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Ref: QP/LPR-

LF/01
Rev:00
WORK INSTRUCTION Edition Date:
5/13
Page: 1 / 7

THOROUGH EXAMINATION AND TESTING


OF
MOBILE LIFTING A FRAMES & GANTRIES
WORK INSTRUCTION NO. - 1

REV. DATE DESCRIPTION PRE. BY CHE. BY APP. BY


Ref: QP/LPR-
LF/01
Rev:00
WORK INSTRUCTION Edition Date:
5/13
Page: 2 / 7

CONTENTS

1. SCOPE..................................................................................................................

2. REFERENCES....................................................................................................

3. INSPECTION :....................................................................................................

4. PROOF LOAD TESTING :................................................................................


Ref: QP/LPR-
LF/01
Rev:00
WORK INSTRUCTION Edition Date:
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1. SCOPE

This work instruction details about thorough examination and Proof Load testing of
Mobile Lifting Gantries/ A Frames.

2. REFERENCES

2.1. PDO Lifting Equipment Procedure

2.2. British Standard- BS 5744,

2.3. Relevant Standards applicable to Lifting Appliance installed on the Gantry.

2.4 Relevant American Standard ASME 30.2: 2001

3. INSPECTION:
INSPECTION FREQUENCY
FOR OFFSHORE ENVIRONMENT: EVERY SIX (6) MONTHS.
FOR ONSHORE ENVIRONMENT: EVERY Twelve (12) MONTHS.

Thorough examination of Mobile Lifting Gantries shall be carried out as under

3.1. All statutory safety requirements as to safety on working on cranes, hoists,


ladders, scaffolding and other equipment must be observed.

3.2. The adequacy of anchorage and points of suspension to or from which


equipment is to be attached or suspended, must be checked or assured, taking
full account of the load that is to be applied.

3.3. Prior to commencement of examination of gantry Inspector shall ensure that

1. Serial Number and Model Number are present and clearly marked.
2. Record of maintenance and any Major repairs / Alteration carried out after
last Inspection, is available for review.
3. safe working load and any conditions or restrictions pertaining to same are
correct and clearly marked.
4. Manufacturers test certificate / Previous certificate of exam. is available for
review.
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3.4. The examination shall be carried out in adequate natural or artificial light.

3.5. Construction

The runway beam would be designed and constructed in accordance with BS


2853 when using universal beams. The beam is normally supported on 'A'
frames made of structural hollow section suitably braced to provide a rigid
support between 'A' frame and runway beam. Inspection of the Runway Beam
should be carried out as per of BS 2853.

3.6. Parking Jacks

Parking jacks are usually of the screw down type and mounted in board of the
'A' frame legs. These jacks are fitted to prevent any movement of the gantry
once the load is fitted. At no time should they be used to support the load by
jacking casters off the ground.
The parking jacks should never be used to compensate for a sloping or uneven
surface.
Thorough examination of the Jacks to be carried out as per applicable relevant
standard.

3.7. Lifting Appliance

Lifting Appliance such as Hand operated chain blocks , Trolleys , Manual


Hoists should be examined as per the relevant applicable standard.
A thorough functional examination of the lifting appliance will be carried out to
ascertain correct functioning of the appliance.

3.8. The examination shall cover all fixings and components:

Running surfaces, Welded Joints & fittings, Web plates, Bolts, nuts and
washers, Casters ,Jacks.

All the components should be individually and together inspected for


distortion , damages, wear , cracks, corrosion etc. Suspected areas of welds
should be subjected to NDE and report submitted to Inspectors for review.

3.9. Reporting & Certification

After satisfactory completion of examination, the Mobile Gantry shall be


colour coded and Examination Certificate is issued .
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A Defect Report will be issued for Mobile Gantry failing the acceptance
criteria for Thorough Examination .

4. PROOF LOAD TESTING :

FREQUENCY

Mobile Lifting Gantries to be proof load tested before being put into use, or
major repair, or substantial alteration, or every four (4) years.

Proof load testing of Mobile Lifting Gantries shall be done as described here.

4.1. Prior to proof load testing of the Gantry crane, the Surveyor should ensure
that,
a. Serial Number and Model Number are present and clearly marked
b. Record of maintenance and any Major repairs / Alteration carried out
after last Inspection , is available for review.
c. safe working load and any conditions or restrictions pertaining to same
are correct and clearly marked.
d. Manufacturers test certificate / Previous certificate of exam. is reviewed.
e. That the maximum allowable stresses and calculated deflections specified
in the British Standard are not exceeded and that all other requirements
of the standard are complied with .

4.2. All statutory safety requirements shall follow for safety while working on
cranes, hoists, ladders, scaffolding and other equipment.
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4.3. Test areas should be carefully selected possibly a well compacted & level
surface.

4.4. Prior to proof load Testing of mobile lifting Gantries shall be examined
as described in Sec. 3.5 to 3.8, followed by a thorough functional
examination to ensure that the equipment is prepared for the proof load test.

4.5. When Sections (4.2) to (4.4) have been successfully completed, the proof load
test may begin.

4.6. Testing an 'A' Frame Gantry

I. The 'A' frame gantry should be placed on a level surface, parking jacks
screwed down and the framework and lifting appliance thoroughly
examined. Make necessary arrangement to measure deflection as necessary.

II. With jacks up so that the structure is sitting freely on the casters the SWL
should gradually be applied as close as possible to one end. With load just
clear of ground traverse load to the opposite end each time paying particular
attention to the casters.

III. Place load in the centre of the gantry and lower off. Take a reference
dimension at beam centre. Lift S W L. Take a second reference dimension at
beam centre and check deflection. Deflection measurement should be within the
specified limits. The allowable deflection of the runway beam if manufactured
from a rolled steel section (universal beam) should not be greater than 1/500 of
the span under the SWL, the span being the distance between the centre lines
of the two 'A' frames.

With no load applied, check that runway beam / Transverse member returns to
its original position and that casters also move back to their original position.

4.7. Application of Test Load

1. The test load to be applied will be 125% SWL plus weight of the lifting
appliance.

2. Under test load the 'A' frame should be loaded in the same manner as for
SWL and deflection checks taken to prove framework returns to original
position with no permanent deflection set.
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WORK INSTRUCTION Edition Date:
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4.8. Inspection and thorough examination during & after the test

During the application of the test load and of the proof load the Mobile Gantry
shall be kept under such observation as will ensure the ready detection of any
obvious defects.

Following the application of the proof load, the Mobile Gantry shall be
thoroughly examined in order to ascertain , that it has withstood the proof load
without injury or permanent deformation. Where in the opinion of the
Inspector a non destructive test such as MPI. is necessary on the welded joints,
the reports for such test will be submitted to the Inspector for review.

4.9. Reporting & Certification

After satisfactory completion of Test & examination, the Mobile Gantry


shall be colour coded and Certificate of Test & Examination is issued .

A Defect Report will be issued for Mobile Gantry failing the acceptance
criteria for Test & Examination

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