TUV SOUTHWEST www.tuvsw.com PROCEDURE FOR INSPECTION AND CERTIFICATION OF MOBILE ELEVATING WORK PLATFORMS Prepared By: Hamza Reviewed By: Naresh Kumar Authorized By: Waqas Arshad Procedure Ref #: SW/TIP-MWP/001_| Rev.3 Issue Date:23/07/2020 ‘Mais.an ote documento TW South West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page 1 of 9TUV SOUTHWEST www.tuvsw.com TOV 1. Intent: To define and outline the responsibilities, sequence and procedural requirements for Mobile Elevating Work Platforms Inspection & load testing in accordance with International Standards mentioned below. i. Objective: This procedure covers all Inspection bodies in all areas. wu, Duties / Responsibilities: + The Inspector assigned for the job has to be a competent person with sufficient ‘experience and knowledge in the inspection’ test of lifting equipment, Lifting head is responsible for the review of this Procedure Lifting head is responsible for the preparation and revision of this procedure. ‘The dept manager is responsible for the review of the procedure and General Manager is responsible for the Approval. iv. Relevant Standards and Code of Practice SN | Applicable Standards Title Identifier UAE. Federal Ministry of Law Federal Ministiy of Law and Social Affairs, 10.1.83- M.O. No: 32 — 10.1.83, Article 20 Mobile elevating work platforms - Design 2 BS EN 280:2013+A1:2015 __| calculations ~ Stability criteria - Construction - Safety — Examinations and tests BS 8460:2017 Code of practice forthe safe use of MEWPS BS 6037-1:2017 (Code of practice for the planning, design, installation and use of permanently installed access equipment ofa, ale LEEA Lifting engineer's hank book LEEA Code of practice for safe use of lifting equipments 7 SEN EDIE! Protection against falls from a height — Anchor devices — Requirements and testing Note: 1. Also, considerations and reference to the standard /code to which the equipment has been built has to be given due attention. 2. Related reference standard may also be referred duringinspecton test. v. Overview of the Procedure for Thorough Examination: 7 oficial document of TUY South West Printed copies without te original seal ofthe company Is “Uncontrelled Copy”. Page2 of 9TUV SOUTHWEST www.tuvsw.com TLV Subsequent to client request, the unit has to be thoroughly examined visually for all its sections ie. Cradle, wire ropes, counter weight, boomi/jib, winches, trolley, all hydraulic! electric hoses/connections, Mast structure, mast fasteners, control panel , foundation, rails, any other leakages etc. Then test the Equipment functionally prior to any loading. Apply applicable codes/standards to evaluate any discontinuities either as Satisfactory OR Unsatisfactory with any part or function. ‘Also inspect the foundations and ties prior to loading for any defects and or deviations from the recommendations of the manufacturer. Refer also the design for proper measurements and locations of ties. This ensures that there are no visible discontinuity/s that may be detrimental during a lift later vi. The Documents to be reviewed prior to examination are: Record of Pre use & in-services check lists Previous Reports of thorough examination Wire rope certificate, (if replaced) Safe Working Load clearly marked on the crane and duty charts fixed to it Lifting attachments marked with their safe working load Individual Certifications of personnel involved Maintenance records Prior to performing any tests loads, the manufacturer's instructions should be obtained or alternatively, a referenced authority on the design and construction of the crane, The said Information should be consulted, understood and implementation prior to test load VV VVVVVY vil. Procedure Instructions: > Barricade the area and ensure only relevant personnel are within the boundary and no one under the platform > Identify the hazards in the area of inspection, try to eliminate them. If not practical, at least isolate them. Make sure there are no obstructions in the range of Equipments area of coverage. Make sure that the visibility is good and the weather is clear. Ensure that there is a safe distance maintained from high voltage lines all the time and wind speed is within permissible limits as per project specifications limits. > Ensure no loose or uncovered electrical cables running over the structure, Make sure they are safely secured and properly grounded. Earth resistance measured and the values compared with the manufacturer's manual. vy Preparations: By reviewing the load chart, select your weights based on what kind of inspection the Equipment is due for. LEEA requires the weight to be within +1.0 % acuracy and also the accuracy of weighing scale/gauge shall be within +1,0 % . The scale shall be calibrated with valid certificate available for review. » Inform the client representative and all others involved what you are intending to do, preferably conduct a small tool box talk and fix authorities and responsibilities. vvy ‘Mais.an ote documento TW Sout West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page3 of 9TUV SOUTHWEST www.tuvsw.com TLV > Ensure that a client approved representative is present with you all the time and that he is in agreement with your decisions. A. Toolbox Meeting & General Risk Assessment Before proceeding in any kind of job, test or inspection, a Toolbox Meeting should be conducted that focuses on safety topics related to the specific job, such as workplace hazards and safe work practices. B. Test weights Test wolgualgp rou be: Weights of proven accuracy to within + 2% Weights proven on weighbridge, valid 12 months calibration certificate required, > Weights suspended from calibrated weighing device, 12 month calibration certificate required wy v C. Preparation of PPE & Tools: The inspector should ensure that: > Personal safety equipment that is appropriate for the conditions of the location is available, such as helmets, safety spectacles, fall protection equipment, safety boots, ear defenders and life jackets or other buoyancy aids; > Equipment is inspected before and after use and maintained in good working order Ensure all the equipment used during inspection/test i.e caliper, Spirit Level, measuring tape, Load cell etc shall be in good condition and shall be certified where ever applicable. ¥ D. Thorough Examination: Chassis and stabilizers: > Inspect the automatic safety device in accordance shall be fitted to prevent the travel of pedestrian controlled MEWPs and power driven MEWPs when the work platform out of the transport position. y Any travel speed restriction for self propelled MEWPs, when the work platform is out of the transport position, shall be automatic. v Inspect the level device (e.g. spirit level) to indicate whether the inclination of the chassis is within the limits permitted by the manufacturer. This device shall be protected against damage and accidental change of its setting. > For MEWPs with power driven stabilizers the indication shall be clearly visible from each control position of the stabilizers. > On MEWPs of vertical type (e.g.scissor lft) reaching the extreme limits of inclination this shall be indicated by an acoustic signal audible at the work platform. ‘Mais.an ote documento TW South West. Printed copies wthouttecrigna sel of he company Is “Uncontolled Copy” Page 4 of 9TUV SOUTHWEST www.tuvsw.com TLV v Check the Contro-bars of pedestrian controlled MEWPs and tow bars shall be securely fastened to the chassis. v For MEWS which are constructed for operation with stabilizers, the stabilizers shall be capable of leveling the chassis to within the maximum allowable inclination when operating on the maximum slope permitted by the manufacturer. > Vehicle mounted MEWPs shall be equipped with an indicator visible from the travelling controls within the cab to indicate if any component of the MEWP is not in its transport position. MEWPs shall be equipped with a device to prevent unauthorized use (e.g. lockable switch). > It shall not be possible to exceed the following travel speeds with manned work platforms out of the transport position on MEWPs: v a) 1,5 d s for vehicle mounted MEWPs when using the travelling controls inside the cab; ® — b) 3,0 ds forrail mounted MEWPs; > — c)0,7ds forall other self-propelled MEWPs. Load sensing system: > The load sensing system is a safety device and shall operate in the following way: > a) It shall prevent any normal movement of the work platform from a stationary working position after the rated load is reached and before 120 % of the rated load is. exceeded. v b) When normal movement is prevented according to a) a warning consisting of a flashing red light at the preselected control position together with an acoustic signal audible at each control position shall be activated. The light shall continue to flash all the time condition a) prevails and the acoustic alarm shall sound for periods of at least 5 seconds repeated every minute. % ¢) Normal movement can only restart if the overload is removed. > d) To avoid overturning of the MEWP or exceeding the permissible stresses in the structure of the MEWP, the permissible positions of the extending structure shall be limited automatically by mechanical stops non-mechanical limiting devices or electrical safety devices. > e) hydraulic/pneumatic parts of these devices/systems which act directly on full-flow valves of hydraulic/pneumatic systems need to be duplicated if a failure of one component does cause a dangerous situation, Pilot operated control valves in these device systems shall be so designed and installed that they fail to safety (ie. stop of the corresponding movement) in the event of power failure. > Verification: by visual examination & functional test. ‘Mais.an ote documento TW South West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page of 9TUV SOUTHWEST www.tuvsw.com TLV Structure test: > — Inspect the whole structure of the mast for any visible damage, signs of corrosion, cracks, weld joints and arrangement of mast sections. v All the connecting fasteners that are installed fixed tightly to the correct torque limits. v Look for the electrical cables for any damage, and make sure they are properly tied up v Visually inspect for any cracks, wear, fasteners being loose etc. Proper lubrication is. essential. > The mechanism shall be capable of smooth operations without giving any jerky movements due to improper engagements or gaps between the gears Static tests: > The test should be carried out on level ground if the test loads are re-calculated to include the effects of the maximum allowable inclination of the chassis defined by the manufacturer plus 0. 5° > Apply the test load (during the over load test) at any suitable strong point, if necessary, to avoid over-stressing any part of the MEWP. Dynamic tests: 1- Kerb test 2 Braking test 4-Kerb test : Drive the MEWP (except rai-mounted) on level ground at the maximum permitted travel speed to drive and check. a) each leading wheel in turn into contact with a kerb with a height of 0, m perpendicular to the driving direction; and b) Both leading wheels simultaneously into contact with the same kerb; and c) Each leading wheel in turn off the same kerb; and d) Both leading wheels simultaneously off the same kerb. The tests are to be repeated driving in both forward and reverse directions, in each extended position of the MEW and, if different travel speeds are allowed for different heights, at each of those heights at the maximum permitted speeds for those heights. During these tests it is not necessary to simulate the effect of the permissible wind speed. ‘Mais.an ote documento TU South West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page 6 of 9TUV SOUTHWEST www.tuvsw.com TLV During the above tests the MEWP shall not overturn. 2- Braking tests MEWPs (expect vehicle mounted) shall be stopped as rapidly as the controls allow in both forward and reverse directions in each MEWP position and combination of slope, loads and forces which together create conditions of minimum stability and, if different travel speeds are allowed for different heights, at each of those heights at the maximum permitted speeds for those heights. " During these tests it is not necessary to simulate the effect of the permissible wind speed. Load Test: * Objective of load testing is to determine whether the equipment is structurally ‘sound and fit for the purpose for which it was designed. The test should include every load-bearing member. Overload Test: * The test load shall be 125 % of the rated load for power operated MEWPs, and 150 % of the rated load for manually operated MEWPs. + All movements with the test loads shall be carried out at accelerations and decelerations appropriate with safe control of the load. Where several movements with the test load have to be carried out (ie. lifting, lowering, slewing, travelling), the intended movements shall be carried out separately and with care taking into due account the least favorable positions and when vibrations associated with preceding movements have subsided * During the overload test the Equipment should be capable of handling the overload and the brakes on each motion should be proved to function effectively + The platform should be evenly loaded with its rated load (which by necessity may include operators) and operated over its full range of movement, During this test the suspension rig should be observed closely to determine whether it functions correctly under load and whether any deterioration which could affect, the safe operation of the equipment is apparent. All limit switches and under/overload detection devices should also be observed during the test to determine whether they are functioning correctly. * When, due to the various combinations of loads or outreaches of a MEWP, tests with different test loads are necessary, all movements shall be carried out with all test loads except where the least favorable conditions can be sufficiently simulated by one performance test. ‘Mais.an ote documento TW South West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page 7 of 9TUV SOUTHWEST www.tuvsw.com TLV * During the overload test the braking systems shall be capable of stopping and sustaining the test load(s). After removing the test load(s) the MEWP shall show no permanent deformation. * On completion of the test a Thorough examination of the Equipment should be carried out to look for any defects such as cracking, permanent deformation, paint flaking, loosening of or damage to structural connections. Any additional tests such as NDT may be recommended if required, to aid the examination of suspected areas. * During testing with overloads all operations should be carried out with extreme care and every permissible Equipment motion carried out singly at the lowest possible speed. + During the load test Functional tests shall demonstrate that: a) The Equipment can operate smoothly for all motions whilst carrying 110 % of the rated load at the rated speeds; b) All safety devices work correctly; c)Maximum permitted speeds are not exceeded; d) Maximum permitted accelerations and decelerations are not exceeded. Note: * Duration of Thorough examination and /OR Test of the Equipment, are subjected to Local Regulations, International standards and project specifications. These are to be reviewed prior to conducting any type of Test for the Equipment vil. Certifica H n * After completion of every thorough examination, a Test Certificate has to be prepared covering all the minimum information specified under relevant standard/specification. + If the Equipment examination is not found satisfactory, a “Pre Examination Report” must be submitted to the client, in which the defect and the Tecommendations are clearly mentioned. Also a statement saying that the “Equipment shall be re inspected after repair for its Certification” to be clearly written Where the thorough examination is to be carried out in accordance with a written examination scheme, a site-specific risk assessment should be carried out to allow the examination scheme to be drawn up. ix. RECORDS SN Control Name Retention Period Inspection Report or Certificate of Inspection Syears 2 Filled-up Inspection Checklist / Rough Reports Tyears ‘Mais.an otal documento TW South West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page 8 of 9TUV SOUTHWEST www.tuvsw.com ‘Mais. ote documento TU Sout West. Printed copies wthoutte origina sel of he company Is “Uncontolled Copy” Page of 9