MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES

IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER)

Revision Amendment Detail Prepared By E !oe"ield

MMSL-006

P !" 1 #$ 11
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MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) W()*+",

MMSL-006

P !" 2 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1)

T&orou'& examination (ill comprise o" )ut not limited to t&e "ollo(in'* E@ 0() %(#) P&#*"3.&" 1>0 +,+ +,$ +,1 +,2 +,3 +,% +,5 +,7 +,8 +,+ +,++ +,+$ U%(1(%' W()*+ Clarity o" mar-in's o" serial num)er. sa"e (or-in' load and plant num)er /i" applica)le0 and t&at details correspond (it& Test Certi"icate, Examine all mountin' )olts and "ixin's "or security and correct tensile 'rade, Examine all (elded mountin' structures and tie do(n plates, NOTE= A ,.(% 81" NDT I),/"*%(#) ,+#.13 8" * &&("3 #.% ($ 3""0"3 )"*",, &' 8' %+" *#0/"%")% /"&,#)> Examine all air connections and "ittin's "or condition and inte'rity, Pay particular attention to )ra-e control lines /i" "itted0 nippin' or cuts, Visually examine )ra-e )and are also "ree "rom dirt. 'rease or 'rit, In t&e case o" (inc&es (it& inte'ral )ra-in' system c&ec- last maintenance report "or condition o" drum and )ra-e, Examine (inc& )ra-e drum "or scorin'. (ear. "ittin' or )uild up scale on sur"ace /'la4in'0 c&ec- "or trueness o" drum, Examine all )ra-e mountin' )rac-ets and pin "or )endin' and (ear, C&ec- "or sei4in' o" pins in )ores and all loc-in' pins6split pins are present, Examine (inc& structure "or de"ormation o" t(istin', C&ec- oil levels and operation o" drum loc-s i" "itted, Examine )ra-e operation lin-a'es "or (ear and distortion, Examine all parts can move "reely and are not corroded, Examine control lever6system "or "reedom o" movement and t&at lever returns to neutral position on release and t&at t&e direction o" operation is clearly mar-ed, Ensure rope is spooled in t&e ri'&t direction in relation to )ra-e operation and is correctly mounted to t&e drum, Examine in accordance (it& relevant procedure, I" air supply is "itted. run (inc& to c&ec- operation o" all "unctions, C&eclu)ricators "or oil level and drain de9&umidity traps,

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) W()*+",

MMSL-006

P !" 3 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1)

E@ 0() %(#) P&#*"3.&" (C#)%()."3) +,+1 +,+2 +,+3 I" air (inc& is "or man ridin' purposes ensure t&at it is o" an approved desi'n and clearly mar-ed "or man ridin' purpose. proo" load applied, Examine (inc& (ire "or correct "actor o" sa"ety "or man ridin' purposes, I" (inc& is "itted (it& limit s(itc&es a "ull c&ec- s&ould )e carried out to veri"y satis"actory operation and settin's are correct, T&is s&ould )e done )y actual operation o" (inc& t&rou'& all "unctions )ot& &oistin' and lo(erin', I" any "aults are "ound at t&e time o" examination (&ic& (ould e""ect t&e sa"e use o" item t&en it must )e (it&dra(n "rom service and details recorded on inspection report, :ote* ;inc& (ire rope anc&ora'es are not desi'nated "or li"tin', P)".0 %(* W()*+ Examine t&e (inc& )ase "or crac-ed (elds. crac-s around )olt &oles. impact dama'e. distortion and elon'ation. ensure t&at all "ixin' )olts are properly "itted and secure and o" su""icient 'rade6stren't&. t&at all (elds are intact and "ree "rom crac-s and t&at supportin' steel(or- is capa)le o" (it&standin' (inc& loads, Examine (inc& structure "or de"ormation and t(istin', Examine rope 'uard "or (ear. distortion and dama'e t&at could o)struct or dama'e (ire rope < ensure it is secure, Examine t&e )ra-e )ands and drum "or (ear. ensure t&at t&ey are clean and "ree "rom contamination, Examine t&e )ra-e mountin' )rac-ets. lin-a'es and pins "or (ear and distortion. ensure t&at lin-a'es and pins are not sei4ed and t&at loc-in'6cotter pins are "itted, Examine t&e (inc& drum "or (ear. distortion. scorin' and crac-s. ensure t&at drum runs true and t&at t&e rope is anc&ored correctly, Examine automatic )ra-e. sprin's. lin- arms and pins "or (ear. distortion and stretc&, Examine automatic )ra-e cylinder and pipe(or- "or lea-s, Examine c&romed piston rod "or (ear. scorin' and corrosion, Examine operatin' lever "or "reedom o" movement. ensure t&at it returns to neutral position (&en released,

2>0 $,+

$,$ $,1 $,2 $,3 $,% $,5 $,7 $,8 $,+

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) W()*+",

MMSL-006

P !" 6 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1)

E@ 0() %(#) P&#*"3.&" (C#)%()."3) $,++ $,+$ $,+1 $,+2 $,+3 Ensure t&at all operatin' levers are clearly mar-ed (it& direction o" operation, C&ec- t&at oil level is correct, Ensure t&at po(er supply is su""icient "or t&e sa"e (or-in' load o" t&e (inc&. i" air supply is "itted operate (inc& to ensure t&at it "unctions correctly, I" (inc& is "or man9ridin' purposes. ensure t&at it is an approved desi'n. "itted (it& t(o independent )ra-e systems and clearly mar-ed SUITA5LE FOR LIFTING PERSONNEL> =imit s(itc&es /i" "itted0 to prevent over9ridin'. under9ridin' and over9speedin' s&ould )e "unction tested to veri"y satis"actory operation, NOTE= W(&" &#/" (($ $(%%"3) ,+#.13 8" ,/##1"3 *#&&"*%1' #)%# ?()*+ 3&.02 )3 %+"&" ,+#.13 8" % 1" ,% 3 %.&), #$ ?(&" &#/" #) %+" 3&.0 % 11 %(0",2 ?(&" &#/" ,,#*( %"3 $(%%()!, ,+#.13 8" "@ 0()"3 () **#&3 )*" ?(%+ %+" &"1"< )% "@ 0() %(#) /&#*"3.&",> W(&" &#/" )*+#& !" (, )#% 3",(!) %"3 $#& 1($%()!> H'3& .1(* W()*+", C&ec- clarity o" mar-in's o" S;=. identi"ication num)er. plant num)er and operational instructions and t&at it corresponds (it& t&e test certi"icate, C&ec- all mountin' )olts and "ixin's "or security and correct tensile 'rade, C&ec- all (elded mounts and tiedo(ns "or security /:DT may )e re>uired i" deemed necessary )y t&e competent person0, Ensure t&at t&e supportin' structure is o" ade>uate stren't&, C&ec- all &ydraulic couplin's. &oses and "ittin's "or condition and lea-a'e, Examine )ra-es and linin's "or security. (ear and contamination, Ensure "ree movement in &in'e pins and security "ittin's and ensure parts are not corroded,

3>0 1,+ 1,$ 1,1 1,2 1,3

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) W()*+",

MMSL-006

P !" 7 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1)

E@ 0() %(#) P&#*"3.&" (C#)%()."3) 1,% 1,5 1,7 1,8 1,+ 6>0 2,+ 2,$ 2,1 2,2 2,3 2,% 2,5 6>8 C&ec- )ra-e actuator "or lea-a'e. corrosion. dama'e and ensure t&at it is secure, C&ec- mountin' pins are secure and not corroded examine. &ydraulic lines "or dama'e. corrosion and lea-a'e, ?unction. test. system, C&ec- control lever "or "ree movement, Ensure t&at t&e lever returns to t&e neutral position (&en released, C&ec- t&e rope is spooled correctly on to t&e drum and t&at t&e @dead endA is correctly terminated, I" t&e (inc& is a man9ridin' purpose. ensure t&at t&e (inc& is correctly mar-ed and ensure t&at t&e correct "actors o" sa"ety are applied, I" limit s(itc&es are "itted ensure correct operations and "ully "unctional, Examine all ca)les and6or &ydraulic lines "or dama'e corrosion or lea-a'e, M ). 1 W()*+ DIRECT DRIAE4WORM GEAR WINCHES Examine t&e (inc& structure "or (ear. crac-s. distortion and corrosion, Ensure t&at all "ixin's )olts are correctly "itted and secure. all (elds are intact and "ree "rom crac-s. and t&at all supportin' steel(or- is capa)le o" (it&standin' (inc& loads, Examine t&e (indin' &andle "or "reedom o" movement. ensure t&at it is not sei4ed or distorted, Examine t&e (inc& drum "or (ear. distortion. scorin' and crac-s. ensure t&at drum runs true and t&at t&e rope is anc&ored correctly, ;&ere applica)le examine ratc&et or (orm 'ear /mounted on side o" drum0 "or (ear. )ro-en teet& and misali'nment, Examine t&e pa(l and pa(l sprin'6(orm "or (ear and distortion. ensure t&at pa(l "unctions correctly. and t&at t&e (orm drive mes&es correctly (it& t&e (orm (&eel, ?unction test t&e (inc& t&rou'& one complete revolution o" t&e 'ear train to ensure t&at (inc& "unctions correctly and t&at 'ears mes& correctly, E),.&" %+ % %+" .)(% ,.,% (), 1# 3 () %+" +#(,% /#,(%(#) $#& 0()(0.0 #$ $(<" 0().%",>

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) W()*+",

MMSL-006

P !" 6 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1)

E@ 0() %(#) P&#*"3.&" (C#)%()."3) ADDITIONAL (SPUR GEAR WINCHES) 2,8 2,+ Examine t&e )ra-e assem)ly and operate t&e (inc& &andle to ensure t&at it "unctions correctly, Examine all spur 'ears "or ali'nment. (ear and c&ippin' on 'ear teet&. trut& o" 'ear s&a"ts and smoot& runnin' o" )earin' /i" "itted0, NOTE= W(&" &#/" (($ $(%%"3) ,+#.13 8" ,/##1"3 *#&&"*%1' #)%# ?()*+ 3&.0 )3 %+"&" ,+#.13 8" % 1" ,% 3 %.&), #$ ?(&" &#/" #) %+" 3&.0 % 11 %(0",2 ?(&" &#/" )3 ,,#*( %"3 $(%%()!, ,+#.13 8" "@ 0()"3 () **#&3 )*" ?(%+ %+" &"1"< )% "@ 0() %(#) /&#*"3.&"2 ?(&" &#/" )*+#& !" (, )#% 3",(!) %"3 $#& 1($%()!> I" any "aults are "ound at t&e time o" examination. (&ic& (ould a""ect sa"e use o" t&e item. t&en it must )e (it&dra(n "rom service and details recorded on t&e inspection,

3,

MMSLSERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) E@ 0() %(#) 1>0 +,+ +,$ +,1 P&#*"3.&"= W()*+",

MMSL-006

P !" 7 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", T+#&#.!+ E@ 0() %(#) (A(,. 1) )3 T",% P&#*"3.&" $#& M ) R(3()! W()*+",

T&e ne( style and types o" man9ridin' (inc&es #)1' &"-.(&" SWL $.)*%(#) %",%. %# *+"*; %+" 8 ," ?"13, )3 %+" , $"%' *.% #.%, , T&e (inc&es are all present and tested )y t&e manu"acture. and as suc& (e are not allo(ed to touc& or adBust t&ese settin's, Visual examination s&ould )e carried usin' t&e appropriate examination procedure "or (inc&es,

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) T",% 1>0 +,+ +,$ +,1 U%(1(%' W()*+", W()*+",

MMSL-006

P !" 8 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", N"?2 R"/ (&"32 M#3($("32 R"-,(%"3>

I" durin' t&e course o" examination. no "aults are "ound (&ic& (ould a""ect t&e sa"e (or-in' load o" t&e e>uipment t&en a proo" load test may )e carried out as "ollo(s* A proo" load e>ual to (or-in' load limit o" t&e e>uipment plus $3C s&all )e applied and a c&ec- made o" t&e load )earin' parts, T&is test may )e applied )y a static I" no de"ects are apparent t&en t&e load s&all )e raised /(&ere practical0 t&rou'& a &ei'&t o" li"t (&ic& (ill ensure t&at every part o" t&e (inc& mec&anism comes under load, T&is load s&all )e &eld "or a period o" "ive minutes, T&e )ra-e s&all s&o( no si'ns o" slippa'e or creep, R"/" % #/"& %(#), 1>2 %# 1>3 $#& " *+ 8& ;" ($ ?()*+ $(%%"3 ?(%+ 3. 1 8& ;",> R"/#&%()! A (ritten report s&all contain t&e "ollo(in' in"ormation* a0 Uni>ue identi"ication num)er )0 A "ull description o" t&e e>uipment c0 Sa"e (or-in' load d0 Proo" load applies e0 Date o" test and t&orou'& examination "0 A statement o" type use. e,', @Approved "or #an9Ridin'A or @Utility ;inc&A '0 Any limitations or restriction to use &0 :ame and address o" company per"ormin' t&e test and examination i0 Act or re'ulation under (&ic& t&e test and examination (as carried out B0 Position and location o" e>uipment D"$"*%(<" E-.(/0")% ;&ere t&e test is not satis"actory. a responsi)le representative o" t&e user s&all )e in"ormed )y means o" a de"ect report, I" t&e test en'ineer considers t&e de"ect to )e o" a dan'erous nature t&en arran'ements must )e made "or its immediate (it&dra(al "rom service,

2>0 $,+

3>0 1,+

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) T",% 1>0 +,+ W()*+",

MMSL-006

P !" 9 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", N"?2 R"/ (&"32 M#3($("32 R"-,(%"3>

+,$ +,1 +,2 2>0 $,+

W()*+", C#)<"&%"3 $#& %+" P.&/#," #$ R (,()!4L#?"&()! P"&,#))"1 ;inc&es used "or t&e raisin' and lo(erin' o" personnel (ill &ave a dual )ra-in' system usually consistin' o" one manual )ra-e and one automatic )ra-e /(&ic& (ill activate s&ould t&ere )e a loss o" po(er0, T&ese )ra-es are to )e over&auled to manu"acturers speci"ication, ;&ere limit s(itc&es are "itted to prevent over9travel in )ot& &oistin' and lo(erin'. "unction test to ensure t&eir operation, Ensure t&e (inc& &as )een ade>uately de9rated to re"lect a "actor o" sa"ety o" no less t&an + 9+, Ensure t&at t&e (inc& is clearly mar-ed t&at it is to )e used issued )y solely "or raisin' and lo(erin' personnel, T",%()! Bolt do(n (inc& to suita)le test )ed and "it a (ire o" suc& len't& t&at no "e(er t&an "ive turns remain on drum durin' any part o" t&e test, a0 Test + /Dynamic0 Raise a proo" load S;= D $3C to t&e re>uired &ei'&t to allo( one "ull rotation o" drum under load /t&is test can )e simulated on a &ydraulic test )ed (&ere a varia)le pressure relie" valve &as )een "itted0, Apply manual )ra-e to sustain load and c&ec- (inc& drum "or creep, :ote* ;&en testin' (inc&es (it& an automatic )ra-e on a &ydraulic test )ed. t&ere (ill )e a sli'&t drop in t&e load due to t&e time it ta-es "or t&e )ra-e to activate,

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) T",% 2>0 )0 T",%()! (C#)%()."3) W()*+",

MMSL-006

P !" 10 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", N"?2 R"/ (&"32 M#3($("32 R"-,(%"3

Test $ /Static0 Disconnect po(er source to (inc& and apply )ra-e, Usin' an alternative pullin' source i,e, pull li"t6c&ain )loc- on t&e (inc& rope. apply a proo" load o" S;= D 3 C to c&ec- t&e )ra-in' e""iciency /t&e )ra-e may re>uire adBustin' to ac&ieve t&is0, Sustain t&e load "or a s&ort time and c&ec- (inc& drum "or creep, Re9 connect t&e automatic )ra-e and (it& t&e manual )ra-e in t&e o"" position. repeat test $ so "ull load is ta-en on automatic )ra-e, NOTE= S+#.13 )' #$ %+" 8& ;" 3&.0, 8" "@/#,"3 %# %+" "1"0")%,2 %+" $#&"0")%(#)"3 %",%, ,+#.13 8" * &&("3 #.% ?(%+ %+" 3&.0 ?"%2 %# ,(0.1 %" #/"& %()! *#)3(%(#),> M ;" )' 8& ;" 3B.,%0")%, , &"-.(&"3> Test 1 /?unction0 Re9connect po(er supply to (inc& and pull up to S;= /to ensure t&e )ra-e &as not )een over ti'&tened to suc& an extent as to a""ect t&e (inc&Es per"ormance0, NOTE= E),.&" 11 1"<"&,4*#)%&#1, &"%.&), %# )".%& 1 #) &"1" ,"> Re9examine (inc& to ensure t&at proo" load testin' &as not exposed any de"ects, T&e a)ove tests are (itnessed, ?it (inc& drum 'uard (&ere applica)le, Examiner to do "inal platin', NOTE= E),.&" SWL )3 11 3(&"*%(#) 1 &&#?, &" 0 &;"3 )3 *1" &1' <(,(81">

c0

$,$ $,1 $,2

MMSL SERVICE PROCEDURES Examination and Test Procedures THOROUGH EXAMINATION AND TEST OF LIFTING APPLIANCES AND ACCESSORIES IN COMPLIANCE WITH SI2306 (PUWER) SI2307 1998 (LOLER) C %"!#&' E-.(/0")% D",*&(/%(#) T",% 3>0 1,+ R"/#&%()! W()*+",

MMSL-006

P !" 11 #$ 11

U%(1(%'2 P)".0 %(*2 H'3& .1(*2 M ). 1 W()*+", )3 M ) R(3()! W()*+", N"?2 R"/ (&"32 M#3($("32 R"-,(%"3>

T&is s&all )e carried as per utility (inc& test procedure. Section $, ,