www.waterweightsinc.com

History

Established in 1979 - Water Weights was

the originator of the water-filled load bag,

used in proof load testing of cranes and

lifting equipment.

What are Water Weights?

Water Weights proof load test bags are

used for suspended or deck loads using

any number of bags for loads up to 1500

tons.

• empty bags weigh >2% of achievable load

• savings in transportation, labor, and downtime of

equipment under test

• minimum floor loading during staging of weights

• load measured accurately with certified load cell or flow

meter

• wide range of bags for all sorts of testing parameters

• different weight capacities achieved with single rigging

using manifold and valve systems.

Typical 100 ton test transport and labor savings

Performed with

conventional weights

requires 5 tractor trailer

Loads and 5 men on site

Performed with

Water Weights ™

Requires 1 pickup truck

with trailer

and 2 men on site

ISO 9001:2008

FS 96689

Water Weights bags are fully

certified and tested in accordance

with government requirements and

regulations.

How are they tested?

ISO 9001:2008

FS 96689

ISO 9001:2008

FS 96689

After every job….

After every job….

Environmental Responsibility

We fulfill this commitment by:

Lowering the carbon footprint when crane testing compared to traditional methods

Invasive species mitigation and prevention

Conducting operations in an environmentally sound manner

without disturbing local ecosystems during testing

Promoting environmental responsibility among our employees

Pursuing continuous improvement in our environmental performance

• Global supplier of monitoring /measurement solutions

• Load, force, torque and strain

• Asset management

Applications include:

•Above the hook (sheaves, drums. trolleys)

•Below the hook (links, shackles, canisters, beams)

•In the hook block (trunnion, sheave pin, hook)

•Rope dead end (A2B, wedge socket, clamp-on, line rider)

•Cabled or wireless telemetry

Standard Below-the-hook Product Range LE Series Wireless Load Link SL Series Wireless Load Shackles GL112 Wireless Handheld Load Indicator

www.waterweightsinc.com

NORTHWEST HYDROELECTRIC

ASSOCIATION

Technical Seminar

Hood River, Oregon

May 23 & 24, 2013

Maximising Remaining Useful

Life of Lifting Assets

Jim Bentley

Vice President, Imes Inc

My Glossary of Terms

• Design Life – Original life of asset based

on the as designed (specified)condition

(design code used, loads to be carried, for

how long and in what environment etc).

• Life Extension – Operation under the as

designed criteria for extended period.

• Change of use – Alteration to one or

more of the original design criteria (loads

to be carried, frequency of lift, environment

etc).

Change in Methodology

• Traditional approach based on prescriptive test and inspection.

This approach has in generally served us well but tends to manage assets on a day to day, week to week basis.

• Risk Based approach based on design condition, actual service loadings and degradation with sights set on required life of asset. This approach produces an “organic” maintenance plan based on results of each inspection/maintenance cycle.

Limitations of Prescriptive Testing

Overload Testing

Potentially More Harm

Than Good

Lack of Flexibility

Unable to Benefit From

Experience

IN SERVICE DATA

INSPECTION DATABASE

TESTING

DEFECT REPORTS

DATA MINING

& ANALYSIS TOOL

DESIGN DATA

MANUFACTURING DATA

STRUCTURAL ANALYSIS

LOAD TESTING

BASELINE NDE SAFETY CASE

STATISTICAL DATABASES

RISK RISK BASED

INSPECTION

SCHEDULE

Evaluation of Current Condition

Risk Based - Objectives

• Continued safe, cost effective operation and management of mechanical handling assets through programmed life.

– Compliance with relevant legislation and corporate requirements

– Risk based system to target inspection and mitigation measures

– Provide an auditable trail

– Traceability for all decisions made

– Manage information interfaces

– Effective control of costs and resources

– Reduce Life Cycle Cost

– Added value

Crane Condition Monitor (CCM)

Software Hook Height

Telemetry

Motor Temp.

Motor Current

Load

Cross Travel

Long Travel

Block Diagram

Future expansion...

Software

• Displays assets current status

• Allows viewing of all recorded historical data – Allows detailed analysis of the

assets usage

– Can be used for incident investigation

• Data can be viewed from any location on corporate network – Remote access possible using

VPN technology

Crane Example

• Installed Crane

– 1989 i.e current 24 years of service

– Design Life 25 years to CMAA 70

– Regular use intermittent operation 100K to

500K cycles

– Mean Effective Load Factor 0.671 to 0.85

• Customer desire to operate crane until

2040 as a hard target with stretched

targets of 2060 and 2080.

• At 2080 crane would be 90 years old.

Life Extension Approach

• Establish current condition

– Review design code and any legislation changes

– Visual inspection

– Instrumented load test (AE/Strain gauges etc)

– Review existing or develop Finite Element Model

– Apply current inspection conditions to model

– Review current inspection, test and maintenance

activity

• Complete risk assessment of design and

operational use past, present and future.

Life Extension Cont.

• Against identified risks map current

inspection, test and maintenance activity

to give level of mitigation

• Continue doing activity that underpins risk

mitigation

• Stop doing activity that does not

contribute

• Start doing activity that reduces risk to

acceptable level – ALARP/ALARA

Life Extension Cont.

• Collect usage data (fatigue) and apply to

design calculations.

• Establish where crane lies on “fatigue

clock”

• Use fatigue history to establish when in

future crane will exceed maximum mean

effective load factor – end of life date

• Use information to plan re-capitalization of

asset

Mean Effective Load Factor

Hook Load

(lbs)

Recorded lifts

during lifetime 24

years

(288 months)

Load/Rated

Capacity

W

W3

Est. lifts/total lifts, P

k3 = W3P

<1000 2493 0.1 0.001 0.4003 0.0004

<2000 540 0.2 0.008 0.0867 0.0007

<3000 1080 0.3 0.027 0.1734 0.0047

<4000 189 0.4 0.064 0.0303 0.0019

<5000 9 0.5 0.125 0.0014 0.0002

<6000 315 0.6 0.216 0.0506 0.0109

<7000 387 0.7 0.343 0.0621 0.0213

<8000 9 0.8 0.512 0.0014 0.0007

<9000 639 0.9 0.729 0.1026 0.0748

<10000 504 1.0 1.000 0.0809 0.0809

≥10000 63 1.25 1.953 0.0101 0.0197

Totals 6228 - - 1.0000 0.2225

Estimated value of k = 3√0.2225 = 0.6082

For a Service Class D (Heavy Service) crane, Load Class L3 and N2 load cycles k =

0.671 to 0.85 (ref. CMAA#70 Table 2.8-1)

Hence the crane usage to date is within the mean effective load derived from the

load spectrum

Projected Life

• For the crane the mean effective load

factor k = 0.85 max.

• Hence k3 = 0.6141 compared with 0.2225

at present.

• Hence, for the same load distribution the

crane life will be (0.6141/0.2225) x 24 =

66.24 years.

• If the installation date was at the beginning

of 1989, the max mean load factor will be

met in the year 2055.

And Finally……………. • In all you do just remember that when faced

by a strong challenge an appropriately strong

response is needed………