Crane Safe Load Monitoring

APPLICATION: Crane safe load monitoring systems are a vital tool in crane safety. These systems detect the moment of lifting a load, which can be compared to the cranes maximum safe load limit. They typically use load measuring pins that replace existing load bearing pins in the crane header block to sense the load, although in instances where there is not a suitable load bearing pin to replace, below hook measuring solutions can be used.

The system increases operational efficiency and improves safety by providing a tool that alerts the crane operator to imminent excess lifting conditions that may cause harm to personnel and equipment. If the load being lifted exceeds the safe lifting load, either audible or visual alarms can be triggered, or, if part of a control system, that action will automatically stop the lift. Additionally, having a real-time display of the lifted load allows crane operators to lift the maximum allowable amount, improving productivity by reducing the number of lifts required to complete a task. 

LCM Systems have supplied hundreds of crane load monitoring systems for all types of cranes, and can supply both the load cell and a range of instrumentation and displays to provide a total solution.

Crane Weighing & Overload Protection

APPLICATION: LCM Systems supply crane weighing and overload systems that aid the operator by providing the total weight being lifted by the crane in real time, and therefore also preventing overload situations. We have been supplying these systems for over 35 years, and they have been installed in all types of hoists and cranes, including overhead travelling cranes, shipyard and port cranes, as well as marine and offshore cranes.

Load measuring pins that dimensionally replicate existing load bearing pins in the header block of the crane are used to provide a signal proportional to the measured load, meaning no modifications to the crane are required. The crane weighing and overload system can then be used to alert the crane operator of potential lifting hazards and assist them with safe load management. Pre-set audible and visual alarms can also be incorporated, as can triggers to shut down the crane if a lift weighing above the safe load limit is detected.

For demanding applications such as on oil rigs and FPSOs etc, we can supply equipment that is ATEX and IECEx certified and have both Explosion Proof (Ex d) and Intrinsically Safe (Ex i) approvals. We can also supply below hook solutions where a permanent installation is not required or the use of a load measuring pin not feasible.

Hydraulic Jacking Systems

APPLICATION: Due to lack of space or access, cranes are often not the best method of lifting heavy structures, and in these instances hydraulic jacking systems are often used instead. Typically they are used for the jacking of bridges and modules from construction height to final position. Hydraulic jacks are also the main method of lifting or moving permanent existing structures and buildings to overcome structural problems, undertake repairs or when they need to be relocated.

Monitoring and measuring are critical parts of many jacking projects, as during these operations it is essential that engineers know precisely when to apply or reduce jacking forces and that structures remain structurally safe and are not at risk of collapse. Hydraulic jack monitoring consequently plays a vital role in both short and long term projects to achieve maximum safety and minimum disruption.

LCM Systems have supplied many load cells to heavy lift companies, jacking specialists and private building contractors. By incorporating a load cell into the jacking procedure, real time load measurement data can be provided. This can be used to confirm that the correct jacking force is being applied and also to provide continuous load monitoring to ensure structural integrity is being maintained.

Material Test Machines

APPLICATION: Material testing machines are commonly used to test the tensile and compressive strength of a wide range of raw materials, components and finished goods to evaluate the physical properties of the material (particularly in relation to its strength and performance), by subjecting it to tension, compression, bending etc. 

These tests are required for a number of reasons, including for production testing, quality control, laboratory testing, research and education. The types of materials tested range from plastics, rubbers, electronic components, metals, packaging, adhesives and textiles.

The material testing machine incorporates a load cell to measure the compressive, tensile or bending force the material is being subjected to, and a wide series of tests are available for establishing tensile strength, shear strength, compressive strength, stiffness, puncture and burst resistance, to name but a few. Many of these are required to demonstrate compliance with international testing standards that have been put in place to ensure the material meets specific safety criteria.

LCM Systems designs and manufactures a range of load cells that are suitable for this application, some of which are available from our standard range, while others are custom designed to meet the criteria needed to fit a specific material test machine.

Mooring Line Load Monitoring (MLM)

APPLICATION: With the ever increasing size of oil and gas tankers and container vessels, mooring operations have become increasingly safety critical. If mooring lines are subject to uneven loading due to vessel drift, the mooring line is at risk of failing, which could result in injury to port personnel and significant damage to berth infrastructure.

The installation of a mooring line load monitoring system can reduce these risks by providing real time monitoring of the tension in each mooring line during loading and unloading operations. This facilitates safe and efficient securing of a vessel to its berth by alerting port operators and vessel masters to any instance of uneven loading, allowing remedial action to be taken. This ensures mooring remains secure and personnel protected.

For smaller vessels the use of a mooring line load monitoring systems may also be used to ensure that mooring line stays within its safe working load limit and the possibility of line failure resulting in vessel drift off eliminated.

The system monitors line tension via the installation of strain gauged load measuring pins into quick release mooring hooks or through the use of load shackles or load links attached to the mooring line and secured to mooring bollards, rings or cleats.

Mooring Tension Measurement

APPLICATION: Ports and terminals worldwide face the challenge of dealing with ever larger vessels and cruise ships. Also, due to climate change, more extreme weather conditions are having an impact on the levels of strain the mooring lines are subjected to. Strong wind, waves and currents mean that even when docked, ships are constantly in motion. This means the tension placed through mooring lines is changing all the time, contributing to material fatigue and reducing service life. Additionally, if one or several mooring lines experience higher tension levels than others, there is a real risk of the mooring line breaking, resulting in potential damage to the jetty and to personnel.

To ensure a vessel stays securely docked, the tension in each mooring rope must be subject to the same loading or tension, or as close to as possible. This can be achieved through the installation of a mooring tension measurement system, which continually monitors the loads on each mooring line, so that any instances of overload or underload can be identified immediately. Port operators can then alert vessel masters so that they can take prompt corrective action to evenly redistribute mooring line loads.

The mooring measurement systems that LCM Systems supply use either load measuring pins installed into quick release mooring hooks, or load shackles/load links that are installed into the mooring line structure and secured to existing port mooring facilities. The load measurement data provided is then usually fed into a PLC system, but a separate read out can be provided where appropriate (usually in smaller ports and harbours). This can also include alarms that are triggered in the event of overload situations.

Quick Release Hooks (QRH)

APPLICATION: Quick release mooring hooks form the foundation for most modern mooring systems. They enable mooring lines to be safely secured and quickly and easily released, even when loaded to their safe working limit. This improves both the safety and efficiency of mooring operations in demanding maritime settings such as oil, gas, coal, iron, chemical and grain terminals.

By installing a load measuring pin into the quick release hook, a constant measurement of the forces on the mooring lines can be provided, allowing immediate action to be taken in the event of a slack or overload situation. Load information is displayed in real time and alarms can be set up to trigger in the event of the safe working load being exceeded.

LCM Systems have supplied hundreds of load pins to quick release mooring hook OEMs and to end users to facilitate the retrofitting of a mooring load monitoring system or to simply replace damaged or older load pins. We can supply them with amplified outputs, external greaseways and with cable glands and cables that meet individual customers specifications. We have also designed and supplied many ATEX/IECEx options for use in hazardous areas.

Single Point Mooring Systems (SPM)

APPLICATION: A single point mooring (SPM) is a floating buoy anchored offshore that allows the handling of liquid cargo in areas where a dedicated onshore facility for loading and unloading cargo is not available. They serve as a link between shore-based facilities and large oil tankers for loading or offloading oil and gas cargo. 

The SPM buoy is moored to the seabed using a mooring arrangement that it permits the buoy to move freely within defined limits that take into consideration waves, current and wind conditions. The incorporation of a single point mooring monitoring system provides protection to the mooring by ensuring it is not overloaded. This allows for safe transfer of product and reduces the risk of accidents and expensive unscheduled down-time. This is particularly critical during product transfer operations due to the increased risk of spillage.

LCM Systems can manufacture load monitoring pins that are installed in the mooring bridle to provide real time load information to SPM operators that allows them to continuously monitor mooring loads and take action as soon as a potential overload system is identified. We can also supply subsea load shackles and load links for inline mooring load measurement. All are manufactured to the highest standards to ensure many years of trouble-free, reliable operation.

Tensile Test Machines

APPLICATION: Tensile test machines measure the uniaxial force applied to a sample in tension. This is required to determine its strength, and therefore identify whether a component, part or product is suitable for its intended use. Testing consists of monitoring how the test sample reacts when a static or dynamic force is applied to it and is one of the most fundamental and common types of mechanical testing.

By measuring the material while it is being pulled, it is possible to obtain a complete profile of its tensile properties. When plotted on a graph, this data results in a stress/strain curve which shows how the material reacted to the forces being applied. The point of break or failure is typically the main purpose of the testing, but other important properties that can be measured include elasticity, yield strength and the effect the exposure to strain has on the sample.

LCM Systems has supplied many load cells for use in tensile test machines and can supply either a load cell from our standard range or can design a load cell to suit an individual tensile test machine. In addition to the load cell, we can also provide instrumentation and displays to provide a complete load measurement solution.

Towing & Mooring Tension Load Monitoring

APPLICATION: Towing lines are one of the most used pieces of equipment in the marine industry. However, because they are subject to high tensile forces and significant friction during each use, as well as often sustaining damage whilst being used in rough seas in extreme weather conditions, they frequently need to be replaced. One way to maximise the longevity of the towing line is to use a towing tension monitoring system that constantly monitors cable tension throughout its service life to reduce overload instances and to ensure safe operation.

LCM Systems towing tension monitoring systems have been designed to give vessel masters a direct reading of tension in the towing hawser during towing operations. The system comprises of load cell or a load pin installed in the towing hook, mooring hook or winch and a digital readout. It can also include an alarm that is programmed to trigger when overload thresholds have been reached, which are set to suit the rope or wire being used.

We can also supply simple towing tension monitoring using a load shackle or load link installed directly in the towing line path. These are especially suitable for occasions where a permanent system is not required, and tension line monitoring only needed for a specific one-off assignment.