Midco Lifting Manual Sow PDF

DOC. REF.
INSP-E6-M-01
Written By:
NO.
Operation Manager Rev #/DATE 01/01.09.2016
Approved By :
PAGE 1 OF 47
Executive Manager
Title:
(LIFTING) - MANUAL
MIDCO
Lifting Manual
Quality Health, Safety & Environmental Management System Standard Procedures
Warning: The controlled source document is stored on MIDCO shared QHSE folder. Any paper version is uncontrolled and
Quality
should be compared with Health, Safety
the source & Environmental
document Management
at the time of use to ensure it System Standard
is up-to-date unlessProcedures
stamped “Controlled”.
Document Title: Doc. Ref. #: Rev # / DATE: PAGE:
(LIFTING) MANUAL INSP-E6-M-01 01/01.09.2016 2 OF 47
Warning: The controlled source document is stored on MIDCO shared QHSE folder. Any paper version is uncontrolled
and should be compared with the source document at the time of use to ensure it is up-to-date unless stamped
“Controlled”.
Amendment Sheet
01 01.09.2016 First Issue Operation Manager Executive Manager

Rev. Date Amendment Description Originator Approved
“Controlled”.
1. Introduction
1.1. Scope
This work instruction describes how to examine and test various lifting
equipments. It provides a link with the international standards specifications
and considered the guidelines required to support the inspection process
within the company.
This work instruction should be read by all concerned parties involved in
carrying out examinations or tests of lifting appliances and lifting gears. It
should be read in conjunction with relevant national/international standards,
codes of practice and manufacturer's instructions in order to ensure the
quality of inspections, examinations and tests.
1.2. Reference Documents

The following documents shall be used as references in establishing this
work instruction:
 LOLER Lifting operation Lifting Equipment Regulation
 BS British Standards for Lifting Equipment
 LEEA code of Practice
All documents referenced in this guideline shall be maintained.
The below table specified the standard for equipments inspected by

MIDCO
Equipment Standard Equipment Standard
Wire rope BS1290 Shackles BS 6994

slings BS EN 13414 BS EN 13889
RR-C-271DIV
BS3032
Chain blocks BS 3243, Lever hoists BS 4898,
BS EN 13157 BS EN 13157
Containers BS7072,
BS EN 12079
“Controlled”.
2. Health and safety instructions

MIDCO employees and contractors shall be committed to HSE instructions.
The MIDCO Group has established and maintains a HSE management
programme for achieving its objectives. Management demonstrates their
commitment to improving HSE performance through actions accomplished
and ensuring necessary resources are available.
It is the duty of each inspector charged with responsibility for performing
inspection to adhere to all applicable Company rules and regulations
regarding health and safety. To accomplish this, each inspector must ensure
safe working conditions and that the necessary protective equipment has
been provided for the task to be performed.
2.1. Supervisor and section heads responsibilities

The Supervisor responsibilities regarding HSE shall include:
 Be familiar with the Company Safety and Environment Policy and

Manuals;
 Ensure that persons in their department are adequately trained and aware
of any hazards associated with their work activity;
 Ensure that the appropriate safety equipment is available for the range
and type of work required to be carried out;
 Ensure that adequate supervision is available;
 Ensure that all safety rules are observed and that personal protective
equipment is worn or used where and when appropriate;
 Ensure that equipment used in inspection is properly maintained in a safe
condition and that regular inspections/calibration are carried out;
 Investigate all accidents and incidents as soon as they are known, to
discover the cause and eliminate a recurrence;
 Ensure that accidents and incident reports are completed correctly and
accurately for all such accidents and incidents which may or may not
involve injury, damage etc.;
2.2. Company inspectors

Company employees at all levels must ensure that:-
“Controlled”.
 They make themselves familiar with and conform to the Health and
Safety and Environment program at all times;
 They shall observe all safety rules at all times;
 They shall wear appropriate personal protective equipment / safety
equipment and use appropriate safety devices at all times;
 They will conform to all instructions given by Management and others
with a responsibility for Health and Safety;
 They report all accidents and damage to the Section Supervisor, Foreman
or Departmental Head whether persons are injured or not;
2.3. Personal Protective Equipment

 Inspectors must use PPE properly;
 Inspectors must Wear PPE in a proper manner and check prior to use;
 PPE shall be stored properly when not in use;
 Remove any PPE which could cause contamination before eating,
drinking, smoking or using the toilet;
 Report to management any defects discovered in any item of personal
protective equipment.
2.4. HSE Risk Management

Risk assessment is highly proactive and identifies hazards and hazardous
situations before they give rise to injury or damage. Risk Assessments shall
be conducted on all hazards and tasks performed by MIDCO Group. Under
no circumstances is a task to be performed without a clear understanding of
the hazards involved and identification of those control measures that are to
be used to minimise risks to an acceptable level,
MIDCO developed risk assessment system for work area to reduce and the
control the risks for each job.
Managers will provide relevant information to employees on the identified
risks, the control measures to be taken, emergency procedures and risks
where work areas are shared with other employees. The risk assessment will
be carried out and recorded on the standard risk assessment forms in use by
the Company or as provided by the customer.
Risk Assessment team must review the risk assessment and add any
additional risks as appropriate. Major hazard organisations require
competent staff that has the necessary skills, knowledge and experience to
undertake critical tasks.
“Controlled”.
2.5. Accident Control and Reporting

It is the responsibility of all employees to ensure that all injuries sustained
are reported to their immediate Supervisor or senior person as soon as
possible and also that any specified dangerous occurrence is reported at the
earliest opportunity.
Where employees are injured while working they or their representative

must report the accident to their immediate Manager as soon as possible,
even if treatment is received off site.
Incidents shall be reported in a timely manner to facilitate management
oversight of internal/external notifications and investigations. Intentional
failure to report serious incidents as required by this procedure shall result in
disciplinary action, up to and including termination.
Investigation of incidents is a line responsibility and all investigations shall

be led by a line manager or supervisor with training on conducting incident
investigation and also with Operational Integrity and other specialists
participating as required in a support or facilitation role. In the event of a
catastrophic incident an independent investigation team shall be assembled
and comprised of operations and Operational Integrity employees
independent from the local business involved in the incident.
Incidents involving contractors under MIDCO operational control shall be

investigated by MIDCO with assistance from the contractor’s parent
organisation, supported and supervised where necessary by MIDCO Group
Operational Integrity employees and other specialist advisers.
3. Personnel Qualification
3.1. Personnel Qualification

Inspection of a lifting appliance or lifting gear shall be carried out by a
competent person. A competent person is regarded as competent if he is well
trained and possesses adequate knowledge and practical experience in
handling the similar type of lifting appliances or lifting gear. He should be
able to detect and assess defects and potential hazards that could limit the
safe performance of the lifting appliances or lifting gear.
“Controlled”.
A competent person should be fully familiar with and apply the following
aspects of knowledge and skill:
• The operation or use of the lifting appliance or lifting gear that he has to
inspect;
• The location and function of safety devices;
Personnel performing NDT inspection shall be qualified to NDT Level I/II
as per ASNT SNT-TC-1A and/or EN 473.
Personnel that supervise the job or the senior inspector shall be qualified in
the equipments being inspected.
The Business and the Operation Managers shall identify the ongoing training
needs/plan.
4. Inspection Of Wire Rope And Wire Rope Sling
4.1. Scope of work

 Visual inspection
4.2. Preparation& Equipment

 It must be ensured that appropriate and sufficient lighting is present to
enable an effective examination.
 The environment within which the examination is to be undertaken must
be assessed by appropriate means prior to commencement of working.
The engineer surveyor may utilise the following:

 Wire Bruch
 Magnifying glass
 Coloured paint / Cable Ties
 Vernier
 Torch if needed
4.3. Marking requirements

Marking requirements:
Single leg sling (single part or endless)
- CE Mark
- Manufacturers identifying mark
“Controlled”.
- Numbers and/or letters identifying the sling with the manufacturer‟s certificate.
- Working load limit
- Year of manufacture
- Material Grades
Multi-leg sling
- CE Mark
- Numbers and/or letters identifying the sling with the manufacturer‟s certificate.
- Working load limit and the angles applicable.
- Material grades
4.4. Inspection Method

Check that the sling markings correspond with previous Reports of Thorough
Examination (ROTE) and the Manufacturer’s Declaration of Conformity (DOC).
 Marking should be clear and legible.
 Master link
Check wear, damage, distortion, corrosion, or cracking
Ensure that the working load limit of master link shall be at least equal to that
of the sling.
 Intermediate master link
Check wear, damage, distortion, corrosion, or cracking
Ensure that the working load limit of any intermediate link fitted to a
three-leg or four-leg sling shall be at least equal to 1,6 times the WLL
of one of the legs suspended from it.
 Ferrule-secured eye slings
The minimum length of plain rope between the inside ends of
ferrules terminating a sling leg shall be 20 times the nominal rope
diameter.
 Turn Back Loop
Ensure that the rope is fully engaged within the ferrule
Ensure ferrule free from defects
 Tail Length
should be no more than one half of the rope diameter
 Thimbles
Check damage, wear, corrosion, or loose.
 Grade of Rope
“Controlled”.
Ensure that the rope grade shall be either 1770 or 1960. If wire rope complies with
EN 131414-1.
Ensure that the rope grade shall be either 1770N/mm2. If wire rope complies with
BS 1290
 Length single-leg slings
Ensure that the measured length of a ferrule-secured sling shall not differ from the
nominal length by more than two rope diameters or 1 % of the nominal length,
whichever is the greater.
 Length of Multi – Leg Slings / wire rope sling comply with EN 13414-1
Ensure that the length shall be that measured between the bearing points of the
sling.
 The measured individual leg lengths shall not differ from the nominal length of
the sling by more than two rope diameters or 1 % of the nominal length, whichever
is the greater.
 The difference in length between the individual legs of any multi-leg sling under
no load shall not exceed 1.5 times the rope diameter or 0.5 % of the nominal
length, whichever is the greater.
 Multi – Leg Slings/ wire rope sling comply with BS 1290
This length shall be measured under no load. In the case of two-, three- and four-
leg slings, the discrepancy in length between any of the legs, in millimetres, shall
not exceed that given by the equation: Maximum discrepancy = (9 d + 9L)/ 3
Where d is the nominal rope diameter, in millimetres,
And L is the nominal length of sling leg, in metres.
 Formation of a Sling
 The rope size type and grade for each leg shall be the same.
 Wire rope sling comply with EN 13414-1
Ensure that the working load limits and the angles applicable, i.e. the WLL 0° to
45° to vertical and, additionally, the WLL 45° to 60° to the vertical if applicable
 Wire rope sling comply with BS 1290

Ensure that the number of legs and angle of use, i.e. 0°to 90° or 90° to 120°
 Ensure that in a four-leg sling each of the two pairs shall be joined by
an intermediate master link to the master link.
 Check the Entire length of the wire rope sling for wear, corrosion,
damage, reduction in diameter, broken wires, kink and insufficient
lubrication.
 Terminal Fittings (Hooks)

Ensure that the working load limit of the lower terminal fitting(s) shall be at least
equal to that of the leg(s) to which it is/they are fitted.
Ensure that the hooks fittings shall be same grade
Check hooks opening up and safety latches not operating correctly, twisted or
corroded
“Controlled”.
4.5. Inspection Areas of Wire Rope slings
4.6. Wire Rope Slings Withdrawn Criteria
 Illegible markings
 wear, damage, distortion, corrosion, or cracking at master link and
Intermediate master link.
 Damage or wear to any of protective thimbles and ferrules.
 Mechanical damage to the rope, Kink, weld splatter, evidence of arcing
and corrosion or drying out of lubricant.
 Disturbance to the position of the wires in the strands or strands in the
rope or protrusion of the core.
 . The measured length differs from the nominal length by more than
. or 1 % of the nominal length in single-leg slings and
0.5 % of the nominal length in Multi-leg slings
 Broken wires.
“Controlled”.
Randomly Distributed Broken Wires

6 randomly distributed broken outer wires in a length of 6d but no more
than 14 randomly distributed broken wires in a length of 30d where d is the
nominal rope diameter.
Concentrated Broken Wires
 3 adjacent broken outer wires in one strand.
 Rope Wear
The sling should be withdrawn from service if there is wear above
10% of the nominal rope diameter.
 Opening out of hooks, i.e. noticeable increase in the throat opening, or
any other form of distortion, Ineffective safety catches on hooks.
4.7. Reporting
If the competent person find the inspected item free from any of the above
mentioned withdrawing defects ,he can issue the thorough examination report to
the client .
If the competent person find a serious and significant defect, he shall immediately
mark the defected item with red color and inform the client to take the lifting
equipment out of service.
Then the competent person shall issue the defect report which the client &
enforcing authority shall signed for acknowledgement.
References
 BS 1290 wire rope slings
 BS EN 13414 wire rope slings
 LEEA Code of Practice
“Controlled”.
5. Inspection Of Shackles
5.1. Scope of Work

5.2. Preparation
5.3. Equipment
 Wire Bruch
 Vernier
 Torch if needed

 Check that the shackle markings correspond with previous Reports of
Thorough Examination (ROTE) and the Manufacturer’s Declaration of
Conformity (DOC).
 Check if there is distortion of the body
 Check the alignment of the Jaw (holes on opposite sides of the shackle).
 Check the free working of the pin.
 Check if there is wear on thread of screw pin shackles, thread should be
finger tight and complete.
 In case of safety pin shackles, the nut should jam on the end of the thread
and not the body of the shackle; this will allow the pin to rotate in the
shackle when fully tightened.
 Check wear in pin and body of shackle; this must not exceed 8% of the
original diameter.
 Check the shackle from dents, nicks or cracks as a result of service.
“Controlled”.
 Check that the correct pin is fitted.

 Check that the pin of the correct type, and the length of pin and thread
length should be correct for the shackle body.
 Holes must align. The pin hole should not be too large so as to allow a gap
when the pin is in place
5.5. Inspection Areas of Shackle
5.6. Shackle Withdrawn Criteria
Shackle should be withdrawn from service and referred to the Client’s

Responsible Person if:
 Identification missing or unreadable.
 Safe Working Load missing or unreadable.
 Incorrect pin.
 Damaged thread on pin or in tapped eye.
 Distorted body or pin.
 Worn body or pin (Wear exceeds 8 % shall be withdrawn).
 Nicks, gouges, cracks, corrosion
 Twist at body and holes not align.
5.7. Types of Shackle Body and Pin:
There are two types of shackle pin in common use, the screw pin and the bolt, nut and
cotter pin.
“Controlled”.
Bow shackles are designed to enable three or more items to be joined.

Dee shackles are generally used for joining two items in a straight line.
5.8. Marking requirements
- CE Mark
- Working load limit in tonnes
- Grade number
- Manufacturers name, symbol or code
- Traceability code.
BS EN 13889 require that pins of less than 13mm diameter are marked
with either:
Grade mark or,

Traceability code
Pins greater than 13mm diameter are marked with:
Grade mark
Traceability code
Manufacturer‟s symbol
5.9. Reporting
If the competent person find the inspected item free from any of the above mentioned
withdrawing defects ,he can issue the thorough examination report to the client .
If the competent person find a serious and significant defect, he shall immediately mark the
defected item with red color and inform the client to take the lifting equipment out of
service.
Then the competent person shall issue the defect report which the client & enforcing
authority shall signed for acknowledgement.
5.10. Reference
 BS 6994
 BS EN 13889
 ISO 2415
 RR-C-271DIV
 BS3032
“Controlled”.
6. Inspection of Chains and Chain Sling
6.1. Scope of Work

6.2. Preparation &Equipment

 It must be ensured that appropriate and sufficient lighting is present
to enable an effective examination.
 The environment within which the examination is to be undertaken
must be assessed by appropriate means prior to commencement of
working.

 Wire Bruch
 Vernier
6.3. Marking
Single leg sling.
- CE Mark
- Sling manufacturers name or symbol
- WLL in tonnes (t)
- Identification mark
- Sling grade
Multi-leg sling.
- CE Mark
- Sling manufacturers name or symbol
- WLL in tonnes (t) and range of angles.
- Identification mark
- Sling grade
“Controlled”.
- Number of legs
Chain Sling Construction
Chain slings assembled by:
a) Mechanical joining devices
b) Welding
 Check that the marking is legible and corresponds with the test
certificate.
 Master link
Check wear, damage, distortion, corrosion, bending, twist or cracking
Ensure that the working load limit of master link shall be at least equal to
that of the sling.
 Intermediate link (Assembled by welding)

-Check wear, damage, distortion, corrosion, bending, twist or
cracking
-Ensure that the upper and lower intermediate links shall have a working
load limit not less than that of the chain(s) to which they are connected in a
chain sling.
 Joining link (upper and lower) Assembled by welding

cracking
“Controlled”.
-Ensure that the upper and lower Joining links and shall have a working
load limit not less than that of the chain(s) to which they are connected in a
chain sling.
Chain Shorteners
The shorteners are commonly supplied as clutches or grab hooks.
Check wear, damage, distortion, corrosion, bending, twist
 Chain
-Ensure that the chain shall be in accordance with BS EN 818-2 (grade 8) or BS
EN 818-3 (grade 4), medium tolerance (4,5,6,8,10,12) and short links chain
-Check wear, damage, distortion, corrosion, stretch, elongation, nicks
and gouges
-Ensure that the working load limit of master link shall be at least equal to
that of the sling.
-Check Grade Quality Mark on chain to establish grade of chain, mark
should be every 20th link or 1M whichever is the lesser distance.
 Tolerances on Leg Length
 Maximum tolerance between longest and shortest leg for slings joined by
mechanical devices with nominal lengths up to and including 2m is 10mm
maximum

mechanical devices with nominal lengths over 2m is 5mm/m

assembled by welding with nominal lengths up to and including 2m is 6mm
maximum

assembled by welding with nominal lengths over 2m is 3mm/m
 Or Mechanical joining device (upper and lower) Joined by mechanical
devices
cracking
- Ensure that the coupling device is fitted correctly
- Ensure that the assembled mechanical joining devices shall have a
working load limit not less than that of the chain(s) to which they are
connected in a chain sling.
Hooks
 Check hook from wear in the cross sectional area maximum allowable wear
is 8% .
 Check that the marking is clear and legible
 Check hook free from any mechanical damage i.e. nicks, cuts, gouges etc.
 check throat opening distance shall not exceed of 15%.
 Check hook free from any thermal damage or evidence of welding on the
hook i.e. nuts welded to hook shanks.
 No cracking or stretch.
 Hooks with latch: Ensure safety catches is present and operates
“Controlled”.
correctly.
 Self-Locking Hook: Ensure locking mechanism is activated and operates
correctly.
 Check manufacturer’s tables to ensure the safe working load is correct

for the diameter of chain.
 Check all components used are compatible with the safe working load of
the chain.
 If any faults are found at the time of examination, which would affect the
safe use of the item of lifting gear, then it must be withdrawn from
service and details recorded on the Inspection Report and manufacturers
specifications.
6.5. Inspection Areas of Chain Sling
6.6. Chain Withdrawn Criteria

If any of the following defects are found, chain should be withdrawn
from service:
 Illegible markings.
“Controlled”.
 Master link
Signs of wear, damage, distortion, corrosion, bending, twist or cracking

 Intermediate link (Assembled by welding)
 Joining link (upper and lower) Assembled by welding
Mechanical joining device (upper and lower) Joined by mechanical devices

Incorrect assembly of the mechanical joining devices.
 Chain shorteners
Load Chain
 Load chain (Round Link) Wear in excess of 5% of original link dimensions.
 Load chain (Plate Link) Wear in excess of 8% of original link dimensions.
 Cuts, heat damage, severe nicks, gouges or distortion of links.
 Excessive corrosion, pitting or any chemical attack.
 Stretched chain, bent or twisted links
Hooks
 Maximum wear in the cross sectional area of the hook is 8% .
 Missing or illegible Identification Number or Safe Working Load.
 Any mechanical damage i.e. nicks, cuts, gouges etc.
 Increase in throat opening distance in excess of 15%.
 Any thermal damage or evidence of welding on the hook i.e. nuts welded to
hook shanks.
 Any cracking or stretch.
 Hooks with latch: safety catches missing, or damaged or not operates
correctly.
 Self-Locking Hook: locking mechanism is stuck or damaged or not
operates correctly.
 All wrought iron chain and mild steel chain should be withdrawn from
service.
“Controlled”.
6.7. Reporting
If the competent person find the inspected item free from any of the above
mentioned withdrawing defects ,he can issue the thorough examination report to the
client .
If the competent person find a serious and significant defect, he shall immediately
mark the defected item with red color and inform the client to take the lifting
equipment out of service.
Then the competent person shall issue the defect report which the client &
enforcing authority shall signed for acknowledgement.
6.8. Reference
 - 4: Chain slings - Grade 8
 - 5: Chain slings - Grade 4
 BS EN 1677-1: Components for slings - Safety - Part 1:
Forged steel components - Grade 8
Forged steel lifting hooks with latch - Grade 8
Forged steel self-locking hooks - Grade 8
 BS EN 1677-4: Components for slings - Safety - Part 4: Links
- Grade 8
Forged steel lifting hooks with latch - Grade 4
 BS EN 1677-6: Components for slings - Safety - Part 6: Links
- Grade 4
 LEEA Code of Practice
“Controlled”.
7. Inspection of Chain Block
7.1. Scope of Work
 Function Test
 Operational Testing
 Light Load Test
7.2. Preparation
 The environment within which the examination is to be undertaken must be
assessed by appropriate means prior to commencement of working.
7.3. Equipment
 Wire Bruch
 Vernier
 Torch
 Ensure that the chain blocks have a factor of safety of at least 4:1
 Both top and bottom hooks checked for excessive wear, stretch, nicks
gouges, cuts, cracks, deformation and stretching of the hook opening
security of mountings and effectiveness of safety catches, The top hook
shall be capable of swiveling for correct positioning.
 Free rotation and movement of hooks.
 If there is excessive movement or float of the hook in the cross head it will
be necessary to remove the hook from its housing in order to examine the
seating and bearing surfaces.
 Well-designed housings are bolted together to allow this but in many cases
they are riveted, in which case the rivets must be drilled out and
subsequently replaced with bolts and nuts.
 Ensure that the hook latch engage in the point of the hook to form a
complete closure of mating surfaces, The spring shall be constructed from
corrosion protected material.
 All parts should be clean and free from deleterious matter.

 Check the Security of chain anchor point or damage to load chain stop
“Controlled”.
where one is fitted.

 Check General damage to the block body including any gear cover and
chain guides.
 Check that the Hand wheel is not damaged and freedom of movement.
 The load chain should be checked from worn or damaged, check for heat
damage, weld splatter, exposure to chemicals (pitting and discolouration)
particular attention should be given to wear on the inside of the link and to
damage in the form of bent, notched and stretched or corroded links.
 Ensure the load chain is marked correctly and is of the correct grade and
size.
 Load chains shall be in accordance with EN 818-7, for fine tolerance short
link chains (grade T) and the coefficient of utilization shall be at least 4 for
welded load bearing calibrated link chains.
 The hand chain and hand chain wheel should be checked for worn or
damaged, particularly on the bearing surface or is corroded bearing in mind
possible injury to operative hands and shall resist without permanent
deformation a force of at least 120 daN.
 Check chain load chain for pitch elongation and link reduction in material
diameter
 The load chain sprocket should be checked for wear and build-up of debris
in pockets, as this will prevent the chain from seating correctly.
 Chain guides must be provided for both the hand chain and load chain to
prevent them jumping off of the chain wheels.
 Function test block to ensure brake mechanism operates satisfactorily.
 If any faults are found at the time of examination, which would affect the
safe operation of the machine then it must be withdrawn from service and
details recorded on the Inspection Report.
 Wherever practical, all equipment must be operated through a full cycle of
its operation, before and after inspection.
 Light Load Test should be carried out to check the brake.
7.5. Inspection Areas of Chain Block
“Controlled”.
“Controlled”.
7.6. Chain Block Withdrawn Criteria
Hooks
 Any thermal damage or evidence of welding on the hook i.e. nuts welded to
hook shanks.
 Replacing the correct pin for the swivel and cannot rotates freely.
Load Chain
 Load chain (Round Link) Wear in excess of 5% of original link dimensions.
 Load chain (Plate Link) Wear in excess of 8% of original link dimensions.
 Cracks, heat damage, severe nicks, gouges or distortion of links.
 Load chain reeving incorrect.
 Maximum elongation (due to wear) is 3%
Chain Anchorage
 Any cracks or distortion.
 Wear in excess of 5% of original diameter.
Chain End Stop

Hand Chain
 Any worn or damaged, particularly on the bearing surfaces on the
inside of the links, or is corroded, bearing in mind possible damage
to the operative‟s hands.
 Any sharpness around the welds
Block Body
 General damage to the block body, including any gear covers or chain
guides.
 When operated under load there is any jumping or excessive noise of either
the hand chain or load chain, any undue effort is required or any visible
slipping of the brake.
“Controlled”.
7.7. Tests
Functional Test
Used in lifting machines to verify that the unit operates correctly with no load. This is
a necessary part of any thorough examination and should be carried out both
before and after any thorough examination.
Light Load Test
Used in lifting machines to verify that the brake functions correctly. Between 2% - 5%
of its SWL. which shall be raised and lowered through a height of between 250 mm
and 500 mm.
When the hand chain is released at any point during raising and lowering cycle, the
brake shall hold the load. This is a necessary part of any thorough examination and
should be carried out both before and after any thorough examination.
Operational Testing
Used in lifting machines to verify that it functions correctly with up to full SWL. Used
periodically and after repair of a machine. Always carried out if commencing an
overload test.
7.8. Marking
The following information shall be permanently and legibly marked on a suitable
part of the block:
- CE Mark
- Business name and address of the manufacturer
- Identification mark; if any
- Safe working load
- The series or type designation.
- Size and grade of the load chain
- Year of manufacture.
Operating and maintenance instructions shall be supplied.
Units
Safe working loads of less than 1000 kg shall be marked in kilograms, i.e. „kg‟, to the
nearest whole kilogram.
Safe working loads of 1000 kg or more shall be marked in ton
nes, i.e. as „tonnes‟ or „t‟. The value shall be given to a single place of decimals,
except where the figure after the decimal point would be O, in which case it shall be
omitted, and except in the case of 1.25 t, which shall be given to two decimal places.
“Controlled”.
7.9. Reporting
If the competent person finds the inspected item free from any of the above-mentioned
withdrawing defects, he can issue the thorough examination report to the client.
If the competent person finds a serious and significant defect, he shall immediately mark the
defected item with red color and inform the client to take the lifting equipment out of service.
Then the competent person shall issue the defect report which the client & enforcing
authority shall signed for acknowledgement.
7.10. Reference
 BS 3243
 BS EN 13157:2004 + A1-2009 cranes safety hand powered hand
equipment
“Controlled”.
8. Inspection on Lever Hoist/Pull Lifts
8.1. Scope of Work

 Function Test
 Operational Testing
 Light Load Test
8.2. Preparation
8.3. Equipment
 Wire Bruch
 Vernier
 Torch
 Chain Elongation Gauge

 Check both top and bottom hooks for swivels freely, and there is no
excessive stretch, nicks, gouges, wear, security of shank and body
safety catches is present and operates correctly.
 Check the body of the machine has no cracks, missing bolts and
screws.
 Check the lever assembly for correct operation of pawl changing
mechanism, freedom of operation and deformation.
 Check End stop for security and effectiveness
 Check link chain for excess wear, stretched or twisted links, wear,
damage, corrosion, nicks and gouges.
 Check that when operated there is no jumping and excessive noise or
that undue effort is required.
 Check that ratchet and pawl operated. Ensure no slippage of brake.
 Function tests the block to ensure satisfactory operation of the brake
mechanism.
“Controlled”.
 Light Load Test should be carried out to check the brake.
8.5. Inspection Areas of Chain Lever Hoist
8.6. Chain Lever Hoist Withdrawn Criteria
Hooks

 Any thermal damage or evidence of welding on the hook i.e. nuts
welded to hook shanks.
 Replacing the correct pin for the swivel and cannot rotates freely.
“Controlled”.
Load Chain
 Load chain (Round Link) Wear in excess of 5% of original link
dimensions.
 Load chain (Plate Link) Wear in excess of 8% of original link
dimensions.
 Cracks, heat damage, severe nicks, gouges or distortion of links.
 Load chain reeving incorrect.
 Maximum elongation (due to wear) is 3%
Chain End Stop

 Shall be withstand 2.5 times the tension in the chain
Lever Assembly
 Any crack, damaged, distortion and broken parts in lever and
hand wheel
 Incorrect operation of pawl changing mechanism
Block Body
 General damage to the block body, including any gear covers or chain
guides.
 When operated under load there is any jumping or excessive noise of
either the hand chain or load chain, any undue effort is required or any
visible slipping of the brake.
8.7. Tests
Functional Test
Applied for lifting machines to verify that the unit operates correctly with no load.
This is a necessary part of any thorough examination and should be carried out
both before and after any thorough examination.
Light Load Test

Applied for lifting machines to verify that the brake functions correctly. Between
2% - 5% of its SWL. which shall be raised and lowered through a height of
between 250 mm and 500 mm.
When the hand chain is released at any point during raising and lowering cycle,
the brake shall hold the load. This is a necessary part of any thorough
examination and should be carried out both before and after any thorough
examination.
Operational Testing
Used in lifting machines to verify that it functions correctly with up to full SWL.
Used periodically and after repair of a machine. Always carried out if
commencing an overload test.
“Controlled”.
8.8. Marking
The following information shall be permanently and legibly marked on a suitable
part of the block:
- CE Mark
- Business name and address of the manufacturer
- Identification mark; if any
- Safe working load
- The series or type designation.
- Size and grade of the load chain
- Year of manufacture.
8.9. Reporting
 If the competent person finds the inspected item free from any of
the above-mentioned withdrawing defects, he can issue the
thorough examination report to the client.
 If the competent person finds a serious and significant defect, he
shall immediately mark the defected item with red color and inform
the client to take the lifting equipment out of service.
 Then the competent person shall issue the defect report which the
client & enforcing authority shall signed for acknowledgement.
8.10. Reference
 BS 4898
 BS EN 13157:2004 cranes safety hand powered hand equipment
 LEEA Code of Practice
“Controlled”.
9 Inspection of Offshore Container
9.1 Scope of Work

 NDT Test
 Load Test
9.2 Preparation
9.3 Equipment
 Wire Bruch
 Vernier
 Torch
 Letter and Number Stamp
9.4 BS7072 offshore container
9.4.1 Inspection
Check exterior, interior and the lifting accessories of the CCU to ensure that
it is fit tor
its intended use.
Primary load bearing structure
The structure shall be visually inspected for corrosion, mechanical damage
and deformation.
Carry out a thorough visual inspection on :
Top and bottom side rails
Top and bottom end rails
“Controlled”.
Corner posts
Pad eyes
Pad eyes
Pad eyes I lifting points shall be visually inspected tor distortion, mechanical
damage, excessive wear and overload.
Ensure that the lifting points are aligned in the direction of the line of the lift.
Ensure that the lifting points are accurately positioned with a maximum
deviation not exceeding 5 mm.
Secondary structure
Floors, walls and roofs shall be visually inspected to ensure they are
predominantly flat with no signs of excessive damage.
Drainage holes in floors where fitted shall be cleared of debris.
Internal cargo tie-down rings shall be examined and they are securely
anchored
Doors
Doors, frames, seals, hinges and locks shall be visually inspected to ensure
that they operate in a satisfactory manner without the exertion of undue
force.
Check locking devices is secure against opening during transportation and
lifting, locking directly to the top and bottom frame.
Ensure the locking arrangements and hinges are operates and not damaged
.
9.4.2 Marking Requirements and Data Plates
BS 7072 Container Safety Marking:
For closed CCU's

Check a band of solid contrasting colour not less than100 mm wide round
the roof perimeter of closed CCU's
For open sided CCU's
Check the CCU identification number is displayed on the roof, in characters
not less than 300 mm high.
Check that the CCU roofs coated with a permanent non-slip medium
“Controlled”.
Check the CCU identification number and ensure from that the ID are
prominently displayed on all sides in characters of a contrasting colour, not
less than 75 mm high
Check the fabricator's serial number welded on in characters at least 50mm
high
Check the fork Lift Pocket Markings ensure the characters must not be
smaller than 50mm high.
Check the CCU a matt black square not less than 400 mm x 400 mm is
provided for information markings such as destination, cargo hazard.
Information Markings
Check the tare weight, the SWL I payload, and the maximum gross weight is
displayed in characters not less than 50 mm high
Container Inspection Plate
Ensure the plate is made of corrosion resistant material securely attached in a

prominent position, on a container with doors, on the door.
Ensure the information on the plate shall be in the English language primarily.
Check that the inspection plate is combined with the original data plate and
corresponds with the test certificate.
9.4.3 Inspection of wire rope slings:
Inspect each individual leg of the sling along its entire length and check for:
• Wear
• Corrosion
• Abrasion
• Mechanical Damage
• Broken Wires
• Internal Deterioration
The rope diameter should be measured for any reduction from its original size that
could indicate wear on the outer wires, wear shall not exceed 10% of the nominal
rope diameter.
“Controlled”.
Inspect wire rope for partial collapse of the core or stretch due to overload
Inspect each ferrule for excessive damage and ensure the correct size of ferrule has
been fitted
Inspect each thimble and check for correct fitting, snagging damage and elongation.
(Stretched thimbles I eyes could indicate possible overload)
Inspect wire rope around thimbles as It is often abraded due to the sling being
dragged over rough surfaces. If fitted, Inspect master link I quad assembly and
check for wear, corrosion and cracking
Multi leg sling assemblies should be rated at 1.3 times the specified MGW of the
CCU to which it is to be fitted (factor of safety should be 5:1).
Sling legs should be constructed from wire rope of at least 13 mm diameter.
Master links, if fitted, should have a minimum internal dimension of 270 mm x 140
mm.
Multi-leg slings shall be attached to the CCU pad eyes without twisting of the legs
at the master link.
All slings and shackles should be certified in accordance with relevant standards.
The unique identification of the sling, and of each shackle shall be noted on the
certificate.
The owner shall maintain certificate records for each set of slings and shackles in
accordance with SI 1998 No 2307 Lifting Operations and Lifting Equipment
Regulations.
Each lifting set shall be marked on a prominent location with the following
information
- CE Mark
- Numbers and/or letters identifying the sling with the manufacturer’s certificate.
- Working load limit and the angles applicable.
- Material grades
9.4.4 shackle inspection:

• Remove shackle pin and examine for wear, deformation and cracking
• Ensure it is the correct pin for the shackle. (i.e. NOT a higher tensile pin in an
alloy shackle)
• Check pin threads for wear I deformation
• Examine shackle body and check for wear in the crown and pin holes,
deformation and cracking
“Controlled”.
• In the case of safety pin shackles, ensure split pins are fitted
Check that the marking is legible and corresponds with the test certificate.
Each shackle shall be marked with the following information
- CE Mark
- Working load limit in tonnes
- Grade number
- Manufacturers name, symbol or code
- Traceability code.
9.4.5 Testing
The CCU must be inspected before and after the application of the proof load test.
This is to ensure that it is suitable for testing and the CCU is not damaged or
deformed in any way after the application of the proof load.
Testing involves a top lift by slings with an included angle of 90 degrees. If the
CCU is normally fitted with a sling, this sling should not be used to carry out the
proof load test.
The proof load applied to the CCU shall be twice the maximum gross weight.
The test load shall be uniformly distributed over the floor and shelf, if applicable.
The proof load shall be held for a minimum of 5 min.
Test Weights:
The load may be applied using calibrated weights
All weights, gauges, load cells, which may affect the accurate determination of the
proof load shall be calibrated annually and a record retained by the test company.
Load cells and hand sets when used are required by EN ISO 7500-1 to have an
accuracy of ± 2% and be calibrated annually.
Test weights should be certified as accurate to better than 1 % of their nominal
weight.
9.4.6 BS7072 Inspection and Testing Periods

CCU's shall be inspected, tested and NDT carried out at regular intervals in
accordance with the schedule listed below.
“Controlled”.
“Controlled”.
9.5 BS EN 12079 offshore container
9.5.1 Inspection
Check exterior, interior and the lifting accessories of the CCU to ensure that
it is fit tor
its intended use.
Primary load bearing structure
and deformation.
welds and shall be visually inspected to ensure freedom from visible defects.
Top and bottom side rails
Top and bottom end rails
Corner posts
Pad eyes
Pad eyes
Pad eyes lifting points shall be visually inspected tor distortion, mechanical
damage, excessive wear and overload.
Ensure that the lifting points are aligned in the direction of the line of the lift,
with a maximum manufacturing tolerance of± 2.5 degrees.
Ensure that the lifting points are accurately positioned with a maximum
deviation not exceeding 5 mm.
Check the diameter of holes in pad eyes is match the shackle used,
Ensure the clearance between shackle pin and pad eye hole shall not exceed
6 % of the nominal shackle pin diameter.
Ensure the tolerance between pad eye thickness and the inside width of
shackle shall not exceed 25 %.
Secondary structure
or excessive deformation.
Intermittent fillet welding of the secondary structure is acceptable
“Controlled”.

• Doors, walls and roof panels
• Panel stiffeners and corrugations
• Structural components used for tank protection only
• Internal securing points
The floor shall be visually inspected to check that it Is not excessively
deformed and that it shows no signs of distress or overload.
Drainage facilities, shall be inspected and clear of debris.
Check the internal securing points from deformation
Forklift pockets
shall be visually inspected for corrosion, mechanical damage and excessive
deformation.
Doors
Doors, frames, seals, hinges and locks shall be visually inspected to ensure
that they operate in a satisfactory manner without the exertion of undue
force.
Check locking devices is secure against opening during transportation and
lifting, locking directly to the top and bottom frame.
Ensure the locking arrangements and hinges are operates and not damaged
9.5.2 Marking Requirements and Data Plates

BS EN 12079 Container Safety Marking:
For closed CCU's
Check a band of solid contrasting colour not less than100 mm wide round
the roof perimeter of closed CCU's
For open sided CCU's
Check the CCU identification number is displayed on the roof, in characters
not less than 300 mm high.
Check that the CCU roofs coated with a permanent non-slip medium
Check the CCU identification number and ensure from that the ID are
prominently displayed on all sides in characters of a contrasting colour, not
less than 75 mm high
“Controlled”.
Check the fabricator's serial number welded on in characters at least 50mm

high
Check the fork Lift Pocket Markings ensure the characters must not be
smaller than 50mm high.
Check the CCU a matt black square not less than 400 mm x 400 mm is
provided for information markings such as destination, cargo hazard.
Information Markings
Each CCU shall be clearly marked with:
Check the relevant electrical hazard classification and zone marking
Relevant dangerous goods indicator
Tare weight in Kg
the SWL payload in Kg
the maximum gross in Kg weight is displayed in characters not less than 50
mm high
Container Inspection Plate

The plate shall be headed “OFFSHORE CONTAINER INSPECTION PLATE - EN 12079-
3: 2006".
Ensure the plate is made of corrosion resistant material securely attached in a prominent
position, on a container with doors, on the door.
Ensure the information on the plate shall be in the English language primarily.
Check that the inspection plate is combined with the original data plate and corresponds
with the test certificate.
9.5.3 BS EN 12079 Slings

wire rope slings, shall be in accordance EN 13414-1, 6x19 or 6x36, grade 1770 or
1960
chain slings, shall be in accordance EN 818-4, grade 8, medium tolerance
The sling shall not be rated for an angle of the sling leg to the vertical in excess of
45 °
Chain slings
The original test certificate and obtain the date the sling went into service, chain
diameter and length from bearing to bearing (measure chain length to check for
stretch}
Lay out chain sling on floor or suspend, remove all twists from legs
Match up legs to check for signs of stretch deformation in individual legs
Visually examine the chain sling along its entire length and check for:
“Controlled”.
• Distortion in chain links (nicks, bends, twists, elongated links)

• Wear between chain links
• Wear between chain links and components
• Heat damage
• Chemical damage
• Wear, stretch, twisting on end terminations
• Correct identification number and SWL
“Controlled”.
“Controlled”.
9.5.4 Shackle inspection:

Shackles shall meet all requirements of EN 13889
Check that the marking is legible and corresponds with the test certificate.
Shackles shall be of a bolt type pin fitted with a split I cotter pin.
• Ensure it is the correct pin for the shackle. (Not a higher tensile pin in an alloy
shackle)
• Check pin threads for wear I deformation
• Examine shackle body, pin and check for wear in the crown and pin holes and
deformation
“Controlled”.
9.5.5 BS EN 12079 Testing

an NDT inspection and visual inspection of the pad-eyes and required structural
areas shall be carried out to ensure that it is suitable for testing
If a load cell and handset is used it shall be calibrated annually, in accordance with
EN ISO 7500-1, to an accuracy of+ 2 %.
Where used, test weights shall be calibrated, as a minimum, every two-years in
accordance with acceptable international or national standards. The measured
weight, in kilograms, of each test weight shall be legibly and durably marked on.
Lifting Test
The container shall be lifted by a lifting set with an angle to the vertical equal to the design
angle.
The container shall be clear of the ground during the test.

The container shall be carefully lifted in such a way that no significant acceleration forces
occur. It shall be held for 5 minutes before measurements are taken.
All-Point Lifting Test
The container shall be loaded to a total mass of 2.5 x maximum gross mass (R-Rating) and
lifted clear of the ground using all pad eyes. The total mass can be obtained by loading an
internal test mass of 2.5 x R – T.
No deflections during testing shall be greater than 1/300 of the span of the member. After
the test no permanent deformation or other damage will be shown.
Two-Point Lifting Test
An offshore container fitted with 4 pad eyes shall also be lifted using 2 diagonally situated
pad eyes.
The total test mass for the 2-point lifting test shall be 1.5 R.
“Controlled”.
9.5.6 BS EN 12079 Inspection and Testing Periods
CCU's and lifting sets shall be periodically inspected, examined and if necessary
tested in accordance with the schedule listed below.
When the schedule includes a lifting test, the non-destructive examination and visual
inspection shall both be carried out after the lifting test
“Controlled”.
Examination of welds
The NDT of welds on pad eyes and adjoining structures shall be carried out in
accordance with the schedule of examination and tests.
Welds between essential non-redundant and non-essential primary structures shall
be examined as for non-essential primary structures.
When fuel gas welding is applied, ultrasonic and magnetic particle examination
shall be required in addition to radiographic examination
Non-destructive examination (NDE) of structural welds
NDE acceptance criteria
Acceptance levels for indications
“Controlled”.
9.6 Reporting
 If the competent person finds the inspected item free from any of
the above-mentioned withdrawing defects, he can issue the
thorough examination report to the client.
 If the competent person finds a serious and significant defect, he
shall immediately mark the defected item with red color and inform
the client to take the lifting equipment out of service.
 Then the competent person shall issue the defect report which the
client & enforcing authority shall signed for acknowledgement.
9.7 References
 B.S 12079
 B.S 7072
 BS EN 13414
 BS 6994
 BS EN 13889
 RR-C-271DIV
 BS3032
“Controlled”.

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DOC. REF.

Quality Health, Safety & Environmental Management System Standard Procedures

01 01.09.2016 First Issue Operation Manager Executive Manager

1.2. Reference Documents

The below table specified the standard for equipments inspected by

Equipment Standard Equipment Standard

Wire rope BS1290 Shackles BS 6994

2. Health and safety instructions

2.1. Supervisor and section heads responsibilities

 Be familiar with the Company Safety and Environment Policy and

2.2. Company inspectors

2.3. Personal Protective Equipment

2.4. HSE Risk Management

2.5. Accident Control and Reporting

Where employees are injured while working they or their representative

Investigation of incidents is a line responsibility and all investigations shall

Incidents involving contractors under MIDCO operational control shall be

3.1. Personnel Qualification

4. Inspection Of Wire Rope And Wire Rope Sling

4.1. Scope of work

4.2. Preparation& Equipment

The engineer surveyor may utilise the following:

4.3. Marking requirements

4.4. Inspection Method

 Wire rope sling comply with BS 1290

 Terminal Fittings (Hooks)

4.5. Inspection Areas of Wire Rope slings

4.6. Wire Rope Slings Withdrawn Criteria

Randomly Distributed Broken Wires

5.1. Scope of Work

5.4. Inspection Method

 Check that the correct pin is fitted.

5.5. Inspection Areas of Shackle

5.6. Shackle Withdrawn Criteria

Shackle should be withdrawn from service and referred to the Client’s

Bow shackles are designed to enable three or more items to be joined.

Grade mark or,

6. Inspection of Chains and Chain Sling

6.1. Scope of Work

6.2. Preparation &Equipment

The engineer surveyor may utilise the following:

6.4. Inspection Method

 Intermediate link (Assembled by welding)

 Joining link (upper and lower) Assembled by welding

 Check manufacturer’s tables to ensure the safe working load is correct

6.5. Inspection Areas of Chain Sling

6.6. Chain Withdrawn Criteria

Signs of wear, damage, distortion, corrosion, bending, twist or cracking

Signs of wear, damage, distortion, corrosion, bending, twist or cracking

 Stretched chain, bent or twisted links

7. Inspection of Chain Block

7.1. Scope of Work

The engineer surveyor may utilise the following:

 Free rotation and movement of hooks.

 All parts should be clean and free from deleterious matter.

where one is fitted.

7.5. Inspection Areas of Chain Block

7.6. Chain Block Withdrawn Criteria

Chain End Stop

Light Load Test

Operating and maintenance instructions shall be supplied.

8. Inspection on Lever Hoist/Pull Lifts

8.1. Scope of Work