PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

OFFSHORE CRANE – 20 TONS

PTS 20.129

DECEMBER 1983

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,operation and maintenance of processing units and facilities. Where appropriate they are basedon, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied byPETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemicalplants, marketing facilities or any other such facility, and thereby to achieve maximum technicaland economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration anddecision to implement. This is of particular importance where PTS may not cover everyrequirement or diversity of condition at each locality. The system of PTS is expected to besufficiently flexible to allow individual operating units to adapt the information set forth in PTS totheir own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for thequality of work and the attainment of the required design and engineering standards. Inparticular, for those requirements not specifically covered, the Principal will expect them to followthose design and engineering practices which will achieve the same level of integrity as reflectedin the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from hisown responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.2) Other parties who are authorised to use PTS subject to appropriate contractual

arrangements.3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with

users referred to under 1) and 2) which requires that tenders for projects,materials supplied or - generally - work performed on behalf of the said userscomply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements withusers, PETRONAS disclaims any liability of whatsoever nature for any damage (including injuryor death) suffered by any company or person whomsoever as a result of or in connection with theuse, application or implementation of any PTS, combination of PTS or any part thereof. Thebenefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliatedto PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractualarrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed byusers to any company or person whomsoever and the PTS shall be used exclusively for thepurpose they have been provided to the user. They shall be returned after use, including anycopies which shall only be made by users with the express prior written consent of PETRONAS.The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safecustody and PETRONAS may at any time require information satisfactory to PETRONAS in orderto ascertain how users implement this requirement.

CONTENTS

SECTION

1.0 SCOPE

2.0 GENERAL

3.0 DESIGN CRITERIA

4.0 CORROSION PROTECTION

5.0 INSPECTION AND TESTING

6.0 SPECIAL TOOLS

7.0 SPARES

8.0 PACKAGING

9.0 LUBRICANTS

10.0 VENDOR DATA REQUIREMENTS

11.0 ATTACHMENTS

1.0 SCOPE

This specification describes the requirements for a revolving diesel-hydraulic crane to be pedestalmounted on an offshore platform located in the South China Sea off the coast of E.Malaysia.

The crane shall be a complete operating unit, including all ancillary equipment, necessary for safeand reliable operation at an exposed location with environmental conditions as stated herein.Vendor shall be responsible for design, procurement, fabrication, painting, assembly and testingin accordance with this specification and the referenced codes, standards and specifications.

2.0 GENERAL

2.1 Codes and Standards

The following codes, standards and specifications are referred to in this specification.

Reference to Only

API Spec 2C Specification for Offshore Cranes, latest edition.

API RP 2D Recommended Practice for Operation and Maintenance of Offshore Cranes.

Institute of Model Code of Safe Practice (British) Petroleum (IP)

AWS D1.1 Structural Welding Code, latest edition.

SIS 05 5900 Swedish Standard on Pictorial Surface Preparation for Painting Steel Surfaces,latest edition.

PTS 30.48.00.31-P Protective Coatings and Lining

2.2 Extent of Supply

2.2.1 The Vendor shall furnish all components and ancillary equipment to make a complete,safe and operable deck crane.

2.2.2 The Vendor shall provide a fully qualified representative to conduct the following :-

a. Provide all necessary supervision for Installation, assembly, and receiving workrequired to place the crane in operation offshore.

b. Perform a complete inspection and acceptance test in accordance with therequirements of API Spec 2C (latest edition), and issue an inspection and testcertificate to the Purchaser.

c. Train Company's employees in the operation and maintenance of the crane.

2.3 Location Conditions

Location : Platforms offshore coast of Sarawak East Malaysia in the South China Sea.

Ambient Air : 65° F to 90° FTemperature

Altitude : 100 ft above sea level (platform deck)

Atmosphere : Sea Air, Salt Laden, High Relative Humidity

Surface Winds : Maximum instantaneous gust is 120 mph at 100 ft above sea level.

Wave Heights : Significant wave heights exceed 8 ft, 30 percent of the time in December toFebruary. The period for significant waves is 5 to 8 seconds.

2.4 Utilities Available

Instrument Air : 125 psig (clean and dry)

Utility Air : 150 psig (sat.)

Diesel Fuel : 'Light Distillate, Grade No. 2 at 30 psig

Water : Potable, chlorinated

Electrical : 415/240 volts, 3 phase, 4 wire, 50 Hertz

Vendor shall state specific utility requirements in his proposal..

2.5 Area Classification

Area classification will be determined by Purchaser and relevant information will be included inthe purchase requisition.

3.0 DESIGN CRITERIA

3.1 Lifting Capacities

Main Hoist : Must be capable of a minimum of:

• 20 short tons at 40 ft radius

• 15 short tons at 60 ft radius

• 10 short tons at 70 ft radius

Auxiliary Hoist : 7.5 short tons at radius up to 90 ft

All above specified lifting capacities shall be with the boom plus jib assembled in place. Vendorshall state the hoist hook speed for each lifting capacity given above.

3.2 Boom

The crane shall be supplied with a 100 ft steel boom with replaceable bushing at the boom foot.

The boom shall have four lifting pad eyes with sufficient capacity to allow the entire boom to belifted in a two-point lift.

A jib shall be provided for the auxiliary hoist such that it provides a 3ft clearance from the mainhoist at minimum boom radius. Consideration should be given to location of boom rest support onthe platform.

3.3 Hooks

All hooks shall be of the swivel safety lock type, rated as applicable for main and auxiliary hoist.They shall be of sufficient weight to prevent unraveling of cable on the winch drums duringunloaded lowering operations.

3.4 Winches and Wire Rope

3.4.1 The main, auxiliary, and boom winches shall be driven by hydraulic motors. Operation ofthe boom shall be completely independent from all other line operations. Duration ofcontrolled power lowering shall be no longer than one minute from minimum to maximumradius.

3.4.2 Main and auxiliary hoist winches shall also be power lowering.

3.4.3 API Spec 2C provides a minimum strength factor of 5.0 for line or running ropes that windon drums or pass over sheaves. For this specification, the "total force applied to the ropesystem" shall include:

The force resulting from the effects of 1.33 times the rated load.

The force equivalent to the maximum bending stress on each wire in the rope multipliedby the cross sectional area of steel in the wire rope.

The force needed to overcome friction in the rope system.

Any applicable dead load.

3.4.4 Wire rope supplied with the crane shall be non-galvanized, non-rotating, and be suitablefor the high humidity and salty atmosphere.

3.4.5 Both load hoists shall have sufficient rope capacity to lift loads from sea level with theboom at minimum radius, with at least two full wraps left on each winch drum. A boomfoot pin height of 100 feet above sea level shall be assumed.

3.4.6 If more than 3 layers are put on the drum, the wire rope shall have an independent wirerope core (IWRC), in which case the fleet angle shall be restricted to 2° and correctspooling shall be provided.

3.5 Structural

3.5.1 All structural components connecting the crane's rotating superstructure to a fixedpedestal shall be designed such that they are fully capable of carrying all loads,moments, etc. generated by the crane. Four lifting eyes symmetrically located about thecrane's center of gravity for offshore handling and installation of the crane shall beincluded in the design.

3.5.2 This lift system shall be designed with an impact factor of 200 percent for installation ofthe crane superstructure onto the platform pedestal.

3.5.3 The Vendor shall submit with his proposal a drawing showing all details relating to theinstallation/welding-out of the crane onto the section of pedestal provided as part of thePurchaser's offshore platform, including steel and welding specifications applicable. Inaddition, the design parameters necessary for the Purchaser to complete the design ofthe pedestal shall also be supplied by the Vendor when submitting his proposal (e.g.forces, moments, etc., all in the lbs and ft lbs system). All structural welding shall be inaccordance with AWS D1.1.

3.6 Rotating Superstructure

3.6.1 The cab shall be a fully enclosed steel structure with shatterproof, tinted glass windows. Itshall be designed such that a seated operator has full view of the main or auxiliary hookin all operating positions from sea level to the maximum height of the boom, and also ofany obstructions above the cab. A walkway for ready access to all components of thecrane which might need maintenance or repair shall be provided and shall be equippedwith handrails and toe plates. The crane superstructure shall be capable of rotating 360degrees with a swing speed of 0 to 1.5 revolutions per minute. Manually adjustablerotating stops (limit switches) shall be provided so that the crane rotation can be limited ifnecessary.

3.6.2 A positive-mechanical locking device to prevent movement of the rotating superstructurewhile the crane is not in use shall be provided. This device is in addition to the brakeused during normal working operations.

3.6.3 The prime mover shall be a General Motor's or Purchaser approved equal, heavy dutyindustrial diesel engine, naturally aspirated, equipped with spark arresting exhaust, andelectric starter. An emergency shutdown shall be provided to allow the operator topositively stop the diesel engine without leaving his seat,

3.6.4 A back-up, totally self-contained hydraulic starting system shall also be provided forengine starting, capable of providing 6 start attempts. The engine shall also be fitted witha Barber "Fail Safe" Rig Saver on the air inlet.

3.6.5 Engine cooling system shall be adequate for continuous full power operation in anambient temperature of 92° F. Radiator fan shall be driven from engine shaft, and shallhave aluminium or fiberglass blades.

3.6.6 The engine shall be furnished in accordance with the attached data sheets.

3.6.7 The capacity of the diesel fuel day tank shall be 60 gallons (U.S.). The day tank will befilled by manual operation of a fill valve from a pressurized header.

3.7 Instrumentation, Controls and Accessories

3.7.1 Minimum instrumentation shall consist of engine tachometer, engine oil pressure gauge,ammeter, engine jacket water temperature gauge, and engine hour meter. A boom angleindicator graduated in 5° increments with corresponding load radius shall also beprovided. All of the foregoing shall be readily visible to a crane operator seated in thecab. Controls shall be designed for two hand-controlled manoeuvres, i.e., boom hoist orswing drive or either load hoist operated together as an "any two" combination, withoutloss of any other operation. The engine shall be controlled by a foot throttle.

3.7.2 All control levers shall be of the "dead man" type, automatically returning to neutralposition when released by the operator, disengaging power to the relevant winch(es) andapplying a brake. Brakes shall also engage automatically on engine or winch failure or onhydraulic line rupture.

3.7.3 The boom hoist shall be provided with a device to disengage power and apply a brakewhen the boom approaches minimum operating radius. The unit shall have a mechanicalboom elevation stop with a built in shock absorbing feature.

3.7.4 Crane should be equipped with an automatic brake which will engage whenever thecontrol handle is returned to neutral.

3.7.5 Main and auxiliary hoist travel stop features shall be provided to prevent the operatorfrom pulling hooks into the boom. Tripping of either stop feature shall initiate an alarmhorn and illuminate an alarm light in the cab. The cab shall also be provided with amanual horn for operator use and windshield wipers where appropriate.

3.7.6 a) All electrical equipment shall be suitable and certified for operation in thespecified hazardous area classification. All external electrical equipment shallhave a minimum degree of protection of IP 54 in accordance with IEC 144.

b) A complete lighting system shall be provided for the crane, being powered froman alternator driven by the crane diesel engine. The following is required.

Swivel type floodlights on the boom, six in total, located as follows:

- two at boom tip,

- two at 70 ft from boom foot pins,

- two at 50 ft from boom foot pins.

Two red aircraft warning blinker lights as follows:

- one on the end of the jib extension,

- one on top of the A-frame structure.

Interior cab light,

Panel instrument lights.

The foregoing shall be controlled by individual switches in the cab.

3.8 Wylie Crane Load Moment Indicator System

The Vendor shall procure and be responsible for the fitting, calibration, etc. of a Wylie DLAutomatic Safe Load Indicator to the crane to monitor main and auxiliary loads and boomangle/radius. The console shall be mounted inside the operator's cab, conveniently located forease of reference. The warning system shall be set for 85% and 100% of rated load.

3.9 Marking Plates

Marking plates giving details of the crane capacity shall be clearly located inside the cab for easeof operator reference, a total of 2 plates being required as follows:

Plate 1 : Giving details of main and auxiliary hoist rope data.

Plate 2 : Providing a capacity chart for the crane as supplied to comply with this requisitions i.e.,lifting capacities versus radius for main and auxiliary hoists.

Plate 1 shall be kept as small as possible, with Plate 2 being larger and placed in a predominantposition near the operator.

Fixed and loose gear and accessories shall be marked with SWL and identification mark relatedto test certificates.

4.0 CORROSION PROTECTION

Vendor shall paint the crane in accordance with PTS 30.48.00.31-P Protective Coatings and Lining.

Color: B.S. 4800 Code 10.E 53 (Yellow)

Boom to be painted with yellow and black diagonal stripes approximately 3 metres wide.

5.0 INSPECTION AND TESTING

5.1. The responsibility for inspection and testing to ensure compliance with the applicablespecifications and codes rest solely with the Vendor. However, the Vendor shallengage the services of an independent inspection authority familiar with cranemanufacturing. This authority shall be responsible for preparing a fully documentedreport on the crane, including, but not limited to, confirmation of materialsspecifications, weld acceptability (ultrasonic, radiographic, magnetic particle, dyepenetrant, etc.), coating system dry film thicknesses, and witnessing runningequipment tests, load test, etc. The inspector shall also check and sign the following :

- welders test and/or certificates

- welding procedure qualification test and/or records

- welding procedure specifications

- NDT procedures and operators qualifications

- Compliance with fabrication specification and approved drawings

5.2 The Vendor shall fully assemble the crane (with all accessories) at his works. Thefollowing tests shall be performed prior to stripping down the crane for packaging andshipment:

Functional test with static load test. A detailed test programme and procedure shallbe submitted to Purchaser for approval well in advance of testing.

General verification that all operations are working correctly and that all protectiveequipment and devices are fully effective. For the boom stop and main and auxiliaryhoist travel stop devices, the testing shall be for the unloaded condition at maximumline speed.

5.3 The Purchaser reserves the right of access to the Vendor's works at any time for thepurpose of ensuring quality, workmanship and general compliance with thisspecification.

5.4 Vendor shall provide Purchaser's inspector at least 21 days notice to witness tests asspecified.

5.5 Vendor shall perform the necessary vibration and sound level tests to satisfy thePurchaser's inspector that they are within the specified limits.

5.6 Vendor shall prepare and submit a detailed site acceptance test programme toPurchaser for approval prior to shipment of the crane.

6.0 SPECIAL TOOLS

Vendor shall provide two set of tools required for erection and maintenance of one (1) deck crane.

7.0 SPARES

7.1 Vendor shall provide the necessary spare parts lists for the deck crane specifiedherein for ; commissioning and start-up, and the first year of operation. Equipmentmanufacturer's recommendations must be followed in the preparation ofrecommended spare parts list. This should take into account related factors ofequipment reliability, effect of equipment down time upon production or safety, cost ofparts and availability of equipment service facilities.

7.2 All spare parts furnished by Vendor shall be wrapped and packaged so that they willbe preserved in original as new condition under the normal conditions of storage tobe anticipated in Malaysia, and shall be properly tagged and coded so that lateridentification as to its intended equipment usage will be facilitated. They shall bepackaged separately and clearly marked as "Spare Parts" and shipped at the sametime as the equipment in accordance with the instructions from Purchaser. Packinglists shall be furnished so that the parts can be handled without uncrating if desired.

8.0 PACKAGING

Once the crane has satisfactorily passed all tests it shall be dismantled and packaged for shipment.

9.0 LUBRICANTS

All mechanical equipment for installation and use with this requisition is to be guaranteed by theVendor to operate satisfactorily and within their guarantees when lubricants of PETRONASmanufacture are used in the equipment. It is the Vendor's responsibility to state on the makersnameplate the specific types and grades of PETRONAS lubricants which are to be used in theoperation of the equipment and to ensure that only such lubricants are used when testing theequipment in his works.

10.0 VENDOR DATA REQUIREMENTS

Vendor shall furnish data for proposal, approval, and dossier in accordance with attached"Vendor Data Requirements."

11.0 ATTACHMENTS

Internal Combustion Engines (Sheets 1 and 2)

Vendor Data Requirements

ATTACHMENT 1 - DATA COMBUSTION ENGINES - SHEET 1

ATTACHMENT 1 - DATA COMBUSTION ENGINES - SHEET 2

ATTACHMENT 2 - VENDOR DATA REQUIREMENTS