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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA

KRAKATAU DAYA LISTRIK 120 MW COMBINE CYCLE POWER PLANT PROJECT

CILEGON - INDONESIA

1.1.

Crane Inspection

Page 2 of 14
DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

All cranes prior to selection and after entering the KDL 120 MW CCPP Project will be inspected by the work of HSE Inspector and Rigging Engineer or by qualified personnel before they can put to work. The inspection will be carried out in accordance with the equipment inspection checklist. 1.1.1. Inspection Personnel Inspection team was consisting of following personnel: HSE Inspector : Mr. Yunan Edhie Rigging Engineer : Mr. Bayu Adjie KPI Representative : Mr. Hazairiadi 1.1.2. Inspection Data Inspection data record: Day Date Time Weather Terrain Location

: : : : : :

Thursday 14 November 2012 14:00 to 15:00 WIB Cloudy Concrete, level. PT. Superkrane Workshop, Jakarta

1.1.3. Crane Parts Inspection Point The crane was inspected for: Structural damage, Result: good, no damage Hydraulic leaks, Result: There is oil leaking, the crane mechanics claims that it was oil spills from the recent crane oil change Broken wires in the hoist lines and correct termination Result: No broken wires, hoist lines are in correct termination Structural integrity of the load block and overhaul ball Result: good structural integrity for the load block and overhaul ball Correct spooling of the hoist lines on the both drum Result: Spoolings are correct for the both drum Tire or crawler inflation and wear Result: Crawlers are in good condition Correct counterweight as recommended by the manufacturer Result: Counterweights are in correct number and weight 1.1.4. Crane Documents Inspection At the time of the inspection, the following document was checked: A valid DEPNAKERTRANS or equivalent Test Certificate for the crane (mandatory) Result: Direktorat Jenderal Minyak dan Gas Test Certificate is available and valid. The crane load capacity chart (mandatory) Result: Crane load capacity chart is available

Page 3 of 14
DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

1.2.

The crane operator valid license (mandatory) Result: Crane operator license (SIO) is not shown to inspection team.

Load and Functional Testing A long radius, full capacity load test was performed to certify that: A load indicator is working properly and is in calibration (within 5%) Result: available, device is working properly. The overload function for each drum is working properly and disengage when the maximum working radius is reached for the rated load being lifted, this test will be applicable only if the crane is equipped with a Load Moment Indicator (LMI) Result: Load Moment Indicator is available and functional. The boom will telescope in and out, and boom up and down under a rated capacity load. Result: Not available, the crane is using lattice boom. The brakes release smoothly and will hold the rated load Result: The brakes functioning properly. The crane is stable at the rated capacity radius Result: The crane is stable. The crane can perform multi-functions at the same times, i.e. swing, hoist and boom, etc. Result: The crane is able to perform multi-function in the same time. The crane load capacity chart will be displayed in cab of the crane in full view of the operator Result: The crane load capacity is present inside the operator cabin, not in the direct line of sight of the operator. The crane operator is competent and familiar with the machine, including the safety systems and is fully capable of reading and understanding the load chart Result: The operator is competent and familiar with the crawler crane Kobelco 7450. Both the load on the main hoist line and the overhaul ball on the whip line will be raised to maximum height to ensure that the vertical limit switch kick outs are working properly and disengage the drum. Result: The crane vertical limit switches are working properly Test Load for Crane 1.3.1. Crawler Crane 450 ton Kobelco 7450 After proper inspection, there will be a test load for the 450 ton Crawler Crane Kobelco 7450, we was conduct the load test on following condition: Test Load of 30.5 ton as read on the Load Indicator (using crane crawler) Crane boom length of 60.96 meter (attached main boom) Working radius of 10.0 meter holding up elevation is set to 1000 mm above ground Holding time of 10 minutes, checked before and after test load.

1.3.

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

230 ton hook block Wire rope size 2 x 2m length x 4 pcs 5 meter measuring tape.

1.3.2. Load Test Procedure Prepare the 450 ton crawler crane Kobelco 7450 for load test. Prepare the 30.5 ton crane crawler block, lifted using 2 sling wire rope to 400 ton crawler crane 230 ton hook. The load block lifted and hold to elevation 1000 mm above ground. Holding time will be 10 minute, data collecting measurement will be before and after load test Take the load test measurement data. End the load test, lower the load block and remove all sling wire rope and secure the load block to proper lay down storage. Check the 230 ton hook block before and after load test for any deformation. Disengage the 450 ton crawler crane Kobelco 7450. 1.3.3. Result of Load Test The test load blocks elevation height measurement: First measurement, - Time: 0 minute (start of test) - Measured load block height: +1000 mm above ground Second measurement, - Time : 10 minute - Measured load block height : +1000 mm above ground (no change) 1.4. Final Conclusion The 450 ton crawler crane Kobelco 7450 passes the inspection and all parts are in good condition and functioning properly. Please verify the mechanics claims that the oil leak during crane inspection was the over flow from recent hydraulic oil change, thus there is no leak. The 450 ton crawler crane Kobelco 7450 passes the safety inspection by the HSE standard (please refer to HSE Inspection Report). The 450 ton crawler crane Kobelco 7450 have shown some of the mandatory document such as the valid Dirjen Migas certificate, and crane load chart. Please verify the availability of the operator license (SIO) which was not shown to the inspection team during inspection. The 450 ton crawler crane Kobelco 7450 passes the load test, able to hold the load block properly. Please note that crawler crane Kobelco 7450 is RECOMMENDED for HRSG Module Lifting, because the Kobelco 7450 load chart are above the required load capacity for HRSG Module Lifting including the safety

Page 5 of 14
DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

factor of 1.2, which is 234 ton for 10 meter work radius using 42 meter boom, while the Kobelco 7450 have lifting capacity over 253.5 ton at work radius of 10 meter while using 42 meter main boom (19.5 ton more load capacity) with Safety Factor of 1.3 (prerequisite for minimum safety factor is 1.2).

Crane Inspection Process

450 ton crawler crane front view

450 ton crawler crane left side view

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane left side view

450 ton crawler crane boom mechanism view

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane sling spooling drums inspection

450 ton crawler crane engine inspection

Page 8 of 14
DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane cabin instrument inspection

450 ton crawler crane cabin instrument inspection

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane mast inspection

450 ton crawler crane cabin safety inspection

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane crawler wheel inspection

450 ton crawler crane crawler track inspection

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

450 ton crawler crane crawler hydraulic motor inspection

450 ton crawler crane 230 ton hook block inspection

Test Load Preparation

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

Shackle and wire rope sling attached to the test load piece

450 ton crawler crane test load piece lifting up

Test Load Data Collection

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DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

First data collection, 0 minute marked at elevation 1000 mm above ground

First data collection, 10 minute still holding at elevation 1000 mm above ground

After Load Test

Page 14 of 14
DOCUMENT NO. :

RED SECTION CRANE INSPECTION AND TEST LOAD REPORT FOR CRAWLER CRANE KOBELCO 7450 AT PT. SUPERKRANE MITRA UTAMA JAKARTA UTARA
UNIT ISSUING :

W-G2004-RED004
DATE REVISION :

RED

APPROVED BY :

SITE MANAGER

PAGE

REVISION

Put down the load test piece, remove all lifting gears and disengage the 450 ton crane

Prepared by,

Witnessed by,

Approved by,

Bayu Adjie Site Rigging Engineer

Yunan Edhie Site HSE Inspector

German P. Siahaan Site Manager