Q6 Testing and documentation

Welded joints and materials testing

 

 

Materials and process testing provides extra peace of mind. Our work is verified by in-house or independent testers using state-of-the-art testing systems. Needless to say, all certificates are readily available. We conduct our own tests during production and the mandatory final inspections are always performed by an impartial testing institute.

 

Magnetic particle inspectionc

Magnetic particle inspection is the most commonly used method for detecting surface defects and near-surface defects such as hairline cracks in magnetisable iron and steel raw materials. The leakage flux that appears at surface cracks when the building component is magnetized means that the magnetisable particles in the testing material stick at that location. The effect is visible and results from the contrast between the background and the testing material.

 

Dye penetration

Dye penetration is one of the oldest non-destructive testing procedures for detecting surface defects and can be performed on almost any metallic and non-metallic material. During this process, the capillary action results in the test liquid penetrating any type of surface defect in the material. Following careful washing of the solution, a layer of developer is applied which creates a counter capillary action. This draws out the liquid which had penetrated into cavities and cracks and makes the defects visible.

 

Ultrasound testing

Ultrasound testing is particularly useful for detecting internal and external defects in materials that conduct sound and is thereby able to find errors throughout the entire cross section of the component. The acoustic method for the nondestructive testing of materials is used for quality assurance in tubes, welded joints and cast parts as well as for determining wall thickness.

 

Notched-bar impact test

How tough can a material be? Notched-bar impact tests are carried out to determine the toughness of metallic material and even work at extremely low temperatures.

 

Load testing

 

AXZION-GKS works closely and in partnership with major certification bodies such as TÜV, DEKRA, Lloyds Register and DNV GL.

This means that new designs are often discussed in advance and the required safety features are jointly determined.

Testers are on our premises almost daily to monitor the construction of large lifting equipment as is necessary under the applicable standards or to oversee the obligatory load tests.

The requirements placed on lifting equipment for use offshore are enormous and, as a result, all lifting accessories and equipment used in this area have always been tested with loads exceeding their load-bearing capacities. The intense and prolonged exposure to waves and wind and the overall difficult operating conditions place particular stress on the lifting equipment, meaning that tried-and-tested safety features are of the utmost importance.

Turbines, gas compressors and wind power plants are all extremely valuable. As such, damage during transportation must be avoided at all costs, as very long repair and replacement times would result in dramatic economic consequences.

 

 

600 t test bench

 

 

The 600 t test bench has been used on our premises in Langenfeld for many years and measures 20 m in length, 5 m in height and has an unladen weight of more than 100 t.

The load test can be controlled by hand or by a computer. The latter option generates an evaluation report. The Materials Testing Office NRW has verified the accuracy of the test bench and all measurements are calibrated and certified.

The test bench is open to everyone and even third-party lifting equipment can now be tested here at short notice.

Major certification bodies such as Lloyds Register, Germanischer Lloyd and DEKRA have already overseen load tests on the test bench and were very impressed with the ease with which the equipment can be used.

It has been possible for comprehensive series of tests, such as the testing of new load-attachment points to a tower, to be carried out at the tester’s own pace under completely realistic operating conditions.

In the future, more and more lifting equipment that is already in use will be tested in line with DIN EN 13155. These tests require the equipment to bear a load that is double its load-bearing

capacity to check that it conforms with the standard. An expert from an impartial certification body is on hand to verify the results.

 

 

1500 t test bench

 

 

Until now, testing very large pieces of lifting equipment when loaded with excess weight has been extremely difficult and expensive.

For example, testing a large 800 t lifting beam required a floating crane to be hired.

The process involved ten people attaching the test weights and performing the test over several days. The overall cost of conducting this load test exceeded the value of the lifting solution itself several times over.

The testing system measures 12 m in length, 15 m in height and has an unladen weight of more than 150 t.

The traction force of up to 1,500 t is created by two enormous hydraulic cylinders. The volume of the tank in the hydraulic unit is as large as the heating oil tank found in a detached home. The load test can be controlled manually or by a computer.

 

 

Documentation and document management

 

 

AXZION DocuManager – properly manufactured equipment needs comprehensive documentation

 

The documentation is just as important as the manufactured product itself. In international steel construction and mechanical engineering, the materials used must be precisely documented. In fact, an undocumented component may lead to the entire piece of lifting equipment being rejected. Lifting equipment must therefore always be delivered with comprehensive documentation. The data and content must correspond to the current design of the lifting equipment and the documentation must include evidence of the quality of the components and materials used as well as details of the inspections carried out.

While templates can be used to create the documentation for simple standard constructions, complex customised solutions require their own amended set of operating instructions. To create these, documents from various sources must be compiled and the content is formatted by hand in the same way as documents for printing. The proofreading process takes place over multiple channels, such as email and telephone, making it hard work and time-consuming.

However, the newly developed AXZION DocuManager has made this process easier by generating, managing and archiving documentation semi-automatically and by organising the workflow between the client and manufacturer. Content, which is the part requiring editing, is prepared separately from the design of the document and is only laid out properly on the page once it has been exported to a PDF. The documents produced in this way are archived in the system and can be consulted and sent from the program.

 

Advantages of the AXZION DocuManager:

– Formatting no longer required thanks to standard layout, resulting in a considerably reduced working time

– High-quality documents thanks to standardised document structure and

recurring content

– Client-specific layout possible (documents conform to quality management and/or corporate design)

– Documents comply with current legal standards (AZXION documentation is DEKRA compliant)

– Archive of all project-related data with revisions

– Users are automatically informed of any changes in status to the documents

– In-house ticket system organisms the proofreading process of each document

– Documents can be sent from the system via links

– Print service allows documents to be ordered from the system as booklets (automatic print and logistics jobs without any manual input)

Contact us!

SpanSet Axzion GmbH
Winkelsweg 172
40764 Langenfeld, Germany

Phone: +49 (0) 2173 208920
Email: info@axzion.de

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