Lufkin

Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
INTRODUCTION:
$(is do)ument refers to t(e lifting of mo&ing loads "# using me)(ani)al de&i)es* $(e o"+e)ti&es of t(e
(oisting and rigging program are to prote)t all Lufkin emplo#ees from in+ur# and to prote)t t(e
en&ironment from (arm and e,uipment and propert# from damage*
-mproper design. use or maintenan)e of )ranes. fi/tures or an# ot(er lifting de&i)es and rigging
a))essories )an )ause e,uipment to failure. load to drop from t(e lifting s#stem resulting in personal
in+ur#. deat(. damage to t(e en&ironment or signifi)ant propert# loss* t(e first line super&isor dire)ting
(oisting and lifting is responsi"le for ensuring t(at personnel 0(o t(e# super&ise and 0(o perform
(oisting and rigging a)ti&ities su)( as designing. inspe)ting. maintaining and using (oisting and rigging
e,uipment. preparation and appro&al of lift plans. and re&ie0 of e,uipment )omplian)e are ,ualified to
do so* % person ma# "e ,ualified to perform one of t(ese tasks. "ut not ,ualified to perform anot(er*
Super&isors must "e kno0ledgea"le of t(e spe)ifi) t#pes of (oisting and rigging operations under t(eir
super&ision* 1urt(er. super&isor must "e familiar 0it( appli)a"le rules and pro)edures implemented at
t(e site to ensure t(at (oisting and rigging 0ork under t(eir )ontrol is done effi)ientl# and safel#. 0it(
safet# as top priorit#* Super&isor must ensure t(at emplo#ees full# understand t(e importan)e of safet#
and t(e# )ategori2e t(eir o0n aut(orit# and responsi"ilit# to stop a)ti&it# 0(en safet# is ,uestiona"le*
1. %ll )ranes and lifting applian)es s(all (a&e )urrent &alid test )ertifi)ates in a))ordan)e 0it( t(e#3re
rated )apa)it# and s(all "e full# insured against t(ird part# lia"ilit#* % )op# of t(e test and insuran)e
)ertifi)ate must "e kept 0it( t(e &e(i)le at all times 0(ilst it is on Lufkin sites*
2. $(e 'ontra)tor s(all ensure t(at persons emplo#ed to operate )ranes or lifting e,uipment are
)ompetent to do so and (a&e "een trained in t(e appli)ation of )orre)t of lifting prin)iples and safe
0orking loads*
3. -t is not permitted for an# person to )arr# out 0ork. stand. or 0alk dire)tl#. "elo0 a load suspended
from a )rane or (oist*
4. %ll (ooks must "e fitted 0it( self )losing safet# lat)(es*
5. %ll lifting slings must "e in good )ondition and ma# "e su"+e)t to inspe)tion. "# Lufkin operation
department*
1. scope:
This document applies to all personnel and equipment used to perform any hoisting
and rigging activities. Activities involving the following equipments are included:
1. ranes! hoists! and miscellaneous lifting devices.
2. "igging hardware and accessories.
$laat !age 1 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
3. powered industrial vehicles # for$lifts%
2. Definitions:
1* Free rigging: the direct attachment to or placement of rigging to the tines # for$% of
a powered industrial truc$ &elow 'the ' tines lift.
2* Below the hook lifting device: device that designed to &e used in con(unction with
a hoist to lift specific types of loads .e)amples include tongs!*+oo$s!sheet lifters!
spreader &eams! mill roll lifters! hori,ontal sheet lifters! lift &ails! plate grades!
&attery lifters! pouring &ails! vacuum lifters and trail lifters.
4* Safe upper limit travel: is the highest position of hoist travel that prevents any
strain on the hoist rope! or contact of the hoo$ or lower hoo$ &loc$ with any part of
the hoist or trolley or crane.
4* Sling: wire rope! chain! synthetic we&! and metal mesh made into forms.
5* Designated person- an individual selected or designed as &eing qualified to
perform specific duties.
5* qualified person- a person who! &y possession of a recogni,ed degree! certificate or
professional standing or who &y e)tensive $nowledge training! and e)perience has
successfully demonstrated an a&ility and competence to solve or resolve pro&lems
relating to the su&(ect matter and wor$.
6* Positioning device: is a device designed to cut off the control of the hoist motor
automatically &elow the upper over travel device in the upward direction! the
positioning device generally will &e su&(ect to frequent use during normal hoist
operation.
* Power circuit limit switch: is a device designed to cut off the power to the hoist
motor automatically when tripped. The switch is to &e used automatically only as
an upper over travel device! never a positioning device. The switch shall &e rated for
full nameplate power of the hoist motor.
7* aterial Safet! Data Sheet "SDS#: .aterials #e.g. chemicals! solutions! solvents!
man made fi&er! cranes! slings! chains etc.% ontaining &anned su&stance is not
permitted on the premises.
10. Attachment8 % de&i)e ot(er t(an )on&entional forks or load "a)krest e/tension. mounted permanentl#
or remo&a"le on t(e ele&ating me)(anism of a tru)k for (andling t(e load* !opular t#pes are fork
e/tension )lamps. rotating de&i)es. side s(ifters. and load sta"ili2ers*
11. AUXILLARY HOIST: /upplemental hoisting unit of lighter capacity and usually
higher speed than the main hoist.
12. Bending stress8 stress on 0ires of a 0ire rope imposed "# "ending* $(is stress need not "e added to
dire)t load stresses* W(en s(ea&es and drums are of suita"le si2e. "ending stress does not affe)t t(e
normal life of t(e 0ire rope*
13. Birdcage: a colloquialism descri&ing the appearance of a wire rope that is forced into
compresasion.the outer strands from a cage and at times displaces the core.
$laat !age 2 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
14. Birdcaging: the twisting of fi&er or wire rope in an isolated area in the opposite
direction of the rope lay! causing it to ta$e on the appearance of &irdcage.
1. B!!m "ine #crane%: a wire rope for supporting or operating the &oom on derric$s!
cranes! draglines! shovels! and the li$e.
1#. B!!m: a mem&er hinged to the rotating superstructure and used for supporting the
hoisting tac$le.
1$. Brid"e s"ings: a sling composed of multiple legs #&ranches%! the top ends of which
terminate in a fitting that latches onto the lifting hoo$.
1%. B&"" ring: the main large ring of a sling to which sling legs are attached.
1'. (a)"e: a term loosely applied to wire ropes! wire strands! manila ropes! and electric
conductors.
20. (HO*+R RO,+: A short wire*rope sling used to form a slip noose around t(e o"+e)t to "e
mo&ed or lifted*
21. (RA-+. A machine used for lifting and lo0ering a load &erti)all# and mo&ing it (ori2ontall#
and t(at (as a (oisting me)(anism as an integral part of it*
'R%9ES. $:!ES ;1:
22. A&t!matic (rane: A crane that! when a)ti&ated. operates t(roug( a preset )#)le or )#)les*
23. (a)/O0erated (rane: A crane controlled &y an operator in a )a" lo)ated on t(e "ridge or
$rolle#*
24. (anti"e1er 2antr3 (rane: A gantry or semi gantry crane in which the &ridge girders
;r trusses e/tend trans&ersel# "e#ond t(e )rane run0a# on one or "ot( sides*
2. 4"!!r/O0erated (rane: A crane whose operation is controlled &y use of a pendant in
$(e (ands of an operator on t(e floor or on an independent platform*
2#. 2antr3 (rane: A crane similar to an overhead )rane. e/)ept t(at t(e "ridge for )arr#ing t(e
$rolle# or trolle#s is rigidl# supported on t0o or more legs running on fi/ed rails or ot(er run0a#*
2$. 5i) (rane: A fi)ed crane with a vertical rotating mem"er supported at t(e "ottom <also
%t t(e top in some t#pes= from 0(i)( an arm e/tends to )arr# t(e (oist trolle#* >i" )ranes are most
)ommonl# mounted on a &erti)al 'olumn. supplied as part of t(e +i" )rane. or on e/isting stru)tural
mem"ers <e*g*. a 0all mounted +i" )rane=*
2%. 6!)i"e (rane. 0or the purposes of this )(apter. mo"ile )ranes are defined as 0(eel mounted
'ranes. tru)k )ranes. and )ra0ler )ranes*
$. %&'() S'F)*+ &),-.&))(*S:
ranes are carefully designed! tested and manufactured for safe operation.
1hen used properly they can provide safe relia&le service to lift or move loads.
2ecause cranes have the a&ility to lift heavy loads to great heights! they also have
an increased potential for catastrophic accidents if safe operating practices are
not followed.
rane operators and personnel wor$ing with cranes need to &e $nowledgea&le of
&asic crane capacities! limitations! and specific (o& site restrictions! such as
location or overhead electric power lines! unsta&le soil! or high wind conditions.
3ersonnel wor$ing around crane operations also need to &e aware of hoisting
$laat !age 4 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
activities or any (o& restrictions imposed &y crane operations! and ensure (o& site
coordination of cranes. rane inspectors should &ecome aware of these issues
and prior to starting an inspection! ta$e time to o&serve the overall crane
operations with respect to load capacity! site conditions and any (o& site
restriction in effect. This document defines the minimum hoist design criteria
required for verifying proper operation prior the operation! periodic inspection
requirements and crane isolation for periodic inspection maintenance and repair.
1. 4ach site and it is the responsi&ility of the site supervisor to esta&lish a
documented plan for implementation of the requirements descri&ed in this
document.
2. 5t is the responsi&ility of each location to apply local procedures and processes to
include the specific items in this document to comply with local and national
regulations and to develop and maintain hoist inspection record.
This document defines the minimum hoist design criteria required for verifying
proper operation of the upper over travel device prior the operation! periodic
inspection requirements and crane isolation for periodic inspection maintenance
and repair.
3. 5n 6uf$in where all hoist devices are leased! so! it is the responsi&ility of the site
supervisor to esta&lish a documented plan to ma$e sure of the suita&le
requirements of cranes and chains and also to ma$e sure of the inspection to &e
ta$e place according to the requirements of this document.
4. 5t is the responsi&ility of each location to implement local procedures and processes
to include the specific items in this document to comply with local and national
regulations and to develop and maintain hoist inspection record.
/. &)SP0(S.B.1.*.)S
/.1 2S) anager &esponsi3ilities:
/etting the documented instructions and written program and ma$e sure of
distri&uting this program to all interested parties.
3eriodically verifying monthly test and inspection reports.
5nterpreting crane and hoist safety rules and standards.
3roviding management planning and technical assistance
3erforming periodic audit in every location to ma$e sure of the implementation
of this procedures.
$laat !age 4 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
5nvestigating any incident related to the crane operation whether leased or
owned &y the company.
/.2 Field supervisor responsi3ilities:
4nsuring that employees under their supervision receive the required training
and are certified and licensed to operate the cranes and hoists in their areas.
3roviding training for prospective crane and hoist operators.
4valuating crane and hoist trainees using crane safety chec$list and
su&mitting a qualification form to the operation department or designee to
o&tain operator7s license.
4nsuring that hoisting equipment is inspected and tested monthly &y a
responsi&le! designated individual! that rigging equipment is inspected
annually! and that inspection results are documented on 'site.
/.$ %ranes and 2oist operator are responsi3le for :
8perating hoisting equipment safely.
onducting functional tests prior to using the equipment.
/electing and using rigging equipment appropriately.
+aving a valid operator7s license on their person while operating cranes or
hoists.
3articipating in a medical certification program when required.
8perators shall comply with the following rules while operating the cranes and
hoists:
9o not engage in any practice that will divert your attention while operating
the crane.
"espond to signals only from the person who is directing the lift or an
appointed signal person
8&ey stop signal at all times! no matter who gives it.
9o not move a load over people- people shall not &e placed in (eopardy &y &eing
under a suspended load.
9o not wor$ under a suspended load! unless the load is supported &y &loc$s!
(ac$s! or a solid footing that will safely support the entire weight.
8pen and tag the main electrical disconnect switch
4nsure that the rated load capacity of a crane7s &ridge! individual hoist! or any
sling or fitting is not e)ceeded.
:now the weight of the o&(ect &eing lifted or use a dynamometer or load cell to
determine the weight.
$laat !age 5 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
hec$ that all control of the off position &efore closing the main* line
disconnect switch.
Avoid side pulls and ;or load swinging. These can cause the hoist rope to slip
out of the drum groove! damaging the wire.
To prevent shoc$ loading! avoid sudden stops or starts. /hoc$ loading can
occur when a suspended load is accelerated or decelerated! and can overload
the crane or hoist
1hen completing an upward or downward motion! ease the load slowly to stop.
4. Pre5operational test:
5n 6uf$in where the cranes and all hoist equipment are leased and not owned
&y the company! the supervisor should ma$e sure that the following tests are
done &y the operator of the leased crane.
At the start of the lifting operation &y using cranes! operators should do the
following steps
Test the upper 'limit switch. /lowly raise the unloaded hoo$ until the limit
switch trips.
<isually inspect the hoo$! load lines! trolley and &ridge as much as possi&le
from the operator7s station.
5f provided test the lower limit switch.
Test all direction and speed controls for &oth &ridge and trolley travel.
Test the pendant emergency stop
Test the hoist &ra$e to verify there is no drift without a load.
6oc$out and tagout for repair any crane that shown malfunction. 9o not
return to service until maintenance is completed.
4)cept for under hung hoists! each hoist shall &e equipped with a clearly
identifia&le on; off switch! emergency stop push&utton or power safety switch
that the operator can easily reach to interrupt power to the hoist and set the
hoist &ra$e in any event.
5t is not required to have a separate on ; off switch or hoist emergency stop
push&utton or power safety switch for a hoist if there is such a device for the
entire crane &ra$es regardless of where the operator hoist control is positioned*

4.1 %rane design criteria

To prevent hoist over travel in the raising or upward direction
1. =pper over travel device shall &e provided to prevent the load &loc$ from passing
the safe upper limit of travel of all powered hoisting mechanism.
$laat !age 5 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
2. The upper over travel device shall not &e used for positioning of the hoist. 5t is
used only as a safety device in the event of emergency. 4mployee must wor$ in a
safe manner so as to ensuring safety of himself! his co*wor$ers and other
employees. 9amage to company property is a penal offense.
3. 5t is preferred to implement only a weight actuated power circuit limit switch that
interrupts the power to the hoist motor. 5t should &e electrically or pneumatically
positioned so that it is the last device &efore the motor power input. 5t should &e
on the output# load% side of the power source.
4. 8n all A.3 phase control circuits! where a dou&le pole power limit switch is
employed! a contact or similar device shall &e installed in the control circuit to de*
energi,e the third phase of the motor power connection.
5. 6ower travel limit device should &e provided where the load &loc$ enters a pit ot
hatchway during normal operation.
>. The device shall &e designed to &e chec$ed for proper operation once every twenty
'four hours for automatic material handling hoists once per shift! prior to use for
material handling hoists manually controlled.
4.2 2oist 3rake s!stem
1. 4ach hoist system shall have a &ra$ing system to control load lowering.
2. The hoist &ra$e shall not &e changed to a different specification from that
furnished for the application without written approval of the hoist
manufacturer or qualified person.
3. Any change shall &e documented and the documentation retained including
the written approval of the change.
4. 2ra$es using standard couplings as &ra$es wheels are prohi&ited. A
mechanical load &ra$e is preferred on underhung hoists of 5 &ra$es does not
need to &e replaced.
5. The trip setting of each upper over travel device shall &e determined &y tests
with an empty hoo$ or reeve in device traveling in increasing speeds up to the
ma)imum speed.
>. The actuating mechanism of the upper over travel device shall &e located so
that it will trip under all conditions in sufficient time to prevent any strain on
the crane rope.
6* -f "elo0 ? t(e (ook lifting de&i)e or (ook atta)(ed de&i)e is used. t(en t(e tests s(ould also "e
)ondu)ted 0it( t(e de&i)e in pla)e or determined "# a ,ualified person*
$laat !age 6 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
* $(e (oist rope or )(ain s(all not "e )(anged to different spe)ifi)ations from t(at furnis(ed for
t(e appli)ation 0it(out 0ritten appro&al of t(e (oist manufa)turer or ,ualified person* %n#
su)( )(ange s(ould "e do)umented and t(e do)umentation retained. in)luding t(e 0ritten
appro&al of )(ange*
.3 means of interruption of hoist power 3! the operator:
1* E/)ept for under (ung (oists. ea)( (oist s(all "e e,uipped 0it( a )learl# identifia"le on/ off
s0it)(. emergen)# stop pus("utton or po0er safet# s0it)( t(at t(e operator )an easil# rea)( to
interrupt po0er to t(e (oist and set t(e (oist "rake in an# e&ent*
2* it is not re,uired to (a&e a separate on / off s0it)( or (oist emergen)# stop pus("utton or po0er
safet# s0it)( for a (oist if t(ere is su)( a de&i)e for t(e entire )rane "rakes regardless of 0(ere
t(e operator (oist )ontrol is positioned*
/./ 2oist 3rake s!stem
?. 4ach hoist system shall have a &ra$ing system to control load lowering.
1@. The hoist &ra$e shall not &e changed to a different specification from that
furnished for the application without written approval of the hoist
manufacturer or qualified person.
11. Any change shall &e documented and the documentation retained including
the written approval of the change.
12. 2ra$es using standard couplings as &ra$es wheels are prohi&ited. A
mechanical load &ra$e is preferred on underhung hoists of 5 &ra$es does not
need to &e replaced.
6.7.1 inspection requirements for mo3ile crane:
1. 3rior to the initial use of any crane during each lift! the crane operator shall verify
the operation of the primary device. The primary device is defined as the first device
intended to stop the upward direction of hoist travel that the hoist actuates in the
raising direction. 5f the primary device shall is used as a positioning device! &oth
devices shall &e chec$ed prior to the individual use of the hoist during each lift.
2. The device shall e chec$ed &y raising the crane in the slowest possi&le speed as the
lower &loc$ approaches the device trip point.
3. Additional pre* operation visual chec$s may &e required as determined &y each
location such as hoist rope;chain! hoist;chain &ra$es.
8. 3asic requirement for the inspection :
$laat !age 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
To do the effective and standard inspection for all mo&ile cranes! the following
requirements are required to perform such inspection:
inspection standards requirements according to 8/+A
crane inspection
inspection records
how to conduct a mo&ile crane inspection
2asic crane inspection list.
8.1 Standard requirements:
1. ompetent person need to do the inspection.
2. Any deficiencies should &e corrected immediately.
3. .aintain inspection record. All plug and soc$ets shall &e industrial type.
8.2 crane inspection t!pes:
There are two distinct types of inspection which are frequent inspection and periodic
inspection.
1. Frequent inspection
9aily to monthly intervals
3erformed at the start of each process where the operator wal$s around the
crane loo$ing for defects or pro&lem areas.
omponents that may change from day to day must &e inspected daily! and
when possi&le o&served during operation for any defects that could affect the
operation.
0requent inspections should include &ut are not limited to the following:
o '(e)k t(at all e/posed mo&ing parts are guarded* % remo&ed guard ma# indi)ate t(at a
me)(ani) is still 0orking on part of t(e )rane*
o @isuall# inspe)t ea)( )omponent of t(e )rane used in lifting. s0inging. or lo0ering t(e
load or "oom for an# defe)ts t(at mig(t result in unsafe operation*
o -nspe)t all 0ire rope <in)luding standing ropes=. s(ea&es. drums rigging. (ard0are. and
atta)(ments* Remem"er. an# (ook t(at is deformed or )ra)ked must "e remo&ed from
ser&i)e* Hooks 0it( )ra)ks. e/)essi&e t(roat openings of 15A. or (ook t0ists of 10
degrees or more. must "e remo&ed from ser&i)e*
o '(e)k for freedom of rotation of all s0i&els*
o @isuall# inspe)t t(e "oom and +i" for straig(tness and an# e&iden)e of p(#si)al damage.
su)( as )ra)king. "ending. or an# ot(er deformation of t(e 0elds* Look for )orrosion
under an# atta)(ments t(at are )onne)ted to t(e )(ords and la)ing* Wat)( )arefull# for
)ra)king or flaking of paint* $(is ma# indi)ate fatigue of t(e metal 0(i)( often pre)edes
$laat !age 7 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
a failure* ;n latti)e "ooms. look for "ent la)ing* -f t(e# are kinked or "ent. t(e main
)(ord )an lose su"stantial support in t(at area* W(en la)ing is "ent. t(e ends also tend to
dra0 toget(er 0(i)( pulls t(e main )(ords out of s(ape* $(is pre)aution is espe)iall#
important on tu"ular "ooms 0(ere e&er# )omponent must "e straig(t and free from an#
dents* Do not attempt to straig(ten t(ese mem"ers "# (ammering or (eating t(em and
dra0ing t(em out* $(e# must "e )ut out and repla)ed 0it( la)ing to t(e manufa)turerBs
spe)ifi)ations. pro)edures. and appro&al*
o -nspe)t tires for )uts. tears. "reaks. and proper inflation*
o @isuall# inspe)t t(e )rane for fluid leaks. "ot( air and (#drauli)*
o @isuall# )(e)k t(at t(e )rane is properl# lu"ri)ated* $(e fuel. lu"ri)ating oil. )oolant and
(#drauli) oil reser&oirs s(ould "e filled to proper le&els*
o '(e)k t(at t(e )rane is e,uipped 0it( a full# )(arged fire e/tinguis(er and t(at t(e
operator kno0s (o0 to use it*
o '(e)k all fun)tional operating me)(anisms su)( as8 s(ea&es. drums. "rakes. lo)king
me)(anisms. (ooks. t(e "oom. +i". (ook rollers "ra)kets. outrigger )omponents. limit
s0it)(es. safet# de&i)es. (#drauli) )#linders. instruments. and lig(ts*
o '(e)k t(e turnta"le )onne)tions for 0eld )ra)ks and loose or missing "olts* -f t(e# are
loose. t(ere is a good )(an)e t(at t(e# (a&e "een stret)(ed*
o W(en )(e)king t(e outriggers "e sure t(at neit(er t(e "eams nor t(e )#linders are
distorted* '(e)k t(at t(e 0elds are not )ra)ked and t(at "ot( t(e "eams and )#linders
e/tend and retra)t smoot(l# and (old t(e load* '(e)k t(e )ondition of t(e floats. and
)(e)k t(at t(e# are se)urel# atta)(ed*
o -nspe)t and test all "rakes and )lut)(es for proper ad+ustment and operation*
o %l0a#s inspe)t "oom (oist lo)kout and ot(er operator aids. su)( as antiCt0oC"lo)k
de&i)es <%$D= and load moment indi)ators <LM-=. for proper operation and )ali"ration*
o W(ile t(e engine is running. )(e)k all gauges and 0arning lig(ts for proper readings and
operate all )ontrols to see t(at t(e# are fun)tioning properl#*
o '(e)k for an# "roken or )ra)ked glass t(at ma# affe)t t(e &ie0 of t(e operator
2. Periodic inspection:
This is not a tas$ performed &y 6uf$in supervisor or 6uf$in inspector in the present
time! since all cranes are leased! &ut it needs to &e mentioned here for the future
usage and to &e useful for inspecting the crane of the supplier.
0rom 1 : 12 month
5ncludes items listed in daily inspection as well as structural defects! e)cessive
wear! hydraulic or air lea$.
0rom 1 : 12 month
5ncludes items listed in daily inspection as well as structural defects!
e)cessive wear! hydraulic or air lea$ it may &e summari,ed as follows:
$laat !age 10 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
-nspe)t t(e entire )rane for stru)tural damage* De )areful to )(e)k for distortion or )ra)ks in
main frame. outrigger assem"lies. and stru)tural atta)(ments of t(e upper 0orks to t(e )arrier*
-nspe)t all 0elded )onne)tions for )ra)ks* -nspe)t t(e main )(ords and la)ings and ot(er
stru)tural items for paint flaking and )ra)king 0(i)( ma# indi)ate potential failure. as 0ell as
for dents. "ends. a"rasions. and )orrosion* '(e)k (#drauli) "ooms for "ending. side s0a#. or
droop*
'(e)k for deformed. )ra)ked. or )orroded mem"ers in t(e load/stress "earing stru)ture*
Magneti) parti)le or ot(er suita"le )ra)k dete)ting inspe)tion s(ould "e performed at least on)e
ea)( #ear "# an inspe)tion agen)# retained "# t(e o0ner* -nspe)tion reports s(ould "e re,uested
and retained in t(e )rane file*
-nspe)t )ra)ked or 0orn s(ea&es and drums*
-nspe)t for 0orn. )ra)ked. or distorted parts su)( as8 pins. "earings. s(afts. gears. rollers.
lo)king de&i)es. (ook roller "ra)kets. remo&a"le outrigger atta)(ments lugs. and 0elds*
-nspe)t for e/)essi&e 0ear on "rake and )lut)( s#stem parts. linings. pa0ls. and rat)(ets*
-nspe)t all indi)ators. in)luding load and "oom angle indi)ators. for proper operation and
)ali"ration*
-nspe)t all po0er plants for proper operation*
-nspe)t for e/)essi&e 0ear on dri&e spro)kets and/or )(ain stret)(*
-nspe)t for )orre)t a)tion of steering. "raking. and lo)king de&i)es*
'(e)k t(at t(e )ounter0eig(t is se)ure*
'(e)k t(at t(e identifi)ation num"er is permanentl# and legi"l# marked on +i"s. "lo)ks.
e,uali2er "eams. and all ot(er a))essories*
-nspe)t all (#drauli) and pneumati) (oses. fittings. and tu"ing* %n# deterioration of an# s#stem
)omponent s(ould )ause t(e inspe)tor to ,uestion 0(et(er furt(er use 0ould )onstitute a safet#
(a2ard* 'onditions. su)( as t(e follo0ing. re,uire repla)ement of t(e part in ,uestion*
%n# e&iden)e of oil leaks on t(e surfa)e of fle/i"le (oses or at t(e point at 0(i)( t(e (ose in
,uestion +oins t(e metal and t(e )ouplings*
%n# a"normal deformation of t(e outer )o&ering of (#drauli) (ose. in)luding an# enlargement.
lo)al or ot(er0ise*
%n# leak at )onne)tions 0(i)( )annot "e eliminated "# normal tig(tening*
%n# e&iden)e of a"rasi&e 0ear t(at )ould (a&e redu)ed t(e pressure retaining )apa"ilities of t(e
(ose or tu"e effe)ted* $(e )ause of t(e ru""ing or a"rasion must immediatel# eliminated*
$.3 crane inspection records :
1. date of inspection
2. signature of person conducting inspection
3. serial num&er of inspection
$laat !age 11 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
9.7 Sling properties and .nspection
/lings should &e visually inspected &efore each use to ensure their effectiveness.
5mproper use of hoisting equipments ' including slings may result in overloading!
e)cessive speed or sudden acceleration or deceleration of equipment.
There are generally si) types of slings: chain! wire rope! metal mesh! natural fi&er
rope! or synthetic we&s.
1hen selecting a wire rope sling to give the &est services. There are four
characteristics to consider- strength! a&ility to withstand! fatigue #to &end without
distortion! a&ility to withstand a&use.
1. Strength: is a function of its si,e!grade!and construction and must &e sufficient to
accommodate the ma)imum applied load.
2. Fatigue: 0atigue failure of wire rope is caused &y the development of small crac$s
during small radius &ends. The &est means for preventing fatigue failure of wire
rope slings is to use &loc$ing or padding to increase the &end radius.
3. '3rasive to wear: The a&ility of wire rope to withstand a&rasion is determined &y
the si,e and num&er of the individual wires used to ma$e up the rope. /maller
wires &end more readily and offer greater fle)i&ility! &ut are less a&le to withstand
a&rasion. 6arger wires are less fle)i&le! &ut withstand a&rasion &etter
4. '3use: .isuse or a&use of wire rope slings will result in their failure long &efore
any other factor. A&use can lead to serious structural damage! resulting in $in$s
or &ird caging. #5n &ird caging! the wire rope strands are forci&ly untwisted and
&ecome spread outwards.% To prevent in(uries to wor$ers and prolong the life of the
sling! strictly adhered to safe and proper use of wire rope slings.
'.0 Safe lifting practices:
/election of the sling is only the first step in the rigging process. The ne)t step is
learning how to safely use it to hold and move a suspended load. There are four
primary factors to consider when lifting a load safely. These are:
a. Load Size, Weight, and Center of Gravity
The center of gravity of an o&(ect is that point at which the entire weight may &e
considered to &e concentrated. To ma$e a level lift! the hoist hoo$ must &e located
directly a&ove this point. 5f the hoo$ is too far to either side of the center of gravity!
dangerous tilting will result! causing unequal stress in the sling legs. 6oad
im&alances must &e corrected immediately.
3. Number of Legs and Angle with the Horizontal
$laat !age 12 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
The smaller the angle &etween the sling legs and the hori,ontal! the greater the stress
on the individual sling legs. This increased stress effectively decreases the weight that
can &e safely lifted with any given sling si,e. 6arge #heavy% loads can &e safely moved
&y $eeping this angle as large as possi&le and! when necessary! distri&uting the weight
of the load among more sling legs.
c. Rated Caa!ity of the Sling
The rated capacity of a sling varies depending upon the type of material the sling is
made of! the si,e of the sling! and the type of hitch. 1or$ers must $now the capacity
of the sling! and can o&tain this information through charts or ta&les availa&le
through the manufacturer. The rated capacity of a sling must not &e e)ceeded! under
any circumstances.
d. History of Care and "se
.ishandling and misuse of slings are the leading causes of sling failure. 0ollowing the
manufacturer7s recommendations for proper care and use are essential for ma)imum
sling service life and safety
17.7 training
People involved in hoisting and rigging operation should have
training in the following:

1. /ling and hitch types
2. /ling capacity determination
3. Equipment inspection, care, and maintenance
4. Load weight and center of gravity determination
5. /afe lifting techniques.
Appendi) 1. 8/+A inspection items
-nspe)tion -tems and Des)ription
-$EM DES'R-!$-;9 / !ER!;SE
<1= Manufa)turerBs operating and Maintenan)e Manuals Manufa)turerBs operating and maintenan)e
manuals s(all a))ompan# all mo"ile
(oisting e,uipment* $(ese manuals set fort(
spe)ifi) inspe)tion. operation and
maintenan)e )riteria for ea)( mo"ile )rane
and lifting )apa)it#*
$laat !age 14 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
<2= Fuarding %ll e/posed mo&ing parts su)( as gears.
)(ains. re)ipro)ating or rotating parts are
guarded or isolated*
<4= S0ing 'learan)e !rote)tion Materials for guarding rear s0ing area*
<4= Hig(C@oltage Warning Sign Hig(C&oltage 0arning signs displa#ing
restri)tions and re,uirements s(ould "e
installed at t(e operatorBs station and at
strategi) lo)ations on t(e )rane*
<5= Doom Stops S(o)k a"sor"ing or (#drauli) t#pe "oom
stops are installed in a manner to resist
"oom o&erturning*
<5= >i" Doom Stops >i" stops are restraints to resist o&erturning*
<6= Doom %ngle -ndi)ator % "oom angle indi)ator reada"le for t(e
operator station is installed a))uratel# to
indi)ate "oom angle*
<= Doom Hoist Dis)onne)t. %utomati) Doom Hoist
S(utoff
% "oom (oist dis)onne)t safet# s(utoff or
(#drauli) relief automati)all# stops t(e
"oom (oist 0(en t(e "oom rea)(es a
predetermined (ig( angle*
<7= $0oCDlo)king De&i)e 'ranes 0it( teles)oping "ooms s(ould "e
e,uipped 0it( a t0oC"lo)king damage
pre&ention feature t(at (as "een tested onC
site in a))ordan)e 0it( manufa)turer3s
re,uirements* %ll )ranes (#drauli) and fi/ed
"oom used to (oist personnel must "e
e,uipped 0it( t0oC"lo)king de&i)es on all
(oistlines intended to "e used in t(e
operation* $(e antiCt0o "lo)king de&i)e (as
automati) )apa"ilities for )ontrolling
fun)tions t(at ma# )ause a t0oC"lo)king
)ondition*
<10= !o0er 'ontrolled Lo0ering 'ranes for use to (oist personnel must "e
e,uipped for po0er )ontrolled lo0ering
operation on all (oistlines* '(e)k )lut)(.
)(ains. and spro)kets for 0ear*
<11= Le&eling -ndi)ating De&i)e % de&i)e or pro)edure for le&eling t(e )rane
must "e pro&ided*
<12= S(ea&es S(ea&e groo&es s(all "e smoot( and free
$laat !age 14 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
from surfa)e defe)ts. )ra)ks. or 0orn pla)es
t(at )ould )ause rope damage* 1langes must
not "e "roken. )ra)ked. or )(ipped* $(e
"ottom of t(e s(ea&e groo&e must form a
)lose fitting saddle for t(e rope "eing used*
Lo0er load "lo)ks must "e e,uipped 0it(
)lose fitting guards* %lmost e&er# 0ire rope
installation (as one or more s(ea&es
? ranging from tra&eling "lo)ks 0it(
)ompli)ated ree&ing patterns to e,uali2ing
s(ea&es 0(ere onl# minimum rope
mo&ement is noti)ed*
<14= Main Hoist and %u/iliar# Drums S#stem Drum )rus(ing is a rope )ondition
sometimes o"ser&ed 0(i)( indi)ates
deterioration of t(e rope* Spooling is t(at
)(ara)teristi) of a rope 0(i)( affe)ts (o0 it
0raps onto and off a drum* Spoiling is
affe)ted "# t(e )are and skill 0it( 0(i)( t(e
first larger of 0raps is applied on t(e drum*
Manufa)turerBs )riteria during inspe)tion
usuall# spe)if#8
Minimum num"er of 0raps to
remain on t(e drum*
'ondition of drum groo&es
'ondition of flanges at t(e end of
drum*
Rope end atta)(ment*
Spooling )(ara)teristi)s of rope*
Rope )ondition*
<14= Main Doom. >i" Doom. Doom E/tension Doom +i"s. or e/tensions. must not "e
)ra)ked or )orroded* Dolts and ri&ets must
"e tig(t* 'ertifi)ation t(at repaired "oom
mem"ers meet manufa)turers original
design standard s(all "e do)umented* 9onC
)ertified repaired mem"ers s(all not "e used
until re)ertified*
<15= Load Hooks and Hook Dlo)ks Hooks and "lo)ks must "e permanentl#
la"eled 0it( rated )apa)it#* Hooks and
"lo)ks are )ounter0eig(ted to t(e 0eig(t of
$laat !age 15 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
t(e o&er(aul line from (ig(est (ook
position* Hooks must not (a&e )ra)ks or
t(roat openings more t(an 15A of normal or
t0isted off )enter more t(an 10
o
from t(e
longitudinal a/is* %ll (ooks used to (oist
personnel must "e e,uipped 0it( effe)ti&e
positi&e safet# )at)(es espe)iall# on
(#drauli) )ranes*
<15= H#drauli) Hoses 1ittings and $u"ing 1le/i"le (oses must "e sound and s(o0 no
signs of leaking at t(e surfa)e or its +un)tion
0it( t(e metal and )ouplings* Hoses must
not s(o0 "listering or a"normal deformation
to t(e outer )o&ering and no leaks at
t(readed or )lamped +oints t(at )annot "e
eliminated "# normal tig(tening or
re)ommended pro)edures* $(ere s(ould "e
no e&iden)e of e/)essi&e a"rasion or
s)ru""ing on t(e outer surfa)es of (oses.
rigid tu"ing. or (#drauli) fittings*
<16= ;utriggers ;utrigger num"er. lo)ations. t#pes and t#pe
of )ontrol are in a))ordan)e 0it(
manufa)turerBs spe)ifi)ations* ;utriggers are
designed and operated to relie&e all 0eig(t
from 0(eels or tra)ks 0it(in t(e "oundaries
of t(e outriggers* -f not. t(e manufa)turerBs
spe)ifi)ations and operating pro)edures
must "e )learl# defined* ;utriggers must "e
&isi"le to t(e operator or a signal person
during e/tension or setting*
<1= Load Rating '(art % dura"le rating )(art<s= 0it( legi"le letters
and figures must "e atta)(ed to t(e )rane in
a lo)ation a))essi"le to t(e operator 0(ile at
t(e )ontrols* $(e rating )(arts s(all )ontain
t(e follo0ing8
% full and )omplete range of
manufa)turerBs )rane loading ratings
at all stated operating radii*
;ptional e,uipment on t(e )rane
su)( as outriggers and e/tra
)ounter0eig(t 0(i)( effe)t ratings*
$laat !age 15 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
% 0ork area )(art for 0(i)(
)apa)ities are listed in t(e load rating
)(art. i*e* o&er side. o&er rear. o&er
front*
Weig(ts of au/iliar# e,uipment. i*e*
load "lo)k. +i"s. "oom e/tensions*
% )learl# distinguis(a"le list of
ratings "ased on stru)tural. (#drauli)
or ot(er fa)tors rat(er t(an sta"ilit#*
% list of noCload 0ork areas*
% des)ription of (oist line ree&ing
re,uirements on t(e )(art or in
operatorBs manual*
<17= Wire Rope Main (oist and au/iliar# 0ire rope
inspe)tion s(ould in)lude e/amining for
Droken 0ires*
E/)ess 0ear*
E/ternal damage from )rus(ing.
kinking. )utting or )orrosion*
<20= 'a" 'ontains all )rane fun)tion )ontrols in
addition to me)(ani)al "oom angle
indi)ators. ele)tri) 0ipers. das( lig(ts.
0arning lig(ts and "u22ers. fire
e/tinguis(ers. seat "elts. (orn. and )lear
un"roken glass*
<21= Draking S#stems $ru)k )ranes and selfCpropelled )ranes
mounted on ru""erCtired )(assis or frames
must "e e,uipped 0it( a ser&i)e "rake
s#stem. se)ondar# stopping emergen)#
"rake s#stem and a parking "rake s#stem*
Enless t(e o0ner/operator )an s(o0 0ritten
e&iden)e t(at su)( s#stems 0ere not
re,uired "# t(e standards or regulations in
for)e at t(e date of manufa)ture and are not
a&aila"le from t(e manufa)turer* $(e
"raking s#stems must (a&e "een inspe)ted
and tested and found to "e in )onforman)e
0it( appli)a"le re,uirements*
$laat !age 16 11/10/200
Lufkin
Middle East
Lufkin Hoisting and Rigging
Written program
HSE 10
issue 1
Date 15/04/200
!repared "# $alaat Elkader
%ppro&ed "# 'raig guillor#
'ra0ler )ranes are pro&ided 0it( "rakes or
ot(er lo)king de&i)es t(at effe)ti&el# (old
t(e ma)(ine stationar# on le&el grade during
t(e 0orking )#)le* $(e "raking s#stem must
"e )apa"le of stopping and (olding t(e
ma)(ine on t(e ma/imum grade
re)ommended for tra&el* $(e "rakes or lo)ks
are arranged to engage or remain engaged in
t(e e&ent of loss of operating pressure or
po0er*
<22= $urnta"le/'rane Dod# Make sure t(at t(e rotation point of a )rane
gears and rollers are free of damage. 0ear
and properl# ad+usted and t(e )omponents
are se)urel# lo)ked and free of )ra)ks or
damage* $(e s0ing lo)king me)(anism
must "e fun)tional <pa0l. pin= and operated
in t(e )a"*
<24= 'ounter0eig(t $(e )ounter0eig(t must "e appro&ed and
installed a))ording to manufa)turerBs
spe)ifi)ations 0it( atta)(ment points
se)ured*
$laat !age 1 11/10/200