LEI Mod2 Procedures PDF

LIFTING EQUIPMENT INSPECTOR
CERTIFICATION PROCEDURES
MODULE 2 : WINCHES & POWERED HOISTS
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Intellectual Ownership & Copyright of

NSL Training Products and Materials
North Sea Lifting Ltd (NSL) & its subsidiary NSL America has, in recent years, invested well in
excess of Two and a half Million Pounds ($5,000,000) in the development of training products
and materials which in turn have been translated into the relevant languages required by the Oil
and Gas Industry worldwide.
The creation of first-rate training products and materials involves extensive research, liaising
with government bodies, attending fact-finding meetings both nationally and internationally,
liaising with equipment manufacturers, gaining approvals where necessary, the use of
technical authors, artists, cartoonists, employing full-time engineers and graphic designers,
etc. In addition, a vast amount of time, effort and expense is incurred in keeping the training
materials up-to-date, reflecting the latest legislation, regulations, guidelines, industry practice
and equipment.
The end products are of the highest quality, totally accurate and specific to the Oil and G a s
Industry which we serve.
We do, on request, customise our products to suit various clients needs but
ownership and copyright always remains with NSL i.e. on these occasions,
clients are only charged for the customising. Occasionally, we allow clients
to adapt our products and materials for their own internal use but this must
be authorised, in writing, by NSL. To prevent our products and materials
being used out of context and possibly relaying the wrong message, any
amendments must also be approved by NSL.
The instructors employed by NSL to deliver the training are specially
selected for their knowledge on the subject matter and their
ability, not only deliver the training, but be able to answer any
questions arising during the training courses. For this reason,
NSLs instructors are trained internally and are also qualified skills
assessors.
We carry out practical training at our facilities in both Aberdeen UK &
Broussard LA, USA. However, where we train on the clients premises,
be it onshore, offshore or overseas, the facilities are vetted by NSL to
ensure that the training can be delivered effectively.
Our instructors are constantly updated with the latest information and
are issued with the most up-to-date media presentation equipment to
facilitate professional delivery of the training materials.
NSLs Safety and Training documents are not for resale nor are they to be used for
personal / commercial gain by 3rd party training companys training courses. This
includes any reference to, or the use of NSLs Handbooks, Posters, Video/DVD,
Viewgraphs, etc.
To maintain the overall quality of our training products and materials, they must
remain totally under our control and consequently, we vigorously enforce their
copyright. NSL will actively pursue through the courts, any company or individual found
in breach of this copyright.
NSL LTD :
42 Queens Road,
Aberdeen AB15 4YE UK
tel +44 (0) 1224 208988
NSL America INC

2500 CITYWEST BLVD
SUITE 300
Houston TX 77042
tel +1 (713) 405 1877
www . nsl-uk.com
MODULE 2 : WINCHES AND POWERED HOISTS PROCEDURES
INDEX
Introduction
2.1 Manual Winches
2.2 Utility Winches
2.3 Man-riding Winches
2.4 Powered Hoists
2.5 Lifeboat / Liferaft Davit Winches
2.6 Report Examples
2.7 Blank Reports
2.8 Appendix
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MODULE 2 : WINCHES AND POWERED HOISTS PROCEDURES
INTRODUCTION
The testing and inspection of lifting equipment shall only be carried out by a competent person. It is essential
that a competent person engaged in this work must be aware of current regulations, standards, best industry
practices and relevant company procedures.
Competence can only be achieved and recorded through training, experience and assessment in the workplace.
The inspector must act with the necessary degree of impartiality, be free from any external pressures or
influences, make decisions regarding the extent of testing requirements and issue certificates stating that the
lifting equipment is suitable, and if used correctly, safe to use during a specific period of time.
For the most part, it is unlikely that any one person or even company, will be able to provide the knowledge
and expertise required to test and inspect, the vast range of lifting equipment used in todays industries. The
inspector will need to utilise information from standards, regulations and manufacturers guidelines to ensure an
informed decision is made.
The inspection of lifting equipment by the competent person, will determine if it is fit for purpose. The criteria
used to determine this, must be applied to new and used equipment alike, the inspector must never assume new
equipment is free of patent defects.
The purpose of an overload or proof load test is to prove the design, materials used, and the workmanship during
assembly of the equipment. The sole use of calculations to prove the integrity of equipment may not accomplish
this. It should be borne in mind that lifting equipment undergoing an overload test, might not withstand the
applied loadings.
All personnel not essential to the test must be kept clear of the area, with the inspector also positioned, where he
is unlikely to be injured if equipment fails.
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MANUAL WINCHES
2.1 : MANUAL WINCHES

EXAMINATION & TESTING PROCEDURE
Bolts
Drum
Worm Gear
Handle
Frame
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MANUAL WINCHES

EXAMINATION PROCEDURE

Sight the original test certificate
Ensure Safe Working Load and Identification numbers are legible and correspond with the test certificate
Examine winding handle, check for distortion and correct connection
Examine winch drum and check for distortion, wear or cracking (if accessible, examine rope anchorage
and ensure it is secure)
Where applicable, examine ratchet or worm gear and check for wear / broken teeth
Examine pawl and pawl spring / worm and check for wear / distortion
Ensure the pawl functions correctly and ensure the worm meshes correctly with the worm wheel
Examine winch frame and check for distortion, wear and cracking
Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy yourself that
the support steel work is capable of sustaining the winch under load
Should wire rope be fitted, it must be examined
ADDITIONAL (SPUR GEARED WINCHES)

Visually examine the brake assembly and operate the winch handle to ensure it functions correctly
Examine all spur gears checking for alignment, wear on gear teeth, truing of gear shafts and smooth
running of bearings (where fitted)
Function check the winch through one complete revolution of the drum
If all satisfactory, record relevant details and issue report.

Record winch wire rope details (if fitted), including certificate number on winch examination report.
This procedure is to be followed as a guideline to NSLs minimum requirements.
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MANUAL WINCHES

PROOF LOAD TESTING
Proof load to be applied: 50% above SWL.
Load to be applied in the same direction as the forces it would be subjected to under normal working conditions.
Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the
winch through one complete revolution of the drum.
Although the winch should be fully certified prior to reaching the worksite, once it has been sited and secured,
the anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage
via the winch.
ACCEPTABLE METHODS OF TESTING

Carry out performance test at SWL before commencement of proof load
If satisfactory, use test weights or a test clock with suitable anchor point, apply a proof load of SWL + 50%
Sustain load and examine anchorage checking for deflection / distortion
Release load and re-examine to ensure proof loading has not exposed any defects
Any welding should be N.D.T.D after load test
Re-examine after proof load testing to ensure this has not exposed any defects.
If all satisfactory, hard stamp with ID number, SWL and issue certificate.
This procedure is to be followed as a guideline to NSLs minimum requirements for a proof load test.
Live test weights should be weight-checked annually and be accurate to better than 1% of the nominal weight.
The accuracy of testing machines shall be in accordance with BS 1610 and BS EN 10002.
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MANUAL WINCHES
MANUAL WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
B = WORN BUT SERVICEABLE
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Handle
2 Drum
3 Ratchet wheel / worm wheel
4 Ratchet pawl / worm
5 Ratchet pawl spring
6 Winch frame
7 Friction discs
8 Spur Gears
9 Spur gear shafts
10 Bearing
11 Hold down bolts / clamps / welding
12 Support steel work
Tick relevant boxes / delete where applicable
SIGNED : ....................................................................................................................................................... DATE :.............................................
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UTILITY WINCHES
2.2 : UTILITY WINCHES

Rope guard
Controls
Brake
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Base
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UTILITY WINCHES


Sight the original test certificate
Ensure Safe Working Load and Identification numbers are legible and correspond with the test certificate
Confirm controls operate in the direction that arrows are marked
Examine rope guard and ensure there is no damage / distortion which may obstruct and / or abrade the
winch rope
Examine winch drum and check for wear, distortion or cracks
Examine brake bands / brake drums and check for wear
Ensure the brake bands / brake drums are clean and free from contamination
Where fitted, examine the automatic brake checking springs, link arms and pins
Examine automatic brake cylinder and check for leaks
Examine chromed piston rod and check for corrosion
With power disconnected, check that all operating levers return to neutral when released
Ensure directional arrows / markings are in place and clearly visible
Check oil level
Examine winch base and check for cracked welds, cracks around bolt holes, distortion or impact damage
Anchorage: Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy
yourself that the support steel work is capable of sustaining the winch under load
Check that the power supply is adequate for that particular model of winch
Connect power supply and function test the winch
Should wire rope be fitted, it must be examined

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UTILITY WINCHES

PROOF LOAD TESTING
winch through at least one complete revolution of the drum
The winch may well be fully certified prior to reaching the worksite, once it has been sited and secured, the
anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage via
the winch.
Comply with company procedures to determine the type of load test required.

Bolt down winch to suitable test bed and fit a wire of such length that no fewer than five turns remain on
drum during any part of the test
TEST 1

If satisfacory, raise a proof load of the SWL + 25% to the required height to allow one full rotation of drum
under load
This test can be simulated on a hydraulic test bed where a variable pressure relief valve has been fitted
Apply manual brake to sustain load and check winch drum for creep
NOTE
When testing winches with an automatic brake on a hydraulic test bed, there will be a slight drop in load
due to the time it takes for the brake to activate
TEST 2

Disconnect power source to winch and apply brake
Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL
+ 50% to check the braking efficiency. (The brakes may require adjusting to achieve this)
Sustain the load for a short time and check winch drum for creep
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UTILITY WINCHES
TEST 3

Re-connect power supply to winch and pull up to SWL
Ensure the brake has not been over tightened to such an extent as to affect the winchs performance
ENSURE ALL LEVERS / CONTROLS RETURN TO NEUTRAL ON RELEASE

The above tests are to be witnessed.
Re-examine winch to ensure that proof load testing has not exposed any defects.
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UTILITY WINCHES
UTILITY WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Rope Guard
2 Winch drum
3 Brake bands & drums
4 Automatic brake springs
5 Automatic brake cylinder
6 Automatic brake link arms & pins
7 Operating levers (function)
8 Directional / SWL markings
9 Oil level
10 Winch base
11 Winch anchorage
12 Power supply
13 Function test
SIGNED : ....................................................................................................................................................... DATE :.............................................
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MODULE 2 : WINCHES & POWERED HOISTS MAN-RIDING WINCHES
2.3 : MAN-RIDING WINCHES

Manual brake
Automatic brake
Controls
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Slack wire device
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ADDITIONAL INSTRUCTIONS

Winches converted for the purpose of raising / lowering personnel
Winches of this type will be fitted with a dual braking system usually consisting of one manual brake and
one automatic brake
Examine the winch and ensure the winch does not have a disengaging clutch or pawl and ratchet
mechanism
Check that the winch has been adequately de-rated to reflect the appropriate factor of safety
(Note: Man-riding winch rope to have F.O.S. of 10:1)

NOTE
It is recommended that this type of winch is not used for general duties.
STANDARD MAN-RIDING WINCHES

Where limit switches are fitted to prevent over travel in both hoisting and lowering, function test to ensure
their operation
Function test slack wire device and emergency lowering system if fitted
Ensure the winch is clearly marked stating it can be used for raising and lowering personnel

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PROOF LOAD TESTING
winch through one complete revolution of the drum
Where limit switches are fitted to prevent over-travel in both hoisting and lowering, function test to ensure their
operation.
Ensure that the winch has been adequately de-rated to reflect a factor of safety of no less than 8:1.
Ensure the winch is clearly marked that it is to be used solely for raising and lowering personnel.
The winch may well be fully certified prior to reaching the worksite, once it has been sited and secured, the
anchorage of the winch has to be tested. This is normally achieved by applying a proof load to the anchorage via
the winch.
Bolt down winch to suitable test bed and fit a wire of such length that no fewer than five turns remain on drum
during any part of the test
TEST 1

Disconnect automatic brake
If satisfactory, raise a proof load of SWL + 25% to the required height to allow one full rotation of drum
under load. (This test can be simulated on a hydraulic test bed where a variable pressure relief valve has
been fitted)
Apply manual brake to sustain load and check winch drum for creep
Re-connect automatic brake and with the manual brake in the off position, repeat test 1 so full load is
taken on automatic brake
TEST 2

Disconnect power source to winch and apply brake
Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL +
50% to check the braking efficiency. (The brakes may require adjusting to achieve this)
Sustain the load for a short time and check winch drum for creep
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NOTE
Should any of the brake drums be exposed to the elements, the aforementioned tests should be carried out with
the drums wet, to simulate operating conditions. Make any brake adjustments as required.
TEST 3
If tests 1 & 2 are acceptable raise a load of SWL + 10%, stop load during test to ensure the brake sustains the
load without any drum creep.
TEST 4

Re-connect power supply to winch and pull up to SWL (To ensure the brake has not been over tightened to
such an extent as to affect the winchs performance)
Ensure the manual brake has not been over tightened to such an extent as to affect the winchs
performance
Function test slack wire device and emergency lowering system if fitted
Ensure all levers / controls return to neutral on release
The above tests are to be witnessed.
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MAN-RIDING WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Rope Guard
2 Winch Drum
3 Brake bands & drums
4 Automatic brake springs
5 Automatic brake cylinder
6 Automatic brake link arms & pins
7 Operating levers (function)
8 Directional / SWL markings
9 Oil level
10 Winch base
11 Winch anchorage
12 Power supply
13 Function test
14 Upper limit
15 Lower limit
16 Slack wire device
17 Overload protection
18 Emergency lowering system
SIGNED : ....................................................................................................................................................... DATE :.............................................
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POWERED HOISTS
2.4 : POWERED HOISTS

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POWERED HOISTS

POWERED CHAIN OR WIRE ROPE HOISTS
HOIST MOTOR / FRAME / BODY

The frame should be free from damage or defects
All bolts and screws should be tight
Examine for signs of overheating
Bearings should be in good condition and adequately lubricated
PENDANT CONTROL

Examine case for damage
Examine emergency stop and control buttons for correct operation
Examine catenary wire (if fitted)
Examine suspension wire
Push buttons should be free and making good contact
Directional decals
LIMIT SWITCH

Check for wear and damage
Ensure correct adjustment and good contact surfaces
All moving parts are to be lubricated
BRAKES

Function test to ensure correct operation
Brake linings to be checked for wear (if accessible)
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POWERED HOISTS
GEARS / SHAFTS

If gears sound unduly noisy, send ashore for checking and examination
LOAD SHEAVE / SPROCKET

Check for wear and correct seating of load chain in sprockets
LOAD CHAIN

Check for wear, stretch or distortion
Check for faulty welds or cracks in the links
Examine dead end connection
Examine chain bucket for security of fitting
ROPE DRUM (if fitted)

Check for cracks or damage, particularly to the grooves
LOAD ROPE

Check for wear or damage
Ensure adequate lubrication
Check rope dead end connection for damage
Ropes should be considered unusable when broken wires exceed 10% over a length of eight times the diameter
of the rope or any sign of necking indicating internal damage or excessive wear.
TROLLEY UNIT (if fitted)

Examine for wear, distortion
Smooth operation of wheels, bearings and drive
Security of fittings
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POWERED HOISTS

BOTTOM BLOCK

Examine for wear in the sheave, grooves or sprocket
Examine for wear in the crosshead
Check that wear in saddle of hook does not exceed 10%
Ensure top nut is locked
Safety catch functions correctly
TOP HOOK

Examine yoke / swivel
Distortion or wear in the hook
Safety catch functions correctly
SAFE WORKING LOAD / IDENTIFICATION NUMBER

Should be clearly marked
SUPPLY / CONNECTIONS

Check for damage or wear
Check the smooth running of supply cable trolleys (festoons)
Security of connections

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

PROOF LOAD TESTING
ELECTRICALLY / PNEUMATIC POWERED CHAIN OR WIRE ROPE HOISTS
Load to be applied in the same direction as the forces it would be subjected to
under normal working conditions.
Before proof load testing, carry out a visual inspection to ensure no defects are present. Function check the hoist
through one complete revolution of the gears / drum.
Where limit switches are fitted to prevent over-travel in both hoisting and lowering, function test to ensure their
operation.

If satisfactory, subject the hoist to a proof load of SWL + 25%
In such a fashion that all the gearing makes one full revolution under load
Check for efficient operation of the brakes
ENSURE ALL LEVERS / CONTROLS RETURN TO NEUTRAL ON RELEASE

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

EQUIPMENT TYPE :
CONDITIONS
PLANT NO. :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
DESCRIPTION
CONDITION
A
1 Top hook
2 Safety catch
3 Bottom hook
4 Safety catch
5 Top hook swivel / yoke
6 Load sprocket or sheaves
7 Body casing
8 Load chain / wire rope
9 Function test
10 Hook load pins
11 Hook swivels / yokes
12 Direction controls (pendant / pull cord)
13 Button / switch function
14 Direction decals
15 Emergency stop button
16 Suspension / catenary wire
17 Trolley unit (if fitted)
18 Gears and shafts (if visibly accessable)
19 Limit switches
20 Power connection / supply
21 Security of fittings
22 Lubrication
23 Dead end connection
24 Chain bucket
25 Drum
SIGNED (CANDIDATE) : ................................................................ DATE :................................ENGINEER:.............................................................
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POWERED HOISTS
2.5 : LIFEBOAT / LIFERAFT DAVIT WINCHES

Rope Hoists

Examine winch drum and check for wear, distortion or cracks
Ensure drum flange height projects at least 1.5 times the rope diameter above upper most layer
Examine brake release device for distortion and is located in the on position
Crank handle is located close to the winch, is undamaged and locates correctly onto winch
Check power supply cables for damage, wear or perished insulation
Examine push button controls and casing (if fitted) for damage and are (with power shut off) free to move
Winch body is undamaged and securely attached
Winch is sufficiently lubricated
Examine winch wire rope
Comply with company procedures regarding function testing.

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POWERED HOISTS
2.5 : LIFEBOAT / LIFERAFT DAVIT WINCHES

PROOF LOAD TESTING
All such tests must be planned in advance with all certification and records updated before the test. The
authorised / competent person must carry out these checks.
It is important that all personnel involved in the test agree the actual procedure in advance of any testing taking
place.
Before proof load testing, carry out a visual inspection to ensure no defects are present.
Refer to company procedures for NDT inspection requirements on base welds before and after load testing.

Load boat with weights that together with the weight of the boat, represents 1.1 times the full load of
personnel and the boat equipment
The method of loading weights must be such that no one enters the boat once 90% of the total load is reached.
If this cannot be achieved then the weight of the boat must not be taken by the falls during loading, but by a
crane (the capacity of the crane shall be at least 2.2 times the loaded weight of the boat) and a spreader bar.
If a crane and spreader bar are used, this should then be lowered so the weight of the boat is taken on the falls.
Under no circumstances should anyone enter the boat at this time.
The area under and around the boat must now be checked to ensure it is clear of personnel and obstructions

The boat is now lowered by lifting the brake fully to enable the boat to reach maximum speed on the
centrifugal brake
The mechanical brake is then applied suddenly, before the boat enters the water, and the test paused to
ensure that the position of the boat is held
The winch shall be capable of lowering the lifeboat under gravity conditions at speeds not less than 0.30
m/s nor greater than 0.60 m/s
The results of the test should be recorded on a test certificate produced by the competent person and signed by
the witnessing authorised person.
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POWERED HOISTS
UK Regulation and SOLAS requires that at least once every five years rescue boats and lifeboats shall be turned
out and lowered when loaded with weights to simulate 1.1 times the total mass of the lifeboat or rescue boat
when loaded with its full complement of persons and equipment.
If liferaft davits and winches are to be tested, weights are to be suspended directly from the davit rather than
using a liferaft.
TESTS CARRIED OUT AT MANUFACTURERS WORKS FOR THE ACCEPTANCE OF THE WINCH BY THE
PURCHASER
TEST WITHOUT LOAD

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

The winch shall hoist a load related to the weight of the lifeboat and its required equipment
At the speed of 0.05 m/s for lifeboats and with a speed not less than 0.3 m/s for emergency boats
To a height of not less than 15 m
BRAKE TEST

The brake shall be applied and a static test load equivalent to the working load times 1.5 shall be applied
to a rope secured to and wound on the drum fully and evenly reeled to the specified two or three layers
The drum shall not rotate and it shall be demonstrated that it is possible to release the brake
It shall also be demonstrated that the winch can slowly lower the static test load, under control of the
brake, for at least one complete revolution of the drum and then hold the load
LOWERING TEST

A load equivalent to the working load shall be applied to a rope secured to and wound on the drum fully
and evenly reeled to the specified two or three layers
The drum shall be declutched from the prime mover and the drum brake released
The governing brake shall govern the speed of descent to comply with not less than 0.30 m/s nor greater
than 0.60 m/s
The total lowering height for this test shall not be less than 15 m
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POWERED HOISTS
The results of the test should be recorded on a test certificate produced by the competent person and signed by
the witnessing authorised person.
LIFEBOAT / LIFERAFT DAVIT WINCHES
EQUIPMENT TYPE :
CONDITIONS
PLANT NO. :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
DESCRIPTION
CONDITION
A
1 Drum
2 Drum flange
3 Brake release device
4 Crank handle
5 Power supply cables
6 Power supply connections
7 Push button controls
8 Winch body casing
9 Lubrication
10 Function test as per company procedure
11 Winch wire
12 Winch base
13 ID / SWL markings
14 Oil levels
SIGNED (CANDIDATE) : ................................................................ DATE :................................ENGINEER:.............................................................
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MODULE 2 : WINCHES & POWERED HOISTS REPORT EXAMPLES
2.6 : REPORT EXAMPLES

VISUAL INSPECTION REPORT
PROOF LOAD TEST CERTIFICATE
NDT CERTIFICATES
DEFECT REPORT
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MODULE 2 : WINCHES & POWERED HOISTS BLANK REPORTS
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NSL 2004
REPORT OF THOROUGH EXAMINATION AND / OR TEST OF LIFTING APPLIANCE OR ACCESSORY

STATUTORY INSTRUMENTS 1998 No. 2307
The Lifting Operations and Lifting Equipment Regulations 1998
The Supply of Machinery (Safety) Regulations 1992
The Provision and Use of Work Regulations 1998
54321/001
J. Bloggs
CERTIFICATION NO : ..............................................................................................
TESTER / EXAMINER:............................................................
EAL Module 2
19.08.07
QUALIFICATION : ...................................................................................................
DATE OF TEST / EXAMINATION : ..........................................
IDENTIFICATION
NO.
QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
ABC 0001
Air Powered man-riding lever controlled
150kg
N/A
18.02.08
winch manufacturer: Ingersoll rand

Model: LS150RLP.L.B.E
Serial No:0100010
Winch fitted with main air emergency stop
device
Upper & lower limit switches
Emergency lowering system
Overload protection device
Slack wire device
Protective cover to be fitted when not in use
winch wire inspection report: 12345/001
ORIGINAL CERTIFICATE NO.
ORIGINAL CERTIFICATE DATE
12345/001
NAME OF CERTIFYING BODY
21.08.06
DATE OF LAST EXAMINATION
NSL
PARTICULARS OF DEFECTS FOUND WHICH ARE, OR COULD,

BECOME A DANGER TO PERSONS OR NONE
20.02.07
PARTICULARS OF ANY REPAIR, ALTERATION TO REMEDY DEFECT

OR NONE
NONE
NONE
NAME AND ADDRESS OF EQUIPMENT OWNER:
ADDRESS OF PREMISES WHERE TEST / EXAMINATION WAS HELD:
Up & Down Engineering Ltd
Platform Alpha
Big Road, Aberdown, AD12 1AD
19.08.07
We hereby certify that on ............................
(date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
J. Bloggs
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
19.08.07
DATE ..................................................................................................................DOC
REF NO : NSL C 001
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12345/001
J. Bloggs
CERTIFICATION NO : ..............................................................................................
TESTER / EXAMINER:............................................................
EAL Module 2
20.02.07
QUALIFICATION : ...................................................................................................
DATE OF TEST / EXAMINATION : ..........................................
IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
ABC 0001
Air Powered man-riding lever controlled
150 kg
225kg Static test
19.08.07
winch manufacturer: Ingersoll rand

Model: LS150RLP.L.B.E
188kg function test
Serial No:0100010
Winch fitted with main air emergency stop device
165kg dynamic test
Upper & lower limit switches

Emergency lowering system
Satisfactory
Overload protection device
emergency
Slack wire device
lowering test @ 150kg
Note: full operating instructions & procedures to be
nitrogen source
posted at winch location, including emergency

lowering procedures
Air intake shut-off valve to be clearly marked
& not obstructed
Proctective cover to be fitted when not in use
Winch wire inspection report : 12345/ 002
N/A
N/A
N/A

20.08.06

OR NONE
NONE
NONE
Platform Alpha
Big Road, Aberdown. AD12 1AD

21.02.07
We hereby certify that on ............................
(date) the item/s described in this report was/were thoroughly examined, so far
to operate.
J. Bloggs
21.02.07
DATE ..................................................................................................................DOC
REF NO : NSL C 001
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NSL 2004
MAGNETIC PARTICLE INSPECTION REPORT

CLIENT
LOCATION
INSPECTION DATE
Platform Alpha
20.02.07
Big Road, Aberdown
NSL JOB NO
REPORT NO
AD12 1AD
G12345
G12345 /001
CLIENT ORDER NO
SHEET
ABCD00001
one
of
one
COMPONENT / DESCRIPTION / DRAWING NO.

Winch base welds
Loacated at drill floor winch ABC00001
MATERIAL
SURFACE CONDITION
Carbon Steel
Acceptable
PROCEDURE / WORK / INSTRUCTION / TECHNIQUE
ACCEPTANCE STANDARD
Carried out in accordance with NSL Inspection Procedures
BS 6072
EQUIPMENT
POWER / CURRENT
MATERIAL THICKNESS
Permanent magnet
18kg minimum pull
20mm
METHOD
MEDIUM
BACKGROUND
Black & white contrast
Ely supramor 4 black
Ely white contrast paint 712
RESULT
100% magnetic particle inspection was carried out on winch No ABC00001 base welds pre & post load test
No defect was found at time of inspection and is acceptable to specifications
This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of the
inspection body and the client.
NSL INSPECTOR
ISSUING AUTHORITY
CLIENT
Sign
Sign
Sign
Name
Joe Bloggs
Name
Name
Quals
Module 2
Quals
Quals
NSL LTD
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CLIENT :.................................................................................................................................................................................................................
J.Bloggs
INSPECTION ENGINEER:........................................................................................................................................................................................
Workshop, Big Road, Abertown
INSTALLATION :.....................................................................................................................................................................................................
17.02.05
DATE : ...................................................................................................................................................................................................................
CD09
TO BE COMPLETED BY INSPECTING ENGINEER
INSTALLATION STAFF USE ONLY
PLANT & CERT

NO.
DEFECTIVE ITEM
(DESCRIPTION ,
LOCATION, SERIAL
NO.)
PARTICULARS
REPAIR BY
OF DEFECT
(INCLUDING RETEST
IF APPLICABLE
TO BE REPORTED
TO ENFORCING
AUTHORITY
JOB CARD NO.
REMARKS
(MANIFEST NO.
ETC.)
123/001
Safety pin
Deformed body
N/A
00010/001
Removed from
Bow shackle
Remove from
service
service 18.02.08
SWL 3.25 Tons

welders swing
arm jib
06712
Chainblock, SWL Safety catch
Fit safety catch
1 tonne,
missing from
before use
HOL 3m,
bottom hook
N/A
66616/002
New safety
catch fitted
18.02.05
welders Swing
arm jib
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2.7 : BLANK REPORTS

VISUAL INSPECTION REPORT
PROOF LOAD TEST CERTIFICATE
NDT CERTIFICATES
DEFECT REPORT
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CERTIFICATION NO : .............................................................................................. TESTER / EXAMINER:............................................................
QUALIFICATION : ................................................................................................... DATE OF TEST / EXAMINATION : ..........................................
IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION


OR NONE
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
to operate.
DATE ..................................................................................................................DOC REF NO : NSL C 001

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IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION


OR NONE
to operate.

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IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION


OR NONE
to operate.

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IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION


OR NONE
to operate.

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IDENTIFICATION
NO.
QTY
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION


OR NONE
to operate.

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MAGNETIC PARTICLE INSPECTION REPORT

CLIENT
LOCATION
INSPECTION DATE
NSL JOB NO
REPORT NO
CLIENT ORDER NO
SHEET
of
COMPONENT / DESCRIPTION / DRAWING NO.
MATERIAL
SURFACE CONDITION
PROCEDURE / WORK / INSTRUCTION / TECHNIQUE
ACCEPTANCE STANDARD
EQUIPMENT
POWER / CURRENT
MATERIAL THICKNESS
METHOD
MEDIUM
BACKGROUND
RESULT
This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of the
inspection body and the client.
NSL INSPECTOR
ISSUING AUTHORITY
CLIENT
Sign
Sign
Sign
Name
Name
Name
Quals
Quals
Quals
NSL LTD
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CLIENT :.................................................................................................................................................................................................................
INSPECTION ENGINEER:........................................................................................................................................................................................
INSTALLATION :.....................................................................................................................................................................................................
DATE : ...................................................................................................................................................................................................................
CD09
TO BE COMPLETED BY INSPECTING ENGINEER

PLANT & CERT
NO.
NSL LTD
DEFECTIVE ITEM
(DESCRIPTION ,
LOCATION, SERIAL
NO.)
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INSTALLATION STAFF USE ONLY
PARTICULARS
REPAIR BY
OF DEFECT
(INCLUDING RETEST
IF APPLICABLE
TO BE REPORTED
TO ENFORCING
AUTHORITY
JOB CARD NO.
REMARKS
(MANIFEST NO.
ETC.)
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APPENDICES
2.8 : APPENDIX
WINCH DRUM CAPACITY
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APPENDICES
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APPENDICES
2.8 : APPENDICES
WINCH DRUM CAPACITY
L = Length of rope (metres)
A = Desired depth of winding (mm). The depth of the
flange is normally reduced by 40 to 50 mm to allow
ground clearance for the rope.
B = Diameter of barrel (mm)
C = Width between flanges (mm)
K = A constant developed according to the diameter of

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

ROPE DIAMETER (MM)
ROPE DIAMETER (MM)
1274
24
183300
2865
26
215200
5093
28
249600
7958
32
326000
11470
35
389900
15600
38
459700
20370
40
509300
25780
44
616300
11
38520
48
733300
13
53800
51
828100
14
62400
52
860800
16
81490
54
928300
18
103100
56
998200
19
114900
60
1147000
20
127400
64
1304000
22
154100
67
1429000
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APPENDICES
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APPENDICES
2.8 : APPENDIX
WINCH DRUM CAPACITY
FORMULA

L = (A+B) x A x C
K
EXAMPLE
Drum dimensions :

A = 400mm
B = 600mm
C = 700mm
K : Rope diameter 16mm = 81490
Length of rope on drum =

(400 + 600) x 400 x 700

81490
= 280,000,000
81490
= 3437m
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APPENDICES
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NSL 2004

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LIFTING EQUIPMENT INSPECTOR

l T : +44 (0) 1224 208988 l E : INFO@NSL-ABERDEEN.COM l WWW.NSL-UK.COM

Intellectual Ownership & Copyright of

NSL America INC

LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES AND POWERED HOISTS PROCEDURES

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES AND POWERED HOISTS PROCEDURES

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

2.1 : MANUAL WINCHES

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

2.1 : MANUAL WINCHES

Sight the original test certificate

Examine winding handle, check for distortion and correct connection

Should wire rope be fitted, it must be examined

ADDITIONAL (SPUR GEARED WINCHES)

If all satisfactory, record relevant details and issue report.

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

2.1 : MANUAL WINCHES

Carry out performance test at SWL before commencement of proof load

Sustain load and examine anchorage checking for deflection / distortion

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

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

B = WORN BUT SERVICEABLE

3 Ratchet wheel / worm wheel

4 Ratchet pawl / worm

5 Ratchet pawl spring

9 Spur gear shafts

11 Hold down bolts / clamps / welding

12 Support steel work

Tick relevant boxes / delete where applicable

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

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

2.2 : UTILITY WINCHES

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LIFTING EQUIPMENT INSPECTOR

MODULE 2 : WINCHES & POWERED HOISTS

2.2 : UTILITY WINCHES

Sight the original test certificate

Confirm controls operate in the direction that arrows are marked

Examine winch drum and check for wear, distortion or cracks

Examine brake bands / brake drums and check for wear

Examine automatic brake cylinder and check for leaks

Examine chromed piston rod and check for corrosion

Ensure directional arrows / markings are in place and clearly visible

Check oil level

Connect power supply and function test the winch

Should wire rope be fitted, it must be examined

If all satisfactory, record relevant details and issue report.

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LIFTING EQUIPMENT INSPECTOR