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EN 13000 Mobile Cranes, rated capacity limiter Situation May 2010

EN 13000 Mobile Cranes, rated capacity limiter Situation May 2010. By Hans-Dieter Willim. Content of the presentation. EN13000, 2010 amendment Concerns of SC&RA ESTA and FEM proposal for a compromise, accepted by SC&RA in Amsterdam. European Machinery Directive.

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EN 13000 Mobile Cranes, rated capacity limiter Situation May 2010

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  1. EN 13000 Mobile Cranes, rated capacity limiterSituation May 2010 By Hans-Dieter Willim FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  2. Content of the presentation • EN13000, 2010 amendment • Concerns of SC&RA • ESTA and FEM proposal for a compromise, accepted by SC&RA in Amsterdam FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  3. European Machinery Directive • The European Machinery Directive is a European law! • European standards give a guideline how to fulfill the requirements of the European Machinery Directive 2006/42/EC FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  4. EN 13000 Version 2011 2004 2010 New Revisionof EN 13000may be finished 2014 European acceptance procedure finished Amendment EN 13000: 2010 Rated Capacity Limiter Published in the Offical Journal of the European Union With Warning clause 4 ff. http://ec.europa.eu/enterprise/newapproach/standardization/harmstds/reflist/machines.html Harmonized Standard EN 13000:2004 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  5. Amendment of the EN 13000: 2010 „rated capacity limiter“ • There is an agreement between the European Manufacturers united in the FEM regarding the date of implementation in Europe: • First May 2010 Stage 65.31: Date of announcement is 2010-04-30 Stage 65.51 Date of publication is 2010-07-31 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  6. amendment of EN 13000:2010arrangement of bridging devices(comming into force may 2010) Display 1 Set up button (no key required) Driver´s seat Switching cabinet FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  7. Set Up Button No.1EN 13000chapter4.2.6.3.3 Two different functions: • rigging and derigging of the crane • escape out of special operating conditions such as dead lock of the rated capacity limiter The rated capacity limiter automatically changes the function of the set up button No. 1: If a capacity chart cannot be found: rigging and derigging mode If a capacity chart can be found: operating mode FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  8. Set Up Button No.1 EN 13000 chapter 4.2.6.3.3 Functions if activated: • If a capacity chart cannot be found by the rated capacity limiter (rigging/derigging mode): All movements free and no limitations. Therefore all movements to erect the crane can be done with full speed without limitations • If a capacity chart can be found by the rated capacity limiter (operation mode): Shut off limits of the rated capacity limiter are increased to 110% (for example to escape out of dead lock situations). All speeds are reduced to 15% (25% at hydraulically controlled cranes) to reduce the dynamic forces • Acoustic and optical warning inside and outside the operator´s cab if the set up button No. 1 is activated; cannot be switched off FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  9. Set Up Button No.1EN 13000chapter4.2.6.3.3 Self hold function active if: • Control lever is in neutral position and • Load is less than 110% of the capacity chart or • No capacity chart can be found by the rated capacity limiter (rigging/derigging mode) Self hold function deleted if: • control lever is longer than 10 s in neutral position or • load >110% of the capacity chart or • engine stop or • sensor defect or • repeated activation of the set up button FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  10. Capacity chart available? Yes No Operation dead lock situation boom swinging, capacity close to 100 % Rigging/derigging • Set up button activated: • speed reduced to max. 15% • max. capacity 110% • data recorder activated • automatical reset of the set up botton • if the control lever is in neutral • position, or the engine stops • Set up button activated: • all limit switches bridged • rated capacity limiter bridged FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  11. Example Area with speed reduced to 15% Max. capacity with Set up button : 110 % capacity 1 Rigging, derigging, no capacity chart available 100% capacity Working area, capacity chart available Max. radius Radius Min. radius FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  12. amendment of EN 13000: 2010arrangement of bridging devices override key for “derricking in a suspended load“ - already in place since many years Display 1 Set up button (no key required) Driver´s seat 2 EN 13000 chapter 4.2.6.3.2 Switching cabinet FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  13. Override key No. 2: „for derricking in a suspended load“already in place since many years EN 13000 chapter 4.2.6.3.3 Functions if activated: • This override key is used to boom up in overload condition to reduce the loading of the crane under 100 % of the rated capacity • No speed reductions FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  14. amendment of EN 13000: 2010arrangement of bridging devices override key for “derricking in a suspended load“ - already in place since many years Display 1 Set up button (no key required) Driver´s seat Bridging device Outside the cab and lockable 2 Switching cabinet EN 13000 chapter 4.2.6.3.3 3 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  15. Bridging device No. 3 outside the operator´s cab Functions: • All movements free and not limited • Max. speed reduced to 15% (25% at hydraulically controlled cranes) • Acoustic and optical warning inside and outside the operator´s cab if the rated capacity limiter is bridged, cannot be switched off Self hold function active if: • Master switch is in neutral position Self hold function deleted if: • Latest after 30 minutes after the control lever is in neutral position • engine stop FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  16. location of bridging device No. 3 During the Health & Safety meeting in Manchester, 16th October, the positioning of the override key was discussed as well: A position outside of the cabin (key in a locked cabinet or as keyswitch) was seen as appropriate. Most European manufacturers will locate it at the rear of the crane operator`s cab on the outside. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  17. amendment of EN 13000: 2010arrangement of bridging devices(comming into force may 2010) override key for “derricking in a suspended load“ - already in place since many years Display 1 Set up button (no key required) Driver´s seat Bridging device Outside the cab and lockable 2 Switching cabinet Data logger 3 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  18. Datalogger EN 13000 chapter 4.2.6.3.3 • data is recorded automatically, independant of the crane operator • Each actuation of the set-up button or the bridging device, which leads to an overloading of the crane(>100% of the set load chart), is recorded. The size of the overloading is recorded • If the set-up button or the bridging device is activated all date which is relevant to reconstruct the last load case is recorded • The data can be read out by an interface • Manipulation of the data in the recorder is not possible • The data recorder is automatically checked each time the crane is put in operation. Data recorder malfunction is indicated to the crane operator FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  19. Datalogger Recorded data at least: • time, date • Selected configuration (boom configuration, ballast, outrigger extension, reeving, hook block) • Actual load • Percentage of loading • Radius • Main boom angle, luffing jib angle • Total length of tele boom, length of each tele section • All bridging devices FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  20. Datalogger Read out of the data logger via a manufacturer specific interface Analyse or convert the latest data set and statistic via a software driver and a software filter, delivered by the manufacturer, to an Excel readable format The read out can be done by the owner of the crane. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  21. Datalogger The read out displays the last actual load case with the defined data. The relevant data is fixed at the time the crane was maximum loaded Furthermore statistic data will be evaluated, The time frame for the collection of the statistic is defined by the manufacturer. The number of load cases exceeding 100% of the rated capacity chart are stored in 10 % steps FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  22. Datalogger Proposal of the read out as an Excel chart FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  23. Datalogger Proposal of an event logger *exampel Event logger Increases by 1 if there is a relevant loading FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  24. Data of the data logger All data logged by the data logger belong to the owner of the crane! In case of an accident authorities may ask for the data. Data for accident research can only be interpreted by the manufacturer! FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  25. amendment of EN 13000: 2010arrangement of bridging devices(comming into force 1.5.2010) • override key • derricking in a suspended load to reduce the loading of the crane under 100% • - already in place since many years • Set up button • rigging/derigging • special operating conditions Display 1 • Bridging device • Outside the cab and lockable • Use in case of a failure of components • Use in emergency situations Driver´s seat 2 Switching cabinet Data logger 3 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  26. Content of the presentation • FprEN13000, 2009 amendment • Concerns of SC&RA • ESTA and FEM proposal for a compromise, accepted by SC&RA in Amsterdam FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  27. Extract from theletter by SC&RA • “SC&RA adamantly opposes the amendments to the standard due to potential safety consequences that could result in serious accidents and/or loss of life. It is the opinion of SC&RA and its members that these are critical safety issues which will have an immediate impact on the industry.” • “Eliminating the standard override key would not result in safer crane operations but could, in fact, result in serious consequences. The override key is provided, among other function, to assist operators and provide them with an efficient and timely way to avoid and/or correct a dangerous situation” FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  28. World Meeting of Crane ExpertsEhingen 2008, November- Conclusions • FEM and ESTA try to find a mutual compromise between the requirements of SC&RA and the European Health and Safety Officials • If a compromise can be found, it could be worked in the next revision of EN 13000, coming into force earliest 2014! • In any case cranes put now on the European market must fulfil the amendment of EN 13000: 2010. This is also valid for used cranes! FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  29. Main concerns of the attendees of the International crane summit • Shell: does not allow the operator to walk out of the cabin if load is suspended • ESTA/SC&RA/CICA: In an emergency situation the bridging device outside of the cab cannot be used immediately • SC&RA: Cranes have to be fully functional even if the rated capacity limiter fails. This device is only an operational aid according to US standards. • ESTA/SC&RA/CICA: The speed reduction in emergency situations restricts the crane operator to act quickly. This can be extremely dangerous FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  30. Content of the presentation • FprEN13000, 2009 amendment • Concerns of SC&RA • ESTA and FEM proposal for a compromise, accepted by SC&RA/CICA in Amsterdam but not yet by the European Health&Safety! FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  31. First proposal of FEM/ESTA for the next revision of EN 13000 Additional function of set up button No.1: • If a safety related sensor failes and this is detected automatically by the crane´s control system, the set up button No. 1 allows the bridging with 50 % speed reduction • In case of a defective sensor the crane can work with reduced speed (50%) in countries where work without rated capacity limiter is legally allowed. In Europe it must be stated in the operator´s manual that the rated capacity limiter must be repaired before work is continued. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  32. Second Proposal of FEM/ESTA for the next revision of EN 13000 To mitigate a sudden danger : Emergency operation without any restrictions must be immediately possible • all movements must be directly possible with full speed. Therefore the bridging device must be in the operator´s cab in direct reach of the operator FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  33. Second proposal for a future revision of EN 13000 Proposal: Bridging device No. 3 is transferred to an emergency push button located in direct reach of the crane operator • Self hold function • No key • All movements possible with full speed • Single use only to avoid misuse • Bridging deleted if: loading of the crane is less than 50% of the max. load or at engine stopto avoid misuse • If the emergency bridging device has been used once, it must be difficult to reset it to avoid misuse FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  34. Proposal for a future revision of EN 13000 arrangement of bridging devices (example) • Set up button • rigging, no load chart available, speed 100% • escape out of dead lock situations, speed 15% • bridging if sensor fails, all speeds 50% override key for “derricking in a suspended load“ - already in place since many years Display 1 Driver´s seat 2 Data logger 3 Emergency Bridging device Inside the cab Switching cabinet New FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  35. Proposal for the reset procedure of the emergency bridging device No. 3 After initial use of the emergency bridging device No. 3 the disabling of this device must be displayed to the crane driver Operation of the crane with disabled emergency bridging device is not allowed( operator´s manual!!). This forces the operator to start the procedure for enabling the emergency bridging device The reset procedure must avoid the misuse of the emergency bridging device If the emergency bridging device is activated, the operator is responsible to choose adequate speeds (operator´s manual) FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  36. Advantages of the ESTA/FEM proposal for a future revision of EN 13000 • With this solution the disadvantages of the bridging device outside the cab are avoided • This solution will also meet the international requirements (e.g. ESTA/SC&RA/CICA and Shell) • The actions to be taken to minimize dangers in case of an emergency depend on the actual situation and cannot be foreseen! This is prooven by risk analysis and experience. • In case of an emergency immediate activation of the emergency bridging device can avoid accidents and/or reduce damage. • To avoid misuse, only a single activation is possible FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  37. Proposal to reset the emergency bridging device: Reset of the emergency bridging device via a key switch at the outside of the cab. The key of the switch must be kept seperately from the crane. This is in the responsibility of the crane owner/user. (Remark: To erect the crane the „old key switch“ was required, so the crane owner could not take it out of the crane) Each usage of the emergency bridging device and it´s reset is logged with all data. In the operator´s manual must be listed: • The crane owner or/and user is responsible to check the crane in all relevant parts when the crane was overloaded. A crane expert may be required. • The crane owner/user is responsible that the key of the switch is kept seperately from the crane. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  38. Proposal for a future revision of EN 13000 arrangement of bridging devices (example) • Set up button • rigging, no load chart available, speed 100% • escape out of dead lock situations, speed 15% • bridging if sensor fails, speed 50% override key for “derricking in a suspended load“ - already in place since many years Display 1 Driver´s seat 2 Data logger 3 Emergency Bridging device Inside the cab Reset switch outside the cabin Switching cabinet 4 New New FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  39. Cranes and Transport Dec. 2009 FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  40. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  41. The user associations SC&RA and ESTA as well as the manufacturers have agreed to the proposals FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  42. Result of the WGP 11 meeting in Frankfurt 26th January 2010 • The health&safety officials of England, France and Germany have not agreed yet to the proposal • They first want to get experience with the solution comming into force 1st may 2010 • The experiences shall be collected by a questionnaire send out by ESTA (This can be done earliest end of 2010!!) • During one of the next meetings this point shall be discussed again FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  43. Next steps • In case the FEM/ESTA/SC&RA proposal will be accepted by the WGP 11 we have to open another discussion with the SC&RA : • Even if the proposal will be accepted and listed in the next revision of EN 13000 the cranes cannot be delivered worldwide with the CE sticker if they are programmed with 85% charts. • A crane which can be delivered and traded worldwide can only be programmed with the 75% charts FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  44. Next steps • The opinions are differing not too much: • 75% charts plus 10% to come out of dead lock situations are approx. the same as the 85% charts. Problem: • SC&RA wants to offer the „75% plus 10%“ charts to their customers in a printed version. This is not covered by the EN 13000 and the machine directive FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  45. Next steps • ESTA and FEM must continue the discussion with both parties: • The SC&RA and the European health & safety people FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  46. Thank you FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  47. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

  48. FEDERATION EUROPEENNE DE LA MANUTENTIONPG Cranes and Lifting Equipment

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