05 Tm Lifting Gear Issu a Rev4

KIAS SAFETY CONSULTANCY

P.O. Box 86441 Dubai, U.A.E. Tel. 04 - 2726676 Fax 04 – 2712282

TEST METHOD

THOROUGH INSPECTION OF

LIFTING GEAR

TEST METHOD NO. : KSC/05/TM

RELATED STANDARDS : BS EN 818-4 BS EN 818-5 BS EN 818-6 BS EN 13414-1 BS EN 13414-3 BS EN 13889+A1 BS EN 1492-1 BS EN 1492-2 BS EN 1492-4

DAC REQ -06

RELATED FORMS

QSP09–D–01 QSP09–D–16 QSP09–D–24

QSP09–D–26 QSP09–D–27 QSP09–D–28

QSP09–D–29 QSP09–D–30

COPY NO. : APPROVED BY : GENERAL MANAGER


Document Title: THOROUGH INSPECTION OF LIFTING GEAR

Test Method No. KSC/05/TM Issue A Rev. 4

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C O N T E N T S

Section Description Page #

0 Amendment page 3

1 Purpose 4

2 Scope 4

3 Definitions 4

4 Procedure 4

5 Wire rope sling 4

6 Chain sling 7

7 Webbing belt 8

8 Shackles 10




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0. AMENDMENT PAGE

Amendment No.

Date

Pages affected

Amendment Description Authorized Signature

1 24/10

2013

5

6

Added 3 figures for wire rope

2

24/10

2013

4&5

6

7

Added section 4.0.1,2,3

Added 2 lines

Added 1 line

3

04/01

2014

1

Added reference standards

4

28/02

2015

11

Added related forms




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1.0 Purpose

The purpose of this procedure is to outline the full range of thorough

inspections required to be performed by our inspector.

2.0 Scope

This method statement covers the thorough inspection to be performed by

our inspector to satisfy the customers for inspection of chain block, chain

sling, wire rope sling, shackle and webbing sling.

3.0 Definitions:

3.1 Diameter: The length of a straight line drawn from one side to the other

through the centre of a circle.

3.2 Eyebolt: Lifting ring attached to a load.

3.3 FSWR: flexible steel wire rope sling.

3.4 Grade: Indicates the strength of chain or FSWR.

3.5 Reeve (Nip): A method of slinging where the sling passes back through

itself reducing the safe working load.

3.6 Ring: End link of a chain assembly.

3.7 Safe working load: The maximum load that can be safely lifted by a

particular sling, attachment or machine.

3.8 Shackles: Attachment for joining a sling to a load or a hook..

3.9 Sheave: A pulley through which flexible steel wire rope moves.

3.10 Sling: Lifting gear made from steel wire rope, chain or synthetics.

3.11 Spreader: A beam with a central lifting attachment that reduces the strain

on the lifting gear.

3.12 Swivel: A rotating sling attachment that rotates without spinning the wire,

hook or load.

3.13 Working Load Limit (WLL) Maximum load (mass), lifting equipment

may lift safely in the most efficient configuration. For wire rope, chain

and fiber rope slings this is in direct lift i.e. eye to eye in a straight

vertical line.

4.0 Procedure:

4.0.1 Prior to going to site, the inspector must ensure that all needed

Personnel Protective Equipment are used by him & others engaged




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on this activity, also he must check the critical test equipment prior to

leaving his office or before inspection.

4.0.2 the inspector shall request the manufacturing operations manual, or

maintenance manuals of the loose gear, otherwise the safe working

load charts in English and/or Arabic language and in case not

available and not possible to provide, he shall ensure that an

independent competent person be engaged by the owner to provide

advice and documentation to support the continued use of the lifting

gear sizes, grades and Markings etc.

4.0.3 the inspector shall use the tables attached to each british standards

mentioned on the cover page of this statement as rule for getting the

required values of any lifting gear for the purpose of completing the

inspection properly.

4.1 Wire Rope inspection

a) All wire ropes & slings must have a certificate of test showing size of

rope in mm. number of strands, number of wires per strand, grade of

wires, date of test and the working load limit.

b) The size of a rope is determined by its diameter. The smallest diameter

FSWR that can be used for lifting is 5 mm.

c) The figure to right shows the correct method of measuring the wire rope

using caliper, for soft eye measure the effective length from centre of eye

approximately. The left figure shows sample construction of a wire rope.

A 6/19 (six strands of 19 wires each) is the minimum FSWR

construction that can be used for slings.




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d) The Rule of Thumb. When inspecting wire rope, observe the

construction and lay of the rope, Check for signs of stretching, Check the

whole rope for broken wires. Where broken wires are present count the

number of broken wires in a length of rope eight times the rope diameter.

The total number of broken wires must not exceed 10 per cent of the

total wires.

For example:

In a 6 x 24 rope (6 strands of 24 wires) the total number of wires is 144.

The diameter of the rope is 12 mm.

Length of rope to inspect = 12 (mm) x 8 = 96 mm.

Number of wires = 6 x 24 = 144

10% of 144 = 14.4 wires. Therefore, 14 broken wires in a 96 mm length

would indicate that the rope is unfit for use.

e) Splicing of Wire Rope

A thimble or loop splice made in any wire rope is to have at least three (3)

tucks with a whole strand of the rope and two (2) tucks with one-half of the

wires cut out of each strand, provided that this requirement does not prevent

the use of another form of splice which can be shown to be as efficient as

that laid down in this Paragraph.

f) Condition of Wire Rope

Discard FSWR slings if there is:

1- A single broken wire below a metal socket, end fitting or a machine

splice

2- Abrasion and core collapse, protrusion

3- Corrosion — red oxide powder and loose and springy wires can

indicate serious corrosion. (Check the valleys between the wires for

corrosion beneath the surface).

4- Kinks, knots or fractures from bending or reeving

5- crushed or jammed strands or waviness due to localized damage




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6- Birdcaging — faulty whipping of bare ends allows the strands to

loosen from their proper tight.

7- Lay. It can be caused by rotation of the end of a rope or a sudden

release from high loading.

8- High stranding — where a strand has slipped around the lay and

projects above the surface due to faulty whipping and cutting of the

rope ends.

9- Check splices for damaged, tucks, corrosion and drawing out.

10- Check the swaged splices for fatigue, corrosion, wear and broken

wires where the rope enters a splice.

11- Exposure of red core warning yarn. (For slings containing red core

warning yarn.)

12- Any evidence of heat or chemical damage, including melting of

charring.

13- Metal fittings that are cracked, deformed, pitted, corroded or

excessively worn.

14- Hooks with throat openings increased by more than 15 percent or

twisted out of plane more than 10 degrees.

15- Any other visible damage which causes doubt as to the sling

strength.

16- Wear, if dia reduced to 90%

4.2 Chain sling:

Chain is considerably heavier than FSWR of the same lifting capacity but is

more durable. It can better withstand rough handling and can be stored

without deterioration.

4.2.1 Always check that the grade on the tag matches the grade markings on the

chain.

4.2.2. Grade (T): Most chain being manufactured today for lifting is Grade (T) or

80 alloy steel. It is stamped (T), 800, 80 or 8, HA PWB, or CM and various

combinations of the above. It has become the most commonly used chain for

lifting in industry.

4.2.3 Grade (P) Usually stamped (P), 40, 4, or 04.

4.2.4 Grade (L) or 30 mild grde steel. Can be stamped (L), 30 or 3

4.2.5 Special grade, Some manufacturers of chain have lifting chain with greater

strength than Grade (T). Follow manufacturers load ratings when using this

chain.




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4.2.6 Wrought iron chain and proof coil are not graded and must not be used for

lifting.

4.2.7 the inspector shall clean the chain before inspection., if necessary.

4.2.8 Inspect each link for signs of wear, twisting, stretching, nicks or gouging.

(Links that are frozen together show that the chain has been stretched.)

4.2.9 Find cracks by dusting chain with fine powder. Dust any link that is suspect

and then blow the loose particles away. Dust particles will lodge in any

cracks making them more visible.

4.2.10 Measure all worn links for the degree of wear. Wear must not exceed that

allowed for by the manufacture,

a) The maximum allowable chain wear is 10 per cent.

b) The maximum allowable elongation of a chain is 10 per cent.

c) The maximum increase in hook opening is 5 per cent of the original throat

opening.

d) The maximum allowable wear in the bite of a hook is 10 per cent.

4.2.11 Inspect upper and lower terminal links and hooks for signs of wear at their

load-bearing points and for any signs of distortion.

4.2.12 Inspect links and fittings for signs of wear at their load bearing points and

for excessive play in the load pin between the body halves.

4.3 Flat webbing and round synthetic slings:

4.3.1 check for any external wear such as abrasions or cuts and contusions.

4.3.2 Check for internal wear which is often indicated by a thickening of the sling

or the presence of grit and dirt.

4.3.3 Check for damage to the protective




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coating of the sling.

4.3.4 Check for damage caused by high

temperatures, sunlight or chemicals

(indicated by discolouration)

4.3.5 Check for damage to the label or

stitching.

4.3.6 Check for damage to the eyes or any

terminal attachments or end fittings.

4.3.7 Discard a synthetic sling if:

a) it is considered that it has lost

more

than 10 per cent of its original

breaking

strength.

b) there is any damage to the sleeve

or

protective coating.

c) a nylon sling comes into contact

with acid.

d) a polyester sling comes into

contact with

alkaline substances.

e) a polypropylene sling comes into

contact

with an organic solvent such as

paint,

coal tar or paint stripper.

f) there are any visible cuts on the

sling.




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4.4 shackles:

4.4.1 shackles shall be legibly marked with at least the following information:

WLL / Grade number / Manufacturers name or symbol / Traceability code

4.4.2 All shackle pins 13 mm. diameter and above, shall be legibly marked with

Grade number / Manufacturers name or symbol / Traceability code




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4.4.3 Inspection should take place at least every six months and even more

frequently when the shackles are used in severe operating conditions.

4.4.4 examine Shackles to ensure that:

a) the body and pin are both identifiable as being of the same size, type and

make.

b) the threads of the pin and the body are undamaged;

c) verify that the safety bolt type shackle have the split cotter pin;

d) the body and the pin are not distorted, bent or twisted.

e) Examine the body and pin to be free from nicks, gouges, cracks, corrosion

and other defects by visual means and/or suitable crack detection

processes.

f) heat treated shackle shall be rejected as this may affect their Working Load

Limit;

g) Incorrect seating of the pin may be due to a bent pin, too tight fitting

thread or misalignment of the pin holes. Reject the shackle.

h) Examine shackle for excessive wear, wear reduction of greater than 10%

in the diameter of the bow or pin shall be rejected

5. RELATED FORMS

QSP09–D–01

QSP09–D–16

QSP09–D–24

QSP09–D–26

QSP09–D–27

QSP09–D–28

QSP09–D–29

QSP09–D–30

05 Tm Lifting Gear Issu a Rev4

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