporting structure will be considered as part of the unit’s hullstructure.

When trolleys are travelling on wheels on the upper or lowerflange of fixed beams, the beams and their support are funda-ments.

However, the local effect of the wheels on the support beamsare not considered part of the class engagement. These effectsshall be included in the considerations done by the competentperson certifying the lifting appliance and thus possessing thedetails of the wheel arrangement.

Everything moving, including wheels, is part of the lifting ap-pliance.

A 500 Testing of standard brackets (lifting lugs, pad eyes)

501 Guidance note:

1) Lifting brackets with SWL (Safe Working Load) equal orless than 1 tonne:

a) Visual inspection by a DNV surveyor (support andwelding).

b) Surveyor’s on-the-spot evaluation of brackets scantlingif not a standard type.

c) Marking of individual brackets by SWL or group mark-ing (i.e. common signboard in each room/space withseveral identical brackets. In case of brackets with dif-ferent SWL in the same room/space individual markingor for instance a colour distinguishing system for thebrackets shall be applied).

d) Description of location, SWL and loading directingshall be included in the operations manual.

2) Lifting brackets with SWL above 1 tonne and less or equalto 5 tonnes as for item 1 a), c) and d):Drawing approval locally, and

— load test + spot NDT, alternatively— spot load test + 100% NDT.

If spot load-test is chosen, it will be decided after visual in-spection which lifting brackets shall be load tested.

3) Lifting brackets with SWL above 5 tonnes as for item 1 a)and d):

— drawing approval by DNV, local approval centre— load test— NDT extent to be included in the NDT programme— individual marking.

Load factor for Brackets/Lugs:Lifting brackets/lugs are to be designed with a load factor relativeto the SWL in question:

Load testing of Brackets/Lugs:Where load testing of lifting brackets/lugs are required the test-ing shall be carried out according to the following:

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Safe Working Load Load FactorUp to 5 tonnes 2.05 – 20 tonnes 1.75Above 20 tonnes 1.5

Safe Working Load Test LoadUp to 20 tonnes 1.25 × SWL20 – 50 tonnes 5 tonnes + SWLAbove 50 tonnes 1.10 × SWL

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APPENDIX F REGISTER AND CERTIFICATE FORMS

A. List Forms

A 100 General101 After the previous DNV "Rules for Certification of Lift-ing Appliances."1994 was published, a number of minor im-provements have been included in the forms. (Latest prevailingforms are found in the DNV form system database.)

102 The sample forms shown in this Appendix are those cur-rent at the time of publishing.

A 200 Relevant forms201 The following forms are relevant:

B. Sample Copies

CG 1: Register of Lifting Appliances and Cargo handlingGear(Front page of booklet)

Form No. Title

CG1 Register of Lifting Appliances and Cargo handling Gear

CG2 Certificate of Test and Thorough Examination of Lift-ing Appliances

CG2U Certificate of Test and Thorough Examination of Der-ricks used in Union Purchase

CG3 Certificate of Test and Thorough Examination of Loose Gear

CG4 Certificate of Test and Thorough Examination of Wire Rope

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CG2: Certificate of Test and Thorough Examination ofLifting Appliances

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CG2: Certificate of Test and Thorough Examination ofLifting Appliances (page 2)

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CG2U: Certificate of Test and Thorough Examination ofDerricks used in Union Purchase

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CG2U: Certificate of Test and Thorough Examination ofDerricks used in Union Purchase (page 2)

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CG3: Certificate of Test and Thorough Examination ofLoose Gear

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Standard for Certification of Lifting Appliances, October 2008Ch.2 App.F – Page 79

CG3: Certificate of Test and Thorough Examination ofLoose Gear (page 2)

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CG4: Certificate of Test and Thorough Examination ofWire Rope

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Standard for Certification of Lifting Appliances, October 2008Ch.2 App.F – Page 81

CG4: Certificate of Test and Thorough Examination ofWire Rope (page 2)

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APPENDIX G VERIFICATION GUIDELINE FOR SAFETY FUNCTIONS

A. Application, Scope and Objective

A 100 Application

This guideline provides a recommended and simplified meth-od for 1. part verification (see definition in 200) of safety func-tions and equipment for lifting appliances subject to designverification in accordance with the requirements as presentedin this Certification Standard, see Sec.6 A500.

If so preferred, Customer may use other verification methods.

Successful verification will serve as a condition for issuance ofDNV’s CG2 “Certificate of Test and Thorough Examinationof Lifting Appliances”.

The guideline is intended, primarily, for designers, manufac-turers, yards, operators, and owners applying for DNVcertification of lifting appliances in accordance with the aboverequirements.

A 200 Verification

1. Part verification is the supplier’s responsibility.

The definition of verification: Confirmation by examinationand provision of objective evidence that the requirements havebeen fulfilled (ISO 8402, IEC 61508-4, 3.8.1.).

A 300 Scope

This guideline provides an introduction to the recommendedverification method and corresponding documentation re-quirements.

The basis for this guideline is the requirements to safety func-tions as specified in this Certification Standard (Sec.6 A500),based on the IMO-FSA method for development of risk-basedrules.

The intention of this guideline is to provide an introduction andspecification of:

— the safety function verification method— the verification sheet templates— the basic documentation requirements.

A 400 Objective

The objective of this guideline is to provide a practical and ad-equate method for verification of safety functions and equip-ment as well as to provide the corresponding documentationrequirements for lifting appliances in accordance with theDNV requirements.

B. Verification Procedure

B 100 General

Sec.6 A504 - A519 requires a set of generic risk reductionmeasures (safety functions) as follows:

— overload limiting device (504.a)— Manual Overload Protection System MOPS (504.b) — Automatic Overload Protection System AOPS (504.c)— operational limit protection, general (505.a)— operational limit protection, boom up (505.b)— constant tension system (optional) (506.a)— reduced boom lifting/slewing speed (506.b)— audible alarm (506.c)— emergency stop function (507)

— boom tip camera (508)— communication equipment (509)— slack wire rope detection (510)— failure in control systems, protection and precautions

(511)— failure in the safety systems, precautions (512)— maintenance of braking capacity (513)— maintenance of holding capacity (514)— blackout/shutdown, precautions (515.a)— blackout/shutdown, emergency operation (515.b)— unintended activation of safety functions, protection (516)— spurious trip of safety functions, precautions (517)— hazards due to activation of safety functions, precautions

(518)— gas alarm (519.a)— gas alarm, shut-down (519.b).

Above safety functions are required for reducing the assumedgeneric risk.

In this guideline, most of the above safety functions are repre-sented by a verification form stating a subset of the main func-tional and technical requirements.

The verification process obliges the Customer to fill in (or tickoff, whatever is appropriate) the verification papers and sendthem in completed order to DNV together with correspondingdocuments verifying that the requirements have been compliedwith. Requirements for documentation are specified in C at theend of this Appendix.

However, some of the more detailed functional and technicalrequirements to the safety functions, as specified in Sec.6A504- A519, are not included in the verification forms. It is as-sumed that fulfilment of these requirements also is properlydocumented.

As a part of the verification of compliance with the Standard,it shall be confirmed that the maximum consequence of thestated hazard/risk contributor is one fatality (ref. Sec.6 A502),with the exception of the hazard “Fire, fire ignition” (Sec.6A519).

In case the maximum consequence exceeds one fatality, thisshall appear from the filled-in verification papers. The basisfor the generic requirements to the safety functions is therebynot fulfilled, and the requirements to the safety functions willbe subjected to deviation handling.

Further, also for other cases of deviation from the generic risk/risk contributors as specified by Sec.6 A502, and/or from thegeneric safety functions as specified in Sec.6 A504 – A519,this shall appear from the verification papers and lead to devi-ation handling of the requirements to the safety functions.

In such cases, the customer shall document in detail the actualsafety functions with respect to functional and technical spec-ifications. The actual solution will be subjected to a risk basedassessment where the specific requirements to the safety func-tions will be developed and agreed with the customer.

Generally, there are no requirements to establish detailedinformation for verifying target reliability by means of PFD orMTTF values.

A complete verification of target reliability may be applied, ifpreferred by the Customer, and may be based on methods de-scribed in different standards. Examples on applicablestandards are IEC 61508 (SIL), IEC 62061 (SIL), ISO 13849(PL).

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B 200 Explanation of the verification templates elements

B 300 Verification sheet templates

Text in verification sheet Explanation of elementText reference Reference to the paragraph where the requirements to safety functions are stated.Hazard and risk The generic hazard and initial risk briefly explained in a text.Max consequence Specification of maximum expected number of fatalities if a hazardous situation appears and

the specified safety function is not fitted.Name of safety function Textual name of safety function.Safe state Specification of the assumed safe state. Energy principle (NE,NDE, CE) Energy principle for normal operation (not activated). NE means “Normally Energised”, NDE

means “Normally De-Energised” and CE means “Continuous Energised”.On demand/continuous On demand means that the safety function shall be activated when a given demand or state oc-

curs. In this case the safety function shall establish the safe state as described above. Continu-ous means that the function is assumed to be working during normal operation of the facility.

Automatic/manual activation Automatic activation means that the safety function shall be triggered by the safety system without manual operator intervention. Manual activation means that operator shall trigger the activation by means of button or joystick

Response time Maximum time from system has been triggered to safe state is achieved. Test procedure Name and reference to periodic test procedure. Test procedure should at least include how the

test should be carried out and the success criterion for the test.Test interval Length of test interval between tests.Detector 1 Reference to the detector or activation unit for triggering the safety function.Detector 2 Reference to the redundant or secondary means for triggering the safety function.Actuator 1 Reference to actuating device (valve, brake, etc.) for establishing the safe state. The safe state

of the actuator shall be given.Actuator 2 Reference to redundant or secondary means for establishing the safe state. The safe state of the

actuator should be given.Monitoring of safety function Specifies how the safety function, when active, is monitored - by means of indication and/or

alarm. Ref. also Sec.6 Table A5.Independency to other functions Reference to other specific functions that shall not be impaired by the safety function.

Verification Sheet, Automatic overload shut-down device

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A504.aHazard and risk Overloading Max consequence One fatalityName of safety function Overload limiting deviceSafe state Boom luffing out movement

stopEnergy principle (NE, NDE, CE) CE (monitoring)On demand/continuous On demandAutomatic/manual activation Automatic Response time ImmediatelyTest procedure Designer’s specificationTest interval 12 monthsDetector 1 Load cell or similarDetector 2 NAActuator 1 Boom luffing out stopActuator 2 NAMonitoring of safety function Indication and alarmIndependency to other functions Shall not prevent lowering the

load and boom luffing in safe direction

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Verification Sheet, Manual overload protection MOPS

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A504.bHazard and risk OverloadingMax consequence One fatalityName of safety function Manual overload protection

MOPSSafe state Load paid out / released or

clutched out. Holding force of 10–25 % of platform lift

Energy principle (NE,NDE, CE) CE (monitoring)On demand/continuous On demandAutomatic/manual activation ManualResponse time ImmediatelyTest procedure Designer’s specificationTest interval 12 monthsDetector 1 Operator switch/handleDetector 2 NAActuator 1 Designer’s specificationActuator 2 NAMonitoring of safety function Indication and alarmIndependency to other functions NA

Verification Sheet, Automatic overload protection system AOPS

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A504.cHazard and risk Overloading Max consequence One fatalityName of safety function Automatic overload protection

system AOPSSafe state Load paid out/released or

clutched out, holding force of platform lift capacity. Boom luffing out movement stopped

Energy principle (NE, NDE, CE) CE (monitoring)On demand/continuous On demandAutomatic/manual activation Automatic Response time ImmediatelyTest procedure Designer’s specificationTest interval 12 monthsDetector 1 Load cell or similarDetector 2 Not applicable (NA)Actuator 1 Designer’s specificationActuator 2 Boom luffing out stopMonitoring of safety function Indication and alarm Independency to other functions Shall not prevent boom luffing

in safe direction

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Verification Sheet, Operational limit protection, general

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A505.aHazard and risk Crane movements outside op-

erational limitsMax consequence One fatalityName of safety function Operational limit protection,

generalSafe state Stop of movements outside

given limitations Energy principle (NE,NDE, CE) NEOn demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Manual test procedureTest interval 12 months/DailyDetector 1 Limit switch, physical barrierDetector 2 (required) NAActuator 1 Stop movementActuator 2 NAMonitoring of safety function Indication Independency to other functions Shall not prevent movement in

safe direction

Verification Sheet, Operational limit protection, boom up

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A505.bHazard and risk Boom up movement outside

limits (wire luffing cranes)Max consequence One fatalityName of safety function Operational limit protection,

boom upSafe state Stop of boom movement Energy principle (NE,NDE, CE) NEOn demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 6 months/DailyDetector 1 Limit switchDetector 2 (required) Boom high high detection, fail

safe detectActuator 1 Boom up winch stopActuator 2 NAMonitoring of safety function Indication Independency to other functions Shall not prevent movement in

safe direction

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Verification Sheet, Constant tension system

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A506.aHazard and risk Dangerous lifting gear/cargo

movementsMax consequence One fatalityName of safety function Constant tension system (op-

tional)Safe state Constant tension provided be-

fore lift off. Wire rope tension set to 1-3 tons

Energy principle (NE,NDE, CE) NDEOn demand/continuous On demandAutomatic/manual activation ManualResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 months/DailyDetector 1 Crane operator activation/but-

tonDetector 2 NAActuator 1 Designer’s specificationActuator 2 NAMonitoring of safety function IndicationIndependency to other functions NA

Verification Sheet, Audible alarm

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A506.cHazard and risk Dangerous lifting gear/cargo

movementsMax consequence One fatalityName of safety function Audible alarmSafe state Alarm signal givenEnergy principle (NE,NDE, CE) NDEOn demand/continuous On demandAutomatic/manual activation ManualResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 months/DailyDetector 1 Crane operator activation/but-

tonDetector 2 NAActuator 1 Audible alarm/hornActuator 2 NAMonitoring of safety function AlarmIndependency to other functions NA

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Verification Sheet, Emergency stop function

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A507Hazard and risk Dangerous crane movementsMax consequence One fatalityName of safety function Emergency stop functionSafe state Crane movements stoppedEnergy principle (NE,NDE, CE) NEOn demand/continuous On demandAutomatic/manual activation ManualResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 monthsDetector 1 Crane operator buttonDetector 2 Working personnel activation

(button)Actuator 1 Removal of power or mechani-

cal disconnection (declutching)Actuator 2 Application of brakesMonitoring of safety function Indication and alarmIndependency to other functions NA

Verification Sheet, Slack wire rope detection

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A510Hazard and risk Slack wire rope at drumMax consequence One fatalityName of safety function Slack wire rope detectionSafe state Stop winch motion and re-

tighten of slack wire rope be-fore automatically returning to normal operation.

Energy principle (NE,NDE, CE) NEOn demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 monthsDetector 1 Wire rope tension measuring

deviceDetector 2 NAActuator 1 Stop winch movementActuator 2 Start winch movementMonitoring of safety function IndicationIndependency to other functions NA

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Verification Sheet, Failure in control systems, pro-tection and precautions

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Hazard and risk Failure in control systemText reference Sec.6 A511Max consequence One fatalityName of safety function Failure in control systems, pro-

tection and precautionsSafe state Auto stop and automatic appli-

cation of brakes and alarm sig-nal to operator.

Energy principle (NE,NDE, CE) CE (monitoring)On demand/continuous Continuous monitoring, alarm

on demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Designer’s specificationTest interval 12 monthsDetector 1 Failure in control system mon-

itoringDetector 2 NAActuator 1 Auto stop and automatic appli-

cation of brakes.Actuator 2 Alarm signal to operator.Monitoring of safety function, when active

Indication and alarm

Independency to other functions Shall not override MOPS

Verification Sheet, Monitoring of safety systems

Requirement/Specification

Customer’s verification of compliance with the requre-ments. (“tick-off”), or ref. to

other solution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A512Hazard and risk Failure in safety systemsMax consequence One fatalityName of safety function Monitoring of safety systemsSafe state Indication and alarm signal to

crane operatorEnergy principle (NE,NDE, CE) CE (monitoring)On demand/continuous Continuous monitoring, alarm

on demand Automatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 monthsDetector 1 Failure in safety systems detec-

torDetector 2 NAActuator 1 Indicator and alarm signal to

crane operatorActuator 2 NAMonitoring of safety function Indication and alarmIndependency to other functions Shall not affect/override other

crane functions

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Verification Sheet, Maintenance of holding capaci-ty,hydraulic cranes

Requirement/Specification

Customer’s verification of com-pliance with the requrements.

(“tick-off”), or ref. to other so-lution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A514Hazard and risk Lack of holding capacityMax consequence One fatalityName of safety function Maintenance of holding

capacitySafe state Holding capacity retainedEnergy principle (NE,NDE, CE) CEOn demand/continuous ContinuousAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manual-

lyTest interval 12 months/DailyDetector 1 Customer’s specificationDetector 2 NAActuator 1 Hydraulic system designed to

avoid insufficient hydraulic refilling

Actuator 2 Safety/holding valves on all main circuits

Monitoring of safety function NAIndependency to other functions NA

Verification Sheet, Blackout/shutdown, precautions

Requirement/Specification

Customer’s verification of com-pliance with the requrements.

(“tick-off”), or ref. to other so-lution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A515.aHazard and risk Blackout / shutdownMax consequence One fatalityName of safety function Blackout/shutdown, precau-

tionsSafe state Stop all movementsEnergy principle (NE,NDE, CE) CEOn demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manuallyTest interval 12 monthsDetector 1 Loss of power supplyDetector 2 NAActuator 1 Brakes appliedActuator 2 NAMonitoring of safety function AlarmIndependency to other functions Shall not override MOPS

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Verification Sheet, Blackout / shutdown, emergency operation

Requirement/Specification

Customer’s verification of com-pliance with the requrements.

(“tick-off”), or ref. to other so-lution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A515.bHazard and risk Blackout / shutdownMax consequence One fatalityName of safety function Blackout / shutdown, emergen-

cy operationSafe state Hoisting/slewing/luffing out/

load lowering to safe positionEnergy principle (NE,NDE, CE) NDEOn demand/continuous On demandAutomatic/manual activation ManualResponse time Max 30 sec.Test procedure Test to be carried out manuallyTest interval 12 monthsDetector 1 Loss of power supplyDetector 2 NAActuator 1 Operator controlled power unitActuator 2 NAMonitoring of safety function AlarmIndependency to other functions NA

Verification Sheet, Gas alarm

Requirement/Specification

Customer’s verification of com-pliance with the requrements.

(“tick-off”), or ref. to other so-lution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A519.aHazard and risk Fire/fire ignitionMax consequence Multiple fatalitiesName of safety function Gas alarmSafe state Alarm signal to operator upon

gas in areaEnergy principle (NE,NDE, CE) CE (monitoring)On demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manual-

lyTest interval 6 monthsDetector 1 Gas/explosive atmosphere de-

tector Detector 2 NAActuator 1 Acoustic fire/gas alarm to op-

eratorActuator 2 NAMonitoring of safety function AlarmIndependency to other functions NA

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C. Required Documentation and Information

C 100 DocumentationThe following documentation shall normally be provided:

— filled in verification templates with reference to manufac-turers’ documentation

— functional description of the safety system and the safetyequipment (safe state, etc.)

— schematic diagrams of hydraulic-, pneumatic-, electrical,

control- and monitoring systems— equipment list— components data sheets— design criteria, including applied codes and standards — test procedures for periodic testing— written conclusion.

More detailed information about lambda (du), Safe FailureFraction (SFF), beta-factors, PFD calculation for the systemsmay be delivered to DNV for information.

Verification Sheet, Shutdown

Requirement/Specification

Customer’s verification of com-pliance with the requrements.

(“tick-off”), or ref. to other so-lution

Customer’s document refer-ence/reference to objective evidence verifying compli-

ance

DNV check

Text reference Sec.6 A519.bHazard and risk Fire/fire ignitionMax consequence Multiple fatalitiesName of safety function ShutdownSafe state Shut down of craneEnergy principle (NE,NDE, CE) CE (monitoring)On demand/continuous On demandAutomatic/manual activation AutomaticResponse time ImmediatelyTest procedure Test to be carried out manual-

lyTest interval 6 monthsDetector 1 Fire/explosive atmosphere de-

tectorDetector 2 NAActuator 1 Shut down of craneActuator 2 NAMonitoring of safety function NAIndependency to other functions NA

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