PRE-COMMISSIONING

CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

* All Pre-Commissioning documents shall contain the following sections (1 – 2) which capture generic
asset information

1. REFERENCE INFORMATION
INSPECTION DATA ASSET DATA
PROJECT NAME: MANUFACTURER:

LOCATION: MF SERIAL NO:

INSPECTION DATE: WC FLER / TAG NO:

INSPECTOR NAME: TYPE / MODEL NO / SIZE:

PROJECT / CONTRACT NO: DESIGN CRITERIA:

ATTENDEES:

2. INSPECTION PREPARATION
OSH compliance requirements.
Obtain QA / QC documentation (review outstanding items).
Relevant Water Corporation standards.
Relevant Australian Standards.
Supporting contract documentation / approved drawings.
Provision of required test equipment (portable vibration monitor and temperature sensor).
Provision of required test reports and certificates
Provision of completed construction verification

3. INSPECTION PRELIMINARIES YES NO N/A COMMENTS/DETAILS

“Punchlist” reviewed and free of significant
1 defects preventing asset pre-
commissioning?
Hazard identification and risk assessment for
2
asset pre-commissioning complete?
Electrical construction and pre-
3
commissioning ITPs complete?
Mechanical and electrical site specific pre-
4
requisite ITPs complete? (See Appendix A)

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 PRE-COMMISSIONING
CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

*Contents of Section 4 (Inspection) and Section 5 (Test) are Asset Specific and shall reflect relevant SPS /
Australian Standard(s) where practicable. Entries shall also be worded to reflect the procedures involved in
a step-by-step manner; i.e. “Conduct visual inspection and ensure pre-start photographs are taken”,
“Extract bearing housing covers to expose bearings and full shaft length”.

4. INSPECTION YES NO N/A COMMENTS/DETAILS

GENERAL
Crane testing and pre-commissioning shall
be carried out by a competent person in
accordance with AS 2550 and AS 1418.
1
Such a person would typically be a crane
specialist employed by the Crane
manufacturer or a third party.
HOIST
Hoist operation verified as part of crane testing,
including:
- correct lift and lower direction per
2
controls?
- correct set-up and operation of upper and Max height of lift: _______________
3
lower lift limit stops? mm (with reference to ___________)
- smooth (jerk free) operation of lifting and
4
lowering operation?
TRANSVERSE BRIDGE TROLLEY
Bridge trolley operation verified as part of crane
testing, including:
- correct east-west (cross travel)
5
movement per controls?
6 - obstruction free travel of trolley?
- smooth acceleration and stopping of
7
trolley?
- correct operation of end travel slow down
8
and/or limit stops?
9 - buffer stops functional?
- acceptable clearance from fixed
10 obstructions throughout range of Minimum clearance: __________ mm
movement?
CRANE RUNWAY
Runway trolley operation verified as part of crane
testing, including:
- correct north-south (long travel) direction
11
of movement per controls?
12 - obstruction free travel of crane?
- smooth acceleration and stopping of
13
crane?
- correct operation of end travel slow down
14
and/or limit stops?
15 - buffer stops functional?
- acceptable clearances from fixed
16 obstructions throughout range of Minimum clearance: __________ mm
movement?
INDICATORS AND WARNINGS
Operation of lights, alarms and warning
17
indicators checked as part of crane testing?

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 PRE-COMMISSIONING
CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

5. TEST YES NO N/A COMMENTS/DETAILS

STATIC LOAD TEST
Correct load applied to crane and at worst Static test load: ______________ kg
1 case location (typically at centre of bridge Location of load: ________________
and between runway supports)?
Bridge and runway beam deflections measured
as part of crane testing and compared with
allowable deflections, including:
2 - loaded bridge beam deflection? Deflection: _______________ mm
- final (permanent) deflection of bridge
3 Deflection: _______________ mm
beam after removal of test load?
4 - loaded runway deflection? Deflection: _______________ mm
- final (permanent) runway deflection after
5
removal of test load? Deflection: _______________ mm
OPERATIONAL LOAD TEST
Correct load applied to crane during
6 Operating test load: ___________ kg
operating tests?
Hoist / travel speeds and brake devices assessed
under load, including:
7 - lifting and lowering normal hoist speed? Approximate speed: ________ m/min
8 - lifting and lowering slow hoist speed? Approximate speed: ________ m/min
- hoist brake operation following a power
9
failure?
10 - cross travel normal speed? Approximate speed: ________ m/min
11 - cross travel slow speed? Approximate speed: ________ m/min
- cross travel brake operation following a
12
power failure?
13 - long travel normal speed? Approximate speed: ________ m/min
14 - long travel slow speed? Approximate speed: ________ m/min
- long travel brake operation following a
15
power failure?
Confirm crane can operate within one metre
16
from inside edge of runway beam?
Confirm coverage of remote pendant
17
throughout crane coverage area?
Electrical system checked for voltage drop
and current draw during worst case Voltage drop: ________________ V
18
combined hoisting and travelling at Current draw: ________________ A
maximum acceleration?
Noise levels assessed as acceptable during
19 full load hoist lifting and combined travel
operation?
Emergency stop pushbutton checked as
20
functional under load?
Confirm hoist motor trips and overload light
21 illuminates on pendant when load reaches
110% of crane rated capacity
Confirm load monitoring unit is within
22 allowable tolerances when compared
against a certified weight?
Confirm security of shim plates and
23 fasteners of runway beam and its
supporting structure?
24 Confirm integrity of rail billet welds?
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 PRE-COMMISSIONING
CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

Sections 6 & 7 to be retained in all ITPs.

TARGET
6. REMARKS / REMEDIAL / FOLLOW UP ACTIONS ACTION BY STATUS
DATE

7. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

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 PRE-COMMISSIONING
CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

APPENDIX A – SITE SPECIFIC PRE-REQUISITES

A1. MECHANICAL PRE-REQUISITES DONE NO ITR / DOCUMENT REF.

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 PRE-COMMISSIONING
CRANE-BRIDGE
INSPECTION & TEST PROCEDURE

APPENDIX A – SITE SPECIFIC PRE-REQUISITES (cont’d)

A2. ELECTRICAL PRE-REQUISITES DONE NO ITR / DOCUMENT REF.

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