OISD-RP-205 FOR RESTRICTED CIRCULATION

CRANE OPERATION,MAINTENANCE AND TESTING (For Upstream )

OIL INDUSTRY SAFETY DIRECTORATE 7th FLOOR,"NEW DELHI HOUSE" 27, BARAKHAMBA ROAD NEW DELHI-110 001

OISD-RP-205

Prepared by

COMMITTEE ON RECOMMENDED PRACTICE FOR CRANE OPERATION,MAINTENANCE AND TESTING

(For Upstream )

OIL INDUSTRY SAFETY DIRECTORATE th 7 FLOOR,"NEW DELHI HOUSE" 27, BARAKHAMBA ROAD NEW DELHI-110 001

NOTE

OISD (Oil Industry Safety Directorate) publications are prepared for use in the Oil and Gas Industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the data contained in the document, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. The document is intended to supplement rather than replace the prevailing statutory requirements.

FOREWORD
The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a variety of international codes, standards and practices have been in vogue. Standardisation in design philosophies and operation and maintenance practices at a national level was hardly in existence. This coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state- of- the-art in designing, operating and maintaining oil and gas installations. With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of functional committees of experts nominated from the industry to draw up standards and guidelines on various subjects. The present standard was prepared by the Functional Committee on Recommended Practice for Crane Operation, Maintenance And Testing . The document is based on the accumulated knowledge and experience of industry members and the various national and international codes and practices. This standard is meant to be used as supplement and not as a replacement for existing codes and practices. It is hoped that provisions of this standard, if implemented objectively, may go a long way to improve the safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no standard can be substitute for the judgement of responsible and experienced Engineers/Geo-scientists.. Suggestions are invited from the users after it is put into practice to improve the document further. Suggestions for amendments to this document should be addressed to the Coordinator, Committee on th Recommended Practice for Crane Operation, Maintenance and Testing , Oil Industry Safety Directorate, 7 Floor, New Delhi House, 27, Barakhamba Road, New Delhi 110 001. This standard in no way supercedes the statutory requirements like Factories Act, OMR, CCE etc.

COMMITTEE ON RECOMMENDED PRACTICE FOR CRANE OPERATION,MAINTENANCE AND TESTING ''

NAME

ORGANISATION

POSITION IN THE COMMITTEE

S/SHRI 1. H.N. BHAKTA ONGC LEADER

2.

ROY JOHN

ONGC

MEMBER

3.

SUNIL SOHANI

SCHLUMBERGER

INVITEE

4.

GIRISH KAMAL

EIL

MEMBER

5.

PRADEEP KUMAR

OISD

MEMBER COORDINATOR

CONTENTS

Sl.No. No. -----------1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

Description ----------------------

Page ------------

Introduction Scope Definitions Equipment Control Safety Equipment Operation Inspection Maintenance Load Testing And Certification Incidence/Accident Reporting System Contract Management Personnel Protective Equipment References Annexures A Identification Of Actions On Use Of Hand Signals B Maintenance guidelines CInspection guidelines

1 1 1 3 4 5 5 13 13 14 14 14 14 14

15 17 21

Recommended Practices for CRANE OPERATION, MAINTENANCE AND TESTING foot pin to centerline of boom point load hoist sheave pin, measured along the longitudinal axis of the boom. Boom lift Cylinder : Means for supporting boom and controlling boom angle. Certified : To formally attest as being true or meeting a standard. : Block used to stop the wheels of a truck. Weight used to supplement the weight of the machine in providing stability for lifting working loads and usually attached to the rear of revolving upper structure. A lifting device that is capable of being dynamically loaded when lifting, lowering, or shifting loads by means of a projecting arm. A rotating cylinder with side flanges on which wire rope used in machine operation is wrapped. Loads introduced into the machine or it's components due to accelerating or decelerating forces. A structure mounted on the revolving super-structure of the machine to which the boom support ropes are reeved. A n o n -routine lift which is equal to or greater than 75% of the rated capacity of the crane, at either a dynamic or static condition. Heavy usage applies to those cranes that are used for 50 hours or more per month. These cranes will be 1 the the

1.0

INTRODUCTION In oil industry, material handling using cranes is one of the most important operations requiring utmost care. The primary purpose of this standard is to outline recommended practices for crane operations, maintenance, inspection and testing to crane owners, users and operators in upstream sector of oil industry both offshore and onshore. This recommended practice focuses on safe operation of cranes in order to establish, maintain and further develop an adequate level of safety for personnel, property and environment during planning and execution of lifting operations.

Choke

Counterweight : (BALLAST)

2.0

SCOPE These Recommended Practices cover various aspects related to operating and maintenance practices and procedures for use in the safe operation including the requirement of competent crane operator of various types of revolving cranes on offshore platforms, rigs, floating units. It also covers fixed, mobile (except crawler cranes) and hydraulic telescoping cranes used at onshore installations of upstream operations. These recommended practices are to provide and assist in the proper operation and maintenance of crane, as a supplement to the Manufacturer's instructions, which should be carefully read, retained and followed.

Crane

Drum rope

Dynamic loading

3.0

DEFINITIONS A limiting device that prevents the load block sheaves, auxiliary or fast line ball from contacting the boom tip sheaves. The angle above or below horizontal of the longitudinal axis of the base boom section. The straight line distance from the centerline of boom

Gantry(A-Frame) :

Anti-two block :

Heavy lift

Boom angle

Heavy usage : Category

Boom length

subject to Pre-use, Monthly, Quarterly, and Annual Inspections. Cranes assigned category of heavy usage need not be reviewed to determine the number of hours used each month. Hoist : The device for lifting or lowering of the load in vertical direction. Also called winch. The load being lifted plus the weight of slings and rigging. Hook load may or may not include the weight of the hook block and wire rope. This can be determined from the cranes load rating chart. A crane whose movements are directed by fluid pressure applied to the pumps/gears, hydraulic cylinder, and hoists.

Load -working :

External load in pounds (Kilogram) apply to the crane including the weight of load attaching equipment such load block, shackles and slings Same as derricking. The operation of changing boom angle in a vertical plane. Moderate usage applies to those cranes that are used for more than 10 hours but for less that 50 hours per month, based on the averaged use over a quarter. These cranes will be subjected to Pre-use, Quarterly, and Annual Inspections. Crane usage categories will be reviewed on a periodic basis by the owner to ensure proper inspection intervals. Members attached to the carriers frame which may be blocked up to increase stability. These may be fixed or extendible. A device for positively holding a member against motion in one or more directions.

Luffing

Moderate usage : category

Hook Load

Hydraulic crane :

Out-Riggers Infrequent usage : category Infrequent usage applies to those cranes that are used for 10 hours or less per month, based on the averaged use over a quarter. These cranes will be subjected to a Pre-use Inspection and an Annual Inspection. Crane usage categories will be reviewed on a periodic basis by the owner to ensure proper inspection intervals.

Pawl (Dog)

Pedestal( BASE) : The supporting sub-structure u p o n w h ich the revolving upper structure is mounted. Pull test : A test, using a suspended weight or a dynamometer, to verify crane capability for the expected lift, not to exceed 100% of the rated crane load chart capacity. This is not a LOAD TEST. A person with training and experience who has demonstrated proficiency in the skills and abilities necessary to inspect, maintain, and repair cranes. A person with training and experience who has successfully completed a crane operator training course. The rated load at specified radii as established by the manufacturer and are the 2

Jib(Tip Extension) : An extension attached to the boom point to provide added boom length for lifting specified loads. Lattice boom : Boom of open construction with angular or tubular lacing between main corner members (chords) in form of truss. A safety feature used to stop the movement of a crane or its components beyond a predetermined point that could cause damage to components or the crane to fail. : The test undertaken to validate load rating of the crane.

Qualified crane : inspector

Limit device

Qualified crane : operator

Load test

Rated Capacity :

maximum loads at those radii covered by the manufacturers warranty. Whip line Rigger : A rigger is anyone who attaches or detaches lifting equipment to loads or lifting devices. A qualified rigger who is designated by a qualified crane operator to give hand signals. Same as swing. Rotation of the upper structure for movement of loads in a horizontal direction about axis of rotation. A device used to connect loads to be lifted by a crane or a hoist. Loads introduced into the machine or its components with no accelerating or decelerating forces. : A single length of wire rope equipped with a hook and safety latch, which is capable of handling the maximum capacity of the load. Its use is intended to keep the main hoist load block or auxiliary hoist headache ball from coming in contact with personnel rigging loads. : The swing circle assembly is the connecting component between the crane revolving upper structure and pedestal. This component allows crane rotation and sustains the movement ,radial and axial loads imposed by crane operation. A length of rope/ropes attached at a point to the load and used by riggers to help control its movement. Consists of a base boom from which one or more boom sections are telescoped for additional length. Any crane that is attached to or connected via a substructure to a platform :

and not a permanent part of the structure). A secondary rope system usually of lighter load capacity than provided by the main rope system. Also known as AUXILIARY.

Signalman

4.0

EQUIPMENT

4.1 Slewing :

Prime Mover: Prime mover may be Electric or Diesel engine. Starting system may be pneumatic, manual, hydraulic, electrical or combination of any two. Engine driven generator for power supply in cabin and accessories . Air compressor, receiver and auxiliaries for air starting system and engine shaft driven Hydraulic pump for engine starting system. Air is also required for signal horn, load indicator mechanism and wind screen wiper .Prime mover should be suitably selected for carrying out the main hoisting, Luffing and slewing operations simultaneously at rated capacity and specified radii. The engine should be fitted with a suitably calibrated running hours recorder which is to be positioned so that it can be easily read by the operator. The engine exhaust shall be equipped with spark arrestor and exhaust pipe shall be insulated to protect operator from burn injury. The exhaust should be directed away from the operator.

Sling

Static loading :

Stinger

Swing Circle assembly

4.2

Cabin : The cabin should be mounted on the crane with fully enclosed sturdy door with Lock, shatter proof glass windows on all sides, wind shield wipers and sun visor, horn, lights, fan and adjustable seat. Controls, indicators, alarms, load charts (one dynamic and other static for offshore cranes and static load chart for onshore crane) and boom angle indicator should also be provided in the cabin. Service walkways all around the cabin with handrail should be provided. As far as possible , cabin should be constructed to protect the upper structure machinery , brakes ,clutches and the operators station from the weather.

Tag line

Telescoping boom

Temporary crane :

Unless and otherwise specified, the sound levels at operators station shall not exceed: a. 90dB(A) (Slow response) measured with the prime mover at low idle and crane controls in neutral position b. 95dB(A) (Slow response) measured with the crane operating at full throttle and full rated load of the rotating machinery. 4.3 Hydraulic System A separate hydraulic pumps with motor and automatic braking system should be provided for main hoist, auxiliary hoist, and Boom Hoist for hydraulically operated cranes. A separate hydraulic motor should be provided for swing drive. The swing drive should be provided with Mechanical positive lock arrangement, controllable by operator. Means should be provided for checking manufacturers specified pressure settings in each hydraulic circuit. Each loop shall be fitted with pre-set safety relief valves. 4.4 Electrical System The supply of electrical power for lighting for cabin, Housing, Flood light , Air craft warning and other auxiliaries on the crane through alternator/dynamo which is a part of crane shall be provided. Some of the offshore/ fixed cranes are electrical driven for which electrical power is supplied by available installed electrical power. 4.6 4.6.1 Mounting Fixed Cranes Fixed type of cranes are mounted on suitably designed pedestal. The pedestal construction should be conforming to API2H or other national/international standard. 4.6.2 Mobile Cranes: a. The mobile crane shall be mounted on atleast four pneumatic tyred wheels and shall be provided with air or hydraulic braking on all wheels. An entirely independent hand brake shall be fitted for parking . Emergency towing eyes of approved design shall be fitted at the front and rear of the crane.

practice. Any one wheel may have one or more tyres. 4.7 Out Riggers The manufacturer should specify whether out-riggers are fixed or extendible, whether telescopic or hinged , whether front or rear outriggers or both are supplied and if jacks or supporting floats are available. 5.0 5.1 CONTROLS General Controls should be in accordance with the following requirement : a. The control should be installed in such a way that one operator can easily perform all maneuvers and speed control. b. Control levers for boom hoist, load hoist , swing and boom telescope(when applicable) should return automatically to their centre(neutral) positions on release. c. Foot operated pedals, where provided should be constructed so as the operators feet will not readily slip off. d. Brakes engage automatically when a control is placed in the neutral position in the event of engine power failure, loss of hydraulic pressure or control failure. e. Main hoist line and auxiliary line each should be equipped with antitwo blocking devices with audible and visual warning and is hydraulically operated. f. The crane should be fitted with a load, boom angle & radius indicating and sensing device which automatically weigh load continuously and is being carried with a particular radius. The crane has visual lighting indications inside crane cabin for indicating static and dynamic mode of operations. The normal re-setting of the controls for static lifting should also be provided. g. An emergency stop, to stop all functions of crane instantaneously in case of emergency is provided without stopping the engine. h. The mobile crane should be capable of being steered either right or left in either directions of travel and the control shall be from operators position on the revolving superstructure. 4

b.

Wheel and axle arrangements should be designated as per standard automotive

5.2

Forces and movement of control levers When control levers /pedals are properly maintained as per manufacturers recommendations the forces and movement to operate the crane within its rated limits should not exceed the following: a. Hand levers 20 lbf and 28 inches total travel b. Foot pedal 25lbf and 10inches total travel

1.

A crane operator must have valid certificate for operation of crane from authorised agency. The operator must be physically and mentally fit. (vision, hearing, colour identification & no history of any disabling medical condition) A crane operator must have valid Heavy duty driving license (for mobile cranes) Operator should have undergone operators training (classroom and practical). Operator should be conversant with load chart and stability (available on the crane), use of correct slinging practice, Operator should have clear understanding of standard signals, and safe operating practices

2.

3. 6.0 SAFETY EQUIPMENT Following minimum Safety equipment should be installed/made available on the crane : Weight load indicator Overload (not less than 97.5% of SWL at that radius) alarm & shutdown , visual warning at 90% of SWL. Boom Angle indicator Swing lock device Horn Boom hoist stop Aircraft warning light Latch for main & auxiliary hook Limit switches Walkie-talkie/telephone/pager/any communication device Audio warning Horn / Hooter for alarms Fire extinguisher Anti two block Emergency shutdown valve Guards on moving parts wherever possible to fit Pressure & oil Gauges Spark Arrestor with engine First Aid kit Following shall be displayed in the cabin: -Hand Signals -Load & range charts

7.2

Riggers Qualification A person with training and experience who has knowledge of rigging hardware, slings , safety issues related to rigging, use and selection of proper slings, hitches, shackles, hooks etc..

7.3 i.

Safe Operating Procedure Before starting the operations, operator shall verify that all pre-use inspections as per standard Practices or manufacturers guidelines have been completed. Operator shall be responsible for operations under his direct control. While lifting/placing of the l o a d , n o unauthorised person shall remain within the radius of the boom and underneath the load For any safety reason , the crane operator shall stop handling loads / operations and report the matter to the installation Manager for further instructions. Always follow the operating practices supplied by the manufacturer for each type of crane. The operator shall be familiar with the use of equipment and its care. The operator will respond to signals given by authorised signal person. Before leaving the crane for a long period the operator shall land any attached loads, disengage master clutch, set all locking devices, put controls in off or neutral position and stop the prime mover. Crane will be secured against swinging when not in use. During operations, if power or a necessary control function fails, set all the brakes and locking devices and move all clutches or 5

ii. iii.

iv.

v. Safety equipment specific to Mobile Cranes shall be fitted Reverse alarm Level Gauge Out-rigger controls functions Chokes A brake or alternative device to lock the superstructure in any position when the crane is travelling or working on slopes. In addition a positive locking device to locate the superstructure in its normal travelling position. 7.0 7.1 OPERATION Operator's Qualification

vi. vii. viii.

ix.

x.

xi.

other power controls to off position or neutral position. Relief valves on hydraulic cranes should not be adjusted above manufacturers recommended pressures and current limiting devices on electric cranes should not be bypassed to increase available hoist line pull. During high wind conditions and nights, lift of heavy equipment should be avoided. If unavoidable, the operator shall ensure that there is proper illumination in the night.

power lines is the leading cause of crane related fatalities. Detailed regulations for proximity to high voltage sources must be strictly enforced. Any potential danger should be pointed out to the crane operator or a supervisor-but never touch the crane at this time. c Riding the load or crane hook. This is a serious violation of safety regulations. Crane structures and cables have far lower strength margins for handling material than what is required for lifting personnel. Workers must never be suspended from a crane boom unless an approved personnel basket with mandatory safety equipment is used, and lifting procedures are strictly followed. Visible structural damage on the crane . There is little or no back up system in the load-supporting components of most cranes. A damaged component can fail completely and without warning, causing the boom or load to fall. Modifications made by adding extra counterweight or holding down the rear of the crane. All job initiated modifications are illegal and may permit overloading the crane. If not approved by the crane manufacturer in writing, these modifications can over stress critical structural components, which could cause failure of the crane. A crane operating near a trench o r e x c a v a t i o n. Cranes exert extremely high loads on the soil near the tracks, outriggers, or tires. A crane set up in close proximity to an excavation can cau s e s o i l failure, crane turnover, and possible disaster. The crane is noticeably out of level while operating. There is no faster way to collapse a crane boom than to impose a side force on the boom. Working out of level creates a dynamic side force which means a crane collapse may be imminent. The crane's hoist line is not vertical at all times during operation. This indicates improper operation. A hoist line which is not vertical obviously indicates that the 6

For mobile cranes (except crawler cranes) following additional procedures to be followed: xii. Crane to move on reasonably hard leveled surface. Crane placement programme to be prepared for lifting heavy equipment. Make sure wheels have chokes installed before commencing the job. Out rigger beam should be fully extended before operation. While working on a slope , the crane should be parked with front wheels towards downhill. the load lifted from the rear of the truck. The crane shall not be driven with outriggers extended. The crane level should be checked for stability. A trained rigger/ signalman shall always accompany the crane when it is being moved. The crane hook shall be secured to prevent it from swinging while the crane is traveling. The crane shall not be placed for working in Hazardous area classified by existing DGMS/Statutory notification . The components like light etc. shall be of flame proof type as boom can be used for handling loads in hazardous area. Crane Danger Signs to watch For : While working around crane, the operator should be careful about following eight danger signs of improper operation. If any of the following occurrences are noticed at jobsite, immediately inform to supervisor/competent person before a catastrophe takes place. a Outriggers, crawler tracks, or tires raised off the ground while operating. This is an extremely dangerous condition which indicates the crane is being overloaded and may tip over or collapse. The wrong move in this situation can cause a catastrophe. Operating close to power lines or other dangerous objects. Electrocution due to contact with

xiii. xiv. xv.

xvi. xvii. xviii.

xix. xx.

7.4

load is not hanging straight down. Out of plumb loads can cause crane collapse by generating side forces on the boom. In some instances, the crane may tip over if the load swings. 7.5 Precautions from live power lines Everyone in proximity to a crane, when energized lines are near, must stay alert. It takes employee teamwork to successfully and safely operate under this combination of conditions. Power Line Voltage up to 50k 50k to 75k 75k to 125k 125k to 175k 175k to 250k 250k to 370k 370k to 550k 550k to 1,000k The following guidelines are intended to prevent crane accident due to electrocution : Avoid storing materials around and especially underneath overhead power lines. Locate all power lines on the job and make a drawing of where you will set up the crane. Consider any overhead line "hot" until the owner or utility company verifies that it is not energized and is visibly grounded. The line must be "cold" if minimum clearance cannot be met. Look carefully before the boom is moved, particularly in congested areas of poor visibility. Get additional workers to help with the move if a clear view of all areas is not possible. Place a visual marker, such as a florescent line or flagging to mark off the danger zone. Communicate the lifting plan to all crewmembers every time you set up (after breaks and lunch). Use proper hand signals for directing crane operations. Make sure all crew members understand the signals. Appoint a watch person who does nothing but watch the load every time

Power lines can be hard for the crane operator to see. They sometimes appear to be either further away or much closer than they really are. It is difficult for the human eye to accurately judge the clearance between the crane's boom or line, and a power line. Fellow workers can help assure that safe clearances are being maintained between the crane, the line, the load and the overhead power line. The table below shows basic clearance minimums, w h i c h apply to all areas around the power lineabove, below or to either side: Minimum Clearance 10 feet 11 feet 13 feet 15 feet 17 feet 21 feet 27 feet 42 feet you work in the proximity of power lines. Never work closer to power lines than the code allows. Power lines are not insulated and they can arc across several feet. If working near power lines can not be avoided, contact the utility who owns them, have them de-energized and visibly grounded. This takes preplanning; most utilities require a minimum notice. If lines can not be de-energized, the utility must approve your work plan and install protective barriers. Again, a full time watch person is required. If one cannot move the crane away from the lines, stay in the cabin until the utility company arrives and makes sure the lines are de-energized. If a dangerous situation demands that you must exit the crane , " DON'T CLIMB DOWN". Jump away from the crane ( a distance of 2 to 4 feet is usually far enough) and land with both feet together as there may be areas in the ground with differing voltage. This will avoid having one foot in an area of higher voltage than the other, which can be lethal. Avoid contacting the load, load line or the crane. Ground crew should follow this same advice.

7.6 7.6.1

Load Handling The Load Crane lifting capacities are based on relative motion conditions between the c r a n e a n d the load to be handled. All cranes will have one static and at least one dynamic load rating chart. These charts must show the Rated Lift Capacity for boom lengths and angles. a) The appropriate load rating charts for the configuration in use must be in a position where they are visible to the operator while operating the crane. The Operator should know that the hook load is within the cranes applicable Static or Dynamic Rated Load at the radius at which the load is to be lifted. b) The safe working load on the crane at each radius should not be more than 90% of the test load, but in no case should the rated capacity loads be exceeded. The safe working load of the crane should be legibly marked on it. A scale or weight indicator should be available which can be used to determine weight of unknown load to be lifted. c) Never attempt to operate a crane where the load capacity chart shows no load capacity or where there are no values shown on the charts. This load is more than the safe operating conditions for the crane. The crane can turn over when the boom is extended too far, even with no load. d) To make a safe lift, the operator must know the exact weight of the load, the length of the crane boom, the load radius and the boom angle. e) For lifting heavy equipment , shackles/hooks shall be engaged on lugs/eyes provided for lifting. f) General load moment indicators do not sense extension of outrigger beams .As such, while operating a crane , it should be ensured that the outrigger beams are fully extended. g) Cranes should always be placed horizontally , as load moment indicator parameters are fixed, assuming the crane in horizontal position. Any horizontal imbalance of the crane will result in decrease of the balancing moment not accounted for by the load moment indicator, which may lead to serious over-loading. Attaching The Load a) The load should be attached to the hook by means of slings or other suitable devices. The latch shall be 7.6.3

closed to secure loose slings. Hooks should be self-closing. b) The hoist rope shall not be wrapped around the load. c) Discard defective slings. Each slings metal connector shall be stenciled with the date the sling is placed in service. d) Longer objects should be lifted from both ends to maintain its balance. e) Care and use of wire ropes shall be in accordance with OISD Standard-187. Moving The Load Guidelines for moving the load are as under: I. The Qualified crane operator and the designated signal person directing the lift should determine that: a) The crane is placed on a firm level foundatio n a n d properly secured in place. The load is secured and properly balanced in the sling or lifting device before it is lifted. The lift and swing paths are clear of obstructions and personnel. An appropriate fire extinguisher is kept in the crane cabin or vicinity of the crane.

b)

c)

d)

II.

Before starting to lift, the following conditions should be verified: a. Refer to crane load chart for proper boom angle before lifting any static or dynamic load. Never attempt to lift a load that exceeds the crane l i f t i n g c a p a c ity for a specific boom angle. Multiple part lines are not twisted around each other in such a manner that all of the lines will not separate upon application of load. The hook is brought over the load in such a manner as to minimize swinging. If there is a slack rope conditions, the rope is properly seated on the drum and in the sheaves. The correct slings have been selected for the weight to be lifted. 8

b.

c.

d.

e.

7.6.2

f.

g.

Stops have been provided on crane booms to prevent the possibility of overtopping the boom.

XII

Riding on loads and hooks is strictly prohibited. No fewer than five (5) full wraps of rope will remain on the drum(s) in any operating condition. Due consideration should be given to hoist manufacturers recommended practices, especially for break away anchor type hoists. All the cranes must be equipped with safety cutouts and the weight indicators . Safety cutouts m u s t always be in good working condition. When two or more cranes are used to lift a load, one qualified operator will be responsible for the operation. The responsible operator should analyze the operations and instruct all personnel involved in the proper positioning, rigging of the load and the movements to be made. The positioning of cranes and distribution of load should be ascertained . A p p r o p r i a t e n o n -electrical conducting tag or restraining lines should be used where necessary to guide and control the load. The Operator should not leave the crane controls until the load has been safely landed. He must properly secure the crane and boom before going off duty when shutting down operations.

XIII III During lifting, care should be taken that: a) Acceleration or deceleration of the moving load is accomplished in a smooth manner. Load, boom or other parts of the machine do not contact any obstruction.

b)

XIV

IV

The Operator should engage the controls smoothly to avoid excessive stress on crane machinery. When rotating the crane, sudden starts and stops should be avoided. Rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled. No external forces should be applied to suspended loads which will create side loading of the boom. Care should be taken when swinging the crane so as to minimize the pendulum action of the hook and suspended load. Cranes will not be used for dragging loads unless properly rigged for a vertical pull not exceeding the rated capacity. The operator will not hoist, lower or swing while any personnel are on the load or hook (other than in a personnel basket). While the crane is in operation, no other work shall be performed on the crane. a) The operator should test the brakes each time a load approaching the rated load is handled. The operator should avoid moving loads over personnel. Loads which are suspended by use of slings or hoists should be blocked or cribbed before personnel are permitted to work beneath or between them. Blow horn before moving loads over the area where people are working.

XV

VI

XVI

VII

XVII

VIII

7.7

Slings Sling, their fittings and fasteners, when not in use, should be inspected and retired in accordance with the following guidelines: Suitable protection should be provided between the sling and sharp surfaces of the load to be lifted. Proper storage should be provided for slings while not in use. Slings should never be choked in the splice. Sharp kinks or knots should not be permitted in wire rope slings. Loads should not be lifted with one leg of a multi-leg sling until the unused legs are secured. The sling should show the trademark or name of the manufacturer, the stock number and most importantly the load 9

IX

b) c)

XI

d) e)

f)

rating and types of hitches to be used. Do not use it ,if it is not rated for the capacity g) Slings, which are damaged or defective, shall not be used. h) Slings shall not be shortened with knots, bolts or other makeshift devices. i) Sling legs shall not be kinked. j) Slings shall not be loaded in excess of their rated capacities. k) Slings used in a basket hitch shall have the load balanced to prevent slippage. l) Slings shall be securely attached to their loads. m) Slings shall be padded or protected from all sharp edges of their loads. n) Suspended loads shall be kept clear of all obstructions. o) All persons shall be kept clear of suspended loads or those about to be lifted. p) Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load. q) Shock loading is prohibited. r) A sling shall not be pulled from under a load when the load is resting on the sling. s) Any angle other than vertical at which a sling is rigged increases the loading on the sling. t) Whenever a sling is found to be deficient, the eyes must be cut or other end attachments or fittings removed to prevent further use and the sling body discarded. u) A sling eye should never be used over a hook or pin with a body diameter larger than the natural width of the eye. Never force an eye on a hook. The eye should always be used on a hook or pin with at least the diameter of the rope. v) A sling shall be visually inspected before use to determine if it is capable of safely making the intended lift. Rated loads of a sling is different for each of the three basic method of rigging (vertical, choker, basket etc.) and the rated loads of a sling is different for each of the methods of rigging based on construction of the wire rope, web material and width etc. These rated loads are available from the manufacturers. These rated loads will be indicated on the heavy duty tags attached to each type of sling at the time it is fabricated. Care and use of proper slings and handling procedure should be in accordance with OISD std.-187. 7.8 Personnel Transfer Off loading materials and men from supply vessels to offshore installations and viceversa in a heavy swell, is always hazardous. Of all lifting operations, lifting of personnel presents the greatest risk and

shall only be considered if no alternative method can be found. It requires quite an exceptional level of coordination between the captain of the supply vessel and the platform crane operator. The latter only has a small time window in which to start hoisting the load to avoid it being hit by the heaving deck of the vessel. Personnel transfer shall only be performed after assessing the risk, defining associated prevention and mitigation measures and obtaining approval from the person in charge of the installation. 7.8.1 Transfer of personnel by baskets If sea is rough or wind does not permit vessel drawing alongside or if there is no landing platform, personnel shall be transferred by using unsinkable basket. The personnel basket should be so constructed, that it is capable of serving as a temporary life raft for the maximum number of persons that it is designed to carry. 7.8.2 Baskets Manufacturer's certificate, certificate of application and declaration of conformity, shall be issued prior to operation. 7.8.3 Use of personnel Basket When transferring personnel between an installation and a vessel by means of an offshore crane and a personnel basket, the following precautions are recommended as basis for setting up a procedure. a) 1. General precautions The installation manager may after careful consideration allow transfer by means of personnel basket in each specific case where this for special reasons is necessary or reasonable. Transfer shall take place on a voluntary basis . Transfer of personnel between installation and vessel shall only take place when there is good visibility and adequate illumination and only when the weather conditions permit a safe transfer, unless transfer is necessary with r e g a r d t o the safety of the personnel or the installation. Suitability of the vessel to which personnel are to be transferred must be ascertained. The type of vessel considered suitable to carry out a transfer should be 10

2.

3.

determined by its ability to maintain station alongside the installation and have sufficient clear deck space to safely receive the basket. 4. Instructions shall be drawn up for transfer operations, including rescue instructions in the event of accident during transfer. Personnel basket shall be designed for a maximum of 4 persons, and shall be clearly marked accordingly. Further, it shall be designed so that it can serve as a temporary raft for the number of persons it is designed to accommodate. The personnel basket shall be kept in good condition. It should be tested with a test load twice the maximum workload . The result of the test shall be entered in the records. The basket shall be safely stored when not in use. The basket shall be inspected at least once a week. The personnel basket shall be stowed together with the life jackets in a separate storage room where it will not be subjected to damage of a mechanical or chemical nature.

14. The crane intended to be used for personnel transfer shall be fitted with an emergency release and anti-two-block device. 15. To ensure that the crane hook does not damage anyone using the personnel basket, a suitable loop/sling shall be used. 16. The crane operator should have valid certificate of the crane operation. 17. Transfer during the night shall only be allowed in case of emergencies. b) 1. Operational precautions When transfer of personnel must be carried out, there must be consensus between the installation manager, the crane operator and the safety manager to the effect that the operation can be carried out safely. Prior to use basket thoroughly examined responsible person. shall be by the

5.

6.

7. 8. 9.

2.

3.

The basket shall be fastened to the crane hook with a long sling. The crane hook shall have a positive locking throatlatch. In addition to this, the personal basket must have a designated safety sling for additional safety back-up. The personnel basket shall be equipped with life jackets for the number of persons it is used for. The safety harness should be used during work from a personnel basket. The installation manager or a person appointed by the installation manager shall be in charge of the transfer. Before starting the transfer operation, the starting and landing area for the personnel basket shall be clear to ensure that there is sufficient space for a safe operation. The basket shall not be landed onto other equipment. During transfer of personnel, all unnecessary noise in the crane operator's cabin should be avoided, and the crane operator's complete attention shall be concentrated on the operation. 11

10. All persons riding on the basket should wear life jackets. 11. Any person unfamiliar with the basket shall be given a s h o r t briefing prior to riding the basket and shall be accompanied by an experienced person. Any person sick, suffering vertigo or injured should not be allowed to ride the basket, except if placed inside and escorted by an experienced person. 12. Personnel basket shall not be used for transfer of cargo, except for light personnel hand luggage. Luggage shall not be held by hand but positioned in the middle of the basket. 13. The crane to be used shall have valid certificate of application and shall be in good technical condition.

4.

5.

6.

7.

8.

9.

A designated signalman shall give the hand signals to the crane operator. The crane operator shall have eye contact with the signalman, who in turn shall have eye contact with the personnel basket.

18. Free-fall or non powered lowering should not be adopted when personnel are carried in the basket. 7.9 7.9.1 Signals Standard Signals Signals between the crane operator and the designated signal person will be discernible audibly or visually, at all times. The crane operator will work with a designated signal person who uses standard hand signals and will not respond unless signals are clearly understood. 7.9.2 Use of Hand Signals It is frequently necessary during crane operation for the operator to depend on a signal man for instructions, when moving an equipment into a position where there is very limited clearance or when handling loads that are out-of sight of the operator. The hand signals illustrated are those generally accepted throughout the industry. Ensure both the operator and the signal man are thoroughly familiar with standard hand signals to enable co-operation and teak work The details of use of hand signals are attached at Annexure-A. 7.9.3 Signalman The signalman shall be responsible for relaying signals from the slinger to the crane operator and for initiating and directing safe movement of the crane and hook load. Recommended standard hand and radio signals are identified as mentioned overleaf. Hand signals: Fully conversant with the use of signals. Be placed in the right position. Check that the load is hooked correctly. Give the signals clearly

10. The master of the vessel, the crane operator and the person in charge of the transfer operation shall be in direct radio contact with each other from a time before the personnel basket is hoisted until the transferoperation is completed. 11. If major job is carried over-sea on an offshore installation , a stand by vessel shall be located in the vicinity of the installation. The presence or assistance of catchers, signalmen, spotters and helpers shall be ensured. 12. During transfer the persons transferred shall stand on the ring outside the ropes on the personnel basket, and both hands shall be free to grip on to the ropes. Life jacket or lifesaving suit shall be used during the transfer. 13. Personnel should position themselves so that there is even distribution of load around the rim of the basket. 14. Lifting and lowering of the personnel basket shall take place over open water, and the vessel shall be prepared to stop the propellers during the transfer. 15. The crane operator should raise the basket only high enough above the deck of vessel to clear obstructions, swing it over the water, raise it to a position slightly above landing deck level, swing the basket over the landing area and gently lower it to the deck. The same method should be followed while transferring personnel from the installations to the vessel. Personnel should not get off the basket until it is settled on the deck of the boat or platform. 16. Tag lines shall be used on the basket and a person shall be present to control the direction of the basket on the deck. 17. Use of personnel basket shall be entered into the records.

Radio Signals : correct use of radio. Test the radio communication before starting a lifting operation. Speak clear and slowly. Use continuous radio connection during the lifting operation when the load is out of sight of the crane operator. Avoid unnecessary use of the radio 12

Prior to commencement of a lifting operation the signalman shall satisfy himself that loads may be safely handled. The signalman shall remain in visual or radio contact with the crane operator at all times and with the slinger at initial and at the final phases of the lift as appropriate. If the signalman changes during a lifting operation, both the crane operator and the slinger shall be duly notified of the identity of the new person in charge of signaling. The designated signal person should: a) Be qualified by experience with the operation and knowledge of the standard hand and radio signals as shown in the table . Be in clear view of the Operator to ensure that his signals can be seen. His position should give him a clear view of the load, crane, personnel and area of operation. If the Operators view of the primary signal person is obstructed, an additional signal person will be provided.

Before starting of the crane the basic checks are to be carried out by the operator as per the manufacturers check list requirement or guidelines given in Annexure-B , 8.2 Regular Inspection Regular inspection needs to be done based upon usage of the crane in addition to OEM Manual requirement or as per the inspection details indicated in of Annexure- C. 9.0 MAINTENANCE The maintenance of the crane shall be made on the recommendation of the crane manufacturers standard practices, However, maintenance practices shall be followed based upon utilisation of the crane. The recommended practices for the maintenance has been indicated in Annexure- B 9.1 Preventive Maintenance Periodic/ preventive maintenance schedule shall be followed as per standard manufacturer's practices/operator's recommended practices. 9.2 Repairs & replacement The Repairs & replacement of items shall be followed based upon the recommendation of inspection agency. However, if any major item / part is obsolete / not available the same shall be replaced with compatible parts which has to be approved by competent person/agency. No welding repair can be made to critical components such as booms and swing circle assemblies unless a repair procedure and recommendations are approved . If any critical component such as section of the boom etc. are required to be repaired, a qualified welder shall be deployed for welding jobs. 9.3 Precautions during major repair & maintenance a. Any job will be started only after obtaining the hot / cold work permit at any site as per OISD Std.- 105 . Care should be taken to ensure that arcing does not occur across the bearings. Hooks should not be exposed to excessive heat. 13

b)

7.9.4

Special Signals For operations not covered in section 7.9.2/7.9.3 or for special conditions, additions or modifications to the recommended standard signals may be required. In such cases, these special signals will be agreed upon in advance by the Operator and the designated signal person and should not be in conflict with, or have the potential to be confused with standard signals.

7.10

Simultaneous Operations i. When logging operation is in progress crane operation should not be conducted around the area where the cable is under tension, due to the risk associated with simultaneous operation. During the arming of an explosive device, crane operation should not be conducted around the designated arming area. During helicopter landing/take off crane operation should be stopped and crane boom must be away from the landing/take off area.

ii.

iii.

8.0

INSPECTION

b.

8.1

Pre-Use and After

c.

9.4

Maintenance of Wire rope Maintenance and inspection of wire ropes used in crane shall be done in accordance with OISD Std. 187(Use and care of wire rope)

13.0

PERSONNEL PROTECTIVE EQUIPMENT All personnel working with and around the crane shall wear safety shoes, Hard hat, Hand gloves & overalls. Additionally while checking the pressure & oil gauges or working near air source or moving parts, safety glasses should be used. While working at height (above ten feet), safety harness shall be used. Life vests shall be worn by all personnel being transferred offshore by Personnel basket.

10.0 10.1

LOAD TESTING & CERTIFICATION A copy of the original load test carried out by the manufacturer/contractor during the supply/sale of crane certified by International/National reputed certifying agency shall be made available to the operator/user. In general two types of load testing certifications are required 1) The load testing & certification shall be done after major repair/ replacement of parts of the crane based upon the recommendations of third party certifying agency. Periodic load test and certification : Based on the usage rate of the cranes all those cranes used frequently shall be load tested and certified annually, however for less used cranes the load testing shall be done based upon the recommendation of the certifying agency. 14.0

10.2

REFERENCES The following codes and standards (latest edition) are referenced to and made a part of this specifications : API spec - 2C : Specification for Offshore Cranes Recommended Practice for Maintenance and Operation of Offshore Cranes.

2)

API-RP-2D :

OISD Std.- GDN-192 : Safety practices during construction. OISD Std. 187: Care and use of wire ropes. OISD Std.-105 : Work Permit System IS:807-1976(FirstEdition): Code Of Practice For Design, Manufacture, Erection and Testing(Structural Portion) Of Cranes And Hoists IS : 6717: Specification for Mobile Road Cranes, Fully Slewing.

11.0

INCIDENT SYSTEM

ACCIDENT

REPORTING

Incident/accident reporting shall be done in OISD proforma-107. 12.0 CONTRACT MANAGEMENT If outside contractors are used for crane operations, the contract management section should ensure that minimum qualification for operator is followed, as per recommended practices.

14

ANNEXURE :A IDENTIFICATION OF ACTIONS ON USE OF HAND SIGNALS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Emergency stop : with arms extended, palm down, move hands rapidly right and left. Stop : With arms extended, palm down hold position rigidly. Dog Everything : Clasp hands in front of body. Move slowly : use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. Raise the Boom : with arm extended fingers closed thumb pointing upward and a jerky upward motion. Lower the Boom : with arm extend, fingers closed thumb pointing down-ward and a jerky downward motion. Use Main Hoist : Tap first on head then use regular signals. Use whip Line : (Auxiliary Hook Line)Tap elbow with one hand, then use regular signal Swing : Arm extended point with finger in direction of swing of boom. Travel : Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel Hoist : With forearm vertical, fore-finger pointing up, move hand in small horizontal circle Lower: With arm extended downward, fore-finger pointing down, move hand in mall horizontal circle. Raise the Boom and Lower the Load : with one arm extended fingers closed thumb pointing upward and a jerky upward motion and the other arm extended in a down-ward position palm horizontal with an up-down motion of this palm. Lower the Boom & Raise the Load : With the arm extended finger closed thumb pointing downward and a jerky down-ward motion and the other arm extended finger pointing up move hand in small horizontal circle. Raise the load slowly : with both hands placed in front of the body, palm open and an up-down motion with the lower palm. Lower the Load : With arm extended outwards, palm down and an up-down motion towards the downward direction. Lower the Load Slowly : With both hands placed in front of the body palm open and an up-own motion with the upper palm. Raise the Boom slowly : with arms placed in front of the body and the lower hand with fingers closed thumb pointing upward and a jerky upward motion with the upper hand palm down. Lower the Boom slowly : with arms placed in front of the body and the upper hand with fingers closed thumb pointing down-wards and a jerky down-ward motion with the lower hand palm up. Raise the Boom & Hold the Load : With one arm extended fingers closed thumb pointing upward and a jerky upward motion and the other arm extended in a down-ward position closed first and held firmly. Lower the Boom & Hold the Load : With the arm extended fingers closed thumb pointing downward and a jerky down-ward motion and the other arm extended in a down-ward position closed thumb pointing down-ward and a jerky down-ward motion and the other arm extended in a downward position closed first and held firmly.

14.

15. 16. 17. 18. 19. 20.

21.

15

16

ANNEXURE-B

1. Diesel Engines Refer section 5.0 of OISD STD.121 for engine maintenance.
No. Maintenance Activity

1 2 3 4 5

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Daily Monthl Qtrly y Check lubricating oil level and top-up as required . * Check cooling water level and top up as required . * Check fuel tank level and top-up as required . * Check for any loose bolts , nuts , pipe/line * connection of foundation and tighten if required . Start the unit and record following immediately after start and again after 1/2 to 1 hour of running in the log look . a) Operating oil temperature . * b) Operating oil pressure * c) Engine speed ,. * d) Water temperature . * e) Hour meter reading * f) Any other meter provided on the engine / panel . * Rectification of fuel/lubricating oil leakage including repair/replacement of pipes. Cleaning of radiator with air/water . * Cleaning/changing of air intake filter and pre* cleaner dust pan including associated works. Changing / cleaning oil /fuel / air filter/water / hydraulic filters . Lubricate governor , all linkage etc. * Servicing and testing of injectors including allied works. Checking / setting of rocker and tappet clearance. Checking/tightening of belt drives . * Replacement of radiator with associated works . Replacement of hydraulic and pneumatic starter. Replacement of hydraulic hand pump for starting . Replacement of starting air compressor . Replacement of cooling water pump . Replacement of turbo charger . Servicing / repair of radiator . Servicing of hydraulic and pneumatic starter. Servicing of hydraulic starting pump . Servicing of starting air compressor . Servicing of cooling water pump . Replacement of fuel pumps. Replacement of governor. Changing of acceleration cable . Removal , cleaning and fixing of flame arrestor.

Yearly Condition based

* * * * * * * * * * * * * * * * * * * * *

29 Removal , repair and fixing of air receiver tank . 30 Removal , cleaning and fixing of exhaust muffler . 31 Removal , cleaning and fixing of exhaust pipe . 32 Cleaning , flushing and changing of lubricating oil including cleaning , / changing of lubricating oil filter and breather

17

33 Cleaning , flushing and changing of fuel in fuel tank including cleaning , / changing of fuel filter . 34 Replacement of belts for cooling fans or water pump of compressor or generator . 35 Removal of cylinder head including allied jobs connected with its removal . 36 Assembling of cylinder head in the engine with associated work for total completion of the job and satisfactory testing . 37 Replacement of piston ring , connecting rod , piston ring set etc. Including associated work necessary for completion of the job . 38 Replacement of crankshaft including associated work for total completion of the job. 39 Removal and getting repaired / serviced including calibration of fuel injection pump from authorised agencies and checking for satisfactory performance of the engine with calibrated fuel injection pump . 40 Removal and getting repaired / serviced including calibration of governor from authorised agencies and checking for satisfactory performance of the engine with calibrated governor . 41 Painting of engine including supply of primer and marine epoxy paint as required . 2. No. 1 2 3 CRANES Maintenance Activity Brake System :--Aux./main crane hoist , boom And swing for proper functioning . Safety System :-- Like limit of travels and movements , limits of safe operating load etc for proper functioning . Condition of the hoses & hose connectors , grease to be applied for corrosion prevention at the hose connections ( as required ) Function of control levers and pedals and lubricate as required . Operation of cabin doors , wipers , horns ,fan etc And lubricate / clean as required . Check and top up of oil in following ( as required ) a) Aux. Hoist gear box , b) Swing drive unit gear box , c) Boom hoist gear box . d) Load hoist gear box , e) Hydraulic oil tank . Lubricate / grease Boom tip extention sheaves . Lubricate / grease Boom point sheaves . Lubricate / grease Outer boom extension sheaves . Lubricate / grease Gauntry Sheaves. Lubricate / grease of all pivot pins of boom ,derrick and sheaves including that of telescopic cylinders/chains/wire ropes inside the boom. Lubricate / grease Radius Indicator bearings. Lubricate / grease Boom hoist pawl bearings . Lubricate / grease Upper & lower boom hoist kick-out . Lubricate / grease Front and rear bogie roller / gears . Lubricate slew ring gear Lubricate / grease Position lock/Slew lock . Daily Monthly * * *

* * * *

* *

Qtrly Yearly Condition/ Use based

4 5 6

* * *

7 8 9 10 11

* * * * *

12 13 14 15 16

* * * * * * 18

17 Lubricate / grease Swing chain & lock . 18 Lubricate / grease Main & aux. Block, swivel hook bearings and locking latch on hook/swivel. 19 Lubricate / grease Cross head bearing/main thrust washers. 20 Main aux. Hooks for deformations , cracks and safety latch . 21 Boom for any structural abnormalities , cracks of deformation . 22 Winch mounting -- tighten if required . 23 Checking /lubrication of boom hook anchoring latch on chassis. Swing chain / pinion for proper fitting and functioning . 24 Checking for missing and tightening of slew ring gear mounting nuts and bolts 25 Checking and tightening of counter-weight pins/nuts & bolts. 26 Checking for creeping of derrick(luffing), boom telescopic and outrigger jack cylinders 27 Checking for leakage for hydraulic cylinders 24 Pedestal and other structural mountings - tightened as 28 required 29 Checking for full extension of outrigger beams 30 Checking of cracks/deformation of out-rigger jack plates 31 Checking of boom pad condition and their lubrication(in case of telescopic boom) and missing of members members for lattice boom. 32 Hydraulic pumps and motors mounting - tighten as required . 33 Clean the wire ropes with wire brush,record dimensions and check for any kink ( if any ) . Also check end connections for proper fitting .Lubricate with grease .Boom Rope,main hoist rope and auxiliary hoist rope to be checked. 34 Replacement of wire rope and greasing including all allied job for the same .Boom rope 35 Replacement of wire rope and greasing including all allied job for the same .Main hoist rope 36 Replacement of wire rope and greasing including all allied job for the same .Aux hoist rope 37 Cutting , splicing and connection on hook/drum end of wire rope. 38 Replacement of swing drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings. 39 Replacement of winch drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings. 40 Replacement of auxiliary hook drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings. 41 Replacement of Main hydraulic pump including all associated works for completion of the job and checking for proper operation after fittings. 42 Replacement of swing drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings. 43 Replacement of Swivel hook bearing and checking for proper operation after replacement . 44 Replacement of Boom hoist pawl bearing and checking for proper operation after replacement .

* * * * * * *

* * * * * * * *

* *

* * * * *

* *

19

45 Replacement of Cross head bearing and checking for proper operation after replacement . 46 Replacement of Main thrust washer and checking for proper operation after replacement . 47 Replacement of Swing chain and checking for proper operation after replacement . 48 Replacement of Swing pinion checking for proper operation after replacement . 49 Replacement of Pulley and checking for proper operation after replacement . 50 Servicing of hydraulic pump of motor . 51 Drain , flush and refilling of Aux hoist gear box .52 Drain , flush and refilling of Swing drive unit. 53 Drain , flush and refilling of Boom hoist gear box . 54 Drain , flush and refilling of Load hoist gear box. 55 Drain , flush and refilling of Hydraulic oil tank 56 Drain , flush and refilling of Fuel oil tank . 57 Servicing of slip ring and brushes of collector column ,if provided 58 Cleaning of battery terminals and applying of petroleum jelly and topping up of distilled water . Petroleum jelly to be supplied by the contractor . 59 Servicing of Aviation light on boom including change of bulb etc . 60 Replacement of aviation light including making Servicing of search light on boom/operators cab for illuminating working area and audio/visual warning system for reversing.

* * * * * * * * * * * * * *

* *

Note: The above list of items for maintenance and its frequency is only recommended practice. As far as practical manufacturers guidelines should be followed.

20

ANNEXURE-C Inspection of Components of crane S.NO. COMPONENT 1 Boom Hoist Assembly 2 Boom Point Sheave Assembly 3 Boom Section A. Base B Middle C. Upper D Tip 4. 5 6 7 8 9 10 11 12 Boom Hoist Wire / Rope Joy Stick Hook Block Main Hoist Rope Cabin Overhaul Ball Swing Circle Assembly Whip-line Pedestal TYPE OF CHECK Visual Visual Visual Thickness NDT MPI Visual Visual A) Visual B) MPI Visual Visual Visual Visual Visual Visual Fasteners NDT of welds Operational Visual Operational Operational Limit Switch Operational Main Aux Luff & Slew. Operational By Failing Engine Power. Operational REMARKS

13 14 15 16

17.

Brake Assembly Great Assembly Hydraulic Assembly Control Assembly Boom Control Hoist Control Swing Control Manual & Control Lowering

18.

Electrical Such As Lights Switches, Voltmeter, Ammeter, Wiper , Fan, Horn. Structural Such As Ladder, Catwalk And Rails. Engine

19.

Visual

20

Visual Noise Level/Vibration Air Pr, Oil level, Air filter, Starter Governor

21. 22.

Static Load Test Dynamic Load Test

Performance Operational For Main. Aux. Luff & Slew.

Detailed inspection report of various items to be inspected are placed in table below. The report indicates whether the inspected item is to be re-used, to be provided as new, to be repaired or replaced . 21

1. S.NO. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 ITEM Operator Chair Rubber beading Cabin Door Roller assembly for doors Aluminium sliding window Wiper with wiper motor, blade & switch Cabin light fitting Cabin fan Cabin body Boom angle indicator Lubro set Load cell 2. S.NO. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 ITEM Weight load Indicator Hyd. Main Pressure gauge Hyd. Pilot Pressure gauge Air Pressure gauge Lube oil pressure gauge Lube oil temperature gauge Techo hour meter Techo Hour Meter Chord Chord Control Mechanism Chords for Control Mechanism. Diesel level gauge Hyd. Oil level gauge Emergency shutdown valve Water temperature gauge 3. S.NO. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20

CABIN ITEMS PROVIDE REPLACE SERVICE

REUSE

CONTROL AND SAFETY SYSTEMS REUSE PROVIDE REPLACE SERVICE

ELECTRICAL MECHANICAL AND OTHER HARDWARE ITEMS REUSE PROVIDE REPLACE SERVICE

ITEM Horn & Horn switch Main switch Voltmeter Ammeter Engine Room light Air craft warning lights Flood lights with fittings Electric cables Nuts & Bolts (Assorted) Wedge & Sockets Latches for Main and Aux. Hook Blocks Brake liners / Brake Shoes Plumber Block Bearing "V" Belts Exhaust Bend Engine cooling fan guard Exhaust Manifold Exhaust Bellow Injector overflow pipe Diesel Filter

22

3.21 3.22 3.23 3.24 3.25 3.26 3.27

Lube Oil Filter Anti vibration Pads Grease Nipples(Assorted) Spark Arrestor Air Inlet valve Roller Assemblies for Engine Room Doors Junction boxes 4.EQUIPMENT AND COMPONENTS

S.NO. 4.1 4.2 4.3 4.4 4.5

ITEM Luff Pawl Cylinder Hyd. Starter with dog &pinion Transmission Belts Mechanical Engine Protection unit for hazardous area Oil cooler 5.

REUSE

PROVIDE

REPLACE

SERVICE

PNEUMATIC & HYDRAULIC SYSTEMS REUSE PROVIDE REPLACE SERVICE

S.NO. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18

ITEM Hydraulic Hose pipe Hydraulic pipes for all sizes Hydraulic fittings Suction Hose Pneumatic hoses Drain valve for Diesel tank Drain valve for Air tank NRV-1/2 Hyd. Filter Hyd. Tank Breather Suction Valve Hyd. Tank drain valve Pneumatic switches Hyd. Tank Gasket Hydraulic oil filter Hydraulic Float Pneumatic FITTINGS Main Hydraulic Pump Assy

6. WIRE ROPES S.NO. 6.1 ITEM Wire rope for Main Hoist, Aux. Hoist & luff winch REUSE PROVIDE REPLACE SERVICE

7. STRUCTURAL DAMAGES NO. 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 ITEM Top Catwalk Top covers Cabin Top Diesel Tank with Fittings Engine Room Doors All panels Hand rail Ladder REUSE PROVIDE REPLACE SERVICE

23

8.CRANE BOOM ASSEMBLY NO. 8.1 8.2 8.3 8.4 ITEM Damaged Boom lacings Boom Section joining pins Safety Latch for Main block Safety Latch for Aux. Block REUSE PROVIDE REPLACE SERVICE

9.LIST OF COMPONENTS FOR SERVICING S.NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36 37. 38 39 40 41 42 43. ITEM Accumulator & Relay valve starter All Single & Double Joysticks Electrical Panel & all lights Hyd. Tank Hyd. Hand Pump Magnetic Particle collector Fuel feed pump Fuel pump Injectors All Pulleys Counter shaft Plumber block Hydraulic Starter All valves Hyd. Motor for Main Hoist Hyd. Motor for Aux.Hoist Hyd. Motor for Luff Hoist Hyd. Motor for Slew Drive All Mono blocks Slew free valve Check- Q- Meter Pump Drive All Brakes Grease Lubrication of wire ropes, Pulleys, Shafts, Pins & their greasing points All Hyd. Cylinders Slew Ring Main hook block Auxiliary hook block First aid box Distribution board Lubricator assy Air Receiver A Frame All Limit Switches Generator First aid box Distribution Box Joy Stick Pedestal adapter Sheaves Sheave guards Diesel Engine- thorough overhaul Compressor

Note: The above list of items for inspection/maintenance and their frequencies are only recommended practice. As far as practical, manufacturers guidelines should be followed.

24