MOBILE CRANE SAFETY INSPECTIONS MP- 501

Beaumont Refinery
Maintenance Procedure

MOBILE CRANE SAFETY

INSPECTIONS Approval:_______________________
Mech. Div. Manager

Owner: Central Shops Section Supervisor

Endorsed:______________________
Chairman JH&SC

Purpose To define the minimum frequent, periodic, and annual

inspection criteria for all cranes (ExxonMobil, Contract, or
Rented), to ensure the safety of all personnel, during the
operation, and use of all equipment used for the hoisting, lifting
and handling of materials within, or those facilities maintained
by Beaumont Refinery personnel.

Primary Users and • Qualified and Designated Crane Operators

Responsibilities • Certified ExxonMobil Equipment Inspectors
• Qualified Maintenance Personnel

Safety and • OSHA requires frequent safety inspections of all cranes in

Environmental regular service.
Precautions • OSHA requires periodic safety inspections of all cranes in
regular service

References • OSHA Regulations 1910.180 and 1926.550

• ASME/ANSI B30-5, Mobile and Locomotive Cranes
• EMEPS 118-1993

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 1 of 13
MOBILE CRANE SAFETY INSPECTIONS MP- 501

Definitions • Frequent inspection- In service cranes-Inspection

performed by the qualified and designated crane operator.
Required by OSHA to be done daily or each time the crane
is used.
• Periodic inspection- In service cranes-Inspection
performed monthly by Certified ExxonMobil Equipment
Inspectors. Required by OSHA to be completed, signed and
filed within 30 calendar days of last periodic inspection.
• Annual inspection- In service cranes -Inspection
performed once a year by Certified ExxonMobil Equipment
Inspectors. Required by OSHA to be completed, signed
and filed within 13 months of the last annual inspection.

Documentation and • Attachment 1, Daily Crane Pre-Use Inspection Aid

Records • Attachment 2, Monthly OSHA Crane Inspection Reports
• Attachment 3, Annual OSHA Inspection Reports

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 2 of 13
MOBILE CRANE SAFETY INSPECTIONS MP- 501

Procedure

Procedure Steps
ATTENTION!

TO AVOID PERSONNEL INJURY, ANY DEFICIENCY FOUND DURING

FREQUENT, MONTHLY, OR ANNUAL INSPECTIONS THAT CONSTITUTES
A SAFETY HAZARD, REQUIRES THAT THE CRANE BE IMMEDIATELY
REMOVED FROM SERVICE, THE DEFICIENCY REPAIRED AND THE
CRANE REINSPECTED AND PASSED BEFORE BEING RETURNED TO
SERVICE.

Crane Operator Personnel qualified and designated to operate cranes, who

shall inspect all items listed on the Crane Pre-Use Inspection
Aid Chart.

Certified
Equipment ExxonMobil personnel certified by a third party by means of
Inspector education and experience to be qualified to inspect cranes, who
shall inspect all items listed on the OSHA Monthly and Annual
Inspection Reports and all items on the Incoming crane
inspection reports according to type.

Frequent Perform daily inspection of items on Attachment 1, Pre-Use

Inspection Inspection Aid.
All Frequent inspections are conducted daily by the
1.
qualified and designated crane operator or as per use.
Monthly Complete all sections of Attachment 2, Monthly OSHA Report.
Inspection
1. All Monthly inspections are scheduled and conducted by
Certified Equipment Inspectors.
2. Attachment 2, is kept on file in the Certified Equipment
Inspectors' Office.
Annual Complete all sections of Attachment 3, Annual OSHA
Inspection Inspection Report.
1. All Annual inspections are scheduled and conducted by
Certified Equipment Inspectors.
2. Attachment 3 is kept on file in the Certified Equipment
Inspectors' Office.

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 3 of 13
MOBILE CRANE SAFETY INSPECTIONS MP- 501

Incoming Crane Complete all sections of Attachments 4, Incoming Hydraulic

Inspections Crane Inspection Report, Attachment 5, Incoming Lattice Boom
Hydraulic Truck Crane Inspection Report or Attachment 6,
Incoming Crawler Crane Inspection Report according to the
type of crane that is entering the Beaumont Refinery.

1. All incoming Cranes are inspected by Certified Equipment

Inspectors.
2. Attachments 4, 5, and 6 are kept on file in the Certified
Equipment Inspectors' Office.
3. No plugs in load bearing tires on cranes

Attachments:

• Attachment 1, Daily Crane Pre-Use Inspection Aid

• Attachment 2, Monthly OSHA Crane Inspection Report
• Attachment 3 Annual OSHA Crane Inspection Report
• Attachment 4, Incoming Hydraulic Crane Inspection Report
• Attachment 5, Incoming Lattice Boom Hydraulic Truck Crane Inspection Report
• Attachment 6, Incoming Crawler Crane Inspection Report
• APPENDIX 5 Daily Crane Operating log (Example)
• APPENDIX 6 Hydraulic Crane Daily Inspection Report (Example)

**End of Procedure**

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 4 of 13
MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 1, Daily Crane Pre-Use Inspection Aid

Crane Pre-Use Inspection Aid
Must Be Performed Before Each Shift Machine Is To Be Operated!

Items to be checked are as follows: Page 1 of 2

Pre-Start
1. Crankcase Oil - Should be checked by every Operator prior to use, refill as req'd.
2. Hydraulic Oil - Check level with all rams fully retracted. Refill as req'd. Check system
integrity (no leaks).
3. Electrical - Caution - Batteries emit Hydrogen Gas, keep sparks or flames away, wear
safety glasses, and protective equipment, batteries contain Acid , refill as req'd with
water only.
4. Fuel-When adding fuel, engine MUST be turned off. Check system integrity (no leaks).
5. Coolant - Caution - Check only when engine is cool, opening a hot radiator can result in
severe burns, refill as req'd with 50% antifreeze/water!
6. Operators Manual - Must be on machine, to be stored in a weather resistant enclosure.
7. Belts - Check for general condition and proper tension, adjust tension as req'd
8. Tires - Check for general condition and proper pressure, inflate as req'd.
9. Hoses/Tubing - Check for general condition and coupling integrity (no leaks)
10. Placards/Safety/Operating Decals - All decals MUST be legible.
11. Fire Extinguisher - Check for current inspection, securely mounted and fully charged.
12. Housekeeping - Machine and cab should be clean and free of debris.
13. Machine Guards - All protective guards MUST be in place and secured.
14. Windows/Mirrors - No damaged glass that distorts the operators view.
15. Outrigger/Pads - Check structural integrity, visually check for cracks or broken welds.
16. Boom - Check for damage, visually check for broken welds.
17. Load Block/Ball - Labeled or stamped with manufacturer's name, capacity and weight.
18. Hooks/Safety Latches - Hooks not bent or excessively worn, safety latches of the
correct size, installed correctly and operational.
19. Wedge Sockets - Installed with wire rope terminated per Operator's Manual
20. Sheaves - Should operate freely, no excessive wear, correct size for wire rope.
21. Jib/Pins/Turnbuckles/Cables - Damage free components installed per Operator's
Manual.
22. Wire Rope Reeving - Wire rope on drums wound per Operator's Manual and ExxonMobil
Guides.
23. Load Chart - Permanently affixed or secured and correct for the make and model of
crane.

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MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 1, Daily Crane Pre-Use Inspection Aid

Crane Pre-Use Inspection Aid
Page 2 of 2
ONLY QUALIFIED AND DESIGNATED PERSONNEL SHALL OPERATE
CRANES

Post-Start
1. Gauges - Check gauges initially upon starting machine and periodically during
operation for correct indications. (per Operator's Manual)
2. Steering - Check for excessive slack (no more than 1/4 turn) and operation.

3. Operator Controls - Check to ensure all operate and do not stick (per Operator's
Manual).
4. Boom - Operate through all configurations to ensure unit is operational (per Operator's
Manual).
5. Warning Lights/Alarms - Ensure that all safety lights and alarms are operational (per
Operator's Manual).
6. Back-up Alarm -Alarm Must be operational before placing crane in service.

7. Brakes - Parking (emergency) brake and service brake Must be operational, test both
before placing crane in service (per Operator's Manual).
8. Horn - Must be operational before placing crane in service. (Per Operator's Manual).

9. Lights/Wipers - Check for operation. (Per Operator's Manual).

10. Anti-Two Block - Check device to ensure operation before placing crane in service.
(Per Operator's Manual).
11. Load Handling - Operate crane through all hoisting configurations to check the
following components; boom angle indicator, hoist(s), hoist brake, wire rope on
drum(s) (min: 3 wraps with boom fully extended), wire rope condition, lift cylinder,
boom extension/retraction, swing, swing brake and house lock.

• If the inspection shows any condition that adversely affects the safe operation of
the crane, that condition Must be repaired before the crane is placed in service.

• No burning or welding on cranes without Transportation Supervisors approval!

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MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 2, Monthly OSHA Crane Inspection Report

MONTHLY HYDRAULIC CRANE INSPECTION REPORT

ExxonMobil UNIT NO: _____________

Make: ______ Model: _______ Serial No.: _______ Location: _______ Capacity: ______ Eng. Hours: ______

GENERAL D R S N/A HYDRAULIC D R S N/A

SYSTEMS:
Hydraulic Oil Leaks *Hoses/Piping/Valves
Fire Extinguisher Oil Tank Level
Daily Inspection Reports
Warning Signs/Decals
ENGINE: CARRIER:
Oil Level *Outrigger Cylinders
Fuel Leaks *Outrigger Pads
Cooling System *Tire Condition
Battery/Anchorage *Tire Ply
CARRIER CAB: UPPER WORKS:
Operator Manuals Main Hoist/Auxiliary
Hoist
*Controls *Block Hook/Safety
Latch
*Travel *Ball Hook/Safety
Latch
*Steering/Transmission *Boom
*Alarms/Horn *Boom Connecting
Pins
*Anti Two Block *Jib/Connections
*Computer/LMI Boom Hoist Cylinder
*Boom Angle Indicator Telescoping Cylinder
Gauges/Glass *Extension
Parking Brake *Swing
Assembly/Brakes

MAIN HOIST WIRE ROPE AND HOOK REPORT

Rope Description: HOOK TRAM:
Date Measured Broken Wires Throat Bowl Tip Twist
Diameter in 1 Rope Lay in 1 strand of 1 lay

AUXILIARY HOIST WIRE ROPE AND HOOK REPORT

Rope Description: HOOK TRAM:
Date Measured Broken Wires Throat Bowl Tip Twist
Diameter in 1 Rope Lay in 1 strand of 1 lay

REMARKS:

Inspector: ______________Date:_______ Tagged Out: ‰ Correction of Deficiencies: Awaiting Repairs: ‰

‰
*Denotes deficiency-shutdown
D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE

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 MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 3 Annual OSHA Crane Inspection Report

ANNUAL HYDRAULIC CRANE INSPECTION REPORT

ExxonMobil UNIT NO: ______________

Make: _________ Model: __________Serial No: _______ Location: ____ Capacity: ______ Eng. Hrs. ____

GENERAL D R S N CARRIER CAB: D R S N UPPER WORKS D R S N

/ / /
A A A
*Keepers/Bolts/Fasteners *Operators Manuals *Anti Two-Block

*Warning Signs/Decals *Load Chart *Computer (load test)

Hand Signal Chart *Controls *Boom Angle Indicator
Access Covers/Latches *Steering Main Hoist
Lubrication *Travel Auxiliary Hoist
Non-Slip Surface *Swing Brake *Rope End Connections
Guards *Alarms/Horn *Sheaves/Bushings
Fire Extinguisher All Switches *Block/Hook/Safety
Latch
*Axle Lockouts *Ball/Hook/Safety
Latch
ENGINE: *Windows/Wiper *Block/Ball NDT

*Oil/Leaks Seat/Seat Belt *Boom

*Fuel Leaks Gauges/Glass *Boom Connecting Pins
*Cooling System Lights/Turn Signals *Jib/Connections
*Fan Belts Level *Swing Assembly
*Battery/Anchor Heater/Fan *Boom Hoist Cylinder
*Muffler/Exhaust System Parking Brake *Telescoping Cylinder
*Extension
HYDRAULIC SYSTEM CARRIER:
*Leaks *Frame/Weldments
*Hoses/Piping/Fittings Outrigger Cylinders
*Outrigger
Pads/Keepers
*Tire Ply Rating
*Tire Condition
MAIN HOIST WIRE ROPE AND HOOK REPORT
Rope Description: HOOK TRAM : ___________
Date Measured Diameter Broken Wires Throat Bowl Tip Twist
in 1 Rope Lay in 1 strand of 1 lay

AUXILIARY HOIST WIRE ROPE AND HOOK REPORT

Rope Description: HOOK TRAM: ___________
Date Measured Diameter Broken Wires Throat Bowl Tip Twist
in 1 Rope Lay in 1 strand of 1 lay

D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE

Inspector:__________________ Date: Tagged Out: ‰ Correction of Deficiencies: Awaiting Repairs: ‰
*Denotes deficiency-shutdown. ‰

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MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 4, Incoming Hydraulic Crane Inspection Report

INCOMING HYDRAULIC CRANE INSPECTION REPORT

UNIT NO: ________________

Make ____________ Model ________ Serial No __________ Location ______________

Owner _______Capacity ______Eng. Hrs_____ Rental ______Contractor____ Audit _____
D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE

GENERAL D R S N CARRIER CAB: D R S N UPPER WORKS D R S N

/ / /
A A A
*Annual Insp. Report *Operators Manuals *Anti Two Block
Appearance *Load Chart *Computer

*Keepers/Bolts/Fasteners *Controls/Labels *Boom Angle Indicator

*OEM Accessories *Steering *Main Hoist
*Hand Signal Chart *Travel/Parking Brakes *Main Hoist Wire Rope

Access Covers/Latches *Swing Brake *Auxiliary Hoist

Lubrication *Alarms/Horn *Aux. Hoist Wire Rope

*Non-Slip Surface All Switches *Rope End Connections
Guards *Axle Lockouts *Wire Rope Clips
*Fire Extinguisher *Windows/Wiper *Sheaves/Bushings
*Seat/Seat Belts *Load Block
ENGINE: Gauges/Glass *Block Hook/Safety
Latch
*Oil Level/Leaks Lights/Turn Signals *Block Capacity Wt
Label
*Fuel Leaks Level *Headache Ball
Fuel Tank Heater/Fan *Ball Hook/Safety
Latch
*Cooling System/Leaks *Ball Capacity/Wt
Label

*Fan Belts CARRIER: *Boom

*Battery/Anchors *Frame/Weldment *Boom Wear Pads
*Muffler/Exhaust System *Outrigger Cylinders *Boom Connecting Pins
*Outrigger Pads/Keepers *Jib/Connections

Tire Condition *Boom

Ext./Connections
* Wheels/Lugs *Swing Assembly
*Tire Ply Rating *Boom Hoist Cylinder
*Telescoping Cylinder

REMARKS:

D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE

Inspector: Date: Tagged Out: ‰ Returned to Vendor: ‰ Awaiting Repairs: ‰

*Denotes deficiency-shutdown

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MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 5, Incoming Lattice Boom Hydraulic Truck Crane Inspection Report

INCOMING LATTICE BOOM HYDRAULIC

TRUCK CRANE INSPECTION REPORT
UNIT NO: ________

Make: __________Model: _____________Serial No.: _________ Location: __________

Owner: _______ Capacity: _____ Eng. Hours: ______Contractor _________ Rental ______Audit________
D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE

GENERAL D R S N N UPPER WORKS D R S N

/ / /
A CAB: D R S A A
Lubrication Heater/Fan *Anti Two-Block
Access Covers Steering *Load Moment Device
*Fire Extinguisher *Load Chart *Boom Angle Indicator
*Non-Slip Surface *Gauges/Glass Auxiliary
Hoist
Guards *Horn/Alarms Main Hoist

*Hand Signal Chart Lights Boom Hoist

*Warning Signs *Controls/Labels *Aux. Hoist Wire Rope

*Annual Inspection Windows/Wipers *Main Hoist Wire Rope
*Brakes *Boom Hoist Wire
Rope
ENGINE: Level *Jib
*Battery/Anchor *Standing Ropes
*Muffler/Exhaust CARRIER: *Jib Stops
*Frame/Weldments *Wire Rope Clips
HYDRAULIC *Outrigger Cylinders *Boom/Lattice
SYSTEM:
*Oil Tank/Leaks *Outrigger Pads *Load Blocks
*Hoses/Piping/Fittings *Tires/Wheels *Headache Ball
*Air System/Leaks Sheaves
*Brakes/Clutches
Swing Assembly
*Boom Stops/Cut Out
*Keepers/Pins

REMARKS:

Inspector: Date: Tagged Out: ‰ Returned to Vendor: ‰ Awaiting Repairs: ‰

*Denotes deficiency-shutdown

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MOBILE CRANE SAFETY INSPECTIONS MP- 501

Attachment 6, Incoming Crawler Crane Inspection Report

INCOMING CRAWLER CRANE INSPECTION REPORT

UNIT NO: __________

Make: ________ Model: ___________ Serial No: _______ Location: _____

Owner: ____ Capacity: ____ Eng. Hours: ________ Contractor _______Rental ________Audit_______
D= DEFICIENT. R=RECOMMENDATION. S= SATASFACTORY. N/A=NOT APPLICABLE
GENERAL D R S N CAB: D R S N UPPER WORKS D R S N
/ / /
A A A
Lubrication Heater/Fan *Anti Two-Block

Access Covers Travel *Load Moment Device

*Fire Extinguisher *Load Chart *Boom Angle

Indicator
*Guards *Gauges/Glass *Auxiliary Hoist
*Non-Slip Surface *Horn/Alarms *Main Hoist
Hand Signal Chart *Controls/Labels *Aux. Hoist Wire
Rope
*Warning Signs *Windows/Wipers *Main Hoist Wire
Rope

*Annual Inspection *Boom Hoist Wire

Rope
CARRIER: *Jib
ENGINE: *Frame/Weldments *Standing Ropes
*Battery/Anchorage Track Assembly *Jib Stops
*Fluid Leaks *Air System Leaks *Wire Rope Clips
*Muffler/Exhaust *Boom/Lattice
*Headache Ball
HYDRAULIC *Load Blocks
SYSTEM:
*Oil Tank/Leaks *Sheaves
*Hoses/Piping/Fittings *Clutches/Brakes
*Swing Assembly
*Boom Stops/Cut Out
*Drums/Dogs
*Keepers/Pins

REMARKS:

Inspector: Date: Tagged Out: ‰ Returned to Vendor: ‰ Awaiting Repairs: ‰

*Denotes deficiency-shutdown

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 11 of 13
MOBILE CRANE SAFETY INSPECTIONS MP- 501

APPENDIX 5
Daily Crane Operating log (Example)

DAILY CRANE OPERATION LOG

Crane Type

Inspected
Operator

Capacity

Number
% Chart
Weight

Weight

Radius
Length

Permit
Boom
Lift #

Load

Total
Date

Description of Load

1
2
3
4
5
6
7
8
9
#
#
#
#
#
#
#
#
#
#
#

COMMENTS:_____________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
___________________________________

*Rigging weight and load block, overhaul ball, auxiliary boom point, etc.

Rev. 3, 04/10 Controlled copy. Valid for 72 hours from print date: Thu May 27 2010 07:09:19 GMT-0500 (Central Daylight Time) Page 12 of 13
 MOBILE CRANE SAFETY INSPECTIONS MP- 501

HYDRAULIC CRANE DAILY INPSECTION REPORT

A visual inspection of all items and a test of controls and safety devices are required each day when the hydraulic crane is used.
Each item with *, if the daily inspection is ‘FAULTY’, equipment must be shut down.

UNIT NO: ZONE: MONTH:

DAY OF INSPECTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
ENGINE:
*OIL LEVEL/LEAKS
*FUEL LEAKS/LEVEL
RADIATOR/LEAKS
CAB:
*OPERATOR MANUALS
*CONTROLS
*ANTI TWO-BLOCK
*STEERING / TRAVEL
*BRAKES
*ALARM
LIGHTS
HORN
GAUGES
HYDRAULIC SYSTEM:
*TANK LEVEL
*HOSES/PIPING
*HYDRAULIC LEAKS
CARRIER:
*OUTRIGGER PADS
*TIRES
UPPER WORKS:
*MAIN HOIST
*WIRE ROPE
*HOOKS
*SAFETY LATCHES
*JIBS
*BOOM HOIST CYLINDER
1st INSPECTOR’S INITIALS
2ND INSPECTOR’S INITIALS
3RD INSPECTOR’S INITIALS
4TH INSPECTOR’S INITIALS

COMMENTS:

: - FAULTY, TAG ‘DO NOT OPERATE’ ; - GOOD

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Con