PETRONAS TECHNICAL STANDARDS HEALTH, SAFETY AND ENVIRONMENT
STANDARD LIFTING
PTS 60.2103 OCTOBER 2011
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
PTS 60.2103 October 2011
PTS Circular 2011 PTS No:
60.2103
PTS Title:
Lifting
This PTS 60.2103 - Lifting (October 2010, Revision 0) has been developed to provide standards and guidelines to ensure that all hoisting and rigging operations are performed safely and in conformance with all applicable standards, as well as to minimize the risk of injury to personnel and damage to equipment and property This PTS also includes PETRONAS Lessons Learnt and Best Practice for the subject matter Lifting. The custodian of this PTS is: Manager - HSE MS, Standards & Regulations, Group HSE Division. Please direct any questions regarding this PTS to the above-mentioned. Document Approval
Revision History Date Oct 2011
Version 0
Description of Updates
Author
New PTS document
Ahmad Nadzri Mustapha
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PTS 60.2103 October 2011 PREFACE
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the owner. The right to use PTS rests with three categories of users: 1)
PETRONAS and its affiliates.
2)
Other parties who are authorised to use PTS subject to appropriate contractual arrangements.
3)
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.
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PTS 60.2103 October 2011 ACKNOWLEDGEMENT
No. IWG Members
OPU
1
Ahmad Nadzri B Mustapha (Team Leader)
(PMO/PCSB)
2
Hanafi B Talib
(PMO/PCSB)
3
M Nasir B Osman
(PMO/PCSB)
4
Ibrahim B Ismail
(PMO/PCSB)
5
Ahmad Syahidi B Che Zainal
(SKO/PCSB)
6
Tandel V R
(SKO/PCSB)
7
K Samunathan
(SBO/PCSB)
8
M Jamizal B Zainol
(MD/PCSB)
9
Busari Jabar
10
Zaidi B Mat Dom
11
Michael Jihem Sitang
(PLM/MLNG)
12
M Nizam B Omar
(MCI/PPMSB)
13
W M Razainul Amin B W Zakaria
(MTN/MTBE)
14
A Hakim B A Rahman
(MAINT/PMLSB)
15
Anjuna Lee Foong Yee
(R&T/PETH)
16
Zaini B Minin
(R&T/PETH)
17
Ramle B Awang
(R&T/PETH)
18
M K Shrivastava
(R&T/PETH)
(GHSED) (POD/PGB)
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PTS 60.2103 October 2011 Contents 1. INTRODUCTION ...................................................................................................................................... 7
....................................................................................................................................... 7
1.1.
Scope
1.2.
Definition ....................................................................................................................................... 7
1.3.
Cross-reference .............................................................................................................................. 7
2. DISTRIBUTION , INTENDED USE AND REGULATORY CONSIDERATIONS ...................................... 8 3. ROLES AND RESPONSIBLITIES ........................................................................................................... 8 3.1.
PETRONAS OPU/HCU .................................................................................................................. 8
3.2.
The Contractor................................................................................................................................ 8
3.3.
The Responsibilities of Various Parties .......................................................................................... 9
4. GENERAL REQUIREMENTS ................................................................................................................ 10 4.1.
Lifting Operations ......................................................................................................................... 10
4.2.
Standards & Requirements on Lifting Tackles & Accessories ..................................................... 15
4.3.
Integrity Management ................................................................................................................... 18
4.4.
Training and Competency ............................................................................................................ 21
4.5.
Audit and Monitoring..................................................................................................................... 24
5. OPERATING STANDARDS PRACTICES ............................................................................................. 24 5.1.
Offshore Pedestal Cranes ............................................................................................................ 24
5.2.
Mobile Crane/Crawler ................................................................................................................... 26
5.3.
Overhead and Gantry Crane ........................................................................................................ 27
5.4.
Tower Crane ................................................................................................................................. 28
5.5.
Minimum Standards on Cranes .................................................................................................... 30
6. LIFTING APPLIANCES INSPECTION, MAINTENANCE & TESTING .................................................. 36 6.1.
Offshore Pedestal Cranes ............................................................................................................ 37
6.2.
Mobile Crane/Crawler ................................................................................................................... 42
6.3.
Overhead and Gantry Crane ........................................................................................................ 46
6.4.
Pillar/Jib Cranes and Monorail Systems ...................................................................................... 48
6.5.
Hoist (Applicable for Cranes) ....................................................................................................... 51
6.6.
Other Lifting Appliances/Machinery.............................................................................................. 55
7. REFERENCES ....................................................................................................................................... 62
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PTS 60.2103 October 2011 APPENDIX I : Terms and Definitions .......................................................................................................... 64 APPENDIX II : Pre-Use Inspection Checklist – Pedestal Crane................................................................. 67 APPENDIX III : Monthly Inspection Checklist – Pedestal Crane ................................................................ 68 APPENDIX IV : Quarterly Inspection Checklist - Pedestal Crane ............................................................. 69 APPENDIX V : Semi-Annual Inspection Checklist – Pedestal Crane ......................................................... 70 APPENDIX VI : Annual Inspection Checklist - Pedestal Crane ................................................................. 71 APPENDIX VII : General Guideline of Load Testing .................................................................................. 72 APPENDIX VIII : Pre-Use Inspection Checklist – Mobile Crane................................................................. 73 APPENDIX IX : Annual Inspection Checklist - Mobile Crane .................................................................... 74 APPENDIX X : Pre-Use Inspection Checklist – Overhead/Gantry Crane .................................................. 75 APPENDIX XI : Semi-Annual Inspection Checklist - Overhead/Gantry Crane .......................................... 76 APPENDIX XII : Pre-Use Inspection Checklist – Pillar/Jib Crane............................................................... 78 APPENDIX XIII : Quarterly Inspection Checklist - Pillar/Jib Crane ............................................................ 79 APPENDIX XIV : Annual Inspection Checklist - Pillar/Jib Crane ............................................................... 80 APPENDIX XV : Pre-Use Inspection Checklist - Hoist ............................................................................... 81 APPENDIX XVI : Quarterly Inspection Checklist - Hoist ............................................................................. 82 APPENDIX XVII : Semi-Annual Inspection Checklist – Hoist ..................................................................... 83 APPENDIX XVIII : Annual Inspection Checklist - Hoist .............................................................................. 84 APPENDIX XIX : Standard Hand Signals ................................................................................................... 85 APPENDIX XX : Safety Distance for Lifting Near Power Lines .................................................................. 86 APPENDIX XXI : Lift Plan - SAMPLE ......................................................................................................... 87
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PTS 60.2103 October 2011 1. INTRODUCTION Heavy material handling requiring the use of cranes or hoists is a potentially hazardous activity. To assure the safety of such operations, stringent controls for the use of such equipment, including below-the-hook components should be exercised, and the procurement, maintenance and inspection of all such equipment should be strictly controlled. This publication is intended to provide guidelines with which the management of PETRONAS OPU/HCU can assess its practices and procedures to assure that all hoisting and rigging operations are performed safely and in conformance with all applicable standards, as well as to minimize the risk of injury to personnel and damage to equipment and property. This document should always be used in conjunction with local statutory regulations. Should any significant deviations be made from the requirements of this PTS document, users are required to inform Management of the OPU of the nature and justification for t the deviations. 1.1. Scope This PTS specifies appropriate standards, procedures and guidelines to operation, inspection and maintenance for various types of cranes, lifting appliances and lifting tackles. 1.2. Definition The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier/Vendor is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party that initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal. The word “shall” indicates a requirement. The word “should” indicates a recommendation. Please see Appendix I for other terms and definitions. 1.3. Cross-reference Where cross-references to other parts of this PTS are made, the referenced section number is shown in brackets. Other documents referenced by this PTS are listed in Section 7.
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PTS 60.2103 October 2011 2. DISTRIBUTION , INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined to companies forming part of PETRONAS or managed by a Group company, and to Contractors and Manufacturers/Suppliers nominated by them. This PTS is intended for use in oil refineries, chemical plants, gas plants, exploration and production facilities, supply/marketing installations and project/construction sites. If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are more stringent and which combination of requirements will be acceptable with regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this PTS which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this PTS as closely as possible. 3. ROLES AND RESPONSIBLITIES 3.1.
PETRONAS OPU/HCU a) Lifting operations are generally carried out by Contractors. The Contractor has prime responsibility for the safe lifting operations. However, the PETRONAS OPU/HCU remains accountable responsible for safety on site and also for the safe execution of projects. b) In addition to selecting a competent Contractor, OPU/HCU shall
3.2.
ensure that the established OPU/HCU’s standards and procedures are available, understood and agreed by the Contractor.
verify that the Contractor provides proper training in safe operation of lifting equipment and appliances for his personnel.
verify that the Contractor provides adequate supervision of the work in hand.
be responsible to undertake similar roles and responsibilities as the contractor as per item 3.2 below for lifting equipment or appliances owned by the OPU and operated by its own personnel.
The Contractor The Contractor shall:
Provide qualified lifting engineer to certify crane assembly and erection at site and ensure compliance with national or local regulatory body.
ensure that lifting devices and lifting fixtures used for the work are properly documented and inspected, maintained safely to ensure integrity is not affected or jeopardized during applications (e.g. due to improper use or modifications).
ensure that all its employees adhere to the recognized standard or code of practice with respect to the lifting operations and maintenance of the equipment
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PTS 60.2103 October 2011
3.3.
provide proper training for its personnel in safe operations of lifting equipment and appliances
provide adequate safety clothing and equipment such as gloves, overalls, helmets, safety shoes and harnesses, lifelines, safety nets and life jackets (if working above water) and ensure the proper use of the safety equipment.
carry out regular quality control checks on lifting equipment and appliances.
exercise adequate supervision of lifting work in hand.
The Responsibilities of Various Parties The responsibilities of various parties applicable for typical lifting activities are generally summarized below: a) Supervisors (OPU or contractor) Supervisors shall ensure that personnel know how to safely operate cranes and hoists and how to move objects safely. Supervisors must enforce the use of safe lifting techniques, and ensure lifting equipment in good mechanical and operating condition. b) Employee/Users Employee/users are required to observe all established safety regulations relating to safe lifting and handling techniques. The user should ensure at all times that lifting equipment and appliances are safely used and not modified without authorization. c) Lifting Engineer / Technical or Area Authorities Appointed OPU’s personnel from technical discipline shall review and approve appropriate engineering layout, lifting fixtures and configurations as laid out in the Lifting Plan. d) Area Owner/Project Owner Area owner/project owner is accountable for defining and requesting any move/lift; determining which activities are considered as Critical Lifting; writing lifting procedures where required; providing technical information on relevant characteristics of the apparatus, including special lifting fixtures when required; providing suggestions on rigging and moving; and assigning resources for planning and coordination of all aspects of the job being performed. e) Crane Operator Crane operator is responsible for correct and safe operation of the crane under his or her directs control accordance to PETRONAS and host country guideline. The crane operator shall ensure crane is safe to be used by performing inspection before and after lifting operation and also perform front line maintenance. f)
Rigger Rigger is responsible to attach and detach the load to and from crane load lifting attachment in safe manner and for using correct lifting tackle and accessories.
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PTS 60.2103 October 2011 g) Signalman Signalman is responsible to relay information to crane operator for safe movement or crane and load. The signalman shall stop the lifting operation if he found the condition is not safe to do lifting. h) Inspector Inspector shall inspect and verify the crane safe to be used in accordance to relevant PETRONAS guidelines or host country regulation. 4. GENERAL REQUIREMENTS 4.1.
Lifting Operations 4.1.1.
General a) All use, maintenance, storage, checks, inspection and examination of lifting equipment shall comply with the manufacturer’s instructions. b) Lifting operation shall be carried out using right equipment i.e. crane or hoist suitable for the job. c) Mobile cranes (except crawler crane) shall not be used onboard marine vessel or barge. d) Only personnel who have been trained and/or certified competent (as required by applicable laws and regulations) shall be authorized to operate cranes. (see Section 4.4 - Training and Competencies for details on training requirements).
4.1.2.
Permit to Work (PTW) and Job Safety Analysis(JSA) a) All lifting operations shall be controlled through use of PTW and relevant lifting certificate and checklist completed and approved. In addition to Lifting Certificate, Lifting Plan shall be prepared for critical lifts as listed in item 4.1.3 below b) During the execution of a lifting operation, if there is a change in operational conditions or in the assumptions on which the risk mapping was based, the operation shall cease and the need for a new risk assessment and implementation of any corrective safety measures shall be considered.
4.1.3.
Lifting Plan a) Lifting Plan shall be prepared for critical lifting operations using cranes or other lifting appliances or equipment in order to manage the risks. These operations include, but are not limited to:
Lifting more than 20 tons of load.
Lifting over live or critical/sensitive process equipment or facility.
Lifting load of weight more than 80% of rated capacity of the lifting equipment at the specified working radius and boom angle as per crane load chart.
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PTS 60.2103 October 2011
Personnel transport using lifting appliance.
Lift of special loads such as structures, mobile cranes, boiler and vessel.
Lifting operation using helicopter.
Coordinated lift whereby the weight exceeds the maximum lifting capacity of one of the lifting appliances e.g. using of multiple cranes.
Lifting operation at location less than the specified Safety Distance from live overhead power line (refer to Appendix XX: Safety Distance Calculation)
Lifting operations for testing purposes to ensure integrity or functionality of the lifting equipment after installation, structural repair or modification of the equipment including functional or proof load tests
Subsea operations using offshore crane.
Other lifting operation which are deemed as critical or high risk and determined in the OPU’s Hazards and Effect Register e.g. blind lift, lifting through hatches.
b) Lifting operation shall be planned in order to ensure safe execution and that all predictable risks are taken into consideration. c) The planning shall be carried out by personnel who have the relevant competence deem acceptable by PETRONAS OPUs. d) For repeated or routine operations, such planning is only necessary for the first time, provided that an operating procedure is in place or documented in another way. Periodic revisions shall be carried out to ensure that no critical factors have changed. e) Lifting plan shall be documented and, as a minimum, ensure that
all personnel involved are familiar with the task, i.e. what is to be lifted, weight of the load, what lifting equipment to use, the travel path, and the roles of the persons involved in the lifting operation.
competent and sufficient personnel are present at all phases of the lifting operation, the travel path is clarified and any obstacles are removed before lifting commences,
method of communication is clarified,
the lifting operation can be executed safely in relation to simultaneous operations,
lifting appliances and lifting gear are suitable and will be used in accordance with the manufacturer’s instructions for use,
the landing area can accommodate the load in terms of size and weight,
use of tag line is considered,
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PTS 60.2103 October 2011
personnel involved have sufficient competence and knowledge of the regulations and standards that govern the operation that is to be executed,
lifting or technical authorities is involved in tandem lifts where the weight can exceed the lifting capacity of one of the lifting appliances
work area shall be barricaded,
Load calculation shall be included in Lifting Plan.
NOTE: Example of Lift Plan format or shown in Appendix XXI. 4.1.4.
Pre-Use Inspection a) Each lifting equipment and machinery shall be inspected by a qualified personnel before use, during any given work shift. The inspection can be documented on a tag attached to the crane controls, or it may be documented in a log that is kept with the key that unlocks the crane controls. b) Details on pre-use inspections for various types of lifting equipment and machinery are described in Section 6.
4.1.5.
Communication a) At all times there shall be adequate communication between all personnel who are involved in the lifting operation. b) When performing lifting operations in very noisy areas, radio with head set should be used. c) In case of unclear or failing communication, immediately stop the lifting operation until safe communication has been restored. d) Radio equipment appropriate for the relevant lifting operation shall be used. Radio check shall be carried out prior to the start of the lifting operation. e) When directing the load, instructions shall be clear and unambiguous. f)
The lifting appliance operator can repeat the signal man’s instructions (confirmatory communication) to avoid any misunderstandings during lifting operations.
g) Where appropriate, a communication method can be chosen whereby the signal man gives a continuous signal to continue the movement. The lifting appliance operator shall stop immediately if he does not receive the signal. h) The method of communication to be used shall be agreed as part of the pre-job talk or JSA. i)
Communication shall be in a common language that is understandable by both the lifting appliance operator and signal man. All personnel who are involved shall be competent in the language chosen.
j)
If visual signals are used, the hand signals shown in Appendix XIX shall be used.
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PTS 60.2103 October 2011 4.1.6.
Rigging and Slinging a) The crane operator is responsible for verifying that the load is properly rigged.
Use engineered attachment points and standard hardware (swivel lift rings, shackles, and nylon slings) wherever possible.
Verify that all slings and hardware are rated for more than the expected load, and are appropriate for the intended type of load and direction.
Verify that all slings and special lifting hardware have valid inspection tags.
b) Signal Man and Rigger
Lifting operations with cranes shall be carried out with a minimum of three roles involved: the lifting appliance operator, signal man and rigger.
For all other permanent lifting appliances (traveling cranes, wire line winches, personnel and work winches, etc.) a risk analysis defining the minimum number of staff required to perform lifting operations as and when required.
The signal man and rigger shall not change roles during the performance of a lifting operation. If the lifting appliance operator has a good visual overview of the area, the slinger can, with clearance from the lifting appliance operator, handle the load when it is under control and below hip height (1.3m).
The signal man and rigger shall stand in a safe area at all times when the crane and/or lifting wire is moving. The slinger can manually guide the empty hook to and from the load or load carrier.
If the lifting appliance operator has a good visual overview of the area, the slinger can, with clearance from the lifting appliance operator, handle/maneuver the load when it is under control and below shoulder height.
If the lifting appliance operator has a good visual overview of the area, the signal man can carry out the slinger’s duties. In such circumstances, the signal man can, with clearance from the lifting appliance operator, handle/maneuver the load when it is under control and below shoulder height, and manually guide the empty hook to and from the load or load carrier.
c) Blind Lifts
In connection with blind lifts, there shall always be at least two persons (signal man and rigger) who have visual contact with the load and each other, and have radio contact with the lifting appliance operator. Any closed circuit television that monitors the work area is considered to be an aid, and not a replacement for either of these persons.
If load has to be pushed or pulled into position manually, a signal man shall be present close to the load such that he can direct the lifting appliance safely and thereby address the safety of other involved persons.
Where possible, the signal man should place himself in a position where he can give the stop signal manually in the event of radio failure.
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PTS 60.2103 October 2011 d) Lifting through hatches and in shafts
For lifting operations through hatches and in shafts, the requirements for blind lifts apply,
Lifting through several levels shall be covered by OPU/HCU standard and procedures including JSA. In particular, the risk of the load or load carrier snagging on hatch frames should be assessed.
For crane operations in shafts, the lifting appliance operator shall ensure that the lifting appliance brake function is active and that any function for automatic overload protection is disconnected during the operation.
e) Use of tag line
4.1.7.
Lifting appliance operator shall assess and approve the use of tag line.
The end of the rope shall be secured against fraying, but knots shall not be used at the free end of the rope.
For internal movement of load, tag line can be used.
Tag line should be used to keep control of a load, not to gain control over a load.
If several tag lines are necessary, personnel who are not deck operators can be involved in the operation. JSA shall then be carried out, and the personnel shall have undergone the necessary training related to the use of tag lines.
Obtain assistance from professional rigging crew for loads that require special rigging. Be particularly careful with potentially unstable loads, including choker lifts of long loads and loads with a high center of gravity (e.g., lifting pallet loads with slings).
Other Safety Requirements a) Minimum PPE requirements as per OPU/HCU’s policy and standards shall be used by personnel involved in lifting operation. b) All personnel operating a crane or hoist, participating in the lift or within 15 feet of the vertical plane of the load, where the under carriage of the bridge is more than 12 feet from the ground, must wear approved hard hats. c) Sturdy work gloves must be worn when handling wire rope or loads with rough or sharp edges or splinters. d) Barriers shall be installed at appropriate location where lifting operations take place to prevent personnel from walking or standing under suspended load. e) Any electric powered crane that is not attended by a qualified operator for an entire shift and during off hours must be secured by locked controls, or equivalent means such as preventing access to the crane by locking the doors, or locking up radio/pendant controls. Only authorized user of the secured crane may have control of the locking mechanism.
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PTS 60.2103 October 2011 f)
4.2.
Crane under maintenance shall not be used for lifting operation and proper signage to be displayed.
Standards & Requirements on Lifting Tackles & Accessories 4.2.1.
Sling a) Appropriate and approve sling shall be used. b) The load shall be attached to the hook by means of slings or other suitable lifting gear. Protective material shall be placed between the slings and any sharp edges, and a check shall be carried out to ensure that the bend diameter complies with the manufacturer’s instructions for use. c) If several slings are used in the same eye or hook they shall not lay on top of each other. d) When slings or chains are used, consideration shall be given to the number of legs, the angle and other factors that alter the capacity of the sling. e) The sling shall be tensioned with care, and not jerked. Care shall be taken to ensure that the load is distributed evenly between sling legs
4.2.2.
Chain Special care shall be exercised when using chain. The pre-use check shall focus in particular on corrosion and flexibility of each link.
4.2.3.
Shackles a) When choosing a shackle, the overall load and working angles must be considered carefully. b) If shackle is used to connect two slings to the hook of a lifting machine, it shall be a Bow type shackle assembled with the slings in the shackle body and the hook engaged with shackle pin. The include angle between the slings shall not exceed 120 degree. c) When shackles are used in a lifting lug, the shackle’s Safe Working Limit (SWL) shall be equal or greater than the lifting lug’s Working Load Limit (WLL). d) The load on the shackle must be centered on the shackle pin to avoid lop side loading on the shackle base e) For critical lifting, only shackles with double locking shall be used, for example nut plus split pin or screwed connection with split pin. Other types of pin shall not be used. For securing static loads, other types of shackle can be used. f)
Shackles without rotating bolt should not be used in permanently installed lifting arrangement due to the danger of transferring rotating forces to the shackle bolt.
g) If shackle without rotating bolt is used in lifting arrangement, the bolt shall be properly secured to withstand any rotating forces transferred to the shackle bolt
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PTS 60.2103 October 2011 4.2.4.
Eye bolts and eye nut a) Eye bolts and eye nuts shall always be screwed in to the point where the entire collar is in contact with the surface. b) Pre-use check shall include a check of the threads in the material in which the eyebolt will be mounted, and that the thread dimension and type are the same
4.2.5.
Wire Rope Termination a) Wire rope clamp
If Wire rope clamps need to be used as termination, it shall be of a type with two gripping surfaces. U-bolt clamps shall not be used on lifting equipment.
When using wire rope clamps, the minimum breaking load of the wire rope shall be reduced in accordance with manufacturer’s instructions for use, and the correct number of clamps shall be used.
Wire rope sling with clamp termination shall not be used for lifting
b) Zinc (spelter) and Swaged Socket
4.2.6.
Manufacturer instruction and recommendation shall be followed to ensure 100% efficiency of termination
When inspecting existing socket connection, examine the rope closely for corrosion at the socket base. This corroded wire is very susceptible to fatigue
Beam Clamps and Beam Trolley a) If trolleys are used, end stops on beam shall be installed. b) Trolleys without automatic brake shall always be secured against unintentional movement during and after use c) Beam clamps shall be installed as described in the manufacturer’s instructions for use, and not be subjected to load beyond the stated load angles
4.2.7.
Turnbuckle If turnbuckles are used in the lifting arrangement, they shall be inspected and approved for lifting.
4.2.8.
Lifting Nipples and Lifting Cap a) Lifting nipples and lifting caps shall be certified and approved for lifting. b) Before use, a check shall always be carried out to ensure that the thread section on the pipe and on the lifting nipple or lifting cap are undamaged, that the lifting equipment is correctly installed, and that the thread dimension and type are the same. c) When moving load with lifting nipple or lifting cap, the area below the travel path shall be barricaded
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PTS 60.2103 October 2011 4.2.9.
Single and Multi-sheave Block a) When securing snatch block to the load bearing structure, the operator shall ensure that all split pins, locking and safety pins are in place and in good condition. b) The user shall ensure that the load bearing structure is strong enough to withstand the resultant force (load plus wire tension and any friction forces) and that the snatch block is correctly positioned such that the wire rope does not rub against the side plates. c) For complex arrangements, a lifting/technical authorities shall verify the correct setup and calculations of resultant forces
4.2.10. Load Carrier a) Load carrier shall be designed, constructed, inspected and maintained to applicable codes and standards acceptable by PETRONAS i.e. BS EN12079 Offshore containers. Design, construction, testing, inspection and marking or DNV2.7-1 b) Before use, the slinger shall check that the load carrier and attached lifting set are suitable and that the load is satisfactorily secured. c) The check should include:
load carrier has been controlled and approved,
all load is secured in such a way that it cannot move around,
load does not stick out over the sides of the load carrier,
multi-leg sling on open load carriers, tanks, special containers and modules are secured against snagging the load etc. Net or canvas can be used as covering, or the legs of the slings can be secured with cable ties,
all load is positioned such that it is easy and safe for the receiver to handle the material when unloading the load carrier,
equipment is always placed on pallets when loading containers,
safety net is used to prevent load from falling out of load carriers with doors,
heavy and/or unstable items are secured by means of tensioning arrangement,
there are no loose parts on the load that could fall off during the lift,
when lifting using cranes or hoists, multi-leg chain slings are not crossed when attached to load,
all load are registered on a manifest,
type of dangerous goods is stated on the manifest,
required safety data sheets (SDS), declarations etc. always accompany dangerous goods,
containers are sealed with a seal having a unique number,
tags on load carriers show the correct destination and are signed
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PTS 60.2103 October 2011 d) Load carriers on marine support craft shall not be stacked on top of each other, either on the installation or on the vessel. However, if hooking on can be done from deck level, an exception can be made for empty garbage containers which, in accordance with the instructions for use, can be stacked into each other. Stacking shall be limited to a maximum of three empty garbage containers. In connection with this stacking, particular attention shall be given to increased windbreak, and to ensure prevention of damage to the slings. e) Load and personnel shall not be lifted in a single lift operation. f)
When placing load in load carrier, the load shall be set down on pallets/timber and secured when required. The weight shall be distributed evenly in the load carrier insofar as possible. Heavy loads should be placed at the bottom of containers.
g) Lifting set for offshore load carrier (sling assembly and shackles) should not be removed except for inspection and maintenance, or if load carrier installed for a longer period on an installation 4.2.11. Load Carrier for Gas Bottles Gas bottles shall be transported with fitted protection cap in load carrier designed for the purpose. 4.2.12. Big Bags/Jumbo Bag a) Flexible bulk container used as standard container for transporting of dry material such as sand, plastic granule or other product using lifting appliance. b) Big bags for repeated use shall be documented as lifting gear. Big bags for single use to transport product shall have a type certificate in accordance with European Flexible Intermediate Bulk Container Association (EFIBCA). “Single use” means transport product in big bag from the manufacturer to the loading point. c) Big bags shall only be used in connection with lifting of load to/from load carrier 4.2.13. The following Equipment Should Not Be Used: a) b) c) d) 4.3.
Plate clips Magnetic yoke Vacuum yoke Barrel lifter except for handling barrels into/out of barrel baskets
Integrity Management 4.3.1.
Lifting equipment shall not be modified for purposes other than those stated without the consent of the manufacturer and/or applicable authorities
4.3.2.
Detailed requirements on inspection and testing of lifting equipment are described in Section 6. This includes the requirements for: a) Pre-use Inspection b) Periodic Inspection (Weekly, Monthly, Quarterly or Annually) c) Load Testing
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PTS 60.2103 October 2011 4.3.3.
Lifting appliances shall not be used if safety systems or parts of safety systems are not functioning or have been isolated. Examples of safety systems are a) b) c) d) e) f) g) h) i)
4.3.4.
Limit switches Crane overload protection Safe Load Indicator Anti-2-block system Wind speed indicator Boom angle indicator system Hook safety latch and pin Spark arrester Over speed shut off
Servicing and repair of equipment. a) Structural modifications of lifting equipment shall only be carried out by competent persons. b) When lifting appliances such as slings, hooks and shackles have been modified structurally, they should be load tested, certified, labelled/tagged and/or colourcoded
4.3.5.
Maintenance Frequency and Record of Equipment All inspections, testing and maintenance of lifting equipment and machinery shall be documented. As a minimum the following shall be documented:
Pre use checks performed by the Crane Operator (Operator). All maintenance ctivities Change out of critical items Test certificates Load test and results Any approved modifications Any deviations supported by a MOC with the necessary approval
All records shall be retained for seven years or such a time when a critical item with certificate is expired. 4.3.6.
Storage of loose lifting appliances a) All installations shall have dedicated area(s) where loose lifting appliance not in use shall be stored. Loose lifting equipment shall be protected against the weather and other harmful conditions during storage. Sizeable lifting gear such as lifting beams, pendants, internal load carriers and similar shall insofar as practically possible, be protected against harmful conditions during storage. b) An updated index should be kept of the issue and return of lifting equipment used in connection with setting up of temporary lifting appliances. c) The user shall inspect loose lifting equipment for the correct marking, possible overload, wear and damage, before and after use. d) The user is responsible for returning loose lifting equipment to the storage area after use.
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PTS 60.2103 October 2011 e) Defect and damaged loose lifting equipment shall be marked and set aside at a designated place clearly identified for this purpose 4.3.7.
Design and Maintenance of Lifting Tackles and Accessories a) Design of Lifting Tackles and Accessories
Design, fabrication, and testing of lifting fixtures that are self-fabricated shall be carried out by a qualified engineer. The actual physical testing shall be performed in accordance with the approved test procedures which include, amongst others, the calculation of lifting fixture stresses and deflections.
The design stress for lifting fixtures or lifting attachment points must not exceed one-fifth the ultimate strength of the material at its operating temperature.
If welded fabrication is used, the design stress must take into consideration any weakening effects of welding. Design and fabrication in conformance with the latest standards of the American Welding Society (AWS) or equivalent are required. All welds in lifting fixtures must be certified welds, performed by certified welders, and inspected and certified by certified weld inspectors.
Makeshift lifting fixtures shall be subjected to load test to twice the maximum rated load and followed by a non-destructive examination.
b) Inspection and Testing of Lifting Tackle & Accessories Slings, shackles, lifting eyes, and other Below-the-Hook devices are most vulnerable to damage from wear and abuse and require inspection and testing.
Load test tag/certificate, inspection stickers, or colour code shall be current, where applicable.
All makeshift lifting tackles, accessories or fixtures designed and internally fabricated by the OPU shall be proof-tested to twice their Safe Working Load (SWL) before being placed in service. A Non-Destructive Examination (NDE) is required after the proof test. The rated capacity must be marked on the lifting fixture so that it is clearly visible to the equipment operator.
For commercial lifting fixtures without certified load ratings, relevant engineering documentation or certificates shall be made available to determine the safe load capacity, and to furnish guidance for load testing.
Active lifting devices and fixtures must be examined using NDE at least once every four years (or upon request), using magnetic particle detection or other appropriate methods and the examination records must be maintained. Inactive lifting devices and fixtures must be clearly marked “STOP DO NOT USE,” and must be load tested and certified prior to renewed use.
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PTS 60.2103 October 2011 4.3.8.
Identification & Color Coding of Lifting Appliance a) Every item of lifting equipment, portable and fixed shall be clearly marked with:
Colour code Identification Number / Tag Number of the item Safe Working Load (SWL) Next inspection date
b) The colour code in use shall be prominently displayed on the facility and in the rigging loft on an indicator board as per applicable host country regulations. Note: The colour code strip will slide onto the board so that it can easily be changed periodically as necessary. c) The following are colours code shall be used:
GREEN (Jan till June) YELLOW (July till December)
d) Any Lifting appliance not bearing the valid colour code SHALL NOT be used. An item found with the wrong colour shall be removed from the facility for inspection and re-certification. e) Lifting appliances that found damage or not fit to use shall be destroyed e.g. cut 4.4.
Training and Competency 4.4.1.
General a) All parties involved in lifting operations shall receive a basic training in the relevant code of practice and safety regulations. The training shall cover with safety procedures and technical aspects at various levels. b) The PETRONAS OPU/HCU is accountable for ensuring that in-house lifting supervisors are properly trained and qualified, and that Users have a basic understanding of lifting safety. c) Training for lifting supervisors shall address relevant lifting standards and legislation, safety inspections and safe lifting operations with a basic introduction of structural mechanics. d) The OPU/HCU shall also ensure that a Contractor is made fully aware of the activities being carried out on site and shall be given full notice of potential hazards through Contractor's induction training. e) The Contractor is responsible for providing technical and practical training required for lifting equipment operators, riggers and signalers. It is essential that qualified and competent personnel (as may be required by statutory laws and regulations) are employed to operate and maintain lifting equipment and appliances
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PTS 60.2103 October 2011 4.4.2.
Competency Requirement a) Crane Operator
Crane operator shall undergo Crane Operator course at training centre recognized by national and/or local regulatory bodies. Note: Where local regulation does not exist, training can be conducted by any Crane manufacturer holding an API 2C Monogram License and who are providing such training and certification for Trainers / Assessors. As minimum, training program shall meet API RP 2D requirements.
All crane operators shall be registered with the national and/or local regulatory bodies before they are allowed to operate tower and mobile cranes. Note: In Malaysia; to enforce this directive, the DOSH will use provision 26(1) of the Factories and Machinery (Notification, Certificate of Fitness and Inspection) Regulations1970 to stipulate that all the said cranes must be operated by certificated operators. -
Tower crane (Menara) Mobile crane (Bergerak) Derrick crane (Derik)
Authorization by OPU management is required to operate the crane.
Crane operator shall be reassessed every 3 years.
Crane operator of age 40 years old and below shall undergo full medical check- up minimum every 2 years. Crane operator of age above 40 years shall undergo full medical check-up annually by qualified OSH medical practitioner/PETRONAS panel OSH doctor as per PTS 60.1501.06 Fitness to Work.
Mobile Crane Operator shall obtain valid driving license from the national and/or regulatory bodies. Note: for Malaysia; Class H driving license.
b) Crane Inspector
Crane inspector shall undergo Crane inspector course recognized by national and/or local regulatory bodies. Note: Where local regulation does not exist, training can be conducted by any Crane manufacturer holding an API 2C Monogram License and who are providing such training and certification for Trainers / Assessors. As minimum, training program shall meet API RP 2D requirements.
Crane inspection training program shall be based on OSHA and ASME standard or equivalent. Topic to be included: -
Relevant manufacturer standard, federal, state and all local requirement Inspector responsibilities Equipment design and consideration Equipment usage/ environmental consideration
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PTS 60.2103 October 2011 -
Accidents consideration due to faulty equipment Inspection procedure Wire rope inspection Deficiencies reporting Documentation required and report
Crane Inspector must obtain certification/qualification from -
any crane manufacturer holding an API 2C Monogram License and who are providing such training and certification for Trainers / Assessors OR institution recognized by national and/or local regulatory bodies
Authorization by OPU management is required
Crane inspector shall be reassessed every 3 years
c) Rigger
Rigger must attend rigging and slinging training organized by institution recognized by national and/or local regulatory bodies e.g CIDB/NIOSH for Malaysian operator.
Refresher course shall be attended every 2 years.
d) Forklift Operator
Forklift Operator shall attend training organized by institution recognized by national and/or local regulatory bodies.
Operator shall attend refresher course every 2 years if the frequency of operating Forklift is less than 50 hours for the past 2 years. Authorization by OPU management is required for driving forklift.
Forklift Operator shall obtain valid driving license from the national and/or regulatory bodies if travelling on the road. Note: For Malaysia; Class H driving license.
e) Survival Craft Inspector
f)
Survival craft inspector shall attend training as recommended by respective survival craft OEM. Survival Craft Inspector shall be reassessed every 3 years.
Inspector shall attend training recognized by national and/or local regulatory bodies e.g. IMO
Lift/Elevator Inspector
Lift/elevator inspector shall attend training at training centre recognized by national and/or local regulatory bodies. Lift/elevator inspector shall be reassessed every 3 years.
g) Others lifting appliances
Operator shall be trained and assessed by experienced operator on the specific equipment
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PTS 60.2103 October 2011 4.5.
Audit and Monitoring OPU/HCU should have a system in operation for regular audits and inspections in order to monitor whether:
The Contractor adheres to the agreed standard or code of practice with respect to lifting equipment and appliances and their operations.
The Contractor employs competent personnel.
5. OPERATING STANDARDS PRACTICES 5.1.
Offshore Pedestal Cranes 5.1.1.
The qualified Crane Operator (herein referred as the operator) is responsible for safe operation of the crane. The following are guidelines for good operating practices: a) The operator has the authority to stop work and refuse to handle loads or continue lifting operations in an unsafe condition. b) During bad weather with lightning or strong wind (56 km/hr and above), or poor visibility to see the signal person due to darkness, fog, rain, etc., crane operations can be restricted at the Operator’s discretion and agreed by OPU/HCU representative. c) The operator shall verify the following prior starting the crane
Pre-use inspection has been completed All controls are in the “off” or “neutral” position Area is clear from all personnel
d) Prior lifting the load, exposed brakes shall be warmed and rusted surfaces on the drums cleaned by raising and lowering the boom and the load lines under slight pressure. e) Operator shall never start any movement or rotation unless the load is clearly seen or the signal man / rigger has given the appropriate signal f)
The operator shall respond to only signals from the appointed signal man / rigger except the emergency stop signal from whoever give the signal,
g) Before leaving the control station for prolong period, the operator shall ensure the followings
Land any attached load Boom shall be parked at the boom rest Disengaging the master clutch, where applicable Set all locking devices, Put control levers in the OFF or neutral position Stop the engine / prime mover Assure that the crane will not interfere with normal helicopter flight operations.
h) At the end of the shift, the Operator shall ensure information on lifting operations and usage is recorded in crane log book
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PTS 60.2103 October 2011 5.1.2.
Load Handling The following guidelines shall be adhere by the operator with respect to load handling a) Be aware of the weight of load to be lifted. b) All lifting gears have been certified and colour coded, suitable capacity and gear is correctly attached and positioned to prevent uneven lifting or slippage of the load. c) The signal man/ rigger has correctly positioned the hook over the centre of the lifting point; this shall prevent any "load drift" when it is start to move up. d) Do not start lifting the loads until all personnel are clear from the lifting area e) Observe and monitor closely the safe load indicator for a possible overload situation. f)
Be aware of any activities/obstructions within the crane radius when moving loads across the deck.
g) Avoid the movement of loads over the personnel below. h) Tag line/s of sufficient length must be attached to control the load. i)
Possible, erect barriers around the lifting zone to prevent personnel from entering the lifting area.
j)
When carrying out any "blind" lifts, monitor the safe load indicator for any loss or increase in the weight of the load; this could indicate that the load has snagged.
k) Always keep the load within the specified radius of the crane. l)
When hoisting loads off a moving supply vessel deck packed with cargo, be alert for snagging or wrongly manifested cargo weights.
m) There is a clear view of the embarkation areas, load path and landing areas when it is necessary to transfer personnel to or from a vessel. n) Stop all crane operations during helicopter landings, unless dispensation has been given to carry out special tasks. o) Aviation lights remain switched ON whenever the boom is in the air and the Aframes or masts extended above the helicopter deck. p) No less than five (5) full wraps of rope shall remain on the drum in any operating condition
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PTS 60.2103 October 2011 5.2.
Mobile Crane/Crawler 5.2.1.
The following API and ASME standards, practices and specifications apply to the design, construction, installation, operation, inspection and maintenance of lifting equipment covered in this section
ASME B30.5 : Onshore Mobile Cranes API-9A : Specification for Wire Rope API-RP 2D (sections as applicable) Local regulations
Note: Some of the guidelines as specified for operations and maintenance of Pedestal Cranes is applicable for Mobile cranes, whichever is more stringent 5.2.2.
Mobile Cranes used in OPU/HCU facilities shall meet the standards operation as follow: a) The Crane operator should park the crane properly with the outrigger extended fully regardless of size and weight of the load. Ensure that the wheels are off the ground and never attempt to extend the boom unless all outriggers are extended and down on the hard surface with the crane level. b) The Crane Operator must be guided solely by the load chart/rating plate concerning boom length, boom radius and load to determine maximum capacity. The operator is responsible to ensure that the rated capacity is not exceeded regardless of which quadrant the crane is operating in. c) The Crane Operator shall respond to signals only from the appointed Signal man, but shall obey signal for an emergency stop at anytime from anyone at the working site. d) The riggers shall ensure that all the loose objects are removed from the load/machine to be lifted or, when this is not possible, he shall ensure that the loose objects are properly lashed /secured. e) Tag line/s of sufficient length must be attached to control the load. f)
When lifting a heavy load, the crane operator should lift it a few inches off the ground and hold to check load balance and the crane's lift brakes. If it is in order, the lift shall then proceed.
g) The crane operator/signal man shall warn the people in the area of the lifting activities when he swings the crane and always stay within the rated capacity. Loads shall not be allowed to exceed rated load capacity and working radius. h) No free fall of load is permitted i)
The operator must ensure that the hoist drum has at least 5 full wraps of wire rope remaining on the drum during the time when the boom is fully extended and the lifting hook is on the ground level
j)
For long or bulky loads, at least 2 tag lines to be attached to the load to assist in the control of the lifting or lowering and positioning.
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PTS 60.2103 October 2011 k) Make sure that slewing, derricking (boom up & down), lifting and landing areas are clear of people, vehicles and obstructions during all crane operations. l)
Do not swing a suspended load in quick motion; slewing with a load suspended must be carried out as gently as possible such that the load does not swing out of control when the slewing stops. Special attention to be given to loads partially filled with liquid.
m) Never allow personnel to ride/stay on the load. n) The operator shall safely lower the load and then immediately stop operating the crane if he observes any defects or unsafe conditions during operation that could affect safety operation or on hearing the plant emergency alarm. o) The operator must never leave the control station of his machine while the load is suspended except in cases of emergency p) Before leaving the control station for prolong period, the operator shall ensure the followings
Lower the load to the ground; Lower off long boom Engage the following: -
Swing brake Boom hoist pawl (if any) Disengage master clutch Shut-off engine
q) On completion the crane booms must be fully retracted and lowered to a safe height, The out riggers must be fully retracted and the area are clear before moving out the crane. r)
5.3.
For night lifting activities, adequate lighting at lifting area is required. Radio communication shall be used between crane operator and signal man for lifting instruction
Overhead and Gantry Crane Overhead and gantry cranes must be operated as per the manufacturer’s operating instructions and further guided by the operating procedures and precautions detailed in ASME B30.17: Overhead and Gantry Cranes. This section provides a summary of key basic operating guidelines and precautions. Due to the nature of operation, design and load motion characteristics of these cranes, the following operational procedures shall be observed: a) When handling load of rated capacity, the operator shall test the hoist brake by raising the load a few inches and apply the brake; any slippage or downward motion is unacceptable. b) Side pulls are not permitted, c) No sudden acceleration or deceleration of the moving load,
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PTS 60.2103 October 2011 d) If crane is of variable speed type, always start with the slowest speed, e) Change directions only when the crane motor has been stop. f)
Operators shall be competent in the operations of Gantry cranes or as authorized by the Area Authority.
g) Prior to first use of any hoist during each shift or day, the operator shall perform the Frequent, or Pre-Use Inspection and notify the Area Authority of any hazardous defects immediately, h) The hook shall be positioned directly over the load so as to minimize swinging when start lifting. i)
Ensure the rope is seated in the drum grooves and in the sheaves (i.e. check for the signs of slack rope conditions),
j)
The load shall be moved smoothly, slowly, and never contact any obstructions.
k) The operator shall not lift, lower, or travel the crane whilst anyone is near the load or hook. l)
The load shall never be lowered below the point where five (5) wraps of rope remain on each anchorage of the hoisting drum and shall include those with lower limit device.
m) The operator shall not leave the controls unattended, if the load is suspended over an area accessible to personnel. n) The operator shall not use the limit switches as a mean to stop vertical and horizontal movement. o) Hand signals poster (as in Appendix XIX) shall be displayed clearly at the work location. p) The load block shall be lifted above head level for storage when the crane is not in use 5.4.
Tower Crane 5.4.1.
The qualified Crane Operator (herein referred as the operator) is responsible for safe operation of the crane. The following are guidelines for good operating practices: a) The operator has the authority to stop work and refuse to handle loads or continue lifting operations in an unsafe condition. b) During bad weather with lightning or strong wind (48 km/hr and above), or poor visibility to see the signal person due to darkness, fog, rain, etc., crane operations can be restricted at the Operator’s discretion and agreed by OPU/HCU representative c) Every tower shall be provided with device for measuring wind velocity. Tower crane shall not be operated with wind speed at any time is greater than 48 km/hr. d) Tower crane shall not be raised to a new operating level when the wind speed exceeds 32 km/hr.
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PTS 60.2103 October 2011 e) The operator shall verify the following prior starting the crane
f)
Pre-use inspection has been completed All controls are in the “off” or “neutral” position Area is clear from all personnel
Prior lifting the load, exposed brakes shall be warmed and rusted surfaces on the drums cleaned by raising and lowering the boom and the load lines under slight pressure.
g) Operator shall never start any movement or rotation unless the load is clearly seen or the signal man / rigger has given the appropriate signal h) The operator shall respond to only signals from the signal man / rigger except the emergency stop signal from whoever give the signal, i)
Before leaving the control station for prolong period, the operator shall ensure the followings :
j)
5.4.2.
Land any attached load Boom shall be parked at the boom rest Disengaging the master clutch, where applicable Set all locking devices, Put control levers in the OFF or neutral position Stop the engine / prime mover
At the end of the shift, the Operator shall ensure information on lifting operations and usage is recorded in crane log book
Load Handling The following guidelines shall be adhere by the operator with respect to load handling a) Be aware of the weight of load to be lifted. b) All lifting gear have been certified and colour coded, suitable capacity and gear is correctly attached and positioned to prevent uneven lifting or slippage of the load. c) The signal man/ rigger has correctly positioned the hook over the centre of the lifting point; this shall prevent any "load drift" when it is start to move up d) Do not start lifting the loads until all personnel are clear from the lifting area. e) Observe and monitor closely the safe load indicator for a possible lifting overload situation, f)
Be aware of any activities/obstructions within the crane radius arc when moving loads across the deck.
g) Avoid the movement of loads over the personnel below. h) When possible, erect barriers around the lifting zone to prevent personnel from entering the lifting area.
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PTS 60.2103 October 2011 i)
When carrying out any "blind" lifts, monitor the safe load indicator for any loss or increase in the weight of the load; this could indicate that the load has snagged.
j)
Always keep the load within the specified radius of the crane.
k) There is a clear view of the embarkation areas, load path and landing areas when it is necessary to transfer personnel to or from a vessel. l) 5.5.
Aviation lights remain switched ON
Minimum Standards on Cranes 5.5.1.
Wire Rope a) Wire rope as specified by the Manufacturer or Crane Original Equipment Manufacturer (OEM) shall be used b) When terminated, the wire rope strength shall not reduce to below 80% of the wire rope nominal breaking load c) Design factor of load hoist wire rope shall not less than five (5).
5.5.2.
Wedge Sockets a) Wedge sockets shall be installed with the live-load-side of the wire rope in line with the wedge socket pin. b) Figure 1 below shows methods of securing when using wedge sockets
Figure 1: Methods of securing dead end of rope to wedge sockets 5.5.3.
Sheaves a) Sheave pitch diameter (D) to nominal wire rope diameter (d) ratio (D/d) shall not be less than 18, (Figure 2 below). b) Sheave groove contour shall be smooth and free from defects injurious to the wire rope,
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PTS 60.2103 October 2011 c) Sheave groove angle shall taper outwardly of not less than 30° included angle, d) Groove flange corners shall be rounded, e) Sheave bearings shall be individually lubricated through a separate passage, f)
All sheaves, including running blocks, shall be provided with guards or other suitable devices to prevent the rope from coming out of the sheave groove
Figure 2: Sheave Dimensions 5.5.4.
Load Block Assembly a) The weight of hook block shall be sufficient to prevent rope from slacking when unwinding the main host drum at maximum speed, b) Hooks shall be latched to ensure loose lifting gear always in its position, c) The Safe Working Load (SWL) label(s) shall be permanently affixed to the hook
5.5.5.
Boom Hoist and Load Hoist Mechanisms a) Boom and load hoists shall have a name plate to indicate whether it is used for personnel or non personnel lifting. Brakes (rated at 1.5 times the torque of the hoist) shall capable to stop the drum rotation during load lowering and hold the load indefinitely without attention from the operator, b) Brakes shall be automatically applied when returning the control lever to its neutral position, c) Free fall lowering of the boom or load shall not be permitted, d) Hoists shall be equipped with mechanism to check lubricant. e) The rope boom support machines (a ratchet and pawl or other positive holding device such as integrally mounted check valves) shall be provided to prevent uncontrolled lowering of the boom
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PTS 60.2103 October 2011 5.5.6.
Telescoping Boom Mechanisms a) Extension and retraction of boom may be accomplished by using hydraulic, mechanical or other means. b) A holding device (such as check valves) shall be provided to prevent backward movement of the cylinder
5.5.7.
Swing Mechanisms a) The brake shall capable to restrain movement of the upper structure but not to retard the rotation of the upper structure during operation. b) The brake shall be controllable by the operator and remain in the engaged position even without the attention of the operator. c) If the swing brake is the automatic type, by returning the swing control lever to its neutral position, it must not engage the brake in a manner to abruptly stop the swing motion d) Faulty swing brake shall not be used
5.5.8.
Swing Locks The swing lock (a mechanical device not dependent on friction) shall capable to: a) Withstand maximum swing torque developed during operation. b) Prevent accidental engagement or disengagement. c) Be controllable by the operator at the station
5.5.9.
Prime Movers a) Petrol/gasoline engines are not permitted to be used as prime movers. b) Pneumatic prime movers or auxiliary systems using flammable gas as medium are not permitted, unless a risk assessment has been conducted and approved by management
5.5.10. Exhaust Systems a) Engine exhausts shall be equipped with a spark arrestor, unless a risk assessment has been conducted and approved by management. b) Exhaust gases shall be piped outside of the engine enclosure and discharged away from the operator. c) Exhaust systems shall be properly guarded to prevent injury to personnel when in contact with hot surface 5.5.11. Fuel Tanks Fuel tanks shall be equipped with filler necks and caps to prevent fuel contamination.
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PTS 60.2103 October 2011 5.5.12. Over Speed Shutdown Diesel engines shall be equipped with an over speed shutdown device to shut the engine in case of engine faulty. 5.5.13. Control Mechanisms a) The control levers for boom hoist, load hoist, swing and boom telescope shall return automatically to their centre (neutral) positions when released. b) The control levers shall be clearly marked and visible from the operator station. c) Emergency stop button shall be provided at the operator’s control station 5.5.14. Platforms and Walkways The floor walking surfaces shall be an anti-skid type with guardrails. 5.5.15. Rigging Access For rigging or service requirements, a ladder or steps shall be provided to give access. 5.5.16. Boom Equipment a) Boom shall have a limit switch to automatically stop the boom hoist when it reaches at predetermined height or swing angle. b) Boom stopper shall be provided to prevent the boom from falling backwards. c) Fly jib/extended boom shall be used in accordance to OEM specification (if in use). 5.5.17. Guards for Moving Parts Exposed moving parts such as gears, chains and chain sprockets which may pose hazard during operations shall be guarded. 5.5.18. Clutch and Brake Protection All friction brakes and clutches components shall be protected with rain guards. 5.5.19. Lubrication Points and Fluid Fills Lubricating points shall be accessible without need to remove the guards and shall not collect fluid spills. 5.5.20. Personnel Emergency Load Lowering a) At least one hoist drum should have a mechanism of lowering the load in the event of power or control system failure. An alternate power source, independent of the crane may be used. b) An instruction plate giving detailed instructions shall be provided at the operator's station
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PTS 60.2103 October 2011 5.5.21. Crane Marking All Cranes shall have a nameplate confirming the construction in compliance to standard. 5.5.22. Bypassing, Disabling or Defeat of Equipment Safety Devices Example of safety devices are:
Anti two-block indicating and shutdown devices, which prevent the load block or overhaul ball from coming to contact with the boom or jib tip,
Over booming devices, which prevent the boom from reaching at a predetermined maximum angle,
Load moment or rated capacity alarm and shutdown devices, which alert or shutdown the crane when overloading.
Safety devices can only be bypassed with authorisation for crane inspection, maintenance and testing purposes only. Other than the above, authorization to bypass shall be allowed only for the following conditions:
5.6.
Driven by emergency situation
Supported by a risk-based analysis,
Supported by a MOC, PTW, JSA and approved work procedures,
Carried out under the supervision of a qualified Inspector and witnessed by a person as delegated by the Area Authority.
Other Lifting Appliances/Machines 5.6.1.
Winch a) When selecting a winch, the most important consideration is the required line pull and length of wire rope required for the operation. Some of the selection criteria are as follow:
Most of manufacturer’s line pull ratings are based on half drum performance. The line pull decreases as the winch drum wind up.
Half drum rating establishes average performance
Drum at full capacity can hold 100 meters of wire rope, while at half drum, only 36 meters is left.
A Full Drum provides maximum speed and minimum-pulling force,
Half Drum provides medium speed and medium pulling force,
The First Wrap provides minimum speed and maximum pulling force.
Minimum 5 turns/wraps shall remain on the winch drum to avoid any load being transferred to the rope anchor, which is not a load-bearing component.
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PTS 60.2103 October 2011 b) Winches that are used for hoisting and lowering of personnel must be rated and certified for personnel use only. No other winch shall be used for transporting personnel 5.6.2.
Runway Beam/Monorail General operation practices shall include the following but not limited to: a) Check the runway beam before use - do not use defective beams. b) Ensure the runway beam is clearly painted and marked with the Safe Working Load (SWL). c) Ensure the SWL is visible from the work floor. d) Do not apply side load to the runway beam. e) Do not let the trolley crash onto the stopper, as the load will swing and cause a sudden resultant load increase on the runway structure. f)
5.6.3.
In case of many lifting machines fitted to the runway beams, ensure they are properly arranged to avoid collision or uneven load distribution onto the runway
Fabricated Padeyes and Lifting Points General operation practices shall include the following: a) Fabricated Pad eyes and Lifting Points shall not be used for supporting personnel b) Check the pad eye before use - do not use defective pad eyes c) Ensure the pad eye is clearly identified and marked with the SWL d) Always use the correct size of shackle to avoid high stress at loading point e) Ensure the load is applied “in-line (vertical) only. Do not apply side loads. f)
Pad Eyes, which are fabricated locally without proper design calculation, shall be tested to three (3) times SWL
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PTS 60.2103 October 2011 6. LIFTING APPLIANCES INSPECTION, MAINTENANCE & TESTING Inspection or testing of lifting equipment should be carried out in accordance interval frequency specified in following table. But requirement shall be tailored to meet respective OPU/HCU in ensuring the integrity of asset. As minimum, OPU/HCU shall comply with local regulatory requirements Semi Annual
Pre-use
Monthly
Quarterly
Annual
Offshore pedestal
M*
M*
M*
Mobile /crawler crane
M
Overhead & gantry
M
R
M
Pillar/Jib/Monorail
M
M
M
Hoist (associated with crane)
M
M
M
M* M
M
Others Hoist/winch
M
R
M
Chain block
M
R
M
Pad eye
M
Sling
M
Eye bolt
M
M
Hook
M
M
Gondola/man lift
M
M
Personnel transfer basket
M
M M
M
Lift/elevator
M R
* - Based on running hours M - Mandatory R - Recommended
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M
M
PTS 60.2103 October 2011 6.1.
Offshore Pedestal Cranes 6.1.1.
Inspection a) Offshore pedestal cranes inspection shall be in accordance with API Recommended Practice 2D. However, the inspections may be conducted at more frequent intervals based on manufacturer recommendations, facility experience and severity of the working environment. Type of inspection shall be based on usage or duty cycle as follows: Infrequent Usage
Moderate Usage
Heavy Usage
(10 hours or less per month)
(More than 10 hours but less than 50 hours per month)
( 50 hours or more per month)
Pre-Use Inspection
yes
yes
yes
Monthly Inspection
-
-
yes
Quarterly Inspection
-
yes
yes
Annual Inspection
yes
yes
yes
b) Pre-use inspection (performed by a competent Crane Operator) shall be carried out and documented prior to the first crane use of the day and during shift change of Crane Operator. A log book is compulsory to be filled by the crane operator prior to the crane operation. The following is a summary of pre-use inspection to be carried out. (Refer to Appendix II : Pedestal Cranes Pre-use Inspection Checklist).
Check all fluid levels of the prime mover,
Check all safety devices,
Check control mechanisms including brakes and clutches for proper operation,
Check boom hoist limit and anti-two block devices for proper function,
Visually check for hoist lubricant oil leakage. Check the level through the sight glass, if provided.
Visually check for leakage or damage in the air and non-mechanical systems,
Check the following devices where applicable:
-
Boom hoist pawl, if applicable, Helicopter warning lights, if applicable, Crane hook latch.
Perform a walk round visual examination of the crane boom and support structure to ensure no sign of damage,
Ensure the correct load-rating chart for the configuration in use is visible,
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PTS 60.2103 October 2011
Visually check wire rope for any sign of deterioration and damage, or improper reeving,
Visually check for loose, missing, or corroded bolts, pins, keepers or cotter pins,
Lubricate components and correct deficiencies as required
c) Monthly inspections are performed either by a certified Crane Operator and or a Qualified Inspector. The following is a summary of monthly inspection to be carried out. (Refer to Appendix III : Pedestal Cranes Monthly Inspection Checklist)
Carry out the checks as described in the Pre-use Inspection,
Check the following devices where applicable : -
Boom Hoist Pawl. Helicopter Warning Light. Crane Hook Latch.
Visually check rigging gear to be used, such as slings, sling hooks and shackles.
Further check all control mechanisms for proper adjustment, excessive wear of components and contamination by foreign matter.
Check appropriate electrical apparatus for proper function.
Check boom hoist limit and anti-two block devices for proper operation. Be careful not to damage the crane components
d) Quarterly inspections are performed by a Qualified Inspector. The following is a summary of quarterly inspection to be carried out. (Refer to Appendix IV : Pedestal Cranes Quarterly Inspection Checklist).
Carry out the checks as described in the monthly inspection,
Inspect the boom for bent chord members, missing or broken lacing and cracked welds on critical members.
Inspect the boom section end connections for cracked welds, deformation and corrosion.
Check boom angle/radius indicators over full range for accuracy.
Inspect the sheaves for wear, cracks, and rope path alignment and bearing condition.
Check power plants for proper performance compliance with safety requirements.
Check belts and chains for proper adjustment.
Visually check crane hooks for deformation, and discard if deformations exceed those manufacturer’s recommendations.
Inspect the wire rope as described in Lifting Equipment Manuals by PETRONAS Carigali Sdn Bhd.Section 9.14 : Safe use of Wire Ropes (TO CHECK LEM Section 9.14)
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PTS 60.2103 October 2011
Check lubricant level in all hoists and slew drives, including those not fitted with sight glasses.
e) Annual inspections are performed by a Qualified Inspector. The following is a summary of annual inspection to be carried out. (Refer to Appendix VI : Pedestal Cranes Annual Inspection Checklist)
6.1.2.
Carry out the checks as described in the quarterly inspection,
Check all fluid levels of prime mover.
Check boom angle/radius indicators over full range for accuracy.
Inspect the sheaves for wear, cracks, and rope path alignment and bearing condition.
Check power plants for proper performance compliance with safety requirements.
Check belts and chains for proper adjustment.
Visually check crane hooks for deformation, and discard if deformations exceed those manufacturers’ recommendations.
Inspect wire rope as per Lifting Equipment Manuals by PETRONAS Carigali Sdn Bhd.Section 9.14 : Safe use of Wire Ropes
Check lubricant level in all hoists and slew drives, including those not fitted with sight glasses.
Oil Sample Analysis An annual “Oil sample analysis” is intended primarily to evaluate the mechanical integrity of crane critical component through a qualitative test performed at the field by the Qualified Inspector or Crane Operator. This is done by sampling oil on a cheese cloth, smell and texture test and/or through lab sampling if required.
6.1.3.
Inspection of Critical Crane Components a) Hoist assemblies Annual inspection is determined by OEM based on hoist type, duty cycle and condition. The quality of the hoist lubricant is a primary indicator of the mechanical integrity of the hoist. b) Foundations Annual inspection shall include as a minimum the following:
Visually examine support structure for fracture, deformation and corrosion, Inspect for rust and cracked paints.
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PTS 60.2103 October 2011 c) Swing Circle assembly – General Inspection There are 2 types of swing assembly generally used 1. King Post The inspection shall be carried out in accordance with manufacturer’s recommendations and shall include inspection of the following:
Upper thrust bearing. Upper radial bearing. Lower thrust bearings or radial bearings. King pin wear and condition. Lower king post radial bearings King post to platform structural connection.
2. Ball/ Roller Bearing For this type, there (3) major inspection must be done
Bearing wear – to monitor wear in bearing in order to determine expected service life. One of below method can be used for wear measurement as recommended in API2D. -
Tilt method (quarterly) Depression measurement method (quarterly) or Rotation method Grease sample analysis – on yearly basis and shall be shortened if obvious metal or contaminants are present.
Crane/ Bearing connection integrity -
The Crane/ Bearing may be connected using bolts, welding or combinations of the two. The integrity of this connection is crucial to the life of the swing circle assembly.
-
The inspection guideline for each crane is specific and the OEM shall be referred for guidance when developing the inspection procedures.
Operating characteristic -
Rotate the crane 360° in each direction at slow, intermediate and full speed and monitor the smoothness of rotation.
-
Report any irregular, jerky, bumpy, etc. motions to the relevant authority for immediate remedial action
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PTS 60.2103 October 2011 6.1.4.
Load Testing No load test (proof load test or functional load test) shall be carried-out unless an annual inspection as recommended in this PTS is carried out and any defects rectified prior load test. a) Proof Load Test A proof load test (125% the rated capacity) is required under the following conditions:
New cranes being placed into service,
Cranes that are being permanently relocated,
Temporary cranes after each rig-up or relocation.
After major repair or alteration of structural components. This shall include a crane that has undergone major structural repair work or refurbishment.
b) Functional Load Test A functional load test (100% the rated capacity) may be carried out subject to applicable regulatory requirements in Malaysia and Host Country or when there is a requirement such as:
Prior to a heavy lift or The Area Authority may request for such a load test in anticipation of a forthcoming heavy lift. This decision can be due to the fact that the crane has not been subjected to such a lift in its day to day crane operations. It is recommended that the load test prior a heavy lift shall not exceed 125% of the heavy lift provided this does not exceed the SWL of the crane.
When advised by the Authority in Maintenance and or Reliability Engineering or any person as delegated.
c) General Guidelines on Load Testing can be referred on Appendix VII. d) Test Loads The test load for all lifts shall be based on crane rating chart, wire rope strength, available hoist line pull and number of parts of line. The static test load and test radius shall be calculated as follows in accordance with API RP 2D:
Static Rated Load at a Specific Radius
Test Loads in Excess of Static Rated Load at a Specific Radius
0 to 20 Metric Tonnes
25%
21 to 50 Metric Tonnes
+ 5 Metric Tonnes
51 Metric Tonnes or more
10%
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PTS 60.2103 October 2011 e) Load Application
Suspended weight method Suspended weight method shall be used in offshore applications. Guidelines for the Suspended weight test are as follows: -
Select a suitable test load, Assemble the load, Lift the load, Boom out to the desired radius, With the load suspended, set the load hoist and boom hoist brakes, Check for drum rotation. The test does not require that the test load be boomed or swung.
Dynamometer method This method should be used for purpose of verification only. Guidelines for the Dynamometer test are as follows: -
Determine the available dynamometer tie-down locations, Measure and record the radius value, Align the boom point with the tie-down and attach the dynamometer, Ensure that the load hoist line is vertical, Pull with the load hoist until the desired test load is indicated on the dynamometer, Set the load hoist brake, Check for drum rotation
. 6.2.
Mobile Crane/Crawler 6.2.1.
Inspection a) All mobile cranes shall be inspected and maintained in accordance with any of the following standards (whichever is more stringent) and as acceptable to PETRONAS:
ASME B30.5 “Mobile Cranes” Manufacturer’s recommendations BS7121: Part 1-3 Applicable regulations in Malaysia and Host Country Other industry standards as identified timely.
Note: Prior mobilization of mobile crane into the work site, the crane shall be inspected by qualified/competent crane inspector. Equipment Passport System or equivalent shall be in accordance OPU/HCU HSE requirement. Validation activities shall be governed by the respective OPU/HCU requirement. b) Pre-use Inspections, performed by a qualified Inspector, shall be carried out and documented prior to the first crane use of the day and during each shift change in Crane Operator. A crane log book is compulsory to be filled by the crane operator
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PTS 60.2103 October 2011 prior to the crane operation. The following is a summary of pre-use inspection to be carried out. (Refer to Appendix VIII : Mobile Crane Pre-use Inspection Checklist).
Check and ensure all exposed moving parts are guarded.
Visually inspect each component of the crane used in lifting, swinging, or lowering the load or boom for any defects that might result in unsafe operation.
Inspect all wire ropes (including standing ropes), sheaves, drums, rigging, hardware, and attachments.
The visual inspection of wire rope shall include rope termination, spooling on drums and any anchorage point.
Inspect all hooks for cracks. Replace all hooks with throat openings of 15%, or hook twists of 10 degrees or more.
Check for freedom of rotation of all swivels.
Visually inspect the boom and jib for straightness and any evidence of physical damage, such as cracking, bending, or any other deformation of the welds.
Inspect for any corrosion under attachments that are connected to the chords and lacing.
Inspect for cracking or flaking of paint at critical parts such as chords and other structure.
Inspect lattice booms for bent lacing. (If bent, the main chord can lose substantial support in that area). A bent lacing tends to draw together which pulls the main chords out of shape.
Note: Do not straighten these members by hammering or heating them and drawing them out. They must be cut out and replaced with lacing to the manufacturer's specifications, procedures, and approval.
Inspect tires for cuts, tears, breaks, and proper inflation.
Inspect for any air or hydraulic oil leaks.
Check lubrication.
Ensure fuel, lubricating oil, coolant and hydraulic oil reservoirs are filled to the required levels.
Check and ensure there is a fully charged fire extinguisher.
Inspect and ensure cab windows are clear, free of cracks and windscreen wipers are in good condition.
Inspect crane structure is free from loose materials (i.e. tools) that have a potential to result in falling objects.
Check all operating mechanisms are fully functional such as sheaves, drums, brakes, locking mechanisms traffic and warning lights.
Check the turntable connections for weld cracks and loose or missing bolts. If they are loose, it is an indication of it being stretched.
Check outriggers beams and cylinders are not distorted and welds are not cracked.
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PTS 60.2103 October 2011
Check beams and cylinders extend and retract smoothly and hold the load.
Check the condition of the floats/pad and check that they are securely attached.
Inspect and test all brakes and clutches for proper adjustment and operation.
Inspect boom hoist lockout and other operator aids such as anti-two-block devices (ATB) and load moment indicators (LMI), fully functional.
While the engine is running, check all gauges and warning lights for proper readings and operate all controls to see that they are functioning properly.
c) Annually Inspections shall be performed by a competent person and shall include inspection of wire ropes. The following is a summary of periodic annual inspection to be carried out. (Refer to Appendix IX : Mobile Crane Annual Inspection Checklist)
Carry out all inspections as outlined in “Pre-use Inspection.”
Inspect the entire length of wire rope for damage
Inspect the entire crane for structural damage. Check for distortion or cracks in mainframe, outrigger assemblies, and structural attachments between the superstructure and the carrier.
Inspect all welded joints for cracks.
Inspect the main chords and lacing (on lattice type booms) and other structural items for paint flaking and cracking which may indicate potential failure, as well as for dents, bends, abrasions, and corrosion.
Check hydraulic booms for bending, side sway, or droop.
Check for deformed, cracked, or corroded members in the load/stress bearing structure.
Magnetic particle or other suitable crack detecting inspection (NDT) shall be performed at least once a year and documented.
Inspect for crack or worn sheaves and drums.
Inspect for worn, crack, or distorted parts such as pins, bearings, shafts, gears, rollers, locking devices, hook roller brackets, removable outrigger attachments lugs, and welds.
Inspect for excessive wear on brake and clutch system parts, linings, pawls, and ratchets.
Inspect all indicators, including load and boom angle indicators, for proper operation and calibration.
Inspect engine for proper operation.
Inspect for excessive wear on drive sprockets and/or chain stretch (as applicable).
Inspect the steering, braking, and locking devices are operational.
Check and ensure counterweight is secure.
Inspect all hydraulic and pneumatic hoses, fittings, and tubing. This shall be replaced every five (5) years or as required.
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PTS 60.2103 October 2011
6.2.2.
Check for evidence of oil or air leaks on the surfaces of flexible hoses. Replace defective parts.
Check that the equipment tag number is permanently and clearly marked.
Document all inspection carried out and action taken
Load Testing Mobile cranes shall be load tested in accordance manufacture’s recommendations and/or applicable code & standard. a) Proof Load Test Proof load test shall be conducted for
New cranes being placed into service
No load test shall be carried out unless a thorough annual inspection is carried out and defects (if any) have been rectified. Proof load test shall not exceed 125% of rated capacity. b) Functional Load Test Functional load test shall be done for the following and as per requirement by local regulations in Malaysia and Host Country:
Temporary cranes after each rig-up and/or reassembly.
After major repair or alteration of structural components. This shall include a crane that has undergone major structural repair work or refurbishment.
Prior to any critical lifting
Road or plant incident or accident which affect major crane component
Frequency of load test shall be done subjected to local or host country regulation at 100% of rated capacity as specify in load chart. For any major repair, load test & revalidation shall be conducted by DOSH authorized / registered contractor. c) General Guidelines on Load Testing Load test shall be conducted and documented under the supervision of a Qualified Inspector. Suspended weight method shall be used in load testing. General guidelines on load testing, test load and load application as per Appendix VII.
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PTS 60.2103 October 2011 6.3.
Overhead and Gantry Crane 6.3.1.
Inspection Overhead and gantry cranes shall be inspected in accordance to applicable regulatory requirements and intervals. However, inspections may be conducted more frequently based on manufacturer recommendations, facility experience, and severity of the working environment. The following inspection requirements are based on ASME B30.17: “Overhead and Gantry Cranes” and is applicable to overhead and gantry cranes used at PETRONAS OPU/HCU facilities. Overhead and Gantry Cranes with powered hoist shall comply with Law Malaysia FMD Act 1967 or host country regulation. a) Pre-use Inspection shall be carried out by operators before and during lifting. The following is a summary of pre-use inspection to be carried out (Refer to Appendix X: Overhead/Gantry Pre-use Inspection Checklist)
Pre-use inspections shall include observations during operations.
A designated person shall determine whether conditions found during the inspection constitute a hazard and a more detailed inspection is required.
The following items shall be inspected:
-
Operating mechanisms for proper operation, proper adjustment, and unusual sounds. Upper limit device(s) Tanks, valves, pumps, lines, and other parts of air or hydraulic systems for leakage Hooks and hook latches (if used) Hoist
b) Semi-annual Inspection (6-monthly) to determine the repair or replacement of components required to keep the machine fully functional. The following is a summary of periodic inspection to be carried out. (Refer to Appendix XI: Overhead/Gantry Semi-annual Inspection Checklist)
Perform all checks in the Pre-use Inspection ,
Inspect Hooks for deformation and cracking and hook latches for integrity.
Inspect Hoist rope and end connections (entire length of rope)
Inspect Hoisting chains.
Check for deformed, cracked or corroded structural members.
Check for loose or missing bolts, nuts, pins, or rivets.
Check for cracked or worn sheaves and drums.
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PTS 60.2103 October 2011
6.3.2.
Check for worn, cracked, or distorted parts such as pins, bearings, wheels, shafts, gears rollers, locking and clamping devices, bumpers and stops.
Check for excessive wear of brake system parts, excessive wear of drive chains, sprockets and chain stretch.
Check for deterioration of controllers, master switch contacts, limits switches and push-button stations, but not limited to these items.
Check petrol/gasoline, diesel, electric, or other power plants for proper operation.
Check motion limit devices that interrupt power or cause a warning to be activated.
Check rope reeving for compliance with recommendations of the crane manufacturer.
Check all function, instruction, caution, and warning labels or plates for legibility and need for replacement.
Check that load block capacities are marked on both sides. Markings shall be legible from the ground floor.
Check those fire extinguishers, where applicable.
Check warning devices and audible alarms,
Ensure that there are no over runs when control is released,
Ensure that there is no load slippage
Load Testing Overhead and gantry cranes shall be load tested as stipulated in section 6.2.2 mobile crane requirement. Load test shall be conducted and documented under the supervision of a Qualified Inspector. There are two methods of load application can be used i.e.
Suspended weight method.
Dynamometer method
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PTS 60.2103 October 2011 6.4.
Pillar/Jib Cranes and Monorail Systems 6.4.1.
Inspection a) Pre-Use inspection shall be carried out by the user before lifting, based on based on visual examination as follows. The following is a summary of pre-use inspection to be carried out. (Refer to Appendix XII : Pillar/Jib Cranes Pre-use Inspection Checklist)
Check general conditions of the supporting structure, trolley and railing.
Check that motions are smooth and regular with no hesitations, vibration, binding, unusual noise, or other irregularity.
Test all controls. If any controls do not operate properly, they should be adjusted or repaired before operations begin.
Test the following functions, hoisting and lowering limit switch, Trolley travel, Bridge travel, Limit switches, locking and safety devices.
Test operation of the upper-limit device. The trip-setting of the primary upperlimit switch shall be checked under no-load conditions by inching the block into the limit or running at slow speed.
Visually inspect all ropes and load chains. These visual observations should be concerned with discovering gross damage that may be a hazard.
Visually inspect the hoist for deficiencies that may occur between regular inspections.
Ensure inspections (wire rope, chain, crane or hoist) are current via inspection sticker, tag plate or other documentation from equipment custodian.
b) Quarterly Inspection shall be carried out by making records of apparent external condition. The following is a summary of quarterly inspection to be carried out. (Refer to Appendix XIII : Pillar/Jib Cranes Quarterly Inspection Checklist)
Perform inspection as frequent inspection activities.
Deterioration or leakage in lines, tanks, valves, drains pumps, and other parts of pneumatic, gas or hydraulic systems.
Jib crane structure should be checked for structural damage, corrosion and deformation.
All functional of jib crane operating mechanisms shall be checked for maladjustment.
Moving parts of the jib crane and hoist for which lubrication is specified shall be regularly lubricated.
Hoist inspection shall be in accordance with Pre-use Inspections, Hoist, Hand Chain-, Electric-, and Air-Operated. (Refer to Appendix XV : Hoist Pre-use Inspection Checklist)
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PTS 60.2103 October 2011 c) Annual inspection of jib crane and monorail systems shall be carried by a qualified inspector. The following is a summary of annual inspection to be carried out. (Refer to Appendix XIV : Pillar/Jib Cranes Annual Inspection Checklist)
6.4.2.
The supporting structure or trolley, if used, shall be checked for evidence of damage.
Structure members shall be checked for deformation, cracks, and corrosion.
Bolts, nuts, and rivets shall be checked to ensure that they are not loose.
Pins, bearings, wheels, shafts, gears, rollers, locking and clamping devices, bumpers, switch baffles, interlock bolts, and stops shall be checked for wear, cracks, or distortion.
Travel or parking brake system parts, linings, pawls, and ratchets shall be checked for excessive wear.
Carrier (trolley) chain drive sprockets shall be checked for excessive wear and excessive chain stretch.
Load blocks, suspension housings, hand chain wheels, chain attachments, clevises, yokes, suspension bolts, shafts, gears, bearings, pins, rollers, and locking and clamping devices shall be checked for evidence of wear, corrosion, cracks, or distorted parts.
Moving parts of the jib crane and hoist for which lubrication is specified shall be regularly lubricated.
Both manual and remote lubricating systems should be checked for delivery of lubricant. Care should be taken to follow manufacturer's recommendations as to points and frequency of lubrication, maintenance of lubricant levels, and types of lubricant to be used.
The hoist inspection shall be in accordance with Hoists, Hand Chain-, Electric-, and Air-Operated.
Hand chain-operated hoists shall be checked for evidence of worn, glazed, or oil-contaminated friction disks; worn pawls, cams, or ratchets; and corroded, stretched, or broken pawl spring in braking mechanism.
Electric- or air-powered hoists shall be checked for evidence of excessive wear on motor and load brake.
Electrical components such as, but not limited to, controllers, master switches, contacts, limit switches, and push-button stations shall be checked for deterioration
Drive tires/rollers shall be checked for excessive wear.
The lower load-carrying flange of all track sections in the system, both straight and curved, shall be checked for excessive wear or deformation.
Inspect sheaves and drums for any cracked or worn out sign.
Pre-Operational Check after Maintenance or Repair Pre-Operational Check after Maintenance or Repair shall be performed to verify the proper function of activities such as motion controls and interlocks. Special attention shall be given to those areas likely to have been affected by maintenance or repair
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PTS 60.2103 October 2011 6.4.3.
Operational Tests of Hoist (for Jib Crane and Monorail Systems) Before initial use, new, reinstalled, altered, repaired, or modified hoists that have not been used within the preceding 12 months shall be tested before being placed in service by or under the direction of a designated person to ensure that the hoist is in good operating condition, including the following functions:
6.4.4.
Check hoist(s) as required in Operational Tests,
Check carrier travel.
Check travel-limiting devices.
On monorail systems, check locking and safety devices for interlocking mechanisms, track switches, drop sections, and lift sections
Load Testing Pillar/jib cranes and monorail systems shall be load tested in accordance manufacture’s recommendations. a) Proof Load Test New, reinstalled, altered, repaired, and modified equipment should be load tested before initial use as determined by a qualified person. Load testing of altered, repaired, and modified equipment may be limited to the functions affected by the alteration, repair, or modification, as determined by a qualified person. For equipment engineered on site, the responsible engineer or design authority has the authority otherwise taken by the manufacturer. If a load test is conducted, operations shall be performed as outlined in Load-Test Procedures, or as modified by a qualified person. For any major repair, load test & revalidation shall be conducted by authorized / registered contractor. No load test shall be carried out unless a thorough annual inspection is carried out and defects (if any) have been rectified. Load test shall not exceed 125% of rated capacity. b) Functional Load Test Functional load test shall be done as per requirement by local regulations in Malaysia and Host Country. Test loads shall be 100% of the rated load unless otherwise recommended by the manufacturer. c) General Guidelines on Load Testing Load test shall be conducted and documented under the supervision of a Qualified Inspector. There are two methods of load application can be used i.e.
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PTS 60.2103 October 2011
Suspended weight method. Dynamometer method.
Suspended weight method shall be used in off shore applications. General guidelines on load testing, test load and load application for pedestal crane as per Section 6.1.4 (c, d, e) shall apply 6.5.
Hoist (Applicable for Cranes) This section describes inspection and testing requirements of all crane hoists. Hoist is an important component of any crane. All hoists and associated ancillaries (such as anti two block and sheave) shall be inspected as per manufacture’s recommendations as follows: 6.5.1.
Inspection a) Pre-Use Inspection shall be conducted at the beginning of each shift the hoist is used. These procedures MUST be performed prior to placing the crane into service, and then as necessary during extended operation. The inspection must be performed by a qualified crane operator or qualified crane inspector. The following is a summary of pre-use inspection to be carried out. (Refer to Appendix XV : Hoist Pre-use Inspection Checklist)
Check for external oil leaks and conduct repair work if needed.
The gear lubricant level must always at the proper level as indicated at sight glass, if provided.
Inspect the vent plug to ensure it is not clogged. Clean with solvent or replace if needed.
Check for the proper operation of ratchet and pawl mechanism. Repair or adjust as necessary. Grease the pins and bushings if required.
Check the hydraulic hoses / plumbing for damage or deteriorating hoses, and repair as necessary.
Visually inspect for corroded, loose or missing bolts, pins or other fasteners, and replace or tighten as necessary.
Visually inspect rotation indicator sensors (if equipped).
Engine warm-up procedure is recommended at each engine startup, especially if working at very low ambient temperatures (below +40°F/+4°C). The engine shall be run at its lowest recommended idle RPM with the hoist control lever in neutral position to warm up the hydraulic system.
The hoist shall then be operated at low speeds, hoisting and lowering under no load, several times to prime all the hoist hydraulic lines and circulate lubricant through the planetary gear sets.
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PTS 60.2103 October 2011 b) Quarterly inspection (or monthly for severe duty application) of hoist shall be carried out every three (3) months or monthly in Severe Duty Application by a qualified crane inspector or crane specialist as follow: (Refer to Appendix XVI : Hoist Quarterly Inspection Checklist)
Perform all the Pre-use inspection checks.
Hoists used for personnel lifting shall have the spring set hoist brake, tested as per API RP 2D-Appendix D. For all hoist with integral motor and brake system the following shall apply: -
Brake test shall be performed with no load on the hoist. The weight of the wire rope, hook block and over-haul ball or hook weights is sufficient.
-
Close needle valve for internal braking system. This will lock the brake system
-
For hoist with brake band, detach motor without disconnecting mechanical lines.
-
Power the hoist motor in the downward direction and apply the brake until the motor is stalled.
If the drum rotates or slips during the test, the hoist shall be disassembled for teardown inspection, replace defective parts and test as per manufacturer’s recommendations.
Inspect all fasteners for tightness and the sign of corrosion. Replace ALL corroded fasteners and tighten to their recommended torque value.
Inspect the hoist structural components (base, supports, drum, etc.) for corrosion. Repair or replace as required to ensure high structural integrity of the hoist.
Change the filters of hydraulic system after the first 50 hours of crane operation (for new engine ONLY) and every 500 hours or quarterly afterward, or as per the crane manufacturer's recommendations.
c) Semi-annual Inspections. (Refer to Appendix XVII : Hoist Semi Annual Inspection Checklist)
Perform ALL prior inspections checks (Pre-use and Quarterly inspections).
Take a gear oil sample from the hoist drum as per oil sampling procedure and analyze for wear metals, viscosity, signs of overheating, oxidation, moisture and other contaminants. If the sample contains an unusual amount of metallic particles, the hoist assembly shall be removed from service to undergo a teardown inspection.
d) Annual Inspection (or semi-annually in Severe Duty Applications) (Refer to Appendix XVIII : Hoist Annual Inspection Checklist)
Perform ALL prior inspections checks (Pre-Use, Quarterly and Semi-Annual inspections).
Change the hoist gear oil (after taking an oil sample)
The gear oil shall be changed whenever the ambient temperature changes significantly. Use gear oil of a suitable viscosity range as recommended.
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PTS 60.2103 October 2011 e) Tear down Inspection Tear down inspection shall be carried out depending on usage category. As a minimum all hoist shall undergo a complete teardown inspection every two (2) years. This inspection period may be reduced if the usage is severe or increased if the usage is less. The following guidelines shall apply: Severe usage:
More than 200 hours per month or 50 % of the lifts exceeding 75% of the rated capacity
Normal Usage:
Up to 200 hours per month
Note:
Crane used in drilling and other high activity operations shall undergo a more frequent teardown inspection than the normal 2 yearly inspection.
A typical teardown inspection procedure shall include the following:
The hoist shall be completely disassembled, cleaned, inspected and repaired as required.
Replace all worn, cracked, corroded or distorted parts such as pins, bearings, shafts, gears, brake rotors, drum and base.
Replace all seals and O-rings
Correct all any other deficiencies
Upon assembly, the rebuilt hoist shall undergo the following test - Line pull test at rated load using dynamometers or equivalent load measuring device - Test load shall be the maximum rating of the hoist set at normal relief valve setting - Conduct dynamic test several times in up / down directions using a load of at least 30 % of the lifting capacity - Perform brake test.
Perform other procedures as recommended by OEM.
Upon completion of the above, a test certificate shall be issued in the present of a company representative or third party as approved by the relevant Authority.
An inspection and re-certification plate (see sample below) shall be affixed on the hoist after completion of the refurbishment
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PTS 60.2103 October 2011 6.5.2.
Load Testing New hoists shall be tested by the manufacturer with a test load of at least 100% of the rated load, Hoists in which load-suspension parts have been altered, replaced, or repaired shall be tested statically or dynamically by or under the direction of a designated person. The applied test load shall be at least equal to the rated load or greater as approved by the manufacturer. A record of the test shall be retained in the maintenance file. Before a load test, test anchorages or suspensions will be checked to ensure that they will safely sustain the load. a) Periodic Load Test Scheduled periodic load tests are not routinely required. Hoists may be loadtested up to 100% of rated capacity when or if specified by a Critical Lift Procedure. For hoists that frequently make critical lifts, especially if lifts are at or near rated capacity, a scheduled load-test program may be implemented. Such periodic load-tests shall not exceed the rated capacity. b) Load-Test Weight The load-test weight should be within a tolerance of (+0%, -5%) and shall be traceable to a recognized standard or verified by calculations c)
Load-Test Procedures Load tests shall be conducted in accordance with a written step-by-step procedure. A hold point shall be included in the load-test procedure to verify that inspection is up to date. The following guidelines are for information. Actual conditions may require changes to meet different situations and equipment configurations.
Lift the test load a few inches and hold for 5 minutes; from this position, lift an additional distance, not less than 3 feet above the floor (ground), and hold for 5 minutes. Then slowly lower the load; stop about 1 foot above the floor (ground), and hold for 5 minutes. At intermediate levels during hoisting and lowering, verify that the hoist operates properly and holds the load without slippage of more than 0.5 inch.
For electric- or air-powered hoists, at least once in a raising and once in a lowering condition, at a height of no more than 1 foot, disconnect the electric or air power source. The load shall stop immediately with less than 0.5-inch movement. There should be no slippage of the load or overheating of the brakes after 5 minutes of power off. The holding brakes should control the load throughout the test, and the load should not drop more than 0.5 inch when the lifting motion is again initiated.
For monorail transport the test load with the carrier (trolley) over the trolley's entire range. For jib cranes, rotate the jib boom over the full range of motion while the carrier is at the outside end of the boom. Load transporting should be done with the test load approximately 1 foot or less above the floor (ground) or obstructions.
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PTS 60.2103 October 2011
The test load should not rotate on the load block. Use taglines as appropriate. If the hook has power rotation, rotate the load through the full range of motion.
The hoist and carrier (trolley) shall function smoothly, without sticking or binding. Following the load test, verify that no visible load-bearing part (e.g., gearing, shafting, bearing, and rope or chain end-connection, brake components) has been adversely affected by the test.
6.6.
Other Lifting Appliances/Machinery 6.6.1.
Hoist/Winch This section describes inspection and testing requirements of other machinery using hoists. The machinery covers but not limited to lifeboat, elevator / lift, gondola, pneumatic / gas tugger etc. All hoists and associated ancillaries (such as break system, anti two block and sheave) shall be inspected as per manufacture’s recommendations as follows: a) Lifts/elevator (Passenger and Cargo) All lifts (passenger and cargo) shall comply with the requirements of local authority by host country, codes and standards, and the OEM manuals, and in addition the following requirements shall be adhered with:
All lifts (passenger and cargo) shall be fully inspected, function tested and witnessed by Approved Local Authority at interval specified in regulation.
The number of persons permitted at one time inside the lift and / or SWL shall be governed by OEM.
Maintenance activities shall be conducted as per OEM recommendation and requirement by local authority of host country.
Lifts (passenger and cargo) shall not be used beyond valid period for certification of fitness.
All lifts (passenger and cargo) shall have a logbook to record all the maintenance, inspection and testing history.
b) Gondola / Man Lift / Working Platform All gondola / man lift / working platforms (Hydraulic, Pneumatic and Electric) shall comply with the requirements of local authority by host country, codes and standards, and the OEM manuals. The gross weight shall be considered for SWL calculation of gondola / man lift / working platform:
Average personnel weight shall be 100 kg. Minimum working tools weight shall be 25 kg. Tare weight of the equipment.
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PTS 60.2103 October 2011 All gondola / man lift / working platforms shall be:
Proof Load Tested not more than 125% SWL or functionality test whichever preferred by the Owner after major alteration / repair / relocation from work site to another work site.
c) Pre Use Inspection shall be conducted upon complete erection of above machinery Prior to using the winch, the followings checks shall be carried out:
Ensure SWL is sufficient with the load to be lifted. Check the wire rope guard for any damage / distortion which may obstruct the rope movement.
Check the winch drum for wear, distortion and cracks. Check brake bands and drums for wear, clean and free from contamination Check the automatic brake and check springs, link arms, and pins when applicable.
Ensure when power is disconnected all operating levers return to neutral position when released.
Ensure directional markings are in affixed and clearly visible. Ensure the correct wire rope is fitted and is wound in the correct direction. Ensure the rope is not over wound on or off the drum Note: For gondola, man lift or working platform; as minimum past two (2) years maintenance history record has to be submitted prior preceding installation. 6.6.2.
Runway Beam / Monorails Beam Part of the requirement is covered under section for pillar jib crane. This section describes the requirements related to the selection, maintenance, and inspection of Runway beams I monorails beam. a) General inspection Lifting support steelwork such Runway beams I monorails beam with no moving parts shall be inspected annually. Regular inspection shall be carried out and corrective actions taken when any of the following defects are identified:
Any structural defects, damage, distortion, corrosion, or cracked welds. Loose or missing bolts. Damaged or missing end stops. Tracks not level or running surface uneven. Illegible markings, i.e. identification number, SWL, etc.
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PTS 60.2103 October 2011 6.6.3.
Chain Blocks a) Pre-use Inspection Visual check and inspection
The shape of the top hook and the fit of the safety catch/latch.
The condition of the block or hoist body. In particular, look for distortion of the frame and missing or damaged gear covers which might cause the mechanism to jam.
On a hand chain block, check the hand chain wheel for damage and also the guide or casing which prevents the hand chain from being displaced.
Check the condition of the chain and in particular the link which joins the ends.
On lever hoists, check the condition of the lever, the reversing ratchet and the free wheel mechanism.
The security of the slack end anchor for the load chain.
The condition of the bottom hook and safety catch/latch.
Having completed the above it is always worth doing a function test, preferably with a light load of about 5% of the SWL.
Check that the hand chain runs smoothly over the wheel without jumping. As for the load chain, if jumping does occur, the equipment should be withdrawn from service.
Finally, check that the SWL is clearly displayed and the ID mark is legible.
b) Semi-annual Inspection Chain block shall be inspected and tested semi-annually and must be recorded. Corrective actions taken when any of the following defects are identified:
Damage (chip, bend, etc.) Distortion Corrosion Cracked welds Elongated I stretched bores Illegible markings (Identification, SWL, Tag No., Reg. No.)
NOTE: Checklist to be provided. 6.6.4.
Pad Eyes, Davit, Gin Poles and Lifting Points a) General Inspection Pad eyes and Lifting Points shall be inspected annually if required NDT shall be applied. Regular inspection shall be carried out and corrective actions taken when any of the following defects are identified:
Damage (chip, bend, etc.) Distortion
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PTS 60.2103 October 2011
Corrosion Cracked welds Elongated I stretched bores Illegible markings (Identification, SWL, etc.)
The profile of the pad eye shall be smooth, free from any flame cutting marks, and the hole shall be line bored after the fitting of cheek plates. 6.6.5.
Slings a) Proof Test The OEM or any other certifying body shall proof test all new or repaired items prior to initial use as the situation warrants. A copy of this test certificate shall be made available and record retained by the relevant Authority. b) In-service inspection The following guidelines are recommended for the safe use of round slings:
6.6.6.
Check and ensure round slings are not defective prior to any lifting operations
Ensure the round sling engages correctly with fittings and the lifting hook. Ensure that smooth radii are formed which allow the sling to naturally flattened under load
Ensure that round slings are not twisted or crossed and fittings are not over crowded
Ensure there is no weakening or softening of the material on the sling surface due to Chemical attack
Ensure the use of packing to protect the round sling from sharp edges
Ensure there is no lifting on the point of any hook
Ensure that the round slings are never exposed to direct heat or flames
Do not use round slings with cut or damaged covers
Ensure the correct colour code is on the sling prior to use
Shackles a) Inspection criteria for shackles and rings are listed below.
Shackle pins shall fit freely without binding. (Seated screw pin shackles shall be disassembled by hand after the first-half turn.)
The pin shall show no sign of deformation.
The shackle shall have no defect that will interfere with serviceability.
Shackles and rings for critical-lift service shall have an initial proof load test of two times the SWL (minimum). Before making a critical lift, ensure that the shackle or ring has been proof tested.
Before each use, rings shall be visually inspected for damage, corrosion, wear, cracks, twists, and opening.
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PTS 60.2103 October 2011 b) Proof load test
A proof load test (minimum, two times SWL) is required for shackles and rings used in critical-lift service.
Note:
6.6.7.
A critical-lift procedure may call for additional load testing or proof load testing of rigging and rigging hardware.
Eyebolts Inspection criteria for eyebolts are as follows:
6.6.8.
Careful visual inspection of each eyebolt immediately before use is mandatory. Eyebolts that are cracked, bent, or have damaged threads shall be discarded.
The shank of the eyebolt shall not be undercut and shall be smoothly radii used into the plane of the shoulder
Swivel Rings Inspection criteria for swivel hoist rings are as follows:
The minimum design factor shall be no less than five based on ultimate strength.
Ensure free movement of the bail. The range of movement shall be 360 degrees swivel and 180 degrees pivot.
The work piece shall be tapped for a swivel hoist ring bolt with the axis perpendicular to the mounting surface. The work surface should be flat and smooth to provide flush seating for the bushing flange. The bolt should be tightened to the full torque loading. Unless otherwise recommended by the manufacturer, the torque tolerance is +25%. Note: Loosening of a swivel hoist ring bolt may develop after prolonged service in a permanent installation. Periodically verify proper torque and retighten the mounting bolt as recommended by the manufacturer. In lieu of other direction from the manufacturer, check hoist swivel ring mounting bolts for proper torque before each lift.
Swivel hoist rings shall be provided with instructions from the manufacturer. They shall be marked to clearly identify the manufacturer, the safe working load, and the torque value. Swivel hoist rings are available in both UNC and metric thread sizes, so they shall also be marked to identify UNC or metric threads.
When a swivel hoist ring is installed with a retention nut, the nut must have no less than full thread engagement and shall be torque in accordance with the manufacturer’s recommendations. The nut must meet one of the following standards to develop the safe working load limit: -
ASTM A-563 (A) Grade D Hex Thick (B) Grade DH Standard Hex
-
SAE Grade 8 Standard Hex
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PTS 60.2103 October 2011
6.6.9.
Never use free fit spacers or washers between the swivel host ring bushing flange and the mounting surface.
Never use swivel hoist rings that show signs of corrosion, wear or damage.
Read, understand, and follow the manufacturer’s instructions, diagrams, and chart information before using a swivel hoist ring.
Hooks a) Inspection criteria for rigging hooks are as follows:
Rigging hooks that are not permanently installed in a sling assembly shall be visually inspected for the following deficiencies before use: -
Distortions such as bending, or twisting exceeding 10 degrees from the plane of the unbent hook
-
Increased throat opening exceeding 15%
-
wear exceeding 10% of the original dimension
-
Cracks, severe nicks, or gouges
-
Hook attachment and securing means.
Rigging hooks shall be inspected as a part of the slings to which they are attached.
The NDT of rigging hooks is not routinely required. Rigging hook NDT may be required by a critical-lift procedure.
b) Proof Test No periodic load testing of hooks is required except as necessary to conform to the requirements for the slings or rigging hardware of which they are a part 6.6.10. Personnel Transfer Basket a) Pre-use visual Inspection A visual inspection of the personnel transfer device shall be carried out prior to each use by a competent person. This shall include:
Check for any damage on all parts of the unit
Visually inspect safety load line when attaching the device to the crane hook. This includes the four part sling and all hardware as well as the load line and fabric covered stabilizer.
Look for crimps, broken wires or excessive wear or rust. If exist, take the unit out of service immediately and replace the sling.
Inspect crane hook positive locking device for function and physical condition.
Visually inspect the entire load bearing areas of the device for excessive wear or damage particularly the rigging lines (inner and outer).
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PTS 60.2103 October 2011
b)
Visually inspect the aluminium centre ring section for damage, cracks or excessive wear.
Inspect the stainless quick release clips.
Regularly spray with a lubricant so that they operate smoothly.
Monthly Inspection The monthly inspection of the basket and its ancillaries shall be consistent with OEM’s guidelines. As a minimum the following shall apply:
Perform Pre-use visual Inspection
The polypropylene rope shall be reverse hand twisted so that the internal strands can be inspected for any signs of wear breakage,build up of dirt, grease or salt deposits.
If any strand deterioration is noted, the basket shall be replaced with a new unit.
The bottom-padded ring shall be inspected and checked for any sign of damage or tears.
The main lifting ring shall be inspected and checked for any signs of wear or deformation.
The net shall be washed with fresh water after the inspection.
c) Six (6) Monthly Inspection Every 6 months the personnel transfer device shall be inspected by a qualified inspector.
Check for any damage or defect on all parts of the unit.
Visually inspect safety load line, four part sling and all hardware (paying close attention to broken wires, flattened sections, crimps, rust etc). This should follow API sling inspection guidelines.
Inspect fabric covered stabilizer for tears or excessive wear. This may need replacement if inner rubbers have had significant use and have lost elasticity.
Inspect outer and inner rigging ropes and the bolts that hold them for sufficient tension.
Inspect outer and inner rigging ropes and the bolts that hold them for sufficient tension.
Inspect top and bottom of powder coated aluminium frame including top and bottom ring, expanded metal top, and centre pole. Look for excessive wear, cracks or corrosion.
Turn centre pole (at least three full turns) loosening and then tightening. Swab the threads with lubricant to prevent seizing.
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PTS 60.2103 October 2011 7. REFERENCES In this PTS reference is made to the following publications. NOTE: Unless specifically designated by date, the latest issue of each publication shall be used (together with any amendments/supplements/revisions thereof). PETRONAS STANDARDS Offshore Crane 20 Tons
PTS 20.129
Offshore Crane 12 Tons
PTS 20.130
AMERICAN STANDARDS Specification for Offshore Pedestal Mounted Crane (2004)
API 2C
Operation and Maintenance of Offshore Cranes (2007)
API 2D
Specification for Wire Rope (2004)
API RP 9A
Recommended Practice on Application, Care and Use of Wire Rope For Oil Field Service (1999)
API RP 9B
Inspection, Maintenance, Repair, and Remanufacture of Hoisting Equipment
API 8B
Mobile and Locomotive Crane
ASME B 30.5
Alloy-Steel Chain Slings, Wire Rope Slings, Metal Mesh
ASME B 30.9
Slings, Synthetic Webbing Slings, Synthetic Round Slings (1999) Overhead Hoist (Underhung) (2003)
ASME B30.16
Overhead and Gantry Cranes (Top Running Bridge, Single Girder,
ASME B30.17
Underhung Hoist) (2006) Manually Lever Operated Hoists (2005)
ASME B30.21
BRITISH STANDARDS The following are some of the Standards and Codes (latest Edition) that may be applicable as deemed necessary: Code of Practice for Safe use of Cranes – General
BS 7121 Part 1
Code of Practice for Safe use of Cranes – Inspection,
BS 7121 Part 2
testing and Examination Code of Practice for Safe use of Cranes – Mobile Cranes
BS 7121 Part 3
Code of Practice for Safe use of Cranes – Tower Cranes
BS 7121 Part 5
Code of Practice for Safe use of Cranes – Offshore Cranes
BS 7121 Part 11
Power Driven Overhead Travelling Cranes, Semi-Goliath and
BS 466
Goliath Cranes for General Use
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PTS 60.2103 October 2011 Code of practice for safe use of construction Hoists
BS 7212
High Pedestal or Portal Jib Cranes
BS 2452
Rules for Design of Cranes - Part 1: Classification, stress
BS 2573-1
calculations and design criteria for structures The Design and Testing of Steel Overhead Runway Beam
BS 2853
Verification of Stability of Industrial Trucks Operating In Special
BS 5778
Condition of Stacking with Mast Tilted Forward Offshore Containers-Design, Construction, Testing, Inspection
BS EN 12079
And Marking (1999) Steel Wire Ropes Slings-Safety-Slings for General Lifting Services
BS EN 13414 Part 1
(2003) Steel Wire Ropes Slings-Safety-Specification for Information for
BS EN 13414 Part 2
Use and Maintenance to be Provided by the Manufacturer (2003) Steel Wire Ropes Slings-Safety-Grommets and Cable-Laid Slings (2003)
BS EN 13414 Part 3
MANUAL PETRONAS Carigali Sdn Bhd Lifting Equipment Manual
WW ALL M 04 001
LEGISLATION AND STANDARDS Factories and Machinery (Building Operations and Works of Engineering Construction) (Safety) 1986 Occupational Safety and Health Act, 1994 - PART IV GENERAL DUTIES OF EMPLOYERS AND SELF-EMPLOYED PERSONS Factory and Machinery (Electric Passenger and Good Lift) Regulations 1970 Factory and Machinery (Notification, Certificate of Fitness and Inspection) Regulations 1970 Host country statutory requirement
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PTS 60.2103 October 2011 APPENDIX I : Terms and Definitions Blind lifts Lifting operation whereby the lifting appliance operator does not have a direct view of the load or landing area. (Note : Use of closed circuit television monitoring the work area is not considered to be direct view) Simple lifting appliances Lifting appliances (overhead cranes, winches, chain hoists, monorail cranes, etc.) where use is not considered to involve a hazard to life, health and/or material assets Fixed attachment point for lifting appliance Pad eyes, winch and mobile crane foundations, lifting beams and beams for temporary attachment of beam clamps Installation Facility, plant and other equipment for petroleum activities (however, not ships that transport petroleum in bulk) Note: In this NORSOK standard, supply and standby boats are included in the definition of an installation. Examples of installations include fixed installations, floating production, storage and offshore loading (FPSO) vessels, rigs, barges, crane barges, service vessels etc Snatch block Lifting equipment consisting of at least one sheave in a frame with an attachment point for rope, wire sling or chain that can be attached to a fixed point or to a movable point on the load. Critical lifting operations Operations requiring a work permit, lifting plan and special safety measures in order to address the interface with adjacent activities Note:
These operations include, but are not limited to
Lifting more than 20 tons of load
Lift over live or critical/sensitive process equipment or facility.
Lifting load of weight more than 80% of rated capacity of the lifting equipment at the specified working radius and boom angle as per crane load chart.
Personnel transport with the lifting appliance.
Lift of special loads such as structures, mobile cranes, boiler and vessel.
Lifting operation by using helicopter.
Coordinated lift whereby the weight exceeds the maximum lifting capacity of one of the lifting appliances e.g. using of multiple cranes.
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PTS 60.2103 October 2011
Lifting operation at location less than the specified Safety Distance from live overhead power line (refer to Appendix XX: Safety Distance Calculation)
Specific lifting operations for ensuring integrity or functionality of the lifting equipment after installation, structural repair or modification of the equipment and other testing purposes such as functional or proof load tests
Subsea operations using the offshore crane.
Other lifting operation which are deemed as critical or high risk and determined in the OPU’s Hazards and Effect Register e.g. blind lift, lifting through hatches.
Load carrier All types of container, baskets, tanks, skids and frames that are used to transport load Lifting appliance Combined unit that is used to lift loads, with or without horizontal movement Lifting devices Parts of the structure of, or used as part of a lifting gear such as shackles, swivel hoist rings, eyebolts, rigging hooks, turnbuckles, and other commercial equipment. Lifting devices may become part of a lifting fixture. Lifting fixtures All equipment that is used to lift a load by means of a crane or a similar device. Lifting fixtures include spreader bars, special slings, and other commercial devices. Lifting fixtures also include shipping containers, experimental framework, and structural components of experimental devices if such are used to function in effect as lifting fixtures. Note: Lifting fixtures do not include pallets, shipping containers, or framework that is lifted from below by means of a forklift or pallet jack Lifting gear components or equipment used between the lifting appliance and the load or on the load to grip it, but which is not an integrated part of the lifting appliance NOTE Examples of lifting gear are shown in Annex J. Lifting equipment Common term for lifting gear, lifting appliances and lifting components, used together or individually Material handling plan Plan for moving load on the installation to ensure a safe and efficient operation Note:
The material handling plan takes into account, among other things
the need for type and number of lifting and transport equipment, the need for loading and unloading areas, preparing for the use of lifting and stacking trucks, trolleys etc., access to areas and workplaces for operation and maintenance.
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PTS 60.2103 October 2011 Rigger Anyone who attaches or detaches lifting equipment to loads or lifting devices and issue/control of tags for temporarily assembled lifting appliance Competent person Personnel who has attended the required training at approved and accredited industrial training institution, certified competent and register with relevant authority as per local law and regulation. Qualified inspector: A person so designated by the employer who by reason of appropriate experience and training, has successfully completed classroom-type training on crane maintenance and troubleshooting; on hoist troubleshooting and overhaul; and on the structural aspects of offshore cranes, which gives a knowledge of structurally critical components and critical inspection areas Significant wave height Average height of the highest third of prevailing waves, typically measured over a period of three hours. Note:
As a rule of thumb, significant wave height is about half the maximum wave height.
Safe working load SWL Maximum load the lifting equipment is certified to withstand under normal use Note: SWL is normally used by ILO and shall apply on all floating and other mobile installations and ships that are not covered by EU regulations. Working load limit WLL Maximum load that a sling or a lifting component is certified to withstand under normal use and in a given configuration
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PTS 60.2103 October 2011 APPENDIX II : Pre-Use Inspection Checklist – Pedestal Crane PEDESTAL CRANE PRE-START UP CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane : Pre-Start Up Fit Unfit No Check Items 1 Record engine hours 2 Check lower pedestal area is clear for slow motion 3 Ensure boom walkway gate is securely closed 4 Check boom lock pawl actuator for operation when neutral 5 Check security of boom buffers 6 Check operation of boom 7 Visual check of wire ropes - main & boom 8 Visual check security of boom & hoist winch mounting bolts 9 Check machinery guards are secure 10 Check engine air cleaner 11 Check radiator hose condition 12 Check air reservior - drain water Engine : Pre-Start Up Fit Unfit No Check Items 1 Check radiator water level 3 Check engine oil sump level 4 Ensure fuel tank is full. Drain off water Lubrication : Pre-Start Up Fit Unfit No Check Items 1 Check hydraulic oil level 2 Check transmission gearbox oil level 3 Check pump drive oil level 4 Check diesel fuel level 5 Check slewing gear oil level 6 Check hoist & boom winch oil level Operation Checks Fit Unfit No Check Items 1 Test SLI & function test limits 2 Check annunciation alarms 3 Check engine oil pressure & record 4 Check engine oil temperature & record 5 Check battery charging system 6 Check brake operations on all motions 7 Check engine for leaks 8 Check hydraulic for leaks 9 Check main hoist ATB limit 10 Check auxilliary hoist ATB limit 11 Check boom min/max limit 12 Check slew limit 13 Check navigational lights on boom & A frame 14 Ensure windscreen wipes are operating satisfactorily 15 Check correct spooling of ropes on drums Operation Checks Fit Unfit No Check Items Upon completion of lifting work, put back and secure the crane and 1 related facilities into their original safe position 2 Carried out housekeeping and make safe the area Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Remarks
Remarks
Remarks
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX III : Monthly Inspection Checklist – Pedestal Crane PEDESTAL CRANE MONTHLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items Record engine hours 1 Engine oil level. Add oil as necessary 2 Radiator condition and water level 4 Starter lubricator 5 All hoses for any leakage. 6 Regulator pressure '' 7 Accumulator pressure 8 Diesel fuel level. Add fuel as necessary 9 10 Belting tension, wear and tear. Operator Cabin Condition No Check Items Load chart is vissible at primary control station 1 Main hoist gauge 2 3 Fly hoist gauge 4 All panel for damage Load indicator 5 Angle indicator 6 Boom and Mast Condition No Check Items Lattice/box member for any sign of bent or broken 1 Lattice/box member for sign of corrosion 2 Bridle condition 3 Loose and broken Bolts & pins 4 Boom hoist limit & anti-2 block device function 5 Wire rope Condition No Check Items Boom/Pendant rope for deterioration & damage 1 Fly hoist wire rope for deterioration & damage 2 Main hoist wire rope for deterioration & damage 3 Cable anchor point A frame 4 Cable drum spooling 5 Boom limit switch operation 6 Main hoist limit switch 7 Winch/Brake System Winches oil level. Add oil as necessary 1 Winch mounting bolts torque 2 Winches hydraulic hose and connectors. 3 Winches for physical abnormalities. 4 Winches brake system as per procedure. 5 Hook & Sheaves Condition No Check Items 1 Main hoist Sheave condition 2 Fly hoist Sheave condition 3 Boom, Bridle and Boom top Sheave condition. 4 All sheaves guards and rollers condition. 5 Sheaves bearings for rotation and condition. 6 Main and Auxillary hook safety latch Electrical Condition No Check Items 1 Aviation lights 2 Flood lights 3 Electrical cable & connection 4 Emergency stop button Hydraulic System Condition No Check Items 1 Hydraulic hose for any defect 2 Hydraulic Gauges 3 Physical condition Hydraulic motor & pump 4 Hydraulic oil level.Add oil as necessary 5 Any leaks on hydraulic system General Condition No Check Items 1 Pedestal structure for any sign of corrosion 2 Touch up painting 3 Lubrication on all wire ropes 4 Greasing at all bearing points Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX IV : Quarterly Inspection Checklist - Pedestal Crane PEDESTAL CRANE QUATERLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items Record engine hours 1 Engine oil level. Add oil as necessary 2 Radiator condition and water level 4 Starter lubricator 5 All hoses for any leakage. 6 Regulator pressure '' 7 Accumulator pressure 8 Diesel fuel level. Add fuel as necessary 9 10 Belting tension, wear and tear. Operator Cabin Condition No Check Items Load chart is vissible at primary control station 1 Main hoist gauge 2 3 Fly hoist gauge 4 All panel for damage Load indicator 5 Angle indicator 6 Boom and Mast Condition No Check Items Lattice/box member for any sign of bent or broken 1 Lattice/box member for sign of corrosion 2 Bridle condition 3 Loose and broken Bolts & pins 4 Boom hoist limit & anti-2 block device function 5 Wire rope Condition No Check Items Boom/Pendant rope for deterioration & damage 1 Fly hoist wire rope for deterioration & damage 2 Main hoist wire rope for deterioration & damage 3 Cable anchor point A frame 4 Cable drum spooling 5 Boom limit switch operation 6 Main hoist limit switch 7 Winch/Brake System Winches oil level. Add oil as necessary 1 Winch mounting bolts torque 2 Winches hydraulic hose and connectors. 3 Winches for physical abnormalities. 4 Winches brake system as per procedure. 5 Hook & Sheaves Condition No Check Items 1 Main hoist Sheave condition 2 Fly hoist Sheave condition 3 Boom, Bridle and Boom top Sheave condition. 4 All sheaves guards and rollers condition. 5 Sheaves bearings for rotation and condition. 6 Main and Auxillary hook safety latch Electrical Condition No Check Items 1 Aviation lights 2 Flood lights 3 Electrical cable & connection 4 Emergency stop button Hydraulic System Condition No Check Items 1 Hydraulic hose for any defect 2 Hydraulic Gauges 3 Physical condition Hydraulic motor & pump 4 Hydraulic oil level.Add oil as necessary 5 Any leaks on hydraulic system General Condition No Check Items 1 Pedestal structure for any sign of corrosion 2 Touch up painting 3 Lubrication on all wire ropes 4 Greasing at all bearing points Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX V : Semi-Annual Inspection Checklist – Pedestal Crane PEDESTAL CRANE SEMI-ANUALLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items Record engine hours 1 Engine oil level. Add oil as necessary 2 Radiator condition and water level 4 Starter lubricator 5 All hoses for any leakage. 6 Regulator pressure '' 7 Accumulator pressure 8 Diesel fuel level. Add fuel as necessary 9 10 Belting tension, wear and tear. Operator Cabin Condition No Check Items Load chart is vissible at primary control station 1 Main hoist gauge 2 3 Fly hoist gauge 4 All panel for damage Load indicator 5 Angle indicator 6 Boom and Mast Condition No Check Items Lattice/box member for any sign of bent or broken 1 Lattice/box member for sign of corrosion 2 Bridle condition 3 Loose and broken Bolts & pins 4 Boom hoist limit & anti-2 block device function 5 Wire rope Condition No Check Items Boom/Pendant rope for deterioration & damage 1 Fly hoist wire rope for deterioration & damage 2 Main hoist wire rope for deterioration & damage 3 Cable anchor point A frame 4 Cable drum spooling 5 Boom limit switch operation 6 Main hoist limit switch 7 Winch/Brake System Winches oil level. Add oil as necessary 1 Winch mounting bolts torque 2 Winches hydraulic hose and connectors. 3 Winches for physical abnormalities. 4 Winches brake system as per procedure. 5 Hook & Sheaves Condition No Check Items 1 Main hoist Sheave condition 2 Fly hoist Sheave condition 3 Boom, Bridle and Boom top Sheave condition. 4 All sheaves guards and rollers condition. 5 Sheaves bearings for rotation and condition. 6 Main and Auxillary hook safety latch Electrical Condition No Check Items 1 Aviation lights 2 Flood lights 3 Electrical cable & connection 4 Emergency stop button Hydraulic System Condition No Check Items 1 Hydraulic hose for any defect 2 Hydraulic Gauges 3 Physical condition Hydraulic motor & pump 4 Hydraulic oil level.Add oil as necessary 5 Any leaks on hydraulic system General Condition No Check Items 1 Pedestal structure for any sign of corrosion 2 Touch up painting 3 Lubrication on all wire ropes 4 Greasing at all bearing points Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX VI : Annual Inspection Checklist - Pedestal Crane PEDESTAL CRANE ANUALLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items Record engine hours 1 Engine oil level. Add oil as necessary 2 Radiator condition and water level 4 Starter lubricator 5 All hoses for any leakage. 6 Regulator pressure '' 7 Accumulator pressure 8 Diesel fuel level. Add fuel as necessary 9 10 Belting tension, wear and tear. Operator Cabin Condition No Check Items Load chart is vissible at primary control station 1 Main hoist gauge 2 3 Fly hoist gauge 4 All panel for damage Load indicator 5 Angle indicator 6 Boom and Mast Condition No Check Items Lattice/box member for any sign of bent or broken 1 Lattice/box member for sign of corrosion 2 Bridle condition 3 Loose and broken Bolts & pins 4 Boom hoist limit & anti-2 block device function 5 Wire rope Condition No Check Items Boom/Pendant rope for deterioration & damage 1 Fly hoist wire rope for deterioration & damage 2 Main hoist wire rope for deterioration & damage 3 Cable anchor point A frame 4 Cable drum spooling 5 Boom limit switch operation 6 Main hoist limit switch 7 Winch/Brake System Winches oil level. Add oil as necessary 1 Winch mounting bolts torque 2 Winches hydraulic hose and connectors. 3 Winches for physical abnormalities. 4 Winches brake system as per procedure. 5 Hook & Sheaves Condition No Check Items 1 Main hoist Sheave condition 2 Fly hoist Sheave condition 3 Boom, Bridle and Boom top Sheave condition. 4 All sheaves guards and rollers condition. 5 Sheaves bearings for rotation and condition. 6 Main and Auxillary hook safety latch Electrical Condition No Check Items Aviation lights 1 Flood lights 2 Electrical cable & connection 3 Emergency stop button 4 Hydraulic System Condition No Check Items Hydraulic hose for any defect 1 2 Hydraulic Gauges 3 Physical condition Hydraulic motor & pump Hydraulic oil level.Add oil as necessary 4 Any leaks on hydraulic system 5 General Condition No Check Items Pedestal structure for any sign of corrosion 1 2 Touch up painting Lubrication on all wire ropes 3 Greasing at all bearing points 4 Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX VII : General Guideline of Load Testing Load testing procedures shall incorporate the following minimum guidelines:
The qualified inspector shall be familiar with the crane load chart and the load selected for the load test.
The load-rating chart shall indicate the maximum capacity for each radius,
The qualified inspector shall select test loads that specifically stress the repaired or altered component,
The qualified inspector shall select a test load that is within the capacity of the hoists and wire ropes,
The qualified inspector shall be aware that line pulls on some non-mechanical and electric hoists may be self-limiting. The load test requires only that these hoists, when self-limiting, lift at least 100% of rated load,
Test weights or dynamometer/load cell shall be calibrated and verified for accuracy by the qualified inspector,
All lifts shall be planned in advance taking into account the crane's physical location, the available space for staging and assembling the test loads and the hazardous areas to be avoided,
Relief valves on hydraulic cranes shall not be adjusted above manufacturer's recommended pressures.
Current-limiting devices on electric cranes shall not be by-passed or adjusted to increase available hoist line pull.
The test can be conducted with the hoist’s maximum load as long as it is within the excess of the static rated load
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PTS 60.2103 October 2011 APPENDIX VIII : Pre-Use Inspection Checklist – Mobile Crane MOBILE CRANE PRE-USE INSPECTION CHECK LIST Facility Location Tag No Crane SWL Model/PMA No Operator must check the following items at start of each tour of duty. All remark columns must be filled Visual Inspect Condition No Check Items 1 All exposed moving part guarded 2 All componet in lifting, swinging, lowering, boom 3 All wire rope, sheaves, drums, rigging, hardware and attachment 4 Rope termintaion, spooling and anchorage point 5 All hooks for cracks '' 6 Freedom of rotation of swivel 7 Boom and jib 8 Corrosion under attachment that connected to chords and lacing 9 Cracking or flaking of paint 10 Tire 11 Air/Hydraulic oil 12 lubrication oil and coolant level 13 Fire extinguisher 14 Cab window and windscreen wiper 15 Crance structure free from loose materials 16 Turnable connection 17 Outrigger beam and cylinder 18 Condition of floats/pad 19 Break and clutch 20 Boom hoist lockout 21 Anti-two-block devices (ATB) 22 Load moment indicators (LMI) 23 All gauges 24 Warning light Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
User
Name Signature Date Time
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Remarks
Area Owner
PTS 60.2103 October 2011 APPENDIX IX : Annual Inspection Checklist - Mobile Crane MOBILE CRANE ANNUAL INSPECTION CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled **Must carry out all inspections as outlined in Pre-use Inspection first before do this inspection check list Engine : Condition Remarks No Check Items 1 Entire length of wire rope 2 Entire crane structural 3 Mainframe 4 Outrigger assemblies 5 Structural attachment between supersturcture and the carrier '' 6 Welded joints 7 Main chords and lacing 8 Hydraulic boom 9 Load/stress bearing structure Record magnetic particle and crack detecting inspection(NDT) 10 11 Sheaves and drums 12 Pins 13 Bearing 14 Shafts 15 Gears 16 Rollers 17 Locking devices 18 Hook roller brackets 19 Removable outrigger attachments lugs 20 Welds 21 Excessive wear on brake and clutch system 22 Linings 23 Pawls 24 Ratches 25 Load and boom angle indicators 26 Engine condition 27 Excessive wear on drive sprockets and chain strech 28 Steering, braking and locking device 29 Counterweight 30 Hydraulic and pneumatic hoses, fittings and tubing 31 Evidence of oil/air leaks on surface of flexible hoses 32 Equipment tag number Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
User
Name Signature Date Time
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Area Owner
PTS 60.2103 October 2011 APPENDIX X : Pre-Use Inspection Checklist – Overhead/Gantry Crane OVERHEAD / GANTRY CRANE PRE-START UP CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane Operator must check the following items. All remark columns must be filled Crane : Pre-Start Up Fit Unfit No Check Items Inspect column,support base and beam for corrosion,damage and 1 loose fasteners. Ensure the integrity of the Caged ladders,working 2 platform,walkway, handrails, Tie down points, Coach screw. 3 Check festoon cables,"C"track,collectors for security and condition 4 Visual check of wire ropes / chain for any deformation. 5 Check all the motor for security and guards. 6 Check for hooks for any deformation and safety latch. 7 8 9 10 11 12 Lubrication : Pre-Start Up Fit Unfit No Check Items 1
Ensure for the lubrication of the Wire rope/Chain till termination end
2
Check transmission gearbox oil level Check for lubricate of all sheave bearings,hook blocks thrust bearing, long & cross travel rollers, Gantry rollers and all moving parts inclusive of equilizer assembly.
3
4 5 6 Operation Checks No Check Items 1 Check all the control operate correctly and smoothly 2 Check the function of emergency stop button and main switch 3 Ensure all limits(Hoisting,Cross,Long travel)for safe cut off. 4 Check brake operations on all motions Check all operation(Hoisting,Lowering,Cross,Long Travel) for 5 correct and syncronise function. 6 Check annunciation alarms 7 Check correct spooling of ropes on drums 8 9 10 11 12 13 14 15 Operation Checks No Check Items 1
Remarks
Remarks
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Use certified Crane, Not to be used beyond its statutory Test period
Upon completion of lifting work, put back and secure the crane and related facilities into their original safe position 3 Ensure that the power is shut off after work completion. 4 Carried out housekeeping and make safe the area Operator's Comments on Machine Condition (write down and describe all deficiencies): 2
Crane Operator
Operation Supervisor
Name Signature Date Time
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Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XI : Semi-Annual Inspection Checklist - Overhead/Gantry Crane OVERHEAD / GANTRY CRANE 6 MONTHLY CHECK LIST Facility Location Tag No Crane SWL Model Crane Inspector / Maintenance personnel must check the following items. All remark columns must be filled Functional Tests Fit Remarks No Check Items Unfit 1 Check all the control operate correctly and smoothly Pendant control,check control returns when released & marking, 2 Emergency stop button,strainer wires,Rubber boot. 4 Ensure all limits(Hoisting,Cross,Long travel)for safe cut off. Check all operation(Hoisting,Lowering,Cross,Long Travel) for 5 correct and syncronise function. 6 Check all structures,support for vibration during operation. 7 Check all festoon cables(Cross,Long Travel)for smooth movement Check for long travel motors for syncronized and crane does not 8 slew on the track when travel. Ensure that all travelling brakes are functioning correctly and 9 check all motors for any abnormal sound 10 Ensure correct operation of brakes,Pawl & Ratchet(Manual) 11 12 13 Support Gantry, Bridge, Crab. Fit Remarks No Check Items Unfit Inspect column,support base and beam for corrosion,damage and 1 loose fasteners. 2 Inspect rail for lateral and vertical alignment and security. 3 Check end stopper/buffers for security and condition. 4 Check festoon cables,"C"track,collectors for security and condition 5 Check for all limit switches,strikers for condition,security. 6
Check all the motor for security and guards.
7
Ensure the integrity of the Caged ladders,working platform,walkway, handrails, Tie down points, Coach screw.
8
Check the telescopic Gin Pole for corrosion,bolting.
Lubricate all sheave bearings,hook blocks thrust bearing, long & 9 cross travel rollers, Gantry rollers and all moving parts. 10 Check all gear box oil level, drain sediment and level up. Winches / Hoist / Hooks No Check Items 1 Inspect all winch fasteners for condition,Integrity. 2 Ensure wire rope for correct spooling,fleet angle, type and size. 3 Check whole length of wire rope for condition,damage,wear. Inspect all sheaves for condition,suit to wire size,rotate freely and 4 bearing/bush are not faulty. Inspect hoist blocks, hooks for thrust bearings,Safety catch, wear 5 and throat opening. Inspect Load Chain, Hand Chain, Sprocket wheel for wear, 6 twist,elongation. Inspect all chain terminations, hooks, Anchorage for correct 7 fitment Lubricate all sheave bearings,hook blocks thrust bearing, long & 8 cross travel rollers, Gantry rollers and all moving parts inclusive of equilizer assembly. Ensure for the lubrication of the Wire rope/Chain till termination 9 end Check all transmission gear box oil level, drain sediment and level 10 up. Operator's Cab. No Check Items 1 2 3 4 5
Ensure that there is safe access and engress to and from cabin. Check the condition of the cab for cleanliness, no rugs, aerosols are stored in cabin. Ensure that the fire extinghisher with valid date is kept.
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Fit
Unfit
Remarks
Fit
Unfit
Remarks
PTS 60.2103 October 2011 Electrical No Check Items 1 Check general wiring for condition and connections 2 Check operation of the lights, indicators, warning hazard lights. Check the correct operation of the isolation switch, Junction box 3 and emergency stop. 4 5 General No Check Items Use certified Crane, Not to be used beyond its statutory Test 1 period Upon completion of lifting work, put back and secure the crane and 2 related facilities into their original safe position 3
Ensure that the power is shut off after work completion.
4
Touch up painting for all structural components, winches, hook blocks, body.
Fit
Unfit
Remarks
Fit
Unfit
Remarks
4 5 6 Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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OIM
PTS 60.2103 October 2011 APPENDIX XII : Pre-Use Inspection Checklist – Pillar/Jib Crane JIB CRANE PRE-START UP CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane Operator must check the following items. All remark columns must be filled Crane : Pre-Start Up No Check Items Check for stencilling - Reg. No., SWL, Next Test Date. 1 Column, Jib structure, Caged ladder for mechanical damage, 2 Corrosion,Wear,Cracks Top, Bottom pivot, bearing for contact and Lubrication 3 Control lever for smooth operation and return to neutral when 4 released, marking, adequate height for opeartion Wire rope for corrosion, Lubrication, reeving, Ferrule, Thimble, 5 buldog for termination. Snatch blocks, shackles for looseness, free rotation, Lubrication. 6 Pendant control for operation, strainer wire, Emergency button. 7 Jib top plate, winches, Base foundation fasteners for correct size & 8 Grade, damage, Corrosion. Isolation box, conductor,collector, festoon cable for integrity. 9 10 Check for accumulator, drain valve, pressure gauge, regulator. 11 Check the Gas/Air hose pipes, valve, connectors integrity. 12 Check for Load indicator sensor, connection integrity, performance. Check the condition of wire rope for corrosion, crushing, kinking 13 due to accidental damage or misuse, broken wires. Check the condition of hook particularly at the hook end due to 14 seawater immersion,swivel,Safety latch. 15
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Check the condition of the swing rope, thimble and attachment.
Operation Checks No Check Items 1 2 2 3 4
Use certified Crane, Not to be used beyond its statutory Test period Check and drain condensate from accumulator and filters before starting operation. Check for any unsafe condition and unsafe act during lifting operation.Check for weather and sea swells. Check the gas supply line, valve glands and unions for leakage, pressure. First operation, winch to be driven slowly in both direction for few second with out Load.
5
Lifting and Lowering operation shall be carried out gradually and smoothly, avoid sudden, abrupt, rough stop.
6
Know the weight before lift, never overload the crane.
Post Operation Checks No Check Items 1
Upon completion of lifting work, put back and secure the crane and related facilities into their original safe position
2
Carried out housekeeping and make safe the area
Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XIII : Quarterly Inspection Checklist - Pillar/Jib Crane JIB CRANE QUARTERLY CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane Operator / Sr. Maintenance Tech. must check the following items. All remark columns must be filled Structure / Winch / Wire rope No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22
Check Items
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Check for stencilling - Reg. No., SWL, Next Test Date. Column, Jib structure, Caged ladder for mechanical damage, Corrosion,Wear,Cracks Top, Bottom pivot, bearing for contact and Lubrication Control lever for smooth operation and return to neutral when released, marking, adequate height for opeartion Wire rope for corrosion, Lubrication, reeving, Ferrule, Thimble, buldog for termination. Snatch blocks, shackles for looseness, free rotation, Lubrication. Pendant control for operation, strainer wire, Emergency button. Jib top plate, winches, Base foundation fasteners for correct size & Grade, damage, Corrosion. Isolation box, conductor,collector, festoon cable for integrity. Check for accumulator, drain valve, pressure gauge, regulator. Check the Gas/Air hose pipes, valve, connectors integrity. Check for Load indicator sensor, connection integrity, performance. Check the condition of wire rope for corrosion, crushing, kinking due to accidental damage or misuse, broken wires. Diameter. Check for hook block wear, damage and throat opening, safety latch, swivel. Check the condition of the swing rope, thimble and attachment. Check gear box oil, level up. Check the performance, condition, effectiveness of the winch brake assembly. Lubricate all moving components,bearings,bush,swivels. Check the lubricator oil, leve up. Check gear box oil, level up. Drain the sediments from gearbox,top up level.
Operation Checks No 1 2 3
Check Items Check and drain condensate from accumulator and filters before starting operation. Check for any unsafe condition and unsafe act during lifting operation.Check for weather and sea swells. Check the gas supply line, valve glands and unions for leakage, pressure.
4
First operation, winch to be driven slowly in both direction for few second with out Load.
5
Lifting and Lowering operation shall be carried out gradually and smoothly, avoid sudden, abrupt, rough stop.
6
Know the weight before lift, never overload the crane.
Post Operation Checks No
Check Items
1
Upon completion of lifting work, put back and secure the crane and related facilities into their original safe position
2
Carried out housekeeping and make safe the area
Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XIV : Annual Inspection Checklist - Pillar/Jib Crane JIB CRANE ANNUALLY CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane Operator / Sr. Maintenance Tech. must check the following items. All remark columns must be filled Structure / Winch / Wire rope No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22
Check Items
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Fit
Unfit
Remarks
Check for stencilling - Reg. No., SWL, Next Test Date. Column, Jib structure, Caged ladder for mechanical damage, Corrosion,Wear,Cracks Top, Bottom pivot, bearing for contact and Lubrication Control lever for smooth operation and return to neutral when released, marking, adequate height for opeartion Wire rope for corrosion, Lubrication, reeving, Ferrule, Thimble, buldog for termination. Snatch blocks, shackles for looseness, free rotation, Lubrication. Pendant control for operation, strainer wire, Emergency button. Jib top plate, winches, Base foundation fasteners for correct size & Grade, damage, Corrosion. Isolation box, conductor,collector, festoon cable for integrity. Check for accumulator, drain valve, pressure gauge, regulator. Check the Gas/Air hose pipes, valve, connectors integrity. Check for Load indicator sensor, connection integrity, performance. Check the condition of wire rope for corrosion, crushing, kinking due to accidental damage or misuse, broken wires. Diameter. Check for hook block wear, damage and throat opening, safety latch, swivel. Check the condition of the swing rope, thimble and attachment. Check gear box oil, level up. Check the performance, condition, effectiveness of the winch brake assembly. Lubricate all moving components,bearings,bush,swivels. Check the lubricator oil, leve up. Check gear box oil, level up. Drain the sediments from gearbox,top up level.
Operation Checks No 1 2 3
Check Items Check and drain condensate from accumulator and filters before starting operation. Check for any unsafe condition and unsafe act during lifting operation.Check for weather and sea swells. Check the gas supply line, valve glands and unions for leakage, pressure.
4
First operation, winch to be driven slowly in both direction for few second with out Load.
5
Lifting and Lowering operation shall be carried out gradually and smoothly, avoid sudden, abrupt, rough stop.
6
Know the weight before lift, never overload the crane.
Post Operation Checks No
Check Items
1
Upon completion of lifting work, put back and secure the crane and related facilities into their original safe position
2
Carried out housekeeping and make safe the area
Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XV : Pre-Use Inspection Checklist - Hoist HOIST PRE-START UP CHECK LIST Facility Location Tag No Crane SWL Crane NTD Crane : Pre-Start Up No Check Items 1 Check external oil leaks and repair work needed 2 Check level of gear lubricant 3 Inspect the vent plug to ensure not clogged 4 Check proper operation of ratchet and pawl mechanism 5 Check hydraulic hoses/plumbing for deteriorating hoses 6 Visual check for corrroded,loose or missing bolts,pins or other fasteners 7 Visual check rotation indicator sensors 8 Engine warm-up procedure is recommended at each engine start up
Crane Operator
Operation Supervisor
Name Signature Date Time
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Condition
Remarks
''
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XVI : Quarterly Inspection Checklist - Hoist HOIST QUATERLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items 1 Check external oil leaks and repair work needed 2 Check level of gear lubricant 4 Inspect the vent plug to ensure not clogged 5 Check proper operation of ratchet and pawl mechanism 6 Check hydraulic hoses/plumbing for deteriorating hoses '' 7 Visual check for corrroded,loose or missing bolts,pins or other fasteners 8 Visual check rotation indicator sensors 9 Engine warm-up procedure is recommended at each engine start up 10 Perform brake test for drum rotate or slips 11 Inspect hoist structural components for corrision 12 Change the filters of hyraulic system(as per the crane manufacturer's) Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
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Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XVII : Semi-Annual Inspection Checklist – Hoist HOIST SEMI-ANUALLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition No Check Items 1 Check external oil leaks and repair work needed 2 Check level of gear lubricant 4 Inspect the vent plug to ensure not clogged 5 Check proper operation of ratchet and pawl mechanism 6 Check hydraulic hoses/plumbing for deteriorating hoses '' 7 Visual check for corrroded,loose or missing bolts,pins or other fasteners 8 Visual check rotation indicator sensors 9 Engine warm-up procedure is recommended at each engine start up 10 Perform brake test for drum rotate or slips 11 Inspect hoist structural components for corrision 12 Change the filters of hyraulic system(as per the crane manufacturer's) Take gear oil sample to analyze wear metals,viscocity,signs of 13 overheating,oxidation,moisture and contaminants Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
Page 83 of 93
Remarks
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XVIII : Annual Inspection Checklist - Hoist
HOIST ANUALLY CHECK LIST Facility Location Tag No Crane SWL Model Operator must check the following items at start of each tour of duty. All remark columns must be filled Engine : Condition Remarks No Check Items 1 Check external oil leaks and repair work needed 2 Check level of gear lubricant 4 Inspect the vent plug to ensure not clogged 5 Check proper operation of ratchet and pawl mechanism 6 Check hydraulic hoses/plumbing for deteriorating hoses '' 7 Visual check for corrroded,loose or missing bolts,pins or other fasteners 8 Visual check rotation indicator sensors 9 Engine warm-up procedure is recommended at each engine start up 10 Perform brake test for drum rotate or slips 11 Inspect hoist structural components for corrision 12 Change the filters of hyraulic system(as per the crane manufacturer's) Take gear oil sample to analyze wear metals,viscocity,signs of 13 overheating,oxidation,moisture and contaminants 14 Change the hoist gear oil Operator's Comments on Machine Condition (write down and describe all deficiencies):
Crane Operator
Operation Supervisor
Name Signature Date Time
Page 84 of 93
Platform Superintendent
PTS 60.2103 October 2011 APPENDIX XIX : Standard Hand Signals
Hoist: With forearm vertical, forefinger pointing up, move hand in small circle
Raise Boom: Arm extended, fingers closed, thumb pointing upward
Lower: With arm extended downward, forefinger pointing down, move hand in small horizontal circle
Lower Boom: Arm extended, fingers closed, thumb pointing downward
Emergency Stop: Both arms extended, pointing down, move arms rapidly up and down
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Move slowly: Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal (hoist slowly shown as example)
Swing: Arm extended, point finger in direction of swing boom
Dog Everything: Clasp hands in front of body.
PTS 60.2103 October 2011 APPENDIX XX : Safety Distance for Lifting Near Power Lines Safety Distance required when doing lifting near power lines Safety Distance = 2 x (Crane Boom Radius) + (Buffer Distance) Voltage
Buffer Distance
To 50 kV
10 ft
51 to 200 kV
15 ft
201 to 350 kV
20 ft
351 to 500 kV
25 ft
501 to 750 kV
35 ft
751 to 1000 kV
45 ft
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PTS 60.2103 October 2011 APPENDIX XXI : Lift Plan - SAMPLE
Following is an example of critical lift plan which may be applied for crane operations. Similar plan which addresses key aspects or components (wherever applicable) as listed below shall be developed for critical lifts using other equipment or devices.
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