ABG

VOLUME 1

OPERATION & MAINTENANCE MANUAL

OF

50 MT. CONTAINER HANDLING CRANE(Repeat)

FOR

ABG KANDLA CONTAINER TERMINAL LTD.

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VOLUME 1

OPERATION & MAINTENANCE MANUAL

OF

50 MT. CONTAINER HANDLING CRANE(Repeat)

FOR

ABG KANDLA CONTAINER TERMINAL LTD.

STRUCTURAL PARTS

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TABLE OF CONTENTS

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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1.2 Orientation of Crane

WATER SIDE
LAND SIDE

RAIL GAGE
#4 #3
Corner Corner

#2 #1
Corner Corner

LEFT SIDE RIGHT SIDE

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1.3 Orientation of Spreader/Headlock

WATER SIDE
#4 #3
Corner Corner

LAND SIDE
#2 #1
Corner Corner

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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 Non-
Destructive 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 Remark

Initial Visual Inspection (IVI) 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 I F P P P P P P
V V F V V F V V F
I I I I I I I I I

time
10 10 10 1 1 1 1 1 1
Months Months Months Year Year Year Year Year Year

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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 Hours

Operating Hours * Please use hour counter on “Main Hoist Drive Panel”

Crane No. :
Location Location Detail :
* Please use attached Inspection diagram

○ Crack ○ Loose Bolts ○ Dents

Form of Defect ○ Corrosion ○ Deformation ○ Others

* Please  mark

Size of Defect

○ VT ○ PT ○ MT ○ UT
Test Method
* Please  mark

Photograph or sketch of defect

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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 : MARKED AREA TO BE CHECKED MORE CAREFULLY

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

NOTE : 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 : 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 : MARKED AREA TO BE CHECKED MORE CAREFULLY

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DIAGRAM A-11
(FORESTAY BEAM TO CONNECTION PLATE)

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NOTE : MARKED AREA TO BE CHECKED MORE CAREFULLY

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

NOTE : 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 SLIGHTLY LUBRICATED

M30 JIS F10T 184 kg.m 1330 ft.lbs

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DIAGRAM B-01

(W/S GIRDER SUPPORT BEAM)

FOR LEG FOR TOP LEG

SIZE M30 x 160L – 65S M30 x 135L – 65S

CLASS F10T F10T

Q’TY 100 x 2 = 200 sets 68 x 2 = 136 sets

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DIAGRAM B-02

(L/S GIRDER SUPPORT BEAM)

SIZE M30 x 160L - 65S

CLASS F10T

Q’TY 100 x 2 = 200 sets

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DIAGRAM B-03

(TOP LEG BRACE)

SIZE M30 x 135L - 65S

CLASS F10T

Q’TY 44 x 2 = 88 sets

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DIAGRAM B-04

(LEG DIAGONAL)

SIZE M30 x 135L - 65S

CLASS F10T

Q’TY 44 x 2 = 88 sets

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DIAGRAM B-05

(SILL BEAM)

SIZE M30 x 160L – 65S

CLASS F10T

Q’TY 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 : 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.

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