Subject : HSSE Manual For Lifting & RiggingDocument no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi HSSE Manual FOR Lifting & Rigging Safe Use, Maintenance and Inspection Revision History Revision No Date Description of Changes By 000 15-07-10 10 Original created based on ISO 9001:2008 requirements ZHA009 Page 1 of 38 Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Prepared by DATE Controlled by : Zahra AlHammadi Approved by CEO REVISION NUMBER DATE CHANGED Page 2 of 38 SIGNAATURE Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi TABLE OF CONTENTS Section 0.0 Introduction 1.0 Scope 2.0 Responsibilities 3.0 Training 4.0 Safe Work Practices 5.0 Lifting Register 6.0 Reference Standards Appendix Appendix“A” Lifting Appliances (Cranes and Machines) 9.0 Appendix “B” Lifting Tackle/Lifting Loose Gear 7.0 Attachment “A” Loose Equipment Inspection 8.0 Attachment “B” Rejection Factor Table Page 3 of 38 damage to equipment. Sub Sub-Contract) Contract) working or visiting on Company premises. Page 4 of 38 . shall ensure all lifting equipment and associated gear has its identification marker markerss firmly in place. It is designed to provide personnel involved in lifting operations ions a minimum level guidance regarding the Safe Use. Main Maintenance tenance and Inspection of any and all associated components. Maintenance and Inspection of lifting equipment and associated gear.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani 1. 3.0 Controlled by : Zahra AlHammadi INTRODUCTION By their very nature.0 SCOPE This Standard is applicable to all personnel (Company. equipment and company assets have the potential to be the cause of serious accidents resulting in the loss of life. It is not intended to replace in whole or in part any existing regulatory body regulations or industry accepted standards governing such uch equipment and operations. the environment and to loss of revenue due to an interruption of production. That lifting equipment is only operated by qualified personnel. Shall ensure no lifting equipment or lifting gear gear-requiring requiring certification is used to hoist any load until said certification is in effect and recorded. Each Department Manager shall ensure there is a “Preventative Maintenance System” (PMS) MS) in effect for the maintenance and inspection of all lifting equipment and associated gear. Those records are maintained and are up to date and available for inspection upon request by Port of Bahrain or regulatory body representatives. Each department manager shall ensure that the equipment is inspected and tested annually (every 12 months) months by a competent person who is qualified and certified in the inspection and testing of lifting equipment and is approved to do so. Each Department manager shall develop a lifting gear register to record and track all components requiring certification. Contract. on file and readily accessible for Port of Bahrain auditors or HSSE personnel or regulatory body representative inspection. Accidents involving lifting equipment continue to happen in industry and the only way we can insure against these accidents is to follow strict guidelines regarding the Safe Use.0 RESPONSIBILITY Each Department manager is responsible for ensuring all lifting equipment and associated gear under his control is inspected prior to any use. lifting operations involving personnel. that it is in good working condition and maintained according to industry accepted standards and that all relevant certification is up to date. 2. shall keep the registers up to date. Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani 4. 5.W. Certificates of competency must be produced to a Port of Bahrain representative upon request.1 Lifting Tackle The following procedures shall be strictly adhered to any deviations from these providers can lead to reprimands recorded on ones record and ultimately dismissal. Cargo Handling Due to inherent dangers associated with the transfer of materials between vessels and quaysides or berths..2 • All items of lifting ifting tackle shall be plainly marked with its “Safe Working Load” (SWL) identification numbers and colour coding • A competent person as per the regulations shall inspect all items of lifting tackle or instructions issued by the client or as stated by regulations regulations or degrees by local Governing body in the country of operations operations. 5. manufactured from sound materials with adequate strength. Page 5 of 38 .0 Controlled by : Zahra AlHammadi TRAINING Only competent personnel shall engage in the operation of Port of Bahrain owned lifting equipment and associated lifting gear. All personnel responsible for the operation of lifting equipment must have previously completed and passed a training course ac acceptable ceptable to APMT standards and shall maintain on file a copy of said certification while engaged in lifting related operations. • Competent personnel who have undergone training and certification by a third party company that is acceptable to Port of Bahrain will operate power operated lifting equipment. Failing to do so will result in th the e immediate cessation of work until the certificate of competency can be produced. personnel engaged in the th lifting operations shall ensure that the lifting equipment in use is of the correct S. 5. • All lifting equipment shall be of good mechanical construction. free from defects and shall be properly maintained. • Before commencing any cargo lifting operation.0 SAFE WORK PRACTICES Port of Bahrain and third party contractors shall ensure the following safe working practices are strictly adhered to during any lifting operation un undertaken dertaken by their personnel both onshore and offshore. (See Appendix “A”).L. the following procedures will be strictly adhered to in an effort to minimise the risks associated with these operations. and regulatory bodies can be referenced for technical clarifications regarding lifting equipment. the environment and the corporation as a hole. Lifting Gear • • • • • • Wire Slings/Web Slings Shackles Snatch Blocks Chain Blocks Trolleys Pad Eyes Lifting registers should record the following items.e. equipment. Register Elements: • • • • • • • • 7. materials.0 An ID number for each item Manufacturers name Date of Manufacture A full description of each item The SWL Certificate Date i. 9/20/04 (manufacturers date) Start Date i. LIFTING REGISTER Load bearing components utilised in lifting operations are a part of the lifting operations chain. The consequences of introducing a “weak link” into the chain can be devastating to personnel.0 Controlled by : Zahra AlHammadi • One person will be in charge of giving the Crane Operator the correct signals and shall remain in sight of the crane operator at all times.e. Lifting registers shall track the following gear. 09/10/06 (rectification date) REFERENCE STANDARDS The following Institutes. inspection techniques and frequencies. Lifting registers are a means of managing these load load-bearing bearing components in an effort to prevent weak links being introduced into lifting operations. Organisations. • • • American Petroleum Institute (API) British Standards Institution (BSI) American n National Standards Institute (ANSI) Page 6 of 38 . • “Tag” lines (control lines) shall be utilised to help manage hoisted loads in a safe manner.e. 10/10/04 (in service date) Annual Certificate date i.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani 6. design and construction in accordance with generally accepted Engineering practices and standards and all chains or ropes will be properly secured to drums. At least three turns of chain or rope will remain on the drum in every operating positi position.1. 8.5 Platforms used by drivers shall be of sufficient area. The eye of all looped wire shall be fitted with a proper thimble and whenever possible the return end secured with the correct size of ferrule applied and fitted by means of a proper crimping tool.8 All jib cranes shall have an approved type of automatic safe load in indicator. 8. provided with safe means of access and all dangerous parts of machinery securely fenced.6 Winch drums.R. adequate strength. shall be of good mechanical construction. 8.1. Rails shall have an even run running ning surface and be adequately supported on a surface sufficiently firm to prevent undue movement. The safe working load should be specified on the crane and strictly adhered to. Wire rope ends must never be welded together at the strand ends. repairing or lubricating the lifting appliance.E. anchoring or fixing devices. wire and pulleys will be of a correct diameter. free from patent defects. 8. and be properly maintained.1. stops or buffers shall be provided on each rail at each end of the tracks. toothed sprockets and wheels used in in the construction and drive mechanism shall be properly guarded to avoid injury to personnel.1. 8.4 Safe access shall be provided for persons examini examining. which must be properly maintained. 8.1. shall be properly wire seized and the return (short) end clamped with a correct number of clips with the ‘U’ bolt part around the short end of the rope.1. sound materials. The wire ropes will wind--on evenly and not overlap itself under any circumstance. 8. fenced. Rails shall be laid in straight lines or in curves of such radii that the crane can be moved freely and without risk of Page 7 of 38 .1.2 All cranes shall be operated under the supervision supervision of a competent operator and not be operated under weather conditions likely to affect stability. Such ropes constructed in this manner SHALL NEVER BE USED FOR MEANS OF LIFTING/LIFTING.L. The ratio of drum diameter to rope diameter is important and whenever possible a travelling fairlead shall be installed. Clips to be spaced in accordance with good design practice. Regulations Appendix “A” Lifting Appliances (Cranes and Machines) 8.3 The anchoring or fixing arrangements of all lifting appliances will be adequate and securely supported. 8.0 Controlled by : Zahra AlHammadi International Standards Organisation (ISO) American Society of Mechanical Engineers (ASME) United Kingdom Health and Safety Executive L.1 Lifting appliances including all working gear.1. All gears.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani • • • • 8. ng. for general usage. dicator.1.O.9 For rails mounted cranes.7 Wire rope ends. 8.10 Knots shall not be tied in parts of chains or wire ropes. 8. There are many types of cranes and specific procedures will be established for the handling of each.23 Automatic devices shall be fitted to prevent over-running over running at the highest point for which the platform is constructed to travel. 8. 8.15 Only trained and competent persons shall operate lifting appliances.13 A passageway of 610mm or more shall be maintained between slewing or other moving parts of lifting appliances and the guardrails or other nearby fixtures. chairs. 8. 8. No person under 18 will operate any lifting appliances. easily seen or heard and understood by the person to whom they are given and by others concerned with the lifting operation. the operator and a slinger/signalman.19 Movable ovable jib cranes shall be fitted with radius indicators. s.21 Accessible parts of hoist ways will be protected by substantial enclosures fitted.1.1. muscular co-ordination co ordination and reaction time.17 Signals shall be clear and concise.22 Where applicable. hoists shall be so constructed that they can be operated from one position.1. depth and colour perception. (Signals to be as shown in attachment ‘C’) 8.16 All operating cranes shall be provided with 2 men.1.1.14 Cranes will be operated only by employees who are physically qualified with regard to accuracy of vision. 8. Nor shall they be shortened or joined by means of nuts and bolts inserted through the link or clamped with flat steel plate. 8.1.1. hearing. stops.1. 8.1. or on a slope.1. ropes or chains.20 Supports for the hoists shall be strong enough to carry the maximum load to be imposed on them. unless appropriate precautions are taken to ensure stability.11 Packing or other means shall be used to prevent the edges of a load from coming into contact with slings. 8. with gates. buffers and other equipment must be properly maintained. 8. fishplates. 8. Rails and sleepers will not be used as anchorage.18 Cranes will never be left with a suspended load or the power equipment running. bearer bearers. where access is required.1.1.1. sleepers.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi derailment. Rails.1.12 Lifting appliances shall not be used of soft uneven surfaces. No person under 18 will be allowed to give signals to operators of power driven lifting appliances. and safety devices fitted to support the platform or cage with full load if lifting gear or ropes fail. Page 8 of 38 . 8. etc.1 1. be plainly die-stamped die stamped with an identification number and its safe working load as advised by the manufacturer. chains and slings shall be of sufficient size and strength and of the correct type to accomplish the lift being undertaken. shall be subject to a mandatory examination every six months and be recorded in the register. such items are to b be numbered and the safe working load of the item be recorded in a Register.1. 9.0 Appendix “B” Lifting Tackle/Lifting Loose Gear Ropes. 9.24 Safe working load shall be marked on platform or cage.4 All such equipment. Page 9 of 38 . including eyebolts. A certificate of test shall be required for all new equipment.27 Barricade guards shall be installed installed to protect the operator where necessary. lifting beams. 9.1 All lifting tackle issued for use must be inspected by the user and details entered in a Register. 8.1. it shall be returned to store for full inspection. 9. 8. hooks.1 1.3 No chain.1 1. 8. where possible.1. Every item of lifting tackle shall..25 Guards or loose materials will not be placed directly or a platform unless the latter is enclosed or other precautions is taken to prevent falls of mater materials. It will be returned to store for full inspection. 9.1.2 Equipment shall be free from any obvious defects and any lifting tackle beyond its mandatory life will not be used. No wire rope shall be used if in any length a number of broken wires are observed. material. plate clamps. rope or lifting tackle shall be issued or used unless it is of good construction. lifting dogs. Where marking is not feasible.26 Trucks or wheelbarrows will not be carried on platforms unless scotched or secured. and loaded trucks or wheelbarrows will not be carried on open platforms unless so loaded that no part of load is liable to fall off. and adequate strength and free from patent defects.5 The equipment will also be visually inspected frequently throughout usage. No fibre rope shall be used if it shows undue wear or loosening of the yearn strands.1 1. 9. and the permitted number of persons allowed to travel will be clearly indicated and must not be exceeded.1 1. The safe working load of the item must be made known to the person drawing the equipment from store.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi 8. fibre rope slings shall be hung up where they ey can dry naturally in a free circulation of cool air. or where the fibres have noticeably deteriorated to a marked degree.6 Flexible steel lashing wires.1.1 be known before starting a lift. Page 10 of 38 .1. acid. if the rope is badly chafed externally. of 6 mm (1/4 in.10 Fibre rope slings shall not be used for lifting. plus the weight of the tackle.13 When suspending floating g heads.1 1. 9.11 When not in use. the safe working load at different angles of the legs shall be issued to all personnel involved in this type of work. or lowering. and checked for any detrimental effects of such usage.1 1.1 1. or injurious chemicals. are designed for lashing ladders etc. shall 9.12 Lifting tackle and equipment used in connection with oil.7 Care must be taken by the use of wooden or similar packing.1 1.8 The weight being lifted. and will not be used for suspending loads. 9. to ensure that the sling is not bent over a small curvature or sharp edge. 1. it is important to ensure that the suspension bolts are not bent or distorted. shall be examined daily. when slinging a load. 9. 9.1 1.9 A “Slingers Handbook” showing the safe working loads of every kind and size of chain.14 The above regulations are to be regarded as a brief summary only. 9. manhole doors and similar pieces of equipment from davits.1 1.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi 9..) Diameter. 9. or worn internally. 9. and the person in charge of the equ equipment ipment should be fully knowledgeable of all the relevant safety factors. rope or lifting tackle in use and in the case of a multiple sling. since this may damage the sling. bird cages More than maximum allowed broken wires (table) Exposure of core. internal corrosion Severe distortion – kinks.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi ATTACHMENT # A Inspection of Loose Equipment prior to Use WIRE ROPE SLINGS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection WIRE ROPE (A) (A) (A) (A) (A) (A) (C) Heat damage. knots. loss lubricant More than 10% reduction in rope original diameter High external corrosion. discoloration. EYES (A) (A) (D) 1. damage to thimble Rope defects – see above criteria SECURING (A) (A) Any broken wires near to the ferrule/splice Broken/damaged ferrules or pulling out Page 11 of 38 LE 01 . Distortion Excessive wear. internal damage Broken wires within limits TERMINATIONS 1. crushes. Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) Crushing. pulling out LINKS HOOKS SHACKLES - See LE 02 See LE 05 See LE 03 PROOF LOAD 2.0 x SWL. followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL / SWL @ Angle Colour Code Page 12 of 38 . abrasion of splice. joining. cracks. joining. Table) (A) More than 8% dia wear of terminal. gouges in terminal fittings. intermediate links. joining.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi ATTACHMENT ‘B’ Inspection of Loose Equipment prior to Use CHAIN SLINGS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (C) Service Before Re-Inspection (D) Further Examination Before Acceptance CHAIN SLINGS (A) More than 5% stretch of original length (terminal. chain and hooks (Manuf. cracks and gouges in terminal. joining links (B) Existence of nicks. Table) (A) Existence of nicks. or twisted links. twisted chain (A) Improper shortening devices (A) Repairs by welding (C) Rusty chain (D) Hooks – see LE 05 ONON-WELDED CHAIN (A) More than 8% wear of terminal fittings. joining links (B) Bent. chain and hooks) (Manuf. intermediate links. rings (A) Lack of free articulation between links (A) Distortion of terminal fittings (A) Cracks and faults in welded areas (A) Excessive corrosion (A) Heat discoloration (A) Broken. intermediate links and chain (A) Bent. elongated or twisted joining links (B) Distortion of terminal fittings (B) Replaced parts incorrectly assembled (D) Replaced parts not manufacturer certified Page 13 of 38 LE 02 . elongated. followed by thorough examination and certification MARKINGS (A) Identification Number (B) SWL / SWL @ Angle (C) Quality Marks (D) Colour Code Page 14 of 38 .Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi HOOKS = See LE 05 PROOF LOAD 2.0 x SWL. less than outside face flush (A) Head of pin not bearing on shoulder of untapped hole (A) Thread damage or excessive wear (A) Excessive corrosion Page 15 of 38 LE 03 . Pin not running free (A) Pin screwed.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap SHACKLES (B) Not Acceptable: Repair/Replace (C) Service Before Re-Inspection (D) Further Examination Before Acceptance SHACKLES (A) Wear of pin and body higher than 8% dia (A) Nicks. cracks and gouges in stressed areas (A) Distortion in any axis (A) Misalignment of untapped/tapped hole (A) Excessive wear of untapped hole (A) Incorrect pin inserted. if applicable PROOF LOAD 2.0 x SWL. cracks and gouges in shank and eye (C) Service Before Re-Inspection Page 16 of 38 LE 04 . higher than 8% dia (A) Nicks. followed by thorough examination and certification MARKINGS (A) (B) (C) (D) Identification Number SWL Quality Marks Colour Code Inspection of Loose Equipment prior to Use EYE BOLTS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance EYEBOLTS (A) Wear in eye and link.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) Repairs by welding (B) Missing locking devices. if any. cracks and gouges in shank to collar junction (A) Distortion in any axis (A) Thread damage or excessive wear (A) Excessive Corrosion (A) Any type of repair (C) Cleanliness of thread. followed by thorough examination and certification MARKINGS (A) (B) (C) (D) Identification Number SWL Quality Marks Colour Code Page 17 of 38 .Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) Nicks.0 x SWL. underside of collar PROOF LOAD 2. nuts. Table).Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Inspection of Loose Equipment prior to Use HOOKS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection HOOKS (A) Throat opening higher than 20% original throat (Manuf. damage to cross head pin (B) Damaged or missing locking devices (B) No free running of swivel. gall marks in body (A) Misalignment of shank. scores. defects in trunnion weld joint. excessive wear (A) Thread damage of excessive wear (A) Repair by welding (A) Excessive wear. Bearing damage. if applicable (B) Loose bolts. if applicable (B) Cracks. nicks. (A) Lateral twist higher than 10 degrees (A) Wear in eye and saddle higher than 8% of original thickness (Manuf. Table) (A) Cracks. pins Page 18 of 38 LE 05 . 0 T where SWL > 25T ] Followed by thorough ] examination and Certification MARKINGS (A) (B) (C) (D) Identification Number SWL Quality Marks Colour Code Page 19 of 38 . if applicable (C) Lack of lubrication PROOF LOAD 2.22 x SWL + 2.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) Damaged or missing safety catches.0 x SWL where SWL < 25T (B) 1. SHACKLES (D) See specific criteria - LE 03 (D) See specific criteria - LE 04 (D) See specific criteria - LE 05 (D) See specific criteria - LE 01 (D) See specific criteria - LE 02 (D) See specific criteria - LE 09 EYEBOLTS HOOKS WIRE ROPE SLINGS CHAIN SLINGS FLAT WEBBING SLINGS Page 20 of 38 LE 06 (C) Service Before Re-Inspection . DETACHABLE ITEMS A.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap (D) Further Examination Before Acceptance LIFTING BEAMS AND SPREADER (B) Not Acceptable: Repair/Replace LOOSE GEAR. corrosion of fabricated items (B) Cracks.6 T where 10T SWL <160T Identification Number SWL Colour Code Page 21 of 38 (B) 1. Thread damage or wear Excessive Corrosion PROOF LOAD 2.0 x SWL where SWL < 10T MARKINGS (A) (B) (C) (B) 1.1 x SWL where SWL > 160T [ Followed by thorough examination and Certification] . distortion. distortion or wear of suspension holes (B) Malfunction of locking devices. BEAM (B) (B) (B) (B) (B) (B) Cracks. LOAD ATTACHMENTS POINTS (B) Cracks. buckling of hollow sections Damage to section flanges Loose nuts. excessive wear Crack. distortion.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi CLAMPS (D) See specific criteria - LE 07 & LE 08 B. if applicable (D) Looseness of bolted connections C. excessive wear.04 x SWL + 9. bolts rivets. defective joints Heavy dents. cracks. damage or missing locking devices (A) Nicks.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Inspection of Loose Equipment prior to Use PLATE CLAMPS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection BEAM CLAMPS (A) Distortion of frame (A) Wear at application/suspension points. if applicable (D) Lack of lubrication – see Manuf. bent pins (B) Individual parts incorrectly assembled/replaced. moving parts (A) Wear. gouges (A) Excessive corrosion (B) Worn out. Recommendations ecommendations PROOF LOAD Page 22 of 38 LE 07 . Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi 2. movable jaws – see Manuf. stretched spring in locking lever (B) (B) (B) Improper action of locking lever Tight.0 x SWL. damaged clamping threads Blunted teeth in fixed. gouges (A) Excessive corrosion (B) Broken. followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL Color Code Inspection of Loose Equipment prior to Use PLATE CLAMPS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection FRICTON LIFTING TYPE (A) Distortion of frame (A) Wear on gripping surfaces (A) Nicks. recommendations Page 23 of 38 LE 08 . bent. cracks. cracks. followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL Color Code Page 24 of 38 . bent pins Lack of lubrication – see Manuf recommendations HORIZONTAL LIFTING TYPE (A) (A) (A) (A) (B) (B) (D) Distortion of frame Wear on gripping surfaces Nicks. gouges Excessive corrosion Blunted teeth in fixed.0 x SWL.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) (D) Worn out. bent pins Lack of lubrication – see Manuf recommendations PROOF LOAD 2. recommendations Worn out. movable jaws – see Manuf. PROTECTIVE SLEEVE (D) B. tears. if applicable Any type of repairs ROUND TYPE A. wear and general deterioration – See Inner Core INNER CORE (A) (A) (A) (A) Cuts Holes. crushed web Excessive abrasive wear Broken or worn threads in the stitch patterns Page 25 of 38 LE 09 . if applicable Broken. snags or crushed web Excessive abrasive wear Excessive pitting or corrosion. snags. distorted or broken fittings. cracked. or worn threads in the stitch patterns Melting or charring of any part of the sling Chemical burns Strop eye damage/webbing burst at edges. tears.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Inspection of Loose Equipment prior to Use MANMADE FIBRE SLINGS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (C) Service Before Re-Inspection (D) Further Examination Before Acceptance FLAT WEBBING TYPE (A) (A) (A) (A) (A) (A) (A) (A) (A) Cuts on face or at edge of webbing Holes. Scuffing. wear of hand chain wheel (B) Incorrect seating in hand chain wheel Page 26 of 38 LE 10 . (C) Service Before Re-Inspection HAND CHAIN (B) Cracks. wear or corrosion (B) Cracks.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) (A) (A) Melting or charring Chemical burns Any type of repairs PROOF LOAD See Manufacturer’s Data MARKINGS (A) (B) (C) Identification Number SWL Colour Code Inspection of Loose Equipment prior to Use CHAIN PULLEY BLOCK (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. distortion. distortion. MAIN FRAME (B) Cracks. Wear. slackness of sheave wheel (D) See specific criteria – LE 05 D. gear covers or chain guides (B) Loose nuts. slackness of sheave wheel (B) Incorrect seating in sprocket wheel (B) Damage to slack end or load end anchor (C) Rusty chain (C) Twisted chain in multiple fall (D) See specific criteria – LE 02 HOOKS. ratchet or spring (B) Cracks or uneven wear of pinions. wear. or pins. chain stripper (D) Improper maintenance condition (D) Improper electrical condition. Missing locking devices (B) Corrosion. operating spring and ratchet (B) Malfunction of brakes under load Page 27 of 38 . distortion or wear of blocks.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi B. REPAIR (B) Repair not in accordance with manufacturers recommendations (B) Replaced parts incorrectly assembled (D) Replaced parts not manufacturer certified F. wear or damage to pawl. Thread damage or wear. excessive noise or jumping of chains during lifting/lowering (B) Malfunction of pawl. (C) Rusty chain LOAD CHAIN (B) Cracks. bolts. distortion or wear of blocks. damage to brakes. OPERATIONAL TEST (B) Undue effort. C. rivets. TERMINAL FITTINGS (B) Cracks. gear wheels or bearings (B) Wear. distortion or wear in body. if applicable E. Power driven 1. missing locking devices Corrosion Page 28 of 38 . WIRE ROPE . thread damage or wear. FITTINGS - C.5 x SWL B. Hand driven 1.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) Incorrect action of chain guides PROOF LOAD A. rivets or pins. distortion or wear in body. covers or rope guides Loose nuts. HOOKS.25 x SWL MARKINGS (A) (B) (C) (D) ] Followed by thorough ] examination and Certification Identification Number SWL Quality Marks Color Code Inspection of Loose Equipment prior to Use TIRFOR (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. bolts.See LE 01 B. FRAME (B) (B) (B) LE 11 (C) Service Before Re Re-Inspection See LE 05 Cracks. 5 x SWL. followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL Color Code Inspection of Loose Equipment prior to Use BASKET Page 29 of 38 LE 12 . damaged. excessive noise or slipping of rope during lifting/lowering Malfunction of brake under load PROOF LOAD 1. Damage or wear to levering mechanism Shear pin worn.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) (B) (D) D. REPAIR (B) (B) (D) E. Replaced with non-standard non item Improper maintenance Repair not in accordance with manufacturers recommendations Replaced parts incorrectly assembled Replaced parts not manufacturer certified OPERATIONAL TEST (B) (B) Undue effort. 09 for individual requirements LOAD ATTACHMENT POINTS B. rivets. bolts. 03. Thread damage or wear (B) Excessive corrosion Page 30 of 38 . LOOSE GEAR DETACHABLE ITEMS See LE 01. excessive wear (B) Cracked/defective joints (B) Heavy dents. (B) Cracks. distortion. distortion. distortion or wear of suspension holes (B) Malfunction of locking devices. 02.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection GOODS/GENERAL PURPOSE BASKET A. (B) Cracks. 04. buckling of hollow sections (B) Damage to section flanges (B) Loose nuts. excessive wear. if applicable (D) Looseness of bolted connections STRUCTURE C. corrosion of fabricated items (B) Cracks. 05. wear or corrosion Page 31 of 38 LE 13 . (C) Service Before Re-Inspection HAND CHAIN (B) (B) (C) (D) Cracks. or wear of hand wheel Incorrect seating in hand chain wheel Rusty chain Cracks. distortion. distortion. followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL Color Code Page 1 of 2 Inspection of Loose Equipment prior to Use TRAVELING GIRDER TROLLEYS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A.5 x SWL.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) Door fastening/hinges damaged (B) Excessive mesh size for cargo type PROOF LOAD 1. if applicable Repairs not in accordance with manufacturer’s recommendations Replaced parts incorrectly assembled Replaced parts not manufacturer certified INSTALLED UNIT (TROLLEY + BEAM) (B) (B) (B) Incorrect size for the runway beam Misalignment. defective wheel support brackets Distortion. flanges. Loose nuts. if applicable Incorrect side clearance between wheel flanges and toes of beam (3 to 4 mm required) Page 2 of 2 Inspection of Loose Equipment prior to Use TRAVELING GIRDER TROLLEYS (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance (C) Service Before Re-Inspection Page 32 of 38 LE 13 . defects in joints Cracks. bearings Loose. Missing locking devices. particularly inside plates and load bar Cracks. gear wheels Improper maintenance condition Improper electrical condition.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi B. Thread damage or wear. MAIN FRAME (B) (B) (B) (B) (B) (B) (D) (D) C. relative to center flange of runway. damage to wheel threads. if applicable Wear. REPAIRS (B) (B) (D) D. uneven wear of pinions. bolts rivets or pins. (C) Service Before Re-Inspection LOAD CHAIN Page 33 of 38 LE 14 . if applicable (B) Irregularities during traveling (D) Chain pulley block – See specific criteria .LE 01 PROOF LOAD Separate by Hand – 1.5 x SWL With Power hoist 1. OPERATIONAL TESTS (BLOCK + TROLLEY + BEAM) (B) Incorrect or wrongly fitted chain pulley block (B) Wrongly adjusted anti-tilt tilt device.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi E.25 x SWL (Followed by thorough examination and certification) MARKINGS (A) (B) (C) Identification Number SWL Color Code Inspection of Loose Equipment prior to Use CHAIN LEVER HOIST (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. OPERATIONAL TESTS (B) Chain wheeling not fee (B) Malfunction of change over lever – –lifting/lowering/neutral (B) Malfunction of pawl. BLOCK (B) Cracks. chain-stripper. rivets or pins. damage to Anchorages to casing or stopper. Thread damage or wear. distortion or wear of sprocket wheel Incorrect seating in sprocket wheel Wear. gear wheels or bearings (B) Wear. wear or damage to pawl. HOOKS.Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (B) (B) (B) (C) (C) (D) Cracks. operating spring and ratchet (B) Malfunction of brakes under load (B) Malfunction of chain guides Page 34 of 38 . missing stopper Rusty chain Twisted chain in multiple fall See specific criteria – LE 02 B. slackness of sheave wheel (D) See specific criteria – LE 05 C. REPAIRS (B) Repairs not in accordance with manufacturers recommendations (B) Replaced parts incorrectly assembled (D) Replaced parts not manufacturer certified E. damage to breaks. stripper. bolts. gears covers or operating lever (B) Loose nuts. TERMINAL FITTINGS. MAINTENANCE (B) Cracks. change over lever (D) Improper maintenance condition D. distortion or wear of blocks. Wear. distortion or wear in body. ratchet or spring (B) Cracks or uneven wear of pinions. missing locking devices (B) Corrosion. (C) Service Before Re-Inspection Re BROKEN WIRES RANDOM (A) (D) LE 15 < Maximum allowed (Table) > Maximum allowed – compute rejection factor Page 35 of 38 .Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi PROOF LOAD 1.5 x SWL. followed by thorough examination and certification MARKINGS (A) (B) (C) (D) Identification Number SWL Quality Marks Color Code Inspection of Loose Equipment prior to Use DIAMETER CONSTRUCTION LENGTH (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. crushes. over 6 diameter length Severe. kinks.compute rejection factor MISCELLANEOUS E.compute rejection factor EXTERNAL CORROSION (A) (B) (D) Heavy pitting/corroded areas Stained rope < Heavy .Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi LOCALIZED (A) B. WEAR (A) (D) C. contra rotated F. (A) (B) Thermal damage Core deterioration INTERNAL EXAMINATION . Page 36 of 38 . etc. knots.Rope clamped. > 10% diameter reduction < Maximum allowed – compute rejection factor DISTORTION (A) (D) D. > 3. Less than severe . Local group or same strand. Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi (A) (A) (C) (D) Internal corrosion Core deterioration Lack of lubrication Broken wires ATTACHMENT ‘B’ Inspection of Loose Equipment prior to Use TABLE (A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance REJECTION FACTOR ASSESSMENT (C) Service Before Re-Inspection Rejection Factor Assessment REJECTION FACTOR Points Defects Construct 0 20 40 60 80 100 Page 37 of 38 Remarks . 97d Distortion Nil Light External Corrosion Nil Partial Stain Medium Rough Touch Pitting Sever e Heavy Pitting Total rejection Factor = sum of Factors (Broken. Deterioration. dia Wear 6x.92d .995d .Subject : HSSE Manual For Lifting & Rigging Document no : MAN-HSE-005 Date of effect : 0505-AprilApril-2011 Prepared by : Sameer AlZayani Revision number : 000 Approved by : Sameer AlZayani Controlled by : Zahra AlHammadi Broken 6 x 19 Nil 1 2 3 5 6 Over length Wire 6 x 36 Nil 2 4 6 8 11 of 10 x d Random 8 x 25 Nil 2 4 6 8 10 D = nom. 80 Fit for use Advise replacement w/in time 100 Unfit for Use Scrap immediately Page 38 of 38 .975d . 8x Nil .96d .98d . Wear.98d . Corrosion) Assessment Total Rejection Factor Recommendation/Action < 40 Fit for use 60 Fit for use Increase inspection freq.99d .9d Multi Str Nil .94d .
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