Procedures For Fitness Testing

PROCEDURE FOR FITNESS
TESTING OF CONSTRUCTION
EQUIPMENTS AT SITE
BHEL : PS WR
PW : FEX : T & P : TP
PAGE : 1 OF 11
INDEX
Sl.
No.
Procedure
No.
Revision
No.
Name of Procedures
Effective
Date
01.
FT 01
00
INSPECTION OF WIRE ROPE
11.08.97
02.
FT 02
00
INSPECTION OF PULLING &

LIFTING MACHINE
11.08.97
03.
FT 03
00
INSPECTION OF HAND
OPERATED CHAIN PULLEY
BLOCK
11.08.97
04.
FT 04
00
TEST PROCEDURE FOR DC

ELECTRIC WELDING
GENERATORS
11.08.97
05.
FT 05
00
TEST PROCEDURES FOR ARC

WELDING TRANSFORMER
11.08.97
06.
FT 06
00
TEST PROCEDURE FOR

ELECTRICAL POWERED
WINCHES
11.08.97
07.
FT 07
00
TEST PROCEDURE FOR CRANES
11.08.97

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 2 OF 11
Scope
The procedure detailed herein covers the physical inspection of wire ropes for
ascertaining the fitness and capabilities for use.
2.0
Aim
The main aim of inspection procedures is to assess :
3.0
The possibility of wire rope failure, exists now
To ensure that the wire rope is safe for use
Inspection Details :
3.1
A complete and through examination of all wire ropes must be made prior
of use
3.2
The wire rope is to be replaced according to condition as mentioned in

Annexure - 1
3.3
Test report as per format (refer to Annexure 2) shall be prepared for all
wire ropes once in a year.

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BHEL : PS WR
PAGE : 3 OF 11
ANNEXURE - 1
Replace rope if there
6 or more broken
3 or more broken
strand in one lay
3 or more broken
in standing ropes
are
wire in one lay
wires in one
wires in open lay

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PAGE : 4 OF 11
Wire break inside a rope
Breaks in valleys between strands indicates an abnormal condition possible due to

fatiue or breakage of other wires not readily visible. More than one of these valley
breaks in one rope lay should be cause for replacement.

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PAGE : 5 OF 11
Wire Breaks Near Fittings
Wire breaks occuring near attached fittings are due to fatique stresses concentrated in
these localised section. Replacement of the rope or renewal of attachment by
eliminating fatiqued area suggested.
2.
Worn and Abraded Wires
Each individual wire in a rope when new is

a comlete circle in cross section. Wear due
to friction on sheaves, rollers, drum etc.
eventually causes the outer wire to
become flat on the outside.
The rope must be replaced if this wear exceeds 1/3 of the diameter of the wire.

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3.
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PAGE : 6 OF 11
Reduction in Rope Diameter
Any marked reduction in rope diameter is a critical deterioration factor. It is due to

excessive abrassion of the outside wires, loss of core support internal or external
corrosion, inner wire failure or loosening of rope lay.
The rope must be replaced if the diameter is reduced by more than
1 mm for rope dia up to 19 mm
1.5 mm for rope dia of 22 29 mm
2 mm for rope dia of 32 38 mm

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4.
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PAGE : 7 OF 11
Rope Stretch
Severe stretch or elongation of rope is also a deterioration factor. All wire ropes will
stretch during their initial periods of use. This is caused by the tightening or wires and
strands in to their respective cores.
An approx elongation of 150 mm per 30 mt of rope be expected in a six stranded rope

and approx. 230 mm to 255 mm in an eight stranded rope.
Excessive stretch beyond this should be cause for replacement.

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5.
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PAGE : 8 OF 11
Corrosion
Corrosion develops inside the rope before any evidence is visible on rope surface.
If corrosion is detected by characteristic discolouration of wires or if pitting is observed

the rope must be replaced.
6.
High Stranding
Replace the rope or renew the end connection to reset the rope lay.

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7.
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PAGE : 9 OF 11
Crushed or Jammed Strand
These conditions occur when there are multiple layers on the drum and are dangerous
due to wire deformation. Replace the rope.

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11.
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PAGE : 10 OF 11
If there is any evidence of heat damage, resulting from torch or are caused by
contact with electrical wire, or by welding.

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BHEL : PS WR
PAGE : 11 OF 11

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PAGE : 12 OF 11
SCOPE :
The test procedure herein covers the physical inspection / tests which are to be
done at site, for ascertaining the fitness for use.
2.0
AIM :
- To assess that pulling and lifting machine is capable of handling rated load for
pulling and lifting.
- Rope gripping mechanisms will prevent self lowering of the lad and arrest /
sustain the load in all working conditions.
- To ensure satisfactory operation of all components of machine, and associated
fittings.
3.0
INSPECTION :
Thorough and complete examination of equipment and accessories should be
done prior to use.
Defective components to be attended/replaced incase listed conditions are not
met.
3.1
WEAR TEST :
- Check the wear on jaws in following manner.
The procedure mentioned, herein, is to be carried out without the dismantling of
machine.
- Refer to sketch as enclosed in Annexure 1
Make on one side of casing the position of rope release handle P in its closed
position in without any rope in the machine.
Insert the rope into the machine and close handle = P =
Put another mark on same side of casing
Measure distance between the two marks.

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BHEL : PS WR
PAGE : 13 OF 11
It should never be less than 25.4 mm.

Distance less than 25.4 mm, means that wear has taken place on jaws.
- In such cases jaws should be replaced immediately.
3.2
OPERATION LOAD TEST :

- Select test load equal to the rated safe working load.
- The load may be lifted to a distance of 300 mm, and then be released.
- Machine has cleared the test in case load is held. Without slipping down and it
is sustained.
3.3
Inspect the rope as per procedure for inspection of wire ropes (rofer to PN-FEX
002 00 944 FT01), Prior to use. Replace, if required.
3.4
Fill the test report as per format as enclosed in Annexure Z, once in a year

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ANNEXURE I
BHEL : PS WR
PAGE : 14 OF 11

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PAGE : 15 OF 11
ANNEXURE 2
1.0 Site 2.0 Date of Testing .
3.0 Next Due Date Off Inspection
4.0 Machine Details
4.1 Identification
No.
4.2 Make .
4.3 Nominal Capacity :
Pulling Lifting
4.4 Specification Of Rope In Use

5.0 Observations :
5.1 Fitness Of Rope In Use (In Ref To Pn Fex : 002 : 00 : 94 ; FT01);
. Ok/Not Ok .
5.2 Physical Condition Of Machine :
- Evidence Of Physical Damage .. Yes/No ..
(Damage To The Compnents)
- Cleanliness ... . Ok/Not Ok .
(Evidence Of Eeposites Of Coal Dust /
Clay, Which Can Clog The Machine Components)
-Parts Are Rusty .. Yes/No ..
5.3 Lubrication
For Machine .. Ok/Not Ok .
For Rope . Ok/Not Ok .
5.4 Smoothness Of Operation . Yes/No.
(Any Jerky Operation)
6.0 Inspection Carried Out
6.1 Result Of Wear Test On Jaws (Ref. 3.1) Acceptable/Not Acceptable
6.2 Load Test Results (Ref. 3.2) . Acceptable/Not Acceptable
7.0 Misc (Fitness Of Fittings/Accessories For Rigging) :
Ok/Not/Ok
8.0 Recommendation Of Fitness For Use ..
Recommended .
Not Recommended
..
Engineer (Material
Engineer (QAE)
Engineer (Erection)
Management)/Custodian

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 16 OF 11
SCOPE :
Procedure herein covers, physical inspection and and site test to be conducted before
chain pulley block is declared fit for use.
2.0
AIM :
The Chain pulley block is capable os handling the reated load.

The laod brake will prevent self lowering of load and arrest sustain the load in all
working positions.
3.0
INSPECTION DETAILS :
3.1
The coplete chain pulley block assemblyis mounted on asitable frame capable of
wihstanding caombined load of pulley block, accessories / fittings and rated
load.
3.2
Load chain should be inspected link by link regularly prior to use for eleogation,
distortion, twists, cracks, cuts, or other deformaties.
Load Chain should be replaced in case of following :

3.2.1 Percentage elongation is more than #%
3.2.2 Degree of Wear is more than 10%
3.2.3 Presence of lifted fins at welds
3.2.4 Links affected by gougs, chips, scores, cuts, arcing etc. wher size is reduced
below 10% should be replaced.
3.2.5 Excessively pitted, corroded links.
3.3
Hand wheel chain is completely dry, free from deformities kinks & cute etc.
3.4
All components of chain pulley block should be checked thoroughly incase of

impact loading
3.5
Lubrication :
3.5.1 Load chain should be inspected for proper lubrication.

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PAGE : 17 OF 11
3.5.2 Pulley Block assembly is lubricated properly at all recommended points and to
be checked for smooth operation prior to loading.
3.6
Pulley Block and accessories should also be inspected for visible

damage/distortion/flaw/buckling/or other deformation of body, gears, cover,
chain guides of Pulley Block assembly.
3.7
Hook should be replaced if :

- throat opening of hoojk exceeds by 15%
- presence of crack, deformation, severe corrosion
4.0
LOAD TEST
4.1
Anchorages, fittings, suspension structure, rope ect. Are selected in such

manner that it is able to withstand combined load of equipment, accessories and
test load.
4.2
Test load equivalent to rated lifting capacity of pulley block is selected and
placed directly under the hook with necessary load chain anchorages, associated
fittings. Load is lifted vertically to height of approximately one meter. The load is
held in such condition of sufficient time as to ensure that the load brake is
effective and is capable of preventing self lowering of the load. The load is then
lowered.
4.3
The machine is thoroughly inspected after load test for deformation, cracks,
flaws other defects.
4.4
The observation is then recorded in Format as enclosed in Annexure, once in a

year.
5.0
ACCEPTANCE :
The Hand Operated Chain Pulley Block is considered fit for use, if meets the
criterions listed above.

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PAGE : 18 OF 11
ANNEXURE 2
1.0
Site ...
2.0
Date Of Testing Next Due Date of Testing .
3.0
Equipment Details :
Serial No
Rated Capacity .
Make ..
Chain Spec ..
4.0
Observation On Physical Inspection :
4.1
Load Chain Condition .
4.2
Lubrication (Ref. 3.5) .. Ok/Not Ok
4.3
Load Chain Fit For Use (Ref. 3.2) . Ok/Not Ok
4.4
Hand Chain Fit For Use (Ref. 3.3) Ok/Not Ok
4.5
Pulley Block And Accessories Fitness Ok/Not Ok

(Ref. 3.6 to 3.7)
5.0
OPERATION
Ok/Not Ok
(Smoothness, free for jerks etc.)

6.0
LOAD TEST (Ref. 4.0) .
Ok/Not Ok
7.0
ACCEPTABILITY (Fit for use) .
Recommended /
Not Recommended
______________________
Engineer (Matl. Management)/
Custodian
____________
Engineer
(QUE)
__________________
Engineer (Erection)

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 19 OF 11
SCOPE
The test procedure detailed her in cover the physical inspection/checks/tests, to

be conducted at site, for deciding that the DC Electric welding generator, is fit for
use.
2.0
AIM :
The test shall be conducted to ensure that the welding generator is in sound
condition electrically and mechanically and is in working order in all respects.
3.0
INSPECTION :
3.1
Prior to conducting any test on the machine, it should be should be

subjected to physical inspection from outside and inside.
3.2
Ensure that metallic parts and surfaces of the asembly are suitable
protected against corrosion.
3.3
Clean the machine be from dust and dirt particularly incase the machine
has not been in use for sometime.
3.4
Check the condition of carbon brushes and brush holders.
3.5
Grease all the relevant poins.
3.6
Check the tightness of all electrical parts specially current carrying

including output stud assemblies.
3.7
Check the regulator with the help of multimeter at ohms range.
3.8
Connect two separate and distinct connections to earth of all metallic

parts which are not carrying currents.
3.9
Connect the input supply to terminals ensure shielding against accidental

contact.
3.10
Check the correct fuse rating before starting the machine.

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4.0
TESTS :
4.1
Insulation test :
BHEL : PS WR
PAGE : 20 OF 11
Check the insulation resistance by 500 Volt megger.

- between stator winding and earth
- between current coil, voltage coil to earth
The IR shall not be less than 2 megaohms Record, the IR value, measured
4.2
Direction of rotation test :

Switch on the machine and check its direction of rotation. Interchange two
phases connections, if the direction of machine is found reverse.
4.3
No Load test :
The machine is switched on the see that the same is in operating condition.
Input side is connected to the supply voltage and output side is open circuited.
Measure open circuit voltage with regulator at minimum position and at
maximum position. Check the linear increase and decrease in output voltage.
The output circuit voltage shall be compared with the specified rating of the
machine. It may vary from 40 to 90 V DC.
4.4
Check the vibration and bearing sound when the machine is running at no load
and at full load.
4.5
Loat Test :
The generator output terminals are to be connected to suitable test welding
load. With the generator running at the rated speed the welding current shall be
measured at specified load voltage by suitably adjusting the regulator.
The relation between welding load voltage and welding current within the range
of the welding generator shall be in accordance with the formula.

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BHEL : PS WR
PAGE : 21 OF 11
U=20+0.04 I
Where U is the load voltage is Volts and
I is the load current in ampere
However the variation in load voltage within +/-10 perc. Shall be accepted.
5.0
Record all observations in FORMAT enclosed in ANNEXURE-2 once a year.
6.0
IR test should be repeated if the machine is kept unused for more than a month
or the same is exposed to moisture/water during rainy season.
7.0
ACCEPTANCE :
The machine shall be accepted as fit for use at site in case above listed criterions
are satisfied.

EQUIPMENTS AT SITE
BHEL : PS WR
PAGE : 22 OF 11
ANNEXURE 2
1.0
Site
2.0
Date of Test
3.0
Equipment Details ..
Machine Serial No. ..
Make
Type .
Model ..
Capacity ..
Range
4.0
Physical Inspection .
OK/NOT OK
4.1
General Condition of Machine
OK/NOT OK
4.2
Earthing ..
OK/NOT OK
4.3
Lubrication ..
OK/NOT OK
5.0
Insulation Test .
OK/NOT OK
5.1
Stator Wdg to Earth ..
5.2
Current Coil to Earth ..
5.3
Voltage Coil to Earth ..
5.4
Continuity of Coils
OK/NOT OK
6.0
No load Test ..
OK/NOT OK
6.1
Open Circuit Voltages

Regulator at Min .
Regulator at Max
Linear Increase or Decrease in

Voltage by Regulating the Regulator ..
7.0
8.0
Yes/No
Load Test
Sl.No.
Welding Current
Voltage
Electrode Size
Remarks
1.
_____________
________
____________
_________
2.
_____________
________
____________
_________
3.
_____________
________
____________
_________
Fit for use
______________________
Custodian
Accepted/Not Accepted
____________
Engineer
(QUE)
__________________
Engineer (Erection)

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 23 OF 11
Scope
The test procedure detailed herein covers the physical inspection/checks/tests to
be done, at site, for deciding that welding transformer is fit for use.
2.0
Aim
The test shall be conducted to ensure that welding transformer is in sound
condition electrically and mechanically and is in working order in all respects.
3.0
Inspections/Checks
3.1
Prior to conducting any test on the machine, it may be ensured that two
separate and distinct connections to earth all metallic parts, which are not
intended to carry current, are provided.
3.2
Clean the machine of dust and other dirt particularly, incase machine has not
been in use for some time.
3.3
Ensure that all metallic parts and surface of assembly are suitably protected
against the corrosion.
3.4
Check for the correct fuse rating before starting.
3.5
Check welding regulator and connect properly.
3.6
Input terminals shall be suitably shielded against accidental contacts.
3.7
Quality of oil for oil cooled transformers must be ensured check for the oil level.
4.0
Tests.
4.1
Insulation Test :
IR value between primary/secondary terminals and earth may be checked with
the aid of specified meggar. The IR value shall not be less than 2 mega ohms.
Use 500 volt meggar.

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4.2
BHEL : PS WR
PAGE : 24 OF 11
No Load Test :
The machine is switched on to see that the same is in operating condition.
Input side is connected to supply condition, measure open circuit voltage.
The same is compared with the specified rating of the machine.
4.3
Load Test :
The transformer secondary terminals are connected to suitable test welding
load. Then at the different positions of regulator load voltages and currents are
recorded.
The relationship between current and load voltage is established in accordance
with the formula as under.
U=20+0.04 I
Where;
U = Load Voltage in Volts

I = Current in Amps
4.4
All above listed observation shall be filled up in FORMAT as enclosed in

ANNEXURE-2, once in a year.
4.5
IR test may be repeated in case machine is lying idle for more than a month or
exposed to moisture/water.
5.0
Acceptance
The machine shall be accepted as fit for use incase all above listed criterions are
met.

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PAGE : 25 OF 11
ANNEXURE 2
TEST REPORT FOR ARC WELDING TRANSFORMER
1.0
Site : ..
3.0
Equipment Details :
2.0
Date of testing
Machine Serial No. . Make ..

Capacity/Range .
Model/Type ..
4.0
Physical Inspection :
4.1
General Condition of Machine : .
4.2
Earthing :
4.3
Oil (Level & Condition) .. Ok/Not Ok (If applicable)
5.0
Insulation Test :
5.1
Primary Terminal .
5.3
Continuity of Coil :
Ok/Not Ok .
5.2 Secondary Terminal ...
Primary
: .. Ok/Not Ok ..
Secondary
: .. Ok/Not Ok ..
6.0
No Load Test : . Ok/Not Ok ..
6.1
Open Circuit Voltage : 1 = . V,2 = . V, 3 = .. V etc.
6.2
Other Observations : .
7.0
Load Test
8.0
Sl.No.
Welding Current
Voltage
Electrode Size
Remarks
1.
_____________
________
____________
_________
2.
_____________
________
____________
_________
3.
_____________
________
____________
_________
Fit for use .. Accepted/Not Accepted
______________________
Custodian
____________
Engineer
(QUE)
__________________
Engineer (Erection)

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 26 OF 11
Scope
The test procedure discussed herein covers the details of test/inspection and checks to
be carried out at site for declaring that crane is fit for use.
2.0
Aim :
To check that :
2.1
Crane is capable of handling the rated load.
2.2
Breaks, clutches and safety devices are working satisfactorily.
3.0
Inspection Details
3.1
A through visual inspection should be made after every incidence of severe

snapping, whipping or jerking of boom and jib, due to any cause. Boom, Jib,
structural items, outrigger (if applicable) should be ispected for any visual
damage. LPT method should be used in this case.
3.2
The hook should be visually inspected for deformation. A 15% increase in throat
measurement or a 10% bend should call for hook replacement.
3.3
All crane wire rope should be inspected as per procedure no

PN:FEX:002:00:94:FT01.
3.4
The crane has been maintained and operated as per manufactures

recommendation.
3.5
Check the functioning of engine in all respects for starting and shut off.
4.0
Test Procedure :
4.1
The following points must be ensured :
4.1.1 Machine is to be tested on a firm levelled ground.

4.1.2 Crawler adjustment/tyre pressure setting have been carried out.
4.1.3 Check for air, oil, water leakages if any.

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PAGE : 27 OF 11
4.1.4 Test load should be selected in following manner

The rated lifted capacity - Test load + Weight of crane hook block +
Slings + Lifting tackle.
4.1.5 The angle of the boom should be adjusted as per the boom length and as per
the rated lifting capacity corresponding to test load (refer point No. 4.1.4)
4.2
No Load Test :
4.2.1 Check the satisfactory operation of each respective crane function inclusive of
respective brakes and clutches operation as under :
Travelling (forward and reverse)
Steering
# left (forward and reverse)

# right (forward and reverse)
Travel brake testing (forward and reverse)
Steering brake testing (forward and reverse)
Slewing
# 360 degree clock wise

# 360 degree anti clock wise
Derricking (lowering and raising)
Hoisting (lowering and raising)
4.2.2 Test the functioning of control devices
4.3
Boom hoist kickout device with alaram
Main over hoist with alarm
Load test :
4.3.1 All crane functions and operation of all control devices, as mentioned above,
must be repeated with test load available at site.

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PAGE : 28 OF 11
ANNEXURE 2
1.0
Site : ..
2.0
Date of Testing :
3.0
Equipment Details :
Make : .
Serial No. ..
Model :
4.0
Testing Conditions :
4.1
Test load :
4.2
Boom angle : .
4.3
Boom length :
4.4
Operating Radium : ..
5.0
Tests Carried Out :

No Load
Test Load
5.1.1 Travelling :
Forward : ..
Backward : ..
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
5.1.2 Travelling Break & Clutches :

Forward : ....
Backward : ..
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
Clockwise :
Anticlockwise : .
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
5.2.2 Slewing Brake : ..
Ok/Not Ok Ok/Not Ok
5.2.1 Slewing :
360 #
5.3
Steering :
Left # Forward : ..
Backward :
Right # Forward :
Backward :
Ok/Not
Ok/Not
Ok/Not
Ok/Not
Ok
Ok
Ok
Ok
Ok/Not
Ok/Not
Ok/Not
Ok/Not
Ok
Ok
Ok
Ok

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PAGE : 29 OF 11
ANNEXURE CONTINUED ..
No Load
Test Load
5.4.1 Derricking :
Boom #
#
Raised : ..
Lowered : .
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
5.4.2 Brake & Clutches : .
Ok/Not Ok Ok/Not Ok
5.5.1 Main Hoist :

Raised :.
Lowered :
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
5.5.2 Brake & Clutches : .
Ok/Not Ok Ok/Not Ok
5.6.1 Engine
Starting :
Shut Off :
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
5.6.2 Engine Clutches : ..
Ok/Not Ok Ok/Not Ok
5.6.3 Indicator & Gages : .
Ok/Not Ok Ok/Not Ok
5.7
Control Devices & Alarms :

Boom/over hoist : ..
Main/over hoist : .
6.0
Equipment Fit for use .
______________________
Custodian
____________
Engineer
(QUE)
Ok/Not Ok Ok/Not Ok
Ok/Not Ok Ok/Not Ok
Yes/No
__________________
Engineer (Erection)

EQUIPMENTS AT SITE
1.0
BHEL : PS WR
PAGE : 30 OF 11
Scope :
The test procedure detailed herein covers the physical inspection/checks/site
tests to be done for declaring that electrical powered which is fit for use.
2.0
Aim
Which is capable of handling the rated load.
The brake is capable of holding rated load.
Satisfactory working of all controls/protective devices.
3.0
INSPECTION DETAILS :
3.1
Prior to conducting any test the wire rope of the which shall be completely
unwound form the drum and visually inspected to ensure that it is fit for use.
(Refer to procedure no. PN : FEX : 002 : 00 : 94 : FT01)
3.2
It is to be ensured that which is placed on a firm levelled foundation and to be

properly anchored. Necessary arrangement, for hoisting the load through a set
of guide pulleys, may be made according to site condition.
3.3
Alignment of motors, gears, etc. is to be checked.
3.4
Flexible coupling bolts & rubber bushes should be inspected, prior to use. The
same are to be replaced, whenever found to be in damaged condition.
3.5
The inspection for above listed items, should be repeated after every incidence
of impact loading.
3.6
Oil level in the gear box and thruster motor ect. Is to be ensured, as
recommended by manufacturer.
3.7
Check the setting of brakes, It is to be adjusted if necessary.
3.8
The wear on the brake lining it to be inspected, prior

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PAGE : 31 OF 11
3.9
Structural and other joints should be inspected.
3.10
Effective earthign should be provided for the hoist structure, motor frame and
other metal cases of all electrical equipment. It is to be ensured that there is no
loose connection in electrical circuit.
3.11
Check the lubrication of open gear, wire ropes, pulleys, motor and rope drum.
4.0
NO LOAD TEST :
The which is to be run idle for about 30 minutes, various parameters viz. Voltage
current, time and rope speed meter per minute may be recorded. While hoisting
and lowering at different notch position as per format enclosed. Observation for
undue noise, overheating of the bearing gear box, motor ect. May be recorded.
5.0
LOAD TEST :
5.1
The load equivalent to rated lifting capacity of the which may be selected. The
test load may be placed directly under a hook with necessary lashing etc. for
lifting purposes.
5.2
HOISTING :
After satisfactory completion of no load operation test load is to be lifted with
series resistance in the first notch position. The load may be lifted to approx 1M
height before switching over to next notch.
The voltage load current, time of operation may be recorded, in the format. The
procedure may be repeated from the last notch to the first notch.
5.3
BRAKE TESTING :
Last notch position may be changed to min. position, when the brake is applied
to check the effectiveness. The load may be held in the lifted position for atleast
for fifteen minues. The stability of load is recorded, as such.

EQUIPMENTS AT SITE
5.4
BHEL : PS WR
PAGE : 32 OF 11
Necessary adjustment of the brake is to be made in case of downward

movement of the load.
LOWERING :
Load is lowered by reversing the direction of the drum, after brake testing.
6.0
All listed observations are to be recorded in format, as enclosed in ANNEXURE-2,

once a year.
7.0
Electrical powered which is considered to be fit for use, in case all above listed
criterions are fulfilled.

EQUIPMENTS AT SITE
BHEL : PS WR
PAGE : 33 OF 11
ANNEXURE 2
1.0
Site . 2.0
3.0
Equipment Details :
Date of Testing :...
Make ..
Serial No. : .
..
Capacity :
4.0
Physical Inspection : .
4.1
General Condition of Winch : ..
Ok/Not Ok
4.2
Earthing : ..
Ok/Not Ok
4.3
Gear Oil Level :
Ok/Not Ok
4.4
Thruster Oil Level : ..
Ok/Not Ok
4.5
Lubrication of Gear Box, Wire Rope

Rope Drum, Motor :
Ok/Not Ok
4.6
Ground Floor Level/Condition :
Ok/Not Ok
4.7
Anchoring to the Winch :..
Ok/Not Ok
4.8
Wire Rope Condition :..
Ok/Not Ok
4.9
Coupling Bolts & Rubber Bushes
Ok/Not Ok
4.10
Brake Lining
Ok/Not Ok
Remarks :
.
.
.

EQUIPMENTS AT SITE
BHEL : PS WR
PAGE : 34 OF 11
ANNEXURE 1
5.0
Insulation Test :
IR VALUE
5.1
Motor Winding to Earth :
5.2
Thruster E.M. to Earth : .
5.3
Control wire to Earth : .
6.0
No Load Test :
Sl.
Drum Controller
No.
6.1
6.2
6.3
|.|
.
.
.
7.0
Position
Notch 1
Notch 2
3
||||||||
. 3
. 2
. 1
Current
R
Voltage
B
....
....
....
|
|
|
|
|
|
....
....
....
Rated Load Test :

Sl.
Drum Controller
No.
7.1
7.2
7.3
|.|
.
.
.
Position
Notch 1
Notch 2
3
||||||||
. 3
. 2
. 1
Current
R
Voltage
B
....
....
....
|
|
|
|
|
|
....
....
....
Remarks :
Record the readings for hoisting and lowering of load separetly.
8.0
Fitness for use .. Accepted/Rejected .
______________________
Custodian
____________
Engineer
(QUE)
__________________
Engineer (Erection)

Procedures For Fitness Testing

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Procedures For Fitness Testing

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PROCEDURE FOR FITNESS

INSPECTION OF WIRE ROPE

INSPECTION OF PULLING &

TEST PROCEDURE FOR DC

TEST PROCEDURES FOR ARC

TEST PROCEDURE FOR

TEST PROCEDURE FOR CRANES

PROCEDURE FOR FITNESS

The main aim of inspection procedures is to assess :

The possibility of wire rope failure, exists now

To ensure that the wire rope is safe for use

The wire rope is to be replaced according to condition as mentioned in

PROCEDURE FOR FITNESS

PROCEDURE FOR FITNESS

Wire break inside a rope

Breaks in valleys between strands indicates an abnormal condition possible due to

PROCEDURE FOR FITNESS

Wire Breaks Near Fittings

Worn and Abraded Wires

Each individual wire in a rope when new is

PROCEDURE FOR FITNESS

Reduction in Rope Diameter

Any marked reduction in rope diameter is a critical deterioration factor. It is due to

The rope must be replaced if the diameter is reduced by more than

1 mm for rope dia up to 19 mm

1.5 mm for rope dia of 22 29 mm

2 mm for rope dia of 32 38 mm

PROCEDURE FOR FITNESS

An approx elongation of 150 mm per 30 mt of rope be expected in a six stranded rope

PROCEDURE FOR FITNESS

If corrosion is detected by characteristic discolouration of wires or if pitting is observed

PROCEDURE FOR FITNESS

Crushed or Jammed Strand

PROCEDURE FOR FITNESS

PROCEDURE FOR FITNESS

PROCEDURE FOR FITNESS

PROCEDURE FOR FITNESS

It should never be less than 25.4 mm.

OPERATION LOAD TEST :

PROCEDURE FOR FITNESS

PROCEDURE FOR FITNESS

4.4 Specification Of Rope In Use

8.0 Recommendation Of Fitness For Use ..

PROCEDURE FOR FITNESS

The Chain pulley block is capable os handling the reated load.

Load Chain should be replaced in case of following :

All components of chain pulley block should be checked thoroughly incase of

3.5.1 Load chain should be inspected for proper lubrication.

PROCEDURE FOR FITNESS

Pulley Block and accessories should also be inspected for visible

Hook should be replaced if :

Anchorages, fittings, suspension structure, rope ect. Are selected in such

The observation is then recorded in Format as enclosed in Annexure, once in a

PROCEDURE FOR FITNESS

Date Of Testing Next Due Date of Testing .

Observation On Physical Inspection :

Load Chain Condition .

Lubrication (Ref. 3.5) .. Ok/Not Ok

Load Chain Fit For Use (Ref. 3.2) . Ok/Not Ok

Hand Chain Fit For Use (Ref. 3.3) Ok/Not Ok

Pulley Block And Accessories Fitness Ok/Not Ok

(Smoothness, free for jerks etc.)

LOAD TEST (Ref. 4.0) .