FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

(WILL BE PERFORMED AT PORT OF LOADING IN ITALY)

Document No. :

FAT-C1574_Rev.3

Contractor/Purchaser
Cliente

PT PELABUHAN INDONESIA III (PERSERO)

Company
Cliente Finale

PT PELABUHAN INDONESIA III (PERSERO)

Project
Progetto

PELINDO III

Purchase Order No. / LOI

Nr. Ordine / Lettera Intento

HK.0502/221/P.III-2015

Type
Tipo

TAG

IMHC 2120E

C1574

Intended
Destinazione
PT PELABUHAN
(INDONESIA)

ITALGRU'
Job No.
C1574

30th May 2016

Issued for approval

E.B.

M.T.

E.B.

th
27 May 2016

Issued for approval

E.B.

M.T.

E.B.

13th May 2016

Issued for approval

E.B.

M.T.

E.B.

04th Mar 2016

Issued for comments

E.B.

M.T.

E.B.

Date

Revision

Description of revision

Prepared

Checked

Approved

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

FAT-C1574_Rev.3

Document No. :

REVISION CHANGE SUMMARY

Revision

Location of Change /
Section / Page Affected

Description of Change starting from Rev 1

Page 3

Deleted repetition of Items 1.12 & 1.13 & shifting of relevant following No.

Page 3

Added reference to spec. Tender Par.5.9 for lighting system

Page 3

Added Insulation Resistance Check

Page 6

Added remark on dynamic test relevant the checking of deflection

Page 6

Added Point 1.21) Power Factor Check

Page 3

Point 1.18) & 1.19) - Added Functionality Check

Page 3

Point 1.21) Added Capacitor bank Check

Page 3

Added Point 1.22

Page 6

Added remark on dynamic test relevant the document for the checking of
deflection

Page 3

Added Point 1.23

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

Document No. :

FAT-C1574_Rev.3

1.

VISUAL CHECK

No.

Description

1.1)

Check of compliance of color for the crane with approved color scheme

1.2)

Contractual
Doc. Ref. Par.
(if any)

Result

Tender Par.1.13 &

3.8 h)

Checked ok

Check of presence of name and logo on two sides of the crane

Tender Par.1.13

Checked ok

1.3)

Check that machinery house and E-Room are positioned on the crane superstructure
and that HV transformer is placed in a separate box

Tender Par.3.3
a) & f)

Checked ok

1.4)

Check that machinery house and E-Room are spacious enough to allow easy access of
inside equipments

Tender Par.3.3 b)

Checked ok

1.5)

Check that machinery house and E-Room are rainproof, totally enclosed and with
adequate ventilating system

Tender Par.3.3 c)

Checked ok

1.6)

Check of presence of fire extinguisher in Machinery Room and E-Room and close to
acecess ladder - Class C02

Tender Par.3.3 c) &

6.4

Checked ok

1.7)

Operator cabin - Check of easy access and door with lock

Tender Par.3.4
a) & b)

Checked ok

1.8)

Operator cabin - Check of presence of shielding from direct sunlight, Split Air
Conditioning, fire extinguisher Class C02, wipers, light

Tender Par.3.4
b) & c)

Checked ok

1.9)

Operator cabin - Chair shall be adjustable in order to reach all devices for crane
controlling

Tender Par.3.4
b) & c)

Checked ok

1.10)

Operator cabin - Check of functionality of anemometer (warning signal if wind speed

exceed 20 m/s) - simulated

Tender Par.3.4
d) & Par. 1.9 a) &
6.5

Checked ok

1.11)

Operator cabin - Check the communication system (telephone and loudspeaker)

Tender Par.3.4
c) & e)

Checked ok

1.12)

Operator cabin - Check of presence of service platforms to clean the windows

Tender Par.3.4
c)

Checked ok

1.13)

Operator cabin - Check the functionality of video camera positioned on head boom

Tender Par.6.11

Checked ok

1.14)

Operator cabin - Check the functionality of hours counter and monitorign system

Tender Par.5.14 &

6.10

Checked ok

1.15)

Check the functionality of light system (operator's cab, engine room, electrical room,
ladders, walkways, emergency) and red aircraft warning lights (on boom head)

Tender Par.5.9

Checked ok

1.16)

Check the satisfaction of lighting system relevant Tender Par.5.9

Tender Par.5.9

Checked ok

1.17)

Check of functionality of communication system positioned in machinery room, ERoom, engine generator room and operator cabin

Tender Par.5.11

Checked ok

1.18)

Verify the presence and the functionality of emergency stop buttons in Machinery Room,
E-Room, operator cabin, highest end of structure and on carrier

Tender Par.6.1

Checked ok

1.19)

Verify the presence and the functionality (simulated) of fire alarm in machinery room, ERoom and operator cabin

Tender Par.6.4

Checked ok

1.20)

Spot check of Insulation Resistance for motors, power cable and Generator Set.

Tender Par.5.7 h)

Checked ok

1.21)

Check of power factor anc Capacitor bank

Tender Par.5.6

Checked ok

1.22)

Check of presence of lightning protection

Tender Par.6.3

Checked ok

1.23)

Check of Generator characteristics according to Tender Par.5.3

Tender Par.5.3

Checked ok

Remark: complete Insulation Resistance Check shall be performed during commissioning phase (Pre-FAT) and reports shall be available for review

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

FAT-C1574_Rev.3

Document No. :
2.

DIMENSIONAL & NO LOAD FUNCTIONAL TEST

No.

Description

2.1)

Test of extension and retreat of each outrigger (together in automatic mode and
individually in manual mode)

Tender Par.1.16 d)
& 3.6 a)

Checked ok

2.2)

Test lowering and lifting of each outrigger

Tender Par.1.16 d)

Checked ok

2.3)

Test the steering left and right in forward and reverse

Tender Par.1.16 d)
& 4.4 e)

Checked ok

2.4)

Check the travelling speed (requested 80 m/min equal to 4,8 km/h)

Tender Par.1.16 d)
& 2.1 j.

Checked ok

2.5)

Check the functionality of undercarriage warming lights and siren during travelling

Tender Par.4.4 g) &

5.12

Checked ok

2.6)

Check for no leaks in the hydraulic system of outriggers, steering and travelling

Tender Par.1.16 d)

Checked ok

Contractual
Doc. Ref. Par.
(if any)

measured

Result

After lifting and stabilization of crane without load

2.6)

Check the minimum outreach (11 m)

measured

None

Checked ok

2.7)

Check the maximum outreach (requested minimum 42 m)

Crane' Data 51 m

measured

Tender Par. 2.1 d.

Checked ok

2.8)

Check the lifting heigh above ground at 42m radius (requested

minimum 25 m)

measured

Tender Par. 2.1 e.

Checked ok

2.9)

Checking of slowing and stop positions of minimum and maximum boom reach

Tender Par.1.16 d)
& 6.7

Checked ok

2.10)

Check the luffing time from min to max (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

2.11)

Check the luffing time from max to min (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

2.12)

Checking of slowing and stop positions of hoisting

Tender Par.1.16 d)
& 6.7

Checked ok

2.13)

Check the hoisting speed (no load) - requested minimum 120

m/min

Tender Par.1.16 d)
& 2.1 j.

Checked ok

2.14)

Check the rotation in clockwise and counterclockwise direction

Tender Par.1.16 d)

Checked ok

2.15)

Checking of slowing and stop positions of rotation

Tender Par.1.16 d)
& 6.7

Checked ok

2.16)

Check the anti rotation block system

Tender Par.1.16 d)

Checked ok

2.17)

Check the slewing speed (no load) - requested minimum 2 rpm

Tender Par.1.16 d)
& 2.1 j.

Checked ok

2.18)

Check for no leaks in the hydraulic system of slewing, luffing and lifting

Tender Par.1.16 d)

Checked ok

2.19)

Verify the functionality of deadman switch

Tender Par.6.2

Checked ok

2.20)

Verify the functionality and efficiency of portable board

Tender Par.4.4 f)
and Par.5.8 b)

Checked ok

measured

measured

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

Document No. :
3.

FAT-C1574_Rev.3

LOAD TESTS (WITH HOOK BLOCK)

After lifting and stabilization of crane lifting of 50% of load (50,5ton at 22m radius)
Contractual
Doc. Ref. Par.
(if any)

Result

No.

Description

3.1)

Check the luffing time from min to max (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

3.2)

Check the luffing time from max to min (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

3.3)

Check the slewing speed - requested minimum 1,5 rpm

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

After lifting and stabilization of crane lifting of 100% of load (100ton at 24m radius)
3.4)

Check the luffing time from min to max (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

3.5)

Check the luffing time from max to min (requested 12,5s to

complete 5m radius corresponding to 25 m/min)

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

3.6)

Check the hoisting speed - requested minimum 18 m/min

measured

Tender Par.1.16 d)
& 2.1 j. &
Addendum

Checked ok

3.7)

Check the slewing speed - requested minimum 0,5 rpm

measured

Tender Par.1.16 d)
& 2.1 j.

Checked ok

3.8)

Check the capability of performing luffing, slewing and hoisting operations

simultaneously

Tender Par.1.16 d)

Checked ok

3.9)

Check the functionality of the braking system

Tender Par.1.16 d)

Checked ok

3.10)

Check for no leaks in the hydraulic system of slewing, luffing and lifting

Tender Par.1.16 d)

Checked ok

3.11)

Check that noise level in E-Room is under 85dBA

Tender Par.3.3 g)

Checked ok

3.12)

Check that noise level in Operator Cabin is under 70dBA

Tender Par.3.4 f)

Checked ok

3.13)

Check of voltage and current consumption for each motor

Tender Par.1.16 g)

Checked ok

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

Document No. :
4.

FAT-C1574_Rev.3

DYNAMIC OVERLOAD TESTS (WITH HOOK BLOCK) - FIRST STEP

After lifting and stabilization of crane lifting of 110% of load (110ton at 24m radius) to reach maximum moment configuration
Remark: during this test will be checked the maximum deflection to the machinery and the structure meaning strain gauges to verify compliance
with design model. Relevant strain gauges positions & tolerances are defined in the separate document "Strain gauges map".
Contractual
Doc. Ref. Par.
(if any)

No.

Description

Result

4.1)

Check the capability of performing luffing, slewing and hoisting operations

simultaneously and overload alarm

Tender Par.1.16 d)
& 5.13

Checked ok

4.2)

During movements execution switch on braking device (switching off the motor) and
check that load remains suspended for minimum 10 minutes without lowering

Tender Par.1.16 d)

Checked ok

4.3)

Visual inspection for no damages and no problems after dynamic overload test

Tender Par.1.16 d)

Checked ok

4.4)

Check for no leaks in the hydraulic system

Tender Par.1.16 d)

Checked ok

5.

STATIC OVERLOAD TESTS (WITH HOOK BLOCK) - FIRST STEP

First step - After lifting and stabilization of crane applying of 125% of load (125ton at 24m radius) to reach maximum static
moment configuration
Contractual
Doc. Ref. Par.
(if any)

No.

Description

5.1)

Applying overload in static conditions with fork lift or other lifting device
Load suspended for minimum 10 minutes without lowering

Tender Par.1.16 a)

Checked ok

5.2)

Visual inspection for no damages and no problems after static overload test

Tender Par.1.16 a)

Checked ok

6.

DYNAMIC OVERLOAD TESTS (WITH HOOK BLOCK) - SECOND STEP

Result

After lifting and stabilization of crane lifting of 110% of load (132ton at 14m radius) to reach maximum winch load configuration
Remark: during this test will be checked the maximum deflection to the machinery and the structure meaning strain gauges to verify compliance with
design model. Relevant strain gauges positions & tolerances are defined in the separate document "Strain gauges map".
Contractual
Doc. Ref. Par.
(if any)

No.

Description

Result

6.1)

Check the capability of performing luffing, slewing and hoisting operations

simultaneously and overload alarm

Tender Par.1.16 d)
& 5.13

Checked ok

6.2)

During movements execution switch on braking device (switching off the motor) and
check that load remains suspended for minimum 10 minutes without lowering

Tender Par.1.16 d)

Checked ok

6.3)

Visual inspection for no damages and no problems after dynamic overload test

Tender Par.1.16 d)

Checked ok

6.4)

Check for no leaks in the hydraulic system

Tender Par.1.16 d)

Checked ok

7.

STATIC OVERLOAD TESTS (WITH HOOK BLOCK) - SECOND STEP

After lifting and stabilization of crane applying of 125% of load (150ton at 14m radius) to reach maximum load configuration
on winch
Contractual
Doc. Ref. Par.
(if any)

Result

No.

Description

5.1)

Applying overload in static conditions with fork lift or other lifting device
Load suspended for minimum 10 minutes without lowering

Tender Par.1.16 a)

Checked ok

5.2)

Visual inspection for no damages and no problems after static overload test

Tender Par.1.16 a)

Checked ok

FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

PROCEDURA FAT

FAT-C1574_Rev.3

Document No. :

FINAL ACCEPTANCE
TEST RESULT
Remarks (if any):

Free space for date, signature and stamps

POSITIVE

NEGATIVE