CCE Espoir WHP Crane Condition Audit Reports

Specialist Maintenance Services Ltd
SMS Job No 16983
Condition Audit of Espoir Wellhead Tower Cranes
For
CNRI (CÔTE D’IVOIRE) S.A.R.L.
From
Specialist Maintenance Services Ltd.
(Part of the Enermech Group of Companies)
Revision Control
Rev Date Description By Auth
0 19 May 09 First Issue for Review MB JM
Maintenance of Espoir Wellhead Tower Cranes

1.0 Introduction
At the request of CNR International to carry out a crane condition audit, SMS
mobilised a crane inspector on 2nd April 2009 to CNR International operation
in Abidjan, West Africa.
An SMS Supervisor was also mobilised at the same time to carry out planned
and corrective maintenance activities.
This report summarises the overall condition of the two Nautilus cranes
model: 340BA-80 serial no. 23504C and model: 280B-80 serial no. 04007C,
on the East and West Wellhead Tower platforms.
The inspection was in accordance with the SI 2307 The Lifting Operations and
Lifting Equipment Regulations 1998 and it’s Technical Guidance, and
highlights certain recommendation on the safe fitness for service or otherwise,
of the cranes condition and certification status.
Work Scope
Following the award of the Contract SMS provided experienced Crane

Inspector (Mr Mel Block) who carried out a full condition audit of both the
cranes. His scope included the following (for each crane),
• Check & copy certification status
• Review maintenance records
• Review crane usage (crane operation records, hour meter etc)
• Full visual inspection of the crane structure
• Full visual inspection of the major mechanical components (prime
mover, gearbox, winch etc)
• Full visual inspection of the hydraulic components (Pumps, motors,
cylinders, hoses & fittings etc)
• Full visual inspection of loose gear (rope & terminations, hook
blocks etc)
• Full visual inspection of electrical installation (lights, radio, junction
boxes etc)
• Check status & operation of safety systems (RCI, limits etc)
• Check availability & status of safety equipment (fire extinguisher
etc)
• Check & comment on access and egress to crane and worksite
• Check & comment on welfare facilities offshore
• Collect copies of Operation, Maintenance & Spares manuals for
each of the crane types
• View spares inventory & condition (including certification status)
held by CRNI
• Assess tooling requirements
CNR International Audit Visit Report


2.0 Crane Specifications
The pedestal cranes on the WHTs have the following specifications:
West Wellhead Crane
Crane Nautilus 340BA-80

Serial Number 23504C
Manufacture Date February 2005
Manufacture Oil States
SWL 60.175 lbs = 27.3 tonne
Engine Caterpillar
Model Number 3126
Engine N47787-006
Serial Number 9ZR02895
Arrangement Number 32-4383
Primary Fuel Filter Fleetguard FF5321
Air Filter CAT 6I-2501
Oil Filter CAT 1R-0739
Hydraulic Return Filter P164703 DONALDSON and 6I-2502


East Wellhead Crane
Crane Nautilus 280B-80

Manufacture Date July 2000
Manufacture Oil States
SWL 50.208 lbs = 22.8 tonne
Engine Caterpillar
Model Number 3306
Engine 3N-3790 12
Serial Number 64Z30215
Arrangement 1W-3815
Primary Fuel Filter Fleetguard FF5321
Secondary Fuel filter Caterpillar 1R-02739
Air filter Caterpillar 6I-0273
Oil filter Caterpillar 1R-18


3.0 Audit Findings (See detailed inspection reports Apps I & II)
3.1 Check & copy certification status
The cranes’ certification and documentation were checked. Certificates for the
hoist wire and sockets were not available at time of inspection (See Appendix
1 Inspection Report No.16983)
A thorough examination was performed on the East and West cranes and
certification issued (See Appendix IV, Thorough Examination Report No’s
16983/2-3)
3.2 Review maintenance records
There is currently no approved PM maintenance strategy or PM schedule in

place. There was evidence of engine maintenance, and greasing activities
having been done.
Various maintenance activities were carried out at time of inspection. In the

absence of approved routines interim maintenance schedule have been
proposed. (See Appendix II, Maintenance Report No. 16983/1).
3.3 Review crane usage (crane operation records, hour meter etc)
Crane operator daily checks were being completed and engine hours
recorded. During the inspection visit a daily crane operator log book was
implemented detailing crane operation and maintenance activities.
3.4 Full visual inspection of the crane structure
See Appendix 1 Inspection Report No.16983
3.5 Full visual inspection of the major mechanical components (prime

mover, gearbox, winch etc)
See Appendix 1 Inspection Report No. 16983
3.6 Full visual inspection of the hydraulic components (Pumps,

motors, cylinders, hoses & fittings etc)


3.7 Full visual inspection of loose gear (rope & terminations, hook
blocks etc)
3.8 Full visual inspection of electrical installation (lights, radio,

junction boxes etc)
3.9 Check status & operation of safety systems (RCI, limits etc)
See Appendix 1 Inspection Report No.16983 section 6.0 and Maintenance

Report No.16983/1
3.10 Check availability & status of safety equipment (fire extinguisher

etc)
Fires extinguisher located inside each operator’s cab. There was no safety
harness and life jacket.
3.11 Check & comment on access and egress to crane and worksite
The East and West platforms are tidy and safe egress and access was
observed. See attached Inspection Report No. 16983
3.12 Check & comment on welfare facilities offshore
The wellhead platforms have no accommodation and are manned, on a daily

basis, by a small number of crew that commute via supply boat and FROG to
and from the Espoir FPSO.
3.13 Collect copies of Operation, Maintenance & Spares manuals for

each of the crane types
A hard copy of the East platform crane manual and an electronic copy of the
West crane were obtained.


3.14 View spares inventory & condition (including certification status)

held by CRNI
The following spares are held by CNR store in Abidjan.
2 off hoist motors (1 old, 1 new) - Part No 25273

1 off load cell gauge bracket - Part No N93SK 1-083
1 off valve dump hydraulic - Part No N80299-002
3 off Secondary fuel filters – Part No N47787-510
1 off hoist winch (removed from East crane and repaired, no motor fitted)
1 off Hydraulic starter motor (requiring repair)
1 off hydraulic starter motor (possibly not crane)
1 off hoist counterbalance valve
2 off slew brake packs – Part No 45882/005
20 off fuel filters – Part No cat 1R-0750
8 off engine oil filters – Part No cat 1R-0739
16 off engine oil filters – Part No cat 1R-0739
2 off primary fuel filters 9M-2341
1 off gauze hydraulic suction strainer – Part No N94251(small)
5 off gauze hydraulic suction strainer
6 off diesel injectors – Part No.8N-7005
4 cat fan belt sets – Part No.133-06
The following spares are held in Q Serve depot, Abidjan
1 off hoist rope – Part No. 4067836

1 off two sheave hook block
2 sets of main hydraulic pumps, (1 old 1 new, both require clean)
1 off over hoist cut out valve, used
2 off slew brakes – Part No N25882
1 off DCV
1 off cab, new but damaged
The spares general condition is poor. It is recommended that the spares and
dismantled and were necessary overhauled to allow 100% guarantee of the
components when fitted,
3.15 Assess tooling requirements
Tooling as detailed in the proposed list (Appendix III) is deemed to be

sufficient to carry out most of the day to day maintenance tasks.


4.0 Discussion Points
The following points were discussed with local CNR staff.
• To standardise spares to for the East and West cranes with regards
to the hoist winch, wire rope and hook block.
• Propose spare holding list for running and long lead items.
• Change crane configuration from normally 4 falls of rope to 2 falls to

improve safety when manridding.
• Fabricate a suitable lifting frame for ease of hoist winch removal

when carrying out maintenance activities.
• Fit engine compressor for warning alarms, engine shut-down and

accumulator pumping.
• Training for CNR Nationals working on the platforms was

discussed. A summary of their current training status is attached in
Appendix
5.0 Summary
As can be seen from the notification sheet (See Appendix 1 Inspection Report
No.16983) certain areas do not comply with SI 2307 The Lifting Operations
and Lifting Equipment Regulations 1998 and it’s Technical Guidance.
It was discussed with CNR International personnel in Abidjan that the way
forward would be to implement a plan to firstly bring the crane to LOLER
compliance (See Appendix 1 Inspection Report No.16983 Notification Sheet),
and also actively pursue the additional work requirements.


APPENDIX I
Inspection Reports


Crane Inspection Report
Customer Data
Name CNR International
Address Abidjan – West Africa
Contact Peter Davidson
Purchase Order
Installation Data
Duty Holder CNR International
Installation (s) East and West Wellhead Tower
Location Ivory Coast - West Africa
Report compiled by:
Name: Signature: Date: Report:

Mel Block 14/03/2009 16983


CONTENT
1. Introduction
2. West Wellhead Crane Inspection Sheet
3. West Wellhead Crane Notification & Recommendation Sheet
4. East Wellhead Crane Inspection Sheet
5. East Wellhead Crane Notification & Recommendation Sheet
6. Summary


1.0 Introduction
This report summarises the overall condition of the two Nautilus cranes
model: 340BA-80 serial no. 23504C and model: 280B-80 serial no. 04007C,
on the CNR International Wellhead Tower platforms.
The report makes competent recommendation on the safe fitness for service
or otherwise, of the cranes condition and certification status.
This report highlights certain recommendations in accordance with the SI

2307 The Lifting Operations and Lifting Equipment Regulations 1998 and it’s
Technical Guidance.
Enermech would therefore recommend that the necessary corrective actions

should be addressed with in the following time scales. The number which is
highlighted within the notification sheet is in accordance with our
recommendations.
Category 1. Immediate action required

Category 2. Action within 30 days of this report


2.0 West Wellhead Crane Inspection Sheet
1.0 Crane Details

Manufacture Oil States – Nautilus Marine Crane
Model 340BA - 80
Year Manufactured February 2005
Boom Length 80 ft
SWL 60,175 lbs
Last Load Test 02-03-08 performed by Global Energy (Test load 26.5
tons)
Total Hours Run 348
Description Identificati Report D.O.C N.D.T Date Fitted
on Number No
Main hoist 055292A00 Feb 2005
wire
Main hoist Not Known Required Feb 2005
socket
Luff hoist wire N/A
Luff wire N/A
socket
Aux hoist wire N/A
Aux hoist N/A
socket
Whip hook N/A
block
Main hook 0474037 506555 Feb 2005
block
Slewing 13042-1 4030574 Feb 2005
bearing
Slewing S 60864 20932 Feb 2005
bearing S 59413 20931
fasteners
Air receiver N/A
2.0 Reports and Records Checked Comments
Y/N/NA
2.1 Are there any Y No evidence produced at time of
outstanding items / defects examination
from last SI 2307 report
2.2 Is the crane operating Y All function operating correctly
with any restriction or
limitations
2.3 Is the SWL clearly and Y Maximum SWL and working radius to
suitably marked be clearly marked on pedestal at
working deck level


2.4 Are PM schedules up to Y The first 250 hr engine service has

date been completed. There is no approved
PM maintenance strategy or PM
schedule.
2.5 N.D.T / M.P.I Y There is no PM standard covering N.D.T
examination for primary load path
components.
2.6 Grease sampling analysis Y There is no PM standard covering
slewing bearing grease sampling
analysis.
2.7 Deflection reading Y There is no PM standard covering
slewing bearing rocking deflection.
2.8 Safe load indicator Y Crane is fitted with Martin Decker load
calibration cell were calibration is not required
only tare weight prior to each lift. The
load cell was repaired at time of
examination.
2.9 Other N
3.0 Electrical Components Checked Comment

Y/N/NA
3.1 Power supply and NA
distribution panels
3.2 Covers, cover seals and NA
glands
3.3 Wire and cables and NA
straps
3.4 Power connection at NA
electric motor
3.5 Junction boxes NA
3.6 Slip ring NA
3.7 Solenoids NA
3.8 Main power isolator NA
3.9 Lighting and emergency NA
lighting
3.10 Other NA
4.0 Operators Cab / Checked Comment

Station Y/N/NA
4.1 General condition Y General house keeping is very good
4.2 Safety equipment Y Form fires extinguisher located inside

operator cab.
4.3 Control / instruments Y All controls are suitably marked. Gauge
readings for boom, main hoist and
accumulator are not clearly visible.


4.4 Communication Y Hand held radio is used.

equipment
4.5 Windows / wipers Y Small top window is cracked.
4.6 Manuals Y No manual or operators log book

located in cab
4.7 Electrical items NA
4.7 Access and ladders Y Good condition and suitably secure.
4.8 Walkways and handrails Y Good condition and gratings suitably

secure.
4.9 Other N Door seal require securing. Operator
seat swivel not operation.
5.0 Machinery House Checked Comment
Y/N/NA
5.1 General condition Y Good house keeping. Engine power
pack panels to be fitted.
5.2 Safety equipment NA
5.3 Prime mover Y Satisfactory with no signs of water / oil

leakages. The engine low oil pressure
and high water temperature shut down
device does not shut down the engine
5.4 Transmission system Y Hydraulic piggy back pump in good
condition with no visible oil leaks.
5.5 Coupling and shaft NA
5.6 Guards Y See 5.1 If covers are not going to be

fitted due to engine overheating
suitable protection is required for
moving parts (fan belts, pulleys etc).
5.7 Motors NA
5.8 Pumps Y Good condition
5.9 Filter (s) Y Returned filter replaced at 250 hrs.

Suction strainer have not been
replaced
5.10 Accumulator (s) Y One starting accumulator require pre
charging with nitrogen
5.11 Oil cooler NA
5.12 Oil and tank Y Oil level satisfactory and tank in good
condition
5.12 Gauges Y Gauges reading correct oil level.


5.13 Hoses and fittings Y Great care has been taken to prevent
abrasion damage to rubber hoses. The
piggy back hydraulic suction hoses are
showing signs of cracking.

secure.
5.17 Emergency Escape Y Clear of obstructions
Route
5.18 Other Y
6.0 Safety System / Checked Comment

Devices Y/N/NA
6.1 Safe load indicator Y Martin Decker load cell fitted does not
give audible and visual alarms at 95%
and 110% overload.
6.2 Over hoist cut outs Y Functional checked. No visual or
audible alarm
6.3 Max and min radius cut NA
out
6.4 Boom back stops NA
6.5 Boom pawl NA
6.6 Slewing limits NA
6.7 Overload protection N/A
6.8 Constant tension N/A
6.9 Slack rope N/A
6.10 Emergency lowering Y Equipment requires to be held on

platform and emergency lowering
check to be included in the PM
standard
6.11 Emergency engine stop Y Functional checked ok. Due to position
of the pull stop and the seat, access
could delay operation
6.12 External audible alarm Y There is no external warning for
personnel in the area of a possible
unsafe situation.
6.13 Other N
7.0 A frame / Mast Checked Comment

Y/N/NA
7.1 Structure and fittings NA


7.2 Back stops NA
7.3 Sheave assembly NA
7.4 Bridle sheaves NA
7.5 Pennants and pins NA
7.6 Electrical equipment NA
7.7 Limit switches NA
7.8 Access and ladders NA
7.9 Walkways and handrails NA
7.10 Other NA
8.0 Luffing System Checked Comment

Y/N/NA
8.1 Winch NA
8.2 Motor NA
8.3 Pump Y Good condition no visible leaking
8.4 Hydraulic cylinder (s) Y No signs of oil leakage and cylinder

pivot connections suitably lubricated
8.4 Hoses and fittings Y Good condition and were required have
been extra protected against abrasion
damage
8.5 Control gear Y Control lever linkage satisfactory and
suitably lubricated
8.6 Clutches NA
8.7 Brakes NA
8.9 Pawl NA
8.10 Wire and termination NA
8.11 Wire anchor point NA
8.12 Guards NA
8.13 Other NA
9.0 Main Hoist System Checked Comment

Y/N/NA
9.1 Winch Y Good condition no signs of oil leakage
or corrosion
9.2 Motor Y Good condition no signs of oil leakage
or corrosion


9.3 Pump Y Good condition no signs of oil leakage

or corrosion
9.4 Hoses and fitting Y Good condition. Addition protection is
required against abrasion from the
boom foot turret structure
suitably lubricated
9.6 Clutches NA
9.7 Brakes Y Satisfactory no drum creep when lever

in neutral
9.8 Wire and termination Y Correct wire spooling. Wire rope is
over 5 years old. When hook block is
at sea level there is over two full layers
remaining on drum barrel.
Wedge and socket has no identification
number
9.9 Wire anchor point Y Satisfactory
9.11 Bottom block Y Hook block trunion partially seized.
9.12 Hook and safety catch Y Satisfactory and correct and secure
operation
9.13 Guards Y Sheave rope guards showing no signs
of damage
9.14 Other Y When applying colour code paint 2 inch
square next to identification plate and
not paint complete hook and safety
catch
10.0 Auxiliary Hoist Checked Comments
System Y/N/NA
10.1 Winch NA
10.2 Motor NA
10.3 Pump NA
10.4 Hoses and fittings NA
10.5 Control gear NA
10.6 Clutches NA
10.7 Brakes NA
10.9 Wire anchor points NA


10.11 Headache ball NA
10.12 Hook NA
10.13 Safety catch NA
10.14 Guards NA
10.15 Other NA
11.0 Boom Checked Comment

Y/N/NA
11.1 General condition Y General condition good. Slight paint
damage were boom contacts boom
support rest
11.2 Root section NA
11.3 Intermediate sections NA
11.4 Cathead section NA
11.5 Box section Y No visual evidence of paint flaking,

deformation or crack-like indication
11.6 Jib / tip extension NA
11.7 Foot pins and bushes Y No visual wear in boom foot turret pin
and suitably lubricated and secure.
11.8 Joining bolts / pins NA
11.9 Rope rollers / guard Y Rope guards and wood protection

satisfactory and secure.
11.10 Sheave assembly Y Main hoist boom tip sheave bearing
checked for wear. Suitably lubricated.
11.11 Anchor points NA
11.12 Access and ladders Y No safe access or egress to boom tip

sheave for maintenance purposes.
11.13 Walkways and NA
handrails
11.15 Other N
12.0 Slewing System Checked Comment

Y/N/NA
or corrosion
or corrosion


12.3 Pinion Y Suitably lubricated
damage
suitably lubricated
12.6 Clutch NA
12.8 Slewing bearing Y External gear visually inspected, no

defects found. Bearing is suitably
lubricated
12.9 Slewing bearing Y Visually inspected and hammer
fasteners checked
12.10 Access and ladders Y There is no internal safe access to
slewing bearing grease points for
maintenance personnel.
handrails
12.12 Emergency Escape NA.
Route
12.13 Guard Y Satisfactory and secure


3.0 West Wellhead Crane Notification Sheet
Crane: Nautilus 340BA-80 Location: Wellhead Tower

Serial no: 23504C
Section Comments Recommendation
2.3 Maximum SWL and radius to To be suitably marked with 3 inch high
be clearly marked on lettering ( 3)
pedestal at working deck
level
2.4 The first 250 hr engine Maintenance strategy and schedule to
service has been completed. be introduced as soon as practicable (2)
There is no approved PM
maintenance strategy or PM
schedule.
2.5 There is no PM standard To be included in maintenance strategy
covering N.D.T examination (2)
for primary load path
components.
covering slewing bearing (2)
grease sampling analysis.
covering slewing bearing (2)
rocking deflection.
4.3 Gauge readings for boom, To be replaced (3)
main hoist and accumulator
are not clearly visible.
4.9 Door seal require securing. Requires remedial attention (3)
Operator seat swivel not
operation.
5.3 The engine low oil pressure Requires attention (safety system) (1)
and high water temperature
shut down device does not
shut down the engine
5.6 If covers are not going to be Requires attention (safety) (1)
fitted due to engine
overheating suitable
protection is required for
moving parts (fan belts,
pulleys etc).
6.1 Martin Decker load cell fitted Requires attention. Does not comply
does not give audible and with LOLER Technical guidance (3)
visual alarms at 95% and
110% overload.
6.2 Functional checked. No visual Requires attention. Does not comply
or audible alarm with LOLER Technical guidance (3)


6.12 There is no external warning Requires attention. (3)

for personnel in the area of a
possible unsafe situation.
9.8 Wire rope is over 5 years old. Wire rope to be replaced and
Wedge and socket has no identification and certification required
identification number for wedge and socket (2)
9.11 Hook block trunion partially Require overhaul, inspecting and NDT as
seized. required by LOLER technical guidance
(3)
12.10 There is no internal safe Suitable platform inside pedestal is
access to slewing bearing required (3)
grease points for
maintenance personnel.
The necessary corrective actions should be addressed with in the following

time scales. The number which is highlighted within the notification sheet is in
accordance with our recommendations.



4.0 East Wellhead Crane Inspection Sheet
1.0 Crane Details

Manufacture Oil States – Nautilus Marine Crane
Model 280B - 80
Year Manufactured July 2000
Boom Length 80 ft
SWL 50,208 lbs
Last Load Test 04-02-08 performed by Global Energy (Test load 25
tons)
Total Hours Run 2978
Description Identificati Report D.O.C N.D.T Date Fitted
on Number No
Main hoist Not known June 2008
wire
Main hoist Not Known Required July 2000
socket
Luff hoist wire N/A
Luff wire N/A
socket
Aux hoist wire N/A
Aux hoist N/A
socket
Whip hook N/A
block
Main hook 0027222 170285 July 2000
block
Slewing M023770- A104913 July 2000
bearing A1
Slewing 19297 30437 July 2000
bearing
fasteners
Air receiver N/A
2.0 Reports and Records Checked Comments
Y/N/NA
2.1 Are there any Y No evidence produced at time of
outstanding items / defects examination.
from last SI 2307 report
2.2 Is the crane operating Y All function operating correctly.
with any restriction or
limitations
2.3 Is the SWL clearly and Y Maximum SWL and working radius to
suitably marked be clearly marked on pedestal at
working deck level.


2.4 Are PM schedules up to Y The first 250 hr engine service has been
date completed. There is no approved PM
maintenance strategy or PM schedule.
2.5 N.D.T / M.P.I Y There is no PM standard covering N.D.T
examination for primary load path
components.
2.6 Grease sampling analysis Y There is no PM standard covering
slewing bearing grease sampling
analysis.
2.7 Deflection reading Y There is no PM standard covering
slewing bearing rocking deflection.
2.8 Safe load indicator Y Crane is fitted with Martin Decker load
calibration cell were calibration is not required only
tare weight prior to each lift. The load
cell was repaired at time of
examination.
2.9 Other N
3.0 Electrical Components Checked Comment

Y/N/NA
3.1 Power supply and NA
distribution panels
3.2 Covers, cover seals and NA
glands
3.3 Wire and cables and NA
straps
3.4 Power connection at NA
electric motor
3.5 Junction boxes NA
3.6 Slip ring NA
3.7 Solenoids NA
3.8 Main power isolator NA
3.9 Lighting and emergency NA
lighting
3.10 Other NA
4.0 Operators Cab / Checked Comment

Station Y/N/NA
4.1 General condition Y General house keeping is good.
4.2 Safety equipment Y Form fires extinguisher located inside

operator cab.


4.3 Control / instruments Y All controls are suitably marked. Gauge

readings for boom, main hoist and
return pressure are not clearly visible.
Water and hydraulic temperature
gauges not working.
Engine tachometer is missing.
4.4 Communication Y Hand held radio is used.
equipment
4.5 Windows / wipers Y Small top window is cracked.
4.6 Manuals Y No manual or operators log book

located in cab

secure.
4.9 Other N
5.0 Machinery House Checked Comment

Y/N/NA
5.1 General condition Y Good house keeping. Engine power
pack panels to be fitted.
5.2 Safety equipment NA
5.3 Prime mover Y Satisfactory with no signs of water / oil

leakages. The engine low oil pressure
and high water temperature shut down
device does not shut down the engine
5.4 Transmission system Y Hydraulic piggy back pump in good
condition with no visible oil leaks.
5.5 Coupling and shaft NA
5.6 Guards Y See 5.1 If covers are not going to be

fitted due to engine overheating
suitable protection is required for
moving parts (fan belts, pulleys etc).
5.7 Motors NA
5.8 Pumps Y Good condition
5.9 Filter (s) Y Returned filter replaced at 250 hrs.

Suction strainer have not been replaced
5.10 Accumulator (s) Y All three starting accumulators have
heavy localised corrosion.
5.11 Oil cooler NA
5.12 Oil and tank Y Oil level satisfactory and tank in good
condition


5.12 Gauges Y Gauges reading correct oil level.
5.13 Hoses and fittings Y Great care has been taken to prevent
abrasion damage to rubber hoses. Two
hydraulic suction hoses are partially
collapsed.

Access ladder to engine walkway
requires extending.
secure.
5.17 Emergency Escape Y Clear of obstructions
Route
5.18 Other Y Boom foot pin turret lifting lug welds
are corroding.
6.0 Safety System / Devices Checked Comment
Y/N/NA
6.1 Safe load indicator Y Martin Decker load cell fitted does not
give audible and visual alarms at 95%
and 110% overload.
6.2 Over hoist cut outs Y Functional checked. No visual or audible
alarm
6.3 Max and min radius cut NA
out
6.4 Boom back stops NA
6.5 Boom pawl NA
6.6 Slewing limits NA
6.7 Overload protection N/A
6.8 Constant tension N/A
6.9 Slack rope N/A
6.10 Emergency lowering Y Equipment requires to be held on

platform and emergency lowering check
to be included in the PM standard.
6.11 Emergency engine stop Y Not operational
6.12 External audible alarm Y There is no external warning for

personnel in the area of a possible
unsafe situation.
6.13 Other N
7.0 A frame / Mast Checked Comment

Y/N/NA


7.1 Structure and fittings NA
7.2 Back stops NA
7.3 Sheave assembly NA
7.4 Bridle sheaves NA
7.5 Pennants and pins NA
7.8 Access and ladders NA
7.9 Walkways and handrails NA
7.10 Other NA
8.0 Luffing System Checked Comment

Y/N/NA
8.1 Winch NA
8.2 Motor NA
8.3 Pump Y Good condition no visible leaking
8.4 Hydraulic cylinder (s) Y Left hand cylinder has slight oil leakage
on swivel hoses connection to
counterbalance valve. Cylinder pivot
connections suitably lubricated. There
appears to be excessive movement of
cylinder bottom pivot in cheek plates
damage
suitably lubricated
8.6 Clutches NA
8.7 Brakes NA
8.9 Pawl NA
8.11 Wire anchor point NA
8.12 Guards NA
8.13 Other N


9.0 Main Hoist System Checked Comment

Y/N/NA
9.1 Winch Y Good condition no signs of oil leakage
or corrosion
or corrosion
or corrosion
9.4 Hoses and fitting Y Good condition. Addition protection is
required against abrasion from the
boom foot turret structure
suitably lubricated
9.6 Clutches NA
9.7 Brakes Y Satisfactory no drum creep when lever

in neutral
9.8 Wire and termination Y No certification for wire at time of
examination. Correct wire spooling.
When hook block is at sea level there is
over two full layers remaining on drum
barrel. Wedge and socket has no
identification number
9.9 Wire anchor point Y Satisfactory
9.11 Bottom block Y Hook block has been fitted since 2000
and requires overhaul, NDT and load
testing.
9.12 Hook and safety catch Y Safety catch is worn and does not close
completely.
9.13 Guards Y Sheave rope guards shows no signs of
damage
9.14 Other Y When applying colour code paint 2 inch
square next to identification plate and
not paint block, hook and safety catch.
10.0 Auxiliary Hoist System Checked Comments
Y/N/NA
10.1 Winch NA
10.2 Motor NA
10.3 Pump NA
10.4 Hoses and fittings NA
10.5 Control gear NA


10.6 Clutches NA
10.7 Brakes NA
10.9 Wire anchor points NA
10.11 Headache ball NA
10.12 Hook NA
10.13 Safety catch NA
10.14 Guards NA
10.15 Other NA
11.0 Boom Checked Comment

Y/N/NA
11.1 General condition Y General condition good. Slight paint
damage were boom contacts boom
support rest
11.2 Root section NA
11.3 Intermediate sections NA
11.4 Cathead section NA
11.5 Box section Y No visual evidence of paint flaking,

deformation or crack-like indication
11.6 Jib / tip extension NA
11.7 Foot pins and bushes Y No visual wear in boom foot turret pin
and suitably lubricated and secure.
11.8 Joining bolts / pins NA
11.9 Rope rollers / guard Y Rope guards and rollers satisfactory

and secure.
11.10 Sheave assembly Y Main hoist boom tip sheave bearing
checked for wear. Suitably lubricated.
11.11 Anchor points NA
11.12 Access and ladders Y No safe access or egress to boom tip

sheave for maintenance purposes.
handrails
11.15 Other N


12.0 Slewing System Checked Comment

Y/N/NA
or corrosion
or corrosion
12.3 Pinion Y Suitably lubricated
damage
suitably lubricated
12.6 Clutch NA
12.8 Slewing bearing Y Could not visually inspect internal cog

teeth. No suitable safe access. Bearing
is suitably lubricated
12.9 Slewing bearing Y Visually inspected and hammer
fasteners checked. No certification was available
at time of examination for fasteners
between pedestal tub and platform
structure.
12.10 Access and ladders Y There is no internal safe access in
pedestal to slewing motor drive pinions
for maintenance personnel.
handrails
12.12 Emergency Escape NA.
Route
12.13 Guard Y Satisfactory and secure


5. East Wellhead Crane Notification Sheet
Crane: Nautilus 340BA-80 Location: Wellhead Tower

Serial no: 23504C
Section Comments Recommendation
2.3 Maximum SWL and radius to To be suitably marked with 3 inch

be clearly marked on high lettering ( 3)
pedestal at working deck
level
2.4 The first 250 hr engine Maintenance strategy and schedule to
service has been completed. be introduced as soon as practicable
There is no approved PM (2)
maintenance strategy or PM
schedule.
2.5 There is no PM standard To be included in maintenance
covering N.D.T examination strategy (2)
for primary load path
components.
covering slewing bearing strategy (2)
grease sampling analysis.
covering slewing bearing strategy (2)
rocking deflection.
4.3 Gauge readings for boom, To be replaced (3)
main hoist and return
pressure are not clearly
visible.
Water and hydraulic
temperature gauges not
working.
Engine tachometer is
missing.
5.3 The engine low oil pressure Requires attention (safety system)
and high water temperature (1)
shut down device does not
shut down the engine
5.6 If covers are not going to be Requires attention (safety) (1)
fitted due to engine
overheating suitable
protection is required for
moving parts (fan belts,
pulleys etc).


6.1 Martin Decker load cell fitted Requires attention. Does not comply
does not give audible and with LOLER Technical guidance (3)
visual alarms at 95% and
110% overload.
6.2 Functional checked. No visual Requires attention. Does not comply
or audible alarm with LOLER Technical guidance (3)
6.11 Emergency stop not Requires attention (safety) (1)
operational.
6.12 There is no external warning Requires attention. (3)
for personnel in the area of a
possible unsafe situation.
8.4 There appears to be Further investigation and the
excessive movement of possibility of installing spaces (3)
cylinder bottom pivot in
cheek plates
9.8 No certification for wire at Wire rope certificate to be located or
time of examination. wire to be replaced. Identification and
Wedge and socket has no certification required for wedge and
identification number socket (2)
9.11 Hook block has been fitted Require overhaul, inspecting and NDT
since 2000 and requires as required by LOLER technical
overhaul, NDT and load guidance (3)
testing.
9.12 Safety catch is worn and To be rectified when hook block is
does not close completely. overhauled (3)
12.8 Could not visually inspect Suitable platform inside pedestal is
internal cog teeth. No required (3)
suitable safe access
12.9 No certification was available Certification to be located or fasteners
at time of examination for will be required to be replaced (3)
fasteners between pedestal
tub and platform structure.
The necessary corrective actions should be addressed with in the following

time scales. The number which is highlighted within the notification sheet is in
accordance with our recommendations.



6. Summary
Not all items identified during the thorough examination are included in the East
and West cranes notification sheet and seen as critical to the continuing safe use
and operation of the crane; however such items at some point in the future will be
required to be addressed.
The overall condition of the cranes components and its general operation is good.
As can be seen from the notification sheet, certain areas do not comply with SI
2307 The Lifting Operations and Lifting Equipment Regulations 1998 and it’s
Technical Guidance. These are required to be discussed and a plan implemented
to ensure compliance.


APPENDIX II
Maintenance Report


Maintenance report on Espoir wellhead platform cranes
Compiled by: Colin Brown Date: 11/04/09 Report No. 16983/1
West crane
The west wellhead platform has an Oil States, Nautilus 30 tonne, ram luffing
crane. It is powered by a Caterpillar 3126 engine, driving 4 hydraulic pumps.
The crane has no electrical or pneumatic components. The operator’s
controls are tillers linked to directional control valves under the floor. The
engine is started hydraulically, by 3 accumulators. These are recharged from
the boom cylinder circuit, by booming down against the stops. A Martin
Decker load indicator is fitted. The crane is used for man riding purposes on
a daily bases for crew shift changes and supply boat work. The crane
operates on an average of about 80 hours per month and has a total of 350
hours recorded.
Slewing bearing rocking deflections was taken and the following recorded:
With the boom pointing North 0.71mm
East 0.52mm
South 0.71mm
West 0.50mm
Slew motor pinion back lash measurements were taken using solder at the
green teeth.
RH pinion Top 0.60mm
Bottom 0.65mm
LH pinion Top 0.88mm
Bottom 0.93mm
The load indicator was not working and was primed and bled from the read-
out gauge using the Martin Decker pump. There was no Martin Decker W15
oil on board so normal hydraulic oil was used as it had been before. The
correct oil should be sourced and the system replenished and tested.
The bottom starting accumulator has lost its charge and requires replacing.
There no facility to re-charge offshore.
The engine stop, emergency stop and slew brake controls are obstructed by
the operators seat (awaiting replacement) making them difficult to operate.
The stop controls are cable and very hard to operate. The operator’s seat was
repositioned on its base to ease the operation of the controls.
These cranes are used for man riding purposes. A brake stall test should be
carried out on the hoist winches at 3 month intervals and the hoist oil checked
monthly, sampled 6 monthly then sampled and changed annually (from


Braden manual). A Stall test was carried out on the winch and was
satisfactory; the valve for doing the stall test did not work and needs to be
replaced. The oil level is not easy to check on this crane and required a safety
harness. When the oil is to be sampled or changed, a scaffold platform will be
required.
A stall test was carried out on the slew motors and was satisfactory. The oil
levels were checked. The oil requires sampling and changing. The crane is
free slewing and the brake used for parking only and released automatically
when the crane is slewed. The brake is applied when the engine is stopped.
The Sentinel automatic shut down valve, operated by an over temp switch in
the coolant or low oil pressure, is not functional on either crane and require
repair or replacing. This should be done as a matter of priority. The parts
could be sourced by Enermech, sent to the FSPO Espoir. They can then be
fitted by one of CNR's senior operator/mechanics, who have been carrying out
PM's on the engine as well as other work such as changing the hydraulic
return oil filters.
East Crane
The east crane is laid out differently from the West but the systems are
similar. The engine is a caterpillar 3306. The slew ring gear and pinion are
internal. The access to the pedestal is restricted and the backlash was not
checked at this visit.
The winch has recently been changed; the original Braden CH185A was
replaced by a CH210A. The case drain return hose is fitted to the brake hose.
The shut off valve for carrying out stall tests has been moved to the other side
of the brake and closed, so that oil does not return to tank from the brake
when lowering the boom. Two blanks are required, one male and one female,
¼” JIC, one for the brake T piece and one to blank of the return to tank hose.
I don’t think the return is required any more, its not shown in the manual,
where a hose between the case drain and the counterbalance valve is fitted.
A stall test was carried out on the winch and was satisfactory. The oil level
was checked.
The load indicator was bled the same as the West crane. The load sensing
ram is rusted from the end for about 20mm. A new ram is required.
The emergency stop is not working. The short wire in the Chalwyn valve is
damaged but the valve itself works, the wire needs replacing.
A hydraulic leak at the accumulator hand pump was rectified. The hydraulic
oil was changed last year.


Slewing bearing rocking deflections was taken and the following recorded:
With the boom pointing North 0.37mm
East 0.36mm
South 0.37mm
West 0.38mm
The host emergency lowering equipment needs to be assembled and the

crane operators need to be familiar with its procedure and operation. For
emergency lowering both the hydraulic hoses are removed from the motor
and a stand pipe for oil fitted to one port, the other port blanked of. An
Enerpac is needed to pump of the brakes. The emergency stop equipment
was found at the CNR store in Abidjan in the container with the crane spares.
There looks like there may be enough for both cranes accept there is only one
pump. CNR were wondering if an emergency system could be installed
where recovery back to the platform would be possible.
The platform has limited tooling, although there is some measuring

equipment, a tool container for the cranes are required.
The maintenance requirements from the crane manual, the Braden winch
manual and the engine manual have been combined into a draft service
schedule below, which may still need some changes. Some original tasks
have been deleted or periods changed, such as drain fuel tank drain every 3
months, hydraulic oil drain and clean annually and coolant change annually.
The cranes are in good condition. Safety checks for man riding should be
carried out as detailed in the draft maintenance schedule, as well as other
service tasks not previously done. An improved emergency shut down would
be good. It did not work on either crane, I got the west working but it is very
hard to pull, and the east still does not work, as explained earlier.
Summary of Outstanding Work
West
Renew brake test valve
Change bottom start accumulator
Renew sentinel shut down valve
East
Fit blanks and refit brake test valve at correct side of brake
Renew sentinel shut down valve
Renew Chalwyn valve and rectify emergency shut down
Access for pedestal


Proposed Draft Maintenance Schedule Tasks
Crane operator daily checks Date Engine hours hrs
Visually check boom, rams, ropes and hook block for signs of damage or
loose items.
Hydraulic oil level
Diesel level
Engine oil level
Engine coolant level
Hydraulic hoses, pumps and motors for leaks etc
Cab, controls and gauges
Test over hoist cut out
Test engine emergency stop
Check radio communication
Ensure checks on FROG/manriding basket and accessories have been
completed prior to commencing operations
Conduct tool-box talk with all personnel involved
Weekly crane operators PM
Check hoist oil level in sight glass (required for man riding)
Check and record system pressures
Check pedestal/slew ring area and bolts
Check hoist winch holding down bolts
Lubricate: (Some items do not have grease fittings, but should be lubricated
by hand on exposed shafts)
Boom foot pins
Sheave pins
Luffing cylinder pins
Hook block
Anti two block valve
3 Monthly PM
Lubricate:
Hydraulic throttle linkage
Parking brake spool
Control valve spools
Control lever linkage
Anti two block valve
Slew ring
Sew ring gear and pinion


Inspect:
Slew ring bolts
Hoses
Hoist holding down bolts
All pins and keepers
Superstructure and welds
Renew hydraulic return oil filter

Renew oil and oil filters
Check and adjust fan belts if necessary
Lubricate fan belt pulley
Carry out hoist brake stall test
Check hoist oil level
Check engine shut down device
Take oil & grease samples

Carry out slew ring rocking motions
6 Monthly
As 3 monthly plus,
Lubricate hoist rope

Change fuel filter
12 Monthly
As 6 monthly plus,
Take sample then change hoist winch oil (required for man riding)
Re-torque slew ring and pedestal bolts
Re-torque hoist holding down bolts
Renew hydraulic suction strainers
Carry out pinion backlash checks
Check accumulators are fully charged
Clean crankshaft breather
Renew air filter
Drain exhaust soot trap
Change slew gearbox oils
Check valve clearance
Change slew brake oil if applicable
Renew crane ropes
4 Yearly
Change engine coolant
Change hydraulic oil and clean tank


APPENDIX III
Tooling List


Proposed Tool List
Description Size Q Description Size QTY

T
Y
Combination 3/8” 1 Outside calliper 6” 1
Combination 7/16” 1 Dividers 9” 1
Combination ½” 1 Inside Calliper 9” 1
Combination 9/16” 1 Drive Socket A.F. & Metric ¾” 1
Combination 5/8” 1 Drive Socket A.F. & Metric ½” 1
Combination 11/16” 1 Feeler Gauge 6” 1
Combination ¾” 1 Feeler Gauge 12” 1
Combination 13/16” 1 Chain Wrench 36” 1
Combination 7/8” 1 Stilson 12” 1
Combination 15/16” 1 Stilson 24” 1
Combination 1” 1 Stilson 36” 1
Combination 1 1/16” 1 Adjustable Wrench 8” 1
Combination 1 1/8” 1 Adjustable Wrench 12” 1
Combination 1 ¼” 1 Pry bar 2” 1
Combination 1 3/8” 1 Tape Measure 16” 1
Combination 1 ½” 1 Tape Measure n/a 1
O.E. Wrench 3/8” x 7/16” 1 Hammer 100lb
O.E. Wrench ½” x 9/16” 1 Hammer 14lb 1
O.E. Wrench 5/8”x 11/16” 1 Set files 1
O.E. Wrench 11/16” x ¾” 1 Ball Pien Hammer 1lb 1
O.E. Wrench 13/16” x 7/8” 1 Ball Pien Hammer 3lb 1
O.E. Wrench 1 ¼” x 1 5/16” 1 Crowfoot Tee Piece n/a 1
Int/Ext Circlip Pliers N/A 1 McD to cf adaptor n/a 1
General Purpose Pliers 8” 1 Air Hose (5m lng) n/a 3
Long Nose Pliers N/A 1 Safety ‘R’ Clips n/a 24
1
Lever Wrench Pliers N/A 1 Drill Set /16”-½” 1
Radio Pliers 6” 1 Safety Harnesses n/a 2
Side Cutters N/A 1 Burning Goggles n/a 1
Impact Screw Driver N/A 1 Safety Goggles n/a 2
Terminal Screw Driver 2 ½” 1 Tap Wrench No.3 1
Plain Screw Driver 6” 1 Tap Set (Imp) To ½” 1
Plain Screw Driver 8” 1 Burr Ball Nosed n/a 1
Plain Screw Driver 12” 1 Burr Cylindrical n/a 1
Phillips Screw Driver No.3 1 Steel Rule 12” 1
Phillips Screw Driver No.2 1 Magnetic Base n/a 1
Tool Bag 16” 1 D.T.I. 0”-0.5” 1
Oil Can N/A 1 Torque Wrench ¾”Sq 1
Wire Brush 3 Row N/A 1 Pry Bar 6 Ft 1
Set Allen keys 1/16”-3/8” 1 Pry Bar 4 Ft 1
Set Allen Keys 1.5-10mm 1 Pack Polkadot Gloves n/a 1
POS1 Screw Driver No.3 1 Pack Rigger Gloves n/a 1
Junior Hacksaw N/A 1 Coil of Rope 12mm 1
Hacksaw 12” 1 Coil of Rope 8mm 1
Set of parallel punches 9mm-8mm 1 Box Rags n/a 1
Scriber N/A 1 Air Pistol Drill ½” 1
Cold Chisel ¾” 1 Pencil Grinder N/A 1
Grease Gun N/A 1 Needle Gun N/A 1
Mole Grips 10” 1 Impact Wrench 1” 1
Centre Punch large N/A 1 Tin Snips 14” 1


APPENDIX IV
Thorough Examination Certificates

SPECIALIST MAINTENANCE SERVICES
LIMITED
Record of Thorough Examination of
Lifting Appliances / Lifting Gear Record
No:
16983/2
Name and Address of installation owner: Name and designation of offshore installation:
CNR INTERNATIONAL EAST WELLHEAD TOWER – WEST AFRICA
1. Description of distinguishing mark or number of Pedestal Crane Serial No: 04007C
lifting appliance or lifting gear.
2. Manufacturer and date of manufacture. Nautilus Marine – Manufactured July 2000
3. Date of last record of examination (if seen). 31st August 2008
Name of person who conducted last examination,
and his employer Global Energy Ventures
3. Date first put into service (if known). 01/07/2000
4. Parts not accessible for thorough examination. None
5. Part that require opening at the next examination. None
7. Particulars of defects and remedy: See Notification Sheet
particulars of any defect found in the lifting gear
which affects the safety of the appliance and the
repairs (if any) required, either:
(i) immediately, or
(ii) within a specified time (which must be stated).
to enable the lifting appliance or lifting gear to
continue to be used with safety.
(if no such repairs are required the word 'NONE'
is to be entered).
8. Safe Working Load subject to the repairs, renewals Maximum 50,208 lbs @ 80 degrees on 4 falls
and alterations (if any) specified above.
In the case of a crane with a variable operating
radius, including a crane with derricking jib, the
safe working load at various radii of the job,
trolley or crab is to be stated.
I hereby certify that on 14/03/2009 the item described in this report was thoroughly examined, so far as accessible, and
the above particulars are correct.
Date of next inspection : 13/09/2009
Signature of person conducting examination Counter-signature on behalf of employer
Name of person conducting examination Name of Employer:- Enermech SMS

Mel Block Enermech House, Howes Road
Bucksburn . Aberdeen AB16 7QU
Date: 19/05/09
SPECIALIST MAINTENANCE SERVICES
LIMITED
Record of Thorough Examination of
Lifting Appliances / Lifting Gear Record
No:
16983/3
Name and Address of installation owner: Name and designation of offshore installation:
CNR INTERNATIONAL WEST WELLHEAD TOWER – WEST AFRICA
1. Description of distinguishing mark or number of Pedestal Crane Serial No: 23504C
lifting appliance or lifting gear.
2. Manufacturer and date of manufacture. Nautilus Marine – Manufactured February 2005
3. Date of last record of examination (if seen). 31st August 2008
Name of person who conducted last examination,
and his employer Global Energy Ventures
3. Date first put into service (if known). 03/02/2005
4. Parts not accessible for thorough examination. None
5. Part that require opening at the next examination. None
7. Particulars of defects and remedy: See Notification Sheet
particulars of any defect found in the lifting gear
which affects the safety of the appliance and the
repairs (if any) required, either:
(i) immediately, or
(ii) within a specified time (which must be stated).
to enable the lifting appliance or lifting gear to
continue to be used with safety.
(if no such repairs are required the word 'NONE'
is to be entered).
8. Safe Working Load subject to the repairs, renewals Maximum 60,175 lbs @ 80 degrees on 4 falls
and alterations (if any) specified above.
In the case of a crane with a variable operating
radius, including a crane with derricking jib, the
safe working load at various radii of the job,
trolley or crab is to be stated.
I hereby certify that on 14/03/2009 the item described in this report was thoroughly examined, so far as accessible, and the
above particulars are correct.
Date of next inspection : 13/09/2009
Signature of person conducting examination Counter-signature on behalf of employer
Name of person conducting examination Name of Employer:- Enermech SMS

Mel Block Enermech House, Howes Road
Bucksburn . Aberdeen AB16 7QU
Date: 19/05/09

APPENDIX V
Training Status of National Staff



CCE Espoir WHP Crane Condition Audit Reports

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Specialist Maintenance Services Ltd

SMS Job No 16983

Condition Audit of Espoir Wellhead Tower Cranes

CNRI (CÔTE D’IVOIRE) S.A.R.L.

Specialist Maintenance Services Ltd.

(Part of the Enermech Group of Companies)

Specialist Maintenance Services Ltd.

Following the award of the Contract SMS provided experienced Crane

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

2.0 Crane Specifications

The pedestal cranes on the WHTs have the following specifications:

West Wellhead Crane

Crane Nautilus 340BA-80

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

East Wellhead Crane

Crane Nautilus 280B-80

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

3.1 Check & copy certification status

3.2 Review maintenance records

There is currently no approved PM maintenance strategy or PM schedule in

Various maintenance activities were carried out at time of inspection. In the

3.4 Full visual inspection of the crane structure

See Appendix 1 Inspection Report No.16983

3.5 Full visual inspection of the major mechanical components (prime

See Appendix 1 Inspection Report No. 16983

3.6 Full visual inspection of the hydraulic components (Pumps,

See Appendix 1 Inspection Report No. 16983

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

See Appendix 1 Inspection Report No. 16983

3.8 Full visual inspection of electrical installation (lights, radio,

See Appendix 1 Inspection Report No. 16983

See Appendix 1 Inspection Report No.16983 section 6.0 and Maintenance

3.10 Check availability & status of safety equipment (fire extinguisher

3.12 Check & comment on welfare facilities offshore

The wellhead platforms have no accommodation and are manned, on a daily

3.13 Collect copies of Operation, Maintenance & Spares manuals for

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

3.14 View spares inventory & condition (including certification status)

The following spares are held by CNR store in Abidjan.

2 off hoist motors (1 old, 1 new) - Part No 25273

The following spares are held in Q Serve depot, Abidjan

1 off hoist rope – Part No. 4067836

3.15 Assess tooling requirements

Tooling as detailed in the proposed list (Appendix III) is deemed to be

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

4.0 Discussion Points

The following points were discussed with local CNR staff.

• Change crane configuration from normally 4 falls of rope to 2 falls to

• Fabricate a suitable lifting frame for ease of hoist winch removal

• Fit engine compressor for warning alarms, engine shut-down and

• Training for CNR Nationals working on the platforms was

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

CNR International Audit Visit Report

Specialist Maintenance Services Ltd.

Crane Inspection Report

Report compiled by: