oil industry safety directorate

Page No I

OIL INDUSTRY SAFETY DIRECTORATE

के्रन प्रचालन, अनुरक्षण और परीक्षण के ललए अनुशंलित प्रथाएँ

ओ आई एि डी– आर पी- 205

Recommended Practices

for

Crane Operation, Maintenance & Testing (For Upstream)

OISD- RP- 205

Prepared by

COMMITTEE ON

CRANE OPERATION, MAINTENANCE & TESTING

(FOR UPSTREAM)

Inception October 2002

1st Revision 2019

OIL INDUSTRY SAFETY DIRECTORATE

Government of India Ministry of

Petroleum & Natural Gas

8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)

Website: https://www.oisd.gov.in Tele: 0120-2593833, Fax: 0120-2593802

FOR RESTRICTED CIRULATION ONLY

http://www.oisd.gov.in/

Page No II PREAMBLE

Indian petroleum industry is the energy lifeline of the nation and its continuous performance is

essential for sovereignty and prosperity of the country. As the industry essentially deals with

inherently inflammable substances throughout its value chain – upstream, midstream and

downstream – Safety is of paramount importance to this industry as only safe performance at all

times can ensure optimum ROI of these national assets and resources including sustainability.

While statutory organizations were in place all along to oversee safety aspects of Indian petroleum

industry, Oil Industry Safety Directorate (OISD) was set up in 1986 by Ministry of Petroleum and

Natural Gas, Government of India as a knowledge centre for formulation of constantly updated

world-scale standards for design, layout and operation of various equipment, facility and activities

involved in this industry. Moreover, OISD was also given responsibility of monitoring

implementation status of these standards through safety audits.

In more than three decades of its existence, OISD has developed a rigorous, multi-layer, iterative

and participative process of development of standards – starting with research by in-house experts

and iterating through seeking & validating inputs from all stake-holders – operators, designers,

national level knowledge authorities and public at large – with a feedback loop of constant

updation based on ground level experience obtained through audits, incident analysis and

environment scanning.

The participative process followed in standard formulation has resulted in excellent level of

compliance by the industry culminating in a safer environment in the industry. OISD – except in

the upstream petroleum sector – is still a regulatory (and not a statutory) body but that has not

affected implementation of the OISD standards. It also goes to prove the old adage that self-

regulation is the best regulation. The quality and relevance of OISD standards had been further

endorsed by their adoption in various statutory rules of the land.

Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This

matches the OISD philosophy of continuous improvement keeping pace with the global

developments in its target environment. To this end, OISD keeps track of changes through

participation as member in large number of International and national level knowledge o

rganizations – both in the field of standard development and implementation & monitoring in

addition to updation of internal knowledge base through continuous research and application

surveillance, thereby ensuring that this OISD standard, along with all other extant ones, remains

relevant, updated and effective on a real time basis in the applicable areas.

Together we strive to achieve NIL incidents in the entire hydrocarbon value chain. This, besides

other issues, calls for total engagement from all levels of the stake holder organizations, which we,

at OISD, fervently look forward to.

Jai Hind!!!

Executive Director

Oil Industry Safety Directorate

Page No III FOREWORD

The Oil Industry in India is over 100 years old. As such, various practices have been in

vogue because of collaboration/ association with different foreign companies and

governments. Standardization in design philosophies, operating and maintenance

practices remained a grey area. This coupled with feedback from some serious accidents

that occurred in the past in India and abroad, emphasized the need for the industry to

review the existing state-of-the-art in designing, operating and maintaining of Oil and Gas

installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety

Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the

industry in formulating and implementing a series of self-regulatory measures aimed at

removing obsolescence, standardizing and upgrading the existing standards to ensure

safe operations. Accordingly, OISD constituted a number of functional committees of

experts nominated from the industry to draw up standards and guidelines on various

subjects.

The original document on ―Crane Operation, Maintenance & Testing (For Upstream)‖ was

prepared in the year 2002 by the Functional Committee on Crane Operation, Maintenance

& Testing (For Upstream). This revised document is based on the accumulated

knowledge and experience of industry members and the various standards and practices.

This revised document is based on the accumulated knowledge and experience of

industry members and the various standards and practices.

The figures and annexures used in the document are representative in nature.

We, at OISD, are confident that the provisions of this standard, when implemented in

totality, would go a long way in ensuring safe operation of the target group of locations.

Needless to mention, this standard, as always would be reviewed based on field level

experience, incident analysis and environment scanning. Suggestions from all stake

holders may be forwarded to OISD.

Page No IV

NOTE

Oil Industry Safety Directorate (OISD) publications are prepared for use in the Oil and

Gas industry under Ministry of Petroleum & Natural Gas. These are the property of

Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or

exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the data

contained in these documents, OISD hereby expressly disclaims any liability or

responsibility for loss or damage resulting from their use.

These documents are intended only to supplement and not to replace the prevailing

statutory requirements of PESO, DGMS, Factory Inspectorate or any other Government

body which must be followed as applicable.

Wherever Acts/ Rules/ Regulation and National/ International Standards are mentioned in

the standard, the same relates to in-vogue version of such documents.

Page No V

FUNCTIONAL COMMITTEE

(Second Edition-2019) NAME ORGANISATION TEAM LEADER Shri P K Shome OIL MEMBERS Shri Pankaj Garg (till Jan 2018) ONGC Shri Jayesh Bhandari BGEPIL Shri Anoop Vellacheri VEDANTA CAIRN OIL & GAS MEMBER COORDINATOR Shri Arvind Kumar Jain OIL INDUSTRY SAFETY DIRECTORATE

Page No VI

FUNCTIONAL COMMITTEE

(First Edition-2002)

UNCTIONAL COMMITTEE

(Second Edition-2019) NAME ORGANISATION TEAM LEADER Shri H.N.Bhakta ONGC MEMBERS Shri Roy John ONGC Shri Girish Kumar ONGC INVITEE Shri Sunil Sohani SCHLUMBERGER MEMBER COORDINATOR Shri Pradeep Kumar OIL INDUSTRY SAFETY DIRECTORATE

Page No VII Table of contents

S.N DESCRIPTION Page

1.0 INTRODUCTION 1

2.0 SCOPE 1

3.0 DEFINITIONS 2-5

4.0 EQUIPMENT 6-7

5.0 CONTROL 7-8

6.0 SAFETY EQUIPMENT 8-9

7.0 OPERATION 9-14

8.0 LOAD HANDLING 14-23

9.0 PERSONNEL TRANSFER 23-26

10.0 SIGNAL 26-28

11.0 INSPECTION 28-34

12.0 CRANE MAINTENANCE 34-35

13.0 LOAD TESTING & CERTIFICATION 35-36

14.0 INCIDENT/ACCIDENT REPORTING SYSTEM 36-36

15.0 CONTRACT MANAGEMENT 36-36

16.0 PERSONNEL PROTECTIVE EQUIPMENT 36-36

17.0 REFUELING 36-36

18.0 FIRE EXTINGUISHER 37-37

ANNEXURES

A IDENTIFICATION OF ACTIONS ON USE OF HAND SIGNALS 38-39

B DIESEL ENGINES 40-44

C INSPECTION OF COMPONENTS OF CRANE 45-49

D LIST OF COMPONENTS FOR SERVICING 50-51

E SAMPLE LIFT PLAN 52-53

19.0 REFERENCES 54

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.”

OISD – RP – 205 Page no. 1

RECOMMENDED PRACTICE FOR CRANE OPERATIONS, MAINTENANCE & TESTING (FOR UPSTREAM)

1.0 INTRODUCTION

In oil industry, material handling using cranes is one of the most important operations

requiring utmost care.

The primary purpose of this standard is to outline recommended practices for crane

operations, maintenance, inspection and testing to crane owners, users and operators in

upstream sector of oil industry both offshore and onshore. These recommended practices

focuses on safe operation of cranes in order to establish, maintain and further develop an

adequate level of safety for personnel, property and environment during planning and execution

of lifting operations.

2.0 SCOPE

These recommended practices intended to serve as a guide in developing operating and

maintenance practices and procedures for use in the safe operation of various types of

pedestal mounted revolving cranes on offshore fixed and floating platforms, offshore jack-up

drilling rigs, semi-submersible drilling rigs and other types of mobile offshore drilling units

(MODUs). It also covers, fully mobile full slewing telescoping boom (multiple control system),

fully mobile full slewing telescoping boom (single control system), fully mobile full slewing fixed

boom (multiple control system), used at onshore installations of upstream operations.

SCOPE EXCLUSION

1. Fully mobile part-slewing, fully mobile non-slewing, truck mounted fully mobile full-slewing, truck

mounted fully mobile part-slewing, truck mounted fully mobile non-slewing, semi-mobile types of

any of the above classes, portable cranes.

2. Heavy-lift applications; cranes for heavy-lift applications mounted on barges, self-elevating

vessels or other vessels, and are used in construction and salvage operations above and below

the sea surface.

3. Equipment (e.g. davits, launch frames) used only for launching life-saving appliances (life boats

or life rafts) are not included in the scope of this recommended practice.

4. Lifting devices not covered by this document should be operated, inspected, and maintained in

accordance with the manufacturer’s recommendations.

These recommended practices are to provide and assist in the proper operation and

maintenance of crane, as a supplement to the Manufacturer's instructions, which should be

carefully read, retained and followed.




3.0 DEFINITIONS

Anti-two block:

A limiting device that prevents the load block sheaves, auxiliary or fast line ball from contacting the boom

tip sheaves.

Boom angle:

The angle above or below horizontal of the longitudinal axis of the base boom section.

Boom length:

The straight line distance from the centerline of boom foot pin to centerline of boom point load hoist

sheave pin, measured along the longitudinal axis of the boom.

Boom lift cylinder

An equipment or means for supporting and controlling the boom upward and downward movement.

Certified:

Formally attested as true or meeting a standard.

Choke:

Block used to stop the wheels of a truck.

Counterweight:

Weight used to supplement the weight of the machine in providing stability for lifting working loads and

usually attached to the rear of revolving super structure.

Crane:

A lifting device that is capable of being dynamically loaded when lifting, lowering, or shifting loads by

means of a projecting arm.

Critical lift

Hoisting or lifting operations that presents an increased level of risk beyond normal lifting activities. The

increased risk may relate to personnel injury, damage to property, interruption of plant production, delays

in schedule, release of hazards to the environment, or other jobsite factors.

Drum rope:

A rotating cylinder with side flanges on which wire rope used in machine operation is wrapped.

Dynamic loading:

Loads introduced into the machine or its components due to accelerating or decelerating forces.

Gantry (A-Frame):

A structure mounted on the revolving super-structure of the machine to which the boom support ropes are

reeved.




Heavy lift:

A non-routine lift which is equal to or greater than 75% of the rated capacity of the crane, at either a

dynamic or static condition.

Hoist

A device used for lifting or lowering of the load in vertical direction also called winch.

Hook load

The load being lifted plus the weight of slings and rigging. Hook load may or may not include the weight

of the hook block and wire rope. This can be determined from the crane’s load rating chart.

Hydraulic crane

A crane whose movements are directed by fluid pressure applied to the pumps/gears,

hydraulic cylinder, and hoists.

Jib (Tip Extension)

An extension attached to the boom point to provide added boom length for lifting specified loads.

Lattice boom

Boom of open construction with angular or tubular lacing between main corner members (chords) in

the form of truss.

Limit device:

A safety feature used to stop the movement of a crane or its components beyond a predetermined point

that could cause damage to components or the crane to fail.

Load test

The test undertaken to validate load rating of the crane.

Load - working:

External load in pounds (Kilogram) apply to the crane including the weight of load attaching equipment

such load block, shackles and slings.

Luffing:

Luffing is same as derricking. The operation of changing boom angle in a vertical plane.

Outriggers

Members attached to the carrier’s frame which may be blocked up to increase stability. These

may be fixed or extendible.

Pawl (Dog)

A device for positively holding a member against motion in one or more directions.

Pedestal (Base)

The supporting sub-structure upon which the revolving upper structure is mounted.




Pull test

A test, using a suspended weight or a dynamometer, to verify crane capability for the expected lift, not to

exceed 100% of the rated crane load chart capacity. This is not a LOAD TEST.

Qualified crane inspector

A person with training and experience who has demonstrated proficiency in the skills and abilities

necessary to inspect, maintain, and repair cranes.

Qualified crane operator:

A person with training and experience who has successfully completed a crane operator training course.

Qualified Person

A person who, by possession of a recognized degree in an applicable field or certificate of professional

standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the

ability to solve or resolve problems relating to the subject matter and work.

Rated capacity

The rated loads at specified radii as established by the manufacturer and are the maximum loads at

those radii covered by the manufacturer’s warranty.

Rigger

A rigger is anyone who attaches or detaches lifting equipment to loads or lifting devices.

Signalman

A qualified rigger who is designated by a qualified crane operator to give hand signals.

Slewing:

Same as swing. Rotation of the super structure for movement of loads in a horizontal direction about

axis of rotation.

Sling

A device used to connect loads to be lifted by a crane or a hoist.

Static loading

Loads introduced into the machine or its components with no accelerating or decelerating forces.

Stinger

A single length of wire rope equipped with a hook and safety latch, which is capable of handling the

maximum capacity of the load. Its use is intended to keep the main hoist load block or auxiliary hoist

headache ball from coming in contact with personnel rigging loads.

Swing circle

The swing circle assembly is the connecting component between the crane revolving super structure and

pedestal. This component allows crane rotation and sustains the movement, radial and axial loads

i m p o s e d by crane operation.




Tag line

A length of rope/ropes attached at a point to the load and used by riggers to help control its

movement.

Telescoping:

Consists of a base boom from which one or more boom sections are telescoped for additional length.

Temporary crane

Any crane that is attached to or connected via a substructure to a platform and not a permanent part of

the structure).

Whip line

A secondary rope system usually of lighter load capacity than provided by the main rope system also

known as ―AUXILIARY.




4.0 EQUIPMENT

4.1 PRIME MOVER:

Prime mover may be Electric or Diesel engine. Starting system may be pneumatic, manual,

hydraulic, electrical or combination of any two. Power supply to cabin and accessories should be

through engine driven generator. Air compressor for air starting system and engine shaft driven

hydraulic pump for engine starting system. Prime mover should be suitably selected for carrying

out the main hoisting, Luffing / slewing operations simultaneously at rated capacity and specified

radii.

The engine should be fitted with a suitably calibrated running hours recorder / tachometer which is

to be positioned so that it can be easily read by the operator.

The engine exhaust shall be equipped with spark arrestor and exhaust pipe shall be insulated to

protect operator from burn injury. The exhaust should be directed away from the operator.

4.2 CABIN:

The crane operator’s cabin should be mounted on the crane with fully enclosed sturdy door with

lock, shatter proof glass windows on all sides, wind shield wipers and sun visor, horn, lights, fan

and adjustable seat. Controls, indicators, alarms, load charts (one dynamic and other static for

offshore cranes and static load chart for onshore crane) and boom angle indicator should

also be visible from the cabin. The crane cabin should not have any loose items.

Service walkways all around the cabin with handrail should be provided (for fixed cranes). For

mobile cranes, handholds shall be provided at convenient points above the platform.

As far as possible, cabin should be constructed to protect the upper structure machinery, brakes,

and clutches from the weather.

Unless and otherwise specified, the sound levels at operator’s station shall not exceed:

i) 90dB (A) (Slow response) measured with the prime mover at idle speed and crane controls

in neutral position.

ii) 95dB (A) (Slow response) measured with the crane operating at full throttle and full rated

load of the rotating machinery.

4.3 HYDRAULIC SYSTEM

A separate hydraulic pump( s) with motor and automatic braking system should be provided

for main hoist, auxiliary hoist, and boom hoist for hydraulically operated cranes. A separate

hydraulic motor should be provided for swing drive. The swing drive should be provided with

mechanical positive lock arrangement, controllable by operator (as applicable/ installed).

Means should be provided for checking manufacturer’s specified pressure settings in each

hydraulic circuit. Each loop shall be fitted with pre-set safety relief valves.




4.4 ELECTRICAL SYSTEM

The electrical power supply for lighting of Cabin, Housing, Flood light, Aviation light (for offshore

cranes) and other auxiliaries on the crane shall be provided through alternator/dynamo which

is a part of mobile crane , or electric power supply from installation through swivel or other

suitable mechanism for fixed cranes.

Some of the offshore fixed cranes are electrical driven for which electrical power is supplied by

available installed electrical power.

4.5 MOUNTING

4.5.1 FIXED CRANES

Fixed types of cranes are mounted on suitably designed pedestal. The pedestal construction

should be conforming to API-2H or other national/international standard.

4.5.2 MOBILE CRANES:

I. The mobile crane shall be mounted on at least four pneumatic tyred wheels and shall be

provided with air or hydraulic braking on all wheels. An entirely independent hand brake shall

be fitted for parking.

II. Emergency towing eyes of approved design shall be fitted at the front and rear of the crane.

III. Wheel and axle arrangements should be designed as per standard automotive practice. Any one

axle may have one or more tyres.

IV. Construction of mobile cranes should be conforming to ASME B 30.5 or other National /

International standards.

4.6 OUTRIGGERS

The manufacturer should specify whether outriggers are fixed or extendible, whether telescopic or

hinged, whether front or rear outriggers or both are supplied and if jacks or supporting floats are

available. Means shall be provided to hold all outriggers in the retracted position while traveling or

in the extended position when set for operating.

5.0 CONTROLS

5.1 GENERAL

Controls should be in accordance with the following requirement.

1. The control should be installed in such a way that one operator can easily perform all

maneuvers and speed control.




2. Control levers for boom hoist, load hoist, swing and boom telescope (where applicable) should

return automatically to their centre (neutral) positions on release.

3. Foot operated pedals, where provided should be constructed so as the operator’s feet will not

readily slip off.

4. Brakes engage automatically when a control is placed in the neutral position in the event of

engine power failure, loss of hydraulic pressure or control failure.

5. Main hoist line and auxiliary line each should be equipped with anti-two blocking devices with

audible and visual warning and is hydraulically/ electrically operated.

6. The crane should be fitted with indicating and sensing device for safe load and boom angle /

radius, which automatically weighs load continuously and is being carried with a particular radius.

7. The crane shall have visual lighting indications inside crane cabin for indicating static and

dynamic mode of operations as applicable. The normal re-setting of the controls for static lifting

should also be provided, as applicable.

8. An emergency stop, to stop all functions of crane instantaneously in case of emergency is

provided.

9. The mobile crane should be capable of being steered either right or left in either directions of

travel and the control shall be from operator’s position on the revolving superstructure (applicable

for crawler).

5.2 FORCES AND MOVEMENT OF CONTROL LEVERS

Control levers /pedals are properly maintained as per manufacturer’s recommendations; the

forces and movement to operate the crane within its rated limits should not exceed the following:

1. Hand levers – 20 lbf and 28 inches total travel

2. Foot pedal – 25 lbf and 10inches total travel

6.0 SAFETY EQUIPMENT

Following minimum safety equipment should be installed/made available on the crane: -

Weight load indicator

Overload (not less than 97.5% of SWL at that radius) alarm & shutdown, visual warning at

90% of SWL or Load Indicator along with boom angle indicator and load chart should be made

available.

Boom angle indicator

Swing lock device




Horn

Boom hoist stop

Aviation light for offshore cranes

Latch for main & auxiliary hook

Limit switches

Motion limit device to limit hoisting, swinging and boom extension

Walkie-talkie/telephone/pager/any communication device as applicable

Audio warning Horn / Hooter for alarms

Fire extinguisher

Anti- two block

Emergency shutdown device

Guards on moving parts wherever possible to fit

Pressure, Temperature & Oil gauges

Spark arrestor

First Aid kit

Following shall be displayed in the cabin:

- Hand signals

- Load & range charts

Safety equipment specific to mobile cranes shall be fitted with

Audio visual reverse alarm

Level gauge

Outrigger controls functions

Wheel chokes

A brake or alternative device to lock the superstructure in any position when the crane is

travelling or working on slopes. In addition, a positive locking device to locate the

superstructure in its normal travelling position.

7.0 OPERATION

7.1 CRANE OPERATOR'S QUALIFICATION

1. Crane operator must have valid certificate for operation of crane from authorized agency. The

operator must be physically and mentally fit (vision, hearing, color identification & no history of

any disabling medical condition).

2. The employer of the crane shall ensure that operator qualifications are maintained, at a minimum

every four years, through requalification.

3. A crane operator must have valid heavy motor vehicle driving license as per central motor vehicle

rules, 1989 of Government of India (for mobile cranes).

4. Operator should have undergone operator’s training (classroom & practical) with written and

hands- on examinations on the type of crane to be operated, should be conversant with load

chart and stability (available on the crane), use of correct slinging practice, should have clear

understanding of standard signals, and safe operating practices, should be familiar with all major




crane components, safety devices and anti-two block system.

5. Crane operator should be able to understand the onboard/static and off board / dynamic loading.

7.2 RIGGER’S QUALIFICATION

A person with training and experience and has knowledge of rigging hardware, slings, and safety

issues related to rigging, lifting loads and lift planning. It also includes hands on training on use and

selection of rigging gears (slings, shackles, hooks etc.) and should be able to carry out pre-lift

rigging inspection. He should not have any history of disabling medical condition. He should be

aware of proper use of personnel transfer equipment (for offshore application).

7.3 SAFE OPERATING PROCEDURE

1. Before starting the operations, operator shall verify the following

All pre-use inspections as per standard practices or manufacturer’s guidelines have been

completed.

The controls should be either in the ―off‖ or ―neutral‖ position.

All personnel are in the clear.

2. Operator shall be responsible for operations under his/ her direct control.

3. Crane operator should check for availability of on board/ static and off board/ dynamic load rating

chart specific to the crane.

4. While lifting/ placing of the load, no unauthorized person shall remain within the radius of the

boom and underneath the load. Barricading of the load trajectory may be considered as an

additional control.

5. For any safety reason, the crane operator shall stop handling loads/ operations and report the

matter to the installation Manager for further instructions.

6. Always follow the operating practices supplied by the manufacturer for each type of crane.

7. The operator shall be familiar with the use of equipment and its care. Operator should be aware of

the controls and safety features available.

8 Before starting the machine for handling the load, crane operator must ensure that the load and

the authorized signal person are within his or her range of vision.

9 The operator will respond to signals given by authorized signal person but respond to an

emergency stop signal irrespective of the person who is giving the signal.

10 Before leaving the crane for a long period the operator shall land any attached loads, disengage




master clutch, set all locking devices, put controls in off or neutral position and stop the prime

mover & ensure that crane component will not interfere with normal helicopter flight operations

(for offshore cranes).

11 Crane shall be secured against swinging when not in use.

12 During operations, if power or a necessary control function fails, set all the brakes and locking

devices and move all clutches or other power controls to off position or neutral position & if

practical/possible lower the attached load by controlled lowering and stopping.

13 Relief valves on hydraulic cranes should not be adjusted above manufacturer’s recommended

pressures and current limiting devices on electric cranes should not be bypassed to increase

available hoist line pull.

14 During high wind conditions and nights, lift of heavy equipment should be avoided. If unavoidable,

the operator shall ensure that there is proper illumination in the night at the load and landing area.

15 Pre use inspection log book should be maintained by the crane operator with the date and time of

inspection.

16 In offshore, during helicopter operations crane boom should be secured in such a manner that it

remains clear of approach/ take off path of helicopter.

7.4 SAFE OPERATING PROCEDURE FOR MOBILE CRANES (EXCEPT CRAWLER CRANES)

Following additional procedures to be followed:

1. Crane to move on reasonably hard leveled surface. Crane placement programme to be prepared

for lifting heavy equipment.

2. Make sure wheels have chokes installed before commencing the job.

3. Out rigger beam should be fully extended before operation.

4. While working on a slope, the crane should be parked with front wheels towards downhill. The

load lifted from the rear of the truck.

5. The crane shall not be driven with outriggers and jacks extended.

6. The crane level should be checked for stability.

7. A trained rigger/ signalman shall always accompany the crane when it is being moved.

8. The crane hook shall be secured to prevent it from swinging while the crane is traveling.




9. The crane shall not be placed for working in hazardous area classified by existing DGMS/Statutory

notification. The components like light etc. shall be of flame proof type as boom can be used for

handling loads in hazardous area.

10. Outrigger mat of appropriate size should be placed below the supporting floats depending upon

ground condition.

7.5 CRANE DANGER SIGNS TO WATCH FOR

While working around crane, the operator should be careful about following eight danger signs of

improper operation. If any of the following occurrences are noticed at jobsite, immediately inform to

supervisor person before a catastrophe takes place.

Outriggers, crawler tracks, or tyres raised off the ground while operating- This is an

extremely dangerous condition which indicates the crane is being overloaded and may tip over or

collapse. The wrong move in this situation can cause a catastrophe.

Operating close to power lines or other dangerous objects- Electrocution due to contact with

power lines is the leading cause of crane related fatalities. Detailed regulations for proximity to

high voltage sources must be strictly enforced. Any potential danger should be pointed out to the

crane operator or a supervisor-but never touch the crane at this time.

Riding the load or crane hook- This is a serious violation of safety regulations. Crane structures

and cables have far lower strength margins for handling material than what is required for lifting

personnel. Workers must never be suspended from a crane boom unless an approved personnel

basket with mandatory safety equipment is used, and lifting procedures are strictly followed.

Visible structural damage on the crane- There is little or no back up system in the load-

supporting components of most cranes. A damaged component can fail completely and without

warning, causing the boom or load to fall.

Modifications made by adding extra counterweight or holding down the rear of the crane-

All job initiated modifications are illegal and may permit overloading the crane. If not approved by

the crane manufacturer in writing, these modifications can over stress critical structural

components, which could cause failure of the crane.

A crane operating near a trench or excavation- Cranes exert extremely high loads on the soil

near the tracks, outriggers, or tires. A crane set up in close proximity to an excavation can cause

soil failure, crane turnover, and possible disaster.

The crane is noticeably out of level while operating- There is no faster way to collapse a crane

boom than to impose a side force on the boom. Working out of level creates a dynamic side force

which means a crane collapse may be imminent.




The crane's hoist line is not vertical at all times during operation- This indicates improper

operation. A hoist line which is not vertical obviously indicates that the load is not hanging straight

down. Out of plumb loads can cause crane collapse by generating side forces on the boom. In

some instances, the crane may tip over if the load swings.

7.6 PRECAUTIONS FROM LIVE POWER LINES

Everyone in proximity to a crane, when energized lines are near, must stay alert. It takes

employee teamwork to successfully and safely operate under this combination of conditions.

Power lines can be hard for the crane operator to see. They sometimes appear to be either further

away or much closer than they really are. It is difficult for the human eye to accurately judge the

clearance between the crane's boom or line, and a power line. Fellow workers can help assure

that safe clearances are being maintained between the crane, the line, the load and the overhead

power line. The table below shows basic clearance minimums, which apply to all areas around the

power line-above, below or to either side:

Power Line Voltage (KV) Minimum Clearance (Feet)

up to 50 10

50 to 75 11

75 to 125 13 125 to 175 15

175 to 250 17

250 to 370 21

370 to 550 27

550 to 1,000 42

The following guidelines are intended to prevent crane accident due to electrocution:

While operating cranes in the vicinity of overhead electric transmission line, adequate precaution

shall be taken against accidental contact with the electric transmission line unless the same is

kept de-energised during movement of the crane.

Avoid storing materials around and especially underneath overhead power lines.

Locate all power lines on the job and make a drawing of where you will set up the crane.

Consider any overhead line "hot" until the owner or utility company verifies that it is not energized

and is visibly grounded. The line must be "cold" if minimum clearance cannot be met.

Look carefully before the boom is moved, particularly in congested areas of poor visibility. Get

additional workers to help with the move if a clear view of all areas is not possible.

Place a visual marker, such as a florescent line or flagging to mark off the danger zone.




Communicate the lifting plan to all crewmembers every time you set up (after breaks and lunch).

Use proper hand signals for directing crane operations. Make sure all crew members understand

the signals.

Appoint a watch person who does nothing but watch the load every time you work in the proximity

of power lines.

Never work closer to power lines than the code allows. Power lines are not insulated and they can

arc across several feet.

If working near power lines cannot be avoided, contact the utility who owns them, have them de-

energized and visibly grounded. This takes pre-planning; most utilities require a minimum notice.

If lines cannot be de-energized, the utility must approve your work plan and install protective

barriers. Again, a full time watch person is required.

If one cannot move the crane away from the lines, stay in the cabin until the utility company

arrives and makes sure the lines are de-energized.

If a dangerous situation demands that you must exit the crane, ―DON’T CLIMB DOWN". Jump

away from the crane (a distance of 2 to 4 feet is usually far enough) and land with both feet

together as there may be areas in the ground with differing voltage. This will avoid having one foot

in an area of higher voltage than the other, which can be lethal. Avoid contacting the load, load

line or the crane. Ground crew should follow this same advice.

8.0 LOAD HANDLING

8.1 THE LOAD

Crane lifting capacities are based on relative motion conditions between the crane and the load to

be handled. All cranes will have one static and at least one dynamic load rating chart. These

charts must show the rated lift capacity for boom lengths and angles.

1. The appropriate load rating charts for the configuration in use must be in a position where they

are visible to the operator while operating the crane. The operator should know that the hook load

is within the cranes applicable static or dynamic rated load at the radius at which the load is to be

lifted.

2. The safe working load on the crane at each radius should not be more than 90% of the test load,

but in no case should the rated capacity loads be exceeded. The safe working load of the crane

should be legibly marked on it. A scale or weight indicator should be available which can be used

to determine weight of unknown load to be lifted.

3. Never attempt to operate a crane where the load capacity chart shows no load capacity or where




there are no values shown on the charts. This load is more than the safe operating conditions for

the crane. The crane can turn over when the boom is extended too far, even with no load

(Applicable to mobile crane).

4. To make a safe lift, the operator must know the exact weight of the load, the length of the crane

boom, the load radius and the boom angle.

5. For lifting heavy equipment shackles/hooks shall be engaged on lugs/eyes provided for lifting.

6. General load moment indicators do not sense extension of outrigger beams .As such, while

operating a crane, it should be ensured that the outrigger beams are fully extended.

7. Cranes should always be placed horizontally, as load moment indicator parameters are fixed,

assuming the crane in horizontal position. Any horizontal imbalance of the crane will result in

decrease of the balancing moment not accounted for by the load moment indicator, which may

lead to serious over-loading.

8.2 LIFT PLAN:

A written lift plan is to be made prior to lifting for non-routine (simple/ complicated/ complex) or

critical lift. Lift plan to tentatively include weight, dimension, limiting boom angle with its

corresponding SWL as per load chart and probable lift trajectory.

Classification of a lift as non-routine/ critical should be determined by company policy but may

also be determined independently by site supervision, project management, or a qualified

person. Critical lifts can occur anytime during lifting, preparation for a lift, or dismantling from a

lifting operation.

Lifting operation categorization help to provide the level of control required as per complexity

involved. Company will define lift categories. General guidelines on lift categorizations are given

below.

Non-Routine Lifts

Non-Routine lifts are further divided in to three categories

a. simple

b. complicated

c. complex or critical lifts

Simple Lifts

Below is the list to describe simple lifts

a. load with known weight and center of gravity below lifting points.

b. lifting points / pad eyes available above the load.

c. requires standard rigging arrangement to lift.

d. lifting area involved is standard designated load bay.




Complicated Lifts

Below is the list to describe complicated lifts

a. lifting operations involving two cranes simultaneously.

b. transfer of load from one vessel to other.

c. lifting in restricted area.

d. load having offset center of gravity.

e. lifts with large surface area.

f. signalman is likely to go out of sight of crane operator during course of lifting.

CRITICAL LIFT IDENTIFICATION

Examples of commonly accepted critical lift criteria are as follows:

i. The total load being lifted is in excess of a predetermined threshold. This threshold may vary with

company policy and with consideration given to such criteria as crane capacity, available rigging,

and employee experience.

ii. The lifted load exceeds a predetermined percentage of the crane’s capacity, as shown on the

crane manufacturer’s applicable load rating charts for the configuration being used. Responsible

management may adjust this percentage depending on the jobsite conditions.

iii. The lifting operation involves more than one crane lifting a common load with shared loading of

both cranes.

iv. The lifting operation involves more than one crane lifting a common load with shared loading of

both cranes. Multi-crane lifts utilizing one crane, as a tailing crane, may not be considered a

critical lift unless another of these listed criteria applies.

a. The item being lifted is unique and if damaged, would be irreplaceable or not repairable and

is vital to a system, facility, or project operation.

b. The item is being removed from a structure; such as in demolition work, where the actual

weight and the structural integrity are in doubt.

c. The lifting operation is within a boom length of power lines.

v. Other crane activities such as but not limited to the following, which may be considered as critical

lifts as determined by either site management or project supervision:

a. Lifting with limited clearance or in confined work areas.

b. Lifting at heights that make control of the load difficult.

c. Lifts utilizing specially engineered load rigging system.

PLANNING THE LIFT




The lift plan shall include items necessary to address the special conditions of each lift. These

items should take into consideration, but not be limited to the following components of a safe lift:

1. The total weight to be lifted, which includes, but is not limited to the weights of

a. load

b. block and ball

c. below-the-hook lifting devices, lifting bars, or beams

d. Jib, erected or stowed, as applicable

e. rigging, including slings and hardware

f. rope, load line as applicable

2. The crane placement location with consideration given to

a. foundation, ground support

b. boom swing area, as applicable

c. track or outrigger loading

d. electrical hazards

e. obstructions and clearances

f. load path

3. Identification of the crane(s) to be used describing the required configuration(s) noting

a. capacity

b. lifting arrangement

c. load radius requirements

d. percentage of crane capacity needed

4. Sling and rigging selection, which should include, but not be limited to

a. type of arrangement

b. identified sling angles

c. number and size of slings

d. sling rated capacities and lengths

e. hardware selection and sizing

5. Diagram(s) of lifting area dimensions including

a. site layout information and rigging arrangements

b. pick up and placement locations

c. obstructions and clearances

d. jobsite access and egress for the load

e. load orientation

6. Diagram of rigging configuration including

a. load center of gravity




b. arrangement of slings and below-the-hook lifting devices

c. hardware arrangements

d. capacities of slings and hardware

e. pick points on the load

f. calculated sling angles

g. types of sling hitches

Risk Assessment

Every lifting operation should be risk assessed and ensure that appropriate controls are in place

for those hazards identified in the written assessment. The following are components of a risk

assessment.

a. Complete a job safety analysis (JSA) to identify hazards and reduce risks.

b. Limits and visual inspections.

c. Safe working load (SWL) of crane or working load of rigging is never exceeded.

d. Lifts that exceed an established percentage of the crane SWL require permit to work (PTW)

controls for heavy lift authorization.

e. Lifts that involve blind spots require that a stand-alone signalman is assigned to oversee the

safety on the lift and give hand signals. This person should not be involved with the

rigging/handling of the load being moved.

f. Tag line(s) of proper lengths should be attached to all lifts, if appropriate and deemed

necessary.

g. Persons rigging, slinging/un-slinging loads should remain in a position of safety and have a

designated escape route.

h. No personnel shall stand under suspended loads or allow a load to be swung over their

head.

i. Riggers spotting loads should avoid placing hands on the load and stand clear until tag lines

are accessible.

j. Place the load(s) on level and stable surfaces and on the decks that are rated to support the

weight.

k. All lifting equipment and hardware should be certified, of adequate SWL, and visually

inspected.

l. Only Qualified Riggers should perform rigger functions.




m. Assess the center of gravity.

n. Criteria and limits for safe operation of cranes are addressed in the equipment

manufacturer’s manual.

o. When a Qualified Crane Operator leaves the crane controls, the crane shall be shut down,

all controls left in neutral position, brakes locked, and master clutches disengaged. The

swing lock, where applicable, shall be engaged at all times when the crane is unattended.

p. Cranes should not be left unattended while a load is suspended.

q. Load charts, boom angle or radius indicator, and emergency stops should be available and

all limit switches operational and tested.

CRITICAL LIFT APPROVALS

Lift plans shall be reviewed for approval by responsible jobsite personnel including site

management, rigging supervision, the crane operator performing the lift, qualified personnel

designing the lift, and safety personnel as applicable. These approvals shall be signed and dated.

Any changes to plan should be approved as if it were a new plan. All revisions shall also be

signed and dated.

CRITICAL LIFT PRE-LIFT MEETING

Before performing a critical lift and following any revision(s) to the original plan, participating

personnel shall meet to accomplish the following:

a. Review and discuss the details of the critical lift plan.

b. Discuss any hazards, delays, project coordination, unique conditions, emergency contingencies,

safety concerns, etc.

c. Resolve any questions or concerns before commencing lifting operations.

d. Assign personnel and responsibilities.

e. Establish communication methods.

8.3 ATTACHING THE LOAD

1. The load should be attached to the hook by means of slings or other suitable devices. The latch

shall be closed to secure loose slings. Hooks should be self-closing.

2. The hoist rope shall not be wrapped around the load.

3. Sling use should be in accordance with the lift plan.

4. Discard defective slings. Each sling should have unique identification number. Record should be

maintained capturing date of manufacturing and date of put in service / colour coded as per

company policy.




5. Longer objects should be lifted from both ends to maintain its balance.

8.4 MOVING THE LOAD

Guidelines for moving the load are as under:

1. The qualified crane operator and the designated signal person directing the lift should

determine that:

I. The crane is placed on a firm level foundation and properly secured in place (for mobile cranes).

II. The load is secured and properly balanced in the appropriate sling or lifting device before it is

lifted.

III. The lift and swing paths are clear of obstructions and personnel.

IV. An appropriate fire extinguisher is kept in the crane cabin or vicinity of the crane.

2. Before starting to lift, the following conditions should be verified:

I. The load is free to be lifted and has no loose items which may drop during lifting.

II. Refer to crane load chart for proper boom angle before lifting any static or dynamic load.

III. Never attempt to lift a load that exceeds the crane lifting capacity for a specific boom angle.

IV. Multiple part lines are not twisted around each other in such a manner that all of the lines will not

separate upon application of load.

V. The hook is brought over the load in such a manner as to minimize swinging.

VI. If there is a slack rope conditions, the rope is properly seated on the drum and in the sheaves.

VII. The correct slings have been selected for the weight to be lifted.

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

boom.

3. During lifting, care should be taken that:

I. Acceleration or deceleration of the moving load is accomplished in a smooth manner.

II. Load, boom or other parts of the machine do not contact any obstruction.

4. The operator should engage the controls smoothly to avoid excessive stress on crane

machinery.




5. When rotating the crane, sudden starts and stops should be avoided. Rotational speed shall

be such that the load does not swing out beyond the radius at which it can be controlled.

6. No external forces should be applied to suspended loads which will create side loading of the

boom. Care should be taken when swinging the crane so as to minimize the pendulum action of

the hook and suspended load.

7. Cranes will not be used for dragging loads unless properly rigged for a vertical pull not

exceeding the rated capacity.

8. The operator will not hoist, lower or swing while any personnel are on the load or hook

(other than in a personnel basket).

9. Suspended loads shall be kept clear of all obstructions.

10. All persons shall be kept clear of suspended loads or those about to be lifted.

11. While the crane is in operation, no other work shall be performed on the crane.

12. The operator should test the brakes each time a load approaching the rated load is

handled.

13. The operator should avoid moving loads over personnel. Loads which are suspended by use

of slings or hoists should be blocked or cribbed before personnel are permitted to work

beneath or between them. Blow horn before moving loads over the area where people are

working.

14. Riding on loads and hooks is strictly prohibited.

15. No fewer than five (5) full wraps of rope will remain on the drum(s) in any operating

condition. Due consideration should be given to hoist manufacturer’s recommended practices,

especially for ―break away‖ anchor type hoists.

16. All the cranes must be equipped with safety cutouts and the weight indicators. Safety

cutouts must always be in good working condition.

17. When two or more cranes are used to lift a load, one qualified operator will be responsible for

the operation. The responsible operator should analyze the operations and instruct all

personnel involved in the proper positioning, rigging of the load and the movements to be

made. The positioning of cranes and distribution of load should be ascertained.

18. Appropriate non-electrical conducting tag or restraining lines should be used where necessary

to guide and control the load.

19. The operator should not leave the crane controls until the load has been safely landed. He must

properly secure the crane and boom before going off duty when shutting down operations.




8.5 SLINGS:

1. The slings, as per the standard, IS 2762 of the Bureau of Indian Standards / ASME B 30.9/

API-RP-9B shall only be used.

2. Suitable protection should be provided between the sling and all sharp surfaces of the load

to be lifted.

3. Proper storage shall be provided for all slings while not in use.

4. Slings should never be choked in the splice.

5. Sharp kinks or knots should not be permitted in wire rope slings.

6. Loads should not be lifted with one leg of a multi-leg sling until the unused legs are secured.

7. The sling should show the trademark or name of the manufacturer, the stock number / color

code and most importantly the load rating and types of hitches to be used. Do not use it, if it is

not rated for the capacity.

8. Slings, which are damaged or defective, shall not be used.

9. Slings shall not be shortened with knots, bolts or other makeshift devices.

10. Sling legs shall not be kinked.

11. Slings shall not be loaded in excess of their rated capacities.

12. Slings used in a basket hitch shall have the load balanced to prevent slippage.

13. Slings shall be securely attached to their loads.

14. Slings shall be padded or protected from all sharp edges of their loads.

15. Hands or fingers shall not be placed between the sling and its load while the sling is being

tightened around the load.

16. Shock loading is prohibited.

17. A sling shall not be pulled from under a load when the load is resting on the sling.

18. Any angle other than vertical at which a sling is rigged increases the loading on the sling.

19. Whenever a sling is found to be deficient, the eyes must be cut or other end attachments or

fittings removed to prevent further use and the sling body discarded.




20. A sling eye should never be used over a hook or pin with a body diameter larger than the natural

width of the eye. Never force an eye on a hook. The eye should always be used on a hook or

pin with at least the diameter of the rope.

21. All slings shall be visually inspected before use by a qualified crane operator or rigger to

determine if it is capable of safely making the intended lift.

Rated loads of a sling is different for each of the three basic method of rigging (vertical, choker,

basket etc.) also the rated loads of a sling is different for each of the methods of rigging based

upon the angle of hitch, construction of the wire rope, web material and width etc. These rated

loads are provided by the manufacturer. These rated loads will be indicated on the heavy duty

tags attached to each type of sling at the time it is fabricated.

Care and use of slings and handling procedure should be in accordance with OISD-STD-187/

API-RP-9B/ ASME B 30.9.

9.0 PERSONNEL TRANSFER

Off- loading material and men from supply vessels to offshore installations and vice-versa in

a heavy swell, is always hazardous. Of all lifting operations, lifting of personnel presents the

greatest risk and shall only be considered if no alternative method can be found. It

requires quite an exceptional level of coordination between the captain of the supply vessel

and the platform crane operator. The latter only has a small ―time window‖ in which to start

hoisting the load to avoid it being hit by the heaving deck of the vessel. Personnel transfer

shall only be performed after assessing the risk, defining associated prevention and mitigation

measures and obtaining approval from the person in charge of the installation.

9.1 TRANSFER OF PERSONNEL BY BASKET

If sea is rough or wind does not permit vessel drawing alongside or if there is no landing

platform, personnel shall be transferred by using unsinkable basket. The personnel basket

should be so constructed, that it is capable of serving as a temporary life raft for the

maximum number of persons that it is designed to carry.

9.2 BASKET

Manufacturer's certificate, certificate of application and declaration of conformity, shall be

issued prior to operation.

9.3 USE OF PERSONNEL BASKET

When transferring personnel between an installation and a vessel by means of an offshore

crane and a personnel basket, the following precautions are recommended as basis for

setting up a procedure.




A GENERAL PRECAUTIONS

1. The installation manager may after careful consideration allows transfer by means of

personnel basket in each specific case where this for special reasons is necessary or

reasonable. Transfer shall take place on a voluntary basis; personnel transfer should not be

done by basket against individual’s will.

2. A job safety analysis (JSA) should be conducted before carrying out personnel transfer. All

personnel involved in the transfer, including the personnel to be transferred, shall participate in

the JSA process.

3. Transfer of personnel between installation and vessel shall only take place when there is good

visibility and adequate illumination and only when the weather conditions permit a safe

transfer, unless transfer is necessary with regard to the safety of the personnel or the

installation.

4. Suitability of the vessel to which personnel are to be transferred must be ascertained. The type

of vessel considered suitable to carry out a transfer should be determined by its ability to

maintain station alongside the installation and have sufficient clear deck space to safely receive

the basket.

5. Instructions shall be drawn up for transfer operations, including rescue instructions in the

event of accident during transfer.

6. Personnel basket shall be designed for a maximum of 4 /6 persons, and shall be clearly

marked accordingly. Further, it shall be designed so that it can serve as a temporary raft for

the number of persons it is designed to accommodate.

7. The personnel basket shall be kept in good condition. It should be tested with a test load twice

the maximum workload as per manufacturer’s recommendations. The result of the test shall be

entered in the records.

8. The basket shall be safely stored when not in use.

9. Personnel basket shall be inspected, maintained and refurbished at a frequency specified by OEM

or as per company policy, whichever is earlier.

10. The personnel basket shall be stowed together with the life jackets at a safe location where it

will not be subjected to damage of a mechanical or chemical nature.

11. All persons riding on the basket should wear work vest or Personnel Floatation Device (PFD).

12. Any person unfamiliar with the basket shall be given a short briefing prior to riding the

basket and shall be accompanied by an experienced person. Any person sick, suffering

vertigo or injured should not be allowed to ride the basket, except if placed inside and

escorted by an experienced person.




13. Personnel luggage or cargo should not be permitted inside the transfer basket unless the

transfer basket has designated marked areas for light luggage. In case of doubt what is

classified as light luggage a cargo basket should be used for the transfer of luggage.

14. The crane to be used shall have valid certificate of application and shall be in good

technical condition.

15. A semi-rigid, snag resistant tag line of a minimum length of 10 ft (3.05 m) should be affixed to

all personnel transfer devices.

16. The crane intended to be used for personnel transfer shall be fitted with an emergency

release and anti-two-block limiting device.

17. To ensure that the crane hook does not damage anyone using the personnel basket, a

suitable loop/sling shall be used.

18. Hooks of the crane shall have operable latch which can be closed and positively locked during

personnel transfer to eliminate accidental opening of the hook.

19. The crane operator should have valid certificate of the crane operation.

20. Transfer during the night shall only be allowed in case of emergencies.

B OPERATIONAL PRECAUTIONS

1. When transfer of personnel is carried out, there should be consensus between the

installation manager, crane operator, safety manager and vessel master to the effect that the

operation can be carried out safely.

2. Prior to use basket shall be thoroughly examined by the responsible person.

3. The basket shall be fastened to the crane hook with a long sling. The crane hook shall have a

positive locking latch. In addition to this, the personal basket must have a designated safety

sling for additional safety back-up.

4. The personnel basket shall be equipped with life jackets for the number of persons it is used for.

5. The offshore installation manager or a person appointed by the offshore installation manager

shall be in charge of the transfer.

6. Before starting the transfer operation, the starting and landing area for the personnel basket

shall be clear to ensure that there is sufficient space for a safe operation. The basket shall not

be landed onto other equipment.

7. During transfer of personnel, all unnecessary noise in the crane operator's cabin should be




avoided, and the crane operator's complete attention shall be concentrated on the operation.

8. A designated signalman shall give the hand signals to the crane operator. The crane operator

shall have eye contact with the signalman, who in turn shall have eye contact with the personnel

basket.

9. The master of the vessel, the crane operator and the person in charge of the transfer operation

shall be in direct radio contact with each other from a time before the personnel basket is

hoisted until the transfer-operation is completed.

10. During transfer the persons transferred shall stand on the ring outside / inside (as per basket

configuration) the ropes on the personnel basket and both hands shall be free to grip on to the

ropes. Life jacket or lifesaving suit shall be used during the transfer.

11. Personnel should position themselves so that there is even distribution of load around the rim of

the basket.

12. Lifting and lowering of the personnel basket shall take place over open water, and the vessel

shall be prepared to stop the propellers during the transfer.

13. The crane operator should raise the basket only high enough above the deck of vessel to clear

obstructions, swing it over the water, raise it to a position slightly above landing deck level,

swing the basket over the landing area and gently lower it to the deck. The same method should

be followed while transferring personnel from the installations to the vessel. Personnel should

not get off the basket until it is settled on the deck of the boat or platform.

14. Tag lines shall be used on the basket and a person shall be present to control the direction of

the basket on the deck.

15. Use of personnel basket shall be entered into the records.

16. ―Free-fall‖ or non-powered lowering should not be adopted when personnel are carried in the

basket.

10.0 SIGNALS

10.1 STANDARD SIGNALS

Signals between the crane operator and the designated signal person will be discernible audibly or

visually, at all times. The crane operator will work with a designated signal person who uses

standard hand signals and will not respond unless signals are clearly understood.




10.2 USE OF HAND SIGNALS

It is frequently necessary during crane operation for the operator to depend on a signal man for

instructions, when moving an equipment into a position where there is very limited clearance

or when handling loads that are out of sight of the operator. The hand signals illustrated are

those generally accepted throughout the industry. Ensure both the operator and the signal

man are thoroughly familiar with standard hand signals to enable co-operation and teak work

The details of use of hand signals are attached at Annexure-A.

10.3 SIGNALMAN

The signalman shall be responsible for relaying signals from the slinger to the crane operator

and for initiating and directing safe movement of the crane and hook load. Recommended

standard hand and radio signals are identified as mentioned overleaf.

HAND SIGNALS:

Fully conversant with the use of signals.

Be placed in the right position.

Check that the load is hooked correctly.

Give the signals clearly

RADIO SIGNALS:

Correct use of radio.

Test the radio communication before starting a lifting operation.

Speak clear and slowly.

Use continuous radio connection during the lifting operation when the load is out of sight

of the crane operator.

Avoid unnecessary use of the radio

Prior to commencement of a lifting operation the signalman shall satisfy himself that loads may

be safely handled. The signalman shall remain in visual or radio contact with the crane operator

at all times and with the slinger at initial and at the final phases of the lift as appropriate.

If the signalman changes during a lifting operation, both the crane operator and the slinger shall

be duly notified of the identity of the new person in charge of signaling.

The designated signal person should:




1. Be qualified by experience with the operation and knowledge of the standard hand and radio

signals as shown in the table.

2. Be in clear view of the operator to ensure that his signals can be seen. His position should give

him a clear view of the load, crane, personnel and area of operation. If the operator’s view of

the primary signal person is obstructed, an additional signal person will be provided.

10.4 SPECIAL SIGNALS

For operations not covered in section 10.2/10.3 or for special conditions, additions or

modifications to the recommended standard signals may be required. In such cases, these special

signals will be agreed upon in advance by the operator and the designated signal person and

should not be in conflict with, or have the potential to be confused with standard signals.

10.5 SIMULTANEOUS OPERATIONS

1. When logging operation is in progress crane operation should not be conducted around the

area where the cable is under tension, due to the risk associated with simultaneous operation.

2. During the arming of an explosive device, crane operation should not be conducted around

the designated arming area.

3. During helicopter landing/take off crane operation should be stopped and crane boom must

be away from the landing/take off area.

11.0 INSPECTION

Cranes should be inspected regularly with an objective to ensure safe operations and

identification of any deficiencies as early as possible. Inspection regime should be

commensurate with the usage and loading pattern of cranes. The generic guidelines are

stipulated below, which can be used for devising inspection program.

11.1 CRANE USAGE CATEGORY

11.1.1 INFREQUENT USAGE PRODUCTION DUTY CYCLE

Infrequent usage are those cranes that are used for 10 hours or less per month, based on the

averaged use over a quarter. These cranes shall be subjected to a pre-use inspection and an

annual inspection. If the crane sits idle for three or more months, the crane shall be subject to a

monthly inspection and a full function operational check before committing any lifting operation.

Crane usage should be reviewed on a periodic basis to ensure proper inspection interval.




11.1.2 MODERATE USAGE INTERMITTENT DUTY CYCLE

Moderate usage applies to those cranes that are used for more than 10 hours/month but less

than 50 hours/month, based on the averaged use over a quarter. These cranes shall be subject

to periodic Inspection like pre-use, quarterly and annual inspections. Log of usage should be

maintained to ensure Inspections are carried out at adequate intervals.

11.1.3 HEAVY USAGE

Heavy usage applies to those cranes that are used for 50 hours or more per month based on an

average use over a quarter. These cranes should be subjected to frequent and period

Inspection like pre-use, monthly, quarterly, and annual inspection.

11.2 INSPECTION CATEGORIES

11.2.1 PRE-USE INSPECTION

The pre-use inspection shall be performed prior to the first crane use of the day, prior to or during

each change in crane operator, and then as the qualified crane operator deems necessary during

the day for extended operations and shall be documented.Pre-use inspections performed by a

qualified crane operator, qualified crane inspector or assigned person deemed competent to

carry out the inspection should include, but not limited to following actions.

Visual Inspection of the crane boom and support structure for any damage.

Check oil & coolant levels in engine.

Hydraulic reservoir / day tank level

Fuel level (applicable for diesel engine driven cranes).

Hoists / Gear box oil level.

Any indications of leakage from hoists, engine, control valves or flexible hoses.

Check wire rope reeving is proper and adequately lubricated.

Operation of warning horn and lights (Including navigation warning lights).

Availability and visibility of load chart from the crane operators chair.

Any specific checks as prescribed by manufacturer.

Condition of control levers.

Visual inspection of air filters housing and cut-off mechanism as applicable.

Tyres for recommended inflation pressure (applicable for mobile cranes).

Satisfactory operation of safety limit switches for Boom and Anti-two blocks.

Before starting of the crane, the basic checks are to be carried out by the operator as per the

manufacturers check list requirement. Annexure-B should be referred in addition to minimum

checks to be performed as described in section 11.2.1. Care should be taken to include OEM

specific checks not covered in inspection described in this section.




11.2.2 MONTHLY INSPECTION (FREQUENT INSPECTION)

Monthly inspection shall be performed once per month. A qualified crane operator/crane

inspector or assigned person deemed competent to carry out the inspection shall carry out the

inspection. The inspection should include all the check points indicated in pre-use inspection

and additionally should include, but are not limited to the following actions.

Functioning of all limiting devices like anti-two blocks, boom limits, swing limits.

Visual inspection of wire ropes including terminations.

Visual inspection of slew gears and slew locking devices.

Lubrications of rotating assemblies/components.

All hydraulic hoses, particularly those that flex in normal operation of crane functions.

11.2.3 QUARTERLY INSPECTION (PERIODIC INSPECTION)

Quarterly inspection shall be performed once every three months by a qualified person. The

inspection should include all the check points of a pre-use inspection, monthly inspection and

should include but are not limited to the following actions.

Visual inspection of boom structure for any bends chords or lacings and weld joints.

Visual inspection of gantry and support structure for defects.

Function checks of boom radius and angle indicators.

Visual inspection of sheaves.

Thorough inspection of wire ropes, changes in rope diameters.

Visual Inspection of load blocks and hooks for any deformity or damage and freeness of

rotation.

Lubrication of rotating parts as well as wire ropes and slew bearing.

Brake test of hoists as per manufacturer’s guidelines.

Inspection for looseness in belt drives or coupling drives.

Visual inspection of flexible hoses for blistering or abnormal deformation of the outer

covering of the hydraulic or pneumatic hose; replacement should be carried out for any

damaged hoses.

Function checks of emergency and normal stops of prime movers.

Malfunctioning travel steering, braking, and locking devices (applicable for mobile cranes)

Excessively worn or damaged tires (applicable for mobile cranes)

11.2.4 ANNUAL INSPECTION (PERIODIC INSPECTION)

Annual inspections shall be carried out by qualified person once in every year. The inspection

should include all the check points of Annexure-C, pre-use inspection, monthly inspection,

quarterly inspection and should include, but are not limited to the following actions:

Foundation and Support Structure:

Close visual inspection of pedestal or mounting structure including weld joints.

NDT inspection as per manufacturer’s guidelines should be performed.




PRIME MOVER AND HYDRAULIC COMPONENTS:

Close visual inspections.

Replenishment of filters and lube oils as specified by manufacturer’s guidelines.

Oil analysis and other intrusive inspection of internal components as per manufacturer’s

guidelines should be considered.

Function test of relief valves.

Hydraulic oil analysis and replacement as applicable.

HOISTS AND SHEAVES:

Close visual inspection.

Lube oil replacement or sample analysis as per manufacturer’s guidelines.

Tightness of foundation.

Any Intrusive teardown inspection as specified by manufacturer should be considered

Brake tests.

Inspect for surface defects and grooves profile inspection by appropriate gauges.

SWING MOTORS AND GEARBOXES:

Close visual Inspection.

Lube oil replacement or sample analysis as per manufacturer’s guidelines.

Tightness of foundation.

Any intrusive teardown inspection as specified by manufacturer should be considered.

SLEW BEARINGS AND KING POSTS/TURRET ASSEMBLY:

Inspection of slew pinion and gears.

Clearance of slew bearings should be checked and recorded for any deterioration; clearance

should be measured in line with manufacturer’s recommended method that best suits the

condition.

Grease sample analysis to identify presence of wear particles.

FUNCTION TESTS OF SAFETY SYSTEMS:

It is important to function-test the safety systems to ensure all effects, as desired, are taking

place. Adequate safety assessment and control measures should be identified before such tests

are performed.

Anti-two blocks or limit switches.

Emergency Load lowering (if applicable) should be performed.

Over speed protection of prime movers as applicable.

Calibration of load indicators.

Emergency shutdown of prime mover or motion retarding protections as provided.

Manual Overload Protection System (If applicable).




11.3 INSPECTION OF WIRE ROPE

Wire rope is a structural component of the crane which requires periodic replacement. Initial

dimensional measurement of the rope at the time of installation should be documented in the

crane file and should be referred during subsequent inspection of wire rope.

The owner of the crane shall develop and implement a written policy for wire rope inspection,

lubrication, maintenance and replacement. It shall also include rejection criteria and replacement

schedule considering type of crane, usage, history of maintenance, wire rope manufacturers’

recommendations and crane manufacturers’ recommendations.

11.3.1 INSPECTION

The wire rope inspection programme should be prepared taking into consideration crane type,

frequency of use, wire rope and crane manufacturers’ recommendations.

Visual inspection of wire rope during pre-use and monthly inspection should be performed by

qualified crane operator, while quarterly and annual inspection should be carried out by qualified

inspector. Wire rope inspection items should include, but not be limited to, the following.

1. Reduction of rope diameter below the nominal diameter, or initial wire rope dimensional

measurements, due to wear of outside wires, loss of core support or internal or external

corrosion. Core failure in rotation-resistant rope can be difficult to observe. Typical methods to

check core failure are as follows:

o Diameter measurement; diameter is reduced with core deterioration.

o Length of lay measurement; core failure results in an increase in the lay length.

2. The number of broken outside wires and the concentration of the broken wires. Attention should

be given to valley breaks where the breaks are at the strand to contact points.

3. Worn outside wires.

4. Corroded or broken wires at the end connections. Corroded, cracked, bent, worn, or improperly

applied end connections.

5. Kinking, crushing, cutting, or unstranding.

6. Improper spooling on hoist drum such as:

o strand crushing,

o core protrusion,

o abrasion,

o excessive strand gaps,




o loose and uneven spooling,

o high stranding.

7. Heavy wear and/or broken wires occur in rope sections in contact with certain components of

the crane. Care shall be exercised in inspecting the rope at these points. Inspection shall

include, but not be limited to, the following areas.

o Equalizer sheaves or saddles also referred to as fixed guides or other sheaves.

o End connections including socket or end attachments to running ropes, boom pendants

and other standing ropes.

o Sections of the rope where the rope is continually running over sheaves within the

various hoist systems. This inspection is of particular importance where boom angle and

load block changes are frequent and limited to short distances.

o Crossover and flange points of the rope on the hoist drums.

• The following is the rejection/replacement criteria for wire rope.

The following criteria are based on using the wire rope under maximum load condition, limited

usage can continue until the wire rope is replaced.

1. Running ropes used in the boom hoist:

— Six randomly distributed broken wires within one lay length;

— Three broken wires in one strand within one lay length.

2. Running ropes of rotation-resistant construction used in the main or auxiliary hoist:

— Four randomly distributed broken wires within 30 rope diameters;

— Two broken wires in one strand within six rope diameters.

3. Standing ropes such as boom pendants:

— Three broken wires within one lay length;

— Two broken wires at the end connection.

4. One valley (where strand to strand contact occurs) break can indicate internal rope damage

requiring close inspection of this section of the rope. When one or more valley breaks are found

in one lay length the rope should be retired.

5. The rope construction has been distorted by kinking, crushing, or other distortional damage.

6. There is evidence of heat damage from any source (i.e. engine exhaust, flare towers, stress

corrosion cracking, etc.). Heat can be generated by passing a rope over a frozen or non-turning




sheave, contact with structural members of the crane, improperly grounded welding leads or

lightning strikes.

7. Reductions for the rope diameter, from initial wire rope dimensional measurements, in a

nonworking area (an area away from the sheaves) compared to the lowest diameter of rope

measured in three working areas (areas where the rope regularly goes over a sheave) of more

than the following is observed:

— 3/64 in. (0.047 in.) (1.2 mm) for diameters up to and including 3/4 in. (19.1 mm);

— 1/16 in. (0.062 in.) (1.6 mm) for diameters of 7/8 in. to 11/8 in. (22.2 mm to 28.6 mm);

— 3/32 in. (0.093 in.) (0.8 mm) for diameter of 11/4 in. to 1 1/2 in. (31.8 mm to 38.1 mm);

— For rope diameters greater than 11/2 in., a 5 % diameter loss from baseline measurement.

8. Increase in the length of an individual rope lay is observed. This increase in lay length and

accompanying reduction in diameter can be caused by failure of the core. This can occur more

readily in ropes or rotation-resistant construction.

9. Corrosion that causes pitting to the surface of individual wires is cause for rope replacement.

For further details, please refer OISD-STD-187, API-RP-2D, or ASME-B-30.5

12.0 CRANE MAINTENANCE

The maintenance of the crane shall be made on the recommendation of the crane manufacturer’s

standard practices. However, maintenance practices shall be followed based upon utilisation of the

crane. The recommended practices for the maintenance have been indicated in Annexure- B.

12.1 PREVENTIVE MAINTENANCE

Periodic/ preventive maintenance schedule shall be followed as per standard manufacturer's

practices/operator's recommended practices. Written and dated maintenance records should be

retained as per Asset / company procedure.

12.2 REPAIRS & REPLACEMENT

The repairs & replacement of items shall be followed based upon the recommendation of

inspection agency / OEM. However, if any major item / part is obsolete / not available the same

shall be replaced with compatible parts which have to be approved by qualified person/agency.

No welding repair shall be made to critical components such as booms and swing circle

assemblies without specific repair procedures, material traceability reports (MTR), nondestructive

examination (NDE) reports from a qualified source ( from crane manufacturer, authorized

surveyor, an engineer experienced in the design of crane, as determined by crane owner). Care

should be taken to ensure that arcing does not occur across any bearings.




If any critical components such as section of the boom etc. are required to be repaired, a

qualified welder shall be deployed for welding jobs. Specific repair procedure should be prepared

as per manufacturer’s recommendation.

Documentation of repair of critical components of crane shall include material traceability reports

(MTRs), welder certification and welding procedure(s) identification number. This documentation

shall be maintained in the crane files for the life of the crane.

12.3 PRECAUTIONS DURING MAJOR REPAIR & MAINTENANCE

1. Any job will be started only after obtaining the hot / cold work permit at any site as per OISD-

STD-105.

2. Care should be taken to ensure that arcing does not occur across the bearings.

3. Hooks should not be exposed to excessive heat.

12.4 RE-RATING AND DE-RATING

CRANE RE-RATING:

Where rerating is necessary

1. Crane being rerated in excess of the original load ratings shall be approved and tested under

the directions of the crane manufacturer or a qualified person to confirm compliance and

appropriate action ( new load chart, load test, etc.).

2. Cranes shall be rerated and load charts revised in accordance with the edition of relevant

standards in force.

CRANE DE-RATING:

Temporary de-rating of a crane or component (winch, attachment, or appendage) due to any

deficiency shall be made by the original manufacturer, authorized surveyor, or an engineer

experienced in the design of the crane as determined by the crane owner. The qualified source

shall document the duration on the temporary load chart.

13.0 LOAD TESTING & CERTIFICATION

A copy of the original load test carried out by the manufacturer/contractor during the supply/sale

of crane certified by International/National reputed certifying agency shall be made available to

the operator/user.

In general two types of load testing certifications are required




1) The load testing & certification shall be done after major repair/ replacement of parts of the crane

based upon the recommendations of third party certifying agency. The replacement of the rope is

specifically excluded from this requirement. However, a functional test of the crane under a

normal operating load should be made prior to putting the crane back in service.

2) Periodic load test and certification :

Based on the usage rate of the cranes all those cranes used frequently shall be load tested

and certified annually, however for less used cranes, the load testing shall be done based upon

the recommendation of the certifying agency.

3) The load testing shall be carried out as per the procedure defined in IS: 4573 – 1982, API-RP-2D

14.0 INCIDENT / ACCIDENT REPORTING SYSTEM

Incident/accident reporting shall be done in OISD proforma.

15.0 CONTRACT MANAGEMENT

If outside contractors are used for crane operations, the contract management section should

ensure that minimum qualification for operator is followed, as per recommended practices.

16.0 PERSONNEL PROTECTIVE EQUIPMENT

1. All personnel working with and around the crane shall wear safety shoes, hard hat, hand

gloves & overalls.

2. Additionally while checking the pressure & oil gauges or working near air source or moving

parts, safety glasses should be used.

3. While working at height (above six feet), safety belt with full body harness as per IS:3521 shall

be worn.

4. Life vest or personnel flotation device shall be worn by all personnel being transferred by

personnel basket.

17.0 REFUELING

1. Refueling of cranes should not be done with the engine running.

2. Fuel tanks shall be filled in a manner such that fuel does not spill or overflows onto engine,

exhaust, or electrical equipment.

3. Fuel tank should have spill containment facility to provide environmental protection.




18.0 FIRE EXTINGUISHERS

1. A portable DCP type fire extinguisher (9/10kg, shall be installed in the cabin or at the

machinery housing.

2. Operating and maintenance personnel shall be familiar with the use and care of the fire

extinguishers provided.




IDENTIFICATION OF ACTIONS ON USE OF HAND SIGNALS

ANNEXURE - A

Hoist: With forearm vertical,

forefinger pointing up, move hand

in small horizontal circle.

Lower: With arm extended

downward, forefinger pointing

down, move hand in small

horizontal circles.

Move Slowly: Use one hand

to give any motion signal and

place other hand motionless

in front of hand giving the

motion signal.

Raise Boom: Arm extended,

fingers closed, thumb pointing

upward.

Lower Boom: Arm extended,

fingers closed, thumb pointing

downward.

Swing: Arm extended, point

finger in direction of swing

boom.

Emergency Stop: Both arms Dog Everything: Clasp hands in Use Main Hoist: Tap fist on




extended, pointing down, move

arms rapidly up and down. front of body head, then use regular

signals.

Use Whip Line: (Auxiliary Hoist)

Tap elbow with one hand, and

then use regular signals.

Lower the Boom and Raise the

Load:

With arm extended, thumb

pointing down, flex fingers in and

out as long as load movement is

desired.

Raise the Boom and Lower

the Load:

With arm extended, thumb

pointing up, flex fingers in and

out as long as load movement

is desired.

Extended Boom:

(Telescoping Booms) both fists in

front of body with thumbs pointing

outward.

Retract Boom:

(Telescoping Booms) both fists in

front of body with thumbs

pointing toward each other.

Stop: Arms extended, palm

down, move arm back and

forth horizontally.




ANNEXURE-B 1. DIESEL ENGINES

Refer section 5.0 of OISD STD.121 for engine maintenance

No. Maintenance Activity Daily Monthly Qtrly Yearly Condition

based

1 Check lubricating oil level and top-up as required. *

2 Check cooling water level and top up as required. *

3 Check fuel tank level and top-up as required. *

4 Check for any loose bolts, nuts, pipe/line connection of foundation and tighten if required.

*

5 Start the unit and record following after the start and again after 1/2 to 1 hour of running in the logbook.

a) Operating oil temperature and pressure. *

b) Engine speed. *

c) Water temperature. *

d) Hour meter reading *

e) Any other meter provided on the engine / panel. *

6 Rectification of fuel/lubricating oil leakage including repair/replacement of pipes.

*

7 Cleaning of radiator with air/water. *

8 Cleaning/changing of air intake filter and pre- cleaner dust pan including associated works.

*

9 Changing / cleaning oil /fuel / air/water /hydraulic filters . *

10 Lubricate governor , all linkage etc. *

11 Servicing and testing of injectors including allied works.

*

12 Checking / setting of rocker and tappet clearance. *

13 Checking/tightening of belt drives. *

14 Replacement of radiator with associated works. *

15 Replacement of hydraulic and pneumatic starter. *

16 Replacement of hydraulic hand pump for starting. *

17 Replacement of starting air compressor. *

18 Replacement of cooling water pump . *

19 Replacement of turbo charger . *

20 Servicing / repair of radiator . *

21 Servicing of hydraulic and pneumatic starter. *

22 Servicing of hydraulic starting pump . *

23 Servicing of starting air compressor . *

24 Servicing o f cooling water pump . *

25 Replacement of fuel pumps. *

26 Replacement o f governor. *

27 Changing of acceleration cable . *

28 Removal , cleaning and fixing of flame arrestor *

29 Removal , repair and fixing of air receiver tank *

30 Removal , cleaning and fixing of exhaust muffler *




31 Removal , cleaning and fixing of exhaust pipe . *

32 Cleaning, flushing and changing of lubricating oil including cleaning, / changing of lubricating oil filter and breather.

*

33 Cleaning, flushing and changing of fuel in fuel tank including cleaning, / changing of fuel filter .

*

34 Replacement of belts for cooling fans, water pump of compressor or generator.

*

35 Removal of cylinder head including allied jobs connected with its removal.

*

36 Assembling of cylinder head in the engine with associated work for total completion of the job and satisfactory testing .

*

37 Replacement of piston ring , connecting rod , piston ring set etc. Including associated work necessary for completion of the job .

*

38 Replacement of crankshaft including associated work for total completion of the job.

*

39 Removal and getting repaired / serviced including calibration of fuel injection pump from authorised agencies and checking for satisfactory performance of the engine with calibrated fuel injection pump .

*

40 Removal and getting repaired / serviced including calibration of governor from authorised agencies and checking for satisfactory performance of the engine with calibrated governor .

*

41 Painting of engine including supply of primer and marine epoxy paint as required.

*




1. CRANES

No. Maintenance Activity Daily Monthly Qtrly Yearly Condition/

Use based 1 Brake System :--Aux./main crane hoist , boom

a nd swing for proper functioning .

*

2 Safety System :-- Like limit of travels and movements , limits of safe operating load etc for proper functioning .

*

3 Condition of the hoses & hose connectors , grease to be applied for corrosion prevention at the hose connections ( as required )

*

4 Function of control levers and pedals and lubricate as required.

*

5 Operation of cabin doors, wipers, horns ,fan etc and lubricate / clean as required .

*

6 Check and top up of oil in following ( as required ) a) Aux. Hoist gear box , b) Swing drive unit gear box , c) Boom hoist gear box. d) Load hoist gear box , e) Hydraulic oil tank.

*

7 Lubricate / grease Boom tip extension sheaves. *

8 Lubricate / grease Boom point sheaves. *

9 Lubricate / grease Outer boom extension sheaves. *

10 Lubricate / grease Gauntry Sheaves. *

11 Lubricate / grease of all pivot pins of boom, derrick and sheaves including that of telescopic cylinders/chains/wire ropes inside the boom.

*

12 Lubricate / grease Radius Indicator bearings. *

13 Lubricate / grease Boom hoist pawl bearings. *

14 Lubricate / grease Upper & lower boom hoist kick-out.

*

15 Lubricate / grease Front and rear bogie roller / gears. *

16 Lubricate slew ring gear *

17 Lubricate / grease Position lock/Slew lock. *

18 Lubricate / grease Swing chain & lock. *

19 Lubricate / grease Main & aux. Block, swivel hook bearings and locking latch on hook/swivel.

*

20 Lubricate / grease Cross head bearing/main thrust washers.

*

21 Main aux. Hooks for deformations, cracks and safety latch .

*

22 Boom for any structural abnormalities, cracks of deformation.

*

23 Winch mounting -- tighten if required. *

24 Checking /lubrication of boom hook anchoring latch on chassis. Swing chain / pinion for proper fitting and functioning.

*

25 Checking for missing and tightening of slew ring gear mounting nuts and bolts

*

26 Checking and tightening of counter-weight pins/nuts & bolts.

*




27 Checking for creeping of derrick(luffing), boom telescopic and outrigger jack cylinders

*

28 Checking for leakage for hydraulic cylinders *

29

Pedestal and other structural mountings - tightened as required

*

29 Checking for full extension of outrigger beams *

30 Checking of cracks/deformation of out-rigger jack plates.

*

31 Checking of boom pad condition and their lubrication (in case of telescopic boom) and missing of members for lattice boom.

*

32 Hydraulic pumps and motors mounting - tighten as required.

*

33 Clean the wire ropes with wire brush, record dimensions and check for any kink ( if any ) . Also check end connections for proper fitting .Lubricate with grease. Boom Rope, main hoist rope and auxiliary hoist rope to be checked.

*

34 Replacement of wire rope and greasing including all allied job for the same .Boom rope

*

35 Replacement of wire rope and greasing including all allied job for the same .Main hoist rope

*

36 Replacement of wire rope and greasing including all allied job for the same .Aux hoist rope

*

37 Cutting, splicing and connection on hook/drum end of wire rope.

*

38 Replacement of swing drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings.

*

39 Replacement of winch drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings.

*

40 Replacement of auxiliary hook drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings.

*

41 Replacement of Main hydraulic pump including all associated works for completion of the job and checking for proper operation after fittings.

*

42 Replacement of swing drive motor ( hydraulic) including all associated works for completion of the job and checking for proper operation after fittings.

*

43 Replacement of Swivel hook bearing and checking for proper operation after replacement.

*

44 Replacement of Boom hoist pawl bearing and checking for proper operation after replacement.

*

45 Replacement of Cross head bearing and checking for proper operation after replacement.

*

46 Replacement of Main thrust washer and checking for proper operation after replacement.

*

47 Replacement of Swing chain. *

48 Replacement of Swing pinion checking for proper operation after replacement.

*

49 Replacement of Pulley and checking for proper operation after replacement.

*

50 Servicing of hydraulic pump of motor. *

51 Drain, flush and refilling of Aux hoist gear box .- *

52 Drain, flush and refilling of Swing drive unit. *




53 Drain, flush and refilling of Boom hoist gear box . *

54 Drain, flush and refilling of Load hoist gear box. *

55 Drain , flush and refilling of Hydraulic oil tank *

56 Drain, flush and refilling of Fuel oil tank . *

57 Servicing of slip ring and brushes of collector column ,if provided

*

58 Cleaning of battery terminals, applying of petroleum jelly and topping up of distilled water.

*

59 Servicing of Aviation light on boom . *

60 Replacement of aviation light including making Servicing of search light on boom/operator’s cab for illuminating working area and audio/visual warning system for reversing.

*

Note: The above list of items for maintenance and its frequency is only recommended practice. As far

as practical manufacturer’s guidelines should be followed.




ANNEXURE – C

INSPECTION OF COMPONENTS OF CRANE

S.NO. COMPONENT TYPE OF CHECK REMARKS 1 Boom Hoist Assembly Visual 2 Boom Point Sheave Assembly Visual 3 Boom Section

A. Base

B. Middle

C. Upper

D. Tip

Visual + NDT (Eddy Current/UT etc.)

4 Boom Hoist Wire / Rope Visual

5 Joy Stick Visual 6 Hook Block A) Visual

B) NDT

7 Main Hoist Rope Visual 8 Cabin Visual 9 Overhaul Ball Visual 10 Swing Circle Assembly Visual 11 Whip-line Visual 12 Pedestal Visual for Fasteners

NDT of welds

13 Brake Assembly Operational 14 Gear Assembly Visual 15 Hydraulic Assembly Operational 16 Control Assembly

Boom Control

Hoist Control

Swing Control

Operational & Limit Switch

17 Electrical Such As Lights Switches,

Voltmeter, Ammeter, Wiper, Fan,

Horn.

Operational

18 Structural Such As Ladder,

Catwalk and Rails. Visual

19 Engine Visual, Noise Level, Vibration

Air Pressure, Oil level, Air filter,

Starter, Governor

NDT of Crane Boom: Recommended every 5 years or earlier if any repair job is undertaken on any

structural component of the Boom.




Detailed inspection report of various items to be inspected is placed in the table below. The

report indicates whether the inspected item is to be re-used, to be provided as new, to be

repaired or replaced.

1. CABIN ITEMS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE

1.1 Operator Chair 1.2 Rubber beading 1.3 Cabin Door 1.4 Roller assembly for doors 1.5 Aluminum sliding window 1.6 Wiper with wiper motor,

blade & switch

1.7 Cabin light fitting 1.8 Cabin fan 1.9 Cabin body 2.0 Boom angle indicator 2.1 Lubro set 2.2 Load cell

2. CONTROL AND SAFETY SYSTEMS


2.1 Safe load Indicator 2.2 Hyd. Main Pressure gauge 2.3 Hyd. Pilot Pressure gauge 2.4 Air Pressure gauge 2.5 Lube oil pressure gauge 2.6 Lube oil temperature gauge 2.7 Techo hour meter 2.8 Techo Hour Meter Chord 2.9 Chord Control Mechanism 2.10 Chords for Control 2.11 Diesel level gauge 2.12 Hyd. Oil level gauge 2.13 Emergency shutdown device 2.14 Water temperature gauge




3. ELECTRICAL MECHANICAL AND OTHER HARDWARE ITEMS


3.1 Horn & Horn switch 3.2 Main switch 3.3 Voltmeter 3.4 Ammeter 3.5 Engine Room light 3.6 Air craft warning lights 3.7 Flood lights with fittings 3.8 Electric cables 3.9 Nuts & Bolts (Assorted) 3.10 Wedge & Sockets 3.11 Latches for Main and Aux. Hook 3.12 Brake liners / Brake Shoes 3.13 Plumber Block Bearing 3.14 "V" Belts 3.15 Exhaust Bend 3.16 Engine cooling fan guard 3.17 Exhaust Manifold 3.18 Exhaust Bellow 3.19 Injector overflow pipe 3.20 Diesel Filter 3.21 Lube Oil Filter 3.22 Anti vibration Pads 3.23 Grease Nipples(Assorted) 3.24 Spark Arrestor 3.25 Air Inlet valve 3.26 Roller Assemblies for Engine 3.27 Junction boxes




4. EQUIPMENT AND COMPONENTS


4.1 Luff Pawl Cylinder 4.2 Hyd. Starter with dog &pinion 4.3 Transmission Belts 4.4 Mechanical Engine Protection

unit for hazardous area

4.5 Oil cooler

5. PNEUMATIC & HYDRAULIC SYSTEMS


5.1 Hydraulic Hose pipe 5.2 Hydraulic pipes for all sizes 5.3 Hydraulic fittings 5.4 Suction Hose 5.5 Pneumatic hoses 5.6 Drain valve for Diesel tank 5.7 Drain valve for Air tank 5.8 NRV-1/2‖ 5.9 Hyd. Filter 5.10 Hyd. Tank Breather 5.11 Suction Valve 5.12 Hyd. Tank drain valve 5.13 Pneumatic switches 5.14 Hyd. Tank Gasket 5.15 Hydraulic oil filter 5.16 Hydraulic Float 5.17 Pneumatic fittings 5.18 Main Hydraulic Pump Assy




6. WIRE ROPES

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE 6.1 Wire rope for Main Hoist, Aux.

Hoist & luff winch

7. STRUCTURAL DAMAGES

NO. ITEM REUSE PROVIDE REPLACE SERVICE

7.1 Top Catwalk 7.2 Top covers 7.3 Cabin Top 7.4 Diesel Tank with Fittings 7.5 Engine Room Doors 7.6 All panels 7.7 Hand rail 7.8 Ladder

8. CRANE BOOM ASSEMBLY

NO. ITEM REUSE PROVIDE REPLACE SERVICE

8.1 Damaged Boom lacings 8.2 Boom Section joining pins 8.3 Safety Latch for Main block 8.4 Safety Latch for Aux. Block




ANNEXURE – D

LIST OF COMPONENTS FOR SERVICING

S.NO. ITEM

1. Accumulator & Relay valve starter

2. All Single & Double Joysticks

3. Electrical Panel & all lights

4. Hyd. Tank

5. Hyd. Hand Pump

6. Magnetic Particle collector

7. Fuel feed pump

8. Fuel pump

9. Injectors

10. All Pulleys

11. Counter shaft

12. Plumber block

13. Hydraulic Starter

14. All valves

15. Hyd. Motor for Main Hoist

16. Hyd. Motor for Aux.Hoist

17. Hyd. Motor for Luff Hoist

18. Hyd. Motor for Slew Drive

19. All Mono blocks

20. Slew free valve

21. Check- Q- Meter

22. Pump Drive

23. All Brakes

24. Grease Lubrication of wire ropes, Pulleys, Shafts, Pins & their greasing points

25. All Hyd. Cylinders

26. Slew Ring

27. Main hook block

28. Auxiliary hook block

29. First aid box

30. Distribution board

31. Lubricator assy

32. Air Receiver

33. A Frame

34. All Limit Switches

35. Generator

36 First aid box

37. Distribution Box

38 Joy Stick

39 Pedestal adapter

40 Sheaves




41 Sheave guards

42 Diesel Engine- thorough overhaul

43. Compressor




ANNEXURE-E

SAMPLE LIFT PLAN*

Lift Plan Number: /_/ /

Date:

Work Area: Work Permit No:

Task:

Maximum Weight of Load in Ton to be lifted: Actual / Assumed / Calculated:

Description of Lifting Operation:

Categorisation Of Lifting And Hoisting Operation

Routine Non-Routine (Simple) Non-Routine (Complicated) Non-Routine (Complex or Critical)

Check List: Possible considerations (not exhaustive)

Hazards to personnel in the area Load on pallets requires securing Trial lift required Awkward size / Shape /Sharp edges Transport fastenings removed Working under load Dedicated lifting points on the load Stability of the load an issue Tandem lifts involved Restricted headroom or confined area High Center of gravity (of load) Tag lines Required Correctly installed lifting equipment Adequate lighting and visibility Barriers Required Risk of overturning (for mobile cranes) Conflicting tasks in the area Safe Access available Number of people involved identified Dynamic factors involved Lifting over live plant Method of communication agreed (Radio/ Verbal/ Hand Signal) Lifting near power lines

Route to Be Travelled and Laydown Area Yes No 1 Are the route and laydown area clear of obstructions?

2. Is the laydown / landing area adequate

3. Is the laydown /landing area adequate in term of load bearing

4. Is suitable packing avaialble for protecting the load, lifting equipment, slings etc.

5. Have barriers been positioned to prevent access by unauthorised personnel

6. Have you confirmed that the laydown area is within the operating limits / radius of the equipment.

7. Have environmental conditions been considered with regards to the safety of the lifting operation

8. Will the Lifting Equipment operator be able to see the banksman throughout the operation

9. Are there hazardous process plan or materials in the areas.

Step by Step sequence of the Lifting Operation




SKETCH DETAILING THE RIGGING UP OF THE LIFTING EQUIPMENT AND LIFTING ACCESSORIES

Name of the Plant: Weight of Load: Crane Capacity: (Crane type: *Crane SWL: ………..Tons *Working Radius: ……………Max) *Boom Length: … Meters

(* Refer From Crane Load Chart)

Tools & tackles: Web Slings: No. of Web Sling: ………nos. Sling Details: Length: …. Mts,

Width: ……. inch, SWL: …... ton

Wire Rope Slings: No. of Sling: ……nos. Sling Details: Length: ….. Mts,

Width: ……. inch, SWL : ……. ton

D- Shackles: ……… Nos. D-Shackle SWL……………… tons.

LIFTING EQUIPMENT AND LIFTING ACCESSORIES TO BE USED (SPECIFY TYPE AND SWL) 1

2.

3.

4.

6.

7.

8. AUTHORISATION:

Lifting Authority: I have reviewed the details of the lifting plan and agree the work can proceed

Name: Signature:

DEBRIEF AND LEARNING (Did the lifting opertaion go as planned or are change to plan required)

Note*: Lift plan will be prepared as per company policy



19.0 REFERENCES

The following codes and standards (latest edition) are referenced to and made a part of

these specifications:

API Spec - 2C: Specification for Offshore Cranes

API-RP-2D: Recommended Practice for Maintenance and Operation of Offshore

cranes.

API-RP-9B Application, Care, and Use of Wire Rope for Oil Field Service

ASME B 30.5: Mobile and Locomotive cranes

ASME B 30.9: Slings

OISD - GDN-192: Safety practices during construction.

OISD- STD. – 187: Care and use of wire ropes.

OISD – STD-105: Work Permit System

IS: 807-1976: Code of practice for Design, Erection and testing (Structural Portion)

Of Cranes and Hoists

IS 13367: 1992 Safe use of cranes- code of practices part 1 General

IS 4573: 2015 Specification for power driven mobile cranes

IS 3521: 2014 Industrial safety belt and harness- specification

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting

from the use of OISD Standards/Guidelines.”

oil industry safety directorate

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