Safety Operating Procedure for Testing Lifting Tackles
- 1. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:1 of 14 Prepared By – Approved By – Issued by - 1. PURPOSE The purpose of this procedure is to ensure that all lifting tackles while in use remain in healthy condition and legal compliances are also met. 2. SCOPE This procedure is applicable for all lifting tackles in the company. 3. GLOSSARY SWL Safe Working Load 4. ACCOUNTABILITY & RESPONSIBILITIES The head of mechanical department is overall responsible to ensure that this procedure is followed by all. He may issue additional instructions in this respect. 5. TRAINING & COMMUNICATIONS All persons involved with lifting tackles shall be made aware of the requirements of this procedure and trained where necessary in specific activities regarding testing. The head of mechanical department is for responsible for ensuring awareness and training is appropriately organized. 6. PROCEDURE S No Activity Responsibility 1 Lifting tackle is defined as ‘any item whatsoever which is used or designed to be used directly or indirectly to connect a load to a lifting appliance or lifted equipment e.g., a crane and which does not form part of the load, but which is not itself able to lift, or lower a load. All 2 Lifting tackles that are covered under this procedure are – chains, belts, slings, chain pulley blocks, hooks, D shackles, I bolts, Plate Clamps and others All 3 For purpose of this procedure following are excluded: Guying and stay wires and other items subject to static loading conditions only, Wire ropes and wire rope arrangements used for pulling. All 4 All equipment should be of good construction, sound material, and adequate strength, free from patent defect. Head Mechanical 5 Only standard lifting equipment and tackles should be purchased from reliable suppliers which ensure that the design safety is considered by the manufacturer. List of standard equipment shall be maintained by the company. Head Purchase 6 All equipment should have the SWL clearly marked on it, or in the case of wire ropes and chains, a suitable means of identifying the SWL. Inspection Engineer 7 All equipment shall also be suitably marked so that it can be uniquely identified. Inspection Engineer
- 2. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:2 of 14 Prepared By – Approved By – Issued by - 8 All lifting equipment and accessories should be maintained and records kept of such maintenance. Inspection Engineer 9 For purpose of carrying out lifting tackles inspection, head of mechanical shall assign this responsibility to one of the qualified mechanical engineers on the role of company. The nominated mechanical engineer may be designated as ‘Inspection Engineer’. He shall acquire the full knowledge and skills of testing the lifting tackles – as his role would be to function as expert. He may be helped in providing special training for this purpose. Head Mechanical 10 Prior to being used for the first time, the equipment should be thoroughly examined by a competent person (inspection engineer) and certified to this effect. A similar examination is to be carried out after substantial repair work has been carried out on the equipment. This certificate should be kept with other such certificates and listing of all other lifting equipment on the site. (Often referred to as the general register). Inspection Engineer 11 Ensure that the equipment is certified on a periodic basis as required by statute or as required by a competent person (manufacturers or codes of practice may specify more frequent intervals than those laid down by statute). Inspection Engineer 12 All lifting equipment must be risk assessed and procedures put in place to reduce the risks associated with its use. Such procedures must be documented in the company safety management. Head mechanical 13 Ensure employees using the equipment have been trained in its correct use, and the possible hazards associated with its use and misuse. Employees should also be made aware of their obligation to report defects in any such equipment without unreasonable delay. Head mechanical 14 A failure of any lifting equipment or tackle is reportable to the HSE department immediately. all 15 All lifting accessories shall be thoroughly inspected in accordance with this procedure at time intervals not exceeding 12 months. In cases where lifting tackles and equipment are used for lifting human beings, then frequency of testing must be once in 6 months. At time of initial inspection, the Manufacturer’s Test Certificate shall be produced by the asset custodian / owner for review by the Lifting Inspector to verify equipment details. Failure to provide the original Manufacturer’s Test Certificates will result in the equipment being rejected. Inspection Engineer
- 3. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:3 of 14 Prepared By – Approved By – Issued by - 16 Any defects found during testing that result in the item being unserviceable and not repairable, shall be painted red, placed in a segregated area, and disposed of immediately after the inspection has been completed. If to be repaired it shall be painted black. Inspection Engineer 17 Items of lifting tackle that have been repaired shall be proof load tested before being taken back into service. Note: No repairs shall be carried out on any sling, shackle, ring, or eyebolt. These types of defective lifting items MUST be destroyed. Inspection Engineer 18 All lifting accessories, which have been inspected and found fit for use, shall be color coded. All items shall have as a minimum the unique number and the safe working load (SWL). Inspection Engineer 19 Inspection Criteria for Chains and Chain Slings Ensure the Sling has the Identification Number and Safe Working Load clearly and legibly marked Match up the legs and check for stretch in the individual legs. Inspect each individual leg along its entire length for distortion of links e.g. bends, twists, corrosion, elongation and nicks. Check for wear between chain links and load pins. Check for heat or chemical attack. Inspect end terminations fitted e.g., hooks, connectors etc. for appropriateness. Ensure all coupling components are free from distortion, cracking and the securing/ load pins are secure. Inspection Engineer 20 Rejection criteria for chains and chain slings Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e., nicks, cuts, gouges etc. Wear on the link diameter in excess of 5%. Stretch of more than 3% measured over 10-20 links. Any severe pitting corrosion or general corrosion in excess of 5%. Twist in excess of half a turn in 4 meters (or equivalent). Any chain or fitting made of Wrought iron "T" grade slings used in an Hydrogen enriched atmosphere Hard stamping with low stress stamps Inspection Engineer
- 4. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:4 of 14 Prepared By – Approved By – Issued by - 21 Inspection Criteria for Flat Synthetic Web Sling Ensure the Sling has the Equipment Tag Number and Safe Working Load clearly and legibly marked, and corresponds with the manufacturer’s certificate. Inspect along its entire length for cuts, tears, chafing, chemical damage or heat damage and long term U.V. exposure. Inspect the fibers for the ingress of foreign bodies. Inspect for any paint on the sling. Inspect the point of change in section, from 1 to 2, 2 to 3 layers, as these are high stress areas. Inspect metal eyes fitted for wear, stretch and distortion, corrosion and cracking. Inspect end terminations e.g. hooks, connectors etc. in accordance with the appropriate paragraph of this procedure. Inspection Engineer 22 Rejection criteria for flat synthetic web sling Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e., nicks, cuts, gouges, etc. Any breakage of the stitches on the body or the eye Any worn stitching in load bearing areas Any burn marks i.e., melting, charring etc. Any sign of chemical damage Any friction damage or badly abraded spots Knotted slings Any fiber brittleness or extruding fine dust due to extended UV exposure Any paint or felt tip pen markings on the sling Inspection Engineer
- 5. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:5 of 14 Prepared By – Approved By – Issued by - 23 Inspection Criteria for Wire Ropes and Wire Rope Slings Ensure the Sling has the Equipment Tag Number and Safe Working Load clearly and legibly marked, Inspect each individual leg along its entire length for wear, corrosion, abrasion, mechanical damage, and discoloration due to heat or chemical damage, evidence of shock loading and broken wires. Inspect each ferrule and ensure the correct size of ferrule has been fitted. Check that the end of the loop does not terminate inside the ferrule unless the ferrule is of the long-tapered design, which has an internal step. I.e. Flemish eye. Ensure the ferrule is free from cracks and other deformities. Inspect each thimble, if fitted, for correct fitting, snagging damage and elongation. (Stretched thimbles/eyes could indicate possible overload). Inspect wire rope around thimbles as it is often to be found abraded due to the sling being dragged over rough surfaces. Inspect end terminations e.g. hooks, connectors etc in accordance with the appropriate paragraph of this procedure. Inspection Engineer
- 6. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:6 of 14 Prepared By – Approved By – Issued by - 24 Rejection criteria for wire ropes and wire rope slings Information - Missing or illegible Identification Number or Safe Working Load Mechanical Damage - Nicks, cuts, gouges etc. Wire Breaks - If the number of wires in the sling are known: o 5% of the wires in 10 diameters o 3 or more closely grouped wires Wire Breaks - If the number of wires in the sling is not known: o 5 wires in any 6 diameters o 3 or more closely grouped wires Wear - Any wear resulting in a flat on the outer wires of more than 3/4 of the original wire diameter Loss of Diameter - When the diameter of the rope has decreased by a value of 7% or more, compared to the original rope diameter. Distortion - Due to o kinking o crushing o core collapse o knotting Heat Damage - Discolouration of the wires, weld spatter etc Damaged Ferrules and eyes – o Cracks in the ferrule o Severe crushing or abrasion o Pulling out of the ferrule o Concentration of broken wires near to the ferrule o Fractured wires on the outside surface of the eye o Closing of the thimble Wire Rope Core - Fibre cored wire rope Number Stamps - Hard stamping with low stress stamps Inspection Engineer
- 7. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:7 of 14 Prepared By – Approved By – Issued by - 25 Inspection Criteria for Eyebolts Ensure the Eyebolt has the Equipment Tag Number and Safe Working Load clearly and legibly marked, Inspect threads for wear, stretch or impact damage. The threads must be complete (no broken threads) and full (i.e. no flats on top). The threads should be concentric and fit neatly in a standard nut. Inspect the eye of the bolt for wear, stretch and distortion. Inspect the eye of the bolt for cracking at the crown of the ring (This also applies to any link if fitted) and cracking. Check squareness of shank against shoulder. The complete Eyebolt shall be subjected to non- destructive testing at a period not exceeding 1 year. Inspection Engineer 26 Rejection criteria for eyebolts Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e. nicks, cuts, gouges etc. Any wear or corrosion in excess of 5% of the original dimension Any distortion or stretch Cracking No hard stamping/cast markings of thread type Any thermal damage or evidence of welding on the eyebolt i.e. nuts welded on All "Dynamo" type eye bolts (parallel shank no collar) Any modification to the eye bolt i.e. thread shortening, lengthening etc. Hard stamping with low stress stamps Inspection Engineer
- 8. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:8 of 14 Prepared By – Approved By – Issued by - 27 Inspection Criteria for Shackles Ensure the Shackle has the Equipment Tag Number and Safe Working Load clearly and legibly marked, Ensure that all stamping is done using low stress stamps in the position recommended in BS 3551. Remove the shackle pin and inspect for wear deformation and cracking. Ensure it is the correct pin for the shackle. Inspect pin threads for wear/deformation. Inspect shackle body for deformation and cracking and check for wear in the crown and pin hole. Check alignment of pinhole and ensure the pin fits correctly. In case of safety pin shackles, ensure split pins are fitted. The complete shackle shall be subjected to non-destructive testing at a period not exceeding 1 year. Inspection Engineer 28 Rejection criteria for shackles Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e. nicks, cuts, gouges etc. Excessive movement between the shackle pin and the shackle threaded hole Any wear or corrosion in excess of 5% of the original dimension Any thermal damage or evidence of welding on the shackle Any cracks Stamping out with the recommended positions shown in BS 3551 No split pin fitted in safety or bolt type shackles Hard stamping with low stress stamps Inspection Engineer
- 9. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:9 of 14 Prepared By – Approved By – Issued by - 29 Inspection Criteria for Hooks Ensure the Hook has the Equipment Tag Number and Safe Working Load clearly and legibly marked, Inspect the hook body for wear, distortion and corrosion. Inspect the hook body for cracking at the crown of the hook. Ensure safety catch is fitted and operational. Any stamping is done only in zone “A” There are three main types of hooks Eye Hooks Inspect the eye of the bolt for wear, stretch and distortion. Inspect the eye of the bolt for cracking at the crown of the ring (This also applies to any link if fitted). Shank Hook o Inspect threads for wear, stretch or impact damage. The threads must be complete (no broken threads) and full (i.e. no flats on top). o The threads should be concentric and fit neatly in a standard nut, zone D o Wear on the shank more than 8% of original diameter. o Check squareness of shank against shoulder. o Additional holes drilled in the shank Swivel Hook - The complete hook shall be dismantled for inspection and NDT survey at a period not exceeding 4 years. At the discretion of the Lifting engineer, the dismantling and NDT survey frequency may be changed. Inspection Engineer
- 10. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:10 of 14 Prepared By – Approved By – Issued by - 30 Rejection criteria for hooks Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e. nicks, cuts, gouges etc. For zone A (see sketch) worn more than 15% of original thickness. For zone B (see sketch) worn more than 10% of original thickness. For zone C (see sketch) worn more than 5% loss of original thickness. For zone D (see sketch) minimum thread size and/or 8% loss of original diameter Increase in throat opening distance in excess of 15% Threads that are corroded more than 20% of the nut engaged length. Any thermal damage or evidence of welding on the hook i.e. nuts welded to hook shanks Any cracking or stretch Hard stamping with low stress stamps or hard stamping in Zones “B”, “C” or “D” Inspection Engineer 31 Inspection Criteria for Swivels Ensure the Swivel has the Equipment Tag Number and Safe Working Load clearly and legibly marked Inspect the swivel body for wear, distortion and corrosion. Inspect the eyes of the swivel for wear, stretch and distortion. Inspect the eye of the swivel for cracking at the crown of the ring. Remove the jaw pin and inspect for wear deformation and cracking. Ensure it is the correct pin for the swivel. All dimensions must be within 5% of original dimensions Ensure the swivel rotates freely. The component parts of the swivel assembly shall be subjected to non-destructive testing at a period not exceeding 2 years. Inspection Engineer
- 11. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:11 of 14 Prepared By – Approved By – Issued by - 32 Rejection criteria for swivels Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e. nicks, cuts, gouges etc. Any wear resulting in a loss of more than 5% of the original dimension Any wear or corrosion in excess of 5% of the original dimension Any stretch, distortion or cracking Hard stamping with low stress stamps Inspection Engineer
- 12. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:12 of 14 Prepared By – Approved By – Issued by - 33 Inspection Criteria for Horizontal and Vertical Plate Clamps Horizontal Plate Clamp Ensure the Plate Clamp has the Equipment Tag Number and Safe Working Load clearly and legibly marked Inspect the suspension ring for wear, distortion, corrosion and cracking in the crown of the ring. Check lateral movement of hook ring on load bolt connection to serrated jaws/rocker arms, excessive movement indicates wear/distortion. Check lateral movement of serrated jaws/rocker arms on load bolt connection to main body, excessive movement indicates wear/distortion. Where a toe is fitted, check for lateral movement of swivel toe on load bolt connection to rocker arms, excessive movement indicates wear/distortion Where swivel jaws are fitted, ensure they rotate freely. The complete Plate Clamp shall be subjected to non- destructive testing at a period not exceeding 2 years. Vertical Plate Clamp Ensure the Plate Clamp has the Equipment Tag Number and Safe Working Load and Plate size clearly and legibly marked Inspect the suspension ring for wear, distortion, corrosion and cracking in the crown of the ring. Ensure the ring does not have excessive movement in the clamp. Inspect jaw pin and nut and ensure it is secure and not deformed. Check operation of cam-assembly locking lever/jaw spring. Check lateral movement of hook ring on load bolt connection to serrated jaws/rocker arms, excessive movement indicates wear/distortion. Inspect serrated jaw and serrated pad for wear/deformation. Inspect main body shell and check for wear, cracks or deformation, which may affect the operation of the internal components. The complete Plate Clamp shall be subjected to non- destructive testing at a period not exceeding 2 years. Inspection Engineer
- 13. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:13 of 14 Prepared By – Approved By – Issued by - 34 Rejection criteria (for both horizontal & vertical) Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e. nicks, cuts, gouges etc. Any wear resulting in a loss of more than 5% of the original dimension Any stretch, distortion, or cracking Hard stamping with low stress stamps Inspection Engineer 35 Inspection Criteria for Rigging Screws/Turnbuckles Ensure the rigging screw has the Identification Number and Safe Working Load clearly and legibly marked Inspect threads for wear/deformation. Inspect rigging screw body for deformation and cracking and check for wear in the eyes. Inspect threads for wear, stretch or impact damage. The threads must be complete (no broken threads) and full in form. Inspect the eye of the bolt for cracking at the crown. Check the squareness of screw against the body. The complete Rigging screw shall be subjected to non- destructive testing at a period not exceeding 1 year. Inspection Engineer 36 Rejection criteria for rigging screws/turnbuckles Missing or illegible Identification Number or Safe Working Load Any mechanical damage i.e., nicks, cuts, gouges etc. Any wear or corrosion in excess of 5% of the original dimension Any Shank distortion Any thermal damage or evidence of welding on the rigging screw Any modification to the rigging screw Any stretch, distortion, or cracking Hard stamping with low stress stamps Inspection Engineer 37 Chain Block and Ratchet Lever Block The competent person shall conduct a thorough inspection of the block in its assembled condition. Any of the following defects found during inspection shall be cause for rejection Inspection Engineer
- 14. Company LOGO Procedure for Testing Lifting Tackles Doc No: SOP Issue Date: Page No:14 of 14 Prepared By – Approved By – Issued by - Load Chain (Round Link) a) Wear b) Damage c) Corrosion d) Reeving e) Gauge Length a) Wear in excess of 5% of original link dimensions. b) Cracks, heat damage, severe nicks, gouges or distortion of links c) Excessive corrosion, pitting or any chemical attack. d) Load chain reeving incorrect. e) Load chain gauge length increase greater than 3%. Inspection Engineer Load Chain (Plate Link) a) Wear b) Damage c) Corrosion d). Gauge Length a) Wear in excess of 5% of original link or pin dimensions. b) Cracks, heat damage, severe nicks, gouges or distortion of links c) Excessive corrosion, pitting or any chemical attack. d) Load chain gauge length increase greater than 3%. Inspection Engineer Chain Anchorage a) Wear b) Damage c) Corrosion a) Wear in excess of 5% of original diameter. b) Any cracks or distortion. c) Excessive corrosion, pitting or any chemical attack. Inspection Engineer Hooks As above in (29) As above in (29) Inspection Engineer Block Body a) Damage a) Any mechanical damage or loose covers. Inspection Engineer Manual Drive a) Chain b) Drive sprocket a) Broken or distorted links. b) Any cracks, excessive wear or distortion. Inspection Engineer Ratchet Lever a) Damage - b) Operation a) Cracked or broken operating lever b) Incorrect or labored drive operation. Inspection Engineer 7. REFERENCES 8. RECORDS The inspection records of lifting tackles shall be kept for its life time. 9. VERIFICATION Compliance of the procedure shall be verified by Head HSE and though internal auditing. 10. REVIEW This procedure shall be reviewed for its suitability and adequacy once in 3 years.