W.I.M New

UNIVERSAL PETROLEUM
INVESTMENTS AND AGENCIES

Quality for Life
WORK
INSTRUCTIONS
MANUAL
0
Universal Petroleum Investments and Agenies
Work Instructions Manual
Chapter: Amdmnt Page
Page: i
Amendment Page
Version: UPS 3.0
Issue Date:06Oct06
All amendments clearl mar!ed as descri"ed in UPS#P$6 amendment procedures.
Amendment Disard Insert Amendment
%o. Date Section Page Issue & Section Page Issue & Am. 'pe Appro(ed
i
Universal Petroleum Investments and Agenies
Chapter: 'itle Page
Page: ii
Version: UPS 3.0
Issue Date:06Oct06
UNIVERSAL PETROLEUM
INVESTMENTS AND AGENCIES
WORK INSTRUCTIONS MANUAL
Contat In!ormation
Uni(ersal Petroleum In(estments and Agencies
Storage Area
)as *hari"
)ed Sea
+gpt
Phone: ,-0#6.#36-6.$.
/a0 : ,-0#6.#36-6.$.
+mail : ups1se(en2s.net
'his manual is issued
under the authorit o3
4ahmoud Ashour 4ahmoud
Chairman and 4anaging Director
Uni(ersal Petroleum In(estments and Agencies
Authori5ed Signature
Issue Date: 06 Oct 06 Issue %um"er: 3.0
ii
TABLE OF CONTENTS
1. INTRODUCTION...............................................................................................................................1
1.1 ABOUT UNIVERSAL PETROLEUM.......................................................................................................1
1.2 OUR SERVICES...................................................................................................................................1
1.3 OUR STANDARDS...............................................................................................................................1
1.4 OUR PEOPLE......................................................................................................................................1
2. WORK INSTRUCTIONS FOR TESTING WIRE ROPE SLINGS...............................................2
2.1 SCOPE AND OBJECTIVE.....................................................................................................................2
2.2 REQUIRED TOOLS FOR TESTING WIRE ROPE SLINGS........................................................................2
2.3 WIRE ROPE SLINGS TESTING INSTRUCTIONS....................................................................................2
2.3.1 Slings Testing process overview.................................................................................................2
2.3.2 Test Preparations.......................................................................................................................2
2.3.3 Visual Testing of Wire Rope Slings.............................................................................................4
2.3.4 MPI (Magnetic Particle Inspection Test of Wire Rope Slings..................................................4
2.3.! "ie Penetrant Test of Wire Rope Slings.....................................................................................!
2.3.# Proof $oa% Test of Wire Rope Slings..........................................................................................!
2.4 GENERATING REJECTION REPORTS OF SLINGS..................................................................................6
2.5 GENERATING CERTIFICATES OF SLINGS............................................................................................7
3. WORK INSTRUCTIONS FOR TESTING SHACKLES................................................................8
3.1 SCOPE AND OBJECTIVE.....................................................................................................................8
3.2 REQUIRED TOOLS FOR TESTING SAC!LES......................................................................................8
3.3 SAC!LES TESTING INSTRUCTIONS..................................................................................................8
3.3.1 S&ac'les Testing Process (verview...........................................................................................)
3.3.2 Test Preparations.......................................................................................................................)
3.3.3 Visual Testing of S&ac'les........................................................................................................1*
3.3.4 MPI (Magnetic Particle Inspection Test.................................................................................1*
3.3.! Proof $oa% Test of S&ac'les.....................................................................................................11
3.4 GENERATING SAC!LES REJECTION REPORTS...............................................................................12
3.5 GENERATING SAC!LES CERTIFICATES..........................................................................................12
4. WORK INSTRUCTIONS FOR TESTING HOOKS.....................................................................14
4.1 SCOPE AND OBJECTIVE...................................................................................................................14
4.2 REQUIRED TOOLS FOR TESTING OO!S.........................................................................................14
4.3 OO!S TESTING INSTRUCTIONS......................................................................................................14
4.3.1 +oo's Testing process overview...............................................................................................14
4.3.2 Test Preparations.....................................................................................................................14
4.3.3 Visual Testing of +oo's............................................................................................................1,
4.3.4 MPI (Magnetic Particle Inspection Testing of +oo's.............................................................1,
4.3.! Proof $oa% Test of +oo's.........................................................................................................1)
4.4 GENERATING OO!S REJECTION REPORTS.....................................................................................1"
4.5 GENERATING OO!S CERTIFICATES................................................................................................2#
5. WORK INSTRUCTIONS OF CONTAINERS...............................................................................21
5.1 SCOPE AND OBJECTIVE...................................................................................................................21
5.2 REQUIRED TOOLS FOR TESTING CONTAINERS................................................................................21
5.3 CONTAINERS TESTING INSTRUCTIONS.............................................................................................21
!.3.1 -ontainers. Testing Process (verview.....................................................................................21
!.3.2 Test Preparations.....................................................................................................................21
!.3.3 Visual Testing of -ontainers....................................................................................................23
!.3.4 MPI (Magnetic Particle Inspection of -ontainers.................................................................2#
!.3.! Proof $oa% Test of -ontainers.................................................................................................2#
5.4 GENERATING CONTAINERS REJECTION REPORTS............................................................................28
5.5 GENERATING CONTAINERS CERTIFICATES.......................................................................................2"
6. WORK INSTRUCTIONS FOR TESTING CRANES...................................................................30
6.1 SCOPE AND OBJECTIVE...................................................................................................................3#
6.2 DEFINITIONS....................................................................................................................................3#
6.3 RESPONSIBILITIES OF INVOLVED PARTIES.......................................................................................31
6.4 TEST ELEMENTS OF CRANES TESTING PROCESS.............................................................................32
iii
#.4.1 T&oroug& /0a1ination.............................................................................................................33
#.4.1.1 Visual Testing........................................................................................................................34
#.4.1.2 2unctional Testing.................................................................................................................34
#.4.1.3 Perfor1ance Testing.............................................................................................................34
#.4.1.4 3on4"estructive Testing (3"T............................................................................................34
#.4.1.! Testing of Rate% -apacit5 In%icator6$i1iter (R-I6$...........................................................3!
#.4.1.# 7ssess1ent of Wire Rope -on%ition......................................................................................3!
#.4.2 (verloa% Testing......................................................................................................................3,
#.4.3 (verview of -rane Testing Process.........................................................................................3)
6.5 TESTING OF MOBILE CRANES.........................................................................................................3"
#.!.1 Re8uire% Tools for Inspecting Mo9ile -ranes.........................................................................3:
#.!.2 Preparation..............................................................................................................................3:
#.!.3 Visual Testing...........................................................................................................................4*
#.!.4 2unctional Testing....................................................................................................................41
#.!.! (perational Testing..................................................................................................................41
#.!.# Rate% capacit5 In%icator6$i1iter (R-$6$ -ali9ration -&ec'................................................41
#.!., 3"T (3on4"estructive Test.....................................................................................................42
#.!.) (verloa% Test...........................................................................................................................42
#.!.: (verloa% Test for ;i9 7rrange1ents........................................................................................44
#.!.1* Post $oa% Test /0a1ination...................................................................................................4#
6.6 TESTING OF OVEREAD TRAVELING CRANES.................................................................................47
#.#.1 Re8uire% Tools for Inspecting (ver&ea% -ranes.....................................................................4,
#.#.2 Preparation..............................................................................................................................4,
#.#.3 Visual Testing of (ver&ea% Traveling -ranes..........................................................................4)
#.#.4 2unctional Testing of (ver&ea% Traveling -ranes..................................................................4:
#.#.! Perfor1ance Testing of (ver&ea% Traveling -ranes...............................................................!*
#.#.# Rate% capacit5 In%icator6$i1iter (R-$6$ -ali9ration -&ec'................................................!*
#.#., 3"T (3on4"estructive Test.....................................................................................................!*
#.#.) (verloa% Testing of (ver&ea% Traveling -ranes....................................................................!*
#.#.: (verloa% Testing of (ver&ea% -rane <antries.......................................................................!1
#.#.1* Post $oa% Test /0a1ination...................................................................................................!1
6.8 GENERATING CRANE TEST REPORTS...............................................................................................52
6." GENERATING CRANE CERTIFICATES................................................................................................57
6." RECOMMENDATIONS FOR CRANES FOR LIFTING PERSONS AND SUSPENDED BAS!ETS..................62
APPENDIX A - ABOUT WIRE ROPE SLINGS................................................................................64
APPENDIX B - SHACKLES................................................................................................................8
APPENDIX C ! ABOUT HOOKS.......................................................................................................84
APPENDIX D - ABOUT CONTAINERS............................................................................................88
REFERENCES AND STANDARDS...................................................................................................."1
i(
Universal Petroleum Investment " Agenies
Chapter %o. : #
Page # o3 $#
Chapter $: Introduction
Version : UPS 3.0
Issue Date:06Oct06
#% Introdution
1.1 About Universal Petroleum
Uni(ersal Petroleum is a one#stop source 3or Oil 6 *as Industr inspection and non destructi(e testing
ser(ices. Uni(ersal Petroleum7 headed " its Chairman 6 4anaging Director 4ahmoud Ashour7 has "een
pro(iding its ser(ices to the +gptian Oil 6 *as Industr since -00$ 8ith an impecca"le trac! record.
Uni(ersal Petroleum has gained the trust o3 se(eral !e companies in the +gptian mar!et in such as short
time7 8hich 8as due to its dedication and commitment to pro(ide pro3essional ser(ices " deploing state o3
the art e9uipment7 e0perienced and trained personnel.
Uni(ersal Petroleum has ingrained :ualit and ;S+ as an integral part o3 all management and e0ecuti(e
3unctions. 'his culture is designed 8ith the characteristics o3 sel3#sustaina"ilit and continuous impro(ement
commensurate 8ith the compan<s 9ualit and ;S+ policies.
1.2 Our Servies
Uni(ersal Petroleum o33ers a (ast arra o3 ser(ices in the 3ield o3 %D' and testing o3 li3ting e9uipment such as
cranes7 3or!li3ts7 "as!ets7 "o0es7 containers7 slings and shac!les7 etc. Our suite o3 ser(ices
includes:
Visual testing.
4agnetic Particle Inspection =4PI>
Proo3 ?oad 'est.
4agnetic Particle Inspection a3ter load test.
1.! Our Stan"ar"s
All o3 our ser(ices are pro(ided as per the latest AS%' and @SI7 AAS standards and under the um"rella o3
AS4+ code. Clients< speci3ic standards and speci3ications are easil adhered to7 through a sstematic and
pro3essional 9ualit and standards adaptation and upgrading process.
Ae ha(e ingrained :ualit as an integral part o3 all management and e0ecuti(e 3unctions and 8e are7
there3ore7 committed to meeting and e0ceeding the ser(ice le(els e0pected " our customers7 and to
consistentl pro(ide high quality ser(ices in a safe7 accurate7 expedite7 professional7 et7 cost effective
manner.
1.# Our Peo$le
Ahile our leading#edge technolog plas its part7 our dedicated and moti(ated people are 8hat reall ma!es
the di33erence. Ae ha(e a pool o3 9uali3ied7 trained7 certi3ied and e0perienced 3ield Inspection personnel 8ho
carr out consistent testing Bo"s in the toughest terrains and situations. Our annual training and re#training
program ensures that the testing 8or! is consistent 8ith latest editions o3 the standards and our 9ualit
assurance procedures.
All o3 our ser(ices are carried out " AS%' ?e(el#II %D' certi3ied engineers and 9uali3ied li3ting engineers.
$
Chapter %o. : &
Page & o3 $#
C'a(ter &) *or+ Instrutions !or Testing *ire Ro(e Slings
(According to ASME!"#$ %SI&'#" and %SI('&")
Version : UPS 3.0
Issue Date:06Oct06
&% *or+ Instrutions !or Testing *ire Ro(e Slings
'*& Scope and +,-ective
'his chapter e0plains the procedures o3 testing and inspecting 8ire rope slings. 'he chapter starts " listing
the tools and e9uipments re9uired to per3orm the Bo" and then mo(es to the procedures that are to "e
3ollo8ed 8hen testing slings. 'he chapter goes through the process o3 creating certi3icates and reBection
reports.
'*' .equired /ools for /esting Wire .ope Slings
'he 3ollo8ing tools and e9uipment should "e read "e3ore starting the process o3 testing 8ire rope slings:
$# 4easuring tape
-# ODCID caliper
3# 4agnetic AC o!e
D# ?oad cell =3or proo3 load test>
.# Penetration de chec! spra =i3 3errules are made o3 aluminum>
'*! Wire .ope Slings /esting Instructions
&%,%# Slings Testing (roess overvie-
'he o(erall process o3 testing and inspecting 8ire rope slings is graphicall illustrated in the 3lo8chart sho8n
on page ..
&%,%# Test Pre(arations
$# 'est the AC o!e "e3ore commencing the Bo" as 3ollo8s:
a. connect the AC o!e to the po8er mains
". place the test piece on the 3loor or on a 8ooden ta"le
c. place the o!e on top o3 the test piece
d. S8itch the AC o!e O% " 3lipping the o!e<s O%CO// s8itch to appl magnetic 3ield to the
test piece.
e. 'r li3ting the test piece 8ith the o!e to ensure that it applied su33icient magnetic 3ield
3. Prepare the li3ting point that 8ill "e used to appl tension to the sling during the test.
g. 4a!e sure that the remote<s "atter is in good condition " turning on the remote and
ma!ing sure the E"atter lo8F indicator is not on.
h. Chec! the cali"ration date o3 load cell and ma!e sure that its last cali"ration is still (alid.
i. Determine the proo3 load 8eight using the @ritish Standard 202-.
-
Chapter %o. : &
Page , o3 $#
Version : UPS 3.0
Issue Date:06Oct06
3
/lo8chart $: O(erall Process o3 'esting Aire )ope Slings
Chapter %o. : &
Page . o3 $#
Version : UPS 3.0
Issue Date:06Oct06
&%,%, Visual Testing o! *ire Ro(e Slings
$# 4easure dimensions o3 the sling.
-# 'he Sa3e Aor!ing ?oad and Identi3ication 4ar!s are
legi"le and correspond 8ith the 'est Certi3icate.
3# 'he num"er o3 "ro!en 8ires in a length o3 $0 rope
diameters must not e0ceed .G o3 the total 8ires in
the rope.
D# %o "ro!en 8ires are permitted near an attached
3itting.
.# Chec! 3or 8ear7 corrosion and insu33icient
lu"rication.
6#
2# All end splices shall "e chec!ed 3or 8orn "ro!en
8ires7 pinched or Bammed strands7 loose strands7
crac!ed 3ittings7 tuc!s dra8ing out and distorted 3errules.
H# Corroded7 crac!ed7 "ent7 8orn and incorrectl applied end 3itting.
I# +0amine all thim"les 3or 8ear in cro8n7 3or e(idence o3 throat "iting into rope7 distortion or closure.
$0# Chec! the length o3 the rope 3or !in!s7 "ird#caging7 crushed 3lattened or Bammed strands and core
protrusion.
$$# Inspect 3or heat damage =caused 8hen rope is run o(er sei5ed shea(e> torch "urns and electric
stri!es.
$-# I3 an 3aults are 3ound at the time o3 e0amination 8hich 8ould a33ect the sa3e use o3 the 8ire rope7
then it must "e 8ith dra8n 3rom ser(ice and details recorded on the testing report.
&%,%. MPI /Magneti Partile Ins(etion0 Test o! *ire Ro(e Slings
According to %SI("0'$ AS1/ /raining 2rogra3 for M2I$ AS1/ /raining 2rogra3 of 4ye 2enetrant)
4PI test should "e carried 3or all steel components o3 the sling under test. I3 the sling is multi#legged7 the
master lin! is 4PI tested. Also7 i3 3errules and thim"les are made o3 steel the are 4PI tested. 'he 4PI test
instructions are as 3ollo8ing:
$# ?a the sling do8n on the 3loor or on a 8ooden ta"le
-# AdBust the spacing "et8een the o!e<s pro"es so that 8hen placed on the 3errules7 "oth pro"es
touch the 3errule 3rom "oth sides.
3# S8itch the AC o!e on
D# Appl the dr po8der to the 3errule so that the 8hole 3errule is co(ered
.# @lo8 the po8der o33 the 3errule. Use a "lo8er 8hen a(aila"le
6# Visuall inspect the traces o3 the po8der on the 3errule 3or an indications o3 crac!s
2# I3 an crac!s e0ist7 reBect the sling and issue a reBection report
H# I3 no crac!s e0ist7 continue the test as 3ollo8s
I# S8itch the AC Jo!e o33
$0# /lip the sling o(er to test the other side o3 the 3errule
$$# )epeat steps 3#I 3or the other side o3 the 3errule
$-# )epeat steps 3#I the a"o(e steps 3or other 3errules.
$3# I3 the sling is a -7 3 or D#leg sling7 repeat the a"o(e steps 3or all 3errules on the other legs as 8ell as
the master lin!
$D# I3 an de3ects e0ist7 reBect the sling and issue a reBection report
$.# I3 no de3ects e0ist7 continue to -.3..
%O'+: it is recommended to use the magnetic 8et method 8hen testing rough sur3aces. Instructions 3or
per3orming 8et magnetic testing are as 3ollo8s:
$# Clean the 8elds or sur3aces that are to "e tested " a suita"le cleaning method.
-# Sha!e cans o3 contrast spry can and ,lack ink (er 8ell prior to use.
3# Appl a thin laer o3 the contrast and distri"ute it 8ell o(er the area to "e tested.
D
Chapter %o. : &
Page 1 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
D# Aait 3or the contrast to dr o33.
.# Appl magnetic 3ield to the area to "e tested using a magnetic o!e.
6# Appl the "lac! in! spra o(er the area to "e tested7 8hich is no8 co(ered " contrast.
2# Indications 3or de3ects7 i3 e0ist7 8ill appear immediatel.
&%,%1 Die Penetrant Test o! *ire Ro(e Slings
Die penetrant test is used 3or chec!ing 3rrules o3 the sling under test i3 the are made o3 aluminum. 'he
procedures o3 die penetrant chec! are as 3ollo8s:
$# Appl the cleaning spra to a dr piece o3 cloth and use it to clean the 3errule. 4a!e sure that the
3errule is completel clean o3 all residues o3 the cleaning spra.
-# Appl the Penetrant de all o(er the 3errule so that it<s completel co(ered.
3# ?ea(e the Penetrant 3or a su33icient period o3 time to allo8 it to penetrate through the discontinuities
o3 the 3errule i3 e0ist. 'his time is .#$. minutes on a(erage unless other8ise is speci3ied on the
Penetrant spra container.
D# )epeat steps $ to clean the 3errule.
.# Appl the de(eloper spra to the 3errule.
6# ?ea(e the de(eloper 3or a su33icient period o3 time to allo8 3or an crac!s or discontinuities to appear
and "ecome (isi"le. 'his time is .#$. minutes on a(erage unless other8ise is speci3ied on the
de(eloper spra container.
2#
H# I3 an crac!s e0ist7 reBect the sling and issue a reBection report
I# I3 no crac!s e0ist7 continue the test as 3ollo8s =AS%'#%D' 'raining Program>
&%,%2 Proo! Load Test o! *ire Ro(e Slings
$# Connect the 3irst shac!le to the li3ting point
-# Connect the load cell to the 3irst shac!le
3# O"ser(e the reading on the load cell<s remote reader and ma!e sure that it reads K+)O
D# Connect the second shac!le to the "ottom o3 the load cell
.# O"ser(e the reading on the load cell<s remote reader and ma!e sure that it reads a (alue that is
close to the 8eight o3 the shac!le
6# Kero the load cell reading " pressing the E'+A)F "utton on the remote reader.
2# Connect the sling to the shac!le at the "ottom o3 the load cell
H# Connect the other end o3 the sling to a dead point or a suita"le dead 8eight.
I# Start pulling slo8l using the li3ting point to appl tension to the sling
$0# Continue pulling 8hile o"ser(ing the reading on the remote reader until the tension reaches the
ma0imum proo3 load test 8eight.
$$# Leep the tension applied 3or . min =according to the @ritish Standards7 API and AS4+ codes>
$-# Slo8l relie(e the tension 3rom the sling 8hile o"ser(ing the reading on the remote reader until the
tension is e9ual -0G o3 the ma0imum proo3 load test
$3# Leep this tension 3or another - minutes
$D# Pull on the sling again until the tension reaches the ma0imum proo3 load test again
$.# Leep the tension applied 3or another . minutes
$6# Slo8l release all tension and disconnect the test assem"l 3rom top to "ottom
$2# )edo pre(ious (isual testing test
$H# )edo pre(ious 4agnetic or De Chec!
$I# I3 an crac!s e0ist7 reBect the sling and issue a reBection report
-0# I3 no crac!s e0ist7 continue the test as 3ollo8s
-$# Issue test certi3icate or reBection report
.
Chapter %o. : &
Page 2 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'*5 6enerating .e-ection .eports
6
Chapter %o. : &
Page 3 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'*7 6enerating 8ertificates
2
Chapter %o. : ,
Page 4 o3 $#
C'a(ter ,) *or+ Instrutions !or Testing S'a+les
=According to @S +% $3HHI:-003>
Version : UPS 3.0
Issue Date:06Oct06
,% *or+ Instrutions !or Testing S'a+les
!*& Scope and +,-ective
'his chapter e0plains the procedures o3 testing and inspecting shac!les. 'he chapter starts " listing the
tools and e9uipments re9uired to test shac!les and then mo(es to the procedures that are to "e 3ollo8ed
throughout the test. 'he chapter concludes " documenting the process o3 creating certi3icates and reBection
reports o3 shac!les.
!*' .equired /ools for /esting Shackles
'he 3ollo8ing tools and e9uipment should "e read "e3ore starting the process o3 shac!les:
$# ODCID caliper7
-#
3# Aire "rush 3itted to a "u337
D# 4agnetic AC o!e7
.# ?oad cell7
6# '8o test shac!les =8ill "e re3erred to throughout this document as S;ACL?+#A and S;ACL?+#@
!*! Shackles /esting Instructions
,%,%# S'a+les Testing Proess Overvie-
'he o(erall process o3 testing and inspecting shac!les is graphicall illustrated in the 3lo8chart sho8n on
page $3.
,%,%& Test Pre(arations
$# 'a!e shac!le in3ormation7 measurements and record them into theMMMM
-# Clean the shac!le using the 8ire "rush that is 3itted to the "u33 to remo(e an rust or de"ris 3rom the
shac!le<s metal sur3ace.
3# 4a!e sure that the shac!le<s metal is clearl (isi"le
D# Prepare the li3ting point that 8ill "e used to appl tension to the shac!le during the test.
.# 4a!e sure that the remote<s "atter is in good condition " turning on the remote and ma!ing sure
the E"atter lo8F indicator is not on.
6# Chec! the cali"ration date o3 load cell and ma!e sure that its last cali"ration is still (alid.
2# Determine the proo3 load 8eight using the @ritish Standard @S #202-
H# 'est the AC o!e "e3ore commencing the Bo" as 3ollo8s:
S8itch the AC o!e on " 3lipping on the O%CO// s8itch on the o!e to appl magnetic 3ield to the test
piece.
d. 'r li3ting the test piece 8ith the o!e to ensure that it applied su33icient magnetic 3ield
H
Chapter %o. : ,
Page $ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
I
/lo8chart -: O(erall Process o3 'esting Shac!les
Process
Chapter %o. : ,
Page #5 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
,%,%, Visual Testing o! S'a+les
$# 4a!e sure that the shac!le has a serial num"er set " the
o8ner.
-# 4a!e sure that shac!le<s pin 3its 3reel 8ithout "ending
=Seated scre8 pin shac!les should "e disassem"led "
hand a3ter the 3irst#hal3 turn.>
3# 4a!e sure that the pin sho8s no sign o3 de3ormation.
D# 4a!e sure that 'he SA? =Sa3e Aor!ing ?oad> and
identi3ication mar!ing is stamped on the shac!le7 legi"le and
corresponds 8ith the test certi3icate.
.# 4a!e sure that there is no distortion o3 the "od and holes on opposite sides o3 the shac!le are
aligned.
6# +nsure 3ree 8or!ing o3 the pin.
2# +nsure that there<s no sign o3 8ear or damage on the scre8 pin<s thread o3 the shac!le
H# +nsure that the thread can "e hand tight and complete.
I# In case o3 sa3et#in pin shac!les the nut should Bam on the end o3 the thread and not the @od o3 the
shac!le.
$0# Chec! that 8ear in pin and "od o3 the shac!le does not e0ceed HG o3 the original diameter.
$$# 4a!e sure that there are no dents7 nic!s or crac!s in the "od o3 the shac!le.
All reBection criteria is in accordance 8ith "oth manu3acturers recommendation and the rele(ant +uropean
Standard.
I3 an 3aults are 3ound at the time o3 e0amination 8hich 8ould a33ect the sa3e use o3 the item o3 li3ting *ear
then it must "e 8ith dra8n 3rom ser(ices and details recorded on inspection )eport.
I3 (isual inspection re(ealed no de3ects7 proceed 8ith the magnetic test:
,%,%. MPI /Magneti Partile Ins(etion0 Test
$# ?a the shac!le do8n on the 3loor or on a 8ooden ta"le
-# AdBust the spacing "et8een the o!e<s pro"es so that "oth pro"es esta"lish phsical contact 8ith
shac!les.
3# S8itch the AC o!e O%.
D# Appl the dr po8der to the shac!le =8hile the AC o!e is still on> so that the 8hole shac!le is
co(ered 8ith po8der.
.# @lo8 the po8der o33 the shac!le. Use a "lo8er 8hen a(aila"le.
6# Visuall inspect the traces o3 the po8der on the shac!le 3or an indications o3 crac!s. I3 an crac!s
e0ist7 reBect the shac!le and issue a reBection report. I3 not crac!s e0ist7 continue the test as 3ollo8s.
2# S8itch the AC Jo!e O//.
H# /lip the shac!le o(er and repeat pre(ious steps 3or the other side o3 the shac!le.
$0
Chapter %o. : ,
Page ## o3 $#
Version : UPS 3.0
Issue Date:06Oct06
,%,%1 Proo! Load Test o! S'a+les
$# Connect the S;ACL?+#A to the li3ting point
-# Connect the load cell to the S;ACL?+#A
D# Connect the S;ACL?+#@ to the "ottom o3 the load cell
close to the 8eight o3 the shac!le
2# Connect the test shac!le to S;ACL?+#@ at the "ottom o3 the load cell
H# Connect the test shac!le to a dead point or a suita"le dead 8eight.
I# Start pulling slo8l using the li3ting point to appl tension to the shac!le
$$# Leep the tension applied 3or $0 min =according to the @ritish Standards7 API and AS4+ codes>
$-# Slo8l relie(e the tension 3rom the shac!le 8hile o"ser(ing the reading on the remote reader until
the tension is e9ual -0G o3 the ma0imum proo3 load 8eight
$3# Leep this tension 3or another - minutes
$D# Pull on the shac!le again until the tension reaches the ma0imum proo3 load test 8eight again
$.# Leep the tension applied 3or another . minutes
$6# Slo8l release all tension and disconnect the test assem"l 3rom "ottom to top
$2# testingtestVisual
$H# 4agnetic
$I# Issue inspection certi3icate or reBection report
$$
Chapter %o. : ,
Page #& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
!*5 6enerating Shackles .e-ection .eports
$-
Chapter %o. : ,
Page #, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
!*7 6enerating Shackles 8ertificates
$3
Chapter %o. : .
Page #. o3 $#
C'a(ter #% Introdution Testing 6oo+s
(According to ASME %!"&")
Version : UPS 3.0
Issue Date:06Oct06
.% *or+ Instrutions !or Testing 6oo+s
#.1 So$e an" Ob%etive
'his chapter e0plains the procedures o3 testing and inspecting hoo!s. 'he chapter starts " listing the tools
and e9uipments re9uired to test hoo!s and then mo(es to the procedures that are to "e 3ollo8ed throughout
the test. 'he chapter concludes " documenting the process o3 creating certi3icates and reBection reports o3
hoo!s.
#.2 Re&uire" Tools 'or Testin( )oo*s
'he 3ollo8ing tools and e9uipment should "e read "e3ore starting the process o3 hoo!s:
$# ODCID caliper7
-# Aire "rush 3itted to a "u337
3# 4agnetic AC o!e7
D# ?oad cell7
.# '8o test shac!les =8ill "e re3erred to throughout this document as S;ACL?+#A and S;ACL?+#@>
#.! )oo*s Testin( Instrutions
.%,%# 6oo+s Testing (roess overvie-
'he o(erall process o3 testing and inspecting hoo!s is graphicall illustrated in the 3lo8chart sho8n on page
$2.
.%,%& Test Pre(arations
$# 'a!e hoo!<s in3ormation7 measurements and record them into the 3orm 00000
-# Clean the hoo! using the 8ire "rush that is 3itted to the "u33 to remo(e an rust or de"ris 3rom the
hoo!<s metal sur3ace. 4a!e sure that the hoo!<s metal is clearl (isi"le.
3# Prepare the li3ting point that 8ill "e used to appl tension to the hoo! during the proo3 load test.
D# 4a!e sure that the "atter o3 the load cell<s remote reader is in good condition " turning on the
remote and ma!ing sure the E"atter lo8F indicator is not O%.
.# Chec! the cali"ration date o3 load cell and ma!e sure that its last cali"ration is still (alid.
6# Determine the proo3 load 8eight o3 the hoo! using the @ritish Standard 000000000000.
2# 'est the AC o!e "e3ore commencing the Bo" as 3ollo8s:
d. S8itch the AC o!e on " 3lipping on the O%CO// s8itch o3 the o!e to appl magnetic 3ield to
the test piece.
e. 'r li3ting the test piece 8ith the o!e to ensure that it applies su33icient magnetic 3ield.
3. O"tain the hoo!<s proo3 load 8eight 3rom the AS4+ code or the ta"le 00000000000 on the
3ollo8ing page.
$D
Chapter %o. : .
Page #1 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Rated Load 7
Rated
Load
Proo! Load Test
Tons 8g Tons 8g
0.. D.3.6 -00 $ I02.-
$ I02.- -00 - $7H$D.D
. D7.36 -00 $0 I702-
$0 I702- -00 -0 $H7$DD
$. $3760H -00 30 -27-$6
-0 $H7$DD -00 D0 367-HH
-. --76H0 -00 .0 D.7360
30 -27-$6 -00 60 .D7D3-
3. 3$72.- -00 20 637.0D
D0 367-HH -00 H0 2-7.26
D. D07H-D -00 I0 H$76DH
.0 D.7360 -00 $00 I072-0
60 .D7D3- $I3 $$6 $0.7-3.
2. 6H70D0 $H3 $32 $-D7-H6
$00 I072-0 $66 $66 $.07.I.
$-. $$37D00 $.0 $HH $207..D
$.0 $3670H0 $33 -00 $H$7DD0
$2. $.H7260 $33 -33 -$$732H
-00 $H$7DD0 $33 -66 -D$73$.
-.0 --67H00 $33 333 30-70IH
300 -2-7$60 $33 3II 36$7I23
3.0 3$27.-0 $33 D6. D-$7HDH
D00 36-7HH0 $33 .3- DH-7630
D.0 D0H7-D0 $33 .IH .D-7.06
.00 D.37600 $33 66. 6037-HH
$.
Chapter %o. : .
Page #2 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
$6
/lo8chart 3: O(erall Process o3 'esting ;oo!s
Chapter %o. : .
Page #3 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.%,%, Visual Testing o! 6oo+s
$# 4a!e sure that the hoo! has a serial num"er set " the o8ner.
-# 4a!e sure that 'he SA? =Sa3e Aor!ing ?oad> and identi3ication mar!ing is stamped on the hoo!7
legi"le and corresponds 8ith the test certi3icate.
3# Chec! 3or crac!s7 nic!s7 8ear7 gouges and de3ormation as illustrated in the a"o(e 3igure.
D# 4a!e sure that the latch is not distorted or "ent.
.# Chec! to ensure that the spring 8ill 3orce the latch against the tip o3 the hoo!.
6# Chec! to ensure that cotter is "ent so as not to inter3ere 8ith sling operation.
2# Chec! that 8ear in pin and "od o3 the hoo! does not e0ceed HG o3 the original diameter.
H# 4a!e sure that there are no dents7 nic!s or crac!s in the "od o3 the hoo!.
I# Use the caliper to measure the hoo!s dimensions as sho8n in a"o(e 3igures and ma!e sure that the
3ollo8ing applies to di33erent measurement 5ones =Kone A7 @7 C and D as illustrated in the 3ollo8ing
3igure>.
&" I3 actual measurements o3 KO%+ A are di33erent 3rom standard measurements7 discard the hoo! and
issue a reBection report.
&& I3 8ear in KO%+ @ is more than $0G o3 the standard dimensions7 discard the hoo! and issue a
reBection report.
&' I3 8ear in KO%+ C is more than .G o3 standard dimensions7 discard the hoo! and issue a reBection
report.
&! /or shan! hoo!7 re3er to the minimum thread si5e chart. Discard hoo! and issue a reBection report i3
measurements o3 KO%+ D are less than the minimum si5e.
&5 I3 (isual testing re(ealed no de3ects7 proceed 8ith the 4PI test.
.%,%. MPI /Magneti Partile Ins(etion0 Testing o! 6oo+s
$# ?a the hoo! do8n on the 3loor or on a 8ooden ta"le
-# AdBust the spacing "et8een the o!e<s pro"es so that "oth pro"es esta"lish phsical contact 8ith
hoo!.
3# S8itch the AC o!e O%
D# Appl the dr po8der to the hoo! =8hile the AC o!e is still on> so that the 8hole hoo! is co(ered
8ith po8der
.# @lo8 the po8der o33 the hoo!. Use a "lo8er 8hen a(aila"le
6# Visuall inspect the traces o3 the po8der on the hoo! 3or an indications o3 crac!s
2# I3 an crac!s e0ist7 reBect the hoo! and issue a reBection report
H# I3 not crac! e0ist7 continue the test as 3ollo8s
I# S8itch the AC Jo!e o33
$0# /lip the hoo! o(er and repeat pre(ious steps 3or the other side o3 the hoo!
$2
9igure A) S'an+ 6oo+
9igure :) E;e 6oo+
Chapter %o. : .
Page #4 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.%,%1 Proo! Load Test o! 6oo+s
$# Connect ;OOL#A to the li3ting point
-# Connect the load cell to ;OOL#A
D# Connect the ;OOL#@ to the "ottom o3 the load cell
close to the 8eight o3 the hoo!
2# Connect the test hoo! to ;OOL#@ at the "ottom o3 the load cell
H# Connect the test hoo! to a dead point or a suita"le dead 8eight.
I# Start pulling slo8l using the li3ting point to appl tension to the hoo!
$$# Leep the tension applied 3or 000000 min =according to the manu3acturer<s recommendation or the
AS4+ code>
$-# Slo8l relie(e the tension 3rom the hoo! 8hile o"ser(ing the reading on the remote reader until the
tension is e9ual -0G o3 the ma0imum proo3 load 8eight
$3# Leep this tension 3or another 000000 minutes
$D# Pull on the hoo! again until the tension reaches the ma0imum proo3 load test 8eight again
Leep the tension applied 3or another 000000 minutes
$.# Slo8l release all tension and disconnect the test assem"l 3rom "ottom to top
$6# testingtestVisual
$2# 4agnetic
Notes on Proo! Load testing o! 6oo+s)
a> +ach hoo! o3 $.0#ton capacit or greater and a prototpe o3 each hoo! design o3 less than $.0#ton
capacit shall "e proo3#tested " the manu3acturer.
"> Ahen proo3 tests are used7 the hoo!s shall 8ithstand the proo3 load application 8ithout permanent
de3ormation 8hen the load is applied 3or a minimum o3 $. sec. 'his condition is considered satis3ied
i3 the permanent increase in the throat opening does not e0ceed 0.. percent or 0.0$ in. =0.-. mm>7
8hiche(er is greater.
c> /or a duple0 =sister> hoo! ha(ing a pin ee7 the proo3 load 3or the ee shall "e in accordance 8ith
'a"le "ello8;oo!s that ha(e "een proo3#tested shall "e inspected 8ith 4agnetic Particle
e0amination and shall sho8 no crac!s7 inclusions7 or other rele(ant discrepanciesN castings shall "e
e(aluated " De Chec! 'est =?i9uid Penetrant 'esting>.
d> %o per3ormance testing o3 hoo!s shall "e re9uired7 e0cept as is necessar to con3orm to the
re9uirements 3or the e9uipment o3 8hich the are a part.
$H
Chapter %o. : .
Page #$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
5*5 6enerating 9ooks .e-ection .eports
$I
Chapter %o. : .
Page &5 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
5*7 6enerating 9ooks 8ertificates
-0
Chapter %o. : 1
Page &# o3 $#
C'a(ter 1) *or+ Instrutions !or Testing Containers
(According to %SI 0"0'$ %S E1 &'"0#)
Version : UPS 3.0
Issue Date:06Oct06
1% *or+ Instrutions o! Containers
7*& Scope and +,-ective
'his chapter e0plains the procedures o3 testing and inspecting containers. 'he chapter starts " listing the
tools and e9uipments re9uired to test containers and then mo(es to the procedures that are to "e 3ollo8ed
throughout the test. 'he chapter concludes " documenting the process o3 creating certi3icates and reBection
reports 3or containers.
7*' .equired /ools for /esting 8ontainers
$# measuring tape7
-# ODCID caliper7
3# 4agnetic AC o!e7
D# ?oad cell7
.# Penetration de chec! spra =there an o3 the container<s components are made o3 an aluminum
allo>
7*! 8ontainers /esting Instructions
1%,%# Containers< Testing Proess Overvie-
'he o(erall process o3 testing and inspecting hoo!s is graphicall illustrated in the 3lo8chart sho8n on page
--.
1%,%& Test Pre(arations
$# 'a!e container<s in3ormation7 measurements and record them into the 3orm 00000
-# Clean 0000000000 ;OAM
3# Prepare the li3ting point that 8ill "e used to appl tension to the container during the proo3 load test.
0000000
D# 4a!e sure that the "atter o3 the load cell<s remote reader is in good condition " turning on the
remote and ma!ing sure the E"atter lo8F indicator is not O%.
.# Chec! the cali"ration date o3 load cell and ma!e sure that its last cali"ration is still (alid.
6# Determine the proo3 load 8eight o3 the hoo! using the @ritish Standard 000000000000.
2# 'est the AC o!e "e3ore commencing the Bo" as 3ollo8s:
d. S8itch the AC o!e on " 3lipping on the O%CO// s8itch o3 the o!e to appl magnetic 3ield
to the test piece.
e. 'r li3ting the test piece 8ith the o!e to ensure that it applies su33icient magnetic 3ield.
-$
Chapter %o. : 1
Page && o3 $#
Version : UPS 3.0
Issue Date:06Oct06
--
/lo8chart D: O(erall Process o3 'esting @as!ets and Containers
Process
C'e+ t'e 9loor
C'e+
Doors
C'e+ t'e Sling
C'e+ Pad E;e
C'e+ T'e Mar+ing
C'e+ Lo+s
C'e+
9or+li!t
Po+ets
Chapter %o. : 1
Page &, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
1%,%, Visual Testing o! Containers
$# 'he e0amination must "e carried out in ade9uate light7 3ree 3rom shado8.
-# Chec! to ma!e sure that the sa3e 8or!ing load and identi3ication mar!s are legi"le and corresponds
8ith the test certi3ication in accordance 8ith @S 202-.
3# Visuall e0amine all ee pads "oth 3rom inside and outside to ensure the are 3ree 3rom de3ect. A
non#destructi(e test =4PI.> shall "e carried out at the discretion o3 the test engineer.
D# Visuall e0amine 3loor inside and underneath. A hammer ma "e used to loosen and remo(e an
3la!ing rust to chec! condition o3 3loor.
.# Chec! condition o3 3loor "ears to ma!e sure the are 3ree 3rom corrosion.
6# +0amine the 3loor and ma!e sure that it is su"stantiall 3lat 8ith no sign o3 distress or o(erload.
2# Chec! "ase 8eld7 "oth inside and under side 3or de3ect.
H# Chec! 3or a"normal dents7 or tears.
I# Chec! condition o3 3or! li3t poc!ets particularl the "ottom strap at point o3 entr.
$0# Chec! 3or! li3t poc!ets to ensure that the ha(e a minimum opening o3 -00mm 0 I0mm
$$#
$-# Chec! 3or! li3t poc!ets to ensure that are located no more than -.0.m apartN measured 3rom the
centre o3 poc!et to centre o3 the other poc!et.
$3# Chec! release catches and open the doors 3ull =i3 3itted> chec!ing the 3reedom o3 operation and
alignment.
$D# Chec! condition o3 door seals =i3 3itted>.
$.# 'he diameter o3 holes in pad ees shall match the shac!le used7 tolerance "et8een shac!le "olt and
pad ee hole diameter shall not e0ceed 6G o3 the nominal shac!le "olt diameter.
$6# Chec! to ensure that an di33erence in the diagonal measurements "et8een pad ees< centers does
not e0ceed 0.-G o3 the length o3 the diagonal or . mm 8hiche(er is greater.
$2# 'he pad ee must "e cleaned and 3ree 3rom delirious matter.
$H# +nsure pad ee is smooth and 3ree nic!s 7 gouges and an other de3ects that could act as stress
raisers.
$I# Chec! pad ee 3or 8ear7 distortion7 elongation and signs o3 crac!ing.
-0# Chec! all 8elds and heat a33ected 5ones 3or signs o3 damage 7distortion 7and o(erloading.
-$# Chec! all stenciling and paint mar!ing and ma!e sure the are done according to @S 202-.
--# I3 an 3aults are 3ound at the time o3 e0amination 8hich 8ould a33ect the use o3 machine7 then it must
"e 8ith dra8n 3rom ser(ices and details recorded on test report.
-3
Chapter %o. : 1
Page &. o3 $#
Version : UPS 3.0
Issue Date:06Oct06
S*L
/ Ton 0
Reommend
S'a+le
Dim
A
Dim
:
Dim
C
Dim
D
Dim
E
Dim
9
Dim
G
Dim
6
Dim
=
- D O ' 6. 3. H0 $. 30 $0 -D D. 6
D D O ' 2. D. $00 $. 30 $0 -D D. 6
6 6 P ' I0 .. $.0 -0 D0 $0 -2 60 6
H I P ' $00 60 $H0 -. D. $0 3D 20 $0
$0 $- ' $$. 20 -$0 -. D. $0 32 H0 $-
$- $3 P ' $30 H0 -.0 -. .0 $. D0 I0 $-
$2 $2 ' $60 I0 -.0 30 20 $. D2 $-0 $-
'a"le $: Standard Pad +es dimensions =in mm> and suita"le shac!le si5es =in inches>
According to US /ederal SP+C. ))#C-2$#@

-D
Chapter %o. : 1
Page &1 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
-.
Chapter %o. : 1
Page &2 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'a"le -: Shac!les standard dimensions according 'o US /ederal Speci3ications
All reBection criteria are in accordance 8ith "oth manu3acturer<s recommendation and the rele(ant standards.
1%,%. MPI /Magneti Partile Ins(etion0 o! Containers
Struture *elds) All accessi"le load "earing 8elds should "e 4PI e0amined "
$# AdBust the spacing "et8een the o!e<s pro"es so that "oth pro"es esta"lish phsical contact 8ith
8elds.
-# S8itch the AC o!e O%
3# Appl the dr po8der to the 8elds =8hile the AC o!e is still on> so that the 8hole is co(ered 8ith
po8der
D# @lo8 the po8der o33 the 8elds. Use a "lo8er 8hen a(aila"le
.# Visuall inspect the traces o3 the po8der on the hoo! 3or an indications o3 crac!s
6# I3 an crac!s e0ist7 reBect the containers and issue a reBection report
2# I3 not crac! e0ist7 continue the test as 3ollo8s
H# )epeat pre(ious steps 3or the all 8elds to ensure 3reedom 3rom de3ects.
Li!ting (oints: 'he li3ting points should "e 4PI e0amined 3or distortion7 mechanical damage or an
other sign o3 distress or o(erload to ensure 3reedom 3rom de3ects.
Li!ting set: I3 the container is 3itted 8ith li3ting set this should "e 4PI e0amined to ensure 3reedom 3rom
de3ects " using pre(ious steps 3or the all 8elds to ensure 3reedom 3rom de3ects
Pad e;e should "e 4PI e0amined " using pre(ious steps 3or the all 8elds to ensure 3reedom 3rom
de3ects3or 8ear7 distortion7 elongation and signs o3 crac!ing
6# Appl the "lac! in! spra o(er the area to "e tested.
Chec! all 8elds and heat a33ected 5ones 3or signs o3 damage7 distortion7 and o(erloading.
1%,%1 Proo! Load Test o! Containers
$. Place a uni3orm distri"ution test load o(er the 3loor o3 the container in such a 8a that com"ined
8eight o3 the container and test load is e9ual to t8o times the ma0imum gross 8eight
-. Proo3 load testing 3rom all point li3ting: the container shall "e loaded to a total gross mass o3 -.. .
and li3ted using all pad ees according to @S +% $-02I. =. is the container<s rating i.e. the ma0imum
gross mass o3 the container and its cargo in !g.>
3. Proo3 load testing 3rom t8o point li3ting: An o33shore container 3itted 8ith 3our pad ees shall also "e
3itted 3rom onl t8o pad ees situated diagonall opposite each other 8ith a total mass o3 $.. .
according to @S +% $-02I.
-6
Chapter %o. : 1
Page &3 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
?i3t the container 8ith a li3ting set suita"le 3or test purpose7 i.e. one 8hich as an included angle o3
appro0imatel I0 "et8een the rele(ant sling legs. I3 a container is normall 3itted 8ith a li3ting set this set
should not "e used 3or the proo3 load test.
D. 4aintain the proo3 load on the container 3or a minimum . min.
.. %o de3lections during testing shall "e greater than $C300 o3 the span o3 the mem"er.
6. 'he container shall sho8 no permanent de3ormation.
-2
Chapter %o. : 1
Page &4 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
7*5 6enerating 8ontainers .e-ection .eports
-H
Chapter %o. : 1
Page &$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
... *enerating Containers Certi3icates
-I
Chapter %o. : 2
Page ,5 o3 $#
C'a(ter 2) *or+ Instrutions !or Testing Cranes
(According to %S 0&'&)
Version : UPS 3.0
Issue Date:06Oct06
2% *or+ Instrutions !or Testing Cranes
(*& Scope and +,-ective
'his chapter details the procedures 3or the pre#use chec!s7 in#ser(ice testing7 thorough e0amination and
testing o3 cranes7 including associated e9uipment7 and the means " 8hich tests are to "e carried out.
(*' 4efinitions
T'oroug' e>amination) +0amination " a competent person in such depth and detail as the competent
person considers necessar to ena"le them to determine 8hether the e9uipment "eing e0amined is sa3e to
continue in use.
%O'+: 'he thorough e0amination is not part o3 the maintenance regime 3or the e9uipment "ut pro(ides
o8ners 8ith in3ormation 8hich could he used to determine the e33ecti(eness o3 the regime.
Com(etent (erson) Person 8ho has such practical and theoretical !no8ledge and e0perience o3 the li3ting
e9uipment to "e thoroughl e0amined 8hich ena"les them to detect de3ects or 8ea!nesses and to assess
their importance in relation to the sa3et and continued use o3 the li3ting e9uipment.
Com(etent engineer) Person 8ho has such theoretical !no8ledge o3 the design o3 the li3ting e9uipment to
ena"les them to assess the design o3 the item in order to esta"lish appropriate criteria 3or a thorough
e0amination.
%O'+: Lno8ledge o3 Q3orce analsis< is a great aid to the competent engineer 8hen per3orming crane
thorough e0amination.
Ins(etion ?od;) +mploer o3 the competent person=s> 8ho pro(ide e0amination and testing ser(ices
/ype A inspection ,ody
Inspection "od pro(iding Ethird#partF ser(ices in accordance 8ith @S +% D.00D:$II.7 Anne0 A
/ype % inspection ,ody
Inspection "od 8hich 3orms a separate and identi3ia"le part o3 an organi5ation in(ol(ed in the design7
manu3acture7 suppl7 installation7 use or maintenance o3 the items it inspects and has "een esta"lished to
suppl inspection ser(ices to its parent organi5ation criteria in accordance 8ith @S +% D.00D:$II.7 Anne0 @
/ype 8 inspection ,ody
Inspection "od 8hich is in(ol(ed in the design7 manu3acture7 suppl7 installation7 use or maintenance o3 the
items it inspects or o3 similar competiti(e items and ma suppl inspection ser(ices to other parties not "eing
its parent organi5ation in accordance 8ith @S +% D.00D: $II.7 Anne0 C
9untional testing) Operation o3 each motion o3 the appliance 8ithout a load applied in order to determine
8hether the e9uipment per3orms as the manu3acturer intended
Per!ormane testing) Operation o3 each motion o3 the appliance 8ith the rated load applied in order to
determine 8hether the e9uipment per3orms to the manu3acturer<s speci3ication
Stati Overload testing) Operation o3 the appliance 8ith a load e0ceeding the rated load applied "ut 8ithout
operating the 3ull range o3 motions o3 the appliance in order to determine 8hether the appliance is sta"le7
structurall sound and 3it 3or the use 3or 8hich it 8as designed
30
Chapter %o. : 2
Page ,# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
D;nami Overload testing) Operation o3 each motion o3 the appliance 8ith a load that e0ceeds the rated
load applied in order to determine 8hether the appliance is sta"le7 structurall sound and 3it 3or the use 3or
8hich it 8as designed
Non@destrutive testing /NDT0) 'esting carried out on the structure o3 the appliance to esta"lish the
presence7 location and e0tent o3 an de3ects that can a33ect the integrit o3 that structure
%O'+ 'he techni9ues emploed 3or non#destructi(e testing are such that the do not damage or alter the
material under test. %D' is also !no8n as non#destructi(e e0amination =%D+>.
User) Person or organi5ation that has control o3 "oth the li3ting operation and the crane operator7 and has a
responsi"ilit to ensure that cranes and other e9uipment are properl maintained and thoroughl e0amined
" a competent person.
Rated a(ait; indiatorAlimiter /RCIAL0) De(ice that 8arns and pre(ents the crane 3rom "eing o(erloaded
as descri"ed in the Suppl o3 4achiner =Sa3et> )egulations R6S Schedule 3 +;S) D.-.$.D
%O'+: 'his 8as pre(iousl !no8n as an Eautomatic sa3e load indicatorF and Eo(erload protectionF.
Crane o(erator) Person 8ho is operating the crane 3or the purpose o3 positioning loads or 3or erection o3 the
crane
Load radius indiator) De(ice 3itted to a crane that sho8s the radius at 8hich the crane is operating and its
corresponding rated capacit
Radius) ;ori5ontal distance "et8een the point at 8hich the centre o3 rotation o3 the crane meets the ground
and the (ertical centerline passing through the load li3ting attachment
%O'+: In the case o3 a non#sle8ing crane7 the hori5ontal distance 3rom the centerline o3 a load li3ting
attachment to the centerline o3 the nearest a0le7 "ogie or trac!7 measured at ground le(el7 ma "e assumed
to "e the radius 3or the purpose o3 this de3inition.
Rated a(ait;) 4a0imum load that can "e sa3el handled " a crane at a speci3ied position and under
speci3ied conditions
%O'+: 'he rated capacit 8as 3ormerl !no8n as Esa3e 8or!ing loadF.
In@servie) Condition 8here the crane is handling loads less than the rated capacities 8ithin permissi"le
8ind speeds and other conditions as speci3ied " the manu3acturer
Out@o! servie) Condition 8here the crane is either not re9uired 3or use or is out o3 use7 8ithout a load on
the load li3ting attachment and in conditions as speci3ied " the manu3acturer
%O'+: 'hese conditions ma include a higher 8ind speed than that permitted 3or the in#ser(ice conditions.
Li!ting) 4o(ement o3 loads or persons necessitating7 at a gi(en moment7 a change o3 le(el
Li!ting aessor;) ?i3ting e9uipment 3or attaching loads to machiner 3or li3ting purposes
(*! .esponsi,ilities of Involved 2arties
+.!.1 Res$onsibilities o' t,e Crane User
'he crane user should ensure that the crane is ta!en out o3 use 3or the period o3 time re9uired " the
competent person to carr out the thorough e0amination. 'he user should also ensure that a sa3e sstem o3
8or! is in place to pre(ent the competent person 3rom "eing e0posed to danger " inad(ertent operation o3
the crane.
Ahere the crane is hired 3rom a third part7 the user should ensure that the thorough e0aminations are
underta!en at the re9uired inter(als. 'he user might come to an arrangement 8ith the o8ner 8here" the
o8ner carries out the thorough e0aminations "ut the user should ensure the are carried out.
3$
Chapter %o. : 2
Page ,& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.!.1.1 Provision o' -ailities an" Servies
'he crane user should ensure that 3acilities or ser(ices 8hich are re9uired " the competent person to carr
out the thorough e0amination are pro(ided. 'hese could include the 3ollo8ing.
Appropriate area7 cordoned o33 to pre(ent access " persons not directl in(ol(ed in the e0amination.
Operator 3or the crane.
Person=s> to remo(e co(ers or open up parts o3 the crane.
Preparation o3 parts or areas o3 the crane 3or %D'.
+.!.1.2 Provision o' In'ormation
In3ormation regarding rated capacities7 alterations7 maintenance repairs7 rene8als7 operators< instructions7
should "e made a(aila"le to the competent person i3 these are necessar to carr out the thorough
e0amination.
%O'+: Attention is dra8n to the Suppl o3 4achiner =Sa3et> )egulations R6S 8hich re9uire that cranes and
other e9uipment ac9uired a3ter $F Tanuar $II. are C+ mar!ed and supplied 8ith a Declaration o3
Con3ormit together 8ith the supporting technical documentation.
+.!.1.! Reti'iation o' .e'ets
Ahere the competent person identi3ies de3ects a33ecting the continued sa3e use o3 the crane7 or speci3ies a
timed replacement o3 components etc.7 the crane user should ensure that these de3ects are recti3ied.
%O'+: %ormall the o8ner o3 the crane is responsi"le 3or carring out the 8or! "ut the user is responsi"le
3or ensuring that the crane is not used until the de3ects are recti3ied.
+.!.2 Res$onsibilities o' t,e Com$etent Person
Ahere the competent person identi3ies de3ects 8hich need to "e recti3ied 8ithin a speci3ied timescale7 the
should su"mit a report promptl to allo8 the emploer to ta!e the necessar action 8ithin the re9uired
period.
I37 8hilst carring out a thorough e0amination7 a competent person sees that a li3ting accessor or e9uipment
is not sa3e 3or an reason7 in addition to de3ects caused " deterioration7 this should also "e noti3ied to the
user and o8ner o3 the li3ting accessor or e9uipment.
(*5 /est Ele3ents of 8ranes /esting 2rocess
'esting or cranes is per3ormed " the competent person and could include - main test elements:
$. 'horough +0amination
A. Visual inspection
@. /unctional 'est
C. Per3ormance 'est
D. %D' =%on#Destructi(e 'esting>
+. )CIC? 'estCCali"ration
/. Assessment o3 Aire )ope Condition
-. O(erload 'est
'he competent person should speci3 precisel 8hat is re9uired7 to ensure that such 8or! is e33ecti(el
managed and that the results o3 the 8or! are assessed accuratel in relation to their signi3icance 3or the
crane.
3-
Chapter %o. : 2
Page ,, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.#.1 T,orou(, /0amination
'horough e0amination o3 a crane includes testing. 'his can ta!e man 3orms including 3unctional testing7
per3ormance testing7 non#destructi(e testing =%D'> and o(erload testing.
'he competent person should decide 8hen a test is necessar and determine the most appropriate method
o3 carring it out.
It is important there3ore that the competent person ta!es account o3 the instructions and other rele(ant
in3ormation pro(ided " the manu3acturer or other appropriate specialist
'horough e0amination could "e carried out periodicall or in certain situations as descri"ed "elo8:
A1 Perio"i T,orou(, /0amination
i* SixMonths /horough Exa3ination
Cranes used to li3t persons7 and li3ting accessories should undergo a thorough e0amination " a competent
person at least once e(er 6 months unless the competent person speci3ies a shorter inter(al.
ii* /:elveMonths /horough Exa3ination
Cranes 8hich are not used to li3t persons should "e su"Bect to a thorough e0amination " a competent
person at least once e(er $- months. A3ter carring out the thorough e0amination the competent person
should speci3 8hen the ne0t thorough e0amination is to "e carried out7 8hich ma "e less than "ut not more
than $- months.
21 T,orou(, /0amination 2e'ore Loa" Test
Prior to load testing the competent person should determine " thorough e0amination 8ith the crane
in motion and at rest 8hether it is:
A. 3ree 3rom an de3ect that 8ould preclude it 3rom sa3el handling the test loadN
@. In the correct con3iguration and condition according to the instructionsN
C. +9uipped 8ith su33icient 3alls o3 8ire rope 3or the load under consideration.
All sa3et s8itches7 3or e0ample o(er hoist7 lo8ering limit7 derric!ing limit7 trolle limit7 should "e
chec!ed 3or correct operation.
?i3ting accessories should "e thoroughl e0amined "e3ore the test and the competent person should
determine 8hether the slinging arrangements are sa3e.
C1 T,orou(, /0amination A'ter Loa" Test
A3ter load testing7 a thorough e0amination =see 2.$> should "e underta!en " a competent person to
determine 8hether the crane has 8ithstood testing 8ithout signs o3 structural damage that could a33ect the
sa3et o3 the crane7 such as:
$. Crac!ingN
-. Permanent de3ormationN
3. Paint 3la!ingN
D. ?oosening o3 or damage to structural connections.
.1 T,orou(, /0amination A'ter S$eial Ini"ents
A crane should "e re#inspected a3ter installation on a ne8 site7 a3ter maBor alteration or repair or a3ter the
occurrence o3 e0ceptional circumstances 8hich could Beopardi5e the sa3et o3 the crane.
33
Chapter %o. : 2
Page ,. o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.#.1.1 3isual Testin(
Visual testing is the 3irst component in the crane testing process. It relies on the e0pertise o3 the competent
person to identi3 de3ects and pro"lematic areas or parts o3 the crane that could cause 3uture pro"lems.
Visual testing (aries 3rom one tpe o3 crane to another as elements to (isuall chec! are di33erent 3or di33erent
tpes o3 cranes. Visual testing o3 mo"ile cranes and o(erhead cranes is discussed in detail later in this
chapter.
+.#.1.2 -untional Testin(
/unctional testing should "e carried out 8ithout a load applied. 'he o"Bect o3 3unctional testing is to
determine 8hether the e9uipment per3orms as the manu3acturer intended. 'his should include the operation
o3 all controls =including an remote controls> to determine 8hether the e9uipment operates correctl and
smoothl7 and is 3ree 3rom 8ear and other damage.
/unctional testing should "e carried out on all 3unctions o3 the crane7 including "ra!es and sa3et de(ices
8here it might "e necessar to include the li3ting o3 a suita"le load once these de(ices ha(e "een tested
8ithout a load applied.
+.#.1.! Per'ormane Testin(
Per3ormance testing should "e carried out a3ter 3unctional testing and :ith the rated load applied. 'he o"Bect
o3 per3ormance testing is to determine 8hether the e9uipment per3orms to the manu3acturer<s speci3ication.
'his should include the operation o3 all controls =including an remote controls> to determine 8hether the
e9uipment operates correctl and smoothl at the rated speeds7 and is 3ree 3rom 8ear and other damage.
Per3ormance testing should "e carried out on all 3unctions o3 the crane including "ra!es and sa3et de(ices.
+.#.1.# Non4.estrutive Testin( 5N.T1
During testing o3 a crane the competent person might consider it appropriate to appl %D' techni9ues to
assess the integrit o3 components. 'hese techni9ues can assist in the detection o3 an material crac!s or
de3ects that might gro8 in ser(ice and ultimatel lead to 3ailure. 'he three most common tpes o3 %D' used
are as 3ollo8s:
A1 Ma(neti $artile e0amination
In this techni9ue a magnetic 3ield is induced in the area under e0amination 8hilst the sur3ace is 3looded 8ith
3errous particles suspended in a li9uid. An crac!s or de3ects cause a discontinuit in the magnetic 3ield
8hich in turn causes the 3errous particles to cluster o(er the de3ect7 indicating its presence " a dar! line.
'his techni9ue is onl suita"le 3or magnetic materials =most structural steels and some stainless steels> and
onl detects sur3ace de3ects and large de3ects Bust "elo8 the material sur3ace. =According to %SI("0'$ AS1/
/raining 2rogra3 for M2I$ AS1/ /raining 2rogra3 of 4ye 2enetrant)
21 .6e $enetrant
In this techni9ue the sur3ace o3 the material is 3looded 8ith a li9uid de 8hich penetrates into an sur3ace
crac!s or de3ects. A3ter a speci3ied period the de is cleaned o33 and the sur3ace spraed 8ith an a"sor"ent
Ede(eloperF 8hich dra8s the de 3rom an de3ects indicating the presence o3 the de3ect. 'he techni9ue is
o3ten emploed on non#3errous materials such as aluminum allos7 "ut can onl locate sur3ace de3ects.
=According to %SI("0'$ AS1/ /raining 2rogra3 for M2I$ AS1/ /raining 2rogra3 of 4ye 2enetrant)
C1 Ultrasoni e0amination
In this techni9ue pulses o3 high 3re9uenc sound 8a(es are transmitted 3rom the sur3ace o3 the material into
its interior. An de3ects or discontinuities cause the sound 8a(es to "e re3lected "ac! to the sur3ace 8here
the can "e detected and7 " measuring the time dela 3rom the time o3 transmission7 an estimate o3 the
de3ect<s depth "elo8 the sur3ace can "e made. 'he techni9ue can "e used 3or a 8ide range o3 materials and
detects "oth sur3ace and su"sur3ace de3ects.
3D
Chapter %o. : 2
Page ,1 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.#.1.7 Testin( o' Rate" Ca$ait6 In"iator8Limiter 5RCI8L1
At least e(er $- months the cali"ration o3 an )CIC? de(ice should "e (eri3ied " the suspension o3
cali"rated 8eights.
'horough e0aminations should include con3irmation that the cali"ration o3 the )CIC? has "een chec!ed "
the suspension o3 8eights on the crane. A cali"ration chec! should also "e carried out 8hen an maBor repair
or modi3ication has "een carried out on the )CIC?. At each successi(e cali"ration7 a di33erent con3iguration o3
the crane should "e chosen so that e(entuall all con3igurations are sstematicall co(ered.
Rate" Ca$ait6 In"iator8Limiter 5RCI8L1 Calibration C,e*
'he 3ollo8ing 8arnings should "e gi(en " the )CIC? 8ithin the speci3ied tolerance.
A. Warning of approach to rated capacity: 'he )CIC? should gi(e a clear and continuous 8arning o3
approach to the rated capacit. 'he 8arning should commence at not less than I0G o3 the rated
capacit and not more than I2..G. 'he approach to rated capacit 8arning should continue to
3unction until the percentage o3 load 3alls to "elo8 the (alue at 8hich the 8arning 8as initiated.
@. Warning of overload: 'he )CIC? should gi(e a clear and continuous 8arning o3 o(erload. 'he
8arning should commence at not less than $0-..G o3 the rated capacit and not more than $$0G.
'he o(erload 8arning should continue to 3unction until the percentage o3 the load to the rated
capacit 3alls to "elo8 the (alue at 8hich the 8arning 8as initiated.
%ote: During the cali"ration chec! o3 the )CIC? it is essential that the crane is not loaded "eond $$0 G o3 its
rated capacit. 'he radiusCangle at 8hich the test load corresponds to $$0 G o3 the rated capacit should "e
mar!ed and the test load should not "e ta!en "eond that point.
+.#.1.+ Assessment o' Wire Ro$e Con"ition
'he continued sa3e use o3 8ire ropes depends on regular assessment o3 the condition o3 the ropes and the
e9uipment 8ith 8hich the are used. /igure $ sho8s some points to "e considered as part o3 the
assessment o3 the 8ire rope condition.
Some cranes operate in conditions 8here the 8ire ropes and e9uipment are particularl lia"le to damage7
e.g. corrosi(e atmosphere7 a"rasi(e particles. In such circumstances7 assessment o3 the condition o3 the
rope and the e9uipment should "e care3ull carried out and the rope remo(ed 3rom ser(ice 8hen the damage
a33ects its sa3e operation.
)ecords should "e !ept o3 the e0amination and replacement o3 8ire ropes. 'hese should consist o3 the
reports o3 thorough e0amination 3or the crane and certi3icates o3 test 3or the 8ire ropes at time o3 suppl.
Ahen carring out testings and e0aminations to assess the 3itness o3 the 8ire rope 3or 3urther ser(ice7 "oth
general deterioration and locali5ed deterioration or damage should "e considered. 'here3ore the 8hole
length o3 the rope should "e e0amined7 paing particular attention to the rope adBacent to the terminations7
lengths that ha(e "een running or stationar o(er drums7 shea(es and de3lection pulles and an other areas
li!el to sustain damage.
I3 the competent person has an dou"ts a"out the sa3e operation o3 the 8ire rope it should "e discarded.
3.
Chapter %o. : 2
Page ,2 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
;igure &<
2oints to ,e
considered
during the
assess3ent of
the :ire rope
8e;
@ @loc!
D Drum
? ?oad
S Shea(e
$ +0amine
termination o3
8ire rope at
drum
-
+0amine 3or de3ecti(e coiling7 8hich causes de3ormations =3lattened portions> and 8ear7 8hich can
"e se(ere at cross#o(er positions
3 +0amine 3or 8ire "rea!s
D +0amine 3or corrosion
. ?oo! 3or de3ormations caused " snatch loading
6 +0amine portion that 8inds o(er shea(e 3or 8ire "rea!s and 8ear
2 Points o3 attachment: chec! 3or 8ire "rea!s and corrosionN similarl7 chec! section o3 8ire rope that
lies on or adBacent to compensating pulles
H ?oo! 3or de3ormation
I Chec! 8ire rope diameter
$0 +0amine care3ull the length o3 8ire rope that runs through the "loc!7 particularl the length that lies
on the pulle 8hen the crane is in a loaded condition
$$ +0amine 3or 8ire "rea!s or sur3ace 8ear
$- +0amine 3or corrosion
36
Chapter %o. : 2
Page ,3 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.#.2 Overloa" Testin(
'he o"Becti(e o3 load testing is to determine 8hether the e9uipment is sta"le7 structurall sound and 3it 3or the
use 3or 8hich it 8as designed. 'he load test carried out " the competent person should include e(er load#
"earing part. 'he competent person should determine 8hether the original or i3 appropriate the pre(ious test
certi3icate is satis3actor7 and su"se9uent testing should "e "ased on this 8ith an necessar modi3ications
to suit the re9uirements o3 the particular item o3 e9uipment.
'o pre(ent undue repetition the test program should "e conducted so that each load#"earing part is gi(en
one o(erload7 3or e0ample to test a 8ire rope hoist mechanism and "ra!es it is onl necessar to su"Bect the
mechanism to the o(erload on ma0imum line pull.
%O'+: 'he competent person might 8ish to consult the manu3acturer or other design authorit to ensure that
the selected test program is ade9uate.
During testing 8ith o(erloads all operations should "e carried out 8ith e0treme care and e(er permissi"le
crane motion carried out singl at the lo:est possi,le speed.
O(erloads should "e !ept as close to the ground as possi"le7 generall "et8een $00 mm and -00 mm. It is
pre3erred that o(erloads are not raised a"o(e -00 mm to allo8 them to pass o(er o"structions. Ahere such
limitations e0ist the competent person should consider an alternati(e test to pro(e the crane in the restricted
area. Ahen no alternati(e test is possi"le and the competent person is not satis3ied that all o3 the crane
duties ha(e "een ade9uatel tested7 use o3 the crane should "e restricted to the tested duties and "oth the
certi3icate o3 test and report o3 thorough e0amination endorsed accordingl.
'o ensure that the load is applied at the correct position an dimensions should "e chec!ed using separate
measuring e9uipmentN the crane instrumentation should not "e used 3or this purpose. All measuring
e9uipment should "e accurate to U$ G o3 the measured (alue unless speci3ied other8ise and "e undamaged
and properl maintained.
'he 8eight o3 the li3ting accessories should "e included as part o3 the test load.
During the test the per3ormance o3 the crane should "e monitored " the competent person.
Test Wei(,ts
'he 3ollo8ing considerations regarding test 8eights should "e ta!en into account 8hen per3orming load
tests:
A. Aeights should "e o3 pro(en accurac 8ithin U$.0 G.
@. Aeights should "e pro(en on a 8eigh"ridge7 the 8eigh"ridge ha(ing "een cali"rated 8ithin the last
$- months.
C. Aeights should "e suspended 3rom a cali"rated 8eighing de(ice7 8hich has "een cali"rated 8ithin
the last $- months and that has a pro(en accurac o3 U$.0 G.
Important: A test load should not "e applied to a crane " pulling against an anchor point instead o3 using
test 8eights. Pulling against anchor points can introduce side loading to the crane and the test load cannot
"e hoisted and applied to all parts o3 the gear train.
32
Chapter %o. : 2
Page ,4 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.#.! Overvie9 o' Crane Testin( Proess
/igure -: Crane 'esting Process O(er(ie8
3H
Chapter %o. : 2
Page ,$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
(*7 /esting of Mo,ile 8ranes
%O'+: 'hese recommendations also co(er mo"ile sel3#erecting to8er cranes.
+.7.1 Re&uire" Tools 'or Ins$etin( Mobile Cranes
$. 4easuring tape7
-. ODCID caliper7
3. 4agnetic AC o!e7
D. ?oad cell7
.. Penetration de chec! spra =there an o3 the container<s components are made o3 an aluminum
allo>
6. ?oad 8eight that is appropriate to the load test and condition o3 site.
+.7.2 Pre$aration
Prior to thorough e0amination the mo"ile crane should "e cleaned " appropriate means7 e.g. pressure
8ashed7 to remo(e all spoilCdirt that 8ould other8ise conceal the structure or mechanisms and pre(ent an
e33ecti(e e0amination. 'he e0amination should "e carried out in a logical se9uence7 3or e0ample top to
"ottom7 to ensure that nothing is o(erloo!ed.
Levelin(
'he importance o3 le(eling the crane cannot "e o(er#emphasi5ed. 'he crane should "e le(el to U0.. G slope
and one method o3 determining the le(el o3 the crane is to use a spirit le(el. Alternati(el7 the hoo! "loc!
should "e in the centre o3 the Bi" 8hen (ie8ed 3rom the 3ront 8ith the Bi" 3ull e0tended at or near minimum
radius and 8ith the unladen hoo! "loc! lo8ered to Bust a"o(e ground le(el. 'he procedure should then "e
repeated 8hen the Bi" has "een sle8ed I00. 'his method o3 le(eling can onl "e used 8hen it has 3irst "een
chec!ed that the Bi" is correctl aligned. An "uilt#in le(eling de(ice should "e chec!ed at this time and reset
i3 necessar. 'he le(eling accurac should "e monitored throughout the tests7 particularl 8hen dealing 8ith
long telescopic and lattice Bi"s. 'esting should "e stopped i3 the le(el e0ceeds the limit gi(en7 an load should
"e remo(ed and the crane re#le(eled.
Li'tin( -ree on W,eels
're pressures are a critical 3actor in retaining the desired sta"ilit margin o3 mo"ile cranes. 'he tres o3
cranes under test should "e as speci3ied in the instructions. Some crane manu3acturers stipulate higher tre
pressure 3or 3ree on 8heels =static condition 3ull mo"ile> duties than 3or road tra(el as a (ehicle. Ahere the
manu3acturer permits li3t and tra(el duties these can di33er 3rom the 3ree on 8heels duties and "oth tpes o3
dut should "e su"Bected to test.
Li'tin( a$aities
'he load ratings mar!ed on mo"ile cranes and sho8n on the manu3acturer<s rated capacit charts indicate
the gross loads7 i.e. the loads 9uoted include the 8eight o3 the hoo! "loc!s7 slings and li3ting gear and o3ten
other deductions7 3or e0ample sto8ed 3l Bi". 'his 3act should "e ta!en into account 8hen the crane is "eing
tested and an allo8ance should "e made 3or the 8eight o3 suspended hoo! "loc!s7 slings and li3ting gear.
'he e0act 8eight o3 these items should "e ascertained. Certain cranes can "ecome unsta"le 8hen 8or!ing
8ith long Bi"s and 3l Bi"s i3 the Bi" angle to the hori5ontal is reduced "elo8 the minimum angle gi(en in the
instructions. 'he hoo! "loc! should al8as "e rested on the ground "e3ore an lo8ering o3 the Bi" "eond the
ma0imum operating radius commences.
3I
Chapter %o. : 2
Page .5 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Test Site Con"itions
$. Care3ul consideration should "e gi(en to the condition o3 the site 8here the tests are to "e
conducted. 'he recommendations pro(ided in the operating instructions 3or the crane relate to
operations 8ithin the rated capacit and more stringent re9uirements appl 8hen loads are "eing
applied 3or the purpose o3 testing.
-. 'he ground should "e 8ell consolidated and capa"le o3 8ithstanding the loads applied to it. 'here
should "e no hidden dangers such as ca"le ducts7 drains7 pipes7 "ac!#3illed areas7 cellars or other
su"terranean 8ea!nesses. Cranes should not "e tested in the (icinit o3 o(erhead po8er lines =see
@S 2$-$#$:$IHI7 I.3.->.
3. 'he ground should "e le(eled as speci3ied in the crane<s instructions manual
D. 'he site should "e o3 su33icient area and ha(e unrestricted o(erhead clearance to allo8 the
uno"structed mo(ement o3 the crane and load throughout its test mo(ement7 3or e0ample sle8ing7
derric!ing and tra(eling.
.. It is pre3era"le that tests are not conducted o(er high ris! areas7 3or e0ample a pu"lic high8a7
rail8a7 occupied "uildings or in the 3light path o3 airports =see @S 2$-$#$:$IHI7 I.3.3>. I3 due to the
re9uirements o3 usage this is una(oida"le7 arrangements should "e made 8ith the appropriate
authorities.
6. ?oad testing is designed to pro(e a craneN ho8e(er the crane might not 8ithstand the loading. All
personnel not essential to the test should "e !ept a8a 3rom the area. 'he test area should "e roped
o33 and notices posted prohi"iting unauthori5ed entr. 'he site should "e clear o3 plant and propert
8hich could inhi"it the test.
Weat,er Con"itions
/or cranes operating in situations 8here the are li!el to "e a33ected " the 8eather7 do not per3orm
the 'esting process under certain 8eather conditions such as electric storms7 strong 8ind7 hea(
rains7 ice7 sno8 or e0cessi(e sea state as this can impose loads on a crane or ad(ersel a33ect the
sa3et o3 crane operations.
It is essential that tests are not underta!en 8hen the crane or load cannot easil "e seen "ecause o3
limitations on (isi"ilit =including inade9uate lighting> or 8hen hea(il coated 8ith ice or sno8.
'he crane should not "e operated in 8ind speeds =or in the case o3 8ater#"orne cra3t7 sea
statesCsigni3icant (essel mo(ement> that are in e0cess o3 those speci3ied in the operating instructions
3or the crane. During o(erload testing the limiting 8ind speed is reduced so ad(ice should "e sought
3rom a design authorit "e3ore o(erload testing is carried out.
+.7.! 3isual Testin(
$. Visuall e0amine the tres 3or 8ear7 damage7 and in3lation pressure.
-. Carr out a (isual e0amination and 3unctional chec! on the a0le loc!ing sstem 3or correct operation7
3reedom 3rom lea!s7 damage7 corrosion7 distortion and correct operation o3 all indicators.
3. Visuall e0amine the cra8ler trac!s 3or 8ear and adBustment.
D. Visuall e0amine the crane structure7 including the chassis7 3or signs o3 damage7 distortion7 crac!ing
and corrosion.
.. Visuall inspect all "olts and 3astenings to chec! that the are not coming loose.
6. Visuall e0amine the sle8ing mechanism 3or securit and 8ear during operation o3 the sle8 motion
throughout its 3ull range o3 mo(ement and 8ith the crane at ma0imum reach.
2. Visuall e0amine all pipe 8or! on the crane 3or corrosion7 damage7 lea!age7 securit and 3retting.
H. +0amine all hdraulic clinders 3or lea!age7 corrosion on the rods and alignment. Visuall chec! end
3i0ings 3or 8ear7 securit and lu"rication.
D0
Chapter %o. : 2
Page .# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
I. Visuall inspect the super structure and Bi" o3 the crane 3or corrosion7 damage7 crac!s and distortion.
$0. Visuall e0amine all pi(oting Boints on the Bi" and attachments o3 the crane 3or 8ear7 corrosion7
securit and e(idence o3 lu"rication.
$$. Operate telescoping e0tensions on the crane and (isuall e0amine them 3or 8ear and securit.
$-. Visuall e0amine all 8ire ropes to determine 8hether the are o3 the si5e and tpe speci3ied in the
instructions and ree(ed in accordance 8ith those instructions.
$3. Visuall chec! 8hether all pullesCshea(es and drums are 3ree 3rom damage and 8ear7 8hether the
rope 3its correctl on them and i3 the are e33ecti(el lu"ricated. Chec! 8hether all pullesCshea(es
turn 3reel and that all guards are undamaged and in place.
$D. 'horoughl e0amine the 8hole length o3 the 8ire ropes 3or signs o3 8ear7 damage7 "ro!en 8ires and
corrosion.
$.. Visuall inspect the "ra!ing mechanism 3or 8ear7 damage and adBustment and chec! 8hether it
con3orms to the instructions 3or the crane.
$6. Chec! an means o3 access 3or completeness and securit o3 ladders7 8al!8as and hand
railsChand holds.
$2. Visuall e0amine the outrigger Bac!s and "eams 3or 8ear7 securit7 3reedom o3 mo(ement and
mar!ings to sho8 the correct e0tension 3or the "eams. +0tend the Bac!s and (isuall chec! 8hether
the mo(e 3reel and smoothl and that 8hen le3t supporting the crane7 the do not creep.
$H. Chec! the oil and other 3luids 3or condition =3or e0ample " de"ris monitoring> and le(el o3 the 3luid.
$I. Visuall chec! 8hether the 3i0ings 3or the operator<s seat7 8here 3itted7 and restraint are all in place
and secure.
-0. Chec! 8hether all control le(ers are mar!ed 8ith their 3unction and mode o3 operation.
-$. Visuall inspect the upper and lo8er hoist limit s8itches7 chec! i3 the are in place and 3ree 3rom
damage and e0cessi(e 8ear.
--. Visuall e0amine the hoo!s7 their attachments and sa3et catches 3or 8ear7 3retting7 distortion7
corrosion and securit.
-3. Visuall e0amine the 3l Bi" and mounting attachment 3or corrosion7 crac!ing7 distortion and 8ear.
-D. Chec! 8hether the hoist limit s8itch is in good 8or!ing order.
-.. Chec! 8hether there is a ta"le displaed in the operator<s ca"in sho8ing the rated capacities 3or the
mo"ile crane 3or all crane operating conditions =3ree on 8heels7 3ree on cushion 8heels7 all permitted
outrigger positions etc.>.
-6. Chec! 8hether 8arning signs and other important instructions are present and reada"le7 3or e0ample
rating plate 3or load li3ting.
%O'+: On telescopic Bi" mo"ile cranes the Bi" should "e dismantled at least once e(er D ears to e0amine
an hidden mechanism parts7 3or e0ample rope and rope terminations7 hdraulic clinders.
On lattice Bi" cranes all o3 the Bi" sections should "e co(ered " a test certi3icate.
+.7.# -untional Testin(
/unctionall test all controls 3or smoothness o3 operation and to determine 8hether the are 3ree 3rom 8ear
and other damage.
+.7.7 O$erational Testin(
Operate the mo"ile crane to chec! 8hether all motions operate smoothl and e33ecti(el 8ithout e0cessi(e
pla. 'he load li3ting attachment should not drop e0cessi(el a3ter the motion has "een stopped and all
limiters and sa3et de(ices should operate correctl.
+.7.+ Rate" a$ait6 In"iator8Limiter 5RCL8L1 Calibration C,e*
'esting o3 cranes should include con3irmation that the )CIC? has "een cali"rated to an accurac 8ithin the
tolerances gi(en "elo8. 'his cali"ration is not necessaril part o3 o(erload testing. 'his cali"ration chec!
should "e carried out at no more than $- monthl inter(als. At each successi(e cali"ration7 a di33erent
con3iguration o3 the mo"ile crane should "e chosen so that e(entuall all con3igurations are sstematicall
co(ered.
D$
Chapter %o. : 2
Page .& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
During the cali"ration chec! o3 the )CIC? it is essential that the mo"ile crane is not loaded "eond $$0 G o3
its rated capacit. 'he radiusCangle at 8hich the test load corresponds to $$0 G o3 the rated capacit should
"e mar!ed and the test load should not "e ta!en "eond that point.
+.7.: N.T 5Non4.estrutive Test1
%D' o3 mo"ile cranes might "e necessar7 particularl 8hen there is a suspicion that crac!s or other damage
are present in structural parts o3 the crane. =According to %SI("0'$ AS1/ /raining 2rogra3 for M2I$ AS1/ /raining
2rogra3 of 4ye 2enetrant)
+.7.; Overloa" Test
4o"ile cranes 8ith a rated capacit less than .00 t should "e o(erload tested e(er D ears. 4o"ile cranes
8ith a rated capacit that e0ceeds .00 t should "e o(erload tested during the $- monthl cali"ration o3 the
)CIC? in the chosen con3iguration. At each successi(e cali"ration7 a di33erent con3iguration should "e chosen
so that e(entuall all con3igurations are sstematicall co(ered.
@e3ore the application o3 a load7 (eri3 that the crane is rigged in accordance 8ith the instructions 3or the
crane.
'he competent person should chec! the rated capacit speci3ied on the manu3acturer<s certi3icate o3 test7 the
load radius indicator7 the ta"le o3 rated capacities displaed in the operator<s ca" and those used " the
)CIC?. 'he rated capacities should all "e identical.
4o"ile cranes ha(e a large (ariet o3 support sstems =3or e0ample cra8ler trac!s7 tres and outriggers>7 Bi"
con3igurations7 counter8eights and special attachments7 all o3 8hich a33ect sta"ilit and strength. 'he
competent person should ta!e account o3 all (ariations7 3or 8hich a "rie3 o(er(ie8 is gi(en "elo8:
Outri((ers
Certain manu3acturers gi(e duties 3or intermediate outriggers e0tension. 'he competent person should chec!
the 3ollo8ing items:
A. 'he intermediate e0tension position is clearl and dura"l mar!ed.
@. 'he manu3acturer<s certi3icate indicates the correct rated capacities applica"le to the outrigger
e0tension.
C. 'he dut charts gi(e the speci3ied intermediate e0tensions.
D. Pro(ision is made in the )CIC? to accommodate the speci3ied intermediate e0tension.
Counter9ei(,t
Variations in counter8eights a33ect the sta"ilit o3 the crane. 'he manu3acturer<s dut charts speci3 the
ratings applica"le 3or each counter8eight. Sometimes mo"ile cranes ha(e additional 8eights and special rigs
to enhance the li3ting capacities. 'he competent person should chec! 8hether the correct counter8eight is
on the crane.
<ibs
4anu3acturers might suppl Bi"s 3or di33erent duties 3rom materials o3 di33erent speci3ications7 8hich might not
"e apparent 8ithout care3ul chec!ing. 'he correct Bi" sections should "e used 3or the dut under
consideration. 'here are a large (ariet o3 possi"le Bi" con3igurations on man cranes. 'he crane should "e
rigged in accordance 8ith the instructions 3or the crane7 3or e0ample 3or long Bi"s intermediate ties might "e
re9uired. It is also sometimes necessar to identi3 precisel in 8hich order the sections are 3itted.
-l6 <ibs
D-
Chapter %o. : 2
Page ., o3 $#
Version : UPS 3.0
Issue Date:06Oct06
/l Bi"s should "e erected and used in accordance 8ith the instructions 3or the crane. 'he 3l Bi"7 li!e the hoo!
and "loc!7 has a ma0imum rated capacit. At small radii7 the 3l Bi" should not "e o(erloaded. At larger radii7
the load on the 3l Bi" should "e reduced in accordance 8ith the li3ting capacit o3 the main Bi"C3l Bi"
com"ination.
Ahen a load is li3ted on the main hoo! 8ith the 3l Bi" 3itted7 the load on the main hoo! should "e reduced to
allo8 3or the 8eight o3 the 3l Bi" and 3l hoo!. 'he ma0imum permissi"le angle o3 the main Bi" to the
hori5ontal should not "e e0ceeded 8hen the 3l hoo! is at its minimum radius as there is a danger o3 the Bi"
3alling "ac! due to 8ind and dnamic loading.
An necessar deductions and limitations in load (alue should "e in accordance 8ith the instructions. 4an
3l Bi"s are capa"le o3 (ariation in length andCor angle o3 o33set. 'he tie ropes should "e o3 e9ual length and
3itted in accordance 8ith the instructions. 'he o33set angle =i3 applica"le> should "e chec!ed " calculation
andCor measurement.
3ariable len(t, %ibs
Ahen Bi" lengths are increased " 3itting intermediate sections it is necessar to identi3 them to ensure the
sections are correct 3or the model o3 crane7 3or e0ample to a(oid mismatch o3 metric and imperial sections.
'he identi3ication o3 the Bi" sections tested should "e recorded on the test certi3icate.
%O'+ Attention is dra8n to ?O?+) )egulation 2 R$S 8hich re9uires that all Bi" sections are mar!ed to
indicate to 8hich crane the "elong.
Overloa" Test Proe"ures
Important: @e3ore commencing an o(erload test the pre(ious test certi3icate7 8here a(aila"le7 should "e
e0amined as this 3orms the "asis 3or the test conducted. Ahere no test certi3icate is a(aila"le the crane
manu3acturer<s =or other suita"le design authorit<s> ad(ice should "e sought as to a suita"le test program
=see $3..> and the a"ilit o3 the crane to 8ithstand a -.G o(erload.
$. Chec! the e33icienc o3 the crane<s hoist "ra!e=s> 8ith the rated capacit that gi(es the ma0imum line
pull on the hoist rope=s>.
a. ?i3t the load clear o3 the ground and appl the "ra!e " returning the control to neutral. 'here
should "e no 3all "ac! or creep.
". )e#hoist the load and re#appl the "ra!e to chec! the a"ilit to re#hoist.
c. ?o8er the load and return the control to neutral 8ith the load still clear o3 the ground. 'here
should "e no o(errun or creep.
%ote: At e(er con3iguration in the test program the crane should "e set up 8ith the test load at a
radiusCangle 8ithin the rated capacit o3 the crane.
-. )aise the test load Bust clear o3 the ground and the derric! the crane out to the radiusCangle 8here
the test load is $-. G o3 the rated capacit o3 the crane.
3. )aise the load until e(er tooth in the train o3 the hoist gears has "een su"Bected to the o(erload and
then lo8er the load to "et8een $00 mm and -00 mm a"o(e the ground and hold it there 3or $0
minutes. 'here should "e no o(errun or creep.
D. Sle8 the load at the lo8est possi"le speed in "oth directions through a small arc to determine the
a"ilit o3 the structure to 8ithstand lateral loadings.
.. Sle8 the test load through the ma0imum sle8 angle permitted " the design o3 the crane.
D3
Chapter %o. : 2
Page .. o3 $#
Version : UPS 3.0
Issue Date:06Oct06
%O'+: During raising o3 an load it might "e necessar to derric! the Bi" in so that the radius is not
e0ceeded. Similarl it might "e necessar to Bi" out 8hen lo8ering o33 a load at minimum radius =3ailure to do
so can result in the Bi" 3alling "ac!8ards7 particularl on a rope supported Bi"C3l Bi">.
+.7.= Overloa" Test 'or <ib Arran(ements
All o3 the Bi" and mastCto8er con3igurations gi(en in 'a"le 37 'a"le D and 'a"le . should "e tested 8ith a -.
G o(erload e0cept 8here the pre(ious test certi3icate speci3ies a lo8er test load. Ahere the crane has duties
on outriggers7 3ree on 8heels7 cra8ler trac!s7 li3t and tra(el then the test should "e repeated 3or each
permitted condition.
'a"le 6.$: 'est Con3iguration 3or 'elescopic Ti" Arrangements
DD
Chapter %o. : 2
Page .1 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'a"le 6.-: 'est Con3iguration 3or Strut Ti" Arrangements
'a"le 6.3: 'est Con3iguration 3or 4astC'o8er and Ti" Arrangements
Lon( <ib Len(t,s
$. 'he crane should "e set up 8ith the longest Bi" con3iguration.
-. 'he -. G o(erload 3or ma0imum radius should "e assem"led at a reduced radius 8here it is less
than the rated capacit o3 the crane and at a sle8 position 8here the sta"ilit o3 the crane is minimal.
'he load should "e raised Bust clear o3 the ground and derric!ed out (er slo8l !eeping the load Bust
clear o3 the ground until the ma0imum radius is achie(ed.
3. 'he ma0imum rated capacit 3or the Bi" gi(en on the test certi3icate should then "e assem"led at the
ma0imum radius o3 the Bi" and li3ted Bust clear o3 the ground.
D. I3 the same rated capacit is permitted at a lesser radius7 the load should "e derric!ed in to the
minimum permitted radius !eeping the load Bust clear o3 the ground.
.. 'he load should then "e lo8ered to the ground and increased " -. G. 'he o(erload should "e li3ted
clear o3 the ground and held 3or $0 mm. Ahere possi"le7 the derric!ing motion should "e chec!ed "
3irst derric!ing in the smallest practica"le distance and then derric!ing out to the same position.
6. I3 the same rated capacit is permitted at a greater radius the test load should "e derric!ed out to the
ma0imum permitted radius !eeping the load Bust clear o3 the ground.
2. 'he load should then "e sle8ed at the lo8est possi"le speed in "oth directions through a small arc
to determine the a"ilit o3 the structure to 8ithstand lateral loadings.
H. 'hese tests should "e repeated 3or each con3iguration o3 the Bi" and mastCto8er sho8n in 'a"le 37
'a"le D and 'a"le . e0cept 3or the minimum length o3 Bi" in 'a"le 3 and 'a"le D and 8ith the
minimum to8er height in 'a"le . 8hen this is appropriate.
D.
Chapter %o. : 2
Page .2 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
S,ort <ib Len(t,s
$. /or the minimum length o3 Bi" in 'a"le 3 and 'a"le D and the minimum to8er height in 'a"le . the
crane should "e set up either 8ith the shortest Bi" or the shortest to8er 8ith the shortest Bi".
-. 'he -. G o(erload 3or the ma0imum radius should "e assem"led at a reduced radius 8here it is less
than the rated capacit o3 the crane and at a sle8 position 8here the sta"ilit o3 the crane is minimal.
'he load should "e raised Bust clear o3 the ground and derric!ed out (er slo8l !eeping the load Bust
clear o3 the ground until the ma0imum radius is achie(ed.
3. 'he load should "e sle8ed at the lo8est possi"le speed in "oth directions through a small arc to
determine the a"ilit o3 the structure to 8ithstand lateral loadings and then sle8ed through 3600
8here the design permits.
D. 'he ma0imum rated capacit 3or the Bi" should "e assem"led at the minimum radius and raised until
each tooth o3 the train gear has "een su"Bected to the load. 'he crane should then "e operated
through its permitted motions at the lo8est possi"le speeds including 3ull circle sle8.
.. 'he rated capacit should "e lo8ered o33 and increased " -. G to 3orm an o(erload test load 8hich
should "e hoisted until each tooth o3 the train o3 gears has "een su"Bected to the o(erload7 then
lo8ered to $00 mm to -00 mm a"o(e the ground. 'he crane should "e operated through its
permitted motions at the lo8est possi"le speeds.
%O'+: It is recogni5ed that 3or certain tpes o3 crane the structure does not permit 3ull sle8ing 8ith the load
Bust clear o3 the ground. In these cases it is necessar to rest the test load and reposition the crane to ensure
as much o3 the crane structure as possi"le is su"Bected to the test load.
6. It is important that the derric! "ra!es are tested 8ith the -. G o(erload suspended no more than $00
mm a"o(e the ground " derric!ing in 3rom the ma0imum load radius the smallest practica"le
distance and derric!ing out and appling the derric! "ra!e immediatel. +0treme care should "e
ta!en during this test.
+.7.1> Post Loa" Test /0amination
On completion o3 the load test7 thorough e0amination should "e carried out again.
D6
Chapter %o. : 2
Page .3 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
(*( /esting of +verhead /raveling 8ranes
+.+.1 Re&uire" Tools 'or Ins$etin( Over,ea" Cranes
6# 4easuring tape7
2# ODCID caliper7
H# 4agnetic AC o!e7
I# ?oad cell7
$0# Penetration de chec! spra =there an o3 the container<s components are made o3 an aluminum
allo>
$$# ?oad 8eight that is appropriate to the load test and condition o3 site.
+.+.2 Pre$aration
Prior to thorough e0amination the mo"ile crane should "e cleaned " appropriate means7 e.g. pressure
8ashed7 to remo(e all spoilCdirt that 8ould other8ise conceal the structure or mechanisms and pre(ent an
e33ecti(e e0amination. 'he e0amination should "e carried out in a logical se9uence7 3or e0ample top to
"ottom7 to ensure that nothing is o(erloo!ed.
Test Site on"itions
2. Care3ul consideration should "e gi(en to the condition o3 the site 8here the tests are to "e
conducted. 'he recommendations pro(ided in the operating instructions 3or the crane relate to
operations 8ithin the rated capacit and more stringent re9uirements appl 8hen loads are "eing
applied 3or the purpose o3 testing.
H. 'he ground should "e 8ell consolidated and capa"le o3 8ithstanding the loads applied to it. 'here
should "e no hidden dangers such as ca"le ducts7 drains7 pipes7 "ac!#3illed areas7 cellars or other
su"terranean 8ea!nesses. Cranes should not "e tested in the (icinit o3 o(erhead po8er lines =see
@S 2$-$#$:$IHI7 I.3.->.
I. 'he ground should "e le(eled as speci3ied in the crane<s instructions manual
$0. 'he site should "e o3 su33icient area and ha(e unrestricted o(erhead clearance to allo8 the
uno"structed mo(ement o3 the crane and load throughout its test mo(ement7 3or e0ample sle8ing7
derric!ing and tra(eling.
$$. It is pre3era"le that tests are not conducted o(er high ris! areas7 3or e0ample a pu"lic high8a7
rail8a7 occupied "uildings or in the 3light path o3 airports =see @S 2$-$#$:$IHI7 I.3.3>. I3 due to the
re9uirements o3 usage this is una(oida"le7 arrangements should "e made 8ith the appropriate
authorities.
$-. ?oad testing is designed to pro(e a craneN ho8e(er the crane might not 8ithstand the loading. All
personnel not essential to the test should "e !ept a8a 3rom the area. 'he test area should "e roped
o33 and notices posted prohi"iting unauthori5ed entr. 'he site should "e clear o3 plant and propert
8hich could inhi"it the test.
Weat,er on"itions
/or cranes operating in situations 8here the are li!el to "e a33ected " the 8eather7 care3ul
attention should "e gi(en to this aspect. Certain 8eather conditions such as electric storms7 strong
8ind7 hea( rains7 ice7 sno8 or e0cessi(e sea state can impose loads on a crane or ad(ersel a33ect
the sa3et o3 crane operations.
D2
Chapter %o. : 2
Page .4 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'est sites should not "e located in areas 8hich are !no8n to "e e0posed to e0treme 8eather
conditions. 'he limitations on 8ind speed 3or testing o3 the crane can "e lo8er than the limitations 3or
normal operation and in cases o3 dou"t ad(ice should "e sought 3rom a design authorit or
competent engineer.
It is essential that tests are not underta!en 8hen the crane or load cannot easil "e seen "ecause o3
limitations on (isi"ilit =including inade9uate lighting> or 8hen hea(il coated 8ith ice or sno8.
'he crane should not "e operated in 8ind speeds =or in the case o3 8ater#"orne cra3t7 sea
statesCsigni3icant (essel mo(ement> that are in e0cess o3 those speci3ied in the operating instructions
3or the crane. During o(erload testing the limiting 8ind speed is reduced so ad(ice should "e sought
3rom a design authorit "e3ore o(erload testing is carried out.
+.+.! 3isual Testin( o' Over,ea" Travelin( Cranes
$. Veri3 that the identi3ication and rated capacit mar!ed on the crane are compati"le 8ith the records7
3or e0ample test certi3icate7 declaration o3 con3ormit7 in3ormation 3or use and report o3 last thorough
e0amination.
-. Determine i3 there is an histor o3 de3ects or mal3unctions7 and 8hether an repairs7 alterations or
additions ha(e "een made. 'he last report o3 thorough e0amination should "e consulted.
3. 4a!e the crane sa3e " isolating po8er 8hen necessar and reinstating as appropriate.
D. +0amine the general appearance and condition o3 the crane.
.. +0amine the structure o3 the crane 3or damage7 crac!s7 8ear7 distortion7 corrosion and missing parts
including the 3ollo8ing parts:
+nd carriagesN
4echanism 3or "ridge girdersN
Cra"N
*antr railsN
@olts and 3asteningsN
+nd stops and "u33ers
6. +0amine the long tra(el mechanism 3or damage7 crac!s7 8ear7 alignment7 distortion7 corrosion7
missing parts and lu"rication including the 3ollo8ing parts:
4otorN
*earingN
'ransmission machinerN "earingsN
@ra!esN
?ong tra(el 8heelsN
*ear casesN
Co(ers and guards.
2. +0amine the cross tra(el mechanism 3or damage7 crac!s7 8ear7 alignment7 distortion7 corrosion7
missing parts and lu"rication including the 3ollo8ing parts:
4otorN
*earingN
'ransmission machinerN
@earingsN
@ra!esN
Cross tra(el 8heelsN
*ear casesN
DH
Chapter %o. : 2
Page .$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Co(ers and guards.
H. +0amine the hoist mechanism 3or damage7 crac!s7 8ear7 alignment7 distortion7 corrosion7 missing
parts and lu"rication including the 3ollo8ing parts:
4otorN
*earingN
'ransmission machinerN
@earingsN
)ope spooling mechanismN
@ra!esN
;oist drumN
*ear casesN
Co(ers and guards.
I. +0amine all the 8ire ropesCchains7 anchorages and their 3ittings. @ull dog grips should not "e used.
$0. +0amine the hoo!C"ottomCreturn "loc! assem"l 3or damage7 sei5ure7 alignment7 crac!s7 8ear7
distortion7 corrosion7 missing parts and lu"rication.
$$. +0amine the ca" and seating 3or securit7 integrit and tidiness.
$-. +0amine controls =including pendent and ca"le#less> 3or mar!ings o3 their 3unction and mode o3
operation.
$3. +0amine the audi"le and (isual 8arning de(ices 3or damage7 securit and integrit7 and 3unctionall
test the 8arning de(ices 3or correct operation.
$D. +0amine all limit s8itches 3or damage7 securit and integrit.
$.. /unctionall test all limit s8itches including hoist7 lo8er7 long tra(el7 cross tra(el and pro0imit7 3or
correct operation.
$6. +0amine the plat3orms and access ladders 3or damage7 corrosion7 integrit and securit7 o"structions
and tidiness.
$2. +0amine 3ire e0tinguishers to determine 8hether the are 8ithin date7 seal intact7 o3 appropriate tpe
and 8here possi"le pic! them up to chec! i3 the are 3ull " their 8eight.
$H. +0amine the electrical sstem 3or integrit7 deterioration7 damage and securit including the 3ollo8ing
parts:
IsolatorsN
4otorsN
?eads and collectorsN
?ightingN
AiringN
CatenariesN
'railing ca"les.
+.+.# -untional Testin( o' Over,ea" Travelin( Cranes
Operate the crane through all the motions 8ithout load applied. ?isten 3or an sounds that might indicate
de3ects and o"ser(e an other mal3unctions. /unctionall test all controls 3or smoothness o3 operation and
3reedom 3rom 8ear and other damage.
DI
Chapter %o. : 2
Page 15 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.+.7 Per'ormane Testin( o' Over,ea" Travelin( Cranes
Operate the crane through all the motions 8ithout rated load applied. ?isten 3or an sounds that might
indicate de3ects and o"ser(e an other mal3unctions. /unctionall test all controls 3or smoothness o3
operation and 3reedom 3rom 8ear and other damage.
+.+.+ Rate" a$ait6 In"iator8Limiter 5RCL8L1 Calibration C,e*
'esting o3 cranes should include con3irmation that the )CIC? has "een cali"rated to an accurac 8ithin the
tolerances gi(en "elo8. 'his cali"ration is not necessaril part o3 o(erload testing. 'his cali"ration chec!
should "e carried out at no more than $- monthl inter(als. At each successi(e cali"ration7 a di33erent
con3iguration o3 the mo"ile crane should "e chosen so that e(entuall all con3igurations are sstematicall
co(ered.
During the cali"ration chec! o3 the )CIC? it is essential that the mo"ile crane is not loaded "eond $$0 G o3
its rated capacit. 'he radiusCangle at 8hich the test load corresponds to $$0 G o3 the rated capacit should
"e mar!ed and the test load should not "e ta!en "eond that point.
+.+.: N.T 5Non4.estrutive Test1
%D' o3 mo"ile cranes might "e necessar7 particularl 8hen there is a suspicion that crac!s or other damage
are present in structural parts o3 the crane. =According to %SI("0'$ AS1/ /raining 2rogra3 for M2I$ AS1/ /raining
2rogra3 of 4ye 2enetrant)
+.+.; Overloa" Testin( o' Over,ea" Travelin( Cranes
$. /or o(erhead tra(eling cranes the crane7 gantr and supporting structure should "e thoroughl
e0amined7 tested and certi3ied. ;o8e(er in some circumstances it might "e necessar to treat them
as separate entities7 3or e0ample 8here a gantr supports more than one crane. 'he certi3icate o3
test should clearl identi3 the e0tent o3 such e0amination and testing.
-. A (isual e0amination o3 the crane gantr and trac! 8ithin the test area should "e made prior to
commencing the test to determine their suita"ilit to 8ithstand the test loads.
3. @e3ore the application o3 an load7 a thorough e0amination o3 the crane 3ollo8ed " a 3unctional test
8ith no load applied should "e carried out to determine 8hether the controls7 s8itches7 contactors7
relas and other de(ices operate correctl. 'he operation and correct adBustment o3 the "ra!es and
limit s8itches should "e chec!ed and tests carried out to determine 8hether primar sa3et and
emergenc sstems are operating correctl.
D. At the start o3 the test the crane should "e positioned o(er a supporting stanchion or column o3 the
gantr 8ith the cra" positioned adBacent to the end carriage. Aith the crane in this position7 pro(ision
should "e made 3or measuring the de3lection o3 the crane main girders at the centre span. 'he rated
load should then "e raised until each tooth o3 the train o3 gears has "een su"Bected to the load7 then
the load should "e lo8ered to $00 mm to -00 mm a"o(e the ground. 'he load should "e held in this
position 3or $0 mm to chec! the "ra!e. 'he load should then "e raised 3rom the suspended position
" a 3urther -00 mm and then lo8ered to $00 mm to -00 mm a"o(e the ground. 'he cra" should "e
tra(ersed to mid span and the de3lection measured. 'he load should "e lo8ered to the ground to
relie(e the structure and then raised to determine 8hether the de3lection remains constant.
.. 'he load should "e tra(ersed to the opposite gantr7 and the crane should "e tra(eled along the
trac! until each tooth o3 the train o3 gears o3 the long tra(el motion has "een su"Bected to the load.
'he load should "e tra(ersed across the "ridge to the opposite gantr and the crane should "e
returned to its original li3t position.
.0
Chapter %o. : 2
Page 1# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
6. 'he ma0imum de3lection o3 the main "ridge 8ith the cra" and rated load at the centre o3 the "ridge
should not e0ceed $C2.0 o3 the span.
2. 'he rated load should "e increased " -. G to 3orm an o(erload test load and the o(erload test load
should "e hoisted until each tooth o3 the train o3 gears has "een su"Bected to the o(erload7 then
lo8ered to $00 mm to -00 mm and the procedures detailed in $D.-.$.D7 $D.-. $.. and $D.-.$.6
repeated 8ith the test load suspended 3rom the crane.
H. During the o(erload test the crane should remain sta"le7 structurall sound and 3it 3or the use 3or
8hich it 8as designed and the "ra!es on each motion should 3unction e33ecti(el. 'he tra(erse and
tra(el "ra!es should also 3unction e33ecti(el 8ith the o(erload applied.
I. During the o(erload test the crane should "e operated at speeds appropriate to the sa3e control o3
the load7 3or e0ample the lo8est speed possi"le 3or the crane.
$0. /or cranes 8ith t8o or more hoists7 separate tests should "e carried out 3or each hoist. Ahere the
use o3 more than one hoist at a time is permitted7 all tests including the measurement o3 de3lection
should "e carried out 8ith all these hoists loaded simultaneousl.
+.+.= Overloa" Testin( o' Over,ea" Crane ?antries
$. Crane gantries can "e situated in the open7 supported " stanchions or in a "uilding either on
independent stanchions or on those supporting the roo3 structure. 'he can also "e supported
directl 3rom the roo3 trusses 3or use 8ith under#slung cranes or trans3er "ridges.
-. Unless the crane structure is erected solel 3or the use o3 the crane7 the crane test certi3icate issued
applies onl to the gantr "eams and their direct 3i0ings. A ci(il engineer or architect should con3irm
the integrit o3 the remaining supporting structure.
3. 'esting should "e carried out using the com"ination o3 loadings7 cranes and crane positions that
imposes the ma0imum loadings on the gantr under test. 'his includes cranes in an adBacent "a.
D. Prior to the application o3 the load7 the competent person should carr out an e0amination o3 the
gantr. An unloaded crane should "e tra(eled the 3ull length o3 the gantr.
.. 'he rated load on each crane should then "e li3ted $00 mm to -00 mm a"o(e the ground and
applied simultaneousl to the same point on the gantr " tra(eling the load the complete length o3
the gantr. 'he de3lections should "e measured. /or gantries "uilt in accordance 8ith @S DDI#- the
ma0imum de3lection should not e0ceed $C360 o3 the span. /or gantries "uilt in accordance 8ith @S
.I.0#$ the ma0imum de3lection should not e0ceed $C600 o3 the span. During this test the "eha(ior o3
the gantr7 trac! Boints and supports should "e care3ull o"ser(ed 3or undue mo(ement or 3le0ing.
'he 3unction o3 an sa3et de(ices and gantr limits should "e chec!ed at this time.
6. An o(erload o3 -. G in e0cess o3 the rated load should "e applied to each crane and raised Bust
clear o3 the ground and the "ridges tra(eled the 3ull length o3 the gantr.
+.+.1> Post Loa" Test /0amination
On completion o3 the load test7 thorough e0amination should "e carried out again.
.$
Chapter %o. : 2
Page 1& o3 $#
C'a(ter 2) *or+ Instrutions !or Cranes
Version : UPS 3.0
Issue Date:06Oct06
+.; ?eneratin( Crane Test Re$orts
/ollo8ing is a sample o3 the .#page crane test report:
.-
Chapter %o. : 2
Page 1, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.3
Chapter %o. : 2
Page 1. o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.D
Chapter %o. : 2
Page 11 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
..
Chapter %o. : 2
Page 12 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.6
Chapter %o. : 2
Page 13 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
?eneratin( Crane Certi'iates
.2
Chapter %o. : 2
Page 14 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.H
Chapter %o. : 2
Page 1$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
.I
Chapter %o. : 2
Page 25 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
60
Chapter %o. : 2
Page 2# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
6$
Chapter %o. : 2
Page 2& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
+.= Reommen"ations 'or Cranes 'or Li'tin( Persons an"
Sus$en"e" 2as*ets
Cranes and other e9uipment that are used to li3t persons and the personnel carrier should either "e
thoroughl e0amined at least e(er 6 months or in accordance 8ith a 8ritten scheme o3 thorough
e0amination.
T,e Crane
$. Chec! that the crane has an )CIC? 8ith an appropriate dut 3or personnel li3ting =i.e. hal3 the rated
capacit 3or li3ting other loads>.
-. Chec! that the crane is e9uipped 8ith a motion control sstem that "rings motion to rest
automaticall 8hen the controls are released.
3. Chec! that the crane is e9uipped 8ith an appropriate anemometer or other de(ice to monitor in#
ser(ice 8ind speeds.
%O'+: 'his is intended to ensure that personnel carriers are not used in 8ind speeds in e0cess o3 2 mIs.
D. Chec! that an crane e9uipped 8ith a 8inch has po8er lo8ering. Cranes 8ith 3ree#3all a"ilit should
not "e used to lo8er and raise persons unless the 3ree#3all 3acilit has "een loc!ed out.
.. Chec! that load "earing hdraulic clinders are 3itted 8ith load hold (al(es =o(er#centre (al(es> to
stop mo(ement in case o3 hose rupture or pipe 3racture. Cranes onl e9uipped 8ith simple chec! or
hose rupture (al(es should not "e used 3or the li3ting o3 persons.
6. Carr out a 3unctional chec! to determine 8hether the crane control sstem is a"le to pro(ide a
smooth transition o3 the carrier. 'he control should "e such that the carrier can proceed gentl and
the 8or!ing speed should not e0ceed 0.. mCs on all motions.
2. Chec! that means are pro(ided so that i3 the po8er suppl or control sstem 3ails7 the carrier can "e
positioned to ena"le accessCegress 8ithout ris!.
H. 4easure the 8ire rope used 3or hoisting and lo8ering the carrier. 'he 8ire rope should ha(e a
diameter o3 at least H mm.
T,e Carrier
$. Visuall chec! that storage accommodation 3or e9uipment7 including an emergenc egress
e9uipment =3or e0ample sa3et harness7 lanard>7 is pro(ided in the carrier.
-. Visuall chec! that the carrier is mar!ed 8ith the num"er o3 persons that can "e carried and the
ma0imum load that can "e carried.
3. Chec! that an doors in the carrier do not open out8ards and can "e securel 3astened.
D. Visuall chec! that the carrier has handrails to pro(ide securit 3or persons7 mounted in positions
that do not trap hands.
.. Visuall chec! that the carrier sides pre(ent persons or materials 3alling 3rom the carrier.
6. Visuall chec! that an attachment points 3or sa3et de(ices such as harnesses are secure and
undamaged.
6-
Chapter %o. : 2
Page 2, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
2. Visuall chec! an sa3et de(ices such as harnesses and lanards 3or integrit and completeness.
H. Visuall e0amine the structure o3 the carrier. It should "e 3ree 3rom damage7 corrosion7 crac!s and
other imper3ections.
I. Visuall chec! an mechanism pro(ided to ensure that the 3loor o3 the carrier remains hori5ontal. It
should "e 3ree 3rom damage7 lea!s7 corrosion and 8ear.
$0. Visuall chec! the carrier 3or a uni9ue identi3ication mar! and record this on the report o3 thorough
e0amination.
$$. On the report o3 thorough e0amination state that the crane and carrier ha(e "een thoroughl
e0amined 3or the purpose o3 li3ting persons.
2osun@s ,air
$. Visuall e0amine "oth primar and secondar suspension points. 'he should "e 3ree 3rom damage7
corrosion7 crac!s and other imper3ections.
-. Visuall e0amine the seat structure 3or damage7 securit and contamination.
3. Visuall e0amine the seat "elt=s> 3or damage7 contamination7 securit o3 their 3i0ings and chec! them
3or correct operation.
)arnesses
$. Visuall e0amine the harness 3or signs o3 cuts7 a"rasion7 damaged stitching or contamination.
-. Chec! the harness 3or correct operation o3 all "uc!les7 adBusters7 3asteners etc.
3. Visuall e0amine "oth primar and secondar suspension points. 'he should "e 3ree 3rom damage7
corrosion7 crac!s and other imper3ections.
D. Chec! the age o3 the harness to determine 8hether it is 8ithin the age range recommended " the
manu3acturer.
63
Chapter %o. : A(% A
Page 2. o3 $#
A((endi> A) A?out *ire Ro(e Slings
Version : UPS 3.0
Issue Date:06Oct06
A((endi> A @ A?out *ire Ro(e Slings
De!initions
Sling is an assem"l that connects a load to the material handling
e9uipment. Aire rope slings are generall manu3actured 3rom 8ire
8ith a suita"le tensile strength7 terminations "eing 3ormed "
mechanical splicing commonl !no8n as 3errules. 'he ees o3 the
sling can "e 3itted 8ith or 8ithout thim"les according to its purpose.
Aire rope slings are " 3ar the most commonl used as the are
(ersatile and comparati(el light8eight in relation to their strength.
Sling Manu!aturer is the person or organi5ation that assem"les sling components into their 3inal 3orm 3or
sale to users.
Strand@Laid Ro(e is a 8ire rope made 8ith si0 or eight strands 8rapped around a 3i"er core7 8ire strand
core7 or independent 8ire rope core.
6D
Sling Aire
'him"le
/errule
Chapter %o. : A(% A
Page 21 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
*ire Ro(e La; is a one complete 8rap o3 a strand around the core.
:raided *ire Ro(e is a 8ire rope 3ormed " plaiting component 8ire ropes.
:ridle *ire Ro(e Slings is a sling composed o3 multiple 8ire rope legs 8ith the top ends gathered in a
3itting that goes o(er the li3ting hoo!
Ca?le@Laid Endless Sling /Me'anial =oint0 is a 8ire rope sling made endless " Boining the ends o3 a
single length o3 ca"le#laid rope 8ith one or more metallic 3ittings.
Ca?le@Laid Grommet @6and@Tu+ed is an endless 8ire rope sling made 3rom one length o3 rope 8rapped
si0 times around a core 3ormed " hand#tuc!ing the ends o3 the rope inside the si0 8raps.
Ca?le@Laid Ro(e is a 8ire rope composed o3 si0 8ire ropes 8rapped around a 3i"er or 8ire rope core.
Ca?le@Laid Ro(e Sling /Me'anial =oint0 is a 8ire rope sling made 3rom a ca"le laid rope 8ith ees
3a"ricated " pressing or s8aging one or more metal slee(es o(er the rope Bunction.
Angle o! Loading is the inclination o3 a leg or "ranch o3 a sling measured 3rom the hori5ontal or (ertical
plane.
6.
L
6
S
Chapter %o. : A(% A
Page 22 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
T;(es o! *ire Ro(e Slings
One 8a o3 classi3ing slings is "ased on the num"er o3 legs the ha(e. According to this classi3ication7 8ire
rope slings can "e classi3ied into single#leg and multi#leg slings.
Sling angle and Ca(ait;
$# Sling angle e33ects sling capacit
-# Smaller sling angles reduce the capacit
3# I3 =?> is greater than =S> the sling angle is OL
Sling Angle 9ator
Sling Angle /actor V ?C;
Ahere:
? V ?ength o3 the sling.
; V ;eight o3 the connection point 3rom the
hori5ontal plane o3 the load
66

Multi@Leg Slings
Single@Leg Slings
Chapter %o. : A(% A
Page 23 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Ahen li3ting 8ith multi#leg slings. 'he are rated at a certain toonage 3rom 0
o
to I0
o
and this
SA? should not "e e0ceeded e(en i3 the angle is less than I0
o
.
..3.D.- Ahen using single slings in pairs ho8e(er7 ou must al8as "e a8are o3 the increased loadings in
the slings 8hen li3ting at angle.
/or the a"o(e reason7 the SA? o3 a pair o3 single slings decreases as the angle "et8een them increases as
3ollo8:

Angle S*L
0
o
SA? o3 one sling 0 -
30
o
SA? o3 one sling 0 - 0 0.I66
60
o
SA? o3 one sling 0 - 0 0.H66
I0
o
SA? o3 one sling 0 - 0 0.202
$-0
o
SA? o3 one sling 0 - 0 0..
OR
0
o
SA? o3 one sling 0 -
30
o
SA? o3 one sling 0 $.I3
60
o
SA? o3 one sling 0 $.23
I0
o
SA? o3 one sling 0 $.D$D
$-0
o
SA? o3 one sling onl
62
5
o
5%1 Te ea'
Sling
5%1, Te ea'
Sling
5%14 Te ea'
Sling
5%3 Te ea'
Sling
#%5 Te ea'
Sling
,5
o
25
o
$5
o
#&5
o
Chapter %o. : A(% A
Page 24 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Sa3e Use o3 Aire )ope Slings
Using the sling se(eral times a 8ee!7 e(en at a light load7 is a good practice. )ecords sho8 that
slings that are used 3re9uentl or continuousl gi(e use3ul ser(ice 3ar longer than those that are idle
Slings 8ill "e inspected each da prior to use .An (isual de3ect 8ill "e reported .Damaged slings 8ill
not "e used .In se(ere conditions =e.g.7 temperature7 corrosion 7etc.>7slings 8ill "e inspected
throughout the da.
A(oid se(ere "ending 8hile using slings.
+nsure that the load is suita"le 3or li3ting 8ith a 8ire rope sling. 'he sling should not "e allo8ed to
damage the load nor the sling itsel3 "e damaged.
+nsure that the sling is strong enough. ;a(ing regard to the method o3 slinging7 ma!e sure that SA?
i3 the sling is ade9uate 3or the load to "e li3ted
+nsure that the sling is in a good condition
+nsure that the load 8ill "e in "alance 8hen li3ted. Attach the slings to design li3ting points 8here
pro(ide . I3 li3ting points are not mar!ed on the load7 the position o3 the center o3 gra(it should "e
assessed. 'he tpe o3 sling and the slinging methods used should ensure that the load 8ill not
topple or slip.
+nsure the load contains no loose accessories. I3 the load comprises a num"er o3 pieces7 3or
instance a "undle o3 pipes7 choose a slinging method 8hich 8ill secure all the pieces. Don not attach
sling to "anding or strapping unless the are designed 3or the purpose.
Precautions: 'he 3ollo8ing precautions should "e ta!en:
o Do not allo8 A%JO%+ to ride on the load.
o Do not allo8 the load to "e carried o(er A%JO%+ 8ithout e0ercising due care.
o Do not lea(e a suspended load unattached
o Do not drag slings on the 3loor.
o Do not e0pose the slings unnecessaril to corrosi(e li9uids7 solids7 (apors or e0cessi(e heat.
6H
Chapter %o. : A(% A
Page 2$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Slings Li!ting Met'ods
#@ Vertial or straig't li!t
a. 'otal load that ma "e li3ted is that mar!ed on the sling 3or each purpose.
". A (ertical or straight li3t is onl suita"le 3or li3ting a load 8hich 8ill "e sta"le 8hen suspended
3rom a single li3ting point.
&@ :as+et 'it'
a. 'he total load that ma "e li3ted 8hen the included angle does not e0ceed I0
o
is $.D 0 that
mar!ed on the sling.
". A "as!et hitch should onl "e used 8hen the sling is passed through part o3 the load is
"alanced on the sling.
,@ Dou?led and 'o+ed
'he total load that ma "e li3ted - 0 that mar!ed on the sling.
.@ C'o+e 'it' dou?le -ra((ed)
'he total load that ma "e li3ted is that mar!ed on the sling.
1@ T-o single@leg slings used -it' diret atta'ment or used in 'o+e 'it' )
'he total load that ma "e li3ted 8hen the included angle does not e0ceed I0
o
is $.D 0 that mar!ed
on the single sling.
2@ T-o single@leg slings used in ?as+et 'it' )
'he total load that ma "e li3ted pro(ided that no included angle e0ceed I0
o
is -.$ 0 that mar!ed on
the single sling.
3@ T-o single@leg slings used in dou?le -ra( 'o+e 'it' )
'he total load that ma "e li3ted 8hen the included angle does not e0ceed I0
o
is $.D 0 that mar!ed
on the single sling.
4@ T-o single@leg slings used in dou?le -ra( ?as+et 'it')
'he total load that ma "e li3ted pro(ided that no included angle e0ceed I0
o
is -.$ 0 that mar!ed on
the single sling.
6I
Vertical or Straight ?i3t @as!et ;itch Dou"led 6 Choc!ed Choc!ed
Aith Dou"le Arap
'8o single#leg slings
used in dou"le 8rap
cho!e hitch
used in dou"le 8rap
"as!et hitch
'8o single#leg slings used
8ith direct attachment
used in cho!e hitch
used in "as!et hitch
Chapter %o. : A(% A
Page 35 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
1%,%4%# *ire !or so!t e;e and t'im?le e;e terminations
*ire siBe
/mm0
E;e siBe
/mm0
Allo-ane (er end so!t
e;e
/mm 0
Allo-ane (er end 'ard
e;e
/mm0
D 60 $$0 6.
. 2. $30 2.
6 I0 $.0 $00
H $-0 -$0 $D0
$0 $.0 -20 $6.
$3 $II 3.0 -00
$6 -.. DD0 -..
$H -20 DI. 30.
$I -H. .30 30.
-0 300 .60 3-0
-- 330 .I0 360
-D 360 630 D-0
-6 3I0 200 D-0
-H D-0 220 D.H
3- DH0 H6. .$0
36 .D0 II0 .I0
3H .20 $0D0 6.0
D0 600 $$-0 200
DD 660 $--0 2.0
.- 2H0 $DD0 I.0
6D I60 $H.0 $-.0
22 $--0 -$30 $300
20
Chapter %o. : A(% A
Page 3# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
1%,%4%& *ire Ro(es -it' !i?er ore /Single (art0
Ro(e
Diameter
Sa!e -or+ing load
Single C
leg
Leg angle 5
5
) $5
5
Leg angle $5
5
) #&5
5
T-o leg
T'ree A !our
Leg
T-o leg
T'ree A !our
Leg
mm ' ' ' ' '
. 0.-26 0.3H6 0..2I 0.-26 0.D$D
6 0.3IH 0...2 0.H36 0.3IH 0..I2
2 0..D- 0.2.I $.$0 0..D- 0.H$3
H 0.26- $.00 $.60 0.26- $.$0
I 0.I6- $.30 -.00 0.I6- $.D0
$0 $.-0 $.20 -..0 $.-0 $.H0
$$ $.D0 $.I0 -.I0 $.D0 -.$0
$- $.20 -.D0 3..0 $.20 -..0
$3 -.00 -.H0 D.-0 -.00 3.00
$D -.30 3.-0 D.H0 -.30 3.D0
$6 3.00 D.-0 6.30 3.00 D..0
$H 3.H0 ..30 H.00 3.H0 ..20
$I D.30 6.00 I.00 D.30 6.D0
-0 D.20 6.60 I.H0 D.20 2.00
-- ..20 H.00 $$.I0 ..20 H..0
-D 6.H0 I..0 $D.30 6.H0 $0.-
-6 H.00 $$.00 $6.H0 H.00 $-.00
-H I.30 $3.00 $I..0 I.30 $3.I0
3- $-.$0 $6.I0 -..D0 $-.$0 $H.$0
3. $D..0 -0.30 30.D0 $D..0 -$.20
36 $..D0 -$..0 3-.30 $..D0 -3.$0
3H $2.$0 -3.I0 3..I0 $2.$0 -..60
D0 $I.00 -6.60 3I.I0 $I.00 -H..0
According to @runton Sho8 UL ?imited
2$
Chapter %o. : A(% A
Page 3& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
1%,%4%, *ire Ro(es -it' Steel ore / Single (art 0
Ro(e
Diameter
Sa!e -or+ing load
Single C
leg
Leg angle 5
5
) $5
5
Leg angle $5
5
) #&5
5
T-o leg
T'ree A !our
Leg
T-o leg
T'ree A !our
Leg
mm ' ' ' ' '
H 0.H-- $.$0 $.20 0.H-- $.-0
I $.00 $.D0 -.$0 $.00 $..0
$0 $.30 $.H0 -.20 $.30 $.I0
$$ $..0 -.$0 3.$0 $..0 -.-0
$- $.H0 -..0 3.H0 $.H0 -.20
$3 -.$0 -.I0 D.D0 -.$0 3.$0
$D -..0 3..0 ..-0 -..0 3.20
$6 3.30 D.60 6.I0 3.30 D.I0
$H D.$0 ..20 H.60 D.$0 6.$0
$I D.60 6.D0 I.60 D.60 6.I0
-0 ..$0 2.$0 $0.20 ..$0 2.60
-- 6.-0 H.20 $3.00 6.-0 I.30
-D 2.D0 $0.30 $...0 2.D0 $$.$0
-6 H.60 $-.00 $H.00 H.60 $-.I0
-H $0.00 $D.00 -$.00 $0.00 $..00
3- $3.$0 $H.30 -2..0 $3.$0 $I.60
3. $..20 --.00 33.00 $..20 -3..0
36 $6.60 -3.-0 3D.H0 $6.60 -D.I0
3H $H..0 -..I0 3H.H0 $H..0 -2.20
D0 -0.60 -H.H0 3D.-0 -0.60 30.I0
According to @runton Sho8 UL ?imited
1%,%4%. *ire Ro(e Sling Ca(aities
*ire ro(e
SiBe
S'a+le
siBe
Vertial S'o+er T-o Leg Sling
T'ree " !our Leg
Sling
mm M:L In'
Single
Leg
Angle
#&5
5
5
o
@ .1
o
.1
o
@
25
o
5
o
@
.1
o
.1
o
@ 25
o
H D0.3 3CH .2. .60 $.0. .2. $... $.$0
$0 63.0 2C$6 $.$. .I- $.60 $.$. -.D0 $.20
$- I0.2 $C- $.20 $.36 -.30 $.20 3... -..0
$3 $06 .CH -.00 $.60 -.H0 -.00 D.$. 3.00
$D $-D .CH -.-. $.H0 3$. -.-. D.H0 3.D0
$6 $6$ 3CD 3.00 -.D0 D.-0 3.00 63.30 D..0
$H -0D 2CH 3.20 -.I6 ..-0 3.20 2.H0 ..6.
-0 -.- 2CH D.60 3.6H 6..0 D.60 I.H0 6.I0
-- 30. $ ..6. D..- 2.H0 ..6. $$.H0 H.D0
-D 363 $#$CH 6.20 ..36 I.D0 6.20 $D.00 $0.00
-6 D-6 $#$CH 2.H0 6.-D $$.00 2.H0 $6..0 $$..0
-H DID $#$CD I.00 2.-0 $-..0 I.00 $I.00 $3..0
3- 6D. $#3CH $$.H0 I.DD $6..0 $$.H0 -..00 $2..0
36 H$2 $#$C- $..00 $-.00 $-.00 $..00 3$..0 --..0
2-
Chapter %o. : A(% A
Page 3, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Testing o! *ire Ro(e Slings
*eneral
'he sling should "e (isuall inspected each time it is "eing used " the person 8ho handles it as 8ell as its
attachments. /urthermore7 a periodic 'esting shall "e per3ormed " a designated person7 at least annuall7
and shall include a record o3 the 'esting.
During their use7 slings are su"Bected to conditions that a33ect their sa3e 8or!ing characteristics. It is
necessar there3ore to ensure7 8hene(er possi"le that the sling is still sa3e 3or use.
'he Slings must "e proo3#tested " the manu3acturer to ensure 9ualit at the time o3 production .A certi3icate
(eri3ing rated capacit 8ill accompan each 8ire rope sling .'his certi3icate should "e a(aila"le 3or re(ie8
8hene(er needed.
'he sling should "e inspected 3or damage or deterioration "e3ore "eing issued 3or use7 and therea3ter "e
chec!ed 3or o"(ious de3ects7 at suita"le inter(als during ser(ice. Additionall7 routine thorough e0aminations
should "e carried out " a competent person .I3 at an time there is reason to dou"t the sa3e condition o3 the
sling 7 it should "e 8ithdra8n 3rom ser(ice and su"Bected to a thorough e0amination .
Aire )ope Slings /esting Procedures
#% T'oroug' e>amination
W A thorough e0amination is a (isual e0amination carried out " a competent person7 and 8here
necessar supplemented " other means7 such as non#destructi(e testing7 in order to detect damage
or deterioration 8hich might a33ect the 3itness 3or use o3 the sling.
W It is an essential 3eature o3 this thorough e0amination that results are documented.
A routine thorough e0amination should "e carried out at inter(als not e0ceeding 6 months and this
inter(al should "e less 8here deemed necessar in the light o3 ser(ice conditions or 8here re9uired "
statutor regulations.
'he 3ollo8ing in3ormation is to "e used as a guide 3or inspecting 8ire rope slings.
'esting 3re9uenc should "e "ased on sa3et 3actors7 propert damage7 and the cost o3 replacing
destroed or damaged goods and material dropped due to the use or misuse o3 improper or damaged
8ire rope and slings. Additionall7 slings should "e inspected at regular inter(als .'his inter(al should
"e determined " the user and is dependent upon the particular use o3 the sling.
A sling should "e inspected a3ter an unusual situation that ma ha(e damaged it7 such as o(erload7
accident7 or 3ire .It should not "e returned in ser(ice until continued sa3e operation has "een (eri3ied.
+ach sling should ha(e a serial num"er .I3 no num"er is a(aila"le7 a tag should "e attached at the time
o3 testing .'his num"er should "e listed on the testing report.
W 'esting should "e per3ormed onl " persons 8ith su33icient e0perience and !no8ledge to properl
appl the criteria 3or reBection.
23
Chapter %o. : A(% A
Page 3. o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Note) An ins$etion is a visual ,e* on t,e on"ition o' slin( to i"enti'6 "ama(e or "eterioration
9,i, mi(,t a''et its 'itness 'or use.
a0 :ro+en -ires
$. @ro!en 8ires are detrimental "ecause o3 :
a. 'he possi"ilit o3 inBur to users< hands.
". 'he loss o3 strength in the rope.
-. @ro!en 8ires are usuall caused " mechanical damage7 although corrosion ma "e a signi3icant
3actor.
3. 'he appearance o3 8ell distri"uted "ro!en 8ires has no mar!ed e33ect on the strength o3 the sling7
"ut it might "e indicati(e o3 mechanical or corrosi(e damage. *enerall the loss o3 strength caused
" the mechanical corrosi(e action on the rope as a 8hole is more critical than in strength resulting
3rom the actual 8ire "rea!s.
D. 'o pre(ent inBur to the users< hands protruding 8ires should "e "ro!en o33 in the gusset " re(erse
"ending until 3racture occurs
:ro+en -ires in one strand o! one ro(e la;
/here should ,e no 3ore than five ,roken :ires in any one
strand (single :ire) of any one rope lay*
Randoml; distri?uted ?rea+s
If the total nu3,er of visi,le ,roken :ires in any length of &"
rope dia3eters exceeds 7= of the total nu3,er of :ires in the
rope$ the sling should ,e :ithdra:n fro3 service and referred
to a co3petent person for thorough exa3ination*
A. LoaliBed ?rea+s) I3 there are three or more "ro!en 8ires closel grouped or in an strand 8ithin a
length o3 6 rope diameters7 the sling should "e discarded.
@. A?rasion) 'here should "e no 8earing7 scru""ing7 or preening o3 an outside 8ire causing the
reduction o3 the diameter o3 a single 8ire " more than $C3.
C. E>essive -ear) I3 sur3ace 8ear reduces the measured diameter o3 the rope at an point to "e less
than I0G o3 the nominal diameter7 the sling should "e discarded.
:ird Caging) 'here should "e no opening or
2D
Chapter %o. : A(% A
Page 31 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
D. Signi!iant distortion o! t'e ro(e) 'he sling should "e discarded 8hen distortion due to !in!ing7
crushing7 core collapse or !notting is identi3ied. ;o8e(er in certain circumstances permanent
de3ormation ma occur 8ithout necessaril a33ecting the strength o3 the sling7 3lattening 8hen the
rope is "end around small diameter under hea( loading .In cases 8here it is di33icult to distinguish
"et8een detrimental distortion and accepta"le de3ormation the sling should "e 8ithdra8n 3rom
ser(ice and re3erred to a competent person 3or e0amination .
+. 8in+ing andAor Crus'ing) 'here should "e no !in!ing7 crushing7 or other damage that results in
detrimental distortion o3 the rope structure.
*. Redued Diameter) 'here should not "e an reduction o3 the diameter o3 the rope along the main
length or o3 an section =o(erloading or contact 8ith sharp edges o3 load 8ithout permission>.
;. 6eat damage) 'here should "e no discoloration o3 the 8ires7 nor e(idence o3 o(erheating7 such as
loss o3 lu"rication or pitting o3 8ires caused " electrical arcing7 etc.
A sling 8hich has "een e0posed to high temperatures in e0cess o3 $00
o
C7 3or an length o3 time ma
ha(e a signi3icantl reduced strength. Ahere such heat damage is identi3ied the sling should "e
8ithdra8n 3rom ser(ice and re3erred to a competent person.
T,ere s,oul" be no evi"ene o' ,eat "ama(e inlu"in( bare eletrial on"utorA (roun"in(A
or 9el"in( ar.
*. End Atta'ments) 'here should "e no e(idence o3 crac!s7 de3ormit7 e0cessi(e corrosion7 or
e0cessi(e 8ear o3 the 3ittings 3orming the splice or soc!et.
;. Damaged or de!etive !ittingsD !errules or s(lies) Particular attention should "e paid to signs o3 :
a. Opening up or crac!ing o3 the hoo!.
". Distortion and 8ear o3 lin!s or closing o3 the thim"le.
c. Crac!s in 3errule.
d. Se(ere crushing or a"rasion o3 the 3errule or hand splice.
e. Pulling out o3 splice or 3errule.
3. Concentrations o3 "ro!en 8ires near to the 3errule or splice7 or in the splice.
g. 'he e33ect o3 "ursting stress at the throat o3 the ee due to the use o3 a pin o3 e0cessi(e
diameter or certain tpes o3 thim"le
h. /ractured 8ires on the outside sur3ace o3 the ee7 3or instance 8here a so3t ee has "een
used 8ith an e0cessi(el small pin.
i. +33ect o3 3riction on "earing sur3ace o3 a so3t ee
2.
Chapter %o. : A(% A
Page 32 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
I. Corrosion)
Corrosion ma occur 8here
slings ha(e "een improperl stored or ha(e "een used in particularl corrosi(e conditions such as in
mo(ing loads in and out o3 acid C al!ali "aths. 'he e33ect is readil identi3ied thorough the loss o3
3le0i"ilit and rusting unli!el to a33ect the rope strength7 it ma "e indicati(e o3 internal corrosion7 the
e33ect o3 8hich is not predicta"le.
Ahere internal corrosion or corrosion "eneath the ser(ing o3 a hand splice is suspected7 the sling
should "e 8ithdra8n 3rom ser(ice and re3erred to a competent person 3or thorough e0amination.
T,ere s,oul" be no evi"ene o' $ittin( or ,eav6 oatin( o' rust "ue to orrosion.
26
Chapter %o. : A(% A
Page 33 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
2roof Load /est
All s8aged#soc!et and poured#soc!et assem"lies shall "e proo3 tested to the 8ire rope or 3itting
manu3actures recommendations "ut in no case greater than .0G o3 the component 8ire rope or structural
strands nominal length .
All other assem"lies shall "e proo3 tested 8hen speci3ied " the purchaser. 'he proo3 load 3or s8aged#
soc!et and poured# soc!et assem"lies shall "e a minimum o3 t8o times the (ertical hitch rated load "ut shall
not e0ceed -.. times the (ertical hitch rated load.
'he proo3 load 3or single leg hand tuc!ed sling shall "e a minimum o3 the (ertical hitch rated load and shall
not e0ceed $.-. times the (ertical hitch rated load.
'he proo3 load 3or mechanical splice single leg and endless slings shall "e t8o times the (ertical hitch rated
load.
'he proo3 load 3or multiple leg "ridle slings shall "e applied to the indi(idual legs and shall "e either $.-.7 3or
hand tuc!ed splice7 or -7 3or mechanical splice7 times the (ertical hitch rated load o3 single leg sling o3 the
same si5e7 grade7 and construction o3 rope.
An master lin! to 8hich multiple leg slings are connected shall "e proo3 loaded to t8o times the 3orce
applied " the com"ined legs.
22
Chapter %o. : A((% :
Page 34 o3 $#
Appendi0 @: A"out Shac!les
Version : UPS 3.0
Issue Date:06Oct06
A((endi> : @ S'a+les
3%# T;(e o! S'a+les
3%#%# Round Pin S'a+les) Can "e used in tie do8n7 to8ing
suspension or li3ting applications 8here the load is strictl
applied in line
3%#%& Sre- Pin S'a+les ) Can "e used in an application
8here a round shac!le is used . It can also "e
used 3or applications in(ol(ing side #loading circumstances.
)educed 8or!ing load limits are re9uired
3or side#loading applications . Ahile in ser(ice7 do not
allo8 the scre8 pin to "e rotated " a li(e line7 such as a
choc!er application .
3%#%, :olt T;(e S'a+les ) Can "e used in an applications
8here round pin or scre8 pin are used . In addition 7 the
are recommended 3or long term installations and 8here the
load ma slide on the shac!le pin causing the pin to rotate.
3%& Angle Load
2.-.$ Angle load must "e applied in the lane o3 "o8
2.-.- Shac!les smmetricall loaded 8ith t8o leg slings ha(ing a ma0imum included angle o3 $-0o can "e
utili5ed to 3ull 8or!ing load limit.
Al8as centre the load on the shac!le pin to a(oid angular pulls against the leg o3 the shac!le
2H

Page 3$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
3%, S'a+les Testing
S'a+le
Testing
Pin :o-
An;
Cra+s or
S'ar(
Ni+s
An; Modi!iation or Parts
Missing or ot'er Notes
*ear
E#57
An;
:end
*ear
E#57
An;
C'ange in
s'a(e
Mar+ing and Tagging
$# +ach shac!le "od shall "e permanentl and legi"l mar!ed " the manu3acturer. 4ar!ing 8ill "e
raised or stamped letters on the side o3 the shac!le "o8 8ith an identi3ing manu3acturer<s name or
trademar! 7shac!le si5e 7and sa3e 8or!ing load =SA?>.
$# -# Shac!le pins could "e unmar!ed.
-# 3# Shac!les and rings that ha(e "een proo3 tested 3or critical ser(ice shall ha(e a tag or other
mar!ing to indicate clearl to the user that proo3 testing has "een done.
Testing riteria
'esting criteria 3or shac!les and rings are listed "elo8:
$. @e3ore each use7 shac!les shall "e inspected to the 3ollo8ing criteria
a. Shac!le pins shall 3it 3reel 8ithout "inding.=Seated scre8 pin shac!les shall "e
disassem"led " hand a3ter the 3irst#hal3 turn.>
". 'he pin shall sho8 no sign o3 de3ormation.
c. 'he shac!le shall ha(e no de3ect that 8ill inter3ere 8ith ser(icea"ilit.
-. Shac!les and rings 3or critical#li3t ser(ice shall ha(e an initial proo3 load test o3 t-o times the SA?
=minimum>.@e3ore ma!ing a critical li3t7 ensure that the shac!le or ring has "een proo3 tested.
3. @e3ore each use7 rings shall "e (isuall inspected !or damageD orrosionD -earD ra+sD t-ists and
o(ening%
2%#%1 Proo! Load Testing and Tagging
A proo3 load test /minimumD t-o times S*L0 is re9uired 3or shac!les and rings used in critical#li3t
ser(ice. A (alidated proo3 load test7 conducted " the manu3acturer or the ;an3ord Site contractor7 meets this
re9uirement.
Note: A critical#li3t procedure ma call 3or additional load testing or proo3 load testing o3 rigging and rigging
hard8are.
2I

Page 45 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
2%#%3 Sa!e use o! S'a+les
'he t8o tpe o3 shac!les the most commonl used are the anchor shac!le and the chain shac!le
"oth o3 8hich are a(aila"le 8ith scre8 pin or sa3et.
Shac!les should "e selected to suit the load "eing li3ted allo8ing 3or an increased loadings due to
sling angles.
'he dimensions o3 the shac!le 8ill o3ten "e go(erned " the hole diameter and the thic!ness o3 the
material o3 the li3ting ee.
'he selection "et8een @o8 tpe and Dee tpe 8ill depend on the num"er o3 components "eing
connected.
Sa3et pin shac!les are pre3erred ="o8 tpe "eing the most popular> "ut in certain situation 7 ie di(ing
operation7 scre8 pin are o3ten more practical in either case 7 the pin can "e secured to pre(ent
inad(ertent loosening or E"ac!ing o33F as 3ollo8s:
a> Sa3et pin shac!les X " the use o3 a split pin.
"> Scre8 pin shac!les X " 8iring the head o3 the shac!le pin to the shac!le "od.
Note) 'he (ast maBorit o3 shac!le used in the construction C +ngineering industr are made 3rom allo
materials and constructed to a U.S /ederal speci3ication .
'he SA? is ade9uate 3or the load and the color coding =8here applica"le> is current and the shac!le
has a plant num"erC ID mar!.
@olt 'pe: An application plus permanent or long term use 8here load slippage ma cause the pin
to rotate.
Angle o! Loading Redution to *or+ing Load Limit
D. degrees 30G reduction
I0 degrees .0G reduction
Scre8 pin shac!les s'all not ?e used i! t'e (in an roll under load and unsre-% =A(oid using
the shac!le in such a manner that mo(ement o3 the load rope could unscre8 the shac!le pin >
H0
Page 4# o3 $#
Version : UPS 3.0
Issue Date:06Oct06
%e(er replace the s'a+le (in -it' an ordinar; ?olt as it 8ill not "e as strong as the proper pin
8hich is manu3actured 3rom a high grade material.
2%#%4 S'a+les Dimensions
SiBe
In'
Pin Diameter
: / mm 0
Inside -idt'
A / mm 0
Inside Lengt' / C 0 / mm 0
S*L
Ton
:o- *idt'
D / mm 0
An'or T;(e C'ain T;(e
$C- $6 -- .$ D3 -.00 3-
.CH $I -6 6D .$ 3.-. D3
3CD -- 3$ 26 .I D.2. .$
2CH -6 36 H3 23 6..0 .H
$ -H D3 I. H. H..0 6H
$ $CH 3- D2 $0H I0 I.. 2.
$ $CD 3. .$ $$. ID $-.00 H3
$ 3CH 3H .2 $33 $$. $3..0 I-
$ $C- D- 60 $D6 $-2 $2.00 II
$ 3CD .- 2D $2H $DI -..00 $-6
- .H H3 $I2 $2$ 3..00 $D6
- $C- 20 $0. -.D -03 ...00 $H.
3 H3 $-2 330 -30 H..00 $I0
3 $C- I6 $D6 3H$ -62 $-0.00 -3H
%ote: 4inimum "rea!ing strength V 6 0 SA? Acc. 'o US
/ederal Spec
H$
*ARNING
%e(er replace Shac!le pin 8ith a "olt

'he ?oad 8ill "end the "olt

Page 4& o3 $#
Version : UPS 3.0
Issue Date:06Oct06
S'a+les Standard Dimensions and Corres(onding Li!ting Ca(aities
Nomin
al
SiBe
/in%0
*or+in
g
Load
Limit F
/tons0
Dimensions
/in%0
Toleran
e
GA@
A : C D E 9 G 8 L M N G A
$CD $C- .D2 .3$ .-. .-. .I2 .6$ .HH $..I .$I $.3H $.3D .06 .06
.C$6 3CD ..3 .3H .3$ .3$ $.$6 .2. $.03 $.I$ .-- $.66 $..I .06 .06
3CH $ .66 .DD .3H .3H $.D$ .I$ $.-. -.30 .-. -.03 $.H6 .$3 .06
2C$6 $#$C- .2. ..0 .DD .DD $.63 $.06 $.DD -.66 .3$ -.3H -.$3 .$3 .06
$C- - .H$ .63 ..0 ..0 $.H$ $.$I $.63 3.03 .3H -.6I -.3H .$3 .06
.CH 3#$CD $.06 .2. .6- .63 -.3$ $..0 -.00 3.2. .DD 3.3D -.I$ .$3 .06
3CD D#3CD $.-. .HH .H$ .2. -.2. $.H$ -.3H D..3 ..0 3.I2 3.DD .-. .06
2CH 6#$C- $.DD $.00 .I2 .HH 3.$I -.0I -.H$ ..33 ..0 D..0 3.H$ .-. .06
$ H#$C- $.6I $.$3 $.00 $.00 3.6I -.3H 3.$I ..ID ..6 ..02 D..3 .-. .06
$#$CH I#$C- $.H$ $.-. $.-. $.$3 D.06 -.6I 3..H 6.2H .63 ...I ..$3 .-. .06
$#$CD $- -.03 $.3H $.3H $.-. D..3 3.00 3.ID 2..0 .6I 6.$6 ...0 .-. .$3
$#3CH $3#$C- -.-. $..0 $..0 $.3H ..00 3.3$ D.3H H.-H .2. 6.HD 6.$3 .-. .$3
$#$C- $2 -.3H $.63 $.6- $..0 ..3H 3.6- D.H$ I.06 .H$ 2.3. 6..0 .-. .$3
$#3CD -. -.HH -.00 -.$- $.2. 6.3H D.$I ..2. $0.I2 $.00 I.0H 2.2. .-. .$3
- 3. 3.-. -.-. -.00 -.00 2.-. D.H$ 6.2. $-.-H $.-- $0.3D H.2. .-. .$3
-#$C- .. D.$3 -.2. -.6- -.6- I.3H ..6I H.00 $D.HD $.3H $3.00 Y .-. .-.
H-
Page 4, o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Nomina
l
S'a+le
SiBe
/in%0
*or+ing
Load
Limit F
/tons0
Dimensions
/in%0
Tolerane
A : C D E 9 G 6 8 L M N P R C"G A
3C$6 $C3Z .3H .-. .HH .$I .60 ..6 # $.D2 # .IH # .$I $.-I # .06 .06
$CD $C- .D2 .3$ $.$3 .-. .2H .6$ .2. $.HD $..I $.-H .I2 .-. $..6 .-. .06 .06
.C$6 3CD ..3 .3H $.-- .3$ .HD .2. $.00 -.0I $.I$ $.D2 $.$6 .3$ $.H- .3$ .06 .06
3CH $ .66 .DD $.DD .3H $.03 .I$ $.-- -.DI -.30 $.2H $.D$ .3H -.$2 .3H .$3 .06
2C$6 $#$C- .2. ..0 $.6I .DD $.$6 $.06 $.D- -.I$ -.66 -.03 $.6- .DD -..$ .DD .$3 .06
$C- - .H$ .63 $.HH ..0 $.3$ $.$I $.63 3.-H 3.03 -.3$ $.H$ ..0 -.H0 ..0 .$3 .06
.CH 3#$CD $.06 .2. -.3H .63 $.6I $..0 -.00 D.$I 3.2. -.ID -.3$ .6I 3..3 .63 .$3 .06
3CD D#3CD $.-. .HH -.H$ .2. -.00 $.H$ -.3H D.I2 D..3 3..0 -.2. .H$ D.02 .H$ .-. .06
2CH 6#$C- $.DD $.00 3.3$ .HH -.-H -.0I -.H$ ..H3 ..33 D.03 3.$I .I2 D.2$ .I2 .-. .06
$ H#$C- $.6I $.$3 3.2. $.00 -.6I -.3H 3.$I 6..6 ..ID D.6I 3.6I $.06 ..3$ $.00 .-. .06
$#$CH I#$C- $.H$ $.-. D.-. $.$3 -.I$ -.6I 3..H 2.D2 6.2H ..$6 D.06 $.-. ..I0 $.-. .-. .06
$#$CD $- -.03 $.3H D.6I $.-. 3.-. 3.00 3.ID H.-. 2..0 ..2. D..3 $.3H 6..$ $.3H .-. .06
$#3CH $3#$C- -.-. $..0 ..-. $.3H 3.63 3.3$ D.3H I.$6 H.-H 6.3H ..00 $..0 2.-$ $..0 .-. .$3
$#$C- $2 -.3H $.63 ..2. $..0 3.HH 3.63 D.H$ $0.00 I.06 6.HH ..3H $.6- 2.23 $.6- .-. .$3
$#3CD -. -.HH -.00 2.00 $.2. ..00 D.$I ..2. $-.3D $0.I2 H.H6 6.3H -.-. I.0. -.$- .-. .$3
- 3. 3.-. -.-. 2.2. -.00 ..2. D.H$ 6.2. $3.6H $-.-H I.I2 2.-. -.D0 $0.D$ -.00 .-. .$3
-#$C- .. D.$3 -.2. $0..0 -.6- 2.-. ..6I H.00 $2.HD $D.HD $-.H2 I.3H 3.$3 $3..6 -.6- .-. .-.
3 H. ..00 3.-. $3.00 3.00 2.HH 6..0 H..0 -$..0 $6.HH $D.36 $$.00 3.6- $6..0 3..0 .-. .-.
3#$C- $-0 Z ..-. 3.2. $D.63 3.6- I.00 H.00 # -D.63 # $6..0 # D.$- $I.00 # .-. .-.
D $.0 Z ...0 D.-. $D..0 D.$0 $0.00 I.00 # -..6I # $H.D- # D..6 $I.2. # .-. .-.
'he re9uirements and guidelines 3or shac!les are as 3ollo8s.
$# Shac!les speci3ications are de3ined " the 3ollo8ing documents7 depending on the shac!le si5e:
a. /or shac!les 3C$6 to - 3CD inches7 the speci3ications are deri(ed 3rom /ederal speci3ication ))#
C#-2$7 EChains and Attachments7 Aelded and Aeld#less.F
". /or shac!les $ $C- to D inches7 the speci3ications are deri(ed 3rom 4I?#S#-D-$D7 EShac!les7
Steel7 *eneral Purpose and ;igh Strength.F
c. /or shac!les D $C- to H $C- inches7 AS'4 A$DH47 EStandard Speci3ication 3or steel castings7
;igh Strength7 3or Structural PurposesF should "e used.
-# Shac!les are manu3actured in t8o con3igurations 3or use in rigging: anchor shac!le and chain shac!le.
@oth are a(aila"le 8ith scre8 pins7 round pins7 or sa3et "olts.
3# Shac!les are si5ed " the diameter o3 steel in the "o8 section rather than the pin si5e.
D# Design /actors: Shac!les manu3actured in accordance 8ith ))#C#-2$ and 4I?#S#-D-$D ha(e a
minimum design 3actor o3 .times. Shac!les manu3actured to the re9uirements o3 AS'4 A$DH4 ha(e a
minimum design 3actor o3 D times. )ings manu3actured to the re9uirements o3 ))#C#-2$ ha(e a
minimum design 3actor o3 6 times.
.# )ings should "e 3orged steel and 8eld#less .Aelded rings are not recommended "ut ma "e used i3
designed " a 9uali3ied engineer and su"Bected to 8eld nondestructi(e testing =%D'>.
H3
Chapter %o. : A((% C
Page 4. o3 $#
A((endi> C) A?out 6oo+s
Version : UPS 3.0
Issue Date:06Oct06
A((endi> C C A?out 6oo+s
De!initions
Lat') A mechanical de(ice used to close the throat opening o3 a hoo! =Cle(is hoo!7 Duple0 hoo! =sister>7
+e hoo! and Shan! hoo!>
Mouse) )ope or 8ire used to close the throat opening o3 a hoo!.
Ni+ or gouge) Sharp notch in hoo! ser(ice 8hich ma act as stress riser in the area o3 the notch 9uali3ied
person.
T;(es o! 6oo+s
All tpes o3 hoo!s used in conBunction 8ith e9uipment some hoo!s supporting a load in a direct#pull
con3iguration7 8ith the load carried in the "ase ="o8lCsaddle or pin hole> o3 the hoo! =tpe A>. And other
hoo!s that do not support a load in a direct#pull con3iguration such as gra" hoo!s7 3oundr hoo!s7 sorting
hoo!s7 and cho!er hoo!s =tpe @>.
Sel! CClosing 6oo+) A hoo! 8ith a throat opining that is closed " a spring#loaded latch7 gate7 or "ail that is
manuall opened 3or loading and closes upon release. It ma "e loc!ed in the closed position =Sel3 closing
"ail ee hoo!>.
Sel!@Lo+ing 6oo+) A hoo! 8ith a throat opining that 8ill closed and loc!ed 8hen a load is applied 7 and 8ill
not open until unloaded and the loc! released.= Sel3 loc!ing ee hoo! open # Sel3 loc!ing cle(is hoo!
closed >
HD
+e hoo! *ate latch shan! hoo! Cle(is hoo!
T;(e A 6oo+sD Sel!@Lo+ing
Cle(is hoo! Duple0 hoo! =sister> +e hoo! Shan! hoo!
T;(e A 6oo+s
+e *ra" hoo! Cle(is *ra" ;oo! /oundr ;oo! Sorting ;oo! Choc!er ;oo!
T;(e : 6oo+sD Sel!@Closing
Page 41 o3 $#
Version : UPS 3.0
Issue Date:06Oct06

H.

Single Plate ;oo! ?aminated Plate ;oo!
T;(e AD Plate 6oo+
/lapper latch
Shan! ;oo!
@ail +e
;oo!
/lapper latch
S8i(el ;oo!
/lapper latch
+e ;oo!
'ip#?oc! latch
Shan! ;oo!
'ip#?oc!
?atch +e
;oo!
T;(e A 6oo+sD Sel!@Closing
Page 42 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Sa!e Use o! 6oo+s
DO %O' use a hoo! 8hose throat opening has "een increased7 or 8hose tip has "een "ent more than &"
degrees out o3 plane 3rom the hoo! "od7 or is in an other 8a distorted or "ent.
1ote< A latch 8ill not 8or! properl on a hoo! 8ith a "ent or 8orn tip.
+e hoo!s7 shan! hoo!s and s8i(el hoo!s are designed to "e used 8ith 8ire rope or chain. +33icienc o3
assem"l ma "e reduced 8hen used 8ith snthetic material.
%e(er use a hoo! that is 8orn "eond the limits. %e(er side load7 "ac! load7 or tip#load a hoo!.

4a!e sure that the hoo! supports the load. 'he latch must ne(er support the load =as sho8n in the 3igure
"elo8>.
%e(er appl more 3orce than the hoo!<s assigned Aor!ing ?oad ?imit =A??> rating.
Ahen placing t8o sling leg in hoo!7 ma!e sure the angle 3rom the (ertical to the outermost leg is not greater
than D. degrees7 and the included angle "et8een the legs does not e0ceed I0 degrees.

H6
*RONG

Side ?oad @ac! ?oad 'ip ?oad
Page 43 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
Lat' 6oo+
$. Al8as inspect hoo! and latch "e3ore using.
-. %e(er use a latch that is distorted or "ent.
3. Al8as ma!e sure spring 8ill 3orce the latch against the tip o3 the hoo!.
D. %e(er use a cotter pin 8ith a smaller diameter or di33erent length than recommended.
.. %e(er use a nail7 a 8elding rod7 8ire7 etc.7 in place o3 recommended cotter pin.
6. Al8as ensure cotter is "ent so as not to inter3ere 8ith sling operation.
2. ?atches are intended to retain loose sling or de(ices under slac! conditions.
H. ?atches are not intended to "e an anti#3ouling de(ice.
I. Ahen using latch 3or personnel li3ting7 select proper cotter pin 3or proper installation instructions.
Ste( # Ste( & Ste( , Ste( .D 1 D 2 Ste( 3
Place hoo! at
appro0imatel a D.
degree angle 8ith
the cam up.
Position coils o3
spring o(er cam
8ith legs o3 spring
pointing to8ard
point o3 hoo! and
loop o3 spring
positioned do8n
and ling against
the hoo!.
Position latch to
side o3 hoo! points.
Slide latch onto
spring legs
"et8een loc!#plate
and latch "od until
latch is partiall
o(er hoo! cam.
'hen depress latch
and spring until
latch clears point o3
hoo!
D. ?ine up holes in
latch 8ith hoo!
cam.
.. Insert "olt
through latch7
spring7 and cam.
6. 'ighten sel3#
loc!ing nut on one
end o3 "olt.
-or Personal
Li'tin(
Aith latch in closed
position and rigging
resting in "o8l o3
hoo!7 insert cotter
pin through hoo!
tip and secure "
"ending prongs
H2
Chapter %o. : A((% D
Page 44 o3 $#
Appendi0 D: A"out @as!ets and Containers
Version : UPS 3.0
Issue Date:06Oct06
A((endi> D @ A?out Containers
General
ContainerA:as+et De!inition
A container or a "as!et is an item o3 e9uipment li3ted " slings7 8hose primar purpose is the transportation
o3 goods7 materials or e9uipment7 8hich ma "e permanentl installed in the container7 to7 3rom and "et8een
o33shore installations.
Primar; struture
?oad carring and supporting 3rames and load carring panels. Primar structure is di(ided into su"groups:
#% /ssential an" non4re"un"ant $rimar6 struture
a. 'op and "ottom side rails
". 'op and "ottom end rails
c. Pad ees
2. Non essential $rimar6 struture
a. Doors7 8all and roo3 panels
". Panel sti33eners and corrugations
c. Structural components used 3or tan! testing onl
d. Internal securing points
S;m?ols
): the rating i.e. the ma0imum gross mass o3 the container and its cargo in !g.
': the tare mass i.e. the mass o3 an empt container in !g.
P: the paload i.e. the ma0imum permissi"le mass o3 cargo 8hich ma "e sa3et transported " the
container in !g.
%ote: P V ) X '
*elding
+ssential and %on essential primar structure mem"ers shall "e 8elded 8ith 3ull penetration Aelds. /or
other primar structure7 the use o3 3illet 8elds shall "e Busti3ied appraisal.
Intermittent 3illet 8elding o3 secondar structure is accepta"le ho8e(erN care shall "e ta!en to a(oid
corrosion.
Minimum Material T'i+ness

/or e0ternal parts o3 corner posts and "ottom rails i.e. parts 3orming the outside o3 the container
/or ) =ma0imum gross mass> [ $000!g7 thic!ness =t> V 6mm
/or ) =ma0imum gross mass> \ $000!g7 thic!ness =t> V Dmm
HH
Page 4$ o3 $#
Version : UPS 3.0
Issue Date:06Oct06
9or+li!t (o+ets
Ahen 3itted7 3or! li3t poc!ets shall "e installed in the "ottom structure and shall ha(e a closed "ottom and top7
and pass through the "ase.
'he minimum opening o3 the 3or! li3t poc!ets shall "e -00mm 0 I0mm Poc!ets shall "e located as 3ar apart
as practica"le "ut need not "e more than -.0.m apart 3rom the centre o3 poc!et to centre o3 poc!et.
Pad e;es
In order to pre(ent lateral "ending moments on pad ees the shall "e aligned 8ith the sling to the centre o3
li3t 8ith a ma0imum manu3acturing tolerance U -..
o
An di33erence in the diagonal measurements "et8een li3ting point centers shall not e0ceed 0.-G o3 the
length o3 the diagonal or . mm 8hiche(er is greater.
'he diameter o3 holes in pad ees shall match the shac!le used7 tolerance "et8een shac!le "olt and pad
ee<s hole diameter shall not e0ceed 6G o3 the nominal shac!le "olt diameter.
'he tolerance "et8een pad ee thic!ness and inside 8idth o3 shac!le not e0ceed -.G o3 the inside 8idth o3
the shac!le.
E>amination and Test o! Containers
Containers should "e e0amined at regular inter(als in accordance 8ith the schedule listed in ta"le "elo8:
S'edule o! e>amination and test
Time or interval
Test A E>amination
Proo! load Test / &G0
/ # 0
NDE o!
Li!ting Points
T'roug'
Visual
E>amination
Su!!i> to
?e mar+ed
on (late
@e3ore "eing used 3or the 3irst time or
=3or e0isting containers 8ithin 6
months o3 the date 8hen this @S
comes into e33ect>
Jes Jes Jes T
At inter(als not e0ceeding 6 months %o
At the discretion
o3 the inspector
Jes V or VN =->
At inter(als not e0ceeding $- months %o Jes Jes VN
At inter(als not e0ceeding -D months Jes Jes Jes T
A3ter su"stantial repair or alteration =3> Jes Jes Jes T
=$> * is the sm"ol 3or the ma0imum gross 8eight used in the test calculation.
=-> 'his is dependent on 8hether non#destructi(e e0amination =%D+> has "een carried out.
=3> A su"stantial repair or alteration means an repair7 and C or alteration carried out 8hich ma7 in the
opinion o3 a competent person7 a33ect the load "earing elements o3 the container7 or 8hich contri"ute
directl to its structural integrit.
It is the speci3ic responsi"ilit o3 the o8ner to report an su"stantial repair or alteration to the competent
person carring out the e0amination or test. Ahen the schedule re9uires a proo3 load test he non# destructi(e
e0amination and thorough (isual e0amination should "oth "e carried out a3ter the proo3 load test.
,%3 Sa!e use o! ontainer
&* A lot o3 e9uipments and material is transported in containers larger or hea(ier as 8argo /ransport
>nits (8*/*>* S)
HI
Page $5 o3 $#
Version : UPS 3.0
Issue Date:06Oct06
'* 'he loading o3 C.'.U s must "e carried out in strict accordance 8ith our e0isting procedures paing
particular attention not to mi0 chemicals and or gases 8hich 8hen com"ined =possi"l through
transit damage> could "ecome to0ic7 highl 3lamma"le or e0plosi(e.
!* %e(er e0ceed the SA? o3 the container. 'he gross 8eight should "e chec!ed during loading onto
(ehicles prior to shipment
5* Secure the load at the container
7* Ahen loading C.'.U. s speciall open tops do not put sharp items alongside drums or plastic
container 8hich could "e punctured and lea! possi"le ha5ardous su"stance
(* Do not allo8 items to protrude o(er the side or "e in position 8here the are lia"le to roll or 3all o33
the open top container.
0* Al8as e0ercise e0treme care 8hen opening container doors. Should there "e an hint o3 a
dislodged load resting against the door attach a rope to the handle and attempt to open the door
remotel.
?* %e(er la a container on its "ac! to 3ill it. 'hin! a"out the operator at the end o3 the line 8ho has to
empt it.
I0
Chapter %o. : A((% E
Page $# o3 $#
Appendi0 +: )e3erences and Standards
Version : UPS 3.0
Issue Date:06Oct06
Re!erenes and Standards
AS4+#@ 30#$0
AS4+#30#I
@SI#$-I0
@SI #3..$
@SI#6-$0
@SI#202-
@SI#$-02I
@SI#602-
@S#2$-$C-
@S +% $3HHI:-003
AS%' %D' 'raining Program o3 4PI
AS%' %D' 'raining Program o3 De Penetrant
'his is a test
I$

W.I.M New

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

W.I.M New

Uploaded by

Copyright:

Available Formats

UNIVERSAL PETROLEUM

INVESTMENTS AND AGENCIES

You might also like