STANDARDIZING THE COMMISSIONING PHASE OF

RTG CRANES TO IMPROVE PRODUCT SAFETY AND

QUALITY

16WA RTG Commissioning procedure

Bachelor’s thesis

Supply Chain Management

Forssa 18.03.2014

Isaac Olufuwa
 ABSTRACT

Forssa
Degree programme in Supply Chain Management

Author Isaac Olufuwa Year 2013

Subject of Bachelor’s thesis Standardizing the commissioning phase of

RTG cranes to improve product safety and
quality

ABSTRACT

Konecranes is one of the leading organizations in the lifting business whose origin dates
back to the 1900s. Today the organization has grown and is able to serve different in-
dustries with high quality technical products and services to reach and exceed customer
demands. To be able to sustain product efficiency and effectiveness, Konecranes has to
ensure that products continue to show a steady improvement in quality and safety.

In alignment with the company’s strategy, this thesis is intended to improve the quality
and safety of RTG (Rubber Tired Gantry) cranes, by standardizing and improving the
commissioning phase process during the crane assembly. The commissioning phase is a
systematic one which occurs after a crane has been fully erected. During this process,
the standard of the product can be confirmed before delivery. Therefore, effective
standardization of this process will result in the quality and safety features of the prod-
uct to be enhanced. In addition, technical knowledge was a key factor required to having
this thesis completed. This technical knowledge helped to a large extent to understand
the product’s operations, also how and when to use which terms during the development
of the commissioning phase process.

As this thesis was focused on developing and improving a phase, it was very important
to participate and be involved in the current state of the commissioning phase in order to
help to develop an understanding of what should be done for improvement. Materials
used during this project included technical documents, and software programs which
were related to the product. At the end, the result of this thesis is a refined commission-
ing phase process. Tasks were clearly defined and the procedures well documented in-
cluding tasks to be done during the commissioning phase and how they should be per-
formed.

The author of this thesis project was able to conclusively explain how and what should
be done during the commissioning process. In this project, it was also stated that some
developments can be done in the future, one of which includes improving the testing
procedure relating to product accessories. Another future development project is record-
ing details about any improvement made on the product in order to keep this document
constantly up to date.

Keywords commissioning, start up and testing.

Pages 81 p. + appendices 3 p.
ACRONYMS

A – Amperes

CEN – European Committee for Standardization

CMS – Crane Management System

EBIT – Earnings Before Interests and Taxes

IEC – International Electrotechnical Organization

IP – Internet Protocol

ISO – International Organization for Organization

LED – Light Emitting Diode

LT – Long Ton

PA – Public Address system

PLC – Programmable Logic Controller

QA – Quality Assurance

RTG – Rubber Tired Gantry

SFS - Finnish Standards Association / Suomen Standardisoimisliitto

SOP – Standard Operating Procedure

SW – Software

SWL – Safe Working Load

TCP/IP – Transmission Control Protocol

V - Volts

VDC – Direct Voltage

CONTENTS

1 INTRODUCTION TO THE COMPANY ................................................................... 1

1.1 Konecranes business areas .................................................................................. 1
1.1.1 Equipment................................................................................................ 2
1.1.2 Service ..................................................................................................... 2
1.2 Company strategy................................................................................................ 2

2 KONECRANES INDUSTRIES AND EQUIPMENT ................................................ 2

2.1 Container handling equipment ............................................................................ 3
2.1.1 Rubber Tired Gantry Crane and its use ................................................... 3

3 THESIS AND RESEARCH METHODS .................................................................... 5

3.1 Description of research method........................................................................... 6
3.2 Qualitative and quantitative methodologies ........................................................ 7

4 PROCESS MANAGEMENT ...................................................................................... 8

4.1 How processes are managed ............................................................................. 10
4.2 Process improvement and ownership ................................................................ 11
4.3 Process mapping and design ............................................................................. 12
4.4 Benefits of process management ....................................................................... 14

5 PRODUCT QUALITY .............................................................................................. 14

5.1 Quality assurance .............................................................................................. 15
5.2 Quality and process development ..................................................................... 16

6 COMMISSIONING PHASE ..................................................................................... 17

6.1 Safety................................................................................................................. 19
6.2 General description of tools and personnel required ......................................... 19
6.3 Crane start-up stage ........................................................................................... 20
6.3.1 Pre-start-up checks ................................................................................ 21
6.3.2 RTG power up ....................................................................................... 22
6.3.3 RTG main power on .............................................................................. 24
6.4 Energizing crane in sections .............................................................................. 24
6.4.1 Electrical room domestic loads ............................................................. 25
6.4.2 Program download and Crane set-up on CMS computer ...................... 26
6.4.3 Crane function set-up ............................................................................ 31
6.4.4 E6 domestic loads .................................................................................. 32
6.4.5 Trolley domestic loads .......................................................................... 33
6.4.6 Operator’s cabin loads ........................................................................... 34
6.4.7 Fibre optic, termination resistors and bus addresses ............................. 35
6.4.8 Touch panel program download ............................................................ 38
6.4.9 Energizing the moving parts .................................................................. 38
6.4.10 Limit switches adjustment and faults clearing ...................................... 39
6.5 Crane testing stage ............................................................................................ 41
6.5.1 Operational tests .................................................................................... 42
6.5.2 Miscellaneous ........................................................................................ 46
6.6 Crane set up ....................................................................................................... 47
 6.6.1 Hoist set up ............................................................................................ 48
6.6.2 Load cell calibration .............................................................................. 54
6.6.3 Trolley position calibration and limits .................................................. 56
6.6.4 Skew set up ............................................................................................ 62
6.6.5 Spreader function test ............................................................................ 64
6.6.6 Spreader flippers and Greasing ............................................................. 65
6.7 Interlocks and safety tests ................................................................................. 65
6.7.1 General safety devices ........................................................................... 66
6.7.2 Hoist safety ............................................................................................ 67
6.7.3 Trolley traverse safety test..................................................................... 69
6.7.4 Gantry travel safety ............................................................................... 69
6.7.5 Load tests ............................................................................................... 70
6.7.6 Working speeds and accelerations......................................................... 71
6.7.7 Spreader trim ......................................................................................... 75
6.7.8 Spreader skew ........................................................................................ 75
6.7.9 Gantry wheel testing and spreader tests ................................................ 76
6.7.10 Endurance test (100 % of S.W.L. With spreader) ................................. 77
6.7.11 Accessories ............................................................................................ 77
6.8 Customer testing................................................................................................ 78

7 CONCLUSION ......................................................................................................... 78

SOURCES ...................................................................................................................... 81

Appendix 1 Commissioning checklist

Appendix 2 Proface panel program download procedure
Appendix 3 Crane test specification manual
Standardizing the commissioning phase to improve RTG cranes product safety and quality

1 INTRODUCTION TO THE COMPANY

Konecranes is an engineering company that focuses on manufacturing lift-
ing equipment. The company’s history dates back to 1910 when KONE
Corporation was founded as an electrical motor repair shop.
Konecranes corporation later developed from the repair of motors to
build the sizeable overhead travelling cranes in 1933, the manufacture of
electric wire rope hoist was introduced in the 1936 and the introduction of
harbor cranes into the product range which experienced tremendous
growth in the 1950s. The Konecranes division was introduced into the
corporation and the corporation spent the coming years growing, expand-
ing internationally and acquiring companies in different countries. In
1994, Konecranes was formed as a result of a structural change within the
KONE Corporation, when the corporation sold all operations of the crane
divisions. However, KONE Corporation is not considered as Konecranes’
mother company. After Konecranes establishment, it also became listed on
the Helsinki Stock Exchange in 1996. Konecranes also started to grow by
making company acquisitions and the first acquisition was made in Ger-
many. The acquisition of more companies further projected the newly
founded organization to provide an additional range of products and op-
portunities for growth in maintenance services to their customers. As years
passed on until today, Konecranes has continued to grow into a reputable
organization and into new emerging markets such as in the Asian and Af-
rican regions expanding more and reaching more customers, providing
lifting solutions and services. (Konecranes history 2013.)

1.1 Konecranes business areas

A business area simply describes how an organization has been divided in-
to functional areas or units. The Konecranes organization focuses on two
business areas, service and equipment. Each business area contributes a
certain percentage to the entire business in Sales and EBIT (Earnings Be-
fore Interests and Taxes) as seen below; a description of business area di-
vision for the organization in year, 2012. (Konecranes Business Area
2013.)

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Figure 1 Sales and EBIT percentages for each business area (Konecranes Business ar-
ea 2013).

1.1.1 Equipment

Equipment, one of the company’s business areas offers crane equipment,

components and material handling solutions to different companies in var-
ious industries. The equipment manufactured by Konecranes belongs to
several categories: Overhead cranes, Hoists, Lift trucks, Nuclear cranes
and equipment, Port cranes, Container handling equipment, Shipyard
cranes, Bulk handling equipment and Workstation lifting products.
(Konecranes Equipment 2013.)

1.1.2 Service

Through this business area, Konecranes offers services and maintenance

of products to customers. The services are offered for all crane brands,
port equipment and machine tools. The services offered by Konecranes
helps to improve the relationship between the company and customers,
therefore enabling Konecranes obtain a good market position and competi-
tive advantage. (Konecranes Service 2013.)

1.2 Company strategy

Konecranes’ strategy aims at providing customers with the best products

and services. This is achieved by differentiation through services and
technology innovation, lifting people by improving the capability of their
employees and continuous investment in employee training, global foot-
print, dual-channel strategy, global demand-driven supply chain, and real-
time information. (Konecranes Strategy, 2013.)

The company’s strategy is divided into three main focus areas: mission,
values and vision. Each main focus area includes statements which sum-
marize what the strategy is, and how the company aims to implement the
strategy. (Konecranes Strategy 2013.)

2 KONECRANES INDUSTRIES AND EQUIPMENT

As one of the leading companies in the sector, Konecranes serves several
industries with a number of different products which is able to suit every
of the customer’s needs in their particular industry. These industries in-
clude: Automotive, Energy from Waste, Intermodal and Rail, Manufactur-
ing, Mining, Nuclear, Petrochemical, Ports, Power, Pulp and Paper, Ship-
yards and Steel industries. (Konecranes Industries 2013.)

Though, the types of lifting machinery or equipment needed in the listed

industries are different. Konecranes is also able to provide the industries
with the right equipment in order to contribute to lifting their business by
supplying the industries with what they need, when they need it and where
they need it.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Konecranes provides their customers equipments of high quality standards
which are suitable for the industry’s processes. Their equipments have
high safety standards, referencing organizations such as; International Or-
ganization for Standardization and European Standards. (Konecranes
Equipment 2013.)

In addition, all the equipments are manufactured with the latest technolo-
gy, thereby, keeping their customers and maintenance team abreast of the
latest technology in vogue. The use of improved technology on the equip-
ments will also help industries reduce their usage and consumption of en-
ergy. The improved technology also makes maintenance and troubleshoot-
ing an easier task for the maintenance personnel and for operators, the
ease of operating the equipments.

2.1 Container handling equipment

Container handling equipment as mentioned in chapter 1.1.1 is one of the

equipment categories manufactured by Konecranes. This category in-
cludes equipments or cranes that are designed for handling containers. The
cranes manufactured in this category are: automatic stacking cranes, rail
mounted gantry cranes, rubber tired gantry cranes, ship-to-shore gantry
cranes, straddle carriers, yard IT for container handling (Konecranes Con-
tainer handling cranes 2013.)

Of the crane equipments mentioned above, the Rubber Tired Gantry crane
(RTG) shows an example of how Konecranes has proven to be smart in
their design. The RTG is equipped with innovative features which im-
proves the equipment performance and reliability, therefore reducing the
cost of maintaining the equipments. (Konecranes Rubber Tired Gantry
cranes 2013.)

The Konecranes RTGs are self-selling in the market, making the cranes
known to customers and competitors as a leader. It has also being yielding
results by breaking into markets in countries around the world, such as
countries in continents like Africa, America, Asia and Europe.

2.1.1 Rubber Tired Gantry Crane and its use

The Rubber Tired Gantry crane is one of the equipments used to handle
containers. The cranes are also primarily used to transport containers from
one location to another location within a predefined stacking area, inside a
container terminal. These cranes are the called gantry cranes because the
load carrier or hoisting unit is able to travel together with the whole crane
structure. Usually this hoisting unit is always attached to another unit
called a trolley which carries and moves the hoist unit forward and back-
wards. See figure below, a detailed structure of a rubber tired gantry crane.

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 Standardizing the commissioning phase to improve RTG cranes product safety and quality

Hoist drum A2 Trolley

Horizontal beam

Hoist drum A1

Main girder

Operator cabin
Diesel
side

Access side

Diagonal
beam

Leg structure

Electrical
room

Sill beam
Container
Diesel
(40 foot)
generator

Spreader (in(4040 Hoist rope

Bogie
Bogie foot position)

Figure 2 Rubber tired gantry crane with parts labeled

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
As illustrated in figure 2 above, the RTG does not use hydraulics or
pneumatics technology. It operates mainly with electric motors. The use of
electric motors allows for easy maintenance, easy troubleshooting and
lower product cost of the RTG cranes. Konecranes’ RTG energy con-
sumption is also lower and can easily be controlled when compared to
other competitors’ RTGs. It can also easily be kept clean because of the
absence of hydraulics technology. All these features make the
Konecranes’ RTGs one of the best options for customers.

Typically, a RTG is a good equipment to be used in terminals where the

number and movement of containers are high. Usually in such cases opti-
mization of space in the terminal is a very important issue. Using an RTG
to optimize space will really help to properly arrange or stack the contain-
ers in the predefined stacking areas within the terminal. The containers can
be stacked in rows, as high as five containers, see the figure below. There
is also a possibility of moving one more container over the containers
stacked five high. Note that Konecranes manufactures two models of
RTG: 8 Wheeler and 16 Wheeler RTGs. For each model there are two
types; the 8W and 8WA for the 8 Wheeler and 16W and 16WA for the 16
Wheeler. The major differences between the two models are the anti-sway
system design and the number of gantry wheels.

Figure 3 Rubber tired gantry crane in container stacking operation (Konecranes Rub-
ber tired gantry cranes 2013).

3 THESIS AND RESEARCH METHODS

The application of any research method requires that the author has specif-
ic theoretical and practical knowledge related to the thesis subject. There-
fore, good theoretical and practical knowledge of both process and quality
management were very critical during the research and actual work stages

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
of this thesis project. It is important to be able to merge the research skills
with the theoretical knowledge to achieve the aims of the thesis.

This thesis aims to improve the commissioning phase as a whole by doc-

umenting the activities performed during the phase in detail. The research
method chosen will help to get the best data collection method for the pro-
ject and to know which data collected is needed during the project to avoid
wasting time on irrelevant data. Hence, we are going to look through and
gather information concerning the tasks to be completed, what devices and
materials are needed and how the tasks in the process are to be performed.
After collecting the information, we will be able to answer the following
questions significant to this project:

 What the commissioning phase entail?

 What are the start up and testing stages?
 What activities are performed during the phase and stages men-
tioned above?
 What are the proper sequences of activities during the phase and
stages?
 What are interlocks?
 What types of interlocks exist on RTGs?
 Functions of the interlocks?
 How do these interlocks enhance the safety features of the cranes?
 How will safety and quality be improved by this project?

The creation of the commissioning phase document will help improve the
way the activities in the process are performed and show which activities
precede the other one in the process. It will also help ensure that all neces-
sary checks, especially those relating to safety and quality are conducted
and that overall site operations can be standardized. Hence, the quality of
the cranes sold to customers as well as the relationship with customers will
be improved.

The manufacturing of an RTG involves the assembly of various electrical

and mechanical parts. Some of the parts used in the assembly are procured
from other suppliers while some other parts are designed and manufac-
tured by Konecranes. All the parts arrive at the assembly site with the right
specification, ensuring swift and efficient assembly. At a later stage, the
commissioning phase of the RTG begins. It is also one of the most critical
phases during the manufacturing of any RTG at Konecranes. The individ-
ual leading this phase should possess attributes such as good technical
knowledge of the crane, an understanding of how the various functions of
the crane should work, good organization and communication skills. This
individual is normally the commissioning engineer.

3.1 Description of research method

This thesis project was based on a development project type. In simple

terms, the author of this project was commissioned to make improvement
on a process. In this case there was a set target and a clear goal for the pro-
ject to be completed.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Development can be carried out on any product type, either on tangible or
intangible products. It can also be about a process or an activity that will
lead to the manufacturing of a product, as in the case of this thesis. Hence,
a good in-depth understanding of the product or process to be developed is
quite crucial.

When conducting a project such as this, research work needs to be con-

ducted in order to have a clear knowledge of what is to be done, how it is
to be done, and who are those responsible. There are two methodologies
used when conducting research: qualitative and quantitative methodolo-
gies. These research methods are different in their applications and they
also differ in the data collection methods. In other words, the type of re-
search methodology to be used is influenced by the type of data to be col-
lected, this idea will be explained further in the next chapter.

Since the author’s task was not to develop a process from scratch, it was
necessary for the author to be involved in how the process was conducted.
From the understanding gathered during the involvement, the author could
develop the process according to pre-set target.

3.2 Qualitative and quantitative methodologies

The qualitative method usually applies to research based on a real life sce-
nario and the researcher using this method being required to observe, take
notes and describe situations. Using a method such as this enables the re-
searcher to gain knowledge about the task to be done. In most cases, this
method is applied at the beginning of projects and a specific target group
is chosen, but not randomly. When using this method the researcher can
introduce techniques or tools which can be helpful to the research and help
to improve the knowledge already acquired concerning specific areas in
the research. Data collection can be done using any of these methods: in-
terviews, reviews and case studies, observations, and biography stud-
ies. At the end of the research, the researcher should be able to come up
with concrete theoretical conclusions and not generic ones. (Qualitative
and quantitative research 2012.)

Quantitative research methodology differs from the qualitative, since with

most qualitative researches materials are more readily available. Quantita-
tive methodology simply implies that using this method requires counting
or dealing with numbers and statistics. This method is used when the prob-
lem or the research being done has to deal with numerical
facts. Therefore, the researcher uses any of the data collection methods: a
survey by using questionnaires, interviews, experimental case studies, and
observation studies to collect necessary data. It is important that the da-
ta collected are very accurate, acceptable, current and suitable because the
data will serve as a basis for the conclusions for the research. (Qualitative
vs. quantitative research 2012.)

If the data collected is not accurate, it is most likely that this will not be
noticed during research since there may be no reference to compare the
data collected but the overall outcome of the research will most likely be

7
Standardizing the commissioning phase to improve RTG cranes product safety and quality
flawed. After having used a quantitative research method, the researcher
will be able to make logical conclusions based on the statistical analysis
conducted using the data collected.

In some cases when conducting research for a project, both quantitative

and qualitative methods are combined. In cases where such a project is
new, the researcher will first have to develop a good knowledge of what is
involved. Hence, the qualitative method will be used at an earlier stage of
the research. When a firm knowledge has been developed, there may then
be a need to conduct an analysis which may involve the collection of nu-
merical data. This is mostly done during the core phase of the research.
(Qualitative vs. quantitative research 2012.)

4 PROCESS MANAGEMENT
In order to understand what process management is all about, we must
first have an interpretation of what a process is. A process can be defined
as a set of related actions, properly structured and associated with each
other by precedence with the aim of achieving a set target. In another way,
we can also describe a process as a system which takes input and trans-
form it into output. Processes are usually a part of an operation or we can
say processes are embedded within an operation. If we look into any type
of organization, we will find out that there are different types of opera-
tions, such as sales operations, purchasing operation, distribution opera-
tion, manufacturing operation, and marketing operation. Within each of
the aforementioned operations are certain activities (or process steps) re-
quired for the operations to achieve the set desired result. For example
within the purchasing operation, there exist the purchase order process,
vendor selection process, and payment process.

We also described a process to be transforming inputs into outputs. So

what are inputs and outputs? We can think about how simple equipment
such as a printer and the complete printing process of a document using
the. First, we insert a blank sheet of paper into the printer, send the file we
need to print, the printer performs the necessary transformation, and then
we get the printed document. In this case the inputs are the paper and in-
formation we sent to the printer and the output is the printed document
from the printer. Usually inputs that are used into a process can either be
material, information or customers. The outputs are usually what we get
from the process after the inputs have been transformed during the pro-
cess. These outputs are either products, services or a combination of prod-
ucts and services depending on the process or the operation. It is impera-
tive to note that not all processes leads to the inputs to be physically trans-
formed. In some processes the input’s physical state will change to be-
come outputs while in other processes the input’s physical state does not
change but it is still also transformed during the process into an output.

Inputs used in any process usually fall into two categories: transformed
inputs and transforming inputs. Transformed inputs are those input that are
transformed during the process as they go in and out of the process model
and as explained above their physical state does not necessarily have to be

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
altered. Every process must always have a transformed input else there is
no output. While transforming inputs are those inputs that help in the
transformation of the transformed inputs during the process. Transforming
inputs take part in the process by facilitating the inputs to be transformed
into outputs. “There are two types of transforming resources that form the
building blocks of all process. They are facilities – the buildings, equip-
ment, plant and process technology of the operation – and people – who
operate, maintain, plan and manage the operation.” (Nigel, Stuart, Robert
& Alan 2009, 11.)

Typically for processes to transform inputs into output, it would involve a

certain set of activities. Since processes are different, obviously the activi-
ties involved in performing the different processes will differ from each
other. For instance, the activities performed by the printing machine when
printing a document is totally different from the set of activities that would
be performed during the purchase process. Hence, every process has its
own unique set of activities. As this thesis is focused on developing a
commissioning procedure, in doing so we also have to go through the ac-
tivities involved in the commissioning phase process. The commissioning
phase involves two main stages or activities: crane start-up stage and test-
ing stage. These two stages form the overall activities involved in the
commissioning phase and each stage is further sub-divided into other stag-
es which will be explained in details in later chapters.

So what are the inputs and outputs of the commissioning process? The
transformed input into the commissioning process is the fully erected
RTG. Transforming inputs are the tools and equipments used, materials
and documents, facilities (erection site) and personnel (commissioning en-
gineer). The output from the commissioning process is the fully commis-
sioned RTG. Some of the inputs may be involved throughout the whole
process such as the fully erected RTG, facilities and personnel. While
some other inputs are only used at certain stages of the process or may
even be used only once during the process such as some of the tools used
and some of the documents used.

Figure 4 Inputs and Outputs of the commissioning phase process.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
4.1 How processes are managed

We already understand that processes differ from each other as each pro-
cess has its own unique activities. This is simply because every process
normally has different outputs. As with the printing machine, the output is
a printed document and the purchase process, the output is purchased
good(s). Such difference explained above can be described as a technical
difference between the processes. “However, processes also differ in terms
of the nature of demand for their products or services” (Nigel, et al. 2009,
21). There are four features of demand that determine how a process will
be managed: volume, variety, variation and visibility. (Nigel, et al. 2009,
21.)

Volume typically refers to the quantity of the output from the process,
which is the quantity of products and/or services the process generates.
Normally, a process with a high output volume will also involve highly
repeated activities. As a result personnel involved in the process tend to
learn the steps very well, unit cost of products can be lower, the process
can be easily standardized, and cost of production can be reduced and so
on. For example, the volume of output from the manufacturing of the RTG
is somewhat low. If we will consider a fast food restaurant where the vol-
ume of output is quite high, this gives the restaurant a possibility of stand-
ardizing the process more easily and ensuring that their outputs (meals)
tastes the same and not vary.

Variety is a description of the processes which produces products with

high variety. In the restaurant for instance, where they are able to provide
different types of meals with high quality. This will require that the per-
sonnel involved in the process have a high skill level and are also able to
diversify into different variety of meal production processes. “A high level
of variety may also imply a relatively wide range of inputs to the process
and the additional complexity of matching customer requirements to ap-
propriate products or services” (Nigel, et al 2009, 21). High variety pro-
cesses typically means higher cost of production and higher unit cost of
the products. Variety also means that products can be customized by the
customers to what they want while also keeping the customization within
the range of what the process can offer. The manufacturing of the RTG
falls into the category of high customized products.

Variation refers to the level of fluctuation in the demand of the product

from the process. Typically a process with a high variation in demand re-
quires a lot of change in capacity from time to time. If the demands of
products are unpredictable or very seasonal this creates more problem of
allocating resources, thereby increasing the cost of production and unit
cost of products. (Nigel, et al. 2009, 21.)

In relation to the RTGs, the demand of the RTGs varies quite much be-
cause it depends on the customers’ growth and other varying factors.
There may be peak demand periods and also low demand periods.

“Process visibility is a slightly more difficult concept to envisage. It indi-

cates how much of the processes are ´experienced` directly by customers,

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
or how much the process is ´exposed´ to its customers” (Nigel, et al 2009,
21.). This principle in a way focuses on how much satisfaction the cus-
tomer derives as a result of being exposed to the process. Some processes
are more visible than the other. The exposure of the process to the custom-
ers also involves the level of communication the customers experience
about the progress of the process. Hence, processes with higher visibility
are usually more expensive. As with the commissioning of the RTG, we
can say that some of the process stages are somewhat visible to the cus-
tomer than the other. The visibility RTG commissioning also largely de-
pends on the assembly site location, if the RTG is assembled at the cus-
tomer’s site or the company’s site.

These four demand features also called the “four Vs”, are some of the fac-
tors considered by operations or process managers to determine how a cer-
tain process should be managed. It is important to know that processes
with high volume, typically are always low in variety, variation and level
of visibility. While processes with low volume are typically high in varie-
ty, variation and level of visibility.

4.2 Process improvement and ownership

Process improvement is a necessity for any process run by organizations.

The improvement to any process is to be done with certain considerations:
the customers, eliminating process defects and increasing the process
productivity. The customers are usually the next on the output side of the
process or the customers can also be the direct end user of the product or
service. Whenever a process is being improved, it is imperative that the
company has the point of view of the customer (or determine the voice of
customer). In other words, it is totally unnecessary to try to improve a pro-
cess without thinking like the customer of the process. For instance, if a
grocery store is trying to improve their customers’ shopping experience
and the store only thinks that the customers come into the store, pick the
items, pay and then leave. The store is not properly thinking from the cus-
tomers’ point of view. Thinking from the customers’ view point means
thinking about what the customers experience should be immediately they
step into the store, start and complete their shopping and step out of the
store. (Donna 2009, 320.)

When driving a vehicle, someone has to take charge of the steering to en-
sure that the vehicle is steered in the right direction continually. When fly-
ing an airplane, there also has to be a pilot in charge of flying the plane.
Similarly every process requires an owner. Ownership of a process means
identifying who should take responsibility of the process. The process
owner usually has a very good knowledge and understanding of the pro-
cess, can make changes to the process (only when necessary) and is re-
sponsible to ensure that the customers are satisfied of the process output.
(Donna 2009, 323.)

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
4.3 Process mapping and design

A map is a graphical representation usually used to explain a pathway to a

place. A process map is also sometimes called different names such as
process flowcharts, process flow diagrams and so on. “A process map is a
graphical representation of all the steps involved in an entire process”
(Donna 2009, 325).

With a process map, we can depict the current status of a process and
clearly see what activities are to be done and in what sequence these activ-
ities are to be carried out. When a process has been mapped, we can easily
see which activities precede which, be able to determine which activities
are none value adding, and so on. In order to create a map for a process,
certain techniques are used. These techniques have two main characteris-
tics that they depict the process inputs (material or people or information)
flow throughout the process and they also show the various activities
which take place during the process. (Nigel, et al 2009, 143.)

Typically processes vary from each other in terms of their complexity and
sometimes size. For instance, if we think about all the activities necessary
for the complete production of a product from the purchase of the raw ma-
terial (by the purchasing department) to the usage of the raw material (by
the manufacturing department) for the production of the final products and
compare to the printing process activities. We will observe that the prod-
uct production process involves more activities than the printing process.
This is why when designing large processes from scratch or mapping an
already existing large process, it is usually done by dividing the map into
different levels. Although, this is not necessary in all cases. The highest
aggregated level is known as the highest level of the process map. Usually
this highest level does not contain so much information because it is just
drawn as a simple transformation process with less information. The next
level (lower level) of the process which will describe the individual trans-
formation process in the highest level is then mapped with more details in-
cluded. This lower level can also be called an outline process map. (Nigel,
et al 2009, 143.)

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Figure 5 Example of higher and lower level process mapping (Nigel, et al 2009, 145).

Figure 5 above is a supply and installation process of lightning equipment.

We can see in the figure that there are two different process levels. At the
higher level, the process flow looks like a simple “input-transformation-
output” flow. The second level explodes each stage at the higher level
process into more details; in this case the “install and test” was exploded.
Note that the figure above does not show the exploded process for the oth-
er higher level stages.

A further level from the outline process map can also be created. At this
level, further description to the smallest details of the steps to be taken to
complete each activity stage from the preceding higher level can be men-
tioned. This is usually done in processes, such as those of fast food restau-
rant. Usually process mapping at this level will include documents needed,
tools to be used, time consumed and so on. (Nigel, et al 2009, 143.)

Creating or designing a process map is usually done following certain

steps. These steps are quite easy and simple to follow.

1. First, we have to identify where the process starts and finishes.

2. Determine the process steps or activities. By using brainstorming
methods for new process and observation for existing processes.
3. Arrange the process steps in the order in which they should be per-
formed.
4. Use appropriate process flow diagram symbol.
5. Check for process reliability and possible improvement opportuni-
ties. (Donna 2009, 325.)

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
4.4 Benefits of process management

When an organization has its operations processes focused, they can easily
achieve the process goals and most importantly the overall business goals.
The overall business goals are achievable because personnel are aligned
with the activities involved in the process and the activities are in align-
ment with the business strategy. From the personnel view point, since ac-
tivities to be performed during the operation is properly mapped as a pro-
cess, process owners can easily develop a very clear understanding of how
their operation should run and their process goals. The personnel also un-
derstand why they have to stick to the process flow activities and know
that following the process will help achieve the process goal. Also clear to
the process owner, is the relationship that exists between the activities. An
operation that is focused on its targets ensures that the customers are able
to get what they want and that the customers are satisfied. The product
quality also maintains the same standard all the time as long as there is no
deviation from the process. Therefore, any improvement made to the pro-
cess should have the same effect to the quality of the products the process
has been used for. (Donna 2009, 316.)

During this thesis project work, the author aims to ensure that customer
satisfaction can be improved by process improvement. Successfully com-
pleting the standardization of the commissioning phase process and docu-
menting the result will help improve how the commissioning phase is be-
ing currently performed. The process will also be completed faster and the
cranes delivered to the customer for testing are problems free. Avoiding
hiccups and delay during customer testing.

Organization can also achieve good costs benefits, such as lower costs of
running their operation, shorter process throughput time, more quantities
of products can be easily produced, customer demands can be easily met,
reduced labor work force and most importantly there a is room for con-
stant improvement of the process.

5 PRODUCT QUALITY
One of the most important purposes of going through the rigorous exercise
of creating a procedure is to ensure that cranes handed over to the custom-
ers go through a standard process and have been properly checked. Basi-
cally, one definition of quality can be described as the degree of satisfac-
tion which customers derive from certain products. This means that the
product should be able to do what it has been manufactured or designed to
do. This is why the importance of the product quality is emphasized and
we have to ensure that the customers are always satisfied with the products
delivered to them and possibly supersede their expectations. (Bhat 2010,
6-7.)

For products such as an RTG, customers will assess the product quality
using several criterions. In an effort to satisfy the customers, the company
has to ensure that these criterions are met. Examples of the criterion in-
clude: product durability, speed, eases of operations, defect rates, safety

14
Standardizing the commissioning phase to improve RTG cranes product safety and quality
features and technical solutions. These criterions are not just assessed be-
fore handing over the crane to the customers. These criterions with which
the company’s customers measure the product quality should also be ef-
fective after the RTG has been handed over. Therefore, we must ensure
that the commissioning phase is effectively performed accordingly in or-
der to be able to capture potential problems thereby keeping the RTG
problem free.

In addition, this commissioning procedure will also help to improve the

product quality by capturing “infant” problems which the product may in-
hibit. Infant problems mean problems that occur during the start up of new
equipments. Although, this does not occur in all of the products but such
problems are likely to occur and are due to several reasons. One possible
reason is as a result of defects carried over from the factory where the
crane parts are manufactured. Finding these problems at their infant stage
basically means finding the root cause of such problems and creating sys-
temic fixes. Also avoiding the problems to last longer beyond the commis-
sioning phase and not captured. The learning gathered from such infant
problems can then be cascaded to other RTGs being commissioned as in-
spections, so that these problems can be captured and corrected earlier

5.1 Quality assurance

Quality assurance (QA) actually involves a systemic way of improving

product quality. QA can be said as the set of activities put together in or-
der to achieve a high quality product or service. Quality of any product or
service is the obligation of everyone involved in the manufacturing of the
product and services. Using this system will help to improve and ensure
that the customers are satisfied plus an overall improvement in product
quality. (Bhat 2010, 407.)

“Every organization should have a quality assurance system focused on

achieving defect-free products and services that consistently meet specifi-
cations. A basic quality assurance system includes well-designed and doc-
umented procedures for product and process control, inspection and test-
ing, control of measuring and test equipment (calibration) appropriate sta-
tistical techniques. ISO 9000 standards provide a basis framework for such
a system.” (Bhat 2010, 407.)

Quality is one of the important factors that differentiate products from

other of the same type and also a reason for customer decision making to
purchase a product. Therefore, it is imperative to ensure that quality of the
product is of utmost concern during the manufacturing process of the
product or service. Organizations try to impose the importance of product
quality via different methods, such as creating and implementing quality
policy, process improvement, creating standard operating procedures
(SOP) and so on. As in the case of this thesis, the development of this
commissioning procedure document can be described as a method with
which the company intends to improve the RTG’s quality. Another aspect
to the quality assurance system is quality control. Quality control system is
simply a system that helps to check and ensure that product quality is the

15
Standardizing the commissioning phase to improve RTG cranes product safety and quality
same as the set standard by the organization. It also involves checking for
any defects in the product before it gets to the customers. Though, a com-
pany may develop a quality standard and procedure for product’s quality
to be monitored but some defective products for some reason, always find
their ways to the finished product section and even to the customers.
Sometimes such mistakes can be caused by the personnel or defective
tools. This is why quality is also everyone’s responsibility and the training
of personnel about the quality control system will help spot those kinds of
products. Another method typically used is to develop quality inspection
methods or procedures to check for defective products. Customer satisfac-
tion is a key to an organization’s success. Therefore, the customers’ satis-
faction has to be at the core of the business. It is a huge task for a business
to win over a customer. Hence, companies always try as much as possible
to keep their customers. (Bhat 2010, 405-408.)

5.2 Quality and process development

From the chapters above, we can understand that companies use processes
to develop the quality of their products. So the improvement of a process
increases quality as much as it helps to save cost. Companies such as Fed-
Ex and Citibank have used this ideology to improve their customer’s satis-
faction. (James & William 2008, 333.)

In the case of this project, the impact on quality via the process is done by
describing every activity and gathering all possible information about the
activity. The author is required to work through the whole commissioning
phase, collecting information such as:

 how individual activities are to be performed

 the importance of the activity
 tools and personnel needed to complete individual activity/process and
input and output of the process stages
 is there any in-process measurement that has to be identified
 identify which activity is to occur before the other ones within the
process

With the information listed above, we will now try to find out if the activi-
ties are actually done correctly and which of the activities should be im-
proved by keeping the customer’s interest in mind. (James & William
2008, 341 – 342.)

This simple rigorous exercise translates into improving the crane quality
when all the processes involved in executing the commissioning phase
have been improved. Therefore the activities performed during commis-
sioning phase of any should now be the same, even if the commissioning
engineer in-charge of the phases may be different. This implies that the
commissioning phase has been improved and standardized. Ensuring that
the RTG quality remains the same irrespective of where it has been as-
sembled. In the future, any improvement that may be done to the process
will be documented so that the translation into a more improved quality
product can be realized for all RTGs.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

6 COMMISSIONING PHASE
As we now understand this is a phase lead by the commissioning engineer
and it is also a very essential phase in the complete manufacturing of the
RTG before the RTG is handed over to the customer.

Figure 6 Crane assembly process showing the commission phase in the assembly pro-
cess

The commissioning phase involves two main stages which are the start up
and testing stages as seen in figure 7 below. The checking activities done
during commissioning phase are divided into two types: Static checks and
Dynamic checks. These check types is a general idea that also applicable
when commissioning any new equipment. Static checks involve carrying
out tests on equipment without (or before) energizing the equipment while
the dynamic checks involves test to be done on the equipment after it has
been energized. The type of activities carried out on the equipment in ei-
ther of the two checks mentioned earlier depends on the type of equipment
that is being commissioned. Normally, these checks may be a series of
tasks or may just be a simple short set of tasks. In the case of equipment
such as an RTG, quite number activities are involved.

The start-up stage which is the first of the commissioning phase involves
checking and powering up the RTG. During this stage, activities are car-
ried out are mostly of the static checks types mentioned earlier. The start-
up stage is further divided into sub-stages where a certain stage in the pro-
cess precedes another stage in the process (meaning that a stage is required
to be completed before another stage starts).However, some stages can al-
so be performed in parallel with others. During the start-up stage the main
activities done are: pre-start-up checks, RTG power-up, fibre connection
and program download. The tasks carried out and the list of activities per-
formed during the start up stage will be further explained later on in this
procedure. The second stage of the commissioning phase is the Testing
stage and can also be called internal testing stage. The main activities dur-
ing this stage include: operational test, set-up and interlocks and safety
test. The main aim of this stage is to get the crane ready for checks and

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
tests supervision to be carried out with the customer. Once the crane has
been internally tested, passed all necessary tests and has been certified by
the commissioning engineer. Then the commissioning process is complet-
ed. The crane is now ready to be tested with the customer; this is known as
the “customer testing” stage.

Figure 7 Commissioning phase process flow

After completing the stages during the commissioning phase, checks have
to be conducted to confirm that the previous stage is completed, to be able
to move on the next stage within phase. A commissioning checklist is used
for the checks; see appendix 1. This checklist serves as an input to be used
in predefined stages of the phase and also an output of the whole commis-
sioning phase process. The checklist is made to be completed and ap-
proved by the commissioning engineer in charge.

A successful completion of the commissioning phase would mean that the

RTG has been successfully assembled and tested. The crane has also
passed all safety and quality standard tests required for the crane to be
signed off to the customer. To achieve this success, it is important to have
every material, tool and the right personnel available for the completion of
all the stages involved in the phase.

It is also imperative to note that this commissioning procedure is written

using the crane model 16WA (sixteen-wheeler) which was being assem-
bled during the time this procedure was written. Therefore, if this proce-
dure will be used for other sixteen wheeler cranes, there might be slight
little differences. These differences may be noticed as additional equip-
ments or accessories requested for by the customers. In the case of such
differences, the commissioning engineer should refer to the automation
personnel for brainstorming ideas

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
6.1 Safety

Safety is an important aspect during manufacturing of the various parts of

the RTG and also plays an integral role in the assembly of the RTGs.
Konecranes also ensures to follow all local and international safety regula-
tions during all activities involving the assembly of the RTG. Irrespective
of where the assembly is done, either at a Konecranes site or customer’s
site. Similarly, when designing the cranes, all necessary international and
local standards stated in the design considerations for equipments such as
an RTG are always followed. The international regulatory bodies include
ISO (International Organization for Standardization), IEC (International
Electro-technical Organization), CEN (European committee for standardi-
zation) and a local organization, SFS (Finnish Standards Association / Su-
omen Standardisoimisliitto). The safety requirements also encompass the
use of the electrical hardware devices and software designs. (Haanpää, in-
terview 1.4.2013.)

6.2 General description of tools and personnel required

Personnel

To complete these tasks it is important to have at least two trained per-

sons:

 Electrical personnel
 Mechanical personnel

Having persons that have the operational, electrical and mechanical

knowledge of the crane is very important as this will become useful during
the phase. If the personnel listed above are not available the minimum re-
quirement is have two electrical persons that have the operational, electri-
cal and mechanical know-how of the crane.

Tools and Materials

Throughout the period of this process, certain tools and materials are
needed to aid a fast and smooth completion. Below is a list of important
tools and materials needed during the project:

Table 1 Tools

Tools (description) Quantity (pieces)

Clamp on ammeter 1
Fibre optic tester 1
Grease gun 1
Measuring tape 2
Megger tester/Insulation resistance tester 1
Multi-meter 2
Phase sequence tester 1
Pressure gauge (0 to 10 bars scale) 1

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Scope-meter 1
Set of flat head screw driver 2
Set of star head screw driver 2
Set of Allen keys (1mm to 8mm range) 2
Set of spanners wrench (6mm to 20mm 2
range)
Side cutter pliers 2
Torque wrench 1
Walkie-talkie 2

Table 2 Materials

Materials (description) Quantity (pieces)

Commissioning specification document 1
Crane electrical drawing 1
Diesel generator electrical drawing 1
Laptop with installed programs 1
Other equipment manual 1

Each person involved in completing the tasks should have their own basic
personal tools such as screw drivers and pliers while the materials used
can be shared amongst them. This is basically because a minimum of one
tool will be needed at each stage of the procedure and the persons in-
volved are not going to be at the same place all the time during the activi-
ties. However, one of each material listed will be enough for the phase,
and the persons do not need to have one of each material all the time.

6.3 Crane start-up stage

It is important to note that the tasks performed in this stage follow the fact
that some pre-checks have been done to the assembly parts at the factory.
Some of the parts are delivered to the assembly site, pre-assembled. These
parts are:

 Bogies
 Electrical room (E. room)
 E6 (Access side)
 Diesel generator
 Head-block (optional unit)
 Operator’s cabin
 Spreader
 Trolley

These parts comprises of mechanical parts, electromechanical equipments

and electrical equipments. After the pre-assembly of these parts at the fac-
tory, the parts are tested to ensure that they work as they should and any
faults found during testing in the factory are fixed. When the factory tests
have been conducted successfully, the parts are then shipped to the respec-

20
Standardizing the commissioning phase to improve RTG cranes product safety and quality
tive sites where they should be delivered to. Obviously, since the parts
have been tested and certified at the factory before transportation they do
not necessarily have to be tested before they are assembled on site.

As we already know, this stage is the inception of the tasks to come after
the complete assembly, erection and electrical wiring of the RTG. Alt-
hough, all the phases involved after the erection are important but any
mistake at this stage may cost a lot and maybe even prevent or prolong the
completion of the commissioning phase. Hence, it is important to have
everything and the right personnel for the successful completion of the
stage. Below is a process flow of activities performed during the start-up
stage. This start up stage is only about 25% of the whole commissioning
phase.

Figure 8 Start up stage process flow

6.3.1 Pre-start-up checks

This involves the first set of activities to be performed on the crane before
energizing the crane. These checks are considered to be static checks (as
explained earlier) and are conducted in order to ensure that the process of
energizing the crane is problem free.

Diesel generator

Simple checks are conducted on the diesel generator irrespective of the

factory check and test that has been done. These checks have to be con-
ducted in order to capture any possible problems that might have happen
during transportation and to replenish important solvents to operate the
generator.

 Inspect oil filters.

 Inspect fuel filters.
 Check oil level and top up if necessary.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Check fuel level and top up.

 Check coolant level and top up if necessary.
 Inspect for any leakage and repair if any is found.
 Measure the diesel generator battery voltages, should be 12 volts on
each battery.

General inspection

 Check motor gear box oil level and top up if necessary.

 Inspect electrical wirings in E. Room, access side (E6), trolley electri-
cal cubicle, operator’s cabin electrical cubicle for any loose connec-
tions.
 Ensure that all circuit breakers in the electrical cubicles are in off posi-
tions.
 Check that all crane emergency stops are released.
 Check that diesel emergency stops are released.
 Ensure that “main isolator switch for crane” “O-Q1” and “main isola-
tor switch for machinery” “O-Q2” are in off position.
 Measure the insulation resistance of the motors using the megger test-
er (this action is also called megger testing). This is usually done by
the contracting company.
 Inspect bogie tires air pressure and pump the tires if needed.

Typically, the diesel inspections and checks can be done before the gener-
ator is assembled to the RTG. These activities on the diesel generator will
typically take about 120 minutes. For the general inspections and checks,
they should be done after the RTG erection is completed and these tasks
typically should only take about 120 minutes to also complete.

6.3.2 RTG power up

After the pre-start-up checks have been completed and all checks con-
firmed okay, we can now move on to the next stage in the process which is
powering up the RTG. This stage of the process involves energizing the
crane, starting up the diesel generator to get power to the crane and then
energizing the crane equipments. Obviously, this should be done follow-
ing a predefined process, for example the diesel generator should be start-
ed to ensure there is power to the crane before switching on the breakers
and not vice versa.

Diesel generator start up procedure

 Connect the diesel generator batteries using an 11mm spanner wrench.

 Switch on the battery switch, F22.
 Switch on diesel generator main disconnect, Q1.
 Switch circuit breakers in diesel generator cubicles to ON position.
 Switch on circuit breaker, D-F1 in E. room at location E1.6.
 Disconnect the can bus profibus cable, Z1-D7 from PLC rack in E.
room.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Turn “main control” switch key to ON position to switch on the diesel

control module, “intelligence module”.
 Reset all faults shown on the intelligence module if any.
 Open all diesel doors, to be able to observe the generator.
 At this point, the generator start mode will be on manual mode (this
means the generator can only be started from the module buttons) start
diesel generator from intelligence module start button.

Figure 9 Diesel intelligence module

 With the diesel doors still opened, keep the generator running for a
minimum ten minutes to observe for any problems in the diesel gener-
ator engine such as leakages.
 Stop the diesel generator after ten minutes.
 If any problem is observed while running the engine, stop the genera-
tor after the ten minutes run, let the generator cool down and then fix,
if no problem was observed during the run.

The following steps below are not really necessary if the diesel intelli-
gence program download have been done from the factory. But if the pro-
gram is to be downloaded during this process, then the steps below should
be followed to do the download.

 Now connect the RS 232 cable from laptop to diesel intelligence

module to link up to the module and download the intelligence mod-
ule program.
 After the program download, the generator start mode changes to
“off”. To change the start mode, first enter the module password usu-
ally 1234, 0 or 1 and press enter.
 Change start mode to automatic mode and now generator can be start-
ed using the key switch.
 Start generator from the key switch.

If the program running on the module is the recent program, then only the
start mode is needed to be changed to automatic. Therefore follow the
steps below:

23
Standardizing the commissioning phase to improve RTG cranes product safety and quality

 The generator start mode is in manual as earlier mentioned, first enter

module password usually 1234, 0 or 1 and press enter.
 Change start mode to automatic mode and now generator can be start-
ed using the key switch.
 Start generator from the key switch.

6.3.3 RTG main power on

Now that the diesel generator has been started and the engine is running,
there should be a three phase voltage supply up to 500 volts supplied from
the diesel generator through the main disconnect, Q1 of the diesel genera-
tor to the crane main isolation switch. Hence, we have to confirm that
there is a three phase voltage supply present at the crane mains before en-
ergizing the crane. Typically the phase sequence can also be checked after
checking the voltage using the phase sequence tester. But the phase se-
quence check would be been done by O-L1 (the device which is directly
after Q1).

 Close E1.1 door and switch on “Main isolator for crane” O-Q1 on the
door.
 There should be voltage present at the terminals and this can be meas-
ured at the input terminals 1, 3 and 5 of circuit breaker O-F102 at
E1.2.

6.4 Energizing crane in sections

At this point we are sure there is voltage supply to the crane, all we have
left to do is to switch on all circuit breakers in a sequential order to ener-
gize various sections on the crane one after the other. At this point, we
must first understand that there are typically two types of loads present on
the crane, they are the domestic loads or non-moving parts loads and mov-
ing parts loads or machinery loads. The idea of switching on the circuit
breakers sequentially is to ensure safety of equipments and personnel. The
main reasons for not switching on the machinery loads first and sequential
switching are:

 To avoid sudden movement of moving parts machinery, it is therefore

typically advisable to switch on domestic loads before other loads.
 To prevent sudden voltage surge from damaging equipments on the
crane in a case where there might be a fault in wiring connections.
Hence, when switching on circuit breakers, either for the domestic
loads or the moving part loads it is important to note that higher rated
breakers should be switched on before the lower rated breakers in the
series circuit. This simply means that when switching on the breakers,
we will start by first switching on the breakers which have higher trip
settings in the circuit. Then, we will proceed to the next higher trip
setting breakers in the series circuit and so on until we get to the bot-
tom breaker of the circuit. For example, if we had circuit breakers of
trip ratings 100A, 80A and 60A serially connected in the circuit. We

24
Standardizing the commissioning phase to improve RTG cranes product safety and quality
will first switch on the 100A breaker, then 80A and finally 60A but
not vice versa.

We will also start to switch on the circuit breakers starting from the E.
room and then we move on to other electrical cubicles on the crane until
all are completed.

Personnel required

 Electrical personnel

Tools and materials required

 Laptop and cable accessories

 Crane electrical drawings
 Screw driver (flat head)
 Side cutter pliers
 10 - 13mm spanner wrench
 Allen key set

6.4.1 Electrical room domestic loads

Starting with the domestic loads, this includes: lightning and heating con-
trol, lightning and heating for gantry side and lightning and heating for E.
room. First, we will switch on the charging circuit, lightning, heating and
air conditioning circuit for the E. room to get illumination in the room,
PLC circuit and then other domestic loads energized. Below is a list of the
sequence of the breakers to be switched on for domestic loads, the breaker
locations and usage.

Table 3 Charging circuit

Breaker name Location Purpose

O-F102 E1.2 DC – circuit charging circuit
O-F01 E1.2 main supply feedback contactor
O-F3 E1.5 control transformer
O-F10 E1.5 charging circuit

Table 4 E. room Lightning and heating

Breaker name Location Purpose

T-F01 E1.5 main supply selection trans-
former
T-F011 E1.5 main supply selection circuit
T-F1 E1.5 transformer
T-F11 E1.5 gantry
T-F119 E1.5 electric room heating
T-F120 E1.5 electric room lightning

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

T-F123 E1.5 diesel heater etc

T-F124 E1.5 air conditioning unit

Table 5 Other domestic loads

Breaker name Location Purpose

T-F111 E1.5 power supply E6
T-F22 E22 power supply trolley and cabin
T-F114 E1.5 socket outlet
T-F115 E1.5 socket outlet
T-F116 E1.5 floodlights gantry
T-F117 E1.5 gantry and locking motor heat-
ing Bogie B and Bogie spare C
T-F118 E1.5 spare
T-F121 E1.5 gantry floodlights control
T-F122 E1.5 gantry travelling alarm bogie
B/C
T-F125 E1.5 spare
T-F126 E1.5 spare
T-F127 E1.5 spare
T-F128 E1.5 spare
T-F129 E1.5 GPS power supply
T-F130 E1.6 main filter power supply
T-F131 E1.5 electric room PLC power supply
T-F02 E1.5 shore power selection trans-
former
T-F03 E1.5 phase relay
T-F012 E1.5 shore power selection circuit
O-F14 E1.5 spare

Table 6 PLC inputs, encoders and other systems

Breaker name Location Purpose

Z1-F1 E1.6 spare
Z1-F2 E1.6 encoder power supply bogie
B/C
Z1-F11 E1.6 PLC inputs
Z1-F12 E1.6 PLC inputs
Z1-F13 E1.6 PLC inputs
Z1-F14 E1.6 master PLC fibre-optic interface
Z1-F15 E1.6 TOS system
Z1-F16 E1.6 CMS

6.4.2 Program download and Crane set-up on CMS computer

After switching on the circuit breakers above, we can now move on to per-
forming other tasks, that is, program downloads and setting up the crane.
First, we must download the PLC program and the Can bus program. Be-

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
fore downloading the PLC program to the master PLC module, we must
ensure that the generator is running full speed, which is at least,
1500RPM. To run the generator at this required speed, “maintenance
mode” has to be switched on and then download the can bus program and
then select the crane “hybrid” function on the CMS computer. The genera-
tor can now run at idle speed of 800RPM (this will also normally during
operation happen if the RTG has stopped to be in use for about 3 minutes).

Since the diesel generator will only run full speed until the can bus pro-
gram is downloaded, hence it is logical to download the PLC program be-
fore downloading the can bus program.

PLC program download

First, we will have to configure the IP settings of the laptop so that the
PLC device can be found, the IP configuration setting must be set to man-
ual and not automatic (automatic is usually the default setting on the lap-
top). The procedure for the IP configuration described below is valid if
windows operating system is used on the laptop.

Internet protocol configuration procedure

 Click on the “windows start icon” at the left bottom corner of the lap-
top screen to display the start menu.
 On the start menu click on “control panel”, usually a new explorer like
in the figure below should display.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Figure 10 Control panel category view

 Click on the “category” drop down menu at the top of the page and se-
lect “large icons” from the drop down list. The page display should
change to the view below.

Figure 11 Control panel large icon view

 From the icon on this view select `Network and Sharing center` and
the explorer should display a new page.
 On the new page, at the left side, select “change adapter settings” and
a new page will display all the network connection methods used on
the laptop.
 Now double click on “Local Area Connection Properties” and a dialog
box “Local Area Network Properties” will be displayed.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Figure 12 Local area connection properties dialog box display

 Again double click on “Internet Protocol Version 4 (TCP/IPv4)” from

the list and an additional dialog box is displayed, “Internet Protocol
Version 4 (TCP/ipv4) properties”.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Figure 13 TCP/IPv4 properties dialog box

 In the new dialog box choose use the following IP address option be-
low.
 Type in a new IP addresses 192.168.0.15. Note that only numbers
from 15 and 50 can be used.
 Type subnet mask, 255.255.255.0 and then click the OK button.
 Also click OK on the “Local Area Connection Properties” and now
the computer should be configured for this IP address and ready to
use.

PLC program download procedure

 Connect an RJ45 cable from the laptop to the port in the E. room to
establish connection with the master PLC.
 Put the PLC switch to stop.
 Open the “step 7 simatic manager” program on the laptop.
 Open the right program file to download.
 Click on “download user program to memory card”.
 Follow the further instructions and download.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 After download is complete reset the PLC.

 Then put the switch to run and wait for about 2 minutes for the PLC to
be ready.

Note that the program download can also be done from the CMS computer
if the Siemens simatic program has been installed on the CMS computer
and the CMS computer is always linked to the PLC at all times.

Can bus program download

This program download task is also an optional task. This should have al-
ready been done at the factory as it should be normally but if it has not
been done at the factory, follow the procedure below.

 Connect can bus module (Z1-D7) to the laptop using the RS232 cable
to create a connection link.
 Open the can bus program from the computer.
 Select and open the right program software to be downloaded.
 Download the program and wait for download to complete.
 After the download is complete remove the RS232 cable and now
connect the can profibus cable to the “can bus” port of the module.

Other programs such as for the hoist drive inverters, trolley drive invert-
ers, skew driver inverters, “DYNACON” inverter and “DYNAGEN” drive
inverter are not going to be downloaded because the program downloads
are always done, tested and certified from the factory, therefore it would
not be necessary to make another download.

6.4.3 Crane function set-up

Now that both programs have been downloaded, the other necessary crane
set ups can now be completed. Crane function implies selecting the crane
function and devices that are specific to the crane. All cranes manufac-
tured by Konecranes have some basic set of devices and functions but ad-
ditional devices and functions can be added to the crane based on the cus-
tomer’s need and specification. Hence, during this set-up, we will select
what functions the crane has been built to have and what devices are to be
in use on the crane.

To do this set-up the CMS computer has to be online and this can be
checked simply from the CMS computer monitor at the bottom left corner
of the screen. An icon indicates the status of the CMS; the icon color is red
when the CMS is offline and green when it is online. When we have con-
firmed the CMS to be online, we then have to enter the administrator
password “2140”. After entering the password, two extra tabs will appear,
“Settings” and “Bypass”. First we will select which emergency stops are
going to be used on the crane; using the mouse cursor first click on the
“settings” tab, next click on the “CMS settings” tab and finally on the “E-
stop” tab. A display such as in the figure below will appear on the screen.
Now all we have to do is to check the box next to which emergency stop

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
will be in use on the crane and which of the contactors are going to be in
use and select those.

Figure 14 Emergency stop page on CMS computer

Next is to set-up the crane configuration. To get to the “Crane config” tab,
first click on “settings” tab, click on the “crane config” tab and lastly
“crane” tab. A display such as in the figure below will appear on the
screen. Now we select which devices and functions which are to be used
on the crane by checking the box next to the device or function. One very
important selection that should be done now is the hybrid function for the
diesel generator which was discussed earlier. If the hybrid box was
checked, uncheck the box and check again, the diesel generator should
immediately slow down to run idle speed since it is not in operational us.

Figure 15 Crane config page on CMS computer

6.4.4 E6 domestic loads

After the domestic loads in the E. room have been switched on and other
tasks have been completed, next is to switch on loads in other electrical
cubicles. The next cubicle is the E6 cubicle.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Table 7 E6 Domestic loads

Breaker name Location Purpose

T-F301 E6 socket outlet
T-F318 E6 checker cabin
T-F319 E6 socket outlet
T-F302 E6 truck-lane floodlights
T-F303 E6 gantry and locking motor heat-
ing Bogie A and Bogie D)
T-F311 E6 walkway lights
T-F312 E6 cubicle heating and cooling
T-F313 E6 gantry travelling alarm bogie
A/D
T-F314 E6 walk way light control
T-F315 E6 PLC power supply
T-F316 E6 spare
T-F317 E6 checkers cabin
T-F320 E6 camera

Table 8 PLC inputs, encoders and other systems

Breaker name Location Purpose

Z6-F11 E6 input, fibre-optic, encoder
Z6-F12 E6 encoder
Z6-F13 E6 pendant, outputs
Z6-F14 E6 remote PLC

6.4.5 Trolley domestic loads

The next circuit breakers to switch on are in the trolley electrical cubicle,
E2.1 to E2.4.

Table 9 Domestic loads

Breaker name Location Purpose

T-F201 E2.4 cabin power supply and trolley
T-F202 E2.4 spreader power supply
T-F210 E2.4 maintenance hoist power supply
T-F203 E2.4 hoist A1 motor cooling fan
T-F204 E2.4 hoist A2 motor cooling fan
T-F206 E2.4 socket outlet
T-F211 E2.4 trolley floodlights, front
T-F212 E2.4 trolley floodlights, rear
T-F213 E2.4 trolley walkway lights
T-F214 E2.4 maintenance lights
T-F215 E2.4 cubicle lightning
T-F216 E2.4 spare

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

T-F217 E2.4 trolley motor heating

T-F218 E2.4 motor heating: hoist, traversing
and skew motors
T-F219 E2.4 cubicle heating
T-F220 E2.4 alarm horn
T-F221 E2.4 trolley PLC power supply
T-F222 E2.4 cabin air conditioning

Table 10 PLC inputs, encoders and other systems

Breaker name Location Purpose

Z2-F21 E2.2 input
Z2-F22 E2.2 input
Z2-F23 E2.2 encoder power supply
Z2-F24 E2.2 interface
Z2-F25 E2.2 spare
Z2-F26 E2.2 spare

6.4.6 Operator’s cabin loads

We now have to switch on the domestic circuits for the cabin. Basically,
only domestic load switches are located in the cabin cubicle which means
that all the breakers will be switched on in the cabin unlike in the E. room,
E6 cubicle and the trolley cubicle. Below is a list of circuit breakers to be
switched on which can be found in the E4 cubicle.

Table 11 Domestic loads and PLC circuit

Breaker name Location Purpose

T-F401 E4 cabin sockets 230V and stand-
by heating
T-F402 E4 air curtains
T-F403 E4 air curtains
T-F404 E4 230V socket outlet/electric cu-
bicle
T-F411 E4 seat heating and compressor
T-F412 E4 camera system
T-F413 E4 supply to PLC
T-F414 E4 supply to windscreen transform-
er
T-F415 E4 12VDC power supply
T-F416 E4 supply for windows heating
T-F417 E4 spare
T-F431 E4 heating for cabin glasses
T-F432 E4 heating for cabin glasses
Z4-F11 E4 PLC inputs
Z4-F12 E4 PLC inputs
Z4-F13 E4 PLC inputs

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Z4-F14 E4 PLC inputs

Z4-F15 E4 PLC inputs
Z4-F16 E4 loudspeaker system
Z4-F17 E4 cabin LED light
Z4-F18 E4 cubicle light

Note that we have not checked any circuit breakers in the E5 and E3 cubi-
cles because there are no breakers in the E5 cubicles and the E3 cubicle is
located on the spreader. Since the spreader is still at a seemingly unreach-
able height, we will therefore not focus on the E3 cubicle until later on in
the process.

6.4.7 Fibre optic, termination resistors and bus addresses

When all the domestic loads have been switched on the cubicles, as de-
scribed above and the master PLC, slave PLC and other devices in the pro-
fibus circuit have been powered. Then we can move on to the connection
of the fibre optics and checking the termination resistors dip switches of
devices in the cubicles. Doing this will enable the master PLC link up or
create the connection with the other devices within the profibus circuit.
We can also check from the CMS computer, the progress of the profibus
connection as the fibres are connected in the respective cubicles. To navi-
gate to the profibus page on the CMS screen, we do not need to enter the
administrator password. First click the “monitoring” tab and then click the
“profibus” tab. A display of the profibus circuit should appear on the
screen. Now using the electrical drawings, follow the fibre optic connec-
tions; to connect the right fibre optics to the right device and check the po-
sitions of the termination resistors dip switches. This fibre connection will
also be done in the section order which the domestic loads breakers were
switched earlier, that is moving from one cubicle to another.

Note that there are different sets of the fibre optics and some are color
coded while others are only number. Usually there are two sets of fibre op-
tic cable, cable numbers “595” and “596” runs from the E. room to the
trolley cubicle (one of these set is usually a spare). Another set of the fibre
optic cable runs from the trolley cubicle to the cabin cubicle; cable number
is “810”. The last set runs from E6 to E. room, which cable’s number is
“670”. It is also important that while connecting each fibre cable, to check
that the status LEDs are on after connecting each fibre cables. Therefore
we can have one personnel checking the profibus connection status from
the CMS in the E. room while the other personnel can focus on the fibre
cable connections.

Basically the termination resistors dip switches of some devices have been
connected from the factory and are also preset from the factory. However,
we will also include some of those devices in our checks. The position
which the dip switches should be can be checked from the electrical draw-
ing. Normally the dip switch for the termination resistor should be in ON
position if there is only one profibus cable connected to the termination re-
sistor or OFF position if there are two profibus cable connected to the ter-
mination resistor.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
The bus addresses are also important inspections that will be conducted.
Although, not all bus addresses will be checked as these addresses should
normally be preset from the factory. Hence, a quick check on the bus ad-
dresses of the devices listed below is imperative. Also below is a list of
devices that the fibre cables are to be connected to.

Table 12 E. room fibre optic connections

Breaker name Location Purpose

A1-D1 hoist one encoder optical fibre
receiver
A2-D1 hoist two encoder optical fibre
receiver
E-D1 trolley traversing optical fibre
receiver
Z1-X01 phoenix contact converter
Z1-X02 phoenix contact converter
Z1-B20 phoenix contact Ethernet switch
X1W fibre optic connector

Table 13 E. room termination resistors

Breaker name Location Purpose

Z1-A1 master PLC module
Z1-X01 phoenix contact converter
Z1-D7 can bus module

Table 14 E. room side bus address

Breaker name Location Purpose

Z1-D102 bogie B digital input detector
ZR3-B1 bogie B absolute encoder
ZR4-B1 bogie B absolute encoder
Z1-D103 bogie B digital input detector
ZR5-B1 bogie C absolute encoder
ZR6-B1 bogie C absolute encoder

Table 15 E6 fibre optic connection

Breaker name Location Purpose

Z6-X101 phoenix contact converter
Z6-B20 phoenix contact Ethernet switch
N-A35 optical fibre transmitter

Table 16 E6 termination resistors

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Breaker name Location Purpose

Z6-X101 phoenix contact converter
Z6-A1 interface module

Table 17 E6 / Access side bus addresses

Breaker name Location Purpose

Z1-D101 bogie A digital input detector
ZR1-B1 bogie A absolute encoder
ZR2-B1 bogie A absolute encoder
Z1-D104 bogie D digital input detector
ZR7-B1 bogie D absolute encoder
ZR8-B1 bogie D absolute encoder

Table 18 E2 fibre optic connection

Breaker name Location Purpose

A1-D2 hoist one encoder optical fibre
transmitter
A2-D2 hoist two encoder optical fibre
transmitter
E-D2 trolley traversing optical fibre
transmitter
Z2-X01 phoenix contact converter
Z2-B20 phoenix contact Ethernet switch
X2W fibre optic connector

Table 19 E2 termination resistors

Breaker name Location Purpose

Z2-A1 interface module
Z2-X01 phoenix contact converter

Table 20 E2 bus addresses

Breaker name Location Purpose

ZA1-D3 hoist one position encoder
ZA2-D3 hoist two position encoder
ZB1-B3 skew position encoder
ZB2-B3 skew position encoder

Table 21 E4 fibre optic connection

Breaker name Location Purpose

Z4-X01 phoenix contact converter
Z4-X02 phoenix contact converter

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Z4-B20 phoenix contact Ethernet switch

N-A20 optical fibre receiver

Table 22 E4 termination resistors

Breaker name Location Purpose

Z4-A1 interface module
Z4-X01 phoenix contact converter

It is imperative to know that in some cases not all the fibre optic cables
listed above are needed to be connected. Examples are fibres for devices
N-A35 and N-A20, which are used for camera on the crane. Since the
camera is an optional device on the crane, some customers may not re-
quire it.

6.4.8 Touch panel program download

Z4-A5, the “Proface panel” (operator’s touch panel) should now be on and
if the Ethernet circuit has been correctly done, there should be Ethernet
connection link established with the touch panel already. But the touch
panel cannot be used until the program is also downloaded. The program
download can be done from the electrical room via the CMS computer or
using a laptop. It can also be done in the operator’s cabin by directly con-
necting to the touch panel device using a laptop computer. Appendix 2 de-
scribes the program download procedure for the touch panel.

6.4.9 Energizing the moving parts

At this point, we have powered all domestic loads and downloaded all
programs. Next task is to energize the moving parts also called the ma-
chinery. This will involve switching on the remaining circuit breakers that
power the moving parts circuits. Follow the steps below energize the mov-
ing parts.

Table 23 Moving parts

Breaker name Location Purpose

O-Q2 E1.1 main isolator switch for ma-
chinery
O-F11 E1.5 main contactor
O-F12 E1.5 machinery on trolley
O-F13 E1.5 machinery on gantry
R-F1 E1.3 hoist motor A1 and gantry drive
R-F2 E1.3 hoist motor A1 and gantry drive
R3-F1 E1.4 gantry motor 3
R4-F1 E1.4 gantry motor 4
R5-F1 E1.4 gantry motor 5
R6-F1 E1.4 gantry motor 6

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

O-F71 E1.5 locking pin machinery

S3-F1 E1.5 gantry motor 3 locking pin
S4-F1 E1.5 gantry motor 4 locking pin
S5-F1 E1.5 gantry motor 5 locking pin
S6-F1 E1.5 gantry motor 6 locking pin
R-F71 E1.5 travelling brakes
AB-F7 E1.5 hoist/skew/trolley brake supply
R1-F1 E6 gantry motor 1
R2-F1 E6 gantry motor 2
R7-F1 E6 gantry motor 7
R8-F1 E6 gantry motor 8
R-F76 E6 travelling brakes
S1-F1 E6 gantry motor 1 locking pin
S2-F1 E6 gantry motor 2 locking pin
S7-F1 E6 gantry motor 7 locking pin
S8-F1 E6 gantry motor 8 locking pin
A1-F7 E2.1 hoist A1 brake
A2-F7 E2.1 hoist A2 brake
B1-F11 E2.3 motor 1 selected
B2-F11 E2.3 motor 2 selected
B-F7 E2.3 brake supply400V
E-F11 and E-F21 E2.3 traversing motors
E-F7 E2.3 brake supply 400V

At this point, all circuit breakers have now been switched on and all crane
sections should be energized.

6.4.10 Limit switches adjustment and faults clearing

There are several limit switches on the crane and each of them works for a
specific purpose. In this task, we will only focus on few of the limit
switches. The intent of this task is to correctly position (or adjust) the ac-
tuation lever of the switches so that they actuate the switching mechanism
whenever the levers are triggered.

Adjust actuation lever for all cat whisker limit switches (R-S01, R-S03, R-
S05, and R-S07) on the bogies. Below are figures which show the cat
whiskers actuation lever (white colored) before and after the lever adjust-
ment.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Figure 16 Cat whisker and actuation lever before adjustment

Figure 17 Cat whisker and actuation lever after actuation

We should also conduct quick checks (and adjustments if necessary) on

the limit switches for the ladder O-S10, diesel doors, shore power T-S01,
cabin side access gate O-S05, and cabin access gate gantry side O-S07.

Finally to complete this stage, we have to check that there are no active
faults that can prevent us from operating the crane. Though, after adjusting
the cat whiskers and checking the other switches, the active faults that ap-
pear on the CMS computer screen should now be fewer. Some faults will
still be active and can be seen on the screen, these faults will not prevent
some of the basic crane operations that are going to be checked during the
next stage of the process. Hence, we should be able to start the crane
“DRIVES” in order to check the basic crane operations, crane safety fea-
tures and complete crane operational set-ups. Note that on completion of
this stage, the commissioning phase would have been twenty five percent
(25%) completed.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
6.5 Crane testing stage

This stage is also being called the internal testing stage because it is solely
performed by Konecranes’ personnel only. As earlier mentioned, the main
activities performed at this stage are: Operational test, Crane set up, and
Interlock and safety tests. The main activities altogether make up the re-
maining 75% of the commissioning phase. However, the operational test
makes up about 15%, the crane set up makes up about 50% and the inter-
lock and safety makes up the last 10%.

Figure 18 Simple crane testing stage process flow

During this stage, we will test all the crane operational functions, to ensure
that the crane works as it should and problems can be spotted and fixed
immediately. Some of the operations are: bogie turning, crane movement
(gantry) at different bogie positions, hoisting operation, traversing (or trol-
ley) operation and so on. We now move on to the crane operational set
ups, which involve limits adjustment, setting the operational boundaries
on the crane and invariably enhancing the crane operations and safety fea-
tures. The interlock tests can also be called the safety tests. We have to en-
sure that all the safety features (which include operational interlock) work
as they should because this is an important value of the Konecranes RTG.
We must ensure that all safety devices are in place and this is one reason
why all the previous tasks should be carried out as explained.

Having known all these, we are now set to operate the crane. But first, we
have to put on the “DRIVES”. Drives is a term used to generally describe
all the moving parts of the crane and when we switch on the drives, we
have energized the control circuit which also means that we can now initi-
ate operational commands to the moving parts of the crane. The drives can
be started from four different places: the E. room (CMS computer), E6
pendant, trolley cubicle and operator’s cabin. Normally, the operator’s
cabin is where the drive should be switched on whenever the crane is in-
tended to be used for operational purpose while the other three locations
are intended for use only when any sort of maintenance task is to be car-
ried out on the crane. Because starting the crane from any other location
beside the operator’s cabin will bypass some functions and the crane oper-
ator has to be careful when operating the crane from any of the other three
locations.

Furthermore, the crane can operate in two modes, the maintenance mode
(designed only to be used for maintenance activities) and the normal mode
(designed for the crane normal operation). When carrying out the tasks in
this stage, it is preferable to do this using the crane normal mode because
in maintenance mode some devices and functions on the crane are by-
passed, therefore if there is a problem we may not notice this in mainte-
nance mode. Especially with the operational set ups, they should not be
done in maintenance mode. If we do this in maintenance mode and there

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
was a damaged device we may not see the impact of this device until we
go back to normal mode and this will surely lead to rework and wasted
time. This is because some devices are bypassed in maintenance mode.

6.5.1 Operational tests

Operational test is checking means checking operational functions of the

crane. We will check the emergency stop, bogie operations, gantry opera-
tions, hoist operations, trolley operations. Normally, when performing
these tests, we do not expect any problem to occur. However, we may ex-
perience some problems and these problems should be solved immediate-
ly. Care should be taken when performing these operations, ensure that
gantry, hoist and trolley operations are performed at low speed or so that
the crane moving parts do not move fast.

Figure 19 Simple operational test process flow

Emergency stop

To complete this task, one personnel is to check the faults in the E. room
while the other personnel activate the emergency stop switches.

Personnel required

 Electrical personnel
 Mechanical / electrical personnel

Tools and materials required

 Screw driver (flat head)

 Screw driver (start head)

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Crane electrical drawings

Procedure

 Activate the E. room emergency stop switch, O-S105. Check on the

CMS screen that the emergency stop fault is displayed and that the
emergency stop circuit is inactive.
 Also check from the CMS screen that contactor O-K11 is inactive.
 Release the emergency stop switch to activate the emergency stop cir-
cuit and also check that the fault disappears from the CMS screen.
 Repeat the steps above for emergency stop switches: O-S102, O-S104,
O-S61, O-S103, O-S201, O-S202 and R-S8
 Push the diesel engine emergency stop switches in the cabin, D-S471,
the engine should shut down.
 Reset fault and restart diesel engine. After the engine has started, push
the emergency stop at the diesel control panel and the diesel engine
should shut down.

Now, restart the faults and start up the diesel engine after the check is
completed. Note that any problem encountered must be corrected immedi-
ately.

Now, before we go any further, we will select the RTG program type for
the crane. This will be done from the touch panel Z4-A5. Follow the steps
below:

 First enter maintenance password “0202” and press enter, a new icon
will appear “service”.
 Follow the path to the RTG type page.
 Select the type, in this case 16WA.
 Close the page to go back to the main menu.

We also have to switch off the following switches: E-S479 for trolley anti-
sway, R-S478 for gantry anti-sway, R-S476 for the GPS and M-S477 for
the spreader.

Bogie operations and encoder calibration

During this test, we will check all operations performed with the bogies,
such as the directions of the locking pins, wheel turning directions on all
bogies and bogie turning to different modes. We will also calibrate the bo-
gie encoder in order to get accurate readings when turning the wheels.
Note that this encoder calibration can also be done from the CMS comput-
er. See the calibration steps below.

 First switch on the drives.

 Enter maintenance password “0202” and press enter, the “service”
icon should appear.
 First select “service” icon, and then select “single mode” icon to go to
the single mode page.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
After completing the steps above and we have got to the single mode page,
we will notice that the encoder values are not zero. These values are incor-
rect (they can only be zero if they have been calibrated). Now check the
“up” and “down” indicators for the locking pins, all the down indicators
should have a “1” status because all locking pins are down. We should al-
so notice the “ON” and “OFF” buttons which are used to switch the single
mode operation, on and off.

When performing this task, it is very important to confirm that the locking
pin goes in the right direction when it is being operated and also important
to check that the wheels turn in the right direction when operated. Pins and
wheels that go in the wrong directions should be corrected immediately.
 Select the “ON” button to switch on the single mode operation.
 Now select “1” (this means wheel number 1) to switch on to wheel 1.
 Select “calibrate” and the encoder value for this wheel should change
to “0.0”.
 Twist the left joystick clockwise to raise locking pin up. The locking
pin up indicator should now change to “1” when the pin is fully up.
 Push the left joystick to the right to see that the selected wheel turns
clockwise; the encoder value should also change as the wheel turns. A
little push is only required as the intent is just to ensure that the wheel
turns and the direction it turns is correct.
 Now push the left joystick to the left, to get the wheel back to the
locking pin position. We can stop when the encoder value is anywhere
from negative 0.5 to positive 0.5).
 Twist left joystick counterclockwise to lower locking pin and the
down indicator should now change to “1”.
 Now select “1” again to switch off the wheel.
 Repeat the steps above for wheels number two through eight.
 After completing all the wheels, select the “OFF” button to switch off
the single mode operation.

Bogie turning and gantry operations

After confirming that the wheels turn correctly when operated, we can
now check the automatic wheel turning operations. We will also check
some other gantry operations at the same time. The four bogie positions
that will be checked are: normal, cross, turn, and park position. The bogie
position at this point before any movement is always the normal position,
as this is the position of the bogies during erection.

During this bogie test, we will check that:

 The beacon light flashes during the bogie turning operations and any
of the gantry travel operations.
 The gantry alarms, sounds during the bogie turning operations and any
of the gantry travel operations.

Bogie test procedure

 Switch on the drives.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 In bogie normal mode, gently push the left joystick to the left to gan-
try travel slowly to the left and then stop.
 Now, push the joystick to the right to gantry travel slowly to the right.
 When crane comes to halt, select bogie cross position and observe the
behavior of all the bogies during this operation.
 When all bogies are in cross position, gently push the left joystick
forward to gantry travel slowly forward and then stop.
 Now push the joystick backwards to gantry travel slowly backwards.
 When crane comes to halt, select bogie normal position and observe
the behavior of all the bogies during this operation.
 When all bogies are in normal mode, select bogie turn mode and ob-
serve the behavior of all the bogies during this operation.
 When all bogies are in turn position, gently push the left joystick to
the left to slowly turn the crane counterclockwise.
 And then to the right turn to slowly turn the crane clockwise.
 When crane comes to halt, select bogie normal position and observe
the behavior of all the bogies during this operation.
 When all bogies are in normal mode, select bogie park mode and ob-
serve the behavior of all the bogies during this operation.
 When all bogies are in park mode, select bogie normal mode and ob-
serve the behavior of all the bogies during this operation.

Hoist operational test procedure

Note that there is no real need to perform the hoist operation for long,
since the intent here is only to check.

 Switch on the drives.

 Gently push the right joystick forward to slowly lower the spreader
down.
 Gently push the right joystick backward to slowly raise the spreader
up.
 On the right joystick press the trim button and hold the button down.
At the same time push the joystick left to trim spreader left side down
and then also push to the right to trim the spreader right side down.

Trolley operations test procedure

 Switch on the drives.

 Ensure that bogies are in normal mode.
 Gently push the left joystick forward to traverse forward slowly and
also try to observe any strange behavior or sounds.
 Gently push the left joystick backward to trolley backward slowly and
also try to observe any strange behavior or sounds.

Skew operation test procedure

 Switch on the drives.

 Enter maintenance password and the service icon will appear.
 Select the service icon and then select “skew” to go the skew page.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Select the “ON” icon to switch on the skew single mode.

 Select button “1” on the touch panel to select skew motor one.
 While pressing the skew button on the left joystick twist the joystick
clockwise and check that the spreader rotates clockwise.
 While still holding the skew button, twist the joystick counterclock-
wise and check that the spreader rotates counterclockwise.
 Release joystick and push button “1” to deselect skew motor.
 Push button “2” on the touch panel to select skew motor two.
 While pressing the skew button on the left joystick twist the joystick
clockwise and check that the spreader rotates clockwise.
 While still holding the skew button, twist the joystick counterclock-
wise and check that the spreader rotates counterclockwise.
 Release joystick and push button “2” to deselect the skew motor.
 Select the “OFF” icon to switch the skew single mode and exit from
the page.

If the spreader is noticed to turn counterclockwise when it should turn

clockwise when any of the two motors is selected, this should be noted so
that the direction of rotation of the motor can be changed afterwards.

6.5.2 Miscellaneous

This part involves checking the functionality of some safety device such
as the cat whiskers, ultrasonic sensors and limit switches for the ladder,
shore power and operator’s cabin gates. During this test, especially the
limits at the gate and gate locks, it is important to ensure that the switches
actuate properly. Therefore any necessary adjustments should be made.

Cat whiskers and Ultrasonic

 On the CMS computer, click on “monitoring” and then click on “gan-

try” to get to the gantry page.
 Go to bogie, A, corner, actuate the cat whisker limit by moving the ac-
tuation lever and release.
 While doing the step above, check that the relevant switch indicator
status changes on the screen from “1” to “0” at the same time when
the switch is actuated and it changes from “0” to “1” when the lever is
released.
 Next, block the ultrasonic sensor view at corner A. To do this stand at
about 60cm in front of the sensor to activate the sensor and then un-
block to deactivate.
 While doing the step above, check that the right ultrasonic indicator
status changes from “1” to “0” when the view is blocked and changes
from “0” to “1” when unblocked.
 Repeat the cat whisker and ultrasonic sensor tests of others at bogies
B, C and D corners.

Ladder and Shore power

 Remain on the gantry page of the CMS screen.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Remove the E. Room access ladder to deactivate limit switch and

check that the indicator on the screen changes from “0” to “1”.
 Now stow the ladder to activate the switch and check that the indicator
changes from “1” to “0”.
 Remove shore power plug from the socket to deactivate the limit
switch and check that the indicator changes from “1” to “0”.
 Insert the plug back into the socket to activate the switch and check
that indicator changes from “0” to “1”.

Operator’s cabin gates

 Open cabin side gate and check from the operator’s cabin screen that
gate lock Z-S411 and limit switch O-S05 events are displayed.
 Close the cabin side gate and confirm that the events mentioned above
disappear or become inactive.
 Open gantry side gate and check from the operator’s cabin screen that
gate lock Z-S101and limit switch O-S07 events are displayed.
 Close the cabin side gate and confirm that the events mentioned above
become inactive.

Note that at the end of this operational test, the commissioning phase
would then be forty percent (40%) completed.

6.6 Crane set up

This set up involves setting up the encoders and limits switches to ensure
that the crane operational functions work as required. Here, we will set-up
the load cells, hoist limits, trolley limits, and skews limits. Note that all
values used here are in meters, the only exception is the load cell calibra-
tion and all set ups are going to be described to be done from the operator
cabin.

Figure 20 Simple crane set up process flow

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
6.6.1 Hoist set up

The limits for the hoists are either software initiated or hardware initiated
depending on the limits. There are also two absolute encoders, one for
each hoist motor. Before the limit adjustment, we have to calibrate the en-
coders so that the readings of the encoder from both hoists motor change
concurrently.

Personnel required

 Electrical personnel
 Mechanical / electrical personnel

Tools required

 10mm spanner wrench

 13mm spanner wrench
 2.5mm allen key wrench
 4mm allen key wrench
 Screw driver (small flat head)
 Measuring tape

First, we will do these tasks below

 Ensure that the drive switch is off.

 Unscrew encoder guard box bolts and remove box. This box is beside
the hoist brake.
 Open the hoist limit switch box cover.
 Check that the encoder coupling is tight and does not slip. This can be
done by just trying to turn the coupling (it should be firm) and check-
ing the lock screws are tightened.
 Slacken the limit switch lock nut to release the limit switch cams.

Figure 21 Encoder coupling

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
The purpose of doing the above tasks is to ensure that we get accurate
hoist position values when hoisting and also to adjust the cam when we
have.

Hoist position calibration

If while performing this task, the up stop limit or emergency stop limit is
activated, then go to the cam assembly and turn the cams by hand so that
the cam sides are down and then the drives can be restarted.

 Switch on the drives and check that crane maintenance mode is acti-
vated.
 Slowly drive the crane to an area with a leveled ground as possible.
 Lower the spreader until it is just below the sill beam of the access
side, as seen below.

Figure 22 Spreader in leveled position with the sill beam

 While other personnel observes, try to level the spreader using the sill
beam as a reference, ensuring that the spreader is straight when com-
pared with the beam.
 When the above has been achieved, lower the spreader to measure one
meter from spreader to ground level. Confirm the distance by measur-
ing from twist-lock frame to the ground.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

1 meter to ground
level

Figure 23 A spreader side shown at a meter to ground level

 Confirm measurement from at least two sides of the spreader, for in-
stance side B and C.
 Enter maintenance password “0202”, to enable additional service
functions on the hoist limit page.
 Select “monitoring” and then select “hoist limits”.
 If it is certain that the spreader has been correctly leveled and it is at
one meter from the ground, push the “calibrate” button and check that
hoist 1 and hoist 2 values change to “1.00”.

Hoist limits

It is recommended that two persons perform this task but one person is al-
so able to perform the task. In the event of two persons performing this
task, one person checks the status of the limits from the operator’s cabin
touch panel while the other person does the actual limit adjustment. Four
limit adjustments will be made for each hoist; one adjustment will be
made on each hoist at a time. Always, we will start with the hoist calibra-

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
tion limit adjustment (done at 8.00 meter spreader height from ground lev-
el). Next is the hoist up stop limit adjustment (done at 18.40 meter spread-
er height from ground level), emergency stop limit adjustment (done at
18.50 spreader height from ground level) and down stop limit adjustment
(done while the spreader on the ground with slack rope). There are five
cams on each limit switch assemblies. From left to right: the first cam is a
spare, the second cam is for down limit, the third and biggest cam (also the
lead cam) is for eight meter calibration limit, fourth cam is for up stop lim-
it and the fifth cam is for emergency stop.

Now, we have to adjust the cams so that they activate the switch at the ap-
propriate spreader heights.

Figure 24 Hoist limit switch cams

8.00 meter calibration limit.

 Check that the drives switch is on, service mode is active on the touch
panel and crane maintenance mode is on. If maintenance mode is not
on, the crane will always try to level the spreader every time.
 Hoist up slowly until both hoist positions values are 8.00 meter and
stop. Ensure that the required value is got while hoisting up only be-
cause of the gearbox backlash.
 At hoist one cam assembly, turn the 8.00 meter calibration cam screw
so that the cam rotates counterclockwise.
 Continue turning the screw and stop immediately the cam activates the
switch (the switch makes a click sound when activated). We can also
confirm this by checking that the status for the 8.00 meter calibration
limit changes to “1” when the switch is activated on the hoist limit
page.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Note that the adjustment must be stopped immediately the click sound of
the switch is heard or when the status for the limit is activated; “1” on the
hoist limit page of the touch panel.

 Tighten the cam assembly lock nut to the required torque limit.
 Repeat this same cam adjustment procedure on the hoist two, cam as-
sembly. Tighten the cam lock nut to the required torque limit when it
is done.
 Now after both hoist cams have been adjusted, we have to check that
the adjustment was properly done.
 Slowly lower the spreader, until both hoists one and two 8.00 meter
calibration indicator changes to “0” and stop.
 Now slowly raise the spreader, while raising check at what spreader
height does the 8.00 meter indicator for both hoists activate.

Note that the limits must be adjusted so that both hoist limits reach the
8.00 meters height at the same time. Only a tolerance of positive or nega-
tive 0.01 meter is acceptable if necessary, ensuring that the tolerance of
the height difference between hoist 1 and 2 is positive or negative 0.01
meter. If these criterions are not met, the set-up must be repeated on the
hoist that does not meet the criterion until it is properly done.

If the calibration set up is properly done, next is to set up the hardware

stop limit, the height at which the hardware limit and the safety limit are
activated depends on the RTG’s lifting height, which can be found on the
“rating plate” of the crane. In other words, the height at which this hard-
ware limit will be set up is dependent on the lifting height of this spreader.
Remember that the cam assembly lock nut must remain tightened all
through the rest of the cam adjustments.

 Raise the spreader up slowly until the software limit stop is reached at
18.20m spreader height from ground level. Now, hoisting up is not
possible, only hoisting down is possible.
 On the hoist limit page, select the “SW bypass” button to enable the
hoisting up operation.
 Hoist up the spreader until the height reaches 18.40 meter for both
hoists values, ensure that the value is gotten while hoisting up only as
before.
 On the hoist one cam assembly, turn the “up stop limit cam screw” so
that the cam rotates counterclockwise.
 Continue turning the screw and stop immediately the cam activates the
switch (the switch makes a click sound when activated). We can also
confirm this by checking that the status for the up stop limit indicator
changes to “1” when the switch is activated on the hoist limit page.
 Repeat this same cam adjustment procedure on the hoist two, cam as-
sembly.
 Now after both hoist cams have been adjusted, we have to check that
the adjustment was properly done.
 Slowly lower the spreader, until both hoists one and two 18.40 meter
up stop limit changes to “0”.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Now slowly raise the spreader and while raising check the value at
which the spreader height of the up stop limit indicator for both hoists
activate.

Similar to the hoist calibration limit, both up stop limit indicators must be
activated at the same time for both hoists and the their activation values
should be 18.40 meter, a possible tolerance of positive or negative 1 ac-
ceptable.

After the completion of the up stop limit cam, we are going to set up the
emergency stop limit cam. Now that the up stop limit is reached, hoisting
up will be impossible but it will be possible to hoist down. But to set up
the emergency stop limit, we have to hoist up more. Therefore, the
maintenance mode has to be made active to set up the emergency stop lim-
it.

 Check that the maintenance mode is still on, if not, put it on.
 Hoist up slowly until the hoist position values of both hoists reach a
value of 18.50 meter. While hoisting to the required height, simulta-
neously monitor the distance between the top of the spreader (or head
block) and underneath the trolley to confirm there is considerable gap
between them.
 On the hoist one cam assembly, turn the emergency stop limit cam
screw so that the cam rotates counterclockwise.
 Continue turning the screw and stop immediately the cam activates the
switch (the switch makes a click sound when activated). We can also
confirm this by checking that the status for the emergency stop indica-
tor changes to “1” when the switch is activated.
 Repeat this same cam adjustment procedure on the hoist two, cam as-
sembly.
 Now after both hoist cams have been adjusted, we also have to check
that the adjustment was properly done

Note that the drives will be off because the emergency stop circuit has
been triggered. Push the reset push button A-S13, in the trolley E2.1 cubi-
cle to reset the circuit.

 Start the drives.

 Slowly lower the spreader until both hoist one and two, emergency
stop limit change to “0”.
 Now slowly raise the spreader and while raising check the spreader
height value at which the emergency stop limit indicator for both
hoists activate.
 Repeat the emergency stop limit set up for both hoists if they do not
activate at the 18.50 meter. Although, a tolerance of negative 2 is ac-
ceptable and the most important thing is that the hoist activation value
must not be greater than 18.50 meter.

Finally on the hoist, is to set up the down stop limit cam. After the emer-
gency stop limit has been completed, we can put off maintenance mode
and also remember to remove the SW bypass.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Check that the drives switch is on and maintenance mode is off.

 Slowly hoist down until the spreader touches the ground.
 To slack the rope, push the slack rope button at the same time pushing
the right joystick to slack the hoist rope.
 Continue to slack the hoist rope until both hoist position values reach
about negative 0.13 meter.
 On the hoist one cam assembly, turn the down limit cam screw so that
the cam rotates clockwise.
 Continue to turn the cam until it activates the limit switch and stop
immediately. Just as the previous cams, this can also be checked from
the hoist limit page. The down stop limit indicator should change to
“1” when the switch is activated.
 Repeat this same cam adjustment procedure on the hoist two, cam as-
sembly
 To check, slowly raise the spreader up until the down stop indicator
changes to “0”
 Slowly lower the spreader again until the down stop limits for both
hoists are activated.
 If they do not activate at the same time repeat the set up procedure un-
til they both activate at the same time. Tolerance of positive or nega-
tive 2 is acceptable.

After all the cams have been set up, we can now hoist the spreader through
all the limit heights to check that the set ups were properly done.

6.6.2 Load cell calibration

There are four load cells on the trolley assembly, each one measuring the
load on each rope. ZA1-B1 and ZA1-B2 for hoist one and ZA2-B1 and
ZA2-B2 for hoist two. Each rope load cell measures a certain amount of
load and to measure properly the load cells have to be calibrated. Also so
that the net load measured by the four load cells is the same as the actual
spreader weight (although there might a little difference). If this set up is
not done, the load cells may assume that there is either no load or too
much load thereby affecting the crane hoist operation. The usual problem
is that the net load measured by the load cells collectively is lower than the
net load of the spreader and the typical symptom is that the hoist operation
is slow during operation.

The set up may be done either from the E. room or from the operator cab-
in, but this procedure will be described for set up to be done from the op-
erator cabin. Typically this calibration may be required to be done several
times. To do this calibration correctly, we need to know how much load
each load cell measures as the rope “weight rope” and “spreader weight”.
Because each rope is situated at each load cell, therefore, each load cell
measures own rope weight plus the spreader weight. The spreader weight
is evenly distributed amongst all the four load cells. This means that since
the spreader weight is about 12tonnes, the spreader weight carried by each
load cell is approximately 3tonnes. The spreader weight depends on the
type of the RTG. This spreader weight measured by the load cells will ei-

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
ther be the spreader weight only or the weight of the spreader plus head
block (if the head block is used).

Calibration procedure

 Switch on the drives, enter maintenance mode password “0202” and

do not switch on maintenance mode.
 Lower the spreader down to ground level, until spreader touches the
ground.
 Slacken the rope, just a little to relief the load cells from the spreader
weight; this means the load cell will only be measuring the rope
weight.
 On the touch panel, select “service” and then select “load cells” to
open load cell page; each load cell is displayed to be on four corners
on the touch panel screen.
 Note the rope weight on each of the load cells; it should normally,
about 1tonne.
 Remain on this page and hoist up the spreader. Stop just as the spread-
er lifts up from the ground.
 Now check the weight on each of the load cells from the touch panel
screen (this new weight should be greater than the rope weight), let us
call this measured weight “X”
 Now subtract the rope weight from the “X” (“X” – rope weight). Now
note the value for each of the load cell.
 Whatever value got from the above mathematical expression, let us
call this “Y”. This is what the load cell assumes to be the spreader
weight carried by each rope.
 Each load cell should measure a spreader weight of about 3tonnes.
 If “Y” is less than 3tonnes. Subtract “Y” value from the 3tonnes (3 -
Y). But if Y is greater, the equation is Y - 3.
 The value got from above, say “Z”, for each load cell, is what should
be added to (or subtracted from) each load cell value on the screen to
calibrate the load cells.
 Still on the load cell page, select rope 1; an indicator bar should ap-
pear. Add “Z” to the current value of the load cell (X + Z).
 Value from the above addition is now the final calibration weight for
“rope 1” load cell. Now, set the load cell value to value that was de-
rived from the equation.

Note that if the value, Y is greater than 3tonnes. The calculation will be
done in the form Z – X instead of (X + Z).

 Repeat the steps above for rope 2, rope 3 and rope 4 and set the load
cell values.
 After all ropes have been done, cancel the load cell page and raise the
spreader to about 13 meters height and lower the spreader again to
about 2 meters to check if the calibration was properly done.
 If the symptom such as slow hoist speed occurs, then we may need to
recalibrate in order to compensate.
It is important to know that the load cell values or weight should be the
same values or almost equal after calibration.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
6.6.3 Trolley position calibration and limits

For the trolley calibration and limit set ups, there are magnetic switches
and limit switches needed to complete this procedure. There are two mag-
netic switches, one for the forward travel direction of the trolley and the
second for the backward travel direction of the trolley. The backward
magnetic switch (when activated by the green magnet) triggers the back
slow down of the trolley speed and re-calibrates the trolley encoder when
the switch travels over the magnetic only when the trolley travels in the
backward direction. The forward magnetic switch (activated by the red
magnet) is only responsible for trolley speed slow down when trolley is
travelling in the forward direction. The forward magnet (red magnet) is al-
so responsible for regulating the maximum travel distance (can be found
on the rating plate) of the trolley, which is also dependent on the project.
There is only one limit switch, which is responsible for the forward and
backward stop limits. The limit switch is triggered by the cam at either the
forward position or backward position. First part of the procedure is to do
the position calibration while the second part involves setting up the stop
limits. The position calibration set up involves positioning the magnet at
exactly where it should be when the magnetic switch travels over it.

Figure 25 Trolley backward limit magnet

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Figure 26 Trolley forward limit magnet

Personnel required

 Electrical personnel
 Mechanical / electrical personnel

Tools and materials required

 10mm spanner wrench

 13mm spanner wrench
 Measuring tape
 Two 17mm spanner wrench

First, we will start with the backward slow down. To this calibration, we
need to define a reference point as the starting point of the trolley because
whenever the magnetic switch travels backward over the green magnet,
the trolley position is re-calibrated to be at 2.97 meters from the reference
point. The reference point we have to define is always the trolley gate po-
sition, which means that whenever the trolley is at the trolley gate position
it is at its starting point, “0.00”. Therefore, will have to travel over the
green magnet to find out where the trolley gate position (or the 0.00 point)
is.

Procedure

 Switch on the drives, check maintenance mode is inactive and bogies

should be in normal position.
 On the touch panel screen main menu, select monitoring and then trol-
ley limit to open trolley limits page.
 Slowly trolley forward by pushing the left joystick, forward.
 Continue to trolley forward until the backward magnetic switch trav-
els over the green magnet.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Stop and push the left joystick backwards to slowly start to trolley
backwards and travel over the back magnet. When the switch passes
over the magnet; the backward slow down status on the limit page
should change to “1”.
 Continue to trolley backwards until the cabin trolley gate is in line
with the gantry cabin access gate, as in the figure below

Figure 27 Gate aligned when trolley is at gate position

 Try to get the gates as aligned as possible as seen in the figure above.
 Now, note the trolley position value from the trolley limit page, say X
(if not sure about the value, drive the trolley forward and backward
again to re-check the value)

Since we want the gate alignment as the “0.00” position, we will now have
to do the set up by moving the green magnet either forward or backward
depending on the value of X. Hence, only one of the two steps below will
be done depending on value of X.

 If X is greater than 0.00, we have to move the green magnet back-

wards by the value of X; so if X is 0.05 (5cm), then we move the
green magnet backwards by 5cm.
 If the X is less than 0.00, we have to move the green magnet forward
by the value of X; so if X is 5cm, then we will move the green magnet
forward by 5cm.

Ensure that the magnet is properly tightened on the rail and set the rail
properly so that the switch passes properly over magnet. After the magnet
adjustment has been done, continue with the procedure below.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Drive the trolley forward to go over the magnet until the backward
slowdown status changes to “0” and stop.
 Drive trolley backwards to go to the gate position, the trolley software
stop should automatically stop the trolley when the trolley position
value gets to “0.00”.
 Check that the gates are still properly aligned when the trolley stops at
the gate position.

Note that it may be required to do some more little adjustment of the mag-
net if the gates are not aligned. When this is complete, we can now move
on to set up the backward stop position.

 Now the trolley should be at trolley position of 0.00.

 Enter maintenance password “0202” and go to trolley limit page.
 Select the “SW bypass” to activate the software bypass.
 Slowly drive trolley backwards to a trolley position value of negative
0.05 meter and stop.
 Now position the limit switch actuation lever down, as seen in the fig-
ure below.

Figure 28 Trolley forward and backward stop limit switch with actuation lever posi-
tioned

 Now, slacken and move the backward stop limit cam, to push the limit
switch actuation lever.
 Stop just when the limit switch is activated, this cam movement can
be done several times to be sure that it exactly actuates the limit
switch when you stop, a click sound is heard when the switch is acti-
vated. This can also be confirmed by the other person checking the
status of the backward stop limit indicator on the trolley page; it
changes to “1” when the switch is activated.
 When the cam is properly set with the limit switch, tighten the cam to
remain in that position

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 To check, drive the trolley forward until the switch is deactivated (or
the backward stop limit indicate on the screen is “0”). Then drive
backwards again to check at what trolley position does the backward
stop limit indicator change status from “0” to “1”; this position should
be at about -0.05 meter on the screen.
 If the trolley position is not -0.05 meter on the screen, we will repeat
the procedure until we get it at the value.
 After this has been done, remain at the backward stop limit position
and confirm that the two rear trolley wheels are still on the main gird-
er rails as seen in the figure below.

Figure 29 Trolley wheel on rail (still shows some gap on the rail)

 After completion select the “SW bypass” to deactivate software by

pass.

Now the trolley backward calibration and set up has been completed, next
is to do the forward set up calibration.

 Remain on the trolley limit page.

 Trolley forward to a trolley position value of 18.20 meters.
 Remaining at this trolley position, slowly slide the red magnet back-
wards, under the forward slow down magnetic switch until the indica-
tor on the touch panel screen changes to “1”. This can be done several
times to get the exact magnet position when the switch is activated.
 Note the right magnet position and lock magnet in that position, en-
sure that the magnet is properly on the rail and properly underneath
the magnetic switch.
 To check, drive the trolley backward slowly until the forward slow-
down indicator status changes to “0”.
 Now trolley forward and check at what trolley position value does the
forward slow down indicator status change to “1”
 The trolley position must be at “18.20”. If the position is incorrect, re-
peat the set up procedure.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
When the forward slow down has been set up and properly completed,
next is to set up the forward stop limit

 Remain on the trolley limit page, trolley forward more until the trolley
reaches the forward software stop position; 21.16 meter.
 Now select the “SW bypass”.
 Again slowly trolley forward more until the trolley position is at 21.21
meter and stop.
 Now, slacken and move the forward stop limit cam to push the limit
switch actuation level.
 Stop just when the limit switch is activated. This cam movement can
be done several times to be sure of the exact position the limit switch
is actuated (a click sound is heard when the switch is activated). This
can also be confirmed by the other person checking the forward stop
limit indicator status on the trolley page; it changes to “1” when the
switch is activated.
 When the cam is properly set with the limit switch, tighten the cam to
remain in that position.
 To check, drive the trolley backward until the switch is deactivated or
the forward stop limit indicator changes to “0”. Then drive forward
again to check at what trolley position does the forward stop limit in-
dicator changes status from “0” to “1”; position should be 21.21.
 If the trolley position is not 21.21, repeat the procedure until it is
properly set up.

Figure 30 Trolley hardware limit switch shown actuated in forward end position after
set up

 After this has been done, remain at the forward stop limit position and
confirm that the two front trolley wheels are still on the main girder
rails, as done previously for the rear wheels.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 After completion select the “SW bypass” to deactivate software by

pass.
 Trolley backwards to trolley gate position.
 Place the guard plate (in the figure below) over the magnetic switch
and tighten in position, to protect the switches from mechanical dam-
age and rain.

Figure 31 Magnetic switch guard plate shown in picture yet to be placed in guard posi-
tion

After all the tasks have been done, we have now completed the trolley set
ups.

6.6.4 Skew set up

Remember that during the operational tests, we have confirmed the direc-
tion of rotation of the skew motors and also checked that both motor work
properly. We are now left to complete the skew set up. There is one en-
coder on each skew motor, which gives the feedback value of the skew
motor position and there are also two limit switches, one on each skew
winch; each responsible as an hardware stop limit in a case where the
skew goes beyond the software limit.

Personnel required

 Electrical / mechanical personnel

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Tool required

 Two 13mm spanner wrench

Procedure

 Remove the two skew limit switch stoppers from each of the skew
winch (four stoppers in total).
 Switch on the drives and check that maintenance mode is inactive.
 First trolley forward to about 1.00 meter.
 Lower the spreader to the sill beam level, in order to use the sill beam
as a reference to check the horizontal straightness of the spreader.
 Skew the spreader until it is horizontally straight, also using the sill
beam as a reference.
 Enter maintenance password and go to the skew page.
 Select skew motor 1 to activate the motor.
 Select calibrate on the page, the motor skew position changes to “0.0”
after calibration.
 Select skew motor 2 to activate the motor.
 Select calibrate on the page, the motor skew position changes to “0.0”
after calibration.
 Now, go to the main page on the touch panel.
 Select “angles” as one of the screen displays (this includes skew angle
positions), the skew position should be “0.0 degree” now
 To check the calibration, skew full clockwise, the skew operation
should stop automatically when the skew position reaches a value of
“5.6 degrees”.
 Skew full counterclockwise, the skew operation should stop automati-
cally when the skew position reaches a value of “-5.6 degrees”.
 Return skew to the 0.0 degree position (we can also use the skew reset
button). This is now the spreader primary position at 0.0 degree.
 If the check does not work as described above repeat the calibrate pro-
cedure again.

Skew hardware stop limit

 First, set the limit switch actuation levers of switch for both winch one
and two, so that the lever roller side is down; as seen below.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

Mark point

Figure 32 Skew hardware stop limit switch with the actuation lever positioned

 Mark winch one and two position just under the limit switch lever
(this is to help note the direction of winch rotation), see the figure
above.
 Skew full clockwise until skew position software limit is reached, 5.6
degrees.
 Position and tighten the stopper of both skew winches, so that the
stopper will activate the switch if it skew goes past the software limit.
 Now, skew full counterclockwise until skew position software limit is
reached, -5.6 degrees.
 Position and tighten the stopper of both skew winches, so that the
stopper will activate the switch if it skew goes past the software limit.
 Now, skew the spreader back to the “0.0 degrees” position.

On completion of the skew set up and the spreader is set to skew zero (0.0)
degree position, we will notice that each limit switch actuation lever will
be just in the middle of the two stoppers on each winch. Now that set ups
have now been completed, we are can now proceed to checking the
spreader functions.

6.6.5 Spreader function test

The spreader is normally factory tested and should be in good working

condition before it is transported. Basically, we will only need to check all
the spreader devices. Also depending on the project, the spreader arm can
be set to four different positions: 20 foot, 30, foot, 40 foot and 45 foot po-
sitions. All selection options are available on the crane but in this proce-
dure only the 20 foot and 40 foot positions are discussed.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Procedure

 Switch on spreader switch, M-S477.

 Switch on the drives.
 Lower the spreader to about 0.50 meter.
 Switch on spreader main isolator switch.
 Open spreader cubicle to switch on all circuit breakers.
 Check that spreader emergency stop is deactivated.
 On the right hand console, push the “40 foot” button to extend.
 After full extension of the spreader, push the “20 foot” button to re-
tract the spreader.
 Extend the spreader to 40 foot, push the spreader emergency switch
during the extension operation to test the emergency switch.
 Release emergency and retract spreader back to 20 foot position.
 Note and fix any problems that may occur.

Now, all operational tests, calibrations and set ups have been done and
completed. Before leaving the cabin, we have to raise the spreader up to
about 13 meters height and check that trolley is at trolley gate position.

6.6.6 Spreader flippers and Greasing

The spreader is normally delivered to the erection site without the flippers
attached to it. Hence, the flippers are to be attached at this stage. To do
this, the spreader has to be lowered to a workable height and then the flip-
pers can be fixed to the spreader.

Some mechanical parts of the crane are to be greased in order to aid swift
movement of the mechanical parts and also prevent rust. These parts are
greased using special grease types, therefore it is very important to ensure
that only the specified grease types are used when greasing. The parts to
be greased include: hoist ropes, hoist drums grooves, skew ropes, spreader
chain, trolley wheel bearings, skew machinery bearings, gantry bogie king
pin bearings, gantry wheel bearings and electrical room door. However
some of these parts may have been greased already during the cranes erec-
tion.

After the tasks above have been completed, the commissioning phase has
now reached about ninety percent completion (90%).

6.7 Interlocks and safety tests

This testing process stage involves testing the crane interlocks and covers
the remaining 10% of the commissioning phase. The interlocks are electri-
cally triggered functions of the crane which acts as a form of safety feature
for the crane. These interlocks are controlled by both hardwired control
and software program. There are different interlock functions on the crane
for the different operational functions of the crane, they include: gantry in-
terlocks, trolley interlocks, hoist interlocks, spreader interlock and emer-
gency stops. We will also inspect other operational safety features of the

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
crane such as the crane SWL, overload test, and speed test (with load and
without load). In order to complete this stage, we will have to make use of
a “test specification manual” (see appendix 3). The manual includes crane
safety tests and other tests that must be done to certify the crane quality.

The specification manual is divided into six chapters and each chapter will
be further described separately. Note that the test specification manual
used during this test is usually the same used during the final test with the
customer. This specification manual is a standard test manual developed to
test all RTGs before they are delivered to the customers. In the following
chapters, we will see the procedures of how to perform the tasks in the
specification manual. A minimum of 2 personnel is required for the com-
pletion of the tasks during this stage. The use of basic tools such as screw
drivers, side cutters and pliers may also come in handy at some point.

Figure 33 Simple interlock and safety test process flow

6.7.1 General safety devices

First we will start with the inspection of all general safety devices on the
crane, these are: emergency stops, hazard plates and warning horns. To
perform the emergency stops inspection, the drives will be switched on,
any of the crane operations will be performed and then the emergency stop
will then be pushed during the operation. Note that this test should be per-
formed only in crane normal operation mode and not maintenance mode.
Only use maintenance mode when specified.
Procedure

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Emergency stops

 Switch on the drives from the operator’s cabin.

 Slowly gantry the crane to any desired direction, and while perform-
ing the gantry operation push the operator’s cabin E. stop switch (R-
S8).
 The drives should shut down after pushing the E. stop and stopping
the gantry operation.
 Release the E. stop and start the drives to repeat the test with all other
crane E. stops.

Diesel emergency stops

 Switch on the drives from the operator’s cabin.

 Slowly perform any of the crane’s basic operation and push the diesel
emergency stop, D-S471, in the operator’s cabin.
 This will cause the diesel generator engine to shut down.
 Restart the engine and repeat the steps above to test the diesel E. stop
at the diesel panel.

Next is to check that all the hazard plates are present at their respective lo-
cations on the crane. The operator cabin’s warning horn and travel alarm
can be inspected in parallel with the emergency stop inspections.

Warning horn and travel alarm inspection

 Switch on the drives.

 Press the warning on button on the right joystick and listen to hear the
horn sound.
 Gantry the crane to any direction. During the operation try to listen for
the travel alarm sound. There is one alarm located at each bogie cor-
ner.

6.7.2 Hoist safety

This check involves simulating the specific faults in order to confirm that
the devices and software commands are triggered when a fault occurs.
Some tests at this stage also require that the hoist limit set up is completed.

Fault test procedures

Hoist motion prohibited if hoist brake(s) not released

To also perform this task, a simulation is required and this can be done us-
ing either hoist 1 or hoist 2 brake modules, A1-G7 or A2-G7 respectively.

 First, check that the drives are off

 In the trolley cubicle E2.1, remove the fuse from any of the brake
modules, A1-G7 or A2-G7.
 Switch on the drives from the operator’s cabin.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 With the joystick try hoisting in any direction.

 A motion prohibited fault should display, stating that; a hoist brake is
not released.
 Once confirmed, switch off the drives and return brake module fuse.

Over speed switch

For this task, any of the hoist drive inverters can be used: AR1-A1 and
AR2-A1. Also avoid touching any of the cards with bare hands as this may
damage the electronic devices on the card. An electrostatic discharge hand
glove can be used when removing the card from the inverter.

 Hoist up the spreader to height of about 11 meters.

 Switch off the drives and check that the hoist inverters, AR1-A1 and
AR2-A1 are off.
 Open the cover of any of the inverters to access the speed supervision
card unit.
 Configure the dip switch setting to set for over speed trip.
 Switch on the drives from the operator’s cabin.
 With the joystick try hoisting in any direction.
 A hoist speed supervision fault should display while hoisting, there-
fore preventing and stopping the hoist operation.
 Switch off the drives and wait until the inverters turns off.
 Return the speed card unit dip switch setting back to normal
 Close the inverter cover

Other tests

 Switch on the drives from the operator’s cabin

 First, hoist down at full speed and continue to the hoist down until the
speed slows down to confirm “Lower slowdown”
 After the hoist slows down, continue to hoist down until the spreader
touches the ground.
 Use the slack rope bypass button and still hoisting down to slack the
rope.
 Hoisting should stop when the down limit is reached to confirm
“Lower normal stop rotating limit switch”.
 Now, slowly hoist up and continue until the spreader does not touch
the ground anymore, at spreader height of about one meter.
 Hoist up at full speed until the speed slows down to confirm “Upper
slowdown”.
 Continue to hoist up until the software stop limit is reached.
 Enter the maintenance password, navigate to hoist limit page and acti-
vate the SW bypass.
 Continue to hoist up until the up stop limit is activated to confirm
“Upper normal stop rotating limit switch”.
 Now, switch on the maintenance mode and once again continue to
hoist up until the hoist limit emergency stop is activated to confirm
“Upper emergency stop rotating limit switch”.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 When the check is complete, push the reset button in the trolley cubi-
cle.
 Switch on drives, deactivate the SW bypass, switch off maintenance
mode and lower the spreader.

6.7.3 Trolley traverse safety test

Procedure

 Switch on the drives from the operator’s cabin.

 Hoist up the spreader to height of about 13.50 meters.
 With the trolley at the access side end, traverse forward at full speed
towards the diesel engine side.
 Continue to traverse and check that the speed slows down when ap-
proaching the diesel engine side to confirm “Slow down limit, access
side”.
 Now enter the maintenance password, navigate to trolley page and se-
lect the “SW bypass” to activate bypass.
 Continue to traverse forward; to check that the trolley operation stops
at the end stop limit to confirm “End stop limit, access side”.
 Now remove the SW bypass to deactivate.
 Next, start to traverse backwards to the access side at full speed to
check the backward slow down and confirm “Slow down limit, diesel
engine side”.
 Continue to traverse backwards to trolley position to confirm “Trolley
parking position”
 Now select SW bypass to activate bypass.
 Start to traverse backwards to check that the trolley operations stops at
the end stop limit to confirm “End stop limit, diesel engine side”
 Traverse backwards to park position.
 Remove the SW bypass
 Traverse forward to about three meters and stop, check that trolley
side gate and the gantry side gate cannot open.
 Now, traverse backwards to trolley park position.
 Open the trolley side gate and try to traverse to any direction; the trol-
ley operation should be inhibited.
 Open gantry side gate and again try to traverse to any direction; the
trolley operation should be inhibited.

6.7.4 Gantry travel safety

Procedure

 Switch on the drives from the operator’s cabin.

 Put bogie selector switch to park position to change bogie position.
 Try to gantry the crane in any direction to confirm “Gantry travel
prevented if all bogies not in same mode” this operation should be
inhibited.
 Return bogies back to normal position.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Enter maintenance password and navigate to bogie single page screen.

 Switch on single mode and select any of the bogie wheels from the
screen.
 Raise the locking pin of the selected wheel up.
 Leave the pin in raised position and switch off single mode.
 Now, try to gantry the crane in any direction to confirm “Gantry
travel prevented if at least one locking device open” this operation
should be inhibited.
 Switch on single mode select the same wheel and put the locking pin
back down.
 Remove the E. Room access ladder from the rack.
 Try to gantry travel the crane in any direction to confirm “Gantry
travel prevented if E-house ladder not in rack”, this operation
should be inhibited.
 Put the E. room access ladder back to the rack.
 Open anyone of the diesel doors.
 Now, try to gantry travel in any direction to confirm “Gantry travel
prevented if not all diesel house doors closed”, this operation should
be inhibited
 Close the diesel door(s) opened earlier.
 Remove shore power plug from the socket, try to gantry travel in any
direction to confirm “Gantry travel prevented if shore power plug
is not stowed”, this operation should be inhibited.
 Put the shore power plug back in the socket.
 With the bogie position in normal mode, slowly gantry travel in any
direction.
 While travelling actuate corner, A, cat whisker switch to confirm “Cat
whisker limit switches”, the gantry operation should stop.
 Repeat the last step above to check cat whiskers at corners B, C and
D.
 To confirm “Ultrasonic sensor, forward detection approx. 6 m”,
create an obstruction about 60cm in front of corner A ultrasonic sen-
sor and slowly gantry travel in towards the obstruction.
 The operation should be inhibited, repeat the step for corners B, C and
D.
 Now slowly gantry travel in any direction, during the operation check
that the alarms and beacon lights at corners A, B, C and D are working
to confirm “Travel alarm bells and beacons”.

6.7.5 Load tests

Dynamic load test (125 % of S.W.L.)

The safe working load for the crane is 40LT but based on the specification
manual a 25 percent increase of load test has to be conducted. Hence, a
test load of 50 tonne load is needed for this test.

Note that the weight of the test load used also depends on the project, as
the value of the safe working load may be different. Therefore a different
weight value will be needed for this test in the case of another project.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Procedure

 Have a 50 tonne loaded container placed under the crane.

 Enter maintenance password on the CMS computer.
 Navigate to the CMS setting tab to enter the change for the crane
“maximum load” setting from 40LT to 50LT.
 Switch on the drives from the operator’s cabin.
 Lower the spreader on the loaded container and activate the twist
locks.
 Lift up the load container from the ground to a height of about 50cm
 Hold container at the height for about 5 minutes.
 Lower the container and release the twist locks.
 Change the load setting on the CMS back to 40LT.

Tests of overload protection (110 % of S.W.L.)

If a flat rack was used in the previous load test, it is easier to just reduce
the load on the flat rack for this test rather than changing the container (if
a container was used). A test load of about 44 tonne is needed for this test.

Procedure

 Place the 44 tonne load container under the crane.

 With the spreader pick up the load and hoist load up.
 An overload fault should be displayed because the load is more than
40LT; the hoisting up operation will be inhibited.
 Also check that the trolley operation is inhibited.
 Lower the load back on the ground and release the twist locks to raise
the spreader up.

6.7.6 Working speeds and accelerations

During these tests, the driving operations are done in a slightly erratic
manner. Therefore care must be taking when performing this procedure
and the test area should be cleared. Also when performing this test, either
hoist upward direction or downward direction can be done first and the
same applies to the trolley and gantry tests.

Hoist speeds / acceleration / deceleration procedure (without load)

 Switch on the drives from the operator’s cabin.

 Navigate to the hoist page on the CMS computer and click on the
“speeds” tab.

Hoist maximum speed

 First, drive the hoist to about 13 meters height.

 Hoist the spreader down at full speed by pushing the joystick to the
end.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 While the hoisting at full speed, check the hoist speed value reached
on the hoist speed page of the CMS; this should is the maximum
speed
 Compare the value above with the contractual speed value written on
the specification document.
 Hoist spreader up at full speed and also check that the maximum
speed value reached matches that in the specification document.

Note that this speed value can be changed from the settings page of the
CMS computer if the value is either lower or higher than the contractual
value required.

Hoist acceleration and deceleration

 Go to the desktop screen page of the CMS computer.

 Open new Microsoft offices excel worksheet.
 Press the “CART” button when prompted and a tool opens on the ex-
cel worksheet.
 In the “discrete values” box, by double clicking select A1 for the hoist
test (note that either A1 or A2 can be selected).
 In the time box enter 30 seconds and press the start button on the excel
worksheet.
 Now hoist up, pull the hoist joystick instantly (not gradually) from ze-
ro speed position to full speed position so as to check the hoist up ac-
celeration time.
 When hoist maximum speed is reached, instantly (not gradually) re-
lease the joystick from the full speed to zero speed position to check
the deceleration time.
 When the hoisting operation stops, press the “trend” button on the
CMS screen.
 An acceleration/deceleration time graph will be displayed on the
screen.
 Check that the acceleration and deceleration times match the contrac-
tual values. The graph can be closed after the check is done.
 Repeat these steps above but this time conduct the test to check accel-
eration and deceleration in hoist downward direction.

Hoist speeds / acceleration / deceleration procedure (with load)

This test is similar to the test previously done. The only difference is that
it has to be done with load. The weight of load stated in the specification
document should be used. In this case the weight is 40 tonnes. Use the
same procedure described for the hoist maximum speed and hoist accel-
eration and deceleration above, just ensure that the procedure is done with
the hoist handling the required test load.

Trolley traversing speed / acceleration / deceleration (without load)

With respect to this specification manual used, the trolley traversing test
without load in reverse direction and trolley traversing with load in for-
ward direction operations are both omitted in this specification document.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
However, this procedure will include details of the omitted checks stated
above since they may be included in other specification manuals for other
customers. When performing this test, it is a good practice to ensure as
much as possible that the trolley speed test is done in somewhere around
the mid-point of the main girder rails.

 Switch on the drives from the operator’s cabin.

 Navigate to the trolley page and click on the “speeds” tab on the CMS
computer.

Trolley maximum speed

 Hoist spreader up to about 13 meters height, in order to avoid too

much swing during the test, and maintain this spreader height
throughout this trolley procedure only if stated otherwise.
 From trolley gate position or from about one meter trolley position,
trolley forward until the maximum speed is reached.
 While at maximum speed, check the maximum speed reached from
the CMS computer and compare with the contractual value on the
specification document.
 Also trolley backwards (reverse) until full speed is reached, check the
maximum speed reached and compare the value with contractual val-
ue.

Trolley traversing acceleration and deceleration

 Go to the desktop screen page of the CMS computer.

 Open new Microsoft offices excel worksheet.
 Press the “CART” button when prompted and a tool opens on the ex-
cel worksheet.
 In the “discrete values” box, by double clicking select E1 for trolley
(note that either E1 or E2 can be selected).
 In the time box enter 30 seconds and press the start button on the excel
worksheet.
 Trolley forward instantly (not gradually) from zero speed position to
maximum speed position to check the acceleration time.
 When trolley maximum speed is reached, instantly (not gradually) re-
lease the joystick from the full speed to zero speed position to check
the deceleration time.
 When the trolley traversing operation stops, on the CMS screen press
the “trend” button.
 An acceleration/deceleration time graph will be displayed on the
screen.
 Check that the acceleration and deceleration times match the contrac-
tual values. The graph can be closed once the check is done.
 Repeat these steps but this time conduct the test to check acceleration
and deceleration in trolley traversing backward direction

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Trolley traversing speed / acceleration / deceleration (with load)

The test procedure for the trolley traversing without load is similar to this
trolley test with load; just as in the case of the hoist speed test. The pur-
pose is to check trolley speed with the specified test load weight. After
picking the load, ensure that the spreader is hoisted to a height of about 13
meters before starting the trolley speed test; the reason as already men-
tioned is to reduce the swing as much as possible.

Gantry travel speeds / acceleration / deceleration

This test procedure requires the use of a large area because during this test
procedure the crane will be driven to attain full speed in bogie normal po-
sition.

 Switch on the drives from the operator’s cabin.

 Navigate to the gantry page and click on the “speeds” tab on the CMS
computer.

Gantry travel maximum speed

 Hoist the spreader up to about 13 meters and traverse to about 1 meter

trolley position to ensure visibility to all gantry sides.
 Gantry to the right until maximum speed is reach.
 While at full speed check that the maximum speed value reached dur-
ing the travel is the same as the contractual value on the manual.
 Now, gantry full speed to the left and check that the maximum speed
value reached is the same as the contractual value.

Gantry travel acceleration and deceleration

 Go to the desktop screen page of the CMS computer.
 Open new Microsoft offices excel worksheet.
 Press the “CART” button when prompted and a tool opens on the ex-
cel worksheet.
 In the “discrete values” box, by double clicking select AR1 for trolley
(note that either AR1 or AR2 can be selected).
 In the time box enter 30 seconds and press the start button on the excel
worksheet.
 Gantry travel to the right instantly (not gradually) from zero speed po-
sition to maximum speed position to check for acceleration time.
 When maximum speed is reached, instantly release the joystick so that
the gantry travel speed reduces to zero, to check for deceleration time.
 When the gantry travel operation stops, on the CMS screen press the
“trend” button.
 An acceleration/deceleration time graph will be displayed on the
screen.
 Check that the acceleration and deceleration times match the contrac-
tual values. The graph can be closed once the check is completed.
 Repeat the steps described above but this time gantry travel to the left
to check acceleration and deceleration of gantry travel in the left di-
rection.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
6.7.7 Spreader trim

The spreader trim operation is one which simply involves the operation of
one hoist motor at a time depending on the side of the spreader being
trimmed. There is also a certain trim angle that the spreader must reach
when trimmed which also correlates with a certain length measurement.
This measurement must be checked to confirm that the required trim angle
for the operation can be reached at all times. Note that the spreader meas-
urements checked during this procedure is done using the spreader twist
lock corner as the datum point.

Procedure

 Switch on drives from the operator’s cabin.

 Lower the spreader to about 1,5 meters. Ensure that the spreader is
leveled and at zero trim position.
 Extend the spreader arm 40 foot position.
 At the right side of the spreader, measure the spreader distance to the
ground level, A.
 Slowly trim the right side of spreader down to its full trim position.
 Measure the new spreader position to the ground level, B.
 Find the difference between values A and B, the value must be the
same as the contractual value.
 Also confirm from operator’s monitor screen and CMS that the trim
angle is the same as the contractual value.
 Trim the spreader right side back up to return the spreader to height,
A, measured previously.
 Confirm that the spreader is straight and that the spreader’s distance to
ground is A.
 Now, slowly trim the right side of spreader up to its full trim position.
 Measure the new spreader position to the ground level, B.
 Again find the difference between values A and B, the value must be
the same as the contractual value.
 Also confirm from operator’s monitor screen and CMS that the trim
angle is the same contractual value.
 Return the spreader back to leveled position.

6.7.8 Spreader skew

When the skew command is given, the spreader is seen rotating either
clockwise or counterclockwise depending on the direction command.
When the spreader is skewed, the skew angle can be seen on the operator’s
monitor screen and on the CMS. This spreader rotation is also equivalent
to a certain length when measured and should also be confirmed. To do
this procedure, a straight object such wood of dimension, of about 20cm
by 20cm by 60cm is needed. There is no special object for this, so if we
get anything close to that dimension, that should also be usable. The im-
perative thing is that the object should have a straight edge and should be
long enough for its purpose.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Procedure

 Switch on the drives from the operator’s cabin.

 Traverse forward a bit to create some gap for the spreader when
skewed.
 Lower the spreader to a height of about 1 meter from the ground level.
 Extend the spreader arms to 40 foot position.
 Ensure that the spreader is at zero skew position and place the wood
straight side at flipper C corner of the spreader, so that the wood
straight edge rests on the flipper.
 Once again, ensure that the spreader is steady and not swinging while
the wood rests on the flipper.
 Now, slowly skew the spreader clockwise to the maximum skew posi-
tion while the wood remains stationary.
 Wait for the spreader to stop swinging.
 Now measure the distance between the wood and the flipper (at its
new position).
 Confirm that the value measured is the same as mentioned in the spec-
ification document. Also confirm that the skew angle shown on the
operator’s screen and the CMS.
 Return the spreader back to skew zero position and wait until the
spreader is steady.
 Place the wood straight side at D corner of the spreader.
 Slowly skew the spreader counterclockwise to the maximum skew po-
sition while the wood still remains stationary.
 Wait for the spreader to stop swinging.
 Now measure the distance between the wood and the flipper (at its
new position).
 Confirm that the value measured is the same as mentioned in the spec-
ification document. Also confirm that the skew angle shown on the
operator’s screen and the CMS.
 Finally, return the spreader back to skew zero position.

6.7.9 Gantry wheel testing and spreader tests

The gantry wheel testing to be conducted at this stage is the same as that
conducted earlier, during the bogie turning test at the “operational test”
stage. Therefore these tests have been done already and a repetition will
not be necessary at this stage. The spreader tests will also not be necessary
to repeat since the operation has already been done several times.

The spreader interlock test simply means testing the spreader emergency
stop functionality. To do this test, if the spreader arm is at 20 foot position,
extend the spreader arm to 40 foot position and push the emergency stop
during the extension operation.

Miscellaneous tests and visual checks include only visual checks of some
simple devices. For example, the floodlights only have to be switched on
to check if they are working, the fire extinguisher should be checked if it
has been place at its location and so on. Devices such as the intercom have

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
been already tested. Very important at this stage is to confirm that the oil
levels in the units mentioned are good and the areas to be greased have
been effectively greased. It is important to have done the insulation test
earlier so that any possible problems can be captured early. However, the
test values should be duplicated in the specification manual.

6.7.10 Endurance test (100 % of S.W.L. With spreader)

The endurance test can also be said as a reliability test. This test is done to
ensure that the crane work efficiently without problem for a specified pe-
riod of time. Usually, the endurance test done for eight hours and the crane
is expected to operate problem-free for eight hours. To perform this test, a
considerable large space is needed and test load(s) are required. The aim is
to basically run the equipment for several hours. When the crane is con-
tinuously operated for a long period of time for the first time, there is a
likelihood of the crane to experience infant problems. Any problems en-
countered should be fixed and the endurance test should be continued or
repeated if needed. Always refer to the specification documentation in use
to confirm what tests are required to be done during the endurance test and
the time agreed.

This test does not necessarily have to be performed now because an en-
durance test will be performed with for the customer. However, it is good
to run the crane for some few hours after all the tests are completed.

6.7.11 Accessories

This is basically the last set of task for this stage. Some of the accessories
are optional devices and are only installed if the customer request for these
additional devices. In other words, some tasks at this stage are optional
since the installation of these devices is dependent on the specification of
the crane ordered by the customers.

PA system, Intercom system and Camera system

PA system procedure

 In the operator’s cabin, connect the speaker wire to the amplifier, con-
nect microphone to the amplifier and connect PA system amplifier
power supply.
 Switch on the amplifier and set the selector switch to “intercom”.
 Speak to the microphone, and try to confirm that sound is produced
from the speakers.

Intercom system procedure

 First check that the intercom system operator’s cabin is on and that the
RJ45 cable is connected to the intercom unit in the checker’s cabin.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Dial the intercom speaker number to dial the speaker and speak to mi-
crophone to check if it is working. After the check remember to press
“C” to cancel the call.
 While another person is in the checker’s cabin, dial the intercom unit
in the checker’s cabin and communicate with personnel, after the
check cancel the call.
 Now, call the intercom unit in the operator’s cabin from the checker’s
cabin and test that the system also works.

Camera system procedure

 Check that the camera system monitor is switched and that there is a
video feed on monitor.
 Now, switch on the drives and put bogies to normal mode.
 Gantry crane to the left and check that the left side (corner C) camera
feed video feed in displayed on the monitor.
 Gantry crane to the right and check that the right side (corner B) cam-
era feed video feed in displayed on the monitor.

Note that there is a possibility of encountering some problems during the

testing stage described in this chapter but any problems or faults should be
fixed as soon as possible. When all tasks have been completed, the com-
missioning phase has reached a hundred percent (100%) completion.

6.8 Customer testing

This is the phase where the equipment has to be tested in the presence of
the customer. The purpose of the customer’s presence here is to conduct
checks on the crane while following predefined test procedure which has
been agreed upon both by Konecranes and the customer. There is a stand-
ard test specification document which in this case will likely be the same
as that which must have been used during the internal testing. The cus-
tomer can include some checks which they may want to be conducted dur-
ing the test (but this should have been agreed earlier before this test). The
customers will check that devices requested to be installed are present on
the crane and that all necessary operations work as they should, so that any
outage found can be fixed before handover of the crane.

The tests conducted include operational functions, interlocks and safety

tests, and so on. Basically, these tests must have been done earlier, in or-
der to avoid problems during customer testing, as this may prolong this
test phase than it should normally be.

7 CONCLUSION
In conclusion, as it has been stated through this thesis, we were able to ex-
plain what the two literature parts of this report stand for and how the re-
search method used during the project was suitable for the project. We
could see from the actual work documentation, how the knowledge on
process management was utilized during the thesis project. The author was

78
Standardizing the commissioning phase to improve RTG cranes product safety and quality
able to apply the process knowledge acquired to develop a process flow
and also set the right precedence for the activities carried out during the
process. Using research skills, the author was able to ask important ques-
tions related to the thesis project and learn more about the commissioning
phase. Therefore, the author was able to create a narrow path and focus in
order to achieve the thesis results. Being able to combine this literature
and research knowledge will lead to an improved process with products
(cranes) of standard quality.

Properly adhering to this procedure will aid in achieving a successful

commissioning. This procedure was written based on RTG 16WA, which
is the typical model of cranes which have been delivered to the West Afri-
can market. This however, does not mean that this procedure cannot be
used for other Konecranes’ RTG models. Furthermore, this afore-
mentioned model is different from the model that may be delivered to oth-
er parts of the world or even other cranes with the same model, but this
procedure can still be used for those cranes. Most differences with crane
models, RTG 16 or other types lie on the devices been used and even a
crane of the same model but different types may also be equipped with
different equipment. This will definitely alter the electrical drawings,
which means some additions to or subtractions from the electrical draw-
ings. The procedure also shows that customer satisfaction is put into con-
sideration during the process of assembling the RTG, starting from the de-
livery of the erection stage, erection of the crane until the commissioning
phase of the crane.

Furthermore, this thesis has provided better perspectives into the processes
involved in the commissioning phase and describe the activities for pro-
cesses in details. Hence, this documented procedure can also serve some
other important purposes, such as:

 the document can be used for training purposes about the commission-
ing phase, especially for new company employees and even for old
employees newly assigned to the RTG manufacturing department
 the document’s can be used as a manual that can be archived and con-
sulted upon whenever needed
 the document can be used as a manual for the commissioning engineer
and other site engineers to enable them follow the progress during the
commissioning phase
 the document also gives an assurance that commissioning has been
conducted to detail without leaving any stone unturned

In addition continuous development is one of the features of a good pro-

cess. This means that there can be areas within the commissioning phase
that can still be developed (and even further development of this proce-
dure). Examples of some development ideas the author suggests include:

 In the future updating the procedure so that it will cover all the acces-
sories that were not included into the project when this procedure was
written

79
Standardizing the commissioning phase to improve RTG cranes product safety and quality

 Making changes to the commissioning procedure document when

necessary, whenever there are any development changes that may af-
fect the commissioning procedure
 Finding opportunities to reduce the total time used during this phase.
This will be easy to achieve if the procedure is used as a guide con-
sistently.
 Overall, constant review of the document periodically.

Hence, Konecranes as well can benefit a lot from using this document as
their customers. Because this document explains the commissioning phase
in simpler details, that makes it easier for the technical personnel to easily
handle the process. Now the completion rate can be measured easily and
the whole process completed in a timely manner, therefore, translating it
into improved customer satisfaction.

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Standardizing the commissioning phase to improve RTG cranes product safety and quality

SOURCES
Container handling cranes 2013. Accessed 13th April 2013.
http://www.konecranes.com/equipment/container-handling-cranes

Equipments 2013. Accessed 8th April 2013.

http://www.konecranes.com/equipment

Haanpää, R. Trainer. Isaac. Interview 1.4.2013

James, R. & William, M. 2008. The management and control of quality.

7th edition. Mason (OH): Thomson/South-Western.

Konecranes business area 2013. Accessed 11th April 2013.

http://www.konecranes.com/about/business-areas

Konecranes history 2013. Accessed 10th April 2013.

http://www.konecranes.com/about/history

Konecranes industries 2013. Accessed 11th April 2013.

http://www.konecranes.com/industries/port-equipment-services

Konecranes service 2013. Accessed 9th April 2013.

http://www.konecranes.com/service

Konecranes strategy 2013. Accessed 13th April 2013.

http://www.konecranes.com/about/strategy

Nigel, S., Stuart, C., Robert, J. & Alan B. 2009. Operations and process
management: principles and practice for strategic impact. 2nd edition.
Harlow: Prentice Hall/Financial Time.

Port equipments and services 2013. Accessed 8th April 2013.

http://www.konecranes.com/industries/port-equipment-services

Professor Shridhara, K. B. 2010. Total quality management: text and cas-

es. Revised edition. India: Himalaya Publishing House.

Qualitative and quantitative research 2012. Organisational Heartbeats. Ac-

cessed 20th April 2013.
http://www.organisationalheartbeats.com/topicinfo/research.aspx

Qualitative vs. quantitative research 2012. Accessed 20th April 2013.

http://www.aiuniv.edu/Student-Life/Blog/October-2012/Qualitative-Vs-
Quantitative-Research

Rubber tired gantry cranes 2013. Accessed 13th April 2013.

http://www.konecranes.com/equipment/container-handling-cranes/rubber-
tired-gantry-cranes

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Standardizing the commissioning phase to improve RTG cranes product safety and quality
Summers, D. C. S. 2009. Quality management: creating and sustaining or-
ganizational effectiveness. 2nd edition. Upper Saddle River: Pearson Pren-
tice Hall.

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Appendix 1
1/2

COMMISSIONING CHECKLIST

DATE:

CRANE #:
PROJECT #:
CUSTOMER:
COMMISSIONING ENGINEER IN CHARGE:

Checks to be completed before start up

Before starting up the crane, some checks have to be done prior. This start up phase is the first in the commissioning process and
it is a phase critical to others in the commissioning process. Therefore it is necessary to perform these tasks in order to avoid re-
work in the later parts of the process, as explained in the commissioning manual.

1 Inspect diesel generator oil filters

2 Inspect diesel generator fuel filters
3 Check diesel generator oil level and top up if necessary
4 Check diesel generator fuel level and top up
5 Check diesel generator coolant level and top up if necessary
6 Check that generator batteries measure up to 12 Volts
7 Check motor gear box oil level and top up if necessary
8 Inspect electrical wirings electrical cubicle for any loose connections

E. Room,
E2 trolley electrical cubicle
E4 operator's cabin
E6 (Access side)
E5

9 Check that the wind shield liquid tank is topped up

10 Ensure that all circuit breakers in the electrical cubicles are in off positions
11 All crane emergency stops are released
12 Diesel emergency stops are released
13 Isolator switch for crane O-Q1" and main isolator switch for machinery "O-Q2" are both in off position
14 Bogie tire air pressure inspected
15 Check that all programs needed to be downloaded are available
16 All materials needed for commissioning are available

Checks to be completed during and after start up

This part of the included checks that should be conducted after start up has been completed. Doing this will help to confirm
that the start up phase has been conducted successfully and we can now proceed to the testing phase, as explained in the
commissioning manual.

1 Diesel generator started and running

2 All domestic loads are switched on
3 Programs have been downloaded and are running

PLC program
Can bus program
Proface panel program

4 CMS settings

Emergency stops selection

Crane "config" settings

5 All necessary fibre optic are connected and termination resistors and bus addresses checked
6 All machinery loads are on
7 CMS documents have been replaced with the correct documents of recent versions
Standardizing the commissioning phase to improve RTG cranes product safety and quality

Appendix 1
2/2

Checks to be completed during and after operational test

These tasks are to be conducted after the operational tests have been completed. The operational tests are done in order to check
the operational functions of the crane after start up. This stage of the process is explained in the commissioning manual.

1 Emergency stop circuit works

2 Bogie encoder has been calibrated
3 Bogie turning operation have been checked
4 Bogie gantry operations have been checked
5 Hoist operations works
6 Trolley operations works
7 Skew operation works
8 All limit switches actuation lever have been set and properly adjusted

Cat whicker limit switches

Diesel doors limits switches
Ladder limit switch
Shore power limit switch
Operator's cabin gates

9 Drives can be switched on

Checks during and after the crane set up

These checks are to be conducted first after the crane set up and then after internal testing as explained in the manual (meaning
after completing the tests using the test specification manual) explained in chapter 6.6 and 6.7 of the commissioning manual.
The intent of these checks is to ensure that the crane has been successfully tested in all areas before testing with the customer.

1 Check that the hoist limits set ups have been completed
2 Check that load cell calibrations have been completed
3 Check that the trolley limit set ups have been completed
4 Check that skew setups completed
5 Spreader test completed
6 Spreader flippers installed
7 Interlock and safety test completed according to the test specification manual
8 Rated load on spreader is used for testing
9 Accessories installed and tested

RTG IS NOW READY FOR CUSTOMER TESTING / ACCEPTANCE TESTING

COMMISSIONING ENGINEER SIGNATURE:_______________________________

PLACE AND DATE:______________________________________

Standardizing the commissioning phase to improve RTG cranes product safety and quality
Appendix 2

PROFACE PANEL POGRAM DOWNLOAD POCEDURE

This appendix page is intentionally left blank because it contains

company’s confidential information

Appendix 3
Standardizing the commissioning phase to improve RTG cranes product safety and quality
CRANE TEST SPECIFICATION MANUAL

This appendix page is intentionally left blank because it contains

company’s confidential information