Load Test Procedure

OCTG SERVICES PART F
STANDARD WORKING PROCEDURES
Date: 02.2004
Section:
Page: 1
Revision :
of 70
LOAD TEST
Reviewed:
Date: 02/2004
Approved:
Date: 02/2004
Load Test
Index
1.0
1.1
1.2
1.3
1.4
1.5
Application
Preface
Reference Documents
Accident Control And Safety
Proprietary Information And Equipment Security
Personnel Qualification
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
Inspection Procedure
Inspection Of Lifting Equipment
Inspection Of Chain Blocks
Inspection Of Pull Lifts / Lever Hoist
Inspection Of Tirfor Machines
Inspection Of Single and Multi Sheave Blocks
Inspection Of Trolleys
Inspection Of Beam and Plate Clamps
Inspection Of Shackels
Inspection Of Chain
Inspection Of Eye Bolts
Inspection Of Links
Inspection Of Hools
Inspection Of Wire Rope and Wire Rope Slings
Inspection Of Webbing and Round Slings
Inspection Of Containers and Baskets
Inspection Of Inertia Reels
Inspection Of Lifting Beams and Spreaders
Inspection Of Runway Beams and Swing Jibs
Inspection Of Electric / Pneumatic Chain Hosts
Inspection Of Over Haul Balls and Swivels
Inspection Of Cranes
Inspection Of Pad Eyes
Issued by:
Tuboscope Vetco Egypt
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Index (Continued)
2.23
2.24
2.25
2.26
Inspection Of Davits
Inspection Of Winches
Inspection Of Harness / Lanyards
Inspection Of Forklifts
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Repair Procedures
Repair Of Chain Blocks
Repair Of Lever Hoists / Pull Lifts
Repair Of Tifor Machines
Repair Of Sheave Blocks
Repair Of Trolleys
Repair Of Beam Clamps
Repair Of Pneumatic Chain Hoists
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
Test Procedures
Test Of Chain Blocks
Test Of Pull Lifts
Test Of Tirfor Machines
Test Of Sheave Blocks
Test Of Trolleys
Test Of Beam and Plate Clamps
Test Of Shackels, Links, Hooks, Eye Bolts and Similar Gear
Test Of Chain
Test Of Wire Ropes and Wire Rope Slings
Test Of Containers and Baskets
Test Of Lifting Beams and Spreader Frames
Test Of Runway Beams
Test Of Swing Jibs
Test Of Electric / Pneumatic Chain Hosts
Test Of Swivelling Over Haul Balls and Swivels
Test Of Cranes
Test Of Pad Eyes
Test Of Life Boat Davits
Test Of Winches
Test Of Over Head Cranes
Issued by:
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1.0 APPLICATION
1.1 Preface
This working procedure applies to the inspection of Load Test.
1.2 Reference Documents
The following documents shall be used as references in establishing this
procedure:
a. SI 2307 LOLER Lifting operation Lifting Equipment Regulation
b. BS British Standards Lifting Equipment
All documents referenced in this procedure shall be maintained to the latest
revision.
This Standard Operating Procedure can be applicable in its entirety or in
single sections depending on customer's request and/or work order.
In case of conflict between this procedure and a customer specification, the
customer's requirements will prevail.
1.3 Accident Control And Safety
It is the duty of each operator and/or inspector charged with responsibility for
performing inspection to adhere to all applicable Company rules and
regulations regarding health and safety. To accomplish this, each operator
and/or inspector must ensure safe working conditions and that the necessary
protective equipment has been provided for the task to be performed.
Personal protective equipment typically includes, yet is not limited to, hard
hats, goggles and hard toe shoes.
Equipment under calibration control must have valid calibration stickers and/or
calibration certificates.
1.4 Proprietary Information And Equipment Security
Unit operators, inspectors and all other Company personnel are expected and
encouraged to discuss with our Customers and their representatives, the
particulars of the service they are performing. However, proprietary and
technical information pertaining to this equipment and/or service will not be
disclosed to individuals outside the employment of Tuboscope, a Varco
Company, without prior approval of their immediate supervisor. Protective
covers for inspection equipment must be kept in place at all times unless the
equipment is being serviced and all inspection equipment must be secured
under locked doors when not in use.
Issued by:

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1.5 Personnel Qualification

Personnel performing this inspection shall be qualified to NDT Level I/II as per
ASNT SNT-TC-1A and/or EN 473. Personnel performing prove-up and reporting
inspection results shall be qualified to a minimum NDT Level II.
2.0 INSPECTION PROCEDURE
2.1 INSPECTION OF LIFTING EQUIPMENT
1.0
2.0
3.0
4.0
Prior to the inspection, the lifting equipment engineer carrying out the
examination shall have enquired or been informed of the act or regulation
under which the examination is to be carried out so that any special
requirements can be incorporated into the examination and the official
report.
All inspections must be carried out in adequate natural or artificial light.
The equipment shall be clean and free from rust to enable a thorough
examination of all parts to be carried out.
The inspection shall be carried out in accordance with the appropriate
Tuboscope. procedures and in line with both manufacturers
recommendations and the relevant European Standard.
4.1
4.2
4.3
4.4
4.5
5.0
The identification marking and safe working load will be checked

against the Test Certificate and where markings have become
illegible they shall be re-stamped or stencilled.
Where the engineer has reason to doubt the integrity of an item of
lifting equipment, he may carry out a non-destructive test (M.P.I.)
to ensure the item is free from defects.
If required, the engineer will ensure any covers or plates that
prevent thorough examination, are removed to ensure that a full
inspection is carried out. He must also ensure they are correctly
and securely replaced on completion of the examination.
If the engineer has reason to doubt whether an item of lifting
equipment is fit for further use, he will have it removed from
service for further investigation.
If an item of equipment is deemed unfit for further use, it must be
removed from service until the defect has been repaired or the
item replaced.
If on completion of the examination, the item is deemed fit for further use,
an inspection report will be issued detailing the following information:
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5.1
5.2
5.3
Identification / Serial number.

Safe working load or capacity.
A full description of the item.
5.4
A clear statement of its fitness for further use or details of any

defects, which affect the safe working load and the corrective
action to be taken. This should include the time scale within which
the defect must be remedied.
The name of the person carrying out the examination.
Load Test Certificate Number.
Details of any previous examination including date, company and
name of the inspector.
Location of the equipment.
If there was limited access to fully examine the item of equipment
this must be closely stated on the inspection report.
5.5
5.6
5.7
5.8
5.9
6.0
All defective items shall be recorded on a Survey Defects List and a copy
given to the client for action.
7.0
If during the course of the examination any item of equipment is found to

be dangerously defective, then this must be reported to the client for its
immediate removal from service.
8.0
On completion of the equipment survey, the copies of the examination

reports, defects lists and equipment register shall be forwarded to the
client as soon as is practicable.
9.0
Each employee shall familiarise himself with, and observe the working
clients safety and working practices.
10.0
Each employee shall wear the appropriate safety gear:

10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
Issued by:
Coveralls (flame retardant for offshore)

Thermal clothing
Protective foot wear
Hard hat
Ear defenders
Goggles (where necessary)
Welding hood (where necessary)
Gloves

11.0
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Should an employee observe unsafe practices, or be requested to work

contrary to good safe practices, then he will be expected to report this
immediately to the local safety representative and his manager.
The company's Quality Policy applies and each employee is encouraged to

observe and comment on improvements relating to the efficiency and safety of
working practices.
2.2 INSPECTION OF CHAIN BLOCKS
1.0
The machine shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
The safe working load and identification mark is legible and

corresponds with the test certificate.
Both top and bottom hooks checked for excessive wear, stretch,
nicks gouges, security of mountings and effectiveness of safety
catches.
Security of chain anchor point or damage to load chain stop where
one is fitted.
General damage to the block body including any gear cover and
chain guides.
Hand wheel damaged, wear and freedom of movement.
The load chain is worn or damaged, 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.
The hand chain is worn or damaged, particularly on the bearing
surface or is corroded bearing in mind possible injury to operative
hands.
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.
2.0
Function test block to ensure brake mechanism operates satisfactorily.
3.0
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.
Issued by:

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2.3 INSPECTION OF PULL LIFTS / LEVER HOIST

1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9

corresponds
with the test certificate.
Both top and bottom hooks checked for excessive stretch, nicks,
gouges, wear, security of mountings and effectiveness of safety
catches.
Anchor point of the chain is secure.
The body of the machine has no cracks, damage around hook
seating, missing bolts and screws.
The lever assembly for correct operation of pawl changing
mechanism, freedom of operation and deformation.
End stop for security and effectiveness, (particularly on link chain
type as this can be pulled through if deformed).
Ensure chain stripper is present and check for wear.
Load chain:
1.8.1 Examine link chain for excess wear, stretched or twisted
links, nicks and gouges.
1.8.2 Examine roller chain for bends in links, wear on rollers and
freedom of movement.
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.
2.0
Function tests the block to ensure satisfactory operation of the brake

mechanism.
3.0
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2.4 INSPECTION OF TIRFORS

1.0

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
2.0
3.0

corresponds
with the test certificate.
The shear pins are not distorted (this would indicate overloading).
The operation handle is not distorted, indicating applied operating
effort.
The correct diameter and construction of rope is fitted.
The wire rope is free from kinks.
The wire rope is not suffering from obvious wear corrosion.
The wire rope has no broken wires (the danger to the operatives
hands must be considered)
The wire rope terminations are intact (fused and tapered at one
end with eye at other end).
The outer casting should be checked for deformation, cracks and
damage.
Casting screws and nuts are all present and secure.
Reversing lever and release lever are free from damage on
operation.
Function tests the machine to ensure the satisfactory operation.

2.5 INSPECTION OF SINGLE AND MULTI SHEAVE BLOCKS

1.0
The blocks shall be checked for the following defects:

1.1 The safe working load and identification marking is legible and
1.2 Wear / fracture in eye of block.
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1.3 Wear / fracture in shank of head fitting. Where the shank of the head
fitting has been welded to the collar or nut, then the wear on the
shank shall be determined by rotating the head fitting, the wear shall
not exceed a maximum of 1.5 mm to 25 mm shank diameter, or the
shank bent.
1.4 Side plate distorted or chaffed.
1.5 Fracture leading from centre pin holes.
1.6 Side straps distorted or worn.
1.7 Bush worn, distorted or fractured.
1.8 Sheaves, chipped fractured and worn in score or at sheave edge.
1.9 Check that all oil and grease ways in pin and bush, sheave and shell
are clear.
1.10Becket worn, distorted, or fractured (also ensure it is the correct size
for load to be applied to it).
2.0
safe operation of the block then it must be withdrawn from service and
2.6 INSPECTION OF RUNWAY TROLLEYS

1.0

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Issued by:
The safe working load and identification marking is legible and

Distortion of side plate.
Wear on trolley wheels and bearings or damage to flanges.
Check all nuts to ensure tightness.
Wear on load bearing points, in particular suspension points.
Cracked or defective wheels.
Hand chain (on geared trolleys) is worn, damaged or corroded
particularly on the bearing surface, but also on the outside of the
links, bearings in mind possible damage to the operative hands.
Incorrect installation, ensure trolley is centrally aligned with the
flange of the beam, also side clearance between wheel flange and
toes of the beam is correct (usually 3 mm to 4 mm total
clearance).

2.0
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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.
2.7 INSPECTION OF BEAM CLAMPS AND PLATE CLAMPS

1.0
The clamp shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
Shackle or eye for wear, cracks, gouges and corrosion.

Frame opened out.
Ensure mechanism is working freely and lubricated.
Tight, bent or damaged clamping threads.
Wear on gripping surface.
Worn or bent pins.
Broken or stretched spring in locking lever and unsatisfactory action
of locking lever.
Blunt teeth in either fixed or movable jaws.
NOTE: TEETH MUST NOT BE RESHARPENED OR RECUT
Bent or damaged thread bar.
safe operation of the clamp, then it must be withdrawn from service and
2.8 INSPECTION OF SHACKLES

1.0
All shackles shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
Issued by:
The safe working load and identification number marking is legible

and corresponds with the test certificate.
Distortion of the body and alignment of the holes on opposite sides
of the shackle.
Free working of the pin.
Wear on thread of screw pin shackles, thread should be hand 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.
Wear in pin and body of shackle, this must not exceed 8% of the
original diameter..
Dents, nicks or cracks as a result of service.

2.0
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safe use of the item of lifting gear, then it must be withdrawn from service
and details recorded on the Inspection Report.
2.9 INSPECTION OF CHAIN

1.0
All chain shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0

Check Grade Quality Mark on chain to establish grade of chain,
mark should be every 20th link or IM which ever is the lesser
distance.
Check manufacturers 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.
Wear on the links of the chain must not exceed 8% of the original
diameter.
Check for bent or twisted links.
Stretch in the chain shall not exceed 5%.
If the chain forms the legs of a multi-leg set, the sling should be
hung up by the link and the legs checked for elongation. An
elongated leg is an indication of uneven loading.
Examine for nicks, cracks, corroded and pitted links.
and details recorded on the Inspection Report and manufacturers
specifications.
2.10 INSPECTION OF EYE BOLTS

1.1
All eye bolts shall be checked for the following defects:

1.1
1.2
1.3
Issued by:

Thread is worn, corroded or damaged.
If debris is present in thread or underside of collar, if so remove with
a wire brush.

1.4
1.5
1.6
1.7
2.0
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Eye bolts intended for lifting purposes must have a thread run-out
under the collar. Fine and taper threads e.g. N.P.T. are not
recommended and should only be used with extreme caution and
when no other alternative means are possible to complete the lift.
Eye distorted or worn (max permissible wear 8% of original
diameter)
Shank distorted, bent or diameter reduced at undercut
UNDER NO CIRCUMSTANCES SHALL BENT EYE BOLTS BE
STRAIGHTENED.
Examine for nicks, cracks and gouges.
2.11 INSPECTION OF LIFTING LINKS

1.0
All links shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
2.0

Links distorted or worn (max permissible wear 8% of original
diameter).
Check dimensionally for distortion or elongation.
Check for damage i.e. nicks, cracks and gouges.
Check welded join for cracks or defects.
2.12 INSPECTION OF HOOKS

1.0
All hooks shall be checked for the following defects:

1.1
1.2
1.3
Issued by:
Safe working load and Identification Marks are legible and

corresponds
with the test certificates.
Distortion, ensure that the hook is not bent and check opening
against manufacturers tables to ensure that there has been no
overloading of the hook.
Check with manufacturers tables to ensure correct size of hook is
being used for safe working load.

1.4
1.5
1.6
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Nicks, gouges, scores, etc. Some of these defects may be rectified

by filing out so as to remove the defect. If the amount of metal
removed is more than 1/64 per 1 of section, then the hook should
be removed from service.
The eye of the hook must be checked for wear if this exceeds 8%
of the original depth then the hook must be removed from service.
The following extra checks shall be carried out on shank hooks:
1.6.1 Shank is true with centre line of hook.
1.6.2 Swivel hook turns freely.
1.6.3 Soundness of shank thread, fit of thread in nut and
completeness of thread.
1.6.4 Signs of cracks particularly where there are changes of
section at bottom of threads and at cotter pin holes.
1.6.5 BK type hooks should be checked for wear as per
manufacturers specification.
2.0
2.13 INSPECTION OF WIRE ROPE AND WIRE ROPE SLING

1.0
All wire rope slings shall be checked for the following defects:
1.1 The safe working load and Identification Mark are legible and
1.2 BROKEN WIRES
1.2.1 The number of broken wires in a length of 10 rope
diameters must not exceed 5% of the total wires in the
rope.
1.2.2 No broken wires are permitted near an attached fitting.
1.3 Check for wear, corrosion and insufficient lubrication.
1.4 All end splices shall be checked for worn broken wires, pinched or
jammed stands, loose stands, cracked fittings, tucks drawing out and
distorted ferrules.
1.5 Corroded, cracked, bent, worn and incorrectly applied end fittings.
1.6 Examine all thimbles for wear in crown, for evidence of throat biting
into rope, distortion or closure.
Issued by:

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1.7 Check the length of the rope for kinks, bird-caging, crushed flattened
or jammed strands and core protrusion.
1.8 Inspect for heat damage (caused when rope is run over seized
sheave), torch burns and electric arc strikes.
2.0
safe use of the wire rope, then it must be withdrawn from service and
2.14 INSPECTION OF FLAT WEBBING AND ROUND SLINGS

1.0
All slings shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.0
Burning due to wrong positioning of sling. Surface of sling will be

polished an easily reflects light.
Cutting, wear, broken load bearing threads and loose unbroken
load bearing threads the latter must be repaired as the threads can
easily catch and break if left unattended.
Burst stitching particularly in the eye and where the webbing
overlaps in the case of endless slings.
Check entire length of sling for seam damage.
The load bearing point in the eye of the sling shall be checked for
cutting, wear, scuffing and burst leather protection.
In the case of round slings the outer sleeve shall be checked for
cuts and general deterioration.
Chemical attack is very difficult to detect until in an advanced state,
signs are surface powdering and possible loss of colouring.
safe use of the sling, then it must be withdrawn from service and details
recorded on the Inspection Report.
2.15 INSPECTION OF CONTAINERS AND BASKETS

1.0
Check that the Safe Working Load and Identification Mark are legible and
corresponds with the Test Certificate in accordance with BS 7072.
1.1
1.2
1.3
1.4
Issued by:
Visually examine all lifting points both from inside and outside to
ensure they are free from defects. A non destructive test (M.P.I.)
shall be carried out at the discretion of the test engineer.
Visually examine floor plates inside and underneath Hammer test
to loosen and remove any flanking rust to check condition of floor.
Check condition of floor bearers for corrosion.
Check all base welds, both inside and underside for defects.

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1.5
1.6
Check abnormal dents or tears.

Check condition of fork lift pockets, particularly the bottom strap at
point of entry.
1.7 Check release catches and open doors fully (if fitted) checking the
freedom of operation and alignment.
1.8 Check condition of door seals (if fitted)
1.9 Check all stencilling and paint marking to BS 7072.
1.10 Only once the test engineer has fully satisfied himself that the unit
is fit for the application for which it is intended then the test plate is
stamped and an Visual Certificate issued.
2.0
safe use of the machine, then it must be withdrawn from service and
2.16 INSPECTION OF INERTIA SAFETY REELS

1.0
Check the Safe Working Load and Identification Marking is legible and
corresponds with the Test Certificate
1.1
1.2
1.3
1.4
1.5
2.0
Check that the safety hook on wire cable opens and closes freely
and that the hook is not deformed in any way.
Check that the top shackle is not worn in the pin or body (this must
not exceed 8% of the original diameter) and there are not dents,
nicks or cracks as a result of service.
Check that the cable pulls from the reel freely and returns the
same way, and also make sure the brake is working by giving the
cable a quick jerk, the cable should also be carefully inspected for
any damage to strands, or kinks (see procedure). Because of
the nature of this type of equipment, no broken wires are permitted.
Check the status at the indicator buttons to see it the block has
arrested a fall. If this is the case the reel should be removed from
service immediately.
Check that the casing has not been damaged either due to
dropping or misuse.
safe operation of the reel, then it must be withdrawn from service and
Issued by:

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2.17 INSPECTION OF LIFTING BEAMS AND SPREADER FRAMES

1.0
The beam shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
Loose gear and detachable items such as shackles, eyebolts, wire

rope slings, chain slings, webbing slings etc. shall be inspected in
accordance with the relevant Tuboscope procedures.
Pad eyes and bolts shall be inspected to wear, distortion and
physical damage.
Load attachment points for shackles and hooks shall be examined
for wear, elongation and distortion (shackles must be removed to
ensure thorough examination).
Ensure all bolt connections are secure.
Check length of beam for distortion.
Check for localised physical damage paying particular attention to
dents in hollow section, localised buckling and to the flanges of
structural steel.
Check for corrosion damage.
Ensure all welds are free from cracks and distortions.
Check markings and safe working load for legibility and that the
information corresponds with the load test certificate.
safe use of the spreader beam, then it must be withdrawn from service
2.18 INSPECTION OF RUNWAY BEAMS AND SWING JIBS

1.0
The beam shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
Issued by:
The safe working load and Identification marking is legible and

corresponds with the Test Certificate.
Examine running surface, joints, radius sections and turntables for
damage.
All bolts, washers and locking devices must be checked for
security and where doubt exists concerning wear or corrosion a
sample bolt shall be removed for further investigation.
The operation of the appliance used on the beam must be
checked to ensure that it is suitable for use with the beam.
The safe working load of the appliance does not exceed that of
the beam.
Ensure all end stops are secure and effective and that the flange
of the trolley wheels does not operate on the end stops.

2.0
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safeuse of the beam, then it must be reported to prevent its further use
2.19 INSPECTION OF ELECTRIC AND PNEUMATIC CHAIN HOISTS

1.0

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
2.0
Check power feed supply system for freedom of operation,

damaged or loose cables or hoses.
The control pendant for damaged or loose cables or loose hose
connections. Positive operation i.e. clear identification of direction
of control, security of carrier rope.
The load chain for wear, damaged links, stretch and lubrication.
Security of chain anchor point.
Pocketed load wheel for debris, freedom of operation and wear.
Wear on chain stripper.
Positive operation and correct adjustment of brake.
Correct adjustment of overload device if fitted.
Correct operation of limit switches if applicable
BOTTOM BLOCK
1.10.1 Security of chain attachment if single applicable.
1.10.2 Freedom of operation of roller if multi-fall.
1.10.3 All fastenings are secure.
Both bottom and top hook (if fitted) for stretch, nicks, gouges,
excessive wear in saddle are mountings and effectiveness of
safety catch.
Ensure casing of hoist is free from damage or oil leaks from gear
box and check security of mountings.
safe use of the machine, then it must be withdrawn from service and the
details recorded in the Inspection Report.
2.20 INSPECTION OF SWIVELLING OVERHAUL BALLS AND SWIVELS

1.0
Check the Safe Working Load and Identification Marking is legible and
corresponds with the Test Certificate
1.1
1.2
Issued by:
Check that there is no excessive play on swivel and that the

swivel turns freely on the ball bearings.
Check that the eye or clevis is not worn or deformed beyond the
maximum 8% of the original diameter.

1.3
1.4
1.5
2.0
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Check that all grease nipples are clear and have not been
damaged while in service.
Check that all holing bolts are firmly secured.
Check that the safety hook (if fitted) has no excessive wear and
that safety catch is working properly, as per procedure B/13.
safe operation of the overhaul ball / swivel, then it must be withdrawn
from service and details recorded in Inspection Report.
2.21 INSPECTION OF CRANES

1.0 Due to the wide range of items and functions to be checked, such a formal
inspection must be accompanied by a SERVICE INSPECTION CHECK
LIST (see attached), this must be submitted along with inspection reports.
The check list ensure that all vital areas of the crane receives the necessary
inspection.
2.0 Whenever considered necessary, the visual examination may be
supplemented by methods of non-destructive testing that will determine the
condition of any part of the crane. In order to facilitate visual examination and
ascertain extend of damage it may be considered necessary to have parts of
the crane dismantled. The work must only be carried out by skilled
personnel. The examination shall cover, but not be restricted to, the following
areas:
3.0 CHECKS ON BOOM
3.1 Inspect the entire boom for straightness and for any evidence of
physical damage, such as cracking, bending or deformation. Pay
particular attention for signs cracking or flaking paint as this may
indicate yielding of the metal, which may precede failure.
3.2 Check all cords and struts for damage for damage, cracking, bending
or excessive corrosion. No damage to the main cords is permissible,
although a small amount of damage to the lattice work is allowed
(max 3 struts in any section) as long as the damage to the strut and
strut roots is not in the 'Picture Frame Area' which is regarded as
critical.
3.3 Check top of boom for any signs of damage caused by main block.
3.4 Check all connecting pins for wear, damage and distortion, also
ensure that cotter pins are installed.
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3.5 Check boom foot pins for wear, this can be done by putting the boom
into the rests and slewing back and fore if excess movement is
observed then pins may be worn, also boom foot and housing should
be checked for signs of cracking.
4.0 CHECKS ON MACHINERY
4.1 Check all bolts and rivets for corrosion, wear, damage and security.
Any loose or missing bolts should be replaced, not re-tightened as
there is a good chance that they have been stretched.
4.2 Inspect for excessive wear on brake and clutch system, parts, linings,
pawls and ratchets. Ensure that all safety pawls operate correctly and
are in good condition, free to move and sufficiently lubricated.
4.3 Hydraulic and pneumatic systems should be inspected for
deterioration. If any of the following faults are noted then the faulty
part should be replaced.
4.3.1 Oil and air leaks or the surface of flexible hoses or at the
points at which the hose joins the metal end couplings.
4.3.2 Abnormal deformation of the outer covering of hydraulic
hose, including any enlargement, local or otherwise.
4.3.3 Any leakage at connections which cannot be remedied by
normal tightening.
4.3.4 Signs of abrasion on the wall of any hose or tube, which
could reduce their pressure retaining capabilities. It is also
important to eliminate the cause of the abrasion.
4.4 Check all rope drum assemblies for wear and / or damage in score,
damaged or worn bearings and journals. Ensure that at least three full
wraps of rope remain on the drum in all service conditions.
4.5 Ensure that the drum end of the rope is securely anchored to the
drum by a means approved by either the crane or rope manufacturer,
and also that it is clear of the rope windings.
4.6 Inspect all indicators, including those for load and jib angle, and
automatic safe load indicators, for any significant inaccuracies.
5.0 WIRE ROPE CHECKS
5.1 All wire ropes used on the crane shall be inspected in accordance
with ISO 4309 over the their entire length for the following defects,
paying particular attention to the sections that pass through the block
or over the pulleys, form part of the rope that lies on a compensating
pully, is continually exposed to the elements or may be subject to
regular abrasion.
5.1.1 Check for corrosion, kinks, broken wings, changes in rope
diameter, wear, heat damage and lack of lubrication.
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5.1.2 Check terminal fittings for wear, damage and distortion.

Also for signs of overloading (i.e. collapsed thimbles).
Ensure all wedge and socket terminations are as per BS
7166 : 1989.
5.1.3 Examine wire rope test certificate to ensure rope is the
correct size, capacity a construction for the crane.
5.2 Deterioration normally results from a combination of several defects
occurring simultaneously giving a cumulative effect. The overall effect
should be taken into consideration when deciding if a wire rope
should continue in service. However the following defects would result
in the rejection of the rope.
5.2.1 Total number of broken wires in one lay length must not
exceed six.
5.2.2 Total number of broken wires in one stand in one lay length
must not exceed three.
5.2.3 Total number of broken wires in a measured length of ten
rope diameters must not exceed 5% of the number of wires
in the rope.
5.2.4 No broken wires are permitted where the rope enters the
termination.
5.2.5 Wear must not exceed 10% of the original diameter for a
six stand rope and 3% for a multi stand rope.
NOTE: Any broken wire found in the course of the
examination, which do not constitute rejection shall be
broken off in the lay of the rope and their location noted for
future reference.
5.3 The Reeving configuration of the crane must be checked against the
manufacturers schematic, which shall be provided by the operator
prior to the inspection. Particular attention should be paid to any area
where rope could come into contact with the crane structure during
the travel of the jib.
6.0 CHECK ON BOTTOM BLOCK AND SHEAVES
6.1 The blocks and all sheaves shall be checked for the following defects:
6.1.1 The safe working load and Identification marking is legible
and corresponds with Test Certificate.
6.1.2 Wear / fracture in eye of block.
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6.1.3 Wear / fracture in shank of head fitting. Where the shank of

the head fitting has been welded to the collar or nut, then
the wear on the shank shall be determined by rotating the
head fitting, the wear shall not exceed a maximum of 1.5
mm to 25 mm shank diameter, or shank bent.
6.1.4 Side plates distorted or chaffed.
6.1.5 Fracture leading form centre pin holes.
6.1.6 Side straps distorted or torn.
6.1.7 Bush worn, distorted or fractured.
6.1.8 Sheaves, chipped fractured and worn in score or at sheave
edge.
6.1.9 Check that all oil and grease ways in pin and bush, sheave
and shell are clear.
Becket worn, distorted, or fractured (also ensure it is the correct size for load to
be applied to it).
2.22 INSPECTION OF PADEYES
1.0 The procedure describes the method of inspection of padeyes before being
put into use for the first time, after any major alteration or repair and
inspection at intervals not exceeding six months thereafter.
2.0 THOROUGH EXAMINATION
2.1 The examination must be carried out in adequate light, free from
shadow.
2.2 The padeyes must be cleaned and free from delertious matter.
2.3 Identification marks and safe working loads shall be checked against
the test certificate and where markings have become illegible they
must be re-stamped.
2.4 The padeye will be examined for the following defects:
2.4.1 Ensure eye is smooth and free from nicks, gouges and any
other defects that could act as stress raisers.
2.4.2 Check padeye for wear, distortion, elongation and signs of
cracking.
2.4.3 Check all welds and heat affected zones for signs of
cracking also weld profile for correctness.
2.4.4 Check supporting steel work for signs of damage, distortion
and overloading.
2.5 Where the inspection engineer has reason to doubt the integrity of the
padeye of the supporting steel work, then he may carry out N.D.T.
examination to ensure they are free from defects.
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3.0 CERTIFICATION AND REPORTS

Only after the inspection engineer is fully satisfied that the padeye and its
supporting steel work is fit for purpose will be issue the certification.
2.23 THOROUGH EXAMINATION OF LIFEBOAT DAVITS
1.0 This procedure relates to the thorough examination of Lifeboat Davits carried
out by a competent inspection engineer offshore, either on a production
platform or drilling rig.
2.0 The examination will be carried out in compliance with SI 2307 : 1998 and SI
486 : 1977.
3.0 Each installation shall be thoroughly examined at six monthly intervals
unless it has been subject to repair or newly installed when a full function
test, statistic test and proof load test will be carried out.
4.1 The examination should be carried out in adequate lighting.
4.2 The information on the identification plate shall be checked against
the current test certificate and D.O.T. certificate.
4.3 All ancillary equipment shall be checked for identification numbers
and checked against the relevant certificate for each item.
4.4 All parts should be clean and free from delerious matter
4.5 Examination should include:
4.5.1 All bolts - check for tightness, cracks and gouges.
4.5.2 All welds - check for cracks and gouges (if necessary carry
out M.P.I. tests).
4.5.3 Check for distortion of structure and alignment of structure
and alignment of sheaves, winches etc.
4.5.4 Check profile of sheaves for wear and imprinting.
4.5.5 Check sheaves for cracks.
4.5.6 Ancillary equipment (hang-off pennants, hooks, shackles
etc. shall be examined in accordance with the relevant
procedures).
4.6 FUNCTION TEST
4.6.1 In addition to the thorough examination, a functional test
will include:
4.6.2 Full operation of the launching system with a test load
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equal to 1.1 times the S.W.L. of the system.

4.6.3 For this test, it will be assumed that at passenger is 75 kg
and the test load calculated accordingly. The load should
be evenly distributed.
4.6.4 During operation, the system shall be checked for smooth
operation of the winch, sheaves and davit arms (if
appropriate) and ancillary equipment operates correctly.
4.6.5 Controls operate correctly and are correctly labelled.
4.6.6 A thorough examination shall be carried out before and
after the functional test.
4.7 WINCH TEST
4.7.1 The winch will be tested in accordance with the relevant
procedures, at a proof load equal to 1.5 times the S.W.L. of
the winch.
4.8 STATIC TEST
4.8.1 The static test will be carried out on each davit by hanging
off a test load equal to 2.2 x S.W.L. of the davit. The load
should be held for a minimum of five minutes.
4.8.2 Following removal of the load, the davit should be
thoroughly examined as per 4.1. The structure should not
be permanently distorted following the static test.
5.0 CERTICFICATION AND REPORTS
Certification and reports in compliance with SI 2307 shall be issued in
accordance wit the appropriate procedure.
6.0 NOTES:
6.1 SI 486 required that a life saving appliance offshore should be
examined by D.O.T. every two years. Therefore the inspector should
confirm that the D.O.T. certificate is valid.
6.2 The inspector must exercise care for his safety and others during the
examination and any tests. The location of lifeboat davits may be
hazardous. Functional test should only be carried out in favourable
weather.
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2.24 INSPECTION OF WINCHES

1.0
The winch shall be checked for the following defects:

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
Check power or air supplies for security, damaged hoses or

couplings. Check all pipework and hoses for leaks or damage.
Check that the control lever operates freely and smoothly. Ensure
that it returns smartly back to the neutral point of release.
Check the mounting for deformation, cracks or looseness. Check
all bolts for security and examine any welds for cracks or damage.
Check the winch structure for deformation, distortion or any signs
of cracks or damage.
Check the brake mechanism for smoothness of operation and that
all pins and leakages are not bent or worn.
Check brake linings for wear or glazing. Also check for
contamination from oil or grease.
Check the brake drum for scoring, glazing, pitting or contamination
from oil or grease.
Inspect any wire rope fitted as per procedure
Check the motor and gearbox for leaks and condition. Run the
winch and listen for irregular sounds, which may be an indication
of wear or internal damage.
Verify operation and setting of any limits, if fitted, by function test
through hoist and lower modes.
NOTE: Function test means physically operate the winch until the
limit is activated by normal use i.e. raise winch until limit trips.
Then repeat by lowering to check bottom limit. If a new rope has
been fitted, ensure that the limits have been re-set.
1.11
1.12
2.0
Check markings and safe working load are legible and

corresponds with the test load certificate.
Check that type of use i.e. manriding or utility, is clearly marked on
the winch.
.
safe use of the item of lifting equipment, then it must be withdrawn from
service and details recorded on the Inspection Report.
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2.25 HARNESS / LANDYARD INSPECTION CHECKLIST

CLIENT
W/O:
HARNESS / LANDYARD INSPECTION CHECKLIST

Type:
ID Number(s)
Amount:
1) Stitching is unbroken and contrasts in colour with Webbing Straps
&
2) Webbing Straps / Rope are free from chemical contamination, fraying,

cuts and abrasions.
&
3) D Rings are free of corrosion, distortion, cracks, burrs and nicks.
&
4) Adjustment and fastening buckles operate correctly and in good order.
&
5) Details on label are clearly legible.
&
6) Strap belts are in good order.
&
Passed inspection:
Name of Inspector
Signature
Date
REASON(S) FOR FAILING INSPECTION
Failed inspection:
Issued by:
Name of Inspector
Signature
Date

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2.26 INSPECTION OF FORKLIFTS

1.1 Forklifts shall be checked for the following defects:
1.2 Check the load chain for stretch and wear using 2% elongation and 8% wear
as rejection criteria.
1.3 Check the load chain for seized links playing particular attention to the
connection to the load carriage.
1.4 Check all load chain pins for wear or deformation.
1.5 Check chain rollers for wear or damage.
1.6 Check all hydraulic hoses and connectors for leaks wear or external physical
damage.
1.7 Check all hydraulic cylinders for wear, scoring, pitting, corrosion or
deformation.
1.8 Check hydraulic ram seals for oil leaks.
1.9 Check mast cap for wear or damage and securing pin tightness.
1.10
Check mast bearing for wear or damage.
1.11
Check that tilt rams operate equally.
1.12
Check the carriage structure for wear, cracks, damage or distortion.
1.13
Check all structure rollers for wear, seizure or damage.
1.14
Check forks for wear, cracks, nicks or other damage.
1.15
Check both forks for distortion and alignment.
1.16
On steering wheels check track rod ends for wear and play.
1.17
Check track rod ends and steering arms for damage.
1.18
Check rear axle pivot for free movement and lubrication.
1.19 Check condition of wheels and tyres for damage and wear.
Check wheel retaining bolts for tightness, hammer test if necessary.
Note:
All rejection criteria is in accordance with both manufacturers recommendations
and the relevant European Standard.
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3.0 Repair Procedures

3.1 REPAIR OF CHAIN BLOCKS
1.0
2.0
Prior to commencement of work the machine shall be identified against

customer manifest. The identification mark and Safe Working Load are
checked to ensure they are both legible and correct.
The machine shall be dismantled all components degreased cleaned and
checked in accordance with service inspection check list for the following
defects:
2.1
REMOVE HAND CHAIN WHEEL COVER.

2.1.1 Examine cover for cracks, distortion and broken parts
2.1.2 Check pitch of hand chain in hand wheel.
2.1.3 Check free running of hand wheel.
2.2
REMOVE HAND CHAIN

2.2.1 Examine hand chain for wear, nicks and corrosion.
2.3
REMOVE HAND WHEEL (ANTI CLOCKWISE THREAD)

2.3.1 Examine for wear, damage or screwed thread and damage
to edges.
2.4
REMOVE BRAKE ASSEMBLY

2.4.1 Examine splines, threads and ratchet teeth for wear and
damage.
2.4.2 Examine outside surface of ratchet ring to ensure it is
smooth and flat.
2.4.3 Check fit of ratchet ring bush and screwed sleeve.
2.4.4 Replace friction washers.
2.5
REMOVE LOAD CHAIN DEAD END PIN

2.5.1 Examine anchor pin for distortion and wear.
2.6
REMOVE BOTTOM HOOK FROM LOAD CHAIN

2.6.1 Examine load pin for distortion and wear.
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2.6.2 Check that hook swivels freely and there is no excessive

wear on the shank.
2.6.3 Check hook for stretch, distortion and wear.
2.6.4 Check latch kit operates correctly
2.7
REMOVE GEAR COVER

2.7.1 Examine cover for cracks, distortions and broken parts.
2.8
REMOVE SPUR GEARS AND DRIVE PINION

2.8.1 Examine all gears for wear, fracture and alignment.
2.8.2 Examine drive pinion for damage and distortion.
2.9
REMOVE LOAD CHAIN

2.9.1 Clean load chain in rumbler.
2.9.2 Check load chain for bent, notched, stretched worn or
corroded link.
2.10
SPLIT BODY PLATES (This will remove to hook cross bar)

2.10.1 Examine body plates for alignment and ensure they are
free from wear and distortion.
2.10.2 Examine top hook and cross bar for hook opening, wear in
shank and seating also that it swivels freely.
2.10.3 Check latch kit operates freely.
2.11
REMOVE CHAIN ROLLERS AND STRIPPER

2.11.1 Examine chain roller and pin for wear or damage.
2.11.2 Examine chain stripper for wear and damage.
2.12
REMOVE LOAD WHEEL SPROCKET

2.12.1 Check load wheel pockets for wear and damage.
2.12.2 Check seating of load chain and load wheel.
3.0
After the components have been thoroughly examined and where

necessary replaced they can now be re-greased, oiled and reassembled.
Prior to the close up operation the quality control inspector or an
independent test engineer shall examine the unit to ensure all parts have
been assembled correctly paying particular attention to all load pins,
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anchor pins and brake assemblies. Only when he is satisfied that all
internal parts are fitted as per manufacturers instructions, does he sign
the appropriate box on the job card.
4.0
The Chain Block is now ready for Proof Load Testing final examination,
painting and plating.
4.1
4.2
4.3
4.4
4.5
4.6
The proof load test and final examination is carried out by the
Foreman or a test engineer appointed by him.
The chain block is proof load tested to 1.5x W.L.L. with a
suspended load, which should be raised through a sufficient
distance for every part of the mechanism to carry the overload i.e.
every tooth in every gear train. This distance varies according to
the gear ration, but normally a distance of 12" to 18 will suffice. A
light load test of 5% W.L.L. will also be applied.
Repeat 4.2 to ensure brake settings are correct.
The chain block is now re-examined for any defects, which may
have been exposed during proof test. If none are found, the job
card is completed and the block plated.
Every chain block, which has been repaired and proof load tested
shall be fitted with a new test plate. This plate contains the
following information: safe working load, identification number and
test date (the test date must be stamped using two digits for
month and year).
Every chain block will be given a final examination by the works
supervisor.
3.2 OVERHAUL, REPAIR AND TEST CHAIN LEVER HOISTS

1.0
2.0

The machine shall be dismantled all components degreased cleaned and
defects:
2.1
REMOVE LEVER ASSEMBLY

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
Issued by:
Check lever for distortion and cracks.

Check correct operation of pawl changing operation.
Examine pawl for wear.
Examine fit of pawl to stud.
Examine pawl spring for fractures.

2.2
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REMOVE BRAKE ASSEMBLY

2.2.1 Examine splines, threads and ratchet teeth for wear and
damage.
2.2.2 Examine outside surface of ratchet ring to ensure it is
smooth and flat.
2.2.3 Check fit of ratchet ring bush and screwed sleeve.
2.2.4 Replace friction washers.
2.3

2.3.2 Check that hook swivels freely and there is not excessive
wear on the shank
2.3.3 Check hook for stretch, distortion or wear.
2.3.4 Check latch kit operates correctly.
2.4
REMOVE LOAD CHAIN DEAD END PIN OR STOPPER

2.4.1 Check load pin for distortion or wear.
2.4.2 Check stopper for distortion and effectiveness.
2.5

2.5.2 Check that hook swivels freely and there is no excessive
wear on the shank.
2.5.3 Check hook for stretch, distortion and wear.
2.5.4 Check latch kit operates correctly.
2.6
REMOVE REAR GEAR COVER

2.6.1 Examine cover for cracks, distortion and broken parts.
2.7
REMOVE SPUR GEARS AND DRIVE PINION

2.7.1 Examine all gears for wear, fracture and alignment.
2.7.2 Examine drive pinion for damage and distortion.
2.8
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REMOVE LOAD CHAIN

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2.8.1 Clean load chain in rumbler.

2.8.2 Check load chain for bent, notched, stretched, worn of
corroded links.
2.9
SPLIT BODY PLATES

2.9.1 Examine body plates for alignment and ensure they are
free from wear and distortion.
2.9.2 Examine top hook and cross bar for wear in shank, hook
opening, seating and that is swivels freely.
2.9.3 Check latch kit operates freely.
2.10
REMOVE CHAIN ROLLERS AND STRIPPER

2.10.1 Examine chain roller and pin for wear or damage.
2.10.2 Examine chain stripper for wear or damage.
2.11
REMOVE LOAD WHEEL SPROCKET

2.11.1 Check load wheel pockets for wear and damage.
2.11.2 Check seating of load chain in load wheel.
3.0
After the components have been thoroughly examined, and where

necessary replaced, they can now be re-greased, oiled and
reassembled. Prior to the close up operation the quality control inspector
or an independent test engineer shall examine the unit to ensure all parts
have been assembled correctly paying particular attention to all load pins,
anchor pins and brake assemblies. Only when he is satisfied that all
internal parts are fitted as per manufacturers instructions, does he sign
4.0
The pull lift is now ready for proof load testing, final examination and
plating.
4.1
4.2
Issued by:
Foreman or a test engineer appointed by him.
The pull lift is proof load tested to 1.5 x W.L.L. with a suspended
load, which should be raised through a sufficient distance for
every part of the mechanism to carry the overload i.e. every tooth
in every gear train. This distance varies according to the gear
ration, but normally a distance of 12" to 18 will suffice.

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4.3
4.4
Repeat 4.2 to ensure brake settings are correct.

The pull lift is now re-examined for any defects, which may have
been exposed during the proof test. If none are found the work
order is completed and the pull lift plated.
4.5
Every pull lift, which has been repaired and proof load tested shall
be fitted with a new test plate. This plate contains the following
information: safe working load, identification number and test date
(the test date must be stamped using two digits for month and
year).
Every pull lift will be given a final examination by the works supervisor.
3.3 OVERHAUL, REPAIR AND TEST TIRFOR MACHINES
1.0
2.0

The machine shall be dismantled all components degreased, cleaned
and checked in accordance with service inspection check list for the
following defects:
2.1
REMOVE SIDE OPERATINGLEVER OR ANCHOR PIN

2.1.1 Check shear pins for distortion.
2.1.2 Check lever for distortion.
2.1.3 Check anchor pin is not bent or excessively worn
2.2
REMOVE ONE SIDE OF BODY CASING

2.2.1 All nuts, bolts and screws must be checked for distortion.
2.2.2 Rope guide to be examined for wear.
2.2.3 Anchor hooks to be examined for wear, distortion wear to
shank, stretch and operation of safety catch.
2.3
REMOVE COMPLETE INTERNAL MECHANISM

2.3.1
2.3.2
2.3.3
2.3.4
Check all ball bearings and bushes in frame.

Check both side castings for damage.
Connecting side bars must be straight.
Release lever to be checked for damage as this protrudes
from the body and is easily damaged.
2.3.5 Check that two speed mechanism functions satisfactorily.
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2.3.6 Check jaws and half-moon plates for wear and damage
(using special jig)
2.3.7 Ensure spring has correct compressive strength.
3.0

necessary replaced, they can now be re-greased, oiled and
reassembled. Prior to the close up operation the quality control inspector
or an independent test engineer shall examine the unit to ensure all parts
have been assembled correctly paying particular attention to all load pins,
anchor pins, springs and connecting rods. Only when he is satisfied that
all internal parts are fitted as per manufacturers instructions, does he sign
4.0
The tirfor is now ready for proof load testing, final examination and
plating.
4.1
Foreman or a test engineer appointed by him (under no
circumstances shall the engineer, who carried out the repairs, test
and examine his own work).
4.2
The tirfor is proof load tested to 1.5 x W.L.L. with a suspended
load, which is raised through a sufficient distance to check the
operation and holding power of both jaws a distance of 3 to 6 is
quite adequate.
4.3
The tirfor is now re-examined for any defects, which may have
been exposed during the proof test. If none are found the work
order is completed and the tirfor plated.
4.4
Every tirfor, which has been repaired and proof load tested shall
year).
Every tirfor will be given a final inspection by the works supervisor.
Issued by:

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3.4 OVERHAUL, REPAIR AND TEST SINGLE MULTI-SHEAVE BLOCKS

1.0
2.0
Prior to commencement of work the beam trolley shall be identified

against customer manifest. The identification mark and Safe Working
Load are checked to ensure they are both legible and correct.
The beam trolley shall be dismantled all components degreased, cleaned
following defects:
2.1
REMOVE NUTS AND ADJUSTING WASHERS FROM SIDE

PLATES
2.1.1 Check cross bolts for damage to thread, distortion and
wear.
2.1.2 Check side plate for distortion.
2.1.3 Check suspension plates for wear and distortion.
2.2
REMOVE RUNNERS FROM SIDE PLATE

2.2.1 Check bearings for damage and wear.
2.2.2 Check bearing studs from wear and distortion.
2.2.3 Check runners for free running and the outside for damage
and wear.
(GEARED TROLLEYS)
2.3
REMOVE HAND WHEEL AND HAND CHAIN

2.3.1 Check hand chain wheel for wear and damage to edges.
2.3.2 Ensure hand chain is the correct pitch for hand wheel.
2.3.3 Check hand chain for wear (8% of link diameter) nicks,
corrosion and stretch.
2.3.4 Check travel shaft and geared runners for evidence of wear
and broken or deformed teeth.
3.0

necessary replaced, they can now be re-greased, oiled, reassembled
and painted. The work order is then completed and signed by the
engineer.
4.0
The beam trolley is now ready for proof load testing, final examination
and plating.
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4.1
4.2
The beam trolley is proof load tested to 1.5 x W.L.L. (or as per
manufacturers recommendations).
4.3
The trolley is now re-examined for any defects, which may have
been exposed during the proof load test. If none are found the
work order is completed and the trolley plated.
4.4
Every trolley, which has been repaired and proof load tested shall
year).
Every trolley will be given a final examination by the works supervisor.
3.5 OVERHAUL, REPAIR AND TEST BEAM TROLLEYS
1.0
2.0
Prior to commencement of work the beam trolley shall be identified

The beam trolley shall be dismantled all components degreased, cleaned
following defects:
2.1
REMOVE NUTS AND ADJUSTING WASHERS FROM SIDE

PLATES
2.1.1 Check cross bolts for damage to thread, distortion and
wear.
2.1.2 Check side plate for distortion.
2.1.3 Check suspension plates for wear and distortion.
2.2
REMOVE RUNNERS FROM SIDE PLATE

2.2.1 Check bearings for damage and wear.
2.2.2 Check bearing studs from wear and distortion.
2.2.3 Check runners for free running and the outside for damage
and wear.
(GEARED TROLLEYS)
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REMOVE HAND WHEEL AND HAND CHAIN

2.3.1 Check hand chain wheel for wear and damage to edges.
2.3.2 Ensure hand chain is the correct pitch for hand wheel.
2.3.3 Check hand chain for wear (8% of link diameter) nicks,
corrosion and stretch.
2.3.4 Check travel shaft and geared runners for evidence of wear
and broken or deformed teeth.
3.0

engineer.
4.0
The beam trolley is now ready for proof load testing, final examination
and plating.
4.1
4.2
The beam trolley is proof load tested to 1.5 x W.L.L. (or as per
manufacturers recommendations).
4.3
The trolley is now re-examined for any defects, which may have
been exposed during the proof load test. If none are found the
work order is completed and the trolley plated.
4.4
Every trolley, which has been repaired and proof load tested shall
year).
Every trolley will be given a final examination by the works supervisor.
3.6 OVERHAUL, REPAIR AND TEST BEAM CLAMPS
1.0
2.0
Prior to commencement of work the beam clamp shall be identified

The clamp shall be dismantled all components degreased, cleaned and
defects:
2.1
Issued by:
REMOVE LOAD PIN AND SUSPENSION SHACKLE

2.1.1
2.1.2
2.1.3
2.1.4
2.2
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Examine nut for damage to thread.

Examine load pin for wear and distortion.
Examine spacer and washers for damage.
Examine suspension shackle for wear, damage and
distortion.
UNSCREW INNER SECTION FROM SCREWED BAR

2.2.1 Examine for distortion or wear.
2.2.2 Examine jaw for distortion or wear if swivel jaw fitted
ensures it moves freely.
2.2.3 Examine R.H. tread swivel nut for wear.
2.3
REMOVE HANDLE FROM SCREWED ROAD AND UNSCREW

OUTER SECTION
2.3.1 Examine outer section for distortion and wear.
2.3.2 Examine jaw for distortion and wear if swivel jaw fitted
ensures it moves freely.
2.3.3 Check threads in screwed bar for damage and wear ensure
screwed bar is straight.
2.3.4 Examine L.H. thread swivel nut for wear.
2.3.5 Examine tommy bar in handle for damage.
3.0

engineer.
4.0
The beam clamp is now ready for proof load testing, final examination
and plating.
4.1
4.2
4.3
Issued by:
The beam clamp is proof load tested to 2 x W.L.L.
The beam clamp is now re-examined for any defects, which may
have been exposed during the proof load test. If none are found
the job card is completed and the clamp is plated.

4.4
4.5
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Every beam clamp, which has been repaired and proof load
tested shall be fitted with a new test plate or hard stamped. This
plate contains the following information: safe working load,
identification number and test date (the test date must be stamped
using two digits for month and year).
Every beam clamp will be given a final examination by the works
supervisor.
3.7 OVERHAUL, REPAIR AND TEST OF PNEUMATIC HOISTS

1.0
2.0

The machine shall be disassembled all components degreased, cleaned
and checked in goof lighting and in accordance with service inspection
check list.
2.1
CONTROL SYSTEM
2.1.1
2.1.2
2.1.3
2.1.4
2.2
Check control mechanism for damage and integrity.

Check for damaged or loose hose connections.
Ensure a positive "OFF" position can be obtained.
Check control shaft for damage, wear and distortion.
MAIN VALVE AND MOTOR

2.2.1 Check valves and motor for damage and leaks.
2.2.2 Check all springs, levers, gears and seals for wear,
fractures and integrity.
2.2.3 Check motor is free running.
2.2.4 Check vanes, rotor and cylinder for wear, damage or
fractures. Replace vanes if necessary.
2.3
LOAD CARRYING SYSTEM

2.3.1 Check top hook for stretch, nicks, gouges, excessive wear
in saddle, excessive wear in mountings, security in
mounting and correct operation of safety catches. Replace
parts if required.
2.3.2 Check casing for damage, cracks, wear and integrity of
mountings.
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2.3.3 Check load wheel and chain stripper for damage and wear
ensure chain engages correctly.
2.3.4 Check anchor pin for straightness, security and wear (max
8%).
2.3.5 Check load chain freedom of operation, wear (max 8%)
stretch (max 2% increase in length of chain), nicked,
gouged or damaged links, lack of lubrication and corrosion.
2.3.6 Check bottom block for security of anchor pin, anchor pin
wear (max 8%). Freedom of operation of roller (if multi-fall)
security of fastenings.
2.3.7 Check bottom hooks for stretch, nicks, gouges, excessive
wear in saddle, excessive wear in mountings, security in
mounting and correct operation of safety catch.
2.3.8 Overload device (if fitted) and limit switch should be
checked for correct operation.
2.4
TRANSMISSION SYSTEM
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.5
Check gearbox for damage and oil leeks.

Ensure system is smooth running.
Check bearings are free running.
Check gears for damage and wear.
Check transmission shaft for damage, distortion and wear.
Ensure system is adequately lubricated.
BRAKING SYSTEM
2.5.1 Check brake linings for wear, damage and contamination.
2.5.2 Check for positive operation as per manufacturers
specification adjusts if necessary.
3.0

necessary replaced, they can now be re-greased, oiled, reassembled.
Prior to the close up operation the quality control inspector or and
independent test engineer shall examine the unit to ensure all part have
been assembled as per manufacturers instructions, he now signs the
appropriate box on the job card.
4.0
The hoist is now ready for proof load testing, final examination, painting
and plating.
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4.1
4.2
4.3
4.4
4.5
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The hoist is proof load tested to 1,25 x W.L.L. with a suspended
load, which is raised and lowered at full speed, through a distance
sufficient to ensure that every tooth in every gear train is subjected
to overload.
The hoist is now re-examined for any defects, which may have
been exposed during the proof load test. If none are found the job
card is completed and the hoist painted.
Every hoist, which has been repaired and proof load tested shall
be fitted with a new test plate. This plate shall contain the following
year).
Every hoist will be given a final examination by the works
supervisor prior to despatch.
4.0 Test Procedures

4.1 TEST OF CHAIN BLOCKS
1.0 EXAMINTION
1.1 A thorough examination of the piece of equipment shall be carried out
as per Tuboscope
2.0 TESTING
2.1 If, during the course of the examination, no fault are found which
would affect the safe working load of the equipment then a proof load
test may be carried out as follows:
2.1.1 A proof load equal to the working load limit of the piece of
equipment plus 50% shall be raised just clear of the ground
and a check made of the load bearing points.
2.1.2 If no defects are apparent then the load shall be raised
through a height of lift, which will ensure that every part of
the block mechanism and each tooth of the gears comes
under load. This load shall be maintained for a period of
five minutes.
2.1.3 On releasing the proof load, the piece of equipment shall
be examined as per section 1.0.
2.1.4 A light load test of between 2% and 5% of the working load
limit shall be raised and lowered through a height of
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between 250mm and 500mm. When the hand chain is

released during the raising or lower operation the brake
shall hold the weight.
3.0 MARKING
3.1 If the item is not already marked, it shall be clearly stamped or
marked with an identification number and it the test is satisfactory, the
safe working load and date of the test.
4.0 REPORTING
4.1 The written report shall contain the following information:
4.1.1 Unique identification number
4.1.2 A full description of the piece of equipment including make,
model and height of the lift
4.1.3 Safe working load
4.1.4 Proof load applied
4.1.5 Date of test and examination
4.1.6 Name and address of company performing the test and
examination
4.1.7 Act or regulation under which the test and examination was
carried out
5.0 DEFECTIVE EQUIPMENT
Where the test is not satisfactory, a responsible representative of the user
shall be informed by means of a defect report. If the test engineer considers
the defect of a dangerous nature then arrangements must be made for its
immediate withdrawal from service.
4.2 TEST OF PULL LIFTS
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
2.1 If during the course of the examination, no faults are found which
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and a check made of the load bearing parts.
the pull lift mechanism and each tooth of the gears come
under load. This load shall be maintained for a period of
five minutes.
2.1.3 On releasing the proof load the piece of equipment shall be
examined as per section 1.0.
3.0 MARKING
4.0 REPORTNG
examination
4.1.7 Act or regulation under which the test and examination was
carried out
5.1 Where the test is not satisfactory, a responsible representative of the
user shall be informed by means of a defect report. If the test engineer
considers the defect of a dangerous nature then arrangements must be
made for its immediate withdrawal from service.
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4.3 TEST OF TIRFOR MACHINES

1.0 EXAMINATION

as per Tuboscope
2.0 TESTING
2.1 If, during the course of the examination, no faults are found which
the tirfor mechanism comes under load. This load shall be
maintained for a period of five minutes.
3.0 MARKING
4.0 REPORTNG
examination
4.1.7 Act or Regulations under which the test and examination
was carried out
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user shall be informed by means of a defect report. If the test
engineer considers the defect of a dangerous nature then
arrangements must be made for its immediate withdrawal from
service.
4.4 TEST OF SHEAVE BLOCKS
0.0 EXAMINATION
as per Tuboscope
1.0 TESTING
would affect the safe working load of the sheave then a proof load as
listed below may be applied as follows:
1.1.1 Single sheave block and multi-sheave up to 20 Ton.
Working load limit on head fitting or hook + 100%
1.1.2 Multi sheave blocks 20 Ton, up to 40 Ton. Working load
limit + 20 Ton.
1.1.3 Multi sheave blocks over 40 Ton. Working load limit + 50%.
1.2 Proof loads to be applied to the becket are as listed below:
1.2.1
1.2.2
1.2.3
1.2.4
Single sheave = 1/3 of the proof load applied to the block

Double sheave = 1/4 of the proof load applied to the block
Triple sheave = 1/6 of the proof load applied to the block
Four sheave = 1/8 of the proof load applied to the block
1.3 The proof load shall be applied using a suitable wire rope of the
correct diameter for the sheave groove.
1.4 The proof load shall be slowly applied and checks made to ensure
that the wire rope has engaged correctly in sheave groove. The proof
load shall be maintained for five minutes.
1.5 On releasing the proof load, the piece of equipment shall be
examined as per section 1.0
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2.0 MARKING
marked with an identification number, and if the test is satisfactory,
the safe working load on head fitting and line pull. The factor of safety
and date of the test should be also stamped.
3.0 REPORTING
model and height of lift.
3.1.3 Safe working load on head fitting and line pull
examination
was carried out
3.1.8 Factor of Safety
user shall be informed by means of a defect report. If the test engineer
considers the defect of a dangerous nature then arrangements must be
made for its immediate withdrawal from service.
4.5 TEST OF TROLLEYS
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the runway beam trolley then a
proof load test may be carried out as follows:
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2.1.1 A proof load of the working load limit of the piece of

equipment plus 50% shall be applied to the trolley.
2.1.2 The proof load shall be slowly applied and checks made to
ensure that the trolley wheels keep true alignment of the
test beam to ensure equal loading. The proof load shall be
held for five minutes.
3.0 MARKING
4.0 REPORTNG
4.1.2 A full description of the piece of equipment including make
and model
examination
was carried out
service.
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4.6 TEST OF BEAM AND PLATE CLAMPS

1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the clamp then a proof load test
may be carried out as follows:
2.1.1 All proof loads equal to the working load limit of the piece of
equipment plus 100% shall be applied and a check made
of the load bearing points.
2.1.2 The proof load shall be gradually applied, checking all
times for alignment. It is also important to use the correct
width test beam or plate thickness to prevent damage or
distortion to the clamp jaws.
3.0 MARKING
4.0 REPORTNG
and model and range plate thickness capacity
examination
was carried out
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service.
4.7 TEST OF SHACKLES, LINKS, HOOKS, EYEBOLTS AND SIMILAR
GEAR
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the unit then a proof load test
equipment plus 100% shall be applied to the item to be
tested. For shackles with a S.W.L. in excess of 35 tonnes
the proof load will be equal to 1.22 x S.W.L. + 20 tonnes
ensure satisfactory alignment of each component being
tested to prevent damage or distortion. The proof load shall
be held for five minutes.
3.0 MARKING
4.0 REPORTNG
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and model and height of lift
4.1.3 Safe working load on head fitting and line pull
examination
was carried out

service.
4.8 TEST OF CHAIN
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the unit then a proof load test
2.1.1 A proof load equal to the working load limit plus 100% shall
be applied to the chain to be tested.
ensure correct alignment and orientation of chain links. If
the length of the chain exceeds the length of the test
facility, then the chain must be repositioned and the proof
load reapplied to ensure that all sections of the chain are
tested. The proof load shall be held for five minutes.
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3.0 MARKING
3.1 If the item is not already marked, a chain tab, or similar, shall be
clearly stamped or marked with an identification number, safe working
load and date of the test and attached securely to the chain
4.0 REPORTNG
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Unique identification number

A full description of the piece of equipment
Safe working load
Proof load applied
Date of test and examination
Name and address of company performing the test and
examination
was carried out
4.1.8 Grade

service.
4.9 TEST OF WIRE ROPES ANS WIRE ROPE SLINGS
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the wire rope then a proof load
as listed below may be applied as follows:
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single sling leg or wire rope termination plus 100% shall be
applied.
ensure correct alignment and orientation of sling eyes to
prevent damage or distortion. Correct diameter pins must
be used to prevent over stretching of the sling eye or
deformation of the thimble.
3.0 MARKING
marked with an identification number, safe working load and date of
the test.
4.0 REPORTNG
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7

Number of legs and angle of use
Safe working load. If multi-leg sling then angle or angles.
Proof load applied
Name and address of company performing the test and
examination
was carried out
service.
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4.10 TEST OF CONTAINERS AND BASKETS

1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the container or basket then a
proof load test may be carried out as follows:
2.1.1 All containers and baskets shall be tested in accordance
with BS7072.
2.1.2 The proof load shall be equal to twice the gross weight of
the piece of equipment less the tare weight (the tare weight
shall include any items permanently attached to the unit).
2.1.3 The unit shall be weighed using a calibrated load cell and
the proof load to be applied will be calculated.
2.1.4 The proof load shall be applied using steel test weights, the
preferred method shall be to place the weights inside the
unit. In the event of this being impractical then they may be
suspended or placed on the unit. Extreme care must be
taken when using this method to ensure that the structure
supporting the test weights is strong enough.
NOTE: It is imperative that consideration is given to the effects of
a particular method of applying test weights to a unit by slinging.
All slings must be equally spaced to prevent point loading.
Suitable spreader plates, packers or battens should be used to
distribute the load evenly over the structural members. Care
should be taken when a sling passes over a beam flange. Ensure
that proper protection packers are used to prevent the sling cutting
and / or the flange distorting. All test loads should be applied
slowly and the test monitored continually to allow for any
repositioning or adjustment that may be required to the sling or
test weights.
2.1.5 The unit is then raised clear of the ground and suspended
for five minutes.
2.1.6 On release of the proof load an examination as per Section
1.0 shall be carried out.
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3.0 MARKING
the test as per BS 7020.
4.0 REPORTNG
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7

A full description of the container or basket
Safe working load
Tare weight
Proof load applied
Name and address of the company performing the test and
examination
was carried out
service.
4.11 TEST OF LIFTING BEAMS AND SPREADER FRAMES
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the unit then a proof load as
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2.1.2
2.1.3
2.1.4
2.1.5
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equipment plus 100% shall be applied to units with a safe

working load up to 3 Ton.
A proof load equal to the working load limit plus 3 Ton shall
be applied to units with a safe working load of 3 Ton up to 6
Ton.
A proof load equal to the working load limit plus 50 % shall
be applied to units with a safe working load of 6 Ton up to
20 Ton.
A proof load equal to the working load limit plus 10 Ton
shall be applied to units with a safe working load of 20 Ton
up to 40 Ton.
A proof load equal to the working load limit plus 25% shall
be applied to units with a safe working load over 40 Ton.
2.2 The preferred method shall be to suspend steel test weights from the
attachment points of the unit to simulate the above loading in use.
2.3 The proof load shall be raised clear of the ground and held for five
minutes.
2.4 All ancillary equipment shall be examined and tested as required in
accordance with Tuboscope
3.0 MARKING
the test.
4.0 REPORTNG
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6

Safe working load
Proof load applied
examination
was carried out
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service.
4.12 TEST OF RUNAWAY BEAMS
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
2.1 If once the preliminary inspection has been carried out and the test
engineer is satisfied that the runway and its supporting structure is
free from defects, complies with BS2853:1957 and is capable of
sustaining loads, only then can the test loads be applied.
2.2 The test load equivalent to the maximum safe working load, together
with the weight of the heaviest lifting appliance supported by the
runway shall be applied and traversed along the whole length of the
runway. The load shall be halted during its passage along the runway
and kept at rest at suitable positions, in order that stable deflection
readings may be taken and recorded. Sufficient readings shall be
taken to ensure that the maximum reading is obtained.
2.3 A proof load equivalent to the weight of the heaviest lifting appliance
by the runway plus 25% in excess of the safe working load lifted by
this appliance shall now be applied and traversed along the whole
length of the runway. A stable deflection reading shall be taken and
recorded only at the position where the maximum reading was
obtained during the appliance of the load referred to in 2.2
2.4 During the application of both the test load referred to in 2.2 and the
proof load in 2.3 the runway shall be kept under strict observation, to
ensure the ready detection of any deformation or signs of premature
failure.
2.5 After application of the test loads the runway and its supporting
structures shall be visually examined for any signs of deformation or
damage. If necessary parts may be dismantled for further
examination in order to ascertain the suitability of the runway for the
purpose it is intended.
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3.0 DEFLECTION
3.1 BS2853 Clause K4 states: The maximum measured deflection of
runway beams under the safe working load shall not exceed 1/500 of
the span. For cantilever beams the maximum measured deflection
under the safe working load shall not exceed 1/250 of the span.
3.2 It is important to note that the allowable deflection of a runway beam
refers to the beam itself and does not include any additional
deflections attributed to the supporting structure.
NOTE: Most structural engineers ignore fixing moments when designing
runway beams, for this reason it is very rare to find a runway beam
deflect the permissible 1/500 of span. If it does then the installation
should be suspect.
4.0 MARKING
4.1 The safe working load, identification number and any limiting
conditions shall be plainly and permanently marked on the runway in
a manner that makes them clearly visible to the operator.
4.2 It the beam is made from H.Y.S. Steel to BS4360 Grade 50 but this is
not marked on the beam then the manufacturer of the runway shall
stamp G 50 on the beam next to the I.D. mark.
5.0 REPORTNG
5.1 Once the final inspection has been performed and the runway found
to be satisfactory a certificate of Test and Examination can now be
issued containing the following information:
5.1.1 Identification number or mark also grade of steel used.
5.1.2 A complete description of the runway detailing the size and
length of the beam and its precise location.
5.1.3 Date when the proof load was applied and the thorough
examination carried out.
5.1.4 Proof load applied.
5.1.5 Maximum deflection recorded during application of the safe
working load and the ratio of deflection to span.
5.1.6 Maximum deflection recorded during appliance of proof load.
5.1.7 Maximum safe working load and any limiting conditions.
5.1.8 A statement that the runway complies well, BS 2853 and
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that the certificate only applies to the runway beam.

5.1.9 Name and address of maker or supplier of the runway
beam.
5.1.10 Name of company or person, who carried out the test and
examination.
5.1.11 Signature of test engineer.
6.1 When the test is not satisfactory a responsible representative of the
company shall be informed by means of a defect report. If the test
engineer considers the defect to be a dangerous nature then
arrangements must be made to ensure the runway beams cannot be
used until remedial work has been carried out and the beam tested.
4.13 TEST OF SWING JIBS

1.0 EXAMINATION
as per Tuboscope
2.0 TESTING OF OVER STRUTTED JIBS
2.1 Prior to the application of loads, the structural engineer or other
competent authority, shall have satisfied the test engineer that all
supporting structures, for wall and column mounted swing jibs, are
suitable for the loadings to be applied.
2.2 Once the test engineer has satisfied himself that the structure is
capable of supporting the load, a test load equivalent to the safe
working load shall be applied at minimum radius and the deflection
measured at the end of the jib (A)
2.3 Move the load along the jib to the end stops and measure deflection
at the end of the jib (B). This will give the actual deflection of the
cantilever section, which should not exceed 1/250 of cantilever span.
ACTUAL DEFLECTION = DEFLECTION @ B DEFLECTION @ A
2.4 The load shall be moved back to the central position of the simply
supported section of the jib and deflection readings taken at the point
(C) and at the point where the tie rod is attached to the jib (D). This
will give the actual deflection of the simply supported section of the
beam, which should not exceed 1/500 of simply supported span.
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ACTUAL DEFLECTION = DEFLECTION @ C DEFLECTION @ D

2.5 With the safe working load at the maximum radius total measured
deflection shall not exceed 1/250 of maximum radius.
NOTE: Certain manufacturers of proprietary brands work to a higher
deflection for their light weight installations, it is therefore very
important that the test engineer is made aware of this information.
2.6 With the safe working load at maximum radius the jib arm should be
rotated through 90 and deflection reading taken at the end of the jib
position (A)
2.7 The load shall be carefully run out to the maximum radius and
deflection reading taken at position (A)
2.8 Any deflections measured in excess of those recorded in 2.1 and 2.2
would indicate excessive defection of supporting steel work and
should be investigated.
2.9 If no excessive deflection occurs then the jib shall be checked with
the load at maximum radius through the full range of slew.
2.10 An overload of the safe working load plus 25% shall be applied
and the test procedure repeated. Deflection readings should be taken
at 0 and 90 and all motions checked to ensure satisfactory braking,
slewing and no tendency for the trolley to run away.
3.0 TESTING OF THE UNDER STRUTTED JIB
3.1 Testing of under strutted jib cranes shall be carried out as per section
2.0. The only exception being checking of the jib deflection criteria
which will be as follows:
3.1.1 With the safe working load at minimum radius measure
deflection at the end of the jib (A).
3.1.2 Move the load to the end stops, maximum radius, and
measure deflection at the end of the jib (B).
3.1.3 The actual deflection of the beam shall not exceed 1/250 of
the maximum radius minus the minimum radius.
4.0 MARKING
4.1 The safe working load, identification number and any limiting
conditions shall be plainly and permanently marked on the runway in
a manner that it makes them clearly visible to the operator.
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5.0 REPORTING
5.1 Once the final inspection has been performed and the runway found
to be satisfactory a certificate of Test and Examination can now be
issued containing the following information:
5.1.1 Identification number or mark and grade of steel used.
5.1.2 A complete description of the runway detailing the size and
length of the beam and its precise location.
5.1.3 Date when the proof load was applied and the thorough
examination carried out.
5.1.4 Proof load applied.
5.1.5 Maximum deflection recorded during application of the safe
working load and the ratio of deflection to span.
5.1.6 Maximum deflection recorded during application of proof
load.
5.1.7 Maximum safe working load and any limiting conditions.
5.1.8 Name and address of maker or supplier of the runway
beam.
5.1.9 Name of company or person who carried out the test and
examination.
5.1.10 Signature of test engineer
user shall be informed by means of a defect report. If the engineer
considers the defect to be of a dangerous nature the arrangements
must be made to ensure the runway beam cannot be used until
remedial work has been carried out and the beam retested.
4.14 TEST OF ELECTRICAL AND PNEUMATIC CHAIN HOSTS
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the chain hoist then a proof load
as listed below may be applied as follows:
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through a height of lift which will ensure that every part of
the block mechanism and each tooth of the gears come
under load.
2.1.3 On releasing the proof load, the piece of equipment shall
be examined as per Section 1.0.
2.1.4 Reset any regulators / load limiters, which may have been
adjusted to achieve raising the proof load.
3.0 MARKING
the test.
4.0 REPORTNG
model and height of lift
4.1.6 Name and address of the company performing the test and
examination
was carried out
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4.15 TEST OF SWIVELLING OVERHAUL BALLS AND SWIVELS

1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the unit then a proof load as
equipment plus 100% shall be applied to the item to be
tested.
2.1.2 The proof load shall be gradually applied, checking at all
times for alignment to prevent any damage or deformation.
The proof load shall be held for five minutes.
2.1.3 If the overhaul ball or swivel has an integral wedge socket
as a top termination it is critical that the correct diameter
wire rope is used to prevent damage and jamming of the
wedge in the socket body.
2.2 On releasing the proof load the piece of equipment shall be examined
as per Section 1.0
2.3 A magnetic particle inspection should be carried out on the wedge
and socket it applicable after load testing.
3.0 MARKING
the test. If the swivel has an integral wedge socket, the wedge shall
be stamped with the unit identification number to match it to the
socket.
4.0 REPORTNG
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and model.
4.1.6 Name and address of the company performing the test and
examination
was carried out

service.
4.16 TEST OF CRANES IN ACCORDANCE WITH BS 7121 PART 2
1.0 EXAMINATION
1.1 A thorough examination of the crane shall be carried out as per
Tuboscope..and shall ensure the crane is as follows:
1.1.1 Free from any defects that would preclude it from safely
handling the test load.
1.1.2 In the correct configuration and condition according to the
manufacturers instructions.
1.1.3 Equipped with sufficient falls of rope for the load under
consideration and that rope is reeved correctly.
2.0 TESTING
2.1 TEST CONDITIONS
Apart from the obvious danger to personnel, it should be recognised
that adverse weather conditions can impose additional loads on the
crane and that the limitation on wind speed for testing the crane may
be lower than the limitations for normal operations it is therefore the
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decision of the test engineer whether or not to proceed with a test,

taking into account wind speed, rain, snow, mist, and fog etc.
2.2 FUNCITION TEST
Function tests are carried out with no load to establish the satisfactory
operation of all control devices and motion limits and to ensure that
unladen specified speeds are obtained.
2.3 INDICATOR TEST
The setting and satisfactory operation of the automatic safe load
indicator, radius and / or jib angle indicator, if fitted, shall be
confirmed.
This can be achieved by measuring the radius with the known load
suspended and checking this against the readings on the indicators.
NOTE: The radius is the horizontal distance measured between the
vertical centre line of the hook and the perpendicular through the
centre line of rotation.
2.4 SAFE WORKING LOAD TEST
Prior to testing the maximum safe working load for a given radius
shall be raised just clear of the ground and the crane operated
through all its motions to ensure the crane is safe to proceed with the
overload test.
2.5 OVERLOAD TEST
The following proof load shall be applied to the crane depending of
the safe working load at the corresponding radii.
2.5.1 Up to 20 tonnes 25% in excess of safe working load.
2.5.2 Over 20 tonnes and up to 50 tonnes, 5 tonnes in excess of
safe working load.
2.5.3 Over 50 tonnes, 10% in excess of working load.
2.5.4 With the jib set at its appropriate radius for the maximum
safe working, a proof load a specified above shall be raised
just clear of the ground and the crane where possible
slewed through 360 to ensure that the overload is applied
to all parts. The hoist brake and where applicable, the
derrick brake, should be proved capable of sustaining the
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over load.
2.5.5 The above operation shall be repeated with the jib set at its
maximum radius and at least one intermediate radius.
2.5.6 The function of automatic load indicators may be checked
at the beginning of the overload test, thereafter they may
be disconnected in accordance with the manufacturers
instructions for the duration of the test and immediately
reconnected afterwards and then checked to ensure that
they function correctly.
2.5.7 The test shall be considered successful if on completion a
thorough examination of the crane is carried out as per
Section 1.0 and no defects are found.
3.0 REPORTING
3.1 The written reports shall be as per the record of service inspection
and test. See attached.
4.1 Where the test is not satisfactory, a responsible representative of
the user shall be informed by means of a defect report. If the test
arrangements must be made to ensure the crane is not used until
remedial work has been carried out.
4.17 TEST OF PADEYES
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
would affect the safe working load of the pad eye then a proof load as
detailed below may be applied:
2.1.1 For pad eyes with a safe working load up to 10 tonnes a
proof load of 2 x SWL shall be applied.
2.1.2 For pad eyes in excess of 10 tonnes safe working load, the
following formula shall be used
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SWL x 1.04 + 9.6 = Proof Load

Derived from Lloyds code for Lifting Appliances in a Marine
Environment Table 9.1.1.
NOTE: Other certifying authorities (e.g. D.N.V.) and
individual clients may have there own specifications on the
proof load of pad eyes. These should be referred to where
possible.
2.1.3 The proof load may be applied by direct pull using either a
chain block and load cell, calibrated hydraulic jack set, test
weights, water bags or a method that shall suitably apply
the proof load.
2.1.4 The proof load shall be applied in a similar direction to
which the pad eye will be loaded in service.
2.1.5 The proof load shall be maintained for a period of five
minutes.
2.1.6 On release of the proof load, the piece of equipment shall
be examined as per Section 1.0
3.0 MARKING
the test.
4.0 REPORTNG
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6

Safe working load
Proof load applied
Date of test and thorough examination
examination
4.1.7 Position and location of the piece of equipment
was carried out
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4.18 TEST OF LIFEBOAT DAVITS
1.0 The procedure relates to the thorough examination of Lifeboat Davits carried
out by a competent inspection engineer offshore either on a production
platform or drilling rig.
2.0 The examination will be carried out in compliance with SI 2307 : 1998 and SI
486 : 1987.
3.0 Each installation shall be thoroughly examined at sixth monthly intervals

test, static test and proof load test will be carried out.

4.1 The examination should be carried out in adequate lighting.
4.2 The information on the identification plate shall be checked against
the current test certificates and D.O.T. certificate.
4.3 All ancillary equipment shall be checked for identification numbers
and checked against the relevant certificate for each time.
4.4 All parts should be clean and free from deleterious matter.
Examination should include:
4.4.1 All bolts, check for tightness, cracks and gouges.
4.4.2 All welds, check for cracks and gouges (if necessary carry
out M.P.I. tests)
4.4.3 Check for distortion of structure and alignment of structure
and alignment of sheaves, winches, etc.
4.4.4 Check profile of sheaves for wear and imprinting.
4.4.5 Check sheaves for cracks.
4.4.6 Ancillary equipment (hang-off pennants, hooks, shackles
etc. shall be examined in accordance with the relevant
procedures).
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4.5 FUNCTIONAL TEST

4.5.1 In addition to thorough examination a functional test will
include:
4.5.2 Full operation of the launching system with a test load
equal to 1.1 times the SWL of the system.
4.5.3 For this test it will be assumed that a passenger is 75 kg
and the test load calculated accordingly. The load should
be evenly distributed.
4.5.4 During operation the system shall be checked for smooth
operation of the winch, sheaves and davit arms (if
appropriate) and ancillary equipment operates correctly.
4.5.5 Controls operate correctly and are correctly labelled.
4.6 A thorough examination shall be carried out before an after the
functional test.
4.7 Winch Test
4.7.1 The winch will be tested in accordance with the relevant

procedures, at a proof load equal to 1.5 times the SWL of
the winch.
4.8 Static Test
4.8.1 A static test will be carried out on each davit by handling off
a test load equal to 2.2 SWL of the davit.
The load should be held for a minimum of five minutes.
4.8.2 Following removal of the load the davit should be
thoroughly examined as per 4.1. The structure should not
be permanently distorted following static test.
5.0 CERTIFICATION AND REPORTS
5.1 Certification and reports in compliance with SI 2307 shall be issued in
accordance with the appropriate procedure.
6.0 NOTES
6.1 SI 486 required that a life saving appliance offshore should be

examined by D.O.T. every 2 years. Therefore the inspector should
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confirm that the D.O.T. certificate is valid.

6.2 The inspector must exercise care for his safety and others during the
examination and any tests. The location of lifeboat davits may be

hazardous. Functional tests should only be carried out in favourable
weather.
4.19 TEST OF WINCHES
1.0 EXAMINATION
as per Tuboscope
2.0 TESTING
2.1 UTILITY WINCHES
2.2 If during the course of the examination, no faults are found which
equipment plus 25% shall be applied and a check made of
the load bearing parts. This test may be applied by a static
pull or by life weights.
(where practical) through a height of lift, which will ensure
that every part of the winch mechanism comes under load.
This load shall be held for a period of five minutes. The
brake shall show no signs of slippage or creep.
2.2.3 Repeat operations 2.2.1 to 2.2.2 for each brake if winch
fitted with dual brakes.
2.3 MAN RIDING WINCHES
2.3.1 The proof load for man riding winches shall be as follows:
2.3.1.1A functional rest of the SWL + 10% shall be applied.
The winch must have sufficient power capacity to
operate through all functions satisfactorily.
2.3.1.2A Dynamic load test of the SWL + 25% shall be
applied. The rest shall be applied to each brake
individually. Test weights or waterbags are the
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preferred method to apply the test load. Hold the

test load for a period of five minutes. The brakes
shall show no signs of slippage or creep.
2.3.1.3A static load test of the SWL + 50% shall be applied.
This test shall be applied to all brakes
simultaneously and held for a period of five minutes.
The brakes shall show no signs of slippage or
creep.
2.3.1.4Verify operation and settings of limits, if fitted, by
functional test through hoist and lower modes.
NOTE: If new rope has been fitted, the limits may
require resetting.
3.0 MARKING
3.1 If the item is not already marked, it shall be clearly marked with an
identification number, safe working load and date of test. If approved
for man riding purposes, this must be marked clearly on winch.
4.0 REPORTING
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Unique identification number.

A full description of the piece of equipment.
Safe working load.
Proof load applied.
Date of test and thorough examination.
A statement of type of use e.g. Approved for Man riding
or Utility Winch.
4.1.7 Any limitations or restrictions of use.
examination.
4.1.9 Act or Regulation under which the test and examination
was carried out.
4.1.10 Position and location of piece of equipment.
5.0 Where the test is not satisfactory, a responsible representative of the user
the defect to be of a dangerous nature then arrangements must be made for
its immediate withdrawal from service.
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4.20 TEST OF OVERHEAD CRANES

1.0
This procedure relates to the thorough examination of Overhead Cranes
carried out by a competent inspection engineer offshore either on a
production platform or drilling rig.
2.0
This examination will be carried out in compliance with SI 2307 : 1998,
BS 466 1984 and BS 7121 Part 2.
3.0
Each installation shall be thoroughly examined at six monthly intervals
test, static test and proof load test will be carried out.
4.0
THOROUGH EXAMINATION
4.1
The examination should be carried out in adequate lighting
4.2
The information on the identification plate shall be checked
against the current test certificates.
4.3
All ancillary equipment shall be checked for identification number
and checked against the relevant certificate for each item.
4.4
All parts should be clean and free from deleterious matter.
4.5
Examination should include:
4.5.1 Lower main hoist block to deck level and inspect the hoist
drum for cracks and wear, also inspect the rope anchorage
point ensuring the rope locking screws are secure, carry
out rope inspection, check the condition of the wire rope
guide. Check the drum for bearing lift. Re-spool the rope.
4.5.2 In conjunction with task 2, inspect the main block for
sheave wear, hook distortion, check swivel thrust bearing
and rope guards.
4.5.3 Check all drive motors, gear boxes and couplings for loose
fixings and fastenings, if any are found to be loose, tighten
to the correct setting, guards should be checked and
repaired if necessary.
4.5.4 Check the cross travel carriage wheels for flange wear and
bearing slackness, also check all fixings and fastenings on
the cross travel carriage.
4.5.5 Check main gantry beam, end carriages drive wheels and
non drive wheels for flange wear and bearing lift. All gear
driven wheels are to have the gear meshing checked along
with the condition of the gearing, check all axle plates are
fitted secure.
4.5.6 Ensure SWL is prominently displayed and the test plate is
in date.
4.5.7 Check the gantry rails for wear and loose fixings. Every 12
months check the alignment in all planes as per BS 466
1984 (Specification for power driven overhead travelling
cranes).
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OCTG SERVICES PART F

STANDARD WORKING PROCEDURES

Tuboscope Vetco Egypt

OCTG SERVICES PART F

Tuboscope Vetco Egypt

OCTG SERVICES PART F

Tuboscope Vetco Egypt

OCTG SERVICES PART F

1.5 Personnel Qualification

The identification marking and safe working load will be checked

Tuboscope Vetco Egypt

OCTG SERVICES PART F

Identification / Serial number.

A clear statement of its fitness for further use or details of any

If during the course of the examination any item of equipment is found to

On completion of the equipment survey, the copies of the examination

Each employee shall wear the appropriate safety gear:

Coveralls (flame retardant for offshore)

Tuboscope Vetco Egypt

OCTG SERVICES PART F

Should an employee observe unsafe practices, or be requested to work

The company's Quality Policy applies and each employee is encouraged to

The machine shall be checked for the following defects:

The safe working load and identification mark is legible and

Function test block to ensure brake mechanism operates satisfactorily.

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.3 INSPECTION OF PULL LIFTS / LEVER HOIST

The machine shall be checked for the following defects:

The safe working load and identification mark is legible and

Function tests the block to ensure satisfactory operation of the brake

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.4 INSPECTION OF TIRFORS

The machine shall be checked for the following defects:

The safe working load and identification mark is legible and

Function tests the machine to ensure the satisfactory operation.

2.5 INSPECTION OF SINGLE AND MULTI SHEAVE BLOCKS

The blocks shall be checked for the following defects:

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.6 INSPECTION OF RUNWAY TROLLEYS

The machine shall be checked for the following defects:

The safe working load and identification marking is legible and

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.7 INSPECTION OF BEAM CLAMPS AND PLATE CLAMPS

The clamp shall be checked for the following defects:

Shackle or eye for wear, cracks, gouges and corrosion.

2.8 INSPECTION OF SHACKLES

All shackles shall be checked for the following defects:

The safe working load and identification number marking is legible

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.9 INSPECTION OF CHAIN

All chain shall be checked for the following defects:

The safe working load and identification number marking is legible

2.10 INSPECTION OF EYE BOLTS

All eye bolts shall be checked for the following defects:

The safe working load and identification number marking is legible

Tuboscope Vetco Egypt

OCTG SERVICES PART F

2.11 INSPECTION OF LIFTING LINKS

All links shall be checked for the following defects: