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PT. TRANS PACIFIC PETROCHEMICAL INDOTAMA


STANDARD PROCEDURE

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LIFTING EQUIPMENT
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I. PURPOSE
The purpose of this procedure is to establish standard safe working practices in utilizing Lifting Equipment at TPPI
operational area
II. SCOPE
This applies to all lifting equipments whether they are owned by TPPI or by Contractor and used at all TPPI facilities.
The requirements and recommendation of this procedure are aimed to achieve high level of SAFETY in all lifting
operation performed at TPPI.
III. DEFINITION
Contractor
An organization employed by TPPI providing works or services as specified on the contract, contract work orders or
purchase order.
2. Sub Contractor
An organization employed by a Contractor providing works or services to the Contractor.
3. Certified Competent Person
The person concerned with the testing, examination and certification of lifting equipment and who shall have the
registered knowledge and experience to certify with confidence whether it is free from defect and suitable in every way
for the duty for which the equipment is intended. The Certified Competent Person is from company representative which
have been trained as Certified Inspector for Lifting Equipment.
1.

4.

Safe Working Load (SWL)


The Maximum load or mass (As certified by a competent person) that an item of lifting equipment may raise, lower or
suspend under particular service conditions. It is the SWL that is marked on the item and that appears on any
examination report or test records.

5.

Lifting Tackles / Lifting Accessories or Lifting Gears


Any device used to connect a load to a lifting appliance (lifting machine) but which is not it self capable of providing any
movement to lift or lower the load such as:

6.

1.

Chains and wire ropes

2.

Chain, wire rope and webbing slings

3.

Rings, hooks, shackles, eye bolts.

Lifting Appliance / Lifting Equipment


Any lifting machine, driven by manual or mechanical power that is able to raise, lower or suspend loads and includes the
supporting structure and all plant, equipment and gear used in connection with such a machine, but excludes continuous
mechanical handling devices (example: Conveyors).
Following are considered as lifting appliances or machines.
1.

Cranes (mobile, tower, pedestal, etc.)

2.

Wall / pillar cranes, derricks, swing jibs

3.

Overhead crane

4.

Manual and Powered hoist winches

5.

Chain blocks

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IV. Responsibilities For Implementation.


Proper implementation of this procedure requirement depends upon the contribution of various department of TPPI. A brief
description of the responsibilities is outlined as under.
1. Asset Owner
The Asset owners have overall responsibility for all the lifting equipment within their respective areas. In TPPI the Asset
owners are:

Business Team Manager(s)

Maintenance Manager

Project Manager (Contractors Lifting Equipment for Major Projects).

Asset owner shall ensure the following:

The requirement of this procedure will be implemented by all concerned within their areas

The Lifting Equipment used within their respective areas are having current certification and colour coding.

The Lifting Equipment used with in their area are properly maintained. The recommended corrective actions received
through the result of periodic inspection, audit report or reports from Inspection Division are implemented in time.

The Contractor / Sub contractor providing services to TPPI fully comply with this procedure.

Arrange required rigging and Lifting equipment operators (Crane, Forklift) training for applicable personnel within their
group.

2. Safety Health & Environment (SHE)


SHE will carry out checks on Lifting Equipment and Personnel to ensure that uncertified, out of date, and unidentified lifting
equipment are not in use.
Any such equipment shall be immediately removed from service and quarantined, until the discrepancies noted are rectified by
the End User / Contractor. This shall be ensured through the following:
1.

Verification of the Contractors Equipment and Personnel against the supplied Documents (Valid Certificate,log
book), prior to mobilization on TPPI work area.

2.

Onsite surveys on TPPI and Contractors Lifting Operations

3.

Monitoring the Safety of Heavy and Critical Lifting Operations

4.

Co-ordination between Government, Maintenance & Certified Competent Person for inspection and testing of
Lifting Equipments.

5.

Arrange audits on TPPI departments & Contractors to ensure implementation of procedure requirements.

6.

Specify the requirements for examination and test for Company Lifting Equipment as and when required.

7.

Escort (lead) the mobile crane when ever mobile crane moving inside plant.

3. Inspection Section
The Inspection is responsible for the following:
1.

Schedule periodic Inspection and testing of Lifting Equipment.

2.

Maintain annual inspection reports and certificates of all Lifting equipment

3.

Ensures that examination reports and certificates are transmitted to User Department after every periodic inspection

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survey.
4.

Perform NDT test when required/requested by Certified Competent Person

4. Maintenance Section.
The Maintenance Section is responsible for the following:
1.

Maintenance and storage of all Lifting Equipment allocated to TPPI Plant.

2.

Ensure adequate lifting equipment available for daily operations and initiate request for purchasing of new items
whenever required.

3.

Ensure that all Lifting Equipment related to TPPI Plant is offered for periodic inspection and testing and update
with current Certification.

4.

Ensure that all the Certified Special Lifting Equipments are obtained from User and offered for periodic inspection.

5.

Perform all maintenance activities of Lifting Appliances according to this procedure and Vendors recommendations.

6.

Perform periodical lubrication of wire rope slings as per Instruction

7.

Perform minor repair of Lifting Equipment or arrange for external resources for any major repair to be done.

8.

Implement all the corrective actions recommended by Certified Competent Person during biannual Inspection.

9.

Provide necessary assistance to Inspection division and 3rd party for carrying out periodic inspection of Lifting
Equipment.

10. Arrange to check the physical condition of Contractors mobile crane prior to use at TPPI facilities.
11. Ensure that Crane log books are properly maintained by Crane operators.

5. Crane Operator
The Crane Operator shall be responsible for the following:
1.

The Crane Operator must be certified and have validity certificate from government.

2.

Correct operation of the Crane as per manufacturers instructions. The Crane Operator shall ensure that the crane is
functioning correctly and is properly maintained each and every time that the crane is operated. This does not in any
way alleviate the responsibility of the management or owners of the Crane, in ensuring that the Crane meets the
requirements of this Procedure or the appropriate standards.

3.

Follow the sequence and method detailed in lifting plan while executing heavy & critical lifting operation.

4.

Setting the crane level prior to lifting and checking that it remains level throughout the operation.

5.

Establishing which signalling system is to be used and following instructions from only one signaller at a time.

6.

Stopping operations if given any instructions that would take the crane outside its permitted duties.

7.

Informing the supervisor of any problems that arise which would affect the lifting operation.

8.

Recording the daily checks, maintenance and comments relating to the cranes operation in the Log Book for the
Crane. The Crane Operator shall know the weight of the load prior to start of lift. No load is to be lifted where the
weight is unknown.

9.

Ensure that Crane is always attended while a Load is suspended from the Crane hook.

10. Where Operations involve the use of Lifting Equipment in proximity to overhead power lines, it is the
responsibility of the Crane Operator to ensure that it is safe to do so. The Crane Operator shall ensure that the
equipment is operated in such a manner that NO item of Lifting Equipment is within 20 meters proximity of any
live overhead power line.

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11. Ensure that SHE is leading way whenever Crane is moving inside the plant.
6.

Certified Competent Person

The Certified Competent Person shall be responsible for the following :


1.

Review lifting equipment documentation such as valid certificate, crane log book, maintenance record

2.

Carried out periodical lifting equipment inspection

3.

Ensure that lifting equipment meets with the Company requirement

V.
Inspection And Certification Programs
All Lifting Equipment shall be inspected and certified by a Certified Competent Person from TPPI or 3rd party agency as
applicable before being put in to service. Subsequent periodic inspections shall be performed by a Certified Competent Person.
Inspection Frequency
The mandatory inspection and testing frequency intervals pertaining to all lifting equipment are every 6 months. However
following general requirement shall be applied.
Pre-Use Examination
All items of Lifting Equipment shall be examined by the user prior to each use to ensure, so far as is practicable that they
are in a good condition and safe to carry out the task in hand. The details of what to check for during pre-examination
vary according to the type of Lifting Equipment.
The following three common particulars to be checked are:

The required SWL

Unique Identification number

The current colour code.


Where in the opinion of user, if the Lifting Equipment is unsafe to use, that item shall be immediately removed from the
work site.

Six Monthly Examination


All Lifting Equipments shall be subject to thorough visual examination at every six month intervals by a Certified Competent
Person. The thorough visual examination of Lifting Equipment shall be performed as per the inspection and certification rules
of Government.

VI.

Examination Reports & Certification

Initial Examination (New Lifting Equipment)


Initial thorough examination of new lifting equipment is conducted by a Certified Competent Person from TPPI or 3rd party
and certificate received along with the item is reviewed and signed for approval. The copy of the approved certificate is
forwarded to Asset owner through Ware house Receiving Section. The original Certificate is maintained by Document
Control. Validity of this certification will be monitored by Inspection Section. Depnaker certification will valid within 2 years
for New lifting equipment and the lifting equipment shall be re-certified every 1 year.
Six Monthly Examination (Biannual Inspection)
During the bi-annual inspection survey, Certified Competent Persons will issue an interim inspection report with the following
details.

List of items inspected and colour coded.

List of items inspected, colour coded but requires corrective actions with details.

List of items inspected, but not colour coded requires corrective actions with details.

List of items inspected not acceptable for use (scrapped).

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The above interim inspection report will be submitted to Inspection Division, in turn these report will be forwarded to
concerned department for necessary implementation of remarks.

VII.

Unique Identification Number:


In order to have a traceability of the current certification, all lifting equipment (except shackles, eye bolts) shall be
assigned with Unique Identification number
In the case of Shackles, Eyebolts and Swivel Hoist Ring less than or equal to 6.5t SWL, allocation of Unique
Identification Number is not applicable. The certificates of these items will be maintained in master file.
Unique Identification Number (TPPI Number) will be allocated by Logistic during purchase requisition stage or
receiving stage depending on the requirement.
This number shall be clearly marked on the equipment by manufacturer / vendor if specified in the purchase requisition,
if not, shall be marked by User Department.
It is not necessary to give individual Unique Identification Numbers to items of lifting equipment that are permanently
attached to each other. One Unique Identification Number shall be allocated to the whole assembly.

VIII. Colour Coding


All Company Lifting Equipment will be colour coded with a unique colour to indicate the equipment current
certification status. Following colour code shall be used in TPPI that are Blue, Yellow, Green and Orange. Colour
coding shall be selected so that same colour will not be repeated before two years of inspection cycle.
This colour is confirmed and validated by a memorandum and prominent display board. Equipment not colour coded in
accordance with the required colour code shall not be utilized in TPPI operation area.
The red colour will be strictly reserved for equipment to be scrapped or not to be used.
The long term contractors (eg : Shutdown Contractors) operating within TPPI operational area shall colour code their
equipment as per TPPI system. Short term Contractor may comply with their own colour coding system. Contractors
Lifting Equipment Certification shall be reviewed and approved by SHE department before delivery to TPPI plant.
Contractor shall possess Approval Document for their lifting equipment and should be readily available if any TPPI
Employees need to verify the approval status.

YEAR

EVEN
YEAR
(2008)
ODD
YEAR
(2009)
IX.

PERIODE
1ST SEMESTER
(1 Jan ~ 30 June )
2ND SEMESTER
(1 July ~ 31 Dec )
1ST SEMESTER
(1 Jan ~ 30 June )
2ND SEMESTER
(1 July ~ 31 Dec )

COLOR
GREEN
YELLOW
BLUE
ORANGE

Examination And Test


Pre-Survey Requirements
Prior to the planned bi-annual inspection, Certified Competent Person will agree with Maintenance and Contractor /
third-party for start of inspection program. It is the responsibility of Maintenance and Contractor / third-party to coordinate with User Department and to make available all lifting equipments for examination.
Survey Requirements
For each item of Lifting Equipment, the Certified Competent Person shall carry out the following as a minimum:

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Review of current examination report and test certificates.

Check identification and markings.

Thorough Examination, Functional Test and Overload Test when due.

Application of new colour code.

Prepare the current examination report.

Date :

If any suspect defect is noted during the examination of an item, the Certified Competent Person may perform or request
Inspection Division to perform any additional NDT as he considered necessary.
Such NDT shall be performed by suitably qualified technicians designated by Inspection Division.
New colour code will be applied for those Lifting Equipment found to be in a satisfactory and safe condition during the
examination.
If Lifting Equipment that cannot be identified (no Unique Identification Number) and or not properly marked (SWL)
shall be quarantined and efforts shall made to identify the equipment. If identification is not traceable, Certified
Competent Person to decide whether to assign a Unique Identification Number.
For those Lifting Equipment with minor defects (no proper marking, greasing, painting etc) but still satisfactory for use,
at the discretion of Certified Competent Person current colour coding will be applied. Upon receiving an interim report
respective Maintenance Section shall apply every efforts to complete the required corrective actions and items reexamined during the survey period.
For items of lifting equipment, which are found to be unacceptable, not colour coded and require more corrective
actions, the repairs may be carried out either on site or sent to the workshop for further repair by a specialist depending
on the nature of the repairs and the equipment type.
Such repairs shall be arranged by Maintenance Division. Where an item of Lifting Equipment has been repaired (either
by Maintenance or by a Specialist) and require proof load testing, it must be tested according to requirements of this
procedure. The proof load test shall be witnessed by a approved 3rd party before the item is returned to use.
TPPI Certified Competent person or 3rd party will decide whether a lifting equipment is fit for repair or to be scrapped.
Lifting Equipment that are found be defective and where it is beyond repair shall be colour coded with RED colour. End
user department shall ensure that items that are classified as scrapped shall be destroyed .

X.

Attachment

Flow Diagram Lifting Equipment

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