(Pre requirement plan)

Purpose:

This procedure describes the system of inspection & testing of equipment subject to statutory
inspection. To provide standards for the inspection and maintenance of lifting system equipment.

Scope:

Applies to all Hoist, lifting tools and tackles, pressure vessel and pressure plants subject to statutory
inspection and testing.

Definition:

 "design pressure' means the maximum pressure that a pressure vessels or plant is designed
to withstand safety when operating normally;
 "maximum permissible working pressure" means the maximum pressure at which a pressure
vessel or plant is permitted to be operated or used under this rule and is determined by the
technical requirement of the process.
 "plant" means a system of piping that is connected to a pressure vessel and so used to contain
a gas vapour or liquid under pressure greater than the atmospheric pressure and includes the
pressure vessels.
 "pressure vessel" means a vessel that may be used for containing, storing, distributing,
 transferring, distilling, processing or otherwise handling any gas, vapour or
liquid under pressure greater than the atmospheric pressure and includes any
pipelinefitting or
 other equipment attached thereto or used in connection therewith.
 “Hoist” means is a device used for lifting or lowering a load by means of goods, with lift-
wheel around which rope or chain wraps having cage assembly. It may be electrically or
pneumatically driven and may use chain, or wire rope as its lifting medium.
Reference:
GFR
FAC
SOP for Hoist Operation:
PTW

Responsibility:

To ensure all the equipment to be examined : -

Department Maintenance: Identify all the equipment to be inspect as per statutory requirement, as
pressure vessel, pressure plant, Hoist, and lifting tools and tackles as per defined equipment operation
and designee and list as per the annexture-1. and ensure all the required equipment is covered and
inspected. Ensure all the required list interlocks is properly listed and working in order. Prepare
prearrangement for the inspection.

Department Production Manager / Area Supervisor: Acquire equipment for inspection, correlating
to production requirement.

Department EHS: To ensure safe arrangement at the site, and timely co-ordination with internal and
external agencies. Compliance of observation from competent person after testing and , keep record
of certification and inspection.

Frequency of inspection and testing:

Equipment for Frequency of testing Location of inspection

 Hoist
Tools and Tackles
Pressure vessel / plant
(External Inspection)
Pressure Vessel (Internal
Inspection)
Pressure Vessel (Hydro test
where internal examination is
not possible)
Pressure Vessel (Hydro test
where internal examination
carried out)
Non-destructive test to identify
metal thickness and of other
metal defect (If hydro test and
internal examination is not
possible)
Once in every period of six Actual working location.
months
Once in every period of twelve Workshop
months
Once in every period of six Actual working location.
months
Once in every period of twelve Actual working location.
months
Once in very period of two Actual working location.
years
Once in every period of four Actual working location.
years
Once in every period of four Actual working location.
years

Procedure:

1. Hoist Inspection:
a. Visual Inspection for hoist and its parts to be carried out by normal operation of
hoist with carried out maximum load as per the designee safe working load
requirement and identify any physical damages abnormal sound or operation in
the presence of mechanical maintenance team, and competent person.
i. Free from obstruction enclosure, hoist/lift way.
ii. Operation of Landing gate, cage gate, gate fastenings,
iii. Good condition of cage, cage platform, buffers.
iv. Over running device, brakes, worm, spur gears and other electrical
equipment is functioning properly.
v. No damage in suspension ropes or chains and its attachments.
b. Interlock Inspection of hoist to be carried out by total operation of hoist in the
presence of electrical / instrument maintenance team and competent person.
2. Lifting tools and tackles inspection:
a. Visual Inspection for tools tackles and its parts to be carried.
b. Only after no damages found, physical operation inspection to be carried out by
taking 1.5 times load from its safe working load capacity and identify any
abnormal sound or operation in the presence of mechanical maintenance team,
and competent person.
3. Pressure vessel / plant inspection:
a. External Inspection: Visual inspection for damages or shearing to be carried out
in the presence of mechanical maintenance team representative and competent
person.
b. Internal Inspection: Internal examination to be carried out by following PTW
and identify internal damages or shearing in the presence of mechanical
maintenance team representative and competent person.
c. Hydro test:
d. NDT test:
 4.

Maintenance department will;

1. Identify all the equipment for the statutory requirement, as pressure vessel, pressure plant,
Hoist, and lifting tools and tackles as per defined equipment operation and designee and list
as per the annexture-1.
2. Pre arrangement for the inspection.
3.

Carriout all the equipme

Nothing in this rule shall apply to:-

A. Vessels made of ferrous materials having an internal operating pressure not exceeding 1
kilogram per square centimetre;
B. steam boilers, steam and feed-pipes and their fittings coming under the purview of the Indian
Boilers Act. 1923;
C. Metal bottles or cylinders used for storage or transport of compressed gases or liquefied or
dissolved gases under pressure covered by the Gas Cylinder Rules, 1981 framed under the
Indian Explosives Act, 1884;
D. Vessels in which internal pressure is due solely to the static heat or liquid;
E. Vessels with a nominal water capacity not exceeding 500 litters connected in a water-pumping
system containing air that is compressed to service as cushion.
F. Vessels for unclear energy application;
G. refrigeration plant having a capacity of 3 tons or less or refrigeration’s in 24 hours; and
working cylinders of steam engines or prime movers and steam traps; turbine casings;
compressor cylinders; steam separators or dryers; steam strainers; steam de-super-heaters;
oil separators; air receivers for fire sprinkler installations; air receivers of monotype machines
provided maximum working pressure of the air receiver does not exceed 1.33 kilograms per
square centimetre and the capacity of 85 litres; air receivers of electrical circuit breakers; air
receivers of electrical relays; air vessels on pumps, pipe coils accessories of instruments and
appliances such as cylinders and piston assemblies used for operating relays and interlocking
type of guards, vessels with liquids subjected to static heat only: and hydraulically operating
other than any cylinders communicating with an air loaded accumulator.
Form No. 11 Rule no 61 (GFR)

Section 31, & 112 (FAC)