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Load Test Procedure For Over Head Crane

At Circulating Water Pump House
 DOCUMENT NO. :
LOAD TEST PROCEDURE FOR OVER HEAD CRANE P-T3109-RED-013
AT CIRCULATING WATER PUMP HOUSE ISSUED DATE :
28 September 2009

UNIT ISSUING : APPROVED BY : PAGE REVISION

RIGGING Site Manager 2 of 7 0

ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION

- SDCC : Original
- CNEEC : Copy
- Originator: Copy
Hartanto H. Alamsyah Iman Paryaman Agus Subagyo
Rigging Engineer BOPArea Manager Site Manag. Site Manager
Rep
ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE
0 28– 9 – 2009 28 – 9 – 2009 ISSUED FOR APPROVAL

TABLE OF CONTENT
No. Descriptions Page

1 Title 1 of 7

2 Scope 3 of 7

3 Objective 3 of 7

4 Reference 3 of 7
5 Preparation of Load Test 3 of 7
6 Sequence of Load Test 3 of 7

a. Test Run Without Load 3 of 7

b. Dynamics Test Load 4 of 7

c. Static Test Load 4 of 7

7 Flow Chart Sequence of Load Test 5 of 7
8 HSE aspect identification 6 of 7
 DOCUMENT NO. :
LOAD TEST PROCEDURE FOR OVER HEAD CRANE P-T3109-RED-013
AT CIRCULATING WATER PUMP HOUSE ISSUED DATE :
28 September 2009

UNIT ISSUING : APPROVED BY : PAGE REVISION

RIGGING Site Manager 3 of 7 0

1. TITLE

Load Test Procedure For Over Head Crane at Circulating Water Pump
House.

2. SCOPE

This procedure describes the load test over head crane capacity 32 ton and 10
ton at circulating water Pump House, Indramayu 3 x 330 MW Coal Fire Steam
Power Plant. In this connection, if there is any modification to this instruction
shall be carried out after reviewed with the concern person.

3. OBJECTIVE

This procedure is the guidance for related Supervisor or Engineer for load test
over head crane.

4. REFERENCE

1. Instruction Electrical Hoist with Wire by Henanweihua Heavy Machinery

CO.,LTD
2. W – SAF – 026 Crane & Lifting Procedure.
3. Handbook of Rigging by W.E Rossnagel, P.E (Third Edition).

5. PREPARATION OF LOAD TEST

 DOCUMENT NO. :
LOAD TEST PROCEDURE FOR OVER HEAD CRANE P-T3109-RED-013
AT CIRCULATING WATER PUMP HOUSE ISSUED DATE :
28 September 2009

UNIT ISSUING : APPROVED BY : PAGE REVISION

RIGGING Site Manager 4 of 7 0

Before over head crane commissioning, must inspect mechanical and

electrical each parts installation conformity to standard. After Inspect of Over
Head Crane Finished, the preparation works shall be done for load test are
include of area, load and positioning of Over Head Crane.

6. SEQUENCE OF LOAD TEST

a. Test Run Without Load

Test run without load is aimed to inspected the manufacturing defects and
installation defects. Start the motor of each part respectively. Run the
machine in the whole range for 1-2 times. All parts should run properly and no
abnormal condition should occur. Check the electrical control actions to see
whether they are correct. Hoisting speed test for main/auxiliary hooks; speed
test for trolley and bridge; no gnaw-rail phenomenon exist on the bridge and
trolley; all the position limit device act sensitively and reliably(include upper
position limit switch and lower position limit switch); the noise of reducers and
temperature of bearings are in the normal range; no oil-leakage exists
b. Dynamic Test Load

Dynamics load test is aimed to test and verify the functions of brakes and
every part of the crane. First dynamics load test for ever part of crane should
be conducted respectively. Then, conduct coordinated test by starting two
parts in same time (Attn: the main/auxiliary hooks should not be operated in
same times)
Add load exceeds 10% than rated loads on the hoist. During the test, the
test load should not active reversely when air-starting the hanging test load;
when conducting the braking test during the falling process, hook should not
slide off. When test is in process, operation intermission time should be
reserved according to the electrifying persistence ratio of the motor of this
machine and then conduct the control according to operation regulations, and
the accelerated speed, decelerated speed and speed should be limited in the
normal range. If all the parts have successfully passed the functions test, and
during the following visual inspection, no damage have been found on the
parts, no connections is loosen or damaged, motor and their control device
run normally, position limit switches and interlock protection device active
properly and precisely, then, the test result is qualified.

c. Static Test Load

Static load test is aimed to inspect the carrying capacity of crane and each
part of crane. The static test for main hook and auxiliary hook should be
conducted respectively. Before conducting the static load test for main hook,
 DOCUMENT NO. :
LOAD TEST PROCEDURE FOR OVER HEAD CRANE P-T3109-RED-013
AT CIRCULATING WATER PUMP HOUSE ISSUED DATE :
28 September 2009

UNIT ISSUING : APPROVED BY : PAGE REVISION

RIGGING Site Manager 5 of 7 0

place the no-load trolley at the center position of span and determine the
reference point.
Add load exceeds 25% than rated loads on the hoist. The hoisting height
ranges from 100 mm to 200 mm and suspending time should be no less than
10 minutes. After unloading, check the basing-point of girder to see whether
the permanent distortion exist. Repeat the above test for tree times and no
permanent distortion should exist. After static test, if cracks, permanent
distortions, painting damages or damages that affect the performance and
safety of crane have not been found, and no connections is loosened or
damaged, then, the test result is qualified.

7. FLOW CHART SEQUENCE OF LOAD TEST

PREPARATION WORKS

POSITIONING OVER HEAD

CRANE ON LOAD TEST AREA

TRIAL RUN

INSPECTION

DYNAMICS RATED 0.8 LOAD

TEST

INSPECTION
(6.1/6.2/6.3)

DYNAMICS LOAD 1.1 RATED LOAD

INSPECTION

STATIC LOAD 1.25 RATED LOAD

 DOCUMENT NO. :
LOAD TEST PROCEDURE FOR OVER HEAD CRANE P-T3109-RED-013
AT CIRCULATING WATER PUMP HOUSE ISSUED DATE :
28 September 2009

UNIT ISSUING : APPROVED BY : PAGE REVISION

RIGGING Site Manager 6 of 7 0

INSPECTION

FINAL
INSPECTION AND
HANDLING OVER