Attachment 0008 - Appendix B.pdf
PDF 669 KB Posted
- Attached to
- Ship-To-Shore Container Cranes
- Solicitation number
- W56HZV-20-R-0025
About this file
This document contains testing procedures for two 40 long ton ship-to-shore container cranes to be delivered to the Military Ocean Terminal Concord in California. The testing procedures outline verification of lubrication points, brake settings, couplings, emergency stop systems, operational tests of the main hoist drive, trolley drive, boom hoist drive and gantry drive. Tests will include function, speed, load capacity up to 125% of rated load, and endurance testing over 24 hours. Noise, temperature and loss of power will also be checked during testing. Appendix B provides sample testing procedures for verifying the cranes meet technical requirements before acceptance.
View the file
Other files
Show all 40
On GovTribe
Work with this file
- Download the original file
- Contacts named in this file
- Similar government files
- Ask GovTribe AI about this file
Text version
APPENDIX B: (SAMPLE) SHOP TESTING PROCEDURES
APPENDIX B
SAMPLE TEST PROCEDURE
FOR
TWO 40 LONG TON CONTAINER CRANES
AT
MILITARY OCEAN TERMINAL, CONCORD (MOTCO), CALIFORNIA
Customer: Army Contracting Command - Warren Date of Inspection/Test: ___________
Contract No.: ___________________ 6501 E. 11 Mile Road
Warren, MI48397-0001
Test Location: ___________________
Crane Builder: __________________ Crane Serial Number: ____________
Names and Titles of Participating Representatives:
Government Representative: Contractor Representative:
1. General 1
1.1 Instructions 1
1.2 Inspection Code 1
1.3 Equipment Monitoring 1
1.4 Precaution during Testing 1
1.5 Cargo Beam Load Hook 1
2. Verification 2
2.1 Lubrication 2
2.1.1 Main Hoist Drive 2
2.1.2 Trolley Drive 2
2.1.3 Boom Hoist Drive 2
2.1.4 Gantry Drive 3
2.1.5 Travelling Trolley 3
2.1.6 Girder End Section 3
2.1.7 Boom Hinge Section 3
2.1.8 Boom Section 4
2.1.9 Waterside Catenary 4
2.1.10 Landside Catenary 4
2.1.11 Top Beam 5
2.1.12 Forestay 5
2.1.13 Hydraulic System 5
2.2 Brake Settings 5
2.2.1 Hoist Primary (Motor) Brakes, Trolley and Boom Brakes 5
2.2.2 Hoist Drum Caliper Disc Brakes (Caliper Brake) 6
2.2.3 Caliper Brake Release 6
2.2.4 Gantry Brakes 6
2.3 Coupling Alignment 7
2.4 Emergency Stop System 7
2.4.1 Main Hoist Overspeed Switches 7
2.4.2 Boom Hoist Overspeed Switch 7
2.4.3 Emergency Pushbuttons 7
2.4.4 Emergency Stop System Check during Operation 8
2.4.5 Verifying Motion Interlock 8
2.4.6 Spreader Cable Reel System 8
2.4.7 Gantry Cable Reel System 9
2.4.8 Lighting Visual Check 9
2.4.9 Lighting Level Measurement 9
2.4.10 Emergency Egress Lighting 10
2.4.11 Obstruction Lights 10
2.4.12 Sound Level 10
2.4.13 Elevator Operation 11
2.4.14 Air Compressor 11
2.4.15 Anemometer Function 11
2.4.16 Anemometer Display 12
2.4.17 Intercom 12
2.4.18 Fire Detection/Alarm System 12
2.4.19 Convenient Outlets 12
2.4.20 Crane Management System (CMS) 13
2.4.21 Spreader - Normal Mode 13
2.4.22 Spreader - Twin 20 Mode 13
2.4.23 Spreader - Twin 20 Detection System (TTDS) 14
3. Operational Tests 14
3.1 Main Hoist Drive 14
3.1.1 Main Hoist Drive - Hoisting Function 14
3.1.2 Main Hoist Drive - Lowering Function 14
3.1.3 Main Hoist Drive - Motion Interlock Function 15
3.1.4 Main Hoist Drive - Brakes Functional Tests 15
3.1.5 Main Hoist Drive - Emergency Brake Hydraulic System 16
3.1.6 Main Hoist Drive - Emergency Drive Functional Test 16
3.1.7 Main Hoist Drive - Load Weighing System Test 16
3.1.8 Main Hoist Drive - Speed Test 16
3.1.9 Boom Deflection 17
3.1.10 Main Hoist Drive - Hoist Roll Up / Roll Down Test 17
3.1.11 Main Hoist Drive - Trim/List/Skew Test 17
3.1.12 Main Hoist Drive - Trim/List/Skew Interlock Test 18
3.1.13 Main Hoist Drive - Over Load (125% +0/-5%) Test 18
3.2 Trolley Drive 18
3.2.1 Trolley Drive - Forward Function 18
3.2.2 Trolley Drive - Reverse Function 19
3.2.3 Trolley Drive - Motion Interlock 19
3.2.4 Trolley Drive - Brake Tests 19
3.2.5 Trolley Drive - Emergency Drive Functional Test 20
3.2.6 Trolley Drive - Speed Test 20
3.3 Boom Hoist Drive 21
3.3.1 Boom Hoist Drive - Hoisting Function 21
3.3.2 Boom Hoist Drive - Lowering Function 21
3.3.3 Boom Hoist Drive - Motion Interlock Function 21
3.3.4 Boom Hoist Drive - Brake Test 22
3.3.5 Boom Hoist Drive - Emergency Drive Functional Test 22
3.3.6 Boom Hoist Drive - Speed Test 22
3.4 Gantry Drive 23
3.4.1 Gantry Drive - Travel Right Function 23
3.4.2 Gantry Drive - Travel Left Function 23
3.4.3 Gantry Drive - Interlock Function 23
3.4.4 Gantry Drive - Brake Operation 25
3.4.5 Gantry Drive - Speed Test 25
4. Crane Shakedown Test 25
5. Crane Endurance Test 26
6. Noise Level and Temperature Check 26
7. Loss of Power Test 27
8. Machinery House Service (Bridge) Crane Test 27
8.1 General Instruction 27
8.2 Procedures 27
8.2.1 Lubrication 27
8.2.2 Brakes 27
8.2.3 Pendant Control 28
8.2.4 Clearance 28
8.2.5 Motor Controls - Main Hoist 28
8.2.6 Motor Control - Trolley 28
8.2.7 Motor Control - Bridge 29
8.2.8 Bumper and Stops 29
8.2.9 Limit Switches 29
8.2.10 Warning Devices 29
1. General
Minimum Testing
The tests described in this procedure are the minimum acceptable level of testing. Additional testing shall be performed as needed to fully demonstrate compliance with the contract requirements and that the cranes, including all supporting equipment, are safe, reliable, and productive. Additional testing shall be determined by the Contractor’s final design. No less than thirty (30) days prior to the scheduled start of testing, the
Contractor shall provide an updated copy of these test requirements to the Contracting Officer for review and approval. The Government reserves the right to require additional tests which may prove necessary.
1.1 Instructions
Testing shall be in accordance with the appropriate paragraphs of this procedure. The sequence of testing is at the option of the test director, except that no-load tests shall be performed first.
Where not indicated, the “rated load” equals the 100% (-5%/+0) of the crane capacity, and the “test load” equals to 125%, (-5%/+0) of the crane capacity.
A long ton in this test procedure equals to 2,240 lbs.
1.2 Inspection Code
Sat = Satisfactory, Un-sat = Unsatisfactory, NA= Not applicable
1.3 Equipment Monitoring
During testing, check for proper operation and condition of safety devices, electrical components, mechanical equipment, and structural assemblies. Defects critical to continuing testing shall be reported immediately to the test director who shall suspend testing for correction of the deficiency.
Weights and tare weights permanently marked on each solid weight and test weight frames shall be clearly verified.
1.4 Precaution during Testing
Use extreme caution at all times. Only personnel directly involved in the test should be near the crane.
Personnel shall remain clear of suspended loads and areas where they could be struck in the event of component failure.
Raise the test load to a height sufficient to perform the test.
1.5 Cargo Beam Load Hook
Measure the cargo beam hook throat spread before and after the 125 percent (+0, -5 percent) load test by establishing throat dimension base measurements by installing three tram points. Measurement shall be within ± 1/64 of an inch and record the distance between the tram points.
Any increase in the throat opening from the base measurement shall be cause for hook rejection. Record the hook and nut identification number. Check operation of safety latches where provided.
Hook Identification Number: ____________
Nut Identification Number: ____________
Hook Throat Spread before Load Testing: A to B = ______, and A to C = ______
Hook Throat after Load Testing: A to B = ______, and A to C = ______
Hook Throat Evaluation after Test: SAT / UNSAT
Hook Safety Latch: SAT / UNSAT
2. Verification
2.1 Lubrication
The Contractor shall provide a detailed list of all lubrication points on the cranes including supporting equipment. All lubrication points shall be included in the list and tested prior to the start of any motion testing. The lubrication points provided below are only a subset of the expected lubrication points to be tested.
2.1.1 Main Hoist Drive
Group Location Check Point Status
Bearings Drum Pillow Blocks Grease Filling Sat / Un-sat / NA
Gear Box Gear Oil Oil Level Sat / Un-sat / NA
Input & Output Shaft Grease Filling Sat / Un-sat / NA
Geared Motor Gear Oil Oil Level Sat / Un-sat / NA
Couplings Motor and Drum Couplings Grease Filling Sat / Un-sat / NA
Other
Brake Oil Oil Level Sat / Un-sat / NA
Drum Coupling Grease Filling Sat / Un-sat / NA
Brake Coupling Grease Filling Sat / Un-sat / NA
Wire Rope Lubricate Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.2 Trolley Drive
Group Location Check Point Status
Bearings Drum Pillow Block Grease Filling Sat / Un-sat / NA
Gear Box Gear Oil Oil Level Sat / Un-sat / NA
Input & Output Shaft Grease Filling Sat / Un-sat / NA
Geared Motor Gear Oil Oil Level Sat / Un-sat / NA
Couplings Motor and Drum
Couplings Grease Filling Sat / Un-sat / NA
Other
Brake Oil Oil Level Sat / Un-sat / NA
Drum Coupling Grease Filling Sat / Un-sat / NA
Brake Coupling Grease Filling Sat / Un-sat / NA
Wire Rope Lubricate Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.3 Boom Hoist Drive
Group Location Check Point Status
Bearings Drum Pillow Block Grease Filling Sat / Un-sat / NA
Gear Box Gear Oil Oil Level Sat / Un-sat / NA
Input & Output Shaft Grease Filling Sat / Un-sat / NA
Geared Motor Gear Oil Oil Level Sat / Un-sat / NA
Couplings Motor and Drum
Couplings Grease Filling Sat / Un-sat / NA
Other
Brake Oil Oil Level Sat / Un-sat / NA
Drum Coupling Grease Filling Sat / Un-sat / NA
Brake Coupling Grease Filling Sat / Un-sat / NA
Wire Rope Lubricate Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.4 Gantry Drive
Group Location Check Point Status
Bearings Wheel Bearing Grease Filling Sat / Un-sat / NA
Pins
Main Equalizer Pin Grease Filling Sat / Un-sat / NA
4 Wheel Equalizer Pin Grease Filling Sat / Un-sat / NA
Truck Pins Grease Filling Sat / Un-sat / NA
Gear Box Gear Oil Oil Level Sat / Un-sat / NA
Input & Output Shaft Grease Filling Sat / Un-sat / NA
Others Brake Coupling Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.5 Travelling Trolley
Group Location Check Point Status
Bearings
Wheel Shaft Pillow Block Grease Filling Sat / Un-sat / NA
Wheel Guide Roller Grease Filling Sat / Un-sat / NA
Main Hoist Sheaves Grease Filling Sat / Un-sat / NA
Trolley Rope Eq. Sheaves Grease Filling Sat / Un-sat / NA
Push Arm Floating Arm Grease Filling Sat / Un-sat / NA
Others Cable Reel Gear box Oil Level Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.6 Girder End Section
Group Location Check Point Status
Bearings Wheel Bearing Grease Filling Sat / Un-sat / NA
Pins
Main Equalizer Pin Grease Filling Sat / Un-sat / NA
4 Wheel Equalizer Pin Grease Filling Sat / Un-sat / NA
Truck Pins Grease Filling Sat / Un-sat / NA
Gear Box Gear Oil Oil Level Sat / Un-sat / NA
Input & Output Shaft Grease Filling Sat / Un-sat / NA
Others Brake Coupling Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.7 Boom Hinge Section
Group Location Check Point Status
Bearings Boom Hinge Pins Grease Filling Sat / Un-sat / NA
Pins Trolley Mechanical Stop Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.8 Boom Section
Group Location Check Point Status
Bearings
Main Hoist Sheaves Grease Filling Sat / Un-sat / NA
Main EQ. Sheaves Grease Filling Sat / Un-sat / NA
Cat. Trolley Sheaves Grease Filling Sat / Un-sat / NA
Boom Hoist Sheaves Grease Filling Sat / Un-sat / NA
Pins
Boom Hoist Tackle Block
Pin Grease Filling Sat / Un-sat / NA
Outer Forestay Lower Pins Grease Filling Sat / Un-sat / NA
Inner Forestay Lower Pins Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.9 Waterside Catenary
Group Location Check Point Status
Bearings Sheaves Grease Filling Sat / Un-sat / NA
Wheels Grease Filling Sat / Un-sat / NA
Rollers
Guide Roller Grease Filling Sat / Un-sat / NA
Hoist Rope Roller Grease Filling Sat / Un-sat / NA
Trolley Rope Support Roller Grease Filling Sat / Un-sat / NA
Cat. Rope Support Roller Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.10 Landside Catenary
Group Location Check Point Status
Bearings Sheaves Grease Filling Sat / Un-sat / NA
Wheels Grease Filling Sat / Un-sat / NA
Rollers
Guide Roller Grease Filling Sat / Un-sat / NA
Hoist Rope Roller Grease Filling Sat / Un-sat / NA
Trolley Rope Support Roller Grease Filling Sat / Un-sat / NA
Cat. Rope Support Roller Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.11 Top Beam
Group Location Check Point Status
Bearings Sheaves Grease Filling Sat / Un-sat / NA
Wheels Grease Filling Sat / Un-sat / NA
Rollers
Guide Roller Grease Filling Sat / Un-sat / NA
Hoist Rope Roller Grease Filling Sat / Un-sat / NA
Trolley Rope Support Roller Grease Filling Sat / Un-sat / NA
Cat. Rope Support Roller Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.12 Forestay
Group Location Check Point Status
Pins
Outer Forestay Middle Pin (I) Grease Filling Sat / Un-sat / NA
Outer Forestay Middle Pin (II) Grease Filling Sat / Un-sat / NA
Inner Forestay Middle Pin (II) Grease Filling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.1.13 Hydraulic System
Check Point Oil Spec Status
Trim/List/Skew/Snag Hydraulic Oil Level Sat / Un-sat / NA
Hoist Emergency Brake Oil Level Sat / Un-sat / NA
Boom Emergency Brake Oil Level Sat / Un-sat / NA
Gantry Wheel Hydraulic Oil Level Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.2 Brake Settings
Verify brake settings with the approved brake setting records or with brake manufacturer’s recommended clearances, air gap settings and torque settings.
2.2.1 Hoist Primary (Motor) Brakes, Trolley and Boom Brakes
Main (Left) Main (Right) Trolley Boom
Brake
Manufacturer/Model
Air Gap Settings Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Torque Adjusted
Settings Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Shoe Contact Meets
Requirement Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Actual Lining
Thickness Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.2.2 Hoist Drum Caliper Disc Brakes (Caliper Brake)
Brake Manufacturer/Model: ______________________________
Main (Left Side) Main (Right Side) Boom
Brake Manufacturer/Model
Air Gap Settings Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Torque Adjusted Settings Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Shoe Contact Meets
Requirement Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Actual Lining Thickness Sat / Un-sat / NA Sat / Un-sat / NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.2.3 Caliper Brake Release
Each caliper brake has to be released 4 (four) times with the hydraulic pump inoperative. Check system pressure switch settings prior to release.
System Pressure Main (Left Side)
_____ psi
Main (Right Side)
_____ psi Boom _____ psi
First Release
(Actual) _____ psi, Sat / Un-sat / NA _____ psi, Sat / Un-sat / NA _____ psi, Sat / Un-sat /NA
Second Release
(Actual) _____ psi, Sat / Un-sat / NA _____ psi, Sat / Un-sat / NA
_____ psi, Sat / Un-sat /NA
Third Release
(Actual) _____ psi, Sat / Un-sat / NA _____ psi, Sat / Un-sat / NA
_____ psi, Sat / Un-sat /NA
Forth Release
(Actual) _____ psi, Sat / Un-sat / NA _____ psi, Sat / Un-sat / NA
_____ psi, Sat / Un-sat /NA
Verify that the manual backup pump can provide the needed pressure to open the brake.
System Pressure Main _______ psi Boom _______ psi
Manual Backup Pump Work Sat / Un-sat / NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.2.4 Gantry Brakes
Truck
Drive Wheel
Brake
Idler Wheel
Brake
Truck
Drive Wheel
Brake
Idler Wheel
Brake
1 Sat / Un-sat / NA Sat / Un-sat / NA 9 Sat / Un-sat / NA Sat / Un-sat / NA
2 Sat / Un-sat / NA Sat / Un-sat / NA 10 Sat / Un-sat / NA Sat / Un-sat / NA
3 Sat / Un-sat / NA Sat / Un-sat / NA 11 Sat / Un-sat / NA Sat / Un-sat / NA
4 Sat / Un-sat / NA Sat / Un-sat / NA 12 Sat / Un-sat / NA Sat / Un-sat / NA
5 Sat / Un-sat / NA Sat / Un-sat / NA 13 Sat / Un-sat / NA Sat / Un-sat / NA
6 Sat / Un-sat / NA Sat / Un-sat / NA 14 Sat / Un-sat / NA Sat / Un-sat / NA
7 Sat / Un-sat / NA Sat / Un-sat / NA 15 Sat / Un-sat / NA Sat / Un-sat / NA
8 Sat / Un-sat / NA Sat / Un-sat / NA 16 Sat / Un-sat / NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.3 Coupling Alignment
Review approved certification that all couplings are aligned to manufacturer’s installation criteria.
System Verification Status
Hoist, Motor Coupling, Left
Provide alignment measurement reports
Sat / Un-sat / NA
Hoist, Motor Coupling, Right Sat / Un-sat / NA
Hoist, Drum Coupling, Left Sat / Un-sat / NA
Hoist, Drum Coupling, Right Sat / Un-sat / NA
Boom, Motor Coupling Sat / Un-sat / NA
Boom, Drum Coupling Sat / Un-sat / NA
Trolley, Motor Coupling Sat / Un-sat / NA
Trolley, Drum Coupling Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4 Emergency Stop System
2.4.1 Main Hoist Overspeed Switches
Test Equipment Make/Model: ____________________ Calibration Date: _________
Data Test Value Status
Hoist Motor Rated Speed ____ RPM Sat / Un-sat / NA
Hoist Drum Rated Speed ____ RPM Sat / Un-sat / NA
Hoist Drum Mounted Trip
RPM
____ RPM +/- __ %
Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.2 Boom Hoist Overspeed Switch
Data Test Value Status
Hoist Motor Rated Speed ____ RPM Sat / Un-sat / NA
Hoist Drum Rated Speed ____ RPM Sat / Un-sat / NA
Hoist Drum Mounted Trip
RPM
____ RPM +/- __ %
Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.3 Emergency Pushbuttons
Verify De-energization and verify logging at CMS.
Please note this is not a complete list. Edit and add rows for actual locations
Note: this is a static test to verify drops control power and not actually E-stopping motion.
Location Verification Fault Display
Status On CMS In Cabin
Operator Right Console de-energized Sat / Un-sat / NA
OP Cabin Panel 01 Door de-energized Sat / Un-sat / NA
OP Cabin Panel 02 Door de-energized Sat / Un-sat / NA
PLC Panel Door de-energized Sat / Un-sat / NA
- and more as needed -
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.4 Emergency Stop System Check during Operation
This shall be verified from Operator Cabin Console
Location Verification from Operator’s Cab Status
Main Hoist Stop Raising Sat / Un-sat / NA
Stop Lowering Sat / Un-sat / NA
Trolley Stop Travel Forward Sat / Un-sat / NA
Stop Travel Reverse Sat / Un-sat / NA
Boom Hoist Stop Booming Up Sat / Un-sat / NA
Stop Lowering Down Sat / Un-sat / NA
Gantry Stop Travel Right Sat / Un-sat / NA
Stop Travel Left Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.5 Verifying Motion Interlock
Motion Hoist Boom Trolley Gantry Status
Hoist Raise / Lower Unable Forward/Reverse Unable Sat / Un-sat
Boom Unable Up / Down Unable Unable Sat / Un-sat
Trolley Raise/Lower Unable Forward / Reverse Unable Sat / Un-sat
Gantry Unable Unable Unable Left / Right Sat / Un-sat
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.6 Spreader Cable Reel System
Verify proper functioning of upper and lower limits for the spreader cable reel system and fault displayed.
Location Verification Fault Display
Status On CMS In Cabin
Upper limit (drum full) Reel stops Sat / Un-sat / NA
Lower limit (drum empty) Reel stops Sat / Un-sat / NA
Slack cable detection Reel stops Sat / Un-sat / NA
Cable over-tension detection Reel stops
Sat / Un-sat / NA
Cable tension condition Visual NA NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.7 Gantry Cable Reel System
Verify proper functioning of upper and lower limits for the gantry cable reel system and fault displayed.
Location Verification Fault Display
Status On CMS In Cabin
Drum full limit Reel stops Sat / Un-sat / NA
Travel limit Reel stops
Drum empty limit Reel stops Sat / Un-sat / NA
Slack cable detection Reel stops Sat / Un-sat / NA
Cable over-tension detection Reel stops
Sat / Un-sat / NA
Cable cross-over Smooth operation at full speed NA NA Sat / Un-sat / NA
Cable tension condition Visual NA NA Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.8 Lighting Visual Check
Visually verify adequate lighting. Note that table is sample. Add locations per design drawings.
No. Location Verification Status
1 Boom flood light, 1000W Visual Sat / Un-sat / NA
2 Portal flood light, 1000W Visual Sat / Un-sat / NA
3 Logo flood light, 400W Visual Sat / Un-sat / NA
4 M/House Fluorescent light, 32Wx2 Visual
5 To Cabin Walk-Way light, 40W Visual
- and more -
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.9 Lighting Level Measurement
Test Equipment Make/Model: ____________________ Calibration Date: _________
Location Verification Status
Walkways (average, per OSHA requirement) 50 lux Sat / Un-sat / NA
Machinery House 220 lux Sat / Un-sat / NA
Ground level below crane 200 lux Sat / Un-sat / NA
All Maintenance areas for machinery 100 lux Sat / Un-sat / NA
Logo on Machinery House 200 lux Sat / Un-sat / NA
Electrical rooms 300 lux Sat / Un-sat / NA
Sill Beams 100 lux Sat / Un-sat / NA
Lighting is controlled by a photo cell and switch from a panelboard in the machinery house.
PLC controls all lighting and is equipped with an emergency PLC bypass switch. Sat / Un-sat / NA
Floodlights are on separate circuit breaker Sat / Un-sat / NA
Walkway lights have a maximum of 10 individual lights connected to a single circuit breaker located in the machinery house and connected/wired to the PLC to indicate if the circuit breaker is tripped. Segregation of circuits (every other light on same circuit).
Sat / Un-sat / NA
Floodlights have a maximum of 9 individual lights connected to a single circuit breaker located in the machinery house and connected/wired to the PLC to indicate if the circuit breaker is tripped. Segregation of circuits (every other light on same circuit)
Sat / Un-sat / NA
Machinery house lighting circuit control & segregation Sat / Un-sat / NA
Electric house lighting circuit control & segregation Sat / Un-sat / NA
Walkway lighting circuit control & segregation Sat / Un-sat / NA
Circuit breaker trips, a message on the CMS shall be annunciated Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.10 Emergency Egress Lighting
Verify the operation of the battery powered emergency egress lighting which allows personnel to exit the crane from the Operator’s Cab and the Machinery House. Verify that at least 30% of the access lights from operator’s cabin and machinery house to ground level are equipped with battery and charging equipment.
Verify that an emergency light is provided in the elevator cab.
Operation of the battery powered (UPS) emergency egress lighting Sat / Un-sat / NA
At least 30% of the access walkway lights from operator’s cabin and machinery house to ground level are equipped with battery and charging equipment
All walkway lights on stairs/platforms
Walkway light on cab walkway/trolley
Sat / Un-sat / NA
Emergency light is provided in the elevator cab Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.11 Obstruction Lights
Verify obstruction lights at the top cross tie and the boom tip are those of approved type with battery backup.
Lights shall be reachable for re-lamping.
Obstruction Lights Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.12 Sound Level
Verify during crane operation
Equipment Make/Model: _____________ Calibration Date: _______
Location Verification Actual Status
Operator’s Cab No more than 70 dB ____ dB Sat / Un-sat / NA
Electrical Room ____ dB Sat / Un-sat / NA
PLC/CMS Room No more than 75 dB ____ dB Sat / Un-sat / NA
Machinery House ____ dB Sat / Un-sat / NA
2.4.13 Elevator Operation
No. Verification Remark Status
Run the elevator between top and bottom landing without intermediate stop.
Sat / Un-sat / NA
2 Run at fully capacity Sat / Un-sat / NA
3 Check Manual Lowering Sat / Un-sat / NA
4 Check Call Button Function each landing Sat / Un-sat / NA
5 Greasing at the Mast for Roller Sat / Un-sat / NA
6 Check Over Speed Sat / Un-sat / NA
7 Test Overload Sat / Un-sat / NA
8 Test Certificate by the elevator manufacturer Sat / Un-sat / NA
9 State elevator certification Sat / Un-sat / NA
Function Interlock verification
Door open Not working Sat / Un-sat / NA
Roof hatch opens Not working Sat / Un-sat / NA
Door not closed Alarm sounds Sat / Un-sat / NA
Gantry left/right Working Sat / Un-sat / NA
Elevator overload Not working Sat / Un-sat / NA
Upper over-travel switch Stop Sat / Un-sat / NA
Lower over-travel switch Stop Sat / Un-sat / NA
Emergency stop Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.14 Air Compressor
Verify operation and pressure setting
Measurement Status
Turning ON/OFF NA Sat / Un-sat / NA
Pressure setting ______ psi ____ psi Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.15 Anemometer Function
Items Operation and Test Status
Level 1
(44MPH)
Wind Speed Warning
The “High Wind Warning” AMBER light in the cab is
ON.
The warning alarm shall sound through the public address
(PA) system audible in the cab and at ground level.
Sat / Un-sat / NA
Level 2
(55MPH)
High Wind Speed Warning
The ‘High Wind Shutdown” RED light in the cab is ON.
The warning alarm shall sound through the public address
(PA) system audible in the cab and at ground level.
Sat / Un-sat / NA
Wind Limit Bypass Gantry motion is permitted in High Wind Shutdown conditions by using the "Wind limit Bypass" pushbutton.
2.4.16 Anemometer Display
Location Operation and Test Status
Electrical Room Verify display with wind direction Sat / Un-sat / NA
Operator Cabin Verify display with wind direction Sat / Un-sat / NA
PLC display Verify display with wind direction Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.17 Intercom
Location Verification Status
Operator's Cabin Working Sat / Un-sat / NA
Electrical Room Working Sat / Un-sat / NA
Control Room Working Sat / Un-sat / NA
Machinery house Working Sat / Un-sat / NA
Boom Operation Cabin Working Sat / Un-sat / NA
Elevator Working Sat / Un-sat / NA
Landside Gantry Working Sat / Un-sat / NA
Waterside Gantry Working Sat / Un-sat / NA
GE T/L/S Platform Working Sat / Un-sat / NA
Boom Control Station Working Sat / Un-sat / NA
Loud Speaker function Working Sat / Un-sat / NA
Sound distortion during hoist/trolley or gantry
Operator’s Cab Clear with no noticeable distortion Sat / Un-sat / NA
Boom Operation Cabin Clear with no noticeable distortion Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.18 Fire Detection/Alarm System
Location Verification Status
Electrical Room Alarm sounds upon simulation Sat / Un-sat / NA
Control Room Alarm sounds upon simulation Sat / Un-sat / NA
Machinery House Alarm sounds upon simulation Sat / Un-sat / NA
Operator’s Cabin Alarm sounds upon simulation Sat / Un-sat / NA
Suppressant System Fire Marshall testing and certification Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.19 Convenient Outlets
The list shows minimum requirement. Add more per design drawings
Built In Ground Fault Protection Device Sat / Un-sat / NA
One duplex receptacle in the operator's cab Sat / Un-sat / NA
One on the boom at the boom hoist connection Sat / Un-sat / NA
One at the gantry frame pylon top cross tie Sat / Un-sat / NA
Six in the machinery house Sat / Un-sat / NA
Two in the electric room Sat / Un-sat / NA
Eight at wharf elevation (four waterside and four landside) Sat / Un-sat / NA
One at the festoon system service platform Sat / Un-sat / NA
Three in the trolley machinery house Sat / Un-sat / NA
One on the backreach Sat / Un-sat / NA
One in Elevator Sat / Un-sat / NA
One in lower control room Sat / Un-sat / NA
Three power outlet 30 amp to 480 V machinery house, landside gantry, waterside gantry Sat / Un-sat / NA
Six power outlet 60 amp to 480 V machinery house, landside gantry, waterside gantry, boom tip, apex, backreach Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.20 Crane Management System (CMS)
The contractor shall develop the necessary items for verifying functionality of the CMS and presence of features required by technical specifications.
2.4.21 Spreader - Normal Mode
Note: Spreader shall be tested on the test weight frame for twistlock function
Items Operation and Test Method Status
Telescoping
Extension 20' -> 40' Lamp On Sat / Un-sat / NA
Extension 40' -> 42' Lamp On Sat / Un-sat / NA
Extension 20' -> 42' Lamp On Sat / Un-sat / NA
Retraction 42' -> 40' Lamp On Sat / Un-sat / NA
Retraction 40' -> 20' Lamp On Sat / Un-sat / NA
Retraction 42' -> 20' Lamp On Sat / Un-sat / NA
Twist Lock
Locking Lamp On Sat / Un-sat / NA
Unlocking Lamp On Sat / Un-sat / NA
Electrical Interlock Cannot twistlock Sat / Un-sat / NA
Mechanical Interlock Cannot twistlock Sat / Un-sat / NA
Flipper Up & Down Correct pair per selection Sat / Un-sat / NA
Up & Down Pair synchronization Sat / Un-sat / NA
Landing Landing Lamp On Sat / Un-sat / NA
Hoisting Empty Lamp Off Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.22 Spreader - Twin 20 Mode
Items Operation and Test Method Status
Twin-Lift Frame Up Lamp On Sat / Un-sat / NA
Down Lamp On Sat / Un-sat / NA
Twist Lock Locking Lamp On Sat / Un-sat / NA
Unlocking Lamp On Sat / Un-sat / NA
Landing Landing Lamp On Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
2.4.23 Spreader - Twin 20 Detection System (TTDS)
Operation and Test Method Fault Display Status
Telescope spreader at 40 foot mode
Land spreader on twin 20 foot containers
Try to lock the twist locks
Verify twist locks rotation is “Unable”
On CMS In Cabin Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3. Operational Tests
3.1 Main Hoist Drive
3.1.1 Main Hoist Drive - Hoisting Function
Items Verification Fault Display
Status On CMS In Cab
Hoist Up Smart Slowdown Hoist up properly N/A N/A Sat / Un-sat / NA
Hoist Rope Slack Slow Down N/A N/A Sat / Un-sat / NA
Spreader Landed Condition Slow Down N/A N/A Sat / Un-sat / NA
Hoist Normal Up Stop (lower limit) Electrical Stop Sat / Un-sat / NA
Hook Height Design Drawing Sat / Un-sat / NA
Hoist drums One empty groove on each side of drum
NA NA
Hoist Weight Type Limit Switch Activated
(Upper Limit) Mechanical Stop Sat / Un-sat / NA
Hoist Up Slowdown Check Fault Mechanical Stop Sat / Un-sat / NA
Headblock Lock Pin Released (Right Side) Mechanical Stop Sat / Un-sat / NA
Headblock Lock Pin Released (Left Side) Mechanical Stop Sat / Un-sat / NA
Over Load Electrical Stop Sat / Un-sat / NA
Snag Load Mechanical Stop Sat / Un-sat / NA
Eccentric Load Mechanical Stop Sat / Un-sat / NA
Spreader Cable Drum Full Electrical Stop Sat / Un-sat / NA
Spreader two-blocked Electrical Stop
No interference Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.2 Main Hoist Drive - Lowering Function
Items Verification Fault Display
Status On CMS In Cab
Hoist Down Smart Slowdown at Dock Lowering properly N/A N/A Sat / Un-sat / NA
Dock Side Hoist Normal Down Stop
(Lower Limit)
Electrical Stop N/A N/A Sat / Un-sat / NA
Hoist Down Inhibited at Sillbeam Electrical Stop N/A N/A Sat / Un-sat / NA
Hoist Rope Slacked after Landing Electrical Stop Sat / Un-sat / NA
Hoist Down after Spreader Landed Electrical Stop Sat / Un-sat / NA
Dock Side Down Slowdown check Fault Mechanical Stop Sat / Un-sat / NA
Water Side Down Slowdown check Fault Mechanical Stop Sat / Un-sat / NA
Water Side Down Stop Electrical Stop Sat / Un-sat / NA
Hoist Down Smart Slowdown at Water Side Function properly Sat / Un-sat / NA
Spreader Cable Drum Empty Electrical Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.3 Main Hoist Drive - Motion Interlock Function
Items Verification Fault Display
Status On CMS In Cab
#1 Service Brake Closed Motion Inhibited Sat / Un-sat / NA
#2 Service Brake Closed Motion Inhibited Sat / Un-sat / NA
#1 Emergency Brake Closed Motion Inhibited Sat / Un-sat / NA
#2 Emergency Brake Closed Motion Inhibited Sat / Un-sat / NA
#1 Motor Blower De-energized Motion Inhibited Sat / Un-sat / NA
#2 Motor Blower De-energized Motion Inhibited Sat / Un-sat / NA
Boom is in Motion Motion Inhibited Sat / Un-sat / NA
Encoder Fault Motion Inhibited Sat / Un-sat / NA
#1 Hoist Motor Over-temp Fault Motion Inhibited Sat / Un-sat / NA
#2 Hoist Motor Over-temp Fault Motion Inhibited Sat / Un-sat / NA
Any Control Fault
(PLC Communication Cable Disconnection)
Motion Inhibited Sat / Un-sat / NA
Emergency Brake Hyd. Oil Level Low Motion Inhibited Sat / Un-sat / NA
Emergency Brake Hyd. High Temperature Motion Inhibited Sat / Un-sat / NA
Spreader Cable Reel Drive not Ready Motion Inhibited Sat / Un-sat / NA
Spreader Cable Reel Manual Selected Motion Inhibited Sat / Un-sat / NA
Spreader Cable Reel Motor Over Temp. Motion Inhibited Sat / Un-sat / NA
Drum Overspeed switch activated Motion Inhibited Sat / Un-sat / NA
Emergency Motor connected (prox. switch) Motion Inhibited Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.4 Main Hoist Drive - Brakes Functional Tests
Hoist up and down from ground level to upper limit with different speeds and verify proper operation of the brakes with e-stops, both loaded and unloaded. Ensure adequate time is provided between tests to avoid overheating brakes.
Item Operation and Test Method Status
Motor Brakes
Brake Function at Empty
Spreader, normal and E-stop
Brake A Sat / Un-sat / NA
Brake B Sat / Un-sat / NA
Brake Function at Rated
Load, normal and E-stop
Brake A Sat / Un-sat / NA
Brake B Sat / Un-sat / NA
Emergency Brakes
Hydraulic Pressure ____ psi Sat / Un-sat / NA
Brake Function at Rated Load
Condition, normal and E-stop Both Brakes Sat / Un-sat / NA
3.1.5 Main Hoist Drive - Emergency Brake Hydraulic System
Items Operation and Test Method Status
System Max. Pressure (Pump-Motor
Power On/Off) Approx. ____ psi Sat / Un-sat / NA
Pressure for Brake Release Signal Approx. ____ psi Sat / Un-sat / NA
Motor 'On' Time _____ sec. Sat / Un-sat / NA
Motor 'On' Interval _____ min. Sat / Un-sat / NA
Release by Manual L/S On Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.6 Main Hoist Drive - Emergency Drive Functional Test
Turn off power for the main drive to simulate emergency situation for testing the emergency drive.
Manually release the drum brakes. Manually connect the emergency motor and verify the followings:
Items Verification Status
Motor Brakes Brakes opened by emergency power Sat / Un-sat / NA
Hoisting function from ground to max height Hoist up in appx. _______ minutes Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.7 Main Hoist Drive - Load Weighing System Test
Load Verification (allows + 5%) Status
No Load
(0 lb)
Weight Display in Op. Cab ____ lbs Sat / Un-sat / NA
Weight Display at Gantry location ____ lbs Sat / Un-sat / NA
Rated Load
( ____ lbs)
Weight Display in Op. Cab ____ lbs Sat / Un-sat / NA
Weight Display at Gantry location ____ lbs Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.8 Main Hoist Drive - Speed Test
All hoisting and lowering for no load and rated load shall be at full speed, full acceleration, and full deceleration rates. Record all data using strip chart recorders.
Actual Weight: ____________ lbs.
Verification Actual Status
Empty Spreader
(No-Load)
Voltage / Current Up ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Up: 490 fpm, min Sat / Un-sat / NA
Voltage / Current Down ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Down: 490 fpm, min Sat / Un-sat / NA
Acc/Dec: 4 seconds Sat / Un-sat / NA
Spreader
Rated Load
Voltage / Current Up ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Up: 250 fpm, min Sat / Un-sat / NA
Voltage / Current Down ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Down: 250 fpm, min Sat / Un-sat / NA
Acc/Dec: 2 seconds Sat / Un-sat / NA
Hoist Up
Cargo Beam and Hook
(Rated Load)
Voltage / Current Up ____ Volt / ____ Amp Sat / Un-sat / NA
Voltage / Current Down ____ Volt / ____ Amp Sat / Un-sat / NA
Min. ___ fpm Sat / Un-sat / NA
Lowering
Cargo Beam and Hook
(Rated Load)
Voltage / Current Up ____ Volt / ____ Amp Sat / Un-sat / NA
Voltage / Current Down ____ Volt / ____ Amp Sat / Un-sat / NA
Min. ___ fpm Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.9 Boom Deflection
Record the amount of main/boom girder deflection with the trolley positioned at the backreach with no load and at the outreach limit with the rated load. The difference of the two measurement is
Trolley with No Load at Backreach ____feet ____inches ____feet ____inches
Trolley with Rated Load at Outreach Limit ____feet ____inches ____feet ____inches
Boom Deflection ____inches ( Sat / Un-sat / NA )
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.10 Main Hoist Drive - Hoist Roll Up / Roll Down Test
Raise rated load to sufficient height for this test. Verifying roll up and roll down by watching hoist drum rotation.
Status
Rated Load
Actual Weight: __________ lbs.
Hoisting rated load from a stop Sat / Un-sat / NA
Lowering rated load from a stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.11 Main Hoist Drive - Trim/List/Skew Test
The functions of Trim/List/Skew shall be tested with both an empty container and with the maximum rated eccentric load. Time measurement shall be taken in operator’s cabin display.
Correction Speed Check Requirement Actual Status
Trim Right Down 0o - 3o 10 sec +10% ______ sec Sat / Un-sat / NA
Trim Left Down 3o - 0o 10 sec +10% ______ sec Sat / Un-sat / NA
List Forward 0o - 3o 10 sec +10% ______ sec Sat / Un-sat / NA
List Backward 3o - 0o 10 sec +10% ______ sec Sat / Un-sat / NA
Skew Clockwise 0o - 3o 10 sec +10% ______ sec Sat / Un-sat / NA
Skew C-Clockwise 3o - 0o 10 sec +10% ______ sec Sat / Un-sat / NA
3.1.12 Main Hoist Drive - Trim/List/Skew Interlock Test
The contractor shall develop testing step for any interlock function of the Trim/List/Skew feature.
T/L/S HPU
low oil level Electrical stop Sat / Un-sat / NA
T/L/S HPU
Oil temperature high Electrical stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.1.13 Main Hoist Drive - Over Load (125% +0/-5%) Test
Verify overload protection prevent lifting and bypassing it allowing lifting. Raising and lowering hoist at various slow speed and stop to verify brake operation.
Perform above test at between legs and at boom end
Stop the load at sufficient height. Mark the hoist drum and carefully release the pair of motor brakes to test the drum disc brakes for the 10 minutes holding. After the test, carefully release the pair of drum disc brakes to test the motor brakes for the 10 minutes holding. Verify each pair of hoist brake is capable of holding the test load without load lowering.
Status
125% (-5% / +0) of Rated Load:
Actual Weight: _________ lbs.
Overload protection and bypassing Sat / Un-sat / NA
Function and dynamic braking test between legs Sat / Un-sat / NA
Function and dynamic braking test at boom end Sat / Un-sat / NA
Motor brake # 1 and 2static test Sat / Un-sat / NA
Drum caliper brake # 1 and 2 static test Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.2 Trolley Drive
3.2.1 Trolley Drive - Forward Function
Items Verification Fault Display
Status On CMS In Cab
Forward Smart Slowdown Functional N/A N/A Sat / Un-sat / NA
Forward Emergency Stop LS Activated Mechanical Stop Sat / Un-sat / NA
Forward Normal Stop Activated Electrical Stop Sat / Un-sat / NA
Outreach Distance Design Drawing Sat / Un-sat / NA
Forward Land Side Sillbeam Protection Electrical Stop Sat / Un-sat / NA
Forward Water Side Sillbeam Protection Electrical Stop Sat / Un-sat / NA
Forward Normal Stop LS Activated When
Boom is slightly Up (out of level)
Electrical Stop Sat / Un-sat / NA
Forward Normal Stop LS Activated When
Boom Up Position
Electrical Stop Sat / Un-sat / NA
Forward Slowdown Check Fault Mechanical Stop Sat / Un-sat / NA
3.2.2 Trolley Drive - Reverse Function
Items Verification Fault Display
Status On CMS In Cab
Reverse Smart Slowdown Functional N/A N/A Sat / Un-sat / NA
Reverse Emergency Stop LS Activated Mechanical Stop Sat / Un-sat / NA
Reverse Normal Stop Activated Electrical Stop Sat / Un-sat / NA
Backreach Distance Design Drawing Sat / Un-sat / NA
Reverse Water Side Sillbeam Protection Electrical Stop Sat / Un-sat / NA
Reverse Land Side Sillbeam Protection Electrical Stop Sat / Un-sat / NA
Reverse Slowdown Check Fault Mechanical Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.2.3 Trolley Drive - Motion Interlock
Items Verification Fault Display
Status On CMS In Cab
Boom Position Interlock (Intermediate Position) Motion Inhibited Sat / Un-sat / NA
Brake Closed Motion Inhibited Sat / Un-sat / NA
Cab Access Gate L/S (cab side) Open Motion Inhibited Sat / Un-sat / NA
Cab Access Gate L/S (leg side) Open Motion Inhibited Sat / Un-sat / NA
Cat. Trolley Rope Tensioner Low Pressure Motion Inhibited Sat / Un-sat / NA
Trolley Rope Tensioner Cylinder Max
Extend/Retract switch activated Motion Inhibited Sat / Un-sat / NA
Trolley Stowage Pin Released P/S Not Activated Motion Inhibited Sat / Un-sat / NA
Over Load Motion Inhibited Sat / Un-sat / NA
Snag Load Motion Inhibited Sat / Un-sat / NA
Hoist Rope Slack Motion Inhibited Sat / Un-sat / NA
Spreader Landed Motion Inhibited Sat / Un-sat / NA
Any Control Fault (PLC Communication Cable
Disconnection) Motion Inhibited Sat / Un-sat / NA
Encoder Fault Motion Inhibited Sat / Un-sat / NA
Headblock Lock Pin Released (Right Side) Motion Inhibited Sat / Un-sat / NA
Headblock Lock Pin Released (Left Side) Motion Inhibited Sat / Un-sat / NA
Trolley Motor Over-temp Fault Motion Inhibited Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.2.4 Trolley Drive - Brake Tests
Travel trolley with different speeds and making stops to verify trolley brake proper operation. Travel the trolley and E-stop to verify brakes functionality.
Brake Operation Status
Rated Load
Actual Weight: ____________ lbs.
Brake Function at Empty Spreader, normal and E-stop Sat / Un-sat / NA
Brake Function at Rated Load, normal and E-stop
Test Load
Actual Weight: ____________ lbs.
Brake Function at Test Load, normal and E-stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.2.5 Trolley Drive - Emergency Drive Functional Test
Turn off power to simulate emergency situation for testing the emergency drive. Manually connect the emergency motor to trolley drive and verify the followings:
Items Verification Status
Motor Brakes Brakes opened by emergency power Sat / Un-sat / NA
Trolley function from boom end back to pass boom hinge point Trolley time (appx.) ____ minutes Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.2.6 Trolley Drive - Speed Test
Travel the trolley forward and reverse with the rated load and with an empty spreader at full acceleration, full speed, and full deceleration to verify and record the following. Provide strip-chart record of tests.
Actual Weight: __________ lbs.
Verification Actual Status
Spreader with
Rated Load
Voltage / Current Forward ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Forward: 600 fpm, min.
Sat / Un-sat / NA
Voltage / Current Reverse ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Reverse: 600 fpm, min.
Sat / Un-sat / NA
Acc/Dec: 5 seconds Sat / Un-sat / NA
Stopping distance from full speed is less than 60ft.
Sat / Un-sat / NA
Cargo Beam and Hook
With Rated Load
Voltage / Current Forward ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Forward: 600 fpm, min.
Sat / Un-sat / NA
Voltage / Current Reverse ____ Volt / ____ Amp Sat / Un-sat / NA
Speed Reverse: 600 fpm, min.
Sat / Un-sat / NA
Acc/Dec: 5 seconds Sat / Un-sat / NA
Stopping distance from full speed is less than 60ft.
3.3 Boom Hoist Drive
3.3.1 Boom Hoist Drive - Hoisting Function
Items Verification Fault Display Status
On CMS In Cab
Boom Up Emergency Stop LS Activated Mechanical Stop Sat / Un-sat / NA
Boom Up Slow Down Activated Slow Down N/A N/A Sat / Un-sat / NA
Boom Up Normal Stop Activated Electrical Stop Sat / Un-sat / NA
Boom Angle, Stowed & Passing Position Design Drawing N/A N/A Sat / Un-sat / NA
Boom Angle, Maintenance 80 degrees, min N/A N/A Sat / Un-sat / NA
Boom Drum One empty groove left on each side Sat / Un-sat / NA
Boom Up Normal Stop LS Activated Electrical Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.3.2 Boom Hoist Drive - Lowering Function
Items Verification Fault Display Status
On CMS In Cab
Boom Down Slow Down Activated Slow Down N/A N/A Sat / Un-sat / NA
Boom Down Back-Up Stop Mechanical Stop Sat / Un-sat / NA
Boom Down Normal Stop LS (Rope Slack
LS) Activated
Electrical Stop Sat / Un-sat / NA
Boom Drum
Min. 2 full wraps of rope on each side
Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.3.3 Boom Hoist Drive - Motion Interlock Function
Items Verification Fault Display
Status On CMS In Cab
Trolley Position Interlock Motion Inhibited Sat / Un-sat / NA
Service Brake Closed Motion Inhibited Sat / Un-sat / NA
Emergency Brake Closed (Upper Side) Motion Inhibited Sat / Un-sat / NA
Emergency Brake Closed (Lower Side) Motion Inhibited Sat / Un-sat / NA
Any Control Fault
(PLC Communication Cable Disconnection) Motion Inhibited Sat / Un-sat / NA
Encoder Fault Motion Inhibited Sat / Un-sat / NA
Boom Lock Pin Not Unlocked (Left Side) Motion Inhibited Sat / Un-sat / NA
Boom Lock Pin Not Unlocked (Right Side) Motion Inhibited Sat / Un-sat / NA
Boom Motor Over-temp Fault Motion Inhibited Sat / Un-sat / NA
Emergency Brake Hyd. Oil Level Low Motion Inhibited Sat / Un-sat / NA
Emergency Brake Hyd. High Temperature Motion Inhibited Sat / Un-sat / NA
Emergency Motor Connected P/S Motion Inhibited Sat / Un-sat / NA
Dead Man Feature Interlock Motion Inhibited Sat / Un-sat / NA
Drum Overspeed sw. Activated Motion Inhibited Sat / Un-sat / NA
Boom Stowage PIN Engaged (Left Side) Motion Inhibited Sat / Un-sat / NA
Boom Stowage PIN Engaged (Right Side) Motion Inhibited Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.3.4 Boom Hoist Drive - Brake Test
Boom up and down and stop to verify brakes operation. E-stop during boom up and down to verify the brake stops boom motion.
Item Operation and Test Method Status
Both Brakes Brakes functionality, normal stop Sat / Un-sat / NA
Brakes functionality, E-stop Sat / Un-sat / NA
Emergency Brake
Hydraulic Pressure ____ psi Sat / Un-sat / NA
Brake Released Pressure ____ psi Sat / Un-sat / NA
Motor ON time ____ seconds Sat / Un-sat / NA
Motor ON Interval ____ minutes Sat / Un-sat / NA
Position the boom a few degrees from horizontal such that the boom weight is supported by the boom hoist wire rope for the brake holding test. Mark the boom hoist drum and carefully release each of the two brakes, one at a time leaving only one brake to hold the boom in position for 10 minutes to verify each hoist brake is capable of holding the boom without lowering.
Status
Boom position at a few degrees from horizontal to be supported by wire ropes
Motor brake static test Sat / Un-sat / NA
Drum caliper brake static test Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.3.5 Boom Hoist Drive - Emergency Drive Functional Test
Turn off power to simulate emergency situation for testing the emergency drive. Manually release the drum brake. Manually connect the emergency motor to boom hoist drive and verify the followings:
Items Verification Status
Brake Brakes opened by emergency power Sat / Un-sat / NA
Raise boom from operating position to stowed position
Boom Up time (appx.) ____ minutes Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.3.6 Boom Hoist Drive - Speed Test
Raising and lowering the boom in full speed between the horizontal and upper limit stop. Measure the time it takes the boom to travel from one stop to the other.
Motion Verification Actual Status
Raising Voltage / Current Raising ____ Volt / ____ Amp Sat / Un-sat / NA
Raising: Appx. 5 minutes Sat / Un-sat / NA
Lowering Voltage / Current Lowering ____ Volt / ____ Amp Sat / Un-sat / NA
Lowering: Appx. 5 minutes Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.4 Gantry Drive
3.4.1 Gantry Drive - Travel Right Function
Note: Crane may not be traveled for gantry drive testing.
Items Verification Fault Display
Status On CMS In Cab
Boom to Ship Anti-Collision Right L/S
Activated Mechanical Stop Sat / Un-sat / NA
Gantry Right Crane to Crane anti-collision Electrical Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.4.2 Gantry Drive - Travel Left Function
Items Verification Fault Display
Status On CMS In Cab
Boom to Ship Anti-Collision Left L/S
Activated Mechanical Stop Sat / Un-sat / NA
Gantry Left Crane to Crane anti-collision Electrical Stop Sat / Un-sat / NA
Verified by: Contractor: ______________ / Government: ______________ Date: ________
3.4.3 Gantry Drive - Interlock Function
Simulate the situations in table below to verify gantry function interlock.
Items Verification Fault Display
Status On CMS In Cab
#1 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#2 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#3 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#4 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#5 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#6 Motor Brake Closed Motion Inhibited Sat / Un-sat / NA
#7 Motor Brake…
This is the start of the file's text. The full file is on GovTribe.
File details come from the government source that posted it. Updated .