ITP-PC-M-HOIST-

PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
INSPECTION & TEST PROCEDURE

A) INTRODUCTION

The following procedure is intended to ensure that the quality of constructed product and its associated
activities are completed by competent persons and:
1. Comply with current and applicable specified requirements (including Corporation specifications /
contract terms and conditions, national / international standards, manufacturer’s
recommendations and industry best practices.
2. Are conducted in a safe and professional manner.
3. Provide an audit trail for verification of Quality Assurance and Quality Control compliance.

This procedure is for all HOIST-MONORAIL. This may include monorails with trolley mounted electric
hoist or chain block. Note some trolleys maybe electrically driven to transport the load while others are
driven by a manual chain block. The monorail is a static beam often simply supported between two
supports. This procedure is not suitable for bridge or jib cranes.

Competent personnel shall complete all inspection / construction activities and record all activities on
Water Corporation Document ITP-PC-M-HOIST-MONORAIL for each asset constructed.

NOTE:
• Please ensure that all ITP documents are completed by a competent person and that all Water
Corporation SAFETY and operational requirements are to be complied with at all times in
relation with Water Corporation and AS/NZS Standards where applicable.

B) COMPLETED DOCUMENTS

Completed documents are to be scanned and saved as a .pdf file in the relevant AQUA folder utilising
the following naming convention:

LOCATION - DISCIPLINE - ASSET – ASSET TYPE – VENDOR NAME – DOCUMENT TYPE – P&ID
TAG – REVISION NUMBER

E.g. RavenswoodPS_M_Valve_Butterfly_Tyco_PC_1000BV3422_1

The commissioning manager shall coordinate incorporation of completed ITPs in conjunction with the
CAMEL.

Feedback on improvements to ITPs should be directed to MESB Mechanical for incorporation into future
versions.

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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
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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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
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
Monorail testing and pre-commissioning
shall be carried out by a competent person
in accordance with AS 2550.1/3 and AS
1
1418.1/18. Such a person would typically be
a crane specialist employed by the Crane
manufacturer or a third party.
ELECTRIC HOIST OR CHAIN BLOCK
Hoist or chain block operation verified as part of
monorail testing, including:
- correct lift and lower direction per
2
controls?
- correct set-up and operation of upper
Max height of lift: _______________
3 and lower lift limit stops on electric
mm (with reference to ___________)
hoists?
- smooth (jerk free) operation of lifting and
4
lowering operation?
ELECTRIC DRIVEN OR CHAIN DRIVEN TROLLEY
Trolley operation verified as part of crane testing,
including:
- correct movement per controls or chain
5
operation?
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?
INDICATORS AND WARNINGS
Operation of lights, alarms and warning
11 indicators checked as part of monorail
testing?

5. TEST YES NO N/A COMMENTS/DETAILS

STATIC LOAD TEST
Correct load applied to monorail at worst Static test load: ______________ kg
1 case location (typically at centre of bridge Location of load: ________________
and between runway supports)?
Monorail beam deflection measured as part of
testing and compared with allowable deflections,
including:
2 - loaded beam deflection? Deflection: _______________ mm
- final (permanent) deflection of beam after
3 Deflection: _______________ mm
removal of test load?
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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
INSPECTION & TEST PROCEDURE

OPERATIONAL LOAD TEST

Correct load applied to crane during
4 Operating test load: ___________ kg
operating tests?
Electric Hoist / travel speeds and brake devices
assessed under load, including:
5 - lifting and lowering normal hoist speed? Approximate speed: ________ m/min
6 - lifting and lowering slow hoist speed? Approximate speed: ________ m/min
- hoist brake operation following a power
7
failure?
8 - travel normal speed? Approximate speed: ________ m/min
9 - travel slow speed? Approximate speed: ________ m/min
- travel brake operation following a power
10
failure?
Confirm coverage of remote pendant (if
11
applicable) throughout coverage area?
Electrical system checked for voltage drop
and current draw during worst case Voltage drop: ________________ V
12
combined hoisting and travelling at Current draw: ________________ A
maximum acceleration?
Noise levels assessed as acceptable during
13 full load hoist lifting and combined travel
operation?
Emergency stop pushbutton checked as
14
functional under load?
Confirm hoist motor trips and overload light
15 illuminates on pendant when load reaches
110% of monorail rated capacity
Confirm load monitoring unit is within
16 allowable tolerances when compared
against a certified weight?
Confirm security of shim plates and
17 fasteners of runway beam and its
supporting structure?

Sections 6 & 7 to be retained in all ITPs.

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

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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
INSPECTION & TEST PROCEDURE

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

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
INSPECTION & TEST PROCEDURE

APPENDIX A – SITE SPECIFIC PRE-REQUISITES

A1. MECHANICAL PRE-REQUISITES DONE NO ITR / DOCUMENT REF.
ITP-SV-M-CRANE-BRIDGE
ITP-CV-M-CRANE-BRIDGE

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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
 ITP-PC-M-HOIST-
PRE-COMMISSIONING MONORAIL
HOIST - MONORAIL
INSPECTION & TEST PROCEDURE

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

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

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AQUADoc No: 8321061 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017