ABG

VOLUME 1

OPERATION & MAINTENANCE MANUAL

OF
50 MT. CONTAINER HANDLING CRANE(Repeat)
FOR
ABG KANDLA CONTAINER TERMINAL LTD.

O&M Manual
Structural

ABG
VOLUME 1

OPERATION & MAINTENANCE MANUAL

OF
50 MT. CONTAINER HANDLING CRANE(Repeat)
FOR
ABG KANDLA CONTAINER TERMINAL LTD.

STRUCTURAL PARTS

O&M Manual
Structural

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TABLE OF CONTENTS

O&M Manual
Structural

1.

INTRODUCTION

2.

ABBREVIATIONS

3.

TEST PROCEDURE

4.

FREQUENCY OF INSPECTION

5.

REPORTING PROCEDURE

6.

INSPECTION DIAGRAM AND LOCATION

7.

WELDING TO STRUCTURE

8.

STRUCTURAL DEFELECTION CONTROL

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1. INTRODUCTION
1.1

Name of Structural Member

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Structural

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Orientation of Crane

#4
Corner

#2
Corner

LEFT SIDE

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Structural

#3
Corner

#1
Corner

RIGHT SIDE

RAIL GAGE

LAND SIDE

WATER SIDE

1.2

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#4
Corner

#2
Corner

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Structural

#3
Corner

#1
Corner

WATER SIDE

Orientation of Spreader/Headlock

LAND SIDE

1.3

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1.4

Structural Inspection General

Welded steel structures contain undetectable cracks, usually at welded

joints. When these joints are subject to fluctuating stresses beyond a very
small value, the cracks grow. This is fatigue crack growth.
The allowable stress levels used in the design of the structure take this
phenomenon into account.

Allowable stress levels are determined by

analyzing laboratory tests of typical details subjected to two(2) Million

cycles of stress fluctuation and by applying a factor of safety to the lower
limit of the test data scatter band.
Eventually, the fatigue cracks will become large enough to be detectable by
visual inspection before fracture is likely.
Even if fracture occurs, in many cases the remaining elements of the
structure will prevent serious damage if the crane is immediately taken out
of service and repaired.

Periodic inspection is required to detect fatigue cracks that have grown to a

significant size in order to avoid serious failure in the crane structure.
When a crack is found, repair is necessary. Reporting the structure to its
original condition is always acceptable.
Sometimes this is not practical, and a change in a geometry by means of
cutting and grinding is more economic.

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2. ABBREVIATIONS

BASIC TESTING SYMBOLS

TYPE OF TEST

SYMBOL

Visual

VT

Magnetic Particle

MT

Dye-Penetrate

DPT

Ultrasonic

UT

These symbols are in accordance with AWS A2.4 76 Symbols for NonDestructive Testing

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3. TEST PROCEDURE
3.1 VISUAL (VT)
FOR WELDING PARTS
Dirt and grease should be removed from surface by wiping with a rag.
One should look for cracked paint and rust showing through paint.
If you find out some suspect points of crack, use DPT or MT for further
detail inspection.
FOR BOLTING PARTS
Dirt and grease should be removed from surface by wiping with a rag.
One should look for loose bolts, cracked bolts and any relative
motion(slip) between faying surface.

3.2. DYE PENETRANT (DPT)

The test surface must be thoroughly cleaned and dried. This can be
done with chemical solvents, Vapor degreasing, or by mechanical
methods.
However, cleaning mechanically, such as grinding, blasting, or wire
brushing, might prove detrimental to the test because surface
discontinuities can be masked by cold working of the surface.

3.3 MAGNETIC PARTICLE (MT)

The test surface must be free of loose rust scale, moisture, and painted
surfaces must be cleaned at all points of electrode contact.
Grinding, brushing, or blasting do not affect results of this method of
testing in most instances.

3.4 ULTRASONIC (UT)

Testing should be done in accordance with approved method.
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4. FREQUENCY OF INSPECTION

Inspection Class

Inspection Period

Initial Visual Inspection (IVI)

Remark

Every ten (10) months for the first

thirty (30) months after commercial
operation

First Full-scale Inspection (FFI)

Thirty (30) months after commercial

operation

Periodic Visual Inspection (PVI)

Every one (1) year after FFI

Periodic Full-scale Inspection Every three (3) years after FFI (or
(PFI)

10000 hours of main hoist time).

Commercial
Operation start

I
V
I

I
V
I

F
I

P
V
I

P
V
I

P
F
I

P
V
I

P
V
I
time

10
10
Months Months

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Structural

10
Months

1
Year

1
Year

1
Year

1
Year

1
Year

1
Year

F
I

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5. REPORTING PROCEDURE
DOOSAN may receive reports of the result of any structural inspection for
comparison with other similar structures.
Please use attached form as inspection report.
Data of container boxes handled by each crane will be useful to evaluate
fatigue damage of crane.

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STRUCTURAL INSPECTION REPORT

Date :

Inspector

Supervisor

Main Hoist
Operating Hours

Hours
* Please use hour counter on Main Hoist Drive Panel
Crane No.

Location

Location Detail :
* Please use attached Inspection diagram

Form of Defect

Crack

Loose Bolts

Dents

Corrosion

Deformation

Others

* Please mark
Size of Defect
Test Method

VT

* Please mark

Photograph or sketch of defect

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Structural

PT

MT

UT

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6. INSPECTION DIAGRAM AND LOCATION

6.1 LOCATION OF WELDED CONNECTIONS AND
DIAGRAMS
6.2 LOCATION OF STRUCTURAL BOLTING PARTS

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6.1 LOCATION OF WELDED CONNECTIONS AND DIAGRAMS

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LOCATION OF WELDING CONNECTION

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DIAGRAM A-01
(BACK STAY CONNECTION PLATE TO GIRDER)

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DIAGRAM A-04
(INNER STAY CONNECTION PLATE TO BOOM)

NOTE :

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Structural

MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-05
(OUTER STAY CONNECTION PLATE TO BOOM)

NOTE :

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Structural

MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-06
(BOOM HINGE)

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DIAGRAM A-07
(TOP BRACE TO T/L/S SUPPORT BEAM)

NOTE :
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Structural

MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-08
(TOP LEG BRACE TO TOP BEAM)

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DIAGRAM A-09
(BOOM HOIST CONNECTION PLATE TO TOP BEAM)

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DIAGRAM A-10
(TOP BEAM STAY CONNECTION PLATE)

NOTE :

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Structural

MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-11
(FORESTAY BEAM TO CONNECTION PLATE)

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NOTE :

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MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-12
(BOOM HOIST CONNECTION PLATE TO BOOM CROSS BEAM)

NOTE :

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Structural

MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-13

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6.2 LOCATION OF STRUCTURAL BOLTING PARTS

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LOCATION OF STRUCTURAL BOLTING PARTS

HIGH STRENGTH BOLT TIGHTENING TORQUE

GRADE
M30

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Structural

JIS F10T

SLIGHTLY LUBRICATED
184 kg.m

1330 ft.lbs

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DIAGRAM B-01
(W/S GIRDER SUPPORT BEAM)

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Structural

FOR LEG

FOR TOP LEG

SIZE

M30 x 160L 65S

M30 x 135L 65S

CLASS

F10T

F10T

QTY

100 x 2 = 200 sets

68 x 2 = 136 sets

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DIAGRAM B-02
(L/S GIRDER SUPPORT BEAM)

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Structural

SIZE

M30 x 160L - 65S

CLASS

F10T

QTY

100 x 2 = 200 sets

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DIAGRAM B-03
(TOP LEG BRACE)

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Structural

SIZE

M30 x 135L - 65S

CLASS

F10T

QTY

44 x 2 = 88 sets

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DIAGRAM B-04
(LEG DIAGONAL)

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Structural

SIZE

M30 x 135L - 65S

CLASS

F10T

QTY

44 x 2 = 88 sets

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DIAGRAM B-05
(SILL BEAM)

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Structural

SIZE

M30 x 160L 65S

CLASS

F10T

QTY

32 x 4 = 128 sets

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7. WELDING TO STRUCTURE
The structural integrity of this crane generally requires that no attachments or
fixtures of any kind be welded to any part of the crane without prior written
approval of the crane manufacture.
Certain areas of main structure requires more tight control of welding
attachments.
The following diagram shows the members required to take special care for
welding attachments.

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MEMBERS TO AVOID UNAUTHORIZED
WELDING ATTACHMENTS

NOTE :

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Structural

MARKED AREA ARE DESIGNED TO FATIGUE CLASS DETAIL F.

IN ANY CASE, ANY ATTACHMENTS, WHICH DEGRADE THE FATIGUE
DETAIL CLASS, WILL NOT BE ALLOWED.
PLEASE CONSULT DOOSAN BEFORE ANY WELDING ATTACHMENTS
IN THIS AREA.