MacGregor Crane - FAT procedure

Customer Supplier Project number, supplier

Mawei Shipbuilding Ltd. Macgregor Norway AS SP2552-2
Andøyveien 23
NO-4623 Kristiansand Project name, customer
NORWAY MW610-2

P.O. number, customer

na

FAT Procedure
Equipment: MacGregor Offshore Crane

Type: HMC 2201 LKO 120-18 / 100-20

Factory acceptance test procedure in accordance with

ABS Guide for the Certification of Lifting Appliances

Revision Description Date Author Checked by

A Issued for information 23.03.2014 OHA LAG

This document and all information and data herein or herewith is the confidential and proprietary property of Cargotec Norway AS and is not to be
used, reproduced or disclosed in whole or in part by or to anyone without the written confirmation from Cargotec Norway AS.

© Cargotec Norway AS
www.cargotec.com

Pages: 12

SP2552-2-Z-KA-003 FAT 1
MacGregor Crane - FAT procedure

CONTENT

1. INTRODUCTION

2. PREREQUISITES

3. FUNCTION TEST EMPTY HOOK

4. OVERLOAD TESTING CRANE & MAIN WINCH

5. LOAD & FUNCTIONAL TEST SWL CRANE & MAIN WINCH

6. TESTING OF WHIPLINE WINCH

7. LOAD AND FUNCTIONAL TEST OF TUGGER WINCHES

8. TESTING OF MONITORING AND SAFETY INSTALLATIONS

9.TESTING OF CABIN ACCESSORIES

10. RADIO REMOTE CTRL

11. AFTER TEST

12.APPROVAL OF COMPLETED FAT / SIGNATURES

13.DEVIATION AND PUNCH LIST

Abbreviations
KJ : Knuckle Jib
MJ : Main Jib
MW: Main Winch
WW: Whiline winch
CT : Constant tension system
AOPS : Automatic Overload Protection system
MOPS : Manual Overload Protection system
SWL : Safe Working Load ( Rated load / capacity /Actual hook load for given condition)
LS : Load sensing
Ctrl system : Crane control system ( PLC )
AHC: Active Heave Compensation
AT: Auto Tension system

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MacGregor Crane - FAT procedure

1.1 Introduction
This document describes the factory acceptance test for MacGregor crane according to specific regulation.

The crane is designed in accordance to ABS Guide for the Certification of Lifting Appliances

1.2 References
Ref General Arrangement drawing : SP2552-2-R-XD-001 / SP2552-2-R-XD-002

1.3 Specification

SWL Max outreach

Test load FAT
(t) (m)
(t)

Loadcase 1
12 18 13,2
( max load )
Main winch
Loadcase 2
single line 12 14 13,2
(interm.pos)
Safe
Loadcase 3
Working 5 20 6,25
Load (SWL):
(max reach)
Main winch
na na na
double line:
Whip winch
na na na
single line:
Whip winch
na na na
Personnel:
Whip winch
na na na
double line:
Project no: SP2552-2
Client: Mawei Shipbuilding Ltd.
Project MW610-2
Test site:
Test date:
Project manager: Leif Arne Grødem
Test manager:
Approving auth.
All loads in this document are specified in metric tonnes ( t )

When approved and signed by approval authorities, this document shall be scanned and saved in project folder
with observed data and comments

“NOTE! The speeds mentioned in this technical specification are based on average volumetric
efficiencies provided by our suppliers of hydraulic components. A speed tolerance of +10 to -5% is
within the accepted range and should be taken into consideration.”

If electrical power / frequency at test stand differ from the specific for the particular crane, an estimate
for corresponding speeds during test has to be calculated / provided for verification.

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2. PREREQUISITES
Ref.: Description of activity: Specified data: Verification: Accepted
2,1 All test weights needed for load Weight according to
testing shall be made available load/overload test
before FAT start
2.2 Specified main supply Voltage:
3x440 V
Specified main supply frequency:
60Hz
Specified crane electrcal power
Max specified power: ( kW)
1 x 215
Aux suply:
230V
2.3 Available supply Voltage:
___ V
Available main supply frequency:
__Hz
Crane hooked up to test power suply
Max available power: ( kW)
____
Available Aux suply:
__
2.4 A Certified load cell is installed All testweight controlled prior to
between hook and testload testing.
2.5 Slew ring overtuning moment which
Max moment:
the fundation has to be designed to
withstand incl. factors according to
5130kNm
class requirement
2.6 Crane is welded / bolted to teststand
acc. to drawings
2.7 NDT of weld to teststand accepted. 100 % visual, 20% MPI
2.8 Start pumps, and with pumps Verify function of emergency stop
running, press the emergency stop

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Ref.: Description of activity: Specified data: Verification: Accepted

3. FUNCTION TEST, NO LOAD
Hydraulic pumps to be activated 3
3.1. Main / Knuckle JIB MOVEMENT
3.1.1. Move main jib and knuckle jib in MJ topping speed: MJ speed:
extreme positions. 60 ________sec
Verify speed by reading time from
MJ lowering speed: MJ speed:
endstop to endstop
( maximum specified time full stroke) 60 ________sec
KJ topping speed: KJ speed:
50 ________sec
KJ lowering speed: KJ speed:
50 ________sec
3.1.2. Check performance on joystick when
starting and stopping movement.

3.2. Main winch up/ down

3.2.1 Check performance on joystick when
starting and stopping movement.
3.2.2 Check wire length counter up/down Hoist 10,0m from ctrl system and Measured up:
both absolute and incremental length verify correct counting ________m
(+/- 0.05m dev ) Measured
down:_____m

3.2.3 Check hook stop in upper position ( Movements stops when upper Verify SW stop
both SW and mechanical / final stop) limit is reached. Moving to a and alarm
better position is allowed Verify final stop
and alarm
3.2.4 Check hook stop down Change the set point ( by Verify alarm
simulation in software) and
check that the lowering stops

3.3. Whip winch up/ down NA

3.4. Slew motion in both directions

3.4.1. Check performance on joystick when

starting and stopping movement.
3.4.2. Check slewing clockwise CW R<15m (sec/360º): CW speed =:
Start / stop / speed & slew position _____sec/360º
60
counter
CW R max (sec/360º)(R>20m): CW speed =:
60 _____sec/360º

3.5. Main Winch radius

3.5.1. Check max and min radius R max = Monitor=_____m
(Rmax+/- 0.2m dev Monitor / Meas.=______m
20,0
measurem.
(Rmin+/- 0.4m dev Monitor / R min = Monitor=_____m
measurem.)) Meas.=______m
5,5

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Ref.: Description of activity: Specified data: Verification: Accepted

4. OVERLOAD TESTING CRANE & MW
4.1. Testload (t) Load case 1
Max reach (m)
(Max load)
13,2 18
4.1.1 Testload to be hoisted, slewed and 90%: Alarm Crane monitor
luffed at slow speed in all positions 100%: Alarm +Bullhorn ______t
according to loadchart Load _____t
Verify overload
alarms activated
4.1.2 With 100% alarm activated Move the jibs in / out Verify only
possible to move
to smaller radius

4.2. Testload (t) Load case 2 Max reach (m)

13,2 14
4.2.1. Testload to be hoisted, slewed and 90%: Alarm Crane monitor
luffed at slow speed. 100%: Alarm +Bullhorn _____ t
Verify all position according to Load ____t
Load chart Verifi overload
alarms

4.3. Testload (t) Load case 3

Max reach (m)
(max reach)
6,25 20
4.3.1. Testload to be hoisted, slewed and 90%: Alarm Crane monitor
luffed at slow speed. 100%: Alarm +Bullhorn _______t
Load ____t
Verifi overload
alarms

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Ref.: Description of activity: Specified data: Verification: Accepted

5.
LOAD AND FUNCTIONAL TEST SWL CRANE & MW
5.1. LOAD AND FUNCTIONAL TEST Load case 1 (Max load )
5.1.1. Testing of main jib performance
SWL (t): Max outreach (m):
12 18
5.1.1.1 Move main jib up and down within Crane monitor
limitations in Loadchart. ______ t
Check performance / start /stop Load _____ t
5.1.1.2 Move MJ in and then out to increase Verify alarm and
radius until 100% alarm is trigged jib stops
Verify still
possible to hoist
the winch
5.1.1.3. Check performance on movement Movement stops when
when emergency stop is activated emergency stop is activated.

5.1.2 Testing of Knuckle Jib

Performance
NA
SWL (t): Max outreach (m):
12 18
5.1.3. Testing of Main winch
Performance
SWL (t): Max outreach (m):
12 18
5.1.3.1. Check performance on movement Movement stops when
when emergency stop is activated emergency stop is activated.
To be done at low speed!
5.1.3.2. Check reading of load on monitor Max deviation +/- 5% Load monitor:
compared to load cell in hook ______t
Loadcell:
________t
5.1.3.3. Check hoisting
5.1.3.4. Check lowering
5.1.3.5. Main winch brake test Lower load by the main winch.
Stop operation instantly 3 times,
observe braking function.
Visual observation of movement(
some movement due to software
ramping)
5.1.3.6 MW speed check Note ! Maks rated speed with
Run winch up / down and read speed available pumps / power
on crane monitor Number of available pumps : 3
Max speed up: (m/s) Speed up :
0,50 ______m/s
Max speed down: ( m/s) Speed down :
______m/s
0,50

5,2 LOAD AND FUNCTIONAL TEST Load case 2 "Intermediate position" NA

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Ref.: Description of activity: Specified data: Verification: Accepted

5.3. LOAD AND FUNCTIONAL TEST Load case 3
( Max reach )
5.3.1 Testing of main jib performance
SWL (t): Max outreach (m):
5 20
5.3.1.1 Move main jib up and down Operate in all extreme positions
5.3.2 Testing of Knuckle Jib
performance
SWL (t): Max outreach (m):
5 20
5.3.2.1 Move knuckle jib out / in
5.3.2.2. Move knuckle jib and main jib in 90% Load alarm active at above Verify alarm
combination to check safety alarm is specified radius
trigged on max allowed outreach

5.3.3. Testing of winch Performance

SWL (t): Max outreach (m):
5 20
5.3.3.1. Check reading of crane load on Max deviation +/- 5% Load monitor:
monitor compared to external load _____t
cell in hook Loadcell:
_____t
5.3.4 Testing of slewing performance
SWL (t): Max outreach (m):
5 20
5.3.4.1 Slew crane with load in max possible
outreach both clockwise and counter
clockwise

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Ref.: Description of activity: Specified data: Verification: Accepted

5.4 MAIN WINCH CONSTANT TENSION SHIP TO SHIP
5.4.1 Connect the hook to the test load. Testload ( t ): 5
Radius ( m ): 14
Weight of actual testload : __________t
5.4.2 Select Ship to Ship mode Verify Constant tension is
Constant tension available
5.4.3 Lift the testload above ground and Verify CT is not activated with
then try to activate CT load in hook ( load>1 t)
5.4.4 Lower the load to ground and
activate CT
5.4.5 Lower the load to ground and Read the CT force from external
activate CT by pushing button and loadcell when activated
operate joystick to max hoisting Tension:______t
position
5.4.6 Simulate vessel movement up by Check winch pays out wire Tension force
extending the MJ cylinder( MJ up). Verify load not lifted from ground when paying out
Max tension force appr ( t ): wire:
__________t
4
5.4.7 Simulate vessel movement down by Check winch runs in wire Tension force
extracting the MJ cylinder( MJ Observe for slack wire when running in
down). Min. tension force appr ( t ): wire:
__________t
0,2
5.4.8 With CT active, simulate lift off from Verify test load is lifted from
suply vessel by lowering MJ slowly, ground with full speed as soon as
deativate CT and release MJ down CT is de-activated
5.4.9 Stop lifting with the load in air Verify loadholding / observe load
steady in air

6. WHIP WINCH LOAD AND FUNCTIONAL TEST NA

7. TESTING OF TUGGER WINCHES NA

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Ref.: Description of activity: Specified data: Verification: Accepted

8. TESTING OF MONITORING AND SAFETY DEVICES
8.1 Load charts Available in cabin
8.2 Emergency procedure Available in cabin / crane king
8.3 Check audio warning from crane Verify function
cabin
8.4 Camera and lights for monitoring of Verify function for winch camera
MW
8.6. Check function of wind speed
_____ m/s
monitoring
8.5 Shut down main power and connect Testload =Max SWL Main winch
the emergency power cables Check movement of:
Check that the Emergency Pump MJ/KJ/MW/Slew
Unit is working.
Run the different crane functions
from cabin.
8.6 Simulate a utility (230V) power Testload =Max SWL Main winch
failure( switch off ) and operate the Check movement of:
crane by means of the Emergency MJ/KJ/MW/WW/Slew
operational panel
In emergency operating mode, press Verify MOPS is still available
emergency stop

8.7 Main winch MOPS Testload: ( t ) (10 -20 %,of SWL))

Connect test load to the hook on the Testload:_____t
2
Main winch.
Hoist the load approx. 1 meter.
With pumps running, activate MOPS Verify function/ load lowers
8.8 -Hoist the load approx. 1 meter. Activate 3 times and let it be
–Stop the pumps and simulate a activated for total 5 min
power failure. Observe the capasity to keep
brake off and the behaviour of the Remaining
Activate the MOPS button
winch accumulator
Visual observation of: pressure :
-Load lowered _______ bar
-Not "free fall drop" ( > 50bar)
Observe the behaviour of the
winch

Verify acustic alarm in cabin

8.9 Activate the Emegrency stop with
MOPS active
8.10 Main winch AOPS
Simulate in the control system
overload on both loadcell channels
according to AOPS load chart for the
Main Winch.
8.11 Simulate in the control system
overload on one loadcell channels
according to AOPS load chart for the
Main Winch (deviation).
Verify bullhorn alarm
Verify MOPS not deactivated
Crane radius / SWL according to
AOPS Loadchart Radius:_____m
Observe lowering of winch.
Simulated load:
________t
Verify no lowering of winch.

10
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Ref.: Description of activity: Specified data: Verification: Accepted

9. TESTING OF CABIN ACCESSORIES & OPTIONS ETC.
9.1 Check air conditioning system
9.2 Fire extinguisher Date:
9.3 VHF/UHF radio

9.4 Radio / CD player

9.5 Check function of windscreen wipers
9.6 Check function of windscreen washer
9.7 Check function of cabin heater
9.8 Check function of floodlights
9.9 Check function of helilights
9.10 Check sun blinds
9.11 Check cabin lights
9.12 Software version at FAT PLC: Sp_____PlcMain_v_____
HMI: Sp______Hmi_v________

10 TESTING OF RADIO REMOTE CTRL

Select " Remote ctrl " from cabinet
10.1 and verify that remote ctrl is
operational
Verify correct operation of all normal
10.2 crane functions ( only for Internal lift)
by using portable panel
Verify load monitoring and alarm
10.3 indication
Verify function of stop button on
10.4 Remote ctrl

11. AFTER TEST

11.1 Visual check for physical and Visual check by competent
structural damages after testing. person
11.2 Visual inspection of crane Oberve leakages, saftey rails ,
painting etc.
11.3 MW Hook verification Hook serial:
___________________________
Socket serial no:
__________________________

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Ref.: Description of activity: Specified data: Verification: Accepted

12. APPROVAL OF COMPLETED FAT / SIGNATURES
Representative Name Signature Date

MacGregor

13. DEVIATION AND PUNCH LIST

No: Description and correction Ref. Appr. Date Sign

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

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