Bespoke Safe Load Indicator System Created for North Sea Operator

Benefits

• Combined crane control system/SLI solution delivered, eliminating the need for two separate systems
• Modular design utilises modern technologies and readily available, off-the-shelf components for more straightforward maintenance
• Engineered to take account of the client’s unique requirements for sensor data and fault diagnostics
• Designed to Automatic Safe Load Indicator Standards BS7262-1990 and Offshore Crane Standard BS- 13852-2013

Challenge

Having previously worked with the operator on other projects, the company approached us to upgrade the control system on the offshore cranes aboard one of its platforms.

Previously, our standard system setup would use our control system alongside a third party SLI. This would require the operator to work with two screens in the cab and depend on third party support to make any modifications to the SLI.

The client expressed a preference to have one point of contact for the system, therefore we designed a bespoke SLI system in-house, delivering an integrated system within one unit.

In developing this new system, we had several parameters to work within. First, the client required us to create a modular design that used modern technologies and standard, off-the-shelf components. The system needed to be accessible for the end user to calibrate all sensors and perform fault diagnostics without additional OEM support. It had to be designed according to industry current standards to ensure the system was compliant, safe, and functional to make it operational. The client requested the system would incorporate functionality to allow platform personnel to carry out calibrations and for easy annual testing of the gross overload protection (GOP) systems. And lastly, the design had to be suitable for safe area and hazardous area options.

Solution

With a complete understanding of the client’s requirements and using tried and tested components, our design and engineering teams carried out in-house research and development to create our first SLI.

Throughout this process, consideration was given to BS 7262-1990, BS 13852-2013, and BS 13849-2015 to ensure we were building an SLI that was safe and fit for purpose on an offshore crane.

The Siemens S7-1500 series PLC and associated input/output modules was selected for the processing. Incorporating Siemen's latest 'Unified Comfort Panel' that has a Linux based operating system, the SLI data and standard crane operator data are presented clearly on a singular 10" touchscreen display. Supporting our automation team, who undertook its programming, our electrical and design teams worked on the required interconnection wiring, calculations and drawings, which included the crane operation geometry for moment and hook position calculations. The fully integrated system was then manufactured by electrical technicians in our workshop.

In line with the client’s brief, the system has been specifically designed to be used in hazardous zoned areas, per BS EN 60079 equipment for explosive atmospheres. The system also allows for simplified annual testing of the GOP systems, with access to a test function via an operator-friendly testing screen.

Before deployment, we conducted thorough internal testing to ensure the SLI operation was operating as required and to confirm that it would activate the GOP system in the event of a gross overload. A client-witnessed test was also carried out before formal acceptance and mobilisation for installation.

Our team provided the client with a comprehensive range of materials, including the operational manual and drawing package. And because this integrated system was built entirely in-house, we can provide 24/7 support.

The new system is operational on three of the client’s cranes on the initial platform, and feedback from the crane operators has been incredibly positive. As the system was well received, it has also been deployed on an additional platform for the same client.

Client feedback

The project was the first for us in not using the OEM for a PLC.

The main drivers were:

• Cost
• Expert knowledge of cranes
• Willingness to include in the system what we wanted, such as maintenance functions, as opposed to a standard off the shelf from the OEM
• We could use the same system on various models of cranes and not just systems based on crane manufacturer. This is a big advantage for spares and training.

Summary

• First Altrad Sparrows Safe Load Indicator System developed in-house
• Solution integrates multiple functions into a single unit, eliminating the need for two separate screens
• System incorporates modular design, modern technologies, and off-the-shelf components
• Allows end-users to calibrate sensors and perform fault diagnostics without additional support
• Design meets industry standards for safety and performance
• Siemens S7-1500 series PLC used for processing, with a 10" touchscreen display for data presentation
• Flexible design can integrate with different crane configurations
• Thorough internal testing and client-witnessed tests conducted before deployment
• Full training and supporting documentation provided to client, with 24/7 support available
• Successfully deployed on two client platforms, receiving positive feedback from crane operators
• System developed via multi-discipline collaboration between in-house Engineering, Design, Automation and Electrical teams