Indra: MHE-Demag (M) SDN BHD Nghi Son Refinery and Petrochemical LLC
Indra: MHE-Demag (M) SDN BHD Nghi Son Refinery and Petrochemical LLC
Indra: MHE-Demag (M) SDN BHD Nghi Son Refinery and Petrochemical LLC
D R A
N
I 12-MA R - 2 015
Doc No.: VS2155-501-A-604
Rev. No.: 1
Page 1 of 5
`
INSPECTION & TEST PROCEDURE
1. Material Inspection 2
2. Welding Inspection 2
3. Painting Inspection 2
6. Sequence Check 3
9. Packing Inspection 5
D R A
N
I 12-MA R - 2 015
Doc No.: VS2155-501-A-604
Rev. No.: 1
Page 2 of 5
1. Material Identification
1.1 Raw material ie. steel plates shall be checked against the mill certificates. The surface, dimension and
characteristic of steel plates shall be checked for conformity.
1.2 The hook, wire rope, hoist and drive motors shall be checked against test certificates.
Acceptance Criteria
i. QC Sheet : QM.PD.QC.01.00
2. Welding Inspection
2.1 All welds shall be visually inspected in accordance with AWS D1.1 or equivalent. A weld shall be
acceptable by visual inspection if it shows that,
a) The weld has no crack.
b) Welds shall be free from overlap.
c) There are no arc strikes on any base metal outside of the permanent weld area.
e) Welds shall be of sufficient size (i.e. weld leg, throat, etc.) specified in the drawing.
f) No excessive undercut.
2.2 10% of the total length of the crane girder butt weldment shall be checked by radiographic examination.
2.3 10% of the total length of the crane girder fillet weldment shall be checked by magnetic
particle inspection.
Acceptance Criteria
i. AWS D1.1
ii. QC Sheet : QM.HC.QC.01.35
3. Painting Inspection
Total dry firm thickness shall be measured with an Elcometer. Painting activities shall be performed in
accordance with the surface preparation & painting procedure.
Acceptance Criteria
i. QC Sheet : QM.HC.QC.01.37
The girders, crab/winch, shall be assembled separately at the workshop and the crane dimensions shall be
checked against the Approval Drawing / Manufacturing Drawing. Wire rope, hook, hoist and drive motor
shall be witnessed by SKC QC or should be submitted by QC report.
D R A
N
I 12-MA R - 2 015
Doc No.: VS2155-501-A-604
Rev. No.: 1
Page 3 of 5
The allowable tolerance (MHE-Demag Standard) for all the dimensions shall be as indicated in the individual
Q.C. Reports.
Acceptance Criteria
i. QC Sheet : QM.HC.QC.01.38
ii. QC Sheet : QM.HC.QC.01.40
iii. QC Sheet : QM.HC.QC.01.84
iv. QC Sheet : QM.HC.QC.01.16
v. QC Sheet : QM.HC.QC.01.17
After the crane has been assembled, the insulation of the electrical system shall be tested. A voltage of
1000 VDC shall be used for testing. All 3 phases of each crane motion shall be tested. The insulation
resistance of the system tested shall not be less than 0.5-Megaohms
Acceptance Criteria
i. QC Sheet : QM.RE.QC.01.09
6. Sequence Check
Electrical sequence check shall be performed on the individual control panels upon completion of panel
wiring. Functional test for control, brake & limit switches shall be performed.
Acceptance Criteria
i. QC Sheet : QM.RE.QC.01.06
The functional and correct adjustment of brakes and limit switches shall be checked and tested to ensure
that primary safety and emergency systems are operating correctly. The correct operation of each motion
throughout its range of operation shall checked
a) Hoist unit - Lifting unit shall be tested by rotating the drum with the wire rope installed.
b) Cross travel motor – The crab will be placed on top of the crane girders. The wheel will then be moved
from one end of the girder to the other end.
c) Long travel motor – The crane will be set up on stands. The long travel motors will be activated. The test
will be considered successful if the wheel turn freely and no defects are found during testing.
D R A
N
I 12-MA R - 2 015
Doc No.: VS2155-501-A-604
Rev. No.: 1
Page 4 of 5
The test shall be considered successful if no cracks, permanent deformation, paint flaking or damage that
affected the function and safety of the crane is visible and no connection has been loosened or been
damaged.
Acceptance Criteria
i. QC Sheet : QM.RE.QC.01.10
ii. QC Sheet : QM.HC.QC.01.19
iii. QC Sheet : QM.HC.QC.01.20
The test shall be considered as successful when cracks, permanent deformation, paint flaking or damage
that affect the function and safety of the crane are not observed and no connection has been loosen or been
damaged. The hooks shall be free to rotate 360angle when supporting rated load. The maximum stress in
the hook at its rated load shall not exceed 20% of the ultimate strength of the material.
Load shall be placed stationary at mid-span of girder. The load so then lifted and the vertical
deflection of the crane girder is recorded. The vertical deflection must not does not exceed L/1000
of crane span.
The crane is rigidly support at both of the end carriages. The test load block will be used and place
in between of the bottom of 2 crane girders.
Acceptance Criteria
i. QC Sheet : QM.HC.QC.01.21
TCVN 4244 : 2005
BS 466
8.2 Load Test with 125% Load
The crane shall be tested such that the lifting unit, the crab and the crane as a whole are subject to
125% of their safe working load.
a) Lifting units – The lifting unit drum(s) shall be rotated through one revolution such that all gear
teeth are tested under overload conditions.
b) Cross travel – The crab of the crane shall be moved 1 revolution of its travel wheel to ensure
that each gear tooth of the cross travel system is subjected to the overload condition.
Acceptance Criteria
i. QC Sheet : QM.HC.QC.01.21
TCVN 4244 : 2005
BS 466
IN DR-20A
AR
15
12-M
Doc No.: VS2155-501-A-604
Rev. No.: 1
Page 5 of 5
Dynamic test is done after load test with 125% load. This test will check the overall crane structure
and brakes.
During the test(s), trial load is lifted up and down at least 3 times and the structure on carrying load
must be checked.
Acceptance Criteria
The packing inspection will be performed prior to shipment which in accordance to the packing procedure
and packing list.
Acceptance Criteria
i. Packing List
10. Attachment of QC Form Reports (This QC forms are MHE standard - No changes on this documents)
i. QC Sheet : QM.PD.QC.01.00
ii. QC Sheet : QM.HC.QC.01.35
iii. QC Sheet : QM.HC.QC.01.38
iv. QC Sheet : QM.HC.QC.01.40
v. QC Sheet : QM.RE.QC.01.10
vi. QC Sheet : QM.HC.QC.01.19
vii. QC Sheet : QM.HC.QC.01.20
viii. QC Sheet : QM.RE.QC.01.09
ix. QC Sheet : QM.RE.QC.01.06
x. QC Sheet : QM.HC.QC.01.37
xi. QC Sheet : QM.HC.QC.01.21
xii. QC Sheet : QM.HC.QC.01.16
xiii. QC Sheet : QM.HC.QC.01.17
xiv. QC Sheet : QM.HC.QC.01.84
D R A
N
I 12-MA R - 2 015
DOC NO : QM.PD.QC.01.00
CLIENT/PROJECT : NETWORK NO :
MILL
MECHANICAL SURFACE
CERTIFICATE
No. DESCRIPTION QUANTITY MATERIAL SIZE HEAT NO. PROPERTIES CONDITION
VERIFIED? (Ref
VERIFIED? Grade A or B
No.)
REFERENCE:
EN 10025 S275JR* 275 410 0.21 - 1.5 0.035 0.035 0.012 0.55
S355JR* 355 470 0.24 0.55 1.6 0.035 0.035 0.012 0.55
DIN 17100 ST52* 355 510 0.2 0.55 1.6 0.04 0.04 - -
Inspected by :
Approved by :
D R A
IN2-MAR 15
1
- 2 0
QM.HC.QC.01.
Form NO.:
35
QC inspection report
ISSUED BY: C L CHONG
WELD CHECK & N.D.T
CLIENT/PROJECT: JOB NO :
VISUAL RT MT/DPI UT
LOCATION THICKNESS
BUTT FILLET BUTT BUTT FILLET BUTT FILLET
B) ATTACHMENTS : ________________
Inspected by:
D R A
Approved by:
IN AR 15
12-M
- 2 0
Form NO.: QM.HC.QC.01.38
QC inspection report
CRAB DIMENSIONAL CHECK ISSUED BY: Martin Yeo
CLIENT/PROJECT: JOB NO :
ACCEPT/ ACCEPT/
REF TOLERANCE DESIGN MEASURED REF TOLERANCE DESIGN MEASURED
REJECT REJECT
TG3 +- 3 W3 +-3
TG4 +- 3 W4 +-3
D1 +-3 IE3 +-5
D2 +-3 IE4 +-5
REMARKS :
1) All dimensions in mm
Inspected by:
D R A
Approved by:
IN2-MAR 15
1
- 2 0
Form NO.: QM.HC.QC.01.40
QC inspection report
ISSUED BY: Martin Yeo
CRANE DIMENSIONAL CHECK
CLIENT/PROJECT: JOB NO :
ACCEPT/ ACCEPT/
REF TOLERANCE DESIGN MEASURED REF TOLERANCE DESIGN MEASURED
REJECT REJECT
LR IE1 + - 20
LL IE2 + - 20
D1 TG1 +-4
D2 TG2 +-4
W1 TG3 +-4
W2 HA1 + - 50
CH +-8 HA2 + - 50
REMARKS :
1) All dimensions in mm 4) W1 & W2 – W < = 3000 = + - 3
2) LR & LL – Span < = 15000 = + - 2 W > 3000 = + - W divide by 1000
> 15000 = + - [2+0.15*(Span-15000)/1000] 5) Spring force required, < = 28m – 10kgf,
3) D1 & D2 – Span < = 10000 = + - 5 > 28 < = 40m – 12.5kgf
> 10000 < = 20000 = + - 7
> 20000 < = 30000 = + - 9
Inspected by:
D R A
Approved by:
IN AR 15
12-M
- 2 0
Form NO.: QM.RE.QC.01.10
QC inspection report
MOTOR CURRENTS RECORD ISSUED BY: JESLINE YIP
(CRANE)
EFFECTIVE DATE: 19/7/2011 SUPERSEDES NO.: 15/6/2007
APPROVED BY: ALEX YEO
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: NETWORK NO :
L1 L2 L3
NO. MOTOR CURRENTS (WITH/WITHOUT) LOAD REMARKS
(A) (A) (A)
Slow up
1 HOIST Slow down
Fast up
Fast down
Slow right
2 CROSS TRAVEL Slow left
Fast right
Fast left
Slow forward
3 LONG TRAVEL Slow reverse
Fast forward
Fast reverse
OTHER REMARKS:
Inspected by:
D R A
Approved by:
IN2-MAR 15
1
- 2 0
QM.HC.QC.01.
Form NO.:
19
QC inspection report
FUNCTIONAL TEST – LIMIT ISSUED BY: C L CHONG
SWITCH
EFFECTIVE DATE: 1/1/97 ITEM NO.:
APPROVED BY:
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: JOB NO :
Inspected by:
Reviewed by:
D R A
Approved by:
N
I A R
12-M
- 2 015
QM.HC.QC.01.
Form NO.:
20
QC inspection report
FUNCTIONAL TEST – MOTOR ISSUED BY: C L CHONG
AND SPEED CHECK
EFFECTIVE DATE: 1/1/97 SUPERCEDES NO.:
APPROVED BY:
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: JOB NO :
DESCRIPTION COMPLIANCE
%
SPECIFIED MEASURED WITH TSS
DEVIATION
WITH/WITHOUT LOAD AT (SHOP/SITE) C/NC
Inspected by:
Reviewed by:
D R A
Approved by:
IN2-MAR 15
1
- 2 0
QM.RE.QC.0
Form NO.:
1.06
QC inspection report
JESLINE
ELECTRICAL SEQUENCE CHECK ISSUED BY:
YIP
FOR CONTROL BOX
EFFECTIVE DATE: 24/5/2002 ITEM NO.: APPROVED BY: ALEX YEO
CLIENT/PROJECT: JOB NO :
JOYSTICK/
PUSH
BUTTON
RELAY/
CONTACTORS
REMARKS :
WIRING DIAGRAM REF NO. _______________
Inspected by:
Reviewed by:
D R A
Approved by:
N
I A R
12-M
- 2 015
QM.RE.QC.01.
Form NO.:
09
QC inspection report
ELECTRICAL INSULATION ISSUED BY: JESLINE YIP
CHECK
EFFECTIVE DATE: 24/5/2002 ITEM NO.:
APPROVED BY: ALEX YEO
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: JOB NO :
2 LONG TRAVEL
3 LONG TRAVEL
4 CROSS TRAVEL
5 CROSS TRAVEL
OTHER REMARKS :
Inspected by:
Reviewed by:
D R A
Approved by:
N
I A R
12-M
- 2 015
QM.HC.QC.01.
Form NO.:
37
QC inspection report
ISSUED BY: C L CHONG
PAINTING CHECKLIST
CLIENT/PROJECT: JOB NO :
COMPLIANCE TO SPEC.
DESCRIPTION COMPLIANCE : C, Non-Compliance : NC REMARKS
A) SURFACE PREPARATION
• Manual Brush St 2
• Manual Brush St 3
• Shot/Grit Blast, SA 2 or 2 1/2
B) PAINT APPLICATION
• Indoor
• Handbrush
• Airless Spray
• Outdoor
• Roller
• Hoist Unit
• Winch Unit
• Main Drive Unit, LT
• Crab Drive Unit, CT
• Slewing Drive Unit
• Portal Drive Unit
F) Others
Inspected by:
Reviewed by:
D R A
Approved by:
IN2-MAR 15
1
- 2 0 P24
QM.HC.QC.01.
Form NO.:
21
QC inspection report
FUNCTIONAL TEST - ISSUED BY: C L CHONG
DEFLECTION
EFFECTIVE DATE: 17/05/10 SUPERCEDES NO.: 1/1/97
APPROVED BY:
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: JOB NO :
COMPLIANCE WITH
DEFLECTION TEST PROCEDURE AT WORKSHOP/SITE CHECKED
TSS C/NC
Actual Span(L) : __________ mm
Safe Working Load(100%) : __________ kg
Deflection Criterior(L/750) : __________ mm
Design Deflection : __________ mm
8 Lift 100% SWL with crab/hoist at the centre of girder & read
the deflected measurement mm
Inspected by:
D R A
Approved by:
N
I A R
12-M
- 2 015
QM.HC.QC.01.
Form NO.:
QC inspection report 16
CLIENT/PROJECT: JOB NO :
Inspected by:
D R A
Reviewed by:
IN2-MAR 15
1
- 2 0
Approved by:
Form NO.: QM.HC.QC.01.17
QC inspection report
COMPONENT IDENTIFICATION ISSUED BY: MARTIN YEO
RECORD (3)
EFFECTIVE DATE: 17/05/2010 SUPERSEDES NO.: 15/07/2009 K.M. Niemann
APPROVED BY:
PRODUCT TYPE:
PAGE 1 OF 1
CLIENT/PROJECT: JOB NO :
Inspected by:
D R A
Approved by:
IN2-MAR 15
1
- 2 0
QC INSPECTION REPORT FORM NO : QM.HC.QC.01.84
COMPONENT IDENTIFICATION
RECORD ISSUED BY : MARTIN YEO
Type
Safe-Working-Load (kg)
Bearing Type
kW / RPM / %ED
Main Motor / Brake Ex-proof classification
(if any)
kW / RPM / %ED
Creep Motor / Brake Ex-proof classification
(if any)
Single/Ramshorn Hook
Markings on hook
kW / RPM / %ED
C/T Motor / Brake Ex-proof classification (if
any_)
Remarks :
Inspected by :
Approved by :
D R A
N
I 12-MA R - 2 015
PAGE 1 OF 1