0264 GustoMSC_PowerPointTemplate_08_2010[1].PPT

COMMISSIONING & LOAD TESTING
5000 T CRANE
Gusto model E-5000-SBX-L
Location, Date
Schiedam, 17 January 2011

Agenda
 Objectives
 Safety
 Organization
 Commissioning (A/B/C – scope)
 Load Testing
 Ballast procedure Vessel
 A-frame lowering/upending
 After load testing
 Clarifications

Objectives
Clarification of the presentation
The purpose of this presentation is to provide information and instructions on how
the CRANE will be commissioned and load tested in order to demonstrate the
CRANE complies with the requirements of the contract.
All the information and instructions together are bundled in a Commissioning & Load
Testing Book which will be the theme of this presentation.
The Commissioning & Load Testing Book comprises mainly of:
• Safety Plan
• Commissioning & Testing Manual
• Load Testing Manual
• Ballast Procedure Vessel

Safety
Safety issues:
• Control of access / Controlled Area
• Evacuation drill
• Define interface with DFDS, IHC (ERT room), Gusto, Muller, Traffic Control
of Port Authority
• Personal protective
• Weather (Conditions/Forecast)
• Emergency response
• Daily toolbox meeting

Organization
 Overall organization (IHC)
 Commissioning & Load Testing organization (Gusto)
 Overview members Commissioning & Load Testing team
 Chain of Command

Organization
Overall Organization (IHC)
Captain
Overall Vessel
Supervisor
(IHC)
Project Management
IHC
Oleg Strashnov
Port Authority
Port of Rotterdam
Ronald van Son Traffic Control
Vessel General
Team
(IHC)
Vessel Ballasting
Team
(IHC)
Crane
Commissioning &
Load Testing Team
Johan de Bruin Jelmer Gerdingh Arie van Dijken

Organization
Commissioning & Load Testing organization (Gusto)
Co-ordinator
Commissioning Team
Siemens
Rob Reddering
Sven Luessen
Test Pontoons
&
Tug Boat
Muller Transport
Crane driver
Kees Baggerman
Rigger Foreman
Test Pontoons &
Test Weights
Timo van Gils (Franklin)
Ballast Engineer
Test Pontoons
Jack Verzijl (Muller)
Co-ordinator
Commissioning Team
SAS
Martin de Bruin
Engineering
Commissioning
Co-ordinator
Scott Marpole
Arjo van Putten
Superintendent
Load Testing
Procedures
Cees de Heer
HSSE
Arie van Dijken
Ballast Co-ordinator
IHC
Oleg Strashnov
Jelmer Gerdingh
Overall
Co-ordinator
Crane Commissioning
&
Load Testing

Organization
Overview members Commissioning & Load Testing Team
Company Function / Discipline Name Telephone Substitution Telephone
Gusto Overall Co-ordinator Arie van Dijken 06-20246992 Rob Kloos 06-25004734
Gusto Co-ordinator Procedures Cees de Heer 06-15839461 Arjo van Putten 06-11392295
Gusto Expert Engineer Arjo van Putten 06-11392295 Wim Woldring 06-46613154
Gusto Superintendent Rob Reddering Arie van Dijken 06-20246992
Gusto Co-ordinator Commissioning Scott Marpole 06-55734093 Zeljko Karels 06-11626334
Gusto Construction Manager Rob Kloos 06-25004734 Arie van Dijken 06-20246992
Gusto Project Manager Michael Roosen 06-29349662 Rob Kloos 06-25004734
Siemens Co-ordinator Commissioning Sven Luessen +49(174)1591961 Willy Maas
SAS Co-ordinator Commissioning T.B.A. Martin de Bruin 06-51092561
Muller Captain Tugboat T.B.A. T.B.A.
Muller Ballast Engineer Jack Verzijl 06-51987564 T.B.A.
Franklin Rigger Foreman Timo van Gils 06-57568046 Jerry Bakx 06-57568042
IHC Captain T.B.A. T.B.A.
IHC Vessel Co-ordinator Johan de Bruin 06-14010513 Jaco van Vlaanderen 06-12720790
IHC Ballast Co-ordinator Jelmer Gerdigh 06-21224624 Jelte Buiteman 06-51987564
IHC Crane driver Kees Baggerman 06-22239126 No replacement
IHC Project Co-ordinator Marcel Smits 06-10429853 T.B.A.
IHC Project Manager Ronaldvan Son 06-12268400 T.B.A.

Commissioning A/B/C/ Scope
Based on report provided by Scott at end of Thursday

Load Testing
 Load Testing Manual
 Test Weights
 Sling Arrangements
 Load Testing Location
 Load Testing Arrangements

Load Testing
Load Testing Manual
The Load Testing Manual provides information and instructions on how the CRANE
will be load tested in order to demonstrate the CRANE complies with the
contractual requirements.
The tests described are in agreement with the applicable DNV standard for
Certification of Lifting Appliances January 2007, which is a reprint of the 1994
Rules.
The load testing comprises of loading the CRANE with loads at corresponding radii
as per load-radius curve. The loads at the breaking points in the curve have to be
applied as a minimum, completed with an intermediate load at corresponding
radius.
The test loads chosen are based on the different load cases as per document
GT264.CGG91010 5000 T Crane Loads on System Report showing the (high)
loaded components.

Load Testing
Test weights
Movable, certified weights will be used:
 Test pontoon 256-2 for loads from 35 t up to 250 t
 Test pontoon 5511 for loads from 250 t up to 1250 t
 Test pontoon 6619 for loads from 1250 t up to 5500 t
 Water bag for loads up to 35 t
Because of their size the weight of the test pontoons cannot be checked with a
separate load cell, therefore the test weight will be based on the certified own
weight and amount of water ballast multiplied by the measured water density.
The amount of water ballast will be based on the sounding tables of the ballast
tanks of the test pontoon.
The test weight including the weight of the required sling arrangement will be the
total weight suspended in the hook of the applicable hoisting system.

Load Testing
Test Pontoon 256-2

Load Testing
Test Pontoon 5511

Load Testing
Test Pontoon 6619

Load Testing
Water bags

Load Testing
Sling arrangements
 Sling arrangement for test pontoon 256-2
 Sling arrangement for test pontoon 5511
 Sling arrangement for test pontoon 6619

Load Testing
Sling arrangement for test pontoon 256-2

Load Testing
Sling arrangement for test pontoon 5511

Load Testing
Sling arrangement for test pontoon 6619

Load Testing
Location of Load testing at DFDS terminal

Load Testing
Load Testing Arrangements – Whiphoist 110t @ 118m

Load Testing
Load Testing Arrangements – Aux. Hoist 1 500 t @ 113 m

Load Testing
Load Testing Arrangements – Aux. Hoist 1 800 t @ 72 m

Load Testing
Load Testing Arrangements – Main Hoist 740 t @ 84.5 m

Load Testing
Load Testing Arrangements – Main Hoist 3800 t @ 43 m

Load Testing
Load Testing Arrangements – Main Hoist 5000 t @ 32 m

Ballast Procedure Vessel
 Refer to Ballast System Operation Philosophy

A-frame Lowering/Upending
Due to limited height when passing the bridge over the Bosporus, the CRANE has
the possibility to lower the A-frame to allow a safe passage.
For lowering /upending the procudere is as follows:
Lowering
1. Vessel must be even keel and preferably 1 - 2 trim (aft ship lower).⁰ ⁰
2. Boom must be in the boom rest. Sea fastening (anti-rotation pins, ballast
box support and safety clamp system) is not required to be engaged.
3. Lower blocks must be in the pockets and give slack wire till the load is on
the pocket and not in the wires. Give not more rope than required to. When
unexpected movements of the A-frame would occur, the weight of the blocks will
help to keep the boom down.
4. Park trolley in middle of boom and position hook halfway between boom
and deck.
5. Give rope of the boom winch till the rope load (indicated by the load pin at
A-frame aft leg) has dropped till about 15 t.

6. Remove covers on boom hoist roof behind rope passage and make sure rope
passage can travel backwards.
7. Make sure that hydraulic jacks at hinge points of A-frame aft leg are not
pushing. Remove locking blocks at aft legs A-frame, two at each leg.
8. At both aft legs, two hydraulic jacks are mounted to push the A-frame. Both
systems have there own manual, local controls. First push all jacks with a
stroke of 50 mm. When at maximum pressure of 230 bar nothing happens,
the cause of that must be investigated.
9. Push all jacks more or less simultaneously with steps to 100 mm, 150 mm
and 200 mm. The maximum stroke is 250 mm. Make sure the A-frame can
move without pulling on the hydraulic hoses.

10. Give boom rope with 5% speed until A-frame starts to lower or when rope
load (indicated by the load pin at A-frame aft leg) has dropped till 4.6 t.
Theoretically, it should start to move at 5.8 t. Rope pull at drum is then 4.5 t.
11. When A-frame didn’t start to move, push cylinder to maximum stroke.
12. When A-frame still doesn’t move, attach rope of both of load tuggers to the
pad-eyes on mini A-frame. Set load tuggers in CT mode and increase the
load until A-frame moves. Reduce the force to 1 t when A-frame is lowered
more than 10 .⁰
13. When hydraulic jacks are no more in contact with upper leg, pull in the jacks
completely and push them 1 or 2 mm to be sure that no pressure is on the
system. Now disconnect hydraulic hoses.
14. Give rope with the boom hoist until it’s final position is reached with a
maximum speed of 10%. In the mean time rope has to be given on the MH1,
MH2, AH1, AH2 and WH. This process has to be done in steps. After every
step of A-frame lowering, lower blocks need to be given some rope. Also the
rope force (indicated by the load pin at A-frame aft leg) has to be observed
during lowering. Theoretically, the value must be 16.8 t at the lowest position.
When it is exceeding 18.5 t, the operation has to be stopped to investigate the
cause.

Upending
1. Start upending the A-frame by booming in with boom hoist at a speed of
maximum 10% until upper and lower leg are (almost) in line or rope load
(indicated by the load pin at A-frame aft leg) has increased till 15 t.
In the mean time rope has to be hauled in on the MH1, MH2, AH1, AH2 and
WH. This process has to be done in steps. After every step of A-frame
upending, the rope of the lower blocks need to be hauled in. Also the rope
force (indicated by the load pin at A-frame aft leg) has to be observed during
upending.
2. When gap at locking blocks is less than 15 mm, normal bolts can be installed
and by fastening the bolts, gap will be closed. When gap is too large for the
bolts, the force on the ropes can be increased till 20 t. It’s possible that the
boom will start to lift while the blocks are in the block pockets. If this doesn’t
help, threaded rods of 500 mm long can be used to pull upper and lower leg to
each other. It might be needed to decrease the rope load to 10-15 t to reduce
friction.
3. Bolts of locking blocks must be on the correct torque (2500 Nm).
4. Close covers on the boom hoist roof behind rope passage.

After Load Testing
General
After execution of the load tests the CRANE, including gear accessories, has to be
examined to observe whether any part has been damaged or permanently
deformed by the test.
Special attention has to be paid to high stressed spots and/or components of the
CRANE which are indicated in so-called ‘ wolken tekeningen’ (clouds drawings).
Dismantling and/or non-destructive testing may be required if deemed
necessary by the Surveyor and/or SHL.
The above applies to the lower blocks and loose gear as well.
Any overload protection system and automatic safe load indicators that may have
been disconnected or by-passed during the load testing have to be re-
connected. Safety valves and or electrical circuit breakers have to be adjusted
accordingly and set points have to be verified and sealed by the Surveyor.

After Load Testing
Activities to be executed after Load Testing
The activities to be executed are, but not limited to, as follows:
 Examine crane components for (permanently) damages or distortion.
Components, location and method of examination as per so-called ‘ wolken
tekeningen’ and within the discretion of the Surveyor and/or SHL.
 Inspect all bolted or welded connections along with the boom, hoists and slew
transmission.
 Check and verify all bolting torques applied on main items.
 Take oil/grease samples to determine to check for damage or wear
 Check all components in systems for lubricating, air, hydraulic oil, etc. for
leakage or damages

Meeting Closed
eeh…Biertje?

0264 GustoMSC_PowerPointTemplate_08_2010[1].PPT

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