38DXA58910_00_A01.pdf

Ship/HULL NO. Ship/HULL NAME I ICN: Rev: Key Op:

LPD-22 USS SAN DIEGO

JON: 38DXA58910 A01

TITLE:

Knuckle Boom Crane; periodic load test

JOB SPECIFICATION

Anticipated Award Date: Production Completion Date: PREPARING ACTIVITY:

// I/J3/.0Al L 1.;>_/¥/UJ.2..6 POP Start Date: POP End Date: SASEBO

II IJ. J/>d~ /JI /31 /.u:u?

PREPARED BY: CODE DATE

K.SAITO M SK 8/17/2026

APPROVED BY: SH\ll CODE

S.MURAKAMI 5225

CONCURRED BY: -

CODE

N.SASHI 5232

ASSIST PLANNER'S NAME: CODE

Y.HAMABE H HA

ASSIST PLANNER'S NAME: CODE

D.AKAMINE E AK

ASSIST PLANNER'S NAME: CODE

DESCRIPTION:

JSN(S): EA04-ZAF9 CASREP# DTG:

5/F CONTACT: CIV CWP# CCNS#

Approved by 5300/5900 z:=~te Date: 2o A\.)(.p "1-o1,0 AVL: 7A1

LWC:

Work Completed

5/Force: Rate: Date:

Ship Supt: Date: SRF CONTROL NO.:

WORK CERTIFICATION SIGNATURES

COMPLETION OF WORK REVIEW: BADGE NO.: SHOP/CODE: PHONE: DATE:

1301407562

Ship/HULL NO. Ship/HULL NAME ICN:

LPD-22 USS SAN DIEGO JON: 38DXA58910

TITLE:

Knuckle Boom Crane; periodic load test

1. SCOPE:

1.1 Title: Knuckle Boom Crane; periodic load test

1.2 Location of Work:

1.2.1 Boat and Cargo Crane (01-82-2-X)

1.3 Identification:

Rev: Key Op:

I A01

1.3.1 Quantity (One EA), Knuckle Boom Crane (KBC) located in 1.2.1, MFR Allied Systems Company, MFR ID K80-65-2020, APL No.57A050002

2 . REFERENCES :

2.1 Standard Items (FY27)

2.2 SG811-CF-MMC-010 Rev 10, Boat and Cargo Crane, Knuckleboom, Model K80-65, Chapters 1 Through 8 and Appendices A Through F

2.3 320-7318482 Rev J, PWR SYS Deck Plan, Electrical Zone No.7 (Sheet 3B I Zone 48-G)

2.4 Test File No.26198, Test No.58911-4-003 R0O, Knuckle Boom Crane

3 . REQUIREMENTS:

(V) (G) "LOAD TEST"

3.1 Accomplish the requirements of 2.4 for load test and inspection of KBC listed in 1.3.1, using 2.2 and 2.3 for guidance. -S246

3.2 Accomplish the requirements of 009-032 of 2.1 for each new and disturbed surface.

4. NOTES:

4.1 Initial Condition - *HSC 58911 *PRIDKBC MRN

GCMAAUXILMA03787LOMAINTENANCE STANDARD: S9086-T4-STM-010 last completed 03/01/2024. (I-58920-A0C) crane requires load test.

4.2 SRF-JRMC Tool Room will issue pressure gages, torque wrenches, and dial indicators when required.

4.3 SRF will issue test weights when required, except the weight for fine adjustment and sand bag.

4.4 Design official response to ESR LPD22-0259 concurs to apply ESR LPD18-420 which specifies the appropriate procedure for adjusting the PCDH dampening rope to LPD-22. This has already been applied to 2.4.

Ship/HULL NO. Ship/HULL NAME ICN: Rev: Key Op:

LPD-22 USS SAN DIEGO

JON: 38DXA58910 A01

TITLE:

Knuckle Boom Crane; periodic load test

5. GOVERNMENT FURNISHED MATERIAL (GFM):

5.1 SRF will provide the following materials.

MATERIAL LIST

M QTY

ITEM PC REF I STOCK HAZ DOC REQD/ PARA

NO. NO. NO. C DESCRIPTION NUMBER MAT NO. UNIT NO.

001 7-8-12 2.2 C

FIBER ROPE ASSEMBLY, PN

98 4020 015242891 N 62048021 4/EA -

245470, FIGURE 7-8-12

100 - - C GASKET, P/N: 67053-3-A 98 5330 011721914 N 62048022 1/EA -

101 - - C WASHER.LOCK, P/N: 34017-13-AB 98 5310 012712039 N 62048023 6/EA -

102 - - C

BOLT.MACHINE, 5/16-18UNC-2A,

98 5306 002264827 N 62048024 1/HD -

1"L, STEEL,

EMP CONDUIT, EMP CONDUIT,

BRASS METAL CONDUIT CORE,

103 - - C

SIZE: 3/4" ID, OUTER JACKET:

98 5975 SA2601291 N 6222CW06 33/FT -

BLACK NEOPRENE,

3/4"ID, P/N: CC249-24

HOSE, NONMETALLIC, HOSE,

NONMETALLIC,

MFR P/N: 381-6,

104 - - C 3/8"ID X 0.75"OD, WORKING 98 4720 SA2400713 N 6204CW50 10/FT -

PRESSURE: 5,000PSI, BURST

PRESSURE: 20,000PSI

HYDRAULIC HOSE, HYDRAULIC

HOSE, 4.75K WP ISO 1436-1

104 C

ISO 1436-1 TYPE 2SN / SAE J517

98 4720 SAPKU0444 N 6210E201 10/FT - -

100R2AT /

SAE J1942 I EN853 TYPE 2SN

P/N: 302-6

CLEANING COMPOUND,S,

200 - - C

SOLVENT, USE FOR CLEANING

98 6850 014742320 y 62258802 5/CN -

OF WIRE ROPE, MIL-PRF-680

TYPE Ill, 5GUCO

GREASE.WIRE ROPE-EX, WIRE

ROPE-EXPOSED GEAR,

201 - - C

CORROSION RESISTIVE, LOW

98 9150 005306814 y 62258803 3/CN -EVAPORATION AND SALT WATER

RESISTANT, MIL-PRF-18458,

35LB/CN

WIRE ROPE ASSEMBLY .. WIRE

ROPE ASSEMBLY., 1 INCH

202 - - C POWERFLEX 19 UNCOATED WIRE 98 4010 015219954 N 62258005 1/EA -

ROPE WOUND RIGHT WITH OPEN

SPEL TER SOCKET

CUI

TP FILE#: 26198 REV: 00 ICN: 38DXA58910

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

TITLE

PREPARED BY

REVIEWED BY

APPROVED BY

SHIP/HULL#

JCN

SCOPE

SRF-JRMC DET SASEBO TEST PROCEDURE

S246 STANDARD TEST PROCEDURE PREPARATION

KNUCKLE BOOM CRANE

PRINT NAME & SIGNATURE PHONE

D. KUBO

KUBO. DAI. 15949938 D,gitally s,gned by

41 ~~t~02~:~ 6~~;:;!a;; 02 +09•00·

252-BOS2

S. IIDA

S. PHILLIPS

JOB SPECIFIC TEST PROCEDURE PREPARATION

USS SAN DIEGO / LPD-22

EA04-ZAF9

(Z] PERIODIC □ OTHER

DESCRIPTION:

PRINT NAME & SIGNATURE PHONE

PREPARED BY D. KUBO

APPROVED BY S. IIDA

TEST PROCEDURE COMPLETION

REV: 00 KEYOP: A01

CODE DATE

S246E 09-Jul-2026

S246A 09-Jul-2026

S246CTE 1 0-Jul-2026

CODE DATE

S246E 1 O-Jul-2026

S246A 1 0-Jul-2026

PRINT NAME & SIGNATURE ORGANIZATION BADGE/RANK DATE

LWC

S246 SRF-JRMC

DET SASEBO

TEST RESULTS REVIEW & APPROVAL

PRINT NAME & SIGNATURE

REVIEWED BY (Test Certified Complete and Test Results Satisfactory)

S. IIDA

APPROVED BY (Test Results Reviewed and Approved)

COMMENTS

PHONE

CUI

CODE DATE

S246A

S246CTE

TP FILE#: 26198 REV: 00 ICN: 38DXA58910 REV: 00 KEYOP: A01

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

ST ANDA RD TEST PROCEDURE REVISION RECORD

I I I EFFECTIVE

REVISION NO. DATE DESCRIPTION PAGE/PARA

TP FILE# 26198 REV: 00 ICN: 38DXA58910 REV: 00 KEYOP A01

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

TEST PROCEDURE GENERAL NOTES

1. TEST SEQUENCE: Unless otherwise specified in the test document, this test procedure (TP) shall be completed in provided order.

2. VERIFICATION: The person designated to sign for an action verifies, based on personal observation, objective evidence, or watch stander reports and certifies by signature that the action has been performed in accordance with the specified requirements.

3. USE ORIGINAL DOCUMENTS: All data attached to the Master TP shall have original pen and ink entries on the data sheets (unless otherwise specified in the test procedure).

4. USE DARK INK: All signature and data shall be in dark, water insoluble ink.

5. CORRECTIONS: When an error was made, it shall be corrected by drawing a single line through the error, recording the correct entry, initialing, dating and printing the name of the person making the correction in accordance with JOINT FLEET MAINTENANCE MANUAL (JFMM), COMUSFL TFORCOMINST 4790.3, VOLUME

V, QUALITY MAINTENANCE.

6. LATEST APPLICABLE REVISION: Use the latest applicable revision of plans, instructions, technical manuals, and other reference material cited in this test procedure.

7. INSTRUMENT CALIBRATION: All measuring equipment shall be in current calibration as required by

NAVSHIPREPFACINST 4734.1.

8. OPERATION OF COMPONENTS: Only authorized personnel shall operate ship's permanently installed equipment.

The cognizant Shop shall control and operate their temporary test equipment. Ship's Force shall operate temporary systems and equipment formally turned over to the ship.

9. SAFETY INSTRUCTION: The Test Director is responsible for the safe conduct of this test. The safety precautions of NAVSHIPREPFAC M-5100.8 shall be observed at all times.

10. TEST STOPPAGE: The Test Director shall stop the test once a problem has been found in the system or equipment being tested. S246 Testing Standard Operating Procedure (SOP) shall be used to determine course of action prior to resuming the test procedure.

11. ENERGIZED EQUIPMENT: NSTM 300, para 300-2.4 shall be followed when working on energized equipment.

12. DATA COLLECTION: The test documents may require collection of additional data for which there is no acceptance criteria, provided the data sheet identifies that data is for information only.

13. SUPPLEMENTATION: When supplementation is made, annotate the supplemental information on the page with 'See Remarks' followed by a sequential numbering system corresponding in the Remarks section.

14. USE ASTERISK{*): When supplementation, correction and/or signature is made but there is not enough space, annotate using an asterisk (*) followed by sequential number adjacent to the portion then clarify on the same page using the same annotation.

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

KNUCKLE BOOM CRANE - LOAD TEST

1. PURPOSE

1-1 The purpose of this test is to certify the satisfactory structural integrity and proper operation of the partial/entire system of Knuckle Boom Crane, by performing the tests specified in Table 1-1 .

Table 1-1:

6-2.2 INSPECTION 3 : STRUCTURAL COMPONENTS

4 : MECHANICAL COMPONENTS

6-2.3 NO-LOAD TEST 3 : JIB BOOM SYSTEM

4 : SWING SYSTEM

6-3 STATIC LOAD TEST 6-3: STATIC LOAD TEST 44 092 LBS

6-4.2: WINCH SYSTEM WITH SHEAVE-2 27,557 LBS

6-4.3: WINCH SYSTEM WITH SHEAVE-3 27 557 LBS

6-4 DYNAMIC LOAD TEST 6-4.4: MAIN BOOM SYSTEM 27,557 LBS

6-4.5: JIB BOOM SYSTEM 27,557 LBS

6-5.2: WINCH SYSTEM WITH SHEAVE-2 22,046 LBS

6-5.3: WINCH SYSTEM WITH SHEAVE-3 22 046 LBS

6-5 RATED LOAD TEST 6-5.4: MAIN BOOM SYSTEM 22,046 LBS

6-5.5: JIB BOOM SYSTEM 22,046 LBS

6-5.6: SWING SYSTEM 22 046 LBS

2. REFERENCES

2-1 SRF-JRMC DET SASEBO S245 ESR RESPONSE

2-1.1 ESR CONTROL NO. LPD22-0259: EXTENSION OF APPLICABILITY OF ESR LPD18-420

2-2 NAVSEA TECHNICAL MANUAL

X X X X X X X X X X X X X X X X X

2-2.1 SG811-CF-MMC-010; BOAT AND CARGO CRANE, KNUCKLEBOOM, MODEL K80-65 CHAPTER 1 THROUGH

8 AND APPENDICES A THROUGH F

2-3 PMS-PLANNED MAINTENANCE SYSTEM

2-3.1 MIP 5891/030; Crane, Rotating, Knuckle Boom

(1) MRC 3KE3 N; 1. Inspect Dampening Ropes.

(2) MRC 2FD2 N; 1. Check Crane Mounting Bolts Pre-Load Indicator.

(3) MRC 9RWJ N; 1. Clean, Inspect, and Lubricate Crane Wire Ropes and Drums.

(4) MRC 9RWF Y; 1. Inspect Crane Components.

(5) MRC 9ZBN N; 1. Load Test Crane in Accordance with NSTM Chapter 589 and Applicable Test Document.

(6) MRC T4S1 U; 1. Perform Visual Inspection/Cold Checks and Perform Operational Tests.

TP FILE#: 26198 REV: 00 ICN: 38OXA58910 REV: 00 KEYOP: A01

TEST#: 58911-4-003 R00

TITLE KNUCKLE BOOM CRANE (LPD-17 CL)

2-4 GSO-GENERAL SPECIFICATION FOR OVERHAUL OF SURFACE SHIPS; S9AA0-AB-GOS-010

2-4.1 SEC 092; SHIPBOARD TESTS

2-5 NSTM-NAVAL SHIPS' TECHNICAL MANUAL

2-5.1 S9086-KC-STM-01 0/CH-300; ELECTRIC PLANT - GENERAL

2-5.2 S9086-KE-STM-01 0/CH-302; ELECTRIC MOTORS AND CONTROLLERS

2-5.3 S9086-T4-STM-010/CH-589; CRANES

2-6 JFMM-JOINT FLEET MAINTENANCE MANUAL

2-7 NAVSHIPREPFAC M-5100.8; SAFETY AND HEALTH PROGRAM MANUAL

2-8 NAVFAC-NAVAL FACILITIES ENGINEERING COMMAND P-307; WEIGHT HANDLING PROGRAM MANAGEMENT

3. TEST AND SUPPORT EQUIPMENT/MATERIAL

3-1 Test weights (e.g. Ingots, water bag and etc.)

3-2 Necessary Rigging gear

3-3 Load indicating device (e.g. Dynamometer)

3-4 Caliper

3-5 Sheave groove radius gage (1 inch Dia. +3/128")

3-6 Weighing scale (for dampening ropes inspection)

3-7 Megohmmeter

3-8 Multimeter

3-9 Thermometer

3-10 Voltmeter

3-11 Ammeter

3-12 Support Hoisting Device (e.g. crane)

3-13 Scaffolding (for inspection before and after load test)

3-14 Tag lines

3-15 Stopwatch

3-16 Walkie-talkies

3-17 Warning signs, ropes and/or barricades to ensure area affected by load testing is secured

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

4. GENERAL PRECAUTIONS

4-1 Only those personnel actively engaged in performing or witnessing this test shall be permitted in the testing area. All specified safety regulations shall be strictly observed.

4-2 To prevent injury or death, ensure that proper test equipment is used during testing.

4-3 Safeguarding of personnel and equipment shall be adhered to at all times.

4-4 To prevent personnel injury, Tag-Out procedures shall be in accordance with the Tag-out Users Manual (TUM), and/or local tagout instruction.

5. WEIGHT HANDLING PLAN

NOTE

ALL RIGGING GEAR SHALL HAVE A RATED CAPACITY GREATER THAN THE LOADS AND STRAIN IMPOSED UPON THE RIGGING

GEAR. ALL RIGGING GEAR SHALL ACCOMPLISH REQUIREMENTS OF P307.

5-1 WEIGHT HANDLING PLAN Prepare and submit a weight handling plan to S246 for load testing at least 5 working days prior to conducting the load test. If the service crane will be used for load testing, submit weight handling plan to S980D (WHE manager) also. Omit this step if test weight is not used.

6. TESTING STEPS

6-1 PRETEST BRIEFING Conduct a pre-test briefing (e.g. safety precaution, station assignments, testing steps) with all involved test personnel.

6-2 INSPECTION & NO- LOAD TEST Perform inspection & no-load test as follows and record the data and result in the

TEST DATA SHEET.

6-2.1 TMDE Record all Test, Measuring & Diagnostic Equipment (TMDE) type, range, serial number and calibration due date. TMDE shall be calibrated and has not expired.

NOTE

OPERATE/POSITION EQUIPMENT AS NECESSARY TO FACILITATE THE INSPECTION. TAG OUT/ISOLATE EQUIPMENT AS

REQUIRED TO PROTECT PERSONNEL & EQUIPMENT WHEN PERFORMING INSPECTIONS.

NOTE

DISCREPANCIES FOUND DURING ANY PRE-WEIGHT TEST INSPECTION THAT DOES NOT AFFECT THE SAFE OPERATION OR THE LOAD CARRYING CAPABILITY OF THE SYSTEM SHOULD BE NOTIFIED SHIP'S FORCE. THESE TYPES OF DISCREPANCIES

ARE NOT CAUSE FOR WEIGHT TEST FAILURE. NOTE IN REMARKS.

6-2.2 INSPECTION Before No-Load Test, perform partial/full inspection specified in Table 1-1. When any defects are found as "UNSAT", record the defective items (e.g., main boom) & its condition (e.g., crack) in the blank space below the results and submit CFR or DL form. Inspection described herein may be performed in any convenient sequence. See Figure 6-1 for the Knuckle Boom Crane Assembly.

In case pre-inspection (e.g., Pl) has already been performed: For items that have been confirmed as "SAT" in any inspection such as preliminary inspection (Pl) included in the same specifications during the same construction period, if it is confirmed that the condition is maintained, the inspection item may be omitted. In this case, the data & result will be transcribed from the pre-inspection.

TP FILE#: 26198 REV: 00

TEST#: 58911-4-003 ROD

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

• ·1·-·

' fu.. p~

1.::. . i.Lll -

D

8-

A

A. PEDESTAL

B. SLEW BEARING

C. SWING DRIVE

F. MAIN BOOM

G. WINCH

H.JIBBOOM

L

CUI

ICN 38DXA58910

PO

Q 'i'

R-·-

N~

H

G 6 •

M~~

J

,,J~, s; .c.~1!

r ·~.

L. JIB LINK

M. MAIN LINK

N. JIB CYLINDER

D. TURRET J. POSITIVE CONTROL DERRICK HEAD (PCDH) P. OPERATORS CAB

E. MAIN CYLINDERS x2 K. WIRE ROPE AND LIFTING RING Q. HYDRAULIC SWIVEL

Figure 6-1: Knuckle Boom Crane Assembly

(1) WIRE ROPES & DRUMS

REV: 00 KEYOP: A01

R. HVAC

1 ''

JU~

S. HYDRAULIC POWER UNIT

a. Operate crane as required to pay out hoist wire rope until down stop limit is reached. Clean accessible portions of hoist wire rope using wire brush, rags, and turbine oil. Inspect wire rope. See Figure 6-2

Acceptance criteria: Wire rope must be replaced when any of one of the following conditions exists.

a. Pitting due to corrosion, or nicks, extending one lay length or more ..

b. Six (6) broken wires in one rope lay-length or three (3) broken wires in one strand lay-length.

c. One broken wire within one lay-length of any end fitting.

d. Kinking, crushing, birdcaging or any other physical damage resulting in distortion of rope structure.

e. Wear of 1/3 the original diameter of outside individual wires, evidenced by flat spots almost the full width of the individual wire, extending one lay length or more.

f Evidence of heat damage from any cause.

TP FILE# 26198 REV: 00 ICN: 38DXA58910 REV: 00 KEYOP: A01

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

&--·' STIWClS

CORE·---

W~ES _ _;-

• - 11.- Lay ., STRANO LAY LENGTH i-- On. RQpe le)' --~

RO?E LAY LENGTH

Figure 6-2: Nomenclature of Wire Rope Parts & Measuring Wire Rope Diameter

b. Measure wire rope diameter with vernier caliper in at least 6 places and inspect wire rope. See Figure 6-2.

Acceptance criteria: Average diameter of wire rope shall not be smaller than 15116 (0.937) inch.

c. Inspect wire rope end fittings.

Acceptance criteria: Cracks, deformation or evidence of wire rope slippage and broken wires should not be present.

d. Inspect poured socket end fitting, as applicable for:

Acceptance criteria: The following conditions should be met.

a. Socket is in line with axis of wire rope.

b. Ensure no axial movement of zinc with respect to socket.

c. Zinc is flush with top of socket basket.

d. Indication of zinc penetration at base of socket.

e. There is no unlaying of wire rope at base of socket.

f No slack in any strands.

e. Inspect hoist drum.

Acceptance criteria: Deterioration, excessive corrosion or cracks should not be present. Fastening device shall be properly secured to drum.

CAUTION

TO PREVENT DAMAGE TO PCDH THE WEIGHT OF THE CRANE SHOULD NOT REST ON IT.

(2) DAMPENING ROPES

a. Position the crane in the maintenance position with main boom horizontal parallel to the boat deck. The jib boom should be vertically (perpendicular to the boat deck) with the tip of the jib resting on wood blocks or other deck protective cover. The Positive Control Derrick Head (PCDH) should be in the horizontally position parallel to the deck also supported with wood block or wood pallet to protect the deck.

b. Remove the plasma line shields.

c. Remove covers over the adjustment nuts for the plasma lines.

d. Inspect the four dampener plasma lines for the following.

Acceptance criteria: The following conditions should not be present.

a. Damage of line splice terminations.

b. Abrasion wear on surface strands and yams.

c. Discoloration or any other evidence of excessive sun exposure or rope contamination.

d. Damage splice eye connection.

e. Damage caused by external or friction heat or fiber melting. Cover yams are glaze and fused together.

f Debris or damage caused by foreign materials.

e. Lift PCDH so that it is just above the deck and is hanging free.

TEST#: 58911-4-003 R00

TITLE KNUCKLE BOOM CRANE LPD-17 CL

f. Inspect inner plasma lines tension in accordance to Figure 6-3. Use scale and ruler to verify that a 30-lb force applied moves the line a maximum of 1/2" deflection. Adjust slacks as necessary.

Acceptance criteria: The outer plasma line deflection shall be a maximum of 112".

Figure 6-3: Plasma Lines Tension Detail & Dampening Ropes

g. Stow PCDH and secure to the jib.

h. Inspect outer plasma lines tension in accordance to Figure 6-3. Use scale and ruler to verify that a 30-lb force applied moves the line a maximum of 1/2" deflection. Adjust slacks as necessary.

Acceptance criteria: The inner plasma line deflection shall be a maximum of 112".

NOTE

MINOR SURFACE CORROSION ON NONSTRUCTURAL METAL SURFACES (WHICH ARE NOT CALLED OUT IN THIS INSPECTION CRITERIA) IS ACCEPTABLE AND MAY BE REMOVED IN ACCORDANCE WITH SHIP'S

REGULAR PRESERVATION SCHEDULE. IF CORROSION DEPTH IS MORE THAN 25% OF ORIGINAL

COMPONENT THICKNESS, COMPONENT SHOULD BE REPLACED.

NOTE

CORROSION, CRACKS, AND/OR PITTING ON LOAD BEARING AND STRUCTURAL JOINTS SHOULD BE IDENTIFIED FOR FUTURE REMOVAL AND FUTURE VISUAL INSPECTION OF UNDERLYING AREA. MAGNETIC

PARTICLE OR LIQUID PENETRANT TESTING MAY NEED TO BE SCHEDULED ANO PERFORMED BY A

QUALIFIED NOT INSPECTOR IF CRACKS OR PITS ARE FOUND DURING VISUAL INSPECTION.

IF CORROSION HAS RESULTED IN A REDUCTION OF ORIGINAL WELD THICKNESS OF MORE THAN 1/16-INCH OR A 25% REDUCTION OF ORIGINAL WELD CROSS SECTIONAL AREA, WELD SHOULD BE REPAIRED.

(3) STRUCTURAL COMPONENTS (See Figure 6-1)

a. Inspect full length of main boom, jib boom, turret and Positive Control Derrick Head (PCDH).

Acceptance criteria: The following conditions should not be present.

a. Bent or deformed structural surfaces or members.

b. Missing or loose fasteners.

c. Corroded or cracked structural surfaces; especially in areas where water may accumulate.

d. Cracked or corroded joints; Inspect for flaking or cracked paint in vicinity of all joints; expose suspected area with wire brush and chipping hammer.

e. Heavily corroded, loose, or missing grounding straps.

b. Inspect boom link and hinges.

Acceptance criteria: The following conditions should not be present.

a. Physical damage, cracks and corrosion on bearing block or cap.

b. Loose boom hinge pin Jocking (keeper) plate and bolts, and signs of shearing off

c. Loose or missing holding nut on link/hinge pins.

d. Obvious wear on busing halves or /ink/hinge pins as shown by evidence of metal particles.

TP FILE# 26198 REV: 00 ICN 38DXA58910 REV: 00 KEYOP: A01

TEST#: 58911 -4-003 ROD

TITLE: KNUCKLE BOOM CRANE (LPO-17 CL)

(4) MECHANICAL COMPONENTS

a. Inspect hoist sheave assemblies (See Figure 6-4). Use radius gages for sheave groove inspection (See Figure 6-5).

Acceptance criteria: The following conditions should not be present.

a. Cracked or corroded sheave surfaces.

b. Worn bearings or pins, as shown by evidence of metal shaving or particles; inspect for obvious misalignment or any side-to-side wobble. (May not be able to move sheaves with wire rope installed; do not remove wire ropes) .

c. Physical damage to sheave assembly support brackets; inspect for bent or deformed bracket surfaces or members.

d. Cracked or corroded bracket surfaces or members; especially in areas where water may accumulate.

e. Cracked or corroded joints on sheave assembly support brackets; inspect for flaking or cracked paint in vicinity of all joints;

expose suspected area with wire brush and chipping hammer.

f Loose or missing fasteners.

g. Loose sheave pin locking (keeper) plates and bolts which show signs of shearing off

h. Wear in wire rope sheave grooves.

SHEAVE-1 SHEAVE-3

SHEAVE-2

Figure 6-4: Shave Location

b. Inspect PCDH .

Acceptance criteria: The following conditions should not be present.

a. Loose or missing fasteners.

b. Hydraulic motor shaft seal fluid leakage.

c. Inspect HPU assemblies.

Acceptance criteria: The following conditions should not be present.

OBSERVE THE GROOVE SO THAT IT MAY BE

CLEARLY SEEN WHETHER THE CONTOUR OF

THE GAGE MATCHES THE CONTOUR OF THE

BOTTOM Of THE GROOVE. ANY SHEAVE WITH

A GROOVE RADIUS SMALLER THAN THE

SHEA VE GAGE RADIUS IS UNSATISFACTORY.

Figure 6-5: Shave Groove Inspection

a. Missing tag with installation date on hydraulic hoses and overdue for replacement (6 years ±6 months).

b. Leaks, kinks, cracks, sharp bends and heavy corrosion.

d. Inspect all hydrau lic cyl inders.

Acceptance criteria: They shall be leak-free and exposed rod shall not be corroded.

e. Inspect winch assemblies . Expose suspected area with wire brush and ch ipping hammer.

Acceptance criteria: The following conditions should not be present.

a. Bent or deformed components.

b. Cracked or corroded components.

c. Cracked or corroded joints.

d. Missing or loose fasteners.

e. Broken or missing lubrication fittings.

f. Hydraulic leaks.

TP FILE#: 26198 REV: 00 ICN 38DXA58910 REV: 00 KEYOP A01

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

f. Inspect swing drive and gear assemblies (Figure 6-6).

Acceptance criteria: The following conditions should not be present.

a. Uneven wear of gear teeth (chipping, flaking, pitting, fretting, discoloration, looseness, lack of full tooth contact, or excessive tooth wear) .

b. Corrosion on pinion or gear teeth.

c. Missing or damaged gear or pinion teeth.

d. Evidence of foreign particles in meshing area.

e. Leak of slew gear reducer and hydraulic motor shaft seals I gaskets.

LEGEND

1. BRAKE 3

2. HYDRAULIC MOTOR

3 BEARING SUPPORT

4. PINION

7, 8 5. CAPSCREW

6. CAPSCREW

7 CAPSCREW

8 WASHER

9 PLUG

10. SLEW RING

Figure 6-6: Swing Drive

g. Inspect hydraulic swivel.

Acceptance criteria: The following conditions should not be present.

a. Evidence of leaks on gaskets, hydraulic connections or leaks around swivel.

b. Loosen or broken mounting bolts.

c. Evidence of deformation or any other damage.

h. Inspect mounting bolts as follows.

1) Find permanently mark lower bearing assembly (pedestal) mounting bolts; bolt number one, if non marked proceed to mark FWD most bolt as bolt number one with permanent marker.

2) Check mounting bolts by griping top cap indicator between tip of thumb and tip of index finger as shown in Figure 6-7 - Do not use any other part of finger other than tips - and applying a light rotation .

Figure 6-7 : Mounting Bolt Inspection

3) If top cap does not spin , mounting bolt is at full torque.

4) If top cap does spin , keep torquing mounting bolts in 100 to 150 ft-lbs until top cap no longer spins .

5) Re-check all crane bolt cap pre tension indicator free spinning caps.

6) Record spinning indicator and iteration if any bolt cap pretension indicator spin .

TP FILE#: 26198 REV 00 ICN 38DXA58910 REV 00 KEYOP: A01

TEST# 58911 -4-003 ROD

TITLE: KNUCKLE BOOM CRANE LPD-17 CL

7) Inspect the bolts cond ition .

Acceptance criteria: They shall not show signs of backing out, any kind of physical damage, and shall be only hand tight.

8) Repeat the steps above for all bolts in upper bearing (turret) and lower bearing (pedestal) assembly.

9) Inspect the bolts looseness.

Acceptance criteria: The following conditions should be met.

a. Total number of loose pre-tension indicator caps is equal to or less than 14 per each bearing assembly.

b. Number of loose pre-tension indicator caps in a 90 ° quadrant in each bearing assembly is equal to or less than 5.

c. Number of loose pre-tension indicator caps in a 180 ° quadrant in each bearing assembly is equal to or less than 8.

d. Number of successive bolts with loose pre-tension indicator caps in each bearing assembly is equal to or less than 3.

(5) ELECTRICAL COMPONENTS

a. Inspect motors (Figure 6-8).

Acceptance criteria: There shall be no loose bolts and mechanical fittings.

SY5 TFV

Ph ss_~

15 HP STARTER

GAUGE. TE~ P

100 HP STARTER

Figure 6-8: HPU and Motor I Control Cabinets

b. Inspect crane control cabinets (Figure 6-8).

Acceptance criteria: The following conditions should not be present.

a. Loose electrical connections.

b. Corrosion and presence of water of control cabinet enclosure.

c. Evidence of overheating, chafing, and frayed or chipped insulation of all wiring.

d. Loose electronics modules and printed circuits.

c. Inspect cable runs.

Acceptance criteria: They shall be strapped in cable racks. There shall be no in-line splices, chafing, and frayed insulation.

d. Inspect anti-2-block proximity switch (Figure 6-9). Operate proximity switch lever manually several times.

Acceptance criteria: The fo llowing conditions should not be present.

a. Loose fasteners, cracks, or other signs of deterioration and heavy corrosion of mounting bracket.

b. Heavy corrosion, weather damage, broken or missing parts of enclosure.

c. Missing stuffing tubes at electrical cable entry point.

d. Binding or sticking of moving parts.

TP FILE#: 26198 REV 00 ICN 38DXA58910 REV 00 KEYOP A01

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

CUTAWAY VIEW

(Sriown In 2 Oloc..: poUlonJ

------ J

Figure 6-9: Anti-2-Block Proximity Switch

e. Inspect load moment indicator (LMI ) components (Figure 6-10).

Acceptance criteria: The following conditions should not be present.

a. Loose fasteners , cracks, or other signs of deterioration and heavy corrosion of mounting brackets.

b. Heavy corrosion, weather damage, broken or missing parts of enclosures.

c. Looseness and heavy corrosion of swing angle encoder, winch encoder, load pin, main boom sensor, jib boom sensor, LMI display unit and electrical connections.

F

A

B

E

A -- SWING ANGLE ENCODER

B - WINCH ENCODER

C-- LOAD PIN

C

D

D -- JIB BOOM ANGLE SENSOR LOCATED INSIDE

THE JIB BOOM JUNCTION BOX

E - MAIN BOOM ANGLE SENSOR LOCATED INSIDE

THE MAI N BOOM JUNCTION BOX

F -- LMI DISPLAY UNIT

Figure 6-10: LMI Components

f. Inspect operator's console. Operate each pushbutton and selector switch . Remove access cover.

Acceptance criteria: The following conditions should be met.

a. Moving parts of pushbutton and selector switch shall operate freely without binding or sticking.

b. There shall be no in-line splices, evidence of overheating, chafing, and frayed or chipped insulation of electrical wires and cable runs.

c. Loose and heavy corrosion of electrical connections.

d. All switch fixtures and mounting brackets shall not be broken.

e. There shall be no cuts and tears of access cover gasket

TP FILE# 26198 REV: 00 ICN 38DXA58910 REV: 00 KEYOP A01

TEST#: 58911 -4-003 R00 Page 14 of 57

TITLE KNUCKLE BOOM CRANE (LPD-17 CL)

g. Inspect crane control levers Uoysticks) (Figure 6-11 ). Move each control lever (in both directions) from NEUTRAL to its maximum position and release lever.

Acceptance criteria: The following conditions should not be present.

a. Loose fasteners.

b. Control lever does not return back to NEUTRAL.

c. Binding or sticking.

d. Signs of burning of contact assembly and cracks on enclosure.

e. Looseness and corrosion of electrical connections.

f. Missing identification labels.

INBOARD RIGHT

LEFT-HAND

OUTBOARD RI GHT

Figure 6-11 : Cab Control Levers

h. Conduct cold insulation resistance test as follows . If motor has been overhauled/rewound/replaced , mark "step 2)" on TEST DATA SHEET and proceed to step 2) .

1) COMBINED INSULATION RESISTANCE Measure the equipment temperature using a thermometer and measure the insulation resistance to ground with the motor connected to the controller using a 500volt megohmmeter.

a. If neither of the following conditions i) nor ii) is satisfied , the measured value of insulation res istance requires correction to 25°C (77°F) using Table 6-2 and Formula 6-1.

i) The measured resistance is equal to or greater than the 4 megaohms and the temperature at the time of measurement is 25°C (77°F) or higher.

ii) The measured resistance is equal to or greater than 8 megaohms and the temperature at the time of measurement is 15°C (59°F) or higher.

Acceptance criteria: The combined insulation resistance shall be 4 megaohms or higher.

b. If the insulation resistance is less than 4 megaohms, record the data, mark "step 2)" and proceed to step 2)

2) INDIVIDUAL INSULATION RESISTANCE Select the applicable acceptance criteria from Table 6-1 and record the criterion . Measure the equipment temperature using a thermometer and measure the motor and controller insulation resistance separately using a 500volt megohmmeter.

a. If neither of the following conditions i) nor ii) is satisfied , the measured value of insulation resistance requires correction to 25°C (77°F) using Table 6-2 and Formula 6-1.

i) The measured resistance is equal to or greater than the minimum value (Acceptance criteria) and the temperature at the time of measurement is 25°C (77°F) or higher.

ii) The measured resistance is equal to or greater than twice the minimum value (Acceptance criteria) and the temperature at the time of measurement is 15°C (59°F) or higher.

Acceptance criteria: The motor insulation resistance shall be equal or higher than the selected value. The controller insulation resistance shall be 1 megaohms or higher.

CUI

17/.

/60

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

Table 6-1 : Motor Insulation Resistance Acceptance Criteria Motor Condition Sealed Insulation System (SIS) Other than SIS

Existing 2. 0 MD Minimum 0 2 MD Minimum

Recondition 500 MD Minimum 25 MD Minimum

New/rewind 1,000 MD Minimum 200 MD Minimum

Formula 6-1 : Insulation Resistance Correction

CORRECTED RESISTANCE (MO) = MEASURED RESISTANCE (MO) x CORRECTION FACTOR

Table 6-2: Insulation Resistance Correction Table

EQUIPMENT TEMP CORRECTIO EQUIPMENT TEMP CORRECTION EQUIPMENT TEMP CORRECTION

OF oc N FACTOR OF oc FACTOR OF oc FACTOR

41 .0 5 0.25 73.4 23 0.87 105.8 41 3.03 42 .8 6 0.27 75.2 24 0.93 107.6 42 3.25

44.6 7 0.29 77.0 25 1.00 109.4 43 3.48

46.4 8 0.31 78.8 26 1.07 111 .2 44 3.73

48.2 9 0.33 80.6 27 1.15 113.0 45 4 .00

50.0 10 0.35 82 .4 28 1.23 114.8 46 4 .29 51 .8 11 0.38 84.2 29 1.32 116.6 47 4 .59

53.6 12 0.41 86.0 30 1.41 118.4 48 4.92

55.4 13 0.44 87.8 31 1.52 120.2 49 5.28

57.2 14 0.47 89.6 32 1.62 122.0 50 5.66

59.0 15 0.50 91.4 33 1.74 123.8 51 6.06

60.8 16 0.54 93.2 34 1.87 125.6 52 6.50

62.6 17 0.57 95.0 35 2.00 127.4 53 6.96

64.4 18 0.62 96.8 36 2.14 129.2 54 7.46

66.2 19 0.66 98.6 37 2.30 131 .0 55 8.00

68.0 20 0.71 100.4 38 2.46 132.8 56 8.57

69.8 21 0.76 102.2 39 2.64 134.6 57 9.19 71 .6 22 0.81 104.0 40 2.83 136.4 58 9.85

TEST# 5891 1-4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

6-2.3 NO-LOAD TEST Perform partial/full No-Load Test as specified in Table 1-1.

(1) WINCH SYSTEM

a. LIMIT SWITCH & LMI TEST

1) Raise hook and verify hoist slow down operation prior to 2-blocking.

Acceptance criteria: The hoist shall slow down 3 feet prior to 2-blocking.

2) Manually actuate anti-2-block limit switch (Figure 6-9).

Acceptance criteria: The hoist shall stop upon switch activation.

3) Verify upper hoist limit.

Acceptance criteria: The hoist shall stop prior to 2-blocking {hoist upper hoist limit switch should stop hoist before actuating anti 2-block).

4) Verify lower hoist limit.

Acceptance criteria: The limit switch shall actuate with minimum of 2-112 turns of wire rope remaining on drum.

b. LOSS OF POWER CHECK Lower the hook at slow speed and disconnect the power source by pushing the E-STOP buttons in locations listed below. Repeat this step to verify all the E-STOP buttons.

(a) Inside cab on operators left-hand console .

(b) On junction box located at maintenance platform inside pedesta l.

(c) On HPU junction box.

(d) Remote switches located inboard of boat deck enclosure (BOE).

(e) Remote switches located outboard of BOE.

Acceptance criteria: The hook shall stop lowering upon loss of power.

c. OPERATION (WITH SHEAVE-2)

1) Position the job and main boom to allow the wire to ru n on Sheave-2 (see Figure 6-4 ).

2) Raise and lower hook through full range of travel at rated speed for 3 complete cycles . During operation, check for unusual noise, vibration , or overheating in machinery and control components, and proper operation of all indicator lights and gauges. Also, measure and record the parameters listed in Table 6-3 during first and final cycle.

Acceptance criteria: The crane shall operate without unusual noise, vibration, overheating or other signs of malfunction in machinery and control components, and all indicator lights and gauges shall operate properly.

Data shall meet the criterion in Table 6-3.

Table 6-3: Operatinq Parameter & Acceptance Criteria (Winch System) Parameter Acceptance Criteria Parameter Acceptance Criteria

100 HP Motor Input Voltage 396 - 484 Volts AC Hoist speed JOO ft/ min ± 10%

100 HP Motor Current 114Amps (Max) System Pressure 3,500 psig (Max)

100 HP Motor Speed 1785 - 1800 RPM Oil Temp. (Reservoir) 200 °F (Max)

100 HP Motor Frame Temp. 145 °C(Max)

d. OPERATION (WITH SHEAVE-3)

1) Position the job and main boom to allow the wire to run on Sheave-3 (see Figure 6-4 ).

2) Repeat step c. 2)

TP FILE# 26198 REV 00 ICN 38DXA58910 REV 00 KEYOP: A01

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

(2) MAIN BOOM SYSTEM

a. LMI TEST Raise the Main Boom towards its highest position until it stops automatically.

Acceptance criteria: The Main Boom shall stop automatically when it reaches the maximum angle of approximately 80 degrees.

b. LOSS OF POWER CHECK Lower the boom at slow speed and disconnect the power source by push ing the E-STOP buttons in locations listed below. Repeat th is step to verify all the E-STOP buttons.

(a) Inside cab on operators left-hand console.

(b) On junction box located at maintenance platform inside pedestal.

(c) On HPU junction box.

(d) Remote switches located inboard of boat deck enclosure (BOE).

(e) Remote switches located outboard of BOE.

Acceptance criteria: The boom shall stop lowering upon loss of power.

c. OPERATION Raise/lower main boom/cylinder at rated speed between maximum and minimum for 3 complete cycles. During operation , check for unusual noise, vibration, or overheating in machinery and control components, and proper operation of all ind icator lights and gauges. Also, measure and record the parameters listed in Table 6-4 during first and final cycle .

Acceptance criteria: The crane shall operate without unusual noise, vibration, overheating or other signs of malfunction in machinery and control components, and all indicator lights and gauges shall operate properly.

Data shall meet the criterion in Table 6-4.

Table 6-4· Ooeratino Parameter & Acceptance Criteria (Main/Jib Boom/PCDH System) Parameter Acceptance Criteria Parameter Acceptance Criteria

100 HP Motor Input Voltage 396 - 484 Volts AC 100 HP Motor Frame Temp. 145 °C(Max)

100 HP Motor Current 114 Amps (Max) System Pressure 3,500 psig (Max)

100 HP Motor Speed 1785 - 1800 RPM Oil Temp. (Reservoir) 200 °F (Max)

(3) JIB BOOM SYSTEM

a. LMI TEST Lower the Jib Boom towards its lowest position until it stops automatically.

Acceptance criteria: The Jib Boom shall stop automatically when the Jib Angle reaches (approximately -120) degrees.

b. LOSS OF POWER CHECK Lower the boom at slow speed and disconnect the power source by push ing the E-STOP buttons in locations listed below. Repeat th is step to verify all the E-STOP buttons.

(a) Inside cab on operators left-hand console.

(b) On junction box located at maintenance platform inside pedestal.

(c) On HPU junction box.

(d) Remote switches located inboard of boat deck enclosure (BOE).

(e) Remote switches located outboard of BOE.

Acceptance criteria: The boom shall stop lowering upon loss of power.

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TEST#: 58911 -4-003 R00 Page 18 of 57

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

c. OPERATION Raise/lower jib boom at rated speed between maximum and minimum outreach for 3 complete cycles. During operation , check for unusual noise, vibration , or overheating in machinery and control components, and proper operation of all indicator lights and gauges. Also, measure and record the parameters listed in Table 6-4 during first and final cycle.

Acceptance criteria: The crane shall operate without unusual noise, vibration, overheating or other signs of malfunction in machinery and control components, and all indicator lights and gauges shall operate properly.

Data shall meet the criterion in Table 6-4.

(4) SWING SYSTEM

a. LMI TEST

1) Ensure the crane is in the parking position and verify on the LMI display that the swing angle reads 0 degree.

2) Swing the crane clockwise (CW) until it stops automatically.

Acceptance criteria: The swing motion shall stop automatically when it reaches approximately 400 degrees.

3) Swing the crane counter-clockwise (CCW) until it stops automatically .

Acceptance criteria: The swing motion shall stop automatically when it reaches approximately 0 degree.

b. OPERATION Slew crane CW and CCW with hook ra ised and boom in normal operating position at no specified speed through full rotational range. During operation, check for unusual noise, vibration , or overheating in machinery and control components , and proper operation of all indicator lights and gauges. Also, measure and record the parameters listed in Table 6-5.

Acceptance criteria: The crane shall operate without unusual noise, vibration, overheating or other signs of malfunction in machinery and control components, and all indicator lights and gauges shall operate properly.

Data shall meet the criterion in Table 6-5.

Table 6-5: Operatinq Parameter & Acceptance Criteria (Swinq System) Parameter Acceptance Criteria Parameter Acceptance Criteria

100 HP Motor Input Voltage 396 - 484 Volts AC Swing speed 180deg/min ± 10%

100 HP Motor Current 114 Amps (Max) System Pressure 3,500 psig (Max)

100 HP Motor Speed 1785 - 1800 RPM Oil Temp. (Reservoir) 200 °F (Max)

100 HP Motor Frame Temp. 145 °C(Max)

(5) PCDH SYSTEM

a. OPERATION Rotate PCDH CW and CCW at no specified speed for 3 complete cycles . During operation , check for unusual noise, vibrat ion , or overheating in machinery and control components , and proper operation of all ind icator lights and gauges. Also, measure and record the parameters listed in Table 6-4 during first and final cycle .

Acceptance criteria: The crane shall operate without unusual noise, vibration, overheating or other signs of malfunction in machinery and control components, and all indicator lights and gauges shall operate properly.

Data shall meet the criterion in Table 6-4.

6-2.4 COMPLETION OF INSPECTION & NO-LOAD TEST LWC and S246 shall sign on the TEST DATA SHEET upon completion of the component inspection and no-load test.

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE LPD-17 CL

NOTE

LEAD WORK CENTER SHALL VERIFY THAT ALL RIGGING EQUIPMENT USED FOR THIS TEST IS LISTED IN SUBMITTED WEIGHT HANDLING PLAN AND THEY ARE IN PROPER CONDITION, APPROPRIATE TYPE/SIZE AND PROPERLY RIGGED.

6-3 STATIC LOAD TEST Perform static load test as follows and record the data and result in the TEST DATA SHEET.

LWC and S246 shall sign on the TEST DATA SHEET upon completion of static load test.

6-3.1 TMDE Record all Test, Measuring & Diagnostic Equipment (TMDE) type, range, serial number and calibration due date. TMDE shall be calibrated and has not expired .

6-3.2 LOAD TEST (WITH SHEAVE-2)

(1) Position the job and main boom to allow the test load to be applied on Sheave-2 (Figure 6-4).

(2) 200% static shall be performed at boat launch and retrieval configuration , outreach shall not exceed 40 ft .

with boom at or near horizontal and jib at or near vertical. See Figure 6-12 for reference.

lb

,I

::; 10

""' ::, 8 L.

""' t, ; I

Q

{I

DISTANCE IN METERS

Figure 6-12: 200% Static Load Test Configuration

(3) Slowly apply the static test load of 44,092 - 45,194 LBS on the wire rope socket. Suspend the test load for 10 minutes.

Alternate method:

Attach a test load up to a maximum of 125 percent of rated load (27,557 LBS) to the crane and lift clear of the test load support. Slowly add the remainder of the static test load with a supporting device.

Acceptance criteria: The crane shall hold the test load for 10 minutes without brake slippage or component malfunction .

...Ll

'¼tt

TEST#: 58911-4-003 R00

TITLE: KNUCKLE BOOM CRANE LPD-17 CL

(4) After 10 minutes, remove the test load.

(5) POST-TEST INSPECTION

a. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking and malfunction of components.

b. Inspect wire rope.

Acceptance criteria: There shall be no slippage in rope sockets and fittings.

6-3.3 LOAD TEST (WITH SHEAVE-3)

(1) Position the job and main boom to allow the test load to be applied on Sheave-3 (Figure 6-4).

(2) Follow step 6-3.2 (2) th rough (5).

TP FILE#: 26198 REV: 00 ICN 38DXA58910 REV: 00 KEYOP: A01

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

NOTE

LEAD WORK CENTER SHALL VERIFY THAT ALL RIGGING EQUIPMENT USED FOR THIS TEST IS LISTED IN SUBMITTED WEIGHT HANDLING PLAN AND THEY ARE IN PROPER CONDITION, APPROPRIATE TYPE/SIZE AND PROPERLY RIGGED.

6-4 DYNAMIC LOAD TEST Perform partial/full dynamic load test as follows and record the data and result in the TEST DATA SHEET. LWC and S246 shall sign on the TEST DATA SHEET upon completion of applicable dynamic load test.

6-4.1 TMDE Record all Test, Measuring & Diagnostic Equipment (TMDE) type, range, serial number and cal ibration due date. TMDE shall be calibrated and has not expired.

6-4.2 WINCH SYSTEM (WITH SHEAVE-2)

(1) Position the jib and main boom to allow the test load to be appl ied on Sheave-2 (Figure 6-4).

(2) Attach the dynamic test load of 27,557 to 28,659 LBS to the wire rope socket.

(3) LOAD TEST As far as practicable , test loads shall be moved completely through the equipment operating range, within the limits. The equipment with test load shall be stopped at least three (3) times in each direction to ensure proper brake operation. No speed is specified; however, the maximum speed attainable with the required test load shall be used. The load shall be accelerated and decelerated slowly and smoothly at all times. Speeds and operating ranges may be reduced somewhat for safety considerations, at the discretion of the test director.

(4) INSPECTION & OBSERVATIONS (DURING TEST) During the dynamic load test, the following inspections shall be made.

a. Measure the parameters listed in Table 6-5 at the maximum speed attainable.

Acceptance criteria: For information only.

b. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation , cracking, and malfunction of components.

c. Inspect brakes.

Acceptance criteria: The brake shall properly stop without overheating in brake operation.

d. Inspect machinery drive (winch drive).

Acceptance criteria: There shall be no abnormal noise, vibration, and overheating in machinery drive components.

e. Inspect hoisting trains, wire rope sheaves and drum spooling.

Acceptance criteria: They shall operate properly with freedom of movement and without abnormal noise or vibration.

f. Inspect hydraul ic system.

Acceptance criteria: They shall operate smoothly without abnormal noise, vibration or leaks.

(5) Remove the test load , as necessary. If add itional test ing is to be performed, maintain the test load.

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE LPD-17 CL

(6) INSPECTION & OBSERVATIONS (POST-TEST) Immediately after the dynamic load test, the following inspections shall be made, as applicable.

a. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

b. Inspect wire rope .

Acceptance criteria: There shall be no slippage in rope sockets and fittings.

c. Inspect machinery drive (winch drive) .

Acceptance criteria: There shall be no overheating in machinery drive components.

d. Inspect hydraulic system.

Acceptance criteria: There shall be no leaks or other signs of defects.

6-4.3 WINCH SYSTEM (WITH SHEAVE-3)

(1) Position the jib and main boom to allow the test load to be applied on Sheave-3 (Figure 6-4).

(2) Follow step 6-4.2 (2) through (6) .

6-4.4 MAIN BOOM SYSTEM

(1) Set the main boom to a convenient position.

(2) LOAD TEST As far as practicable, test loads shall be moved completely through the equipment operating range, within the limits. The equipment with test load shall be stopped at least three (3) times in each direction to ensure proper brake operation. No speed is specified; however, the maximum speed attainable with the required test load shall be used . The load shall be accelerated and decelerated slowly and smoothly at all times. Speeds and operating ranges may be reduced somewhat for safety considerations , at the discretion of the test director.

(3) INSPECTION & OBSERVATIONS (DURING TEST) During the dynamic load test, the following inspections shall be made.

a. Measure the parameters listed in Table 6-4 at the maximum speed attainable.

Acceptance criteria: For information only.

b. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

c. Inspect hydraulic system.

Acceptance criteria: They shall operate smoothly without abnormal noise, vibration or leaks.

(4) Remove the test load, as necessary. If additional testing is to be performed, maintain the test load .

TEST#: 58911 -4-003 R00

TITLE: KNUCKLE BOOM CRANE (LPD-17 CL)

(5) INSPECTION & OBSERVATIONS (POST-TEST) Immediately after the dynamic load test , the following inspections shall be made, as applicable.

a. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

b. Inspect wire rope.

Acceptance criteria: There shall be no slippage in rope sockets and fittings.

c. Inspect hydraulic system.

Acceptance criteria: There shall be no leaks or other signs of defects.

6-4.5 JIB BOOM SYSTEM

(1) Set the jib boom to a convenient position .

(2) LOAD TEST As far as practicable, test loads shall be moved completely through the equipment operating range, within the limits. The equipment with test load shall be stopped at least three (3) times in each direction to ensure proper brake operation. No speed is specified; however, the maximum speed attainable with the required test load shall be used. The load shall be accelerated and decelerated slowly and smoothly at all times. Speeds and operating ranges may be reduced somewhat for safety considerations , at the discretion of the test director.

(3) INSPECTION & OBSERVATIONS (DURING TEST) During the dynamic load test, the following inspections shall be made.

a. Measure the parameters listed in Table 6-4 at the maximum speed attainable.

Acceptance criteria: For information only.

b. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

c. Inspect hydraulic system.

Acceptance criteria: They shall operate smoothly without abnormal noise, vibration or leaks.

(4) Remove the test load , as necessary. If additional testing is to be performed, maintain the test load.

(5) INSPECTION & OBSERVATIONS (POST-TEST) Immediately after the dynamic load test, the following inspections shall be made, as applicable.

a. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

b. Inspect wire rope.

Acceptance criteria: There shall be no slippage in rope sockets and fittings.

c. Inspect hydraulic system.

Acceptance criteria: There shall be no leaks or other signs of defects.

TEST#: 58911 -4-003 R00

TITLE KNUCKLE BOOM CRANE LPD-17 CL

6-4.6 SWING SYSTEM

( 1) Set the crane to a convenient position.

(2) LOAD TEST As far as practicable, test loads shall be moved completely through the equ ipment operating range, within the limits. The equipment with test load shall be stopped at least three (3) times in each direction to ensure proper brake operation. No speed is specified ; however, the maximum speed attainable with the required test load shall be used . The load shall be accelerated and decelerated slowly and smoothly at all times. Speeds and operating ranges may be reduced somewhat for safety considerat ions, at the discretion of the test director.

(3) INSPECTION & OBSERVATIONS (DURING TEST) During the dynamic load test , the following inspections shall be made.

a. Measure the parameters listed in Table 6-5 at the maximum speed attainable.

Acceptance criteria: For information only.

b. Inspect crane structure.

Acceptance criteria: There shall be no binding, warping, permanent deformation, cracking, and malfunction of components.

c. Inspect brakes.

Acceptance criteria: The brake shall properly stop without overheating in brake operation.

d. Inspect machinery drive (swing drive).

Acceptance criteria: There shall be no abnormal noise, vibration, and overheating in machinery drive components.

e. Inspect hydraulic system.

Acceptance criteria: They shall operate smoothly without abnormal noise, vibration or leaks.

(4) Remove the test load.

(5) INSPECTION & OBSERVATIONS…