sample inspection report for kobelco 7450

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RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER

CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA – JAKARTA

UTARA

DOCUMENT NO. :W-G2004-RED–004

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APPROVED BY :SITE MANAGER

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RED SECTION CRANE INSPECTION AND TEST LOAD REPORT

FOR CRAWLER CRANE KOBELCO 7450AT PT. SUPERKRANE MITRA UTAMA – JAKARTA UTARA

KRAKATAU DAYA LISTRIK 120 MW COMBINE CYCLE POWER PLANT PROJECT

CILEGON - INDONESIA

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1.1. Crane InspectionAll cranes prior to selection and after entering the KDL 120 MW CCPP Project will be inspected by the work of HSE Inspector and Rigging Engineer or by qualified personnel before they can put to work. The inspection will be carried out in accordance with the equipment inspection checklist.

1.1.1.Inspection PersonnelInspection team was consisting of following personnel: HSE Inspector : Mr. Yunan Edhie Rigging Engineer : Mr. Bayu Adjie KPI Representative : Mr. Hazairiadi

1.1.2.Inspection DataInspection data record: Day : Thursday Date : 14 November 2012 Time : 14:00 to 15:00 WIB Weather : Cloudy Terrain : Concrete, level. Location : PT. Superkrane – Workshop, Jakarta

1.1.3.Crane Parts Inspection PointThe crane was inspected for: Structural damage,

Result: good, no damage Hydraulic leaks,

Result: There is oil leaking, the crane mechanics claims that it was oil spills from the recent crane oil change

Broken wires in the hoist lines and correct terminationResult: No broken wires, hoist lines are in correct termination

Structural integrity of the load block and overhaul ballResult: good structural integrity for the load block and overhaul ball

Correct spooling of the hoist lines on the both drumResult: Spooling’s are correct for the both drum

Tire or crawler inflation and wearResult: Crawlers are in good condition

Correct counterweight as recommended by the manufacturerResult: Counterweights are in correct number and weight

1.1.4.Crane Documents InspectionAt the time of the inspection, the following document was checked:

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A valid DEPNAKERTRANS or equivalent Test Certificate for the crane (mandatory)Result: Direktorat Jenderal Minyak dan Gas Test Certificate is

available and valid. The crane load capacity chart (mandatory)

Result: Crane load capacity chart is available The crane operator valid license (mandatory)

Result: Crane operator license (SIO) is not shown to inspection team.

1.2. Load and Functional TestingA long radius, full capacity load test was performed to certify that: A load indicator is working properly and is in calibration (within ±

5%)Result: available, device is working properly.

The overload function for each drum is working properly and disengage when the maximum working radius is reached for the rated load being lifted, this test will be applicable only if the crane is equipped with a Load Moment Indicator (LMI)Result: Load Moment Indicator is available and functional.

The boom will telescope in and out, and boom up and down under a rated capacity load.Result: Not available, the crane is using lattice boom.

The brakes release smoothly and will hold the rated loadResult: The brakes functioning properly.

The crane is stable at the rated capacity radiusResult: The crane is stable.

The crane can perform multi-functions at the same times, i.e. swing, hoist and boom, etc.Result: The crane is able to perform multi-function in the same time.

The crane load capacity chart will be displayed in cab of the crane in full view of the operatorResult: The crane load capacity is present inside the operator

cabin, not in the direct line of sight of the operator. The crane operator is competent and familiar with the machine,

including the safety systems and is fully capable of reading and understanding the load chartResult: The operator is competent and familiar with the crawler

crane Kobelco 7450. Both the load on the main hoist line and the overhaul ball on the

whip line will be raised to maximum height to ensure that the vertical limit switch kick outs are working properly and disengage the drum.Result: The crane vertical limit switches are working properly

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1.3. Test Load for Crane1.3.1. Crawler Crane 450 ton Kobelco 7450After proper inspection, there will be a test load for the 450 ton Crawler Crane Kobelco 7450, we was conduct the load test on following condition: Test Load of 30.5 ton as read on the Load Indicator (using crane

crawler) Crane boom length of 60.96 meter (attached main boom) Working radius of 10.0 meter holding up elevation is set to 1000 mm above ground Holding time of 10 minutes, checked before and after test load. 230 ton hook block Wire rope size 2” x 2m length x 4 pcs 5 meter measuring tape.

1.3.2. Load Test Procedure Prepare the 450 ton crawler crane Kobelco 7450 for load test. Prepare the 30.5 ton crane crawler block, lifted using 2” sling

wire rope to 400 ton crawler crane 230 ton hook. The load block lifted and hold to elevation 1000 mm above

ground. Holding time will be 10 minute, data collecting measurement will

be before and after load test Take the load test measurement data. End the load test, lower the load block and remove all sling wire

rope and secure the load block to proper lay down storage. Check the 230 ton hook block before and after load test for any

deformation. Disengage the 450 ton crawler crane Kobelco 7450. 1.3.3. Result of Load TestThe test load blocks elevation height measurement: First measurement,

- Time: 0 minute (start of test)- Measured load block height: +1000 mm above ground

Second measurement,- Time : 10 minute- Measured load block height: +1000 mm above ground (no

change)

1.4. Final Conclusion The 450 ton crawler crane Kobelco 7450 passes the inspection

and all parts are in good condition and functioning properly. Please verify the mechanics claims that the oil leak during crane

inspection was the over flow from recent hydraulic oil change, thus there is no leak.

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The 450 ton crawler crane Kobelco 7450 passes the safety inspection by the HSE standard (please refer to HSE Inspection Report).

The 450 ton crawler crane Kobelco 7450 have shown some of the mandatory document such as the valid Dirjen Migas certificate, and crane load chart.

Please verify the availability of the operator license (SIO) which was not shown to the inspection team during inspection.

The 450 ton crawler crane Kobelco 7450 passes the load test, able to hold the load block properly.

Please note that crawler crane Kobelco 7450 is RECOMMENDED for HRSG Module Lifting, because the Kobelco 7450 load chart are above the required load capacity for HRSG Module Lifting including the safety factor of 1.2, which is 234 ton for 10 meter work radius using 42 meter boom, while the Kobelco 7450 have lifting capacity over 253.5 ton at work radius of 10 meter while using 42 meter main boom (19.5 ton more load capacity) with Safety Factor of 1.3 (prerequisite for minimum safety factor is 1.2).

Crane Inspection Process

450 ton crawler crane front view

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450 ton crawler crane left side view

450 ton crawler crane left side view

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450 ton crawler crane boom mechanism view

450 ton crawler crane sling spooling drums inspection

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450 ton crawler crane engine inspection

450 ton crawler crane cabin instrument inspection

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450 ton crawler crane cabin instrument inspection

450 ton crawler crane mast inspection

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450 ton crawler crane cabin safety inspection

450 ton crawler crane crawler wheel inspection

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450 ton crawler crane crawler track inspection

450 ton crawler crane crawler hydraulic motor inspection

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450 ton crawler crane 230 ton hook block inspection

Test Load Preparation

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Shackle and wire rope sling attached to the test load piece

450 ton crawler crane test load piece lifting up

Test Load Data Collection

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First data collection, 0 minute marked at elevation ±1000 mm above ground

First data collection, 10 minute still holding at elevation ±1000 mm above ground

After Load Test

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Put down the load test piece, remove all lifting gears and disengage the 450 ton crane

Prepared by, Witnessed by, Approved by,

Bayu Adjie Yunan Edhie German P. Siahaan Site Rigging Engineer Site HSE Inspector Site Manager