Crane Operation

Sr.
Number:OISD/DOC/2016/419
Page No. I
OISD-RP-205
FIRST EDITION - OCTOBER, 2002
FOR RESTRICTED CIRCULATION ONLY
“CRANE OPERATION,MAINTENANCE AND TESTING”

(For Upstream )
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2016/419
Page No. II
OISD-RP-205
FIRST EDITION - OCTOBER, 2002
FOR RESTRICTED CIRCULATION ONLY
Prepared by
COMMITTEE ON RECOMMENDED PRACTICE

FOR
CRANE OPERATION,MAINTENANCE AND TESTING
(For Upstream )

8th Floor, OIDB Bhavan,
Plot No. 2, Sector - 73,
Noida – 201301 (U.P.)
Page No. III
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is essential for sovereignty
and prosperity of the country. As the industry essentially deals with inherently inflammable substances throughout its
value chain – upstream, midstream and downstream – Safety is of paramount importance to this industry as only safe
performance at all times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian petroleum industry, Oil
Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural Gas, Government of India as
a knowledge centre for formulation of constantly updated world-scale standards for design, layout and operation of
various equipment, facility and activities involved in this industry. Moreover, OISD was also given responsibility of
monitoring implementation status of these standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and participative process
of development of standards – starting with research by in-house experts and iterating through seeking & validating
inputs from all stake-holders – operators, designers, national level knowledge authorities and public at large – with a
feedback loop of constant updation based on ground level experience obtained through audits, incident analysis and
environment scanning.
The participative process followed in standard formulation has resulted in excellent level of compliance by the industry
culminating in a safer environment in the industry. OISD – except in the Upstream Petroleum Sector – is still a
regulatory (and not a statutory) body but that has not affected implementation of the OISD standards. It also goes to
prove the old adage that self-regulation is the best regulation. The quality and relevance of OISD standards had been
further endorsed by their adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content requiring its operation to
keep pace with the relevant world scale standards & practices. This matches the OISD philosophy of continuous
improvement keeping pace with the global developments in its target environment. To this end, OISD keeps track of
changes through participation as member in large number of International and national level Knowledge Organizations
– both in the field of standard development and implementation & monitoring in addition to updation of internal
knowledge base through continuous research and application surveillance, thereby ensuring that this OISD Standard,
along with all other extant ones, remains relevant, updated and effective on a real time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides other issues, calls for
total engagement from all levels of the stake holder organizations, which we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director

Page No. IV
FOREWORD
The Oil Industry in India is more than 100 years old. Because of various collaboration
agreements, a variety of international codes, standards and practices have been in vogue.
Standardisation in design philosophies and operation and maintenance practices at a national level was
hardly in existence. This coupled with feed back from some serious accidents that occurred in the recent
past in India and abroad, emphasised the need for the industry to review the existing state- of- the-art in
designing, operating and maintaining oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council
assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and
implementing a series of self regulatory measures aimed at removing obsolescence, standardising and
upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of
functional committees of experts nominated from the industry to draw up standards and guidelines on
various subjects.
The present standard was prepared by the Functional Committee on “Recommended Practice for Crane
Operation, Maintenance And Testing ”. The document is based on the accumulated knowledge and
experience of industry members and the various national and international codes and practices.
This standard is meant to be used as supplement and not as a replacement for existing codes and
practices.
It is hoped that provisions of this standard, if implemented objectively, may go a long way to
improve the safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no standard
can be substitute for the judgement of responsible and experienced Engineers/Geo-scientists..
Suggestions are invited from the users after it is put into practice to improve the document further.
Suggestions for amendments to this document should be addressed to the Coordinator, Committee on
“Recommended Practice for Crane Operation, Maintenance and Testing ”,
Oil Industry Safety Directorate,
8th Floor, OIDB Bhavan,
Plot No. 2, Sector - 73
Noida – 201301 (U.P.)
This standard in no way supersedes the statutory requirements like Factories Act, OMR, CCE etc.
Page No. V
NOTE
OISD (Oil Industry Safety Directorate) publications are prepared for use in the Oil and Gas
Industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum &
Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written
consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the data contained in
the document, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from their use.
The document is intended to supplement rather than replace the prevailing statutory requirements.
Page No. VI
COMMITTEE
ON
RECOMMENDED PRACTICE FOR
“CRANE OPERATION,MAINTENANCE AND TESTING ''
NAME ORGANISATION POSITION IN

THE COMMITTEE
S/SHRI
1. H.N. BHAKTA ONGC LEADER
2. ROY JOHN ONGC MEMBER
3. SUNIL SOHANI SCHLUMBERGER INVITEE
4. GIRISH KAMAL EIL MEMBER
5. PRADEEP KUMAR OISD MEMBER -

COORDINATOR
Page No. VII
CONTENTS
Sl.No. Description Page No.

---------- ---------------------- ---------------
1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 1
4.0 Equipment 4
5.0 Control 5
6.0 Safety Equipment 6
7.0 Operation 6
8.0 Inspection 17
9.0 Maintenance 17
10.0 Load Testing And Certification 17
11.0 Incidence/Accident Reporting System 18
12.0 Contract Management 18
13.0 Personnel Protective Equipment 18
14.0 References 18
15.0 Annexures
A– Identification Of Actions On Use Of Hand Signals 19
B– Maintenance guidelines 21
C- Inspection guidelines 25
OISD – RP – 205 Page No. 1

RECOMMENDED PRACTICES FOR CRANE OPERATION,
MAINTENANCE & TESTING (FOR UPSTREAM)
Recommended Practices
for
“CRANE OPERATION, MAINTENANCE AND TESTING”
1.0 INTRODUCTION
In oil industry, material handling using cranes is one of the most important operations requiring
utmost care.
The primary purpose of this standard is to outline recommended practices for crane operations,
maintenance, inspection and testing to crane owners, users and operators in upstream sector of oil
industry both offshore and onshore. This recommended practice focuses on safe operation of
cranes in order to establish, maintain and further develop an adequate level of safety for
personnel, property and environment during planning and execution of lifting operations.
2.0 SCOPE
These Recommended Practices cover various aspects related to operating and maintenance
practices and procedures for use in the safe operation including the requirement of competent
crane operator of various types of revolving cranes on offshore platforms, rigs, floating units. It also
covers fixed, mobile (except crawler cranes) and hydraulic telescoping cranes used at onshore
installations of upstream operations.
These recommended practices are to provide and assist in the proper operation and maintenance
of crane, as a supplement to the Manufacturer's instructions, which should be carefully read,
retained and followed.
3.0 DEFINITIONS
Anti-two block : A limiting device that prevents the load block sheaves, auxiliary or fast line ball from
contacting the boom tip sheaves.
Boom angle : The angle above or below horizontal of the longitudinal axis of the base boom
section.
Boom length : The straight line distance from the centerline of boom foot pin to centerline of boom
point load hoist sheave pin, measured along the longitudinal axis of the boom.
Boom lift Cylinder : Means for supporting the boom and controlling the boom angle.
Certified : To formally attest as being

true or meeting a
standard.
Choke : Block used to stop the wheels of a truck.

Counterweight : Weight used to
(BALLAST) supplement the weight of the machine in providing stability for lifting working loads
and usually attached to the rear of revolving upper
structure.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”

Crane : A lifting device that is capable of being dynamically loaded when lifting, lowering, or
shifting loads by means of a projecting arm.
Drum rope : A rotating cylinder with side flanges on which wire rope used in machine operation is
wrapped.
Dynamic : Loads introduced into the

loading machine or it's components due to accelerating or
decelerating forces.
Gantry(A-Frame) : A structure mounted on the revolving super-structure of the machine to which the
boom support ropes are reeved.
Heavy lift : A non-routine lift which is equal to or greater than 75% of the rated capacity of the
crane, at either a dynamic or static condition.
Heavy usage : Heavy usage applies to

Category those cranes that are used for 50 hours or more per month. These
cranes will be subject to Pre-use, Monthly, Quarterly, and
Annual Inspections. Cranes assigned category of heavy usage need not be
reviewed to determine the number of hours used each month.
Hoist : The device for lifting or lowering of the load in vertical direction. Also called winch.
Hook Load : The load being lifted plus the weight of slings and rigging. Hook load may or may not
include the weight of the hook block and wire rope. This can be determined from the
crane’s load rating chart.
Hydraulic crane : A crane whose movements are directed by fluid pressure applied to the
pumps/gears, hydraulic cylinder, and hoists.
Infrequent usage : Infrequent usage applies

category to those cranes that are used for 10 hours or less per month, based on
the averaged use over a quarter. These cranes will be subjected to a Pre-use
Inspection and an Annual Inspection. Crane usage
categories will be reviewed on a periodic basis by the owner to ensure proper
inspection intervals.
Jib(Tip Extension) : An extension attached to the

boom point to provide added boom length for lifting specified loads.
Lattice boom : Boom of open construction

with angular or tubular lacing between main corner members (chords) in form of
truss.
Limit device : A safety feature used to stop the movement of a crane or its components beyond a
predetermined point that could cause damage to components or the crane to fail.
Load test : The test undertaken to validate load rating of the crane.
Load -working : External load in pounds (Kilogram) apply to the crane including the weight of load
attaching equipment such load block, shackles and slings
Luffing : Same as derricking. The operation of changing boom angle in a vertical plane.
Moderate usage : Moderate usage applies

category to those cranes that are used for more than 10 hours but for less that 50 hours per
month, based on the averaged use over a quarter. These cranes will be subjected to
Pre-use, Quarterly, and Annual Inspections. Crane usage categories will be
reviewed on a periodic basis by the owner to ensure proper inspection intervals.
Out-Riggers : Members attached to the carrier’s frame which may be blocked up to increase
stability. These may be fixed or extendible.
Pawl (Dog) : A device for positively holding a member against motion in one or more directions.
Pedestal( BASE) : The supporting sub-structure upon which the revolving upper structure is mounted.
Pull test : A test, using a suspended weight or a dynamometer, to verify crane capability for the
expected lift, not to exceed 100% of the rated crane load chart capacity. This is not a
LOAD TEST.
Qualified crane : A person with training and inspector experience who has
demonstrated proficiency in
the skills and abilities
necessary to inspect,
maintain, and repair cranes.
Qualified crane : A person with training and

operator experience who has successfully completed a crane operator training
course.
Rated Capacity : The rated load at specified radii as established by the manufacturer and are the
maximum loads at those radii covered by the manufacturers warranty.
Rigger : A rigger is anyone who attaches or detaches lifting equipment to loads or lifting
devices.
Signalman : A qualified rigger who is designated by a qualified crane operator to give hand
signals.
Slewing : Same as swing. Rotation of the upper structure for movement of loads in a
horizontal direction about axis of rotation.
Sling : A device used to connect loads to be lifted by a crane or a hoist.
Static loading : Loads introduced into the machine or its components with no accelerating or
decelerating forces.
Stinger : A single length of wire rope equipped with a hook and safety latch, which is capable
of handling the maximum capacity of the load. Its use is intended to keep the main
hoist load block or auxiliary hoist headache ball from coming in contact with
personnel rigging loads.
Swing Circle : The swing circle

assembly assembly is the connecting component between the crane revolving upper
structure and pedestal. This component allows crane
rotation and sustains the movement ,radial and axial loads imposed by
crane operation.
Tag line : A length of rope/ropes attached at a point to the load and used by riggers to help
control its movement.

Telescoping : Consists of a base boom

boom from which one or more boom sections are
telescoped for additional length.
Temporary crane : Any crane that is attached to or connected via a substructure to a platform and not a
permanent part of the structure).
Whip line : A secondary rope system usually of lighter load capacity than provided by the main
rope system. Also known as “AUXILIARY”.
4.0 EQUIPMENT
4.1 Prime Mover:
Prime mover may be Electric or Diesel engine. Starting system may be pneumatic, manual,
hydraulic, electrical or combination of any two. Engine driven generator for power supply in cabin
and accessories . Air compressor, receiver and auxiliaries for air starting system and engine shaft
driven Hydraulic pump for engine starting system. Air is also required for signal horn, load indicator
mechanism and wind screen wiper .Prime mover should be suitably selected for carrying out the
main hoisting, Luffing and slewing operations simultaneously at rated capacity and specified radii.
The engine should be fitted with a suitably calibrated running hours recorder which is to be
positioned so that it can be easily read by the operator.
The engine exhaust shall be equipped with spark arrestor and exhaust pipe shall be insulated to
protect operator from burn injury. The exhaust should be directed away from the operator.
4.2 Cabin :
The cabin should be mounted on the crane with fully enclosed sturdy door with Lock, shatter proof
glass windows on all sides, wind shield wipers and sun visor, horn, lights, fan and adjustable seat.
Controls, indicators, alarms, load charts (one dynamic and other static for offshore cranes and
static load chart for onshore crane) and boom angle indicator should also be provided in the
cabin.
Service walkways all around the cabin with handrail should be provided.
As far as possible , cabin should be constructed to protect the upper structure machinery , brakes
,clutches and the operator’s station from the weather.
Unless and otherwise specified, the sound levels at operator’s station shall not exceed:
a. 90dB(A) (Slow response) measured with the prime mover at low idle and crane controls in
neutral position
b. 95dB(A) (Slow response) measured with the crane operating at full throttle and full rated load
of the rotating machinery.
4.3 Hydraulic System
A separate hydraulic pumps with motor and automatic braking system should be provided for
main hoist, auxiliary hoist, and Boom Hoist for hydraulically operated cranes. A separate
hydraulic motor should be provided for swing drive. The swing drive should be provided with
Mechanical positive lock arrangement, controllable by operator.

Means should be provided for checking manufacturer’s specified pressure settings in each
hydraulic circuit. Each loop shall be fitted with pre-set safety relief valves.
4.4 Electrical System
The supply of electrical power for lighting for cabin, Housing, Flood light , Air craft warning and
other auxiliaries on the crane through alternator/dynamo which is a part of crane shall be
provided.
Some of the offshore/ fixed cranes are electrical driven for which electrical power is supplied by
available installed electrical power.
4.5 Mounting
4.5.1 Fixed Cranes
Fixed type of cranes are mounted on suitably designed pedestal. The pedestal construction should
be conforming to API-2H or other national/international standard.
4.5.2 Mobile Cranes:
a. The mobile crane shall be mounted on atleast four pneumatic tyred wheels and shall be
provided with air or hydraulic braking on all wheels. An entirely independent hand brake
shall be fitted for parking .
b. Emergency towing eyes of approved design shall be fitted at the front and rear of the crane.
Wheel and axle arrangements should be designated as per standard automotive practice. Any one
wheel may have one or more tyres.
4.6 Out Riggers
The manufacturer should specify whether out-riggers are fixed or extendible, whether telescopic or
hinged , whether front or rear outriggers or both are supplied and if jacks or supporting floats are
available.
5.0 CONTROLS
5.1 General
Controls should be in accordance with the following requirement :

a. The control should be installed in such a way that one operator can easily perform all
maneuvers and speed control.
b. Control levers for boom hoist, load hoist , swing and boom telescope(when applicable)
should return automatically to their centre(neutral) positions on release.
c. Foot operated pedals, where provided should be constructed so as the operator’s feet will
not readily slip off.
d. Brakes engage automatically when a control is placed in the neutral position in the event
of engine power failure, loss of hydraulic pressure or control failure.
e. Main hoist line and auxiliary line each should be equipped with anti-two blocking devices
with audible and visual warning and is hydraulically operated.
f. The crane should be fitted with a load, boom angle & radius indicating and sensing
device which automatically weigh load continuously and is being carried with a particular
radius. The crane has visual lighting indications inside crane cabin for indicating static and
dynamic mode of operations. The normal re-setting of the controls for static lifting should
also be provided.

g. An emergency stop, to stop all functions of crane instantaneously in case of emergency is

provided without stopping the engine.
h. The mobile crane should be capable of being steered either right or left in either directions
of travel and the control shall be from operator’s position on the revolving superstructure.
5.2 Forces and movement of control levers
When control levers /pedals are properly maintained as per manufacturer’s recommendations the
forces and movement to operate the crane within its rated limits should not exceed the following:
a. Hand levers – 20 lbf and 28 inches total travel
b. Foot pedal – 25lbf and 10inches total travel
6.0 SAFETY EQUIPMENT
Following minimum Safety equipment should be installed/made available on the crane : -
 Weight load indicator

 Overload (not less than 97.5% of SWL at that radius) alarm & shutdown , visual warning at
90% of SWL.
 Boom Angle indicator
 Swing lock device
 Horn
 Boom hoist stop
 Aircraft warning light
 Latch for main & auxiliary hook
 Limit switches
 Walkie-talkie/telephone/pager/any communication device
 Audio warning Horn / Hooter for alarms
 Fire extinguisher
 Anti two block
 Emergency shutdown valve
 Guards on moving parts wherever possible to fit
 Pressure & oil Gauges
 Spark Arrestor with engine
 First Aid kit
 Following shall be displayed in the cabin:
-Hand Signals
-Load & range charts
Safety equipment specific to Mobile Cranes shall be fitted

 Reverse alarm
 Level Gauge
 Out-rigger controls functions
 Chokes
 A brake or alternative device to lock the superstructure in any position when the crane is
travelling or working on slopes. In addition a positive locking device to locate the
superstructure in its normal travelling position.
7.0 OPERATION
7.1 Operator's Qualification
1. A crane operator must have valid certificate for operation of crane from authorised agency.
The operator must be physically and mentally fit. (vision, hearing, colour identification &
no history of any disabling medical condition)

2. A crane operator must have valid Heavy duty driving license (for mobile cranes)
3. Operator should have undergone operator’s training (classroom and practical). Operator
should be conversant with load chart and stability (available on the crane), use of correct
slinging practice, Operator should have clear understanding of standard signals, and safe
operating practices
7.2 Rigger’s Qualification
A person with training and experience who has knowledge of rigging hardware, slings , safety
issues related to rigging, use and selection of proper slings, hitches, shackles, hooks etc..
7.3 Safe Operating Procedure
i. Before starting the operations, operator shall verify that all pre-use inspections as per standard
Practices or manufacturer’s guidelines have been completed.
ii. Operator shall be responsible for operations under his direct control.
iii. While lifting/placing of the load, no unauthorised person shall remain within the radius of the boom
and underneath the load
iv. For any safety reason , the crane operator shall stop handling loads / operations and report the
matter to the installation Manager for further instructions.
v. Always follow the operating practices supplied by the manufacturer for each type of crane.
vi. The operator shall be familiar with the use of equipment and its care.
vii. The operator will respond to signals given by authorised signal person.
viii. Before leaving the crane for a long period the operator shall land any attached loads, disengage
master clutch, set all locking devices, put controls in off or neutral position and stop the prime
mover. Crane will be secured against swinging when not in use.
ix. During operations, if power or a necessary control function fails, set all the brakes and locking
devices and move all clutches or other power controls to off position or neutral position.
x. Relief valves on hydraulic cranes should not be adjusted above manufacturer’s recommended
pressures and current limiting devices on electric cranes should not be bypassed to increase
available hoist line pull.
xi. During high wind conditions and nights, lift of heavy equipment should be avoided. If unavoidable,
the operator shall ensure that there is proper illumination in the night.
For mobile cranes (except crawler cranes) following additional procedures to be followed:
xii. Crane to move on reasonably hard leveled surface. Crane placement programme to be prepared
for lifting heavy equipment.
xiii. Make sure wheels have chokes installed before commencing the job.
xiv. Out rigger beam should be fully extended before operation.
xv. While working on a slope , the crane should be parked with front wheels towards downhill. the load
lifted from the rear of the truck.
xvi. The crane shall not be driven with out-riggers extended.
xvii. The crane level should be checked for stability.
xviii. A trained rigger/ signalman shall always accompany the crane when it is being moved.
xix. The crane hook shall be secured to prevent it from swinging while the crane is traveling.
xx. The crane shall not be placed for working in Hazardous area classified by existing DGMS/Statutory
notification . The components like light etc. shall be of flame proof type as boom can be used for
handling loads in hazardous area.

7.4 Crane Danger Signs to watch For :

While working around crane, the operator should be careful about following eight danger signs of
improper operation. If any of the following occurrences are noticed at jobsite, immediately inform to
supervisor/competent person before a catastrophe takes place.
a Outriggers, crawler tracks, or tires raised off the ground while operating. This is an
extremely dangerous condition which indicates the crane is being overloaded and may tip
over or collapse. The wrong move in this situation can cause a catastrophe.
b Operating close to power lines or other dangerous objects. Electrocution due to

contact with power lines is the leading cause of crane related fatalities. Detailed
regulations for proximity to high voltage sources must be strictly enforced. Any potential
danger should be pointed out to the crane operator or a supervisor-but never touch the
crane at this time.
c Riding the load or crane hook. This is a serious violation of safety regulations. Crane
structures and cables have far lower strength margins for handling material than what is
required for lifting personnel. Workers must never be suspended from a crane boom
unless an approved personnel basket with mandatory safety equipment is used, and lifting
procedures are strictly followed.
d Visible structural damage on the crane . There is little or no back up system in the load-
supporting components of most cranes. A damaged component can fail completely and
without warning, causing the boom or load to fall.
e Modifications made by adding extra counterweight or holding down the rear of the
crane. All job initiated modifications are illegal and may permit overloading the crane. If
not approved by the crane manufacturer in writing, these modifications can over stress
critical structural components, which could cause failure of the crane.
f A crane operating near a trench or excavation. Cranes exert extremely high loads on
the soil near the tracks, outriggers, or tires. A crane set up in close proximity to an
excavation can cause soil failure, crane turnover, and possible disaster.
g The crane is noticeably out of level while operating. There is no faster way to collapse
a crane boom than to impose a side force on the boom. Working out of level creates a
dynamic side force which means a crane collapse may be imminent.
h The crane's hoist line is not vertical at all times during operation. This indicates
improper operation. A hoist line which is not vertical obviously indicates that the load is not
hanging straight down. Out of plumb loads can cause crane collapse by generating side
forces on the boom. In some instances, the crane may tip over if the load swings.
7.5 Precautions from live power lines
Everyone in proximity to a crane, when energized lines are near, must stay alert. It takes employee
teamwork to successfully and safely operate under this combination of conditions.
Power lines can be hard for the crane operator to see. They sometimes appear to be either further
away or much closer than they really are. It is difficult for the human eye to accurately judge the
clearance between the crane's boom or line, and a power line. Fellow workers can help assure
that safe clearances are being maintained between the crane, the line, the load and the overhead
power line. The table below shows basic clearance minimums, which apply to all areas around the
power line-above, below or to either side:
Power Line Voltage Minimum Clearance
up to 50k 10 feet

50k to 75k 11 feet

75k to 125k 13 feet
125k to 175k 15 feet
550k to 1,000k 42 feet
The following guidelines are intended to prevent crane accident due to electrocution :
 Avoid storing materials around and especially underneath overhead power lines.
 Locate all power lines on the job and make a drawing of where you will set up the crane.
 Consider any overhead line "hot" until the owner or utility company verifies that it is not
energized and is visibly grounded. The line must be "cold" if minimum clearance cannot be
met.
 Look carefully before the boom is moved, particularly in congested areas of poor visibility. Get
additional workers to help with the move if a clear view of all areas is not possible.
 Place a visual marker, such as a florescent line or flagging to mark off the danger zone.
 Communicate the lifting plan to all crewmembers every time you set up (after breaks and
lunch).
 Use proper hand signals for directing crane operations. Make sure all crew members
understand the signals.
 Appoint a watch person who does nothing but watch the load every time you work in the
proximity of power lines.
 Never work closer to power lines than the code allows. Power lines are not insulated and they
can arc across several feet.
 If working near power lines can not be avoided, contact the utility who owns them, have them
de-energized and visibly grounded. This takes pre-planning; most utilities require a minimum
notice.
 If lines can not be de-energized, the utility must approve your work plan and install protective
barriers. Again, a full time watch person is required.
 If one cannot move the crane away from the lines, stay in the cabin until the utility company
arrives and makes sure the lines are de-energized.
 If a dangerous situation demands that you must exit the crane, " DON'T CLIMB DOWN".
Jump away from the crane ( a distance of 2 to 4 feet is usually far enough) and land with both
feet together as there may be areas in the ground with differing voltage. This will avoid having
one foot in an area of higher voltage than the other, which can be lethal. Avoid contacting the
load, load line or the crane. Ground crew should follow this same advice.

7.6 Load Handling
7.6.1 The Load
Crane lifting capacities are based on relative motion conditions between the crane and the load to
be handled. All cranes will have one static and at least one dynamic load rating chart. These
charts must show the Rated Lift Capacity for boom lengths and angles.
a) The appropriate load rating charts for the configuration in use must be in a position where they
are visible to the operator while operating the crane. The Operator should know that the hook
load is within the crane’s applicable Static or Dynamic Rated Load at the radius at which the
load is to be lifted.
b) The safe working load on the crane at each radius should not be more than 90% of the test
load, but in no case should the rated capacity loads be exceeded. The safe working load of the
crane should be legibly marked on it. A scale or weight indicator should be available which can
be used to determine weight of unknown load to be lifted.
c) Never attempt to operate a crane where the load capacity chart shows no load capacity or
where there are no values shown on the charts. This load is more than the safe operating
conditions for the crane. The crane can turn over when the boom is extended too far, even
with no load.
d) To make a safe lift, the operator must know the exact weight of the load, the length of the
crane boom, the load radius and the boom angle.
e) For lifting heavy equipment , shackles/hooks shall be engaged on lugs/eyes provided for
lifting.
f) General load moment indicators do not sense extension of outrigger beams .As such, while
operating a crane , it should be ensured that the outrigger beams are fully extended.
g) Cranes should always be placed horizontally , as load moment indicator parameters are fixed,
assuming the crane in horizontal position. Any horizontal imbalance of the crane will result in
decrease of the balancing moment not accounted for by the load moment indicator, which may
lead to serious over-loading.
7.6.2 Attaching The Load
a) The load should be attached to the hook by means of slings or other suitable devices. The
latch shall be closed to secure loose slings. Hooks should be self-closing.
b) The hoist rope shall not be wrapped around the load.
c) Discard defective slings. Each sling’s metal connector shall be stenciled with the date the sling
is placed in service.
d) Longer objects should be lifted from both ends to maintain its balance.
e) Care and use of wire ropes shall be in accordance with OISD Standard-187.
7.6.3 Moving The Load
Guidelines for moving the load are as under:
I. The Qualified crane operator and the designated signal person directing the lift should
determine that:
a) The crane is placed on a firm level foundation and properly secured in place.
b) The load is secured and properly balanced in the sling or lifting device before it is
lifted.
c) The lift and swing paths are clear of obstructions and personnel.
d) An appropriate fire extinguisher is kept in the crane cabin or vicinity of the crane.
II. Before starting to lift, the following conditions should be verified:

a. Refer to crane load chart for proper boom angle before lifting any static or
dynamic load.
b. Never attempt to lift a load that exceeds the crane lifting capacity for a specific
boom angle.
c. Multiple part lines are not twisted around each other in such a manner that all of
the lines will not separate upon application of load.
d. The hook is brought over the load in such a manner as to minimize swinging.
e. If there is a slack rope conditions, the rope is properly seated on the drum and in
the sheaves.
f. The correct slings have been selected for the weight to be lifted.
g. Stops have been provided on crane booms to prevent the possibility of
overtopping the boom.
III During lifting, care should be taken that:
a) Acceleration or deceleration of the moving load is accomplished in a smooth

manner.
b) Load, boom or other parts of the machine do not contact any obstruction.
IV The Operator should engage the controls smoothly to avoid excessive stress on crane
machinery.
V When rotating the crane, sudden starts and stops should be avoided. Rotational speed
shall be such that the load does not swing out beyond the radius at which it can be
controlled.
VI No external forces should be applied to suspended loads which will create side loading of
the boom. Care should be taken when swinging the crane so as to minimize the pendulum
action of the hook and suspended load.
VII Cranes will not be used for dragging loads unless properly rigged for a vertical pull not
exceeding the rated capacity.
VIII The operator will not hoist, lower or swing while any personnel are on the load or hook
(other than in a personnel basket).
IX While the crane is in operation, no other work shall be performed on the crane.
X The operator should test the brakes each time a load approaching the rated load is
handled.
XI The operator should avoid moving loads over personnel. Loads which are suspended by
use of slings or hoists should be blocked or cribbed before personnel are permitted to
work beneath or between them. Blow horn before moving loads over the area where
people are working.
XII Riding on loads and hooks is strictly prohibited.
XIII No fewer than five (5) full wraps of rope will remain on the drum(s) in any operating
condition. Due consideration should be given to hoist manufacturer’s recommended
practices, especially for “break away” anchor type hoists.
XIV All the cranes must be equipped with safety cutouts and the weight indicators . Safety
cutouts must always be in good working condition.

XV When two or more cranes are used to lift a load, one qualified operator will be responsible
for the operation. The responsible operator should analyze the operations and instruct all
personnel involved in the proper positioning, rigging of the load and the movements to be
made. The positioning of cranes and distribution of load should be ascertained .
XVI Appropriate non-electrical conducting tag or restraining lines should be used where
necessary to guide and control the load.
XVII The Operator should not leave the crane controls until the load has been safely landed. He
must properly secure the crane and boom before going off duty when shutting down
operations.
7.7 Slings
Sling, their fittings and fasteners, when not in use, should be inspected and retired in accordance
with the following guidelines:
a) Suitable protection should be provided between the sling and sharp surfaces of the load to be
lifted.
b) Proper storage should be provided for slings while not in use.
c) Slings should never be choked in the splice.
d) Sharp kinks or knots should not be permitted in wire rope slings.
e) Loads should not be lifted with one leg of a multi-leg sling until the unused legs are secured.
f) The sling should show the trademark or name of the manufacturer, the stock number and most
importantly the load rating and types of hitches to be used. Do not use it ,if it is not rated for the
capacity
g) Slings, which are damaged or defective, shall not be used.
h) Slings shall not be shortened with knots, bolts or other makeshift devices.
i) Sling legs shall not be kinked.
j) Slings shall not be loaded in excess of their rated capacities.
k) Slings used in a basket hitch shall have the load balanced to prevent slippage.
l) Slings shall be securely attached to their loads.
m) Slings shall be padded or protected from all sharp edges of their loads.
n) Suspended loads shall be kept clear of all obstructions.
o) All persons shall be kept clear of suspended loads or those about to be lifted.
p) Hands or fingers shall not be placed between the sling and its load while the sling is being
tightened around the load.
q) Shock loading is prohibited.
r) A sling shall not be pulled from under a load when the load is resting on the sling.
s) Any angle other than vertical at which a sling is rigged increases the loading on the sling.
t) Whenever a sling is found to be deficient, the eyes must be cut or other end attachments or fittings
removed to prevent further use and the sling body discarded.
u) A sling eye should never be used over a hook or pin with a body diameter larger than the natural
width of the eye. Never force an eye on a hook. The eye should always be used on a hook or pin
with at least the diameter of the rope.
v) A sling shall be visually inspected before use to determine if it is capable of safely making the
intended lift.
Rated loads of a sling is different for each of the three basic method of rigging (vertical, choker, basket
etc.) and the rated loads of a sling is different for each of the methods of rigging based on construction
of the wire rope, web material and width etc. These rated loads are available from the manufacturers.
These rated loads will be indicated on the heavy duty tags attached to each type of sling at the time it
is fabricated.
Care and use of proper slings and handling procedure should be in accordance with OISD std.-187.

7.8 Personnel Transfer
Off loading materials and men from supply vessels to offshore installations and vice-versa in a
heavy swell, is always hazardous. Of all lifting operations, lifting of personnel presents the greatest
risk and shall only be considered if no alternative method can be found. It requires quite an
exceptional level of coordination between the captain of the supply vessel and the platform crane
operator. The latter only has a small “time window” in which to start hoisting the load to avoid it
being hit by the heaving deck of the vessel. Personnel transfer shall only be performed after
assessing the risk, defining associated prevention and mitigation measures and obtaining approval
from the person in charge of the installation.
7.8.1 Transfer of personnel by baskets
If sea is rough or wind does not permit vessel drawing alongside or if there is no landing platform,
personnel shall be transferred by using unsinkable basket. The personnel basket should be so
constructed, that it is capable of serving as a temporary life raft for the maximum number of
persons that it is designed to carry.
7.8.2 Baskets
Manufacturer's certificate, certificate of application and declaration of conformity, shall be issued

prior to operation.
7.8.3 Use of personnel Basket
When transferring personnel between an installation and a vessel by means of an offshore crane
and a personnel basket, the following precautions are recommended as basis for setting up a
procedure.
a) General precautions
1. The installation manager may after careful consideration allow transfer by means of
personnel basket in each specific case where this for special reasons is necessary or
reasonable. Transfer shall take place on a voluntary basis .
2. Transfer of personnel between installation and vessel shall only take place when there is
good visibility and adequate illumination and only when the weather conditions permit a
safe transfer, unless transfer is necessary with regard to the safety of the personnel or the
installation.
3. Suitability of the vessel to which personnel are to be transferred must be ascertained. The
type of vessel considered suitable to carry out a transfer should be determined by its
ability to maintain station alongside the installation and have sufficient clear deck space to
safely receive the basket.
4. Instructions shall be drawn up for transfer operations, including rescue instructions in the
event of accident during transfer.
5. Personnel basket shall be designed for a maximum of 4 persons, and shall be clearly
marked accordingly. Further, it shall be designed so that it can serve as a temporary raft
for the number of persons it is designed to accommodate.
6. The personnel basket shall be kept in good condition. It should be tested with a test load
twice the maximum workload . The result of the test shall be entered in the records.
7. The basket shall be safely stored when not in use.

8. The basket shall be inspected at least once a week.
9. The personnel basket shall be stowed together with the life jackets in a separate storage
room where it will not be subjected to damage of a mechanical or chemical nature.
10. All persons riding on the basket should wear life jackets.
11. Any person unfamiliar with the basket shall be given a short briefing prior to riding the
basket and shall be accompanied by an experienced person. Any person sick, suffering
vertigo or injured should not be allowed to ride the basket, except if placed inside and
escorted by an experienced person.
12. Personnel basket shall not be used for transfer of cargo, except for light personnel hand
luggage. Luggage shall not be held by hand but positioned in the middle of the basket.
13. The crane to be used shall have valid certificate of application and shall be in good
technical condition.
14. The crane intended to be used for personnel transfer shall be fitted with an emergency
release and anti-two-block device.
15. To ensure that the crane hook does not damage anyone using the personnel basket, a
suitable loop/sling shall be used.
16. The crane operator should have valid certificate of the crane operation.
17. Transfer during the night shall only be allowed in case of emergencies.
b) Operational precautions
1. When transfer of personnel must be carried out, there must be consensus between the
installation manager, the crane operator and the safety manager to the effect that the
operation can be carried out safely.
2. Prior to use basket shall be thoroughly examined by the responsible person.
3. The basket shall be fastened to the crane hook with a long sling. The crane hook shall
have a positive locking throatlatch. In addition to this, the personal basket must have a
designated safety sling for additional safety back-up.
4. The personnel basket shall be equipped with life jackets for the number of persons it is
used for.
5. The safety harness should be used during work from a personnel basket.
6. The installation manager or a person appointed by the installation manager shall be in

charge of the transfer.
7. Before starting the transfer operation, the starting and landing area for the personnel
basket shall be clear to ensure that there is sufficient space for a safe operation. The
basket shall not be landed onto other equipment.
8. During transfer of personnel, all unnecessary noise in the crane operator's cabin should
be avoided, and the crane operator's complete attention shall be concentrated on the
operation.

9. A designated signalman shall give the hand signals to the crane operator. The crane
operator shall have eye contact with the signalman, who in turn shall have eye contact
with the personnel basket.
10. The master of the vessel, the crane operator and the person in charge of the transfer
operation shall be in direct radio contact with each other from a time before the personnel
basket is hoisted until the transfer-operation is completed.
11. If major job is carried over-sea on an offshore installation , a stand by vessel shall be
located in the vicinity of the installation. The presence or assistance of catchers,
signalmen, spotters and helpers shall be ensured.
12. During transfer the persons transferred shall stand on the ring outside the ropes on the
personnel basket, and both hands shall be free to grip on to the ropes. Life jacket or
lifesaving suit shall be used during the transfer.
13. Personnel should position themselves so that there is even distribution of load around the
rim of the basket.
14. Lifting and lowering of the personnel basket shall take place over open water, and the
vessel shall be prepared to stop the propellers during the transfer.
15. The crane operator should raise the basket only high enough above the deck of vessel to
clear obstructions, swing it over the water, raise it to a position slightly above landing deck
level, swing the basket over the landing area and gently lower it to the deck. The same
method should be followed while transferring personnel from the installations to the vessel.
Personnel should not get off the basket until it is settled on the deck of the boat or
platform.
16. Tag lines shall be used on the basket and a person shall be present to control the direction
of the basket on the deck.
17. Use of personnel basket shall be entered into the records.
18. “Free-fall” or non powered lowering should not be adopted when personnel are carried in
the basket.
7.9 Signals
7.9.1 Standard Signals
Signals between the crane operator and the designated signal person will be discernible audibly or
visually, at all times. The crane operator will work with a designated signal person who uses
standard hand signals and will not respond unless signals are clearly understood.
7.9.2 Use of Hand Signals
It is frequently necessary during crane operation for the operator to depend on a signal man for
instructions, when moving an equipment into a position where there is very limited clearance or
when handling loads that are out-of –sight of the operator. The hand signals illustrated are those
generally accepted throughout the industry. Ensure both the operator and the signal man are
thoroughly familiar with standard hand signals to enable co-operation and teak work The details of
use of hand signals are attached at Annexure-A.
7.9.3 Signalman

The signalman shall be responsible for relaying signals from the slinger to the crane operator and
for initiating and directing safe movement of the crane and hook load. Recommended standard
hand and radio signals are identified as mentioned overleaf.
Hand signals:
 Fully conversant with the use of signals.
 Be placed in the right position.
 Check that the load is hooked correctly.
 Give the signals clearly
Radio Signals :
 correct use of radio.
 Test the radio communication before starting a lifting operation.
 Speak clear and slowly.
 Use continuous radio connection during the lifting operation when the load is out of sight of the
crane operator.
 Avoid unnecessary use of the radio
Prior to commencement of a lifting operation the signalman shall satisfy himself that loads may be
safely handled. The signalman shall remain in visual or radio contact with the crane operator at all
times and with the slinger at initial and at the final phases of the lift as appropriate.
If the signalman changes during a lifting operation, both the crane operator and the slinger shall be
duly notified of the identity of the new person in charge of signaling.
The designated signal person should:
a) Be qualified by experience with the operation and knowledge of the standard hand and
radio signals as shown in the table .
b) Be in clear view of the Operator to ensure that his signals can be seen. His position should
give him a clear view of the load, crane, personnel and area of operation. If the Operator’s
view of the primary signal person is obstructed, an additional signal person will be
provided.
7.9.4 Special Signals
For operations not covered in section 7.9.2/7.9.3 or for special conditions, additions or
modifications to the recommended standard signals may be required. In such cases, these special
signals will be agreed upon in advance by the Operator and the designated signal person and
should not be in conflict with, or have the potential to be confused with standard signals.
7.10 Simultaneous Operations
i. When logging operation is in progress crane operation should not be conducted around
the area where the cable is under tension, due to the risk associated with simultaneous
operation.
ii. During the arming of an explosive device, crane operation should not be conducted
around the designated arming area.

iii. During helicopter landing/take off crane operation should be stopped and crane boom
must be away from the landing/take off area.
8.0 INSPECTION
8.1 Pre-Use and After
Before starting of the crane the basic checks are to be carried out by the operator as per the
manufacturers check list requirement or guidelines given in Annexure-B ,
8.2 Regular Inspection
Regular inspection needs to be done based upon usage of the crane in addition to OEM Manual
requirement or as per the inspection details indicated in of Annexure- C.
9.0 MAINTENANCE
The maintenance of the crane shall be made on the recommendation of the crane manufacturer’s
standard practices, However, maintenance practices shall be followed based upon utilisation of the
crane. The recommended practices for the maintenance has been indicated in Annexure- B
9.1 Preventive Maintenance
Periodic/ preventive maintenance schedule shall be followed as per standard manufacturer's

practices/operator's recommended practices.
9.2 Repairs & replacement
The Repairs & replacement of items shall be followed based upon the recommendation of
inspection agency. However, if any major item / part is obsolete / not available the same shall be
replaced with compatible parts which has to be approved by competent person/agency.
No welding repair can be made to critical components such as booms and swing circle assemblies
unless a repair procedure and recommendations are approved .
If any critical component such as section of the boom etc. are required to be repaired, a qualified
welder shall be deployed for welding jobs.
9.3 Precautions during major repair & maintenance
a. Any job will be started only after obtaining the hot / cold work permit at any site as per OISD
Std.- 105 .
b. Care should be taken to ensure that arcing does not occur across the bearings.
c. Hooks should not be exposed to excessive heat.
9.4 Maintenance of Wire rope
Maintenance and inspection of wire ropes used in crane shall be done in accordance with OISD
Std. 187(Use and care of wire rope)
10.0 LOAD TESTING & CERTIFICATION
10.1 A copy of the original load test carried out by the manufacturer/contractor during the supply/sale of
crane certified by International/National reputed certifying agency shall be made available to the
operator/user.

10.2 In general two types of load testing certifications are required
1) The load testing & certification shall be done after major repair/ replacement of parts of the
crane based upon the recommendations of third party certifying agency.
2) Periodic load test and certification :
Based on the usage rate of the cranes all those cranes used frequently shall be load
tested and certified annually, however for less used cranes the load testing shall be done
based upon the recommendation of the certifying agency.
11.0 INCIDENT / ACCIDENT REPORTING SYSTEM
Incident/accident reporting shall be done in OISD proforma-107.
12.0 CONTRACT MANAGEMENT
If outside contractors are used for crane operations, the contract management section should
ensure that minimum qualification for operator is followed, as per recommended practices.
13.0 PERSONNEL PROTECTIVE EQUIPMENT
 All personnel working with and around the crane shall wear safety shoes, Hard hat, Hand
gloves & overalls.
 Additionally while checking the pressure & oil gauges or working near air source or moving
parts, safety glasses should be used.
 While working at height (above ten feet), safety harness shall be used.
 Life vests shall be worn by all personnel being transferred offshore by Personnel basket.
14.0 REFERENCES
The following codes and standards (latest edition) are referenced to and made a part of this
specifications :
API spec - 2C : Specification for Offshore Cranes
API-RP-2D : Recommended Practice for Maintenance and Operation of Offshore Cranes.
OISD Std.- GDN-192 : Safety practices during construction.
OISD Std. – 187: Care and use of wire ropes.
OISD – Std.-105 : Work Permit System
IS:807-1976(FirstEdition): Code Of Practice For Design, Manufacture, Erection

and Testing(Structural Portion) Of Cranes And Hoists
IS : 6717: Specification for Mobile Road Cranes, Fully Slewing.

ANNEXURE :A
IDENTIFICATION OF ACTIONS ON USE OF HAND SIGNALS
1. Emergency stop : with arms extended, palm down, move hands rapidly right and left.
2. Stop : With arms extended, palm down hold position rigidly.
3. Dog Everything : Clasp hands in front of body.
4. Move slowly : use one hand to give any motion signal and place other hand motionless in front
of hand giving the motion signal.
5. Raise the Boom : with arm extended fingers closed thumb pointing upward and a jerky upward
motion.
6. Lower the Boom : with arm extend, fingers closed thumb pointing down-ward and a jerky down-
ward motion.
7. Use Main Hoist : Tap first on head then use regular signals.
8. Use whip Line : (Auxiliary Hook Line)Tap elbow with one hand, then use regular signal
9. Swing : Arm extended point with finger in direction of swing of boom.
10. Travel : Arm extended forward, hand open and slightly raised, make pushing motion in direction of
travel
11. Hoist : With forearm vertical, fore-finger pointing up, move hand in small horizontal circle
12. Lower: With arm extended downward, fore-finger pointing down, move hand in mall horizontal
circle.
13. Raise the Boom and Lower the Load : with one arm extended fingers closed thumb pointing
upward and a jerky upward motion and the other arm extended in a down-ward position palm
horizontal with an up-down motion of this palm.
14. Lower the Boom & Raise the Load : With the arm extended finger closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended finger pointing up move hand in
small horizontal circle.
15. Raise the load slowly : with both hands placed in front of the body, palm open and an up-down
motion with the lower palm.
16. Lower the Load : With arm extended outwards, palm down and an up-down motion towards the
downward direction.
17. Lower the Load Slowly : With both hands placed in front of the body palm open and an up-own
motion with the upper palm.
18. Raise the Boom slowly : with arms placed in front of the body and the lower hand with fingers
closed thumb pointing upward and a jerky upward motion with the upper hand palm down.
19. Lower the Boom slowly : with arms placed in front of the body and the upper hand with fingers
closed thumb pointing down-wards and a jerky down-ward motion with the lower hand palm up.

20. Raise the Boom & Hold the Load : With one arm extended fingers closed thumb pointing upward
and a jerky upward motion and the other arm extended in a down-ward position closed first and
held firmly.
21. Lower the Boom & Hold the Load : With the arm extended fingers closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended in a down-ward position closed
thumb pointing down-ward and a jerky down-ward motion and the other arm extended in a down-
ward position closed first and held firmly.

ANNEXURE-B
1. Diesel Engines
Refer section 5.0 of OISD STD.121 for engine maintenance.
No. Maintenance Activity Daily Monthl Qtrly Yearly Condition

y based
1 Check lubricating oil level and top-up as required . *
2 Check cooling water level and top up as required . *
3 Check fuel tank level and top-up as required . *
4 Check for any loose bolts , nuts , pipe/line *
connection of foundation and tighten if required .
5 Start the unit and record following immediately
after start and again after 1/2 to 1 hour of running
in the log look .
a) Operating oil temperature . *
b) Operating oil pressure *
c) Engine speed ,. *
d) Water temperature . *
e) Hour meter reading *
f) Any other meter provided on the engine / panel . *
6 Rectification of fuel/lubricating oil leakage including *
repair/replacement of pipes.
7 Cleaning of radiator with air/water . *
8 Cleaning/changing of air intake filter and pre- *
cleaner dust pan including associated works.
9 Changing / cleaning oil /fuel / air filter/water / *
hydraulic filters .
10 Lubricate governor , all linkage etc. *
11 Servicing and testing of injectors including allied *
works.
12 Checking / setting of rocker and tappet clearance. *
13 Checking/tightening of belt drives . *
14 Replacement of radiator with associated works . *
15 Replacement of hydraulic and pneumatic starter. *
16 Replacement of hydraulic hand pump for starting . *
17 Replacement of starting air compressor . *
18 Replacement of cooling water pump . *
19 Replacement of turbo charger . *
20 Servicing / repair of radiator . *
21 Servicing of hydraulic and pneumatic starter. *
22 Servicing of hydraulic starting pump . *
23 Servicing of starting air compressor . *
24 Servicing of cooling water pump . *
25 Replacement of fuel pumps. *
26 Replacement of governor. *
27 Changing of acceleration cable . *
28 Removal , cleaning and fixing of flame arrestor. *
29 Removal , repair and fixing of air receiver tank . *
30 Removal , cleaning and fixing of exhaust muffler . *


31 Removal , cleaning and fixing of exhaust pipe . *

32 Cleaning , flushing and changing of lubricating oil *
including cleaning , / changing of lubricating oil filter
and breather
33 Cleaning , flushing and changing of fuel in fuel tank *
including cleaning , / changing of fuel filter .
34 Replacement of belts for cooling fans or water *
pump of compressor or generator .
35 Removal of cylinder head including allied jobs *
connected with its removal .
36 Assembling of cylinder head in the engine with *
associated work for total completion of the job and
satisfactory testing .
37 Replacement of piston ring , connecting rod , piston *
ring set etc. Including associated work necessary
for completion of the job .
38 Replacement of crankshaft including associated *
work for total completion of the job.
39 Removal and getting repaired / serviced including *
calibration of fuel injection pump from authorised
agencies and checking for satisfactory
performance of the engine with calibrated fuel
injection pump .
40 Removal and getting repaired / serviced including *
calibration of governor from authorised agencies
and checking for satisfactory performance of the
engine with calibrated governor .
41 Painting of engine including supply of primer and *
marine epoxy paint as required .
2. CRANES
No. Maintenance Activity Daily Monthly Qtrly Yearly Condition/

Use based
1 Brake System :--Aux./main crane hoist , boom *
And swing for proper functioning .
2 Safety System :-- Like limit of travels and movements , *
limits of safe operating load etc for proper functioning .
3 Condition of the hoses & hose connectors , grease to be *
applied for corrosion prevention at the hose
connections ( as required )
4 Function of control levers and pedals and lubricate as *
required .
5 Operation of cabin doors , wipers , horns ,fan etc *
And lubricate / clean as required .
6 Check and top up of oil in following ( as required ) *
a) Aux. Hoist gear box ,
b) Swing drive unit gear box ,
c) Boom hoist gear box .
d) Load hoist gear box ,
e) Hydraulic oil tank .
7 Lubricate / grease Boom tip extention sheaves . *
8 Lubricate / grease Boom point sheaves . *

9 Lubricate / grease Outer boom extension sheaves . *

10 Lubricate / grease Gauntry Sheaves. *
11 Lubricate / grease of all pivot pins of boom ,derrick and *
sheaves including that of telescopic cylinders/chains/wire
ropes inside the boom.
12 Lubricate / grease Radius Indicator bearings. *
13 Lubricate / grease Boom hoist pawl bearings . *
14 Lubricate / grease Upper & lower boom hoist kick-out . *
15 Lubricate / grease Front and rear bogie roller / gears . *
Lubricate slew ring gear *
16 Lubricate / grease Position lock/Slew lock . *
17 Lubricate / grease Swing chain & lock . *
18 Lubricate / grease Main & aux. Block, swivel hook *
bearings and locking latch on hook/swivel.
19 Lubricate / grease Cross head bearing/main thrust *
washers.
20 Main aux. Hooks for deformations , cracks and safety *
latch .
21 Boom for any structural abnormalities , cracks of *
deformation .
22 Winch mounting -- tighten if required . *
23 Checking /lubrication of boom hook anchoring latch on *
chassis. Swing chain / pinion for proper fitting and
functioning .
24 Checking for missing and tightening of slew ring gear *
mounting nuts and bolts
25 Checking and tightening of counter-weight pins/nuts & *
bolts.
26 Checking for creeping of derrick(luffing), boom telescopic *
and outrigger jack cylinders
27 Checking for leakage for hydraulic cylinders *
24 Pedestal and other structural mountings - tightened as *
28 required
29 Checking for full extension of outrigger beams *
30 Checking of cracks/deformation of out-rigger jack plates *
31 Checking of boom pad condition and their lubrication(in *
case of telescopic boom) and missing of members
members for lattice boom.
32 Hydraulic pumps and motors mounting - tighten as *
required .
33 Clean the wire ropes with wire brush,record dimensions *
and check for any kink ( if any ) . Also check end
connections for proper fitting .Lubricate with grease
.Boom Rope,main hoist rope and auxiliary hoist rope to
be checked.
34 Replacement of wire rope and greasing including *
all allied job for the same .Boom rope
all allied job for the same .Main hoist rope
all allied job for the same .Aux hoist rope
37 Cutting , splicing and connection on hook/drum end of *
wire rope.

38 Replacement of swing drive motor ( hydraulic) including *

all associated works for completion of the job and
checking for proper operation after fittings.
39 Replacement of winch drive motor ( hydraulic) including *
40 Replacement of auxiliary hook drive motor ( hydraulic) *
including all associated works for completion of the job
and checking for proper operation after fittings.
41 Replacement of Main hydraulic pump including all *
associated works for completion of the job and checking
for proper operation after fittings.
42 Replacement of swing drive motor ( hydraulic) including *
43 Replacement of Swivel hook bearing and checking for *
proper operation after replacement .
44 Replacement of Boom hoist pawl bearing and *
checking
for proper operation after replacement .
45 Replacement of Cross head bearing and checking for *
46 Replacement of Main thrust washer and checking for *
47 Replacement of Swing chain and checking for proper *
operation after replacement .
48 Replacement of Swing pinion checking for proper *
49 Replacement of Pulley and checking for proper *
50 Servicing of hydraulic pump of motor . *
51 Drain , flush and refilling of Aux hoist gear box .- *
52 Drain , flush and refilling of Swing drive unit. *
53 Drain , flush and refilling of Boom hoist gear box . *
54 Drain , flush and refilling of Load hoist gear box. *
55 Drain , flush and refilling of Hydraulic oil tank *
56 Drain , flush and refilling of Fuel oil tank . *
57 Servicing of slip ring and brushes of collector column ,if *
provided
58 Cleaning of battery terminals and applying of petroleum *
jelly and topping up of distilled water . Petroleum jelly
to be supplied by the contractor .
59 Servicing of Aviation light on boom including change of *
bulb etc .
60 Replacement of aviation light including making *
Servicing of search light on boom/operator’s cab for
illuminating working area and audio/visual warning
system for reversing.
Note: The above list of items for maintenance and its frequency is only recommended practice. As far as
practical manufacturer’s guidelines should be followed.

ANNEXURE-C
Inspection of Components of crane
S.NO. COMPONENT TYPE OF CHECK REMARKS

1 Boom Hoist Assembly Visual
2 Boom Point Sheave Assembly Visual
3 Boom Section
A. Base Visual
B Middle Thickness
C. Upper NDT
D Tip MPI
4. Boom Hoist Wire / Rope Visual

5 Joy Stick Visual
6 Hook Block A) Visual
B) MPI
7 Main Hoist Rope Visual
8 Cabin Visual
9 Overhaul Ball Visual
10 Swing Circle Assembly Visual
11 Whip-line Visual
12 Pedestal Visual
Fasteners
NDT of welds
13 Brake Assembly Operational
14 Great Assembly Visual
15 Hydraulic Assembly Operational
16 Control Assembly Operational
Boom Control Limit Switch
Hoist Control Operational
Swing Control Main Aux Luff & Slew.
17. Manual & Control Lowering Operational By Failing
Engine Power.
18. Electrical Such As Lights Operational

Switches, Voltmeter,
Ammeter, Wiper , Fan, Horn.
19. Structural Such As Visual

Ladder, Catwalk And
Rails.
20 Engine Visual
Noise Level/Vibration
Air Pr, Oil level, Air filter,

Starter
Governor
21. Static Load Test Performance
22. Dynamic Load Test Operational


For Main. Aux.

Luff & Slew.
Detailed inspection report of various items to be inspected are placed in table below. The report
indicates whether the inspected item is to be re-used, to be provided as new, to be repaired or
replaced .
1. CABIN ITEMS
S.NO. ITEM REUSE PROVIDE REPLACE SERVICE

1.1 Operator Chair
1.2 Rubber beading
1.3 Cabin Door
1.4 Roller assembly for doors
1.5 Aluminium sliding window
1.6 Wiper with wiper motor, blade &
switch
1.7 Cabin light fitting
1.8 Cabin fan
1.9 Cabin body
2.0 Boom angle indicator
2.1 Lubro set
2.2 Load cell
2. CONTROL AND SAFETY SYSTEMS

2.1 Weight load Indicator
2.2 Hyd. Main Pressure gauge
2.3 Hyd. Pilot Pressure gauge
2.4 Air Pressure gauge
2.5 Lube oil pressure gauge
2.6 Lube oil temperature gauge
2.7 Techo hour meter
2.8 Techo Hour Meter Chord
2.9 Chord Control Mechanism
2.10 Chords for Control Mechanism.
2.11 Diesel level gauge
2.12 Hyd. Oil level gauge
2.13 Emergency shutdown valve
2.14 Water temperature gauge
3. ELECTRICAL MECHANICAL AND OTHER HARDWARE ITEMS

3.1 Horn & Horn switch
3.2 Main switch
3.3 Voltmeter
3.4 Ammeter
3.5 Engine Room light

3.6 Air craft warning lights

3.7 Flood lights with fittings
3.8 Electric cables
3.9 Nuts & Bolts (Assorted)
3.10 Wedge & Sockets
3.11 Latches for Main and Aux. Hook
Blocks
3.12 Brake liners / Brake Shoes
3.13 Plumber Block Bearing
3.14 "V" Belts
3.15 Exhaust Bend
3.16 Engine cooling fan guard
3.17 Exhaust Manifold
3.18 Exhaust Bellow
3.19 Injector overflow pipe
3.20 Diesel Filter
3.21 Lube Oil Filter
3.22 Anti vibration Pads
3.23 Grease Nipples(Assorted)
3.24 Spark Arrestor
3.25 Air Inlet valve
3.26 Roller Assemblies for Engine Room
Doors
3.27 Junction boxes
4. EQUIPMENT AND COMPONENTS

4.1 Luff Pawl Cylinder
4.2 Hyd. Starter with dog &pinion
4.3 Transmission Belts
4.4 Mechanical Engine Protection unit
for hazardous area
4.5 Oil cooler
5. PNEUMATIC & HYDRAULIC SYSTEMS

5.1 Hydraulic Hose pipe
5.2 Hydraulic pipes for all sizes
5.3 Hydraulic fittings
5.4 Suction Hose
5.5 Pneumatic hoses
5.6 Drain valve for Diesel tank
5.7 Drain valve for Air tank
5.8 NRV-1/2”
5.9 Hyd. Filter
5.10 Hyd. Tank Breather
5.11 Suction Valve
5.12 Hyd. Tank drain valve
5.13 Pneumatic switches
5.14 Hyd. Tank Gasket

5.15 Hydraulic oil filter

5.16 Hydraulic Float
5.17 Pneumatic FITTINGS
5.18 Main Hydraulic Pump Assy
6. WIRE ROPES

6.1 Wire rope for Main Hoist, Aux.
Hoist & luff winch
7. STRUCTURAL DAMAGES
NO. ITEM REUSE PROVIDE REPLACE SERVICE

7.1 Top Catwalk
7.2 Top covers
7.3 Cabin Top
7.4 Diesel Tank with Fittings
7.5 Engine Room Doors
7.6 All panels
7.7 Hand rail
7.8 Ladder
8.CRANE BOOM ASSEMBLY
NO. ITEM REUSE PROVIDE REPLACE SERVICE

8.1 Damaged Boom lacings
8.2 Boom Section joining pins
8.3 Safety Latch for Main block
8.4 Safety Latch for Aux. Block
9.LIST OF COMPONENTS FOR SERVICING
S.NO. ITEM
1. Accumulator & Relay valve starter
2. All Single & Double Joysticks
3. Electrical Panel & all lights
4. Hyd. Tank
5. Hyd. Hand Pump
6. Magnetic Particle collector
7. Fuel feed pump
8. Fuel pump
9. Injectors
10. All Pulleys
11. Counter shaft
12. Plumber block
13. Hydraulic Starter
14. All valves
15. Hyd. Motor for Main Hoist

16. Hyd. Motor for Aux.Hoist

17. Hyd. Motor for Luff Hoist
18. Hyd. Motor for Slew Drive
19. All Mono blocks
20. Slew free valve
21. Check- Q- Meter
22. Pump Drive
23. All Brakes
24. Grease Lubrication of wire ropes, Pulleys, Shafts, Pins & their greasing points
25. All Hyd. Cylinders
26. Slew Ring
27. Main hook block
28. Auxiliary hook block
29. First aid box
30. Distribution board
31. Lubricator assy
32. Air Receiver
33. A Frame
34. All Limit Switches
35. Generator
36 First aid box
37. Distribution Box
38 Joy Stick
39 Pedestal adapter
40 Sheaves
41 Sheave guards
42 Diesel Engine- thorough overhaul
43. Compressor
Note: The above list of items for inspection/maintenance and their frequencies are only recommended
practice. As far as practical, manufacturer’s guidelines should be followed.

Crane Operation

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Sr.

“CRANE OPERATION,MAINTENANCE AND TESTING”

Oil Industry Safety Directorate

COMMITTEE ON RECOMMENDED PRACTICE

Oil Industry Safety Directorate

Page No. III

Oil Industry Safety Directorate

NAME ORGANISATION POSITION IN

1. H.N. BHAKTA ONGC LEADER

2. ROY JOHN ONGC MEMBER

3. SUNIL SOHANI SCHLUMBERGER INVITEE

4. GIRISH KAMAL EIL MEMBER

5. PRADEEP KUMAR OISD MEMBER -

Page No. VII

Sl.No. Description Page No.

6.0 Safety Equipment 6

10.0 Load Testing And Certification 17

11.0 Incidence/Accident Reporting System 18

12.0 Contract Management 18

13.0 Personnel Protective Equipment 18

OISD – RP – 205 Page No. 1

“CRANE OPERATION, MAINTENANCE AND TESTING”

Certified : To formally attest as being

Choke : Block used to stop the wheels of a truck.

OISD – RP – 205 Page No. 2

Dynamic : Loads introduced into the

Heavy usage : Heavy usage applies to

Infrequent usage : Infrequent usage applies

Jib(Tip Extension) : An extension attached to the

Lattice boom : Boom of open construction

Moderate usage : Moderate usage applies

OISD – RP – 205 Page No. 3

Qualified crane : A person with training and

Sling : A device used to connect loads to be lifted by a crane or a hoist.

Swing Circle : The swing circle

OISD – RP – 205 Page No. 4

Telescoping : Consists of a base boom

4.1 Prime Mover:

4.3 Hydraulic System

OISD – RP – 205 Page No. 5

4.4 Electrical System

4.5.1 Fixed Cranes

4.5.2 Mobile Cranes:

4.6 Out Riggers

Controls should be in accordance with the following requirement :

OISD – RP – 205 Page No. 6

g. An emergency stop, to stop all functions of crane instantaneously in case of emergency is

6.0 SAFETY EQUIPMENT

Following minimum Safety equipment should be installed/made available on the crane : -

 Weight load indicator

Safety equipment specific to Mobile Cranes shall be fitted

7.1 Operator's Qualification

OISD – RP – 205 Page No. 7

7.2 Rigger’s Qualification

7.3 Safe Operating Procedure

OISD – RP – 205 Page No. 8

7.4 Crane Danger Signs to watch For :

b Operating close to power lines or other dangerous objects. Electrocution due to

OISD – RP – 205 Page No. 9

50k to 75k 11 feet

OISD – RP – 205 Page No. 10

7.6 Load Handling

7.6.1 The Load

7.6.3 Moving The Load