Lifting appliances

OPERATION & MAINTENANCE STRATEGY

Operation & Maintenance Strategy Wires & Sheaves

Version 1
Date xx-xx-2015

SMIT LAMNALCO

INDEX
Page

INDEX

xx

1. INTRODUCTION

xx

2. DEFINITIONS

xx

3. OFFICIAL REQUIREMENTS

xx

4. OPERATIONAL STRATEGY

xx

5. xxx MAINTENANCE STRATEGY

5.1 General
5.2 Inspection intervals
5.3 Assessment criteria
5.4 Record Keeping
5.5 Maintenance schedule

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6. Xxx MAINTENANCE STRATEGY

6.1 General
6.2 Inspection intervals
6.3 Assessment criteria
6.4 Record Keeping
6.5 Maintenance schedule

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ATTACHMENTS:
I
MEASURE POINTS STEEL WIRE
xx
II
FORM FOR ASSESSING STEEL WIRE
xx
III
CONVERSION STEEL WIRE DIAMETER-SHEAVE GROOVE xx
RADIUS
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1. INTRODUCTION
This pragmatic generic Operation & Maintenance strategy for lifting appliances is
developed for fleet wide implementation by the Group Technical Department of Smit
Lamnalco.
This lifting appliances Operation & Maintenance strategy is applicable for all lifting
appliances that are used for general cargo use and where described as such for lifting
appliances in use for lifting personnel and lifesaving appliances.
It is important for clarity sake to note that varying rules and regulations apply depending
on for what purpose a lifting appliance is used; for our purpose we can divide the
purposes in three sections namely:
- Lifting appliances in use solely for general cargo use.
- Lifting appliances in use for personnel lifting.
- Lifting appliances in use for life saving appliances.
This Maintenance Strategy is only applicable for the named lifting appliances in previous
paragraph, and -equipment fixed at that specific moment to the lifting appliance.
excluded are lifting appliances in use for ROV and/or diving operations, a note to make is
that for such operations the same rules and regulations apply as those for lifting of
personnel.
For each appliance a separate chapter is written, describing:
1.
2.
3.
4.
5.

a general section
a section describing the inspection intervals,
a section defining the approval and rejection criteria and
a section describing the procedure of record keeping
a Maintenance Schedule

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2. DEFINITIONS
a) Lifting appliance:
In general a lifting appliance can be described as equipment that performs the lifting
(Cranes, jacks, pad eyes, forklifts, powered hoists, manual hoists, lever hoists, beam
trolleys beam clamps etc).

b) Lifting accessory/equipment
The term equipment is in use both as a description for the lifting appliances themselves
as for any device that is used or designed to be used directly or indirectly to connect a
load to a lifting appliance. (slings, hooks, swivels, turn blocks, wedge sockets etc), for
clarity sake when the appliance (e.g. crane) itself is meant the term lifting appliance
should be used and where devices that can be disconnected directly or indirectly are
meant the term lifting accessory should be used.

c) Thorough inspection (examination)

A detailed visual examination by a competent person, supplemented if necessary by other suitable
means or measures in order to arrive at a reliable conclusion as to the safety of the lifting appliance or
item of loose gear examined.

d) Competent person
A person possessing the knowledge and experience required for the performance of thorough
inspections/examinations and tests of lifting appliances (and loose gear) who is acceptable to the
competent authority.

e) Competent authority
A minister, government department or other authority empowered to issue regulations or other
instructions having the force of law.

f) Visual Inspection
A Inspection by sight carried out by a responsible person (on board) with the purpose to come to a
decision so far as can be ascertained in such manner, if the lifting appliance and/or lifting accessories
are safe for continued use.

g) Cargo gear record book/Lifting appliance register

A register of the lifting appliances and items of loose accessories in a form prescribed by the
competent authority, usually in a model recommended by the ILO No. 152 25(2).

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3. OFFICIAL REQUIREMENTS
3.1 Documents
International regulations apply, the main one being the International Labour organization
and EC (European commission) directives, which provides general instructions and
references, however where applicable national regulations may be in place which shall
override the international codes:
a) International labour organization: Register of lifting appliances (and items of loose
gear) article 25(2) ILO convention concerning occupational safety and health (No.
152)
b) Framework directive 89/391/EEC as amended by (EC) 1882/2003 and 2007/30/EC
and (EC) 1137/2008, noted is that a version of 89/391/EEC including later
amendments is available and Work equipment directive 2009/104/EC (replaces the
repealed directive 89/655/EC including amendments)
For Flag states without specified regulations the ILO and European regulations are
considered as leading however (additional) national regulations may apply.
Aside from above named directives there are several documents dealing with lifting
appliances, for this lifting appliances Operation & Maintenance Strategy we made use of:
a) Bureau Veritas: BV rules for the certification of lifting appliances onboard ships
and offshore units. NR526 DT R01 E
b) Lloyds register: Code for lifting appliances in a marine environment and Survey
of examination of ships lifting appliances (In conjunction with UK P&I club,
Liebherr and Macgreggor)
c) OCIMF/OVID: Recommendations fot the labeling, testing and maintenance,
documentation/certification for ships lifting equipment.
d) SLIMS PRC-VSL-06-6006 Lifting and hoisting operations, SLIMS PRC-VSL06-6007 Personnel transfer operations.
e) MSC LSA (IMO/SOLAS) code (MSC.48(66)) (applicable for Life saving
appliances)
f) ISO, (DIN, BS and NEN) codes, mainly describing material specifications:
ISO 4309-2004 (Guidelines for installation, maintenance and examination of wire
rope in service on a crane), others possible relevant codes being:
ISO 2232-1990 (specifications round drawn non-allow wire),
ISO 2408-2004 (minimum requirements steel wire for general purpose),
ISO 3108-1988 (determination of actual breaking load steel wire),
ISO 3178-1988 (terms of acceptance steel wire for general purpose),
ISO 6892-1984 (tensile testing metallic materials),
ISO 7800-1984 (simple torsion test metallic materials),
ISO 7801-1984 (reverse bend test metallic materials),
ISO 7802-1983 (wrapping test metallic materials)
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It is worth to mention that other class societys (IACS) such as Det Norske Veritas, GL
(Noble Denton) have similar guidelines, for the purpose of this strategy guide we have
limited the sources to LR, and BV; those being the class societies generally involved with
our vessels.
Quote:
It is the employer's obligation to ensure the safety and health of workers in every aspect related to
work and he may not impose financial costs to the workers to achieve this aim. Alike, where an
employer enlists competent external services or persons, this shall not discharge him from his
responsibilities in this area.
By combining all mentioned information, an Operational & Maintenance Procedure for
lifting appliances is compiled, consisting of:

General section, describing the identification of equipment

Define inspection intervals for individual parts and implement this Preventive
Maintenance in the companies MMS (Marad)
Define Approval/Rejection criteria
Recording of Maintenance done / Inspections carried out
Formulation of a general maintenance plan

3.2 ILO
Requires that a register of the lifting appliances and items of loose gear shall be
kept in a form prescribed by the competent authority, account being taken of the model recommended
by the International Labour Office
Rules and regulations apply for:

1 Initial testing.
1.1 Every lifting appliance shall be certified by a competent person before being
taken into use for the first time;
1.2 the competent person shall witness and supervise the testing and shall
thoroughly examine the lifting appliance.
1.3 Every item of loose gear shall be thoroughly tested and certified by a
competent person before taken into use the first time and with accordance to
national rules and regulations
1.4 Upon completion the competent person shall complete and issue the Register
of lifting appliances and attach appropriate certificates; an entry shall be made in
part 1 of the register
1.5 A rigging plan showing the arrangements of the lifting appliances shall be
provided
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2 Periodic testing.
2.1a All lifting appliances Thorough examination at least annually (12 monthly)
and semi-annual (6 monthly) when in use for the transfer of personnel, the
particulars of this thorough examination by competent person to be entered into
part I of the lifting appliance register.
2.1b All loose Lifting gear/equipment Thorough examination at least annually (12
months) , the particulars of this thorough examination by competent person to be
entered into part I of the lifting appliance register.
2.2a Retesting of lifting appliances after any substantial alteration/renewal, repair
and at least every 5 years.
2.2b Retesting of lifting loose gear after any substantial alteration/renewal, repair
and at least every 5 years.
(Note; In experience of our technical staff lifting wires will not last 10 years and it
would be recommended to renew the wires completely after 5 years at special
survey date)
2.4 Thorough examinations after renewal or repair shall be entered into part I of
the register
2.5 No new item of loose gear shall be manufactured of wrought iron, advise;
identify and take out of service all wrought iron components, replace with modern
types.

3 Regular inspections by responsible person on board.

3.1 Regular inspections of every item of lifting appliance and loose gear shall be
carried out by a responsible person before use, these inspections shall be entered
in part II of the Registered IF a defect has been indicated.

Structure of the lifting appliance register/cargo gear record book.

Certificates
The certification forms to be used in conjunction with this Register (Form No. 1)
are as follows:
Form No. 2 Certificate of test and thorough examination of lifting appliances.
Form No. 3 Certificate of test and thorough examination of loose gear.
Form No. 4 Certificate of test and thorough examination of wire rope.
Register part I
If all the lifting appliances are thoroughly examined on the same date it will be sufficient
to enter in column (1) All lifting appliances and loose gear. If not, the parts which have
been thoroughly examined on the dates stated must be clearly indicated, advisable is to
note all appliances and accessories separate also in the case of a combined examination.
The thorough examinations to be indicated in column (3) include:
- Initial
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- 12 monthly (6 monthly if in use for personnel transfer operations)

- Five yearly
- Repair/damage
- Other thorough examinations including those associated with heat treatment.
Register part II
All loose gear to be inspected before use, however; entries need only be made when inspection
discloses a defect.
For the purpose of a clear example ILO forms No 1 till 4 will be included within this document for
maintenance guidelines on loose gears and wires reference is made to the applicable Operational &
Maintenance strategys concerning those topics in conjuncture with this document.
Specific test loads mentioned
Lifting appliances
T = Tonne = 1000Kg, SWL = Safe working load
SWL

Test load

< 20 T

25% in excess of SWL

> 20 T < 50 T

5 T in excess of SWL

> 50 T

10% in excess of SWL

In the case of cranes, the test load is to be hoisted, slewed and luffed at slow speed.
Gantry and travelling cranes together with their trolleys, where appropriate, are to be
traversed and travelled over the full length of their track.
In the case of variable load-radius cranes, the tests are generally to be carried out
with the appropriate test load at maximum, minimum and at an intermediate
radius.
In the case of hydraulic cranes where limitations of pressure make it impossible to
lift a test load 25 per cent in excess of the safe working load, it will be sufficient
to lift the greatest possible load, but in general this should not be less than 10 per
cent in excess of the safe working load.
As a general rule, tests should be carried out using test loads, and no exception should
be allowed in the case of initial tests. In the case of repairs, replacement or when the periodic
examination calls for re-test, consideration may be given to the use of spring or hydraulic
balances (SWL max 15 Tonnes). Where aspring or hydraulic balance is used it shall be calibrated and
accurate to within 2 per cent and the indicator should remain constant for five minutes, If test
weights are not used this is to be indicated in column 3 of the lifting appliance register.

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3.3 EC (European commission) Directives

The results of inspections shall be recorded and kept at the disposal of the authorities
concerned. They must be kept for a suitable period of time. When work equipment is used
outside the undertaking it shall be accompanied by physical evidence that the last
inspection has been carried out, Member States shall determine the conditions under
which such inspections are made.
Provisions concerning the use of work equipment for lifting loads.
1 General considerations
1.1 Work equipment which is mobile or can be dismantled and which is designed for
lifting loads must be used in such a way as to ensure the stability of the work equipment
during use under all foreseeable conditions, taking into account the nature of the ground.
1.2 Persons may be lifted only by means of work equipment and accessories provided for that
purpose.
Without prejudice to Article 5 of Directive 89/391/EEC, exceptionally, work equipment which is not
specifically designed for the purpose of lifting persons may be used for that purpose, provided
appropriate action has been taken to ensure safety in accordance with national legislation and/or
practice providing for appropriate supervision, which in any case means a thorough inspection at half
the periodic (6 monthly), due to this fact it is highly advised to avoid personnel transfer with the ships
own equipment where possible and if absolutely necessary to do so, have accessories identified for
this purpose specifically and measures in place to ensure that periodic inspections are adhered to.
While workers are on work equipment designed for lifting loads the control position must be manned
at all times. Persons being lifted must have reliable means of communication. In the event of danger,
there must be reliable means of evacuating them.
1.3 Measures must be taken to ensure that workers are not present under suspended loads, unless such
presence is required for the effective operation of the work, Loads may not be moved above
unprotected workplaces usually occupied by workers, where that is the case, if work cannot be carried
out properly any other way, appropriate procedures (MOC) must be laid down and applied.
1.4 Lifting accessories must be selected according to the loads to be handled, gripping points,
attachment tackle and atmospheric conditions having regard to the mode and configuration of
slinging. Lifting accessory tackle must be clearly marked so that users are aware of its characteristics
where such tackle is not dismantled after use.
1.5 Lifting accessories must be stored in a way that ensures that they will not be damaged or
degraded.

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2 Work equipment for lifting non-guided loads.

2.1 When two or more items of work equipment used for lifting non-guided loads are installed or
erected on a site in such a way that their working radii overlap, appropriate measures must be taken to
avoid collision between loads or the work equipment parts themselves.
2.2 When using mobile work equipment for lifting non-guided loads, measures must be taken to
prevent the equipment from tilting, overturning or, as the case may be, moving or slipping. Checks
must be carried out to ensure that these measures are executed properly.
2.3 If the operator of work equipment designed for lifting non-guided loads cannot observe the full
path of the load either directly or by means of auxiliary equipment providing the necessary
information, a competent person must be in communication with the operator to guide him and
organizational measures must be taken to prevent collisions of the load.
2.4 Work must be organized in such a way that, when a worker is attaching or detaching a load by
hand, it can be done safely, in particular through the worker retaining direct or indirect control of the
work equipment.
2.5 All lifting operations must be properly planned, appropriately supervised and carried out in such a
way as to protect the safety of workers, in particular, if a load has to be lifted simultaneously by two
or more items of work equipment designed for lifting non-guided loads, a procedure must be
established and applied to ensure good coordination on the part of the operators.
2.6 If work equipment designed for lifting non-guided loads cannot maintain its hold on the load in
the event of a complete or partial power failure, appropriate measures must be taken to avoid
exposing workers to any resultant risks, suspended loads must not be left unsupervised.
2.7 Open-air use of work equipment designed for lifting non-guided loads must be halted when
meteorological conditions deteriorate to the point of jeopardizing the safe use of the equipment and
exposing workers to risks. Adequate protection measures, in particular measures to avoid work
equipment turning over, must be taken to avoid any risks to workers.
If such protective and preventive measures cannot be organized for lack of competent personnel in
the undertaking and/ or establishment, the employer shall enlist competent external services or
persons, in all cases:
The workers designated must have the necessary capabilities and the necessary means.
The external services or persons consulted must have the necessary aptitudes and the necessary
personal and professional means.
The workers designated and the external services or persons consulted must be sufficient in numbers.

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3.4 Bureau Veritas/Lloyds register (IACF)

Lloyds register
A lifting appliance generally has no redundancy so a single failure is enough to cause a
major accident.
Various national regulatory schemes require that lifting appliances should be thoroughly
examined by a competent person at least once every 12 months. Some legal frameworks
may require more frequent examinations, depending on the national authority, the
competent person, and whether the equipment is used for lifting personnel, In any case a
vessel operating in a certain geographical area shall inform oneself if the national
requirements exceed the standard.
Classification is used in two situations:
Mandatory where the lifting appliance is the essential feature of a classed
ship. This applies for example to a heavy lift crane on a heavy lift barge, or lifting
arrangements for diving operations on diving support ships.
Optional when the owner requests classification, even though the lifting appliance
may not be an essential feature of a classed ship
General considerations
Before commencing a thorough examination of a lifting appliance (excluding LSA
davits), it will be necessary for the attending surveyor to see the Register of Lifting
Appliances and Cargo Handling Gear, The surveyor will need to:
check the existing certificates for the appliances, the ropes, and the
loose gear
look at the survey history of the appliance
check for any issues which are outstanding from the last examination
check if there are any recurring problems which will require particular
attention in the examination
review slew bearing rocking test/grease sampling data, where applicable (Note 1)
Secondly, it will be necessary to see any maintenance and service records and check:
what has been serviced
which components have been replaced
what lubrication has been carried out.
Finally, to confirm everything is in its correct location, it will be necessary to look at:
general arrangement plans
reeving diagrams
block lists.

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(Move to separate section?)

Note 1:

Wear of the slew bearing and loss of bolt integrity

Slew bearings are the mechanical components which allow the crane to rotate, or slew.
Slew bearings are subjected to continuous wear. There are commonly three types of slew
bearings fitted to ships cranes:
single ball bearing generally found on deck cranes
twin ball bearing generally found on deck cranes
three roller bearing generally found on offshore and heavy lift cranes.
Several slew bearings have failed in recent years with catastrophic results. The failures
have mainly been on cranes more than 10 years old with the single ball bearing type.
Slew bearing measurements (Rocking test):
It is a test which is carried out to find, wear down of the sleeve bearing of the deck crane.
This measures the play (or relative movement) between the inner and outer bearing race,
to give an indication of the wear taking place.
Measurements are typically taken in four positions on the slew bearing, with the jib
pointing:
forward to the ship
starboard
aft to the ship
port side.
Neither a load nor any cargo handling equipment should be attached to the hook.
It is important for the same positions to be marked as a datum reference, the
measurements has to be taken when the ship have as little list/trim as possible
Cranes which are particularly at risk are those with single ball race slew bearings. Cranes fitted with
this type of slew bearing must have rocking tests carried out, in accordance with manufacturers
instructions, to determine that the amount of wear in the bearing races is within permitted limits.
Lloyds Register surveyors are being instructed to review the results of rocking tests at all future
Annual Thorough Surveys.
Over the years the slewing bearing will have some wear, and to be able to know if there is a need for
changing the slewing bearing it is needed to keep a record of the wear.
The measurements shall be taken regularly, every 6 months.
Measurements can be sent to the lifting appliance manufacturer for evaluation.

If no rocking test has been carried out in the previous six months, the crane in
question will not be certified for further use.

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Procedure measuring the gear ring play or rocking test:

By using a venire caliper(1) instead of dial indicator(2) the result would be wrong. With the dial
indicator the measurement is more accurately.

(1)

(2)

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On the cranes bottom plate two reference point need to be marked. The reference points have to be
always used for the future measuring. The marked surfaces should be on the front and rear bottom
plate of the crane, it is important to use about the same position for all further measurements to be
able to compare the measurements therefore evident markings shall be used and maintained in visible
state.
The dial indicator should be positioned between the rotating and nonrotating bearing races and crane
jib must be raised maximum up and maximum down.
Measurements shall be taken on four positions of the slewing bearing. With the jib pointing: forward,
starboard, aft, port side, set the indicator at zero then raise the crane jib at maximum up and record
the value. The indicator of dial indicator should return to zero when the crane jib is lowered back to
its original position.
Above one method is presented, but there are other methods of slewing gear ring measuring like:
rotation method or tilt method, before doing the test you should become familiar with the crane and
manufacturers recommendations shall be checked.
2 Slew bearing measurements (Grease sampling test):
Another way of measuring slewing wear is by sampling the grease:
Take 4 samples at 90 degrees around the ring, of which one under the jib and one 180 degrees
opposite.
take samples by pushing new grease into the nipples and collect the first used grease to come out,
grease samples to be taken as far away from the nipple as possible, samples should typically be taken
at the inner seal of the bearing.
(Wear down of the sleeve bearing can be found by analyzing the grease sample.
The metal content of the sample may give indication of wear down).
3 Slew bearing measurements (Tightening of bolts and nuts by torque):
In each case of slew bearing measurement whether by rocking test, grease sampling or any other
approved method the tightening of the nuts and bolts should be adjusted according to torque
recommendations of the manufacturer.

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Proof load testing

Proof load testing is a legal requirement and is needed for Lloyds Register certification
for almost all lifting appliances and loose gear. It must be carried out:
before new equipment is taken into service
at set periods as required by national regulations, typically every five years
after structural modification and repair
The provisions for use of devices other than weights are the same as in use under ILO 25(2) No 152
Specific test loads mentioned
Lifting appliances:
T = Tonne = 1000Kg, SWL = Safe working load
SWL

Test load

< 20 T

25% in excess of SWL

> 20 T < 50 T

5 T in excess of SWL

> 50 T

10% in excess of SWL

Lifting accessories: (Move to loose equipment?)

T = Tonne = 1000Kg, SWL = Safe working load
Accessory

Test load

Single sheave blocks

4x SWL

Multi sheave blocks < 25 T

2x SWL

Multi sheave blocks > 25 T < 160 T

(0.933 x SWL) + 27

Multi sheave blocks > 160 T

1.1 x SWL

Hooks/Schackles/Chains/Swivels etc. < 25 T

2x SWL

Hooks/Schackles/Chains/Swivels etc. > 25 T

(1.22 x SWL) + 20

Lifting beams/Spreaders/Frames < 10 T

2x SWL

Lifting beams/Spreaders/Frames > 10 T < 160 T

(1.04 x SWL) + 9.6

Lifting beams/Spreaders/Frames > 160 T

1.1 x SWL

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4. OPERATIONAL STRATEGY

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