Hiab DT

DanTysk
DanTysk Sandbank Offshore Wind GmbH & Co. KG
Method Statement
Annual Service & Maintenance of HIAB service crane
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Sap doc number: 1005343699
Confidentiality: C2 - Internal
Table of Content
1 Revision history ............................................................................................................................... 2
Approval .................................................................................................................................... 2
Changes ..................................................................................................................................... 2
2 General ........................................................................................................................................... 5
Abbreviations ............................................................................................................................ 5
Introduction ............................................................................................................................... 6
Purpose of document .................................................................................................................. 7
References ................................................................................................................................. 7
3 Roles and Responsibilities ................................................................................................................ 8
4 Requirements.................................................................................................................................. 8
Related documents ..................................................................................................................... 8
Specific HSE requirements ........................................................................................................... 8
4.2.1 PPE ....................................................................................................................................... 8
4.2.2 Awareness ............................................................................................................................ 9
Specific technical requirements ................................................................................................. 10
Tools ........................................................................................................................................ 10
Materials .................................................................................................................................. 10
Recommended team size........................................................................................................... 11
Estimated duration ................................................................................................................... 11
5 Work instruction ........................................................................................................................... 12

Checking the labels ................................................................................................................... 12
Slewing house, oil level check .................................................................................................... 15
Steel structure and other mechanical items ................................................................................ 16
Hoist wire rope inspection ......................................................................................................... 19
Hoist, rope end switch inspection (3 windings left) ...................................................................... 21
Hoist, rope layer switch inspection ............................................................................................. 22
Hoist gear oil level check ........................................................................................................... 23
Hooks and hook weight inspection ............................................................................................. 24
Rope damper (rubber) inspection............................................................................................... 25
Top roller inspection ................................................................................................................. 26
Hydraulic system inspection ...................................................................................................... 27
Electronic system inspection. ..................................................................................................... 28
Top roller removal and installation before load test ..................................................................... 30
5.13.1 Removal of top roller ........................................................................................................... 30
5.13.2 Installation of top roller ........................................................................................................ 31
Boom hook removal and installation .......................................................................................... 33
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5.14.1 Removal of boom hook ........................................................................................................ 33
5.14.2 Installation of boom hook..................................................................................................... 34
Annual test (load cell test) ........................................................................................................ 34
5.15.1 90 % pre-warning, 100 % load and 110% load test .................................................................. 36
Functional test with load attachment ......................................................................................... 41
Surface treatment inspection ..................................................................................................... 43
Lightning protection system inspection ...................................................................................... 44
Lubrication ............................................................................................................................... 45
Specification of consumables ..................................................................................................... 46
Torque values ........................................................................................................................... 47
Slewing oil, top up..................................................................................................................... 47
Hoist, rope end switch adjustment ............................................................................................. 48
Hoist, rope layer switch adjustment ........................................................................................... 50
Hoist gear, top up or exchange oil .............................................................................................. 51
Hoist, wire rope removal and installation .................................................................................... 52
5.26.1 Wire rope removal ............................................................................................................... 52
5.26.2 Wire rope installation........................................................................................................... 53
Return to normal operation ....................................................................................................... 53
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2 GENERAL
Abbreviations
Table 1: List of abbreviations
Abbreviation Definition
AT Authorized Technician
AWP Approved Written Procedure
CT Competent Technician
CTV Crew Transfer Vessel
DOC Documentation
DT DanTysk Offshore Windfarm
DTSB DanTysk, Sandbank
ERP Emergency Response Plan
HSE Health Safety Environment
LMRA Last minute Risk Assessment
MCC Marine Coordination Centre
MS Method Statement
PPE Personal Protective Equipment
RA Risk Assessment
RAMS Risk Assessment & Method Statement
REF References
SL Service Lead
SOV Service Operation Vessel
VF Vattenfall
WTG Wind Turbine Generator
WTSR Wind Turbine Safety Rules
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Introduction
The DanTysk Offshore Windfarm is located 70 kilometers west of the North Sea Island of Sylt in the
Exclusive Economic Zone of the Federal Republic of Germany. The 80 wind energy generators with a
nominal output of 3,6 MW each (total capacity of 288 MW) are in waters with a depth of 21 to 31 meters.
Figure 1: DanTysk offshore wind farm in the German North Sea
This document is a description on how to perform the annual service on the HIAB service crane. The
HIAB service crane is located in the nacelle of the wind turbine. See (figure 2) for an overview of the
nacelle and the location of the HIAB service crane. The HIAB service crane is marked with a red square.
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Figure 2: HIAB service crane location in nacelle
Purpose of document
The purpose of this method statement document is to describe the work steps that must be carried out
when performing an annual service on the HIAB service crane. This document will refer to the related
documents for approved written procedures and risk assessments to be used when performing the
annual service on the HIAB service crane.
References
Ref.Nr. Name: Doc name. Sap Doc.
Number.
General Method Statement

1 GENERAL Method Statement DanTysk 1005343743
DanTysk
2 Emergency Response Plan NMSHOW – 1333506825-6660
DTSB Incidents, accident, DTSB Incidents, accidents, and

3
reporting reporting
4 Lifting and Hoisting NMSHOW-1972685076-9943
5 HSE training Matrix NMSHOW-1333506825-2154d90
6 Wind Turbine Safety Rules Wind-Turbine-Safety-Rules-4th-Edition
DTDT Manual Handling

7 DTDT – Manual handling
Procedure
Arbeitsschutzgesetz (ArbSchG) Arbeitsschutzgesetz (ArbSchG)

8
(Operational Safety Law) (Operational Safety Law)
DGUV Vorschriften Deutsche

Gesetzliche https://www.dguv.de/medien/inhalt/praev
9 Unfallversicherungsträger (DGUV ention/vorschriften_regeln/vorschrift_1_
regulations German statutory en.pdf
accident insurance institutions)
Operational Control Procedure

10 NMSHOW-1333506825-1287
Personal Protective Equipment
11 Approved Written Procedure Use applicable AWP (determined by AT)
12 Risk Assessment RA_DT_Service HIAB 1005343698
13 HIAB maintenance manual Maintenance Manual v1.9 HIAB DT EN
Siemens maintenance work ZWI1032919_EN-US_HIAB-SWP2-

14
instructions crane
20210318_11464_SN_VF_Inspection_
15 Solidnord maintenance manual
MS_HIAB_Crane_rev02
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DT_WTG_0261-OM_-_DT WTG 4786
16 HIAB operators manual OM Operator_s Manual EN HIAB
SWP2
3 ROLES AND RESPONSIBILITIES

For the annual service on the HIAB service crane, the authorised technician will be team lead. The
team lead is the person to contact offshore. He is also responsible to ensure sufficient communication
with VF DT service lead and other involved stakeholders e.g., MCC and surveillance centre. There is
minimum one team member who needs to be authorized technician (AT) according to the wind turbine
safety rules (WTSR) (ref. 6). The AT is responsible for all electrical work and other isolation procedures
on the turbines at DT.
4 REQUIREMENTS
Related documents
Before the technicians can perform the annual service on the HIAB service crane, the following
documents must be followed, read and understood:
 General RAMS for DT - (Ref. 1)

 Emergency response plan - (Ref. 2)
 Wind Turbine Safety Rules – (Ref. 6)
 Approved Written Procedure (Ref. 11)
 Risk Assessment (Ref. 12)
Specific HSE requirements
4.2.1 PPE
PPE must be worn or used when the technicians perform the annual service of the HIAB service crane.
The required PPE must fulfill the VF requirements as stated in the Operational Control Procedure –
Personal Protection Equipment, (Ref. 10).
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4.2.2 Awareness
Prior to commencing the annual service for the HIAB service crane the risk assessment must be fully
read and understood (Ref. 12). Electrical works has to be done according the "five safety rules":
1. Disconnect completely
Meaning that the electrical installation must be disconnected from live parts on all poles.
2. Secure against re-connection
Reliably prevent an accidental re-connection of an installation where work is in progress. This
is achieved by just replacing the unscrewed fuses in the low-voltage system by lockable lock-
out devices.
3. Verify that the installation is dead
Is the installation in fact dead now? Use a suitable measuring / test equipment such as a voltage
detector to verify on all poles that the installation is dead. Check the correct function of the
voltage detector prior to using it.
4. Carry out earthing and short-circuiting
If the installation is dead, connect the cables and the earthing system with short-circuit-proof
earthing and short-circuiting devices. Important: The relevant parts must be earthed before they
are short-circuited!
5. Provide protection against adjacent live parts
According to the five safety rules, adjacent parts are parts located in the vicinity zone. If parts
of an electrical installation in the vicinity zone of the work location cannot be disconnected,
additional precautions must be taken before work starts. In this case use insulating protective
shutters or covering material as protection against accidental contact.
The technicians should also make a Last-Minute Risk Assessment (LMRA) on the SOV or at site before
the job can be started. Check the document (Ref. 12) for the full list, some of the risks are mentioned
below:
 Crushing Hazard
 Working with electricity
 Load testing
If an incident, accident, or a near miss occur during the work this must be reported immediately, and it
is everyone’s responsibility to report this event in the Intelex system but also follow the description in
(Ref. 3).
Inform the MCC about the event of a (accident, incident or near miss) use the tetra radio for this use
the (red button to make the call).
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Specific technical requirements
Only competent and trained technicians may perform the annual service on the HIAB service crane,
and they must have the correct training and courses.
 OEM / HIAB Service Training

 Authorized Technician
 Slinger/banksman
 Crane operator
 Electrical IP/EUP or SP/EFK for electrical works
Tools
Tool description Vattenfall Requirement UoM
SAP number quantity
Crowbar 600 mm 29988737 1 Pcs

Cutter for Inspection Sticker 29988738 1 Pcs
Empty bucket (pump should fit in) 4016124ll2 1 Pcs
Grease gun SOV_General Tools 1 Pcs
Sticky scraper Gedore 40153925 1 Pcs
Torque Wrench 160-800nm 3/4" 29988579 1 Pcs
Load test kit Load test kit 1 Pcs
Mechanical tools bag Mechanical tools bag 1 Pcs
Web sling 40136331 1 Pcs
Weight bag with 140 kg 4 Pcs
Weight bag with 150 kg 1 Pcs
Materials
Material description Vattenfall Requirement UoM
SAP number quantity
Background Sticker Crane 40160639 1 Pcs

Clean rag 40144290 25 Pcs
Cleaning spray SOV_General Consumables 0,5 Liter
Fresh water n/a 15 Liter
Gear oil Tribol VG320 1710/320 40083754 3 Liter
Grease Optimol Optipit 40146630 100 Gram
Hoist gear oil Tribol VG320 1710/320 1,5 Liter
Hoist rope lubricant 40157527 100 Gram
Inspection Sticker (next inspection) 40157683 1 Pcs
KIT, FILTER CARTRIDGE AND O-RING 1 Pcs
Slewing house oil Tribol VG320 1710/320 22 Liter
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Recommended team size
The minimum requirement for each location is 3 persons, so a 2-person team is only allowed if you
have a secondary team on the same location.
Estimated duration
The hour estimate for the service job on the HIAB service crane is approximately 6 hours for each
technician.
2 Technicians x 6 hours = 12 Hours approximately
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5 WORK INSTRUCTION
Make sure the AWP (Ref. 11) and RA (Ref. 12) is available before the annual service can be started.
The technicians must follow the Wind turbine safety rules (Ref. 6) when the technicians perform work
at the DT site.
If there are any doubts about how the service should be performed, then the technician should refer
to the documents for HIAB service crane (Ref. 13, 14, 15 and 16) and report back to office so the
document can be changed if needed.
Checking the labels

Pay attention to the following acceptance criteria when performing the maintenance check:
 The text on the labels is legible

 The labels are fixed and are not damaged
 The labels are not missing
1. Check that the service label is present.
Figure 3: Service label
2. Check that the load label for “max 840 kg” is present.
Figure 4: Load label “MAX 840 kg”
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3. Check that the load label is present.
Figure 5: Load label
4. Check that the winch label is present.
Figure 6: Winch label
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5. Check that the emergency labels are present.
Figure 7: Emergency labels
6. Check that the load label “Winch+wire 600kg/Boom + Hook 840g” are present.
Note: it’s important to be aware that the crane in normal use is only for 600kg
Figure 8 winch and wire.
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Slewing house, oil level check
Figure 9: Level gauge
1. Check the floor around the slewing house for leaked oil.
2. Check the oil level of the slewing housing of the crane via the level gauges on the side. The
oil level should be just visible at the bottom of the max level gauge.
Note: if the oil is above the upper max level gauge, there is possible a defect in the slewing
house sealing and hydraulic oil is leaking into the gear oil, this needs to reported.
3. If necessary, top up according to lubrication chart for crane. (For lubricant top up procedure,
see chapter 5.21) (For lubricant type - see chapter 5.20).
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Steel structure and other mechanical items
In following inspection items, pay special attention to:
 Deformation (bends, shape changes)
 Cracks (specially in welds and other high load areas).
NOTE: a crack in the paintwork can indicate a crack in steel structure as well.
 Signs of wear, collisions and/or bad adjustments (paint damage)
 Signs of oil leaks, traces of oil on the floor.
1. Carry out visual inspection on the crane mounting bolts (base).
Figure 10: Crane base mounting bolts
2. Check the torque of the mounting bolts Torque setting 800 Nm. (Every fifth year)
3. Visually check the crane base.
Figure 11: Crane base
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4. Check the crane column.
Figure 12: Crane column
5. Check all (shaft locking) flange bolts, torque setting 85 Nm.
Figure 13: Shaft locking bolt
6. Check the boom, shaft connections etc.

 Torque setting for shaft nut is 340 Nm
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7. Check the boom extensions and slide pads.
Figure 14: Slide pads bottom
Figure 15: Slide pads top
8. Check all locking pins and security clips.
Figure 16: Security clip
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Hoist wire rope inspection
NOTE: during all winding and unwinding, the rope should
remain tensioned as much as possible. Always verify that
the rope is spooled correctly on the drum:
1. Unwind the entire wire rope and check it for damage

(Length 150 metres).

The hoist must stop automatically when there is
3 windings left. If not refer to chapter 5.23 for
adjustment.
2. Check the wire rope for:
 Contamination
 Insufficient lubrication
 Corrosion
 Damaged rope clamps
 Damage to the surface of the wire rope.
3. The wire rope must be discarded if (see chapter 5.26
Figure 17: Wire rope damage
for information about changing wire rope):
 There are more than 2 wire breaks on a length of 42 mm.
 There are more than 5 wire breaks on length of 210 mm.
 Any of the defects in figure 16 are found.
 Corkscrew deformation that produces a “wave” height of 1/3 of the cable diameter.
The wire rope must be free of rotational stresses which means that the wire rope and
counterweight must hang freely, and that no rotational torsion is built up.
4. Check the ferrule:
 Pay attention to damage to the rope at the place where the rope enters the ferrule.
 Cracks in the ferrule material.
 Verify that the SWL (if indicated on the ferrule) is higher than 600 kg.
Figure 18: Ferrule
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5. Replace the wire rope if the wire rope ferrule is damaged.
6. Check that the diameter of the wire rope is minimum 6.3 mm.
 Measure the first five meters of the wire rope.
 Measure the last one meter on the drum when the wire rope reaches the ground.
 Replace the wire rope if the diameter is below 6.3 mm
Figure 19: Wire rope measurement
Warning: Keep fingers and other body parts, clothes, etc. away from operating winch.
Attention: Wear glasses, breathing protection and gloves acc. MSDS.
 Clean the wire rope with clear water and a brush, if necessary.
 Verify that the wire rope is clean and dry.
 Apply sufficient protection with wire spray (Rotzler 004282 0008) on the rope to
provide good penetration.
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Hoist, rope end switch inspection (3 windings left)
NOTE: during all winding and unwinding, the rope should remain tensioned as much as
possible. Always verify that the rope is spooled correctly on the drum:
The hoist function relies on the friction between the rope and the drum. It is necessary that at least 3
windings (rotations) of the rope stay in contact with the drum. Therefore, the hoist is equipped with a
switch (3) that is activated by a roller (4) when there are 3 windings left on the drum (see figure 19).
The hoist stops unwinding when the switch is activated.
Figure 20: Hoist safety switches
Warning: Do not touch a moving hoist.
 Switch the hydraulics off but leave the crane electronics switched on.
 Inspect the roller (4) for signs of wear and abrasion. Replace in case of doubt.
 Verify that the roller-arm can move.
 Open the cover of switch (3).
 Check that the Voltage over the two cable contacts in the switch is 24V.
 (With the help of a tool), push the switch in.
 Check the voltage again to verify that is now 0V, ensuring that the switch has now switched.
 Mount the cover of the switch.
If needed, the switch can be adjusted; (see chapter 5.23). If no adjustment is needed jump to chapter
5.6.
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Hoist, rope layer switch inspection
When the hoist rope is unwound until the second layer of wire on the drum, the hoist capacity is
reduced to prevent overload of the hoist. This is activated by roller (2) in combination with switch (1).
The touch roller (2) scans the rope during winch operation. As the second layer of the rope is pulled
from beneath the touch roller, the touch roller (2) drops and pushes the adjustment screw (5) onto a
lever (6). The lever activates the switch (1) which signals to the safety system (figure 19).
Warning: Do not touch a moving hoist.
 Switch the hydraulics off but leave the crane electronics switched on.
 Inspect the roller (2) (figure 19) for signs of wear and abrasion. Replace in case of doubt.
 Verify that the roller-arm can move.
 Open the cover of switch (1) (figure 19).
 Check that the Voltage over the two cable contacts in the switch is 24V.
 (With the help of a tool), push the switch in.
 Check the voltage again to verify that is now 0V, ensuring that the switch has now switched.
 Mount the cover of the switch.
If needed, the switch can be adjusted, (see chapter 5.24). If no adjustment is needed jump to chapter
5.7.
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Hoist gear oil level check
a. Check the oil level in the hoist gearbox
 Stop crane and switch off.
 Remove plate (1) (figure 20)
 Remove screw (2) (figure 20) and check if oil is leaking out. The oil should be flowing
from the opening.
 Tighten screw (2) (figure 20) if oil is flowing out.
 Mount plate (1) (figure 20) again.
 If the hoist gear needs topping up (see chapter 5.25).
Figure 21: Hoist gearbox overfill plug
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Hooks and hook weight inspection
The crane is equipped with 2 hooks:
 Hoist hook, attached to hook weight of the hoist system.
 Separate hook. can be mounted to boom end with the mounting pin. The hooks are similar.
1. Check both hooks
 Check the hook for deformation and damage.
 Check the safety latch (3) (figure 21) and the spring of the latch.
 Check the cotter pin (2) (figure 21) in the hook.
 Verify that the hook can rotate freely.
Figure 22: Hook boom system and hoist hook
2. Check the weight

 Verify that the rubber bumpers are in good shape. Replace any damaged rubber bumper.
 Check the hook weight for damage.
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3. Check that the pin bolts are correctly fitted on the weight.
a. Check that the pin bolt (3) goes through the wire rope eye (1) (figure 22).
b. Check that the pin bolt (4) goes through the lifting eye on the hoist hook (2) (figure 22).
c. Check that the pin bolts (5) and (6) are locked with locking pins (figure 22).
Figure 23: Pin bolts in counterweight
Rope damper (rubber) inspection

1. Check the rubber for deformation and damage.
2. Check for cracks due to drought or age.
Figure 24: Rope damper
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Top roller inspection
Figure 25: Top roller
1. Check the condition of the top roller.

2. Check that the mounting bolts are tightened correctly. Torque setting 180 Nm.
 There should be no axial distance between the bushings and the eyes of the boom.
Figure 26: Seal wire
3. Inspect the wear of the parts that come in contact with the rope.
 One of these parts is the nylon pads on the underside. Replace it if it shows grooves
of more than 3 mm depth (the grooves cannot be so deep to make the rope touch
lever plates) or other severe damage.
4. Check the completeness and functionality of the rollers and pins.
5. Verify that the pulley rotates freely.
6. Verify that that brake-arm can move freely.
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Hydraulic system inspection
Visual inspection of hydraulic items consists of:
 Check for damage
 Check for leakage
 Check hoses for small cracks as result of aging
o The hydraulic hoses must be changed after 6 years of use and 10 years after
production.
 Check for damaged surface protection
1. Inspect the main control valve for damage and leakage.

2. Verify that the control levers return to neutral position smoothly.
Figure 27: Manual control valve and control levers
3. Inspect the boom elevation cylinder and load holding valve for damage and leaks.
Figure 28: Load holding valve
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4. Inspect the extension cylinders and load holding valve for damage and leaks.
Figure 29: Load holding valve
5. Inspect the hydraulic pipes and connections for damage and leaks.
6. Inspect all hoses for weathering and aging.
7. Inspect the pressure reducer filter for leakage.
Electronic system inspection.

Check the electronic components for:
 Appearance and damage of the control boxes:
o interface box (Space box)
o remote control transmitter
o receiver box
o column box
o battery charger of remote battery
 Damage of the pressure sensor (boom cylinder)
 Condition of plugs and connectors
 Mounting and guidance of cables
 Correct placement of cable-clips (at the underside of the boxes).
 Mounting of box-covers (no gaps)
 Correct functioning
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1. Check the control panel: carry out a lamp test.
 Press the on/off button for at least 2 seconds
- All the red LED’s are illuminated.
 Release the on/off button.
 Test the functioning of the emergency stop button.
- After 3 seconds all the green LED’s are illuminated.
 Test the functioning of the emergency stop button.
2. Check the remote-control receiver box for damage.
3. Check the remote-control functionality and test the emergency stop.
4. Check the connection box on the hoist for damage.
5. Check the spool sensor housing for damage.
6. Check the functionality of the battery charger.
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Top roller removal and installation before load test
5.13.1 Removal of top roller

Note: Danger of injury or crushing.
An unsecured top roller may drop at assembly and cause serious injury and
crushing. Secure the top roller with hoisting gear or prop it up professionally.
1. Remove the counterweight.

2. Pull out the quick pin (1) (figure 29).
3. Remove the roller (2) (figure 29).
4. Remove the rope from the top roller and fit the rope end with the clip (3) (figure 29).
5. Assemble the roller (2) and secure it with quick pin (1) (figure 29).
Figure 30: Wire removal from top roller
6. Remove the locking wire from the bolts on either side of the top roller assembly. Locking
wires (wire & seal) to be discarded.
7. Loosen the bushing (1) and (2) (figure 30) from the top roller with a suitable spanner/tool for
the bolt size.
8. Remove the top roller safely.
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9. Assembly the bushings (1) and (2) (figure 30) in the top roller.
Figure 31: Top roller removal
5.13.2 Installation of top roller

Note: Danger of injury or crushing.
An unsecured top roller may drop at assembly and cause serious injury and
crushing. Secure the top roller with hoisting gear or prop it up professionally.
1. Loosen the mounting bushings (1) and (2) (figure 31) from the top roller with a suitable
spanner/tool for the bolt size.
2. Place the top roller in the crane tip.
3. Fit the bushing (1) (figure 31), so that the spring-loaded pins engage into the top roller. If fitted
incorrectly, the spring-loaded pins will protrude on the outside of the bushing, which will not
allow you to fit a spanner to tighten the bolt.
4. Fit the bushing (2) in the same way as the bushing (1) (figure 31).
5. Tighten the mounting bolts (180 Nm).
6. Apply locking wires to mounting bolts.
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7. Seal both locking wires with a correct seal.
Figure 32: Top roller installation
8. Pull the quick pin (1) while holding the roller (2) (figure 32).
9. Remove the roller (2) (figure 32).
10. Release the rope from the clip (3) (figure 32).
Figure 33: Installing rope through top roller
11. Insert the rope in the top roller as shown at (4) (figure 33).
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12. Assemble the roller (2) and secure it with the quick pin (1) (figure 33).
Figure 34: Installing rope through top roller
Boom hook removal and installation
5.14.1 Removal of boom hook

1. Remove the locking pin (3) (figure 34).
2. Remove the nut (2) (figure 34).
3. Remove the shaft (1) (figure 34).
Figure 35: Boom hook removal
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5.14.2 Installation of boom hook
1. Put the hook in place and fit the shaft (3) (figure 35).
2. Tighten the nut (2) (figure 35).
3. Secure with the locking pin (1) (figure 35).
4. Perform a successful dynamic load test before putting the crane back into operation.
Figure 36: Boom hook installation
Annual test (load cell test)

Equipment:
 Load cell and display
 Manual hoist (ratchet type) rated capacity min. 4000 kg.
 D-shackle(s) with rated cap. min. 4000 kg.
NOTE: In this chapter, the recommended method is described. It is possible to follow
alternative methods, but:
 the method must follow the same principle
 the method must be approved by a competent person
 the weights of chains, shackles, counterweight, etc. must be considered
Preparation
1. Remove counterweight and top roller from the boom system end (see chapter 5.13.1).
2. Mount the other (standard, 5T) hook to the boom system end (see chapter 5.14.2).
3. Attach the load cell to the crane hook.
4. Zero the load cell (calibrate).
5. Attach the manual ratchet hoist to the load cell.
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6. Move the crane boom system straight over a test point (see figure 36).
7. Operate the boom system until it is fully down (end of stroke).
8. Extend the boom system hydraulically until the hook is exactly straight over the test point.
9. Raise the 1st boom cylinder a little to ensure that the pressure sensor is working.
10. Stop the hydraulic system but leave the crane electronics switched on.
11. Unwind the manual ratchet hoist and attach to the attachment point.
Figure 37: Load cell test points
Figure 38 Test load cell overview.
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Test point Nominal load (kg) 110% at 125% at Remark
3° (kg) 0° (kg)
A 2860 3150 3575 Man. boom extensions retracted
B 2585 2840 3230 Man. boom extensions retracted
C 2160 2375 2700 Man. boom extensions retracted
D 1460 1600 1820 Man. boom extensions retracted
Table 3: Test point loads
NOTE: points A and D are not always available.
5.15.1 90 % pre-warning, 100 % load and 110% load test

1. Tighten the manual ratchet hoist until there is tension on the chain. See figure 36-38 for setup
of load test.
2. Verify again that the chain is exactly vertical. Change the crane position if necessary.
3. Continue to slowly tighten the manual hoist. Keep an eye on the load indication of the crane
User Interface. Verify that the safety system indicates a 90% prewarning at approximately
1900 kg. when doing the test, make sure that LED A, B and C is flashing when reaching 90%
prewaring.
Figure 39 LED indicators
36 | P a g e
Figure 40 LED flashing 90% prewarning
4. Continue to slowly tighten the manual hoist. Verify that an overload condition is signaled at
approximately the nominal load (see figure 40).
5. Continue to slowly tighten the manual hoist until the load cell indicates 110% of nominal load
(see figure 41). this needs to be done with great care! Execute provisional inspections on the
installation before the final test load has been reached. STOP the test immediately in case of
any discomforts or uncertainties! When doing the test, make sure that that LED A, B, And C is
constantly on.
37 | P a g e
Figure 41 LED on 110% warning
6. Inspect the installation carefully when the 110% test load has been reached.
7. Verify that the load holding valve of the elevation cylinder is working (the measured load value
does not decrease quickly.
125% test
1. Restart the hydraulic system.
2. Raise the boom system until the 1st boom cylinder is extended approx. 20 cm.
3. Stop the hydraulic system.
38 | P a g e
Figure 42 Cylinder clamping tool
39 | P a g e
1. Take the clamping tool and verify that the plastic rings are placed in the grooves on the inside
of the tool.
2. Mount the clamping tool around the cylinder piston. Following remarks apply:
 The plastic rings are on the top side
 The bolt flange is parallel to the boom system
 The tool rests against the piston head (as high as possible)
3. Tighten the four bolts with a torque setting of 175 Nm.

4. Move the boom system slowly down until the blocking tool rests on the cylinder.
6. Slowly tighten the manual hoist until the load cell indicates 125% of nominal load (see table
3). This needs to be done with great care! Execute provisional inspections on the installation
before the final test load has been reached.
7. STOP the test immediately in case of any discomforts or uncertainties! Inspect the crane
structure and welds carefully when the final test load has been reached. Pay attention to
cracks, deformations, etc.
8. Release the tension of the manual hoist and detach the upper shackle (when used).
9. Restart the hydraulic system.
10. Raise the boom system a little.
Remove the clamping tool and inspect the cylinder’s piston rod for damage.
Hoist safety test

1. Remove the manual ratchet hoist.
2. Switch the load cell off and remove it from the crane hook.
3. Remove the boom hook in accordance with chapter 5.14.1
4. Install top roller in accordance with 5.13.2
5. Start the crane and move the boom up.
6. Lower the hydraulic hoist and attach the load cell to the hoist hook.
7. Zero the load cell (calibrate).
8. Attach the manual ratchet hoist to the load cell.
9. Move the boom end straight over a test point.
10. Reel in the hoist rope until you can comfortably connect the manual hoist to the test point.
Stop the crane, but leave the electronics switched on.
11. Tighten the manual ratchet hoist until there is tension on the chain.
12. Verify again that the chain is exactly vertical, correct of necessary.
40 | P a g e
13. Continue to slowly tighten the manual hoist until a load of 690 kg is applied. Verify that the
LED load indicator is blinking red (90 % pre-warning).
14. Continue to tighten the manual hoist until the LED load indicator has a constant red light.
a. This must happen between 700 kg and 750 kg.
15. Verify that the load cell indication is more or less constant (the brake of the hydraulic hoist is
working).
16. Start the crane hydraulics.
17. Switch the remote controller to slow speed.
NOTE: only carry this out once:
Slowly try to operate the hoist (up) function.
18. Verify that the safety system goes in overload immediately (and opens the dump valve to
prevent further overloading).
19. Switch the crane off.
20. Carry out a visual inspection for damage on the hoist components.
21. Release the tension of the manual hoist and detach the lower shackle.
End of test
1. Retract the manual ratchet hoist, remove it from the crane and store it.
2. Switch the load cell off and remove it from the hoist hook.
3. Put the crane back in working condition.
Functional test with load attachment

Equipment for this task:
 1 websling with 4 hooks

 Sling 1,5 meter
 4 Weight bags with 150 kgs each
 1 Weight bag with 140 kgs
41 | P a g e
Use the web sling with 4 hooks to attach the bags for the load test, in that way we make sure to
minimize the manual handling as much as possible. The web sling below is not how it looks like but is
to demonstrate an overview of the setup.
Before any craning can happen, make sure there has been established radio contact between
the slinger banksman on the TP and the crane operator in the Nacelle.
Activate the remote display of the crane scale and watch the displayed value.
Disable the switch on the extension cord when a weight of 540 kg (0,9 x 600 kg) is reached.
Figure 43: Load chart

1. Warning device:
Check that the alarm for 90% SWL is working. (540 kg) load
2. Activate the remote display of the crane scale and watch the displayed value.
Disable the switch on the extension cord when a weight of 600 kg is reached.
3. Dynamic brake test:
42 | P a g e
The dynamic load test has to be performed with the below mentioned loads.
Load 90 % = 540 kg
Load 100 % = 600 kg see load chart figure 37
Load 110 % = 660 kgs.
NOTE! We could experience that with this setup that has been provided for the HIAB
crane from (SGRE and the manufacturer) that this test has to be performed with 700 kgs
to make it stop descending.
Lower the load at full speed and stop lowering.

Watch the distance as the crane hook stops.
The crane hook with the load should stop within 1 meter.
Activate the remote display of the crane scale and watch the displayed value.
Disable the switch one the extension cord when a weight of approx. 700 kg (1,0 x 600 kg -> 1,1
x 600 kg) is reached.
1. OLP test:
Check that the OLP (overload protection) for 100% - 110% SWL is working. The hook must be at
TP platform level and the rope layer switch must be activated. The OLP must be triggered at max
1,1 SWL.
Surface treatment inspection

Note: A crack can indicate a structural defect of the material beneath.
1. Visually inspect the surface protection for cracks, scratches, and other damages.
2. If a crack is found verify that the underlying steel structure is not cracked or damaged. If a
crack or damage is found, report to higher maintenance level.
3. If no structural damage is found, repair the surface protection (refer to chapter 7.1 in the HIAB
maintenance manual).
43 | P a g e
Lightning protection system inspection
1. Verify that the earth cables are undamaged, and connectors are tight.
 Refer to chapter 5.21 for torque values
Figure 44: Cables for electrical bonding
44 | P a g e
Lubrication
Figure 45: Lubrication points
Lubrication – Maintenance interval
Position Interval Item Quantity Remarks
1 Yearly First main boom pivot 1x Grease gun
2 Yearly Hoist wire rope Lubricant for wire rope
3 Yearly First boom cylinder 2x Grease gun
4 Yearly Slewing bearing, top 2x Grease gun
5 Yearly Slewing house Top up with oil
6 Yearly Moving parts on top roller Oil can
7 Yearly Hoist hook 2x Oil can
7 Yearly Hoist hook swivel bearing Oil can
Figure 46: Lubrication chart
45 | P a g e
1. Grease book main pivot with one grease gun stroke.
2. Clean and lubricate the hoist wire rope.
3. Grease first boom cylinder with two grease gun strokes.
4. Grease slewing bearing with two grease gun strokes.
5. Top up the slewing house if the oil level is low.
6. Grease moving parts on the top roller with oil can.
7. Grease hoist hook with two grease gun strokes.
8. Grease the hoist hook swivel bearing with oil can.
Specification of consumables
Designation Application
Hydraulic oil
- Average ZPS1006020, ISO VG32 as: Mobil DTE 13M

Hydraulic system
conditions
ZPS1006363, ISO VG32 as: Shell Tellus arctic

- Artic conditions Hydraulic system
oil 32
- Biodegradable ZPS1006364 Hydraulic system
Lubrication grease Optimol Optipit Grease nipples
Gear oil Tribol VG320 1710/320 Hoist gears and slewing house
Hoist rope lubricant ROCOL® Wire Rope Spray Hoist rope
46 | P a g e
Torque values
General table
Tightening torque for bolt and screw connections
Property class
Bolt size 8.8 10.9 12.9
Nm Nm Nm
M4 3 - 5
M5 6 - -
M6 11.5 - -
M8 27 38 46
M10 53 - 60
M12 - - 153
M16 221 - -
Slewing oil, top up

NOTE!
This chapter is only relevant if a lack of slewing oil is found during the inspection in chapter
5.2
1. Place an oil container to catch leaking oil, and have spill kit on hand.
2. Carefully loosen level gauge (3).
3. Add oil until the level is just visible through the opening. (total volume is approx. 22 L)
4. Carefully mount gauge (3) again.
Figure 47: Slewing house
47 | P a g e
Hoist, rope end switch adjustment
NOTE!
During all winding and unwinding, the rope should remain tensioned as much as possible.
Always verify that the rope is spooled correctly on the drum:
 Each turn of rope is close to previous turn

 No gap between each turn that allows the rope to move down into layer below
1. Unwind the hoist until the last 5 windings remain on the drum.
2. Slowly unwind further, until the spring-loaded arm is moving towards the drum and activating
the switch (3).
3. The hoist should stop unwinding. If it’s not, push the switch (3) in manually (with the help of a
wrench, tool, etc) to check if the switch is working (hoist stops unwinding). If this does not
work either, the switch must be replaced.
Figure 49: Rope end switch
If it needs adjustment:
48 | P a g e
1. Adjust the appropriate adjustment screw (5) so that it pushes against lever (6) when the roller
(4) leaves the last rope windings, and the hoist stops unwinding. Lock the adjustment screw.
2. Check the correct functioning after adjustment.
3. Spool the rope on the drum.
49 | P a g e
Hoist, rope layer switch adjustment
NOTE!
During all winding and unwinding, the rope should remain tensioned as much as possible.
Always verify that the rope is spooled correctly on the drum:
 Each turn of rope is close to previous turn

 No gap between each turn that allows the rope to move down into layer below
1. Unwind the hoist until the last 2 layers of rope remain on the drum.
2. Slowly unwind further, until the spring-loaded arm with roller (2, figure 52) is moving towards
the drum and activating the switch.
3. Verify that the hoist capacity is reduced. In order to do so, read the load cell while the switch
is activated and the hoist lifts upwards.
4. If it is not, push the switch in manually (with the help of a wrench, tool, etc.) to check if the
switch is working. If this does not work either, the switch must be replaced.
Figure 51: Rope layer switch
50 | P a g e
If it needs adjustment:
5. Adjust the appropriate adjustment screw (5) so that it pushes against lever (6) when the
scanning roller (2) moves from the second to the first layer of rope on the drum. Lock the
adjustment screw.
6. Check the correct functioning after adjustment.
7. Spool the rope on the drum.
Hoist gear, top up or exchange oil

NOTE!
This chapter is only relevant if a lack of slewing oil is found during the inspection in chapter
5.10
Figure 52: Drain/fill plug
1. Reel out the rope so much, that you get access to opening (3).
2. Remove plate (1) and screw (2)
3. Turn the drum so opening (3) is above centre line.
4. Place an oil container under the drum and remove screw (3).
5. Fill the drum with oil until it starts leaking out of the opening at the side. (Content approx. 1.2 -
1.4 litre) (see chapter 5.20 for lubricant).
6. Mount both screws and the plate again.
51 | P a g e
7. Reel in the rope.
Figure 53: Overfill plug
Hoist, wire rope removal and installation
5.26.1 Wire rope removal
Figure 54: Wire rope cast in pocket and wedge
1. Keep the compression roller disengaged.

 Insert a screwdriver in lower hole behind the hoist drum
 Push screwdriver to the right, and safety stop will be moved forward.
 Press in an additional screwdriver in upper hole to keep safety stop in place.
 Keep the over hoist protection switch in override position.
Figure 55: Disengaging compression roller
2. Spool off the old rope, until the last three safety windings are reached.
 Wind the old rope around an empty drum or spool
52 | P a g e
 or place it on the floor in the shape of a figure eight (a left turn followed
 by a right turn, etc.) to prevent loops and tangling
3. Turn the hoist drum until you have access to the cast-in pocket (1).
4. Detach the rope wedge (2) in the direction of the arrow.
5. Pull the old rope inlet (3) and remove the rope from the drum.
 Bundle it and discard.
5.26.2 Wire rope installation
Figure 56: Wire rope cast-in pocket and wedge
1. Prepare the positioning of the rope (see image) to ensure that the rope does not twist or form
loops.
2. Guide the smooth end of the new rope to the rope outlet of the hoist.
3. Guide the rope end through the inlet (3). Insert rope around rope wedge (2) as indicated and
insert both in the cast-in pocket (1) in the direction of the arrow.
4. Spool on the rope. Keep it tensioned as much as possible, to ensure that the rope is spooled
flat and tight on the drum.
 The first layer must follow the grooves on the drum; the subsequent layers are wound
similarly.
 Constantly verify visually that the rope is wound correctly on the drum.
 Stop and correct if needed.
WARNING:
Verify that the rope and rope wedge are perfectly clamped in the rope pocket.
5. To mount the rubber damper: Clamp the damper horizontally in a vice. Tighten the vice just
enough to pass the eye of the rope through the rubber damper. Release the vice.
Return to normal operation

Close AWP as per procedure. Only put WTG back in normal operation if all AWPs are closed.
 De-isolate according to the AWP (Ref. 8) and follow the instructions in the AWP.
 Clean up the area for any garbage / spares and dispose of correctly.
53 | P a g e

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DanTysk

DanTysk Sandbank Offshore Wind GmbH & Co. KG

Sap doc number: 1005343699

3 Roles and Responsibilities ................................................................................................................ 8

5 Work instruction ........................................................................................................................... 12

Sap doc number: 1005343699

Sap doc number: 1005343699

Table 1: List of abbreviations

AWP Approved Written Procedure

CTV Crew Transfer Vessel

DT DanTysk Offshore Windfarm

DTSB DanTysk, Sandbank

ERP Emergency Response Plan

HSE Health Safety Environment

LMRA Last minute Risk Assessment

MCC Marine Coordination Centre

PPE Personal Protective Equipment

RAMS Risk Assessment & Method Statement

SOV Service Operation Vessel

WTG Wind Turbine Generator

WTSR Wind Turbine Safety Rules

Sap doc number: 1005343699

Figure 1: DanTysk offshore wind farm in the German North Sea

Sap doc number: 1005343699

Ref.Nr. Name: Doc name. Sap Doc.

General Method Statement

2 Emergency Response Plan NMSHOW – 1333506825-6660

DTSB Incidents, accident, DTSB Incidents, accidents, and

4 Lifting and Hoisting NMSHOW-1972685076-9943

5 HSE training Matrix NMSHOW-1333506825-2154d90

6 Wind Turbine Safety Rules Wind-Turbine-Safety-Rules-4th-Edition

DTDT Manual Handling

Arbeitsschutzgesetz (ArbSchG) Arbeitsschutzgesetz (ArbSchG)

DGUV Vorschriften Deutsche

Operational Control Procedure

11 Approved Written Procedure Use applicable AWP (determined by AT)

12 Risk Assessment RA_DT_Service HIAB 1005343698

13 HIAB maintenance manual Maintenance Manual v1.9 HIAB DT EN

Siemens maintenance work ZWI1032919_EN-US_HIAB-SWP2-

Sap doc number: 1005343699

3 ROLES AND RESPONSIBILITIES

 General RAMS for DT - (Ref. 1)

Specific HSE requirements

Sap doc number: 1005343699

Sap doc number: 1005343699

 OEM / HIAB Service Training

Crowbar 600 mm 29988737 1 Pcs

Background Sticker Crane 40160639 1 Pcs

Sap doc number: 1005343699

Sap doc number: 1005343699

Checking the labels

 The text on the labels is legible

1. Check that the service label is present.

Figure 3: Service label

Figure 4: Load label “MAX 840 kg”

Sap doc number: 1005343699

Figure 5: Load label

4. Check that the winch label is present.

Figure 6: Winch label