TRACESPEC GLOBAL RESOURCES Doc. No.

TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

EXAMINATION PROCEDURE FOR

OFFSHORE CRANE INSPECTION

APPROVAL
Prepared By: Reviewed By: Approved By:

Name: ELDRED OFUA KAYODE OSHIN FRANK NWANODI

Position: QAQC MANAGER TECHNICAL DIRECTOR MANAGING DIRECTOR

Sign:
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Specification/Legislation: API RP 2D, API RP 9A, ASME B30.9, HSG 221

BS 2573 Parts 1 & 2, BS EN 13414-1,
BS EN 12385 Part 1 - 5,
BS 463, ISO 4309, BS 4536, PM46, BS 7262, TGRL NDT
Inspection Procedure, LEEA user pocket guide,
Offshore crane inspection checklist.

Applicable Test New, Primary Load Path Repairs, Modification, Boom,

Change Out, (Check Company Procedure)

Proof Loads Under 20 tonne: SWL + 25%

20 tonne to 50 tonne: SWL + 5 tonnes
Over 50 tonne: SWL + 10%

Examination Requirement As Per SI2307 1998 requirements; or

As Per Clients Specification

Internal Examination Clients Planned Maintenance System

Identification Manufacturer, Date Manufactured, Serial No, Clients, ID

No, Slewbearing, ID No, Wire Ropes ID No, Test Date
of Crane, SWL.

Certification Crane Test Certificate

Slewbearing Certificate
Wire Rope & Hook Block Certificate
Wire Termination Certificates
NDT Examination Report
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

The thorough examination will comprise of but not limited to the following main areas further
comprehensive breakdown of component parts that will be examined during crane
examination are to be found in Appendix A of this procedural section.

Examination Procedure

1.0 Main Areas

1.1 Access Egress

1.2 Pedestal
1.3 A Frame
1.4 Boom
1.5 Control Cab
1.6 Machinery House
1.7 Wire Ropes (Running)
1.8 Wire Ropes (Support)
1.9 Hook Blocks
1.10 Slew bearing
1.11 The condition of component parts will be recorded and any defects/structural damage
will be reported on the Defects Report and handed to the Area Supervisor.

2.0 Examination Procedure

2.1 Due to the wide range of items and functions to be checked, such a formal
examination must be accompanied by a examination CHECK LIST, this must be
submitted along with routine inspection reports. These check lists ensure that all vital
areas of the crane receives the necessary inspection.
2.2 Whenever considered necessary, the visual examination may be supplemented by
methods of non-destructive testing that will determine the condition of any part of the
crane. In order to facilitate visual examination and ascertain extent of damage it may
be considered necessary to have parts of the crane dismantled. This work must only
be, carried out by skilled personnel. The examination shall cover, but not be restricted
to, the following areas.
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Examination Procedure (Continued)

3.0 Checks on Boom

3.1 Inspect the entire boom for straightness and for any evidence of mechanical damage,
such as cracking, bending or deformation. Pay particular attention for signs of
cracking of flaking paint as this may indicate yielding of the metal, which may precede
failure.
3.2 Check all cords and lattices for damage, cracking, bending or excessive corrosion. No
damage to the main chords is permissible, although a small amount of damage to the
lattice work is allowed (max 3 lattice in anyone section) as long as the damage to the
lattice roots is not in the "Picture Frame" area which is regarded as critical.
3.3 Check boom tip for any signs of damage caused by main block.
3.4 Check all connecting pins for wear, damage and distortion, also ensure that cotter pins
are installed.
3.5 Check boom foot pins for wear, this can be done, by putting the boom into the rest and
using the slew in a left and right motion, to detect excess movement if this is observed
then pins may be worn, also the boom foot and housing should be checking for signs
of cracking.

3.6 Boom Corrosion

This part of the procedure covers the examination elements of corrosion and coating
breakdown.

To ensure the client is given a detailed survey report on the extent and severity of any
corrosion identified, the following guidelines should be applied to both angle and
round chord (tubular boom).
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Examination Procedure (Continued)

3.7 Main Chords

Using the diagrammatic drawings of the boom sections, i.e. Boom Foot, Intermediate
or Head Section. Indicate precisely the position of the corrosion, approximate area
covered and the depth of the corrosion. These can also be used for dents and wear
on the chords. It should be remembered, some crane manufacturers recommend
boom section change outs for any major chord any picture frame defect. Checks
should be made through the clients maintenance departments for clarification on the
subject. Note: Leibharr Cranes have an insitu repair policy. Any severe dents or
mechanical damage to the chord should be NDT/MPI inspected and the area closely
monitored by installation staff.

3.8 Boom Lacings

Using the diagrammatic drawings indicate the severity of the corrosion or mechanical
damage to the lacings.

Some crane manufacturers will not allow more than one bent lacing per section, i.e.
National Cranes.

The recognized industry criteria are 3 bent lacings per section before repairing. This
can be carried out in two ways, either sleaving or complete replacement. To monitor
bent lacings check the severity of the damage checking if the welds to the boom chord
is pulled/torn or cracked. If this has occurred carry out an NDT/MPI inspection to
ascertain if cracking has penetrated the chord, if this has not occurred, indicate in your
report (defect) this area has to be monitored regularly.

Ensure your drawings have accurate measurements and descriptions of the damage.
The use of Digital Camera photographic evidence is also acceptable.

Copies should be signed, by the area supervisor and the TGRL inspector, copies to be
left on the platform with defect report
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Examination Procedure (Continued)

3.9 Crane General Area

Using the appropriate drawing for the area causing concern, make precise measurements and
sketches. All fixings and fastenings should be inspected and reported in exactly the method as
for lacing and chords.

3.10 Tools Required

Engineers foot rule/straight edge
Engineers 6" rule and vernier gauge
Spring calipers (outside/inside)
Box of plasticine
NDT/MPI Equipment
UT Equipment
Load cell and Accessories

4.0 Checks on Machinery

4.1 Check all fixings and fastenings for corrosion, wear, damage and security. Any loose or
missing bolts should be replaced, not re-tightened as there is a good chance that they have
been stretched.
4.2 Inspect for excessive wear on brake and clutch system, parts, linings, pawls and ratchets.
Ensure that all safety pawls operate correctly are in good condition, free to move and
sufficiently lubricated.
4.3 Hydraulic and pneumatic systems should be inspected for deterioration. If any of the following
faults are noted then the faulty part should be replaced.
(a) Oil or air leaks on the surface of flexible hoses at the points at which the hose joins the
metal end couplings.
(b) Abnormal deformation of the outer covering of hydraulic hose, including any
enlargement, local or otherwise.
(c) Any leakage at connections, which cannot be remedied by normal tightening.
(d) Signs of abrasion on the wall of any hose or tube which could reduce their pressure
retaining capabilities. It is also important to eliminate the cause of the abrasion.

4.4 Machinery Pressure Ratings, all units that are driven or are operated by pressurized systems
will have these ratings recorded on the appropriate checklist and reviewed against the
Manufacturers Recommended Ratings; any major discrepancies will be highlighted and
reported to the appropriate authority.
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Examination Procedure (Continued)

4.5 Check all rope drum assemblies for wear and/or damaged by in scoring, damaged or
worn bearings and journals. Ensure that at least three full wraps of rope remain on the
drum and all in good condition.
4.6 Ensure that the drum end of the rope is securely anchored to the drum by means
approved by either the crane or rope manufacturer, and also that it is clear of the rope
windings.
4.7 Inspect all indicators, including those for load and jib angle, and automatic safe load
indicators, for any significant inaccuracies.

5.0 Wire Rope Checks

5.1 All wire ropes used on the crane shall be inspected in accordance with ISO 4309 over
their entire length for the following defects, paying particular attention to the sections
that pass through the block or over pulleys, or is continually exposed to the elements,
or may be subject to regular abrasion.
5.2 Check for corrosion, kinks, broken wires, changes in rope diameter, wear, heat
damage and lack or lubrication.
5.3 Check terminal fittings for wear, damage or distortion. Also, for signs of overloading
(i.e. collapsed thimbles). Ensure all wedge and socket termination's are as per BS EN
13411-6.
5.4 Examine wire rope test certificate to ensure rope is the correct size, capacity and
construction for the crane.
5.5 Deterioration normally results from a combinations of several defects occurring
simultaneously giving a cumulative effect. The overall effect should be taken into
consideration when deciding if a wire rope should continue in service. However the
following defects would result in the rejection of the rope.
5.6 Total number of broken wires in one lay length must not exceed six.
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Examination Procedure (Continued)

5.7 Total number of broken wires in one strand in one lay length must not exceed
three.
5.8 Total number of broken wires in a measured length of ten rope diameters must not
exceed 5% of the number of wires in the rope. Refer to ISO 4309 for further
discard criteria.
5.9 No broken wires are permitted where the rope enters the termination.
5.10 Wear must not exceed 10% of the original diameter for a six strand rope and 3% of
a multi strand rope
NOTE: Any broken wire found in the course of the examination, which do not
constitute rejection shall be broken off in the lay of the rope and their
location noted for the future reference.

5.11 The reeving configuration of the crane must be checked against the
manufacturers schematic, which shall be provided by the operator prior to the
inspection. Particular attention should be paid to any area where rope could come
into contact with the crane structure during the travel of the jib.

6.0 Checks on Main & Aux Hoist Blocks and Sheaves

6.1 The blocks and all sheaves shall be checked for the following defects:
6.2 The Safe Working Load and identification making is legible and corresponds with
the Test Certificates.
6.3 Wear/fracture in eye of block.
6.4 Wear/fracture in shank of head fitting. Where the shank of the head fitting has
been welded to the collar or nut, then the wear on the shank shall be determined
by rotating the head fitting, the wear shall not exceed a maximum of 1.5mm per
25mrn shank diameter, or shank bent.
6.5 Side plates distorted or chaffed.
6.6 Fracture leading from centre pin holes.
6.7 Side straps distorted or torn.
6.8 Bush worn, distorted or fractured.
6.9 Sheaves chipped, fractured and worn in groove or at sheave edge.
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

6.10 Check that all oil and grease ways and fittings in pin and bush, of the sheaves are
clear and functional.

6.11 Becket worn, distorted or fractured (also ensure it is the correct size for load to be
applied to it).
If any faults are found at the time of examination, which would affect the safe use of
the item, then it must be withdrawn from service and details recorded on the
Inspection Report.
7.0 Slew Bearing Bolt Check Procedure

7.1 Rota Bolts. The following will be carried out as part of the thorough examination of
any Crane using Rota bolts as part or Total fixing and fastening for its slew bearing
retention. Inner and Outer Slew Bearing Ring Bolts/Studs will be individually
numbered (as per client requirements) this may be hard stamping or stenciled
numbers on the ring or flange and bolt.
7.2 Each Rota Bolt will be checked using the following methods: TGRL Examiners will use
a divers wheel supplied by Rota bolt, this will ensure all bolts examined are continually
checked and monitored to the same specification on each examination. There are 3
specific symptom areas for the tension cap checks and are as follows:
1. Locked Out
This area of tension is when the tension cap has no movement and is set at the
correct tension, and there has been no bolt relaxation (correct setting)
2. Resistance/Drag
This occurs when there is a slight relaxation of the bolt, and indicates the
tension is still within Rota Bolts 5% criteria for the tensioning figures of the bolt,
(acceptable setting).
3. Free Spin
This occurs when the bolt has lost the 5% criteria on the bolt tensioning which
may have been caused by joint settlement, overload or shock loading situations
occurring. Should this fault be detected in a group of 4 bolts in one area the
client must be informed immediately.
Single bolts showing this symptom should be monitored over 2 successive
examinations and bolts adjacent to the free spin bolt should be monitored for
any changes occurring during 2 successive examinations, these will be
indicated to client representative on site immediately after the examination
(reportable setting)
4. The checklist is in a tick box application and it is imperative that it is marked up
correctly, with the types of settings highlighted. Comments on the overall
condition of the slew bearing and fastenings should also be written up.
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

5. Prior to any examinations taking place, the client should approve method of
examination.
6. The second method of testing the Rota Bolt setting is the thumb and finger grip
Method, this should be carried without gloves to apply a uniform grip. The fore
going procedure also applies to this method of examination.

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Test New, Modified, Repairs to Primary Load Path

Safety: Cordon of test area and carry out work permit requirements;
obey installation/site safety rules at all time. Should the test
require water bags inform Control Room if fire main systems is
required to fill water bags.

1.0 Preparation of Test Equipment

Ensure that test equipment is available on the installation prior to commencement of testing, and
is placed in a convenient "pick up" position within the crane's working radius.
Ensure that each test weight is clearly identified and the exact weight is marked there on.
Ensure each weight is fitted with a suitable certified lifting set secured in such a manner that it
cannot be inadvertently dislodged.
Ensure the lifting cradle complete with slings and shackles has current certification and is capable
of carrying the total test load.
If water bags are being used ensure they are free from any defects and a suitable water supply is
available (NOTE: Special permission is required to connect into the firewater mains).
The certified and calibrated test clock/dynamometer or load cell to be used in conjunction with the
water bags should be stored safely until the test commences.
Where possible ensure any obstructions on the deck of the platform, which are within the working
radius of the crane (during testing), are cleared.

Prior to any testing a thorough examination of the crane must be carried out. This and all subsequent
actions required for the test must be performed by a test technician who is:

(i) Trained, qualified and fully experienced with the type of crane to be tested
and
(ii) Fully conversant with all related operating requirements and safety
rules/regulations.

NOTE:
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

1. As part of the visual examination all exposed clutch and brake linings must be
examined for signs of wear and checked for ingress of oil or grease on the
linings and drums.
2. Wire ropes are to be inspected in accordance with manufacturer's laid down
specification and procedures.

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Test New, Modified, Repairs to Primary Load Path (Continued)

Function Tests

A thorough function test of the crane must be carried out without load, and any defects or
adjustments found should be repaired in accordance with the manufacturer's
recommendations. When all defects have been rectified proceed with the safe working load
and proof load tests.

Function Test as follows:

Boom Hoist System

Raising the boom - Prior to raising the boom where applicable engage the pawl
Raise the boom and test the efficiency of the hoisting mechanism, brake and pawl.

Lowering the Boom - Prior to lowering the boom where applicable, disengage the pawl.
Lower the boom and test the efficiency of lowering mechanism and brake.
Ensure the boom angle indicator is functioning correctly (if fitted).
Check maximum and minimum radius limits are functioning and are correctly set.

Main Hoist Line

Raise and test the efficiency of hoisting mechanism and brake.
Lower and test the efficiency of hoisting/lowering mechanism and brake.
Check the over hoist limit
Check lower limit
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

Aux Hoist (if fitted)

Raise and test the efficiency of hoisting/lowering mechanism and brake.
Check over hoist limit.
Check lower limit

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Test New, Modified, Repairs to Primary Load Path (Continued)

Slewing
Slew left and test the efficiency of the brake (and clutch where applicable).
Slew right and test the efficiency of the brake (and clutch where applicable).
If fitted, ensure any slew limits function correctly.

Testing Procedures

Safe Working Load Test

Position and stack test weights at approximately measured radius. (All radius
measurements must be taken from the centre of the pedestal to the hoist line).
Raise the approximate test load weights just clear of the deck, operate the crane in all
modes and slew (as far as possible) through 360 degrees
Check the accuracy of the safe load and radius indicators

Proof Load Test

The proof load applied will vary with the crane radius but shall not exceed the percentage
overload as indicated below.
Up to 20 tonnes: Capacity + 25%
Between 20 tonnes and 50 tonnes Capacity + 5 tonnes
Above 50 tonnes: Capacity + 10%
The proof load is to be applied at minimum radius, maximum radius and at least one
radius in between. The proof load shall include the weight of the test cradle and rigging.
Raise the appropriate proof load test weights just clear of the deck, slew the crane
through 360 degrees (or as far as possible).
 TRACESPEC GLOBAL RESOURCES Doc. No.
TGRL-LEP-010
LIMITED
Rev. 02

LIFTING EQUIPMENT
INSPECTION/EXAMINATION PROCEDURE-
OFFSHORE CRANE

At the commencement of overload testing, correct function of the safe load alarm systems
should be verified.
Automatic safe load indicators may then be disconnected for the duration of the overload
tests but they must re-connect immediately afterwards.
After re-connection, the safe load indicators must be tested to establish that they are
functioning.

Category Cranes

Equipment Description Offshore Pedestal Crane

Examination Thorough Examination

Test New, Modified, Repairs to Primary Load Path (Continued)

Action Upon Completion of Tests

Carry out thorough examination of the crane to establish that all parts have withstood the
test programme without defect.
All test weights, water bags, test clocks, load cells and associated equipment must be
returned to a suitable storage position until it can be back-loaded.
The Company must be informed immediately of any defects found which would prevent
the crane becoming certified.
A copy of the certification and/or report form is to be left onboard the installation and
official typed copy is to be sent to the relevant onshore, company representative.