8 inspection of cranes in campos basin

11TH NORTH SEA OFFSHORE CRANE CONFERENCE

INSPECTION OF CRANES IN CAMPOS BASIN BUSINESS UNIT (UNBC)

EVOLUTION AND FORESEEN FUTURE

RONALDO G. CRUZ04/2006

CAMPOS BASIN AND ITS VALUE TO PETROBRAS

LOCATION

CAMPOS BASIN AND ITS VALUE TO PETROBRAS

BEGINING OF PRODUCTION 1977

PRODUCTION PLATFORMS in 2005 30

PRODUCTION NOWOIL 838.150 bpd

CORRESPONDING TO ALMOST 50% OF PETROBRAS PRODUCTION IN BRAZIL

NATURAL GAS 11.800 m3

HISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASIN

Eighties

Few units in operation; The use of own personnel for operation and maintenance;Little experience on specific characteristics of the offshore service ; Equipments adapted for offshore use;A inspection team is organized; Inspection as guarantee of safety.


THE PIONEERS CRANES

AMERICAN 5750


Nineties

Increase of the quantitative of Operational Units; Recruiting of the maintenance services; Contracts of short duration, by the smallest price with each Operational Unit; High level of unavailability of equipments;Unavailability in the market of specialized companies; Inspection as complement of preventivemaintenance plans.


The new generation

LIEBHERR GOS 25/550

STALPRODUKTER KHO


Years 2000

Revision of the strategy for recruiting of O&M companies; Previous selection for register; Contracts of long duration, by the best price with each Assets; Search of specialized companies in the international market; Inspection as a special tool for auditing the maintenance services.


The evolution

Distribution of cranes instalation datesin UN-BC

600%

705%

8044%90

42%

20009%

AMERICAN 5/9750 18

CLARKE CHAPMAN 3

HR GB 60M 7

LIEBHERR 11

NATIONAL OS 435 6

STALPRODUKTER 15

TEMA TERRA 7

WEATHERFORD 4

HYDRALIFT 1

SEATRAX 2

AKER 2

Internal norms, inspection plans and job of new technologies

References

Lack of specific regulation for offshore services in Brazil;BR Internal Norm N-1930 dated 1984 Inspection in service of Offshore cranes : Frequency _ adjusted in accordance with the

operational severity 4 Inspection levels Procedures _ specific for each crane model

These actions must be carried on by BR personnel.


References

Load tests were also previewed for every 4 years.Along these 20 years the inspection and load test procedures were improved, as the knowledge on these kind of equipment was increased;


References

Norms for wire rope (N-2161) and rigging (N-2170) inspection were stated in 1985;

It was implanted in 1995 a plan for wire rope eletromagnetic inspection in service;

N-1930 updated in 2002 (rev.C) the main target of inspection was confirmed as auditing the O&M contracts;

As part of the actions that reviewed the politics for conducting the cranes O&M services, it was defined in 2004 a plan for certifying the crane operators.

The maintenance of cranes - the partners' search

Whats the profile for this partner ?

Brazilian companies or foreign companiesestablished in Brazil;

Services companies or manufacturers withproved experience in cranes O&M;

Engineering support;

Qualified personnel;

Companies certified in ISO, health, safety andenvironment;


In 2000 the inspection team was officially transferred to the Management of Maintenance and Inspection Engineering, and one of the first missions was:

Reviewing the Criteria to register and the actual register of companies for cranes O&M in UNBC;

Actions

" To accomplish technical visits to specialized companies in operation and maintenance services of offshore cranes, the operators customers, as well as to a manufacturer of these equipments that also executes these services.

" To know and to evaluate the processes of offshore cranes O&M in world extent.


Results

The register of Brazilian companies used by UNBC was totally reviewed;

In 2002 two specialized companies, one crane manufacturer and three clients of them were visited in Europe;

Nowadays one of those companies is working with BR in UNBC and a crane manufacturer is associated with a O&M company contracted by BR;

The search is not concluded

Characterization in maintenance engineering of cranes

Why did it happen ?

The knowledge acquired on the equipment in the periodic inspections;

The global vision of the equipments in UNBC;

The great involvement in the maintenance services in the first years;

The identification of chronic problems and the lack of support by manufacturers and maintenance companies;


This actuation was noted by actions as:

Treating and analyzing the data on performance of the equipments observed in periodic inspections, not being limited in reporting problems;

Designing structural components;

Adjusting load tables because of components limitations;

Proposing modifications on cranes design;

Specifying new cranes.


Example *Data

Equipment AMERICAN 5750 Problem - Premature wear in luffing wire

ropeUseful life 300 hoursAspect abrasion in wiresQuantity of cranes affected - 15

* Prado,H.P., Project alterations implemented in the cranes American 5750 of UN-BC seeking the improvement of the operational acting of the luffing system, Natal, april/2004.


Analysis


Analysis

High traction effort in the luffingwire rope crane geometrySmall drum diameter

= Consequent high contact pressure caused by the wire rope on the drum


Analysis

Comparison with other equipments

Liebherr GOS 25/550 ---- 1600 PSI

HR GB 60 M ------------ 2000 PSI

Tema Terra 380 L ------- 2400 PSI

American 5750 ---------- 3800 PSI


Actions done

To reduce the traction effort: It was modified the crane geometry, installing a highest A-frame

Reduced the friction between sheaves and their axis, by the use of bearings.

Increased the diameter of the luffingdrum.


The result

Contact pressure: 1800 psi

Useful life of the wire rope: 1700 hours

Conclusion

The specialized group has as target for the next yearsto support technically the Assets on the cranes O&Mprocess, to be seen by: Evaluation on the performance of the O&M

companies contracted by UNBC; Updating the register of O&M companies; indication of references for a Brazilian offshore

regulation; Development of new technologies for cranes

maintenance; Analysis of remaining life for equipments; Training for supervisors and technicians.

Thank you for your attention,

Ronaldo G. CruzTechnical Consultant Senior EngineerContact :Phone - + 55 22 2761 4363email [email protected]

11TH NORTH SEA OFFSHORE CRANE CONFERENCE CAMPOS BASIN AND ITS VALUE TO PETROBRASCAMPOS BASIN AND ITS VALUE TO PETROBRASHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINHISTORICAL OF THE INSPECTION SERVICES IN CRANES IN CAMPOS' BASINInternal norms, inspection plans and job of new technologies Internal norms, inspection plans and job of new technologies Internal norms, inspection plans and job of new technologies The maintenance of cranes - the partners' search The maintenance of cranes - the partners' search The maintenance of cranes - the partners' searchCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesCharacterization in maintenance engineering of cranesConclusion

8 inspection of cranes in campos basin

Documents

inspection services

inspection plans

organized inspection

cranes om services

offshore services

maintenance of cranes

inspection levels procedures

main target of inspection