NOAA Standard Specification AMC-573-1C Testing of Davits and Weight Handling Gear.pdf

AMC-573-1C

OCTOBER 1996

SUPERSEDING

AMC-573-1B

MAY 1993

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION (NOAA)

ATLANTIC MARINE CENTER

STANDARD SPECIFICATION AMC-573-1C

TESTING OF DAVITS AND WEIGHT HANDLING GEAR

1. SCOPE. This specification contains the general requirements for testing of davits, cranes, A-frames, and other weight handling gear on NOAA ships.

2. REFERENCES.

None

3. REQUIREMENTS.

3.1 General.

3.1.1 Prior to conducting any weight test, the Contractor

shall conduct a short briefing with the COTR, ship personnel, and Contractor personnel involved with the tests to review test procedures and safety precautions. Discuss the courses of action to be taken in the event an equipment failure or other casualty occurs during the tests.

3.1.2 All tests shall be conducted with the davits and

weight handling gear rigged in the normal operating condition.

Hydraulic equipment, winches, electric motors and other associated equipment shall be used and tested with their related weight handling gear or davits.

3.1.3 Except as otherwise stated herein, test loads to be

used for the tests shall be as specified in the detail specifications or other applicable procurement document. In the event the test loads are not specified in the detail specifications or other applicable procurement document, the test loads shall be as specified by the COTR.

3.1.4 Take and record the following electrical and

hydraulic measurements in conjunction with the tests:

a. Complete insulation megger inspections of all winch motors immediately prior to conducting the weight tests.

b. Complete insulation megger inspections of all winch motors immediately after weight tests.

c. Amperage being used by each winch motor during the no-load, normal load (boat winch motors only), and proof load tests.

d. Hydraulic pressures at pump outlet during proof load tests.

3.1.5 For purposes of these specifications, the "COTR" for

work ordered by purchase order shall be the person specified by the authorizing official that signed the purchase order.

3.2 Mandatory Pre-test Inspections. Prior to performing any of the weight tests, conduct preliminary inspections as follows:

3.2.1 Disassemble and reassemble equipment and components

to the extent required to conduct the specified inspections.

Sheaves, blocks, foot pins, topping lifts, and vang swivels are required to be disassembled only if specifically required elsewhere.

3.2.2 Conduct a complete dimensional and visual inspection

of all chains, shackles, bolts, swivels, chain plates, eye bolts, sheaves, and all other fittings associated with the rigging.

Record all dimensions which are more than 10 percent less than original. Visually inspect for evidence of any deformation, wear, corrosion, surface cracking, and other conditions which would interfere with continued safe operation.

3.2.3 Inspect and lubricate all wire rope as follows:

a. Remove all wire rope from rigging system, davits, and winches, reeling it top-to-top or bottom-to-bottom onto a spare wire reel or drum.

b. During removal, inspect wire rope and fittings for excessive wear, corrosion, physical damage, broken wires, and other defects which could make it unsafe. Specifically inspect for, and report, areas where more than five composing wires within one rope lay or more than two wires within one strand have been broken.

c. Lubricate all removed wire rope (excluding electro-mechanical wire) with a light bodied lubricant (chain lubricant MIL-G-18458, Type II or Lubra-plate). Lubricate while the wire rope is being bent in a sheave, applying lubricant to the top of the bend and working it into the strands and core.

d. Reinstall each wire rope onto the same davit, rigging system and winch from which it was removed. For boat falls, the wire rope shall be end-for-ended during reinstallation unless their end terminal configuration prevents end-for-ending.

e. If new wire rope is provided by the government, lubricate and install it in lieu of the existing wire rope.

3.2.4 Inspect all hydraulic hoses and fittings for wear, deformation, chafing, deterioration, and other conditions which may cause failure.

3.2.5 After completion of inspections and before

reassembling or testing, submit a report to the COTR documenting all inspections, observations, and dimensions made or recorded, including recommendations for additional repairs needed (if any).

Do not proceed with any reassembly or tests until the report has been reviewed and accepted by the COTR.

3.3 Double-Arm and Single-Point Davit Tests.

3.3.1 All boat davit tests shall be conducted with the boat

suspended over water. Both arms and falls of double-arm davits shall be tested concurrently.

3.3.2 Perform a normal load test of each boat davit as

follows:

a. Using sandbags or other weights acceptable to the COTR, load test weight into the boat of the davits to be tested.

Weights shall be arranged with one-half forward and one-half aft, as near to the hoisting fittings as practical. The test weight to be added for this test shall be the amount required to establish the normal 100 percent operating load consisting of the boat, equipment, and persons allowed (165 pounds per person).

b. Lower and raise the boat for a complete operational cycle, stopping the boat at several locations of the operation to demonstrate proper operation of brakes.

3.3.3 After satisfactory completion of the normal load

test, each boat davit shall be tested with a 125-percent proof load test as follows:

a. With the boat suspended over the water no higher than the main deck level, load additional test weights into the boat to achieve a total weight equal to 125 percent of the normal load. Arrange weight with one-half forward and one-half aft, as near to the hoisting fittings as practical.

b. Hold the 125-percent proof load for five minutes and inspect all davit and boat structure for excessive strain or deformation.

c. After satisfactory completion of the static test, lower and raise the boat through a complete operational cycle, stopping the boat at several locations during the operations to demonstrate proper operation of the brakes. For single-point davits, the test shall include rotation and topping motions used during unstowing and stowing of the boat. During the test, carefully examine all parts of the boat, davits, winch, and fittings for evidence of deformation or excessive strain.

3.3.4 After satisfactory completion of the 125-percent

proof load test, each boat davit shall be tested with a 150-percent proof load test as follows:

a. With the boat suspended over the water no higher than the main deck level, load additional test weights into the boat to achieve a total weight equal to 150-percent of the normal load. Arrange weight with one-half forward and one-half aft, as near to the hoisting fittings as practical.

b. Hold the 150-percent proof load for ten minutes and inspect all davit and boat structure for excessive strain or deformation.

c. Remove all test weights and return the boat to its stowed position.

3.4 Tests of Cranes and Booms (Excluding HIAB Articulating).

NOTE: This test procedure does not apply to HIAB articulating Sea Cranes.

3.4.1 Prior to conducting load tests, operate each crane

and boom for 5 minutes in all directions and modes with no load.

3.4.2 After satisfactory completion of the no-load test, perform 125-percent proof load tests as follows:

a. Lower the boom to its fully outreached and lowest angle approved for the crane or boom. Position fixed-length booms at 15-degree elevation. Hoist the proof load with the winch approximately one foot and hold for five minutes to verify that the brake holds. If practical, lift the proof load from the dock alongside the ship. While holding the load, inspect structures and equipment for deformation and excessive strain.

b. After holding the load for five minutes, lift the weight with the winch as high as practical without raising the boom and slowly swing the proof load weight as far as possible in all directions. Frequently (at least every 30 degrees of rotation) stop the load to test the brakes for satisfactory operation. The boom may be raised and lowered where required to clear deck obstructions.

c. Without removing the proof load weight, top the boom to a 60-degree elevation and return to its previous horizontal elevation. Stop the proof load at the midpoint on the boom swing when topping and when lowering.

d. For cranes having retractable booms, fully retract the boom extension with the boom in the horizontal position and with the proof load weight lifted on the hook. Return the boom to its fully extended position.

e. For each crane having a higher rated load capacity at a minimum radius outreach, position the boom at the minimum radius outreach and increase the proof load weight to 125 percent of the crane's maximum safe working load. Lift the weight with the winch only as high as necessary to clear deck obstructions and slowly swing the proof load weight as far as possible in each direction.

f. Some cranes/booms may not be able to lift the 125-percent proof load due to hydraulic system limitations. In that event, perform the proof load test using the maximum test load which the crane/boom can lift and swing. Record the actual proof load with which the test was satisfactorily completed. In addition, perform a static test by placing the 125-percent proof load on the hook and hold the weight for 10 minutes with the brake set.

g. Remove the test weight and restow the booms to their existing position.

3.5 Tests of HIAB Articulating Sea Cranes.

3.5.1 Prior to beginning the tests, perform the following

preparations:

a. Remove the protective shielding from the control valve operating station.

b. Tie a tarp underneath the control station platform to catch any dripping hydraulic fluid.

c. Using a government-furnished Hiab Crane Test Kit, install the pressure gage on the pressure side of the control valve manifold.

d. Run the hydraulic pump for 5-10 minutes. Operate the crane and booms in all directions and modes with no load.

e. After satisfactory completion of the no-load test, de-energize the pump and replace the No. 2 (lower boom cylinder) and the No. 3 (upper boom cylinder) relief valve cartridges with government-furnished plugs on the A side valve port of the control valve manifold (piston side of hydraulic cylinder). Tag the relief valve cartridges to identify their location to allow correct reinstallation after completing tests.

3.5.2 Test HIAB Model 110 Sea Cranes as follows:

a. Energize the pump and reset the main relief valve to the 3500 psig (24.5 MPa) to enable the crane hydraulic system to lift the test weights.

b. With the proof load positioned along side of the pier, fully extend the crane to its maximum outreach of 27 feet-3 inches from the center of the crane rotation. The outer boom should be horizontal and the inner boom should be 10-15 degrees to horizontal.

c. Attach a 125-percent proof load of 3,450 pounds to the crane hook. Hoist the proof load with the winch to about four feet above the pier and hold for 5 minutes.

d. Inspect the structures and equipment for deformation and excessive strain, measure the pressure, and measure the sink rate while holding the proof load for 5 minutes.

If noticeable sinkage occurs, observe both the inner and outer boom cylinders to determine where leakage may be occurring.

Record results.

e. After holding the proof load for five minutes, hoist the weight with the winch as high as practical without changing the position of the booms. Slowly swing the proof load as far as possible in all directions. Frequently (at least every 30 degrees of rotation) stop the load to test the brakes for satisfactory operation. The booms may be raised and lowered where required to clear deck obstructions.

f. After returning the proof load and booms to the original position (27 feet-3 inches extension), use the extension cylinders to fully retract the boom and then return to its fully extended original position. Using the luffing cylinders, lift the load through the crane's entire operating positions.

g. Remove the test load and reposition the crane hook to an outreach radius of 14 feet from the center of crane rotation. Hold this position and lift a 6000-pound test load with the winch approximately 6 inches off the deck. Hold the test load for five minutes and then remove the test load. If the winch will not lift and hold the 6000-pound test load, reduce the weight to the maximum that the winch will lift and hold. Record the actual test load.

h. Position all boom parts horizontal with boom extended so that the hook is 18 feet-9 inches from the center of crane rotation and place a 5000-pound test load on the hook.

Using the lower luffing cylinder, luff down and up to the limits of the cylinder travel. Use winch to keep test load close to deck. Return to the horizontal position and remove the test load.

i. Fully extend the lower luffing cylinder and partially retract the upper luffing cylinder so that the boom is horizontal. Partially retract boom sections so that the hook is 10 feet-3 inches from the center of the crane rotation. Using the upper luffing cylinder, luff down and up to the limits of the cylinder travel. Use winch to keep test load close to deck.

Return boom to the horizontal position and remove the test load.

j. De-energize the pump. Remove the two hydraulic plugs and replace the No. 2 (lower boom cylinder) and No. 3 (upper boom cylinder) relief valves in their original locations of the control valve manifold. Do not adjust the main relief valve at this time.

k. Attach a 2,760 pound test load to the crane, with the crane fully extended (27 feet-3 inches). Hoist the load with the crane and hold above the pier for 5 minutes. While hoisting the load, record the hydraulic pressure. If the pressure is higher than 3060 psi (21.5 MPa), reset the main relief valve at this recorded pressure setting. If the recorded pressure is less than the normal setting of 3060 psi (21.5 MPa), reset the main relief valve to 3060 psi.

l. Remove the test load and return the crane to its stowed position.

3.5.3 Test HIAB Model 120 Sea Cranes as follows:

a. Energize the pump and reset the main relief valve to the 3600 psig (25.3 MPa) to enable the crane hydraulic system to lift the test weights.

b. With the proof load positioned along side of the pier, fully extend the crane to its maximum outreach of 26 feet- 11 inches from the center of the crane rotation. The outer boom should be horizontal and the inner boom should be 10-15 degrees to horizontal.

c. Attach a 125-percent proof load of 3,750 pounds to the crane hook. Hoist the proof load with the winch to about four feet above the pier and hold for 5 minutes.

d. Inspect the structures and equipment for deformation and excessive strain, measure the pressure, and measure the sink rate while holding the proof load for 5 minutes.

If noticeable sinkage occurs, observe both the inner and outer boom cylinders to determine where leakage may be occurring.

Record results.

e. After holding the proof load for five minutes, hoist the weight with the winch as high as practical without changing the position of the booms. Slowly swing the proof load as far as possible in all directions. Frequently (at least every 30 degrees of rotation) stop the load to test the brakes for satisfactory operation. The booms may be raised and lowered where required to clear deck obstructions.

f. After returning the proof load and booms to the original position (26 feet-11 inches extension), use the extension cylinders to fully retract the boom and then return to its fully extended original position. Using the luffing cylinders, lift the load through the crane's entire operating positions.

g. Remove the test load and reposition the crane hook to an outreach radius of 14 feet from the center of crane rotation. Hold this position and lift a 6000-pound test load with the winch approximately 6 inches off the deck. Hold the test load for five minutes and then remove the test load. If the winch will not lift and hold the 6000-pound test load, reduce the weight to the maximum that the winch will lift and hold. Record the actual test load.

h. Position all boom parts horizontal with boom extended so that the hook is 19 feet-9 inches from the center of crane rotation and place a 5000-pound test load on the hook.

Using the lower luffing cylinder, luff down and up to the limits of the cylinder travel. Use winch to keep test load close to deck. Return to the horizontal position and remove the test load.

i. Fully extend the lower luffing cylinder and partially retract the upper luffing cylinder so that the boom is horizontal. Partially retract boom sections so that the hook is 10 feet-3 inches from the center of the crane rotation. Using the upper luffing cylinder, luff down and up to the limits of the cylinder travel. Use winch to keep test load close to deck.

Return boom to the horizontal position and remove the test load.

j. De-energize the pump. Remove the two hydraulic plugs and replace the No. 2 (lower boom cylinder) and No. 3 (upper boom cylinder) relief valves in their original locations of the control valve manifold. Do not adjust the main relief valve at this time.

k. Attach a 3,000 pound test load to the crane, with the crane fully extended (26 feet-11 inches). Hoist the load with the crane and hold above the pier for 5 minutes. While hoisting the load, record the hydraulic pressure. If the pressure is higher than 3350 psi (23.5 MPa), reset the main relief valve at this recorded pressure setting. If the recorded pressure is less than the normal setting of 3350 psi (23.5 MPa), reset the main relief valve to 3350 psi.

l. Remove the test load and return the crane to its stowed position.

3.5.4 After completion of the crane tests, remove and clean

the pressure gage from the control valve manifold and return the test kit to the COTR. Remove the tarp from the control station manifold and reinstall the protective shielding for the control valve operating station.

3.6 Tests of A-frames.

3.6.1 With the A-frame in the fully extended position, lower the proof load onto the wire rope hook using a dockside or floating crane. The proof load shall be 125 percent of the A-frame's rated capacity. Hold the proof load for 5 minutes and inspect for structural deformation and excessive strain.

3.6.2 After holding the proof load for 5-minutes, raise and

lower the proof load using the winch. Repeat the raising and lowering for two complete cycles, stopping at several positions to demonstrate proper operation of the brakes. If the winch will not lift the proof load, reduce the weight of the proof load to the maximum that the winch will lift. Record actual weight of proof load lifted.

3.6.3 Using the hydraulic cylinders, swing the proof load

through the entire arc of A-frame's travel for two complete cycles. If the A-frame is unable to swing the proof load due to hydraulic limitations, reduce the weight of the proof load to the maximum that the A-frame can swing. Record the actual load which the A-frame was able to swing.

3.7 Inspection After Tests. After completion of the proof

tests, conduct a thorough examination of all structure and equipment for evidence of deformation, excessive strain, and any other condition which could affect safe operation. Inspect hydraulic hoses, piping, and fittings for leaks, deformation, and ruptures.

3.8 Test Plate. If adequate space is available on existing test plates, engrave or stamp the date and place of test for each tested crane, boom, A-frame, davit and boat. If adequate space is not available on the existing test plate, renew it with a new government-furnished test plate using stainless steel fasteners.

Test data shall be engraved or stamped on the plate with uppercase 3/16-inch high letters and numbers.

3.9 Test Report. Submit to the COTR, within 24 hours after

completion of inspections and tests, a report of all inspection and test results, test loads used, and measurements taken.

4. QUALITY ASSURANCE.

4.1 All tests shall be witnessed by the COTR.

4.2 Provide to the COTR a certificate attesting to the accuracy of the weights being used or verify the weight of the test loads to the COTR immediately prior to conducting the tests.

END OF SPECIFICATION