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A) PROGRAM : WINCH TEAR-DOWN

A1. Objective
-

To inspect, service and replace spare parts where necessary for existing main winch, fly
winch and luff winch.

To purchase 3 units of winches as a temporary replacement during the repair job.

As per LEM
8.5.5 Tear down Inspection
Tear down inspection shall be carried out depending on usage category.
As a minimum all hoist shall undergo a complete teardown inspection
every two (2) years.

API RP 2D 6th 2007


A2. Work pack
Work flow (onshore winch tear down)
1. Inertial data collection.

2.

3.

Budget.

Crane data (crane model, winch model, part numbers).

Crane existing data (capacity, speed, elevation height).

Modification kit (fitting, hose).

Plan.

Procurement of long lead material.

Scheduling.

Producing new rerated load data chart.

Site Survey.

4.

Detail data on modification (space, mounting, obstruction, limitation)

Fabrication of adapter

Engineering structural study, simplify.

Drawing.

Fabrication.


5.

6.

Try fitting.

Material readiness offshore.

Winch

Wire rope

Anchor termination

Crane operator awareness on new load data chart

Material readiness onshore.

Standard service (seal kit, brake kit, bearing)

Extended service (gear terrain)

Crane Involved:

Platfor
m

Locati
on

Reg
No

EWQA

Main
Deck

309
18

SMDPA

Main
Deck

295
00

EWDP
B

Main
Deck

703
83

SUDPA

Main
Deck

307
38

EWA-C

Main
Deck

703
85

TBG-A

Main
Deck

400
50

SMQ-A
SMG-A
SMP-C
SUPGB
ZEDP

Main
Deck
Main
Deck
Main
Deck
Main
Deck
Main

Tag
No
PC70
00
PC
53
00
J98
0
B70
20
PC74
00
ME35
0

Manufact
ure

Model

S/N
no

Unit
Mariner

150H

20361

Main
winc
h
CH1
0

Fly
winc
h
-

Luff
winc
h
PD1
5-77

CH1
0

PD1
5-77

Unit
Mariner

150H

1261

Nautilus

358325

03880
1-C

Seacrane

R650

K0108
7

CH2
40

CH1
50

CH3
30

Favco

60RL

1119

Seacrane

R450

K0119
7

CH2
10

PD
15

CH1
75

Favco

60RL

1261

SEACRAN
E

R450

K0122
9

FAVCO

60RL

1806

FAVCO

8/10K

1384

NAUTILUS

35B4

SUJT-C
EWGA
EWDPB
KINDP
A
KNPGB
KNPGB
KNJT-C

Deck
Main
Deck
Main
Deck
Main
Deck
Main
Deck
Main
Deck
Main
Deck
Main
Deck

FAVCO

60RL

1433

SEAKING

2300

1869

FAVCO

6/10K

1118

FAVCO

8/10K

1596

FAVCO

7.5/1
0K

1597

HERKULE
S

RM260

RM26
0-09212

NAUTILUS

A3. Item to purchase:


- Fly hoist pd 15 b short drum
- Main hoist ch 210 a long drum
- Boom hoist must ch 210 b short drum p.
- Wire rope (3 sets) - Existing wire rope if smaller can be utilised BUT if bigger, than need to be
replaced with new rope.
- This winch set is for the green color crane.
- For crane heel pin elevation at about 15 m to 30 m from sea.
i) Fly winch need 110m of 16 mm wire.
ii) Main winch need 290m of 19 mm wire.
iii) Boom hoist need 215m and 305m of 19 mm wire.
Info
1. All hoist will be mounted on adapter plate.
2. Crane will be re-rated as per winch available and be given new load chart.
3. Minimum performance will be 65% of crane capacity.
A4. Scope of Works (SOW)

- Normal service
- Replaced seal
- Service plate
- Remove corrosion
- Stall test
Additional Scope (if necessary)
- Replaced spare parts
- Bushing alignment
- Load testing
- Rebuilt and chrome for shaft
A5. Tear-Down Duration
1. Seal procurement - 2 weeks
2. Perform SOW - 1-2 weeks
Total - 3-4 weeks per winch

A6. Manpower
1. Site visit for mounting, space, - 1 person
2 Adapter fabrications - 3 person
3 Hook up and test - 3 person.

A7. Budgetary

NO

ITEM

QTY

Crane to
Utilise

PRICE PER
UNIT (RM)

TOTAL
PRICE (RM)

ITEM : FLY WINCH PD 15 B 41064 04 - 1


SHORT DRUM
BRAND : BRADEN

172,000.00

172,000.00

ITEM : MAIN WINCH CH210 A 36120 02 1


long DRUM
BRAND : BRADEN

220,000.00

220,000.00

ITEM : BOOM CH 210A 36120 02 -1 long


DRUM P
BRAND : BRADEN

252,000.00

252,000.00

ITEM : FLY WINCH CH 210A 36120 01 -1


SHORT DRUM
BRAND : BRADEN

ITEM : MAIN WINCH CH280 A 54120 02 1


long DRUM
BRAND : BRADEN

ITEM : BOOM CH 280A 54120 01 -1 short


DRUM P
BRAND : BRADEN

For favco crane X/10K series we to get from


favco. Since their winch are custom. We
need winch motor, gear box, brake.

ITEM : MAIN WIRE ROPE


LENGTH : 290M
DIAMETER : 19MM
QTY : 1 LENGTH
TYPE : Dyform 18 bridon 1960 grade, fused &
taped, RHRL, GAL, IWRC

9,000.00

9,000.00

ITEM : FLY WIRE ROPE


LENGTH : 110M
DIAMETER : 16MM
QTY : 1 LENGTH
TYPE : Dyform 18 bridon 1960 grade, fused &
taped, RHRL, GAL, IWRC

15,300.00

15,300.00

6a

ITEM : LUFF WIRE ROPE


LENGTH : 215M
DIAMETER : 19MM
QTY : 1 LENGTH
TYPE : Dyform 6 bridon 1960 grade, fused &
taped, RHRL, GAL, IWRC

18,900.00

18,900.00

6b

ITEM : LUFF WIRE ROPE


LENGTH : 305M
DIAMETER : 19MM
QTY : 1 LENGTH
TYPE : Dyform 6 bridon 1960 grade, fused &
taped, RHRL, GAL, IWRC

18,900.00

18,900.00

TRANSPORTATION COST (USA-MALAYSIA)

22,000.00

22,000.00

SUB-TOTAL PRICE (RM)

709,2
00.00

6% GST (RM)

42,5
52.00

GRAND TOTAL (RM)

751,752.00

B) PROGRAM : HYDRAULIC SEAL REPLACEMENT


B1. Objective
To minimize downtime as the equipment cant be used.
To improve safety as oily work place.
To minimize premature of brake element from premature failure.
To minimise crane operation control issue as crane may jerk, less respond and may lost control.
B2. Work Pack

Survey and data collections

List of seal to be replace base on priorities (by contractor and pcsb).

Procurement of the seal.

Material, manpower readiness and windows.

Report percentage work done.

B3. Scope of Works:


-

All hydraulics seal


All mechanical seal

B4. Duration
Depending on complexity of the crane system. Per item such gear pump will take 3 man hours.
B5. Manpower

Sr Mechanical x 1 Pack
Jr Mechanical x 1 Pack

B6. Budgetary

Material RM60,000 to RM80,000 per crane.

C) PROGRAM : SLEW RING TEST


C1. Objective
C2. Work Pack
C3. Scope of Works:
As per LEM
8.3.4 Swing Circle assembly - Wear Assessment by Grease Sample
Analysis.
1. Preparation
a. Clean the raceway to minimize contamination of the sample.
b. Position the crane boom at the minimum radius to allow a full 360
rotation.
c. Use grease that is recommended by the Crane Manufacturer.
2. Collection of Sample
a. Pump grease while slowly rotating the crane 360.
b. A sufficient bead of grease should be observed all the way around
the lip seal.
c. Select eight points equally spaced to obtain a sufficient sample.
d. Collect the sample in a clean container, such as a clear plastic
bag, sample jar, etc.
e. Clean off excess grease after taking the sample.
3. Evaluation of Sample

a. Take a small portion of the sample and spread it out on a light


colored material such as a white cotton cloth, coffee filter, etc.
b. Dilute the grease sample with a solvent to expose any
contaminates.
c. Inspect the sample looking for metal particles, sand, nylon, rust,
water, etc.
Note: Special attention should be given to metal particle size,
shape and quantity.
d. The Crane Manufacturer or an experienced engineer shall be
consulted if the sample is questionable and further evaluation is
required.
e. The Area Authority shall be informed accordingly
8.3.5 Wear Assessment by Rotation method
The Rotation method is based on the fact that the bearing may always be
fully tilted forward in the direction of the boom and the tilt. By measuring
this tilt will provide an indication of the bearing integrity.
Note: On certain facilities the crane may not be installed for 360
rotation and hence reading taken shall be to the maximum slew
limits.
Procedure
a. Clean the surface of the bearing to be measured and ensure it is
clean, and rust free
b. Position a dial indicator, with a magnetic base, on the pedestal with
the needle of the indicator positioned on the clean surface of the
bearing or crane (see Figure below).
c. This dial indicator shall be positioned in the front or rear of the crane
in line with the boom
d. The boom must be positioned such that the bearing is fully tilted
forward with no excessive moment load.
e. Set the indicator to zero
f. Slowly rotate the 360 with the dial indicator reading recorded every
45 of crane rotation.
g. The dial indicator should return to zero when the crane is rotated 360
back to its original position.
h. Reposition the dial indicator every 900 in order to perform 4 individual
tests

i. Record readings and compare with the last reading taken or when fist
installed and commissioned.

C4. Duration

Per crane will take 2 days to complete.


1) Preparation to clean work area
2)

C5. Manpower
This inspection must be done by crane inspector and assist by technician.
C6. Budgetary

D) PROGRAM : SLEW BOLT INSPECTION


D1. Objective

Ensure crane swing assembly bolt torque are correct.

To minimize possibilities of slewing assembly premature damage

For crane more than 25 years (more than design life) 25% of slew bolt need to be dye
pend free of surface crack.

D2. Work Pack


8.3.6 Crane/ Bearing connection integrity
The Crane/ Bearing may be connected using bolts, welding or
combinations of the two. The integrity of this connection is crucial to the
life of the swing circle assembly.
The inspection guideline for each crane is specific and the OEM shall be
referred for guidance when developing the inspection procedures.
As a minimum the following guidelines shall apply:
a. Check the bolts are torque to OEMs specification.
b. Rotate the crane 360 in each direction at slow, intermediate and
full speed and monitor the smoothness of rotation.
c. Report any irregular, jerky, bumpy, etc. motions to the relevant
authority for immediate remedial action.

D3. Scope of Works:

D4. Duration
D5. Manpower
D6. Budgetary

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