WW All X X S 04 001 I Lifting Equipment Guideline-1

WW ALL X X S 04 001 I
Rev 1 JUNE 2017
LIFTING EQUIPMENT
GUIDELINE
PETRONAS CARIGALI SDN BHD
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Lifting Equipment Guideline WW ALL X X S 04 001 I
Rev 1 JUNE 2017
Rev1 May 2017
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Rev 1 JUNE 2017
DOCUMENT AUTHORIZATION Rev1 May 2017
Prepared By:
Signature
PRAKASH SUNDARAM
Name/Position Mechanical - Static, Upstream Operational Excellence, Centre of
Excellence (COE), Maintenance Excellence
Date
Approved By:
Signature
MK SHRIVASTAVA
Position
GTA - Custodian (Static Equipment - Unfired)
Date
Document Custodian:
Signature
M NAZORI JANOR
Position
Head, Operational Excellence (OE)
Date
Proprietary Information
This document contains proprietary information which belongs to
PETRONAS and must not be wholly or partially reproduced nor disclosed
without prior permission from PETRONAS
Internal
Rev 1 JUNE 2017
TABLE OF CONTENTS Rev1 May 2017
Section Page
DISTRIBUTION LIST I
AMENDMENT SUMMARY II
PREFACE III
1.0 INTRODUCTION
1.1 General…………………………………………………………………………………. 1
1.2 Objective………………………………………………………………………………. 1
1.3 Scope……………………………………………………………………………………. 1
1.4 Order of Document’s Precedence………………………………………… 2
1.5 Definition of Terms………………………………………………………………. 2
2.0 LIFTING EQUIPMENT OVERVIEW
2.1 Categories of Lifting Equipment…………………………………………… 3
2.2 Pedestal Crane – Lattice Boom Type…………………………………… 4
2.3 Pedestal Crane- Box Boom Type (Ram Luffing Crane)………. 5
2.4 Telescopic Boom Cranes………………………………………………………. 6
2.5 Pedestal Crane-Kingpost Type…………………………………………….. 7
2.6 Single Girder Bridge Cranes…..……………………………………………. 8
2.7 Double Girder Bridge Cranes……….…………………………………..…. 9
2.8 Pillar Jib Crane….……………………………………………………………..….. 10
2.9 Monorails………………………………………………………………………………. 11
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3.0 PART 1: OFFSHORE PEDESTAL CRANES Rev1 May 2017
3.1 Offshore Pedestal Cranes………………………………………………………

12
3.1.1 Standards……………………………………………………………………. 12
3.2 Offshore Pedestal Crane - Minimum Standards and

Requirements……………………………………………………………………….. 13
3.2.1 Wire Rope……………………………………………………………………. 13
3.2.2 Wedge sockets……………………………………………………………. 13
3.2.3 Sheaves………………………………………………………………………. 15
3.2.4 Load Block Assembly………………………………………………….. 16
3.2.5 Boom Hoist and Load Hoist Mechanisms…………………… 16
3.2.6 Telescoping Boom Mechanisms…………………………………. 17
3.2.7 Swing Mechanisms……………………………………………………… 17
3.2.8 Swing Locks………………………………………………………………… 18
3.2.9 Prime Movers………………………………………………………………. 18
3.2.10 Exhaust Systems………………………………………………………. 18
3.2.11 Fuel Tanks…………………………………………………………………. 19
3.2.12 Over Speed Shutdown……………………………………………… 19
3.2.13 Controls…………………………………………………………………….. 19
3.2.14 Platforms and Walkways…………………………………………… 20
3.2.15 Rigging Access………………………………………………………….. 20
3.2.16 Boom Equipment………………………………………………………. 20
3.2.17 Guards for Moving Parts…………………………………………… 21
3.2.18 Clutch and Brake Protection…………………………………….. 21
3.2.19 Lubrication Points and Fluid Fills……………………………… 21
3.2.20 Personnel Emergency Load Lowering………………….…… 21
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3.2.21 Making………………………………………………………………………. 21
3.2.22 Safety Devices………………………………………………………….. 22
3.2.23 Documentation…………………………………………………………. 22
3.2.24 Crane Manuals…………………………………………………………… 23
3.2.25 Operations With Service Vessels……………………………… 24
3.3 Heavy Usage…………………………………………………………………………. 25
3.3.1 Pre-use Inspections……………………………………………………. 25
3.3.2 Monthly Inspections……………………………………………………. 25
3.3.3 Quarterly Inspections…………………………………………………. 25
3.3.4 Annual Inspections……………………………………………………… 25
3.4 Inspection of Critical Crane Components……………………………. 26
3.4.1 Hoist Assemblies…………………………………………………………. 26
3.4.2 Foundations………………………………………………………………… 26
3.4.3 Swing Circle assembly –General Inspection……………… 26
3.4.4 Swing Circle Assembly………………………………………………… 27
3.4.5 Wear Assessment by Rotation method……………………… 29
3.4.6 Crane/ Bearing connection integrity………………………….. 30
3.5 Load Test………………………………………………………………………………. 31
3.5.1 Proof Load Test…………………………………………………………… 31
3.5.2 Functional Load Test…………………………………………………… 31
3.5.3 General Guidelines……………………………………………………… 32
3.5.4 Test Weights for Proof Load Test………………………………. 33
3.5.5 Load Application…………………………………………………………. 33
3.5.5.1 Suspended Weight Method……………………………. 33
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3.5.5.2 Dynamometer Method……………………………………

Rev1 May 201734
3.5.6 Test Report………………………………………………………………… 34
3.6 Crane Hoist Inspection…………………………………………………………. 35
3.6.1 Pre-Use Inspection……………………………………………………… 35
3.6.2 Monthly / Quarterly Inspections………………………………… 35
3.6.3 Semi-Annual Inspections……………………………………………. 36
3.6.4 Annual Inspection………………………………………………………. 36
3.6.5 Tear Down Inspection………………………………….……………. 36
3.7 Maintenance of Pedestal Cranes………………………………………….. 37
3.7.1 Repairs and Replacements…………………………………………. 37
3.7.2 Lubrication…………………………………………………………………… 38
3.7.3 Records Archive………………………………………………………….. 38
3.8 Standard Hand Signals for Load Handling…………………………… 39
3.9 Operating Practices……………………………………………………………… 40
3.10 Load Handling……..……………………………………………………………… 41

Part 2: Mobile Cranes
3.11 Mobile Cranes……………………………………………………………………… 43
3.11.1 Standards………………………………………………………………. 43
3.11.2 Contracted Mobile Crane Requirements………………… 43
3.12 Mobile Cranes – Minimum Requirements………………………….. 43
3.12.1 Minimum Requirements…………………………………………. 43
3.12.2 Safety Devices……………………………………………………….. 44
3.12.3 Documentation………………………………………………………. 45
3.13 Inspection and Testing of Mobile Cranes…………………………… 45
3.13.1 General Requirements…………………………………………… 45
3.13.2 Personnel Competency………………………………………….. 45
3.14 Programmed maintenance…………………………………………………. 47
3.15 Load Testing……………………………………………………………………….. 47
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Part 3: Jib Crane

Rev1 May 2017
3.16 Introduction………………………………………………………………………… 49
3.17 Operations………………………………………………………………………….. 49
3.18 Inspections…………………………………………………………………………. 50
3.18.1 Pre-Use Inspection………………………………………………… 50
3.18.2 Monthly Inspection………………………………………………… 50
3.18.3 Quarterly Inspection………………………………………………. 50
3.18.4 Annual Inspection…………………………………………………… 50
3.19 Maintenance……………………………………………………………………….. 50
Part 4: Overhead and Gantry Cranes
3.20 Overhead and Gantry Cranes……………………………………………. 54
3.20.1 Selection and Use Criteria……………………………………… 54
3.21 Inspection…………………………………………………………………………… 54
3.21.1 Pre-Use Inspection………………………………………………….. 55
3.21.2 Periodic Inspection…………………………………………………. 55
3.22 Load Test……………………………………………………………………………. 55
3.23 Maintenance……………………………………………………………………….. 56
3.23.1 Adjustments and Repairs……………………………………….. 56
3.23.2 Lubrication………………………………………………………………. 57
3.24 Operation……………………………………………………………………………. 57
3.24.1 Specific Procedures Only for Overhead and Gantry 58

Cranes……………………………………………………………………..
3.24.2 Other Operating Procedures and Precautions……….. 58
Part 5: Others
3.25 Winches………………………………………………………………………………. 60
3.25.1 Selection Criteria…………………………………………………… 60
3.25.2 Personnel Use………………………………………………………… 60
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3.25.3 Pre-use Inspection…………………………………………………. 61

Rev1 May 2017
3.25.4 Periodic Inspection………………………………………………… 61
3.25.5 Maintenance of Winch Frame and Fittings……………. 62
3.25.6 Maintenance of Winch Wire Rope…………………………. 62
3.25.7 Teardown Inspection and Certification…………………. 62
3.26 Runway Beams / Monorails……………………………………………….. 63
3.26.1 General Inspection………………………………………………… 63
3.26.2 General Maintenance……………………………………………… 63
3.26.3 General Operation…………………………………………………. 64
3.26.4 Repair and Certification…………………………………………. 64
3.27 Fabricated Pad Eyes and Lifting Points……………………………… 65
3.27.1 General Inspection………………………………………………… 65
3.27.2 General Maintenance…………………………………………….. 65
3.27.3 General Operation…………………………………………………. 66
3.27.4 Cheek plates………………………………………………………….. 67
PART 6: FORKLIFT
3.28 Introduction……………………………………………………………………….. 68
4.0 LIFTING TACKLES
4.1 Objectives……………………………………………………………………………… 69
4.1.1 Minimum Requirements……………………………………………… 69
4.2 Identification & Color Coding of Lifting Tackle……………………. 69
4.2.1 Identification………………………………………………………………. 69
4.2.2 Color Coding……………………………………………………………….. 70
4.3 Tracking System…………………………………………………………………… 70
4.4 Test Certificates……………………………………………………………………. 71
4.5 Personnel Competency………………………………………………………… 71
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4.6 Information Of Lifting Tackle……………………………………………….. 71
4.6.1 Maintenance………………………………………………………………… 71
4.6.2 Replacement Lifting Tackles………………………………………. 72
4.7 Block/Hoist Replacement……………………………………………………… 72
4.8 Rigging / Slinging Practices…………………………………………………. 72
4.9 Safe Use of Wire Slings……………………………………………………….. 73
4.9.1 Safe Use of Slings………………………………………………………. 73
4.9.2 Sling Replacement……………………………………………………… 75
4.9.3 Storage………………………………………………………………………… 76
4.10 Safe Use of Synthetic Rope Slings……………………………………. 76
4.10.1 Proof Test…………………………………………….…………….……. 76
4.10.2 In-service Inspection…………………………………….………… 76
4.10.3 Storage…………………………………………………….……………… 77
4.11 Safe Use of Flat Woven Webbing Slings…………………………… 77
4.11.1 Proof Test…………………………………………………….….………. 77
4.11.2 In-service Inspection……………………………………….…….. 77
4.11.3 Storage…………………………………………………………….……… 78
4.12 Safe Use of Round Slings…………………………………………………… 78
4.12.1 Proof Test………………………………………………..………………. 78
4.12.2 In-service Inspection……………………………….……………… 78
4.12.3 Storage………………………………………………………….………… 79
4.13 Safe Use of Hooks, Shackles and Other Lifting Gears……… 79
4.13.1 Safe Use of Hooks……………….………………………….……... 80
4.13.2 Proof Test…………….…………………………………….……………. 80
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4.13.3 Safe Use of Shackles………………………………………………. 81
4.13.4 Safe Use of Eyebolts………………………………………………. 82
4.13.5 Storage……………………………………………………………………. 83
4.13.6 Safe Use of Turnbuckles…………………………………………. 84
4.13.7 Storage……………………………………………………………………. 85
4.13.8 Safe Use of Plate Clamps……………………………………….. 85
4.13.9 Storage……………………………………………………………………. 86
4.13.10 Safe Use of Lifting Beams and Frames……………….. 86
4.13.11 Maintenance of Lifting Beams and Frames…………. 87
4.13.12 Proof Test………………………………………………………………. 87
4.14 Safe Use of Wire Ropes……………………………………………………… 88
4.14.1 Replacement Criteria………………………………………………. 88
4.14.2 Replacement Guidelines…………………………………………. 88
4.14.3 Installation Guidelines…………………………………………….. 89
4.14.4 Maintenance of Wire Ropes……………………………………. 90
4.15 Recommended Inspection Tools………………………………………… 91
4.16 Internal Examination of Wire Rope…………………………………… 91
4.17 External Examination – Cracking Noise…………………………….. 93
4.18 Inspection of Wire Rope At The Fitting…………………………….. 93
4.19 Lubrication (Recommended Methods)………………………………. 94
4.20 Factors Affecting Rope Performance…………………………………. 94
4.21 Slinging Angle Information………………………………………………… 96
4.22 Slinging of Tubular…………………………………………………………….. 98
4.23 Wrapping…………………………………………………………………………….. 98
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4.24 Bundles……………………………………………………………………………….. 99
4.25 Stacking………………………………………………………………………………. 99
4.26 Other Concerns…………………………………………………………………… 100
4.27 Protection of Slings & Loads……………………………………………… 101
4.27.1 Protection of Slings…………………………………………………. 101
4.27.2 Protection of Loads…………………………………………………. 101
4.28 Selection and Labelling of Slings………………………………………. 102
5.0 LIFTING LOADS
5.1 Lifted Loads…………………………………………………………………………… 104
5.1.1 Categories of Lifted Loads (Equipment)……………………. 104
5.2 Personnel Platform……………………………………………………………….. 104
5.2.1 Specifications……………………………………………………………… 104
5.2.2 Rigging Requirements……………………………………………….. 105
5.3 Inspection and Testing……………………………………………………….. 106
5.3.1 Pre-Use Visual Inspection…………………………………………. 106
5.3.2 Trial Lift……………………………………………………………………… 106
5.3.3 Final and Balance Check…………………………………………… 107
5.3.4 Six (6) Monthly Inspection……………………………………….. 107
5.3.5 Annual Inspection……………………………………………………… 108
5.4 Personnel Platform Operation…………………………………………….. 108
5.4.1 Loading Guidelines……………………………………………………. 109
5.4.2 Work Practices…………………………………………………………… 109
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5.5 Cranes for Lifting Personnel Platform…………………………………. 110
5.6 Personnel Transfer Device……………………………………………………. 111
5.6.1 Definition of Personnel Transfer………………………………… 111
5.6.2 Common Type of Personnel Transfer Device……………. 111
5.6.3 Design and Construction……………………………………………. 111
5.6.4 Minimum Specifications……………………………………………… 112
5.6.5 Frog……………………………………………………………………………… 113
5.7 Inspection, Testing and Certification…………………………………… 115
5.7.1 Pre-Use Visual Inspection…………………………………………… 115
5.7.2 Monthly Inspection……………………………………………………… 116
5.7.3 Six (6) Monthly Inspection…………………………………………. 116
5.7.4 Annual Inspection………………………………………………………. 117
5.7.5 Every Two (2) Years Refurbishment…………………………. 118
5.8 Safe Operations and Practices……………………………………………… 118
5.8.1 Safe Operations and Practices…………………………………… 118
5.8.2 Transfer During Darkness…………………………………………… 119
5.9 Cargo Containers………………………………………………………………….. 120
5.9.1 Standards and Specifications…………………………………….. 120
5.9.2 Definitions…………………………………………………………………… 120
5.9.3 Minimum Requirements……………………………………………… 121
5.9.4 Containers for Lifting With Lifting Set………………………. 122
5.9.4.1 Design of Primary Structure…………………………. 122
5.9.4.2 Design of Pad Eyes………………………………………… 122
5.9.5 Containers for Lifting With Forklift……………………………. 123
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5.9.6 Identification Marking………………………………………………. 123
5.9.7 Information Marking…………………………………………………. 123
5.9.8 Information Plate………………………………………………………. 124
5.9.9 Inspection Plate………………………………………………………… 125
5.10 Container Pre-Use Inspection……………………………………………. 125
5.11 Certificate of Conformity…………………………………………………… 126
5.11.1 Documentation………………………………………………………… 126
5.11.2 Certificate………………………………………………………………… 127
5.12 Periodic Inspection, Test and Repair…………………………………. 127
5.12.1 Schedule of Examination and Tests for Containers 128
5.12.2 Schedule of Examination and Tests for Lifting 129

Sets………………………………………………………………………….
.
5.12.3 Lifting Test………………………………………………………………. 129
5.12.4 Non-Destructive Examination (NDE) of Welds………. 130
5.12.5 Visual Examination………………………………………………….. 131
5.12.6 Marking of The Inspection Plate…………………………….. 131
5.12.7 Inspection Report……………………………………………………. 131
5.12.8 Damage and Repair Procedures…………………………….. 132
6.0 COMPETENCY AND CERTIFICATION
6.1 Training and Certification……………………………………………… 133
6.2 Minimum Requirements…………………………………………………. 133
6.3 Key Requirements…………………………………………………………. 134
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7.0 SAFE LIFTING OPERATION AND DECK MANAGEMENT
7.1 Safe Lifting Operation and Deck Management…………………… 138
7.1.1 Permit To Work………………………………………………………….. 138
7.1.2 Lifting Plan………………………………………………………………….. 139
7.2 Job Hazard Analysis……………………………………………………………… 140
7.3 Confined Space Entry Procedure…………………………………………. 140
7.4 Permit To Work…………………………………………………………………….. 140
7.5 Deck Management………………………………………………………………… 140
7.5.1 No Load Areas…………………………………………………………….. 141
7.5.2 Restricted Load Area………………………………………………….. 141
7.5.3 Equipment Placement…………………………………………………. 141
7.5.4 Access Ways……………………………………………………………….. 142
7.5.5 Escape Routes…………………………………………………………….. 142
7.6 Responsibilities of Personnel……………………………………………….. 142
7.6.1 Area Owner…………………………………………………………………. 142
7.6.2 Area Authority…………………………………………………………….. 143
7.6.3 Crane Operator…………………………………………………………… 143
7.6.4 Rigger…………………………………………………………………………. 143
7.6.5 Supervisor…………………………………………………………………… 143
7.6.6 Signalman…………………………………………………………………… 143
8.0 APPENDICES
8.1 Glossary…………………………………………………………………………. 144
8.1.1 Abbreviations……………………………………………………….. 144
8.1.2 Definitions……………………………………………………………. 146
8.2 Taskforce……………………………………………………………………….. 154
8.3 Reference Document……………………………………………………… 155
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8.4 Pedestal Crane Inspection List……………………………………….

Rev1 May 2017158
8.5 Crane Hoist Inspection Check List………………………………… 161
8.6 Mobile Crane Selection Check List…………………………………. 167
8.7 Mobile Crane Safety Check/Service Check List…………….. 168
8.8 Mobile Crane Inspection Report…………………………………….. 170
8.9 Mobile Crane Operator Maintenance Inspection Report… 175
8.10 Mobile Crane Inspection Check List……………………………. 178
8.11 Jib Crane Inspection Check List…………………………………… 184
8.12 Over Head Crane Inspection Check List……………………… 186
8.13 Appliance Pre-Load Out Inspection Check List…………… 189
8.14 Examples of Good (Safe) Packing Methods………………… 191
8.15 Training And Competency Requirement……………………… 193
Internal
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DISTRIBUTION LIST Rev1 May 2017
No. Position Location
1 Vice President, Malaysia Asset Kuala Lumpur
2 Vice President, International Asset Kuala Lumpur
3 Vice President, LNG Asset Kuala Lumpur
4 Vice President, Center of Excellence Kuala Lumpur
5 MD/CEO, MLNG Bintulu
6 Head, Upstream HSE Kuala Lumpur
7 Head, Operation Excellence Kuala Lumpur
8 Head, Peninsular Malaysia Asset Kerteh
9 Head, Sabah Asset Kota Kinabalu
10 Head, Sarawak Oil Miri
11 Head, Sarawak Gas Bintulu
12 Head, Indonesia Operations INO
13 Head, Iraq Operations Iraq
14 Head, Myanmar Myanmar
15 Head, Turkmenistan Operations Turkmenistan
16 Head, Vietnam Vietnam
Internal
InterInternana PETRONAS CARIGALI SDN BHD Page I
Rev 1 JUNE 2017
AMENDMENT SUMMARY Rev1 May 2017
This sheet must be completed in detail at each revision once this document has
been approved.
Details must include revision number, description and indication of which pages
and paragraphs have been revised, date of revision approval, approvers title
and signature.
Rev Description Date Approver Title

Lifting Equipment Manual WW ALL M
05 001Rev 0 Aug 2009 has been
1 June 2017
rewritten and superseded by this
Lifting Equipment Guidelines
Notes:
i. Document Holders to update Amendment Record as and when

amendments / new revisions are received.
ii. For description of amendment the Document Holder should

indicate correction, modification, and update or deletion issue.
iii. Document Holder to enter their company reference number, sign

and date the record of entry.
iv. Where part amendments are issued, the relevant page(s) will be
identified with a lower case letter in the revision status line in the
header
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PETRONAS CARIGALI SDN BHD Page II

Rev 1 JUNE 2017
Rev1 May 2017

PREFACE
This Lifting Equipment Guidelines herein referred as LEG provides the

guidelines and procedures to assure all lifting, hoisting and rigging
operations are performed safely and in conformance with all applicable codes
and standards, as well as to minimize the risk of injuries to personnel and
damage to Equipment. It is the aspiration of PETRONAS CARIGALI
Management to have a safe lifting operation by ensuring compliance to all
procedures and guidelines as set forth in this document and adopting other
best practices that are identified and accepted by PETRONAS CARIGALI. This
document include guidelines to eliminate all lifting incidents or minimize that
to a level that shall be as low as reasonably practical (ALARP).
This Guidelines also covers the competency and training requirement for the
personnel involved in the operation, inspection and maintenance of Lifting
Equipment.
This is a controlled document. It shall be revised or updated if there is any

changes in regulations/ statutory/ PETRONAS requirements or feedback
from end users or any other influencing circumstances dictate.
All requirements and guidelines stipulated in this document shall be adhered

to by all parties concerned. Any deviation or waiver from this guideline shall
be governed by the latest PETRONAS CARIGALI MOC procedure.
This guidelines is supplement to PCSB Inspection & Maintenance Guidelines

(CIMG) WW ALL M 04002 Latest Revision or its superseding and prevailing
document.
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PETRONAS CARIGALI SDN BHD Page III

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1.0 INTRODUCTION Rev1 May 2017
1.1 General
The Lifting Equipment Guidelines documented herein, form the
reference for management and personnel involved in day to day
activities associated with lifting equipment in Operations.
1.2 Objective
The objective of this document is:
i. To set guidelines for the safe operation, inspection and

maintenance of all Lifting Equipment and their associated
accessories installed on offshore fixed facilities and onshore
facilities, in order to assure safe operation and mechanical
integrity.
ii. Provide the guidelines and strategies for an effective
maintenance and inspection to eliminate or minimize incidents.
iii. Clearly define roles and responsibilities, training, certification
and minimum level of competency of personnel involved in
operating, inspecting, maintaining and testing the lifting
equipment.
These objectives, while based on sound economic principles shall

be achieved with due regard to safety, environment, OEMs
recommendation and best practices.
1.3 Scope
The purpose of this guidelines is to ensure that all Lifting
Equipment and their accessories installed on Offshore fixed
facilities and onshore facilities are properly inspected, maintained
and operated according to the manufacturer’s recommendations,
API RP 2D, API RP 2C, applicable OSHA regulations, and other best
practices adopted worldwide.
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PETRONAS CARIGALI SDN BHD Page 1
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1.4 Order of Documents Precedence Rev1 May 2017
i. Where differences and/or conflicting issues occur between the

referenced documents themselves or the requirements of this
document, the following hierarchy of adherence to standards
shall be followed
 PETRONAS Technical Standards.
 PETRONAS Manuals and Standards.
 International Codes and Standards.
 International Recommended Practices / Specifications.
 OEMs recommendation and best practices.
1.5 Definition of Terms

Throughout this document, the following words when used in the
context of actions by or others, have specific meanings as follows:
i. “May” is used where alternatives/actions are equally

acceptable.
ii. “Should” is used where provision is preferred.
iii. “Shall” is used where a provision is mandatory / vital.
iv. “Company” is PETRONAS CARIGALI SDN BHD.
v. “Contractor” is the party which carries out all or part of the
operation, inspection and maintenance of a facility.
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2.0 LIFTING EQUIPMENT OVERVIEW Rev1 May 2017
2.1 Categories of Lifting Equipment
Lifting Equipment
Lifting Lifting Tackle Lifted Load Life boat

Appliances/Machine Davits
&Winches*
Cranes (including) Wire rope slings Containers Survival Crafts

Offshore Pedestal Chain & Chain Skids Launching
Cranes slings Spreader beams Appliances
Pillar Jib Cranes Manmade fiber Drum cages
Mobile Cranes slings Gas cylinder
Tower Cranes Round slings racks
Overhead/Gantry Shackles Frames
Cranes Plate clamps- Baskets
Runway Horizontal Pipe racks
beams/Monorail Plate clamps- Pallets
hoists Vertical
Powered overhead Eye bolts & Swivel Any other
Chain hoist rings similar
Tirfors® Turnbuckles equipment /
Chain Pulley blocks Rigging screws Containers
Pad eyes (fixed Wedge sockets
structure) Hooks
Winches Pallet hook
Forklift Trucks Lifting harness
Beam Trolleys Beam clamps
Sheave blocks
Any other similar

lifting equipment
*Lifeboat Davits and Winches are covered in Lifeboat inspection and maintenance
manual (LIMM) MYALL M 07 005
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2.2 Pedestal Crane- Lattice Boom Type

Rev1 May 2017
Pedestal is the supporting substructure on which the revolving
upper structure is mounted Lattice Boom is of open construction
with lacing between main corner members (chords) in the form of
a truss.
Figure 1: Pedestal Crane
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2.3 Pedestal Crane – Box Boom Type (RAM Luffing Crane)

Rev1 May 2017
The ram luffing offshore crane, also called a box boom crane, is a
pedestal mounted crane with a ram cylinder luffing boom of box
steel construction. Box boom cranes are typically used on fixed
platforms and FPSO due to their compact design, requiring only
limited space and less weight.
Figure 2: Ram Luffing Crane
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2.4 Telescope Boom Cranes

Rev1 May 2017
Telescopic boom Cranes are typically called as hydraulic Cranes.

The booms are composed of a series of rectangular, trapezoidal or
other shapes of symmetrically cross sectional segments fitting in to
each other. The largest section at the bottom of the boom is called
the base section or boom butt. The smallest section at the top of
the boom is called the tip section or boom tip. In between there
can be more sections called first, second and so forth. With the
boom fully retracted the telescopic boom cranes are highly
maneuverable.
The power source for telescopic boom is the hydraulic fluid. In most
cases the main carrier engine drives the hydraulic pump that
supplies the hydraulic fluid to hydraulically controlled components.
Power is diverted to hydraulic cylinders by the valve body at
operators control station.
Figure 3: Telescopic Boom Crane

Courtesy: Pellegrini (2017),Telescopic Cranes, www.Offshore marine cranes.com
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Rev1 May 2017

2.5 Pedestal Crane-Kingpost Type
A fixed tubular member that acts as a centerline of rotation for the

revolving upper structure and as the connective member to the
platform.
The King Post design offers superior modular safety assemblies,

and simpler maintenance procedures.
With simplified main bearing assembly inspection is much easier.
Site installation time is shortened significantly over a slew bearing

mounted crane.
Maintenance costs are relatively less over the cranes design life
compared to other designs.
Main and auxiliary winches are placed in the boom, eliminating two
blocking when booming down.
Minimal tail swing radius saves valuable deck space.
Figure 4: King Post Pedestal Crane

Courtesy: Seatrax (2017), Kingpost Crane,www.Seatrax.com
Internal
Rev 1 JUNE 2017
2.6 Single Girder Bridge Cranes Rev1 May 2017
The crane consists of a single bridge girder supported on two end

trucks. It has a trolley hoist mechanism that runs on the bottom
flange of the bridge girder.
Single girder bridge cranes generally have a maximum span

between 20 and 50 feet with a maximum lift of 15-50 feet.
They can handle 1-15 Tonnes with bridge speeds approaching a

maximum of 200 feet per minute (fpm), trolley speeds of
approximately 100 fpm and hoist speeds ranging from 10-60 fpm.
They are suitable for light to moderate service are cost effective for
use as a standby Crane.
Figure 5: Single Girder Bridge Crane

Courtesy: A.Bhatia (2012), EOTCranes & Hoists, www.PDHOnline.org
Internal
Rev 1 JUNE 2017
2.7 Double Girder Bridge Cranes Rev1 May 2017
The crane consists of two bridge girders supported on two end

trucks. The Trolley runs on rails on the top of the bridge girders.
Double girder cranes are faster, with maximum bridge speeds,

trolley speeds and hoist speeds approaching 350 fpm, 150 fpm
and 60 fpm, respectively.
They are useful cranes for variety of usage levels ranging from
infrequent, intermittent use to continuous severe service. They
can lift up to 100 Tonnes.
Figure 6: Double Girder Bridge Crane

Courtesy: A.Bhatia (2012), EOTCranes & Hoists, www.PDHOnline.org
Internal
Rev 1 JUNE 2017
2.8 Pillar Jib Crane

Rev1 May 2017
Jib Cranes lift and transport materials in semi circles or full circles
around their support structure. These jib cranes are primarily used
in areas which are not accessible by the platform main cranes and
used for light duty.
Figure 7: Pillar Jib Crane
Internal
Rev 1 JUNE 2017
2.9 Monorails
Rev1 May 2017
A monorail is a rail based transport system based on a single rail
which acts as its sole support and guide way primarily used to
transfer equipment, components, valves etc from areas which are
not accessible by main platform crane to the main maintenance
area.
Figure 8: Monorail
Internal
Rev 1 JUNE 2017
3.0 PART 1: OFFSHORE PEDESTAL CRANES

Rev1 May 2017
3.1 Offshore Pedestal Cranes
This section describes the requirements related to the selection,

inspection, maintenance and operation of Pedestal Cranes.
3.1.1 Standards
The following API & ASME standards, practices and

specifications apply to the design, construction, installation,
operation, inspection and maintenance of lifting equipment
covered in this section.
i. API Recommended Practice 9B “Recommended

Practice in Application, Care, and Use of Wire Rope for
Oilfield Service,
ii. API-9A Specification for Wire Rope,
iii. API Specification 2C, Specification For Offshore
Cranes,
iv. API Recommended Practice 2D, Operation and
Maintenance of Offshore Cranes,
v. ASME B30.5 – Onshore Mobile Cranes,
vi. ASME B30.11- Monorails and Underhung Cranes.
vii. ASME B30.17 – Overhead & Gantry Cranes
viii. ASME B56.10 – Forklifts.
NOTE:
No lifting equipment shall be modified, in any manner and
or re-rated in excess of the original rated capacity unless a
detailed engineering study conducted and MOC raised,
reviewed and approved by Original Crane Manufacturer
(OEM) or any of the following:
i. An API 2 licensed 2C crane manufacture
ii. Certified engineer experienced in the design of the
crane
iii. Authorized Third Party Engineering Consultants
Internal
Rev 1 JUNE 2017
3.2 Offshore Pedestal Crane - Minimum Standards and 2017

Rev1 May
Requirements
Each pedestal crane both rental and fixed at offshore facilities shall
meet the standards as specified in API 2C for offshore pedestal
mounted cranes for use drilling and production operations.
The following are some of the critical component’s standards and

requirements related to operations and maintenance.
3.2.1 Wire Rope
All wire shall comply with the following requirements:
i. As specified by the Manufacturer and or Crane Original

Equipment Manufacturer.
ii. When terminated, this shall not reduce the wire rope
strength to below 80% of the wire rope nominal
breaking load.
iii. The design factor of load hoist wire rope of not less than
five (5) as required by API Specification 2C,
Specification of Offshore Crane.
3.2.2 Wedge Sockets
Wedge sockets shall be installed with the live-load-side of

the wire rope in line with the wedge socket pin.
Figure below shows methods of securing when using wedge

sockets.
Internal
Rev 1 JUNE 2017
Rev1 May 2017
Figure 9: Methods of securing dead end of rope when using wedge

socket
Internal
Rev 1 JUNE 2017
3.2.3 Sheaves Rev1 May 2017
The minimum standards and requirements related

to operations and maintenance shall be as follows:
i. Sheave pitch diameter (PD) to nominal wire rope diameter

(R) ratio (PD/R) shall not be less than 18, refer figure
below).
ii. Sheave groove contour shall be smooth and free from
defects injurious to the wire rope.
iii. Sheave groove angle shall taper outwardly and shall not
be less than a 30° included angle.
iv. Groove flange corners shall be rounded.
v. Sheave bearings shall be individually lubricated through
a separate passage.
vi. All sheaves, including running blocks, shall be provided
with guards or other suitable devices to prevent the
rope from coming out of the sheave groove.
Figure 10: Sheave Dimensions
Internal
Rev 1 JUNE 2017
3.2.4 Load Block Assembly Rev1 May 2017
The minimum standards and requirements related to

operations and maintenance shall be as follows:
i. The weight of the hook block shall be sufficient to

prevent rope slack when the main hoist drum is
unwinding at maximum speed.
ii. Hooks shall be equipped with a latch to retain loose
lifting gear under non-lifting conditions.
iii. The latch shall be lockable if the hook is to be used for
transporting personnel.
iv. The rating label(s) shall be permanently affixed to the
hook. This shall indicate:
 Rated for Personnel / non personnel

 Service temperature
 Assembly weight
3.2.5 Boom Hoist and Load Hoist Mechanisms

i. Boom and load hoists shall have a name plate to

indicate whether used for personnel or non-personnel.
ii. Brakes (rated at 1.5 times the torque of the hoist)
shall hold the drum from rotating in the lowering
direction and capable of holding the rated load
indefinitely without attention from the operator.
iii. Brakes shall be automatically applied upon return of
the control lever to its neutral position.
iv. Free fall lowering of the boom or load shall not be
permitted.
v. All hoists shall be equipped with means to check
lubricant.
Internal
Rev 1 JUNE 2017
vi. On rope boom support machines, a ratchet and pawl

Rev1 May 2017
or other positive holding device (such as integrally
mounted check valves) shall prevent uncontrolled
lowering of the boom. Refer Section 3.26 for Winches.
3.2.6 Telescoping Boom Mechanisms

i. All extension and retraction may be accomplished

through hydraulic, mechanical, or other means.
ii. A holding device (such as check valves) shall be
provided with telescoping cylinders to prevent
uncontrolled movement of the cylinder.
3.2.7 Swing Mechanisms

i. A brake, with holding power in both directions, is to

restrain movement of the upper structure but not to
retard the rotation motion of the upper structure
during operation.
ii. The brake shall be controllable by the operator, and
capable of remaining in the engaged position without
the attention of the operator.
iii. If a swing brake is of the automatic type, return of the
swing control lever to neutral, shall not engage the
brake in a manner to abruptly arrest the swing motion
iv. An automatic swing brake that is faulty shall not be
used.
Internal
Rev 1 JUNE 2017
3.2.8 Swing Locks

Rev1 May 2017
A swing lock, a mechanical device (not dependent on

friction) for positively locking the superstructure in one
or more fixed positions, when provided, it shall:
i. Withstand maximum swing torque developed by

the swing mechanism,
ii. Prevent accidental engagement or
disengagement,
iii. Be controllable by the operator at the station.
3.2.9 Prime Movers

i. Gasoline engines are not permitted as prime movers.

ii. Pneumatic prime movers or auxiliary systems, which
use flammable gas as the fluid medium, are not
permitted, unless a risk assessment has been
completed and appropriate management approval
obtained.
3.2.10 Exhaust Systems

i. Engine exhausts shall be equipped with a spark

arresting type silencer, unless a risk assessment has
been completed and the appropriate management
approval obtained.
ii. Exhaust gases shall be piped to the outside of the
engine enclosure and discharged in a direction away
from the operator.
Internal
Rev 1 JUNE 2017
iii. All exhaust systems shall be guarded in areas where

Rev1 May 2017
contact by personnel in the performance of their
normal duties is possible.
3.2.11 Fuel Tanks

Fuel tanks, equipped with filler necks and caps are

designed to prevent fuel contamination from external
sources; removable caps, where fitted, shall be securely
tethered to the filler.
3.2.12 Over Speed Shutdown
Diesel engines shall be equipped with a device to shut the

air engine intake in the event of a diesel engine runaway.
3.2.13 Controls
As a minimum, the standards and requirements related

to operations and maintenance shall be as follows:
i. Control levers for boom hoist, load hoist, swing and

boom telescope (when applicable) shall return
automatically to their centre (neutral) positions on
release.
ii. Control operations and functions shall be clearly
marked and easily visible from the operator station;
this can be done by marking each control or by a
control arrangement diagram
iii. Provisions shall be made for emergency stop of the
crane operations by the operator at the operator’s
control station.
iv. Foot operated pedals, where provided, shall be
constructed so the operator's feet will not readily slip
off.
Internal
Rev 1 JUNE 2017
v. Controls for normally

operating prime movers
Rev1 May 2017
mounted on the crane superstructure shall be within
easy reach of the operator and shall include means to
start/stop, control speed of internal combustion
engines, stop prime mover under emergency
conditions and shift selective transmissions.
3.2.14 Platforms and Walkways
As a minimum, the standards and requirements related to

Principle walking surfaces shall be an anti-skid type.

Outside platforms, if furnished, shall be provided with
guardrails.
3.2.15 Rigging Access
Rigging access shall be characterized as follows:
Where necessary for rigging or service requirements,

a ladder or steps shall be provided to give access.
3.2.16 Boom Equipment
As a minimum, the standards and requirements related to

i. Boom shall have limits to automatically stop the boom

hoist when the boom reaches a predetermined height
or swing angle.
ii. Boom stops shall prevent the boom falling backwards
in any operating situation or whether condition.
Internal
Rev 1 JUNE 2017
3.2.17 Guards for Moving Parts

Rev1 May 2017
Exposed parts such as gears, chains, chain sprockets or

rotating parts, which may constitute a hazard under normal
operating conditions, shall be guarded.
3.2.18 Clutch and Brake Protection
All friction brakes and clutches shall be provided with rain

guards. Pins, shafts, and bolts in clutch and brake linkages
shall be protected against corrosion.
3.2.19 Lubrication Points and Fluid Fills
Lubricating points on all parts shall be accessible without

the necessity for removing guards or other parts and shall
not collect fluid spills.
3.2.20 Personnel Emergency Load Lowering
At least one hoist drum shall be provided with a means of

lowering in the event of a power or control system failure.
This means shall provide controlled lowering and stopping

of the drum under all load conditions. The controls shall be
arranged in a manner that it will prevent inadvertent
engagement.
An alternate power source, independent of the crane may

be used.
An instruction plate giving detailed instructions shall be

provided at the operator's station.
3.2.21 Marking
All Cranes shall have a nameplate confirming the

construction in compliance to API Specification 2C.
Internal
Rev 1 JUNE 2017
3.2.22 Safety Devices Rev1 May 2017

Cranes may be equipped with a variety of mechanical or
electronic devices to aid, provide information or override
the operator.
Safety devices must never be routinely bypassed,

defeated, or disabled.
Examples of such safety devices are:
i. Anti-two-block indicating and shutdown devices,

which prevent the load block or overhaul ball from
coming to contact with the boom or jib tip.
ii. Over booming devices, which prevent the boom from
reaching at a predetermined maximum angle.
iii. Load moment or rated capacity alarm and shutdown
devices, which warn or shutdown crane operations
during overloading.
3.2.23 Documentation
General Requirements
All lifting, inspections, testing and maintenance of

offshore pedestal cranes shall be documented. As a
minimum the following shall apply:
i. The crane operator shall update the daily crane

operations log,
ii. All maintenance activities,
iii. Change out of critical items,
iv. Test certificates,
v. Load test and results,
vi. Any approved modifications,
vii. Any deviations supported by a MOC with the
necessary approval.
Internal
Rev 1 JUNE 2017
Record retention Rev1 May 2017

All records shall be retained for seven years (7) or such a
time when a critical item with certificate is retired.
3.2.24 Crane Manuals
Fixed marine facilities
A Crane Manual shall be provided for all cranes installed at

fixed marine facilities. The manual shall include but not
limited to the followings:
i. Design standards and operation,

ii. Manufacturer’s maintenance, inspection, and testing
information on the slew / swing circle assembly,
iii. All limitations during normal and emergency operations
with respect to:
 safe working load,
 safe working moment,
 maximum wind,
 design temperatures,
 braking systems,
 all safety devices,
iv. Diagrams for electrical, hydraulic, and pneumatic
systems and equipment,
v. Materials used in construction, welding procedures, and
extent of non-destructive testing
vi. Guidance on maintenance and periodic inspection.
Internal
Rev 1 JUNE 2017
3.2.25 Operations with Service Vessels Rev1 May 2017
In addition to the above requirements, Crane Manuals for

fixed and mobile installations that are used for the loading or
unloading of offshore supply or other service vessels shall be
furnished with:
Rating tables or curves that take into consideration the

Inspection of pedestal cranes
Offshore pedestal cranes shall be inspected in accordance

with API Recommended Practice 2D. Inspections may be
conducted at more frequent intervals, as determined and
guided by manufacturer recommendations, facility experience
and severity of the working environment.
Inspection procedures are divided into on 3 categories based

on usage or duty cycle as follows:
Infrequent usage
Applicable for cranes that are used for 10 hours or less per
month. These cranes shall be subject to:
i. Pre-use Inspection
ii. Annual Inspection
Moderate usage
Applicable for cranes that are used for more than 10 hours
but less than 50 hours per month. These cranes are subject
to:
ii. Quarterly Inspection
iii. Annual Inspection
Internal
Rev 1 JUNE 2017
3.3 Heavy usage Rev1 May 2017
Applicable to those cranes that are used for more than

50 hours per month. These cranes are subject to:
ii. Monthly Inspection
iii. Quarterly Inspection
iv. Annual Inspection
3.3.1 Pre-use Inspections
The pre-use inspection, performed by a competent Crane

Operator/Qualified inspector, shall be carried out and
documented prior to the first crane use of the day and during
each change in Crane Operator. This shall apply to all cranes
regardless of usage as per checklist in Appendix 8.4
3.3.2 Monthly Inspections
Monthly inspections are performed by a Qualified Crane

Operator/Qualified Inspector as per check list in Appendix 8.4.
3.3.3 Quarterly Inspections
Quarterly inspections are performed by Qualified inspector as

per check list in Appendix 8.4.
3.3.4 Annual Inspections
Annual inspections are performed by a Qualified inspector as

per check list in Appendix 8.4.
Internal
Rev 1 JUNE 2017
3.4 Inspection of Critical Crane Components
Rev1 May 2017
The annual inspection of critical components will differ depending on
the type of crane.
There are three general categories of critical components:
i. Hoist assemblies
ii. Foundations
iii. Swing Circle Assembly
3.4.1 Hoist Assemblies
Annual inspection and maintenance are determined by OEM

as a function of the hoist type, duty cycle and condition. The
quality of the hoist lubricant is a primary indicator of the
mechanical integrity of the hoist.
Refer Section 3.25 for Winches
3.4.2 Foundations
Annual inspection and maintenance shall include as a

minimum the following:
i. Visually examine elements in crane’s pedestal checked

and support structure for fracture, deformation and
corrosion.
ii. Inspect for areas of rust and cracked paints.
3.4.3 Swing Circle Assembly –General Inspection
There are 2 types of swing assemblies
i. King post.
ii. Ball/ Roller bearing.
King Post
The inspection shall be carried out in accordance with

manufacturer’s recommendations and shall include inspection
of the following but not limited to:
Internal
Rev 1 JUNE 2017
i. Upper thrust bearing.

ii. Upper radial bearing. Rev1 May 2017
iii. Lower thrust bearings or radial bearings.

iv. King pin wear and condition.
v. Lower king post radial bearings: The radial bearings
condition is critical as it protects the king post from the
lower thrust rollers or radial bearings. On cranes not
equipped with wear bearings or wear material, the
wear zone on the king post shall be carefully monitored
to ensure the structural integrity of the king post.
vi. King post to platform structural connection.
Ball/ Roller Bearing
The inspection Ball/ Roller Bearing shall be carried out in

accordance with manufacturer’s recommendations and shall
include Bearing Wear Assessment by grease sample and
tilt procedure
The wear in the bearing must be monitored to determine its

expected service life.
The wear assessment shall be done every twelve months and

shall be shortened if obvious metal or contaminations are
present.
3.4.4 Swing Circle assembly

Wear Assessment by Grease Sample Analysis.
Preparation
i. Clean the raceway to minimize contamination of the

sample.
ii. Position the crane boom at the minimum radius to allow
a full 360° rotation.
iii. Use grease that is recommended by the Crane
Manufacturer.
Internal
Rev 1 JUNE 2017
Collection of Sample
Rev1 May 2017
i. Pump grease while slowly rotating the crane 360°.
ii. A sufficient bead of grease should be observed all the
way around the lip seal.
iii. Select eight points equally spaced to obtain a sufficient
sample.
iv. Collect the sample in a clean container, such as a clear
plastic bag, sample jar, etc.
v. Clean off excess grease after taking the sample.
Evaluation of Sample
i. Take a small portion of the sample and spread it out on

a light colored material such as a white cotton cloth,
coffee filter, etc.
ii. Dilute the grease sample with a solvent to expose any
contaminates.
iii. Inspect the sample looking for metal particles, sand,
nylon, rust, water, etc.
Note: Special attention should be given to metal

particle size, shape and quantity.
iv. The Crane Manufacturer or an experienced engineer

shall be consulted if the sample is questionable and
further evaluation is required.
v. The Area Authority shall be informed accordingly.
Internal
Rev 1 JUNE 2017
Rev1 May 2017

3.4.5 Wear Assessment by Rotation method
The Rotation method is based on the fact that a bearing may

always be fully tilted forward in the direction of the boom and
the tilt. Measuring this tilt will provide an indication of the
bearing integrity.
Note:
On certain facilities the crane may not be installed for 360°
rotation and hence reading taken shall be to the maximum slew
limits.
Procedure
i. Clean the surface of the bearing to be measured and

ensure it is clean, and rust free.
ii. Position a dial indicator, with a magnetic base, on the
pedestal with the needle of the indicator positioned on
the clean surface of the bearing or crane (see Figure 11).
iii. This dial indicator shall be positioned in the front or rear
of the crane in line with the boom.
iv. The boom must be positioned such that the bearing is
fully tilted forward with no excessive moment load.
v. Set the indicator to zero.
vi. Slowly rotate 360° with the dial indicator reading
recorded every 45° of crane rotation.
vii. The dial indicator should return to zero when the crane
is rotated 360° back to its original position.
viii. Reposition the dial indicator every 900 in order to

perform four (4) individual test.
ix. Record readings and compare with the last reading taken
or when fist installed and commissioned.
Figure 11: Rotation Method
Internal
Rev 1 JUNE 2017
Rev1 May 2017
Figure 11: Rotation Method
3.4.6 Crane/ Bearing Connection Integrity
The Crane/ Bearing may be connected using bolts, welding or

combinations of the two. The integrity of this connection is
crucial to the life of the swing circle assembly.
The inspection guideline for each crane is specific and the OEM
shall be referred for guidance when developing the inspection
procedures. As a minimum the following guidelines shall
apply:
i. Check the bolts are torque to OEM’s specification.

ii. Rotate the crane 360° in each direction at slow,
intermediate and full speed and monitor the smoothness
of rotation.
iii. Report any irregular, jerky, bumpy, etc. motions to the
relevant authority for immediate remedial action.
Internal
Rev 1 JUNE 2017
3.5 Load Test

Rev1 May 2017
References: API RP 2D Latest Edition
A crane load test is not required to determine the fitness of repairs or

alternation, provided that such repair and replacement of critical
components are in accordance with or exceed OEM recommendations.
No load test (proof load test or functional load test) shall be

carried-out unless an annual inspection as recommended in
this LEG is carried out and any defects rectified prior load test.
3.5.1 Proof Load Test
A proof load test (125% the rated capacity) is required under

the following conditions:
i. New cranes being placed into service.

ii. Cranes that are being permanently relocated.
iii. Temporary cranes after each rig-up or relocation.
iv. After major repair or alteration of structural components.
This shall include a crane that has undergone major
structural repair work or refurbishment.
3.5.2 Functional Load Test
A functional load test (at 100% of the SWL at respective

angle /radius) to be carried out every 24 months or when
there is a requirement such as:
i. Prior to a heavy lift - Heavy lift is defined as load of more

than 90% of SWL.
ii. The Area Authority (OIM) may request for such a load
test in anticipation of a forthcoming heavy lift subject to
TA approval. This decision can be due to the fact that the
crane has not been subjected to such a lift in its day to
day crane operations.
Internal
Rev 1 JUNE 2017
Note:
The functional load test shall beRev1 May 2017
witnessed by approved
third party inspection agencies and load test certificate
endorsed by OSR inspector for Malaysian Assets /
Regulatory authority in Host country.
3.5.3 General Guidelines
Load testing procedures shall incorporate the following

minimum requirements:
i. The qualified inspector shall be familiar with the crane

load chart and the load selected for the load test.
ii. The load-rating chart shall indicate the maximum
capacity for each radius.
iii. The qualified inspector shall select test loads that
specifically stress the repaired or altered component.
iv. The qualified inspector shall select a test weight that is
within the capacity of the hoists and wire ropes.
v. The qualified inspector shall be aware that line pulls on
some non-mechanical and electric hoists may be self-
limiting. The load test requires only that these hoists,
when self-limiting, lift at least 100% of rated load.
vi. Test weights or dynamometer/load cell shall be
calibrated and verified for accuracy by the qualified
inspector.
vii. All lifts shall be planned in advance taking into account
the crane's physical location, the available space for
staging and assembling the test loads and the hazardous
areas to be avoided,
viii. Relief valves on hydraulic cranes shall not be adjusted
above manufacturer's recommended pressures
ix. Current-limiting devices on electric cranes shall not be
bypassed or adjusted to increase available hoist line
pull.
x. The test can be conducted with the hoist’s maximum load
Internal
Rev 1 JUNE 2017
as long as it is within the excess of the static rated load,
Rev1 May 2017
3.5.4 Test Weights for Proof Load Test
The test weights for all lifts shall be based on crane rating chart,
wire rope strength, available hoist line pull and number of parts
of line. The static test load and the test radius shall be
calculated as follows:
Static Rated Load in Metric Test Loads in Excess of Static

Tonnes at a Specific Radius Rated Load at a Specific
Radius
0 to 20 Metric Tonnes + 25%
20 Metric Tonnes to 50 Metric + 5 Metric Tonnes
Tonnes
50 Metric Tonnes or more + 10%
Table 1: Test Weights for Proof Load Test
3.5.5 Load Application
There are two methods of applying the test load:
i. Suspended weight method.

ii. Dynamometer method.
3.5.5.1 Suspended Weight Method
Guidelines for the Suspended weight test are as

follows:
i. Select a suitable test load, based on crane

rated capacity.
ii. Assemble the load.
iii. Lift the load.
iv. Testing duration shall be as required by third
party inspector/surveyor.
v. Boom out to the desired radius.
vi. With the load suspended, set the load hoist
and boom hoist brakes.
vii. Check for drum rotation.
Internal
Rev 1 JUNE 2017
viii. The test does not require that the test load
be boomed or swung. Rev1 May 2017
Note:
It is recommended to use water bags for load test
instead of solid weights due to the advantage of
identifying defects if any by gradual increase in
weight before reaching maximum test load.
3.5.5.2 Dynamometer Method
Guidelines for the Dynamometer test are as follows:
i. Calibrated and certified Dynamometer shall be

used.
ii. Testing duration shall be as required by third
party inspector/surveyor.
iii. Determine the available dynamometer tie-
down locations.
iv. Measure and record the radius value.
v. Align the boom point with the tie-down.
vi. Attach the dynamometer.
vii. Verify that the load hoist line is vertical.
viii. Pull with the load hoist until the desired test
load is indicated on the dynamometer.
ix. Set the load hoist brake.
x. Check for drum rotation.
3.5.6 Test Report
The load test report shall include but not be limited to

the following:
i. Equipment Tag Number and manufacturer’s serial

number.
ii. Description of crane under test.
iii. Manufacturer of the crane.
iv. Date of manufacture of the crane.
v. Make and model of safe load indicator, if applicable.
Internal
Rev 1 JUNE 2017
vi. Date of last thorough inspection of the crane.

Rev1
vii. Auxiliary line rated capacity, Mayload
test 2017and test
radius, if applicable.
viii. Main hoist line rated capacity, number of parts of
line, test load and test radius.
ix. Name and signature of third party
inspector/surveyor with company stamp.
x. Load test certificate endorsed by OSR Inspector for
Malaysian Assets.
3.6 Crane Hoist Inspection
All crane hoists shall be inspected as per manufacture’s

recommendations. As a minimum all associated ancillaries for
the hoist such as anti-two block/limit switch and sheaves shall
be inspected as follows:
3.6.1 Pre-Use Inspection:
(At the beginning of each shift the hoist is in use)
These procedures MUST be performed prior to placing

the crane into service, and then as necessary during
extended operation.
This inspection must be performed by a qualified crane

operator or qualified crane inspector.
Refer Appendix 8.5 for Pre-use inspection check

list for Hoist
3.6.2 Monthly / Quarterly Inspections:
Every three (3) months or monthly in Severe Duty

Application, or prior to placing the machine in service if
it has not been used for a period of 3 months or longer.
This inspection must be carried out by a qualified crane

operator and/or crane technician or qualified crane
inspector.
Internal
Rev 1 JUNE 2017
Refer Appendix 8.5 for monthly/quarterly inspection
check list. Rev1 May 2017
3.6.3 Semi-Annual Inspections:
Every six (6) months

Refer Appendix 8.5 for Six monthly inspection
check list.
3.6.4 Annual Inspection:
Semi-annually in Severe Duty Applications

Refer Appendix 8.5 for annual inspection check
list.
3.6.5 Tear Down Inspection Every Two (2) Years
Tear down inspection shall be carried out on personnel

handling hoist. As a minimum all hoist shall undergo a
complete teardown inspection every two (2) years.
The interval between inspections may be reduced if the
usage is severe or increased if the usage is less with
proper risk assessment. The following guidelines shall
apply:
Severe usage:
More than 200 hours per month or 50 % of the lifts
exceeding 75% of the rated capacity
Normal Usage:
Up to 200 hours per month
Note:
A crane used in drilling and other severe duty operations
shall therefore undergo a more frequent teardown
inspection than the normal 2 years tear down inspection.
Refer Appendix 8.5 for Tear down inspection

checklist
Upon completion of tear down inspection a certificate
shall be issued by approved third party agencies.
Internal
Rev 1 JUNE 2017
A sample of the inspection and re-certification plate (see
below) shall be affixed on the hoist
Rev1after
Maycompletion
2017 of
the refurbishment.
NAME OF THE SERVICE AGENCY

Hoist Model No:
Hoist Serial No:
Date of inspection:
Work Order No:
Service Technician:
Inspector Name:
Table 2: Service Agency
3.7 Maintenance of Pedestal Cranes
A preventative maintenance program shall be established taking

into consideration crane type, frequency of usage, history of
maintenance and manufacturer's recommendations.
Written and dated maintenance records shall be readily available

for a period of seven (7) years.
3.7.1 Repairs and Replacements
i. Repairs or replacements of critical components shall

be made promptly.
ii. Written reports shall be maintained by the Crane
Owner and the Crane & Lifting Contractor,
iii. All major replacement shall equal or exceed the
original equipment manufacturers recommended
practices.
iv. No welding repairs shall be made to critical
components, such as booms and slew/swing ring
assemblies without specific repair procedures and
recommendations from the Original Crane
Manufacturer and or Crane & Lifting Contractor.
v. Care shall be taken while welding, to ensure that
arcing does not occur across the bearings.
vi. Field welding shall not be performed on load hooks.
Internal
Rev 1 JUNE 2017
3.7.2 Lubrication
Rev1 May 2017
The crane or component manufacturer's
recommendations as to points and frequency lubrication,
maintenance of lubricant levels shall be maintained.
3.7.3 Records Archive
The Crane Custodian will keep and maintain a log of all

maintenance, repairs and modifications with the name of
the inspector and the date of the inspection. Records of
such maintenance, repairs, and modifications shall be
kept readily available for a period of seven years.
3.8 Standard Hand Signals for Load Handling
Hand communications shall be consistent with standard

convention, agreed upon in advance of the operation, and used
by all personnel involved in the lifting operations. Standard API
hand communications are depicted in the API Hand Signals. (See
Attachment 1)
Internal
Rev 1 JUNE 2017
Attachment 1 Rev1 May 2017

Crane Hand Signals
Figure 12: Standard Hand Signals for Controlling Crane Operation

Courtesy: Compliane Signs (2017),www.ComplianceSigns.com
Internal
Rev 1 JUNE 2017
3.9 Operating Practices

Rev1 May 2017
The qualified Crane Operator (herein referred as the operator)
is responsible for safe operation of the crane and all those
under this person’s control. The following are guidelines for
good operating practices:
i. The operator has the authority to stop and refuse to

handle loads or continue operations if safety is a concern
ii. During periods of bad weather, such as lightning or high
winds, or where the Operator’s ability to see the signal
person is impaired by darkness, fog, rain, etc., crane
operations should be restricted at the Operator’s
discretion. For permissive weather conditions refer MY
ALL E04 024 Guidelines for working in adverse weather.
iii. The operator shall be aware of the operating
characteristics of the crane since Mechanical and non-
mechanical cranes have different operating techniques,
especially with regards to engine speed, control
operations and braking
iv. Operator shall be familiar with the crane and minor
maintenance and adjustments required for safe
operation.
v. Operator shall verify the following prior starting the
crane
 Pre-use inspection has been completed

 All controls are in the “off” or “neutral” position
 Area is clear of all Personnel
vi. For mechanical cranes, the Operator shall test the brakes
each time a load approaching the rated load is to be
handled
vii. Prior raising the load, exposed brakes shall be warmed
and rusted surfaces on the drums cleaned by raising and
lowering the boom and the load lines under slight
pressure.
Internal
Rev 1 JUNE 2017
Rev1 May 2017

viii. Operator shall never start machine movement unless the
load is within his range of vision or the appointed banks
man/ rigger has
ix. given the appropriate signal
x. The operator shall respond to only signals from the banks
man/ rigger, but shall obey an emergency stop signal at
any time, no matter who gives the signal, and
xi. Before leaving the control station unattended for
prolonged period, the operator shall ensure the
following:
 Land any attached load

 Disengaging the master clutch, where applicable
 Set all locking devices,
 Put controls in the off or neutral position
 Stop the prime mover
 Assure that no component of the crane will
interfere with normal helicopter flight operations.
xii. At the end of the shift the Operator shall ensure details
of lifting operations and usage is documented in crane
log book and Operator’s record book.
3.10 Load Handling
The following guidelines shall apply with regards to the

responsibilities of the operator with respect to load handling.
The Operator shall ensure the following.
i. Be aware of the load to be lifted.

ii. All lifting gear being used is certified (i.e. color
coded), of sufficient capacity and is correctly attached
and positioned, to prevent uneven lifting or slippage
of the load
iii. The banks man / rigger has correctly positioned the
hook over the centre of the lifting point; this shall
alleviate any "drift" in the load as it is lifted clear of
Internal
Rev 1 JUNE 2017
the deck,
Rev1
iv. Do not commence lifting baskets May 2017 until
or containers
personnel are clear of the immediate area of the lift,
v. Monitor safe load indicator for a possible overload
situation when the load is being lifted,
vi. Be aware of any activities/obstructions within the
crane radius arc when moving loads across the deck,
vii. Avoid the movement of loads over the heads of other
personnel,
viii. When possible, erect barriers around the lifting zone
to stop personnel from entering the lifting area,
ix. When carrying out any "blind" lifts, monitor the safe
load indicator for any loss or increase in the weight of
the load; this could indicate that the load has
snagged,
x. Keep the load within the specified radius of the crane,
xi. When hoisting loads off a moving supply vessel deck
packed with cargo, be alert for snagging or wrongly
manifested cargo weights,
xii. There is a clear view of the embarkation areas, load
path and landing areas when it is necessary to
transfer personnel to or from a vessel,
xiii. Stop all crane operations during helicopter landings,
unless dispensation has been given to carry out
special tasks,
xiv. Aviation lights remain switched on when the boom is
in the air and when A-frames or masts extend above
the helideck.
Internal
Rev 1 JUNE 2017
Part 2: MOBILE CRANES
Rev1 May 2017
3.11 Mobile Cranes
This section describes the requirement related to the

selection, inspection, maintenance and operation of mobile
cranes.
3.11.1 Standards
The following API & ASME standards, practices and

specifications apply to the design, construction,
installation, operation, inspection and maintenance of
lifting equipment covered in this section.
i. ASME B30.5 – Onshore Mobile Cranes.
ii. API-9A Specification for Wire Rope.
iii. API-RP 2D (sections as applicable).
iv. Department of Safety and Health (DOSH).
v. Local Regulations in Hoist Countries.
3.11.2 Contracted Mobile Crane Requirements
Contracted Mobile Crane requirements are described

by the terms of the Contract, which shall incorporate
the requirements of this Guideline through
appropriate reference to standards and regulations.
3.12 Mobile Crane – Minimum Requirements
Mobile Cranes used in offshore & onshore facilities shall

meet the standards for its applications and be equipped with
the following equipment, devices, and charts:
3.12.1 Minimum Requirements
i. Cab shield or canopy to protect the operator

from falling materials. This shall include all
mobile cranes with operator cabs or
compartments,
ii. Boom angle indicators,
Internal
Rev 1 JUNE 2017
iii. Rated load capacity charts which include all

boom configurations, Rev1 May 2017
iv. Anti-two blocking device and a load indicating

system,
v. Boom stops provided on the boom to prevent the
possibility of over hoisting the boom,
vi. Limit switches on hoist lines,
vii. Lights and horn
viii. Fire extinguisher,
ix. Labelled with their wire rope size, their rated
load capacity, and their weight,
x. Fitted with safety latches.
3.12.2 Safety Devices
Bypassing, disabling or defeat of equipment safety

devices
Mobile Cranes may be equipped with a variety of

mechanical or electronic devices to aid the operator,
provide information to the operator, or override the
operator.
Safety devices (similar as offshore cranes) can only be

bypassed for crane inspection, maintenance, and testing
purposes.
Approval for bypass at any other time shall be:
i. Driven by extreme circumstances.

ii. Supported by a risk-based analysis.
iii. Supported by a MOC, Permit, JHA and approved
work procedures.
iv. Carried out under the supervision of a qualified
Inspector and witnessed by a competent person as
delegated by the Area Authority.
Internal
Rev 1 JUNE 2017
Rev1 May 2017
All lifts, inspections, testing and maintenance for offshore

pedestal cranes shall be documented. As a minimum the
following shall be documented:
i. Pre lift checks performed by the Crane Operator

(Operator).
ii. All maintenance activities.
iii. Change out of critical items.
iv. Test certificates.
v. Load test and results.
vi. Any approved modifications.
vii. Any deviations supported by a MOC with the necessary
approval.
Record retention
All records shall be retained for seven years (7) or such a

time when a critical item with certificate is retired.
3.13 Inspection and Testing of Mobile Cranes
3.13.1 General Requirements
All mobile cranes shall be inspected and maintained

in accordance with any of the following standards
(whichever is stringent) and as acceptable to
PETRONAS CARIGALI:
i. Manufacturer’s recommendations
ii. ASME B30.5 “Mobile Cranes”
iii. As per applicable regulations applicable in
Malaysia and Host Countries
iv. Other industry standards as identified timely
3.13.2 Personnel Competency
Any inspection, maintenance and repair of Mobile

Internal
Rev 1 JUNE 2017
Cranes shall only be carried out by personnel who
are competent by professional Rev1
trade May 2017
or are deemed
proficient and have the necessary skills and
knowledge as recognized by Original Equipment
Manufacturers (OEM), and Industry Standards
acceptable to PETRONAS CARIGALI.
The following recommended inspection procedures,

based on ASME B30.5 Mobile Cranes, shall apply
for all Mobile Cranes. There are three categories
based on the following criteria:
i. Initial Crane Inspections
The initial inspection, also referred as pre-use,

carried out by the Crane Operator (Operator)
prior to the first crane use of the day.
ii. Inspections of Mobile Cranes in regular use
This shall apply for all mobile cranes that have

a continuous idle period of less than one
month.
The inspection required shall be:
 Frequent inspections
 Periodic inspections
Refer Appendix 8.6 for Mobile Crane

inspection check list
iii. Inspections of Mobile Cranes not in regular use.
Inspections for mobile cranes not in

regular use
Inspection procedures for cranes that are not

in regular service are divided into two types
based upon the length of time of the idle
period.
Internal
Rev 1 JUNE 2017
i. Idle period of one (1) to Six (6) months
require an inspectionRev1 May 2017
conforming to the
requirements of “Pre-use Inspections”
before being placed in service. All standby
cranes shall be inspected at least every 6
months.
ii. Idle period of over Six (6) months require
an inspection conforming to the
requirements of “Periodic Inspections”
before being placed in service.
3.14 Programmed Maintenance
All mobile cranes shall have a maintenance programs

established based on the crane manufacturer’s
recommendations. This shall be performed by a competent
person and documented.
Lubrication
All moving parts of the crane for which lubricant is

specified shall be regularly lubricated as follows:
i. All lubrication points specified by the crane

manufacturer regarding type of lubricant,
frequency, and maintenance of levels,
ii. The Crane lubricating systems shall be checked for
proper delivery of lubricant,
iii. Unless equipped for automatic or remote lubrication
or appropriate protection is applied, the crane shall
be stationary while lubrication is performed.
3.15 Load Testing
Mobile cranes shall be functional load tested every fifteen

(15) months in accordance with the manufacturer’s
specifications and limitations and as per “ASME B30.5”.
Internal
Rev 1 JUNE 2017
No load test shall be carried out, unless a thorough
annual inspection is carried outRev1
andMay
any2017
defects
rectified prior load test
Key elements of the load testing process are as follows:

i. New cranes being placed into service,
ii. After a major repair or alteration of a critical
component such as replacement of a hoist, boom
cylinder, slew ring, etc.
iii. Test loads shall be at 110% of the SWL.
Internal
Rev 1 JUNE 2017
PART 3: JIB CRANE
Rev1 May 2017
3.16 Introduction
i. Jib crane is a lifting equipment that is mostly used at

remote or satellite platforms where there is no
requirement for lifting high/heavy load.
ii. Jib cranes are preferred on platforms with minimal lifting
activity as it is quick to install, can be operate by any
qualified personnel and maintenance is relatively simple.
iii. However, with limited SWL capacity, jib cranes pose
difficulty when there is need to heavy loads. This situation
also applies during dynamic lifting from vessel as shock
loading can cause load to exceed way beyond the jib
crane SWL.
3.17 Operations
3.17.1 Jib cranes shall be operated by a qualified personnel.

Such personnel must attend Jib Crane training and
well-versed about the equipment operation, and
have basic knowledge on the equipment inspection
and maintenance. Personnel can be from site
technicians or appointed contractors.
i. Major parts of jib cranes are:
Pillar
Jib
Hoist – consist of hook, sheaves and wire rope
Winch
Slew motor
Controller
ii. Three types of jib crane driver:

Driven by high pressure gas,
Driven by compressed air,
Driven by electric motor.
3.17.2 Jib crane operates by two movements: hoist up and

down, and, swing clockwise and anti-clockwise. Due
Internal
Rev 1 JUNE 2017
to the absence of slip ring, jib crane can only swing
Rev1degree.
to maximum rotation angle of 270 May 2017
3.18 Inspection
Jib crane inspection can be separated into four major

interval:
3.18.1 Pre-use inspection – to be performed by crane

operator.
3.18.2 Monthly inspection – to be performed by crane
operator.
3.18.3 Quarterly inspection – to be performed by crane
Inspector.
3.18.4 Annual inspection – to be performed by crane
inspector.
Refer Appendix 8.11 for Pre-use, Monthly/Quarterly

and Annual inspection check lists.
3.19 Maintenance
Periodic maintenance shall be performed on jib crane on

QUARTERLY basis by qualified crane inspector. Minimum
maintenance to performed are:
i. Wash down crane.

ii. Re-lubricate all moving parts :
iii. Wire rope
iv. Swing gear
v. Sheaves
vi. Hook block
vii. Replace lubrication oil for winch gear, swing motor and
winch motor if applicable.
viii. Re-tighten all fittings for air/gas hose and electric
cable.
ix. Re-tighten bolts for swing motor, winch and swing
gear as per manufacturer’s specification.
Internal
Rev 1 JUNE 2017
x. Ensure proper housekeeping after each maintenance
activity. Residual oil and greaseRev1
shallMay
be 2017
stored on
disposed properly.
Non-routine maintenance shall be performed by crane

technician on a specified basis as following:
i. Wire rope replacement

ii. Running wire rope shall be replaced in every 5 years
interval.
iii. Hoist strip down and overhaul shall be done every two
(2) years. Refer section 3.6.5 for strip down inspection
for Pedestal Crane hoist
iv. Air/Gas hose replacement
v. Hose replacement shall be based on the condition
revealed by weekly and monthly inspection reports.
Total Refurbishment:
i. Crane shall be refurbished at a recommended period

after a thorough assessment by PETRONAS CARIGALI
approved third party inspection agencies.
The brief scope of refurbishment work shall include

the following:
 Review of Crane working history and

calculation of remaining life against usage.
 Physical inspection/survey of Crane to
establish the integrity of the Crane with
regards to structural, mechanical, electrical
and control system components
 Furnish detailed refurbishment activities
check list
 Provide engineering support for
Refurbishment such as design of structural
and mechanical components.
 Fabrication and installation of Refurbished
Internal
Rev 1 JUNE 2017
components
 Conduct load test and Rev1 Mayof
issuance 2017
load test
certificate
ii. Corrective maintenance shall be performed by crane

technician at an on-call basis.
iii. The maintenance shall rectify defects as found during
inspection by crane operator and crane inspector.
iv. Parts provided for corrective maintenance shall be
from OEM, OEM recommended party or technically
equivalent parts as per OEM specifications.
v. Repair on structural parts shall not be performed
without proper assessment of the defect. Repair shall
be executed by certified third party agencies to
restore crane into original SWL capacity.
vi. Crane shall be de-rated if defects are found on crane
structure. Proper de-rating procedure shall
accompany with the process which include MOC, de-
rated load chart, modified operation procedure and
modified inspection plan as instructed by competent
personnel.
Load Test:
i. Proof Load Test
 New, reinstalled, altered, repaired and modified

Cranes shall be load tested before initial use.
 No load test shall be carried out unless a thorough
annual inspection is carried out and all the defects
(if any) have been rectified.
 Load test shall be at 125% of the Crane SWL.
ii. Functional Load Test
 Functional load test shall be done as per the

requirements of local regulations in Malaysia and
Host country regulations.
Internal
Rev 1 JUNE 2017
 No load test shall be carried out unless a thorough
Rev1
annual inspection is carried out andMay 2017
all the defects
(if any) have been rectified.
 Load test shall be at 100% of the Crane SWL.
iii. General Guidelines on Load Testing
Test loads, load application for Proof load test and

Functional load test of Jib Cranes shall follow the
requirements specified in clause 3.5 for Pedestal
Cranes.
Internal
Rev 1 JUNE 2017
PART 4: OVERHEAD AND GANTRY CRANES
Rev1 May 2017
3.20 Overhead and Gantry Cranes
This section describes the requirements related to the

selection, inspection, maintenance and operation of
overhead and gantry cranes.
3.20.1 Selection and Use Criteria
Overhead and gantry cranes are designed and

installed as permanent equipment to serve the lifting
needs of the locations. There is no specific selection
process but strictly based on the following:
i. Suitability of crane for the lifting operations,

ii. Rated capacity of the crane,
iii. Gross weight of the load,
iv. Lift classification and lift plan requirements.
3.21 Inspection
Inspection Requirements
Overhead and gantry cranes shall be inspected in accordance
to applicable regulatory requirements and intervals.
However, inspections may be conducted more frequently
based on manufacturer recommendations, facility
experience, and severity of the working environment.
The following inspection requirements are based on ASME

B30.17: “Overhead and Gantry Cranes”.
Inspection procedures are divided into two categories

depending on usage or duty cycle as follows:
i. Regular Use
Applicable for cranes that are regularly used whose idling

period is less than one month. These cranes shall be
subject to:
Internal
Rev 1 JUNE 2017
• Pre-use Inspection
• Periodic Inspection Rev1 May 2017
3.21.1 Pre-use Inspection
The following is a summary of the pre-use

inspection to be carried out by operators before
and during lifting:
Refer Appendix 8.12 for Pre-use

3.21.2 Periodic Inspection
These inspections shall be conducted on

monthly basis to determine the repair or
replacement of components required to keep
the machine fully functional.
Refer Appendix 8.12 for Periodic

Note: A checklist based on the particular crane

manufacturers’ format and requirements may
be utilized for this frequent inspection
ii. Not in Regular Use
Applicable for cranes that are not in regular service and

whose idle period is one month and more. These cranes
shall be subject annual periodic Inspection based on last
usage.
3.22 Load Test
Overhead and gantry cranes installed at offshore facilities

shall be load tested every two years (2) in accordance
manufacture’s recommendations and in line with ASME
B30.17
Internal
Rev 1 JUNE 2017
Rev1 May 2017

Load test is required when:
i. Prior to first use of the cranes

ii. Alteration, replacement and repair to load
sustaining part / component.
iii. Requirement by regulations in Malaysia and Host
Country.
The following guidelines shall apply:
i. No load test shall be carried out unless a

thorough annual inspection is carried out and
defects (if any) have been rectified.
ii. Load test shall be at 100% of Crane SWL.
Load test shall be conducted by approved third party

agencies, load test certificate endorsed by OSR Inspector for
Malaysian Assets and by Regulatory Authority in Host
Country.
3.23 Maintenance
Maintenance programs for overhead and gantry cranes shall

be developed and implemented based on the crane
manufacturer’s recommendations.
3.23.1 Adjustments and Repairs
Any adjustment and repairs shall be as per

manufacturer’s recommendations. As a minimum
the following precautions (as guided by the Permit
To Work system) shall be taken whenever any
maintenance is repair is carried out:
i. Permit To Work (PTW) and procedures in

place.
ii. Adequate inspection space and other access,
iii. Controls in off positions or locks/warning
signs applied,
Internal
Rev 1 JUNE 2017
iv. Warning signs and barriers in place near the
crane Rev1 May 2017
v. Full time watch/signal person to prevent
disturbance from other operations nearby,
vi. Starting rendered inoperative,
vii. Boom and blocks properly secured,
viii. Hydraulic systems relieved,
ix. Runway barriers in place, and
x. Tag/ lockouts in place,
xi. Procedures for returning the crane back to
service.
3.23.2 Lubrication
All moving parts of the crane must be lubricated

regularly as per the following:
i. Lubricate all points as specified by the crane

manufacturer and its frequency.
ii. Use the correct type of lubricant.
iii. Check for on time delivery of lubricant,
iv. Crane shall not be operated while lubrication
is performed.
3.24 Operation
Overhead and gantry cranes must be operated as per the

manufacturer’s operating instructions and further guided by
the operating procedures and precautions detailed in ASME
B30.17: Overhead and Gantry Cranes.
This section provides a summary of key basic operating

guidelines and precautions.
Internal
Rev 1 JUNE 2017
3.24.1 Specific Procedures Only ForRev1

Overhead and
May 2017
Gantry Cranes
Due to the nature of operation, design and load

motion characteristics of these cranes, the following
operational procedures shall be observed:
i. When handling load of rated capacity, the

operator shall test the hoist brake by raising the
load a few inches and apply the brake; Any
slippage or downward motion is unacceptable,
ii. Side pulls are not permitted,
iii. No sudden acceleration or deceleration of the
moving load,
iv. If crane is of variable speed type, always start
with the slowest speed,
v. Change directions only when the crane motor
has been stop.
3.24.2 Other Operating Procedures and Precautions
Other operating procedures and precautions are as

follows:
i. Operators shall be competent in the

operations of Gantry cranes or as authorized
by the Area Authority.
ii. Prior to first use of any hoist during each shift
or day, the operator shall perform the
Frequent, or Pre-Use Inspection and notify
the Area Authority of any hazardous defects
immediately,
iii. The hook shall be positioned directly over the
load so as Ensure the rope is seated in the
drum grooves and in the sheaves (i.e. check
for the signs of slack rope conditions),
iv. The load shall be moved smoothly, slowly,
and never contact any obstructions.
Internal
Rev 1 JUNE 2017
v. The operator shall not lift, lower, or travel the
Rev1
crane whilst anyone is near May
the 2017
load or hook.
vi. The load shall never be lowered below the
point where five wraps of rope remain on each
anchorage of the hoisting drum and shall
include those with lower limit device.
vii. The operator shall not leave the controls
unattended, if the load is suspended over an
area accessible to personnel.
viii. The hoist upper limit device that controls the
upper limit of travel of the load block shall
never be used as an operating control in
ix. Normal operation unless additional backup
means are provided to prevent damage from
over-travel.
x. Hand signals shall be posted clearly at the
work location
xi. To minimize swinging when start lifting.
Internal
Rev 1 JUNE 2017
PART 5: OTHERS
Rev1 May 2017
3.25 Winches

selection, maintenance, and inspection of winches.
3.25.1 Selection Criteria
When selecting a winch, the most important

consideration is the required line pull and length of
wire rope required for the operation.
Some of the selection criteria are as follow:
i. Most of manufacturer’s line pull ratings are

based on half drum performance. The line pull
decreases as the winch drum wind up.
ii. Half drum rating establishes average
performance.
iii. Drum at full capacity can hold 100 meters of
wire rope, while at half drum, only 36 meters is
left.
iv. A Full Drum provides maximum speed and
minimum-pulling force.
v. Half Drum provides medium speed and medium
pulling force.
vi. The First Wrap provides minimum speed and
maximum pulling force.
vii. In extreme case, minimum five (5) wraps
must remain on the winch drum to avoid any
load being transferred to the rope anchor,
which is not a load-bearing component.
3.25.2 Personnel Use
Winches that are used for hoisting and lowering of

personnel must be rated and certified for personnel
use only. No other winch shall be used for
transporting personnel.
Internal
Rev 1 JUNE 2017
3.25.3 Pre-use Inspection
Rev1 May 2017
Prior to using the winch, the followings checks shall
be carried out:
i. Ensure SWL is sufficient with the load to be
lifted.
ii. Ensure color coding, if applicable, is valid and
Winch Tag Number is clearly marked.
iii. Ensure greasing and lubrication.
iv. Check the wire rope guard for any damage /
distortion which may obstruct the rope
movement.
v. Check the winch drum for wear, distortion and
cracks.
vi. Check brake bands and drums for wear, clean
and free from contamination.
vii. Check the automatic brake and check springs,
link arms, and pins when applicable.
viii. Check exposed parts of the piston rod for any
corrosion.
ix. Ensure when power is disconnected all
operating levers return to neutral position
when released.
x. Ensure directional markings are in affixed and
clearly visible.
xi. Ensure correct oil level.
xii. Ensure the correct wire rope is fitted and is
wound in the correct direction.
xiii. Ensure the rope is not over wound on or off
the drum.
3.25.4 Periodic Inspection
The winch assembly shall be inspected regularly in

accordance with the manufacturer’s
recommendations and consistent with the
requirements of the Computerized Maintenance
Internal
Rev 1 JUNE 2017
Management System (CMMS) or equivalent system.
Rev1 May 2017
3.25.5 Maintenance of Winch Frame and Fittings
After each inspection, the winch frame and

associated fittings shall be rectified immediately as
follow:
i. Winch frame is corroded, damaged or

distorted.
ii. Rope drum flanges are chipped or cracked
iii. Rope anchorage is damaged.
iv. Ratchet / pawl is damaged, worn, or
corroded.
v. Brake is worn or slipping.
vi. Gears are worn / damaged.
vii. Loose / missing bolts, keys, or fixtures and
supports.
viii. Color coding, if applicable, has expired and
markings not clearly visible.
3.25.6 Maintenance of Winch Wire Rope
Inspection of winch wire rope shall in accordance to

inspection of wire ropes as defined in Section 4.14:
Safe use of Wire Ropes.
3.25.7 Teardown Inspection and Certification
All winches shall undergo a tear down inspection

every two (2) years or as recommended by OEM,
regulatory requirements or other standards as
acceptable to PETRONAS CARIGALI. This shall
include:
i. Replacement of all defective parts as per OEM’s

specifications.
ii. Repairs consistent with OEM’s
recommendations.
Internal
Rev 1 JUNE 2017
iii. Brake and Line pull test for all hoist after each
tear done inspection. Rev1 May 2017
iv. An inspection certificate complete with the
following information:
 Hoist Model.
 Serial number.
 Name and employer of repair / inspection
Technician.
 Functional test reports and repairs.
3.26 Runway Beams / Monorails

selection, maintenance, and inspection of Runway beams
and monorails.
3.26.1 General Inspection
Lifting support steelwork such Runway beams I

monorails with no moving parts shall be inspected
annually. Regular inspection shall be carried out
and corrective actions taken when any of the
following defects are identified:
i. Any structural defects, damage, distortion,

corrosion, or cracked welds.
ii. Loose or missing bolts.
iii. Damaged or missing end stops.
iv. Tracks not level or running surface uneven
v. Illegible markings, i.e. identification number,
SWL, etc.
3.26.2 General Maintenance
Maintenance requirements are minimal and shall

include general inspection plus the following but not
limited to:
Internal
Rev 1 JUNE 2017
i. Inspection and maintenance as per applicable
regulatory requirements. Rev1 May 2017
ii. Inspection of bolts, fixtures and supports to
insure they are tight and, if necessary, re-
torque.
iii. Inspection of running surface of the track to
ensure it is kept smooth, clean and free of
debris and obstruction.
iv. Ensuring end stops in place, correctly set, and
secure.
3.26.3 General Operation
General operation practices shall include the

following but not limited to:
i. Check the runway beam before use - do not use

defective beams.
ii. Ensure the runway beam is clearly painted and
marked with the Safe Working Load (SWL).
iii. Ensure the SWL is visible from the work floor.
iv. Do not apply side load to the runway beam.
v. Do not let the trolley crash onto the stopper, as
the load will swing and cause a sudden
resultant load increase on the runway
structure.
vi. In case of many lifting machines fitted to the
runway beams, ensure they are properly
arranged to avoid collision or uneven load
distribution onto the runway.
3.26.4 Repair and Certification
All Runway beams I monorails shall be inspected

once a year or as recommended by OEM, regulatory
requirements or other standards as acceptable to
PETRONAS CARIGALI. This shall include:
Internal
Rev 1 JUNE 2017
i. Replacement of all defective parts as per OEM’s
specifications. Rev1 May 2017
ii. Repairs and adjustments as per OEM’s
recommendations.
iii. An inspection certificate complete with the
following :
 Model and manufactures (Equipment tag

number is acceptable).
 Serial number (if any).
 Name and employer of repair or inspection
performed.
 Functional Load test at 100% SWL shall be
performed prior to usage and shall be
performed after repair.
3.27 Fabricated Pad Eyes and Lifting Points
This section describes the requirements related to

inspection and maintenance of Fabricated Pad eyes and
Lifting Points, one of many fixed lifting equipment.
3.27.1 General Inspection
Fabricated Pad eyes and Lifting Points shall be

inspected annually. Regular inspection shall be
carried out and corrective actions taken when any
of the following defects are identified:
i. Damage (chip, bend, etc.)

ii. Distortion
iii. Corrosion
iv. Cracked welds
v. Elongated I stretched bores
vi. Illegible markings (Identification, SWL, etc.)
3.27.2 General Maintenance
Maintenance requirements are minimal and shall

include general inspection plus the following:
Internal
Rev 1 JUNE 2017
i. Inspection and maintenance as per
Rev1 May 2017
applicable regulatory requirements.
ii. Checks to ensure if they are adequately
coated I protected to prevent corrosion.
iii. Annual NDT Inspection of welds (if frequently
used)
iv. NDT test once every three (3) years (if
infrequently used)
3.27.3 General Operation
General operation practices shall include the

following:
Fabricated Pad eyes and Lifting Points shall not be

used for supporting personnel.
Check the pad eye before use - do not use defective
pad eyes.
Ensure the pad eye is clearly identified and marked

with the SWL.
Always use the correct size of shackle to avoid high

stress at loading point.
Ensure the load is applied “in-line” only. Do not

apply side loads (see diagram below).
Figure 13
Internal
Rev 1 JUNE 2017
3.27.4 Cheek Plates
Rev1 May 2017
The profile of the pad eye shall be smooth, free from
any flame cutting marks, and the hole shall be line
bored after the fitting of cheek plates.
Internal
Rev 1 JUNE 2017
PART 6: FORKLIFT Rev1 May 2017
3.28 Introduction
In warehouse, factories, shipyards, freight terminals and

other workplaces, forklifts are widely used to lift, stack and
transfer loads. While forklifts offer a practical materials
handling solution for many business, each year they
continue to be associated with workplace deaths and
injuries. The human and financial cost of forklift related
incidents for employees, industry and community is
substantial.
PTS 18.52.34 FORKLIFT OPERATION provides minimum

requirement and non-mandatory safety & health
recommendations. It shall be used in conjunction with local
regulations, guidelines and statutory requirements.
PTS 18.52.34 applies to all operating facilities where forklift

is used including projects and construction sites. It applies
to anyone, including employees as well as contractors or any
third party responsible for the safe operation of forklifts.
Refer PTS 18.52.34 for detailed inspection and maintenance

checklist for Forklifts.
Internal
Rev 1 JUNE 2017
4.0 LIFTING TACKLES Rev1 May 2017

4.1 Objectives
The following guidelines on Lifting Tackle maintenance and

practices are to ensure that all items for rigging and slinging are
maintained and used in a safe manner.
4.1.1 Minimum Requirements

As a minimum the following shall be adhered:
i. All rigging and slinging shall be carried out by
competent personnel.
ii. Compliance to standards and procedures as defined
in this LEG, acceptable industry standards,
PETRONAS CARIGALI and regulations in Malaysia
and Host Country.
4.2 Identification & Color Coding of Lifting Tackle

4.2.1 Identification
Every item of lifting equipment, portable and fixed shall be

clearly marked with:
i. Identification Number / Tag Number of the item.

ii. Safe Working Load (SWL).
iii. Manufacturer’s recommendations.
iv. As per applicable regulations in Malaysia.
v. As per applicable regulations in the respective
overseas operations.
vi. Other industry standards as applicable.
Internal
Rev 1 JUNE 2017
4.2.2 Color Coding Rev1 May 2017
The following three (3) Color coding is applicable to all lifting

tackles. The color code in use shall be prominently displayed
on an indicator board at the facility.
The following are the suggested colors to be used:
i. PETRONAS Green
ii. Yellow
iii. Blue
Any lifting tackle not bearing the current color code SHALL
NOT be used.
An item found with the wrong color shall be removed from

the facility for inspection and re-certification.
The color red shall only be used to identify items to be

scrapped.
If extra equipment is to be used for one specific job such as

shutdown or wire line work, the items should follow
standardised colour coding as displayed on the facility.
4.3 Tracking System
All lifting tackle must have a tracking system with the following
details:
i. Color Coding,
ii. Inspection Records,
iii. Manufacturer Information,
iv. A card system to show the location where item is being used
in the plant and name of personnel who authorize removal of
the item from the store.
Facilities shall develop a tracking system (if none existing) for all
lifting tackle.
Internal
Rev 1 JUNE 2017
4.4 Test Certificates Rev1 May 2017
The OEM or approved third party certifying agencies shall provide

test certificates for all new or repaired items prior to initial use as
the situation warrants. A copy of this certificates (where applicable)
shall be made available and record retained by the asset owner.
4.5 Personnel Competency
Any inspection, maintenance and repair shall only be carried out

by personnel who are competent by professional trade, or are
deemed proficient and have the necessary skills and knowledge as
recognized by Original Equipment Manufacturers (OEM), API RP 2D
and other Industry Standards.
4.6 Information of Lifting Tackle
All critical lifting tackle shall be inspected for proper operation,

adjustment, and for unusual sounds such as binding noise of the
chain, bearing squeal, etc. Any item inspected found to be
defective shall be replaced.
4.6.1 Maintenance
These actions may include any of the following, depending

on the type of repair required:
i. Adjustments
ii. Lubrication
iii. Cleaning
iv. Replacement of parts.
v. Testing.
The above maintenance actions will be determined by

the following factor:
i. Date of last inspection/test date.
Internal
Rev 1 JUNE 2017
ii. Severity of wear/tear.
Rev1 May 2017
iii. Type of faulty equipment.
iv. Environment.
v. Condition.
vi. Untraceable of test certificates.
4.6.2 Replacement Lifting Tackles
Replacement of lifting tackles parts shall meet or exceed

the original equipment manufacturers’ (OEM)
specifications
4.7. Block/Hoist Replacement
The inspection activities must be conducted regularly. Any defects

shall be reported to Area Authority or the person as delegated for
immediate action.
i. Sign of wear, distortion, cracking, corrosion or other

damages to any part of the block/hoist.
ii. Elongated hooks
iii. Stretched chain
iv. Ineffective or missing safety latches
v. Illegible inspection data information plate
All block / hoists shall be changed out every six (6) months and
sent to an approved workshop for inspection and re-certification.
4.8 Rigging / Slinging Practices
Rigging / Slinging is an integral part of any lifting operations. It is

therefore important that safe work practice as defined in the Permit
to Work (PTW) system shall apply.
i. Select correct hitch that will control and hold the load.
ii. Attach the lifting slings above the load’s Centre of Gravity
(COG).
Internal
Rev 1 JUNE 2017
iii. Select correct lifting equipment for each task.
iv. Inspect the sling prior to use. Rev1 May 2017
v. Protect the slings from sharp edges.
vi. Attach tag lines to the item to be lifted.
vii. Keep all non-essential personnel clear of the load.
viii. Erect barriers around the lift area up to the final set down
point.
ix. Lift the load clear of the deck slowly and check all riggings.
x. Use clear and proper hand signals or radio.
xi. Ensure only the banks man can give out the directions.
xii. The banks man shall be clearly identified by wearing a colored
bib or hat.
xiii. Move the load to the location in a safe manner.
xiv. Keep the load as close to the ground as possible during the
movement of the load.
4.9 Safe Use of Wire Slings
Reference: API-RP 2D & ASME B30.9 and other industry standards
4.9.1 Safe Use of Slings
Slings forms an important part of any lifting equipment

operations and shall be inspected, maintained and used for
its intended purpose.
i. Visually inspect slings condition prior to use.
ii. Ensure weight of lifted load does not exceed the SWL
of the slings.
iii. When using multi leg slings, note that the SWL is
quoted for the included angle at the master link of 0º
to 90º.
iv. Note that the tension in the sling leg varies with the
inner angle at the hook. A single angle is usually
Internal
Rev 1 JUNE 2017
denoted by the inner angle at the lifting points, which
is: Rev1 May 2017
 Two leg slings, the angle between the sling legs,
 Three leg slings, the angle between one leg and

the vertical (0º to 45º)
 Four legged slings, the angle between any two

diagonally opposite legs.
v. Care shall be taken not to “Kink” the sling. Kinked

sling shall be removed from service and replaced.
Kinks are usually caused by:
 Incorrect slinging practice, e.g. Tensioning a
sling over sharp edges or rounded to small
diameter,
 Pulling on a loop accidentally formed in a sling.
vi. Slings shall not be joined together by threading the

sling eyes. They shall be joined by using a shackle of
the same SWL as the slings to be joined
vii. Do not bend the sling around a small diameter. The

minimum radius the sling is 6 times the rope
diameter,
viii. Do not bend slings around sharp edges. This could

damage the sling and reduce the SWL of the sling. Use
wood or other suitable padding as packing around the
sharp edges.
ix. Do not choke sling in the splice area,
x. Do not lift with one leg of a multi-leg bridle sling until

the unused legs are secured,
xi. Lift the load vertically and not in an angle as it will

increase the loading on the sling,
xii. Do not use defective sling. Remove it from worksite.
Internal
Rev 1 JUNE 2017
xiii. Avoid using a hook or pin of diameter larger than the
Rev1into
sling eye. Never force oversize hook Maythe
2017
eye. The
size of hook or pin shall be less than diameter of the
rope.
xiv. The load ratings (available from OEM) shall be

stamped on heavy duty tags and attached to the sling
when received from supplier.
4.9.2 Sling Replacement
Slings, which are integral part of any lifting operations

shall be inspected regularly. Any defects shall be notified
to the Area Authority or the person as delegated for
immediate action.
The following are some of the defects that needs
replacement or rectification:
i. Evidence of wear, distortion, cracking, corrosion,

discoloration due to heat, or other damage to any
part of the sling.
ii. Evidence of movement at splices or ferrules.
iii. Broken or cut wires.
iv. Kinks (some permanent setting due to previous use

around a load is acceptable, but a careful check for
other local damage shall be conducted).
v. Protrusion of the core.
vi. Ineffective or missing safety latches.
vii. Illegible inspection and data information tag plate.
Internal
Rev 1 JUNE 2017
4.9.3 Storage Rev1 May 2017
A good storage practice is as follow:
i. Store the slings in a clean and protected place.
ii. Use only non-acidic lubricants.
iii. Lubricate slings every two (2) months.
iv. Send all wire slings for inspection and certification

every 6 months.
4.10 Safe Use of Synthetic Rope Slings
Reference:
ASME B30.9 and other industry standards Synthetic rope sling is
another important item that needs to be inspected, maintained and
used for its intended purpose.
The OEM or any third party certifying agencies shall proof

load test all new items prior to initial use as the situation
warrants. A copy of this test certificate shall be made
available and record retained by the asset owner.
4.10.2 In-Service Inspection
i. Inspect for abnormal wear
ii. Ensure no powdered fibre between strands
iii. Inspect for broken or cut fibres
iv. Ensure no rotting or acid or caustic burns
v. Inspect for distortion of associated hardware
Internal
Rev 1 JUNE 2017
i. Store the slings in a clean and protected place e.g.

container.
ii. Clean with water and allow drying naturally.
iii. Remove all defective slings from work area.
iv. Send all slings for inspection and certification every 6

months.
4.11 Safe Use of Flat Woven Webbing Slings
Reference: ASME B30.9: Slings and other industry standards

Flat Woven Webbings Slings are also an important
part of any lifting equipment operations. It is therefore
important that these are inspected, maintained used
for its intended purpose

load test all new or repaired items prior to initial use as the
situation warrants. A copy of this test certificate shall be
made available and record retained by asset owner.
4.11.2 In-service inspection
i. Inspect for abnormal wear

ii. Ensure there is no acid or caustic burns
iii. Inspect for melting or charring of any part of surface
iv. Inspect for snags, punctures, tears or cuts
v. Inspect for broken or work stitches and rotting
vi. Solar degradation
vii. Damaged or deformed end fittings
viii. Ensure that wear or elongation does not exceed
the limit set by manufacturer
Internal
Rev 1 JUNE 2017
ix. Illegible inspection and/or data information tag plate
Rev1 May 2017
4.11.3 Storage
i. Store Flat Woven Webbing Slings in a clean and

protected place such as a container.
ii. Clean with water and allow it to dry naturally.
iii. Remove all defective slings from work area.
iv. Caution: never use chemicals to clean webbing

slings as it will damage the fibres and stitching
v. Send all slings for inspection and certification every

6 months.
4.12 Safe Use of Round Slings
Reference:
ASME B30.9 and other industry standards
Round slings are another important item between the lifting
machine and load. It is therefore important that these are
inspected, maintained and used for its intended purpose. The
following guidelines shall apply:

load test all new or repaired items prior to initial use as the
made available and record retained by the asset owner.
4.12.2 In-Service Inspection
The following guidelines are recommended for the safe

use of round slings:
i. Check and ensure round slings are not defective prior

to any lifting operations
Internal
Rev 1 JUNE 2017
ii. Ensure the round sling engages correctly with fittings
Rev1
and the lifting hook. Ensure that May 2017
smooth radii are
formed which allow the sling to naturally flattened
under load
iii. Ensure that round slings are not twisted or crossed

and fittings are not over crowded
iv. Ensure there is no weakening or softening of the

material on the sling surface due to chemical attack
v. Ensure the use of packing to protect the round sling

from sharp edges
vi. Ensure there is no lifting on the point of any hook
vii. Ensure that the round slings are never exposed to

direct heat or flames
viii. Do not use round slings with cut or damaged covers
ix. Ensure the correct color code is on the sling prior to

use
4.12.3 Storage
i. Clean with water and allow drying naturally.

ii. Send all slings for inspection and certification every
Six (6) months
4.13 Safe Use of Hooks, Shackles and Other Lifting Gears
Reference:
ASME B30.9 and other industry standards
Hooks, Shackles and other lifting gears are an integral part
between the lifting machines and load. It is therefore important
that these are also inspected, maintained and used for its intended
purpose.
Internal
Rev 1 JUNE 2017
4.13.1 Safe Use of Hooks Rev1 May 2017
i. All hooks (excluding grab hooks) shall be equipped

with safety catches.
ii. Check and ensure hooks, are not defective prior to a
lifting operations
iii. Any sign of wear greater than 10 % at point of rope
contact shall be removed from service
iv. Any sign of crack, sharp nick or gouge on the surface
of hooks shall be removed from service
v. Any modification of the hook is not permitted
vi. Inspection procedures and record keeping
requirements for hooks in regular service shall be
determined by the kind of equipment in which they
are used.
vii. The OEM manufacturer or any third party certifying
agencies shall proof load test all new and repaired
hooks prior to initial use to ensure compliance with
the recommended standards.
viii. Proof load test certification and inspection records
shall be retained by asset owner for the life of the
hook (applicable to single hook, not applicable if hook
is part of equipment)
ix. Hooks shall undergo an inspection annually or as and
when required and witnessed by a certified third party
agency
4.13.2 Proof load Test
The OEM or approved third party certifying agencies shall

proof load test all new items prior to initial use as the
made available and record retained by the asset owner
Internal
Rev 1 JUNE 2017
4.13.3 Safe use of Shackles Rev1 May 2017
The following guidelines are provided for the safe use of

Shackles.
i. Check and ensure shackles are not defective prior to

lifting operations.
ii. Use suitable type of shackle and pin for each

application
iii. Ensure that shackles are fitted so that the body takes
the load along its center line and is not subjected to
bending.
iv. Ensure that when connecting several sling legs to

the shackle, they are positioned at the bow of the
shackle to avoid forces that tend to spread the
shackle jaw.
v. Ensure the pin is screwed fully / tightly into the

shackle eye,
vi. Ensure that the thread is fully tightened to the

shackle body, but not to cause damage / deform the
body.
vii. With bolt and nut type pins, ensure the nut jams on
the inner end of the thread and not on the eye of the
shackles.
viii. The bolt shall be free to rotate with minimal side

float. The split cotter pin must be fitted before
making a lift.
ix. Avoid applications where movement can unscrew

the pin e.g. when used with a sling in choke hitch.
Position the pin away from the moving part or use
a nut and bolt type pin, which can rotate
without unscrewing.
x. Never replace the pin with a bolt.
Internal
Rev 1 JUNE 2017
xi. Wear in shackles greater than 10 % on point of rope
contact shall be removed from Rev1 May 2017
service.
xii. Any sign of crack, sharp nick or gouge in the surface

of shackles shall be removed from service
xiii. New items Proof load tested and certified before first
usage
xiv. Any modification of the shackles is not permitted
xv. Record when due for next inspection.
4.13.4 Safe Use of Eyebolts

Eyebolts
i. Check the eyebolts before use - do not use a defective

eyebolt.
ii. New items Proof load tested and certified before first
usage
iii. Always check the thread of both the eyebolt and hole,
ensure they are compatible, fully formed, of sufficient
length, undamaged and clear of any debris which may
prevent proper engagement.
iv. Ensure the contact surface around the hole is flat,

clean, perpendicular to the thread axis and big enough
to support the entire eyebolt collar.
v. Tighten the eyebolt down firmly by hand. The collar

must sit evenly on the contact surface.
vi. Never use bars, grips or wrenches to tighten eyebolts.
vii. With collar eyebolts used in pairs, ensure that both

the eyes are in the same plane. Using shims is
acceptable, but not machining the collar or over
tightening.
Internal
Rev 1 JUNE 2017
viii. A hook of similar capacity must be engaged directly
into the eye of a dynamo eyeboltRev1 May
or link of 2017
an eyebolt
with link. Collar eyebolts must be fitted with a shackle
or link to accept hooks.
ix. The hooks must move freely and are not permitted to
be wedged or forced into position
x. Never reeve a sling through the eye links or shackles

fitted to eyebolts used in pairs as this will impose a
severe resultant force onto the eyebolts.
xi. Dynamo eyebolts are only suitable for axial loading.

Never use dynamo eyebolts for angular loading
xii. When using eyebolts with multi leg slings, use

eyebolts with links or collar eyebolts taking care to de-
rate them for angular loading.
xiii. Where a single eyebolt is used, use a swivel or swivel

hook to prevent the eyebolt unscrewing if the load
rotates.
xiv. Ensure the correct color code is on the sling prior to

use.
xv. Do not attempt to straighten bent eyebolts or re-cut

the thread. No repairs are allowed on eyebolts.
4.13.5 Storage

i. Clean and protect from corrosion and thread damage.
ii. All eye bolts shall be sent for inspection and re-
certification every Six( 6) months
Internal
Rev 1 JUNE 2017
Types of Eye Bolts Rev1 May 2017
Regular Nut Eye Bolt Shoulder Nut Eye Bolt Machinery Eye Bolt
G-291 G-277 S-279
Figure 14: Types of Eye bolts
4.13.6 Safe use of Turnbuckles

Turnbuckles
i. Check the turnbuckles before use - do not use a

defective turnbuckle
ii. New items Proof load tested and certified before first
usage
iii. Select the correct type of turnbuckle and suitable for

the application
iv. If used in high vibration area, lock the end-fittings of

the turnbuckle to the frame or body to prevent
unscrewing and possibly releasing the load
v. Check for worn, stretched or damaged threads
vi. Ensure the eye or hooks are not worn or stretched
vii. Ensure clevis pin or pin holes are not worn or stretched
viii. Ensure the correct color code is on the Turnbuckles

prior to use.
Internal
Rev 1 JUNE 2017

Equipment returned to storage shall be inspected,
cleaned, inspected, and lubricated (as appropriate).
4.13.8 Safe Use of Plate Clamps

Plate Clamps
i. Check the clamp before use- do not use a defective

plate clamp
ii. New Items to be Proof load tested and certified before

first usage
iii. Ensure that the clamps are suitable for the thickness
of plate to be lifted
iv. Never exceed the maximum or minimum

thickness, for which the clamps are designed
v. Put the clamp onto the plate as far as it will go
vi. Do not use clamps at an angle to the edge of the plate

or for lowering from vertical or horizontal or vice
versa, unless they are designed for that purpose
vii. Keep the jaws, (which use a friction grip material to

hold the plate) free of oil, grease and other
contaminant.
viii. Never use the plate clamps on hard or polished plate

unless they have been specifically manufactured for
that purpose
ix. Take extra care to ensure the plate is fully supported

before attempting to release the clamp
x. Keep all persons clear of the danger zone. Note that a

falling plate can glide sideways whilst a large thin plate
is likely to glide further
Internal
Rev 1 JUNE 2017
xi. Check for defects and damage such as:
Rev1 May 2017
 Distortion to fixed and moving jaws
 Frame opening bent out or cracked
 Insecure, worn, or bent pins, bolts, etc.
 Worn friction grip material
 Damaged, bent, or unsatisfactory locking lever
 Tight, bent, or damaged clamping threads
 Unacceptable corrosion
4.13.9 Storage
i. Clamp returned for storage shall be inspected and

cleaned.
ii. The teeth of Jaws shall be inspected for wear and

tear, and shall not be sharpened or re-cut
4.13.10 Safe use of Lifting Beams and Frames
The following guidelines are provided for the safe use

of Lifting Beams and Frames.
(Note: Many lifting beams are designed for a specific
job function and shall not be used for other purposes).
i. Check the lifting beams and frames before use

— do not use a defective beam
ii. The weight of the beam and the attachments,

must be added to the weight load when calculating
the total load that will be imposed on the hook
iii. The beam weight shall be clearly marked on the

beam
iv. Ensure that the SWL on the lifting points is not

exceeded. Extra care is needed where these points
Internal
Rev 1 JUNE 2017
are adjustable or where there is a choice of lifting
points Rev1 May 2017
v. Ensure that the load remains stable and that the

beam remains at its intended attitude during use
vi. Extra care is required when the lifting points are

below the centre of gravity of the load
vii. Use tag lines to control long loads
viii. Do not permit the beam to foul the undersides

of the crane or any other obstructions when rising
or transporting loads
4.13.11 Maintenance Lifting Beams and Frames
Maintenance requirements for Lifting Beams and Frames

are minimal. A good maintenance practice includes the
following:
i. Regularly inspect for any defects
ii. Beam distorted, damaged, or corroded
iii. Worn, loose, or missing bolts or cracked welds
iv. Attachment points worn, damaged, or distorted

holes and eyes worn or elongated
The OEM or approved third party certifying agencies shall

proof load test all new or repaired items prior to initial
use as the situation warrants. A copy of this test
certificate shall be made available and record retained by
the asset owner.
Internal
Rev 1 JUNE 2017
4.14 Safe Use of Wire Ropes Rev1 May 2017
References:
API-RP 2D, API 9A, 9B, ISO 4309 and other industry standards
All wire ropes are an integral part of any lifting equipment requiring
periodic maintenance and replacement. It is therefore important
that compliance to maintenance procedures and guidelines are
strictly adhered to.
When broken wires appear, it is an indication of an imminent failure

and therefore inspection shall be more frequent and timely
replacement of the wire rope.
4.14.1 Replacement Criteria
i. Similar diameter, length, construction, grade (either

galvanized or bright) and minimum break load
ii. End connection similar with originally furnished or as
recommended by OEM
iii. Load Tested and certified to specification by OEM
iv. Copies of documents shall be kept and made available
4.14.2 Replacement Guidelines
i. All running wire ropes shall be replaced after 5 years

in service.
ii. All pendants wire ropes shall be replaced after 8 years
in service
The minimum replacement criteria are as defined in API-

RP 2D Appendix G. This includes but not limited to the
following:
Running Ropes used in Boom Hoist:

i. Six (6) randomly distributed broken wires within
one (1) lay length, (See Figure below)
Internal
Rev 1 JUNE 2017
ii. Three (3) broken wires in one strand within one (1)
lay length. Rev1 May 2017
Running Ropes of Rotation Resistant Construction used

on the Main and Auxiliary hoist:
i. Four (4) randomly distributed broken wires within

one (1) lay length
ii. Two (2) broken wires in one strand within one (1)
lay length.
Standing Ropes such as Pendants:
i. Three (3) broken wires within one (1) lay length
ii. Two (2) broken wires at the end connection
One (1) valley break may indicate internal loop

damage requiring close inspection of this section of
rope.
When two (2) or more valley breaks are found in

one (1) lay length the rope shall be removed from
service.
One rope lay

Distance of one rope lay
Figure 15: Rope Lay
4.14.3 Installation Guidelines
i. Avoid introduction of twist into the rope while

reeving, remove the rope from the same side of the
reel as it will be operated on the drum, top to top or
bottom to bottom
Internal
Rev 1 JUNE 2017
ii. Spool rope under tension to properly seat the rope
on the drum. Rev1 May 2017
iii. Particular care shall be taken in spooling the first

layer
iv. Care shall be taken to ensure that the boom, main

and auxiliary hoist systems reeved for the specific
crane configuration in use
v. When reeving through the sheave system, avoid

kinks or looping which could damage the rope
vi. Cut off all welded ends of the rope before installing
in a wedge socket or wedge in the drum
vii. Swivels shall not be used at the dead end of multi-

part hoist systems with rotation-resistant rope
viii. Swivels shall be installed at the dead end of single

part systems following the recommendation of
the crane and/or wire rope manufacturer. The
swivel is typically an integral part of the overhaul
ball and may be of a top or bottom swivel design
ix. New rope, when first installed, shall be broken in by

slowly lifting and lowering a light load several
cycles through the entire hoist mode. Begin cycling
the rope at zero degrees boom angle to minimize
twist caused by sheave resistance
x. Do not install rotation resistant rope to replace boom

hoist ropes
4.14.4 Maintenance of wire ropes
All wire ropes are load bearing critical components and

shall be internally and externally examined for their true
conditions. The practice of inspecting a wire rope
externally and assuming the result shall be avoided.
Internal
Rev 1 JUNE 2017
Experience has shown that that internal deterioration,

Rev1 May 2017
mainly as a result of corrosion and the normal progress of
fatigue, is the prime cause of many rope failures.
Lubricate the wire ropes in accordance with API 9B

Application, Care and Use of Wire ropes for Oil Filed Service
4.15 Recommended Inspection Tools
i. Steel tapes
ii. Sheave grove gauges
iii. Quality calipers and or micrometers with at least 1/1000th

of an inch resolution
iv. Chalk or tape measure
4.16 Internal Examination of Wire Rope
(Based on Annex D of ISO 4309)

The following method of inspecting the internal condition of a wire
rope is as follows:
i. Rope to be examined are at zero tension
ii. Check lubrication
iii. Clamps to be attached firmly to the rope as shown in the

following diagram.
iv. Apply a force and when the wire ropes slightly open
Internal
Rev 1 JUNE 2017
Rev1 May 2017
v . Using a small probe, such as a screwdriver, remove grease

or debris which could hinder observation of the interior of
the rope
vi. The essential points, which shall be observed, are:
 The state of the internal lubrication
 The degree of internal corrosion
 Indentation of wires caused by pressure or wear
 Presence of wire breaks (these are not necessarily easily

visible)
After examination, introduce a service dressing into the opened

part and rotate the clamps with moderate force to ensure correct
replacement of the strands around the core.
After removal of the clamps, the outer surface of the rope is to be

greased. Since it is impossible to examine the interior of the wire
rope over the whole of its length, suitable sections must be
selected.
In the case of wire ropes, which wind onto a drum or pass over
pulleys or rollers, it is recommended that the lengths, which engage
the pulley grooves when the appliance is in a loaded condition, shall
be examined.
Those localized areas in which shock forces are arrested (i.e.

adjacent to drum and jib head pulleys) and those lengths, which
are particularly exposed to the weather for long periods, shall also
be examined.
Attention shall be given to the area of rope close to its termination;

this being particularly important in the case of fixed ropes, such as
stays or pendants.
Internal
Rev 1 JUNE 2017
Rev1 May 2017
4.17 External Examination – Cracking Noise
To detect wire breaks inside the rope the following procedure is

another proven method:
Figure 16
i. Run the bend back and forth through the length
ii. Check lubrication
iii. Run cotton to check for broken wires
iv. Hold a length of the rope up to the ear and bend
v. A cracking or popping sound indicates there are broken

wires inside the rope
vi. Carry out this check at 3 locations along the length of

the rope: at the tip, at the center and as close to the
other end.
vii. Replace if cracking or popping sound is heard.
4.18 Inspection of Wire Rope at the Fitting
Inspect the wire rope and replace the fitting if there is any broken
wire
Internal
Rev 1 JUNE 2017
Rev1 May 2017
Figure 17
4.19 Lubrication (Recommended Methods)
i. Pouring of lubricant onto rope as it passes over a sheave
ii. Swap the rope when not in motion with lubricant soaked rags
iii. Brush of spray with lubricant
iv. Pressure lubricant
4.20 Factors Affecting Rope Performance
Refer API 9B for details on factors which affects rope performance
Multi-coiling of the rope on the drum can result in severe distortion

in the underlying layers.
Bad coiling (due to excessive fleet angles or slack winding) can

result in mechanical damage, shown as severe crushing, and may
cause shock load during operation.
Small diameter sheaves can result in permanent set of the rope,

and will certainly lead to early wire breaks.
Oversize grooves offer insufficient support to the rope leading to

increased localized pressure, flattening of the rope and premature
wire fractures. Grooves are deemed to be oversize when the groove
diameter exceeds the nominal rope diameter by more than 15%.
Internal
Rev 1 JUNE 2017
Undersize grooves in sheaves will crush and deform the rope, often
Rev1 May
leading to two clear patterns of wear and associated 2017
wire breaks.
Excessive angle of fleet can result in severe wear of the rope due
to scrubbing against adjacent laps on the drum.
Rope deterioration at the Termination may be exhibited in the form

of broken wires. An excessive angle of fleet can also induce rotation
causing torsion imbalance.
Particular attention shall be paid to those sections of rope which

experience has shown to be liable to deterioration. Excessive wear,
broken wires, distortions and corrosion are the more common
visible signs of deterioration (see below).
Wear is a normal feature of rope service and the use of the correct
rope construction ensures that it remains a secondary aspect of
deterioration. LUBRICATION may help to reduce wear.
Broken wires are a normal feature of rope service towards the end
of the rope’s life, resulting from bending fatigue and wear. The local
break up of wires may indicate some mechanical fault in the
equipment. Correct lubrication in service will increase fatigue
performance.
Distortions are usually as a result of mechanical damage, and

if severe, can considerably affect rope strength. Visible rusting
indicates a lack of suitable lubrication, resulting in corrosion. Pitting
of external wire surfaces becomes evident in some circumstances.
Internal corrosion occurs in some environments when lubrication is

inadequate or of an unsuitable type. Reduction in rope diameter
will frequently guide the observer to this condition. Confirmation
can only be made by opening the rope with clamps or the correct
use of spike and needle to facilitate internal inspection.
Internal
Rev 1 JUNE 2017
4.21 Slinging Angle Information Rev1 May 2017
Figure 18
At SWL =
0° SWL of one sling x 2
30° SWL of one sling x 2 x 0.966
Table 3
Above table does not include effect of offshore dynamic lift. Refer
PTS 11.22.17 Marine Lifting design for additional factor of safety
on offshore dynamic lift.
In addition to sling angle, an additional factor, which requires
consideration, is the Mode Factor, as is illustrated in the following
figures.
Figure 19
Internal
Rev 1 JUNE 2017
Rev1 May 2017
Figure 20
Figure 21
To determine the configuration-specific SWL, multiply the SWL of

one leg by the Mode Factor “M”. Note that if slings are used with a
choke or reeving hitch, the angle at the bight must be considered.
Internal
Rev 1 JUNE 2017
4.22 Slinging of Tubular Rev1 May 2017
The slinging of tubular is a very common lifting operation. Slings

ideally shall be positioned approximately 25% (of the total length)
in from either end. This practice significantly reduces sagging of
the tubular to a minimum. Not Recommended for Offshore Lifts.
Figure 22
4.23 Wrapping
Slings shall be double-wrapped with a choke hitch, taking care not

to cross over the wires on the underside of the pipe or tubular
bundle. The choke hitch shall be pulled tight to secure the bundle
and a bulldog grip shall be fitted. A tie wrap shall also be fitted to
prevent the reeved eye from slipping over the bulldog if the bundles
loosen in transit. Not recommended for Offshore Lifts.
Figure 23
Internal
Rev 1 JUNE 2017
This type of hitch compresses the load and prevents it from slipping
Rev1 May 2017
out of the sling. Each sling shall have a SWL approximately equal
to the gross weight of the load. With respect to the bulldogs, only
DIN 1142-type bulldogs are permitted for this use and, in order to
prevent damage to the wire rope, personnel shall ensure that
bulldog grips are not over tightened.
4.24 Bundles
Care shall be taken when releasing bundle slings, as individual

tubes are likely to roll. In addition, the landing site shall be
identified and prepared so that the bundles may be landed without
crushing the slings. Not recommended for Offshore Lifts.
Figure 24
4.25 Stacking
When tubular are to be stacked, personnel shall ensure that timber

packing or a similar material is inserted so as to prevent damaging
the slings. Not recommended for Offshore Lifts.
Figure 25
Internal
Rev 1 JUNE 2017
4.26 Other Concerns Rev1 May 2017
When slinging cargo, ensure to never sling tubes of different

diameters
Figure 26
When slinging cargo, do not sling a mixture of tubular, angle, flat

bars, etc. as this may result in the smaller items slipping out. Not
recommended for Offshore Lifts.
Figure 27
When slinging the cargoes, never tighten the choke by hammering

as this will increase the effective sling angle, resulting in a
weakening of the sling.
Internal
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Rev 1 JUNE 2017
4.27 Protection of Slings & Loads Rev1 May 2017
4.27.1 Protection of Slings
Avoid bending the sling (wire, chain or fibre) around sharp

corners or edges as this will severely weaken the sling and
often result in sling failure. Use suitable packing to protect
the sling.
Figure 28
4.27.2 Protection of Loads
Apart from protecting the lifting slings, it is the nature of

certain loads that they require protection from the slings.
In most cases where polyester slings cannot be used,
timber packing is often suitable.
Figure 29
Internal
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Rev 1 JUNE 2017
Rev1 May 2017

4.28 Selection and Labelling of Slings
Sling selection is an integral part of the lift planning

process. Slings s h a l l b e selected to ensure they are:
i. Not loaded beyond the manufacturer’s recommended safe

working loads
ii. Used within the working load limits specified in the applicable
loading tables from the manufacturer or the referenced
standards.
Lift planners, riggers, and work leaders involved in rigging shall:
i. Be knowledgeable regarding sling types, sling applications

and limitations
ii. Be aware of applicable regulatory requirements and
industrial standards.
iii. Not use natural or synthetic rope for rigging crane loads.
Labelling of Slings
All slings shall have durable and legible labels, permanently affixed
by the sling manufacturer. The labels (see next page) shall contain
the following information as guided by ASME B30.9 requirements:
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Rev1 May 2017
Type of Labeling Requirements

Sling
Name, symbol, or trademark of manufacturer
Chain Sling Chain grade and size
Rated load and angle on which it is based
Color Coding
Wire Rope Rated load for the type of hitches and angle basis
Diameter or size
Color Coding
Web Name, symbol, or trademark of manufacturer
Synthetic Manufacturer’s code or stock number
Rated load for the type of hitches and angle basis
Type of material and construction
Color Coding
Synthetic Manufacturer’s code or stock number
Round Rated load for the type of hitches and angle basis
(endless) Type of material and construction
Sling Cover material if different from core material
Color Coding
Table 4
Internal
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Rev 1 JUNE 2017
5.0 LIFTING LOADS Rev1 May 2017

5.1 Lifted Loads
This section describes requirements related to selection, inspection

and maintenance of lifted equipment for personnel and cargoes.
5.1.1 Categories of Lifted Loads (equipment)
There are three (3) categories of lifted loads (equipment)
i. Personnel Platforms
ii. Personnel Transfer Device
iii. Containers
The following standards shall be referred to for the design,

certification and inspection of the above equipment.
i. API2C: Offshore Pedestal Mounted Cranes

ii. EN12079: Offshore Containers and associated lifting
sets.
iii. ASMEB30.23: Personnel Lifting Systems.
5.2 Personnel Platform
This section describes the standards and requirements related

to operation and maintenance of Personnel Platforms.
5.2.1 Specifications

i. Personnel transfer platform shall be equipped with a

guard rail and enclosed at least from the toe board to
the mid-rail with solid construction or expanded metal
with openings less than 1/2 inch (1.27 cm).
ii. Platform deck shall be installed with anti-skid surface.
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iii. Access gates, if installed, shall not swing outward
during hoisting. Rev1 May 2017
iv. Sliding or folding gates shall be equipped with a

locking device to prevent accidental opening.
v. Overhead protection may be provided if there is

exposure to falling objects.
vi. Sufficient headroom shall be provided to allow

personnel to stand.
vii. The designed should minimize tipping of the platform

due to movement of personnel inside the platform.
viii. The maximum number of personnel shall be clearly

stamped for the designated personnel platform
Note: Personnel platform shall not be used for any other

purpose other than hoisting personnel only.
5.2.2 Rigging Requirements
Other equipment used in personnel transfer platform shall

comply with the following:
i. When a wire rope bridle is used to connect the

personnel rigging platform to the load line, each bridle
leg shall be connected to a master link or shackle in
such a manner to ensure that the load is evenly
divided among the bridle legs.
ii. Hook latches on load blocks and overhaul ball
assemblies or other types of assemblies, shall be of a
type that can be closed and locked. Alternatively, a
safety pin bow shackle with a bolt, nut and retaining
pin must be used.
iii. Wire rope, shackles, rings, master links and all other
rigging hardware must be capable of supporting of at
least 5 times the maximum intended load to be lifted.
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Rev 1 JUNE 2017
iv. Where rotation resistant rope is used, the slings shall
be capable of supporting of atRev1
leastMay
10 2017
times the
maximum intended load.
v. All eyes in wire rope slings shall be fabricated with
thimbles,
vi. Bridles and associated rigging for attaching the
personnel platform to the hoist line shall be used for
the platform and the necessary personnel only
5.3 Inspection and Testing
Personnel transfer platform shall be inspected in accordance to

applicable regulatory requirements and other guidelines as
applicable
As a minimum the following pre-use inspection and trial lift shall

be carried out prior to any personnel lifting
5.3.1 Pre-use Visual Inspection
A visual inspection of the personnel transfer platform shall

be carried out before each use. This shall include:
i. Ensure that wire rope; shackles, rings, master links

and all other rigging hardware are in satisfactory
condition.
ii. Access gates, if installed, shall not swing outward.
iii. Ensure that sliding or folding gates locking device are
functional
5.3.2 Trial Lift
Upon successful completion of the Visual Inspection, a trial

lift shall be performed before allowing personnel go on
board the personnel transfer platform. The procedure shall
include:
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Rev 1 JUNE 2017
i. Load the platform with weights of at least the
anticipated lift weight. Rev1 May 2017
ii. Lift the load and move from location the personnel enter
the platform to the location at which the personnel
platform is to be hoisted and positioned.
iii. During the course of the Trial Lift, the Operator shall
ensure that:
 All systems, controls and safety devices are
activated and fully functional.
 No interference exist,
 All configurations necessary to reach those work
locations shall allow the operator to remain under
the 50% limit of the hoist’s/crane’s rated capacity.
5.3.3 Final and Balance Check
After the trial lift and just prior to hoisting personnel, the
personnel transfer platform shall be hoisted a few inches
and checked to ensure that it is secure and properly
balanced.
5.3.4 Six (6) Monthly Inspection
An inspection of the personnel transfer platform shall be

conducted every six months and shall include of the
following items:
i. Structural integrity of the personnel platform,

ii. Integrity of all fasteners, welds, and attachments,
iii. integrity of all slings, shackles, and associated rigging,
iv. Antiskid surface not excessively worn.
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Rev 1 JUNE 2017
5.3.5 Annual Inspection Rev1 May 2017
An inspection of the personnel transfer platform shall be

conducted annually and shall include of the following items:
i. All checks in the six (6) monthly inspection,

ii. Proof Test - At each lift site, prior to hoisting personnel,
the platform and rigging shall be proof tested to 125%
of the platform rated capacity. Procedure for load
testing shall include:
 Holding the platform in a suspended position for 5
minutes with the test load evenly distributed on the
platform. After load testing a competent person shall
inspect the platform and rigging.
 Any deficiencies found shall be corrected and
subjected to same load test
iii. Upon testing, a sample of the inspection and re-
certification plate (see below) shall be affixed on the
Personnel Platform after completion of the test.
Figure 30
5.4 Personnel Platform Operation
This section will provide guidelines for safe operations of the

Personnel Platform.
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Rev 1 JUNE 2017
5.4.1 Loading Guidelines Rev1 May 2017
i. Do not load the platform in excess of rated load

capacity
ii. Do not carry beyond the approved number of
personnel, tools, equipment and material necessary to
perform the intended work.
iii. Do not hoist any material or tools when not hoisting
personnel
iv. Distribute evenly the materials and tools when used
during a personnel lift.
5.4.2 Work Practices
i. Boarding a suspended personnel platform is

prohibited,
ii. Before allowing personnel to board, ensure the
platform is secured rigidly to a structure, provided
that securing to the structure will not create an unsafe
situation
iii. Personnel shall stay inside the platform fully during
raising, lowering, and positioning
iv. Tag lines shall be used unless their use creates an
unsafe condition
v. The crane operator shall be at the controls all the
times, especially when the engine is running and the
platform is occupied
vi. The operator and all personnel working in suspended
platforms must understand and use API standard
hand signals
vii. Personnel being hoisted shall remain in continuous
sight of, and in direct communication with, the
operator or designated signal person.
viii. Except hoisting over water, personnel occupying the
platform shall use an approved body belt/harness
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Rev 1 JUNE 2017
system with lanyard appropriately attached to the
Rev1 May
main/auxiliary block, or to a structural 2017within
member
the personnel platform capable of supporting a fall
impact for personnel using the anchorage. Before
deployment Personnel platform intended for Offshore
lift, shall be subjected to risk analysis and TA
approval.
ix. Over the water, personnel occupying the platform
shall use an approved lifejacket or Personal Floatation
Device and a workboat shall be provided and arranged
for immediate launching.
x. Hoist ropes shall be free of all defects, such as kinks,
cuts, crushed or broken wires, etc.
xi. Multiple part lines shall not be twisted around each
other,
xii. The primary attachment for the lifting hook shall be
entered over the platform
xiii. If the load line has been slacked then the hoisting
system shall be inspected to ensure all ropes are
seated properly in sheaves and on drums
xiv. Any safety hazard and defects found during
inspections shall be corrected or repaired before
hoisting personnel.
xv. To install additional safety sling of stinger
5.5 Cranes for Lifting Personnel Platform
The cranes used for Personnel Platforms shall comply with the
following guidelines:
i. Hoisting of any personnel transfer platforms shall be

performed in a slow, controlled and cautious manner with no
sudden movements of the crane or derrick, or the platform
ii. Load and boom hoist brakes, swing brakes, and locking
devices such as pawls or dogs shall be engaged when the
occupied personnel platform is a stationary position
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Rev 1 JUNE 2017
iii. The crane shall be on a uniform level and located on firm
footings. Rev1 May 2017
iv. Those cranes with outriggers shall have them fully
deployed (as per OEM Specifications) when hoisting
personnel.
v. Cranes with variable angle booms shall be equipped with a
boom angle indicator, visible to the operator from his
operating position.
5.6 Personnel Transfer Device
This section describes the standards and requirements related

to operation and maintenance of Personnel Transfer Device.
5.6.1 Definition of Personnel Transfer
Personnel transfer is the movement of personnel from one

installation, or vessel, to another vessel or installation by
using a purpose built basket or carrier, lifted by an on-
board crane.
5.6.2 Common type of Personnel Transfer Device
A "Billy Pugh" type personnel transfer device (typical type

is the X-871 and X-904).
5.6.3 Design and construction
The Billy Pugh X-871 personnel transfer devices are

manufactured under the American Bureau of Shipping
(ABS) equipment approval program for compliance with
the requirements of API Specification 2C, 6th edition.
Internal
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Rev 1 JUNE 2017
5.6.4 Minimum Specifications Rev1 May 2017
The “Billy Pugh” Personnel Transfer Device shall meet the

following minimum specifications (See Figure 1):
i. API Spec 2C 6th edition S.W.L 500 kg with a design

factor of 10.
ii. Lifting ring - 7/8" forged steel.
iii. Has an overall length of 29 feet (stabilizer and load
line extended),
iv. Incorporates a rough seas type net
v. Has hand spliced eyes (no swages)
vi. Is equipped with a safety load line
vii. Has a stabilizer unit covered with plastic
impregnated fabric
viii. Has ¾-inch netting lines of 9950 lbs test each
ix. Has a padded 30-inch top ring,
x. Has padded bottom ring with a 72-inch overall
dimension,
xi. Has shock absorbing padding and synthetic flotation
material,
xii. Is 9 feet from bottom to top ring,
xiii. Incorporates 5 chaffing pads at the bottom of the
net,
xiv. Is of collapsible design for ease of storage,
xv. Has a proven stabilizing system
Internal
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Rev1 May 2017
Figure 31
5.6.5 Frog
i. Robust stainless steel frame with a fixed buoyancy
configuration to provide tetrahedral configuration with
a very centre of gravity and feet protection.
ii. Excellent stability at inclination up to 350 provided.
iii. Seats are mounted on a spring suspension system
including shock absorbed feet protection for heavy
landings up to 4m/s.
iv. A minimum of three (3) to Nine (9) persons can be
accommodated based on tetrahedral configuration.
Internal
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Rev 1 JUNE 2017
v. Conversion to stretcher mode is possible (for 3-or-6
person size only). Rev1 May 2017
vi. Fitted with quick release system
vii. Buoyancy configuration ensures FROG is self-righting
afloat in a stable upright position.
Figure 32
Internal
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Rev 1 JUNE 2017
5.7 Inspection, Testing and Certification Rev1 May 2017
Personnel transfer devices shall be inspected and certified in

accordance to OEM guidelines, applicable regulatory requirements
and others as approved by PETRONAS CARIGALI:
5.7.1 Pre-use visual Inspection
A visual inspection of the personnel transfer device shall

be carried out prior to each use by a competent person.
This shall include:
i. Check for any damage on all parts of the unit

ii. Visually inspect safety load line when attaching the
device to the crane hook. This includes the 4 part
sling and all hardware as well as the load line and
fabric covered stabilizer.
iii. Look for crimps, broken wires or excessive wear or
rust. If exist, take the unit out of service immediately
and replace the sling.
iv. Inspect crane hook positive locking device for
function and physical condition.
v. Visually inspect the entire load bearing areas of the
device for excessive wear or damage particularly the
rigging lines (inner and outer).
vi. Visually inspect the aluminium center ring section for
damage, cracks or excessive wear.
vii. Inspect the stainless quick release clips.
viii. Shackle shall have safety pin which is properly
secured.
ix. Regularly spray with a lubricant so that they operate
smoothly.
Internal
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Rev 1 JUNE 2017
5.7.2 Monthly Inspection Rev1 May 2017
The monthly inspection of the personnel transfer device

and its ancillaries shall be consistent with OEM’s guidelines.
As a minimum the following shall apply:
i. Perform Pre-use visual Inspection

ii. The polypropylene rope shall be reverse hand
twisted so that the internal strands can be inspected
for any signs of wear breakage, buildup of dirt,
grease or salt deposits.
iii. If any strand deterioration is noted, the basket shall
be replaced with a new unit.
iv. The bottom-padded ring shall be inspected and
checked for any sign of damage or tears.
v. The main lifting ring shall be inspected and checked
for any signs of wear or deformation.
vi. The net shall be washed with fresh water after the
inspection.
5.7.3 Six (6) Monthly Inspection
Every s i x ( 6) months the personnel transfer device shall

be inspected by a qualified inspector.
i. Check for any damage or defect on all parts of the unit.

ii. Visually inspect safety load line, four part sling and all
hardware (paying close attention to broken wires,
flattened sections, crimps, rust etc.). This should
follow API sling inspection guidelines.
iii. Inspect fabric covered stabilizer for tears or excessive
wear. This may need replacement if inner rubbers
have had significant use and have lost elasticity.
iv. Inspect outer and inner rigging ropes and the bolts
that hold them for sufficient tension.
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Rev 1 JUNE 2017
v. Inspect outer and inner rigging ropes and the bolts
Rev1 May 2017
that hold them for sufficient tension.
vi. Inspect top and bottom of powder coated aluminium
frame including top and bottom ring, expanded metal
top, and center pole. Look for excessive wear, cracks
or corrosion.
vii. Turn center pole (at least three full turns) loosening
and then tightening. Swab the threads with lubricant
to prevent seizing.
viii. Check top and bottom flotation coverings and bats for
deterioration or damaged closed cell foam.
ix. Inspect rubber feet on bottom of this device for
deterioration or damage or missing feet. These are
critical as they lessen landing shock for riders.
x. Inspect for modifications or non OEM supplied
components. Non OEM components or modifications
should be removed.
xi. Defective or worn parts should be replaced by a
qualified individual as required.
5.7.4 Annual Inspection
The annual inspection of the basket and its ancillaries is

conducted by qualified inspector and shall be consistent
with OEM’s guidelines. As a minimum the following shall
apply:
i. Carryout inspection as in Monthly Inspection.

ii. The basket will be tested with a total test weight of
2.5 MT min per manufacturer recommendation which
will be hung from four equidistant points on the lower
ring.
iii. The basket will be clearly marked with a fabric tag
stating "MAX CAPACITY = XX MEN".
iv. The identity tag attached to the lifting ring will state
that the SWL = XXXKG.
Internal
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5.7.5 Every Two (2) Years Refurbishment

Rev1 May 2017
The personnel transfer device shall be refurbished and re-

certified every 2 years (or earlier if required). The factors
to be considered are:
i. Availability of authorized specialized resources for

refurbishment
ii. How the unit is stored.
iii. Frequency of usage.
iv. Cost (replacement vs. refurbishment).
5.8 Safe Operations and Practices
This section provides guidelines for safe operation in the use

Personnel Transfer Device
5.8.1 Safe Operations and Practices
i. Personnel riding on the "Billy Pugh" type of personnel

transfer device shall first be trained in its proper
usage.
ii. Training shall include, standing on the outer rim at the
rope openings, facing inwards, with arms crossed in
front of their chests, holding the net roping firmly,
iii. No more than 4 personnel (with light hand baggage)
shall be allowed to ride the "Billy Pugh" at any one
time,
iv. While waiting for the crane to hoist the personnel
basket, it is advisable to keep one foot on the deck
to stabilize the body,
v. The personnel basket shall not be used to lift cargo,
vi. The manufacturer, 'Billy Pugh Company', does not
recommend a tag or guide lines be attached to the
devices, due to it can easily fouled by wrapping
themselves around objects on the deck or vessel.
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Rev 1 JUNE 2017
vii. However, if a tag or guide line is required, 'Billy Pugh
Rev1
Company' has developed a system Mayincorporates
that 2017
horizontal wrapping on a urethane dipped polydactyl
base rope. This tag line is much stiffer than a normal
rope and resists fouling and has a much better
gripping surface. Common lengths are or 15 feet,
viii. Lifejackets, or other appropriate Personal Floatation
Devices, safety helmets shall be worn by all personnel
during transfer.
5.8.2 Transfer During Darkness
Personnel transfer during the hours of darkness shall be

avoided if possible. However, if unavoidable, a transfer is
permitted provided the operation is conducted consistent
with the following minimum guidelines:
i. An approved Permit to Work with all the required

precautions, controls and recovery plans shall be in
place.
ii. The transfer areas are adequately illuminated,
iii. The operation must be conducted under
supervision of a person appointed by the Area
Authority.
iv. Weather condition or potential of weather change
that may affect the transfer operation.
v. The wave height and duration must be within the
limit as defined in the PTW system
vi. The vessel must have the ability to hold its position
especially during adverse weather condition.
vii. Care shall be taken to the followings during adverse
weather such as:
 Crane hook control and boom tip motion,
 Persons suffering from sea sickness and the

difficulties of embarking to and/or debarking
from basket onto the rolling and pitching deck,
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 The ability to accurately throw or otherwise
deploy lines and/or Rev1 May 2017
personal lifesaving
floatation devices,
 The need of having safety lines for holding

/ crossing the exposed areas,
 Poor visibility that may reduce the ability to see

potential risks,
 Unsafe condition due to wet deck and hand

holds slippery
5.9 Cargo Containers
This section describes the standards and requirements related to

operation and maintenance of Cargo Containers in offshore
operations
5.9.1 Standards and Specifications
The minimum standard and specifications related to

operations and maintenance of cargo containers shall be
as follows:
Standard: EN 12079 Offshore Containers
5.9.2 Definitions
Offshore containers
A portable unit for repeated use to transport goods or
equipment, handled in open seas, to, from and between
fixed and/ or floating installations and ships.
Permanent equipment
Equipment that is attached to the container and not the
cargo
Primary structure
Load carrying the support frames and panels.
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5.9.3 Minimum Requirements Rev1 May 2017
The Minimum Requirements Related To Design,

Operations, Inspection And Maintenance Of Container Shall
Be As Follows:
i. Offshore Containers should be fitted with special pad

eyes, suitable for the attachment for purpose built
slings connected with slings. Where ISO corner fittings
are mounted in conjunction with pad eyes, these corner
fittings are not intended for lifting offshore. Containers
not meeting this requirement should be modified in
accordance with EN 12079 and certified before they are
used for offshore material transfer.
ii. In order to facilitate handling in open seas, offshore
containers should be pre-slung. Such slings should be
permanently attached to the container and considered
to be part of container. Slings shall be lubricated on
regular basis. The dynamic forces which occur when
handling containers in open seas will be higher than
those encountered during normal quay side handling.
This should be taken in to account when determining
the requirements for slings on offshore containers by
multiplying the normal safety factor for slings by an
additional factor. The fact that light containers will be
subject to relatively higher dynamic forces than heavier
containers should also be taken in to account. Minimum
material requirements for impact toughness should be
specified when high strength steel is used in e.g.,
chains, links and shackles.
iii. Container must be strong enough for safe loading
and unloading operations from supply vessels
iv. Container can withstand impact from rough sea with
wave heights of 6 meters.
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v. Capable to withstand tilting at 300 in any direction

Rev1 May 2017
without overturning when loaded at maximum gross
weight. Centre of Gravity (COG) shall be at middle of
the container.
vi. No protruding parts (door handles, hatch cleats, etc.)
to avoid contact with other containers or structures.
vii. Company color coding philosophy shall be followed.
5.9.4 Containers for Lifting with Lifting Set
5.9.4.1 Design of Primary Structure
Design safety factor of the primary structure

shall be 2.5 Rg (Total mass of the container and
cargo)
5.9.4.2 Design of Pad eyes
Pad eyes shall be so designed to as to permit free

movement of the shackle and sling termination
without fouling of pad eye.
Pad eyes should not protrude outside boundaries

of the container other than vertically upward, and
shall as far as possible be designed to avoid
damage from other containers. Lifting points
shall be positioned on the container to preclude
as far as practicable, the risk of slings fouling
against the container or its cargo during normal
use.
Pad eyes shall be welded to the frame with full

penetration welds. If the lifting force is
transferred through the thickness of a plate,
plates with specified through thickness
properties in accordance with EN 10164 shall be
used.
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Pad eyes shall be able to withstand force of 3.0
Rev1and
Rg (Total mass of the container Maycargo)
2017
For containers with one pad eye, it shall be

designed for a total vertical force of 5 Rg (Total
mass of the container and cargo)
5.9.5 Containers for Lifting with Forklift
Design of the primary structure shall be 1.6 Rg (Total

mass of the container and cargo MARKING
Each container shall be marked with a container number
which shall be the common cross-reference on all in-
service certification and shipping documentation.
5.9.6 Identification Marking
The Container number shall be prominently displayed on

all sides of the container (as viewed from ground level).
The following guidelines shall apply
i. Wordings shall be of a contrasting color and size not

less than 75 mm high
ii. For container with roof, the container number shall be
displayed on the roof, in characters of 300mm high or
more
5.9.7 Information Marking
On each Container, a matt black square shall be used

display information such as destination, cargo hazard and
others. The following shall apply:
i. Matt black square shall be not less than 400 mm x 400

mm
ii. This matt black square shall be located on one door
(where fitted) or on one side of the container.
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iii. The Gross, tare and payload shall be displayed just
below the matt black square. Rev1 May 2017
iv. Any other marking for electrical hazard classification,
including earth connection shall be displayed in this
location.
5.9.8 Information Plate
This plate shall be headed “Offshore Container Data Plate,

EN 12079 and contain the following information:
i. Fabricator’s serial Number

ii. Maximum gross weight in kilogram, at the design sling
angle
iii. Tare weight in kilogram,
iv. Payload in kilogram, and intermediate deck payload (if
applicable)
v. Certificate number
vi. Design temperature
Figure 33
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5.9.9 Inspection Plate
Rev1 May 2017
This plate shall contain the following information:
i. Owner’s container number

ii. Owner’s name and international telephone number
iii. Date of last inspection
iv. Provision on the plate to facilitate permanent marking
to record a minimum of 9 inspections
v. A letter after the date of inspection to type of
examination. Letter “T”- Proof load test, letter “VN”-
nondestructive and visual inspection and letter “V” –
Visual inspection only.
Note: To avoid confusion, the plate will not carry the

next date of inspection
Sample format for Offshore Container Inspection Plate:
OFFSHORE CONTAINER INSPECTION PLATE
Container No:
Owner:
Telephone No:
Inspection Date:
DD-MM-YYYY T DD-MM-YYYY VN DD-MM-YYYY V
Table 5
5.10 Container Pre-Use Inspection
Immediately before transporting a container offshore and before

its return trip a competent person shall inspect the container.
The appointed person shall check the validity of certification by
reference to the inspection plate and verify the container, including
its lifting gear is free from obvious defects rendering it unfit for use.
It is recommended this inspection should include as a minimum the
following checks.
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Rev1 May 2017
PRE-USE INSPECTION CHECK LIST

Fail Pass
a. Check inspection plate to ensure the
inspection date is current
b. Check safety markings to ensure they meet
the standard requirement
c. Check lifting set for obvious signs of damage
d. Check lifting set to establish all parts are

present, correct, properly connected and
secure
e. Check container roof, forklift pockets, frames
etc, for loose items
f. Check safety nets are in position where
necessary and tie down points are in place
and are fit for purpose.
g. Check container doors are closed, secured
and locking mechanism undamaged.
h. Check drainage holes are clear on open
containers
Table 6
5.11 Certificate of Conformity
All containers used at offshore shall be issued with a certificate of

conformity based on EN 12079. This certificate shall be retained by
the owner.
The certificate of conformity shall be based on

the following documentation and shall be retained by the
fabricator for at least 5 years:
i. Structural calculations;
ii. Drawings including a general arrangement drawing;
iii. Specifications for welding procedures (WPS);
iv. Welders’ certificates;
v. Material inspection documents;
vi. Report on traceability of materials;
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vii. Report from fabrication inspection;
viii. Report from dimensional control;Rev1 May 2017
ix. Report from non-destructive examination (NDE);
x. Report from prototype testing;
xi. Report from proof testing;
xii. Report from final inspection
5.11.2 Certificate
The certificate shall contain the following information:
i. Container fabrication number;

ii. The certificate number;
iii. Description of the container, including:
iv. External dimensions;
v. Number of lifting points;
vi. Name of fabricator;
vii. Month/ year of fabrication;
viii. Maximum gross mass in kilograms;
ix. Tare mass in kilograms;
x. Payload in kilograms;
xi. Reference to the as built dossier;
Total gross mass in kilograms applicable to “the all points

lifting test” and the actual method of test;
i. Angle of lifting set legs (from vertical);

ii. Shackle bolt diameter;
iii. Conformity to other requirements and/or codes;
iv. A statement that the container described has been
designed, fabricated and tested in accordance with EN
12079
v. Signature on behalf of the certifying body.
5.12 Periodic Inspection, Test and Repair
All periodic inspection and tests shall be carried out by a certified

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inspection body authorized by PETRONAS CARIGALI
Rev1 May 2017
5.12.1 Schedule of examination and tests for Containers
Containers shall be periodically examined and tested in

accordance with the schedule as listed in the table below.
Inspection / Examination / Test

Suffix
Non-
Time or to be
destructive Visual
Interval Lifting test marked
examination inspection
on
(NDE)
platec
Initial as required by EN 12079-1
Certification
At intervals
Not
not exceeding Not applicableb Yes V
applicableb
12 Months
At intervals
Not
not exceeding Yes Yes VN
applicableb
48 Months
After
substantial
Yes Yes Yes T
repair or
alterationa
a. A substantial repair or alteration means any repair and/or
alteration carried out, which may, in the opinion of an inspection
body, affect the primary elements of the offshore container, or
elements which contribute to its structural integrity.
b. The inspection body may require other or additional inspections,

examinations and or tests.
c. Suffix V: visual inspection only, Suffix VN: Visual inspection and

NDE, Suffix T: Proof load test, NDE and visual inspection
Table 7
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Rev1 May 2017

5.12.2 Schedule of examination and tests for Lifting Sets
Inspection / Examination / Test

Time or Interval Applicable to Load NDE Visual Suffix marked
test examination inspection on sling tag
Initial Complete
as required by EN 12079-2
Certification lifting set
At intervals not
exceeding 12
Months Complete
N/A N/A Yes V
lifting set
Sling
components
and joining Either load test or
Yes T or VNa
At intervals not links NDE
exceeding 48 excluding
Months legs
Chain sling Either load test or
Yes T or VNa
legs NDE
Shackles N/A N/A Yes N/A
After substantial
Complete
repair or Yes Yes Yes T
lifting set
alteration
a Dependent upon whether tested or examined
Table 8
5.12.3 Lifting Test
The lifting test shall be carried out as described in EN 12079

Section 7.3.1 and 7.3.2. A summary of the tests are as
follows
All-Point Lifting
i. The container shall be loaded to a 2.5 times the gross

mass of the container.
ii. Lift the container using all the pad eyes.
iii. Hold for 5 minutes.
iv. Deflection shall not be greater than 1/300 of the span
of the member
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v. Container shall show no sign of deformation or other
damage after testing. Rev1 May 2017
Two-Point Lifting
An offshore container fitted with 4 pad eyes shall be lifted
from only 2 pad eyes, situated diagonally. The following
shall apply:
i. The container shall be loaded to a 1.5 times the gross

mass of the container.
ii. Lift the container using all the pad eyes.
iii. Hold for 5 minutes.
iv. Deflection shall not be greater than 1/300 of the span
of the member
v. Container shall show no sign of deformation or other
damage after testing.
vi. Drop test
Vertical impact test

This test shall be carried out with the container loaded to
its maximum allowable payload. The following shall apply:
i. Suspend the container from a quick release hook

ii. Release the hook and the container shall drop freely
for at least 50 mm
iii. Inspect the container.
iv. No significant permanent damage or damage,
deformations shall show after the test.
v. Document the results.
5.12.4 Non-destructive examination (NDE) of welds
The NDE of welds on pad eyes and adjoining structures

shall be carried out according to “Schedule of
examination and tests”. The inspection methods and the
quality of the welds shall be described by the NDE operator
and included in the inspection report.
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5.12.5 Visual Examination
Rev1 May 2017
The thorough visual examination shall be of the exterior
and the interior of the container to ensure that the
container is fit for its intended use. Visual inspection shall
include the following for defects, corrosion, deformations,
overload, and or other damages:
i. All load bearing parts,

ii. Base structure,
iii. Markings and plates shall be checked to ensure that
they meet the requirements
iv. Welds in the primary structure
v. All pad eyes and lashing points
vi. The complete structure.
vii. Doors, frames, seals, hinges, locks, etc.,
viii. The floor shall be visually examined to check that it is
not deformed and that it shows no signs of distress or
overload.
ix. Drainage facilities, where fitted, shall be examined,
e.g. drain holes shall be clear of debris.
5.12.6 Marking of The Inspection Plate
On satisfactory completion of the examination and/or

test(s), the plate shall be marked as specified in
“Schedule of examination and tests.
5.12.7 Inspection Report
When a container has been tested and suitable for

service, an inspection report, signed by the Inspector shall
be issued. This report shall show the following information
as a minimum:
i. Container identification (including owner’s container

number);
ii. Owner’s name, or delegated nominee
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iii. Certificate number
iv. Total gross mass in kilograms Rev1 May 2017
applicable to the all
points lifting test and the method of test (where
relevant)
v. Details of NDE carried out (where relevant)
vi. A statement that the container described was
thoroughly examined and that the particulars are
correct
vii. Reference, where appropriate, to any report issued to
the owner arising from the test/inspection process
viii. Confirmation that the inspection plate was marked
ix. Date of examination (date of signature or report also
to be shown if different from date of examination)
x. Name of organization and the signature and unique
identification mark of the person carrying out the
examination
xi. Any defect or deviation from the requirements of this
standard shall be recorded
5.12.8 Damage and Repair Procedures

All containers shall be maintained in accordance with the
standards as defined in this LEG.
Any structural damage or corrosion which may affect the
load bearing integrity of the container shall be repaired
accordance with the requirements for design and
manufacture of containers and inspected by an approved
inspection authority.
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Rev1 May 2017

6.0 COMPETENCY AND CERTIFICATION
6.1 Training and Certification
This section defines the minimum training and certification

requirements for all personnel involved in operations and
maintenance of Lifting Equipment.
Competency of Personnel
All lifting equipment shall be operated and maintained by personnel

who have received adequate training and certification to ensure
safe operations and maintenance of all lifting equipment.
Competency and Certification are required for the following

positions:
i. Trainer and/or Assessor

ii. Crane Operator
iii. Crane Inspector
iv. Riggers
v. Banksman (Signalman)
6.2 Minimum Requirements
The training and certification of Banksman (Signalman), Crane

Operator, Forklift Operator and Inspector shall consist of a
formalized written training program and hands-on training.
The competency level of training shall be consistent with any of the

following standards applicable:
i. Training and certification provided by any training centre that

meets all the requirements as set forth in API RP-2D (APP. A1,
A2, and A3).
ii. Offshore Petroleum Industries Training Organization (OPITO).
iii. Competency Standards as defined by Regulatory Authorities
in Malaysia as applicable.
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iv. Competency Standards as defined by Host Country’s
Regulatory Authority as applicable. Rev1 May 2017
v. Other standards as recognized by PETRONAS CARIGALI
6.3 Key Requirements
This section (refer table in page 135) spells out the key
requirements such as physical requirements, training requirements
and level of competency for trainers/assessors, crane operator, jib
crane operator, crane inspector, riggers and Banksman
(signalman).
More detail description on the training requirements can be seen in

Appendix 8.15.
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Rev1 May 2017
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Rev 1 JUNE 2017
Rev1 May 2017
Internal
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Rev1 May 2017
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7.0 SAFE LIFTING OPERATION AND DECK MANAGEMENT

Rev1 May 2017
7.1 Safe Lifting Operation and Deck Management
This section describes the requirement for the safe operation of all
lifting equipment and to ensure all lifting activities are carried out
in compliance with safe working practices.
7.1.1 Permit to Work
All lifting operations are considered Non Routine Work and

hence require a permit as defined in the Permit to Work
System.
Operational checks and inspection on a Crane before use are

considered as Routine Work provided it is done without load.
A lifting plan and lifting certificate is required for the following
activities or working conditions but limited to the following:
i. Lifting load over “unprotected” process equipment or

wellheads.
ii. Lifting dangerous goods.
iii. Lifting load weight exceeding 8 tons or lifting load of
weight more than 80% of rated capacity of the lifting
equipment at specified working radius and boom angle
as per crane load chart whichever governs.
iv. Lifting inside confined space.
v. Lifting using slings not made of wire rope.
vi. Lifting container with legs.
vii. Strong wind exceeding 15-20 knots
viii. Poor visibility less than 30 metres.
ix. Sea wave height 1.5-2.5 metres.
x. Sea current 1-2 knots.
xi. Load not fully illuminated.
xii. Load path not fully illuminated.
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xiii. When removing or installing wellhead catch
cover/gratings. Rev1 May 2017
xiv. Other lifting operations which are deemed as critical or
high risk and determined in OPU’s hazards and effects
register namely blind lifts, lift through hatches etc.
7.1.2 Lifting Plan

All lifting plans shall be documented and as a minimum ensure
the following
i. All personnel involved are familiar with the task, ie.,
what is to be lifted, weight of the load, what lifting
equipment to use, the travel path and the roles and
responsibilities of the personnel involved in the lifting
operation.
ii. Competent and sufficient personnel are present at all
phases of lifting operation, the travel path is clarified and
obstacles if any are remove before lifting commences.
iii. Method of communication established.
iv. Lifting operation can be executed safely in relation to
simultaneous operations.
v. Lifting appliances and lifting gear are suitable and will be
used in accordance with manufacturer’s instruction for
use.
vi. Landing area can accommodate the load in terms of size,
weight and strength.
vii. Use of Tag lines considered.
viii. Personnel involved have sufficient competency and
knowledge of the regulations and standards that governs
the lifting operation.
ix. Sea wave height 1.5-2.5 metres.
x. Work area shall be barricaded.
xi. Load calculation included in lifting Plan.
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7.2 Job Hazard Analysis Rev1 May 2017
In line with “Permit to work” system, all lifting activities require a

Job Hazard Analysis (JHA) study before a permit to work is
approved and issued.
Detail of job hazard analysis, control measures and recovery are
described in “Permit to work system WW ALL S 05 002”.
7.3 Confined Space Entry Procedure
In line with Permit to work system, all lifting activities which

requires entry in to confined space shall be carried out in
compliance with Confined space entry procedure WW ALL 05
004 latest revision.
7.4 Permit to Work
All personnel involved in operations and maintenance of the lifting

equipment are required to attend “Permit to work” training.
Those who are required to enter confined space must attend the
specialized training on “Confined space entry procedure”.
7.5 Deck Management
The purpose of this section is to ensure that a proactive approach

is established and sustained with regards to deck management in
order to ensure all activities are carried out in a safe manner and
lifting incidents are minimized or eliminated.
The key requirements in deck management includes but limited to
the following.
i. No-Load and restricted areas sign board are to be clearly

marked and communicated.
ii. There shall be no loads in the No-Load areas.
iii. Loads in restricted areas shall be controlled.
iv. Access ways shall be kept clear at all times.
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v. Escape routes shall be identified, marked and kept clear at all
times. Rev1 May 2017
vi. Lifting plans shall be prepared and discussed in the meetings.
vii. Unusual lift plans a special planning meeting.
7.5.1 No Load Areas

i. The area authority or a person as delegated shall be
responsible for ensuring that all no load areas are
properly identified, painted with black and yellow
stripes clearly marked and communicate to all
personnel.
ii. The Crane operator or Area Authority is responsible to
ensure no –load areas are kept free of all loads.
7.5.2 Restricted Load Area

i. The area authority or a person as delegated shall be
responsible to ensure that all restricted load areas
are:
 Properly identified
 Painted with red and white stripes.
 Clearly marked and communicated to all
personnel
ii. Crane Operator or Area Authority shall be responsible to
ensure excessive weight loads are not placed in restricted
areas.
7.5.3 Equipment Placement

The area authority or a person as delegated shall be
responsible to ensure equipment placed on decks are
arranged effectively and safely such that walkways
and escape routes are neither blocked nor restricted.
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Rev1 May 2017

7.5.4 Access Ways
i. All personnel are responsible to ensure access ways
are kept free of obstructions at all times.
ii. The Operations Supervisor and or Area Authority on
Site will inspect all access ways for obstructions on a
daily basis.
iii. The Crane Operator or Area Authority on Site is
responsible to ensure all obstructions if any are
removed on a timely manner.
7.5.5 Escape Routes

i. Area Authority or a person as delegated is responsible
to ensure all escape routes from all parts of the work
area are identified, clearly marked and communicated
to all personnel.
ii. The Operations Supervisor and or Area Authority on
Site will inspect all escape routes for obstructions.
iii. The Crane Operator or Area Authority on Site is
responsible to ensure all obstructions if any on escape
routes are removed on a timely manner.
Note: Minimum no of personnel required at the point of lift

and at destination shall be as follows.
i. Point of lift: Three (3) comprising Riggers and Signal

Man
ii. Point of destination: Three (3) comprising Riggers and
Signal man.
7.6 Responsibilities of Personnel

7.6.1 Area Owner
Area Owner is responsible for defining and requesting a
move/lift, determining which activities are considered as
critical lift, writing lifting procedures where required,
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providing technical information on relevant characteristics
Rev1 May
of apparatus including special lifting fixtures 2017
when required,
providing suggestions on rigging and moving , assigning
resources for planning and co-ordination of all aspects of the
job being performed.
7.6.2 Area Authority

Appointed OPU’s personnel from technical discipline shall
review and approve appropriate engineering layout, lifting
fixtures and configurations as laid out in the lifting plan.
7.6.3 Crane Operator

Crane operator is responsible for correct and safe operation
of the crane under his/her direct control in accordance with
PETRONAS and host country regulations/ guidelines. Crane
operator shall ensure crane is safe to use by performing
inspection before and after operation.
7.6.4 Rigger
Rigger is responsible to attach and detach the load from
crane load lifting attachment in a safe manner and also for
using correct lifting tackles and accessories.
7.6.5 Supervisor
Supervisor shall ensure personnel know how to safely
operate cranes and hoists and how to move objects safely.
Supervisor must enforce the use of safe lifting techniques,
ensure lifting equipment in good mechanical and operating
condition.
7.6.6 Signalman
Signalman is responsible to relay information to crane

operator for the safe movement of crane and load. The
signalman shall stop the operation in unsafe conditions.
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8.0 APPENDICES
Rev1 May 2017
8.1 Glossary
8.1.1 Abbreviations
ANSI American National Standards Institute

ASME American Society of Mechanical Engineers
API American Petroleum Institute
CIMG Carigali Inspection and Maintenance Guidelines
CM Corrective Maintenance
COG Centre of Gravity
DGR Dangerous Goods Regulations
DOSH Department of Safety and Health
HAZID Hazard Identification
HSE Health, Safety and Environment
HOL Height of Lift
ISO International Standards Organization
IMDG International Maritime Dangerous Goods Code
JHA Job Hazard Analysis
MAR Maintenance Action Report
MPI Metal Particle Inspection
MCI Material, Corrosion and Inspection
MOC Management of Change
NDT Non Destructive Test
OEM Original Equipment Manufacturer
OSR Offshore Self Regulation
OSR Offshore Self Regulatory Inspector
Inspector
OIM Offshore Installation Manager
OPITO Offshore Petroleum Industry Training Organization
PA Public Address
PIC Person In Charge
PPM Planned Preventive Maintenance
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PSI Pounds per Square Inch
PTD Personnel Transfer Device Rev1 May 2017
PTS PETRONAS Technical Standards

RM Routine Maintenance
SIMPOS Simultaneous Operations
SWL Safe Working Load
SLI Safe Load Indicator
SSBOC Safety System Bypass and Override Certificate
SSLP Site Specific Lifting Procedure
Tonne Metric Ton (Te)
UV Ultraviolet Inspection
VCOC Vendor’s Certificate of Conformity
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8.1.2 Definition
Rev1 May 2017
AC Alternating Current
AcoP Approved Code of Practice
Anti-two block A device which, when activated, disengages the

device hoisting operation to prevent the hook block
assembly from coming into contact with the
boom point sheaves assemblies. This is also
referred as an “over hoist assembly” ATB
Auxiliary Hoist A secondary hoist rope system, usually of

lighter load capacity than provided by the main
rope system; also known as “whip line” or “fast
line”
Backstop Structure On the ‘A’ Frame that stops the boom

from going over the back of the crane in a high
wind or sudden release of the load
Band Brake Circular brake, of either external expanding or

internal expanding type, with a contacting
surface of heat and wear resistant material
Banksman See “Signal Man”
Bight The bend of a line, rope, or cable
Block Sheaves or grooved pulleys in a frame

supporting a hook, also known as a “hook
block”
Boom (crane) A member hinged to the rotating

superstructure and used for supporting the
hoisting tackle
Boom angle The angle of the longitudinal axis of the base

boom section above or below horizontal
Boom chords Main structural members of a lattice type boom
Boom foot The base of the boom, where it is

attached to the rotating superstructure
Boom head Sheaves, pins, and other mechanisms at the

top, or peak, of the boom; also known as the
“cathead”.
Boom hoist brake Brake to control the drum that the boom hoist
line winds on
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Boom hoist line Rope used to control boom movement in a
vertical plane Rev1 May 2017
Booming The movement of the boom through an angle
from one radius to another; also known as
“luffing”.
Boom lacing Structural truss members at angles to, and

supporting, the boom chords of a lattice type
boom
Boom length The straight line distance from the centre of the
boom foot pin to the centreline of the boom
point load hoist sheave pin
Boom sections A crane boom is usually in two sections, upper

and lower, and it may be lengthened by
insertion of one or more intermediate sections
Boom stop A device used to limit the angle of the boom at

the highest recommended position
Booming in/out Retracting or extending, respectively, a

telescopic boom
Booming up/down Raising or lowering, respectively, the boom
Bridle A frame equipped with sheaves and connected

to the boom by stationary ropes usually called
pendants; usually known as a floating harness
Centre pin A large pin or vertical shaft acting as the centre

of rotation for the revolving frame; also known
as the “kingpin” or “kingpost”
Centre of rotation The centre pin or rotational centre point on the

crane from which the lifting radius is measured.
It is the centre of the circle scribed by a full
rotation of the crane
Certificate of A certificate issued by the competent person

Examination (see Competent Person) giving the results of a
thorough equipment. This will detail any
defects found or include a statement that the
equipment is fit for continued use. The
Certificate must be retained for inspection
when required
Change A change is a deviation from or a modification

to an approved system and or equipment.
Internal
Page 147
Rev 1 JUNE 2017
Color Code A method of marking equipment, (normally
with paint) to give a readily
Rev1 visible indication of
May 2017
its certification status. This color shall be
changed at each periodic examination
Competent Person A person who has the appropriate worksite site

experience and training that shall comprise
class-room type and Hands-on training on
cranes and lifting equipment
Contractor A Company or persons who have a direct

contract with the “Parent Company”
Counterweight Weight used to supplement the weight of the

machine in providing stability for lifting loads.
The weight is also known as “ballast” and
usually attached to the rear of the machine
Critical Any component of the crane assembly and/or
Component restraining device whose failure would result in
an uncontrolled descent of the load or an
uncontrolled rotation
Cross-over In multiple layer spooling of a rope on a drum,

those points of rope contact where the rope
crosses the preceding rope layer
Delegated A person so delegated who holds the authority

and responsibilities of the person who
delegated him/her
Drum The cylindrical member around, which a rope

is wound for lifting and lowering the load or
boom
Dynamic loading Loads introduced into the machine or its

components due to accelerating or
decelerating forces
Factor of Safety The ratio of the load that would cause failure
to an item of lifting equipment to the load that
is imposed upon its service, i.e. SWL The
Factor of Safety is to allow for detrimental
criteria such as wear and tear and dynamic
loading
Fly Jib An extension fitted to the main boom over

which a secondary hoist system is fitted; also
known as an “auxiliary jib”
Free Fall A boom or hook block descending by its own

weight
Internal
Page 148
Rev 1 JUNE 2017
Gantry A structural frame, extending above the
superstructure to which the boom
Rev1 May support
2017
ropes is reeved; also known as “mast” or “A
Frame”
Gross capacity Total crane lifting capacity as printed in the

load chart. Includes load weight, rigging
weight, hoisting line weight, etc
Guy Rope A non-operating standing wire which maintains

a constant distance between the points of an
attachment to the components connected by
the wire rope; also known as a “pendant wire”
Hoist drum brake Brake to control the drum containing the load
hoist line
Hoist mechanism A hoist drum and rope reeving system used for
lifting and lowering loads. Hook block see:
Load block
Hoist System The process of raising or lowering loads
Hook Rollers Rollers which prevent the lifting of the

revolving superstructure from the roller path.
Hook rollers are the means to connect the
Super structure to the foundation or pedestal
Jib An extension attached to the boom point to

provide added boom length. The jib may be in
line with the boom or offset to various angles
in the vertical plane of the boom
Jib backstop A device which will restrain the jib from

turning over backward
Lattice Boom Boom of open construction with angular or

tubular lacing between main corner members
(chords) in the form of a truss
Lifting Appliance Any machine which is able to raise, lower, or

suspend a load (e.g. crane, forklift, powered
hoist), including its attachments for
anchoring, fixing, or supporting it (e.g.
beam trolleys, beam clamps, sheave blocks,
winches, runway beams, and pad eyes), but
excluding machines incorporating a guided
load (e.g. lifts) and continuous mechanical
handling devices (e.g. conveyors)
Load block A metal frame suspended from the hoist line

for mounting wire rope sheaves (pulleys) and
Internal
Page 149
Rev 1 JUNE 2017
having a hook at the lower end to attach the
load. Also known as a hook block
Rev1 May 2017
Lifting capacity The load that a lifting equipment can safely
handle
Lifting equipment A generic term used to indicate, loosely, all

lifting gear and machines
Lifting tackle An item used to connect a load to a lifting

machine but which is not itself capable of
providing any movement to lift or lower the
load
Limiting Device A device fitted to the boom and hoist motions

designed to prevent over booming or over
hoisting by sounding and/or isolating the
motion
Line pull The maximum pulling force exerted by a drum

on the wire rope at full load
Load chart A table published by the crane

manufacturer showing the allowable gross
lifting capacity for various lifting radii and
boom lengths for each crane or crane
configuration; also known as a “capacity
chart”, “rating chart”, “lift chart”, and
“maximum allowable capacity chart
Load hoist Line wire rope used to raise and lower the load
being lifted. This is also referred as a lift line
Load indicator A device that measures and displays the

weight of the load
Load radius A device to show the crane operator the radius

indicator at which his boom is set and the safe working
load at that radius; also known as “safe load
indicator”
Load Test See ‘Proof Test’
Luffing Changing boom angle (see also booming

up/down)
Manufacturers A certificate issued by the manufacturer

Certificate stating that their product conforms to a
particular standard and containing such
information as is required by the referenced
standard
Internal
Page 150
Rev 1 JUNE 2017
MAR Maintenance Action Request

Rev1 May 2017
Plant A unique number given to an item of lifting
Identification No equipment for registration purpose and to
facilitate traceability
Power-controlled A system or device in the power train, other

lowering than the load hoist brake, which can control
the lowering speed of the load hoist
mechanism
Proof Test A Proof (or Load) Test is a process whereby a

load (exerted by gravity or other means)
applied by the manufacturer or competent
person for the purpose of a test. The applied
load appears on the test certificate
Qualified Person A person who, by possession of a recognized

degree, certificate, or professional standing, or
who by extensive knowledge, training and
experience has successfully demonstrated the
ability to solve or resolve problems relating to
the subject matter
Radius of Load The horizontal distance from the centre of

rotation to a vertical line measured through
the suspension point of a load on the hook;
also known as the “operating radius”
Reeving The passing of wire rope over sheaves, drums

and pulleys
Rg Rating based on the Gravitational forces i.e.

the maximum gross weight of the container
including permanent equipment and cargo but
excluding the lifting set
Rotation resistant A wire rope consisting of an inner layer of

ropes strands lay in one direction covered by an
outer layer of strands laid in the opposite
direction. This has the effect of reducing the
tendency of the finished rope to rotate by
developing counteracting balance torques
Running rope A rope which travels around sheaves or drums,

as opposed to a standing rope or pendant line
Load (SWL) The maximum load, as certified by a

competent person, which a lifting equipment
may raise, lower, or suspend under particular
Internal
Page 151
Rev 1 JUNE 2017
service conditions; the Safe Working Load can
be lower than the Working Load
Rev1 Limit
May 2017
Side load A load applied at an angle to the vertical plane
Signal Man A person, also referred as the “Banksman”,

who is responsible for giving direction to the
crane operator. This may be via hand signals
or radio communication
Slewing Commonly used offshore to describe swinging.

See: Swing
Sling A pre-assembled rope, chain or synthetic

component for attaching a load to a lifting
device and supporting that load in tension
Snellen A particular type of vision (eye) test
Spreader Bar A strut type of structural member to separate

two static ropes or slings
Standing (guy) A supporting rope which maintains a constant

rope distance between the points of attachment
Superstructure The rotating upper frame structure of the

machine and the operating machinery
mounted thereon
Swing Rotation of the superstructure for

movement of loads in a horizontal direction
about the axis of rotation; also known as
“slew”
Swing Gear External or internal gear with which the swing

pinion on revolving superstructures meshes to
provide swing motion; also known as “ring
gear” or “bull gear”
Tackle An assembly of ropes and sheaves arranged

for lifting, lowering or pulling
Tag line Rope, usually fibre, attached to load and used

to control horizontal movement, swinging or
twisting of a load during a lift
Tailswing The horizontal distance from the centre line of
rotation of a crane to the maximum rear
extension of the revolving superstructure also
known as “rear end radius”
Internal
Page 152
Rev 1 JUNE 2017
Telescoping Consists of a base boom from which one or
Boom more boom sections are Rev1
telescoped for
May 2017
additional length
Test Certificate A certificate to confirm that an inspection and

test have been carried out and the equipment
is safe for its intended use
Third Party A Company or persons who are hired in by the

“Contractor” to carry out work for them under
their contract with the “Parent Company”
Thorough An examination carried out by a competent

Examination person carefully and critically, and where
necessary supplemented by other means such
as measurement or non-destructive testing, in
order to detect damage or deterioration
Toolbox Talk A system of discussing and documenting the

task ahead to ensure all work parties
understand what has to be carried out,
including any potential hazards
Two-blocking The condition in which the hook block

assembly comes in contact with the upper load
block or boom point sheave assembly
Whip line A secondary rope system usually of lighter

load capacity than that provided by the main
rope system
Working radius The horizontal distance from the centre of

gravity of the load to the crane’s centre of
rotation. Also known as lifting radius
Internal
Page 153
Rev 1 JUNE 2017
8.2 Taskforce
Rev1 May 2017
No Name Position OPU
1 Prakash Sundaram Specialist-Static OE MX
Equipment
2 Bijoy Jose Verghese Specialist-Static OE MX
Equipment
3 Mohamad Bastawy Youssef MCI Specialist OE MX
4 Jamaluddin Mustakim Manger-Mech Static SK-OIL
5 Hanafi Basri Manager-Mech Static PMA
6 M Taariq B A Hamid Manager-MCI PMA
7 Zurahimi Muslim Executive-MCI PMA
8 Ahmad Bakrane B Abu Crane Specialist PMA
Bakar
9 Muhammad Ibrahim Ismail Crane Engr PMA
10 Mohd Zulkarnain Hashim Executive-Mech Static PMA
11 Kaharin Ezzaty Executive-Mech Stati PMA
12 Maryam Seth Executive-MCI SK-OIL
13 Tandel. V.R Executive-Mech Static SK-OIL
14 Poon Kah Fung Executive –Mech Static SK-OIL
15 Rizal Hamidi Executive-Mech Static SBA
Internal
Page 154
Rev 1 JUNE 2017
8.3 Reference Document
Rev1 May 2017
CODES/STANDARDS DESCRIPTION
ASME B30.5 Mobile Crane
ASME B30.9 Slings
ASME B56.10 Forklifts
ASME B30.16 Overhead Hoist
ASME B30.17 Overhead and Gantry Cranes
ASME B30.21 Manually Lever Operated Hoist
ASME B30.23 Personnel Lifting Systems
ASME-HST-1 Performance Standard for Electric Chain

Hoists
ASME-HST-2 Performance Standard for Hand Chain

Manually Operated Chain Hoists
ASME-HST-3 Performance Standard for Hand Chain

Manually Lever Operated Chain Hoists
ASME-HST-4 Performance Standard for Overhead

Electric Wire Rope Hoists
ASME-HST-5 Performance Standard for Air Chain Hoists
ASME-HST-6 Performance Standard for Air Wire Rope

Hoists
API RP 8B Procedures for Inspection, Maintenance,

Repair and Remanufacture of Hoisting
Equipment
API RP 2C Specification for Offshore Cranes
API RP 2D Operation and Maintenance of Offshore

Cranes
API RP 9A Specification for Wire Ropes
API RP 9B Application, Care and Use of Wire Ropes
EN 12079-1 Offshore Containers and associated lifting

sets- Offshore Containers Design,
Manufacture and Marking
Internal
Page 155
Rev 1 JUNE 2017
Rev1 May 2017
set-Lifting Sets Design, Manufacture and
Marking

sets-Periodic Inspection, Examination and
Testing
ISO 4309 Wire Ropes-Code of Practice for

Examination and Discard
ISO/TR 25599 Jib Cranes-International Standards for

design, Manufacturing, Use and
maintenance Requirements
LOLER Lifting Operations and Lifting Equipment

Regulations (LOLER) 1998
MY ALL P 05 001I Offshore Self-Regulation Implementation

Procedure
MY ALL E 04 024 Guidelines for working in adverse weather
OSHA Occupational Safety and Health

Administration
PTS 15.31.02 Inspection Manual for Offshore
PTS 11.22.17 Marine Lifting Design

PTS 18.52.06 Lifting Standard
PTS 12.23.01 Pedestal-Mounted Cranes for Offshore
PTS 18.52.34 Forklift
CIMG-WW ALL M 04 Inspection and Maintenance Guidelines

002
SI 2007/1573 The carriage of dangerous goods and use

of transportable pressure equipment
regulations
UHSE GU 0009 Guidelines-Upstream HSE Leaders, HSE

Critical Positions & HSE Regulatory
Competent Persons Competency
Management
WW ALL 005 001 Simultaneous Operations Guidelines
WW ALL S 05 002 PETRONAS UPSTREAM PTW Rev4

Internal
Page 156
Rev 1 JUNE 2017
WW ALL 05 004 Confined Space Entry procedure

Rev1 May 2017
WW ALL S 04 109 PETRONAS UPSTREAM Bypass SCE

Guidelines
BS EN 1089 Transportable Gas Cylinders-Gas

Cylinders Identification (Excluding LPG)-
Part 3 Color Coding
BS 1290 Specification for Wire Rope Slings and

Sling Legs for General Lifting Purposes
BS EN 13414-1 Steel Wire Rope Slings Safety, Slings for

General Lifting Purpose
BS EN 1492-1 Textile Slings, Safety, Round Slings made

of manmade fibres for general purpose
use
BS EN 1968 Transportable Gas Cylinders-Periodic

Inspection and Testing of Seamless Steel
Gas Cylinders
BS 5073 Stowage of Goods in Freight Containers
BS 6210 Code of Practice for the Safe Use of Wire

Rope Slings
BS 7072 Code of Practice for Inspection and Repair

of Offshore Containers
HSG 78 Dangerous Goods in Cargo Transport

Units
MOPO Manual of Permitted Operations
Note: A number of international standards exist on each of

the topics and are not in the above list. These are referred
inside the above referenced documents
Internal
Page 157
Rev 1 JUNE 2017
8.4 PEDESTAL CRANE INSPECTION CHECK LIST
Rev1 May 2017
Internal
Page 158
Rev 1 JUNE 2017
PEDESTAL CRANE INSPECTION CHECK LIST-Cont..
Rev1 May 2017
Internal
Page 159
Rev 1 JUNE 2017
PEDESTAL CRANE INSPECTION CHECK LIST-Cont.. Rev1 May 2017
This check list is a generic extract from various OEM maintenance manuals.
Internal
Page 160
Rev 1 JUNE 2017
8.5 CRANE HOIST INSPECTION CHECK LIST Rev1 May 2017
Internal
Page 161
Rev 1 JUNE 2017
CRANE HOIST INSPECTION CHECK LIST-Cont..
Rev1 May 2017
Internal
Page 162
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 163
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 164
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 165
Rev 1 JUNE 2017
Rev1 May 2017
Notes:
1. Based on the site tear down inspection if there is a need for
major refurbishment, the complete hoist assembly shall be
sent onshore for service and parts replacement and tested.
2. For testing offshore it is recommended to use water bags
instead of dead(solid) weights to have better control on
incremental loading
Internal
Page 166
Rev 1 JUNE 2017
8.6 Mobile Crane Selection Check List
Rev1 May 2017
Internal
Page 167
Rev 1 JUNE 2017
8.7 Mobile Crane Safety Check/Service Check List
Rev1 May 2017
Internal
Page 168
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 169
Rev 1 JUNE 2017
8.8 Mobile Crane Inspection Report
Rev1 May 2017
Internal
Page 170
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 171
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 172
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 173
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 174
Rev 1 JUNE 2017
8.9 Mobile Crane Operators Maintenance Inspection Report
Rev1 May 2017
Internal
Page 175
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 176
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 177
Rev 1 JUNE 2017
8.10 MOBILE CRANE INSPECTION CHECK LIST
Rev1 May 2017
Internal
Page 178
Rev 1 JUNE 2017
MOBILE CRANE INSPECTION CHECK LIST-Cont..
Rev1 May 2017
Internal
Page 179
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 180
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 181
Rev 1 JUNE 2017
Rev1 May 2017
Internal
Page 182
Rev 1 JUNE 2017
ASME & API Recognized Hand Signals Rev1 May 2017
The Hand Signals for mobile cranes are similar as applicable for pedestal
cranes. In addition the following 2 signals are for extending and retracting the
boom.
EXTEND BOOM (Telescoping Boom) RETRACT BOOM (Telescoping Boom)

One Hand Signal One fist in front of One Hand Signal One fist in front of
Chest with thump tapping chest Chest, thump pointing out-ward and
heel of fist taping chest
Internal
Page 183
Rev 1 JUNE 2017
8.11 Jib Crane Inspection Check List
Rev1 May 2017
Internal
Page 184
Rev 1 JUNE 2017
Jib Crane Inspection Check List-Cont..
Rev1 May 2017
Internal
Page 185
Rev 1 JUNE 2017
8.12 Overhead Crane Inspection Check List
Rev1 May 2017
Internal
Page 186
Rev 1 JUNE 2017
Overhead Crane Inspection Check List-Cont.. Rev1 May 2017
Internal
Page 187
Rev 1 JUNE 2017
Overhead Crane Inspection Check List-Cont..
Rev1 May 2017
Internal
Page 188
Rev 1 JUNE 2017
8.13 Appliance Pre-load out inspection check list
Rev1 May 2017
Company Name : Project Name :
Destination : Vessel Name :
Appliance No (if applicable) : Prepared & Checked By :
Date :
Inspected Remarks
(initial)
DOCUMENTATION Con PU OP
1 Check manifest / consignment of goods against container’s contents
are correct If not reject shipment
2 Is a copy of test certificates in date and corresponding with
appliance
a) Design criteria certificates (EN 12079) compliant
3 Are correct IMDG and MSDS available? (if applicable)
If not reject shipment
4 Check loaded items is within the weight limit against manifest
certificates
5 Remove old Pre-Transfer sticker
6 Attach new sticker once the checks are completed and safe for
transfer
APPLIANCE
1 Is appliance and accessories marked with a SWL and unique ID
number matching the test certificate? If not reject shipment
2 Check for physical damage/corrosion (including floor, forklift
pockets, front/back/right/left sides, ceiling/roof, doors and bottom
support under carriage the container) prior to loading.
3 Check for loose object on top/inside/outside/forklift channel of
appliance.
4 Check door hinges, handles and locking device in good condition.
5 Check for tag line (availability and adequate length, old & broken
tagline to be removed).
6 Check that the doors are locked and secured correctly.
SLINGS Con PU OP
1 Inspect sling assembly against test certificate to ensure inspection
date is valid and correct colour coding is viable.
2 Inspect ferrule / ID tag on sling assembly to ensure correct serial
number and SWL.
3 Inspect slings for physical damage (kinks/bird caging/broken
wire/corrosion)
4 4 legged slings container – check for master link & 5th leg (if
applicable)
5 Check slings are correctly fitted and not twisted and not dragging on
the floor
6 Check slings for adequate lubrication
SHACKLES Con PU OP
1 Inspect shackles for correct SWL and ID no matching test certs.
2 Inspect shackles for physical damage.
Internal
Page 189
Rev 1 JUNE 2017
Appliance Pre-load out inspection check list
Company Name : Project Name : May 2017
Rev1
Destination : Vessel Name :
Appliance No (if applicable) : Prepared & Checked By :
Date :
3 Inspect shackles for correct colour coding.

4 Ensure only 4 parts shackles used with correct nut
fastened & safety pin installed.
LOAD Con PU OP
1 Check that load in open top container are secure/tied
down for easy handling
Check load does not extend above top of container
2 Check for load inside container :
Palletized material safely and correctly stacked
Safety net secured (if applicable)
Has the dangerous good requirement met for
transporting dangerous goods and has the item
labelled properly and MSDS available (if applicable)
Check for proper packing
TUBULARS Con PU OP
1 Inspect sling assembly against test certificate to ensure
inspection date is valid and correct colour coding is
visible.
2 Inspect load is slung correctly, double choke hitch,
dogged and tie wrapped.
3 Ensure no loose object inside tubulars (i.e. Timbers,
stones, rigging tools etc)
4 Is the protectors (casing only) secured properly
Note – Use the remarks section to record any anomalies as well as compliance Y/N
LEGEND: Con-Contractors, OP-Offshore Personnel, PC-PETRONAS CARIGALI
Checked & Prepared By: (Contractors) Verified By: (PC Supply Base Received By:(Offshore
Personnel) Personnel)
Name: Name: Name:

Position: Position: Position:
Signature: Signature: Signature:
Date: Date: Date:
Internal
Page 190
Rev 1 JUNE 2017
8.14 Examples of Good (Safe) Packing Methods
Rev1 May 2017
No Description Illustration
1 Air Bag
2 Insert Basket
For loading inside
a closed container
(also known as
stillage)
Do not overload
3 Container Net
Ensure bottom
and top skirt is
fully tightened
Internal
Page 191
Rev 1 JUNE 2017
4 Corded Polyester
Lashing Rev1 May 2017
Ensure Lashing is
Certified
5 Door secondary
securing device
Typical methods
include:
a. Custom
type metal
seals
b. Metal
Karabiner
c. Heavy duty
tie-wrap
(7.6mm
minimum
width)
d. Wire door
seal
e. Inspection
tags
Internal
Page 192
Rev 1 JUNE 2017
8.15 Training and Competency Requirement Rev1 May 2017
Below is the recognized training centers for trainers/assessors:
i. Offshore Petroleum Industries Training Organization (OPITO)

ii. Any crane manufacturer holding an API 2C Monogram License and who
are providing such training and certification for Trainers/Assessors.
iii. Other training centers or individuals who have been evaluated and
approved by PETRONAS CARIGALI.
Training requirement for a crane operator shall cover as following:
1. Types of Cranes
 Mechanical cranes
 Non-mechanical cranes
 Electric powered cranes
 Other types of crane
2. Crane components and lifting capacities
 Components of a stationary mounted crane
 Boom angle and load radius, reading a range diagram or load
rating chart.
 Number of parts of line and relationship to rated load.
 Limitations of the size and type of wire ropes used in boom hoist
lines, pendants and load hoist line.
 Lifting capacity of the auxiliary hook.
 Lifting capacity of load and boom hoist drums.
 Consideration of sea state on operating conditions.
3. Wire rope construction and use
 Mechanics of wire rope.
 Classes, designation and characteristics of wire rope.
 Handling of wire rope
 Guidelines for replacement of wire rope
 Wire rope slings
4. Mounting features of the revolving upper structure
 Hook rollers
 Ball ring
 King post
Internal
Page 193
Rev 1 JUNE 2017
 Others
5. Boom structure Rev1 May 2017
 Types of boom construction (lattice, box, etc.)
 Wire rope guides
 Boom bolts
 Pin connections.
6. Limit device
 Boom-hoist limit
 Load hoist limit
 Boom stops
 All locking devices
 Anti-two block devices
7. Additional items
 Sheaves
 Hand signals
 Control markings
 Engine emergency stop
 Gauges and indicators
Competency Level of Crane Operator
1. Trainee Operator
A trainee crane operator is deemed to be a person who has met the
following requirements:
 Physical fitness
 A 60 to 80% pass in classroom training
 Complete a satisfactory period (minimum 15 hours) of hands-on
training under the guidance of the Instructor or until such time
when the instructor certifies that the trainee can operate a crane
satisfactorily.
Upon completion of the hands-on training, the trainee can operate the
crane on platform but subject to the following conditions:
 Can only operate the crane with the presence of qualified crane
operator in the cabin to supervise
 No personnel lifting on a personnel basket
 No load lifting with safety system in bypass mode
Internal
Page 194
Rev 1 JUNE 2017
 No load lifting which normally requires a lift permit
 Rev1
No lifting of any load exceeding 20& SWL of the May 2017
crane
2. Level 1 Offshore Crane Operator
A Level 1 offshore crane operator is deemed to be a person who has met
the following requirements:
 At least a 60 to 80% pass mark in hands-on training
 Completing hands-on training and pass the proficiency test
 Failed candidates shall undergo a review session before re-training
 Refresher courses will be carried out every 4 years
 Will not lift any load above 8MT, unsupervised, which is considered
a special lift or 50% of the SWL.
3. Level 2 Offshore Crane Operator

A Level 2 offshore crane operator is deemed to be a person who has met
and sustained the following requirements:
 80 to 100% pass mark in hands-on training
 Can operate a crane unsupervised and load will not exceed 100%
of the SWL of the particular crane
With this minimum training, the operator is also qualified to perform the
crane inspections as stated in clause 4.12.2 of API RP 2D, with the
exception of the initial Quarterly and Annual Inspection.
Training requirements for riggers are as following:
1. Rigging hardware consists of

 Sheaves and blocks
 Hooks and latches
 Rings, links, swivels
 Shackles
 Turnbuckles
 Spreader and equalizer beams
 Cable clips
Internal
Page 195
Rev 1 JUNE 2017
 Pad eyes, eyebolts and other attachments
Rev1 May 2017
2. Slings
 Sling configuration
 Sling angle
 Rated load
 Sling types (synthetic, wire, chain, etc.)
 Cargo nets, personnel baskets, and other basket type
3. Procedures and precautions
 Load control/taglines
 Lifting planning (load weight, center of gravity, etc.)
 Sling inspection/rejection criteria
 Unbinding loads
 Personnel transfer
 Sling handling and storage
4. Rigging basics
 Pinch points/body position
 Personnel; protective Equipment (PPE)
 Signals/communications
 Load stability
Internal
Page 196
Internal

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Rev 1 JUNE 2017

PETRONAS CARIGALI SDN BHD

Rev1 May 2017

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DOCUMENT AUTHORIZATION Rev1 May 2017

TABLE OF CONTENTS Rev1 May 2017

1.4 Order of Document’s Precedence………………………………………… 2

1.5 Definition of Terms………………………………………………………………. 2

2.0 LIFTING EQUIPMENT OVERVIEW

2.1 Categories of Lifting Equipment…………………………………………… 3

2.2 Pedestal Crane – Lattice Boom Type…………………………………… 4

2.3 Pedestal Crane- Box Boom Type (Ram Luffing Crane)………. 5

2.4 Telescopic Boom Cranes………………………………………………………. 6

2.5 Pedestal Crane-Kingpost Type…………………………………………….. 7

2.6 Single Girder Bridge Cranes…..……………………………………………. 8

2.7 Double Girder Bridge Cranes……….…………………………………..…. 9

2.8 Pillar Jib Crane….……………………………………………………………..….. 10

3.0 PART 1: OFFSHORE PEDESTAL CRANES Rev1 May 2017

3.1 Offshore Pedestal Cranes………………………………………………………

3.2 Offshore Pedestal Crane - Minimum Standards and

3.2.2 Wedge sockets……………………………………………………………. 13

3.2.4 Load Block Assembly………………………………………………….. 16

3.2.5 Boom Hoist and Load Hoist Mechanisms…………………… 16

3.2.6 Telescoping Boom Mechanisms…………………………………. 17

3.2.7 Swing Mechanisms……………………………………………………… 17

3.2.8 Swing Locks………………………………………………………………… 18

3.2.9 Prime Movers………………………………………………………………. 18

3.2.10 Exhaust Systems………………………………………………………. 18

3.2.11 Fuel Tanks…………………………………………………………………. 19

3.2.12 Over Speed Shutdown……………………………………………… 19

3.2.14 Platforms and Walkways…………………………………………… 20

3.2.15 Rigging Access………………………………………………………….. 20

3.2.16 Boom Equipment………………………………………………………. 20

3.2.17 Guards for Moving Parts…………………………………………… 21

3.2.18 Clutch and Brake Protection…………………………………….. 21

3.2.19 Lubrication Points and Fluid Fills……………………………… 21

3.2.20 Personnel Emergency Load Lowering………………….…… 21

Rev1 May 2017

3.2.22 Safety Devices………………………………………………………….. 22

3.2.24 Crane Manuals…………………………………………………………… 23

3.2.25 Operations With Service Vessels……………………………… 24

3.3 Heavy Usage…………………………………………………………………………. 25

3.3.1 Pre-use Inspections……………………………………………………. 25

3.3.2 Monthly Inspections……………………………………………………. 25

3.3.3 Quarterly Inspections…………………………………………………. 25

3.3.4 Annual Inspections……………………………………………………… 25

3.4 Inspection of Critical Crane Components……………………………. 26

3.4.1 Hoist Assemblies…………………………………………………………. 26

3.4.3 Swing Circle assembly –General Inspection……………… 26

3.4.4 Swing Circle Assembly………………………………………………… 27

3.4.5 Wear Assessment by Rotation method……………………… 29

3.4.6 Crane/ Bearing connection integrity………………………….. 30

3.5 Load Test………………………………………………………………………………. 31

3.5.1 Proof Load Test…………………………………………………………… 31

3.5.2 Functional Load Test…………………………………………………… 31

3.5.3 General Guidelines……………………………………………………… 32

3.5.4 Test Weights for Proof Load Test………………………………. 33

3.5.5 Load Application…………………………………………………………. 33

3.5.5.1 Suspended Weight Method……………………………. 33

3.5.5.2 Dynamometer Method……………………………………

3.6 Crane Hoist Inspection…………………………………………………………. 35

3.6.1 Pre-Use Inspection……………………………………………………… 35