Saudi Aramco 7_030 Inspection Lift Equip

Saudi Aramco 7180 (5/89)

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) GENERAL INSTRUCTION MANUAL ISSUING ORG.: SUBJECT:

INSPECTION DEPARTMENT

INSPECTION AND TESTING REQUIREMENTS FOR ELEVATING/LIFTING EQUIPMENT

G. I. NUMBER

Approved 7.030

ISSUE DATE 03/01/2002

REPLACES 12/01/96

APPROVAL

PAGE NUMBER Page 1 of 11

PURPOSE The purpose of this instruction is to establish requirements and guidelines for the inspection of elevating/lifting equipment operating on Saudi Aramco projects and facilities. Both Saudi Aramco and contractor equipment are covered. CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

1.

Definitions Applicable Standards Inspection Marine and Offshore Cranes (Mounted on Barges, Boats and Platforms) Mobile Cranes Fixed Cranes and Hoists Side Boom Tractors Elevators/Escalators Powered Platforms/Sky Climbers Elevating Work Platforms Vehicle Mounted Elevating and Rotating Aerial Devices Articulating Boom Cranes Storage/Retrieval Machines Crane Suspended Personnel Platforms (Manbaskets) Lifting/Spreader Beams A-Frames/Mobile Gantries

DEFINITIONS ANSI API ASME IMO/SOLAS SAE

-

American National Standards Institute American Petroleum Institute American Society of Mechanical Engineers International Maritime Organization/Safety of Life at Sea Society of Automotive Engineers

COMPETENT PERSON- A person who, by possession of a recognized degree or certificate of professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work. DESIGNATED PERSON - A person selected or assigned by the owner, or the Saudi Aramco USER department, as being proficient to perform specific duties and determine if the crane deficiencies constitute a hazard. DAILY PRE-OPERATIONAL INSPECTION - A visual inspection carried out by a COMPETENT person (Daily, prior to use, and during shift changes, or whenever operators are changed.) EXTENSIVE REPAIR - Any repair, alteration or modification to a load sustaining part, gearing, booms, counterweights, etc. INITIAL INSPECTION - An acceptance inspection carried out on new, modified, or extensively repaired equipment.

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G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


PERIODIC INSPECTION - A visual inspection carried out by a COMPETENT person (Usually quarterly, annually or after modifications, repairs, or in the case of crawler lattice boom cranes, after relocation or boom reconfiguration.) USER - Saudi Aramco proponent department or other organization authorized to act on behalf of the Saudi Aramco proponent department.

2.

APPLICABLE STANDARDS All elevating/lifting equipment covered by this instruction shall be tested and inspected to the relevant ANSI, ASME, API or other noted Standard. It is the responsibility of Contractors and Saudi Aramco USERS to make themselves familiar with these requirements: ASME ANSI ANSI ANSI ANSI ASME ASME

A17.1 A92.2 A92.3 A92.5 A92.6 A120.1 B30.2

ASME ASME ASME ASME ASME ASME ASME ASME ASME ASME ASME ASME

B30.3 B30.4 B30.5 B30.6 B30.7 B30.8 B30.10 B30.11 B30.13 B30.14 B30.16 B30.17

ASME ASME ASME API API ANSI/ SAE SAES-M-001 12-SAMSS-007 SAES-M-008 G. I. 7.024 G. I. 7.025 G. I. 7.027 G. I. 7.028

B30.20 B30.22 B30.23 Spec. 2C RP2D J765

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Safety Code for Elevators and Escalators Vehicle-Mounted Elevating and Rotating Aerial Devices Manually Propelled Elevating Work Platforms Boom-Supported Elevating Work Platforms Self-Propelled Elevating Work Platforms Safety Requirements for Powered Platforms for Building Maintenance Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) Construction Tower Cranes Portal, Tower, and Pillar Cranes Mobile and Locomotive Cranes Derricks Base-Mounted Drum Hoists Floating Cranes and Floating Derricks Hooks Monorails and Underhung Cranes Storage/Retrieval (S/R) Machines and Associated Equipment Side Boom Tractors Overhead Hoists (Underhung) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist) Below-the-Hook Lifting Devices Articulating Boom Cranes Personnel Lifting Systems API Specification for Offshore Cranes Operation and Maintenance of Offshore Cranes Crane Load Stability Test Code Structural Design Criteria for Non-Building Structures Fabrication of Structural and Miscellaneous Steel Design Criteria for Lifting Equipment Marine and Offshore Crane, Hoist, and Rigging Operations Mobile Heavy Equipment Operator Testing and Certification Crane Suspended Personnel Platform Operations (Manbasket) Crane Lifts: Types and Procedures

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3.



G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


INSPECTION 3.1

Daily Pre-Operational Inspections 3.1.1

Prior to daily use, during shift changes or whenever operators are changed, mobile cranes shall have DAILY PRE-OPERATIONAL INSPECTIONS performed by a COMPETENT person designated by the USER and using the appropriate daily inspection checklist (See Section 5 of this G.I.).

3.1.2

The USER shall designate a COMPETENT person to carry out a daily pre-operational inspection on all other elevating/lifting equipment listed in this G.I., using a checklist developed by the USER in accordance with the manufacturer’s operator’s manual and the relevant standards. The checklist shall include (if applicable), but is not restricted to, the following: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)

3.2

All control functions for proper operation All safety devices for proper operation All hydraulic systems Hooks and lifting tackle Wire rope and reeving Electrical system for proper operation Tires, wheels or tracks Air system leaks Coolant system Inspection sticker validity Any other items recommended by the equipment manufacturer

3.1.3

All deficiencies for mobile cranes and other elevating/lifting equipment shall be reported in the daily pre-operational inspection checklists.

3.1.4

Any defects, reported in the daily pre-operational inspection, that could affect the safe operation of mobile cranes and other elevating/lifting equipment shall be corrected prior to use.

Periodic Inspections 3.2.1

The USER shall establish a schedule for PERIODIC inspections of their elevating/lifting equipment in accordance with the relevant standards.

3.2.2

The USER shall request the Inspection Department to perform PERIODIC inspections on elevating/lifting equipment that will be operated on Saudi Aramco projects and facilities. PERIODIC inspections shall be carried out by the Inspection Department in accordance with appropriate standards referenced in this G.I. The Inspection Department shall witness all load tests.

3.2.3

All elevating/lifting equipment USERS shall request PERIODIC inspections by notifying the Inspection Department. The notification shall be at least seven (7) days prior to the due date of the inspection. Remote areas inspections require at least fourteen (14) days notification prior to the due date of inspection.

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3.3

3.4



G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


3.2.4

The PERIODIC inspection frequency for cranes shall be annual, unless otherwise specified in this G.I. or as determined by the Inspection Department.

3.2.5

No crane shall be operated unless it has a valid Saudi Aramco Crane Safety Inspection Sticker.

3.2.6

Cranes that have been involved in any type of an incident, causing damage to the crane, shall have their sticker or certification immediately invalidated. The crane shall not be used until it has passed a reinspection. A load test is also required if the damage affects a load bearing member.

3.2.7

All equipment inspections mentioned in this General Instruction, requiring PERIODIC inspections by the Inspection Department Representative, shall be carried out using an internal inspection checklist.

3.2.8

The USER shall provide all necessary test weights, equipment, and at least one COMPETENT person to serve as an operator for INITIAL, PERIODIC and any additional load tests. (See G.I. 7.025 for more information.)

3.2.9

Equipment that has failed the PERIODIC inspection shall be removed from service until all deficiencies have been corrected, and the crane re-inspected and certified by the Inspection Department. Repairs shall conform to the manufacturer's instructions and the relevant standards.

Initial Inspection 3.3.1

All new or EXTENSIVELY repaired, modified, or altered equipment shall have an INITIAL inspection and a load test prior to putting into service. The load test shall be conducted by the proponent and witnessed by the Inspection Department.

3.3.2

All new equipment requires a manufacturer’s written test certification to be furnished by the USER to the Inspection Department prior to the initial inspection.

3.3.3

The INITIAL inspection shall be conducted according to the relevant manufacturer’s recommendations and relevant standards.

Inspection & Testing Requirements – General 3.4.1

The USER shall furnish the Inspection Department representative with the manufacturer's assembly, operating, and maintenance instructions for the equipment (in the English language). The USER of the equipment shall keep copies of these instructions.

3.4.2

Any EXTENSIVE repair, modification, or alteration to any elevating/lifting equipment requires a manufacturer’s written certification to be furnished by the USER to the Inspection Department upon request. This certification shall state that the repairs were completed in compliance with the manufacturer's specifications, Saudi Aramco standards, and by utilizing a COMPETENT person. A crane jib is considered to be an extension of the main boom and repairs to a jib shall be treated in the same way.

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3.5

3.6

4.



G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


3.4.3

Where the re-rating of equipment is necessary (e.g., crawlers, truck and wheel-mounted cranes, etc.), the equipment shall be tested in accordance with SAE J765 and other relevant standards. All certification tests shall be witnessed by the Inspection Department.

3.4.4

When a Load Test is required, the User shall develop a Load Test Procedure and submit it to the Inspection Department at least seven (7) days prior to the test date.

3.4.5

The Load Test shall be carried out by a COMPETENT person and witnessed by the Inspection Department.

Record Keeping 3.5.1

Records of DAILY PRE-OPERATIONAL INSPECTIONS for all elevating/lifting equipment shall be maintained by the USER for a minimum of two years and made available for audit. Random audits to verify daily pre-operational inspections shall be performed by the Inspection Department. Failure to maintain these records shall result in immediate sticker or certification invalidation.

3.5.2

Records of PERIODIC inspections performed by the Inspection Department shall be maintained by the Inspection Department for the active life of the equipment.

Safety 3.6.1

A copy of the manufacturer's operator’s manual (in the English language) shall be made available to the operator upon request by the USER responsible for the safe operation of any elevating/lifting equipment.

3.6.2

A sign shall be posted on each crane, warning the operator not to rely solely on any automatic device as a substitute for safe operating practices (e.g., safe load indicators).

3.6.3

All warning signs required by applicable standards shall be posted in the English language.

MARINE & OFFSHORE CRANES (MOUNTED ON BARGES, BOATS, and PLATFORMS) 4.1 4.2

Inspection and Testing Requirements per ASME B30.8, API Spec. 2C, &/or API RP 2D, as applicable Classification Societies 4.2.1

Offshore barge and boat cranes shall be approved and certified by the classification society under which the vessel is registered, and shall be verified during the inspection.

4.2.2

All classification societies shall be subject to Saudi Aramco approval.

4.2.3

Where no classification society is available, the API Spec 2C (Specification for Offshore Cranes) or the ASME B30.8 (Floating Cranes and Floating Derricks) standards shall apply.

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4.3

4.4

4.5


Approved 7.030


REPLACES 12/01/96

APPROVAL


Pedestal Cranes 4.3.1

Pedestal cranes installed on offshore barges or boats shall be designed to comply with the requirements of the classification society or API Spec. 2C.

4.3.2

Hull structural drawings for connecting foundations of pedestal cranes shall be approved by the classification society under which the vessel is registered.

4.3.3

For unregistered vessels, a qualified naval architect shall approve foundation drawings in addition to design calculations.

4.3.4

Load Test Certificates shall be provided by the classification society and certified by a COMPETENT engineer or marine surveyor.

Deck Mounted Mobile Cranes 4.4.1

Deck mounted mobile cranes shall only be installed on barges or boats with decks of sufficient strength to support wheel, fully extended outrigger, or track loading.

4.4.2

The Inspection Department shall verify that the classification society has approved the deck structural drawings. They shall clearly state the deck strength that is required to support mobile crane operations. The drawings shall clearly state the maximum permissible bearing pressure on deck plating and show the boundary of all permissible crane operating areas.

4.4.3

Deck mounted mobile cranes installed on barges or boats shall comply with G.I. 7.024.

4.4.4

Trim-and-stability-books (in the English language) are required to install and operate deck mounted mobile cranes on barges or boats. They must comply with the requirements of IMO SOLAS regulations showing loading conditions that take into account the specific crane operation.

4.4.5

Mobile cranes installed on barges or boats, and their dynamic load charts, shall be approved by a COMPETENT engineer for offshore use.

4.4.6

All main boom sections, including power pinned section, shall be extended and inspected for corrosion, proper operation and damage.

Inspection Of Offshore Cranes 4.5.1

5.


G. I. NUMBER

Offshore cranes shall receive a PERIODIC inspection every ninety (90) days or as determined by the Inspection Department.

MOBILE CRANES 5.1

Inspection and testing requirements per ASME B30.5

5.2

Load Charts and Signs

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5.4

Approved 7.030


REPLACES 12/01/96

APPROVAL


5.2.1

All mobile cranes shall have a conspicuously posted load chart and range diagram stating lift capacity based on boom length, attachments, boom angle, outrigger configuration, radius, and lift quadrant. Instruction plaques shall be permanently affixed to the cab of the crane where it is available to the operator while he is seated at his control station. Environmentally protected books may be approved as an alternate to plaques. (All plaques and books shall be in the English language.)

5.2.2

A sign warning of the danger of overhead power lines shall be mounted on each mobile crane where it can be easily seen by the operator. This sign shall warn that the crane must not be operated if any part of the crane will come within the following minimum distances of energized power lines: Line Voltage Up to 250,000 volts Over 250,000 volts

5.3

G. I. NUMBER

Absolute Limit of Approach 6.1 Meters (20 Feet). 7.6 Meters (25 Feet).

Safety Devices 5.3.1

Anti-two block devices, if fitted, shall be operational.

5.3.2

Safe Load Indicators, if fitted, shall be operational.

5.3.3

All cranes shall be equipped with an accurate level indicator.

Inspection and Testing Requirements 5.4.1

Mobile cranes shall receive a PERIODIC inspection every ninety (90) days or as determined by the Inspection Department.

5.4.2

The operator of a Saudi Aramco owned mobile crane shall perform a daily pre-start safety inspection, prior to operating his assigned crane, on Saudi Aramco form SA 9466. All Saudi Aramco mobile crane deficiencies shall be reported DAILY to the Area Roads and Heavy Equipment Department. (See G. I. 7.028 for more information.) The contractor mobile crane operator shall perform a daily pre-start safety inspection, prior to operating his assigned crane, by using the crane manufacturer’s daily inspection checklist or Saudi Aramco form SA 9466. All contractor mobile crane deficiencies shall be reported DAILY to the contractor mobile crane operator’s direct supervisor. (See G. I. 7.028 for more information.) NOTE: Form SA 9466 can be obtained from the USER.

5.4.3

The USER shall furnish the Inspection Department representative the appropriate manufacturer's assembly, operating, and maintenance instructions for the crane, when so required (in the English language).

5.4.4

All main boom sections, including power pinned sections, shall be extended and inspected for corrosion, proper operation, and damage.

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6.

REPLACES 12/01/96

APPROVAL


5.4.5

If equipped, swingaway boom sections shall be inspected for corrosion and damage.

5.4.6

Any assembling, disassembling or change of lattice boom configuration requires re-inspection by the Inspection Department.

Inspection and Testing Requirements per ASME B30.2, B30.3, B30.4, B30.6, B30.7, B30.11, B30.16 & B30.17 6.1.1

Fixed cranes and hoists covered by ASME Standards shall receive a PERIODIC annual inspection or as determined by the Inspection Department.

6.1.2

Any fixed crane that is relocated, repaired, modified, or altered shall be retested prior to use.

6.1.3

Any EXTENSIVE repair, modification, or alteration to a fixed crane requires a manufacturer’s written certification to be furnished by the USER to the Inspection Department upon request. This certification shall state that the repairs were completed in compliance with the manufacturer's specifications, the applicable ASME standards listed above, Saudi Aramco standards, and by utilizing a COMPETENT person.

Inspection and Testing Requirements per ASME B30.14 7.1.1

Side boom tractors shall receive a PERIODIC inspection every ninety (90) days or as determined by the Inspection Department.

7.1.2

Any EXTENSIVE repair, modification, or alteration to sideboom tractors requires a manufacturer’s written certification to be furnished by the USER to the Inspection Department upon request. This certification shall state that the repairs were completed in compliance with the manufacturer's specifications, ASME B30.14, Saudi Aramco standards, and by utilizing a COMPETENT person.

ELEVATORS/ESCALATORS 8.1

9.


SIDE BOOM TRACTORS 7.1

8.


Approved 7.030

FIXED CRANES AND HOISTS 6.1

7.


G. I. NUMBER

Inspection and Testing Requirements per ASME A17.1 8.1.1

Elevators and Escalators shall receive a PERIODIC annual inspection or as determined by the Inspection Department.

8.1.2

Braking System and Car & Counterweight Safeties shall be tested at three (3) and five (5) year intervals respectively or as determined by the Inspection Department.

8.1.3

The USER shall furnish the Inspection Department with the appropriate manufacturer's assembly, operating, and maintenance instructions, upon request (in the English language).

POWERED PLATFORMS/SKY CLIMBERS 9.1

Inspection and Testing Requirements per ASME A120.1 *CHANGE

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9.2



G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


9.1.1

Powered Platforms/Sky Climbers shall receive a PERIODIC inspection every ninety (90) days or as determined by the Inspection Department.

9.1.2

The initial inspection and load test shall be carried out whenever a Powered Platform/Sky Climber is installed or relocated. The load test shall be conducted by the USER and witnessed by the Inspection Department.

Safety 9.2.1

Powered platforms for permanent installations shall be used according to the requirements of ANSI A120.1.

10. ELEVATING WORK PLATFORMS 10.1

Inspection and Testing Requirements per ANSI A92.3, A92.5, & A92.6 10.1.1

Elevating work platforms shall receive a PERIODIC inspection every six (6) months or as determined by the Inspection Department.

11. VEHICLE MOUNTED ELEVATING AND ROTATING AERIAL DEVICES 11.1

Inspection and Testing Requirements per ANSI 92.2 11.1.1

The USER is solely responsible for developing a PERIODIC inspection and testing program on the electrical insulating components and systems per ANSI A92.2. The results of the electrical testing and inspection shall be made available to the Inspection Department for review prior to performing the PERIODIC mechanical inspection.

11.1.2

Vehicle Mounted Elevating and Rotating Aerial Devices shall receive a PERIODIC inspection every six (6) months or as determined by the Inspection Department.

12. ARTICULATING BOOM CRANES 12.1


Articulating boom cranes adapted for marine and offshore use shall meet the installation requirements of Section 4 of this G.I.

12.1.2

Articulating boom cranes shall receive a PERIODIC inspection every ninety (90) days or as determined by the Inspection Department.

13. STORAGE/RETRIEVAL MACHINES 13.1

Inspection and Testing Requirements per ASME B30.13

13.1.1

Storage/Retrieval Machines shall receive a PERIODIC annual inspection or as determined by the Inspection Department.

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G. I. NUMBER

Approved 7.030


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APPROVAL


14. CRANE SUSPENDED PERSONNEL PLATFORMS (MANBASKETS) 14.1

Inspection and Testing Requirements per ASME B30.5 & B30.23 14.1.1

Crane suspended personnel platforms (manbaskets) shall receive a PERIODIC inspection every six (6) months, or when dedicated rigging has changed, or as determined by the Inspection Department.

14.1.2

DAILY PRE-OPERATIONAL INSPECTIONS and pre-lift proof load tests shall be carried out by a COMPETENT person designated by the USER, in accordance with G.I. 7.027.

14.1.3

Personnel platforms (manbaskets) shall meet all Saudi Aramco fabrication specifications/requirements. The USER may also be required to submit additional fabrication design information to the Consulting Services Department for review and concurrence, prior to certification by the Inspection Department.

15. LIFTING/SPREADER BEAMS 15.1


Lifting/spreader beams shall receive a PERIODIC inspection every six (6) months, or as determined by the Inspection Department.

15.1.2

An inspection shall be performed by a COMPETENT person designated by the USER, prior to each lift.

15.1.3

Lifting/spreader beams require an initial load test of 125% of the rated safe working load. This test shall be witnessed by the Inspection Department.

15.1.4

Lifting/spreader beams shall meet all Saudi Aramco fabrication specifications/requirements. The USER may also be required to submit additional fabrication design information to the Consulting Services Department for review and concurrence, prior to certification by the Inspection Department.

16. A-FRAMES/MOBILE GANTRIES 16.1

Inspection and Testing Requirements per ASME B30.11 & B30.16 16.1.1

A-frames/mobile gantries shall receive a PERIODIC annual inspection or as determined by the Inspection Department.

16.1.2

A pre-inspection shall be performed by a COMPETENT person designated by the USER prior to each use.

16.1.3

A-frames/mobile gantries shall meet all Saudi Aramco fabrication specification/requirements. The USER may also be required to submit additional fabrication design information to the Consulting Services Department for review and concurrence, prior to certification by the Inspection Department.

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16.1.4

G. I. NUMBER

Approved 7.030


REPLACES 12/01/96

APPROVAL


Any EXTENSIVE repair, modification, or alteration to A-frames/Mobile Gantries requires a manufacturer’s written certification to be furnished by the USER to the Inspection Department upon request. This certification shall state that the repairs were completed in compliance with the manufacturer's specifications, ASME B30.11, B30.16, Saudi Aramco standards, and by utilizing a COMPETENT person.

Recommended: Manager, Inspection Dept.

Recommended: Manager, Loss Prevention Dept.

Recommended: Manager, Roads & Heavy Equipment Dept.

Recommended: Director, Job Skills Training Dept.

Concur: Vice President, Industrial Services

Approved: Vice President, Engineering Services

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Saudi Aramco 7_030 Inspection Lift Equip

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