appea guidelines for lifting equipment appendicies

APPENDIX A

REFERENCE DOCUMENTS

LEGISLATION

1. Petroleum (Submerged Lands) Act 1967 [P(SL)A]

2. Petroleum (Submerged Lands) Act: Schedule of Special Requirements as to OffshorePetroleum Exploration and Production

3. Petroleum (Submerged Lands) Act: Petroleum (Submerged Lands) Act (Management ofSafety Of Offshore Facilities) Regulations 1996

4. Navigation Act 1912 and associated Regulations and Marine Orders

MO Part 43 “Dangerous Cargoes”MO Part 44 “Safe Containers”MO Part 59 "Offshore Support Vessel Operations"

5. Explosives and Dangerous Goods Act6. Occupational Health, Safety and Welfare Act7. WA: Occupational Safety and Health Act 1984 and Associated Regulations 19968. NT: Work Heath Act 19929. NT: Work Health - Occupational Health and Safety Regulations 1992

AUSTRALIAN AND NEW ZEALAND STANDARDS ETC.

10. AS ISO-1000 The International System of Units and its Application11. AS 1138 Thimbles for Wire Rope12 AS 1171 Non-Destructive Testing Magnetic Particle Testing of Ferromagnetic

Products, Components and Structures13. AS 1163 Structural Steel Hollow Sections14. AS 1353 Flat Synthetic Webbing Slings15. AS 1380 Fibre Rope Slings16. AS 1418 Cranes (Including Hoists and Winches)17. AS 1438 Wire - Coil Flat Slings18. AS 1504 Fibre Rope – Three Strand Hawser Laid19. AS/NZS 1554 Structural Steel Welding20. AS 1650 Hot-Dipped Galvanised Coatings on Ferrous Articles (superseded in part

by AS/NZS 4534 but remains current)21. AS 1657 Fixed Platforms, Walkways, Stairways, Ladders,22. AS 1664 Aluminium Structures23. AS 1666 Wire Rope Slings24. AS 2068 Flat Pallets for Materials Handling25. AS 2076 Wire Rope Grips for Non-Lifting Applications26. AS 2089 Sheave Blocks for Lifting Purposes27. AS 2207 Non-Destructive Testing for Ultrasonic Testing of Fusion Welded Joint in

Carbon and Low Alloy Steel28. AS/NZS 2312 Guide to the Protection of Iron and Steel against Exterior Atmospheric

Corrosion29. AS 2317 Collared Eye-bolts30. AS 2318 Swivels for Hoists31. AS 2319 Rigging Screws and Turnbuckles32. AS 2321 Short Link Chain for Lifting Purposes (Non Calibrated)33. AS 2550(1982) Cranes - Safe Use34. AS 2741 Shackles35. AS 2759 Steel Wire Rope - Application Guide36. AS 3569 Steel Wire Ropes37. AS/NZS 3678 Structural Steel - Hot Rolled Plates, Floor Plates and Slabs

9

38. AS/NZS 3679.1 Structural Steel - Part 1: Hot Rolled Bars and Sections39. AS/NZS 3679.2 Structural Steel - Part 2: Welded I Sections40. AS 3775 Chain Slings - Grade T41. AS 3776 Lifting Components for Grade T Chain Sling42. AS 3777 Shank Hooks and Large Eye Hooks - Maximum 25 Tonne43. AS 3990 Mechanical Equipment – Steelwork44. AS 4048 Flat Pallets for Materials Handling (1100mm x 1100mm Suitable for use in

ISO Series 1 Freight Containers)45. AS 4100 Steel Structures46. AS 4142 Fibre Rope47. AS 4497 Round slings - Synthetic Fibre, Parts 1 & 248. AS B291 Lifting Rings & Links

INTERNATIONAL STANDARDS49. API RP 2A Recommended Practice for Planning, Designing and Constructing Fixed

Offshore Platforms50. API Spec 2c Specification for Offshore Cranes51. API RP 2D Recommended Practice for Operation and Maintenance of Offshore Cranes52. API Spec 9a Specification for Wire Rope53. API RP 9B Recommended Practice on Application, Care and Use of Wire Rope54. AWS D1.1 Structural Welding Code – Steel for Oil Field Service55. BS 2573 Rules for the Design of Cranes56. BS 2903 Higher Tensile Steel Hooks for Chains/Slings Blocks and General

Engineering Purposes57 DNV Marine Operations - Part 2: Operation Specific Requirements, Chapter 5:

Lifting.58. DNV Marine Operations - Part 2: Operation Specific Requirements, Chapter 6:

Sub-sea Ops.59. DNV Certification notes No 2.7-1. Offshore Containers60. DNV Certification notes No 2.7-2. Offshore Service Containers61. EN 818-2 Short link chain for lifting purposes - Safety - Medium tolerance chain for

chain slings - Grade 862. EN 818-4 Short link chain for lifting purposes - Safety - Chain slings - Grade 863. EN 12079 European Committee for Standardisation. - Offshore Containers-Design,

Construction, Testing, Inspection and Marking.64 IMO Maritime Safety Committee Circular 86065. Lloyds Code for Lifting Appliances in a Marine Environment.66. PREN1677-1 Components for Slings - Safety - Part 1: Forged Steel Components, Grade

867 PREN1677-4 Components for Slings - Safety - Part 4: Links, Grade 8

0

OTHER DOCUMENTS

68. IICL Guide for Container Equipment Inspection69. IICL Repair Manual for Steel Freight Containers70. AMOG/ESSO Factors of Safety for Lifting Slings used in Offshore Supply Boat

Operations71. AMOG Investigation of Dynamic Amplification Effects During Offshore Lifting.72. AMSA Australian Offshore Vessel Code of Safe Working Practice.

Note: Institute of International Container Lessors Ltd. (IICL) references 68 and69 have been prepared for International Shipping Containers and notOffshore Containers. They do however provide a good general guidancefor containers.

APPENDIX B

DEFINITIONS

Alter: To change the design of, add to or take away from the equipment where thechange may affect health and safety, but does not include routinemaintenance, repairs or replacements.

AMSA: Australian Maritime Safety Authority.

Approved: Approved by the Operating Company, regulator, authority or society.

AS: Australian Standard.

Asset Owner: Entity that owns “Lifting Equipment”.

Certificate ofConformity:

A certificate issued by a body as described in Section 2.6 and in accordancewith Section 5.13. The issuance of this certificate indicates to owners,users and transporters of the container that the unit is “fit for intendedservice”.

The certificate is only to be issued when the accredited facility has ensuredthat the container meets all the requirements detailed in APPEA Containermanagement documents.

Where there is an existing doubt, the equipment owner should ensure thatthe container design is verified against the requirements of the APPEAGuidelines by a qualified structural engineer.

Certified visualinspection:

Inspection of “Lifting Equipment” accompanied by a report bearing theendorsement stamp of the appropriate inspection body or classificationsociety.

The inspection must be signed by an authorised signatory. It typicallyincludes visual, material dimensional, and material thickness checks,opening up and dismantling as considered necessary by the Inspector maybe required.

COG: Centre of Gravity.

CompetentPerson:

A person having practical and theoretical knowledge and relevantexperience, such as will enable that person to detect and evaluate anydefects and weaknesses that may affect the intended performance of theequipment.

Container: “Lifted Equipment” used in lifting and transport operations (see Section1.3).

CSC Convention for Safe Containers

DAF: Dynamic Amplification Factor.

DesignatedInspector/Surveyor/Verifying body:

A representative of a Classification Society or an inspection body or averifying body registered with the statutory body to perform certain surveysor inspections and issue certificates of inspection on behalf of the StatutoryAuthority.

DME: Department of Minerals and Energy.

Engineer: A person qualified to be a Member of the Institute of Engineers, Australia(MIE Aust.) or recognised equivalent who is competent and has adequateexperience to assure that the technical requirements of this standard aremet.

Engineered Lift: A lift which due to constraints, circumstances or specialised engineeringinput is beyond the scope of these guidelines. An engineered lift willtypically require modification to acceptance criteria and will thereforerequire a higher level of management and possible approval from therelevant authorities prior to being carried out.

EquipmentContainer:

Enclosure or frame designed specifically for lifting a particular item ofequipment or containing permanent fixtures such as a workshop. Thecontainer with contents remains at a constant mass and centre of gravityand would normally have dedicated rigging attached via pad eyes. Itincludes drilling support equipment, welding units, air compressor unitsand workshops.

Gross Mass: The maximum permissible combined weight of a cargo container and itscontents, ie. Maximum Gross Mass = Tare Weight + Net Weight measuredin kilograms (This is also known as Gross Weight measured in kilograms).

IMO: International Maritime Organisation.

Inshore Lift: Lifting to or from a vessel at a sheltered wharf. This may be performedusing either a vessel based or a shore based crane.

Inspection“body”:

An organisation accredited by the National Association of TestingAuthorities - Australia (NATA) to perform certain types of inspections andissue endorsed reports. These reports meet the requirements of the P(SL)Aschedule for test reports.

Inspector: Any person carrying out inspection of “Lifting Equipment”. Examples ofInspectors are representatives of NATA accredited establishments, riggers,crane drivers, welders, NDT technicians, QC inspectors, QC managers andqualified engineers. The qualifications of the Inspectors are dependent onthe type of inspection being performed. In all cases, the Inspector shallhave experience and training suitable to the inspection being performed.Where inspections referred to in this document require specificqualifications, these have been given in the appropriate section.

LiftedEquipment:

Equipment that the rigging connects to (Refer to Section 1.3).In the case of machinery, valves, etc with attached pad eyes, this termrefers to the machinery or valve.

Lifting Device: An item equipped with mechanical means for moving or placing a freelysuspended load.

LiftingEquipment:

Means an item or an integrated assembly of items designed to convey or foruse in conveying people, equipment or materials and includes “LiftingGear” and “Lifting Devices”. It also may be referred to as materialshandling equipment.

Lifting Gear: An item of equipment for use with a “Lifting Device” for lifting people,equipment or materials. The item is designed to be detachable from thecrane and includes both rigging and “Lifted Equipment”.

Lifting Points: Points on a structure to which rigging is attached, such as pad eyes.

Lift Weight: The total mass of the load including crane wire rope over head sheave,hook, hook block, and all rigging.

Maintenance: The activity of monitoring, inspecting, testing, refurbishing and replacingof plant and equipment within its pre-existing design specifications.

May: Indicates a discretionary action.

MBL: Minimum breaking load.

MGM Maximum Gross Mass

MO: Marine Orders.

MODU: Mobile Offshore Drilling Unit.

MPI: Magnetic particle inspection.

NATA: National Association of Testing Authorities, Australia.

NDT: Non-Destructive testing, including magnetic particle, ultrasonics.

Net Weight: The maximum permissible weight of the contents of a container inkilograms.

New Container: Container constructed after the issue date of this document.

NTDME: The Northern Territory Department of Minerals and Energy.

OffshoreContainer:

An item of Lifted Equipment designed for the movement of equipment ormaterials to, from and at offshore installations.

Offshore Lift: A lift performed in unsheltered waters between two vessels, between aplatform and a vessel, or between a platform and the seabed.

Onshore Lift: Lifting about an onshore location not involving a vessel.

Proof Load: The test load required by the Code or Standard for the specific equipment.

ResponsiblePerson:

A person who is responsible to any one of:• the designer of the equipment• the manufacturer of the equipment• a competent testing establishment• the owner of the equipment• a classification society• the operating company

for carrying out design, testing, inspection, certification or determination ofsafe working loads of “Lifting Equipment”.

Rigging: Equipment which is designed for repetitive use, to be readily detachablefrom a “Lifting Device” and which constitutes all or part of a liftingassembly that connects a load to the “Lifting Device”.

Safe WorkingLoad (SWL):

The maximum gross load which may be imposed for a specific use in orderto allow an adequate margin of safety. The SWL may equal but neverexceed the working load limit (WLL),

eg. In AS 1418 part 1 for Class 3 load applications, the SWL = WLL, for Class 4 and 5 applications, the SWL = 0.8 WLL.

Safe working load of a crane is the maximum mass which is permitted tobe safely handled by the crane. Safe working load of a lifting attachmentis the maximum mass that is permitted to be safely handled by the liftingattachment.

Shall: Indicates a mandatory requirement.

Should: Indicates a recommended requirement.

Sling Angle: The angle the leg of a sling makes with the horizontal. Typically within therange of 60 to 90 degrees.

StatutoryAuthority:

An Authority having statutory powers to control the design, manufacture,use and testing of “Lifting Equipment” in the State or Territory within theCommonwealth of Australia in which the equipment is used.

Tare Weight: The weight of an empty container or the weight of a lifting beam or liftingframe, complete with dedicated components, in kilograms.

Testing: Testing, in the context of inspection, means such tests carried outperiodically by a responsible person, in conjunction with inspection, atperiods defined by this document.

Testing “body”: An organisation accredited by the National Association of TestingAuthorities (Australia) to perform certain types of tests and issue endorsedreports. These reports meet the requirements of the P(SL)A schedule fortest reports.

Tugger Winch Construction aid not intended for lifting

Type TestCertificate

A certificate, similar to a Certificate of Conformity, but issued to indicatethat a generic design of offshore container meets the requirements of theAPPEA Guidelines. Testing requirements are in accordance with DNV2.7-2 and may include drop testing. If a Type Test Certificate is issued for ageneric design then subsequent testing of individual offshore containersfabricated to that design may be less extensive than would otherwise berequired.

VisualInspection:

A detailed visual examination and other such measures considerednecessary by an Inspector to determine the condition of the “LiftingEquipment”. Inspection may include visual, dimensional.

WADME: The Western Australian Department of Minerals and Energy.

Winch A lifting device capable of freely suspending a load by means of a wirerope wound on a drum.

APPENDIX C

OFFSHORE WIRE ROPE AND CHAIN SLINGS

TABLE C1

SAFE WORKING LOADS FOR “OFFSHORE BOAT LIFT” USE OFSINGLE-PART SINGLE LEG SLINGS WITH 1570 GRADE WIRE AND FIBRE-ROPE CORE

WITH FERRULE-SECURED EYES

1 2 3 4 5 6 7 8 9 10 11 12Choke Hitch Basket Hitch

DirectLoaded Round

LoadRectangular

Load Round Load Other than Round Load

Method of Loading

Included Angle (αα) - - - 0 60 90 120 0 60 90 120

10.95

1

0.750.95

1

0.50.95

1

20.95

1

1.730.95

1

1.410.95

1

10.95

1

10.95

1

0.870.95

1

0.710.95

1

0.50.95

1

Loading FactorsRc

Rt

Rm

Ro See Note BelowRope

NominalDiameter

mm

MinimumBreaking

ForcekN

SAFE WORKING LOAD, tRefer AS1666 for “Onshore/Platform Lifts”

131416

182022

242628

32

74.386.2113

143176213

253297345

450

1.241.41.8

2.32.93.5

4.24.95.7

8.1

0.931.071.4

1.72.22.6

3.13.74.3

5.6

0.620.710.94

1.191.41.7

2.12.42.8

3.7Note: The Operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4

Shaded Lift Configurations are not recommended for “Offshore Boat Lifts”

TABLE C2

SAFE WORKING LOADS FOR “OFFSHORE BOAT LIFT” USE OFTWO LEG, THREE LEG AND FOUR LEG SLINGS

WITH 1570 GRADE WIRE AND FIBRE-ROPE CORE WITH FERRULE-SECURED EYES

1 2 3 4 5 6 7 8Choke Hitch

Method of Loading Direct LoadedRound Load Other than Round Load

SingleWrap

DoubleWrap

SingleWrap

DoubleWrap

Included Angle (αα) 0 to 60 90 120 0 to 45 0 to 60 0 to 45 90 to 60

1.730.95

1

1.410.95

1

10.95

1

1.30.95

1

0.870.95

1

Loading FactorsRc

Rt

Rm


NominalDiameter

mm

MinimumBreaking

ForcekN


131416

182022

242628

32

74.386.2113

143176213

253297345

450

2.12.43.2

4.15.06.2

7.89.911.5

15.0

1.752.02.6

3.34.15.0

5.97.39.2

12.2

1.241.431.88

2.32.93.5

4.24.95.7

8.1

1.61.82.4

3.13.84.6

5.46.58.1

11.3Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4


TABLE C3

SAFE WORKING LOADS FOR “OFFSHORE BOAT LIFT” USE OF SINGLE-PART SINGLE LEG SLINGSWITH 1770 GRADE WIRE AND WIRE-ROPE CORE WITH FERRULE-SECURED EYES


DirectLoaded Round

LoadRectangular


Method of Loading


10.95

1

0.750.95

1

0.50.95

1

20.95

1

1.730.95

1

1.410.95

1

10.95

1

10.95

1

0.870.95

1

0.710.95

1

0.50.95

1

Loading FactorsRc

Rt

Rm


NominalDiameter

mm

MinimumBreaking

ForcekN


131416

182022

242628

323640

444852

5660

107124161

204252305

363426494

646817

1010

122014501710

19802270

1.782.02.6

3.44.25.0

6.07.59.4

12.515.819.5

23.628.0

-

--

1.341.552.0

2.53.13.8

4.55.36.2

9.111.814.6

17.721.024.8

28.7-

0.891.031.34

1.702.102.5

3.03.54.1

5.37.19.7

11.814.016.5

19.121.9

Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4Shaded Lift Configurations are not recommended for “Offshore Boat Lifts”

TABLE C4


WITH 1770 GRADE WIRE AND WIRE-ROPE CORE WITH FERRULE-SECURED EYES

1 2 3 4 5 6 7 8Choke Hitch

Direct LoadedRound Load Other than Round Load

Method of Loading

SingleWrap

DoubleWrap

SingleWrap

DoubleWrap


1.730.95

1

1.410.95

1

10.95

1

1.30.95

1

0.870.95

1

Loading FactorsRc

Rt

Rm


NominalDiameter

mm

MinimumBreaking

ForcekN


131416

182022

242628

323640

44

107124161

204252305

363426494

646817

1010

1220

3.13.64.7

5.97.810.2

12.114.216.5

21.627.4

-

-

2.522.93.8

4.85.97.7

9.911.613.4

17.622.327.6

-

1.782.072.68

3.44.25.1

6.17.59.5

12.515.819.5

23.6

2.32.73.5

4.45.56.8

8.810.712.4

16.220.525.4

-Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4


TABLE C5

SAFE WORKING LOADS FOR “OFFSHORE BOAT LIFT” USE OFSINGLE-PART SINGLE LEG SLINGS WITH 1770 GRADE WIRE AND FIBRE-ROPE CORE

WITH FERRULE-SECURED EYES


DirectLoaded Round

LoadRectangular


Method of Loading


10.95

1

0.750.95

1

0.50.95

1

20.95

1

1.730.95

1

1.410.95

1

10.95

1

10.95

1

0.870.95

1

0.710.95

1

0.50.95

1

Loading FactorsRc

Rt

Rm


NominalDiameter

mm

MinimumBreaking

ForcekN


131416

182022

242628

323640

444852

5660

98.4114148

187231280

333391454

594751929

112213341573

18212088

1.641.92.4

3.13.84.6

5.56.78.2

11.514.517.9

21.725.8

-

--

1.231.421.8

2.32.83.5

4.14.85.6

8.010.913.4

16.219.322.8

26.4-

0.820.951.23

1.561.902.3

2.73.23.7

4.96.38.5

10.812.915.2

17.620.2

Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4Shaded Lift Configurations are not recommended for “Offshore Boat Lifts”

TABLE C6


WITH 1770 GRADE WIRE AND FIBRE-ROPE CORE WITH FERRULE-SECURED EYES

1 2 3 4 5 6 7 8Choke Hitch

Method of Loading Direct LoadedRound Load Other than Round Load

SingleWrap

DoubleWrap

SingleWrap

DoubleWrap


1.730.95

1

1.410.95

1

10.95

1

1.30.95

1

0.870.95

1

Loading FactorsRc

Rt

Rm


NominalDiameter

mm

MinimumBreaking

ForcekN


131416

182022

242628

323640

44

98.4114148

187231280

333391454

594751929

1122

2.83.34.3

5.46.99.2

11.113.115.2

19.925.2

-

-

2.312.73.5

4.45.46.8

8.710.612.3

16.220.525.4

-

1.641.902.47

3.13.94.7

5.66.78.3

11.514.517.9

21.7

2.12.53.2

4.15.06.1

7.79.811.4

14.918.923.4

28.3Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Ref. Section 5.4


TABLE C7

SAFE WORKING LOADS FOR “OFFSHORE BOAT LIFT” USE OFSLINGS WITH GRADE T CHAIN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17Single Leg Slings Slings of 2, 3 or 4 legs Endless Slings

StraightSling

AdjustableSling

ReevedSling Straight Sling Reeved Sling Basket/Reeved Sling

Method of Loading

Included Angle (αα) - - - 60 90 120 60 90 120 60 90 120 -

111

0.7511

0.7511

1.7311

1.4111

111

1.3011

1.0611

0.7511

1.3011

1.0611

0.7511

1.511

Loading FactorsRc

Rt

Rm

Ro See Note BelowChain

Size fromAS2321

(Ref Note)1 2 3

MinimumBreaking

ForcekN


10

12

16

20

25

11

1314

18

2224

2728

30

½

5/8

¾

7/8

1

126158197

203213248

317322408

457503621

631724786

811917986

1131

2.212.773.46

3.573.74.3

5.55.67.6

9.010.413.1

13.315.617.2

17.820.722.6

28.8

3.84.85.9

6.26.68.2

11.411.615.2

17.319.427.3

---

---

-

3.13.94.8

5.05.26.1

8.78.912.0

13.715.219.5

19.923.628.2

---

-

2.212.73.4

3.53.74.3

5.55.67.6

9.010.413.1

13.315.617.2

17.820.722.6

28.8Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Refer Section 5.4

Shaded Lift Configurations are not recommended for “Offshore Boat Lifts”1. Preferred Chain Specification (mm), 2. Non-Preferred Chain Specification (mm),3. Temporary Specification (in).

APPENDIX D

DYNAMIC AMPLIFICATION FACTOR

FIGURE D.1

RECOMMENDED DYNAMIC AMPLIFICATION FACTOR (DAF)

(Hs=3.0 Metres Max.)

0

0.4

0.8

1.2

1.6

2

2.4

2.8

3.2

0 5 10 15 20 25

Lifted Mass (tonnes)

Dyn

amic

Am

plif

icat

ion

Fac

tor

(DA

F)

6

2.7

APPENDIX E

PAD EYE DETAILS

RIGGING DESIGN EXAMPLE

Problem:

Obtain sling, shackle and padeye sizes for lifting a 25 tonnes container offshore inaccordance with the APPEA “Guidelines for Lifting Equipment”

Assumptions:

- A 4 sling arrangement is assumed

- A maximum included angle of 60 degrees

- A 100/0 split of sling loads is assumed

- The centre of gravity is at the centroid of the padeyes

Sling size:

Referring to Table C4 in Appendix C of the APPEA “Guidelines for Lifting Equipment”,1770 grade wire rope with a 36mm nominal diameter has a safe working load of 27.4tonnes.

Shackle size:

Rc = 1.73 (refer to Table 1 AS1666.2 (1995))

Rm = 0.80 for shackles (refer to Table 5.4.1)

Rt = 1.00 for shackles (refer to Table 5.4.2)

Ro = 0.92 (interpolated from Table 5.4.3)

Factor of Safety = 4 = 5.43 Rm Rt Ro

SWL = P x Rc = 25.0 t (SWL of sling assembly) FoS x 9.81

P = SWL x FoS x 9.81 = 770.5 kN (Minimum breaking force) Rc

Referring to AS2741-1992 Table 5, the grade S alloy dee shackle with a diameter of 38mmhas a min. destructive test force of 834 kN. This shackle has a WLL of 17 tonnes.

Padeye sizeReferring to the Standard Drawing for Padeyes and Shackles (W2090-SKS01 Rev B), thecorresponding padeye to the shackle designed above is the padeye with a WLL of 17tonnes.

3.2

4.7

6.5

8.5

9.5

12

13

17

25

35

45

55150

130

120

75

85

105

70

65

60

55

55

45

360

340

295

220

230

280

200

185

160

150

135

115

130

115

105

65

70

85

60

55

50

45

40

35

73

66

60

41

44

54

38

35

32

28

25

22

32

25

20

50

50

50

25

32

40

25

25

25

20

16

12

20

16

10

10

10

12

10

8

6

6

6

6

220

190

170

110

120

150

100

90

80

70

60

50

10

8

8

6

6

8

6

6

6

6

6

6

70

63

57

38

41

51

35

32

29

25

22

19

105

95

83

57

60

73

52

46

43

37

32

27

302

253

225

152

166

203

136

124

109

96

83

70

238

212

199

132

145

171

117

106

95

83

71

60

76

72

64

42

46

55

38

34

30

27

24

20

XA

(tonne)

B C T T Et F D W LB LDd

63

57

51

35

38

44

32

29

25

22

19

16

SHACKLESIZE PIN DIA.WELDTHICK. DIA.CHK.PLS.CHK.PLS.D+3mmRADIUSWLL

SHACKLEWITHPIN HOLE WITHOUT CHEEK PLATES NOM BOW DEE

SHACKLES ALLOY GRADE "S" - TO AS2741PADEYES - FOR ALL VALUES OF

55

17

35

45

25

13

12

9.5

WLL(tonne)

3.2

8.5

6.5

4.7

SLIN

G A

NG

LE

PADEYE TYPE 'X' PADEYE TYPE 'Y'DEE SHACKLE WITH PIN

ALLOY SHACKLES GRADE "S"-TO AS2741

BOW SHACKLE WITH PIN

SHACKLE

CP

FTYP

45°

T

45°

RO

OT

GA

PØ

E

t

T

B

A

C R

AD

(D+3)Ø

C R

AD

A

BC

(D+3)Ø

Ød

LB

X

W

ØD

B

Ød

LD

X

W

ØD

3.2

4.7

6.5

8.5

9.5

12

13

17

25

35

45

55150

130

120

75

85

105

70

65

60

55

55

45

360

340

295

220

230

280

200

185

160

150

135

115

130

115

105

65

70

85

60

55

50

45

40

35

73

66

60

41

44

54

38

35

32

28

25

22

32

25

20

50

50

50

25

32

40

25

25

25

-

-

-

20

16

12

10

10

12

10

8

6

-

-

-

220

190

170

110

120

150

100

90

85

-

-

-

10

8

8

6

6

8

6

6

6

-

-

-

70

63

57

38

41

51

35

32

29

25

22

19

105

95

83

57

60

73

52

46

43

37

32

27

302

254

226

152

167

204

137

124

110

97

83

71

238

213

200

132

145

172

118

106

96

84

71

61

76

72

64

42

46

55

38

34

30

27

24

20

XA

(tonne)

B C T T Et F D W LB LDd

63

57

51

35

38

44

32

29

25

22

19

16

SIZE PIN DIAWELDTHICK. DIA.D+3mmSWLWITH CHEEK PLATES BOW DEE

SHACKLES ALLOY GRADE "S" - TO AS2741PADEYES - FOR ALL VALUES OF ß

55

17

35

45

25

13

12

9.5

SWL(tonne)

3.2

8.5

6.5

4.7

SLIN

G A

NG

LE

PADEYE TYPE 'X' PADEYE TYPE 'Y'

SLIN

G A

NG

LE

G

85

78

72

53

56

66

50

47

44

-

-

-

G G

ALTERNATIVE ALTERNATIVE

BOW SHACKLE WITH PIN

DEE SHACKLE WITH PIN

ALLOY SHACKLES GRADE "S"-TO AS2741

TYP

CP

TYPF

APPENDIX F

INSPECTION & TESTING REQUIREMENTS

APPEA Guidelines for Lifting Equipment

Page 61

TABLE F.1

INSPECTION AND TESTING REQUIREMENTS FOR LIFTING DEVICES

PROOF LOAD TEST

ITEM

REFERENCE

CERTIFIED VISUAL

INSPECTION

NDT FREQUENCY LOAD

Cranes (The various types of cranes andlifting appliances are listed in

AS 1418)

Offshore:

• API Spec 2C

• BS 2573

• Lloyds Code for LiftingAppliances in a MarineEnvironment

• Manufacturer’s Specs

1 Year

Subject to:

• Visual inspection

• Failure ModeAnalysis

• IndividualCompany Program

• Initial Certification Test

• Following Repairs

Subject to:

• Visual inspection

• NDT

• Individual Company Program

Individual State Regulations specifyevery 12 months for some devices.

Varies from

SWL x 1.0 to

SWL x 2.2 dependingon type of “LiftingDevice”, as perAS1418.

Overhead Pad eyes AS1418.1 & .2

1 Year *

Subject to visualinspection or maximumof 3 years

Initial test and then subject to visualinspection, NDT and individualcompany program.

1.25 x SWL

Fork-lift tines AS 2359 1 Year

Subject to visualinspection

Initial test and then subject to visualinspection, NDT and individualcompany program.

Subject to individualcompany program

Mono rails P(SL)A AS1418.1 & .2 1 Year * Initial NDT, thensubject to visualinspection

Subject to individual companyprogram

1.25 x SWL

Note: * Certified Visual Inspection includes permanent marking of SWL


Page 62

TABLE F.2

INSPECTION AND TESTING REQUIREMENTS FOR LIFTED EQUIPMENT Notes: 1. This table applies to “Lifted Equipment” up to 25* tonnes Gross Weight that has a Certificate of Conformity.2. “Lifted Equipment” MAY be tested using their own dedicated rigging gear (lifting set). Caution should be exercised because proof testing a sling to more than 1.5 times its

SWL may permanently distort wire rope thimbles if standard shackles are used, especially on the two point lift test.3. “Lifted Equipment” above 25 tonnes Maximum Gross Mass (MGM) may be proof load tested as specified by the design engineer.

PROOF LOAD TEST

ITEM

REFERENCE

CERTIFIED VISUAL

INSPECTION

NDT FREQUENCY LOAD TEST

REQUIREMENTS

“Lifted Equipment” Includes all types of offshore containers,baskets, skids, skips, spreader beams,spreader frames, workshops, labcontainers and workboxes.

APPEA 1 year

• Subject to visual inspection


• Every 3 years thereafter

• Following repairs tostructural members

• Initial Certification Test forNew & Existing Equipment

• Every 6 years thereafter orat the discretion of theinspection body



MGM x 2.5

over 4 lifting points and

MGM x 1.5

over 2 lifting points

Transportable buildings. Includes; Offices, Laboratories etc. Not

intended to transport cargo

APPEA Before liftingunless inspectedwithin the lastyear.

Before lifting unless testedwithin the last three years


(At fabrication, primary structureonly before walls etc areinstalled)

MGM x 2.5


MGM x 1.5


Specialised Lifting EquipmentSpecialised items such as drilling guidebases, conductor casing joints,equipment modules etc

APPEA Before liftingunless inspectedwithin the lastyear.

Before lifting unless testedwithin the last three years

Not generally requireddepending upon individualoperator's requirements

Tanks for Fluids (Includes tanks/containers of all sizes forboth normal and dangerous cargoes)

Note: There are additional requirementsfor IBC's in IMDG code.

APPEA 1 year






• Every 6 years thereafter orat the discretion of theinspection body


• Subject to Visual Inspection

MGM x 2.5


MGM x 1.5



Page 63

Personnel Baskets (Work Box)

AS1418.17

1 year





• Every 2 years


Per Clause 4.2

AS1418.17

Personnel Transfer Basket (Billy Pughetc)

APPEA 1 year • Yearly Refer to ManufacturersRequirements

* Arbitrarily selected limit


Page 64

TABLE F.3

PERIODIC INSPECTION AND TESTING REQUIREMENTS FOR RIGGING

Notes: 1. Offshore containers shall have specifically designed lifting sets, which shall not be removed from the container except for replacement of the lifting set or for examination

of the container.2. For Safety Factors for Rigging Equipment used in Offshore Lifting Operations refer to section 5.4.3. Minimum chain diameter to be 10mm. For containers with Maximum Gross Mass more than 3500kg, the minimum chain diameter must be 13mm.4. Min. Wire Rope diameter to be 13mm. For containers with Maximum Gross Mass more than 3500kg, the minimum wire rope diameter must be 19mm.

PROOF LOAD TEST

ITEM

REFERENCE

CERTIFIED VISUAL

INSPECTION

NDT FREQUENCY TEST REQUIREMENTS

Loose Rigging (Includes all types wire andsynthetic ropes, chains, links,shackles, swivels, rings, sockets,hammerlocks, etc)

APPEA • Not Required

• 3 monthly visualinspections

• Colour coding

• Visual inspectioneach time before use.

Subject to visualinspection


• Subject to Visual Inspection.

• Subject to company program.

Carried out to the requirementsof the relevant AustralianStandard. Refer to Section 8.4.1for SWL.

Lifting Sling(s) Single or multiple leg wire ropeand chain sets, complete with allassociated accessories)

APPEA 1 year

as part of the containerinspection.

Not applicable • Initial Certification Test

• Offshore – Every 6 years aspart of the “Lifted Equipment”Proof Load Test.

Refer to Section 8.4.1

Crane Hooks APPEA 1 year

• Every 2 years

• Subject to VisualInspection

• Initial Certification Test Refer to Manufacture

All Rigging for Man-lifts APPEA As specified above As specified above As specified above 4 × MGM (man-lift rating)specified in above documents


Page 65

TABLE F4

TYPE & PRODUCTION TESTING OF NEW LIFTED EQUIPMENT

ITEM

REFERENCE

TYPE TEST Applies to first item manufactured of

new design

PRODUCTION TESTING (For the No. of units to be tested

refer the table F5 below)

LOAD TEST REQUIREMENTS

Offshore Containers

APPEA • 4 Point Load Test

• 2 Point Load Test

• Drop Test*

• 4 Point Load Test MGM x 2.5


MGM x 1.5


Spreader Frames & Beams APPEA • Load Test only • Load Test only MGM x 2.5

Transportable buildings. Includes; Offices, Laboratoriesetc. Not intended to transportcargo

APPEA • 4 Point Load Test• 2 Point Load Test



MGM x 1.5


Specialised Items. Includes: drilling guide bases,conductor casing joints,equipment modules etc

APPEA • 4 Point Load Test• 2 Point Load Test


* - For very large containers a drop test may be undesirable, hence the drop test should be carried out at the discretion of the accrediting body


Page 66

TABLE F5

Total number in series 1-5 6-10 11-20 21-40 > 40

Number to be tested 1 2 3 4 10%


Page 67

APPENDIX G

GUIDE TO AUSTRALIAN AND INTERNATIONAL STANDARDS


Page 68

Table G1- Guide to Australian and International Standards

Note: This table is intended as a guide only. In many cases, requirements of International standards will be less onerous than Australian standards. Requirements less onerousthan Australian standards are not recommended to be adopted without specific Operator approval.

Aust/NZ No Australian/New Zealand Title ANSI Standard British Standard DNV Std ISO Std

AS ISO-1000 The International System of Units - BS 5555 - ISO 1000AS 1138 Thimbles for Wire Rope - BS 464

BS 3226Rules for Marine OperationsPart 2 Chap 5

-

AS 1171 Non-Destructive Testing MagneticParticle Testing of FerromgneticProducts, Components and Structures

- BS 6072 - -

AS 1353 Flat Synthetic Webbing Slings - BS 3481BS 5053

- -

AS 1380 Fibre Rope Slings - BS 2052BS 4921BS 7648

- -

AS 1418 Cranes (Including Hoists & Winches) ASME B30API RP2DSpec 2C

BS 327BS 357BS 466

BS 1757BS 2452BS 2573BS 2799

BS MA41BS MA79

Rules for Certification ofLifting Appliances

-

AS 1438 Wire - Coil Flat Slings - - - -

AS 1504 Fibre Rope - Three Strand HawserLaid

- - - -

AS/NZS 1554 Structural Steel Welding AWS D1.1 BS 4870 - -

AS 1657 Fixed Platforms, Walkways,Stairways and Ladders – Design,Construction and Installation

A1264.1 BS 4592BS 5395

- -

AS 1664 Aluminium Structures Code AWS D1.2 BS 8118 - -


Page 69


BS CP118

AS 1666 Wire Rope Slings ASME B30.9 BS 1290 Rules for Marine OperationsPart 2 Chap 5

-

AS 2089 Sheave Blocks of Maximum Lift 60Tonne

- BS 4018BS 4344BS 4536

BS MA47

Rules for Marine OperationsPart 2 Chap 5

-

AS 2207 Non-Destructive Testing forUltrasonic Testing of Fusion WeldedJoints in Carbon & Low Alloy Steel

AWS C3.8 BS EN 1714 - -

AS 2317 Collared Eye-bolts ASME B18.15 BS 4278 - -

AS 2318 Swivels for Hoists - - Rules for Marine OperationsPart 2 Chap 5

-

AS 2319 Rigging Screws and Turnbuckles - BS 4429 - -

AS 2321 Short Link Chain for LiftingPurposes (Non Calibrated)

ASME B29 BS 3113BS 3458

BSEN 818-1BS 6304


-

AS 2550 (1982) Cranes – Safe Use ASME B30 - Rules for Certification ofLifting Appliances

-

AS 2741 Shackles - BS 3551BS 6994


-

AS 2759 Steel Wire Rope – Application Guide API RP9B BS 6210BS 6570

- -

AS 3569 Steel Wire Ropes Spec 9A BS 183BS 302BS 525


ISO 3578

AS/NZS 3678 Structural Steel – Hot Rolled Plates,Floor Plates and Slabs

SAE J763SAE J1392

BS 7613 - -

AS/NZS 3679.1 Structural Steel – Part 1 : Hot RolledBars and Sections

SAE J1442 BSEN 10210-2 - -

AS/NZS 3679.2 Structural Steel – Part 2 : Welded ISections

- - - -


Page 70


AS 3775 Chain Slings – Grade T ASME B29 BS 2902BS 6968


-

AS 3776 Lifting Components for Grade TChain Slings

- - Rules for Marine OperationsPart 2 Chap 5

-

AS 3777 Shank Hooks and Large Eye Hooks -Maximum 25 Tonne

ASME B30.10 BS 2903 Rules for Marine OperationsPart 2 Chap 5

-

AS 3990 Mechanical Equipment - Steelwork AISC BS 5950BS 7608

DDENV 1993DDENV 1994

- -

AS 4048 Flat Pallets for Materials Handling(1100mm x 1100mm suitable for usein ISO Series 1 Freight Containers)

ASME MH BS 3810BS 6637BS M69

- -ISO 445

AS 4100 Steel Structures AISC BS 5950BS 7608

DDENV 1993DDENV 1994

- -

AS 4142.1 - 1993 Fibre Rope - Care & Safe Usage - BSEN 698BSEN 701

BSEN 1251BS 7648


-

AS 4142.2 - 1993 Fibre Rope - 3 Strand Hawser laidand 8 Strand Plaited Rope

AS B291 Lifting Rings & Links - - Rules for Marine OperationsPart 2 Chap 5

-

AS/NZS 3711.1 Freight Containers:- Part 1Classification, Dimensions & Ratings

ANSI MH BS 3951 - ISO 668 Amd.1

AS/NZS 3711.2 Freight Containers:- Part 2 –Terminology

ANSI MH BS 3951 - ISO 830 Amd.1,Amd.2

AS/NZS 3711.3 Freight Containers:- Part 3 - CornerFittings

ANSI MH BS 3951 - ISO 1164 Cor.1

AS/NZS 3711.4 General Purpose Containers ANSI MH BS 3951 - ISO 1496.1 Amd.1

AS/NZS 3711.5 Thermal Containers ANSI MH BS 3951 - ISO 1496.2


Page 71


AS/NZS 3711.6 Tank Containers ANSI MH BS 3951 - ISO 1496.3

AS/NZS 3711.7 Dry Bulk Containers ANSI MH BS 3951 - ISO 1496.4

AS/NZS 3711.8 Platform Containers ANSI MH BS 3951 - ISO 1496.5 Amd.1

AS/NZS 3711.9 Coding, Identification and Marking ANSI MH BS 3951 - ISO 6346 Amd.1

AS/NZS 3711.10 Handling and Securing ANSI MH BS 3951 - ISO 3874 Amd.2

APPEA Guidelines for Lifting Equipment - Phase Out of ISO Containers

Page 73

APPENDIX H

GUIDELINES FOR THE PHASE OUT OF ISO SHIPPINGCONTAINERS OFFSHORE


Page 74

SCOPEProvision of procedures & guidelines to manage the use of ISO containersused in the offshore oil and gas exploration and production industry.

The document provides guidelines for the inspection, testing and marking ofISO containers used in the transport of goods to and from offshore locations.

IDENTIFICATION OF“ISO” CONTAINERS

ISO containers are the containers originally built for international shipping andfitted with ISO Corner fittings and lifted in container ports, from these fittings,with a purpose built spreader frame and special “Twist-locks”. The containersare designed and rated for use in still water ports and not for offshore usewhere significant dynamic forces occur during lifting operations.

Most ISO containers are 20ft in length although 10, 30 & 40ft lengths are alsoavailable.

Note: Purpose built offshore containers may also have ISO Corner fittings.This is acceptable, provided that they are used only for securing duringtransport and/or onshore/inshore lifting in accordance with onshore/inshorecontainer lifting guidelines as detailed in AS 3711.10:1993 “FreightContainers – Handling and Securing”.

CONTROLLED USE OFISO CONTAINERS

Containers used in international shipping are controlled by the InternationalConvention for Safe Containers (CSC). When the containers used ininternational and/or coastal shipping reach the end of their service life, eitherthrough condition or a “time life” expiry they are often sold off withoutcurrent CSC compliance.

Existing CSC compliance plates do not apply to the offshore oil and gasexploration and production industry except as a reference for de-rating thecontainer in accordance with this these guidelines.

The CSC compliance plate is to be retained for this purpose. ISO containerswithout compliance plates should be condemned.

REFERENCES• King Bay Supply Base Lifting Equipment Management System,

Woodside Energy Ltd.• Marine Orders, Part 44, Section 11.• International Maritime Organisation Circular 613 (to be replaced by

Maritime Safety Committee, Circular 860).• International Convention for Safe Containers (CSC) IMO, 1982.• DNV 2.7-1 Offshore Containers –Certification Notes.AS3711.10 – 1993 - Freight Containers, Handling & Securing.

Figure 1: ISO Corner Fitting

Figure 2: Typical ISO Container


Page 75

ALLOWABLE ISOCONTAINER STYLES& LENGTHS

Closed roof, ISO containers up to 20 ft. in length are acceptable for offshoretransportation in accordance with these guidelines.

Open top style, ISO containers and any ISO container over 20 ft in length arenot acceptable for offshore transportation.

MODIFICATIONS TOISO CONTAINERS

Any ISO container that has been modified from the original CSC design musthave engineering calculations to support the continued integrity of thecontainer.

Unlike a purpose built offshore container, which is designed to carry full loadon primary structure members, ISO containers rely on the integrity of wallpanels for primary strength.

Such modifications may include:• Addition of extra doorway• Alteration to length• Addition of Pad eyes

PHASING OUT ISOCONTAINERS FROMOFFSHOREINDUSTRY

Contractors currently utilising ISO containers are expected to reduce thenumber in use up to the phase out date of 31 December 2000 and replace themwith purpose built offshore shipping containers.

The APPEA Guidelines for Lifting Equipment provide guidance for the designof purpose built offshore shipping containers.

COMMENTARY ONLIFTING POINTS

• Even in a still water port situation, ISO shipping containers cannot belifted from the ISO Corner fittings by shackles and slings. This applieseven when empty.

• Lifting with spreader frames as used in port situations is not allowed inoffshore lifting operations. Refer to IMO MSC circular 860

ISO containers used in the offshore industry should have pad eyes that arepurpose built. Refer to “Pad eyes” below.

Figure 3: Shackles in ISO corner fittings are not permitted Figure 4: Although not generally required when container isdown-rated, lifting with special lifting beams will be allowedduring phase out. Must be fitted to pad eyes as shown.


Page 76

PAD EYEREQUIREMENTS

The following guidance is provided for the installation of pad eyes:• design by qualified structural engineer;• design verification by independent engineer, who has not been involved in

the design;• carry MGM on 2 diagonally opposite pad eyes;• align to the centre of gravity of the load• shackle pin hole to be +3mm or, not greater than 4% more than the

shackle pin diameter;• width of pad eye to be equal to 75% of the opening of shackle to be fitted.

This may be accomplished by fitting bosses to pad eye;• material trace-ability;• documented welding procedures (To AS1554, AWSD1.1 etc.);• welder qualification trace-ability; and• NDT inspection of all welding associated with pad eyes.

Notes:1. The installation of pad eyes must have engineering trace-ability.2. Refer to section 5.8 for pad eye design.

ALLOWABLE MGM(Maximum Gross Mass)

ISO Containers used in the offshore industry where significant dynamic forcesoccur during lifting from supply vessels must be significantly de-rated.

Subject to inspections in accordance with these guidelines, ISO container useup to the phase out date will be allowed provided that the following is applied:

• The container is de-rated by multiplying original CSC Maximum GrossWeight (or Mass) x 2 and dividing the figure by 5.eg. For a 24 tonne MGM container:

(24 x 2) =9.6 tonnes MGM5

MARKINGREQUIREMENTS

All ISO containers, original or modified, shall have a stencilled markingbeside the CSC data plates indicating “Not Applicable”. The plate shouldremain to indicate the original MGM that is used in the de-rating formulaabove.

Marking plates are required for:• Operational Marking Plate (Tare, Nett & Gross)• Test Plate (date of test and inspections)

Each container should be marked with a unique identification number issuedby the owner. The number should be:1. cross-referenced on all relevant documentation; and2. prominently displayed on a minimum of 2 sides of the container in

contrasting colours with stencilled characters of not less than 75 mm inheight.

Note: Refer to Figures 5 &6 for details of plates.


Page 77

FORKLIFT POCKETS ISO Containers often have more than 1 set of fork-lift pockets. Extremecaution should be used when lifting a laden ISO container from the fork-liftpockets.

If there are two sets of fork-lift pockets, with one set being close to the centreof the container, the inner set are designed for “Empty lifting only”. Thesewords must be stencilled on the base frame adjacent to fork-lift pockets whensuch fork-lift pockets are installed. Stencilling should be 75mm in height.

There are instances where ISO containers have been modified and appear tohave useable fork-lift pockets on more than two sides, this can be a dangeroussituation as fork-lift pockets have been found that have the fork tines bearingon a plywood floor. Check before using and at scheduled inspection.

SLINGS Sling sets may be chain or wire rope. The following is recommended:• four leg sling assemblies are preferred;• maximum included (apex) sling angle of 60 degrees and;• chain used in stingers (or 5th leg) must meet ISO 3076, or ISO 7593

standards.

Note: The use of stingers is discouraged as the redundancy in a 4 leg assemblyis lost.

SHACKLES Shackles must be:• Grade “S” minimum; and• Safety pin type with split pin fitted.

CONTAINERINSPECTIONS

ISO containers must receive a thorough visual inspection both annually andprior to any load testing.• NDT Inspection of pad eyes and floor support structure is to be carried out

annually and prior to load testing.• All thorough visual inspections and NDT must be recorded in a lifting

equipment database.

THOROUGH VISUAL& NDT INSPECTIONS(ANNUALREQUIREMENT)

• door latching mechanisms in good working order (where applicable);• container is free from obvious defects, corrosion, impact damage, cracks,

etc;• under-floor support structure inspection. The floor support structure is

very light in an ISO container and is prone to extensive corrosion andcracking when used in the offshore environment;

• place container on supports to allow full inspection of underside andensure adequate lighting;

• look for corrosion and/or any cracking;• it may be necessary to sand blast corroded steel to allow full inspection;• suspected areas of cracking to have NDT inspections carried out;• steelwork that has suffered significant (greater than 10%) metal loss

through corrosion is to be replaced;• complete structure to be examined for corrosion, cracking, and impact

damage. Particular attention is to be given to inspection of lifting pointsand corner post assemblies;

• visually inspect all welds for defects;• NDT all welds in pad eye area. (NATA accredited NDT facility required);• inspect for signs of mechanical damage;


Page 78

• doors, frames, seals, hinges, locks should be examined and functionallychecked to ensure satisfactory operation without undue force;

• check floor is substantially flat with no signs of damage or otherindications that may indicate overloading. Any internal floor damage mayindicate underside damage- re-check; and

• marking plates should be as per requirements of these guidelines.

VISUAL INSPECTORSKNOWLEDGEREQUIREMENTS

The visual inspector should have, as a minimum, a knowledge and adequatepractical experience of:• the statutory requirements relating to containers;• the various types of containers in service;• the correct methods of slinging and handling the containers;• the loads affecting containers when handled under adverse offshore

conditions, particularly those affecting lifting points and, in the case ofISO containers used offshore, the floor support structure;

• the methods of testing containers as detailed in Maritime Safety.Committee circular 860 or, DNV2.7-1 Offshore Container, CertificationNotes. The provisions of DNV 2.7-1 to be used as a guide only as ISOcontainers do not comply with offshore container standards;

• defects likely to be found in containers and acceptable levels of wear,distortion and deterioration in relation to safety in use;

• welding methods and procedures and qualification of welders;• the various methods of non-destructive testing (NDT) and a good

understanding of how they work and their limitations; and• procedures for measuring container to ensure distortion has not occurred

during service or load testing.

TESTING AN ISOCONTAINER

The target date for the phase out of ISO containers for use in the offshore oiland gas exploration and production industry is 31 December 2000. Hence it isrecommended that any containers currently in use undergo the following loadtest (subject to satisfying inspection requirements) which would see themthrough to phase out date.• Testing of container as per “Testing Requirements” as detailed in IMO

613 & MSC 860. (Drop test will not be required)

TESTINGPROCEDURES

Prior to load testing carry out thorough visual inspection as detailed within thisdocument as there is no value in testing a container that has defects.

4 Point Lifting Test:Internal Load (not to be hung under container): a uniformly distributed load,such that the combined tare of the container and test load is equal to 2.5 timesthe de-rated MGM. The container should be lifted with its lifting set attachedto all four pad eyes.

2 Point Lifting Test:Internal load (not to be hung under container): a uniformly distributed loadsuch that the combined tare of the container and test load is equal to 1.5 timesthe de-rated MGM. It may be necessary to secure the weights to preventslippage during testing. The container should be lifted with slings attached totwo diagonally opposite pad eyes during the test.

Drop Test:Drop testing of ISO containers is not recommended. Drop testing is requiredwhen type testing future new container designs.


Page 79

ALLOWABLEDEFLECTIONDURING &SUBSEQUENT TOLOAD TESTING

Allowable deflection limits are detailed within DNV 2.7-1 Certification notes– Offshore Containers.Refer to sections 3.7.1.2 & 3.7.1.3 of referenced DNV document.

COMMENTS ONDEFLECTIONLIMITS

Where deflection exceeds the maximum allowable limit, the container shouldbe scrapped.

Figure 5: ISO Container Identification Plate

OFFSHORE CONTAINER Name of Manufacturer (if known) Month/year of Manufacture (if known) Manufacturers Serial No. (if known) Maximum Gross Weight kg at deg sling angle Tare Weight kg Payload Container kg

IDENTIFICATIONPLATE MATERIAL &SIZEREQUIREMENTS

• Plates to be of stainless steel or marine grade aluminium, 1 .5 mm thick• Affixed with stainless steel rivets (not aluminium)• 215 mm overall width• 150 mm overall height• Main heading alpha characters to be stamped 10mm in height• Other alpha & numeric characters 5mm in height


Page 80

Figure 6: Offshore Container Inspection Data Plate

INSPECTION DATA-OFFSHORE CONTAINER

Container No.Maximum Gross Mass kgTare Mass kgPayload - Container kg Mid- deck (Not Applicable to ISO containers)

Owner:Tel. No. +

Test Proof Load NDT Visual Inspection

INTERVAL ONCE ONLY 1 YEAR 1 YEARDATE &

“TESTED BY”

Note: The inspection frequencies shown above only apply to ISO containers

INSPECTION DATAPLATE MATERIAL &SIZEREQUIREMENTS

• Plate to be of stainless steel or marine grade aluminium, 1 .5 mm thick• Affixed with stainless steel rivets (not aluminium)• 215 mm overall width• 250 mm overall height• Main heading alpha characters to be stamped 10mm in height• Other alpha & numeric characters 5mm in height


Page 81

OK NO• Container was placed on supports and a full underside

inspection carried out.• Container has no significant corrosion and/or structural fault

affecting integrity• Container floor is in sound condition• NDT of pad eye welds and floor support structure has not

revealed any cracking (or repairs have been effected)• Pad eyes are fitted to the container• Pad eyes have engineering design drawings available• Pad eye design complies with the requirements of this

document.• Container has been de-rated as per requirements of this

document• Container has been load tested as per requirements of this

document• There is no permanent distortion of the container following

load testing• Fork-lift pocket marking is as per the requirements of this

document and the pockets are in a good and safe condition.• Where a 5th leg is used in a chain sling assembly, the chain in

the 5th leg must meet ISO3076 standards for lifting chain.

CHECK LIST

REVIEW PRIOR TOISSUING A TESTCERTIFICATE

• Engineering drawings and structural analysis support anymodifications. All such modifications should haveindependent design verification.

APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

Page 82

APPENDIX I

GUIDELINES FOR THE INSPECTION, TESTING AND MARKING OFOFFSHORE CONTAINERS


Page 83

PREAMBLE

The purpose of these guidelines is to address integrity requirements for existing offshore containers. They donot address the requirements for new container fabrication or the concerns with ISO containers.

These guidelines provide lifting equipment testing facilities guidance on consistent minimum qualityrequirements for testing offshore containers.

APPEA encourages all offshore container owners and their agents to utilise inspection services that have beenaccredited by NATA (or equivalent overseas organisations) to carry out inspections and/or tests in accordancewith this guideline.

If the required documentation needed to obtain a “Certificate of Conformity” as detailed within this guideline isnot available to support the integrity of the container to be inspected and/or tested, the container should not beapproved for offshore use. This may require that engineering drawings be developed and calculations carriedout to verify the design of the container as being fit for intended service. Without all required information, a“Certificate of Conformity” should not be given for the container.


Page 84

DOCUMENT SCOPE Provide guidelines for the inspection, testing and marking of a wide range ofcontainers, baskets, skips etc. used in the offshore oil & gas exploration andproduction industry.

INTRODUCTION The range of shapes, sizes and capacity of containers used in the offshoreindustry makes it difficult to specify all requirements that need to be met foreach individual design. This document provides specifics on some mattersaffecting safety of containers whilst other areas may offer guidance only.

It is the joint responsibility of both the equipment owner and the inspectionand/or testing facility to ensure that all containers used within the offshoreindustry are fit for the intended service.

REFERENCES • International Maritime Organisation MSC Circular 860• DNV 2.7-1 Certification notes for Offshore Containers• APPEA Guidelines for Lifting Equipment IMDG Code• EN12079. Offshore Containers – Design, construction, testing, inspection

and marking.• Petroleum (Submerged Lands) Act 1967 P(SL)A

COMMENTS ONDESIGN OFOFFSHORECONTAINERS

It is recognised that there are many containers in use within the Australianoffshore oil & gas industry that may not be correctly engineered for theservice. The guidelines and procedures provided in this document will assistin ensuring that every container used within the oil and gas exploration andproduction industry has engineering drawings and design calculations tosupport the Maximum Gross Weight indicated on the container.

Without the required documentation the testing facility will have no readymethod of determining if the Maximum Gross Weight (MGM) nominated bythe owner, is in fact a safe working load to be applied.

New containers will be fabricated to stringent guidelines and will be built torecognised standards such as DNV 2.7-1. This will automatically provide thequality that this document seeks to introduce to existing containers.

JUSTIFICATION OFALLOWABLE MGM(Maximum Gross Mass)OF EXISTINGCONTAINERS

Existing containers may need to be down-rated due to the more stringenttesting requirements. It is recommended that container owners carry out areview of existing design MGM ratings to ensure that the container(s) willmeet the testing requirements of 2.5 times MGM. It may be necessary torevise the container MGM and to update drawings as required, indicating newratings.


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PAD EYEREQUIREMENTS

One of the most critical areas in the fabrication of an offshore container is thepad eyes and their attachment to the container. For this reason the followingare recommended for offshore containers.• the installation of pad eyes must be carried out in accordance with good

engineering practices;• no “bolted on” pad eyes are permitted;• pad eyes must be welded to the primary structure of the container;

Note: For existing containers of monocoque construction, a detailedengineering assessment of the pad eye connection is required;

• design carried out by a qualified structural engineer and checked by anindependent engineer;

• for design purposes, the design load is to be carried on two diagonallyopposite pad eyes;

• align to centre of gravity of the loaded container;• shackle pin hole to be +3mm or, not greater than 4% more than the

shackle pin diameter;• width of pad eye to be equal to 75% of the opening of shackle to be fitted.

This may be accomplished by fitting bosses (cheek plates) to pad eye;• material traceability where appropriate material with through thickness

properties is to be specified. (Lamellar Defects);• documented welding procedures (To AS1554, AWSD1.1 etc.);• welder qualification trace-ability; and• NDT inspection of welding by MPI for all fillet welds & a combination of

Ultra Sonic and MPI for full penetration welds.Notes:1. The installation of pad eyes must have engineering trace-ability.2. DNV 2.7-1 provides full details of container design and material

requirements and designers are encouraged to use the DNV document as aguide.

GENERAL DESIGNREQUIREMENTS

• Monocoque construction is not to be used in new offshore containerfabrication and/or designs ie. A “Primary structure” is required.

• For all other design requirements for new offshore containers, refer toDNV2.7-1 “Certification Notes – Offshore Containers”.

.

MARKINGREQUIREMENTS

All Offshore containers shall have the following:• Operational Marking Plate (Tare, Nett & Gross);• Test Plate (date of tests and inspections); and• Each container should be marked with a unique identification number

issued by the owner.Notes:1. The above referenced “unique number” should be cross-referenced on all

relevant documentation, including the “Certificate of Conformity”.2. The number should be prominently displayed on at least 2 sides of the

container in contrasting colours with stencilled characters of not less than75 mm in height.


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COMMENTS ONLOAD TESTING OFOFFSHORECONTAINERS

The load test requirements for offshore containers used in Australian watershave traditionally been taken from Marine Orders Part 32 as published by theAustralian Maritime Safety Authority. However, it is recognised that the tablepublished in Marine Orders Part 32 is not suited to offshore containers andthese guidelines recommend that the requirements of the InternationalMaritime Organisation (IMO) be applied.

IMO have issued a circular (613) that details testing requirements for offshorecontainers. This circular, referenced in Marine Orders part 44, paragraph 11 isto be replaced by circular MSC 860.

LOAD TESTING Prior to load testing, carry out thorough visual inspection as detailed withinthis document. There is no value in testing a container that has defects.

NDTCarry out NDT inspection on pad eye welds prior to and following loadtesting. There will be no point load testing if pad eye welds have existingfaults.

4 Point Lifting Test:Internal Load (not to be hung under container): a uniformly distributed load,such that the combined tare of the container and test load is equal to 2.5 timesthe rated MGM. The container should be lifted with its lifting set attached toall four pad eyes.

2 Point Lifting Test:Internal load (not to be hung under container): a uniformly distributed loadsuch that the combined tare of the container and test load is equal to 1.5 timesthe rated MGM. The container should be lifted with slings attached to twodiagonally opposite pad eyes during the test.

DOCUMENTATIONREQUIREMENTSPRIOR TOLOAD-TESTING

The following requirements apply to any offshore container including baskets,bottle racks, waste skips, completion baskets, workshops, stores and any otherstructure used to transport goods to and from offshore facilities.

The equipment owner (or user) is required to provide the testing facility withadvice regarding design drawings and design calculations as detailed onPage92.This information is required to enable the testing authority to issue aCertificate of Conformity that will confirm that the subject container meets therequirements of these Guidelines.

COMMENTARY ONCLASSIFICATIONSOCIETY APPROVEDOFFSHORECONTAINERS

When a container with classification society certification is presented to aNATA accredited facility for load testing, the facility is not required to verifythe design. The NATA accredited facility can proceed with load testing thecontainer and issue the Load Test Certificate on the strength of the ClassSociety Certification approval and the satisfactory load test.

Advice regarding the engineering drawings and design calculations detailedbelow is not required for a classification society approved container.Maintaining classification society certification will provide acceptance of thecontainer at other locations throughout the world.

NATA ACCREDITED When a container is presented to a NATA accredited facility for inspection


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FACILITYRESPONSIBILITIES

and testing according to these guidelines, the facility management isresponsible for ensuring the safety of offshore containers.

ALLOWABLEDEFLECTIONDURING &SUBSEQUENT TOLOAD TESTING

Allowable deflection limits are detailed within DNV 2.7-1 Certification notes– Offshore Containers.Refer to sections 3.7.1.2 & 3.7.1.3 of referenced DNV document.

COMMENTS ONDEFLECTIONLIMITS

Where deflection exceeds the maximum allowable limit, the container shouldbe either, de-rated, strengthened, or scrapped.

SLINGS Sling sets may be chain or wire rope.

• Material for chain used in 5th leg of a 5 leg assembly must comply withISO 3076.

SHACKLES Shackles must be:• Grade “S” minimum• Safety pin type with split pin fitted• Bow shackles are preferred

CERTIFIED VISUALINSPECTIONREQUIREMENTS

The following should be considered when undertaking certified visualinspection• container is free from obvious defects, significant corrosion, impact

damage, cracks, etc;• under-floor support structure inspection;• place container on supports to allow full inspection of underside and

ensure adequate lighting;• look for extensive corrosion and/or any cracking;• it may be necessary to sand blast corroded steel to allow full inspection;• suspected areas of cracking to have NDT inspections carried out;• steelwork that has suffered metal loss of 10% or greater through

corrosion, is to be replacedNote: This may require UT checks to quantify metal loss;

• complete structure to be examined for corrosion, cracking, and impactdamage. Particular attention is to be given to inspection of lifting points,under-side members and corner post assemblies;

• visually inspect all welds for defects;• inspect for signs of mechanical damage;• doors, frames, seals, hinges, locks should be examined and functionally

checked to ensure satisfactory operation without undue force;• check floor is substantially flat with no signs of damage or other

indications that may indicate overloading. Any internal floor damage mayindicate underside damage- re-check; and

• marking plates in accordance with these guidelines.


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TESTING OFWORKSHOPCONTAINERS,LOGGING UNITSETC.

It is recognised that it is extremely difficult, and in some cases impossible, tofit the required test weights into containers that have work benches, shelvingetc. It is also impossible to fit weights into many logging units and othercontainer style cabins that either are full of specialised equipment used byservice companies or, only have personnel access doors.

In the case of these units it is recommended that more stringent inspectionrequirements apply to these units in lieu of any load testing.

6 YEARLYINSPECTION OFWORKSHOPCONTAINERS,LOGGING UNITSETC. THAT CANNOTBE LOAD TESTED

Where test weights cannot be evenly distributed across the floor area of anycontainer, logging unit etc. the following inspection methods shall be used toensure the on-going integrity of the equipment. These requirements shall beadditional to the annual, thorough visual and NDT inspection requirementspreviously outlined.Note: This method of integrity assurance will be in lieu of load testing and willonly be carried out by facilities accredited with NATA for visual or NDTinspection or Classification Societies (e.g. DNV, Lloyds etc.)

• Place container on racks to allow full underside inspection.Note: Do NOT walk underneath containers suspended by fork-lift orcranes.

• Abrasive blast 25% of under-floor structural welds.• Carry out MPI on all welds cleaned by blasting• Where cracking is found in the underside should be completely abrasive

cleaned and all structural welds inspected by MPI method.• Carry out UT testing of any under-side structural members suspected of

having areas of > 10% metal loss.Note: If any metal loss of > 10% is detected, the remaining structuralmembers shall also be UT checked for metal loss.

• Carry out repairs as required using approved welding procedures,qualified welders and trace-able materials equivalent to the originalstructure members as detailed on the engineering drawings.

• Carry out MPI on all weld repairs and rectify any faults detected.• Re-coat underside of container with a suitable coating for the offshore

environment.• NATA accredited facility shall provide the equipment owner with a “stick

diagram” of the container underside. The diagram shall identify membersand joints inspected.

• The equipment owner should ensure that all QA documents relating torepairs carried out are complied and retained on file for future reference.

Note: Whilst the abrasive blast requirements may, at first seem to be quiteextensive, it will, in most cases be advantageous as many containers willrequire re-application of coatings (particularly underneath) at the end of 6years and this work will fit well with that requirement.


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VISUAL INSPECTORKNOWLEDGEREQUIREMENTS

The inspector must have, as a minimum, a knowledge and adequate practicalexperience of:• The statutory requirements relating to containers.• The provisions of DNV 2.7-1• The various types of containers in service.• The correct methods of slinging and handling the containers.• The loads, stresses and strains affecting containers when handled under

adverse offshore conditions.• The methods of testing containers as detailed in Maritime Safety.

Committee circular 860 or, DNV2.7-1 Offshore Container, CertificationNotes.

• Defects likely to be found in containers and acceptable levels of wear,distortion and deterioration in relation to safety in use.

• Welding methods and procedures and qualification of welders.• The various methods of non-destructive examination (NDE) and a good

understanding of how they work and their limitations• Techniques for measuring container to ensure distortion has not occurred

during service or load testing• Inspection of rigging and lifting equipment as per the category ‘Lifting

Sling(s)’ as detailed in Table F3.


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OK NOREQUIREMENTS TOBE MET PRIOR TOISSUING A“CERTIFICATE ofCONFORMITY”

• Engineering drawings have been prepared or reviewed by a"body" meeting the requirements of section 2.6

• Drawings meet the requirements detailed within thisdocument.

• Container been inspected in accordance with “CertifiedVisual Inspection Requirements” as detailed in Appendix I.

• • • Engineering drawings and structural analysis support any

modifications.• Pad eyes are fitted to the container• Pad eyes have engineering design drawings available• Pad eye design complies with the requirements of this

document.• Container has been de-rated as per requirements of this

document• Container has been load tested as per requirements of this

document• There is no permanent distortion of the container following

load testing (Refer to DNV 2.7-1, section 37.1.2 & 3.7.1.3)• Fork-lift pockets marking is as per the requirements of this

document.• Material for chain used in 5th leg of a 5 leg assembly must

comply with ISO 3076.• NDT of pad eye welds, structural member welds and floor

support structure has not revealed any cracking (or repairshave been effected)

Figure I.1: Suggested Offshore Container Identification Plate

OFFSHORE CONTAINER Name of Manufacturer Month/year of Manufacture Manufacturers Serial No. Maximum Gross Weight kg at deg sling angle Tare Weight kg Payload Container kg Intermediate Deck kg Certificate of Conformity No. Design Temperature Degrees C

IDENTIFICATIONPLATE MATERIAL &SIZEREQUIREMENTS

• Plate to be of stainless steel or marine grade aluminium, approximately 1.5 mm thick

• Affixed with stainless steel rivets (not aluminium)• 215 mm overall width• 150 mm overall height• Main heading alpha characters to be stamped 10mm in heightOther alpha & numeric characters 5mm in height


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FIGURE I.2: SUGGESTED INSPECTION DATA PLATE

215

35 180 (6 x 30)

INSPECTION DATA – OFFSHORE CONTAINER

Container No. Maximum Gross Mass kg @ deg. Apex sling angle

Tare Mass kgPayload Container kg Intermediate deck kg

Owner:Tel. No. +

++

TEST PROOF LOAD NDT VISUALINSPECTION

INTERVAL 6 YEAR TEST 3 YEAR TEST 1 YEAR TESTDATE CERT NO DATE CERT NO DATE CERT NOAT

MANUFACTURE

ATSITE

1.5 mm Stainless Steel Or Marine Grade Aluminium 5 mm LETTERING

Suggested plate incorporates ideas from international documents and localrequirements. All dimensions are shown in mm.

250 mm

70 mm

10 mm LETTERING


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FIGURE I.3 SUGGESTED ALTERNATE IDENTIFICATION PLATE

215 mm

OFFSHORE CONTAINER

Name of Manufacturer Month/year of Manufacture Manufacturer’s serial No. Maximum Gross Mass kg @ deg. Apex sling angle Tare Mass kgPayload Container kg Intermediate deck kg Certificate of Conformity No. Design Temperature oC

The suggested plate complies with international document requirements.

1.5 mm Stainless Steel orMarine Grade Aluminium

150 mm

10 mm LETTERING5 mm LETTERING


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FIGURE I.4 SUGGESTED OPERATIONAL MARKING PLATE

ID No TW-SS01

OWNER WOODSIDE

MANUFACTURER DISON

DATE OFMANUFACTURE

12/96

TYPE OFFSHORE EQUIPMENT CONTAINER

All dimensions shown are in mm.

200

1.5mm Stainless steel orMarine Grade Aluminium

90

3.2


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FIGURE I.5 SUGGESTED IDENTIFICATION NUMBER DETAIL

75mm high lettering, 7.5mm thick

PW - SS01

VARIES


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FIGURE I.6: SUGGESTED ALTERNATE OFFSHORE CONTAINER INSPECTIONDATA PLATE

INSPECTION DATA-OFFSHORE CONTAINER

Container No.Maximum Gross Weight (wt) kg at deg, Apex sling angleTare Weight kgPayload - Container kg Mid- deck kg (Where Applicable)

Owner:Tel. No. +

DATE: DATE: DATE:

TEST TYPE: TEST TYPE: TEST TYPE:

TESTED BY: TESTED BY: TESTED BY:

DATE: DATE:

TEST TYPE: TEST TYPE:

TESTED BY:

DATE:

TEST TYPE:

TESTED BY: TESTED BY:

DATE: DATE: DATE:



DATE:

TEST TYPE:

DATE:

TEST TYPE:

TESTED BY:

DATE:

TEST TYPE:

TESTED BY: TESTED BY:

DATE: DATE: DATE:



INSPECTION DATAPLATE MATERIAL &SIZEREQUIREMENTS

• Plate to be of stainless steel or marine grade aluminium, approximately 1.5 mm thick

• Affixed with stainless steel rivets (not aluminium)• 215 mm overall width• 250 mm overall height (approx.)• Main heading alpha characters to be stamped 10mm in height• Other alpha & numeric characters 5mm in height


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ONGOINGINSPECTION & TESTREPORTS

Ongoing, in-service reports will include the following as appropriate:• Visual Inspection Reports;• Load Test Reports; and• Non Destructive Testing Reports.

appea guidelines for lifting equipment appendicies

Documents

hot rolled

corner post

dynamic amplification

conductor

numeric characters

structural

adverse offshore

uniformly