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Procedure Issue: 3

Document Number: PMS GP 09 Revision: 0


Date: 14/04/2016
Title:
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i Revision Record Sheet
PurposeOf Listofupdated/modified
Revision
Dateofissue Revision sectionsifany
Issue3Rev.0 14/02/2016 FirstIssue





Procedure Issue: 3
Document Number: PMS GP 09 Revision: 0
Date: 14/04/2016
Title:
Petroleum Marine Services Co. LiftingandHoisting Page: Page2of48


Table of Contents:
i RevisionRecordSheet.......................................................................................................1
1. Introduction......................................................................................................................5
1.1 Purpose........................................................................................................................................5
1.2 TargetAudience..........................................................................................................................5
2. Scope&Objectives............................................................................................................6
2.1 Scope............................................................................................................................................6
2.2 Aims&Objectives......................................................................................................................6
2.3 ReviewandImprovement.........................................................................................................6
3. Framework........................................................................................................................7
3.1 Design...........................................................................................................................................7
3.2 Procurement...............................................................................................................................7
3.3 LiftingEquipment.......................................................................................................................8
3.4 Liftingoperationscontrol..........................................................................................................8
3.5 Inspection,Testing,CertificationandQuarantine...............................................................10
3.6 Competence,Training,QualificationsandCertification.....................................................11
3.6.1 Trainingprogramsforseniors.................................................................................................12
3.6.2 Trainingprogramsforriggers.................................................................................................13
3.6.3 Trainingprogramsforheavyliftingoperations....................................................................13
4. LiftPlanningandExecution.............................................................................................15
4.1 Definingthelift.........................................................................................................................15
4.2 Planning.....................................................................................................................................15
4.2.1 RiskAssessment........................................................................................................................15
4.2.2 CategorizingLiftingOperations..............................................................................................16
4.3 Execution...................................................................................................................................19
4.3.1 CommunicationofLiftPlan.....................................................................................................19
4.3.2 ConductingtheLiftingOperation...........................................................................................19
4.3.3 MovingtheLoad.......................................................................................................................20
5. InspectionofLiftingAccessories......................................................................................21
5.1 Definition...................................................................................................................................21
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5.2 InspectionFrequency...............................................................................................................21
5.2.1 InspectionFrequency...............................................................................................................21
5.2.2 ThoroughInspectionat6MonthlyIntervals........................................................................21
5.3 MarkingandColorCodingofLiftingAccessories.................................................................22
5.4 Inspection..................................................................................................................................22
5.4.1 InspectionCriteriaforChainsandChainSlings....................................................................22
5.4.2 InspectionCriteriaforRoundSling........................................................................................23
5.4.3 InspectionCriteriaforWireRopesandWireRopeSlings..................................................23
5.4.4 InspectionCriteriaforShackles..............................................................................................24
5.4.5 InspectionCriteriaforFixedandAdjustableBeamClamps...............................................26
5.4.6 InspectionCriteriaforRiggingScrews/Turnbuckles............................................................26
5.4.7 InspectionCriteriaforMasterLinksandotherRings..........................................................27
6. InspectionandLoadTestingofCranes.............................................................................28
6.1 Definition...................................................................................................................................28
6.2 InspectionandLoadTestofCranes.......................................................................................28
6.2.1 FrequencyofInspection..........................................................................................................28
6.2.2 ThoroughInspection................................................................................................................28
7. Inspection/LoadtestingofLiftingAppliances..................................................................32
7.1 Definition...................................................................................................................................32
7.2 Inspection,LoadTestandOverhaulFrequency...................................................................32
7.2.1 Inspection..................................................................................................................................32
7.2.2 Identification/Marking...........................................................................................................32
7.3 ChainBlockandRatchetLeverBlock.....................................................................................33
7.3.1 Inspection..................................................................................................................................33
7.4 SheaveBlockandSnatchBlock..............................................................................................33
7.4.1 Inspection..................................................................................................................................33
7.5 Tirfor...........................................................................................................................................34
7.5.1 Inspection..................................................................................................................................34
7.6 inch(Powered,ManualorManRiding)................................................................................34
7.6.1 Inspection..................................................................................................................................34
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7.7 Monorails/RunwayBeamsandPadeyes...............................................................................35
7.8 FunctionTest.............................................................................................................................36
7.9 LoadTest....................................................................................................................................36
7.10 Documentation.........................................................................................................................36
7.11 Identification/Marking...........................................................................................................36
8. Inspection/LoadtestingofLiftedEquipment...................................................................38
8.1 Definition...................................................................................................................................38
8.2 InspectionandLoadTestofLiftingBeams,FramesandSpreaderBars...........................38
8.2.1 ThoroughInspection................................................................................................................38
8.2.2 LoadTestofLiftingBeams/FramesandSpreaderBars......................................................38
8.2.3 LoadTestofLiftingBeams/FramesandSpreader...............................................................39
8.3 Identification/Marking...........................................................................................................40
9. Inspection/WeightVerificationofTestWeights...............................................................41
9.1 InspectionFrequency...............................................................................................................41
9.2 ThoroughInspection................................................................................................................41
9.2.1 Welds..........................................................................................................................................41
9.2.2 LiftingPoints..............................................................................................................................41
9.2.3 InformationMarkings..............................................................................................................41
9.3 TestWeightVerification..........................................................................................................41
10. ColorCoding....................................................................................................................43
AppendixesandRecords........................................................................................................44
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1. Introduction
1.1 Purpose

The safe lifting operation is having competent personnel using the correct
equipment/toolsinasafemanner.Thisprocedurewilloutlinetheissuesrelatingtothe
selectionofthecompetentpeopleforthetask.Alsoitdescribes:

The control of lifting operations and the training programs for competent
people.
The framework and means to achieve safe and efficient lifting operations.
Incidentsrelatedtotheseactivitieshaveresultedinlossoflifeanddamageto
assets.
The mandatory requirements for lifting and hoisting operations and lifting
equipmentusedbyPMS.
Inspection,testingandcertificationrequirementsaredetailedinthisdocument
andshouldensureauniformapproach.

1.2 Target Audience

ThetargetaudienceofthisDocumentisanyone(PMSandcontractors)involvedinlifting
equipmentandliftingoperations.


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2. Scope & Objectives
2.1 Scope

Thisprocedureappliestoallliftingandhoistingoperations.Theliftplanningprocessdescribes
the systematic assessment of important load factors and site factors. It is as applicable to
simpleroutineliftsaswellasheavynonroutinelifts.Planninganonroutineliftrequires
considerable effort. In a lift determined to be noncritical, many of the elements can be
determined"byinspection";andthedepthinvolvedinanonroutineliftwillnotberequired.
Nevertheless,theplanningprocessmustbefollowed.

This procedure also covers all lifting equipment owned by PMS and presents the minimum
requirements of inspection; testing and certification of all Lifting Equipment owned and
operatedbyPMS.

2.2 Aims & Objectives

TheProceduredescribeshowthevariousprocessesareappliedinPMSliftingoperations
andprovidesalinkbetweenCorporatePoliciesandtheProcedures,Specificationsand
Guidelinesrequiredtosupporttheseprocesses.
SafeandefficientliftingbycontrollingrisksistheaimofthisProcedure
2.3 Review and Improvement

ThisProcedureandotherrelatedliftingequipmentdocumentsshallbereviewedand
updated on a three yearly basis, or sooner if needed, in order to ensure that the
document reflects the current position with regard to applicable Law, Corporate
Policies, Management Systems, Procedures, Specifications, Guidelines, International
StandardsandindustryacceptedBestPractices
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3. Framework
3.1 Design

PMS departments ensure that lifting equipment is fit for purpose and designed or
modifiedinaccordancewith(inter)nationalrecognizedstandardsand/ormanufacturers
recommendations.
Thefollowingistobenoted:
All engineered lifting points shall be certified by an external
inspection/certificationcompany.
AnyLiftedEquipmentunitsnotcertifiedtoanacceptedcodeshallbestructurally
verifiedbyaqualifiedengineerandloadtested.
3.2 Procurement

It is the procurement departments responsibility to ensure that selected companies


provide lifting equipment with appropriate certification and provide services with
properlycertifiedequipmentandqualifiedpersonnel.
Allliftingequipmentshallbeordered/provided,takingintoaccounttherequirements
asmentionedhereafterandinconsultationwiththerequireddepartment.
Allliftingequipmentshallbesuppliedwithacertificateissuedbythemanufacturer
i. LiftingAppliances
Themanufacturerhastoprovideallliftingapplianceswithdocumentationstatingasa
minimum, permissible operating conditions, design criteria, testing documentation,
maintenancerequirementsandexaminationandinspectionrequirements.
ii. LiftingAccessories
AllLiftingAccessoriesshallcomplywithapplicableinternationalstandardsandindustry
acceptedcodesofpracticeandbeprovidedwiththeappropriatetestcertificates.
iii. LiftingEquipment
All Lifted Equipment shall be designed, fabricated, inspected, tested, and certified in
accordance with applicable international standards and industryaccepted codes of
practice.





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3.3 Lifting Equipment

PMSliftingEquipmentcomprisesofLiftingAppliances(equipmentperformingthelifting),
LiftingAccessories,alsoknownasliftingtackleorliftinggear(deviceswhichconnectthe
loadtotheLiftingAppliance)andLiftedEquipment.Thediagrambelowdescribesthe
above:

LiftingAppliances LiftingAccessories LiftedEquipment


Cranes(including): Wireropeslings OffshoreStructure.
(Offshore)pedestalcrane Chainsandchainslings OffshorePlatforms(Jacket&
Mobilecranes, Shackles Decks).
Crawlercranes BeamandPlateclamps SteelPipes.
Aframes&Davits. Eyebolts&swivelrings Skids.
Towercranes, Hoistrings Drumracks
Overhead/gantrycrane. Turnbuckles Gascylinderracks.
Fixedliftingbeams& Liftingharnesses Frames.
monorails Spreaderbeams Baskets.
Hoists: Hooks Piperacks.
Manuallever. Loadcells Bigbags.
Tirfors/comealong Padeyesandbolts Pallets.
Poweredoverhead Riggingscrew
Manualoverhead Pallethook
Chainblock

Padeyes(fixedstructural)

Winches(incl.Manriding)

Forklifts
Sidebooms
Beamtrolleys
Sheaveblocks



3.4 Lifting operations control

Liftingoperationsarepotentiallydangerousandthereforehavetobecontrolled.Priorto
executiontheactivityhastobecarefullyplanned.

Followingstepsaretaken:
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3.4.1 Planning:
RiskAssessment
TheHazardsandEffectsManagementProcess(HEMP),forwhichtheriskmatrixanda
JobHazardAnalysisisthebasis,isappliedtoallliftingoperations,whichmaybeaRoutine
Lift,oraNonRoutineLift,andshalladdress:
Planningthelift
Identifyingthehazardsandrestrictedareas
Selectingcompetentpersonnel
Specifyingtheminimumnumberofpeopletoconducttheliftingoperation
SelectingLiftingEquipment
Communicatingliftrequirementsandhazards
ProceduresforchangingtheLiftPlan
Emergency,recoveryandcontingencyplans

WorkEnvironmentConditions

Environmentconditionsspecifictotheworklocationareidentifiedandaccountedforin
the planning and execution of all lifting operations. Whenever there is a reasonable
chanceofchangesinenvironmentalconditions,thencontingencyplansandprocedures
willbedevelopedaspartoftheworkplanning.
CategorizationofLiftingOperations
LiftPlan

ForallliftsaJobHazardAnalysis(JHA)andaLiftPlanshallbepreparedanddocumented.
Lift Plans specify conditions under which work shall not be continued, including
unplannedlossofcommunications,andtheassociatedcontingencyplansforensuringa
safesituationiscreatediftheliftisstopped

3.4.2 Execution:
A Toolbox Talk shall be held to ensure that all personnel involved in the lift fully
understandtheJHAandLiftPlan.Priortoalllifts(RoutineLiftsandNonRoutineLifts)the
personinchargeoftheliftensuresthatthefollowing10questionsforasafelifthave
allbeenaddressed

TenQuestionsforaSafeLift
1.Iseveryoneawareofanddotheyfullyunderstandtheliftingandhoistingprocedures
applicabletothelift?
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2.Haseveryoneattendedthetoolboxtalk?
3.HasapreuseinspectionoftheLiftingEquipmentbeencarriedoutandarethe
LiftingAccessoriestaggedormarkedwith:
SafeWorkingLoad
Auniqueidentificationnumber
Avalidcertificationdate
4.Areallsafetydevicesworking?
5.DoeseveryoneknowthePersoninChargeofthelift?
6.Iseveryonecompetentandawareofhistasks?
7.IsthereacurrentLiftPlanandJHAanddoeseverybodyunderstandthejobandprecautions?
8.Doeseveryoneknowtheenvironmentallimits(e.g.maximumpermissiblewindspeed)for
thelift?
9.Istheliftareacontrolledandiseveryonecleariftheloadfallsorswings?
10.Aresignalingmethodsandcommunicationagreedandcleartoyou?

3.5 Inspection, Testing, Certification and Quarantine

All cranes and other lifting equipment, new and existing, used shall undergo testing,
inspection, and certification. It helps ensure its integrity and hence continued safe
operationoftheequipment.
Inspection,testingandcertificationshallbecarriedoutbythirdpartyandshallcomply
withtherequirementsofinternationalStandardsandcodes,andCertificationregarding
frequencyandacceptance/rejectioncriteria.
Allnewliftingequipmentshallbeproofloadtested/inspectedpriortoitsfirstuse,and
providedwithcorrectcertification.Proofloadtestingshallcomplywiththerequirements
ofinternationalStandardsandcodes,andshallbewitnessedbyanapprovedInspection
Company.
Allexistingliftingequipmentshallbesubjectedtoperiodicinspection/functiontesting
(ifapplicable)toverifyoperabilityandincludessafetysystemsandequipment.
Liftingaccessories/appliances,havingpassedthe6monthlyinspections,shallbecoded
withtheapplicablecolor.
Priortoeachuseallliftingequipmentshallalsobevisuallyinspected/functiontestedby
/underthesupervisionofthepersoninchargetoensure,sofarasispracticable,itisina
goodstateofrepairandsafetobeused.
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Thedetailsofallexistingandnewliftingequipment(wire,ropes,shackles,mooringgears,
towing gear, anchor handling rigging,.etc) shall be recorded in a lifting equipment
registerestablishedforeachlocation.Thevesseloperatorisresponsibleformaintaining
theregisterateachlocation.Allliftingappliancesarealsoincludedinamasterlistregister
andcontrolledbyCompetentAuthorizedPerson.
Therejectedrigginggeartobeputinquarantineareaandthenarrangedtosendbackto
companywarehouse.
Departmenttoasonshoreteamforsubstitutetherejection/quarantinedriggingby
workable/newrigging.
When the gear ismobilized again to the offshore it shallbe added to the rigginggear
masterlist.
During offshore works, it is the responsibility of the competent person to check the
conditionsoftherigginggearbeforeusageandautomaticallytumthegeardamagedand/
orsuspectedintoquarantinetoensurethatitwon'tbeused.
The following information shall be recorded in the registers:
Manufactureranddescription.
Identificationnumber.
SWL.
Dates and numbers of certificates of tests, inspections, and examinations, and
nameofthepersonwhoperformedthese.
Duedatesforpreviousandnextperiodicinspectionorperiodicityofinspections.
Quarantinerigging.
3.6 Competence, Training, Qualifications and Certification

Toensurethattasksareperformedadequately,personnelinvolvedinliftingoperations
/liftingequipmentshallbequalified.
TheQualificationprocessshallcompriserequirementson:
Thelevelofcompetency.
Specificapprovedtrainingcoursesandassessments.(Trainerandassessorshall
bedifferentpersons).
Thisprocesstobedocumentedandtherecordsbeavailableforreview.
Uponsatisfactorycompletionofthequalificationprocessthepersonnelwillbeprovided
withacertificate/permit.
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Trainingcoursestobegiventoseniors(engineers,chiefofficers,masters,foremanetc)
andlaboursspecificallyriggers.
Training courses related to the heavy lifting to be given to seniors (OCM, Project
engineers,Fieldengineerschiefofficers,masters,foremanetc)

3.6.1 Training programs for seniors
Lifting operation control course

Understand the application of the Regulations and British Standards regarding


liftingoperationsonsite.
Knowtheirdutiesandresponsibilities.
Recognisetherequirementtohaveadefinedandrecordedsafesystemofwork.
Appreciatetheneedforcommunicationfortheprotectionofthoselikelytobe
affectedbytheseactivities.
Understandtheriskassociatedwithvariousitemsofliftingequipment.
Recognisetheneedforcompetentpersonnelforallareasoftheliftingoperations.
Liftinggearcontrol.

Heavy Lifting operation control course

UnderstandtheapplicationoftheRegulationsandBritishStandardsregardingthe
heavyliftingoperationsonsite.
Knowtheirdutiesandresponsibilities.
Recognisetherequirementtohaveadefinedandrecordedsafesystemofwork.
Appreciate the need for communication for the protection of those likely to be
affectedbytheseactivities.
Understandtheriskassociatedwithvariousitemsofliftingequipment.
Recognisetheneedforcompetentpersonnelforallareasoftheliftingoperations.
Liftinggearcontrol.

Aim of Appointed Persons Lifting Operations course

ObserveregulationsandCodesofPractice.
Followsafesystemsofworkincludingmethodstatements.
Takepersonalresponsibility.
Describedifferenttypesofcranesandassociatedterminology.
Understandcranedocumentation.
Understandcranestability,dutychartsandsafetydevices.
ObserveBritishStandard7121.
Appreciatetowercranes.
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Recognisetheroleofappointedpersons.
Planalift.

3.6.2 Training programs for riggers

HealthandSafetyRegulations/TheLiftingOperationsandLiftingEquipment
Regulations[LOLER]1998
PlanningtheliftRiskAssessmentandMethodStatements
Slinging/BanksmanandCraneOperations
LoadHandling/HandlingMethods[StackingandDeStacking]
WeightAssessmentandCapacities[EffectofSlingAngles]
Selectingappropriateequipment
PracticalLifting[Signalling/ManoeuvringandTransferringLoads]
Cranes:Types&Terms/CraneDocumentation/Cranestability,dutychartsand
safetydevices
3.6.3Training programs for heavy lifting operations

Insight view on modern techniques and equipment for heavy lifting and
transportation
technicalskillsonliftingofloadswithtwoormorecranes
Haveadeeplyunderstandingthetechnicalspecificationsforoffshoreoperations
Develop methodologies and procedures for the most challenging projects in
difficultenvironments
GeneralKnowledge&Introduction
Forces,MassandCentreofGravity
HeavyLiftCranesandEquipment
EnsuringStabilityinHeavyLiftingOperation
HeavyTransportwithHydraulicPlatformtrailers
Liftingofloadswithtwoormorecranes
Skidding,Jacking&MovingTechniques
LoadoutsofextremeHeavyLifts
Casestudies
Methodsusedforoffshoreloadlifting
ChoosetherightHeavyliftvesselsandcranesforyourproject
Challengesofoffshoreheavylifting
Technicalspecificationsforoffshoreoperations

oLoaddynamicscalculations

oWaveinducedmotionduringoffshoreoperations

oHandlingandattachmentofslings
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oOtherenvironmentalinfluenceonheavylift

Hydrodynamic Interaction between Floating Structures during Heavy Lift


Operations
MultiVesselLiftOperationsinDifferentWeatherConditions
Casestudies

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4. Lift Planning and Execution
4.1 Defining the lift

Whenaliftingoperationhastobecarriedout,ithastobecheckedifthisparticularlifting
operationhasbeencarriedoutbeforeonthatsite.AriskassessmentandLiftPlanmight
alreadyexist.
IfariskassessmentandLiftPlandoexistthentheyshallbeassessedtoconfirmthatthey
are still applicable (e.g. changes to personnel, equipment, site layout or work
environmentcouldallresultintheneedforreassessmentofhazards).Assumingthat
significantchangeshavenottakenplacethenliftingoperationsmayproceedunderthe
requirementsoftheLiftPlansubjecttoapprovalbytheliftingengineer.
If the lifting operations have not been carried out before, a competent person will
prepareaLiftPlan.Thishastobeinitiatedbytheexecutingdepartment.
Todefinethelift,thefollowingparametersareestablished:
Loadweight,shape,centerofgravityandavailabilityofadequateliftingpoints
Initialandfinalloadpositionsandhowitwillgetthere
TheenvironmentinwhichtheLiftingEquipmentwillbeused
4.2 Planning

4.2.1 Risk Assessment

Foreveryliftingoperationtheriskshavetobeassessedandcontrolled
AspartoftheHazardEffectManagementProcess(HEMP),ariskassessmentiscarried
out prior to any lifting operation to identify associated hazards, their severity and
likelihood of occurrence. The Group (YG) Risk Assessment Matrix (RAM) for
determiningriskisshowninApp.1andisthebasisoftheriskassessmentprocess,with
theobjectiveofensuringthatalltaskshaveLowRiskthrougheliminationoradequate
control.Allriskassessmentsareformallytobedocumented.Asampleformisattached
Theriskassessmentaddressesthefollowingaspectsandactivities:

Cultural,communicationandlanguagedifficulties
Weight,size,shapeandcentreofgravity(COG)ofload
Availabilityofapprovedliftingpointsonload
Methodofslinging/attaching/detachingtheload

Overturning/loadintegrity/needfortaglines
SuitabilityandconditionofLiftingEquipmenttobeused
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Initialandfinalloadpositionsandhowitwillgetthere
Liftingoverliveequipment
Numberanddurationoflift(s)
Conflictingtasksinarea
Environmentalconditionsincludingweatherandpermissiblelimits
Lightinginthepickupandlaydownareas
Proximity hazards, obstructions, path of load (e.g. potentially live electrical,
hydraulicorpneumaticlines,bridgesandoverheadstructures)
Workingundersuspendedloads
AccessandemergencyescaperoutesfortheLiftingApplianceOperatorandload
handlers(e.g.Banksman,Slinger)
Experience,competenceandtrainingofpersonnel
Numberofpersonnelrequiredfortask
PreUseInspectionofequipmentbyOperator
VisibilityoftheloadatalltimesbyeithertheLiftingApplianceOperatororthe
personguidingtheload(Banksman).Hemustmaintaincommunicationwiththe
Operatoratalltimeseitherviahandsignals,radioorarelaySignalBanksman.
4.2.2 Categorizing Lifting Operations

Asanaidtoidentifyingrisksandsuitablecontrols,liftingoperationsarecategorised
to reflect increasing risk and increasing level of control required as per
categorisation
schemeasgivenbelow:
i. RoutineLifts
Thisclassificationcomprises
Routinecraneoperations
Repetitiveliftingoperationsusingthesameequipment,and
RoutineliftingoperationswithLooseLiftingEquipment
A generic risk assessment and Lift Plan may be used for Routine Lifts. However,
classifyingaliftingoperationasroutinedoesnotautomaticallymakeitasafelifting
operationmostincidentsassociatedwithliftingoccurduringroutineoperations.The
risk assessments and Lift Plans shall always be reviewed during the Toolbox Talk for
continuedapplicability.
Thecontrolrequirementsforeachcategoryofliftareasfollows:
CategoryofLift Documentation/Control CompetentPersonnel
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RoutineLiftingOperations RiskAssessment(Generic) CraneOperator
when: LiftPlan(generic)(initiatedby Banksmanand/or
Grossloadislessthan5tones,or executingdepartment. Slinger/Rigger
Grossloadrepresentslessthan50% JobHazardAnalysis TrainedCrew
oftheloadchartatworkingradius WorkPermit
Liftingovernonsensitiveareas ToolboxTalk
Suitableenvironmentalconditions Safetychecklist
Familiar,competentCraneOperators
Loadhasknownandevaluated
weight,shapeandcenterofgravity
Standardriggingarrangements
Repetitivefunctionswithsame
equipmentandwithsameoperators

ii. NonRoutineLifts
Nonroutineliftingoperationscanbefurthersubdividedtoreflectincreasingrisk:
SimpleliftingoperationsusingLooseLiftingEquipment
Complicatedliftingoperations.
Complex/Critical/HeavyliftingoperationsrequiringaLiftPlanwithengineering
input
Thecontrolrequirementsforeachcategoryofliftareasfollows:
CategoryofLift Documentation/Control CompetentPersonnel
NonRoutineSimple Riskassessment CraneOperator
when: LiftPlaninitiatedbyexecuting Banksmanand/or
Grossloadislessthan25tones,or department/preparedby Slinger/Rigger
Equipmentspecificallyinstalledbya contractor(approvedbylifting TrainedCrew
competentoperator engineer)
Loadhasknownandevaluatedweight JobHazardAnalysis
Centreofgravitybelowtheliftingpoint WorkPermit
Useofacertifiedliftingpointdirectly Safetychecklist
abovetheload ToolboxTalk
Outwithsensitive,difficultorrestricted
areas
Singleliftingappliance
Unlikelytobeaffectedbychanging
environmentalconditions
ExperiencedandcompetentLifting
ApplianceOperator
Standardriggingarrangements
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NonRoutineComplicated Riskassessment CraneOperator
when: SpecificLiftPlaninitiatedby CompetentBanksman
Grossloadisgreaterthan25tones,or executingdepartment (Signaller)
Grossloadisgreaterthan30tonesandis JobSafetyAnalysis CompetentSlinger/
alsogreaterthan80%ofthe WorkPermit Rigger
manufacturersloadchart Safetychecklist
Continuationofaliftingoperationwith ToolboxTalk
differentequipment(duetomalfunction,
inadequacyorunsuitability)
UseoftwoormoreLiftingAppliances
(tandemlifting)
Withinsensitive,difficultorrestricted
areas
NonRoutineComplex/Critical/Heavy Formalworkpackwithmethod CraneOperator
Lift statement,includingcalculations CompetentBanksman
when: LiftPlanpreparedand (Signaller)
Grossloadisgreaterthan75tones,or reviewedbyaqualifiedengineer CompetentSlinger/
Grossloadrepresentsmorethan90%of (approvedby3rdparty) Rigger
theloadchartatworkingradius,or Riskassessment
Grossloadisgreaterthan50tonesandis JobHazardAnalysis
alsogreaterthan80%oftheloadchart. WorkPermit
Continuationofaliftingoperationwith Safetychecklist
differentpersonnel;forexample,shift ToolboxTalk
changeover
Liftingofpersonnel,includingdrillfloor
ManRidingoperations
Overorinsensitiveareas
Liftingwithahelicopter
Transferringtheloadfromonelifting
appliancetoanother(tailinglift)
Inenvironmentalconditionslikelyto
affect
equipmentperformance
Loadwithunknown/difficulttoestimate
weightand/orcenterofgravity
Loadisspecialand/orexpensivewhose
losswouldhaveaseriousimpacton
productionoperations
Nonstandardriggingarrangements
Loadloweredintoorliftedfroma
confinedspace

iii. LiftPlan
ALiftPlanispreparedoridentifiedforeverylift.TheLiftPlancomprises:
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Thecompetentpersonplanningthelift
Calculations
Equipmentrequired
Personnelrequiredandtheirparticularrolesandstandard
Stepbystepinstructions
Communicationmethodstobeused
Contingencyandrescueplans
AllLiftPlansgeneric,specificorengineeredaredeveloped,reviewedandapproved
bypersonscompetenttodoso.Thisshallbeinitiatedbytheexecutingdepartment.
AsampleLiftPlanisincludedinApp.2showingtheelementsrequired
4.3 Execution

4.3.1 Communication of Lift Plan

PriortostartingofliftingoperationsacompetentpersonshallholdaToolboxTalkwith
allpersonnelassignedtocarryoutthelift.
ThePersoninChargeshallbeclearlyidentifiedandmadeknowntoallmembersofthe
liftteamandpersonnelintheproximity.
Allpersonnelinvolvedintheliftingoperationshallhavetheirindividualresponsibilities
clearlyallocated.
Allpersonnelshouldhavetheopportunitytoreviewthefindingsoftheriskassessment
andthedetailsoftheLiftPlantoensurethateveryoneclearlyunderstandsandagrees
withthemethodsandcontrolmeasurestobeused
4.3.2 Conducting the Lifting Operation

LiftingoperationsshallbeconductedinstrictaccordancewiththeapprovedLiftPlan.Any
variationfromtheagreedLiftPlanshallresultinthejobbeingstoppedandreassessedto
ensurecontinuedsafeoperation.
TheLiftingApplianceOperatorshallobeyanemergencystopsignalatalltimes,nomatter
whogivesit.
Whenliftingoperationsneedtobecontrolledbysignals,adesignatedsignalpersonshall
beassigned.SignalsbetweentheLiftingApplianceOperatorandthedesignatedsignal
person(Banksman/Signaller)shallbeaudibleorvisibleatalltimes.
TheappropriateloadradiuschartfortheLiftingApplianceconfigurationinuseshallbe
visibletotheoperator.
Load to be lifted shall be confirmed to be within the rated capacity of the Lifting
EquipmentandattachedbymeansofsuitableLiftingAccessories.
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TheOperatoroftheLiftingApplianceshallnotleavetheoperatingcontrolswhiletheload
issuspended.
4.3.3 Moving the Load

PriortoliftingthePersoninChargeshallbesatisfiedthattheloadissecureand
properly,balancedandthattheloadpathisclearofobstructionsandpersonnel
Atcommencementofthefirstlift,theLiftingApplianceOperatorshallcarefully
checktheoperationofthehoistbraketoensurenoslippageoccurs
TakeupslingslacktoconfirmthattheLiftingAppliancehookhasbeenpositioned
centrallyovertheloadliftingpoint,adjusttheLiftingEquipmentasnecessaryto
minimizeanydriftoftheloadasitislifted
Noexternalforcesshallbeappliedtotheloadthatcreatesignificantsideloading
oftheLiftingEquipment
Forcraneoperationsappropriatetaglinesshallbeusedtocontroltheloadlarge
or long loads with flat sides that could act as a sail are particularly prone to
spinningandtaglinesshallbeusedtaglinesshallbesecuredtotheloadand
nottotheriggingslings
Cranesshallnotbeusedfordraggingaload






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5. Inspection of Lifting Accessories
5.1 Definition

Any item whatsoever which is used or designed to be used directly or indirectly to


connect a load to a lifting appliance or lifted equipment (e.g. a crane, chain block,
spreaderbar)andwhichdoesnotformpartoftheload,butwhichisnotitselfableto
lift,orloweraloade.g.
Slings Liftingcomponents
Wireropeslings Eyebolts
Chainsslings Hooks
Webbingslings MasterLinks
Othertypesofsling PlateClamps
Rings
Shackles
Swivels
BeamClamps
Othertypesofcomponents

5.2 Inspection Frequency

5.2.1 Inspection Frequency

Allliftingaccessoriesshallbethoroughlyinspectedinaccordancewiththisprocedure
attimeintervalsnotexceeding6months
Attimeofinitialinspection,theManufacturersTestCertificateshallbeproducedfor
review by the Lifting Inspector to verify equipment details. Failure to provide the
originalManufacturersTestCertificateswillresultintheequipmentbeingrejected.

5.2.2 Thorough Inspection at 6 Monthly Intervals

Allitemsofliftingaccessoriesshallbesubjecttoathoroughinspectiongivingcritical
appraisaloftheiteminquestion,inaccordancewiththisprocedure.Allinspectionsof
lifting accessories shall be undertaken by a Lifting Inspector, who shall assess the
fitnessforitsintendeduseinaccordancewiththerelevantitem.Thisistheminimum
levelofinspectionrequired.
Anydefectsfoundthatresultintheitembeingunserviceableandnotrepairable,shall
bepaintedred,placedinasegregatedarea,anddisposedofimmediatelyafterthe
inspectionhasbeencompleted.Iftoberepaireditshallbepaintedblack.
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5.3 Marking and Color Coding of Lifting Accessories
Ensurethatallhardstampingofliftingitemsiscarriedoutusinglowstressstamps.
Ensurethatnodamagetotheitemhasoccurredduetothehardstamping.Alllifting
accessories,whichhavebeeninspectedandfoundfitforpurposeforamaximumsix
months,shallbecolorcoded.FordetailsofPMScolorcoding.Allitemsshallhaveasa
minimumtheuniquenumberandthesafeworkingload(SWL).
Chain Slings

The information and other markings shall be stamped on either a metal tag firmly
attachedtotheslingorstampedonthemasterlinkusinglowstressstamps.

Wire Rope Slings

Theidentificationandothermarkingsshallbestampedontheferruleusinglowstress
stamps.Forslingswithoutferrules,theinformationshallbestampedonametaltag
firmlyattachedtothesling

Lifting Beams/Frames and Spreader Bars

LiftingBeams/FramesandSpreaderBarsandotherweldedorfabricateditemsshall
bemarkedincharactersofacontrastingcolor,whereitemsizerestricts,thelargest
letteringpracticableshallbeused.

All Other Lifting Accessories Items

Allstampingshallbeonareas,whicharesubjecttotheloweststress.Forhooksall
stampingshallbedoneonZoneAofthehook.

5.4 Inspection

5.4.1 Inspection Criteria for Chains and Chain Slings

a. EnsuretheSlinghastheIdentificationNumberandSafeWorkingLoadclearlyand
legiblymarked,andcorrespondswiththemanufacturerscertificate.
b. Matchupthelegsandcheckforstretchintheindividuallegs.
c. Inspecteachindividuallegalongitsentirelengthfordistortionoflinkse.g.bends,
twists,corrosion,elongationandnicks.
d. Checkforwearbetweenchainlinksandloadpins.
e. Inspectendterminationsfittede.g.hooks,connectorsetc.in accordancewiththe
appropriateparagraphofthisprocedure.
REJECTIONCRITERIA
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MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
Wearonthelinkdiameterinexcessof5%.
Stretchofmorethan3%measuredover1020links.
Anyseverepittingcorrosionorgeneralcorrosioninexcessof5%.
Twistinexcessofhalfaturnin4meters(orequivalent).
AnychainorfittingmadeofWroughtiron
Hardstampingwithlowstressstamps

5.4.2 Inspection Criteria for Round Sling

a. EnsuretheSlinghastheEquipmentTagNumberandSafeWorkingLoadclearlyand
legiblymarked,andcorrespondswiththemanufacturerscertificate.
b. Inspectalongitsentirelengthforcuts,tears,chafing,chemicaldamage,heatdamage
anddamageduetoUVexposure.
c. Inspectthefibersfortheingressofforeignbodies.
d. Inspectforanypaintonthesling.
e. Inspect end terminations e.g. hooks, connectors etc in accordance with the
appropriateparagraphofthisprocedure.
REJECTIONCRITERIA
MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
Anybreakageofthestitching
Anywornstitchinginloadbearingareas
Anyfrictiondamageorbadlyabradedspots
AnypaintorfelttippenmarkingsontheslingorKnottedslings
5.4.3 Inspection Criteria for Wire Ropes and Wire Rope Slings

a. EnsuretheSlinghastheEquipmentTagNumberandSafeWorkingLoadclearlyand
legiblymarked,andcorrespondswiththemanufacturerscertificate.
b. Inspect each individual leg along its entire length for wear, corrosion, abrasion,
mechanicaldamage,anddiscolorationduetoheatorchemicaldamage,evidenceof
shockloadingandbrokenwires.
c. Inspecteachferruleandensurethecorrectsizeofferrulehasbeenfitted.
d. Checkthattheendoftheloopdoesnotterminateinsidetheferruleunlesstheferrule
isofthelongtapereddesign,whichhasaninternalstep.I.e.Flemisheye.
e. Ensuretheferruleisfreefromcracksandotherdeformities.
f. Inspecteachthimble,iffitted,forcorrectfitting,snaggingdamageandelongation.
(Stretchedthimbles/eyescouldindicatepossibleoverload).
g. Inspectwireropearoundthimblesasitisoftentobefoundabradedduetothesling
beingdraggedoverroughsurfaces.
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REJECTIONCRITERIA
Condition DiscardCriteria
MissingorillegibleIdentificationNumberorSafe
Information WorkingLoad

MechanicalDamage Nicks,cuts,gougesetc
Ifthenumberofwiresintheslingareknown:
a)5%ofthewiresin10diameters
b)3ormorecloselygroupedwires
WireBreaks
Ifthenumberofwiresintheslingisnotknown:
a)5wiresinany6diameters
b)3ormorecloselygroupedwires
Anywearresultinginaflatontheouterwiresof
Wear
morethan3/4oftheoriginalwirediameter
Whenthediameteroftheropehasdecreasedbya
LossofDiameter valueof7%ormore,comparedtotheoriginalrope
diameter
Dueto
a)kinking
Distortion b)crushing
c)corecollapse
d)knotting
Discolorationofthewires,weldspatteretc.
HeatDamage

a)Cracksintheferrule
b)Severecrushingorabrasion
c)Pullingoutoftheferrule
DamagedFerrulesandeyes
d)Concentrationofbrokenwiresneartotheferrule
e)Fracturedwiresontheoutsidesurfaceoftheeye
f)Closingofthethimble
NumberStamps Hardstampingwithlowstressstamps

NOTE:
1 Hand Splice. The only method of hand splicing shall be the "Cross Tuck" or
"Admiralty"splicewhichcomplieswithRegulation
2 Handsplicedslingsterminatedusinganyothertypespliceshallberejected.
5.4.4 Inspection Criteria for Shackles

a. EnsuretheShacklehastheEquipmentTagNumberandSafeWorkingLoadclearly
andlegiblymarked,andcorrespondswiththemanufacturerscertificate.
b. Ensurethatallstampingisdoneusinglowstressstampsintheposition.
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c. Removetheshacklepinandinspectforweardeformationandcracking.
d. Ensureitisthecorrectpinfortheshackle.
e. Inspectpinthreadsforwear/deformation.
f. Inspectshacklebodyfordeformationandcrackingandcheckforwearinthecrown
andpinhole.
g. Checkalignmentofpinholeandensurethepinfitscorrectly.
h. Incaseofsafetypinshackles,ensuresplitpinsarefitted.

REJECTIONCRITERIA
MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
Excessivemovementbetweentheshacklepinandtheshacklethreadedhole
Anywearorcorrosioninexcessof5%oftheoriginaldimension
Anythermaldamageorevidenceofweldingontheshackle
Anycracks
Stampingoutwiththerecommendedpositions
Nosplitpinfittedinsafetyorbolttypeshackles
Hardstampingwithlowstressstamps
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5.4.5 Inspection Criteria for Fixed and Adjustable Beam Clamps
a. EnsuretheBeamClamphastheEquipmentTagNumberandSafeWorkingLoadand
beam size clearly and legibly marked, and corresponds with the manufacturers
certificate.
b. Inspectthesuspensionshackleforwear,distortion,corrosionandcracking.
c. Inspecttheloadbarforwear,stretch,distortionandcracking.
d. Inspect inner and outer clamp for wear, distortion and cracking. Check jaws for
deformation.
e. Inspect adjusting bar for straightness and function. Check threads for wear and
stretch.
f. Inspect female screwed spigots (in each clamp half) and ensure they are not
deformedduetoover/undertightening.
g. Inspect"tommybar"handleandensureitisnotbentordamaged.
h. Whereswiveljawsarefitted,ensuretheyrotatefreely.
i. ThecompleteBeamClampshallbesubjectedtonondestructivetestingataperiod
notexceeding2years.
REJECTIONCRITERIA
MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
Anywearorcorrosionresultinginalossofmorethan5%oftheoriginaldimension
Anystretch,distortionorcracking
Hardstampingwithlowstressstamps

5.4.6 Inspection Criteria for Rigging Screws/Turnbuckles

a. EnsuretheriggingscrewhastheIdentificationNumberandSafeWorkingLoadclearly
andlegiblymarked,andcorrespondswiththeManufacturersCertificate.
b. Inspectthreadsforwear/deformation.
c. Inspectriggingscrewbodyfordeformationandcrackingandcheckforwearinthe
eyes.
d. Inspectthreadsforwear,stretchorimpactdamage.Thethreadsmustbecomplete
(nobrokenthreads)andfullinform.
e. Inspecttheeyeoftheboltforcrackingatthecrown.
f. Checkthesquarenessofscrewagainstthebody.
g. ThecompleteRiggingscrewshallbesubjectedtonondestructivetestingataperiod
notexceeding1year.
REJECTIONCRITERIA
MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
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Anywearorcorrosioninexcessof5%oftheoriginaldimension
AnyShankdistortion
Anythermaldamageorevidenceofweldingontheriggingscrew
Anymodificationtotheriggingscrew
Anystretch,distortionorcracking
Hardstampingwithlowstressstamps

5.4.7 Inspection Criteria for Master Links and other Rings

a. EnsuretheLinkorRinghastheEquipmentTagNumberandSafeWorkingLoadclearly
andlegiblymarked,andcorrespondswiththeManufacturersCertificate.
b. InspecttheLinkorRingbodyforwear,distortion,corrosion,stretchandcracking.
c. Inspectthecentralpinofsnaporhammerlockjoints,bothlaterallyandtransversely
forexcessivewear.
d. ThecompleteLinkorRingshallbesubjectedtonondestructivetestingataperiod
notexceeding1year.
REJECTIONCRITERIA
MissingorillegibleIdentificationNumberorSafeWorkingLoad
Anymechanicaldamagei.e.nicks,cuts,gougesetc.
Anywearorcorrosioninexcessof5%oforiginaldimension
Anywearorcorrosioninexcessof5%oforiginalcentralpindimension
AnythermaldamageorweldingoftheLinkorRing
Anystretch,distortionorcracking
Hardstampingwithlowstressstamps


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6. Inspection and Load Testing of Cranes
6.1 Definition

This section includes all machines onshore/offshore belongs to PMS which be used for
hoistingandloweringloads.
6.2 Inspection and Load Test of Cranes

6.2.1 Frequency of Inspection

All cranes shall be thoroughly inspected and load tested in accordance with this
procedureattimeintervalsandbasedontherequirementslistedinitsManufacturers
manual.
Attimeofinitialinspection,theManufacturersTestCertificateshallbeproducedby
theassetcustodian/ownerforreviewbytheEngineertoverifyappliancedetails.
6.2.2 Thorough Inspection

TheLiftingEngineershallcarryoutathoroughinspectionofthecraneinaccordance
withthissection.Thisistheminimumlevelofinspectionrequired.
Duetothemanyvaryingdesignsofcranes,notallaspectsoftheinspectionwillapply
toeverycrane.
i. PreInspectionFunctionTest
Duringanythoroughexamination,itisnecessarytocarryoutanoperationalfunction
testwithoutloadtoprovetheoperationofthecraneandthefunctionofitssafety
devices. The crane must be operated by a fully qualified crane operator under the
controloftheLiftingEngineer.Priortothetest,theLiftingEngineershallestablish,
Thecraneisfittoperformtherequiredmovements.
Thatthecraneoperatoriscertified,andhasadequateexperience.
That all controls operate correctly and smoothly, and are free from wear and
otherdamage.
Thatanylimitationofcraneoperationsinaccordancewithoperatingsitesafety
requirements,i.e.weatherconditions,etc.areobserved.
Equippedwithsufficientfallsofwireropeforthetestload.
The operational function test shall cover the items listed below. If any defects are
found which adversely affect the safe operation of the crane during the thorough
inspection,thentheyshallbecorrectedbeforeproceedingfurther:
Mainandauxiliaryloadhoistingandloweringmechanism.
Hoistupperandlowerlimits.
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Allbrakesandclutches.
Safeloadindicators.
Boomhoistandloadlimits.
Boomangle(mechanicalorelectronically)andsafeloadindicators.
ii. SafeWorkingLoadandIdentificationNumber
Ensuredurablelegiblemanufacturersratingchart(s),withtextinEnglishand/or
Arabicareprovidedintheoperatorscaborprimarycontrolstation.Thecharts
shallbeforthecranemodelunderinspectionandcoverallpossibleconfigurations
ofthecraneincludingmanualextensionsandflyjibs,ifapplicable.
Ensure the correct loadrating charts for the crane configuration in use, is
accessibletotheoperator.
On cranes with a single load rating, ensure that the SWL is legibly marked in
charactersofacontrastingcolor,ontheboomorstructureofthecrane.
Ensure the unique identification number is legibly marked in characters of a
contrastingcolor,ontheboomorstructureofthecrane.
iii. Structure
Inspectthecranestructureforcorrosionandmechanicaldamageetc.
Inspectallloadbearingweldstoensurefreedomfromdefects.
Ensureallbolts,andfasteningsarecheckedfortightnessandcondition.
If fitted, inspect the antiderailment brackets for corrosion and mechanical
damage.
Inspecttheentirelengthofthelongtravelbeam,railsandsupportstructureas
well as the cross travel beams and crab unit for cracks, weld deformation and
corrosion.
Checkthebeamstoensurethattheyarelevelandparallel.AttheLiftingEngineer
discretionadditionalchecksmaybecarriedoutinaccordancewithBS466.
Checkallanchorageandpivotpins/bushesforsecurity.
AtintervalsatthediscretionoftheLiftingEngineer,ifapplicable,thecriticalload
bearingpartssuchastheboomsectionandareasthatarenotaccessibleduring
theroutineinspectionsshallbedismantledtofacilitateinspection.Criticalload
bearingpartsshallbevisuallyinspectedandNDTdusinganappropriatetesting
methodtoascertaintheirintegrity.Loadbearingpartstobeconsidered:
o MainJib/Boom
o FlyJiband/orattachments
o Slewrings
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o Hookblocksetc.
iv. Hydraulics
Ensureallfluidlevelsarecorrect.
Inspect the hydraulic system pipes, rotary coupling, rubber hoses for leaks,
corrosion,wallsectionlossandmechanicaldamage
ensurethatonlycrimpedendconnectionshavebeenused.
Inspectallhydrauliccylindersforleakage,corrosionontherodsandalignment.
Visuallycheckendfixingsforwear,securityandlubrication.
Ensurethatthereinforcingsteelbraidingoftherubberhosesisnotexposed.
Ensurethatnopartofthehydraulichoseshasbeenpainted.
Inspectallcheck/holdingvalvesforleaks,corrosionandmechanicaldamage.
Ensurethatthestrokelengthofhydrauliccylindersworkingintandemareequal.
v. TelescopicandLatticeBooms
Checktheoperationofthetelescopicboom;ensuretheboomlengthmarkings
are clearly legible. During operation, check if the telescopic motion is through
directorindirectramoperation.
In the case of indirect ram operation inspect the extending/retracting
chains/ropesforcorrosion,mechanicaldamageetc.,refertoTableAforlimits.
Any telescopic booms extending/retracting chains/ropes and any internal
hydrauliccylindersmay,atthediscretionoftheLiftingEngineer,berequiredto
beremovedtofacilitateathoroughinspection.Duringthechains/ropesremoval,
theboomshallbegivenathoroughinternalinspection.
Inspectthetelescopicboomendstops,andtheguidesforsecurityandwear.
Inspecttheentirelengthoftheboom,includingmanualextensionandflyjib,if
fitted,ormechanicaldamage,lossofsectionandcorrosion,fatiguestress,pay
particularattentiontotheboomsectionendconnections.
Inspecttheboomheelpinsandluffingcylinder,topandbottomanchoragesfor
excessivewear.
For lattice jibs, inspect each section of the jib for mechanical damage and/or
corrosion,lossofsectiontothecordsandbracingsensurenobracingsaremissing.
Inspectthelatticejibsectionjointpinsandbushesforwear.
Ensure that a boom angle indicator is fitted and operational (electronically or
mechanical).
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Thethicknessofanypartoftheboom/jibmaybecheckedusinganappropriate
NDTmethod;thiswillbeatthediscretionoftheLiftingEngineer.Thepermissible
levelsofwear,shallbeasadvisedbythecranemanufacturer.
vi. Ropes,HookBlockAssembliesandSheaves
Thoroughly inspect the entire length of all wire ropes fitted, including rope
anchorageforwear,splintering,corrosionand mechanicaldamageetc.Special
attentionshouldbegiventothesectionofropeonstandingorequalisingpulleys.
Inspectallropeendterminations,splicesetc.fordamageandwearwithparticular
attentionbeingpaidtobrokenwiresatferruleconnections.
Inspect the wedge and socket, ensure the correct size of wedge and socket is
fitted,andthereisnomissmatchbetweenthewedgeandsocket.
Ensuretheropefittedisofthecorrectsizeandconstructionforthecrane.
Inspect all sheaves for wear, cracking and rope path alignment and bearing
condition.
Ensurethatatleastfive(5)fullturnsofwireroperemainonthedrumatanytime.
Inspectcranehook
At intervals not exceeding four (4) years, all crane hook assemblies shall be
dismantledforvisualinspectionandNDTsurveyofallloadbearingcomponents.
AttheLiftingEngineersdiscretion,thisroutinemayberequestedduringthetime
ofannualinspection.


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7. Inspection/Load testing of Lifting Appliances
7.1 Definition

ChainBlock,Manual
ChainBlock,Powered
RatchetLeverBlock
SheaveBlock
SnatchBlock
Trolley,Manual
Trolley,Powered
Jack,Hydraulic
Monorails/RunwayBeams
Padeyes
PullingAppliances
Tirfor
Winch,powered
Winch,Manual
Winch,ManRiding
7.2 Inspection, Load Test and Overhaul Frequency

7.2.1 Inspection

Thefrequencyofinspectionof(loose)appliancesshallbeatintervalsnotexceeding6
months,followinginitialregistration.
Whererequired,accuratedimensionalchecksofcomponentsshallbeconductedfor
verification to appropriate design standards and as datums for future comparison
purposes.
Attimeofinitialinspection,theManufacturersTestCertificateshallbeproducedto
verifyappliancedetails.FailuretoprovidetheoriginalManufacturersTestCertificates
willresultintheequipmentbeingrejected.
Note:Theinspectionfrequencyofcompletesystems,e.g.monorails,trolleyandchain
block,shallbesubjectedtoannualthoroughexaminationand4yearlyloadtest.
7.2.2 Identification / Marking

Allappliancesshallbeclearlymarkedwiththefollowinginformation:
a. EquipmentTagNumber(ETN)
b. SafeWorkingLoad(S.W.L.)
c. DateofInspection
d. NextDueDate(ofInspection)
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7.3 Chain Block and Ratchet Lever Block

7.3.1 Inspection

TheLiftingEngineershallconductathoroughinspectionoftheblockinitsassembled
condition. Any of the following defects found during inspection shall be cause for
rejection:
COMPONENT DEFECTTYPE REJECTIONCRITERIA
LoadChain a)Wear a)Wearinexcessof5%oforiginallinkdimensions.
(RoundLink) b)Damage b)Cracks,heatdamage,severenicks,gougesordistortion
c)Corrosion oflinks
d)Reeving c)Excessivecorrosion,pittingoranychemicalattack.
e)GaugeLength d)Loadchainreevingincorrect.
e)Loadchaingaugelengthincreasegreaterthan3%.
LoadChain a)Wear a)Wearinexcessof5%oforiginallinkorpindimensions.
(PlateLink) b)Damage b)Cracks,heatdamage,severenicks,gougesordistortion
c)Corrosion oflinks
d).GaugeLength c)Excessivecorrosion,pittingoranychemicalattack.
d)Loadchaingaugelengthincreasegreaterthan3%.
Chain a)Wear a)Wearinexcessof5%oforiginaldiameter.
Anchorage b)Damage b)Anycracksordistortion.
c)Corrosion c)Excessivecorrosion,pittingoranychemicalattack.
BlockBody a)Damage a)Anymechanicaldamageorloosecovers.
PoweredDrive a)Wear a)Excessivewearondrivemechanism.
(wherefitted) b)Operation b)Incorrectorlaboureddriveoperation.
ManualDrive a)Chain a)Brokenordistortedlinks.
(wherefitted) b)Drive b)Anycracks,excessivewearordistortion.
sprocket
RatchetLever a)Damage a)Crackedorbrokenoperatinglever
b)Operation b)Incorrectorlaboureddriveoperation.

7.4 Sheave Block and Snatch Block

7.4.1 Inspection

TheLiftingEngineershallconductathoroughinspectionoftheblockinitsassembled
condition. Any of the following defects found during inspection shall be cause for
rejection:
COMPONENT DEFECTTYPE REJECTIONCRITERIA
Sheaves(where a)Wear a)Wearofropegrooveinexcessofgaugedepth.
fitted) b)Damage b)Severenicks,cutsorgouges.
c)Corrosion c)Excessivecorrosion,pittingorchemicalattackonsteel
sheaves.
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Sprockets a)Wear a)Excessivewearofchainguide.
(wherefitted) b)Damage b)Cracks,heatdamage,severenicksorgouges.
c)Corrosion c)Excessivecorrosion,pittingoranychemicalattack.
CheekPlates a)Damage a)Cracks,severecuts,gougesordistortion.
b)Corrosion b)Excessivecorrosion,pittingoranychemicalattack.
Pins a)Wear a)Anywearinexcessof10%oforiginaldiameter.
Attachment a)Wear a)Anywearinexcessof5%oforiginaldimensions.
Point b)Damage b)Anycracks,cutsordistortion.
c)Corrosion c)Excessivecorrosion,pittingorchemicalattack.

7.5 Tirfor

7.5.1 Inspection

TheLiftingEngineershallconductathoroughinspectionoftheTirforinitsassembled
condition. Any of the following defects found during inspection shall be cause for
rejection
COMPONENT DEFECTTYPE REJECTIONCRITERIA
Housing a)Damage a)Anycracksorloosebolting.
b)Corrosion b)Excessivecorrosion,pittingoranychemical
attack.
Anchorage a)Damage a)Anycracksordistortion.
Point b)Corrosion b)Excessivecorrosion,pittingoranychemical
attack.
RatchetLever a)Damage a)Crackedorbrokenoperatinglever
b)Operation b)Incorrectorlaboureddriveoperation.
Pins a)Wear a)Anywearinexcessof10%oforiginaldiameter.
WireRope a)Wear,Damage a)5%ofwiresbroken,wornorcorroded
orCorrosion measuredoveralengthoftenropediametersas
givenbyBS302Part1.Furtherrejectioncriteria,if
requiredareobtainablefromISO4309.

7.6 inch (Powered, Manual or Man-Riding)

7.6.1 Inspection

TheLiftingEngineershallconductathoroughinspectionofthewinchinitsassembled
condition. Any of the following defects found during inspection shall be cause for
rejection:
COMPONENT DEFECTTYPE REJECTIONCRITERIA
PoweredDrive a)Wear a)Excessivewearondrivemechanism.
(wherefitted) b)Operation b)Incorrectorlaboureddriveoperation.
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ManualDrive a)Wear a)Anycracks,excessivewearordistortion.
(wherefitted)
WinchHousing a)Damage a)Anycracks,looseboltingorcovers.
b)Corrosion b)Excessivecorrosion,pittingorany
chemicalattack.
RopeDrum a)Wear a)Excessivewearonwireropeanchorage.
b)Damage b)Anycracksordefectsliabletodamagethe
wirerope.
WireRope a)Wear,Damage a)5%ofwiresbroken,wornorcorroded
orCorrosion measuredoveralengthoftenrope
diametersasgivenbyBS302Part1.Further
rejectioncriteria,ifrequiredareobtainable
fromISO4309.
Inspect the structure on which the winch is installed for corrosion and mechanical
damage.Thewinchbaseboltingshallbecheckedforsecurity(NOTE:Onlygrade8bolts
andnuts,orhigher,tobeused)
NB:AdditionalrequirementsforManRidingWinches(onlyapprovedandtypes
markedassuchshallbeused):

BasemountingstobecheckedbyMPIannually
Loadtestingtobeperformedannuallyataproofloadof1.1xSWL
Primaryandsecondarybrakesystemstobeverified
Emergencyloweringsystemtobeverifiedincaseoflossofpower
Allsafetydevicestobechecked,e.g.overhoisting,overlowering,slackwireetc.
Emergencystoptobeverified,iffitted

7.7 Monorails/Runway Beams and Padeyes

Inspectthemonorail/runwaybeamorpadeyeforcorrosion,mechanicaldamage,
deformationandcracks.
Inspectallloadbearingweldsforcracking.Atthediscretionoftheliftingengineer,
theintegrityofweldsmaybecheckedusinganappropriateNDTmethod.
Inspectforwearinthepadeyeholei.e.elongation.
At the discretion of the Lifting Engineer, the thickness of any part of the
monorail/runwaybeamorpadeyemaybecheckedusinganappropriateNDTmethod.
Thepermissiblelevelsofwear,erosionand/orcorrosion.

REJECTIONCRITERIA
Anywearorcorrosioninexcessof5%oftheoriginaldimension
Anycrackingatweldareas
Anydistortionorcracking
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7.8 Function Test

Oncompletionofasatisfactoryinspection,theapplianceshallbeoperatedthroughout
its full working height to check for correct function, freedom of movement and / or
excessivenoise,ifapplicable.
7.9 Load Test

Priortoanyloadtestofaliftingappliance,athoroughinspectionofthelifting
applianceshallbeundertakenbytheLiftingEngineer.
Thepurposeofloadtestingaliftingapplianceistodemonstratethatitisfitfortheuse
forwhichitwasdesigned.Atintervalsnotexceedingfour(4)years,allappliancesshall
beloadtested.Aloadequalto1.25timestheSafeWorkingLoad(SWL)oftheappliance
shallbeapplied.Theloadshouldberaisedandloweredthroughsuchaheightaswill
ensurethateverypartoftheappliancemechanismandeachtoothofthegearingcomes
underload.Tobeacceptablethetestloadmustbeheldbytheapplianceforaminimum
duration of 10 minutes, no lowering shall be discernable. While the appliance is
operatedunderload,theapplianceshouldoperatesmoothlywithoutexcessivenoise.
Anydisturbance,(disassemblyandreassembly)orrepairtoanyloadbearingpart
shallrequiretheliftingappliancetobesubjectedtoaloadtest.TheLiftingEngineer
fromthethirdpartyCertifyingCompanyshallwitnessallloadtests.

7.10 Documentation

Copiesofthecranemaintenanceschedulesandmaintenancerecords,NDTreports
andpreviouscertificatesofinspectionsshallbeprovidedtothethirdpartyCertifying
LiftingEngineerbythecraneowner,forinspection.

Copies of the manufacturer's certificate of test for replacement parts i.e. hoist
cylinders, hoist chains etc. shall be provided to the third party Certifying Lifting
Engineerfollowingtheirreplacement,forinspection.

Details of the certificate/s for the wire rope/s and/or chains to be checked, and
enteredontheCertificate/Report.
7.11 Identification / Marking

Allappliancesshallbeclearlymarkedwiththefollowinginformation:
a) EquipmentTagNumber(ETN)
b) SafeWorkingLoad(S.W.L.)
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c) DateofInspection
d) NextDueDate(ofInspection
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8. Inspection/Load testing of Lifted Equipment
8.1 Definition

Anyitemofliftedequipment(e.g.container,Frames,liftingbeams,spreaderbar,man
basket,skids,engineskidsetc.),whichformspartoftheload.
8.2 Inspection and Load Test of Lifting Beams, Frames and Spreader Bars

8.2.1 Thorough Inspection

EnsuretheLiftingBeam,FrameorSpreaderBarhastheIdentificationNumberand
SafeWorkingLoadclearlyandlegiblymarked.
InspecttheLiftingBeam,FrameorSpreaderBarforwear,deformation,distortion,
andcorrosion.
Inspectweldsforcracking.
Wheremanufactureisbymeansotherthanweldingtheserequiretobeinspected
fordeformation,distortion,corrosionandtightness.
Checktheliftingsetattachedisaspertheoriginaldesignrequirements;anychanges
totheliftingsetwithdissimilarpartswillrequireapprovalfromthedesigner.
The lifting set fitted to the Lifting Beam, Frame or Spreader Bar shall be visually
inspected. As this lifting set will normally be permanently attached to the Lifting
Beam,FrameorSpreaderBartheyshallbeinspectedatthesamefrequencyasthe
LiftingBeam,FrameorSpreaderBar.
Allpadeyesshallbesubjectedtonondestructiveinspectionataperiodnotexceeding1year.
ITEM MATERIALLOSSLIMIT
Asdefinedbytheliftingbeam,frameorspreaderbar
STRUCTURALMEMBERS designer.Wherenomaximumlimithasbeendefineda
maximumof10%atanypoint,shallbetheused.


8.2.2 Load Test of Lifting Beams/Frames and Spreader Bars

LiftingBeams/FramesandSpreaderBarswithasafeworkingloadupto10tons,the
loadshallbetwicethemarkedsafeworkingload.
LiftingBeams/FramesandSpreaderBarswithasafeworkingloadgreaterthan10
tonsbutlessthan160tons,theloadshallbe1.04timesthemarkedsafeworkingload
plus9.6ton.(i.e.1.04XSWL+9.6ton).
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LiftingBeams/FramesandSpreaderBarswithasafeworkingloadover160tons;the
loadshallbe1.1timesthemarkedsafeworkingload.
Theloadshallbesustainedforaminimumof2minutes.
8.2.3 Load Test of Lifting Beams/Frames and Spreader

Forliftingbeams/framesandspreaderbarswithcapacitiesover50tones,loadtesting
maybewaived.Thiswaivershallbeapprovedbyliftingengineeronconditionthatthe
followingarefullyadheredto:
Structural calculations require to be performed and provided on the lifting
beam/frame or spreader bar with Padeyes/trunnions, that demonstrates the lifting
beam/frameorspreaderbaradherestothesafetyfactorsandcalculationsdetailedin
acceptedcodeofpracticeforlifting.
The design of the lifting beam/frame or spreader bar shall be such that through
thicknessloadingofmaterialsisavoided.
Padeyes and any materials that transmit tension loading, have through thickness
properties,arefullytestedforlaminations.
Athoroughinspectionofthestructureandweldsrequiretobecarriedout.Allwelds
requiretobesubjecttoMPIand allfullpenetrationwelds requiretoalsobeultra
sonicallyinspectedpriortotheliftprogramstarting.Adimensionalcheckofthelifting
beam/frameorspreaderbarshallbeundertakentoensureconformancewithmaterial
anddimensiontolerances.
Theliftprogramtobeexecutedusingtheliftingbeam/frameorspreaderbarisclearly
defined,andshallbeofarestrictednature.
Thedesignoftheliftingbeam/frameorspreaderbarinconjunctionwiththeliftthatit
isintendedtobeusedforandliftplanshallbeassessedandapprovedbyarecognized
liftingengineer.
Ifaliftingbeam/frameoraspreaderbarisrequiredtobereusedforanewseparate
liftplan,thentheliftingbeam/frameorspreaderbarshallbesubjectedtoarepeatof
thisparagraph.
Additional NDT techniques maybe utilized if deemed necessary by the lifting
engineer/inspectori.e.UTthicknesschecks.
Iftheliftingbeam/frameorspreaderbarrequiresmodificationpriortobeingreused,
then the lifting beam/frame or spreader bar shall be subject to a repeat of this
paragraph.

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8.3 Identification / Marking

Allappliancesshallbeclearlymarkedwiththefollowinginformation:
e) EquipmentTagNumber(ETN)
f) SafeWorkingLoad(S.W.L.)
g) DateofInspection
h) NextDueDate(ofInspection)

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9. Inspection/Weight Verification of Test Weights
9.1 Inspection Frequency

Test weights require to be NDT and the weight verified in accordance with this
procedureattheintervalsdetailedbelow:
TESTWEIGHT VISUAL+NDT
TIME/INTERVAL
VERIFICATION (TESTWEIGHT)
BEFOREBEINGUSEDFORTHEFIRSTTIME YES YES
NOTEXCEEDING12MONTHS NO YES
NOTEXCEEDING60MONTHS YES YES

9.2 Thorough Inspection

TheLiftingEngineershallcarryoutathoroughinspectionofthetestweightin
accordancewiththefollowing.Thisistheminimumlevelofinspectionrequired.
9.2.1 Welds

Inspectallloadbearingweldsi.e.onPadeyestoensurefreedomfromdefects.Atthe
discretionoftheLiftingEngineer,theintegrityofweldsmaybecheckedusingan
appropriateNDTmethod.
9.2.2 Lifting Points

Inspectallliftingpointsfordistortion,mechanicaldamageoranyothersignsof
distress
9.2.3 Information Markings

Ensuretheweightinkilogramsislegiblymarkedincharactersofacontrastingcolor.
Ensure the Date Inspected and Next Due Dates are clearly and legibly marked in
charactersofacontrastingcolor.
Ensuretheuniqueidentificationnumberislegiblyweldedontothetestweight.



9.3 Test Weight Verification

TheInspectorshallsubmitNDTreportstotheLiftingEngineerpriortotheweight
verification
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Theweightshallbeverifiedusingacalibratedloadcell
TheLiftingEngineerfromthethirdpartyCertificationAuthorityshallwitnessalltest
weightverifications.

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10. Color Coding
Allliftingaccessoriesandliftingappliances,shallbethoroughlyinspectedat6monthly
intervals.
Uponsatisfactoryresultsofthethoroughexamination,theColorCodeshallbepainted
on every piece of lifting gear. The color indicates to the user that a thorough
examinationhasbeenperformedwithintheprescribedperiod.
Incaseofunsatisfactoryresults,theequipmentshallbequarantined,coloredredifto
bedisposed,ifrepairabletobecoloredblackandlockedawaytopreventunintended
use.Iftheequipmentcannotberepaireditshallberendereduseless.
Anewcolorshallbeintroducedeverysixmonthsandeachcolorshallbecurrentfora
periodof8months.Thetwomonthsoverlapistoensureliftinggearisavailableforuse
atalltimes.Therearefourcolorsinthesequenceandthecycleisrepeatedevery2years.
Companypracticeistohaveallavailableliftingaccessories/appliancesexaminedand
colorcodedtwiceperyearinFebruary/MarchandAugust/September.
Anyliftinggearthatdoesnothaveavisiblecolorbandorwherethecolorisoutofdate,
shallnotbeused.Itshallbereturnedtotheriggingstore.Suchequipmentshallnotbe
reissuedoruseduntilaftersatisfactorythoroughexaminationbyaliftingequipment
Inspector.
Painting of the color codes shall be the responsibility of the asset custodian or his
nomineeandshallbewitnessedbytheliftingequipmentInspector.
AllmainworksitesshallhavealiftinggearColorCodeIdentityBoardwiththecurrent
colorcodesdisplayed.
Theboardshalldisplaybothvalidcolorsduringchangeoutperiodandthesinglevalid
coloratothertimes.

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Appendixes and Records

Vessel operator shall keep rigging, equipment and quarantine lists to control all
the rigging on-board vessel.

Appendix 1, Risk Matrix


The RAM provides one means of determining the level of risk associated with any task through
considerationofthepotentialseverityofanyincidentandthelikelihoodofsuchanincidentoccurring.

The following interpretations may assist in determining likelihood when


assessing risks specific to lifting and hoisting operations:
LowRisk Maybeacceptablebutreviewtasktoseeifriskcanbereducedfurther.

MediumRisk Task should only be undertaken with appropriate management authorization after
consultation with specialist personnel and assessment team. Where possible, the task
shouldberedefinedtotakeaccountofthehazardsinvolvedortheriskshouldbereduced
furtherpriortotaskcommencement.

HighRisk Taskshallnotproceed.Itshouldberedefinedorfurthercontrolmeasuresputinplace
toreducerisk.Thecontrolsshouldbereassessedforadequacypriortotask
commencement.
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Appendix 2: Proof load tables

ProofLoadsforLiftingAccessories
Equipmenttype ProofLoad ProofLoad ProofLoad
AllSWLs SWL25t SWL25t
Beamclamps
Plateclamps 1.22xSWL+20
2xSWL
t
Singlelegwireropeslings
1.25xSWL
handsplice
Multilegwireropeslings Eachleg

handsplice 1.25xSWL
Singlelegwireropeslings
2xSWL
mech.splice
Multilegwireropeslings Eachleg

mech.splice 2xSWL
Allchainslings Eachleg2xSWL
Masterlinks 1.22xSWL+20
2xSWL
t
Riggingscrew 2xSWL BS4429
Shackles 2xSWL BS3551
Eyebolts 2xSWL BS4278
Swivels 1.22xSWL+20
2xSWL
t
1.22xSWL+20
Hooksandhookblocks 2xSWL
t

ProofLoadsforLiftingCranes
ProofLoad
ProofLoad ProofLoad ProofLoadSWL
Equipmenttype SWL25,<
AllSWLs SWL<25t 50t
50t
(Offshore)Pedestal
1.25xSWL SWL+5t 1.1xSWL
crane
Overheadcrane/
1.25xSWL
structure
Mobilecrane 1.1xSWL
Gantrycrane 1.25xSWL


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ProofLoadsforAppliances
ProofLoad ProofLoad ProofLoad ProofLoad ProofLoad ProofLoad ProofLoad
Equipment
type SWL10,< SWL25,<
AllSWLs SWL<10t SWL20t SWL<25t SWL160t
20t 160t
Poweredhoists 1.5XWLL WLL+5t 1.25XWLL
Manualhoists
1.5XWLL WLL+5t 1.25XWLL
(chainblocks)
Leverhoists
1.5XWLL
(pulllifts)
Wirerope
2XWLL
hoists(Tirfors)
Beamtrolleys 1.5XWLL WLL+5t 1.25XWLL
Sheaveblocks 1.5XWLL WLL+5t 1.25XWLL
Snatchblocks 1.5XWLL WLL+5t 1.25XWLL
Ginwheel 1.5XWLL WLL+5t 1.25XWLL
Poweredwinch 1.25XWLL
Manualwinch 1.25XWLL
Monorails&
2XWLL
padeyes
Manualjacks 1.5XWLL
Hydraulicjacks 1.5XWLL


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Appendix 3: Alternative Standards and Codes

AmericanNationalStandardsInstitute ANSI
AmericanPetroleumInstitute API
AmericanSocietyofMechanicalEngineers ASME
BritishStandardsInstitute BSI
TheProvisionandUseofWorkingEquipmentRegulations UKPUWER
LiftingOperationsandLiftingEquipmentRegulations LOLER
InternationalStandardsOrganization ISO
OccupationalSafetyandHealthAdministration OSHA
TheInternationalMarineContractorsAssociation IMCA
(GuidelinesforLiftingOperations)IMCASEL019,IMCA187October2007
OffshoreContainers:Design,Construction,Testing,Inspection&MarkingBS BSI
12097:1997
Inspection&RepairofOffshorecontainersBS7072:1989 BSI
OffshoreContainers&associatedsetsBSEN120793:2006 BSI
DNVStandardforcertificationNo.2.73PortableoffshoreunitsMay2011 DNV
DNVStandardforcertificationNo.2.71OffshorecontainersApril2006 DNV
Guidanceonwireropeintegritymanagementforvesselsintheoffshore IMCA
industryIMCASEL022Rev.2,IMCAM194Rev.2December2015
CodeofPracticefortheinitialandperiodicexamination,testingand IMCA
certificationofdivingplant&equipmentIMCAD018Rev.1June2014

Appendix 4: Records

Retention
S/No. Description Reference No.
time
01 LIFTINGOPERATIONPLAN F1/PMSOHSW03
02 HazardIdentification&RiskAssessment F1/PMSOHSW04
03 JobSafetyAnalysis(JSA) F2/PMSOHSW03
04 RiggingandEquipmentMasterregisterList F3/WI29
05 QuarantineregisterList F4/W29
06 FrequentSlingInspectionChecklist
07 RiskMatrix -----------
08 ColorCodes -----------