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APPEA Guidelines For Liting Equipment PDF
APPEA Guidelines For Liting Equipment PDF
LIFTING EQUIPMENT
Issued: March 2000
PREFACE
Lifting operations in the offshore petroleum industry represent potentially one of the highest risk
activities in the industry. Accordingly many standards and individual company guidelines exist to
ensure that lifting operations are performed safely using appropriate equipment.
As well as offshore lifting this guideline does cover some aspects of lifting operations at onshore
sites. In particular personnel competency requirements, registers of lifting equipment and
operational aspects for lifting devices including mobile cranes are covered. During the preparation
of the guideline the technical working group recognised that onshore lifting practices were
generally well established and that a uniform standard already existed. This guideline is intended
only to supplement and does not seek to alter these well established onshore lifting practices.
APPEA has issued these guidelines to facilitate consistent lifting practices across the petroleum
industry, particularly for offshore operations. These guidelines establish appropriate design
requirements for Lifting Gear reflecting the dynamic effects of lifting operations from supply
vessels along with guidance on equipment marking, registers, inspection testing and maintenance.
They also describe the broad expectations for competencies of personnel associated with lifting
activities.
These guidelines generally reference Australian Standards, however the use of equivalent
internationally recognised standards is also acceptable.
Disclaimer
The use of these Guidelines does not in any way diminish the responsibility of individual
operating companies or, their contractors to carry out operations safely having due regard to
their duty of care responsibilities, and to observe statutory requirements. APPEA does not accept
any responsibility for any incident or consequence thereof, whether or not in violation of any law
or regulation, which arises or is alleged to have arisen from the use of these Guidelines.
Amendments
Date Amendment By Reason for Amendment
Oct 2000 Additional Padeye Chart (App E) D. Williams Additional information
May 2001 Rigging Equipment Example (App E) D. Williams Error in calculation
Jun 2001 Rigging Equipment Example (App E) L. Gray Error in calculation
APPEA Guidelines for Lifting Equipment
CONTENTS
1 INTRODUCTION ............................................................................................................................................ 1
1.1 PURPOSE ........................................................................................................................................................ 1
1.2 SCOPE ............................................................................................................................................................ 1
1.3 LIFTING EQUIPMENT TERMINOLOGY................................................................................................................ 2
1.4 RELATIONSHIP WITH REGULATIONS................................................................................................................. 3
1.5 MANAGEMENT SYSTEM .................................................................................................................................. 3
2 COMPETENCY STANDARDS ....................................................................................................................... 4
2.1 MANAGEMENT RESPONSIBILITIES.................................................................................................................... 4
2.2 COMPETENCE OF EQUIPMENT OPERATORS ....................................................................................................... 4
2.3 MAINTAINERS OF LIFTING EQUIPMENT ............................................................................................................ 4
2.4 INSPECTORS OF LIFTING EQUIPMENT ............................................................................................................... 5
2.4.1 Pre-use visual checks............................................................................................................................ 5
2.4.2 Certified visual inspections ................................................................................................................... 5
2.5 NON DESTRUCTIVE TESTING (NDT) LABORATORIES........................................................................................ 5
2.5.1 Proof Load Testing Organisations......................................................................................................... 5
2.6 DESIGNERS & VERIFIERS OF RIGGING FOR ENGINEERED LIFTS, OF LIFTED EQUIPMENT, AND OF LIFTING
DEVICES .................................................................................................................................................................. 6
3 REGISTERS OF LIFTING EQUIPMENT ..................................................................................................... 7
3.1 INTRODUCTION ............................................................................................................................................... 7
3.2 LIFTING EQUIPMENT REGISTER ....................................................................................................................... 7
3.3 LIFTING EQUIPMENT REGISTER CONTENTS ...................................................................................................... 7
4 DESIGN OF OFFSHORE LIFTING DEVICES ............................................................................................. 9
4.1 INTRODUCTION AND SCOPE ............................................................................................................................. 9
4.2 DESIGN, MANUFACTURE AND INSTALLATION (GENERAL) ................................................................................ 9
4.3 CRANES.......................................................................................................................................................... 9
4.4 MOBILE CRANES .......................................................................................................................................... 10
4.5 GANTRY CRANES, MONORAILS & DAVITS ..................................................................................................... 10
4.6 LIFTING POINTS ............................................................................................................................................ 10
4.7 HOISTING EQUIPMENT (MANUALLY OPERATED) ............................................................................................ 11
4.8 MAN-RIDING EQUIPMENT ............................................................................................................................. 11
4.8.1 Cranes Used for Man Riding Operations............................................................................................. 11
4.8.2 Winches.............................................................................................................................................. 12
4.8.3 Man Riding Winches ........................................................................................................................... 12
4.9 SURVEYS AND INSPECTION ............................................................................................................................ 12
4.10 DOCUMENTATION ......................................................................................................................................... 13
5 DESIGN OF OFFSHORE LIFTING GEAR ................................................................................................. 14
5.1 INTRODUCTION ............................................................................................................................................. 14
5.2 DESIGN APPROACH FOR ENGINEERED LIFTS................................................................................................... 14
5.3 OVER CHART LIFTS ...................................................................................................................................... 15
5.4 DESIGN OF RIGGING ...................................................................................................................................... 15
5.5 ACCESS TO CRANE HOOK FOR MARINE CREWS FIFTH LEG ASSEMBLIES....................................................... 18
5.6 DIAGONALLING ............................................................................................................................................ 18
5.7 SPECIFIC REQUIREMENTS FOR OFFSHORE USE ............................................................................................... 19
5.7.1 Synthetic Slings (Refer AS 1353.17.2-1997, AS 4497.1&.2 -1997)........................................................ 19
5.7.2 Safety Shackles ................................................................................................................................... 19
5.7.3 Eyebolts.............................................................................................................................................. 19
5.7.4 Chain Slings ....................................................................................................................................... 19
5.7.5 Wire Rope Slings ................................................................................................................................ 19
5.8 DESIGN OF OFFSHORE CONTAINER PAD EYES & THEIR ATTACHMENT ............................................................ 20
APPEA Guidelines for Lifting Equipment
1 INTRODUCTION
1.1 Purpose
To provide operators, contractors and vendors working in the offshore petroleum industry clear and
consistent guidance on the expected standards for design, manufacture, supply and use of lifting
equipment. These guidelines are intended to ensure safe lifting operations, thereby minimising risks
to personnel and assets.
1.2 Scope
These guidelines apply to Lifting Equipment used on and in the following offshore exploration
and production facilities and onshore loading facilities:
platforms;
supply vessels;
construction vessels;
seismic vessels;
buoys; and
These guidelines do not apply to specialised lifting devices used in the following activities:
pipe laying activities;
specialised drilling rig equipment (ie. draw-works assembly, travelling blocks, drilling
swivels, etc);
escape craft
Most of the Lifting Devices used in drilling related operations are addressed in relevant API
standards or IADC guidelines.
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APPEA Guidelines for Lifting Equipment
LIFTING EQUIPMENT
LIFTED
RIGGING
EQUIPMENT
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APPEA Guidelines for Lifting Equipment
2 COMPETENCY STANDARDS
Competent persons, holding a certificate of competency relevant to the type of equipment, are to
carry out a pre-use visual check each time the equipment is used.
Classification Societies with industry accepted inspection standards for "Lifting Equipment"
(eg. DNV, Lloyds etc.); or
A "body" holding NATA Inspection accreditation to ISO 17020 for in-service inspection of
"Lifting Equipment" to these guidelines. Note: Personnel certification for inspection of lifting
equipment may be developed in the future by AIDNT, AICIP or similar organisations; or
Suitably qualified people working within an Operator's inspection program where the Operator
works within a Safety Case regime which addresses the requirements for training of such
personnel and the standards for such "certified visual inspections".
Refer to Section 8 and Appendix I for further details of the "certified visual inspection".
All "certified visual inspection" reports should bear the endorsement stamp of the accreditation
body (NATA), the Classification Society, or be issued in the form required by the Operator for in-
house "certified visual inspection".
During initial fabrication, repairs and modifications as well as part of the periodic inspection
process, NDT inspection of Lifting Equipment shall be conducted by:
A body holding NATA laboratory accreditation to ISO 17025 for Non Destructive
Testing.
All NDT reports should bear the endorsement stamp of the appropriate NDT accreditation body
(NATA).
Proof load testing organisations shall hold accreditation to these guidelines for the relevant class of
proof load testing. Proof load testing of Lifting Equipment shall be conducted by one of the
following bodies:
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APPEA Guidelines for Lifting Equipment
Classification Societies with industry accepted proof load standards for Lifting
Equipment (eg. DNV, Lloyds etc.);
OR
A body holding NATA laboratory accreditation to ISO 17025 for proof load testing of
Lifting Equipment to these guidelines.
OR
Suitably qualified people working within an Operator's inspection program where the
Operator works within a Safety Case regime which addresses the requirements for training
of such personnel and the standards for such proof load testing.
All proof load testing reports should bear the endorsement stamp of the appropriate proof load
testing accreditation body (NATA) or Classification Society.
Accreditation should be reviewed to ensure that it covers the equipment to be tested.
2.6 Designers & Verifiers of Rigging for Engineered Lifts, of Lifted Equipment, and of
Lifting Devices
Designers & Verifiers of Rigging for Engineered Lifts, of Lifted Equipment, and of Lifting Devices
should be qualified engineers experienced in offshore lifting technology.
The design & verification of "Lifted Equipment and Engineered Lifts should be conducted by
either:
A "body" holding ISO 9001 certification for design and who have qualified structural engineers
experienced in offshore lifting to carry out the design and also the checking of "Lifted
Equipment". A written certificate shall be provided on the design documentation by the "design
body" that it holds ISO 9001 qualification for structural design and that the design conforms to a
standard recognised under these Guidelines.
OR
Where the "design body" does not hold ISO 9001 certification for design, then the design is to
be certified by a classification society, ie Lloyds, DNV etc. In this case all design
documentation should bear the endorsement stamp of the appropriate Classification Society.
(This section applies also to subsequent Sections 4.2, 5.1, 5.3, 5.8, 5.9, and 5.14 of these
Guidelines.)"
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
3.1 Introduction
Each facility or group of facilities shall maintain a register or registers of all types of Lifting
Equipment used on site and owned by the operator. Likewise, contractors should maintain a
register of their Lifting Equipment on each facility. This is a statutory requirement for vessels
operating under the Navigation Act 1912.
All suppliers of Lifting Equipment that is leased to offshore operators and/or contractors should
also maintain a register of all such equipment.
the safe working load (SWL) of the item or maximum gross mass (MGM) as applicable;
the location (or reference to the drawing showing the location - particularly for pad eyes)
of the item. The usage of the item (eg. stores unloading, engine room general lifting etc);
a copy of the Certificate of Conformity, or number of, approval bodies and date of issue;
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
the inspection certificate number, issuing body and date of issue;
for cranes, winches, containers, special Lifting Equipment, pad eyes etc, the design and
fabrication codes and the location of the manufacturer data report;
for Lifting Gear, the national standard to which the item was purchased;
reference to the approved maintenance and operating manual for the item.
These entries shall be supported (as applicable) with the following traceable hard copy records as
issued by an inspection body holding accreditation with NATA in accordance with these guidelines
or a Classification Society with industry accepted design and inspection standards for Lifting
Equipment:
certificate of design verification;
the maintenance and inspection records (including the past inspection reports for visual
inspections, calibrations, adjustments, change out of equipment etc); and
Where applicable, these entries shall be supported with traceable hard copy records of the
following:
original manufacturers data report; and
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
4.3 Cranes
The detailed design of offshore cranes is beyond the scope of this document and is normally
completed by the specialist crane supplier. Common acceptable standards specified for offshore
cranes are:
API Spec 2C Specification for Offshore Cranes;
Lloyds Code for Lifting Appliances in a Marine Environment, together with BS2573
Rules for the Design of Cranes; and
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
4.4 Mobile Cranes
Mobile cranes offshore should be classed as temporary mobile equipment and should only be used
for the purpose agreed by the operating company, the owner and a competent person.
Where mobile cranes are used for operations subject to sea-state induced dynamics, they should
generally comply with Section 4.3. The following items should also be considered:
permissible locations (ie. area of safe operation) including adequacy of supporting
structure;
barriers to prevent the crane colliding with other parts of the installation, or toppling
overboard;
safe limits of operation on floating installations and any associated means of stowing or
securing the crane in adverse weather conditions;
means of securing while lifting from supply vessels or any other sea-state operation;
details should be included in an appropriate manual addressing the use of the mobile crane
in offshore operations.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Testing of pad eyes, lifting lugs etc. should be agreed with a competent person and carried out to
comply with the current requirements.
Refer to Section 5.8 and Appendix E for pad eye detail.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
4.8.2 Winches
All winches should be designed:
with winch controls that automatically return to neutral on release in any operating
position; and
with automatic brakes which will apply whenever the operating lever is returned to neutral
or on loss of power; and
with devices to prevent the winch rope from over- winding or under-winding;
with provision for spooling the wire on the drum to prevent damage or entanglement, this
may include the provision of sufficient fleet angle to ensure the wire spools correctly;
to be capable of lowering the load in the event of an emergency, such as loss of power;
with a brake holding which is less than the minimum breaking load of the rope and more
than the maximum line pull of the winch in the man-riding mode of operation; if a high
load is applied to the winch, the brake must render before the breaking load of the rope is
reached; and
with a suitable guard over the drum to provide protection to the operator in the event of
rope breakage. Such a guard should not inhibit the ability of the operator to see the
spooling action of the rope on the drum.
All man-riding winches shall be clearly labelled "SUITABLE FOR MAN -RIDING".
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
4.10 Documentation
An appropriate operations manual should contain particulars of the relevant Lifting Devices. As a
minimum, the contents should include general arrangements for the machinery and equipment,
wiring and piping diagrams where appropriate, and instructions for the operation of the devices. The
manual should contain operating limits, checks and test procedures, which are required to be carried
out to ensure safe operation of the equipment.
Any special instruction for safe operation of appliances, such as those for man-riding winches in
section 4.8, should be noted.
All Lifting Devices should have an appropriate maintenance manual which gives details of
servicing, repair, essential spares holdings and any special tools required for maintenance purposes.
All Lifting Devices should be provided with a test certificate containing the following
information:
type description;
model description;
serial number;
description;
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
5.1 Introduction
This section of the guidelines covers the general requirements for the design of Lifting Gear as
distinct from Lifting Devices such as cranes, winches, etc. Guidelines for the design of Lifting
Devices for offshore use are presented in Section 4.
Rigging can be selected by equipment users from manufacturers handbooks provided the factors of
safety given in section 5.4 below are met and the load does not exceed approximately 25 tonnes (the
arbitrarily selected limit for Engineering Lifts). It is anticipated that in due course rigging suppliers
will have catalogues available of Lifting Gear suitable for offshore lifting.
Where offshore loads exceed 25 tonnes an engineered lift should be considered [refer to AS 1666.2
(1995), section 9c]. In these cases design of all Lifting Gear should be performed by qualified
engineers experienced in offshore lifting.
With respect to the design of Lifted Equipment regardless of the lifted load, it is expected that the
design will be performed by qualified engineers experienced in offshore lifting. Refer to clause
2.6 for competency requirements.
addressing all relevant design conditions including transport, installation, loading &
unloading, operation, temperature and fatigue considerations.
For engineered lifts where the rigging for a particular load has been specifically designed the
rigging requirements shall be noted in a work order or preferably attached to the load (eg, a plate
which reads "For Rigging requirement refer to Drg. No. ... ").
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
5.3 Over Chart Lifts
An "over chart" lift (ie. a lift that exceed the load radius curves for the crane in question) is an
engineered lift and an analysis shall be carried out in close liaison with the Lifting Equipment
manufacturer, the installation contractor and the Operator. The Dynamic Amplification Factor
(DAF) may be reduced by limiting the sea state in which the lift can be carried out. In the case of
deck or onshore lifts the hoisting speed can be controlled to limit the dynamic effects.
These limitations shall be clearly shown on the design drawings, which are to be duly signed
"Accepted for Lift" by the engineer accepting overall responsibility.
For offshore lifts, codes such as "DNV Marine Operations Part 2 Chapter 5" and "Lloyds Code for
Lifting Appliances in a Marine Environment" provide guidance.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
The Safe Working Load (SWL) can also be expressed in terms of a Factor of Safety (FOS):
SWL = Rc P
FOS x 9.81
Where
FOS = 4/(Rm Rt Ro) Equation. 2
Where the Factor of Safety as specified in Equation 2 is less than the Factor of Safety as specified
in AS1666(1995) for wire rope, the greater value shall be applied. Equation 2 is consistent with the
explicit application of termination efficiency where AS1666(1976) is based on the poorest
performing termination. Although equation 2 would allow a minimum Factor of Safety for a
conventional ferrule secured wire rope sling of 4.21 this guideline is adopting a minimum Factor of
Safety of 5.26 (or 5/Rt where Rt = 0.95 for ferrule secured wire rope) as recommended in
AS1666(1995). It should be noted that for a similar sling the Factor of Safety as specified in
AS1666(1976) would be 5 which includes consideration of the termination efficiency. For further
discussion on the inconsistency of the application of termination efficiency between AS1666(1976)
and AS1666(1995) refer to Reference 64. The Factor of Safety for chains and wire rope are
provided as a function of SWL in Figure 1 and Figure 2 respectively.
Table 5.4.4 lists recommended Factors of Safety for commonly used slings in offshore and onshore
operations for direct loaded lifting arrangements. Values for other types of operations may be
determined by substituting the appropriate values of Rm, Rt and Ro in Equation 2.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Figure 1. Effective FOS for Chain Sling for Offshore Boat Lifts
6
5.8
APPEA (OFFSHORE)
4.4
Factor of Safety
4
AS3775 - 1990 (ONSHORE)
0
0 5 6 10 15 20 25
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Figure 2. Effective FOS for Wire Rope Sling for Offshore Boat Lifts
(Ferrule Secured Terminations)
6.1
6
APPEA (OFFSHORE)
5.3
5
AS1666 -1995 (ONSHORE)
Factor of Safety
0
0 5 6 10 15 20 25
5.5 Access to Crane Hook for Marine Crews Fifth Leg Assemblies
Rigging assemblies should be of sufficient length to allow a rigger at ground or deck level to
connect the rigging assembly to the crane hook from the outside of the Lifted Equipment. During
lifting, the recommended included angle between the sling and the horizontal at pad eye level is 60
degrees.
Rigging assemblies with an included (apex) angle greater than 90 degrees must be approved by the
operator prior to use.
In some instances, consideration should be given to attaching a fifth leg to the top of the assembly
to ensure the top end of the rigging assembly can reach to within one metre of the deck.
Whilst the inclusion of a 5th leg will greatly assist supply vessel deck crews, it does delete the
inherent redundancy in a 4 leg assembly. For this reason a 4 leg assembly is preferred.
Prior to the issue of these Guidelines the WADME stipulated a FOS of 6.5 for single leg
assemblies. Any requirement for the continued use of this FOS should be checked with WADME.
5.6 Diagonalling
For loads up to approximately 25 tonnes using 2, 3 and 4 point lifts, the total load should be taken
by 2 slings as required by AS1666(1995).
Diagonalling effects should be considered for both Lifted Equipment (including pad eyes) and the
rigging. (Not applicable to engineered lifts)
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
5.7 Specific Requirements for Offshore Use
Existing slings using AS2321 grade T chain made from boron modified material may still
be used for lifts where there is redundancy in the rigging arrangement (4 leg assemblies).
They shall not be used for single or two leg sling lifts where there is no redundancy.
Where chain slings are used for Offshore Lifting Operations a minimum chain size of 10mm should
be adopted.
5.7.5 Wire Rope Slings
Where wire rope slings are used for Offshore Lifting Operations a minimum diameter of 13mm
should be adopted.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
The dynamic amplification factor (DAF) is to be taken from the graph in Appendix D
based on the total lifted load.
The Design Load shall be taken as the Resulting Sling Force (RSF) times the DAF.
The resulting sling load will take into account of the sling angle (apex angle of 60 degrees
is common) and the diagonalling effects described in Clause 5.6.
The load factor described in Clause 2.2 of AS1170.1 SAA loading code shall be taken as
1.0 on the basis that the maximum static load is known accurately.
Pad eye local capacity checks should be conducted using AS4100 Steel Structures
Code, Clause 7.5.
A lateral load of 5% times RSF shall be applied concurrently with the RSF. The lateral
load shall be multiplied by the DAF. The lateral load shall be applied perpendicular to the
plane of the pad eye at a minimum height of the shackle pin centre line.
The combined actions of the biaxial bending and tension should be checked using AS4100
Steel Structures Code, Clause 8.3.4.
The above approach assumes the use of Australian Standards. The use of equivalent internationally
recognised standards is also acceptable.
The steel grade used for pad eyes shall be clearly specified on the design drawings. It is recognised
that 350 grade is widely used but where pad eyes are being checked on an existing container the
designer shall assume that grade 250 steel has been used unless justification for a higher grade
exists.
Hole sizes in pad eyes should be bored or drilled to provide a diameter equal to the shackle pin
diameter plus 3mm or 4% greater than the shackle pin diameter, whichever gives the larger hole.
The thickness of the pad eye should be at least 75% of the shackle width to avoid twisting the
shackle. The maximum thickness of the pad eye shall be such that a total minimum gap of 5mm is
maintained to avoid binding. Bolted on pad eyes should not be used on offshore containers.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Where a material other than structural steel is used, a design engineer should determine the
appropriate design standards and load factors.
they should not be loaded above 40% of their ISO Maximum Gross Mass (MGM) rating
(Refer to CSC plate on container) and,
all lifting should be conducted using pad eyes. Twist lock fittings shall not be used for
lifting;
there should be trace-ability of the material used for pad eyes fitted to the container and of
all welding carried out on the container;
Closed ISO containers of greater than 6 metres (20 ft) in length should not be used as
offshore containers.
prior to any intended offshore use, thorough inspections should be carried out on the
containers floor support members and door latching mechanisms. These are critical to the
containers integrity;
Prior to the container phase out date, inspection and testing of ISO shipping containers used in the
offshore oil and gas industry should be performed according to the APPEA Guidelines for the Phase
Out of ISO Shipping Containers (Refer Appendix H).
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
5.11 Design of Sub-sea Lifts
Sub-sea lifts are a specialised form of lift the design of which should only be undertaken by
qualified engineers with experience in this area. Generally, the design of Lifting Equipment
should follow the same approach as that for a similar lift in air. Sub-sea Lifting Equipment should
be designed in accordance with DNV Marine Operations, Part 2 Chapter 6 - Sub-Sea Operations
or a recognised equivalent standard. The lift design should take into account factors specific to the
offshore environment in which the lift is being conducted. As a minimum, consideration should be
given to the following factors associated with sub-sea lifts, many of which are highly dependent on
the shape of the equipment being lifted:
Viscous drag due to diversion of water around the Lifted Equipment (noting that velocity
of equipment in water = winch velocity plus angular velocity due to vessel roll).
Near surface and near seabed stability due to the vibration absorption/amplification of the
surrounding fluid.
When the Lifted Equipment is at or just above the air/water interface, allowing for the
mass of the water to be temporarily supported when waves break over the equipment.
When in water, force due to the apparent additional inertia from accelerated water
= mass of water x g x (DAF - 1.0).
As the hook of the Lifting Device will rise and fall in the water due to vessel roll, rigging for
Lifted Equipment needs to be of sufficient length to avoid the hook striking divers, ROVs and
other sub-sea equipment in the vicinity of the lift. Pad eyes and rigging should be of a suitable
colour and of sufficient size to enable easy location and use by divers or ROVs.
Many of the above factors can be reduced by the use of specialised equipment and techniques.
When a self-compensating winch or other line load control system is used, the effects of vessel roll
on dynamics and velocity in water may be reduced. When an item is lifted off the seabed, suction
effects can be reduced by sliding before raising. Excessive mass due to marine growth and
entrapped sediments may be removed prior to lifting.
The above factors cannot be avoided by assuming motion of the Lifted Equipment is always
downward, as any requirement to stop lowering prior to placement, either planned or in emergency,
may result in their occurrence.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Vendors and fabricators should have quality management systems equivalent to ISO9001, ISO9002
or ISO9003. All materials used in the fabrication of Lifting Equipment shall have documentation
in accordance with the contractors quality control procedures to demonstrate trace-ability. As
applicable, some or all of this documentation may be required to support the equipment register.
Assurance that the lifted item (container) has been designed, fabricated to offshore Lifting
Equipment" standards (eg. DNV, Lloyds etc.). The owner of the equipment shall retain the
certificate.
Tank containers that are required to comply with the International Maritime Dangerous
Goods (IMDG) regulations, should also be certified in accordance with the IMDG code.
drawings;
welder qualifications;
material certificates;
external dimensions;
name of fabricator;
date of fabrication;
the total gross weight in kilograms applicable to the all points lifting test and the actual
method of test;
a statement that the item has been designed, fabricated and tested in accordance with
this guideline;
remarks; and
Proprietary devices and Lifted Equipment, such as drum lifters, plate clamps, etc, should have a
test certificate and be accompanied by a maintenance and operating manual (where required) and
should only be used for onshore, inshore and on platform lifts.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Existing Lifted Equipment is inspected in accordance with Section 8 and Appendix I
and found to have passed the certified visual inspection and NDT where appropriate (eg.
Pad eyes).
Pad eye designs should be reviewed by an experienced Engineer (refer to clause 2.6 for
competency requirements) to ensure compliance with clause 5.8. Where pad eyes do not
meet this standard they should be modified appropriately.
The design of the item has been reviewed by an experienced Engineer (refer to clause
2.6 for competency requirements). The review should confirm that the item of Lifted
Equipment has sufficient structural integrity to pass load tests specified in Table F.2. of
Appendix F.
Rigging shall meet the requirements of Appendix C, where existing rigging is retained
some reduction in the maximum SWL may be required.
The container shall be considered to have passed the initial load test provided there is no permanent
deformation of the container. Deformation can readily be measured using two taut wires strung
between the diagonal corners of the container.
The test masses shall normally be evenly distributed inside the item. When the designer of new
equipment or the design verifier* of existing equipment considers it impracticable to apply
sufficient test load inside an item (other than an offshore container) then the designer or design
verifier shall recommend a method of load test for the item. If it is not possible to place all the test
mass inside the item, some of it may be placed outside or under the item, provided that this gives a
loading on the structure similar to the distribution of the item loading in operating conditions.
(*refer to 2.6 for competency requirements
Note: The alternate method of test loading described above does not apply to offshore freight
containers. All offshore containers MUST have the full test load evenly distributed over the floor
area.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
In addition to complying with other relevant design codes and requirements, tank containers for
fluids shall be suitable for offshore service.
Tanks which could be used to transport fluids shall be designed to conform to relevant sections of:
AS 1692 Tanks for Flammable and Combustible Liquids
AS/NZ 3711.6 Tank Containers
IMDG Code
DNV 2.7-1 Certification Notes - Offshore Containers
EN 12079:1999 Offshore Containers Design, Construction, Testing, Inspection and
marking
These guidelines for offshore tanks for fluids coincide with the requirements of DNV 2.7-1, section
3.5 and EN12079, section 5.5.
Tanks for dangerous cargoes shall fulfil the requirements of the IMDG Code and shall be
designed according to recognised rules for pressure vessels. A tank and its support shall be
able to withstand lifting and impact loads. In addition, due account shall be taken of fluid
surge arising from partly filled tanks.
Note: Chapter 13 of the general introduction to the IMDG Code does not allow tanks with a length
above 3m to be handled by fork-lift in a loaded condition. Special protection of the tank and fittings
in the area near the fork pockets is required.
On tank containers for dangerous cargoes, all parts of the tank and fittings shall be suitably
protected from impact damage by a frame, suitable for offshore service where applicable. In
addition to the IMDG Code, the following shall apply:
Beams, plates or grating, shall protect the top of the tank and its fittings. No part of the
tank or its fittings shall extend above a level 100mm below the top of the framework. It
shall not be possible for any part of the lifting set to foul fittings, manhole cleats or other
protrusions on the tank.
Protective beams shall be placed at or near the location where the tank shell is nearest to
the outer plane of the sides. Beams shall be spaced sufficiently close together to give the
necessary protection.
At the maximum calculated elastic deflection of any side member, the residual clearance
between the member and any part of the tank shell or its fittings shall be at least 10mm.
No part of the underside of the tank shell (including sumps), the bottom valves or other
fittings shall extend below a level 150mm above the bottom of the framework. Any such
part extending below a level 300mm above the bottom of the framework shall be
protected by beams or plating.
Tank containers designed with direct connection between the tank and the side or top frame
elements shall be subject to special consideration by the operator or during operation to
avoid damage.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
7.1 General
All Lifting Equipment shall be marked with an individual identification code (Unique Number)
and the safe working load (SWL) as determined from the design. Where appropriate, for certain
Lifted Equipment, the SWL may be replaced by the tare mass and maximum gross mass. The
identification code shall enable the operator to link the manufacturer and test certification numbers.
For contractor owned equipment, this code should include unique character(s) or colour to indicate
the owner.
Where equipment is used both for onshore and offshore lifts it shall be marked with the offshore
SWL rating.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
If the container has a roof, the container number should be displayed on the roof, in characters not
less than 300 mm high (or less if space is limited). The marking should be carried out in such a way
as to avoid incorrect interpretation (eg. by underlining). Where applicable, the lower edge marking
should be positioned near the side of the container in which the door is located.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
8.1 General
The periodic inspection, testing, and maintenance (including repairs) of all Lifting Equipment,
including contractor owned, shall be conducted by competent personnel. Periodic inspection,
testing and maintenance shall be conducted in a manner to ensure safety to people and plant. When
requested, contractors must supply the operator with copies of all relevant certificates before the
Lifting Equipment is used at any location under the operators jurisdiction.
A specific inspection, maintenance and testing plan should be developed for each Lifting Device,
each item of Lifted Equipment and rigging assembly or item. Where a Safety Case is in place this
plan should be risk based and developed in accordance with the appropriate safety case guidelines.
The inspection, testing and maintenance plan should consider the following factors:
manufacturers recommendations;
statutory requirements;
Records of testing, inspection, maintenance, repair and modification should be included in the
Lifting Equipment Register.
All Lifting Equipment shall be visually checked prior to each use by appropriately certified crane
driver, dogger or rigger (as applicable). This inspection should ensure that:
equipment is appropriate for load to be applied;
Non complying equipment shall be tagged and either removed from site or repaired.
Scheduled testing and inspections should include test loading, non-destructive testing (NDT) and
visual inspection (as appropriate). Recommended inspection and testing frequencies are provided in
Appendix F.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
Variations to these recommended frequencies are acceptable where a reliability based approach is in
place under a facilitys safety case.
All Lifted Equipment should be periodically inspected by an appropriate body. Refer to Clause
2.4.2 for competency requirements.
structure should be visually examined for corrosion, mechanical damage and injurious
deformation;
all accessible load bearing welds should be visually examined to ensure freedom from
defects;
the lifting points should be visually examined for distortion, mechanical damage or any
other sign of distress or overload;
doors, frames, seals, hinges, locks etc. should be visually examined and functionally
checked to ensure that they operate in a satisfactory manner without undue force being
required;
the floor should be visually examined to check that it is substantially flat with no sign of
distress or overload. Drainage facilities, where fitted should be examined, eg. drain holes
should be clear of debris etc.;
the paint markings and plates should be checked to see that they meet the
recommendations of this document;
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
after completion of a proof test load, the equipment should be re-examined for signs of
permanent deformation caused by the test. Any deformation or weld defect caused by the
load test shall result in the withdrawal of the equipment from service until all such faults
have been corrected and a further satisfactory load test completed;
welds to all pad eyes and members directly supporting pad eyes should be subject to
100% magnetic particle inspection (MPI); and
Detailed guidelines for the inspection, testing and marking of offshore containers are provided in
Appendix I APPEA Guidelines for the Inspection Testing and Marking of Offshore Containers.
Where proof loading is not a viable option, (ie. where access for loading is restricted such as for
transportable buildings with small doorways) structural assessment of the container may be
determined by a certified visual inspection. The certified visual inspection of the container shall be
conducted by an appropriate inspection body. Refer to Clause 2.4.2 for competency requirements.
For inspection requirements refer to Appendix I.
8.4 Rigging
8.4.1 Proof Loading of Rigging used for Offshore Lifting (Boat Lifts)
The rigging for the Lifted Equipment shall be subject to a proof force that is not less than 40% of
the rated minimum breaking load (MBL) of the member.
The sling shall withstand the application of the proof force, without sustaining damage that may
affect its intended function or safety. The sling shall also be free from any deleterious permanent set
or defects visible to the unaided eye.
AS1666 (wire rope) & AS3775 (chain) testing requirements for individual legs of a multi leg
assembly shall be complied with.
Proof load testing of rigging and NDT testing as appropriate shall be conducted by an appropriate
body. Refer to Clause 2.5 and 2.5.1 for competency requirements.
After proof loading has been completed, the sling or slings shall be marked with a safe working
load as determined in accordance with these Guidelines. The safe working load shall be marked on
the sling or slings in a manner which is in accordance with AS1666 or AS3775 as applicable.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
For all sling assemblies (both chain and wire rope), AS1666 1995 requires that the head ring be
tested separately from the rigging attached to it. Refer to AS1666 1995 for further details.
Test frequencies and other test requirements are included in Appendix F, Tables F2 and F3.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
9.1.1 Planning
The Australian Offshore Support Vessel Code of Safe Working Practice provides guidance on
lifting operations between platforms and vessels.
The safe conduct of lifting operations involving the transfer of cargo between a platform and a
vessel require planning and a high level of communications among the parties involved in these
operations.
Prior to the start of any lifting operations, the communications between the person in charge of the
facility and the Master of the vessel, or their appointed deputies, should address the following
issues:
the suitability of existing and forecast weather conditions for the required lifting
operations involving the vessel;
communications arrangements between the facility and the vessel during the lifting
operation;
any limitations or restrictions affecting, or which may interrupt, the proposed operations;
the nature and weights of the cargo to be transferred and any special lifting requirements;
whether any of the proposed lifts require special consideration, safeguards or controls
during lifting, or special securing arrangements on the vessel;
procedures to be used in the event of an emergency occurring while lifting operations are
being conducted.
9.1.2 Communications
Safe lifting operations rely on there being effective communications among the Master of the
vessel, the person in charge of the facility, the crane operator, the deck officer in charge on the
vessel and the deck crews on both the facility and the vessel. A reliable radio communication link
on a dedicated channel or frequency should be maintained throughout the operations. The crane
operator on the facility should have direct radio communication with the vessel.
The crane operator should have a clear view of the deck areas on both the facility and the vessel.
Where this is impractical, a dogger should be so stationed as to have a clear view of the deck area to
assist the crane operator. Directions given to the crane operator by the deck crew on the vessel must
only be given by one person who has been clearly identified for that purpose.
9.2.2 Duties
The duties of personnel in supervising or carrying out the personnel basket transfer should be
clearly defined. Generally, this would include the person in charge of the facility, the crane
operator, the Master of the vessel, and other people nominated by the person in charge and the
Master of the vessel to undertake specific duties.
The Person in charge of the facility should:
be aware of the reason for the transfer;
be satisfied with the fitness and training of the people to be transferred;
be satisfied as to the suitability of the vessel;
know the limitations of visibility and sea state;
be aware of the limitations on transfer by night;
be aware of the suitability of the crane for personnel transfer;
check the wind speed limitations on crane operations;
establish satisfactory communications with the Master of the vessel involved in the
transfer;
ensure that participants understand the procedures involved;
be satisfied with the competence and experience of the crane driver; and
be satisfied with the inspection and testing of the personnel basket.
The Master of the vessel should confirm to the person in charge of the facility that:
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
the transfer has been accepted and the procedures have been understood;
the vessel has a satisfactory station keeping capability;
the deck crew have been fully briefed;
the people to be transferred have been adequately briefed and are fit to be transferred.
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APPEA Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers
9.2.4 Weather conditions
Weather conditions are critical factors impacting on the safety of personnel basket transfers. Factors
which should be taken into account include visibility, wind and sea state. Guidelines should be
provided which specify the maximum wind speed and sea state beyond which basket transfer is not
permissible, including the wind speed limitations for crane operations and the effect of weather
conditions on the stability of the vessel.
9.2.5 Communications
Both radio and visual communication should be established and maintained between those
personnel conducting the operation.
9.2.7 Training
Personnel will be transferred by basket in greater safety and with less apprehension if they, and the
personnel conducting the transfer, have received training in the techniques involved. The type of
training required can be included in installation drills. Inexperienced people or those not trained in
the use of personnel baskets should always be accompanied by someone who has been trained in
personnel transfer procedures.
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