Section
13 Testing, marking and surveys
13.1 Testing
13.1.4 The test procedure and test loads are to be submitted to the responsible LR plan
appraisal office for approval.
13.1.5 Testing and examination shall be carried out in accordance with the requirements of
this sub-Section and the agreed Inspection and Test Plan (ITP).
13.1.7 For A-GU type systems (providing unrestricted access) the initial overload tests and
subsequent periodical overload tests are to be carried out using the test loads as
defined in the following:
- A-GU gangway integrity test
The test load shall be applied uniformly along the completely extended
gangway with the test load per square metre defined as follows:
where
FT = 1,5 = test load
factor
UDLP = 360
kg/m2
This integrity test is only required
at the initial survey; the test may be carried out at the manufacturer's
works and does not need to be repeated on board.
- A-GU system test
- For A-GU type systems which are not
designed to carry personnel in the cantilevered position, the test
load is to be applied uniformly along the completely extended
gangway with the test load per square metre defined as follows:
where
TLA-GU.b.i.l = test load, in
kg/m2
FT = 1,5 = test
load factor
g = 9,81
kg/m2
Wgw =
total dead load of the gangway, in kg
Lgw = length of gangway from heel to tip,
in m
Bgw = effective width
of gangway (see
Ch 1, 1.10 Terms and definitions 1.10.9 for a
definition of the effective width), in m
Alternatively, the test load may be applied at the gangway tip
and is defined as follows:
where
TLA-GU.b.i.2 = alternative test load, in
kg
The designer/manufacturer needs to
evaluate whether it can be ensured that the gangway cannot be
used in the cantilevered position. If this cannot be ensured the
system needs to be designed and tested as a cantilevered system
as defined in Ch 1, 13.1 Testing 13.1.7.(b).(i).
- For A-GU type systems which are
designed to carry personnel in the cantilevered position, the test
loads are to be applied at the gangway tip and are defined as
follows:
where
TLA-GU.b.ii.1 = test load, in kg
Alternatively, the test loads may be applied
uniformly along the completely extended gangway with the test
load per square metre defined as follows:
where
TLA-GU.b.ii.2 = alternative test load, in
kg/m2
If the test load
TLA-GU.b.ii.2 is chosen to be applied
along the completely extended gangway, the test as defined in
Ch 1, 13.1 Testing 13.1.7.(a) may be
omitted.
The gangway shall be in the cantilevered position in
both cases (i) and (ii) during the overload test.
Table 1.13.1 Test loads – Overview
| Type of load test
|
OPTS designed to carry personnel in cantilevered
position
|
A-GU
(Access - Gangway Unrestricted)
see Note
1
|
A-GR
(Access - Gangway Restricted)
see Note
1
|
| Gangway integrity test (A-GU only)
|
---
|
TLA-GU.a =
FTUDLP
see Note 2
|
---
|
| OPTS test
|
No
|
see Note 2
or
see Note 3
|
---
|
| Yes
|
see Note 4
or
see Note 5
|
see Note 4
|
Note 1:
- Test load factor: FT = 1,25 for
A-GR systems and FT = 1,5 for A-GU
systems
- Uniformly Distributed Load – Personnel:
UDLP = 360 kg/m2
- Total dead load of the gangway, in kg:
Wgw
- Length of gangway from heel to tip, in m:
Lgw
- Effective width of gangway, in m:
Bgw:
- Safe Working Load – Personnel, in kg:
SWLP
- Safe Working Load – Cargo on Gangway,
in kg: SWLCG:
Note 2: The test load shall be applied uniformly along the
completely extended gangway.
Note 3: Alternatively, the test load may be applied at the
gangway tip.
Note 4: The test load shall be applied at the gangway tip.
Note 5: Alternatively, the test load may be applied uniformly
along the completely extended gangway.
|
13.1.8 For A-GR type systems (providing restricted access) the initial overload test and
subsequent periodical overload tests are to be carried out applying the overload
test load as defined in the following at the gangway tip:
where
|
TLA-GR |
= |
test load, in kg |
|
FT |
= |
1,25 = test load factor |
|
Wgw |
= |
total dead load of the gangway, in kg |
|
SWLP |
= |
safe working load, personnel, in kg |
|
SWLCG |
= |
safe working load, cargo on gangway, in kg |
The gangway shall be in the cantilevered position during the overload test.
13.1.10 Overload test loads deviating from the above will be specially considered.
13.1.12 During overload testing of the OPTS all its possible operating motions
(e.g. slewing, telescoping) are to be carried out at low speed. The load test shall
extend over all operational modes and configurations of the system. Any motion
compensation system (MCS) is only to be engaged during overload testing in case the
MCS of the OPTS has been designed to withstand the test loads as indicated in Ch 1, 13.1 Testing 13.1.7 and Ch 1, 13.1 Testing 13.1.8 in order to avoid overloading the
MCS while being tested. The application duration of the test load shall be twice as
long as the time required to move the OPTS from its stowage position to the target
structure (considering a fully completed landing operation). Alternative durations
of the application of test loads will be specially considered. The overload testing
needs to be carried out on board the mothership. The overall displacement of the
OPTS due to the applied overload shall be measured at the gangway tip and shall be
less than the displacement limits as defined in Table 1.5.1 Displacements limits.
13.1.13 The OPTS is further to be tested with its SWLP and/or
UDLP and SWLCG being applied under all
design working conditions at maximum related design speeds and with any motion
compensation system activated and also de-activated. Both passive and active
compensation modes (if any) shall be tested.
13.1.14 The OPTS shall be subjected to a full functional testing regime for
normal operation during the initial survey ( see
Ch 1, 13.3 Initial survey of new installations), covering
the following items as a minimum:
- electrical systems (including failure testing according to an
approved test schedule derived from the FMEA);
- control systems (including failure testing according to an
approved test schedule derived from the FMEA);
- communication systems;
- safety systems;
- limit switches;
- monitoring systems (if applicable);
- landing arrangements and systems; and
- slewing, telescoping and luffing arrangements and systems.
13.1.15 The OPTS shall be subjected to a full functional testing regime for
emergency events during the initial survey ( see
Ch 1, 13.3 Initial survey of new installations), covering
the following items as a minimum:
- overload protection systems;
- alarm systems;
- emergency disconnection (lift-off) systems;
- emergency retraction/disconnection systems;
- emergency systems;
- redundant and redundancy systems and arrangements; and
- emergency stop.
13.1.16 The functional test during the initial survey ( see
Ch 1, 13.3 Initial survey of new installations) shall
extend to cover the motion compensation system either by:
- Testing by simulation, under the following conditions:
- The motion compensation system may be tested by
factory-based simulation, if it can be demonstrated that the
simulation will not fall short of the dynamic loading and behaviour
of the OPTS supporting mothership.
- The whole range and location of possible loads
(UDLP, SWLP,
SWLCG) shall be taken into consideration in
the simulation.
- It shall further be demonstrated that the motion
compensation performance can also be properly tested.
- The system shall be tested taking account of the
maximum significant wave height the OPTS is required to perform
under.
- Testing in open sea conditions:
- The motion compensation system may be tested in open
sea conditions.
- The whole range and location of possible loads
(UDLP, SWLP,
SWLCG) shall be taken into consideration in
the open sea testing.
- The system shall be tested taking account of the maximum
significant wave height the OPTS is required to perform under.
The test results are required to be recorded and documented. Alternative testing
methods will be specially considered.
13.1.17 Load testing (including any SWLP and/or
UDLP and SWLCG tests) and functional testing
shall be carried out without persons on the OPTS and/or gangway.
13.1.18 No persons shall be in the hazardous zone around the OPTS which will be affected by a
failure of the OPTS during the load and functional testing.
13.1.19 After functional, SWLP and/or UDLP
and SWLCG (as applicable) and overload testing, the OPTS is to be
thoroughly examined for deformations or other defects.
13.1.20 The load testing of the OPTS is to be repeated in the following circumstances using
the approved test loads and procedures as defined in the above:
- Following any structural repair, alteration or re-erection of the
appliances;
- at every fifth Annual Thorough Examination; and
- in accordance with the requirements of the National Administration.
13.2 Marking
13.2.2 Each OPTS is to be clearly and permanently marked at the Operator's
control station with a minimum of the following information:
- designer/manufacturer;
- product name;
- SWLP and/or UDLP and
SWLCG, ideally with a pictogram showing the location of
application of the operational loads;
- access type (unrestricted/uncontrolled or restricted/controlled);
- maximum number of persons on the waiting platform (if any);
- maximum number of persons simultaneously allowed anywhere on the gangway (for
restricted access);
- any restrictions or limitations of safe operation;
- minimum and maximum operational design luffing/inclination angles;
- minimum and maximum length considering the telescopic extension;
- stowage configuration and arrangement;
- manufacturing date;
- an identification mark to enable the system to be readily related to its
appropriate test and certification or classification certificate; and
- with the mark of the Surveyor who witnessed the load and functional
testing.
13.2.3 Limits of telescopic, slewing, luffing motion are to be marked on the OPTS structure
(e.g. maximum and minimum gangway length, range of gangway inclination, etc.).
13.2.4 Each OPTS shall be clearly and permanently marked with at least the following
information at the waiting area and on each end of the gangway:
- maximum number of persons on the waiting platform (if any);
- maximum number of persons simultaneously allowed anywhere on the gangway (for
restricted access);
- any restrictions or limitations of safe operation;
- emergency procedures;
- alarms; and
- access limitations.
13.2.5 The marking language shall preferably be the English language.
Alternatively, and depending on the requirements of the Flag or Coastal State
Authorities, the language may, in addition, be that of the mothership’s crew.
13.2.6 Any interface areas between moving parts shall be marked with a warning pattern in
black and reflecting yellow.
13.2.8 The OPTS parts, components, machinery items, shall be marked with visual
danger signs in accordance with a recognised National or International Standard
(e.g. EN 842 Safety of machinery – Visual danger signals – General requirements,
design and testing or ISO 7010 Graphical symbols – Safety colours and
safety signs – Registered safety signs as considered appropriate), as
applicable.
13.3 Initial survey of new installations
13.3.3 The definition of critical, primary and secondary welds as given in Ch 12 Testing, Marking and Surveys, Table 12.3.1 Minimum requirements for
NDE of the Code for Lifting Appliances in a Marine Environment, July 2022 are redefined as follows for the application in an OPTS:
- Critical welds
are defined as welds where the failure of which may or
will result in harm to persons using the OPTS or in the partial or complete
loss of the OPTS, e.g. foundation/deck welds, slewing bearing/pedestal
welds, base frame welds, main gangway structural welds, walkway support
structural welds, waiting platform support structural welds, etc.
- Primary welds
are defined as welds directly applicable to floorings,
ladders, walkways, waiting platforms, handrails, suspended baskets,
personnel containments, etc.
- Secondary welds
are defined as non-critical and non-primary load-path
member welds (as defined under (a) and (b)) and/or which are not involved in
the prevention of harm to persons using the OPTS, e.g. service fittings
(e.g. electrical, lighting), maintenance equipment, etc.
13.3.4 If the OPTS includes a slewing bearing in its design, initial bearing clearances
shall be recorded by means of a rocking test after the initial proof load test. The
rocking test shall be repeated annually in accordance with the slewing bearing
manufacturer’s recommendations. Acceptable tolerances shall be as per slewing
bearing manufacturer’s recommendations.
13.3.5 The control system shall be subjected to failure testing according to an approved
test schedule derived from an approved FMECA.
13.4 Initial Survey of existing installations
13.5 Periodical thorough examinations
13.5.3 The interval for the thorough examination required for the OPTS and all associated
gear and machinery engaged in personnel transfer operations is six months.
13.5.4 The periodical thorough examination of the electrical arrangements shall be carried
out at the following intervals:
- annual visual inspection of cabling and equipment;
- annual examination of the earthing arrangements;
- annual visual examination of motors;
- five-yearly insulation tests of cabling and motors; and
- five-yearly testing of main circuit breakers (power supply).
13.5.5 The periodical thorough examination of the control arrangements shall be carried out
at the following intervals:
- annual simulation testing of highly critical failures (as identified in the
FMECA);
- five-yearly testing of the approved test schedule derived from the approved
FMECA;
- five-yearly testing of safety systems (e.g. emergency stop);
- five-yearly testing of alarms;
- five-yearly testing of sensors related to operational limits; and
- five-yearly overload testing of the OPTS.
13.5.6 The detailed requirements for the thorough examination of the OPTS and
associated loose gear are given in Table 1.13.2 6-Monthly thorough examination of OPTS.
Table 1.13.2 6-Monthly thorough examination of OPTS
| Item
|
Survey
|
| 0.
General
|
(a) The
following requirements for the 6-monthly thorough examination of
the OPTS shall be applied as applicable and as far as possible
depending on the actual design of the OPTS.
(b) If the design
is novel or deviating from the requirements in this Code the
scope of the thorough examination might need to be extended
to cover the essential items of the actual OPTS.
(c)
The thorough examination shall take into account
designer’s/manufacturer’s maintenance and inspection
instructions and recommendations.
|
| 1.
Certification
|
(a) Check
that certification issued by a competent body, exists for the
OPTS to be examined.
(b) Check the Register and/or the OPTS
initial and periodical thorough examination documentation
for any outstanding endorsements, recurring problems,
down-ratings, etc.
If there is no evidence that the
OPTS has ever been certified, the thorough examination is to
be declined and LR’s certification services for existing
OPTS may be offered.
(c) Check the Register for any
repairs or modifications.
(d) Check the maintenance
records.
|
| 2.
Arrangements
|
Check reeving arrangement are as shown in Rigging
Plan or designer’s/manufacturer’s manual. Check that the
arrangement of hydraulic cylinders (if applicable) is as shown
on the reeving diagram or appropriate plans.
|
| 3. Fixed
sheaves, axle pins and housings
|
(a)
Determine that the sheaves are free from cracks. The extent of
the examination is to be such that a reliable judgement can be
made. Depending on access, it may be necessary to dismantle the
item.
(b) Survey rope groove for scoring or uneven
wear.
(c) Check that lubrication arrangements are in
working order.
(d) Check security (keep plates, cotter
pins, etc.) of fixed axle pins.
(e) Check for free
rotation of sheave on axle pin.
(f) Check for
excessive wear of axle pin and sheave bush.
(g) Check
condition of housing and separation plates and for signs of
ovality in the pin holes.
|
| 4. Gangway heel pins and other pins in the main
load-path
|
(a) Check
lubrication for detrimental wear.
(b) Check security (keep
plates, cotter pins, castle nuts, etc.) of heel
pins.
|
| 5. Slewing
rings for OPTS
|
(a) Listen to the bearing during slewing motion for
any untoward noises. Also note the age of the bearing or its
operational hours (if possible) and check against guidance in
designer’s/manufacturer’s maintenance manual. Older bearings
will be more prone to problems.
(b) Check any
maintenance records for evidence of regular routine
maintenance.
(c) Check condition and
tightness (using a method recommended by the manufacturer)
of inner and outer bearing bolts, removing any protective
caps if fitted. Sample bolts may be removed at the
discretion of the Surveyor to check for the possibility of
stress corrosion cracking.
(d) Review the
results of the latest rocking test measurements and grease
sample analysis carried out in accordance with the
designer’s/manufacturer’s recommendations and check the
recommended limits for either wear or metallic particle
content are not being exceeded. This will give an indication
of the wear in the bearing.
These tests
are usually carried out annually.
(e)
Check the effectiveness of lubrication of the bearing.
(f) Additional inspections are to be carried
out where these are specified by the OPTS or slew ring
manufacturer.
(g) In case the OPTS is
also designed and used as a conventional offshore crane the
requirements of Ch 12 Testing, Marking and Surveys, Table 12.3.6 Annual Thorough Examination of
cranes (incuding derrick cranes) and launch and recovery systems for diving
operations, clause 6
of the Code for Lifting Appliances in a Marine Environment, July 2022 are
required to be complied with.
(h) Any
requirements of National Authority (i.e. Flag State) and/or
Coastal State Authorities are required to be complied
with.
|
| 6. Wire
ropes
|
(a) Confirm that appropriate wire ropes
certificates are on board (LA.4 or equivalent).
(b) Check the general condition of ropes by examining as
much of their length as is possible.
(c)
Check for broken or worn wires. Check for any signs of
internal and external corrosion. Check for changes in rope
diameter. Check for signs of damage and deformation (e.g.
kinks, birdcaging, etc.), or of thermal damage. In general,
the rope is to be replaced immediately, if any of the
discard criteria in ISO 4309 Cranes – Wire ropes – Care
and maintenance, inspection and discard are
exceeded.
(d) Inspect rope terminations,
splices, end fittings, etc. with particular attention to
broken wires at ferrule connections. Any serving on splices
is to be removed for the examination.
(e)
Liverpool splices are to be rejected on any rope where the
ends are not secured against rotation.
(f)
Before re-rigging ensure that the wire rope has been
lubricated.
|
| 7.
Structure and general
|
(a) Check structural bolts for tightness. Where
bolts have been replaced, they are to be of the same type, size
and quality as previously fitted.
(b) Check
pedestal and foundation bolts for signs of corrosion and
flange distortion.
(c) Check main welds
for cracks. Initially by visual examination but NDE can be
used at the Surveyor’s discretion.
(d)
Check welds between pedestal/foundation and the mothership.
Initially by visual examination but NDE can be used at the
Surveyor's discretion.
(e) Inspect the
structure for condition of coating. Inspect the structure
for corrosion, removing paint and carrying out hammer tests
as necessary. If considered necessary, the thickness of
structural items is to be checked by ultrasonic testing or
other suitable methods that do not affect the material or
condition of the structure.
(f) Check
base frame, gangway, walkways, guard rails, handrails,
stanchions, supporting pedestal (or foundation), for any
signs of damages, local indentations, buckling, cracks or
unfairness. Particular attention is to be given to
connections of chords and lattices, hydraulic cylinder
connections, sheave housing attachments, gangway tip, and
other areas where there is significant load input.
(g) Check connection between gangway, guard
rails, handrails and stanchions.
(h)
Check connection of flooring elements with the supporting
structure. Flooring elements and other parts in way of the
walking area shall not pose a tripping hazard.
(i) Check whether the gaps between moving parts
are not excessive posing a crushing hazard.
(j) Check sea-fastening/stowage arrangements
(if applicable).
(k) Check other items
reflecting the intension of the above list or similar to the
above consideration the actual design of the
OPTS.
|
| 8.
Shackles, links, rings, etc.
|
(a) Check loose gear items, can be identified
against appropriate certificates (LA.3 or equivalent).
(b) Examine under proper conditions and check
for cracks, deformation, wear, wastage or other defects.
Items are to be free from paint, grease, scale, etc.
(c) Confirm that the material is recorded on the
test certificate. The certificate should distinguish between
mild steel, higher tensile steel and alloy steel.
(d) Deformed shackles or shackle pins shall be
replaced.
(e) If the shackle pin is
renewed, the whole shackle is to be re-tested and
certified.
|
| 9.
Chains
|
(a) Confirm appropriate chain certificates on board
(LA.3 or equivalent).
(b) The chain is to be
taken to a suitably equipped workshop for examination and
examined after removal of paint, grease, scale, etc. and
wire brushing.
(c) Check for deformation,
wear or other defects. If links require renewal, the chain
is to be suitably heat treated and re-tested. Replacement
links are to be of equivalent material and strength to the
original.
(d) Confirm that material is
recorded on test certificate. The certificate should
distinguish between mild steel, higher tensile steel and
alloy steel.
|
| 10. Rope
drums
|
(a) At
least three turns of wire rope are to remain on the drum.
(b)
Check the effectiveness of wire rope anchorages.
(c)
Check drum for cracks and for defects liable to damage the
rope.
(d) Check the effective working of any fleeting
device fitted.
(e) Check drum flanges for bending or
distortion. This is particularly appropriate for multi-layer
spooling drums.
|
| 11.
Hydraulic arrangements
|
(a) Check hydraulic hoses, pipes, couplings,
actuators, filters, valves, measuring devices, control blocks
and other hydraulic components for leakage and/or damage.
(b) Check hydraulic pumps and motors for
leakage and/or damage.
(c) Check hydraulic
accumulators for leakage, deformation and/or other
damage.
(d) Check pre-fill pressure of
the hydrogen bottles, as applicable.
(e)
Check for correct oil levels.
|
| 12.
Hydraulic cylinders, winches, etc. and attachments
|
(a) Check condition of machinery systems.
(b) Check for leaks and condition of hydraulic
pipes and couplings.
(c) Check piston rod
for scoring and signs of deformation.
(d)
Check end pivot pins and bearings for any excessive wear and
deformation, and the security of the pins.
(e) Check that mounting brackets are free from deformation,
cracks or damage.
(f) Check safety
systems, such as limit switches and slack rope detection
systems.
(g) Check fasteners, pins, gear
boxes, shafts, bearings, lubrication, etc.
(h) Check condition of brake (e.g. pads, brake
linings).
|
| 13.
Electrical and control arrangements
|
(a) Check the Operator station and other operating
arrangements for suitable condition.
(b) Check
operation of audible and visual warnings.
(c) Check electrical arrangements in general and cabling
for state and secure connection.
(d)
Check effectiveness of limit switches.
(e) Check condition of electric motors.
(f) Check OPTS for safe operational behaviour as required
by the instructions for use.
(g) Conduct
earthing test, e.g. megger test.
|
| 14.
Re-testing
|
(a) Loose
gear is to be proof tested if repairs have been carried out
which affect its strength or if certificates are not
available.
(b) Re-testing of the OPTS is necessary at
five-yearly intervals and after repairs or modifications
have been carried out affecting the strength or otherwise as
required by the Surveyors. The test is to demonstrate
satisfactory operation, efficiency of overload and weight
load indicators, effectiveness of limit switches,
etc.
(c) It is essential that the OPTS is operated at
each thorough examination to check gangway luffing, slewing,
telescoping and other motions as applicable, and the correct
operation of associated limit switches for such motions. In
case an overload protection system is installed such system
shall also be checked.
|
13.6 Deferment and range of surveys
13.6.2 If permitted by the Administration (Flag State) the six-monthly thorough examination
date can be held within a time frame of ±3 months.
13.7 Damage surveys
13.8 Design changes or modifications of existing OPTS
13.8.1 Design changes or modifications of an already certified or classed OPTS are required
to be submitted for appraisal in order to maintain the validity of the certification
or classification.
13.8.2 The application of the design changes or modifications are in principle
to be carried out in compliance with Ch 1, 13.3 Initial survey of new installations.
The extent of the survey is to be agreed with the attending Surveyor.
13.9 Classification surveys
13.10 Thorough examinations after emergency situations
13.10.1 Emergency situations are to be clearly defined in the instructions for use and are to
be derived from the risk assessment. Emergency situations may result in loads which
are beyond the certified SWLP and/or UDLP or
other applicable SWL depending on the design and associated intended use.
13.10.2 In case the OPTS has experienced an emergency situation a thorough examination is to
be carried out in order to ensure that there are no damages or defects and that it
is safe to resume normal operation.
13.11 Non-permanently installed OPTS
13.11.1 OPTS which are not permanently installed on the mothership are required to be treated
as new installations for the project phase where the OPTS is installed on the new
mothership. All on-board testing related to the integration of the OPTS with the new
mothership (as required by this Code, including load testing) are to be
repeated.
13.12 Maintenance requirements
13.12.1 The designer/manufacturer shall provide a detailed maintenance manual covering all
components, parts and aspects of the OPTS.
13.12.2 The OPTS and their components (including associated winches, hydraulic cylinders,
loose gear, ropes, etc.) shall be properly maintained as per the requirements of the
designer/manufacturer as stated in the maintenance manual at required intervals.
13.12.3 Every OPTS is to be visually inspected once a week by the crew or Operator to ensure
they are at all times ready for immediate use.
13.12.4 A record of maintenance should be kept for each OPTS.
|