lei mod2 procedures.pdf

8/10/2019 LEI Mod2 procedures.pdf

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LIFTING EQUIPMENT INSPECTOR

CERTIFICATION PROCEDURES

MODULE 2 : WINCHES & POWERED HOISTS

NSL 2004NSL LTD l T : +44 (0) 1224 208988 l E : [email protected] l WWW.NSL-UK.COM


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North Sea Lifting Ltd (NSL) & its subsidiary NSL America has, in recent years, invested well in

excess of Two and a half Million Pounds ($5,000,000) in the development of training productsand materials which in turn have been translated into the relevant languages required by the Oiland Gas Industry worldwide.

The creation of first-rate training products and materials involves extensive research, liaisingwith government bodies, attending fact-finding meetings both nationally and internationally,liaising with equipment manufacturers, gaining approvals where necessary, the use oftechnical authors, artists, cartoonists, employing full-time engineers and graphic designers,etc. In addition, a vast amount of time, effort and expense is incurred in keeping the trainingmaterials up-to-date, reflecting the latest legislation, regulations, guidelines, industry practiceand equipment.

The end products are of the highest quality, totally accurate and specific to the Oil and G a sIndustry which we serve.

We do, on request, customise our products to suit various clients needs butownership and copyright always remains with NSL i.e. on these occasions,clients are only charged for the customising. Occasionally, we allow clientsto adapt our products and materials for their own internal use but this mustbe authorised, in writing, by NSL. To prevent our products and materialsbeing used out of context and possibly relaying the wrong message, anyamendments must also be approved by NSL.

The instructors employed by NSL to deliver the training are specially

selected for their knowledge on the subject matter and theirability, not only deliver the training, but be able to answer anyquestions arising during the training courses. For this reason,NSLs instructors are trained internally and are also qualified skillsassessors.

We carry out practical training at our facilities in both Aberdeen UK &Broussard LA, USA. However, where we train on the clients premises,be it onshore, offshore or overseas, the facilities are vetted by NSL toensure that the training can be delivered effectively.

Our instructors are constantly updated with the latest information and

are issued with the most up-to-date media presentation equipment tofacilitate professional delivery of the training materials.

NSLs Safety and Training documents are not for resale nor are they to be used forpersonal / commercial gain by 3rd party training companys training courses. Thisincludes any reference to, or the use of NSLs Handbooks, Posters, Video/DVD,Viewgraphs, etc.

To maintain the overall quality of our training products and materials, they mustremain totally under our control and consequently, we vigorously enforce theircopyright. NSL will actively pursue through the courts, any company or individual foundin breach of this copyright.

Intellectual Ownership & Copyright of

NSL Training Products and Materials

w w w . n s l - u k . c omNSL AMERICA INC

2500 CITYWEST BLVD

SUITE 300

HOUSTON TX 77042

tel +1 (713) 405 1877

NSL LTD :

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tel +44 (0) 1224 208988


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NSL LTD l T : +44 (0) 1224 208988 l E : [email protected] l WWW.NSL-UK.COM3

LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES AND POWERED HOISTS lPROCEDURES

NSL 2004

INDEX

Introduction

2.1 Manual Winches2.2 Utility Winches

2.3 Man-riding Winches

2.4 Powered Hoists

2.5 Lifeboat / Liferaft Davit Winches

2.6 Report Examples

2.7 Blank Reports

2.8 Appendix


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES AND POWERED HOISTS lPROCEDURES

NSL 2004

INTRODUCTION

The testing and inspection of lifting equipment shall only be carried out by a competent person. It is essential

that a competent person engaged in this work must be aware of current regulations, standards, best industry

practices and relevant company procedures.

Competence can only be achieved and recorded through training, experience and assessment in the workplace.

The inspector must act with the necessary degree of impartiality, be free from any external pressures or

influences, make decisions regarding the extent of testing requirements and issue certificates stating that the

lifting equipment is suitable, and if used correctly, safe to use during a specific period of time.

For the most part, it is unlikely that any one person or even company, will be able to provide the knowledge

and expertise required to test and inspect, the vast range of lifting equipment used in todays industries. The

inspector will need to utilise information from standards, regulations and manufacturers guidelines to ensure an

informed decision is made.

The inspection of lifting equipment by the competent person, will determine if it is fit for purpose. The criteria

used to determine this, must be applied to new and used equipment alike, the inspector must never assume new

equipment is free of patent defects.

The purpose of an overload or proof load test is to prove the design, materials used, and the workmanship during

assembly of the equipment. The sole use of calculations to prove the integrity of equipment may not accomplish

this. It should be borne in mind that lifting equipment undergoing an overload test, might not withstand the

applied loadings.

All personnel not essential to the test must be kept clear of the area, with the inspector also positioned, where heis unlikely to be injured if equipment fails.


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS l MANUAL WINCHES

NSL 2004

2.1 : MANUAL WINCHES

EXAMINATION & TESTING PROCEDURE

Bolts Drum

Worm Gear

Handle

Frame


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NSL 2004


EXAMINATION PROCEDURE

Sight the original test certicate Ensure Safe Working Load and Identication numbers are legible and correspond with the test certicate

Examine winding handle, check for distortion and correct connection

Examine winch drum and check for distortion, wear or cracking (if accessible, examine rope anchorage

and ensure it is secure)

Where applicable, examine ratchet or worm gear and check for wear / broken teeth

Examine pawl and pawl spring / worm and check for wear / distortion

Ensure the pawl functions correctly and ensure the worm meshes correctly with the worm wheel

Examine winch frame and check for distortion, wear and cracking

Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy yourself that

the support steel work is capable of sustaining the winch under load

Should wire rope be tted, it must be examined

ADDITIONAL (SPUR GEARED WINCHES)

Visually examine the brake assembly and operate the winch handle to ensure it functions correctly

Examine all spur gears checking for alignment, wear on gear teeth, truing of gear shafts and smooth

running of bearings (where fitted)

Function check the winch through one complete revolution of the drum

If all satisfactory, record relevant details and issue report.

Record winch wire rope details (if fitted), including certificate number on winch examination report.

This procedure is to be followed as a guideline to NSLs minimum requirements.


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NSL 2004


PROOF LOAD TESTING

Proof load to be applied: 50% above SWL.Load to be applied in the same direction as the forces it would be subjected to under normal working conditions.

Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the

winch through one complete revolution of the drum.

Although the winch should be fully certified prior to reaching the worksite, once it has been sited and secured,

the anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage

via the winch.

ACCEPTABLE METHODS OF TESTING

Carry out performance test at SWL before commencement of proof load

If satisfactory, use test weights or a test clock with suitable anchor point, apply a proof load of SWL + 50%

Sustain load and examine anchorage checking for deection / distortion

Release load and re-examine to ensure proof loading has not exposed any defects

Any welding should be N.D.T.D after load test

Re-examine after proof load testing to ensure this has not exposed any defects.

If all satisfactory, hard stamp with ID number, SWL and issue certificate.

This procedure is to be followed as a guideline to NSLs minimum requirements for a proof load test.

Live test weights should be weight-checked annually and be accurate to better than 1% of the nominal weight.

The accuracy of testing machines shall be in accordance with BS 1610 and BS EN 10002.


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NSL 2004

MANUAL WINCHES

JOB NO : CONDITIONS

MODEL : A = SATISFACTORY

SERIAL NO. : B = WORN BUT SERVICEABLE

SWL : C = CONDEMNEDPLANT NO : D = REPLACED

E = N.D.T.D

DESCRIPTION CONDITION COMMENTS

A B C D E

1 Handle

2 Drum

3 Ratchet wheel / worm wheel

4 Ratchet pawl / worm

5 Ratchet pawl spring

6 Winch frame

7 Friction discs

8 Spur Gears

9 Spur gear shafts

10 Bearing

11 Hold down bolts / clamps / welding

12 Support steel work

Tick relevant boxes / delete where applicable

SIGNED : ...................................................................................................................................................... DATE :.............................................

SATISFACTORY

REQUIRES REPAIR


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS l UTILITY WINCHES

NSL 2004

2.2 : UTILITY WINCHES


Controls

Rope guard

BaseBrake


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NSL 2004



Sight the original test certicate Ensure Safe Working Load and Identication numbers are legible and correspond with the test certicate

Conrm controls operate in the direction that arrows are marked

Examine rope guard and ensure there is no damage / distortion which may obstruct and / or abrade the

winch rope

Examine winch drum and check for wear, distortion or cracks

Examine brake bands / brake drums and check for wear

Ensure the brake bands / brake drums are clean and free from contamination

Where tted, examine the automatic brake checking springs, link arms and pins

Examine automatic brake cylinder and check for leaks

Examine chromed piston rod and check for corrosion

With power disconnected, check that all operating levers return to neutral when released

Ensure directional arrows / markings are in place and clearly visible

Check oil level

Examine winch base and check for cracked welds, cracks around bolt holes, distortion or impact damage

Anchorage: Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy

yourself that the support steel work is capable of sustaining the winch under load

Check that the power supply is adequate for that particular model of winch

Connect power supply and function test the winch

Should wire rope be tted, it must be examined





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NSL 2004


PROOF LOAD TESTING

Load to be applied in the same direction as the forces it would be subjected to under normal working conditions.Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the

winch through at least one complete revolution of the drum

The winch may well be fully certified prior to reaching the worksite, once it has been sited and secured, the

anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage via

the winch.

Comply with company procedures to determine the type of load test required.


Bolt down winch to suitable test bed and t a wire of such length that no fewer than ve turns remain on

drum during any part of the test

TEST 1


If satisfacory, raise a proof load of the SWL + 25% to the required height to allow one full rotation of drum

under load This test can be simulated on a hydraulic test bed where a variable pressure relief valve has been tted

Apply manual brake to sustain load and check winch drum for creep

NOTE

When testing winches with an automatic brake on a hydraulic test bed, there will be a slight drop in load

due to the time it takes for the brake to activate

TEST 2

Disconnect power source to winch and apply brake

Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL

+ 50% to check the braking efciency. (The brakes may require adjusting to achieve this)

Sustain the load for a short time and check winch drum for creep


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NSL 2004

TEST 3

Re-connect power supply to winch and pull up to SWL

Ensure the brake has not been over tightened to such an extent as to affect the winchs performance

ENSURE ALL LEVERS / CONTROLS RETURN TO NEUTRAL ON RELEASE

The above tests are to be witnessed.

Re-examine winch to ensure that proof load testing has not exposed any defects.






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NSL 2004

UTILITY WINCHES

JOB NO : CONDITIONS




E = N.D.T.D


A B C D E

1 Rope Guard

2 Winch drum

3 Brake bands & drums

4 Automatic brake springs

5 Automatic brake cylinder

6 Automatic brake link arms & pins

7 Operating levers (function)

8 Directional / SWL markings

9 Oil level

10 Winch base

11 Winch anchorage

12 Power supply

13 Function test


SIGNED : ...................................................................................................................................................... DATE :.............................................

SATISFACTORY

REQUIRES REPAIR


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS lMAN-RIDING WINCHES

NSL 2004

2.3 : MAN-RIDING WINCHES


Automatic brake

Manual brake

Controls Slack wire device


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NSL 2004



ADDITIONAL INSTRUCTIONS Winches converted for the purpose of raising / lowering personnel

Winches of this type will be tted with a dual braking system usually consisting of one manual brake and

one automatic brake

Examine the winch and ensure the winch does not have a disengaging clutch or pawl and ratchet

mechanism

Check that the winch has been adequately de-rated to reect the appropriate factor of safety

(Note: Man-riding winch rope to have F.O.S. of 10:1)

NOTE

It is recommended that this type of winch is not used for general duties.

STANDARD MAN-RIDING WINCHES

Where limit switches are tted to prevent over travel in both hoisting and lowering, function test to ensure

their operation

Function test slack wire device and emergency lowering system if tted

Ensure the winch is clearly marked stating it can be used for raising and lowering personnel





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NSL 2004


PROOF LOAD TESTING

Load to be applied in the same direction as the forces it would be subjected to under normal working conditions.Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the

winch through one complete revolution of the drum

Where limit switches are fitted to prevent over-travel in both hoisting and lowering, function test to ensure their

operation.

Ensure that the winch has been adequately de-rated to reflect a factor of safety of no less than 8:1.

Ensure the winch is clearly marked that it is to be used solely for raising and lowering personnel.

The winch may well be fully certified prior to reaching the worksite, once it has been sited and secured, the

anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage via

the winch.



Bolt down winch to suitable test bed and fit a wire of such length that no fewer than five turns remain on drum

during any part of the test

TEST 1

Disconnect automatic brake


If satisfactory, raise a proof load of SWL + 25% to the required height to allow one full rotation of drum

under load. (This test can be simulated on a hydraulic test bed where a variable pressure relief valve has

been fitted)

Apply manual brake to sustain load and check winch drum for creep

Re-connect automatic brake and with the manual brake in the off position, repeat test 1 so full load is

taken on automatic brake

TEST 2

Disconnect power source to winch and apply brake

Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL +

50% to check the braking efficiency. (The brakes may require adjusting to achieve this)

Sustain the load for a short time and check winch drum for creep


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NSL 2004

NOTE

Should any of the brake drums be exposed to the elements, the aforementioned tests should be carried out with

the drums wet, to simulate operating conditions. Make any brake adjustments as required.

TEST 3

If tests 1 & 2 are acceptable raise a load of SWL + 10%, stop load during test to ensure the brake sustains the

load without any drum creep.

TEST 4

Re-connect power supply to winch and pull up to SWL (To ensure the brake has not been over tightened to

such an extent as to affect the winchs performance)

Ensure the manual brake has not been over tightened to such an extent as to affect the winchsperformance

Function test slack wire device and emergency lowering system if fitted

Ensure all levers / controls return to neutral on release

The above tests are to be witnessed.Re-examine winch to ensure that proof load testing has not exposed any defects.






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NSL 2004

MAN-RIDING WINCHES

JOB NO : CONDITIONS




E = N.D.T.D


A B C D E

1 Rope Guard

2 Winch Drum

3 Brake bands & drums

4 Automatic brake springs

5 Automatic brake cylinder

6 Automatic brake link arms & pins

7 Operating levers (function)

8 Directional / SWL markings

9 Oil level

10 Winch base

11 Winch anchorage

12 Power supply

13 Function test

14 Upper limit

15 Lower l imit

16 Slack wire device

17 Overload protection

18 Emergency lowering system


SIGNED : ...................................................................................................................................................... DATE :.............................................

SATISFACTORY

REQUIRES REPAIR


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS l POWERED HOISTS

NSL 2004

2.4 : POWERED HOISTS



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NSL 2004



POWERED CHAIN OR WIRE ROPE HOISTS

HOIST MOTOR / FRAME / BODY

The frame should be free from damage or defects

All bolts and screws should be tight

Examine for signs of overheating

Bearings should be in good condition and adequately lubricated

PENDANT CONTROL

Examine case for damage

Examine emergency stop and control buttons for correct operation

Examine catenary wire (if tted)

Examine suspension wire

Push buttons should be free and making good contact

Directional decals

LIMIT SWITCH

Check for wear and damage

Ensure correct adjustment and good contact surfaces

All moving parts are to be lubricated

BRAKES

Function test to ensure correct operation

Brake linings to be checked for wear (if accessible)


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NSL 2004

GEARS / SHAFTS

If gears sound unduly noisy, send ashore for checking and examination

LOAD SHEAVE / SPROCKET

Check for wear and correct seating of load chain in sprockets

LOAD CHAIN

Check for wear, stretch or distortion

Check for faulty welds or cracks in the links

Examine dead end connection

Examine chain bucket for security of tting

ROPE DRUM (if fitted)

Check for cracks or damage, particularly to the grooves

LOAD ROPE

Check for wear or damage

Ensure adequate lubrication

Check rope dead end connection for damage

Ropes should be considered unusable when broken wires exceed 10% over a length of eight times the diameter

of the rope or any sign of necking indicating internal damage or excessive wear.

TROLLEY UNIT (if fitted)

Examine for wear, distortion

Smooth operation of wheels, bearings and drive

Security of ttings


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NSL 2004



BOTTOM BLOCK Examine for wear in the sheave, grooves or sprocket

Examine for wear in the crosshead

Check that wear in saddle of hook does not exceed 10%

Ensure top nut is locked

Safety catch functions correctly

TOP HOOK

Examine yoke / swivel

Distortion or wear in the hook

Safety catch functions correctly

SAFE WORKING LOAD / IDENTIFICATION NUMBER

Should be clearly marked

SUPPLY / CONNECTIONS

Check for damage or wear

Check the smooth running of supply cable trolleys (festoons)

Security of connections


Record wire rope and bottom hook block details (if fitted), including certificate number on examination report.



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NSL 2004


PROOF LOAD TESTING

ELECTRICALLY / PNEUMATIC POWERED CHAIN OR WIRE ROPE HOISTS

Load to be applied in the same direction as the forces it would be subjected to

under normal working conditions.

Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the hoist

through one complete revolution of the gears / drum.

Where limit switches are fitted to prevent over-travel in both hoisting and lowering, function test to ensure their

operation.



If satisfactory, subject the hoist to a proof load of SWL + 25%

In such a fashion that all the gearing makes one full revolution under load

Check for efcient operation of the brakes

ENSURE ALL LEVERS / CONTROLS RETURN TO NEUTRAL ON RELEASE

Re-examine hoist to ensure that proof load testing has not exposed any defects.






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NSL 2004

PNEUMATIC CHAIN HOISTS

EQUIPMENT TYPE : CONDITIONS

PLANT NO. : A = SATISFACTORY


SWL : C = CONDEMNED

DESCRIPTION CONDITION

A B C

1 Top hook

2 Safety catch

3 Bottom hook

4 Safety catch

5 Top hook swivel / yoke

6 Load sprocket or sheaves

7 Body casing

8 Load chain / wire rope

9 Function test

10 Hook load pins

11 Hook swivels / yokes

12 Direction controls (pendant / pull cord)

13 Button / switch function

14 Direction decals

15 Emergency stop button

16 Suspension / catenary wire

17 Trolley unit (if fitted)

18 Gears and shafts (if visibly accessable)

19 Limit switches

20 Power connection / supply

21 Security of fittings

22 Lubrication

23 Dead end connection

24 Chain bucket

25 Drum


SIGNED (CANDIDATE) : ............................................................... DATE : ...............................ENGINEER: ............................................................

SATISFACTORY

REQUIRES REPAIR


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NSL 2004

2.5 : LIFEBOAT / LIFERAFT DAVIT WINCHES



Examine winch drum and check for wear, distortion or cracks

Ensure drum ange height projects at least 1.5 times the rope diameter above upper most layer

Examine brake release device for distortion and is located in the on position

Crank handle is located close to the winch, is undamaged and locates correctly onto winch

Check power supply cables for damage, wear or perished insulation

Examine push button controls and casing (if tted) for damage and are (with power shut off) free to move

Winch body is undamaged and securely attached

Winch is sufciently lubricated

Examine winch wire rope

Comply with company procedures regarding function testing.




Hoists


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NSL 2004

2.5 : LIFEBOAT / LIFERAFT DAVIT WINCHES

PROOF LOAD TESTING

All such tests must be planned in advance with all certification and records updated before the test. Theauthorised / competent person must carry out these checks.

It is important that all personnel involved in the test agree the actual procedure in advance of any testing taking

place.

Load to be applied in the same direction as the forces it would be subjected to under normal working conditions.

Before proof load testing, carry out a visual inspection to ensure no defects are present.


Refer to company procedures for NDT inspection requirements on base welds before and after load testing.


Load boat with weights that together with the weight of the boat, represents 1.1 times the full load of

personnel and the boat equipment

The method of loading weights must be such that no one enters the boat once 90% of the total load is reached.

If this cannot be achieved then the weight of the boat must not be taken by the falls during loading, but by a

crane (the capacity of the crane shall be at least 2.2 times the loaded weight of the boat) and a spreader bar.

If a crane and spreader bar are used, this should then be lowered so the weight of the boat is taken on the falls.

Under no circumstances should anyone enter the boat at this time.

The area under and around the boat must now be checked to ensure it is clear of personnel and obstructions

The boat is now lowered by lifting the brake fully to enable the boat to reach maximum speed on the

centrifugal brake

The mechanical brake is then applied suddenly, before the boat enters the water, and the test paused to

ensure that the position of the boat is held

The winch shall be capable of lowering the lifeboat under gravity conditions at speeds not less than 0.30

m/s nor greater than 0.60 m/s

The results of the test should be recorded on a test certificate produced by the competent person and signed by

the witnessing authorised person.


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NSL 2004

UK Regulation and SOLAS requires that at least once every five years rescue boats and lifeboats shall be turned

out and lowered when loaded with weights to simulate 1.1 times the total mass of the lifeboat or rescue boat

when loaded with its full complement of persons and equipment.

If liferaft davits and winches are to be tested, weights are to be suspended directly from the davit rather than

using a liferaft.

TESTS CARRIED OUT AT MANUFACTURERS WORKS FOR THE ACCEPTANCE OF THE WINCH BY THE

PURCHASER

TEST WITHOUT LOAD

The winch shall be run at light line speed for a period of 10 min, 5 min in each direction

HOISTING TEST

The winch shall hoist a load related to the weight of the lifeboat and its required equipment

At the speed of 0.05 m/s for lifeboats and with a speed not less than 0.3 m/s for emergency boats

To a height of not less than 15 m

BRAKE TEST

The brake shall be applied and a static test load equivalent to the working load times 1.5 shall be appliedto a rope secured to and wound on the drum fully and evenly reeled to the specified two or three layers

The drum shall not rotate and it shall be demonstrated that it is possible to release the brake

It shall also be demonstrated that the winch can slowly lower the static test load, under control of the

brake, for at least one complete revolution of the drum and then hold the load

LOWERING TEST

A load equivalent to the working load shall be applied to a rope secured to and wound on the drum fully

and evenly reeled to the specified two or three layers

The drum shall be declutched from the prime mover and the drum brake released

The governing brake shall govern the speed of descent to comply with not less than 0.30 m/s nor greater

than 0.60 m/s

The total lowering height for this test shall not be less than 15 m


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NSL 2004

The results of the test should be recorded on a test certificate produced by the competent person and signed by

the witnessing authorised person.

Re-examine winch to ensure that proof load testing has not exposed any defects.





LIFEBOAT / LIFERAFT DAVIT WINCHES

EQUIPMENT TYPE : CONDITIONS

PLANT NO. : A = SATISFACTORY


SWL : C = CONDEMNED

DESCRIPTION CONDITION

A B C

1 Drum

2 Drum flange

3 Brake release device

4 Crank handle

5 Power supply cables

6 Power supply connections

7 Push button controls

8 Winch body casing

9 Lubrication

10 Function test as per company procedure

11 Winch wire

12 Winch base

13 ID / SWL markings

14 Oil levels


SIGNED (CANDIDATE) : ............................................................... DATE : ...............................ENGINEER: ............................................................

SATISFACTORY

REQUIRES REPAIR


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS lREPORT EXAMPLES

NSL 2004NSL LTD l T : +44(0)44 1224 208988 l E : [email protected] l WWW.NSL-UK.COM29

NSL 2004

2.6 : REPORT EXAMPLES

VISUAL INSPECTION REPORT

PROOF LOAD TEST CERTIFICATE

NDT CERTIFICATES

DEFECT REPORT


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS lBLANK REPORTS

NSL 2004


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS l LIFEBOAT / LIFERAFT DAVIT WINCHES

NSL 2004

REPORT OF THOROUGH EXAMINATION AND / OR TEST OF LIFTING APPLIANCE OR ACCESSORY

STATUTORY INSTRUMENTS 1998 No. 2307

The Lifting Operations and Lifting Equipment Regulations 1998


The Supply of Machinery (Safety) Regulations 1992


The Provision and Use of Work Regulations 1998

CERTIFICATION NO : ............................................................................................. TESTER / EXAMINER: ...........................................................

QUALIFICATION : ................................................................................................... DATE OF TEST / EXAMINATION : ..........................................

IDENTIFICATION

NO.

QTY DESCRIPTION OF EQUIPMENT SWL PROOF LOAD

APPLIED

DATE OF NEXT

EXAMINATION

ABC 0001 1 Air Powered man-riding lever controlled 150kg N/A 18.02.08

winch manufacturer: Ingersoll rand

Model: LS150RLP.L.B.ESerial No:0100010

Winch fitted with main air emergency stop

device

Upper & lower limit switches

Emergency lowering system

Overload protection device

Slack wire device

Protective cover to be fitted when not in use

winch wire inspection report: 12345/001

ORIGINAL CERTIFICATE NO. ORIGINAL CERTIFICATE DATE NAME OF CERTIFYING BODY DATE OF LAST EXAMINATION

12345/001 21.08.06 NSL 20.02.07

PARTICULARS OF DEFECTS FOUND WHICH ARE, OR COULD,

BECOME A DANGER TO PERSONS OR NONE

PARTICULARS OF ANY REPAIR, ALTERATION TO REMEDY DEFECT

OR NONE

NONE NONE

NAME AND ADDRESS OF EQUIPMENT OWNER: ADDRESS OF PREMISES WHERE TEST / EXAMINATION WAS HELD:

Up & Down Engineering Ltd Platform Alpha

Big Road, Aberdown, AD12 1AD

We hereby certify that on ........................... (date) the item/s described in this report was/were thoroughly examined, so far

as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe

to operate.

SIGNATURE OF PERSON : ................................................................................ NAME OF PERSON...................................................................CONDUCTING EXAMINATION CONDUCTING TEST / EXAMINATION (delete as nessassary)

DATE .................................................................................................................DOC REF NO : NSL C 001

54321/001

19.08.07

J. Bloggs

EAL Module 2

J. Bloggs

19.08.07

19.08.07


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NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION

ABC 0001 1 Air Powered man-riding lever controlled 150 kg 225kg Static test 19.08.07

winch manufacturer: Ingersoll rand

Model: LS150RLP.L.B.E 188kg function test

Serial No:0100010

Winch fitted with main air emergency stop device 165kg dynamic test

Upper & lower limit switches

Emergency lowering system Satisfactory

Overload protection device emergency

Slack wire device lowering test @ 150kg

Note: full operating instructions & procedures to be nitrogen source

posted at winch location, including emergency

lowering procedures

Air intake shut-off valve to be clearly marked

& not obstructed

Proctective cover to be fitted when not in use

Winch wire inspection report : 12345/ 002


N/A N/A N/A 20.08.06




OR NONE

NONE NONE


Up & Down Engineering Ltd Platform Alpha

Big Road, Aberdown. AD12 1AD



to operate.

SIGNATURE OF PERSON : ................................................................................ NAME OF PERSON...................................................................

CONDUCTING EXAMINATION CONDUCTING TEST / EXAMINATION (delete as nessassary)


12345/001

20.02.07

J. Bloggs

EAL Module 2

J. Bloggs

21.02.07

21.02.07


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NSL 2004

MAGNETIC PARTICLE INSPECTION REPORT

CLIENT LOCATION INSPECTION DATE

Up & Down Engineering Ltd Platform Alpha 20.02.07

Big Road, Aberdown NSL JOB NO REPORT NO

AD12 1AD G12345 G12345 /001

CLIENT ORDER NO SHEET

ABCD00001 one of one

COMPONENT / DESCRIPTION / DRAWING NO.

Winch base welds

Loacated at drill floor winch ABC00001

MATERIAL SURFACE CONDITION

Carbon Steel Acceptable

PROCEDURE / WORK / INSTRUCTION / TECHNIQUE ACCEPTANCE STANDARD

Carried out in accordance with NSL Inspection Procedures BS 6072EQUIPMENT POWER / CURRENT MATERIAL THICKNESS

Permanent magnet 18kg minimum pull 20mm

METHOD MEDIUM BACKGROUND

Black & white contrast Ely supramor 4 black Ely white contrast paint 712

RESULT

100% magnetic particle inspection was carried out on winch No ABC00001 base welds pre & post load test

No defect was found at time of inspection and is acceptable to specifications

This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of theinspection body and the client.

NSL INSPECTOR ISSUING AUTHORITY CLIENT

Sign Sign Sign

Name Joe Bloggs Name Name

Quals Module 2 Quals Quals


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NSL 2004

CLIENT : ................................................................................................................................................................................................................

INSPECTION ENGINEER: .......................................................................................................................................................................................

INSTALLATION : ....................................................................................................................................................................................................

DATE : ..................................................................................................................................................................................................................

CD09

TO BE COMPLETED BY INSPECTING ENGINEER INSTALLATION STAFF USE ONLY

PLANT & CERTNO.

DEFECTIVE ITEM

(DESCRIPTION ,

LOCATION, SERIAL

NO.)

PARTICULARS

OF DEFECT

(INCLUDING RETEST

IF APPLICABLE

REPAIR BY TO BE REPORTEDTO ENFORCINGAUTHORITY

JOB CARD NO. REMARKS(MANIFEST NO.ETC.)

123/001 Safety pin Deformed body Remove from N/A 00010/001 Removed from

Bow shackle service service 18.02.08

SWL 3.25 Tons

welders swing

arm jib

06712 Chainblock, SWL Safety catch Fit safety catch N/A 66616/002 New safety

1 tonne, missing from before use catch fitted

HOL 3m, bottom hook 18.02.05

welders Swing

arm jib

Up & Down Engineering Ltd

J.Bloggs

Workshop, Big Road, Abertown

17.02.05


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NSL 2004

2.7 : BLANK REPORTS

VISUAL INSPECTION REPORT

PROOF LOAD TEST CERTIFICATE

NDT CERTIFICATES

DEFECT REPORT


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NSL 2004


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NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION





OR NONE




to operate.




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NSL 2004


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NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION





OR NONE




to operate.




40/56



NSL 2004


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NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION





OR NONE




to operate.




42/56



NSL 2004


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NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION





OR NONE




to operate.




44/56



NSL 2004


45/56



NSL 2004










IDENTIFICATION

NO.


APPLIED

DATE OF NEXT

EXAMINATION





OR NONE




to operate.




46/56



NSL 2004


47/56



NSL 2004

MAGNETIC PARTICLE INSPECTION REPORT

CLIENT LOCATION INSPECTION DATE

NSL JOB NO REPORT NO

CLIENT ORDER NO SHEET

of

COMPONENT / DESCRIPTION / DRAWING NO.

MATERIAL SURFACE CONDITION

PROCEDURE / WORK / INSTRUCTION / TECHNIQUE ACCEPTANCE STANDARD

EQUIPMENT POWER / CURRENT MATERIAL THICKNESS

METHOD MEDIUM BACKGROUND

RESULT

This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of theinspection body and the client.

NSL INSPECTOR ISSUING AUTHORITY CLIENT

Sign Sign Sign

Name Name Name

Quals Quals Quals


48/56



NSL 2004


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NSL 2004

CLIENT : ................................................................................................................................................................................................................

INSPECTION ENGINEER: .......................................................................................................................................................................................

INSTALLATION : ....................................................................................................................................................................................................

DATE : ..................................................................................................................................................................................................................

CD09

TO BE COMPLETED BY INSPECTING ENGINEER INSTALLATION STAFF USE ONLY

PLANT & CERTNO.

DEFECTIVE ITEM

(DESCRIPTION ,

LOCATION, SERIAL

NO.)

PARTICULARS

OF DEFECT

(INCLUDING RETEST

IF APPLICABLE

REPAIR BY TO BE REPORTEDTO ENFORCINGAUTHORITY

JOB CARD NO. REMARKS(MANIFEST NO.ETC.)


50/56



NSL 2004


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LIFTING EQUIPMENT INSPECTOR l MODULE 2 : WINCHES & POWERED HOISTS lAPPENDICES


NSL 2004

2.8 :APPENDIX

WINCH DRUM CAPACITY


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NSL 2004


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NSL 2004

2.8 : APPENDICES

WINCH DRUM CAPACITY

L = Length of rope (metres)A = Desired depth of winding (mm). The depth of the

flange is normally reduced by 40 to 50 mm to allow

ground clearance for the rope.

B = Diameter of barrel (mm)

C = Width between flanges (mm)

K = A constant developed according to the diameter of

the rope.

Table shows the value of the constants from 2 to 67 mm rope diameter.

ROPE DIAMETER (MM) K ROPE DIAMETER (MM) K

2 1274 24 183300

3 2865 26 215200

4 5093 28 249600

5 7958 32 326000

6 11470 35 389900

7 15600 38 459700

8 20370 40 509300

9 25780 44 616300

11 38520 48 733300

13 53800 51 828100

14 62400 52 860800

16 81490 54 928300

18 103100 56 998200

19 114900 60 1147000

20 127400 64 1304000

22 154100 67 1429000

A

B

C


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NSL 2004


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NSL 2004

2.8 : APPENDIX

WINCH DRUM CAPACITY

FORMULA L = (A+B) x A x C

K

EXAMPLE

Drum dimensions : A= 400mm B= 600mm C= 700mm K: Rope diameter 16mm = 81490

Length of rope on drum = (400 + 600) x 400 x 700

81490

= 280,000,000 81490

= 3437m


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lei mod2 procedures.pdf

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