Testing Procedure

(1)

TESTING PROCEDURE

SECTION 1 - GENERAL

1.1 SCOPE

This documents covers the activities associated with the commissioning for Overhead Cranes project and is divided into two sections pre-commissioning and load and overload test.

Cranes should not be tested before the relevant commissioning check sheets are completed.

1.2 INSPECTION OF WORK

All work carried out on site is subject to inspection and approval prior to pre-commissioning by VME Material Handling (M) Sdn Bhd representative.

SECTION 2 – PRE-COMMISSIONING

2.1 GENERAL

Obtain and understand the information contained in the Environmental Health & Safety section.

Ensure all work permits are valid.

2.2 FUNCTIONAL TEST (WITHOUT LOAD)

Function test must be carried out at no load condition to ensure that primary safety and emergency systems are operating correctly. Correct adjustment of brakes and limit switches must be checked prior to the function test.

The correct operation of each motion of the crane throughout its range of operation shall be checked.

(3)

2.3 PERFORMANCE TEST

Performance tests shall be carried out on each motion of the crane with the 100% of nominal safe working load to ensure that they are capable of meeting the specified speeds of operation within a tolerance of plus or minus 10% at the designed supply voltage and frequency. During these tests the correct functioning of the mechanisms and brakes shall be verified.

All brakes shall be tested under full load conditions from maximum speed to rest three times in quick, succession without overheating.

During these test the crane shall be operated in accordance with the MFR’S instructions. Test results shall be recorded as per attached sheet (Functional test form).

SECTION 3 – LOAD AND OVERLOAD TEST

3.1 GENERAL

The crane shall be tested such that each lifting unit, each crab and the crane as a whole are subjected to 125% of their working loads. During the test the crane motions shall be tested as follows:-

a) Lifting units – the lifting unit drum shall be rotated through one revolution such that all gear teeth are tested under overload conditions.

b) Crab – the crab shall be traversed from one and the bridge to the other.

c) Long Travel – the crane shall be moved sufficiently to ensure that each gear touch of the long travel motion is subjected to overload condition. This test shall be repeated with that crab at each end of their traverse.

NOTE: Full motion speeds need not be gained during overload test.

Function check to ensure crane are moving in the same direction during this operation. General movement of crane test as follows:-

a) Observe the movement of hoist and crane in all direction when moving

without loads.

b) Observe the movement of hoist and crane in all direction when moving

(4)

c) Measure the traveling speed of the hoist and crane in all direction moving with load.

Lift load at 125% of nominal safe working load and observe movement in all direction and observe for 10 minutes to demonstrate the efficiency of the brake and the strength of the wire rope including hook block and other components.

3.2 DEFLECTION

TEST

A test shall be carried out with DOSH officer to verify that the vertical deflection of the crane bridge does not exceed 1/750 of the crane span when safe working load (SWL) is in mid span.

The test load to be used is the combination of difference sizes of steel plates or concrete blocks.

Rigidly support the crane at the end carriages. Lift the test load with the crab/hoist at the center of the girder. Checking of level on the crane girder slowly raising the load and keeping it 2-3 minutes at 2 cm from the ground.

Deflection measurement shall be taken after the safe working load (SWL) has been applied by using Teodolite instrument. The vertical deflection of the crane bridge shall not exceed span (L)/750.

Test results shall be recorded as per attached sheet (JKKP test form).

Acceptance Criteria. The tests shall be considered successful if no crack, permanent

deformation, paint flanking of damage that affects the function and safety of that crane is visible and no connection has loosened or been damaged.

(5)

VME MATERIAL HANDLING SDN BHD

(Co. No. 381070-D), Lot 6022, Batu 6, Bukit Naga, 42450 Klang, SELANGOR, MALAYSIA.,

TEL: +603- 5162 1018 FAX: +603-5162 1028

CUSTOMER : PROJECT CODE :

TEST CERTIFICATE TITLE:

BRIDGE CRANES-CRANE AND HOIST FUNCTIONAL CHECK

System : Location : Test date :

Visual inspection test - with no load

ITEM DESCRIPTION OPERATION VERIFIED BY

ITEM DESCRIPTION VERIFIED BY

Y N N/A 1.1 1.2 1.3 1.4 1.5

Push button functional check Hoist hoisting up and braking Hoist hoisting down and braking

Hoist hoisting up and down limit switch stop

OPERATION Incoming power supply checks ok?

1.6 1.7 1.8 1.9 1.10 1.11 1 12

Hoist trolley travel backward and braking

Hoist trolley travel forward and backward limit switch stop Hoist trolley travel forward and backward emergency stop

g p p

Hoist hoisting up and down emergency stop Hoist trolley travel forward and braking

Bridge travel forward and braking

B id l b k d d b ki 1.12 1.13 1.14 1.15 1.16 Signage ok ? Paint finishing ok ?

Bridge travel backward and braking

Bridge travel forward and backward limit switch stop Bridge travel forward and backward emergency stop

Other observation (please specify if any)

Resp. dept: Prepared: Checked: Released:

Eng. & Design Faizah K.C. Chee Adrian

Document No.: Rev. Sheet No.:

(6)

JABATAN KESELAMATAN DAN KESIHATAN PEKERJAAN

PERAK

BORANG UJIAN BEBAN MESIN ANGKAT

1) Butir Mesin Angkat

Jenis Mesin Angkat

Model Serial No :

Nama Pembuat Chasis No :

Negeri Asal Engine No :

Tahun Dibuat No Pendaftaran

JPJ Kenderaan

Kuasa (kw) Kod Kuasa :

2) Butiran Ujian. Tarikh Ujian :

Beban Kerja Selamat (kg) Beban Ujian (kg)

Stability Test Span Length (mm)

Strength Test Initial Reading (mm)

Drop Test Final Reading (mm)

Deflection (mm) Allowable Deflection (mm) 3) Teguran

4) _{Tempat Ujian Dilakukan}

5) _{Nama dan Alamat Pemilik}

6) Disaksikan Oleh : 7) Wakil Syarikat / Pembuat

Tandatangan: Tandatangan :

Nama: Nama :

Jabatan Keselamatan & Kesihatan No K/P :

Pekerjaan Perak Nama Syarikat :

Fail Kelulusan: JKKP IS Rekabentuk: ADA

NO. BIL/TARIKH: NO. RESIT/TARIKH: NO. PENDAFTARAN PMA:

Testing Procedure