APMT Bahrain Lifting and Rigging Standard

APM TERMINALS BAHRAIN Health, Safety and Environment Department Lifting & Rigging Safe use, Maintenance &
inspection
PORT OF BAHRAIN
HSSE Manual
FOR
Lifting & Rigging Safe Use, Maintenance and Inspection
APM TERMINALS BAHRAIN Health, Safety and Environment Department Lifting & Rigging Safe use, Maintenance & inspection
Prepared by Lawrie Holman. HSSE GM May 2006
Approved by CEO Jorgen H Madsen May 2006
DATE
REVISION NUMBER
DATE CHANGED
SIGNAATURE
TABLE OF CONTENTS
Section
1.0 Introduction 2.0 Scope 3.0 Responsibilities 4.0 Training 5.0 Safe Work Practices 6.0 Lifting Register 7.0 Reference Standards 8.0 Appendix A 9.0 Appendix B 10.0 Attachment #1
1.0
INTRODUCTION By their very nature, lifting operations involving personnel, equipment and company assets have the potential to be the cause of serious accidents resulting in the loss of life, damage to equipment, the environment and to loss of revenue due to an interruption of production. Accidents involving lifting equipment continue to happen in industry and the only way we can insure against these accidents is to follow strict guidelines regarding the Safe Use, Maintenance and Inspection of any and all associated components.
2.0
SCOPE This Standard is applicable to all personnel (Company, Contract, Sub-Contract) working or visiting on Company premises. It is designed to provide personnel involved in lifting operations a minimum level guidance regarding the Safe Use, Maintenance and Inspection of lifting equipment and associated gear. It is not intended to replace in whole or in part any existing regulatory body regulations or industry accepted standards governing such equipment and operations.
3.0
RESPONSIBILITY Each Department manager is responsible for ensuring all lifting equipment and associated gear under his control is inspected prior to any use. That lifting equipment is only operated by qualified personnel, that it is in good working condition and maintained according to industry accepted standards and that all relevant certification is up to date, on file and readily accessible for Port of Bahrain auditors or HSSE personnel or regulatory body representative inspection. Each Department manager shall develop a lifting gear register to record and track all components requiring certification, shall keep the registers up to date, shall ensure all lifting equipment and associated gear has its identification markers firmly in place. Shall ensure no lifting equipment or lifting gear-requiring certification is used to hoist any load until said certification is in effect and recorded. Each Department Manager shall ensure there is a Preventative Maintenance System (PMS) in effect for the maintenance and inspection of all lifting equipment and associated gear. Those records are maintained and are up to date and available for inspection upon request by Port of Bahrain or regulatory body representatives. Each department manager shall ensure that the equipment is inspected and tested annually (every 12 months) months by a competent person who is qualified and certified in the inspection and testing of lifting equipment and is approved to do so.
4.0 TRAINING Only competent personnel shall engage in the operation of Port of Bahrain owned lifting equipment and associated lifting gear. All personnel responsible for the operation of lifting equipment must have previously completed and passed a training course acceptable to APMT standards and shall maintain on file a copy of said certification while engaged in lifting related operations. Certificates of competency must be produced to a Port of Bahrain representative upon request. Failing to do so will result in the immediate cessation of work until the certificate of competency can be produced.
5.0
SAFE WORK PRACTICES Port of Bahrain and third party contractors shall ensure the following safe working practices are strictly adhered to during any lifting operation undertaken by their personnel both onshore and offshore.
5.1
Lifting Tackle The following procedures shall be strictly adhered to any deviations from these providers can lead to reprimands recorded on ones record and ultimately dismissal.
All items of lifting tackle shall be plainly marked with its Safe Working Load (SWL) identification numbers and colour coding A competent person as per the regulations shall inspect all items of lifting tackle or instructions issued by the client or as stated by regulations or degrees by local Governing body in the country of operations. (See Appendix A). All lifting equipment shall be of good mechanical construction, manufactured from sound materials with adequate strength, free from defects and shall be properly maintained. Competent personnel who have undergone training and certification by a third party company that is acceptable to Port of Bahrain will operate power operated lifting equipment.
5.2
Cargo Handling Due to inherent dangers associated with the transfer of materials between vessels and quaysides or berths, the following procedures will be strictly adhered to in an effort to minimise the risks associated with these operations. Before commencing any cargo lifting operation, personnel engaged in the lifting operations shall ensure that the lifting equipment in use is of the correct S.W.L. One person will be in charge of giving the Crane Operator the correct signals and shall remain in sight of the crane operator at all times. Tag lines (control lines) shall be utilised to help manage hoisted loads in a safe manner.
6.0
LIFTING REGISTER Load bearing components utilised in lifting operations are a part of the lifting operations chain. The consequences of introducing a weak link into the chain can be devastating to personnel, equipment, the environment and the corporation as a hole. Lifting registers are a means of managing these load-bearing components in an effort to prevent weak links being introduced into lifting operations. Lifting registers shall track the following gear. Lifting Gear Wire Slings/Web Slings Shackles Snatch Blocks Chain Blocks Trolleys Pad Eyes
Lifting registers should record the following items. Register Elements: 7.0 An ID number for each item Manufacturers name Date of Manufacture A full description of each item The SWL Certificate Date i.e. 9/20/04 (manufacturers date) Start Date i.e. 10/10/04 (in service date) Annual Certificate date i.e. 09/10/06 (rectification date)
REFERENCE STANDARDS The following Institutes, Organisations, and regulatory bodies can be referenced for technical clarifications regarding lifting equipment, materials, inspection techniques and frequencies. American Petroleum Institute (API) British Standards Institution (BSI) American National Standards Institute (ANSI) International Standards Organisation (ISO) American Society of Mechanical Engineers (ASME) United Kingdom Health and Safety Executive L.O.L.E.R. Regulations
8.0 Appendix A
Lifting Appliances (Cranes and Machines)
8.1.1
Lifting appliances including all working gear, anchoring or fixing devices, shall be of good mechanical construction, sound materials, adequate strength, free from patent defects, and be properly maintained. All cranes shall be operated under the supervision of a competent operator and not be operated under weather conditions likely to affect stability. The anchoring or fixing arrangements of all lifting appliances will be adequate and securely supported. Safe access shall be provided for persons examining, repairing or lubricating the lifting appliance. Platforms used by drivers shall be of sufficient area, fenced, provided with safe means of access and all dangerous parts of machinery securely fenced. Winch drums, wire and pulleys will be of a correct diameter, design and construction in accordance with generally accepted Engineering practices and standards and all chains or ropes will be properly secured to drums. At least three turns of chain or rope will remain on the drum in every operating position. The wire ropes will wind-on evenly and not overlap itself under any circumstance. The ratio of drum diameter to rope diameter is important and whenever possible a travelling fairlead shall be installed. All gears, toothed sprockets and wheels used in the construction and drive mechanism shall be properly guarded to avoid injury to personnel. Wire rope ends, for general usage, shall be properly wire seized and the return (short) end clamped with a correct number of clips with the U bolt part around the short end of the rope. Clips to be spaced in accordance with good design practice. Wire rope ends must never be welded together at the strand ends. Such ropes constructed in this manner SHALL NEVER BE USED FOR MEANS OF LIFTING/LIFTING. The eye of all looped wire shall be fitted with a proper thimble and whenever possible the return end secured with the correct size of ferrule applied and fitted by means of a proper crimping tool. All jib cranes shall have an approved type of automatic safe load indicator, which must be properly maintained. The safe working load should be specified on the crane and strictly adhered to. For rails mounted cranes, stops or buffers shall be provided on each rail at each end of the tracks. Rails shall have an even running surface and be adequately supported on a surface sufficiently firm to prevent undue movement. Rails shall be laid in straight lines or in curves of such radii that the crane can be moved freely and without risk of derailment. Rails, sleepers, bearers, fishplates, chairs, stops, buffers and other equipment must be properly maintained. Rails and sleepers will not be used as anchorage. Knots shall not be tied in parts of chains or wire ropes. Nor shall they be shortened or joined by means of nuts and bolts inserted through the link or clamped with flat steel plate. Packing or other means shall be used to prevent the edges of a load from coming into contact with slings, ropes or chains.
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.1.12 Lifting appliances shall not be used of soft uneven surfaces, or on a slope, unless appropriate precautions are taken to ensure stability. A passageway of 610mm or more shall be maintained between slewing or other moving parts of lifting appliances and the guardrails or other nearby fixtures. Cranes will be operated only by employees who are physically qualified with regard to accuracy of vision, depth and colour perception, hearing, muscular co-ordination and reaction time. Only trained and competent persons shall operate lifting appliances. No person under 18 will operate any lifting appliances. All operating cranes shall be provided with 2 men, the operator and a slinger/signalman. Signals shall be clear and concise, easily seen or heard and understood by the person to whom they are given and by others concerned with the lifting operation. No person under 18 will be allowed to give signals to operators of power driven lifting appliances. (Signals to be as shown in attachment C) Cranes will never be left with a suspended load or the power equipment running. Movable jib cranes shall be fitted with radius indicators. There are many types of cranes and specific procedures will be established for the handling of each. Supports for the hoists shall be strong enough to carry the maximum load to be imposed on them. Accessible parts of hoist ways will be protected by substantial enclosures fitted, where access is required, with gates. Where applicable, hoists shall be so constructed that they can be operated from one position, and safety devices fitted to support the platform or cage with full load if lifting gear or ropes fail. Automatic devices shall be fitted to prevent over-running at the highest point for which the platform is constructed to travel. Safe working load shall be marked on platform or cage, and the permitted number of persons allowed to travel will be clearly indicated and must not be exceeded. Guards or loose materials will not be placed directly or a platform unless the latter is enclosed or other precautions is taken to prevent falls of materials. Trucks or wheelbarrows will not be carried on platforms unless scotched or secured, and loaded trucks or wheelbarrows will not be carried on open platforms unless so loaded that no part of load is liable to fall off. Barricade guards shall be installed to protect the operator where necessary.
8.1.13
8.1.14
8.1.15
8.1.16 8.1.17
8.1.18 8.1.19
8.1.20
8.1.21
8.1.22
8.1.23
8.1.24
8.1.25
8.1.26
8.1.27
1. Appendix B 2. Lifting Tackle/Lifting Loose Gear
8.2.1
Ropes, chains and slings shall be of sufficient size and strength and of the correct type to accomplish the lift being undertaken. Every item of lifting tackle shall, where possible, be plainly die-stamped with an identification number and its safe working load as advised by the manufacturer. A certificate of test shall be required for all new equipment. Where marking is not feasible, such items are to be numbered and the safe working load of the item be recorded in a Register. The safe working load of the item must be made known to the person drawing the equipment from store. All lifting tackle issued for use must be inspected by the user and details entered in a Register. Equipment shall be free from any obvious defects and any lifting tackle beyond its mandatory life will not be used. No chain, rope or lifting tackle shall be issued or used unless it is of good construction, material, and adequate strength and free from patent defects. All such equipment, including eyebolts, hooks, lifting beams, plate clamps, lifting dogs, etc., shall be subject to a mandatory examination every six months and be recorded in the register. The equipment will also be visually inspected frequently throughout usage. No wire rope shall be used if in any length a number of broken wires are observed; it shall be returned to store for full inspection. No fibre rope shall be used if it shows undue wear or loosening of the yearn strands. It will be returned to store for full inspection. Flexible steel lashing wires, of 6 mm (1/4 in.) Diameter, are designed for lashing ladders etc., and will not be used for suspending loads. Care must be taken by the use of wooden or similar packing, when slinging a load, to ensure that the sling is not bent over a small curvature or sharp edge, since this may damage the sling. The weight being lifted, plus the weight of the tackle, shall be known before starting a lift. A Slingers Handbook showing the safe working loads of every kind and size of chain, rope or lifting tackle in use and in the case of a multiple sling, the safe working load at different angles of the legs shall be issued to all personnel involved in this type of work. Fibre rope slings shall not be used for lifting, or lowering, if the rope is badly chafed externally, or worn internally, or where the fibres have noticeably deteriorated to a marked degree. When not in use, fibre rope slings shall be hung up where they can dry naturally in a free circulation of cool air. Lifting tackle and equipment used in connection with oil, acid, or injurious chemicals, shall be examined daily, and checked for any detrimental effects of such usage.
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8
8.2.9
8.2.10 8.2.11
8.2.12
8.2.13
8.2.14
8.1.15 When suspending floating heads, manhole doors and similar pieces of equipment from davits, it is important to ensure that the suspension bolts are not bent or distorted. The above regulations are to be regarded as a brief summary only, and the person in charge of the equipment should be fully knowledgeable of all the relevant safety factors.
8.2.15
ATTACHMENT # 1
Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap
WIRE ROPE SLINGS
LE 01
(B) Not Acceptable: Repair/Replace
(C) Service Before Re-Inspection
(D) Further Examination Before Acceptance WIRE ROPE (A) (A) (A) (A) (A) (A) (C) Heat damage; discoloration, loss lubricant More than 10% reduction in rope original diameter High external corrosion, internal corrosion Severe distortion kinks, crushes, knots, bird cages More than maximum allowed broken wires (table) Exposure of core, internal damage Broken wires within limits
TERMINATIONS 1. EYES (A) (A) (D) 1. Distortion Excessive wear, damage to thimble Rope defects see above criteria
SECURING (A) (A) (A) LINKS HOOKS SHACKLES PROOF LOAD 2.0 x SWL, followed by thorough examination and certification Any broken wires near to the ferrule/splice Broken/damaged ferrules or pulling out Crushing, abrasion of splice, pulling out See LE 02 See LE 05 See LE 03
MARKINGS (A) (B) (C) Identification Number SWL / SWL @ Angle Colour Code
ATTACHMENT B
Inspection of Loose Equipment prior to Use
CHAIN SLINGS
LE 02
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance CHAIN SLINGS (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (C) (D)
More than 5% stretch of original length (terminal, joining, intermediate links, chain and hooks) (Manuf. Table) More than 8% dia wear of terminal, joining, intermediate links, chain and hooks (Manuf. Table) Existence of nicks, cracks and gouges in terminal, joining, intermediate links and chain Bent, elongated, or twisted links, rings Lack of free articulation between links Distortion of terminal fittings Cracks and faults in welded areas Excessive corrosion Heat discoloration Broken, twisted chain Improper shortening devices Repairs by welding Rusty chain Hooks see LE 05
ON-WELDED CHAIN (A) (B) (B) (B) (B) (D) HOOKS More than 8% wear of terminal fittings, joining links Existence of nicks, cracks, gouges in terminal fittings, joining links Bent, elongated or twisted joining links Distortion of terminal fittings Replaced parts incorrectly assembled Replaced parts not manufacturer certified = See LE 05
PROOF LOAD 2.0 x SWL, followed by thorough examination and certification
MARKINGS (A) Identification Number (B) SWL / SWL @ Angle (C) Quality Marks (D) Colour Code
ATTACHMENT B
SHACKLES
LE 03
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance SHACKLES (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (A) (B) Wear of pin and body higher than 8% dia Nicks, cracks and gouges in stressed areas Distortion in any axis Misalignment of untapped/tapped hole Excessive wear of untapped hole Incorrect pin inserted. Pin not running free Pin screwed, less than outside face flush Head of pin not bearing on shoulder of untapped hole Thread damage or excessive wear Excessive corrosion Repairs by welding Missing locking devices, if applicable
MARKINGS (A) (B) (C) (D) Identification Number SWL Quality Marks Colour Code
ATTACHMENT B
EYE BOLTS
LE 04
(D) Further Examination Before Acceptance EYEBOLTS (A) (A) (A) (A) (A) (A) (A) (C) Wear in eye and link, if any, higher than 8% dia Nicks, cracks and gouges in shank and eye Nicks, cracks and gouges in shank to collar junction Distortion in any axis Thread damage or excessive wear Excessive Corrosion Any type of repair Cleanliness of thread, underside of collar
ATTACHMENT B
HOOKS
LE 05
(D) Further Examination Before Acceptance HOOKS (A) (A) (A) (A) (A) (A) (A) (A) (B) (B) (B) (B) (B) (C) Throat opening higher than 20% original throat (Manuf. Table). Lateral twist higher than 10 degrees Wear in eye and saddle higher than 8% of original thickness (Manuf. Table) Cracks, nicks, scores, gall marks in body Misalignment of shank, excessive wear Thread damage of excessive wear Repair by welding Excessive wear, damage to cross head pin Damaged or missing locking devices No free running of swivel. Bearing damage, if applicable Cracks, defects in trunnion weld joint, if applicable Loose bolts, nuts, pins Damaged or missing safety catches, if applicable Lack of lubrication
PROOF LOAD 2.0 x SWL where SWL < 25T (B) 1.22 x SWL + 2.0 T where SWL > 25T ] Followed by thorough ] examination and Certification
ATTACHMENT B
LIFTING BEAMS SPREADER
AND
LE 06
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. LOOSE GEAR, DETACHABLE ITEMS SHACKLES (D) See specific criteria EYEBOLTS (D) See specific criteria HOOKS (D) See specific criteria WIRE ROPE SLINGS (D) See specific criteria CHAIN SLINGS (D) See specific criteria FLAT WEBBING SLINGS (D) See specific criteria CLAMPS (D) See specific criteria B. LOAD (B) (B) (B) (D)
LE 03
LE 04
LE 05
LE 01
LE 02
LE 09
LE 07 & LE 08
ATTACHMENTS POINTS Cracks, distortion, excessive wear, corrosion of fabricated items Cracks, distortion or wear of suspension holes Malfunction of locking devices, if applicable Looseness of bolted connections
C.
BEAM (B) Cracks, distortion, excessive wear (B) Crack, defective joints (B) Heavy dents, buckling of hollow sections (B) Damage to section flanges (B) Loose nuts, bolts rivets. Thread damage or wear (B) Excessive Corrosion PROOF LOAD 2.0 x SWL where SWL < 10T
(B) 1.04 x SWL + 9.6 T where 10T SWL <160T
(B) 1.1 x SWL where SWL > 160T
[ Followed by thorough examination and Certification]
MARKINGS (A) Identification Number (B) SWL (C) Colour Code ATTACHMENT B
PLATE CLAMPS
LE 07
(D) Further Examination Before Acceptance BEAM CLAMPS (A) (A) (A) (A) (A) (B) (B) (D) Distortion of frame Wear at application/suspension points, moving parts Wear, damage or missing locking devices Nicks, cracks, gouges Excessive corrosion Worn out, bent pins Individual parts incorrectly assembled/replaced, if applicable Lack of lubrication see Manuf. recommendations
PROOF LOAD 2.0 x SWL, followed by thorough examination and certification MARKINGS (A) (B) (C) Identification Number SWL Color Code
ATTACHMENT B
PLATE CLAMPS
LE 08
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance FRICTION LIFTING TYPE (A) (A) (A) (A) (B) (B) (B) (B) (B) (D)
Distortion of frame Wear on gripping surfaces Nicks, cracks, gouges Excessive corrosion Broken, stretched spring in locking lever Improper action of locking lever Tight, bent, damaged clamping threads Blunted teeth in fixed, movable jaws see Manuf. recommendations Worn out, bent pins Lack of lubrication see Manuf recommendations
HORIZONTAL LIFTING TYPE (A) (A) (A) (A) (B) (B) (D) Distortion of frame Wear on gripping surfaces Nicks, cracks, gouges Excessive corrosion Blunted teeth in fixed, movable jaws see Manuf. recommendations Worn out, bent pins Lack of lubrication see Manuf recommendations
ATTACHMENT B
MANMADE FIBRE SLINGS
LE 09
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance FLAT WEBBING TYPE (A) (A) (A) (A) (A) (A) (A) (A) (A)
Cuts on face or at edge of webbing Holes, tears, snags or crushed web Excessive abrasive wear Excessive pitting or corrosion, cracked, distorted or broken fittings, if applicable Broken, or worn threads in the stitch patterns Melting or charring of any part of the sling Chemical burns Strop eye damage/webbing burst at edges, if applicable Any type of repairs
ROUND TYPE A. PROTECTIVE SLEEVE (D) B. Scuffing, wear and general deterioration See Inner Core
INNER CORE (A) (A) (A) (A) (A) (A) (A) Cuts Holes, tears, snags, crushed web Excessive abrasive wear Broken or worn threads in the stitch patterns Melting or charring Chemical burns Any type of repairs
PROOF LOAD See Manufacturers Data
MARKINGS (A) Identification Number (B) SWL (C) Colour Code
ATTACHMENT B
CHAIN PULLEY BLOCK
LE 10
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A.
B.
C.
HAND CHAIN (B) Cracks, distortion, wear or corrosion (B) Cracks, distortion, wear of hand chain wheel (B) Incorrect seating in hand chain wheel (C) Rusty chain LOAD CHAIN (B) Cracks, distortion or wear of blocks, wear, slackness of sheave wheel (B) Incorrect seating in sprocket wheel (B) Damage to slack end or load end anchor (C) Rusty chain (C) Twisted chain in multiple fall (D) See specific criteria LE 02 HOOKS, TERMINAL FITTINGS (B) Cracks, distortion or wear of blocks. Wear, slackness of sheave wheel (D) See specific criteria LE 05 MAIN FRAME (B) Cracks, distortion or wear in body, gear covers or chain guides (B) Loose nuts, bolts, rivets, or pins. Thread damage or wear. Missing locking devices (B) Corrosion, wear or damage to pawl, ratchet or spring (B) Cracks or uneven wear of pinions, gear wheels or bearings (B) Wear, damage to brakes, chain stripper (D) Improper maintenance condition (D) Improper electrical condition, if applicable REPAIR (B) Repair not in accordance with manufacturers recommendations (B) Replaced parts incorrectly assembled (D) Replaced parts not manufacturer certified OPERATIONAL TEST (B) Undue effort, excessive noise or jumping of chains during lifting/lowering (B) Malfunction of pawl, operating spring and ratchet (B) Malfunction of brakes under load (B) Incorrect action of chain guides PROOF LOAD A. Hand driven 1.5 x SWL B. Power driven 1.25 x SWL MARKINGS (A) Identification Number (B) SWL (C) Quality Marks (D) Color Code
D.
E.
F.
] Followed by thorough ] examination and Certification
ATTACHMENT B
TIRFOR
LE 11
(D) Further Examination Before Acceptance A. WIRE ROPE - See LE 01
B.
HOOKS, FITTINGS - See LE 05
C.
FRAME (B) (B) (B) (B) (B) (D) Cracks, distortion or wear in body, covers or rope guides Loose nuts, bolts, rivets or pins, thread damage or wear, missing locking devices Corrosion Damage or wear to levering mechanism Shear pin worn, damaged. Replaced with non-standard item Improper maintenance
D.
REPAIR (B) (B) (D) Repair not in accordance with manufacturers recommendations Replaced parts incorrectly assembled Replaced parts not manufacturer certified
E.
OPERATIONAL TEST (B) (B) Undue effort, excessive noise or slipping of rope during lifting/lowering Malfunction of brake under load
PROOF LOAD 1.5 x SWL, followed by thorough examination and certification MARKINGS (A) Identification Number (B) SWL (C) Color Code
ATTACHMENT B
BASKET
LE 12
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance GOODS/GENERAL PURPOSE BASKET A. LOOSE GEAR DETACHABLE ITEMS See LE 01, 02, 03, 04, 05, 09 for individual requirements B. LOAD ATTACHMENT POINTS (B) (B) (B) (D) C.
Cracks, distortion, excessive wear, corrosion of fabricated items Cracks, distortion or wear of suspension holes Malfunction of locking devices, if applicable Looseness of bolted connections
STRUCTURE (B) (B) (B) (B) (B) (B) (B) (B) Cracks, distortion, excessive wear Cracked/defective joints Heavy dents, buckling of hollow sections Damage to section flanges Loose nuts, bolts, rivets. Thread damage or wear Excessive corrosion Door fastening/hinges damaged Excessive mesh size for cargo type
ATTACHMENT B Page 1 of 2 Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap TRAVELING GIRDER TROLLEYS LE 13
(D) Further Examination Before Acceptance A. HAND CHAIN (B) (B) (C) (D) Cracks, distortion, or wear of hand wheel Incorrect seating in hand chain wheel Rusty chain Cracks, distortion, wear or corrosion
B.
MAIN FRAME (B) (B) (B) (B) (B) (B) (D) (D) Loose nuts, bolts rivets or pins. Thread damage or wear, Missing locking devices, if applicable Wear, damage to wheel threads, flanges, bearings Loose, defective wheel support brackets Distortion, particularly inside plates and load bar Cracks, defects in joints Cracks, uneven wear of pinions, gear wheels Improper maintenance condition Improper electrical condition, if applicable
C.
REPAIRS (B) (B) (D) Repairs not in accordance with manufacturers recommendations Replaced parts incorrectly assembled Replaced parts not manufacturer certified
D.
INSTALLED UNIT (TROLLEY + BEAM) (B) (B) (B) Incorrect size for the runway beam Misalignment, relative to center flange of runway, if applicable Incorrect side clearance between wheel flanges and toes of beam (3 to 4 mm required)
ATTACHMENT B Page 2 of 2 Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap TRAVELING GIRDER TROLLEYS (B) Not Acceptable: Repair/Replace LE 13
(D) Further Examination Before Acceptance E. OPERATIONAL TESTS (BLOCK + TROLLEY + BEAM)
(B) (B) (B) (D)
Incorrect or wrongly fitted chain pulley block Wrongly adjusted anti-tilt device, if applicable Irregularities during traveling Chain pulley block See specific criteria - LE 01
PROOF LOAD Separate by Hand 1.5 x SWL With Power hoist 1.25 x SWL MARKINGS (A) (B) (C) Identification Number SWL Color Code (Followed by thorough examination and certification)
ATTACHMENT B
CHAIN LEVER HOIST
LE 14
(D) Further Examination Before Acceptance A. LOAD CHAIN (B) Cracks, distortion or wear of sprocket wheel (B) Incorrect seating in sprocket wheel (B) Wear, damage to Anchorages to casing or stopper; missing stopper (C) Rusty chain (C) Twisted chain in multiple fall (D) See specific criteria LE 02 HOOKS, TERMINAL FITTINGS, BLOCK (B) Cracks, distortion or wear of blocks. Wear, slackness of sheave wheel (D) See specific criteria LE 05 MAINTENANCE (B) Cracks, distortion or wear in body, gears covers or operating lever (B) Loose nuts, bolts, rivets or pins. Thread damage or wear, missing locking devices (B) Corrosion, wear or damage to pawl, ratchet or spring (B) Cracks or uneven wear of pinions, gear wheels or bearings (B) Wear, damage to breaks, chain-stripper, change over lever (D) Improper maintenance condition REPAIRS (B) Repairs not in accordance with manufacturers recommendations (B) Replaced parts incorrectly assembled (D) Replaced parts not manufacturer certified OPERATIONAL TESTS (B) Chain wheeling not fee (B) Malfunction of change over lever lifting/lowering/neutral (B) Malfunction of pawl, operating spring and ratchet (B) Malfunction of brakes under load (B) Malfunction of chain guides PROOF LOAD 1.5 x SWL, followed by thorough examination and certification MARKINGS (A) Identification Number (B) SWL (C) Quality Marks (D) Color Code
B.
C.
D.
E.
ATTACHMENT B
DIAMETER CONSTRUCTION LENGTH
LE 15
(A) Not Acceptable Scrap (B) Not Acceptable: Repair/Replace (D) Further Examination Before Acceptance A. BROKEN WIRES RANDOM (A) (D) < Maximum allowed (Table) > Maximum allowed compute rejection factor
LOCALIZED (A) B. WEAR (A) (D) C. > 10% diameter reduction < Maximum allowed compute rejection factor > 3, Local group or same strand, over 6 diameter length
DISTORTION (A) (D) Severe, kinks, crushes, knots, etc. Less than severe - compute rejection factor
D.
EXTERNAL CORROSION (A) (B) (D) Heavy pitting/corroded areas Stained rope < Heavy - compute rejection factor
E.
MISCELLANEOUS (A) (B) Thermal damage Core deterioration
F.
INTERNAL EXAMINATION - Rope clamped, contra rotated (A) (A) (C) (D) Internal corrosion Core deterioration Lack of lubrication Broken wires
ATTACHMENT B
TABLE
REJECTION FACTOR ASSESSMENT (C) Service Before Re-Inspection
(D) Further Examination Before Acceptance
Rejection Factor Assessment
REJECTION FACTOR Points Defects Broken Wire Random Wear Construct 6 x 19 6 x 36 8 x 25 6x, 8x Multi Str Distortion External Corrosion 0 Nil Nil Nil Nil Nil Nil Nil 20 1 2 2 .98d .995d Light Partial Stain Rough Touch 40 2 4 4 .96d .99d 60 3 6 6 .94d .98d Medium Pitting 80 5 8 8 .92d .975d 100 6 11 10 .9d .97d Severe Heavy Pitting Remarks Over length of 10 x d D = nom. dia
Total rejection Factor = sum of Factors (Broken, Wear, Deterioration, Corrosion)
Assessment < 40 Total Rejection Factor 60 80 100 Fit for use Fit for use Fit for use Unfit for Use
Recommendation/Action
Increase inspection freq. Advise replacement w/in time Scrap immediately

APMT Bahrain Lifting and Rigging Standard

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APMT Bahrain Lifting and Rigging Standard

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APM TERMINALS BAHRAIN Health, Safety and Environment Department Lifting & Rigging Safe use, Maintenance &

Lifting & Rigging Safe Use, Maintenance and Inspection

Prepared by Lawrie Holman. HSSE GM May 2006

Approved by CEO Jorgen H Madsen May 2006

Lifting Appliances (Cranes and Machines)

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

WIRE ROPE SLINGS

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

Inspection of Loose Equipment prior to Use

(C) Service Before Re-Inspection

PROOF LOAD 2.0 x SWL, followed by thorough examination and certification

Inspection of Loose Equipment prior to Use

(C) Service Before Re-Inspection

PROOF LOAD 2.0 x SWL, followed by thorough examination and certification

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

PROOF LOAD 2.0 x SWL, followed by thorough examination and certification

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

Inspection of Loose Equipment prior to Use

LIFTING BEAMS SPREADER

(C) Service Before Re-Inspection

(B) 1.04 x SWL + 9.6 T where 10T SWL <160T

(B) 1.1 x SWL where SWL > 160T

[ Followed by thorough examination and Certification]

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

Inspection of Loose Equipment prior to Use

(C) Service Before Re-Inspection

Inspection of Loose Equipment prior to Use

MANMADE FIBRE SLINGS

(C) Service Before Re-Inspection

PROOF LOAD See Manufacturers Data

MARKINGS (A) Identification Number (B) SWL (C) Colour Code

Inspection of Loose Equipment prior to Use

CHAIN PULLEY BLOCK

(C) Service Before Re-Inspection

] Followed by thorough ] examination and Certification

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

(D) Further Examination Before Acceptance A. WIRE ROPE - See LE 01

HOOKS, FITTINGS - See LE 05

Inspection of Loose Equipment prior to Use

(C) Service Before Re-Inspection

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

(C) Service Before Re-Inspection

(B) (B) (B) (D)

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

CHAIN LEVER HOIST

(B) Not Acceptable: Repair/Replace

(C) Service Before Re-Inspection

Inspection of Loose Equipment prior to Use

DIAMETER CONSTRUCTION LENGTH

(C) Service Before Re-Inspection

MISCELLANEOUS (A) (B) Thermal damage Core deterioration

Inspection of Loose Equipment prior to Use (A) Not Acceptable Scrap

REJECTION FACTOR ASSESSMENT (C) Service Before Re-Inspection