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SONATRACH
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Direction Régionale Hassi-R’mel
METHOD STATEMENT
FOR LOAD TEST
OF TROLLEY BEAMS, A-FRAME
AND JIB CRANE (DAVIT TYPE)
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HASSIR'MEL BOOSTING PHASE III PROJECT
Owner’s Doc. No.
METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 2 OF 57
INDEX
1. Purpose ................................................................................................................................ 3
2. Scope.................................................................................................................................... 3
3. Definitions ............................................................................................................................ 3
4. References ........................................................................................................................... 4
12. Safety.................................................................................................................................... 8
Appendix-3 : Vendor Drawings for A-frames and Jib Cranes (Davit Type)
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METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 3 OF 57
1. Purpose
The purpose of this procedure is to carry out work as specified on erection drawings,
specification, technical standards and relevant codes for HASSI R’MEL BOOSTING PHASE III
PROJECT.
2. Scope
Scope of this method statement specifically applies to the Methodology and safe practices
adopted to inspect, load test and certify trolley beams and permanently fixed lifting beams listed in the
JGC correspondence by means of thorough examination and testing performed by authorized Third
Party in accordance with applicable standards, laws and regulations for HASSI R’MEL BOOSTING
PHASE III PROJECT.
3. Definitions
Project - Hassi R’mel Boosting Phase III Project.
Company: SONATRACH
Trolley Beam: Structural beam designed, manufactured and installed in order to support and
move the whole length of it a certain load suspended underside.
A-Frame: Structural designed for light duty gantry cranes, they’re typically used for light to
medium lifting requirements manufactured and installed in order to support a
certain load at a certain fixed location of it suspended underside.
Jib Crane (Davit Type): One type of crane where a horizontal member (jib or boom),
supporting a fixed hoist. It is supported by piperack structure. It
may swing through an arc, to give additional lateral movement, or
be fixed.
End Stop: Permanent Fixture at each end of a beam designed, manufactured and installed
in order to prevent moving loads coming off.
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Owner’s Doc. No.
METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 4 OF 57
4. References
S-3000-1675-504 Inspection and Test Plan for overhead crane and Hoist
X-XXXX-XXX- A Inspection and Test Plan for Trolley Beam (To be issued)
S-3000-3130-002 General Specification for Erection of Structural Steel and Miscellaneous Steel
The works shall comply in all respects with Algerian Regulations, Planning Law and other
statutory regulations.
6. Third Party
Structural Steel Supervisor: is responsible for the execution and control of this activity, lead
construction crew to work safely on site.
Material Controller: Deliver all material for erection to site upon request and maintains
records.
The persons in charge of the work package, the superintendents and the person in charge of
the project quality, are responsible for the application of this procedure.
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METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 5 OF 57
8. Method Statement
Agreement shall be reached between Contractor and Third party with regards to inspection and
testing methods employed.
Agreement shall be reached between Contractor and Third party with regards to calibration of
following:
Structural beams listed in JGC correspondence can be categorized as Trolley beams, A-Frames
and Jib Cranes (Davit Type) with testing criteria of each category. Refer to Appendix 1 and 3.
Trolley beams require end stops at each end in order to prevent load bearing trolleys attached
underside coming off while fixed beams support loads in one location only through stationary load
bearing attachment.
a) Evaluation of design drawings, Quality Control inspection and acceptance reports establishes
technical specifications of equipment being examined such as SWL, overall length, span
between main structure supporting points etc. Refer to Appendix 4.
b) Full visual inspection of items being examined establishes conformity of it to its technical
specifications.
c) Function test for running, moving suspended test weights along the whole length of structure
beams being tested.
d) If traveling the whole length is obstructed by permanent Fixtures, traveling one span which is a
distance between two adjacent supporting may be accepted as successful test provided
agreement is reached.
Proof load test confirms that structural beams are physically capable of withstanding a weight
equal to 100% of rated capacity consists of following:
a) Selecting calibrated test weight(s) equal to 100% of rated capacity of structural beams being
tested. Refer to Appendix-5.
b) Keeping structural beams under observation while loaded in such a fashion for a certain period
of time that should be no less than two minutes in order to ensure that structural beams are
structurally sound.
Deflection Check establishes and records the distance between the bottom side of the beam
being tested at its weakest point (e.g. middle of a span between two supporting joints, end of a
cantilever beam, etc.) and a fixed point below it by using Laser measure before, during and after
static or proof load test. By comparing obtained results the test establishes amount of deflection
and of elasticity (e.g. ability to deflect and return to its original form) of the beam being tested.
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METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 6 OF 57
Sometimes due to space restriction usage of suspended weights for load tests is not practical. In
this case upon agreement between parties involved fixed strong points below structural beams
can be used in following manner:
a) Certain strong points below, corresponding to parts of the structural beams subjected to load
test are being identified;
b) Adequate rigging tackle is used to attach these to each other with a Load cell device being
fitted in the string in such a manner that ensures correct and timely reading of load applied;
c) Adequate lifting hoist that is a part of the rigging tackle is being loaded until Load cell records
required load level.
A-frame and Jib crane (Davit Type) load test method and inspection use the Vendor load test
procedure as mention in Appendix-6.
9. Test Record
Inspection test record will be issued as agreed by Contractor and Third party, duly signed by
both parties.
10. Planning
Planning shall be done in full cooperation with Contractor’s relevant personnel to ensure that
area targeted structural beams are located is free to access and no activities carried out in the
vicinity that may be contradictory or hazardous while performed at the same time.
Comprehensive plan and schedule shall be made in co-operation with JGC relevant personnel to
identify and prioritize areas and structural beams testing sequence. All testing then shall be done
in accordance with these plans and schedules and in case any changes are necessary due
consultation shall be held with relevant JGC personnel.
Based on relevant schedules appointed person shall apply and obtain PTW from relevant
authorities (as described in Construction PTW procedure). This Method Statement shall be used
as a base document for such an application.
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METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 7 OF 57
11. Execution
Inspection and testing of QC released trolley beams, A-frame and Jib Cranes listed in the
Contractor’s correspondence shall be carried out in presence of Contractor and Third party
appointed personnel.
Immediate areas that maybe affected during such testing shall be duly barricaded and
appropriate signage posted.
Prior to commencing testing TBT shall be held by Third Party and Contractor appointed persons
describing all parties concerned method and sequence of testing as well as all safety hazards
involved in such activities (as described in JSA). Appointed person shall also ensure that HSE
representative assigned to the area is duly notified as well.
Lifting equipment and rigging tackle used in testing process shall confirm to company
specifications, have valid certification and valid color code and shall be free of defects.
Lifting equipment and rigging tackle used in testing process shall not be subjected to overload
with its WLL/SWL being always well in excess of weight it is intended to carry.
Weight of rigging and lifting equipment used shall be accounted for calculating required test
weights.
Signal to start and stop testing shall be given by Third party representative only
Operating of hoists during load testing shall be done by appointed riggers only.
During testing hoisting devises shall be operated slowly to ensure gradual application of the
weight in order to avoid shock loading.
Prior to testing, Contractor provided Monorail Beam Inspection Checklist shall be completed and
counter signed by Third Party and Company appointed Quality control personnel.
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METHOD STATEMENT FOR LOAD TEST Contractor’s Doc. No. S-3000-1330-101
OF TROLLEY BEAMS, A-FRAME AND
JIB CRANE (DAVIT TYPE) Sheet 8 OF 57
12. Safety
Safety Controls:
Person in charge of the operation shall ensure that all necessary clearances to commence
work are in place. These shall include permit to work, job safety analyses and depending on the
type of the job - green tag, lift plan, rigging sketch or approved rigging study according to
company and contractor procedures as described in Method statement and JSA, construction
PTW procedure:
- PTW to be in place at all times, No job or task to be carried out without a valid PTW,
STARRT to be conducted prior commencing any task(PMC PTW to be obtained for
working inside PMC Area’s).
- Copies of required documents shall be present at work site to provide personnel with
necessary guidance.
Refer to Appendix-8.
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APPENDIX-1
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Static Load
Dynamic Load Test
Test at 1.25
at 1.1 x SWL Check
x SWL
Mechanism,
structural
Check crane Check lifting
Check Visual Check all Check load up and components
Check limit / crab Check Check hoist
No. Lifting Equipment Location Manufacturer SWL (Ton) trolley inspection smooth lifting / /Trolley
switches / travelling / lowering repeated without
smooth for all vital motions for lowering without fail Check each beam
brakes traversing starting and without damage
running components crane / hoist speed (at 100 mm crane / hoist
speed stopping for damage /
to 200 mm motion
each motion connection
from ground without fail
during 1 loosened
level with 10
hour
min. holding
time)
Maintenance Building 7
1 Overhead Crane Ital krane NA X X X X X X X X X X
GTC Shelter 50
A-frame (Type-1)
Pipe Rack Excel Lift 1.2 NA X X NA NA NA X X NA X X
A-frame (Type-2)
2 A-frame (Type-3)
Pipe Rack Excel Lift 0.5
Pig Receiver Piping Technogies 0.5
Jib Crane GTC Inlet Filter Fas 0.5
3 NA NA X NA NA NA X X NA NA NA
(Davit with Crab) PWT Xylem US 0.6
Thern Winches &
PWT 0.9
Cranes
Pipe Rack Excel Lift 1.2
4 Trolley Hoist Common Excel Lift 1.2 NA NA X NA NA NA X X NA NA X
0.5
1.2
2
5 Trolley Beam Various Contractor X NA NA NA NA NA X X NA X NA
2.2
4
5
Note: For trolley beam Dynamic load test is equal to 100% of SWL
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APPENDIX-2
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1 N200 O/Head crane 5000 MECH GTP (N) MECH QC MECH (GTP)
2 N100/200 A-frame 5000 Steel STR GTP (N) MECH QC MECH (GTP)
3 N200 Jib Crane (Electrical Type) 5000 Steel STR GTP (N) MECH QC MECH (GTP)
4 N100/ 200 Jib Crane (Manually Type) 5000 Steel STR GTP (N) MECH QC MECH (GTP)
5 N200 Jib Crane (Manually Type) (GE) 5000 MECH GTP (N) MECH QC MECH (GTP)
6 SBN N100 Jib Crane (Pig receiver) 5000 MECH GTP (N) MECH QC MECH (GTP)
7 N300 Jib Crane (PWT) 5000 Steel STR GTP (N) MECH QC MECH (GTP)
8 N300 Trolley beam (PWT) 5000 Steel STR GIB (JGC D) STR QC Steel STR
9 N100 Trolley beam (Electrical Hoist Type) 3000 Steel STR/MECH GTP (N) STR QC/MECH QC MECH (GTP)
N100/N200/
10 Trolley beam (Manually Type) 3000 Steel STR GIB (JGC D) STR QC Steel STR
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APPENDIX-3
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APPENDIX-4
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Project
MethodnameStatement
: HASSI R'MEL
forBOOSTING PHASE
Load Test Ⅲ PROJECT
of Trolley Beams, A-Fram and JIB Crane (Davit Type) Mechanical Handling Study Report Owner's Doc. No.
Page No.: 34 of 57 .
Owner : SONATRACH Attachment 3 - Monorail list Contractor's Doc. No. : S-3000-1290-001
Monorail List (1/4)
Elevation SWL Total length Operation Level Laydown Level Lifting height Attaced Device
No. Tag No. Area PCWBS Structure ID Description Beam size Structure dwg.
(BOS EL+) (ton) (mm) (TOS EL+) (TOS EL+) (mm)
HOLD
A
INDTR
-2019
Owner's
C
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LLEDJob Code : 0-7577-20
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Project
MethodnameStatement
: HASSI R'MEL
forBOOSTING PHASE
Load Test Ⅲ PROJECT
of Trolley Beams, A-Fram and JIB Crane (Davit Type) Mechanical Handling Study Report Owner's Doc. No.
Page No.: 35 of 57 .
Owner : SONATRACH Attachment 3 - Monorail list Contractor's Doc. No. : S-3000-1290-001
Monorail List (2/4)
Elevation SWL Total length Operation Level Laydown Level Lifting height Attaced Device
No. Tag No. Area PCWBS Structure ID Description Beam size Structure dwg.
(BOS EL+) (ton) (mm) (TOS EL+) (TOS EL+) (mm)
HOLD
A
INDTR
-2019
Owner's
C
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Project
MethodnameStatement
: HASSI R'MEL
forBOOSTING PHASE
Load Test Ⅲ PROJECT
of Trolley Beams, A-Fram and JIB Crane (Davit Type) Mechanical Handling Study Report Owner's Doc. No.
Page No.: 36 of 57 .
Owner : SONATRACH Attachment 3 - Monorail list Contractor's Doc. No. : S-3000-1290-001
Monorail List (3/4)
Elevation SWL Total length Operation Level Laydown Level Lifting height Attaced Device
No. Tag No. Area PCWBS Structure ID Description Beam size Structure dwg.
(BOS EL+) (ton) (mm) (TOS EL+) (TOS EL+) (mm)
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MethodnameStatement
: HASSI R'MEL
forBOOSTING PHASE
Load Test Ⅲ PROJECT
of Trolley Beams, A-Fram and JIB Crane (Davit Type) Mechanical Handling Study Report Owner's Doc. No.
Page No.: 37 of 57 .
Owner : SONATRACH Attachment 3 - Monorail list Contractor's Doc. No. : S-3000-1290-001
Monorail List (4/4)
Elevation SWL Total length Operation Level Laydown Level Lifting height Attaced Device
No. Tag No. Area PCWBS Structure ID Description Beam size Structure dwg.
(BOS EL+) (ton) (mm) (TOS EL+) (TOS EL+) (mm)
Remarks Refer to "MECHANICAL DATA SHEET FOR MECHANICAL HANDLING EQUIPMENT : S-3000-1335-102" regerding A-Frames and Davits.
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APPENDIX-5
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APPENDIX-6
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Total Sheet 7
Vendor’s name : EXCELLIFT SDN BHD
Company 's name : SH / E&P / DP / HRM
Purchaser : JGC CORPORATION, JGC ALGERIA
Project name : HASSI R'MEL BOOSTING PHASE III PROJECT
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TABLE OF CONTENT
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7. Functional Tests
7.1. Functional test shall be performed without load.
7.2. Operate hoist up, hoist down, cross travel left, cross travel right, long travel forward
and backward by pulling the hand chain.
7.3. Demonstrate the travelling of the frame on miter cut of the rail.
(Note: only one out of eight units of A-frame will be tested for Step 6.3)
7.4. ACCEPTANCE CRITERIA:
The Functional Test shall be considered satisfactory if the frame is functioning in all
motions.
8. Dynamic Tests
8.1. Lift up test load equal to 110% safe working load.
8.2. Lift up the test load to clear the floor level. The test load shall be raised to between
100mm and 200mm above ground level.
8.3. Check the deflection of the girder.
Note: According to BS466 section 7, the bridge shall be designed so that the vertical
deflection caused by safe working load and weight of hoist in the central position
shall not exceed 1/750 of the span.
8.4. Transport test load by means of cross travel in both directions by pulling hand chain.
8.5. Transport test load by means of long travel in both directions by pulling hand chain.
8.6. Lower test load to ground.
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6. Functional Tests
6.1. Functional test shall be performed without load.
6.2. For Electric Hoist,
6.2.1. Operate hoist up with slow speed by pressing pendant control button lightly.
Press button harder to operate at fast speed. Ensure direction of movement
corresponds to those shown on push button.
6.2.2. Repeat step 5.2.1 with lowering down.
6.2.3. Measure and record down the hoisting speed.
6.2.4. Operate any motion of hoist and press emergency stop button. All motions
should halt immediately.
6.2.5. Operate davit in slewing motion (clockwise and anti-clockwise) by turning the
steering wheel manually.
6.3. For Manual Hoist
6.3.1. Operate hoist up and hoist down by pulling the hand chain.
6.3.2. Operate davit in slewing motion (clockwise and anti-clockwise) by turning the
steering wheel manually.
6.4. ACCEPTANCE CRITERIA:
The Functional Test shall be considered satisfactory if the davit is functioning in all
motions. The control device and emergency stop must function correctly.
7. Dynamic Tests
7.1. Lift up test load equal to 110% safe working load.
7.2. Lift up the test load to clear the floor level. The test load shall be raised to between
100mm and 200mm above ground level.
7.3. Operate davit in slewing motion (clockwise and anti-clockwise) by turning the
steering wheel manually.
7.4. Lower test load to ground.
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5. Functional Tests
5.1. Functional test shall be performed without load.
5.2. Ensure the crane travel in all motion by pushing the trolley and jacking system
are functioning well.
5.3. ACCEPTANCE CRITERIA:
The Functional Test shall be considered satisfactory if the crane is functioning in
all motions.
6. Dynamic Tests
6.1. Lift up test load equal to 110% safe working load.
6.2. Lift up the test load to clear the floor level. The test load shall be raised to
between 100mm and 200mm above ground level.
6.3. Lower test load to ground.
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1. Visually inspect on the trolley prior to testing. All components shall be in good
condition and painted.
2. Check on trolley load plate to verify its serial number and other data.
3. Vendor standard is used for applicable test code.
4. Functional Tests
3.1 Functional test shall be performed without load.
3.2 Operate the trolley in all motions, including steering and brakes are
functioning well.
3.3 Push and pull the trolley in all directions.
3.4 Acceptance Criteria: wheel motion shall function well.
5. Dynamic Tests
5.1. Put load equal to 110% safe working load onto the trolley.
5.2. Push and pull the trolley in forth and back direction.
5.3. Remove the load.
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APPENDIX-7:
SAMPLE PHOTOS
OF
LOAD TESTING
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
JSA for Load Testing on Trolley Beams, A Frame and Jib Crane ( Davit Type)
Uncontrolled
DESCRIPTION CONTROLS PREVENT, DETECT, CONTROL, RESIDUAL RISK
# HAZARD Risk Responsible
OF TASK STEP MITIGAT
H M L H M L
1.1.1 Crane is regularly maintained, inspected
L
and certified Maintenance SV
1.1.2 Crane operator completes operator's daily
1.1 Crane Failure or malfunction due to L
1 Crane Setup M check and signs checklist Crane operator
mechanically/hydraulic fault or driver error
1.1.3 Operators are qualified/trained and hold
appropriate license for the crane being L Rigging SV/ Crane
operated. operator.
1.2.1 Signalmen attending crane each Rigging SV/ Crane
L
movement operator.
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
Rigging and
2 2.1.1 Safe manual handling methods are used L
testing Rigging SV
2.1.2 Personnel receives safe manual handling
L
training Rigging SV
2.1.3 Personnel medically fit L Rigging SV
2.1.4 Heavy objects handling assisted by crane
2.1 Physical injury caused by manual handling H L
or forklift Rigging SV
2.1.5 Appropriate PPE is worn L Rigging SV
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
Rigging and 2.3.1 Handtools and loose objects are secured
2 L
testing by rope or lanyards Rigging SV
2.3Physical injury caused by objects falling 2.3.2 hard hats worn at all times with chin straps L
H Rigging SV
from height
2.3.3 Scaffolding platforms,manlifts used have
L
toeboards Rigging SV
2.3.4 Barricade the work area. L Rigging SV
2.4.1 Rigger hand gloves worn all times L Rigging SV
2.4.2 Subject is discussed during TBT and
L
STARRT Rigging SV
2.4 Physical injury caused by pinch points H
2.4.3Warning is given before tensioning rigging
L
tackle. Rigging SV
2.4.4 Tag lines used L Rigging SV
2.5.1 Personnel receives safe rigging practices
L
training Rigging SV
2.5.2 Personnel qualified and 3rd party certified. L
2.5 Damage caused to property by Rigging SV
H
inadequate rigging 2.5.3 Manufacturer recommendations are
L
followed Rigging SV
2.5.4 Rigging plan is followed L Rigging SV
2.5.5 Adequate softeners/packing is used L Rigging SV
3.1.1 Crane/Forklift is regularly maintained,
L
inspected and certified. Maintenance SV
3.1.2 Personnel qualified and operator
L
competent Rigging SV
Lifting with 3.1.3 Weight of load is known prior to lift L Rigging SV
3 cranes and 3.1.4 Crane/forklift load charts consulted and
forlifts configuration selected as not to exceed 85% of L
3.1 Crane / Forklift fails due to over load
it at any given moment Rigging SV
3.1.5 Weight of rigging and attachments
H L
included in load calculations Rigging SV
3.1.6 Close supervision at all times L Rigging SV
3.1.7 Crane/forklift is operated slowly to avoid
shock loading, centrifugal increase of radius or L
tripping hazard. Rigging SV
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
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JGC DIRECT WORK
SITE HASSI R'MEL BOOSTING PHASE III
DATE OF ASSESSMENT 22/Aug/19
CONTRACTOR DOC NO N/A (UNDER METHOD STATEMENT)
5.2.1 Good house keeping is maintained at all
5 All Activities L
times Rigging SV
5.2.2 Tools and materials are stored away in
5.2 Poor house keeping H L
proper way. Rigging SV
5.2.3 Subject is discussed during TBT and
L
STARRT. Rigging SV
Maintenance SV
5.3.1 All equipments to be properly maintained L
5.3 Environmental pollution Operator
H
5.3.2 Engines are not left idling for long time. L
Operator
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