LIFTING EQUIPMENT INSPECTION PROCEDURES

Document Title

YARD LIFTING

PROCEDURES

DOCUMENT NO: REVISION NO: NO. OF PAGES: 3

PREPARED BY: REVIEWED BY: APPROVED BY : EFFECTIVE DATE:

SIGNATURE: SIGNATURE: SIGNATURE: ISSUE DATE:

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 LIFTING EQUIPMENT INSPECTION PROCEDURES

STANDARD OPERATING PROCEDURES

1. PURPOSE

It serves to control all lifting operations to prevent accidents, especially lifting of heavy
objects.

It also serves to comply with the Local government Regulations.

2. SCOPE

It applies to all cranes lifting operations carried out in the Yard.

3. DEFINITION

Mobile Crane means a crane mounted on a truck, crawler or on wheels and includes truck
mounted crane; self-propelling wheel mounted crane; self propelling crawler truck mounted
crane and portable crane.
Tower crane means a crane which has a vertical or near vertical tower designed to free standing
up to a specified height, and includes mono-tower, inner and outer tower, telescopic
tower, with saddle-jib and fixed tower and with luffing jib and slewing tower.
Approved person means any person who is authorized by the local government , for the purpose of
carrying out examinations and tests of hoists and lifts, lifting gear, or lifting appliances and lifting
machines.
Lifting gear includes chains, ropes, crab, winch, and any suspended scaffold capable of being
raised or lowered by winches or climbers.

4. INSTALLATION OF A MOBILE AND TOWER CRANE

Any person appointed by the management to install any mobile and tower crane shall ensure that
the crane is installed in accordance with the instructions contained in any manual issued by the
manufacturer of the mobile crane or tower crane.

5. APPOINTMENT OF LIFTING SUPERVISORS

Yard /Operation Manager shall be responsible to appoint lifting supervisors for each
department.

6. DUTIES AND RESPONSIBILITIES

A. Lifting Supervisors

Duties of the appointed lifting supervisor are:

(a) co-ordinate all lifting activities;

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(b) ensure that only registered crane operators, appointed riggers and appointed signalmen participate
in any lifting operation involving the use of a mobile crane or a tower crane;
(c) ensure that the ground conditions are safe for any lifting operation to be performed by any mobile
crane;
(d) unless he is present to supervise a lifting operation, ensure that there is a set of safe lifting
procedures for any lifting operation by a mobile crane or a tower crane;
(e) brief all crane operators, riggers and signalmen of the safe lifting procedures.
(f) if any unsatisfactory or unsafe conditions are reported to him by any crane operator or rigger, take
such measures to rectify the unsatisfactory or unsafe condition or otherwise ensure that any lifting
operation is carried out safely.

In addition, the lifting supervisors’ duties should include the followings: -

 The assessment of the lifting operation is to provide such as planning, selection of

crane and lifting gear. He should also give appropriate instructions and supervision for
the task to be carried out safely. For lifting work involving more than one crane, a lifting
supervisor must be present at site to supervise the work.

 Lifting supervisors shall be responsible to maintain a logbook for all the cranes under
his
charge. He must take all necessary measures to rectify any unsatisfactory or unsafe
conditions reported to him by the crane operator.

 Lifting supervisor must ensure that lifting gears, lifting appliances and lifting machines
are regularly inspected and maintained. He must ensure that all the lifting equipment
have a valid certificate issued by an approved person. He must also ensure that the
equipment are clearly labeled with the safe working load, date of last test and the serial
number.

 Lifting supervisor is authorized to stop any lifting operation whenever he considers that
danger is likely to arise if the operation were to continue.

 It is important to note that duties, but not responsibilities, may be delegated to another
person.

 Lifting supervisors must not appoint crane driver to be in control of the lifting operation.

 For a simple lifting operation, the department using the crane may appoint a trained
rigger to perform the lifting operation
.

B. Crane Operator

The duties of crane operator is stipulated under the local government regulation. Any
person operating a crane:-

a. shall not carry out any lifting operation unless a lifting supervisor is present or has
approved the carrying out of such operation;

b. shall not engage in any act or manoeuvre which is not in accordance with safe and sound
practice;

c. shall ascertain whether the ground conditions, in particular the ground surface on which a
mobile crane is to be operated, are safe for travel any lifting operation, and if he is of the
opinion that it is not safe for travel or any lifting operation, he shall report this to the
lifting supervisor;

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d. shall not use the crane for any operation for which it is not intended, including pulling or dragging a
load;

e. shall not manoeuvre or hold any suspended load over any public road or public area unless that road or
area has been cordoned off;

f. shall ensure that any outrigger when it is required is fully extended and secured;

g. shall before the start of every workshift, carry out operational tests on all limit switches under no load
conditions before any lifting operation is carried out and shall enter the results of such tests in a log-
book or log-sheet;

h. shall report any failure or malfunction of the crane to the lifting supervisor and shall make an
appropriate entry in the log-book or log-sheet of the crane;

i. shall ensure that any stationary truck mounted or wheel mounted crane is adequately and securely
blocked while it is on a slope;

j. shall not hoist any object if he is unable to ascertain the weight of the object;

k. shall not hoist any load if there is any obstruction in the path of manoeuvre and if there is any such
obstruction, he shall report this immediately to the lifting supervisor;

l. shall not hoist any load unless he was received a clear signal from a signalman when this is required
under regulation 19; and

m. shall not operate a mobile crane or a tower crane within 3 metres of any live overhead power line.

C. Crane Operator

The Crane Operator must have successfully completed course approved by Local government before
he is allowed to do the work.

Signalman

The signal must attend in house training conduct by safety department before he is allowed to do the
work.

7 .PROCEDURE FOR LIFTING OF VESSEL’S BLOCK OR A VESSEL

7.1 INTRODUCTION

This procedure sets out the steps to properly carry out lifting operation of heavy objects, such
as hull blocks and other hull structures of at least 5 tons or of a size which requires close
examination to ensure no deformation or collapse of the structure. It also defines the duties
and responsibilities of each individual who is involved with the lifting operation.

7.2 PURPOSE

To ensure safe and effective execution of heavy lifting

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7.3 PROCEDURE

a. It is expected that all major lifting operation to be executed should have been planned for
by the Project Team in their planning of each individual project.

b. The Section Head shall execute their planned maintenance programs for the various cranes
and lifting gears accordingly and to ensure that the testing for certification of
these are carried out in a timely manner when due.

c. Project Manager, should work out the block division. The exact date and time of the lifting
operation.

d. The following information should be provided by the Engineering Department : -

- Estimated weight in tons

- Longitudinal Centre of gravity from frame 0 (LCG)
- Transverse Centre of gravity from centre line (TCG)
- Vertical Centre of gravity from base line (VCG)
- Frame Co-ordinate Chart

e. When a block is ready for lifting, the Steelworks supervisor and the lifting supervisor
should discuss on the method of lifting the block. The lifting supervisor should
inform the Steelworks supervisor of the area to be cleared for the lifting operation.

f. The Project Team should work out the followings based on the weight and the centre of
gravity given by the Engineering Department: -

- Position and direction of all lifting brackets

- Lifting load at each bracket
- Capacity of each eye lug/piece
- Type and capacity of the crane to be used
- Boom length and boom angle of each crane
- Capacity of lifting wires and their lengths
- Type of shackles and their capacity
- Sketch of the lifting

All the above information should be worked out and it should be used to brief the
people involved in the lifting operation.

g. Should there be any change in lifting condition such as weight, method, arrangement and
sequence etc, the step (f) must be repeated.

h. The lifting supervisor should seek his department head or Manager approval before the
lifting should proceed.

j. The Steelworks section shall fabricate and install the lifting lugs and build the required
reinforcement into the block.

k. The Steelworks section shall request QA Section to perform the appropriate non-destructive
testing to the weldment of the lifting lugs and reinforcement structures,
which are built into the block. Welding supervisor shall also verify that the correct type of
electrodes for welding and the material used are as per the design requirement.

I. The lifting supervisor shall prepare and ensure that the right types of lifting gears,
including sling cables, shackles and the appropriate cranes and lifting wires/chains are
used. The lifting supervisor shall ensure that his workers rig up the lifting arrangement
accordingly.

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11. SPECIAL PRECAUTIONS

a. Lifting supervisor must ensure that all tower cranes are provided with an
b. authorised crane attendant.

c. Lifting supervisor taking charge of the crawler truck cranes

must also ensure that the crane has an authorised crane attendant.

c. Crane driver must not operate the tower or crawler crane without any authorized
crane attendant.

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Month January- Feb’ry- March July- August- Sept

April- May- June Oct - Nov - Dec
Color Coding Yellow Red

3.1. REJECTED LIFTING GEAR

Wire rope which found kinked, more than six wires broken, Cracked Hook or Shackle
increased size must be not be used and removed from site and marked with black color.

4 CRANE INSPECTION

4.1 All cranes must be inspected annually by a qualified third party personnel on the overall
Condition of the crane. This would not be limited to visual inspection, Cranes would be
Subjected to load test to ascertain the Safe Working Load, taking into account the wear and
Tear.

4.2 The external party inspection shall lead to a local government recognized certificate.

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4.3 All such certificates shall be handed to the Safety Department for future references.

ISSUE AND CONTROL OF LIFTING EQUIPMENT

1. PURPOSE

a. It serves to control the lifting equipment to be brought into the Yard by Sub-contractors; and
ensure that only valid lifting equipment are issued out by the Yard.

b. It serves to comply with the local regulations. ()

2. LIFTING EQUIPMENT

The lifting equipment includes lifting gears, lifting appliances, and lifting machines.

3. DEFINITION

Lifting machines includes a crane, winch, runway transporter, piling frame, and suspended
scaffold capable of being raised or lowered by climbers or winches.

Lifting appliances includes a pulley block, gin wheel, chain block or set of chain blocks.

Lifting gears includes chains, ropes, chain sling and rope sling, hooks, shackles, swivels and
eyebolts.

4. SCOPE

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This standard applies to PT. NEXUS ENGINEERING INDONESIA.

5. CONTROL BY SECURITY PERSONNEL ON THE LIFTING EQUIPMENT BROUGHT INTO

THE YARD.

a. The sub-contractor who is bringing in the lifting equipment must produce a copy of the valid
certificate to the security personnel on-duty, except for hooks, shackles, swivels and eyebolts.
Only certificates issued by an approved person () should be recognised.
Lifting equipment without a copy of the valid certificate must not be allowed to enter into the
Yard.

b. The security personnel must examine the lifting equipment, and ensure that its safe working load
(S.W.L.), registration number and the date of test are clearly stamped/marked on the lifting
equipment.

If the lifting equipment is not labelled with its S.W.L., registration number and the date of test,
should refer the sub-contractor to the Yard’s Safety Department. The safety personnel should
advice the contractor on the proper way of marking the lifting equipment.

c. The security personnel must also check and ensure that the registration number indicated of the
lifting equipment is the same as the certificate’s registration number.

d. The security personnel shall file the copy of the certificate.

e. A copy of the certificate shall be given to Safety Department. Safety Department shall be
responsible to monitor the expiry date of the lifting equipment.

f. Chief Security Officer shall be responsible to brief all his security personnel on this procedure.

6. CONTROL OF THE ISSUING OF LIFTING EQUIPMENT

a. Section Head must brief their store men on the statutory

requirements before allowing them to issue any lifting equipment.

b. The store man must ensure that only lifting equipment with a valid certificate is issued to the sub-
contractor/employee. He must ensure that the lifting equipment‘s serial number; safe working load
(S.W.L.) and date of test are stated in the loan form, and the lifting equipment is also stamped with
its S.W.L.; serial number and the date of test.

c. The store man must not issue out any lifting equipment under the following conditions: -
Lifting equipment not stamped with S.W.L; date of test; and it’s
registration number.
Lifting equipment without a valid certificate issued by an approved person.

d. One month before the expiry date of each lifting equipment, Section Head shall be responsible to
send a reminder to the borrower to return the equipment for testing. If the reminder is unheeded
after the one month period, a copy of the name list of those who failed to return the equipment
should sent to Safety Department for disciplinary action.

e. Section Head shall ensure that all untested; expired and condemned lifting equipment are properly
labeled and separated from those valid lifting equipment. These lifting equipment must not be
issued out.

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SAFETY REQUIREMENTS FOR CRANE LIFTING OPERATION

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