Appendix C - Little Creek 100 MT MBH Rev. 0.pdf

ATTACHMENT 1

APPENDIX C

Field Test Procedures

Appendix C Sheet 1 of 8 Rev. 0

FIELD TEST PROCEDURES

ONE (1) 100 METRIC TON MOBLE BOAT HOIST

FOR

NAVAL SPECIAL WARFARE GROUP 8

AT

JOINT EXPEDITIONARY BASE LITTLE CREEK

VIRGINIA

Customer: Navy Crane Center Test Start Date: ________________________

Norfolk Naval Shipyard, Bldg. 491 Test Finished Date: _____________________

Portsmouth, VA 23709-5000 Contract No.: __________________________

Crane Builder: ____________________

Test Location: _____________________ Crane Serial Number: ___________________

Names and Titles of Participating Representatives:

Government Representative: Contractor Representative:

Appendix C Sheet 2 of 8 Rev. 0

1. POST-DELIVERY INSPECTION AND TESTING

Prior to testing the MBH, an inspection will be performed by the U.S. Government representative, in the presence of the contractor, is to determine compliance with specification requirements and to verify that the MBH was not damaged during shipment and off-loading.

The contractor shall assure that all components and features that affect load bearing, load controlling, or operational safety devices of the MBH are properly tested. The contractor shall follow the post-delivery test procedure below as applicable. The contractor shall add additional tests as necessary to prove that the MBH meets contract requirements and that additional standard features (beyond those identified below), which affect load bearing, load controlling or operational safety devices are also tested.

The contractor shall provide all personnel and equipment necessary to conduct the tests, including but not limited to MBH operators, riggers, personnel to supervise the test and record results, and calibrated test equipment. The Contractor will provide test weights and rigging gear required to attach the test weights.

The contractor shall perform all tests in the presence of the Government representatives. The contractor shall prepare a certified report of the post-delivery performance testing completely describing the tests performed, data obtained and results.

For purposes of this contract, a metric ton shall be taken as 2,200 pounds, making the rated lifting capacity of the MBH equal to 220,000 pounds. The sequence of testing shall be at the option of the test director, except that the no-load tests shall be performed first. The contractor shall forward all reports to the Contracting Officer within 30 days of completing the inspection/test.

1.1 ACCEPTANCE TEST REPORT

The acceptance test report shall include the MBH number, location, test date, government personnel present including their activity and phone number, and contractor personnel present including their company and phone number. This appendix is designed for use as a working document and may be used to document test results providing any additional items or functions of the crane not included here are added as required.

1.2 EQUIPMENT MONITORING

During the load test, check for proper operation and condition of safety devices, electrical components, mechanical equipment, and structural assemblies. Observed defects critical to continue testing shall be reported immediately to the test director who shall suspend the testing until the deficiency is corrected.

1.3 HOISTING ROPE, SLINGS, AND SHACKLES

Verify all the certifications have been reviewed and approved by the Navy Crane Center Design Department.

SAT UNSAT NA

2. PREREQUISITES TO LOAD TESTING

2.1 TEST AREA

Appendix C Sheet 3 of 8 Rev. 0

A safe test area shall be selected and all traffic and unauthorized personnel and equipment shall be cleared from test area. Test area shall be on a level ground with no more than a 1% grade. This test area shall be roped off or otherwise secured to prevent entry of unauthorized personnel and equipment.

Test Area SAT UNSAT

2.2 EYE HOOKS AND RIGGING

2.2.1 HOOK NON DESTRUCTIVE TEST (NDT)

Review documents to verify the hook IDs matches with approved NDT report.

Hook IDs matches NDT report SAT UNSAT

2.2.2 HOOK EVALUATION

Hooks shall be inspected for free of corrosion, deformation, wear, nicks, cracks and gouges.

Record hooks identification from the NDT certification. Check operation of the hook safety latch. Install or verify two tram points have been installed on each hook. Before the load test measure and record the distance between tram points (±1/64 inch) to establish the base tram dimension for hook throat opening.

Upon completion of the load test, re-measure and record new tram dimension.

Hook(s) showing twist or increase in throat spread from base dimension after completion of the 100% load test are not acceptable.

Hook ID Hook Latch Operation

Hook Tram Measurement

Before Load Test

Hook Tram Measurement

After Load Test Hook Status

SAT UNSAT SAT UNSAT

SAT UNSAT SAT UNSAT

SAT UNSAT SAT UNSAT

SAT UNSAT SAT UNSAT

2.2.3 RIGGING

All rigging used in crane load testing shall be provided by the activity and be previously tested. Verify the rigging load test information.

SAT UNSAT NA

2.2.4 PRECAUTIONS DURING LOAD TESTING

a) This procedure is for an overload test and extreme caution shall be observed at all times. The warning horn, if applicable, shall be tested for proper operation prior to conducting load tests.

b) During tests, normal operating speeds shall be employed to safely control loads through all motions. Rated specified speeds need to be attained gradually. All cycles with the test load should be kept to the minimum necessary to perform the tests.

c) Personnel shall remain clear of suspended loads and areas where they could be struck in the event of component failure.

Appendix C Sheet 4 of 8 Rev. 0

d) Raise the test load only to a height sufficient to perform the test.

e) Check for the proper operation and condition of safety devices, electrical components, mechanical equipment, and structural assemblies.

f) Observed defects critical to continuing testing shall be reported immediately to the test director, who shall suspend the testing until the deficiency is corrected.

g) Attach tag lines to the load to control oscillation as necessary. Test personnel shall stand clear of tires during load test.

2.3 INSPECTIONS

An inspection plan submitted as required by paragraph 4.15.1 of the Specification shall be available at the test site. Perform the MBH inspection in accordance with the plan.

MBH Inspection per Inspection Plan SAT UNSAT

2.4 DIMEMSION CHECKS

Verify dimensions shown in specification paragraphs 2.4, Appendix A and approved design drawings.

Below grades cable drop may be calculated by counting the number of wraps remaining on the drum with load blocks at grade.

Approved drawings Measured

Minimum Inside Clear Height (Loaded) SAT UNSAT

Maximum Overall Width SAT UNSAT

Minimum Inside Clear Width SAT UNSAT

Maximum Overall Height (Unloaded) SAT UNSAT

Minimum Hoist Block Reach Below Dock SAT UNSAT

3. NO-LOAD TESTING

All functions of the crane shall be operationally tested with each controller including, but not limited to all motions, all hoist, travel and steering, and controls, emergency stop buttons, safety devices, interlocks, lighting, engine low oil pressure shut down, engine over temperature shutdown, indictors, load display, audible travel alarm, fire extinguisher, etc.

Verify when one radio control is being used the other will not function.

Measure and record no load conditions for all functions.

Cab Control SAT UNSAT NA

Radio Control #1 SAT UNSAT NA

Appendix C Sheet 5 of 8 Rev. 0

Radio Control #2 SAT UNSAT NA

One radio control can be used at a time. SAT UNSAT NA

3.1 HOIST TEST

Note that hoist is designed to allow two-blocking. Raise and lower each load block through both speeds.

Raise each block assembly at slow speed into the upper load blocks. Test all features of the block limit system, such as; bypass, ability to lower but not raise the hoist blocks when in the limit, as applicable.

UNSAT

UNSAT

UNSAT

UNSAT

Hoist Operations SAT

Upper Limit/Hydraulic Bypass Operation SAT

Verify hoist brakes operation when controller return to neutral SAT

Verify hoist brakes operation when activating POWER OFF SAT

Verify hoist speeds (+/- 10%) are in accordance with contract requirement.

No Load Required Measured

Low Hoisting Speed _____ fpm SAT UNSAT

High Hoisting Speed _____ fpm SAT UNSAT

CAUTION: Ensure each layer of the wire rope is wrapped tightly.

SAT UNSAT

3.2 UPPER EQUALIZER BLOCK TRAVEL (SLIDING BLOCK ASSEMBLIES)

Verify that the upper sliding block assemblies for the pair of hoists travel forward and reverse per the specification.

Sliding block assemblies operation SAT UNSAT

3.3 GANTRY TRAVEL TEST

a. Travel the boat hoist a minimum of 50 feet forward and reverse direction steering left and right testing for proper steering operation. Verify steering is in accordance with OEM instructions. Set the parking brake. Verify that parking brake engages and disengages freely. Test travel alarms and emergency stop switches. At slow speed, disengage the drive levers and verify that the drive motion control system smoothly stops the crane’s travel.

b. Verify gantry brakes operation as controller return to neutral SAT UNSAT

c. Verify gantry brakes operation when activating POWER OFF SAT UNSAT

d. Verify the gantry travel speed (+/- 10%) is in accordance with contract requirement.

No Load Required Measured

Appendix C Sheet 6 of 8 Rev. 0

Gantry Travel Low Speed ____ fpm SAT UNSAT

Gantry Travel High Speed ____ fpm

Travel Functions (steering, brakes, alarm, emergency stop …) SAT UNSAT

e. Travel the MBH on the piers. Verify tire/curbs clearance with the approved drawing.

SAT UNSAT

f. Lower the block to verify the minimum 15 feet under the pier running surface of all hoist.

SAT UNSAT

g. Verify at least two full wraps of wire rope remains on each drum when the hoist block is at the lowest point under the pier running surface.

SAT UNSAT

SAT UNSAT h. Test the boat hoist steering operations on all mode.

i. Test for work area and travel floodlights.

j. Switching drive mode between all-wheel, 2-wheel and carrousel drive form the cab and from the remote controls.

SAT UNSAT

4. LOAD TESTS 100% (+0, - 5%) of 100 METRIC TON CAPACITY - HOISTS 1, 2, 3, and 4 Load tests shall be performed on all hoists combined. The nominal test load shall be 100 % (+0/-5%) of the OEM rated capacity. The rated capacity shall be the capacity shown on the serial number plate.

NOTE: The test weight INCLUDE the weight of rigging used to connect them to the load blocks.

Test weight range: 220,000 lbs. – 209,000 lbs. Record the weights:

Additional (rigging) weights: ___________ lbs. Test weight: ____________________ lbs.

Total test weight: _________________ lbs.

4.1 STATIC LOAD TEST

Place 100% (+0, -5%) of rated MBH load. Raise the test load approximately one foot and hold for 10 minutes. Observe for lowering of the load, which may indicate malfunction of hoisting components or brakes. There shall be no hoist roll back on the hoist drums.

Hoist Static Test/roll back test SAT UNSAT

4.2 DYNAMIC LOAD TEST

1. Raise, stop and lower the test load then stop for a few cycles using low speed and visually observe smooth control.

Hoist Dynamic Test SAT UNSAT

SAT UNSAT

Appendix C Sheet 7 of 8 Rev. 0

2. Verify that the hoist speed (+/- 10%) is in accordance with the contract requirements.

MBH with Test Load Required Measured

Low Hoisting Speed _____ fpm SAT UNSAT

High Hoisting Speed _____ fpm SAT UNSAT

4.3 LOAD INDICATORS

Verify the load indicator display located in the operator’s cab and on the remote control unit(s) provide a continuous readout of the wire rope pull in pounds. Verify when the system detects that the hoists are at 100% of the rated load a warning alarm will sound.

A key controlled by-pass switch shall be provided for the overload testing of the MBH.

Load indicator display SAT UNSAT

Load indicator warning alarm sounds SAT UNSAT

Load indicator system equipped with a by-pass switch SAT UNSAT

4.4 HOIST LOSS OF POWER

Raise the load sufficient height to perform the test. Lower the load slowly and press the power off button.

The brake shall set, and the load shall stop lowering.

Hoist Loss of Power SAT UNSAT

4.5 GANTRY TRAVEL TEST

Travel a minimum of 50 feet forward and reverse direction steering left and right testing for proper steering operation. Verify steering is in accordance with OEM instructions. At slow speed, disengage the drive levers and verify that the drive motion control system smoothly stops the crane’s travel.

Verify that gantry travel speeds (+/- 10%) are in accordance with contract requirements.

MBH with Test Load Required Measured

Gantry Travel Low Speed _____ fpm SAT UNSAT

Gantry Travel High Speed _____ fpm

Travel Functions (steering, brakes, alarm, emergency stop …) SAT UNSAT

5. HOOK TRAM POINTS MEASUREMENT AFTER 100% LOAD TEST

After the load test and the load removal, measure and record the distance between tram points (±1/64 inch) to enter to the cells “Hook Tram Measurement After Load” in table in Section 2.2.2 and complete the “Hook Status”.

Task Completed

6. REMOTE DIAGNOSTIC CAPABILITY

Appendix C Sheet 8 of 8 Rev. 0

If the boat hoist is equipped with remote diagnostic capability, the hardware on the boat hoist that supports connection shall be remove. Before removal of the hard ware, the control shall be programmed to clear the message that the machine may display at start up for missing the hardware.

The removed hardware shall be handed to the Government.

Hardware removed and handed to the Government COMPLETED NA No missing hardware message at start up SAT UNSAT

7. MBH CONDTIONS POST-TEST

Check mechanical and electrical components of all functions for signs of overheating, displaced components, leaking seals, loose fasteners or other damage. Check structural components for loose fasteners, signs of deformation or other damage.

Mechanical, Electrical and Structural Component Condition SAT UNSAT

8. COMMENTS