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Revision Status
0
Rev
04 Feb 02
Date
: [OMS-SOP] MNT/405
: All personnel working for PONSBV Operations
: Senior Superintendent Maintenance
English Version
D.Pastime
Prepared
A.Nikijuluw
Checked
Bahasa Version
E.Korniadi
Disiapkan
Owner
A.Nikijuluw
Diperiksa
Signature
Not Verified
M.Davidson
Approved
Melanie Dewi
Rahayu
Digitally signed by
Melanie Dewi Rahayu
DN: cn=Melanie Dewi
Rahayu, o=Premier
Oil, ou=Production,
c=ID
Date: 2005.03.29
01:11:58 Z
PremierOil Indonesia
Jakarta
1. PURPOSE
1. TUJUAN
2. SCOPE
2. RUANG LINGKUP
Applies to all lifting equipment (this includes lifting devices and lifting gear as
defined) used at PONSBV offshore Facilities.
Prosedur ini berlaku untuk semua peralatan yang dimiliki, disewa atau
dipinjamkan kepada PONSBV. Prosedur ini juga menyoroti ketentuanketentuan inspeksi dan pemeliharaan peralatan yang digunakan oleh kontraktor
di atau pada fasilitas-fasilitas PONSBV.
It applies during normal operations and during shutdown work (except where
specifically exempted in shutdown execution plans or equivalent documents).
This procedure takes into account the industry guidelines and best industry
practice, recommended for lifting equipment.
Prosedur ini memasukkan panduan industri dan praktek industri terbaik yang
direkomendasikan untuk peralatan pengangkat.
3. REFERENCES
3. REFERENSI
Industry Guidelines
Panduan Industri
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4. DEFINITIONS
4. DEFINISI
Alter
Mengubah
Certificate of
design
verification
Sertifikat verifikasi
disain
Certificate
of
inspection (for
new equipment)
Sertifikat Inspeksi
(untuk peralatan
baru)
Certified visual
inspection (in
service
inspection)
Inspeksi Visual
Resmi (Inspeksi in
service)
Crane
Crane
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Designated
inspector/Surve
yor/Verifying
body
Inspektor/Surveyor/
Badan Verifikasi
yang Ditunjuk
CMMS
CMMS
Lifting
equipment
/materials
handling
equipment
Peralatan
pengangkat/peralat
an penghandel
material
Maintenance
The
activity
of
monitoring,
inspecting,
testing,
refurbishment and replacement of plant and equipment
within its pre-existing design specifications
Pemeliharaan
Aktivitas
pemantauan,
inspeksi,
pengetesan,
pembaharuan dan penggantian plant dan peralatan
dalam spesifikasi disain yang sudah ada.
Material or test
certificate
Sertifikat Material
atau Tes
Proof Load
Proof Load
LLE Registers
Register LLE
Responsible
person
Penanggungjawab
Rigging
Perlengkapan
Gear
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(also known as
Cargo Gear)
Rigging (juga
dikenal sebagai
Perlengkapan
kargo)
a)
Pihak Berwenang
Resmi
Testing Service
Jasa pengetesan
Third Party
lifting
equipment
Peralatan
pengangkat pihak
ketiga
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6. TASK/ACTIVITIES
6. TUGAS/AKTIVITAS
6.1.
Responsibilities
6.1.2
Superintendent FPSO
6.1.3
a. Is responsible for all lifting equipment on the Anoa and AGX Platforms.
a.
b. Shall ensure that inspection and maintenance of all lifting equipment used
on the Anoa and AGX Platform is carried out in accordance with this
procedure and that the Facility Lifting Equipment Registers are properly
maintained.
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6.1.4
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6.2.1.
6.2.2.
6.2.6.
Register harus berisi entry-entry berikut ini yang relevan untuk setiap
item peralatan (informasi ini bisa disimpan dalam cara lain di dalam
sistim elektronik yang lain).:
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The safe working load (SWL) for the equipment or maximum gross
weight (MGW) of the equipment as applicable
The location (or reference to the drawing showing the location particularly for padeyes) of the equipment
The location of
documentation
the
design
verification
certificate
and
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6.3.2 These entries shall be supported with traceable hard copy records
(retained on the facility) of the following (as applicable and required
in clause 6):-
6.3.2. Entry-entry ini harus didukung dengan catatan tertulis dengan kopi
karbon (disimpan di fasilitas) dan isinya adalah sebagai berikut
(sesuai dengan ketentuan pasal 6):-
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6.4.
Perubahan Peralatan
6.4.1
6.4.2 Major items of lifting equipment may require approval to repair by the
relevant statutory authority. Advice on requirements for this may be
obtained from Engineering Support Group.
6.4.2
6.5.
Control of Procurement
6.5.
6.5.1 When ordering new equipment the responsible person shall clearly
specify the equipment to the applicable standard and shall list
additional requirements regarding tagging, marking and the level of
certification required.
6.5.1
6.5.2
6.5.3
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6.6.
6.6.
Bila ditentukan, sertifikat inspeksi harus diperoleh dari pihak berwenang resmi
atau wakil-wakilnya untuk peralatan baru. Juga bila sertifikat tes tipe
diperlukan untuk peralatan, sertifikat tersebut harus diperoleh dari pensuplai
atau pihak berwenang resmi yang mengontrol sertifikat-sertifikat tersebut.
Laporan data manufakturur harus dipeoleh (ini sangat penting untuk pekerjaan
inspeksi mendetil seperti tes non-destruktif).
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6.7.
During the use of the equipment the responsible person shall ensure that the
lifting equipment design conditions are not exceeded. If the design
conditions are exceeded an incident report shall be completed in accordance
with the relevant procedure and the equipment shall be immediately removed
from service for inspection as soon as practicable and quarantined.
6.8.1
6.8.2 All work instructions relating to this equipment shall incorporate any
applicable statutory requirements into the scope and reinspection
intervals for the equipment (refer to tables 1, 2 & 3.
6.8.2
6.8.3
6.8.4
6.8.5 Formal planned maintenance systems for all of the materials handling
equipment on the facility are required. The use of the registers, CMMS
and formal maintenance/inspection activities satisfies a large part of
6.8.5
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this requirement.
6.9.
Pengecekan pra-guna.
Inspeksi visual menyeluruh (bisa ditambah dengan NDT bila perlu)
Inspeksi visual resmi (tergantung pada peralatannya, NDT mungkin merupan bagian
yang wajib dari inspeksi).
Pengetesan beban.
6.9.1
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6.9.2
6.9.3 All specialised and certified inspection and testing (load testing, load
cell calibration, non-destructive testing, etc) shall be performed by
approved testing service contractors. The results of the testing shall
be reported.
6.9.3
6.9.4 Visual examination should include but not be limited to checking for
distortion, abrasions, sharp notches, welding arc strikes, cracks, thread
damage, flattening or stranding. Any lifting equipment showing visual
signs of irreparable damage ie. frayed slings, bent shackle pins etc.,
shall be taken out of service immediately and marked for disposal and
destruction.
6.9.4
6.9.5
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6.10.1
6.10.2 Each facility including the Supply Base shall have a clearly marked
quarantine area (under the control of the local Materials Coordinator)
for lifting equipment awaiting disposal or repair. All personnel shall
be made aware of this quarantine area.
6.10.2
6.10.3
6.10.4
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6.11.2 Hard copies of in-service inspection and testing records, (e.g. HDT
Reports, Load Test Certificates etc) shall be retained by the Facility.
6.11.2 Kopi dalam bentuk tertulis untuk inspeksi in-service dan catatancatatan pengetesan, (misalnya Laporan HDT, Sertifikat Tes Beban,
dll.) harus disimpan oleh Fasilitas.
6.11.4 The required inspection and testing intervals for lifting equipment are
summarised in the following tables (refer to clause 6 for details):
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Table 1:
Lifting Devices
ITEM
REFERENCE
VISUAL INSPECTION2
REFERENSI
INSPEKSI VISUAL
NDT
Manufacturers
recommendations.
Migas.
Certified*
1 year
5 years
Rekomendasi
Manufakturur
Dijamin
dengan
sertifikat*
1 tahun
5 tahun
Migas
*Certified inspections and proof
load tests only apply to pedestal
type cranes and to >5t gantry
cranes offshore.
*
Inspeksi-inspeksi
pemberian sertifikat dan
load test hanya berlaku
crane jenis pedestal dan
gantry crane >5t offshore.
untuk
proof
untuk
untuk
PONSBV instruction.
Instruksi PONSBV
Industry
Migas
Praktek Industri/
Migas
Prctice
Thorough
6 mths
Menyeluruh
6 bulan
Thorough
6 mths
Menyeluruh
6 bulan
Internal -
1 year
External -
3 mths
Internal
1 tahun
Eksternal
3 bulan
No requirement although
depending on the application
NDT may be part of the
internal rope inspection.
Tidak
ada
ketentuan,
walaupun tergantung pada
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ITEM
REFERENCE
VISUAL INSPECTION2
REFERENSI
INSPEKSI VISUAL
NDT
aplikasi
NDT,
mungkin
merupakan
bagian
dari
inspeksi tali internal.
Requirements for replacement
of crane wire ropes are made
on the basis of individual
inspection results (see 5.13.6)
Ketentuan untuk penggantian
tali
kawat
crane
dibuat
berdasarkan hasil-hasil inspeksi
individu (lihat 5.13.6).
Note 1:
Note 2:
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Table 2 Rigging
ITEM
REFERENCE
VISUAL INSPECTION2
REFERENSI
INSPEKSI VISUAL
NDT
PONSBV Instruction
Thorough
6 mths
No
requirement
No requirement
Instruksi PONSBV
Menyeluruh
6 bulan
Tidak ada
ketentuan
Thorough
6 mths
No
requirement
No requirement
Tidak ada
ketentuan
PONSBV Instruction
6 mths
No
requirement
1 year
Instruksi PONSBV
6 bulan
Tidak ada
ketentuan
1 tahun
None
Tidak ada
Only after
repair or if
visual
inspection
shows any
damage.
Hanya setelah
direparasi atau
bila inspeksi
visual
menunjukkan
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kerusakan
Eyebolts attached to equipment
None
Only if
damage is
evident from
visual
inspection
No requirement
Tidak ada
Hanya bila
kerusakan
tampak jelas
dari inspeksi
visual.
PONSBV Instruction
Thorough 6 months
Every 1 years
Instruksi PONSBV
No
requirement
Tidak ada
ketentuan
Setiap 1 tahun
Note 1:
Note 2:
Actual proof loads for various equipment types are shown in clause
Proof load aktual untuk berbagai jenis peralatan ditunjukkan.
Before-use visual inspection applies at all times.
Inspeksi visual Sebelum Digunakan berlaku setiap saat.
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Table 3
Lifted Equipment. Also if the lifted equipment is used for dangerous goods extra testing requirements may apply - refer to Dangerous Goods
Code).
Peralatan yang diangkat. Juga bila peralatan yang diangkat digunakan untuk barang-barang berbahaya, ketentuan testing ekstra mungkin
diberlakukan rujuk Peraturan untuk Barang Berbahaya.
ITEM
REFERENCE
REFERENSI
VISUAL INSPECTION2
INSPEKSI VISUAL
International Containers
Thorough visual
inspection
Kontainer Internasional
Inspeksi
menyeluruh
NDT
6 mths
Corner fittings
2 years
No requirement
6 bulan
Corner fittings
2 tahun
Certified visual
inspection
1 year
Padeyes or
corner fittings
2 years
4 years
1 tahun
Padeyes atau
corner fittings
2 tahun
4 tahun
Thorough visual
inspection
6 mths
Inspeksi visual
menyeluruh
6 bulan
Certified visual
inspection
1 year
Padeyes or
corner fittings
2 years
4 years
1 tahun
Padeyes atau
corner fittings
2 tahun
4 tahun
visual
6 mths
Inspeksi visual
menyeluruh
6 bulan
Certified visual
inspection
1 year
Padeyes or
corner fittings
1 year
4 years
Inspeksi visual
menyeluruh
1 tahun
Padeyes atau
corner fittings
1 tahun
4 tahun
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ITEM
REFERENCE
REFERENSI
VISUAL INSPECTION2
INSPEKSI VISUAL
Thorough visual
inspection
6 mths
Inspeksi visual
menyeluruh
6 bulan
NDT
Note 1:
Note 2:
For all loose lifting equipment it will be the required ID numbering system as
used in the Registers.
All loose equipment and cargo gear that is subjected to the 6 monthly
thorough visual inspection shall be coloured coded to indicate its status. The
item itself shall be painted or a tag of the correct colour attached.
Colour coding intervals for thorough visual inspection will cover a period of 6
months duration and colours used will change after each inspection visit with
one exception, as follows:
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Status
Colour
Red
Equipment bearing the wrong colour code must be removed from service,
tagged and shall remain unused until it has been inspected at the next due
date.
Setiap kode warna yang digunakan harus ditandai dengan tanda Notice
dipasang [Pemberitahuan] di tempat-tempat yang mudah dilihat dan area-area
kerja pada Fasilitas agar personil mengetahui kode-kode warna yang
digunakan pada saat itu.
Peralatan dengan kode warna yang salah harus ditarik dari servis, dipasangi
tag dan tidak boleh digunakan sampai diinspeksi pada waktu jatuh tempo
selanjutnya.
Lifting equipment in use at the Anoa Facilities which is not owned by PONSBV
falls into one of the following categories:
Peralatan pengangkat yang digunakan pada Fasilitas Anoa yang bukan milik
PONSBV digolongkan menjadi kategori-kategor berikut ini:
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6.14. Decommissioning
6.14. Menon-aktifkan
When a lifting device is decommissioned for any reason its registration status
shall be suitably amended on the appropriate control system. If required for
the type of device the statutory body shall also be notified of the
decommissioning.
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6.15.1.2. Repairs
Slings having any of the faults listed in clause 6.9.4 shall be discarded
6.15.2 Safety Shackles
It shall be PONSBV policy to use safety shackles, not plain screw pin
shackles, on all equipment. Purchasing documentation shall reflect
our requirement. Locking clips shall be of suitable stainless steel
material to withstand a tropical marine environment. Where screw
pin shackles have not been replaced or arrive on urgent preslung
equipment the pins shall be suitably seized using stainless steel
seizing wire or cable ties.
6.15.3 Eyebolts
6.15.1.2
Reparasi
Sling yang mengalami gangguan seperti yang terdaftar dalam bab
6.9.4 harus dibuang.
6.15.2 Safety Shackles
Adalah peraturan PONSBV untuk menggunakan safety shackles,
tidak hanya screw pin shackle biasa, di semua peralatan. Dokumendokumen pembelian harus mencantumkan persyaratan kita. Klipklip pengunci harus terbuat dari bahan baja tahan karat agar tahan
terhadap lingkungan kelautan tropis. Bila screw pin shackles belum
diganti atau tiba pada peralatan preslung urgen, pin-pin harus
diikat dengan kawat atau kabel baja tahan karat.
6.15.3 Eyebolts
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Valid certified padeyes which have undergone proof loading and non
destructive testing shall be identifiable at point of location as follows:
Padeyes bersertifikat valid yang sudah menjalani pengetesan proofloading dan non-detruktif harus bisa diidentifikasikan pada poin
lokasi sebagai berikut:
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All new purchase of chain slings for offshore use is to specify chain
slings to ISO 3076 (Gunnebo trade name for example), ISO 4778
or ISO 7593.
Existing slings (grade T chain) may still be used for lifts where
there is redundancy in the rigging arrangement. They shall not be
used for single or two leg sling lifts where there is no redundancy.
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system.
6.15.8 Containers With ISO Corner Fittings
It has been practice in some areas to top lift containers that have ISO
corner fittings by inserting shackles or slings into those fittings and
lifting by that means. This practice is potentially dangerous as these
fittings are not designed for that type of loading. Several options
exist Modify the container and design and fit padeyes to enable
shackles to be used. (Remember that this is an engineering
change to the container and design, fabrication and testing need
to be controlled)
Sling underneath the container and bottom lift.
Any containers without the correct lifting pad-eyes at each corner will
be subject to PTW requirements and review of the proposed lifting
arrangement before lifting commences.
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7. ASSOCIATED DOCUMENTATION
7. DOKUMEN TERKAIT
7.1.
7.2.
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Standard Operating
Procedures
Jakarta
LIFTING EQUIPMENT INSPECTION AND MAINTENANCE REQUIREMENTS
AND
RESPONSIBILITIES
7.1.
70
60
50
PROOF LOAD
WORK BOXES
40
GENERAL PURPOSE,
SPECIALISED &
INTRASTATE, AND
OTHER CONTAINERS
30
10
0
0
10
15
20
25
30
SWL
50
Proof Load
40
30
20
0
0
10
15
SWL (tonnes)
20
25
30
35
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PremierOil Indonesia
Standard Operating
Procedures
Jakarta
LIFTING EQUIPMENT INSPECTION AND MAINTENANCE REQUIREMENTS
AND
RESPONSIBILITIES
200
180
160
140
Proof Load
120
100
80
60
40
0
0
10
20
30
40
50
SWL
60
70
80
90
100
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PremierOil Indonesia
Standard Operating
Procedures
Jakarta
LIFTING EQUIPMENT INSPECTION AND MAINTENANCE REQUIREMENTS
AND
RESPONSIBILITIES
7.2.
STANDARD OF
REFERENCE
PROOF LOAD
REMARKS
AS 1418.2
SWL x 1.25
AS 1418.2
AS 1418.2
AS 1418.2
AS 1418.1 &2
SWL x 1.5
SWL x 1.5
SWL x 1.0
SWL x 1.25
AS 1418.1 & 2
SWL x 1.25
AS 1418.3
AS 1418.4
AS 1418.4
AS 1418.5
AS 1418.7
AS 1418.10
AS 1418.13
AS 2359
AS 1735
SWL x 1.1
SWL x 1.0
SWL x 1.0
SWL x 1.25
SWL x 1.25
SWL x 1.25
SWL x 1.25
Various
Various
SWL x 1.25
Other
General
Treat as overhead
padeye
Select most appropriate
of above tests
SWL x 1.25
SWL x 1.5t
SWL x 1.1
SWL <=
20t
20t <SWL <= 50t
SWL > 50t
MO 32 App5, T6
SWL x 2
(SWL x 1.04) +
9.6 t
SWL x 1.1
MO 32 App5, T5
MO 32 App5, T5
PremierOil Indonesia
Standard Operating
Procedures
Jakarta
LIFTING EQUIPMENT INSPECTION AND MAINTENANCE REQUIREMENTS
AND
RESPONSIBILITIES
ITEM DESCRIPTION
SWL <= 12t
SWL <= 20t
SWL > 20t
Personnel work boxes and transfer
nets
Other lifted equipment
SWL <= 3t
SWL <= 12t
SWL <= 20t
SWL > 20t
Lift beams & spreader frames
SWL <= 10t
10t <SWL <= 160t
SWL > 160t
General purpose containers to MO
32
for intrastate use
SWL <= 3t
SWL <= 12t
SWL <= 20t
SWL > 20t
Specialised containers with
dedicated cargo
SWL <= 3t
SWL <= 12t
SWL <= 20t
SWL > 20t
Personnel work boxes and transfer
nets
Other lifted equipment
SWL <= 3t
SWL <= 12t
SWL <= 20t
SWL > 20t
STANDARD OF
REFERENCE
PROOF LOAD
SWL + 3t
SWL x 1.25
SWL + 5t
SWL x 2.2
REMARKS
Min 800kg
MO 32 App5, T5
SWL x 2
SWL + 3t
SWL x 1.25
SWL + 5t
MO 32 App5, T6
SWL x 2
(SWL x 1.04) +
9.6 t
SWL x 1.1
MO 32 App5, T5
MO 32 App5, T5
Min 800kg
MO 32 App5, T5
SWL x 2
SWL + 3t
SWL x 1.25
SWL + 5t
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