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02
MONORAILS AND HOISTS
APPLICATION: TOPSIDES
Rev
Date
Description
Author
Sponsor
08/05
Initial Release
JROF
OTOO
07/10
OTOO
OTOO
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MAC-SU-7.02
CONTENTS
1.0
Scope ..........................................................................................................................3
2.0
References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Standards ...........................................................................................3
3.0
General ........................................................................................................................3
4.0
Monorail ......................................................................................................................5
5.0
Trolleys .......................................................................................................................5
5.1 ......General .............................................................................................................5
5.2 ......Hand Operated Trolleys ...................................................................................6
5.3 ......Air Powered Trolleys ........................................................................................6
5.4 ......Electric Powered Trolleys .................................................................................6
6.0
Hoists ..........................................................................................................................6
6.1 ......General .............................................................................................................6
6.2 ......Hand Chain Operated Chain Hoists .................................................................6
6.3 ......Powered Wire Rope Hoists ..............................................................................8
6.4 ......Load Blocks and Hooks ....................................................................................9
7.0
8.0
9.0
Identification .............................................................................................................10
10.0
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MAC-SU-7.02
SCOPE
This specification defines minimum technical requirements for design, materials, fabrication,
testing and inspection, and documentation of monorails and hoists for offshore platforms.
2.0
REFERENCES
2.1
Purchaser Documents
COM-SU-2.02
2.2
Industry Standards
American Gear Manufacturers Association (AGMA)
2001-D04
Fundamental Rating Factors and Calculation Methods for Involute Spur and
Helical Gear Teeth
908-B89
6010-F97
B30.16
HST-2M
HST-4M
Structural Steel
A325
GENERAL
1. Monorail hoists shall be underhung, trolley mounted, low headroom (army) type hoists
designed for material movement and routine maintenance services.
2. Hoisting equipment shall be suitable for 20-year life under specified operating conditions.
3. Hoisting equipment shall be suitable for installation and operation in a humid, salt laden,
offshore marine environment.
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MAC-SU-7.02
4. Monorail hoists shall be completely self contained units ready for field installation and
operation.
5. Performance of hoisting equipment shall be guaranteed for rated operating conditions
specified in data sheets and technical requirements. Negative tolerance shall not be permitted
for capacity on hoisting equipment.
6. Hoisting equipment and components shall be nonsparking and certified for use in
NEC Class I, Group D, Division 2, classified areas as a minimum.
7. Trolley travel and load hoisting shall be either manual (hand chain) or powered (air or electric)
in accordance with data sheets and technical requirements.
8. Trolley travel may be nonpowered (freewheeling) with written approval of Purchaser.
9. Monorail hoists shall be fabricated in accordance with ASME HST-4M (H3 duty
classifications) and API B30.16.
10. Load bearing parts of monorail hoists shall be designed such that static stress, calculated for
rated capacity, shall not exceed 20% of average ultimate material strength, i.e., safety factor
of 5 as a minimum.
11. Supporting structure for hoist assemblies shall be designed such that static stress, calculated
for maximum capacity of hoist assembly, shall include safety factor of 2 as a minimum.
12. Control devices and systems shall be designed for fail safe operation.
13. Hand operated pendant controls shall include a push-type emergency stop button.
14. Wire rope shall be:
a. Improved plow steel.
b. Independent wire rope core (IWRC).
c. Sized using minimum safety factor of 5 based on rated line pull.
15. Anti-friction bearings shall be sized for B-10 bearing life of 5000 hours minimum based on
full rated speed and vacuum degassed steel rating.
16. Bearings requiring lubrication shall have grease fittings located to facilitate ease of inspection
and service.
17. Bolting shall be carbon steel (in accordance with ASTM A325) and coated with Type II
Class 8 chromated cadmium plating.
18. Unless specified otherwise, structural steel shall comply with ASTM A36.
19. Rigid guards shall be provided to within 1/2-inch of stationary housings adjacent to moving
parts that are potential hazards to personnel.
20. Belt drives shall not be acceptable without prior written approval from Purchaser.
21. Anti-friction bearings shall be used throughout trolley, hoist, and load hook.
22. Bearing points shall have easily accessible lubrication fittings.
23. Gearing shall comply with:
a. AGMA 2001-D04
b. AGMA 6010-F97
c. AGMA 908-B89
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MAC-SU-7.02
MONORAIL
1. Rails shall be sized and selected with capacity that exceeds maximum allowable load
capability of hoist plus weight of trolley, trolley drive, trolley chain, and manufacturer
assembly safety factor.
2. Rail sections shall be designed according to unsupported span requirements as determined
from structural steel support members and based on maximum weight of beam, trolley
assembly weight, and maximum allowable load capability.
3. Rail shall have load bar stops at open ends of rails.
4. Monorail assembly hardware, nuts, bolts, screws, washers, fasteners etc., shall be stainless
steel.
5. Glide switches, if provided, shall be pendant chain operated.
6. Glide switch pendant chains shall be:
a. Fabricated with weld link construction.
b. Stainless steel.
c. Provided with hand ring on free end.
d. Provided with split ring attachment on equipment end.
7. Glide switches shall automatically lock into position and have adjustable stops.
8. Curves, if provided, shall be bolted to joining straight rails with fishplate reinforcements on
both sides of rails.
5.0
TROLLEYS
5.1
General
1. Trolley capacity shall exceed maximum hoist lifting capability plus weight of hoist, hoist and
trolley drive chains, and manufacturer safety factor.
2. Trolleys shall be corrosion resistant.
3. Spacer washers shall be provided to permit trolley wheel adjustment to beam sizing.
4. Trolleys shall have a minimum of four heavy-duty single-flanged nonsparking wheels sized in
accordance with ASME HST-4M, regardless of whether trolley is electric, air, or manually
powered.
a. Each wheel shall have two tapered roller bearings.
b. Wheels shall be adjustable to compensate for bearing wear.
5. Trolleys shall have a minimum of two drive wheels, with gear teeth machine cut into flanges
and driven by steel drive pinion.
6. Trolley wheels and drive gears shall be protected by heavy gauge, rolled steel side plates.
7. Trolleys shall have antitilt rollers to eliminate tilting of trolley on beam if operating unloaded
or with light loads.
8. Trolleys shall have rubber bumpers.
9. If monorail track contains curves or glide switches, trolley shall be articulated design.
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MAC-SU-7.02
5.3
5.4
6.0
HOISTS
6.1
General
1. Monorail hoists shall have load brakes to securely hold load at any level.
2. Brakes shall be ratchet and pawl, positive action, self-adjusting Weston-type.
3. Monorail hoist gear cases shall be cast aluminum alloy, sealed construction.
4. Gear cases shall provide for lifetime lubrication of gears and load brake.
5. Bearings shall be either splash or sealed, lifetime lubricated.
6.2
General
1. Hand chain operated chain hoists shall be either trolley type or hook type.
2. Hand chain hoists shall comply with this specification and ASME HST-2M.
3. Chain hoists shall have maximum overall ratio of 10 feet (3.04 m) of hand chain pull
to 1 foot (0.31 m) of load lift.
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MAC-SU-7.02
4. Hand chain guide shall be supplied to eliminate fouling and permit angular pull on
hand chain.
5. Unless specified otherwise, hand chain drop shall be to elevation 2 feet, 6 inches
(0.76 m) above normal operating level.
6. Hoists shall have automatic load brake that shall:
a. Hold load in all positions under all conditions.
b. Permit smooth control during lowering of hook with and without load.
6.2.2
6.2.3
6.2.4
Chains
1. Load chain shall be nonsparking/corrosion resistant type.
2. Links shall be formed accurately to fit pockets of load wheel.
3. Load chain shall be long enough to allow lowering hook to deck.
4. Load chain guide shall completely shroud the load sheave and shield the load wheel
from entry of foreign objects.
5. Hoists shall have chain bucket for storing load chain.
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MAC-SU-7.02
General
1. Wire rope shall be sized such that maximum load does not exceed 20% of published
breaking strength of rope, i.e., safety factor of 5 as a minimum. Maximum load shall
not be less than the sum of hoist rated capacity, wire rope, and weight of bottom
block/hook, divided by the number of lines (parts) of rope.
2. Hoist drum shall be constructed of steel with deep machined grooves.
3. Drum pitch diameter shall not be less than 18 times the diameter of wire rope.
4. Drum capacity shall be capable of accommodating all of hoisting rope without
overwrapping.
5. At least two full wraps of rope shall remain on drum with load hook at extreme low
point of design lift.
6. Hoist drum shafts shall be supported by heavy duty bearings, either splash or sealed,
lifetime lubricated.
6.3.2
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MAC-SU-7.02
6.4
7.0
FABRICATION REQUIREMENTS
7.1
General
1. Shearing, flame cutting, and chipping shall be done by mechanically guided tools if possible.
2. Laminations or split ends in plate, pipe, or rolled shape shall be cause for rejection of entire
member. Defective member shall be removed and shall not be used.
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MAC-SU-7.02
Welding
1. Welding procedure specifications and qualifications shall comply with AWS D14.1, with the
exception that tolerances for deviation from specified camber and sweep shall be manufacturer
standard rather than tolerances prescribed by AWS D14.1.
2. Weld procedure specifications, weld qualification records, and welder qualifications shall be
subject to Purchaser approval prior to start of fabrication.
3. Welds shall be seal welds as a minimum to prevent corrosion. Areas that cannot be seal welded
shall be boxed in with plate and seal welded.
8.0
PROTECTIVE COATINGS
1. Coating work shall be performed after completion of fabrication and testing.
2. Surface preparation, abrasive blasting, coatings, touch-up and repairs, inspection, testing, and
documentation records shall comply with COM-SU-2.02.
3. Hoisting cable and wire rope shall be coated and protected in accordance with API RP 9B.
9.0
IDENTIFICATION
1. Stainless steel nameplate containing the following information as a minimum shall be
supplied:
a. Name of manufacturer
b. Date of manufacture
c. Manufacturer serial number
d. Purchase order number
e. Item tag number
f.
Load capacity
2. Nameplate shall be permanently mounted on hoist in accessible location using stainless steel
pins.
3. Maximum capacity for lifting equipment shall be clearly marked on each side of equipment in
large letters and shall be clearly visible and legible from floor level.
4. Markings shall be either painted on hoisting equipment or on sign permanently affixed to
equipment with stainless steel screws.
5. Attachment with adhesives shall not be acceptable.
10.0
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