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RP 205 Crane Operation Maintenance and Testing PDF
RP 205 Crane Operation Maintenance and Testing PDF
Prepared by
OISD (Oil Industry Safety Directorate) publications are prepared for use in the Oil and Gas Industry
under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and
shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the data contained in the
document, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their
use.
The document is intended to supplement rather than replace the prevailing statutory requirements.
FOREWORD
The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a
variety of international codes, standards and practices have been in vogue. Standardisation in design
philosophies and operation and maintenance practices at a national level was hardly in existence. This coupled
with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised
the need for the industry to review the existing state- of- the-art in designing, operating and maintaining oil and
gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council
assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and
implementing a series of self regulatory measures aimed at removing obsolescence, standardising and
upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of
functional committees of experts nominated from the industry to draw up standards and guidelines on various
subjects.
The present standard was prepared by the Functional Committee on “Recommended Practice for Crane
Operation, Maintenance And Testing ”. The document is based on the accumulated knowledge and experience
of industry members and the various national and international codes and practices.
This standard is meant to be used as supplement and not as a replacement for existing codes and
practices.
It is hoped that provisions of this standard, if implemented objectively, may go a long way to improve the
safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no standard can be substitute for
the judgement of responsible and experienced Engineers/Geo-scientists..
Suggestions are invited from the users after it is put into practice to improve the document further.
Suggestions for amendments to this document should be addressed to the Coordinator, Committee on
th
“Recommended Practice for Crane Operation, Maintenance and Testing ”, Oil Industry Safety Directorate, 7
Floor, New Delhi House, 27, Barakhamba Road, New Delhi – 110 001.
This standard in no way supercedes the statutory requirements like Factories Act, OMR, CCE etc.
COMMITTEE
ON
RECOMMENDED PRACTICE FOR
“CRANE OPERATION,MAINTENANCE AND TESTING ''
S/SHRI
1
0
CONTENTS
1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 1
4.0 Equipment 3
5.0 Control 4
7.0 Operation 5
8.0 Inspection 13
9.0 Maintenance 13
14.0 References 14
15.0 Annexures
A– Identification Of Actions On Use Of Hand Signals 15
B– Maintenance guidelines 17
C- Inspection guidelines 21
Recommended Practices
for
1
subject to Pre-use, Monthly, Load -working : External load in pounds
Quarterly, and (Kilogram) apply to the crane
Annual Inspections. Cranes including the weight of load
assigned category of heavy attaching equipment such
usage need not be reviewed load block, shackles and
to determine the number of slings
hours used each month.
Luffing : Same as derricking. The
Hoist : The device for lifting or operation of changing boom
lowering of the load in angle in a vertical plane.
vertical direction. Also called
winch. Moderate usage : Moderate usage applies
category to those cranes that are used
Hook Load : The load being lifted plus the for more than 10 hours but
weight of slings and rigging. for less that 50 hours per
Hook load may or may not month, based on the
include the weight of the hook averaged use over a quarter.
block and wire rope. This can These cranes will be
be determined from the crane’s subjected to Pre-use,
load rating chart. Quarterly, and Annual
Inspections. Crane usage
Hydraulic crane : A crane whose movements categories will be reviewed on
are directed by fluid pressure a periodic basis by the owner
applied to the pumps/gears, to ensure proper inspection
hydraulic cylinder, and intervals.
hoists.
Out-Riggers : Members attached to the
Infrequent usage : Infrequent usage applies carrier’s frame which may be
category to those cranes that are blocked up to increase
used for 10 hours or less stability. These may be fixed
per month, based on the or extendible.
averaged use over a quarter.
These cranes will be Pawl (Dog) : A device for positively holding
subjected to a Pre-use a member against motion in
Inspection and an Annual one or more directions.
Inspection. Crane usage
categories will be reviewed Pedestal( BASE) : The supporting sub-structure
on a periodic basis by the u p o n w h ich the revolving
owner to ensure proper upper structure is mounted.
inspection intervals.
Pull test : A test, using a suspended
Jib(Tip Extension) : An extension attached to the weight or a dynamometer, to
boom point to provide added verify crane capability for the
boom length for lifting expected lift, not to exceed
specified loads. 100% of the rated crane load
chart capacity. This is not a
Lattice boom : Boom of open construction LOAD TEST.
with angular or tubular lacing
between main corner Qualified crane : A person with training and
members (chords) in form of inspector experience who has
truss. demonstrated proficiency in
the skills and abilities
Limit device : A safety feature used to stop necessary to inspect,
the movement of a crane or maintain, and repair cranes.
its components beyond a
predetermined point that Qualified crane : A person with training and
could cause damage to operator experience who has
components or the crane to successfully completed a
fail. crane operator training
Load test : The test undertaken to course.
validate load rating of the
crane. Rated Capacity : The rated load at specified
radii as established by the
manufacturer and are the
2
maximum loads at those radii and not a permanent part of
covered by the the structure).
manufacturers warranty.
Whip line : A secondary rope system
Rigger : A rigger is anyone who usually of lighter load
attaches or detaches lifting capacity than provided by the
equipment to loads or lifting main rope system. Also
devices. known as “AUXILIARY”.
Telescoping : Consists of a base boom Service walkways all around the cabin with
boom from which one or more boom handrail should be provided.
sections are
telescoped for additional As far as possible , cabin should be
length. constructed to protect the upper structure
machinery , brakes ,clutches and the
Temporary crane : Any crane that is attached to operator’s station from the weather.
or connected via a
substructure to a platform
3
Unless and otherwise specified, the sound practice. Any one wheel may have one or
levels at operator’s station shall not more tyres.
exceed:
a. 90dB(A) (Slow response) measured 4.7 Out Riggers
with the prime mover at low idle and
crane controls in neutral position The manufacturer should specify whether
b. 95dB(A) (Slow response) measured out-riggers are fixed or extendible, whether
with the crane operating at full throttle telescopic or hinged , whether front or rear
and full rated load of the rotating outriggers or both are supplied and if jacks
machinery. or supporting floats are available.
5
other power controls to off position or power lines is the leading cause of
neutral position. crane related fatalities. Detailed
x. Relief valves on hydraulic cranes should regulations for proximity to high
not be adjusted above manufacturer’s voltage sources must be strictly
recommended pressures and current enforced. Any potential danger
limiting devices on electric cranes should should be pointed out to the crane
not be bypassed to increase available hoist operator or a supervisor-but never
line pull. touch the crane at this time.
xi. During high wind conditions and nights, lift
of heavy equipment should be avoided. If c Riding the load or crane hook.
unavoidable, the operator shall ensure that This is a serious violation of safety
there is proper illumination in the night. regulations. Crane structures and
cables have far lower strength
For mobile cranes (except crawler cranes) margins for handling material than
following additional procedures to be followed: what is required for lifting
personnel. Workers must never be
xii. Crane to move on reasonably hard leveled suspended from a crane boom
surface. Crane placement programme to unless an approved personnel
be prepared for lifting heavy equipment. basket with mandatory safety
xiii. Make sure wheels have chokes installed equipment is used, and lifting
before commencing the job. procedures are strictly followed.
xiv. Out rigger beam should be fully extended
before operation. d Visible structural damage on the
xv. While working on a slope , the crane crane . There is little or no back up
should be parked with front wheels towards system in the load-supporting
downhill. the load lifted from the rear of the components of most cranes. A
truck. damaged component can fail
xvi. The crane shall not be driven with out- completely and without warning,
riggers extended. causing the boom or load to fall.
xvii. The crane level should be checked for
e Modifications made by adding
stability.
xviii. A trained rigger/ signalman shall always extra counterweight or holding
accompany the crane when it is being down the rear of the crane. All
moved. job initiated modifications are
xix. The crane hook shall be secured to prevent illegal and may permit overloading
it from swinging while the crane is traveling. the crane. If not approved by the
xx. The crane shall not be placed for working crane manufacturer in writing,
in Hazardous area classified by existing these modifications can over stress
DGMS/Statutory notification . The critical structural components,
components like light etc. shall be of flame which could cause failure of the
crane.
proof type as boom can be used for
handling loads in hazardous area.
f A crane operating near a trench
o r e x c a v a t i o n. Cranes exert
7.4 Crane Danger Signs to watch For :
extremely high loads on the soil
While working around crane, the operator near the tracks, outriggers, or tires.
should be careful about following eight A crane set up in close proximity to
danger signs of improper operation. If any an excavation can cau s e s o i l
of the following occurrences are noticed at failure, crane turnover, and
jobsite, immediately inform to possible disaster.
supervisor/competent person before a
catastrophe takes place. g The crane is noticeably out of
level while operating. There is no
a Outriggers, crawler tracks, or faster way to collapse a crane
tires raised off the ground while boom than to impose a side force
operating. This is an extremely on the boom. Working out of level
dangerous condition which creates a dynamic side force which
indicates the crane is being means a crane collapse may be
overloaded and may tip over or imminent.
collapse. The wrong move in this
situation can cause a catastrophe. h The crane's hoist line is not
vertical at all times during
b Operating close to power lines operation. This indicates improper
or other dangerous objects. operation. A hoist line which is not
Electrocution due to contact with vertical obviously indicates that the
6
load is not hanging straight down. Power lines can be hard for the crane
Out of plumb loads can cause operator to see. They sometimes appear to
crane collapse by generating side be either further away or much closer than
forces on the boom. In some they really are. It is difficult for the human
instances, the crane may tip over if eye to accurately judge the clearance
the load swings. between the crane's boom or line, and a
7.5 Precautions from live power lines power line. Fellow workers can help assure
that safe clearances are being maintained
Everyone in proximity to a crane, when between the crane, the line, the load and
energized lines are near, must stay alert. It the overhead power line. The table below
takes employee teamwork to successfully shows basic clearance minimums, w h i c h
and safely operate under this combination apply to all areas around the power line-
of conditions. above, below or to either side:
7
7.6 Load Handling closed to secure loose slings. Hooks
should be self-closing.
7.6.1 The Load b) The hoist rope shall not be wrapped
around the load.
Crane lifting capacities are based on c) Discard defective slings. Each sling’s
relative motion conditions between the metal connector shall be stenciled with
c r a n e a n d the load to be handled. All the date the sling is placed in service.
cranes will have one static and at least one d) Longer objects should be lifted from
dynamic load rating chart. These charts both ends to maintain its balance.
must show the Rated Lift Capacity for e) Care and use of wire ropes shall be in
boom lengths and angles. accordance with OISD Standard-187.
a) The appropriate load rating charts for 7.6.3 Moving The Load
the configuration in use must be in a
position where they are visible to the Guidelines for moving the load are as
operator while operating the crane. The under:
Operator should know that the hook
load is within the crane’s applicable I. The Qualified crane operator and
Static or Dynamic Rated Load at the the designated signal person
radius at which the load is to be lifted. directing the lift should determine
b) The safe working load on the crane at that:
each radius should not be more than
90% of the test load, but in no case a) The crane is placed on a
should the rated capacity loads be firm level foundatio n a n d
exceeded. The safe working load of the properly secured in place.
crane should be legibly marked on it. A b) The load is secured and
scale or weight indicator should be properly balanced in the
available which can be used to sling or lifting device before
determine weight of unknown load to it is lifted.
be lifted. c) The lift and swing paths
c) Never attempt to operate a crane are clear of obstructions
where the load capacity chart shows no and personnel.
load capacity or where there are no d) An appropriate fire
values shown on the charts. This load extinguisher is kept in the
is more than the safe operating crane cabin or vicinity of
conditions for the crane. The crane can the crane.
turn over when the boom is extended
too far, even with no load. II. Before starting to lift, the following
d) To make a safe lift, the operator must conditions should be verified:
know the exact weight of the load, the
length of the crane boom, the load a. Refer to crane load chart
radius and the boom angle. for proper boom angle
e) For lifting heavy equipment , before lifting any static or
shackles/hooks shall be engaged on dynamic load.
lugs/eyes provided for lifting. b. Never attempt to lift a load
f) General load moment indicators do not that exceeds the crane
sense extension of outrigger beams l i f t i n g c a p a c ity for a
.As such, while operating a crane , it specific boom angle.
should be ensured that the outrigger c. Multiple part lines are not
beams are fully extended. twisted around each other
g) Cranes should always be placed in such a manner that all of
horizontally , as load moment indicator the lines will not separate
parameters are fixed, assuming the upon application of load.
crane in horizontal position. Any d. The hook is brought over
horizontal imbalance of the crane will the load in such a manner
result in decrease of the balancing as to minimize swinging.
moment not accounted for by the load e. If there is a slack rope
moment indicator, which may lead to conditions, the rope is
serious over-loading. properly seated on the
7.6.2 Attaching The Load drum and in the sheaves.
f. The correct slings have
a) The load should be attached to the been selected for the
hook by means of slings or other weight to be lifted.
suitable devices. The latch shall be
8
g. Stops have been provided
on crane booms to prevent XII Riding on loads and hooks is
the possibility of strictly prohibited.
overtopping the boom.
XIII No fewer than five (5) full wraps of
III During lifting, care should be taken rope will remain on the drum(s) in
that: any operating condition. Due
consideration should be given to
a) Acceleration or hoist manufacturer’s recommended
deceleration of the moving practices, especially for “break
load is accomplished in a away” anchor type hoists.
smooth manner.
b) Load, boom or other parts XIV All the cranes must be equipped
of the machine do not with safety cutouts and the weight
contact any obstruction. indicators . Safety cutouts m u s t
always be in good working
IV The Operator should engage the condition.
controls smoothly to avoid
excessive stress on crane XV When two or more cranes are used
machinery. to lift a load, one qualified operator
will be responsible for the
V When rotating the crane, sudden operation. The responsible
starts and stops should be operator should analyze the
avoided. Rotational speed shall be operations and instruct all
such that the load does not swing personnel involved in the proper
out beyond the radius at which it positioning, rigging of the load and
can be controlled. the movements to be made. The
positioning of cranes and
VI No external forces should be distribution of load should be
applied to suspended loads which ascertained .
will create side loading of the
boom. Care should be taken when XVI A p p r o p r i a t e n o n -electrical
swinging the crane so as to conducting tag or restraining lines
minimize the pendulum action of should be used where necessary
the hook and suspended load. to guide and control the load.
VII Cranes will not be used for XVII The Operator should not leave the
dragging loads unless properly crane controls until the load has
rigged for a vertical pull not been safely landed. He must
exceeding the rated capacity. properly secure the crane and
boom before going off duty when
VIII The operator will not hoist, lower or shutting down operations.
swing while any personnel are on
the load or hook (other than in a
personnel basket). 7.7 Slings
IX While the crane is in operation, no Sling, their fittings and fasteners, when not
other work shall be performed on in use, should be inspected and retired in
the crane. accordance with the following guidelines:
a) Suitable protection should be provided
X The operator should test the between the sling and sharp surfaces of
brakes each time a load the load to be lifted.
approaching the rated load is b) Proper storage should be provided for
handled. slings while not in use.
c) Slings should never be choked in the
XI The operator should avoid moving splice.
loads over personnel. Loads which d) Sharp kinks or knots should not be
are suspended by use of slings or permitted in wire rope slings.
hoists should be blocked or cribbed e) Loads should not be lifted with one leg of a
before personnel are permitted to multi-leg sling until the unused legs are
work beneath or between them. secured.
Blow horn before moving loads f) The sling should show the trademark or
over the area where people are name of the manufacturer, the stock
working. number and most importantly the load
9
rating and types of hitches to be used. Do shall only be considered if no alternative
not use it ,if it is not rated for the capacity method can be found. It requires quite an
g) Slings, which are damaged or defective, exceptional level of coordination between
shall not be used. the captain of the supply vessel and the
h) Slings shall not be shortened with knots, platform crane operator. The latter only has
bolts or other makeshift devices. a small “time window” in which to start
i) Sling legs shall not be kinked. hoisting the load to avoid it being hit by the
j) Slings shall not be loaded in excess of their heaving deck of the vessel. Personnel
rated capacities. transfer shall only be performed after
k) Slings used in a basket hitch shall have the assessing the risk, defining associated
load balanced to prevent slippage. prevention and mitigation measures and
l) Slings shall be securely attached to their obtaining approval from the person in
loads. charge of the installation.
m) Slings shall be padded or protected from all
sharp edges of their loads. 7.8.1 Transfer of personnel by baskets
n) Suspended loads shall be kept clear of all
obstructions. If sea is rough or wind does not permit
o) All persons shall be kept clear of vessel drawing alongside or if there is no
suspended loads or those about to be landing platform, personnel shall be
lifted. transferred by using unsinkable basket.
p) Hands or fingers shall not be placed The personnel basket should be so
between the sling and its load while the constructed, that it is capable of serving as
sling is being tightened around the load. a temporary life raft for the maximum
q) Shock loading is prohibited. number of persons that it is designed to
r) A sling shall not be pulled from under a carry.
load when the load is resting on the sling.
s) Any angle other than vertical at which a 7.8.2 Baskets
sling is rigged increases the loading on the Manufacturer's certificate, certificate of
sling.
application and declaration of conformity,
t) Whenever a sling is found to be deficient,
shall be issued prior to operation.
the eyes must be cut or other end
attachments or fittings removed to prevent 7.8.3 Use of personnel Basket
further use and the sling body discarded.
u) A sling eye should never be used over a When transferring personnel between an
hook or pin with a body diameter larger installation and a vessel by means of an
than the natural width of the eye. Never offshore crane and a personnel basket, the
force an eye on a hook. The eye should following precautions are recommended as
always be used on a hook or pin with at basis for setting up a procedure.
least the diameter of the rope.
v) A sling shall be visually inspected before a) General precautions
use to determine if it is capable of safely
making the intended lift. 1. The installation manager may after
Rated loads of a sling is different for each of careful consideration allow transfer
the three basic method of rigging (vertical, by means of personnel basket in
choker, basket etc.) and the rated loads of a each specific case where this for
sling is different for each of the methods of special reasons is necessary or
rigging based on construction of the wire rope, reasonable. Transfer shall take
web material and width etc. These rated loads place on a voluntary basis .
are available from the manufacturers. These
rated loads will be indicated on the heavy duty 2. Transfer of personnel between
tags attached to each type of sling at the time it installation and vessel shall only
is fabricated. take place when there is good
visibility and adequate illumination
Care and use of proper slings and handling and only when the weather
procedure should be in accordance with OISD conditions permit a safe transfer,
std.-187. unless transfer is necessary with
r e g a r d t o the safety of the
7.8 Personnel Transfer personnel or the installation.
4. Instructions shall be drawn up for 15. To ensure that the crane hook
transfer operations, including does not damage anyone using the
rescue instructions in the event of personnel basket, a suitable
accident during transfer. loop/sling shall be used.
10. All persons riding on the basket 4. The personnel basket shall be
should wear life jackets. equipped with life jackets for the
number of persons it is used for.
11. Any person unfamiliar with the
basket shall be given a s h o r t 5. The safety harness should be used
briefing prior to riding the basket during work from a personnel
and shall be accompanied by an basket.
experienced person. Any person
sick, suffering vertigo or injured 6. The installation manager or a
should not be allowed to ride the person appointed by the
basket, except if placed inside and installation manager shall be in
escorted by an experienced charge of the transfer.
person.
7. Before starting the transfer
12. Personnel basket shall not be used operation, the starting and landing
for transfer of cargo, except for area for the personnel basket shall
light personnel hand luggage. be clear to ensure that there is
Luggage shall not be held by hand sufficient space for a safe
but positioned in the middle of the operation. The basket shall not be
basket. landed onto other equipment.
13. The crane to be used shall have 8. During transfer of personnel, all
valid certificate of application and unnecessary noise in the crane
shall be in good technical operator's cabin should be
condition. avoided, and the crane operator's
complete attention shall be
concentrated on the operation.
11
9. A designated signalman shall give 18. “Free-fall” or non powered lowering
the hand signals to the crane should not be adopted when
operator. The crane operator shall personnel are carried in the basket.
have eye contact with the 7.9 Signals
signalman, who in turn shall have
eye contact with the personnel
basket. 7.9.1 Standard Signals
10. The master of the vessel, the crane Signals between the crane operator and
operator and the person in charge the designated signal person will be
of the transfer operation shall be in discernible audibly or visually, at all times.
direct radio contact with each other The crane operator will work with a
from a time before the personnel designated signal person who uses
basket is hoisted until the transfer- standard hand signals and will not respond
operation is completed. unless signals are clearly understood.
If the signalman changes during a lifting Regular inspection needs to be done based
operation, both the crane operator and the upon usage of the crane in addition to OEM
slinger shall be duly notified of the identity Manual requirement or as per the
of the new person in charge of signaling. inspection details indicated in of
Annexure- C.
The designated signal person should:
9.0 MAINTENANCE
a) Be qualified by experience with the
operation and knowledge of the The maintenance of the crane shall be
standard hand and radio signals as made on the recommendation of the crane
shown in the table .
manufacturer’s standard practices,
However, maintenance practices shall be
b) Be in clear view of the Operator to
followed based upon utilisation of the
ensure that his signals can be
crane. The recommended practices for the
seen. His position should give him
maintenance has been indicated in
a clear view of the load, crane,
Annexure- B
personnel and area of operation. If
the Operator’s view of the primary
9.1 Preventive Maintenance
signal person is obstructed, an
additional signal person will be
provided. Periodic/ preventive maintenance schedule
shall be followed as per standard
7.9.4 Special Signals manufacturer's practices/operator's
recommended practices.
For operations not covered in section
7.9.2/7.9.3 or for special conditions, 9.2 Repairs & replacement
additions or modifications to the
recommended standard signals may be The Repairs & replacement of items shall
required. In such cases, these special be followed based upon the
signals will be agreed upon in advance by recommendation of inspection agency.
the Operator and the designated signal However, if any major item / part is
person and should not be in conflict with, or obsolete / not available the same shall be
have the potential to be confused with replaced with compatible parts which has
standard signals. to be approved by competent
person/agency.
7.10 Simultaneous Operations
No welding repair can be made to critical
i. When logging operation is in components such as booms and swing
progress crane operation should circle assemblies unless a repair procedure
not be conducted around the area and recommendations are approved .
where the cable is under tension,
due to the risk associated with If any critical component such as section of
simultaneous operation. the boom etc. are required to be repaired,
ii. During the arming of an explosive a qualified welder shall be deployed for
device, crane operation should not welding jobs.
be conducted around the
designated arming area. 9.3 Precautions during major repair &
iii. During helicopter landing/take off maintenance
crane operation should be stopped
and crane boom must be away a. Any job will be started only after
from the landing/take off area. obtaining the hot / cold work permit at
any site as per OISD Std.- 105 .
8.0 INSPECTION b. Care should be taken to ensure that
arcing does not occur across the
bearings.
8.1 Pre-Use and After c. Hooks should not be exposed to
excessive heat.
13
9.4 Maintenance of Wire rope 13.0 PERSONNEL PROTECTIVE EQUIPMENT
Maintenance and inspection of wire ropes · All personnel working with and around
used in crane shall be done in accordance the crane shall wear safety shoes,
with OISD Std. 187(Use and care of wire Hard hat, Hand gloves & overalls.
rope) · Additionally while checking the
pressure & oil gauges or working near
10.0 LOAD TESTING & CERTIFICATION air source or moving parts, safety
glasses should be used.
10.1 A copy of the original load test carried out · While working at height (above ten
by the manufacturer/contractor during the feet), safety harness shall be used.
supply/sale of crane certified by · Life vests shall be worn by all
International/National reputed certifying personnel being transferred offshore by
agency shall be made available to the Personnel basket.
operator/user.
14
ANNEXURE :A
1. Emergency stop : with arms extended, palm down, move hands rapidly right and left.
4. Move slowly : use one hand to give any motion signal and place other hand motionless in front
of hand giving the motion signal.
5. Raise the Boom : with arm extended fingers closed thumb pointing upward and a jerky upward
motion.
6. Lower the Boom : with arm extend, fingers closed thumb pointing down-ward and a jerky down-
ward motion.
7. Use Main Hoist : Tap first on head then use regular signals.
8. Use whip Line : (Auxiliary Hook Line)Tap elbow with one hand, then use regular signal
10. Travel : Arm extended forward, hand open and slightly raised, make pushing motion in direction of
travel
11. Hoist : With forearm vertical, fore-finger pointing up, move hand in small horizontal circle
12. Lower: With arm extended downward, fore-finger pointing down, move hand in mall horizontal
circle.
13. Raise the Boom and Lower the Load : with one arm extended fingers closed thumb pointing
upward and a jerky upward motion and the other arm extended in a down-ward position palm
horizontal with an up-down motion of this palm.
14. Lower the Boom & Raise the Load : With the arm extended finger closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended finger pointing up move hand in
small horizontal circle.
15. Raise the load slowly : with both hands placed in front of the body, palm open and an up-down
motion with the lower palm.
16. Lower the Load : With arm extended outwards, palm down and an up-down motion towards the
downward direction.
17. Lower the Load Slowly : With both hands placed in front of the body palm open and an up-own
motion with the upper palm.
18. Raise the Boom slowly : with arms placed in front of the body and the lower hand with fingers
closed thumb pointing upward and a jerky upward motion with the upper hand palm down.
19. Lower the Boom slowly : with arms placed in front of the body and the upper hand with fingers
closed thumb pointing down-wards and a jerky down-ward motion with the lower hand palm up.
20. Raise the Boom & Hold the Load : With one arm extended fingers closed thumb pointing upward
and a jerky upward motion and the other arm extended in a down-ward position closed first and
held firmly.
21. Lower the Boom & Hold the Load : With the arm extended fingers closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended in a down-ward position closed
thumb pointing down-ward and a jerky down-ward motion and the other arm extended in a down-
ward position closed first and held firmly.
15
16
ANNEXURE-B
1. Diesel Engines
17
33 Cleaning , flushing and changing of fuel in fuel tank *
including cleaning , / changing of fuel filter .
34 Replacement of belts for cooling fans or water *
pump of compressor or generator .
35 Removal of cylinder head including allied jobs *
connected with its removal .
36 Assembling of cylinder head in the engine with *
associated work for total completion of the job and
satisfactory testing .
37 Replacement of piston ring , connecting rod , piston *
ring set etc. Including associated work necessary
for completion of the job .
38 Replacement of crankshaft including associated *
work for total completion of the job.
39 Removal and getting repaired / serviced including *
calibration of fuel injection pump from authorised
agencies and checking for satisfactory
performance of the engine with calibrated fuel
injection pump .
40 Removal and getting repaired / serviced including *
calibration of governor from authorised agencies
and checking for satisfactory performance of the
engine with calibrated governor .
41 Painting of engine including supply of primer and *
marine epoxy paint as required .
2. CRANES
18
17 Lubricate / grease Swing chain & lock . *
18 Lubricate / grease Main & aux. Block, swivel hook *
bearings and locking latch on hook/swivel.
19 Lubricate / grease Cross head bearing/main thrust *
washers.
20 Main aux. Hooks for deformations , cracks and safety *
latch .
21 Boom for any structural abnormalities , cracks of *
deformation .
22 Winch mounting -- tighten if required . *
23 Checking /lubrication of boom hook anchoring latch on *
chassis. Swing chain / pinion for proper fitting and
functioning .
24 Checking for missing and tightening of slew ring gear *
mounting nuts and bolts
25 Checking and tightening of counter-weight pins/nuts & *
bolts.
26 Checking for creeping of derrick(luffing), boom telescopic *
and outrigger jack cylinders
27 Checking for leakage for hydraulic cylinders *
24 Pedestal and other structural mountings - tightened as *
28 required
29 Checking for full extension of outrigger beams *
30 Checking of cracks/deformation of out-rigger jack plates *
31 Checking of boom pad condition and their lubrication(in *
case of telescopic boom) and missing of members
members for lattice boom.
32 Hydraulic pumps and motors mounting - tighten as *
required .
33 Clean the wire ropes with wire brush,record dimensions *
and check for any kink ( if any ) . Also check end
connections for proper fitting .Lubricate with grease
.Boom Rope,main hoist rope and auxiliary hoist rope to
be checked.
34 Replacement of wire rope and greasing including *
all allied job for the same .Boom rope
35 Replacement of wire rope and greasing including *
all allied job for the same .Main hoist rope
36 Replacement of wire rope and greasing including *
all allied job for the same .Aux hoist rope
37 Cutting , splicing and connection on hook/drum end of *
wire rope.
38 Replacement of swing drive motor ( hydraulic) including *
all associated works for completion of the job and
checking for proper operation after fittings.
39 Replacement of winch drive motor ( hydraulic) including *
all associated works for completion of the job and
checking for proper operation after fittings.
40 Replacement of auxiliary hook drive motor ( hydraulic) *
including all associated works for completion of the job
and checking for proper operation after fittings.
41 Replacement of Main hydraulic pump including all *
associated works for completion of the job and checking
for proper operation after fittings.
42 Replacement of swing drive motor ( hydraulic) including *
all associated works for completion of the job and
checking for proper operation after fittings.
43 Replacement of Swivel hook bearing and checking for *
proper operation after replacement .
44 Replacement of Boom hoist pawl bearing and *
checking
for proper operation after replacement .
19
45 Replacement of Cross head bearing and checking for *
proper operation after replacement .
46 Replacement of Main thrust washer and checking for *
proper operation after replacement .
47 Replacement of Swing chain and checking for proper *
operation after replacement .
48 Replacement of Swing pinion checking for proper *
operation after replacement .
49 Replacement of Pulley and checking for proper *
operation after replacement .
50 Servicing of hydraulic pump of motor . *
51 Drain , flush and refilling of Aux hoist gear box .- *
52 Drain , flush and refilling of Swing drive unit. *
53 Drain , flush and refilling of Boom hoist gear box . *
54 Drain , flush and refilling of Load hoist gear box. *
55 Drain , flush and refilling of Hydraulic oil tank *
56 Drain , flush and refilling of Fuel oil tank . *
57 Servicing of slip ring and brushes of collector column ,if *
provided
58 Cleaning of battery terminals and applying of petroleum *
jelly and topping up of distilled water . Petroleum jelly
to be supplied by the contractor .
59 Servicing of Aviation light on boom including change of *
bulb etc .
60 Replacement of aviation light including making *
Servicing of search light on boom/operator’s cab for
illuminating working area and audio/visual warning
system for reversing.
Note: The above list of items for maintenance and its frequency is only recommended practice. As far as
practical manufacturer’s guidelines should be followed.
20
ANNEXURE-C
20 Engine Visual
Noise Level/Vibration
Detailed inspection report of various items to be inspected are placed in table below. The report
indicates whether the inspected item is to be re-used, to be provided as new, to be repaired or
replaced .
21
1. CABIN ITEMS
6. WIRE ROPES
7. STRUCTURAL DAMAGES
23
8.CRANE BOOM ASSEMBLY
S.NO. ITEM
1. Accumulator & Relay valve starter
2. All Single & Double Joysticks
3. Electrical Panel & all lights
4. Hyd. Tank
5. Hyd. Hand Pump
6. Magnetic Particle collector
7. Fuel feed pump
8. Fuel pump
9. Injectors
10. All Pulleys
11. Counter shaft
12. Plumber block
13. Hydraulic Starter
14. All valves
15. Hyd. Motor for Main Hoist
16. Hyd. Motor for Aux.Hoist
17. Hyd. Motor for Luff Hoist
18. Hyd. Motor for Slew Drive
19. All Mono blocks
20. Slew free valve
21. Check- Q- Meter
22. Pump Drive
23. All Brakes
24. Grease Lubrication of wire ropes, Pulleys, Shafts, Pins & their greasing points
25. All Hyd. Cylinders
26. Slew Ring
27. Main hook block
28. Auxiliary hook block
29. First aid box
30. Distribution board
31. Lubricator assy
32. Air Receiver
33. A Frame
34. All Limit Switches
35. Generator
36 First aid box
37. Distribution Box
38 Joy Stick
39 Pedestal adapter
40 Sheaves
41 Sheave guards
42 Diesel Engine- thorough overhaul
43. Compressor
Note: The above list of items for inspection/maintenance and their frequencies are only recommended
practice. As far as practical, manufacturer’s guidelines should be followed.
24