Doc. n.

WI-BOSS-MAIN-442-E
BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
Page. 1 OF 11

BOS Shelf LLC. WORK INSTRUCTION

TEST PROCEDURE OF CRANE

WI-BOSS-MAIN-442-E
 Doc. n. WI-BOSS-MAIN-442-E
BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
Page. 2 OF 11

1.0
This procedure has been compiled to ensure a comprehensive and diligent Thorough examination and test
of cranes is conducted in accordance with BS 7121.
Due to the wide range of items and functions to be examined, formal inspection checklists will be submitted
along with the detailed examination reports.
This checklist will ensure that all the vital areas of the crane receive the required examination.
The physical load test shall not commence until all issues that are deemed critical or could prove negative
against the continued safe operation of the crane are fully closed out.
Dispensation for any examination issues that may arise will come in written form from the end client of the
crane.
Whenever considered necessary, the visual examination shall be supplemented by methods of NDT that will
determine the condition of any part of the crane. In order to facilitate visual examination and ascertain the
extent of any damage it may be considered necessary to have the parts of the crane dismantled.
The examination will cover, but will not be limited to the points below.

1.1
The following procedure shall only be carried out by a competent and experienced engineer.
Certificate of Test and/or Thorough Examination of Cranes form to be used as a reporting format – F-511
Before Operation of the crane, the client must approve the operator’s certification.
Only qualified ASNT Level 2 engineers to conduct the NDT.

1.2
Please ensure all PPE is in place at all times.
The following PPE has to be worn at all times:
Hard Hat
Coveralls
Gloves
Safety Boots
Safety Glasses
Be aware of the dangers of working at heights.
Where necessary ensure all ladders are of sound construction, securely footed and anchored where
necessary.
All personnel to be aware of HSDS for NDT substances.

1.3
During the test and examination be cautious of any possible oil/fuel leakages. When possible make the
necessary arrangements to contain all spillage’s that may occur.
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WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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2.0
Pre Examination Checks
Prior to any physical Examination an assessment on the current records and available information shall be
carried out. This will assist in evaluating the present condition of the crane and the levels of diligence
required. Documents requested could include but not limited to the following.
• Past Certificates of test and thorough examinations.
• Component Certification i.e. hook block, wire ropes, sockets etc.
• Maintenance/alteration/repair records.
• Operating instructions.
• Rated Capacity charts including outriggers where applicable.
• Ballast weight certificates
• SLI Calibrations

2.1
It will be at the certification engineers’ discretion as to whether the crane is in an acceptable condition for an
overload test to be safely performed.
The certification engineer shall also ensure the crane is in the right configuration according to the
instructions. This will include appropriate rope falls and sufficient ballast.

3.0
Safe Load Indicators / Load Limiters
An operation check should be made to verify that the readings of the SLI are correct; this can be done with
calibrated live weights of a calibrated load cell.
This should also include a verification of stated radii and boom extension lengths.
All overload devices should be checked to ensure they are operating correctly

3.1
Verification on the SLI should be carried out yearly and records kept.
An audio alarm should give a continuous warning of approach to rated capacity. This should commence at
no less than 90% of the rated capacity and no more than 97.5%
An audio alarm should give a continuous warning of overload. This should commence at no less than
102.5% of the rated capacity and no more than 110%.
Both alarms should continue to function until the load drops below the value at which it was initiated.

4.0
Checks on Boom/Jibs
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WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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Inspect the full boom for straightness and for any evidence of physical damage, such as deformed or
cracked members. Pay particular attention for signs of flaking or cracking paint as this may indicate yielding
of the metal that may precede failure.
Check also for excessive corrosion especially around
the welded areas where paint may have been removed in the past for NDT.
Check around the top of the boom for signs of two-blocking.
Check all connecting pins for wear, damage and distortion. Also ensure all securing pins are in place
Check boom foot pins for signs of wear, this can be done by putting the boom into the rests and slewing back
and forth. If any excess movement is observed then the pins may be worn. The boom foot housings should
also be checked for cracking.
Any guide sheaves or rollers must be fully operational and show no damage that may affect the rope.
A check should be made on the boom supports and buffers to ensure they are of sound construction.
Checks on Machinery
Check all bolts and rivets for signs of corrosion, wear, damage and security. Any loose or missing bolts shall
be replaced. Re-tightening of bolts should be monitored closely as they may be stretched.
Inspect for excessive wear on brake and clutch system parts, linings, pawls and ratchets. Ensure that all
safety pawls operate correctly and are in good condition, free to move and are sufficiently lubricated.
Hydraulic and pneumatic systems shall be inspected for deterioration. If any of the following faults are noted,
the faulty part will require repair or re-newel.
Oil or air leaks on the surface of flexible hoses or at the points where the hose joins the metal couplings.
Abnormal deformation of the outer covering of hydraulic hose, including any enlargement, local or otherwise.
Any leaking at the connections that cannot be remedied by normal tightening.
Signs of abrasion on the wall of any hose or tube that could reduce their pressure retaining capacities. The
cause of the abrasion shall also be rectified if known.
Checks to be made on drum ( load hoist and boom hoist) for wear and/or damage scored, worn or
Otherwise damaged bearings or journals.
The boom hoist drum shall have sufficient rope capacity to operate the boom in all positions, from the lowest
permissible to the highest recommended reeving and rope size. No less than two full wraps of rope will
remain on the drum with the boom point lowered to the level of the crane supporting surface.
The load hoist drum shall have the rope capacity with the recommended rope size and reeving sufficient to
perform crane service within the range of boom lengths, operating radii and vertical lifts specified by the
manufacturer.
No less than two full wraps of rope shall remain on the drum when the hook is in its extreme low position.
The drum flange must extent a minimum of 13mm over the top of the rope at all times.
Ensure all of the drum ends of the rope are securely anchored to the drum by means approved by either the
rope or crane manufacturer and are also clear of all rope windings.
A function test on all braking systems should be completed at light load prior to overload test.
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WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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Wire Rope Checks

Check all rope test certificates to ensure the rope is the right grade and construction suitable for use with that
type of crane and configuration.
Check for corrosion, kinks and broken wires, changes in rope Diameter, wear, heat damage and lack of
lubrication.
Check all terminations and fittings for wear damage and distortion. Also signs of overloading (collapsed
thimbles). Ensure all wedge sockets are made up correct (wedge socket certificate should be accessible).
Deformation normally results in a combination of several defects occurring simultaneously giving a
cumulative effect.
The overall effect shall be taken into account when deciding if a wire rope shall continue in service.
For a more detailed program and assessment please refer to ISO 4309.
Visual inspection can be verified with NDT of the ropes if deemed a requirement.
Note - If the rope is without certificate, a sample must be tested to destruction to verify the break load.
Sheaves and Drums
All sheaves and grooved drums to have a dimensional check to confirm they are suitable for the wire
operating on them. During this check an assessment can be made on the wear in the rope saddle.
A physical examination should be made on the sheaves and drums to highlight damage such as cracking,
gouging, broken lips, bending and mechanical impact.
Sheaves should be turned by hand to ensure the bearings are in operating order, if needed sheave can be
removed to assess the level of lubrication and condition of seals.
All alignments should be confirmed.
Hook Block
The hook block should be inspected to ensure all critical components are in good condition. If there are no
past records available on the planned maintenance of the block it would be deemed good practice to
disassemble and inspect the components individually.
(it is also good practice to have this carried out annually).
Hook Block Strip and examination if required.
Fully split the block into component form.
Examine the threads for cracking using an acceptable method of NDT.
Examine the threads for wear and corrosion. The threaded area my appeared tapered if corrosion has
rounded the thread profile over time.
Examine the hook thoroughly for visible signs of cracks, gouges, stretching and mechanical damages
Full Magnetic Particle Inspection shall be conducted.
Check that there is a method of securing the nut from rotating one located on the hook shank. This may be
retaining pin, set screw of key.
Ensure that hook has a positive locking safety latch.
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WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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Examine the hook pivot, axial and cross pin bearings for wear and ensure the pivot and bearings provide a
freely rotating support for the hook.
All bearing should be examined for wear and operate freely.
During reassembly ensure that all moving areas are lubricated adequately and retaining pins all in place.
Cabin and Controls
The control cabin should be entered and exited to ensure access is not restricted.
All windows and screens should be clear with no obstructions to visibility.
All controls inside the cabin should be clearly indicated and marked with the operation they perform. The
controls should also operate freely.
All ladders, platforms or handrails shall be in position and of strong construction.
Additional Tests
To satisfy the inspector further on the cranes condition additional test may be required out with the scope of
this procedure, these may include
• Torque Values of slew ring bolts.
• Rocker Motion test for slew ring conditional report.
• Gearing back lash survey.
• Grease and oil samples.
• Electric circuit tests.
• Engine compression tests
UT/UT wall thickness measurements.

5.0
All wire ropes used on the cranes shall be inspected over their full length in accordance with
ISO 4309.
Particular attention shall be paid to the sections that pass throughout the block or over the pulleys, pay extra
attention to any part of the rope that may lie over a compensation sheave as this is continually exposed to
the elements.
Any broken wire that is found during the inspection that does not constitute the rejection of the rope shall be
broken off in the lay of the rope; their location should be noted for future reference.
Broken Wires – Randomly distributed broken wires which are visible should not exceed 10% in any length of
wire.
All wire ropes used on the cranes shall be inspected over their full length in accordance with
ISO 4309.
Particular attention shall be paid to the sections that pass throughout the block or over the pulleys, pay extra
attention to any part of the rope that may lie over a compensation sheave as this is continually exposed to
the elements.
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BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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Any broken wire that is found during the inspection that does not constitute the rejection of the rope shall be
broken off in the lay of the rope; their location should be noted for future reference.
Broken Wires – Randomly distributed broken wires which are visible should not exceed 10% in any length of
wire rope equal 8 rope diameters.
Wear – On steel sheaves 6/8 strand ropes should be discarded if they are measuring 90% of their nominal
diameter.
The same will apply with Non-rotating wires however a more detailed examination should be carried out if the
diameter has increased to 105% or reduced to 97%.
Any significant wear on sheaves should be cause for rejection as it can rapidly reduce the condition of the
wire rope.
The hook block must be complete with individual certificate.
Any indication of cracking is reason to remove the block from service.
If the threads are deformed of corroded for a total length that is more that 20% of the thread length the hook
shall be removed from service.
There should be no signs of permanent set in the hook.
If the hook is worn or lost 10% of its original cross sectional area it shall be removed from service.
On completion of rebuild the hook block must be load tested before being fitted to the crane. This test shall
include the becket if fitted.
Load chart and radius plate shall be displayed in a prominent position

5.1
Always wear protective gloves when handling wire ropes as there is the risk of broken wires.

5.2
During the test and examination be cautious of any possible oil/fuel leakages. When possible make the
necessary arrangements to contain all spillage’s that may occur.

6.0
Repairs
All repairs made by other than the manufacturers of the crane, should fall in line with the scope contained
within BS 7121, which would include design procedure and welding procedure.
They must also comply with the manufacturers recommendations.
Only when the findings of the examination are within the above criteria or approval/dispensation has been
given can the following TEST procedure commence.

6.1
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BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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It should be recognized that adverse weather conditions can impose additional loads limitations on wind
speed for testing the crane may be lower than the limitation for normal use, it is therefore the Test Engineers
decision whether or not to proceed with the test, taking into account wind speed, rain , snow, fog etc..
Tool Box talk to be held by Test Engineer to explain to all personnel on site what will happen during test and
all safety requirements which must be met to allow test to proceed.

Test Engineer to carry out a Job Safety Assessment prior to commencement of test. Any points raised during
the JSA must be addressed before the commencement.
A clear area of 1.5 x Boom Length must be cleared around the crane during test. Personnel should be
distributed around this area to make sure it is kept clear at all times during test.

7.0
Post Test Examination
A post load test examination should be carried out on all load bearing areas of the crane to confirm there
were no failures during the test.
The SLI should also be connected and re-confirmed as reading true.

8.0
Reporting
The written reports will be issued in compliance with BS 7121.
ORCA Form F-511 Certificate of Test and/or Thorough Examination of Cranes should be filled in fully. This is
a comprehensive list of the cranes components and will ensure no areas have been overlooked.

9.0
Defective Equipment
Where the test is not satisfactory, a reasonable representative of the user shall be informed by means
of a defect report. If the Inspection Engineer considers the defect to be of a dangerous nature the
arrangements must be made to ensure the crane is not used until remedial work has been carried out.
 Doc. n. WI-BOSS-MAIN-442-E
BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
Page. 9 OF 11

I. Akhundov
J.Aquino M.Giorgetti I.Allan R. McEwan
19/07/18 01 Issued for use General
MAIN MAIN QUAL Sn. OPS MGR
Director

Date Revision Description of Revision Prepared Checked Checked Management Approval

This document is property of BOS Shelf who will safeguard its rights according to the civil and penal provisions of the law.

Revision Summary

Date Revision Description of Revision Prepared Checked Management Approval

I. Akhundov
J.Aquino M.Giorgetti I.Allan R. McEwan
18/07/18 01 Issued for comments General
MAIN MAIN QUAL Sn. OPS MGR
Director
I. Akhundov
J.Aquino M.Giorgetti I.Allan R. McEwan
19/07/18 01 Issued for use General
MAIN MAIN QUAL Sn. OPS MGR
Director

Revision 01 log:

Level of impact of changes in the present revision: Low Medium High.

Function / departments affected by this revision: All departments

Summary of the modifications:

Issued for use

 Doc. n. WI-BOSS-MAIN-442-E
BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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 Doc. n. WI-BOSS-MAIN-442-E
BOS SHELF LLC
WORK INSTRUCTION Rev. 01 Date 19/07/18
TEST PROCEDURE OF CRANE
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1. SCOPE AND PURPOSE

2. REFERENCE DOCUMENTS

3. DEFINITIONS

4. RESPONSABILITIES

5. ACTIVITIES DESCRIPTION

6. FLOW CHART (N/A)

7. ATTACHMENTS