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COMMISSIONING & LOAD TESTING 5000 T CRANE

Gusto model E-5000-SBX-L

Location, DateSchiedam, 17 January 2011

HLV Oleg Strashnov

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 ManagementIHC

Oleg Strashnov

Port AuthorityPort 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 BoatMuller Transport

Crane driver

Kees Baggerman

Rigger ForemanTest Pontoons &

Test WeightsTimo van Gils (Franklin)

Ballast EngineerTest Pontoons

Jack Verzijl (Muller)

Co-ordinator Commissioning Team

SASMartin de Bruin

Engineering

CommissioningCo-ordinator

Scott Marpole

Arjo van Putten

Superintendent

Load TestingProcedures

Cees de Heer

HSSE

Arie van Dijken

Ballast Co-ordinatorIHC

Oleg StrashnovJelmer Gerdingh

OverallCo-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 06-25004734Gusto Co-ordinator Procedures Cees de Heer 06-15839461 Arjo van Putten 06-11392295Gusto 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 06-12720790IHC 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 ManualThe 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 weightsMovable, 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

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:Lowering1. Vessel must be even keel and preferably 1 - 2 trim (aft ship lower).⁰ ⁰2. 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.


Upending1. 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

GeneralAfter 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

After Load Testing

Clarifications

Meeting Closed

eeh…Biertje?

www.GustoMSC.com

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