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(TP – 25) SURVEYS AND TESTING OF LIFTING APPLIANCES ON BOARDPrepared By : Surveyor Manager

Approved By : Technical Director

Issue Date : 12-07-2015 Page: 1/18Rev. Number : 0 Revision Date: -

TABLE OF CONTENTS

1SCOPE

2 REFERENCES

3 RESPONSIBILITIES

4 DEFINITIONS

5ANALYSIS OF THE WORK INSTRUCTIONS

6TRAINING

7QUALITY RECORDS

8 REVISION HISTORY

APPENDICES: “A” REQUIREMENTS FOR TESTING OF LIFTING APPLIANCES“B” REQUIREMENTS FOR TESTING ITEMS OF LOOSE GEAR“C” THOROUGH EXAMINATION“D” LIST OF VALID FORMS“E” REQUIREMENTS FOR TESTING OF LIFTING

ASSEMBLY ACCORDING TO P.D 316/2001

1. SCOPE

The scope of the present Work Instruction is to define and document the standard MARITIME COOK ISLANDS procedure for carrying out surveys and testing of Lifting Appliances installed on board ships.

2. REFERENCES

2.1 Convention No. 152 “Convention concerning occupational safety and health in dock work”, Intenational Labour Organization.

2.2 “Tentative Rules and Regulations for the Classification and Construction of Lifting Appliances in a Marine Environment”, UNITED REGISTRATION AND CLASSIFICATION OF SERVICE LTD, 1995.

2.3 “Tentative Rules and Regulations for the Construction and Certification of Lifting Appliances”, UNITED REGISTRATION AND CLASSIFICATION OF SERVICE LTD, 1995.

2.4 “Survey Procedures Manual”, UNITED REGISTRATION AND CLASSIFICATION OF SERVICE LTD.

2.5 MARITIME COOK ISLANDS QP17 “Authorities and Responsibilities”. 2.6 MARITIME COOK ISLANDS QP10 “Personnel Training”. 2.7 MARITIME COOK ISLANDS QP15 “Service Realization”. 2.8 MARITIME COOK ISLANDS QP02 “Control of Records”.

3. RESPONSIBILITIES

3.1 The primary responsibility for carrying out the survey as per the present Work Instruction is held by the Surveyor assigned to the project.

3.2 The Department Supervisor involved is then responsible to control the work performed by the Surveyor and to review and check documents submitted by him. He is also responsible to ensure that the Surveyor is provided with the applicable Rules, Survey Procedures Manual, Work Instructions and Survey reports required to duly carry out the Survey.

3.3 For surveys performed by MARITIME COOK ISLANDS or MARITIME COOK ISLANDS (Int) authorized Exclusive or non-Exclusive Surveyors outside the H.O area and abroad, the Surveyor Coordinator assigned to monitor the performance of the survey, is held responsible to control the work performed by the Surveyor and to review the documents submitted by him. The Training department Supervisor is held responsible for checking the submission.

3.5The Technical Department Supervisor is then responsible to finally check the documentation and assure that it is duly submitted with regard to the applying procedure.

3.6 The Surveyor in charge is responsible to perform the survey to the extent deemed

Maritime Cook Islands Page | 2 Surveyor Instruction Manual v2

appropriate and retains the authority for the timeliness and completeness of the survey.

4. DEFINITIONS

4.1 The term lifting appliance covers all stationary or mobile cargo-handling appliances used on board ship for suspending, raising or lowering loads or moving them from one position to another while suspended or supported.

4.2 The term loose gear is intended to include any component of lifting appliance (block, shackle, link, chain, hook, ring, eyeplate, swivel, etc.) which upon removal from an assembled unit is a complete component of itself, or it is able to be either utilised as an individual component or placed in service in another unit of cargo gear in a similar manner to that for which the complete component was utilised in the initial unit.

4.3The term thorough examination is intended to include a detailed visual examination, supplemented, if considered necessary by the surveyor, by such other means as non- destructive testing (such as a hammer test, or X-ray e.t.c.), carried out as carefully as the conditions permit in order to arrive at a reliable conclusion with respect to the safety of the appliance examined. Where the surveyor considers it necessary, parts of the lifting appliance or loose gear should be dismantled by a skilled person to the extent required by the surveyor.

4.4The safe working load is the load for which the gear is designed and is approved to support, excluding the weight of the gear itself. The safe working load of rope is the maximum permissible line pull on the rope. For single sheave blocks the safe working load is the maximum load which is permitted to be lifted by the block when the load is attached to a rope which passes around the sheave of the block and when both ends of the rope are parallel to each other. For multiple sheave blocks the safe working load is the maximum resultant load which is permitted to be imposed on the eye or pin of the block.

4.5The proof load is the test load to which a component or an assembled unit is subjected as required

by prevailing regulations and/or to satisfactorily verify the suitable condition of the gear.5. ANALYSIS OF THE WORK INSTRUCTION

PART “A”

5.1 Lifting appliances forming part of a marine equipment are approved, examined, tested and certified before being taken into use for the first time, and thereafter, they are periodically surveyed and tested to maintain the validity of their certification.

5.2 Prior to initial use all new, reinstalled, modified or extensively repaired lifting appliance and every item of loose gear shall be tested , thoroughly examined and certified to ensure that it is of good design and construction, of adequate strength for the purpose for which it is intended and in accordance with the approved plans. Material test certificates are to be available. All welding is to be to the satisfaction of the surveyor. All items of loose gear shall be examined in order to verify that items are the correct for their


proposed location, that they have been manufactured as indicated in the approved plans, and they are individually marked and certified, by a competent authority, for their safe working load. Should any item is not certified the surveyor must proceed to testing and certification of the item, according to Appendix B. In the sequel, the assembled lifting appliance is to be tested, according to Appendix A, to ensure that all equipment operates effectively and safely and any cut outs, controls and similar devices function correctly. After testing, the installation, including the supporting structure, is to be thoroughly examined to ensure that no deformation or distortion has occurred.

5.3 In the case of new appliance, upon satisfactory completion of the procedures described above, and in accordance with the specific written instructions of the Department Supervisor involved, the surveyor shall complete and issue the Register of Lifting Appliances and the appropriate Certificates:• Certificate of test and thorough examination of lifting appliances or• Certificate of test and thorough examination of derricks used in union purchase • Certificate of test and thorough examination of loose gear and • Certificate of test and thorough examination of wire rope.

In the case of existing appliance, an entry shall be made in Part I of the Register and attach the appropriate certificates described above.

5.4 All lifting appliances and every item of loose gear shall be thoroughly examined at least once in every 12 months, according to Appendix C. The particulars of these thorough examinations shall be entered in Part I of the Register. Should the survey reveal any deficiency, the surveyor must inform the Department Supervisor involved and take written approval for imposing recommendations.

5.5 All lifting appliances and every item of loose gear shall be retested, according to Appendices A and B, in the following cases:a) after any substantial alteration or renewal, or after repair of any stress-bearing part, b) in the case of lifting appliances, at least once in every five years.After testing, the lifting appliance and every item of loose gear is to be thoroughly examined to ensure that no deformation or distortion has occurred. Upon satisfactory completion of the above procedures, and in accordance with specific written instructions of the Department Supervisor involved, an entry shall be made in Part I of the Register and attach the appropriate certificates

6. TRAINING

6.1 It is the responsibility of the Department Supervisor involved to ensure that the surveyor assigned to perform the work described in the present Work Instruction is competent person. The term competent person means a person having the knowledge and experience in performing thorough examinations and tests of lifting appliances and who is acceptable to the competent authority.

6.2 The surveyor assigned to perform the work described in this W.I. should have, as a minimum, the qualifications and training described in Resolution A.789(19) “Specifications on the survey and certification functions of recognized organizations acting on behalf of


the administration”.

6.3 Competence in the present W.I. is obtained by performing the work described herein as on-the-job-training under the supervision of a person who has satisfied the requirements of the W.I. Refer to MARITIME COOK ISLANDS QP10. 7. QUALITY RECORDS

7.1 Copy of the Register of Lifting Appliances as well as of the appropriate certificates used in the context of the present work instruction, after being duly filled in by the surveyor in charge, are submitted to MARITIME COOK ISLANDS Head Office for review and checking according to MARITIME COOK ISLANDS QP 15 and thereafter they are forwarded to the Quality Department for processing and storage according to MARITIME COOK ISLANDS QP 02.

8. REVISION HISTORY

REVISION NUMBER REVISION SUMMARY EFFECTIVE DATE


APPENDIX A

Requirements for testing of Lifting Appliances

A.1. Every lifting appliance shall be tested with a prof load which shall exceed the safe workingload (SWL) as follows:

SAFE WORKING LOAD OF PROOF LOADASSEMBLED GEARNot exceeding 20 tons 25 percent in excess

Over 20 tons but not exceeding 50 tons 5 tons in excessOver 50 tons 10 percent in excess

A.2. In the case of derrick systems the proof load shall be lifted with the ship’s normal tackle with the derrick at the minimum angle to the horizontal for which the derrick system was designed (generally 15 degrees), or at such greater angle as may be agreed. The angle at which the test was made should be stated in the certificate of test (FORMS: OGCFO2(1198) or OGCFO2U(1198)). After the proof load has been lifted it should be swung as far as possible in both directions. The SWL is applicable to swinging derrick systems only. When derricks are used in union purchase the SWL(U) is to be as shown on OGCFO2U(1198). In the case of heavy derricks, care should be taken to ensure that the appropriate stays are correctly rigged.

A.3. In the case of cranes, the proof load is to be hoisted, slewed and luffed at low speed. Gantry and travelling cranes together with their trolleys, where appropriate, are to be traversed and travelled over the full length of their track. In the case of variable load-radius cranes, the tests are generally to be carried out with the appropriate test load at maximum, minimum and at an intermediate radius. Where it is not practicable for the lifting appliance to raise the full proof load, as may be the case for hydraulic cranes, a reduced proof load may be accepted but in no case this is to be less than 1.1 times the safe working load.

A.4. As a general rule, tests should be carried out using certified test loads, and no exception should be allowed in the case of initial tests. In the case of repairs, replacement or when periodic examination calls for re-test, consideration may be given to the use of spring or hydraulic balances provided the SWL of the lifting appliance does not exceed 15 tons. Where a spring or hydraulic balance is used it shall be calibrated and accurate to within ±2 per cent and the indicator should remain constant for five minutes. If test weights are not used this is to be indicated in column (3) of FORM:OGCFO2(1198).


APPENDIX B

Requirements for testing items of loose gear

B.1. Every item of loose gear is to be tested and thoroughly examined before being put into use for the first time and after any substantial alteration or repair to any part liable to affect its safety. The proof load to be applied shall be in accordance with the following table:

ARTICLE OF GEAR PROOF LOAD (tons)Chains, rings, hooks, links, shackles, swivels, etc.:SWL≤ 25 tons

SWL>25 tons 2xSWL(1.22xSWL)+20

Single sheave block 4xSWLMultiple sheave block

SWL≤ 25 tons 2xSWL25 tons<SWL<160 tons (0.933xSWL)+27

SWL>160 tons 1.1xSWLLifting beams, spreaders, frames and similar devices:SWL≤ 10 tons 2xSWL

10 tons < SWL ≤ 160 tons (1.04xSWL)+9.6SWL >160 tons 1.1xSWL

Notes: 1. The SWL for a single sheave block, including single sheave blocks with beckets, is to be taken as one half of the resultant load on the head fitting.

2. The SWL of a multi-sheave block is to be taken as the resultant load on the head fitting.

B.2 Wire rope shall be tested by sample, a piece being tested to destruction. The test procedure should be in accordance with an international or recognised national standard. The SWL of the rope is to be determined by dividing the load at which the sample broke, by a coefficient of utilisation, determined as follows

Item Coefficient


Wire rope forming part of sling 5SWL of the sling: 104

SWL ≤ 10 tons (8.85 × SWL ) + 191010 tons < SWL ≤ 160 tons 3

SWL > 160 tonsWire rope as integral part of a lifting appliance

104SWL of the lifting appliance:

SWL≤ 160 tons(8.85 × SWL ) + 1910

3

SWL > 160 tons


APPENDIX C

Thorough Examination

C.1. During the annual survey, or after testing, thorough examination of the lifting appliance and every item of the loose gear is to be carried out. This means a detailed visual examination, supplemented if necessary by other suitable means or measures, in order to arrive at a reliable conclusion as to the safety of the lifting appliance or item of loose gear examined.

C.2. The following important items must be checked in accordance with the schedule established by the Maintenance Requirement Cards (MRCs).

1. Structure in general• Structural members shall be checked for bends, cracks or corrosion. Upon the discretion of the

surveyor hammer tests or other non-destructive tests should be carried out for inspection purposes. If considered necessary the thickness of structural items is to be checked by drilling or other approved method.

• Weldments shall be examined for cracks or excessive corrosion. • Connections shall be checked for loose nuts and bolts. • All components shall be checked for excessively worn parts such as pins, bushings, shafts and gears. • Brake and clutch linings and corresponding metal friction surfaces shall be examined for wear. • Jib, tower, support pedestal, gantry, etc., shall be checked for any sign of local indentation or

unfairness. • Moving parts of control mechanisms shall be checked for operability. • In the case of travelling cranes, rails, stops and stowage arrangements shall be checked. • Controllers, master switches, contacts, limit switches and push-button stations shall be examined for

deterioration. • Tanks, valves, drains and filters shall be checked for air and water and hydraulic lines for dirt. • Wind indicators shall be examined for proper operation.

2. Arrangements• Reeving arrangement and hoist block assembly shall be checked with respect to the Cargo

Gear Particulars Book or manufacturer's manual.3. Wire ropes• Entire length of rope shall be examined for a) broken or cut strands, b) general corrosion or wear, c)

distortion such as kinking, crushing, unstranding, birdcaging, main strand displacement or core protrusion.

• When such damage is discovered, the rope shall either be replaced or repaired. In general, the rope is to be replaced if the number of broken, worn or corroded wires exceeds the limit given in Table C.1. In order to establish data as a basis of judging the proper time of replacement, a continuing inspection record should be maintained.

• Terminal fittings, splices, etc., with particular attention to broken wires at ferrule connections,shall be examined. Any serving on splices is to be removed for the examination. Liverpool splicesare to be rejected on any rope where the ends are not secured against rotation.


• Before re-rigging ensure that the wire rope has been thoroughly lubricated.

4. Rope drums

• Ensure that at least two turns of wire rope are on the drum in all operating positions, including in the case of luffing ropes, when the jib is crutched.

• Check that the anchorages of all wire ropes are effective.• Check drum for cracks and for defects liable to damage the rope.• Check the effective working of any fleeting device fitted.

5. Chains• The chain is to be taken to a properly equipped workshop for examination after removal of all paint,

grease, scale, etc., and wire brushing.• Check for deformation, wear or other defects. If links require renewal the chain is to be suitably heat

treated and re-tested. Replacement links are to be of equivalent material and strength to original.• Confirm that material is recorded on test certificate. The certificate should distinguish between mild

steel, higher tensile steel and alloy steel.

6. Shackles, links, rings, hooks, etc.• Thorough examination under proper conditions and checking for cracks, deformation, wear,

wastage or other defects. Items are to be free from paint, grease, scale, etc.• If deformation of the shackle is found and re-testing is carried out, the shackle is to be suitably heat

treated, re-tested and certified. If the shackle pin is renewed the whole shackle is to be re-tested and certified.

• Confirm that material is recorded on test certificate. The certificate should distinguish between mild steel, higher tensile steel and alloy steel.

7. Jib hell pins• Check lubrication and ensure that there is no detrimental wear.

8. Main pivots, slewing bearing, etc.• Examine main pivots and bearings to ensure that they operate satisfactorily and are free from

scoring, pitting, etc.• Ensure that pivot pins do not have excessive wear or deformation.• Ensure that lubrication arrangements are in working order.

9. Sheaves, blocks, axle pins and bearings, etc.

• Sheaves and sheave bush shall be examined for wear and cracks. The extent of the examination is to be such that a reliable judgement can be made. Where the design is such as to prevent this examination it may be necessary to dismantle the item.

• Examine rope groove for scoring. • Ensure that all lubrication arrangement are in working order. • Check axle pins and bearings with regard to deformation and wear. • Check anchorage of fixed axle pins.


• Check for free rotation of sheaves on axle pins.

10. Hydraulic cylinders• Examine for leaks and check condition of hydraulic pipes. • Check pistons, pivot, pins and bearings, etc., for wear and deformation. • Determine that sheaves are free from cracks or scores and are free to rotate. • Ensure that mounting brackets are free from deformation cracks or damage.

11. Guides• Ensure that the guides do not have excessive wear or deformation and that joints are secure.

12. Seals• Where weathertight seals are fitted ensure that their general condition is satisfactory and check their

effectiveness using a water spray test or other suitable method.

C.3. It is essential that the lifting appliance is in operation at each examination in order to verify efficient safe working and to check hoist, slewing, luffing and travel motions, and the operation of limit switches for over hoisting, over lowering, luffing, slewing and travel.

C.4. Upon the discretion of the surveyor, dismantling of a part of the gear may be required if it is considered necessary for inspection purposes.C.5. Non-destructive tests (dye penetrant, magnetic particle, X-ray, ultrasonic) should be carried out where are suspicions of deficiencies.

C.6 In carrying out the survey of the lifting appliance parts of which are found to be significantly worn or corroded are to be replaced or repaired as appropriate. For guidance purposes indicative values for the maximum acceptable levels of weardown are given in Table C.1, but earlier repair may be required at the surveyor’s discretion.

Table C.1: Limiting values of weardown and corrosion


Item Limiting valueStructural members 10% maximum at any point, based on the

material thicknessLoose gear 5% on any diameter

2% on any diameter of a pin in a hole

Wire ropes5% of broken, worn or corroded wires in

any length of ten rope diametersParticular attention is to be given to the

ISO 4309 standard


APPENDIX D

List of valid forms

No. Code Title Effective Date1 OGC_G(1198) Register of Lifting Appliances 1-12-982 OGCFO2(1198) Certificate of test and thorough examination of 1-12-98

lifting appliances3 OGCFO2U(1198) Certificate of test and thorough examination of 1-12-98

derricks used in union purchase4 OGCFO3(1198) Certificate of test and thorough examination of 1-12-98

loose gear5 OGCFO4(1198) Certificate of test and thorough examination of 1-12-98

wire rope


APPENDIX E

Requirements for Testing of Lifting Assembly according P.D. 316/2001

ITEM TEST LOAD (Tonnes)− Lifting assemblies with working load up 1.25 x working load

to 20 Tonnes

− Lifting gear units with working load The working load plus 5 Tonnesbetween 20 and up to 50 Tonnes

− Lifting gear units with working load The working load plus 10 Tonnesabove 50 Tonnes

WIRE ROPES

− Working load up to 10 Tonnes 5 x working load

− Working load over 10 Tonnes 4 x working load

− Chain cables / hooks, links, swivels, 2 x working loadshackles etc.

BLOCKS 4 x working load

− Lifting tackles with working load up to 20 2 x working loadTonnes

− Lifting tackles with working load between 20 Tonnes plus working load20 and up to 40 Tonnes

− Lifting tackles with working over 40 1.5 x working loadTonnes


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