GÜRALP CRANE SYSTEM DIRECTIVES & STANDARDS 2017

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1 GÜRALP CRANE SYSTEM DIRECTIVES & STANDARDS 2017 DESIGN STANDARDS CRANE SYSTEM DIRECTIVES Safety of machinery Risk assessment LVD Test EMC Test QUALITY REQUIREMENTS for welding Mechanical Design Standard Electrical Design Standard Machinery (MD) Directive 2006/42/EC EN ISO 12100:2010 EN -ISO DIN FEM EN -ISO DIN FEM 305/2011/EU Construction Products Regulation ISO &EN ,2 Cranes - Bridge and gantry cranes EN A1 Limiting and indicating devices EN A1 Low voltage (LVD) Directive 2014/35/EU EN Welding coordination EN ISO Cranes - General design EN Rotating electrical machines EN Electromagnetic Compatibility (EMC) Directive 2014/30/EU EN Electro static discharge(esd) Welder Qualification EN ISO Crane safety - General design - Part 2: Load EN Safety of machinery - Safety-related parts of EN ISO Noise Emission by Outdoor Equipment Directive 2000/14/EC EN ISO EN Electrical Fast WPS EN ISO Rules For The Design Of Hoisting Appliances FEM Safety of machinery - Electrical equipment of EN Health and Safety Conditions Regulation for the Use EN Surge Transients Welding Procedure Qualification EN ISO & EN ISO Measures For Achieving Safe FEM Cranes - Controls and control stations EN EN Voltage dips,short interruptions Welding Operator Qualification EN ISO Power Driven Series - Security FEM Low Voltage Adjustable Frequency FEM EN 55011(Contuded emission) Ndt-personel EN ISO 9712 Hand And Power Driven Hoists For FEM Safety of machinery - Emergency stop EN ISO EN (Radiated emission) Joint preparation EN ISO &2 Cranes - Test and inspection procedures TS TS ISO rotating electrical machines (IP code); EN EN Contucted Immunity Inspection &Testing during welding EN ISO Steel wire ropes EN & CEN/TS Graphical Symbols For Control Devices FEM EN Harmonics Inspection &Testing after welding Cranes - Access EN Selection Of Lifting And Travel Motors FEM EN Flicker Ndt -general rules EN ISO Acceptance levels for NDT Cranes- Safe Use ISO Visual Testing EN ISO EN ISO 5817 Terminations for steel wire ropes EN ( ) Founding - Spheroidal graphite cast irons EN 1563 Radiographic testing EN ISO &2 EN ISO &2 Hook & Hook Traversen TS 2340 DIN DIN15402 Mechanical Design Standard Steel castings - Steel castings for general EN Ultrasonic Testing EN ISO 17640,10863,13588 & EN ISO 11666,15626,22825,232 Cranes- Wire Ropes ISO 4309 EN -ISO Cold formed EN Magnetic particle testing EN ISO EN ISO Cranes - Safety - Design - Requirements EN Cranes - Competency requirements for crane ISO Surface preparation and paint standards Quenched and tempered steels EN ,2,3 Makro &microscopic testing EN ISO EN ISO 5817 Cranes - Information for use and testing TS EN A1 EN A1 Cranes - Monitoring for crane design working ISO Surface preparation ISO 8501,ISO 8503 Case hardening steels EN Quality levels for cutting EN ISO 9013 Wheel shafts DIN Cranes-Classification TS ISO Paint application ISO Hot rolled products of structural steels EN ,2 Group of materials CEN ISO /TR Cranes; steel structures; verification DIN DIN Technical characteristics and ISO 7363 Lifting appliances; groove profiles for wire DIN Cranes - Tolerances for wheels and travel and ISO Wheel Group DIN DIN Crane supporting structures TS EN Classification Of Mechanisms ISO 4301 FEM Asymmetric wedge socket TS EN A1 Rules For The Design - Local Girder Stresses FEM Limit States and proof competence of steel EN Dimensions And Design Of Rope FEM Cranes - Stiffness - Bridge and gantry TS ISO Lifting Force Limiters For Controlling FEM Cranes-Training of drivers TS ISO

2 DNA of QUALITY

3 1.1 Raw Material Controls All raw materials are checked and approved by quality staff after than all following test; Dimentional checks (acc. standarts) Material Checks Visual Via NDT Methods Via Destructive test (Chemical analyses and mechanical tests)

4 2.1 Machining Process Controls All semi finished product are checked and approved by quality staff ; Dimentional checks (acc. drawings) o Machining process starts after first part approved by quality staff o Production goes on with periodically controlls by quality staff Note : We ll be set up SPC Controls Charts after traning process finished

5 2.1 Machining Process Controls All semi finished product are checked and approved by quality staff ; Dimentional checks (acc. drawings) o Machining process starts after first part approved by quality staff o Production goes on with periodically controlls by quality staff Note : We ll be set up SPC Controls Charts after traning process finished Welding Quality Acceptance Criteria : TS EN ISO 5817-B

6 2.2 Hoist and Bridge Production Controls After the control process all semi finished & and finished product (Endcarriages,bodies etc) are labeled and identified by quality staff in this wise it s provided the separation of non-conforming products with the appropriate product at shop floor.

7 2.3 Painting Process Controls (Acc. to TS EN ISO 12944) All painted products controlled and results recorded as in (F105_2 ) PAINT TEST REPORT o Dın-cup 4 viscosity test (Paint Prepreparation) o Surface Treatment Controls (Acc to ISO ) o Visual controls (Colour, paint defects etc.) o Paint Thickness Controls o Cross cut adhesion test ( acc to ISO 2409) DIN CUP 4

8 3.1 FINAL CONTROL and LOAD TESTS Acc to TS EN A1 (1.1 Dynamic, Static 1.25) standart all finished hoists are tested at final load test station. Test results are documentated as in FINAL TEST REPORT (F074_3)

9 3.2 FINAL TESTS All finished hoists, endcarriages etc. are throughout examinated by quality staff Test results are documentated as in FINAL TEST REPORT (F074_3)

10 All finished systems are controlled via checklist by quality staff acc to product list Results are documentated as final shipment control checklist. and also items proof photos are taken and recorded

11 After assembly operation at site all systems are made load tests acc to TS EN A1 (1.1 Dynamic, Static 1.25) All required measurements are taken than results are recorded as in F056_4_StartupAndJobFinishingForm

12 Self Desinged Load Test Station Portative Hardness Measurement Device (Krautkramer MIC 20) Portative Spectrometer Analysis Device (Test Master Pro) Ultrasonic NDT Test Device (Krautkramer USM 35 X) Magnetic NDT Test Device(Magnaflux) Penetrant Test Kit (LVD) Low Voltage Directive Test Device (Metrel MI 2094) Total Station Leika TS 09 Plus Dimensional measuring instruments Nivo Lasermeter Caliper Mikrometer Comparator Other Measurement Devices Elcometer Paint Thickness Measurement Device Temperature and humidity meter Multimeter

13 LVD Low Voltage Test Before and after heat treatment raw material hardness controls Raw material internal structure discontinuity control with Ultrasonic Test Construction 3D measurements Raw material analysis via spectrometer Static ve Dinamic Load Tests Material nondestructive inspections Inspection of machined products

14 GURALP CRANE HAVE INVESTED NEW INVESTMENTS IN THE QUALITY LABORATORY THAT HAS BEEN MADE TO IMPROVE THE IMPROVEMENT OF HIGH PRODUCT QUALITY AND STANDARDS. 1. Zwick Z250SR Tensile Test Equipment

15 2. Portable 3D (CMM) Dimention Control Equipment

16 3. MICROHARDNESS MEASUREMENT DEVICE

17 4. STEREO MACROSCOPE Welding macro controls Raw material macro structure controls ( Nodular cast iron etc..) Investigation of failure surface Welding Macro Dimentional Controls Cast iron nodularity and flake analysis Surface examination, coating thickness measurement

18 VT LEVEL 2 PT LEVEL 2 MT LEVEL 2 UT LEVEL 2 RT LEVEL 2 68 certificated welding operator acc. to approved by TUV AVUST. (EN ISO , ISO 14732) EN ISO Welding Competency Certificate_ TUV AVUST. WPQR approved by TUV Approved welding procedures acc to ISO Gas Shielded Metal Arc Welding 111- Metal Arc Welding via Covered Electrode 121- Submerged Arc Welding

19 Visual Inspection (VT) Penetrant Inspection(PT) Magnetic Particles Inspection (MT) Ultrasonic Inspection (UT)

20 All finished hoists are tested at final load test station Acc to TS EN A1 (1.1 Dynamic, Static 1.25), FEM.1001 (1.25 Dynamic, Static 1.4)

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22 CERTIFICATES TS EN ISO 9001:2008: Quality Management System ISO /EN :Desing production construction and erection of steel in compliance with the requirements EN & 2 Welding Competency Certificate TS EN Cranes - Bridge and gantry cranes HYB Service Qualification Certificate Voluntary verification of conformity According to machinery directive 2006/42/EC Certificated welders approved by certified company Trademark (GÜRALP) FEM Membership Certificate Notified Body TÜV TÜV TÜV TSE TSE TUV-NORD TÜV TPE İSDER

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27 1. In Güralp, Records related to faults in all processes are recorded and monitored, root cause analysis is performed, and permanent actions and mistakes are prevented from being repaired (non-conformity follow-up tables) 5 Neden Analizi - 5 Why Analysis Düzeltici F Corrective A Problemi tanımla Define problem Aksiyonların takip edildiği son tarih The current date of action follow-up A Schmalz ın taşıyıcı arabası ile bizim makinanın mapa delikleri uyuşmamaktadır NEDEN? / WHY? Tanımlanmış uygunsuzlukları araştırmak için bu yolu izleyin Use this path for the specific nonconformance being investigated Bu Yüzden/ Therefore Ana Sebep Root Causes * Talaşlı imalata parça resmi ulaşmaması * Ara bağlantı parçasının proje tarafından stok kodu bazında tanımlanmamış olması sebebiyle parça üretilmeden de üretim sonu kaydı yapılması * Özel ara bağlantı parçasının ayrıca stok kodunun olmaması sebebiyle sevkiyat listelerinde yer almaması TUSAS AN nolu işde standart ara bağlantı plakası sahaya gönderilmiş Bu Yüzden/ Therefore TUSAS AN nolu işin proje tarafından özel tasarlanan ara bağlantı plakası üretilmemiş Bu Yüzden/ Therefore 1) Proje netsist bazınd sağla NEDEN? / WHY? NEDEN? / WHY? Bu Yüzden / Therefore makine montaj bölümün standart makine toplamış Bu Yüzden/ Parça talaşlı imalatta kalmış Bu Yüzden/ Therefore Therefore NEDEN? / WHY? NEDEN? / WHY? Uygunsuzluğun neden saptanamadığını araştırmak için bu yolu izleyin Use this path to investigate why the problem was not detected Proje dosyası ulaşmadığı için iş makine montajı emrine göre yapılmış Bu Yüzden/ Therefore Talaşlı imalata parça resmi ulaşmadığı için parça talaşlı imalatta üretilmemiş A B NEDEN? / WHY? sevkiyat esnasında kontrolleri Sevkiyat kontrol listelerinde göre yapılmakta Bu Yüzden/ Therefore Bu Yüzden/ Therefore NEDEN? / WHY? NEDEN? / WHY? Bu Yüzden / Therefore Bu iş için tasarlanmış bağlantı A plakası sevkiyat listelerinde Bu Yüzden/ gözükmemektedir. Therefore 2) Proj NEDEN? / WHY? Sistemsel ana sebebi araştırmak için bu yolu b sağla izleyin Use this path to investigate the systemic root cause Bu Yüzden/ Therefore NEDEN? / WHY? stok kodu bazındaki parçalar üretim sonu kaydı yapılarak Bu Yüzden/ Bu Yüzden/ üretildiği netsiste kayıt altına Therefore Therefore alınmakta NEDEN? / WHY? NEDEN? / WHY? C Bu Yüzden / Therefore Parçaya ait stok kodu netsis üzerinde direk montajının içerisine hammadde olarak yedirildiğinden üretim sonu kaydı Bu Yüzden/ Therefore B yapılabilmiş NEDEN? / WHY? Bu Yüzden/ Therefore NEDEN? / WHY? 5 Neden Analizinin Yapıldığı Tarih /The Date of 5-Why Analysis Bu Yüzden/ Therefore Ref. No. NEDEN? / WHY? C Müşteri / Customer Ürün - Proses / Product / TAI Process PERGEL VİNÇ SİSTEMİ Bildirim Tarihi/ Communicate to Manufacturer Çıkarılan Dersler / Lessons Learned : Katılımcılar / Participants: