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MAC-SU-7.

02
MONORAILS AND HOISTS

APPLICATION: TOPSIDES

This document is the confidential property of Chevron U.S.A. Inc. Neither


the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior
written consent of Chevron U.S.A. Inc.

Rev

Date

Description

Author

Sponsor

08/05

Initial Release

JROF

OTOO

07/10

Reaffirmation only. No technical content


changes made.

OTOO

OTOO

July 2010 (R)

20052010 Chevron U.S.A. Inc. All rights reserved.

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Monorails and Hoists

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

Fabrication Requirements .........................................................................................9


7.1 ......General .............................................................................................................9
7.2 ......Welding ..........................................................................................................10

8.0

Protective Coatings .................................................................................................10

9.0

Identification .............................................................................................................10

10.0

Preparation for Shipment ........................................................................................10

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Monorails and Hoists


1.0

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

Materials and Application of Painting and Protective Coatings

Industry Standards
American Gear Manufacturers Association (AGMA)
2001-D04

Fundamental Rating Factors and Calculation Methods for Involute Spur and
Helical Gear Teeth

908-B89

Geometry Factors for Determining the Pitting Resistance and Bending


Strength of Spur, Helical and Herringbone Gear Teeth (Information Sheet)

6010-F97

Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives

American Petroleum Institute (API)


RP 9B

Application, Care and Use of Wire Rope for Oil-field Service

American Society of Mechanical Engineers (ASME)


B30.10

HooksSafety Standard for Cableways, Cranes, Derricks, Hoists, Hooks,


Jacks, and Slings

B30.16

Overhead Hoists (Underhung) Safety Standard for Cableways, Cranes,


Derricks, Hoists, Hooks, Jacks, and Slings

HST-2M

Performance Standard for Hand Chain Manually Operated Chain Hoists

HST-4M

Performance Standard for Electric Wire Rope Hoists

American Society for Testing and Materials (ASTM)


A36

Structural Steel

A325

High-Strength Bolts for Structural Steel Joints

American Welding Society (AWS)


D14.1

Welding Industrial and Mill Cranes

National Fire Protection Association (NFPA)


70
3.0

National Electric Code (NEC)

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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4.0

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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5.2

MAC-SU-7.02

Hand Operated Trolleys


1. Trolley hand drive chain shall be aluminum alloy.
2. Hand operated trolley drives shall have maximum overall ratio of 5 feet (1.52 m) of chain pull
to 1 foot (0.3 m) of trolley travel.
3. Chain guide shall be supplied to keep chain aligned and free from fouling.
4. Unless specified otherwise, hand chain drop shall be to elevation 2 feet, 6 inches (0.76 m)
above normal operating level.

5.3

Air Powered Trolleys


1. Air powered trolleys shall be driven by vane-type air motor and pinion reduction drive.
2. Trolley travel speed shall be 40 to 100 feet (12.19 to 30.48 m) per minute.
3. Air powered trolleys shall have air powered brake that can stop bridge within 10% of distance
bridge would travel at full speed with full load in 1 minute.
4. Braking mechanism shall be adjustable to compensate for wear.

5.4

Electric Powered Trolleys


1. Electric powered trolleys shall be driven by squirrel cage, totally enclosed nonventilated
(TENV) electric motor/gear reduction assembly in accordance with data sheets.
2. Motors shall be mill and chemical duty rated for continuous service in accordance with
technical requirements.
3. Unless approved otherwise by Purchaser, motors shall be supplied from Purchaser-approved
manufacturer.
4. Electric powered trolleys shall have electric brake.
5. Trolley controls shall be included with hoist pendant controls.

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

Hand Chain Operated Chain Hoists


6.2.1

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

Gears and Pinions


1. Gears and pinions shall be designed in accordance with ASME HST-4M, regardless of
the fact that hoist is hand chain powered.
2. Gears and pinions shall be heavy pitch spur type.
3. Gears and pinions shall be machine cut from high strength alloy steel forgings that
have been heat treated for durability and long life.
4. Gearing shall be mounted on heavy duty roller bearings.
5. Gear and pinion shafts shall be surface hardened alloy steel, ground for concentricity
and fit.
6. Gear and shaft connections shall be spline fitted or keyed.

6.2.3

Load Chain Wheels


1. Load wheel shall be:
a. Heat treated, cast steel
b. Reversible for double life
c. Spline fitted to load shaft
2. Load wheel shall have:
a. Minimum of four chain pockets
b. Factory-installed overload device calibrated to capacity of hoist

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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6.3

MAC-SU-7.02

Powered Wire Rope Hoists


6.3.1

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

Air Powered Hoists


1. Air powered wire rope hoists shall comply with API B30.16 and ASME HST-4M,
regardless of fact that hoist is pneumatically powered.
2. Hoists shall be air powered, wire rope type with true vertical lift.
3. Hoists shall be designed to operate on utility air at normal operating pressure of
70 to 80 psig, with maximum operating pressure of 100 psig.
4. Air motor and gearing shall be designed to provide hoist load speed of 10 to 30 feet
(3.04 to 9.14 m) per minute at rated capacity.
5. Air motors shall be radial piston type with a minimum of four interchangeable
cylinders.
a. Air motors shall have a filter lubricator.
b. Muffler shall be provided to reduce air exhaust noise levels below the maximum
allowable specified in technical requirements.
6. Both hoist and trolley shall have rope/chain actuated throttle controls that hang to
elevation approximately 4 feet (1.21 m) above operating deck level.
a. Controls shall be direct acting and full flow type.
b. Amount of air delivered to motor shall be directly proportional to amount of pull
on handles.
7. Throttle controls shall return promptly to off (closed) position if released.
8. Hoists shall have an upper limit switch that shuts off air supply if load hook reaches
highest position. In addition, mechanical stop shall be provided.
9. Air powered hoists shall have load brakes. Brakes shall be capable of stopping and
holding load immediately upon loss or air supply under normal operating conditions
with rated capacity.
10. Air connection to hoist shall be swivel type.

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6.3.3

MAC-SU-7.02

Electric Powered Hoists


1. Electric powered wire rope hoists shall comply with API B30.16 and ASME HST-4M.
2. Electric hoists shall be driven by totally enclosed, non-ventilated (TENV), alternating
current (AC) electric motors specifically designed for H3 duty classification in
accordance with ASME HST-4M.
a. Motors shall have Class B insulation.
b. Motors shall have minimum rating of 30 minutes with 126F (52C) rise over
104F (40C) ambient temperature.
3. Motors shall be mill and chemical duty rated for continuous service in accordance
with technical requirements.
4. Unless approved otherwise by Purchaser, motors shall be supplied from
Purchaser-approved manufacturer.
5. Electric driven hoist motors shall have spring opposed, fail-safe brakes.
a. Brakes shall be either of the rectified direct current (DC) magnet actuated disc
type or AC disc type.
b. Torque rating of hoist brakes shall not be less than the full load torque rating of
hoist motor.
6. Brakes shall be interlocked with motor controls to brake and hold load upon
de-energizing of motor or power failure.
7. Hoist shall be operated by pendant-mounted, four-push-button control device.
a. Maximum voltage in pendant control device shall be 120 VAC.
b. Control devices shall be grounded to hoist.
8. Enclosures for control devices shall be NEMA Type 7.
9. Control cables shall be sheath type with either external or built-in strain reliever.

6.4

Load Blocks and Hooks


1. Load blocks and hooks shall be provided in accordance with API B30.10.
2. Load blocks shall be fully enclosed with machine grooved sheaves mounted on sealed,
anti-friction bearings.
3. Top and bottom load blocks shall include integral, forged steel hook mounted on anti-friction
swivel capable of 360 degree rotation. Hooks shall have self locking latches.
4. Load hooks shall be designed such that static stress for rated capacity shall not exceed 35% of
ultimate strength.
5. Load hook and hoist suspension hook shall be stainless steel, with bronze hook sleeves.

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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7.2

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

PREPARATION FOR SHIPMENT


1. Items to be individually shipped shall be uniquely numbered and tagged.
2. Numbers shall be referenced with item description on bill of lading.

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