7856126 Lifting and Rigging Written Program (1)

Lufkin Middle East

Lufkin Hoisting and Rigging Written program

HSE 10issue 1Date 15/04/2008Prepared by Talaat ElkaderApproved by Craig guillory

INTRODUCTION:

This document refers to the lifting of moving loads by using mechanical devices. The objectives of the hoisting and rigging program are to protect all Lufkin employees from injury and to protect the environment from harm and equipment and property from damage. Improper design, use or maintenance of cranes, fixtures or any other lifting devices and rigging accessories can cause equipment to failure, load to drop from the lifting system resulting in personal injury, death, damage to the environment or significant property loss. the first line supervisor directing hoisting and lifting is responsible for ensuring that personnel who they supervise and who perform hoisting and rigging activities such as designing, inspecting, maintaining and using hoisting and rigging equipment, preparation and approval of lift plans, and review of equipment compliance are qualified to do so. A person may be qualified to perform one of these tasks, but not qualified to perform another.

Supervisors must be knowledgeable of the specific types of hoisting and rigging operations under their supervision. Further, supervisor must be familiar with applicable rules and procedures implemented at the site to ensure that hoisting and rigging work under their control is done efficiently and safely, with safety as top priority. Supervisor must ensure that employees fully understand the importance of safety and they categorize their own authority and responsibility to stop activity when safety is questionable.

1. All cranes and lifting appliances shall have current valid test certificates in accordance with they’re rated capacity and shall be fully insured against third party liability. A copy of the test and insurance certificate must be kept with the vehicle at all times whilst it is on Lufkin sites.

2. The Contractor shall ensure that persons employed to operate cranes or lifting equipment are competent to do so and have been trained in the application of correct of lifting principles and safe working loads.

3. It is not permitted for any person to carry out work, stand, or walk directly, below a load suspended from a crane or hoist.

4. All hooks must be fitted with self closing safety latches.

5. All lifting slings must be in good condition and may be subject to inspection, by Lufkin operation department.

1. scope:

This document applies to all personnel and equipment used to perform any hoisting and rigging activities. Activities involving the following equipments are included:

1. Cranes, hoists, and miscellaneous lifting devices.2. Rigging hardware and accessories.

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3. powered industrial vehicles ( forklifts)

2. Definitions:

1. Free rigging: the direct attachment to or placement of rigging to the tines ( fork) of a powered industrial truck below –the – tines lift.

2. Below the hook lifting device: device that designed to be used in conjunction with a hoist to lift specific types of loads .examples include tongs,C-Hooks,sheet lifters, spreader beams, mill roll lifters, horizontal sheet lifters, lift bails, plate grades, battery lifters, pouring bails, vacuum lifters and trail lifters.

3. Safe upper limit travel: is the highest position of hoist travel that prevents any strain on the hoist rope, or contact of the hook or lower hook block with any part of the hoist or trolley or crane.

4. Sling: wire rope, chain, synthetic web, and metal mesh made into forms. 5. Designated person; an individual selected or designed as being qualified to

perform specific duties.6. 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 an ability and competence to solve or resolve problems relating to the subject matter and work.

7. Positioning device: is a device designed to cut off the control of the hoist motor automatically below the upper over travel device in the upward direction, the positioning device generally will be subject to frequent use during normal hoist operation.

8. Power circuit limit switch: is a device designed to cut off the power to the hoist motor automatically when tripped. The switch is to be used automatically only as an upper over travel device, never a positioning device. The switch shall be rated for full nameplate power of the hoist motor.

9. Material Safety Data Sheet (MSDS): Materials (e.g. chemicals, solutions, solvents, man made fiber, cranes, slings, chains etc.) Containing banned substance is not permitted on the premises.

10. Attachment: A device other than conventional forks or load backrest extension, mounted permanently or removable on the elevating mechanism of a truck for handling the load. Popular types are fork extension clamps, rotating devices, side shifters, and load stabilizers.

11. AUXILLARY HOIST: Supplemental hoisting unit of lighter capacity and usually higher speed than the main hoist.

12. Bending stress: stress on wires of a wire rope imposed by bending. This stress need not be added to direct load stresses. When sheaves and drums are of suitable size, bending stress does not affect the normal life of the wire rope.

13. Birdcage: a colloquialism describing the appearance of a wire rope that is forced into compresasion.the outer strands from a cage and at times displaces the core.

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14. Birdcaging: the twisting of fiber or wire rope in an isolated area in the opposite direction of the rope lay, causing it to take on the appearance of birdcage.

15. Boom line (crane): a wire rope for supporting or operating the boom on derricks, cranes, draglines, shovels, and the like.

16. Boom: a member hinged to the rotating superstructure and used for supporting the hoisting tackle.

17. Bridle slings: a sling composed of multiple legs (branches), the top ends of which terminate in a fitting that latches onto the lifting hook.

18. Bull ring: the main large ring of a sling to which sling legs are attached.19. Cable: a term loosely applied to wire ropes, wire strands, manila ropes, and electric

conductors.20. CHOKER ROPE: A short wire-rope sling used to form a slip noose around the object to be

moved or lifted. 21. CRANE: A machine used for lifting and lowering a load vertically and moving it horizontally

and that has a hoisting mechanism as an integral part of it.CRANES, TYPES OF:22. Automatic Crane: A crane that, when activated, operates through a preset cycle or cycles.

23. Cab-Operated Crane: A crane controlled by an operator in a cab located on the bridge or Trolley.24. Cantilever Gantry Crane: A gantry or semi gantry crane in which the bridge girders Or trusses extend transversely beyond the crane runway on one or both sides.25. Floor-Operated Crane: A crane whose operation is controlled by use of a pendant in The hands of an operator on the floor or on an independent platform.26. Gantry Crane: A crane similar to an overhead crane, except that the bridge for carrying the Trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway.27. Jib Crane: A fixed crane with a vertical rotating member supported at the bottom (also At the top in some types) from which an arm extends to carry the hoist trolley. Jib cranes are most commonly mounted on a vertical Column, supplied as part of the jib crane, or on existing structural members (e.g., a wall mounted jib crane).28. Mobile Crane: For the purposes of this chapter, mobile cranes are defined as wheel mounted Cranes, truck cranes, and crawler cranes.

3. CRANE SAFETY REQUIREMENTS: Cranes are carefully designed, tested and manufactured for safe operation. When used properly they can provide safe reliable service to lift or move loads. Because cranes have the ability to lift heavy loads to great heights, they also have an increased potential for catastrophic accidents if safe operating practices are not followed.Crane operators and personnel working with cranes need to be knowledgeable of basic crane capacities, limitations, and specific job site restrictions, such as location or overhead electric power lines, unstable soil, or high wind conditions. Personnel working around crane operations also need to be aware of hoisting

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activities or any job restrictions imposed by crane operations, and ensure job site coordination of cranes. Crane inspectors should become aware of these issues and prior to starting an inspection, take time to observe the overall crane operations with respect to load capacity, site conditions and any job site restriction in effect. This document defines the minimum hoist design criteria required for verifying proper operation prior the operation, periodic inspection requirements and crane isolation for periodic inspection maintenance and repair.

1. Each site and it is the responsibility of the site supervisor to establish a documented plan for implementation of the requirements described in this document.

2. It is the responsibility of each location to apply local procedures and processes to include the specific items in this document to comply with local and national regulations and to develop and maintain hoist inspection record.

This document defines the minimum hoist design criteria required for verifying proper operation of the upper over travel device prior the operation, periodic inspection requirements and crane isolation for periodic inspection maintenance and repair.

3. In Lufkin where all hoist devices are leased, so, it is the responsibility of the site supervisor to establish a documented plan to make sure of the suitable requirements of cranes and chains and also to make sure of the inspection to be take place according to the requirements of this document.

4. It is the responsibility of each location to implement local procedures and processes to include the specific items in this document to comply with local and national regulations and to develop and maintain hoist inspection record.

4. RESPONSIBILITIES 4.1 HSE Manager Responsibilities:

Setting the documented instructions and written program and make sure of distributing this program to all interested parties.

Periodically verifying monthly test and inspection reports. Interpreting crane and hoist safety rules and standards. Providing management planning and technical assistance Performing periodic audit in every location to make sure of the implementation

of this procedures.

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Investigating any incident related to the crane operation whether leased or owned by the company.

4.2 Field supervisor responsibilities:

Ensuring that employees under their supervision receive the required training and are certified and licensed to operate the cranes and hoists in their areas.

Providing training for prospective crane and hoist operators. Evaluating crane and hoist trainees using crane safety checklist and

submitting a qualification form to the operation department or designee to obtain operator’s license.

Ensuring that hoisting equipment is inspected and tested monthly by a responsible, designated individual, that rigging equipment is inspected annually, and that inspection results are documented on –site.

4.3 Cranes and Hoist operator are responsible for :

Operating hoisting equipment safely. Conducting functional tests prior to using the equipment. Selecting and using rigging equipment appropriately. Having a valid operator’s license on their person while operating cranes or

hoists. Participating in a medical certification program when required. Operators shall comply with the following rules while operating the cranes and

hoists: Do not engage in any practice that will divert your attention while operating

the crane. Respond to signals only from the person who is directing the lift or an

appointed signal person Obey stop signal at all times, no matter who gives it. Do not move a load over people; people shall not be placed in jeopardy by being

under a suspended load. Do not work under a suspended load, unless the load is supported by blocks,

jacks, or a solid footing that will safely support the entire weight. Open and tag the main electrical disconnect switch Ensure that the rated load capacity of a crane’s bridge, individual hoist, or any

sling or fitting is not exceeded. Know the weight of the object being lifted or use a dynamometer or load cell to

determine the weight.

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Check that all control of the off position before closing the main- line disconnect switch.

Avoid side pulls and /or load swinging. These can cause the hoist rope to slip out of the drum groove, damaging the wire.

To prevent shock loading, avoid sudden stops or starts. Shock loading can occur when a suspended load is accelerated or decelerated, and can overload the crane or hoist

When completing an upward or downward motion, ease the load slowly to stop.

5. Pre-operational test: In Lufkin where the cranes and all hoist equipment are leased and not owned

by the company, the supervisor should make sure that the following tests are done by the operator of the leased crane.

At the start of the lifting operation by using cranes, operators should do the following steps

Test the upper –limit switch. Slowly raise the unloaded hook until the limit switch trips.

Visually inspect the hook, load lines, trolley and bridge as much as possible from the operator’s station.

If provided test the lower limit switch. Test all direction and speed controls for both bridge and trolley travel. Test the pendant emergency stop Test the hoist brake to verify there is no drift without a load. Lockout and tagout for repair any crane that shown malfunction. Do not

return to service until maintenance is completed. Except for under hung hoists, each hoist shall be equipped with a clearly

identifiable on/ off switch, emergency stop pushbutton or power safety switch that the operator can easily reach to interrupt power to the hoist and set the hoist brake in any event.

It is not required to have a separate on / off switch or hoist emergency stop pushbutton or power safety switch for a hoist if there is such a device for the entire crane brakes regardless of where the operator hoist control is positioned.

5.1 Crane design criteria

To prevent hoist over travel in the raising or upward direction 1. Upper over travel device shall be provided to prevent the load block from passing

the safe upper limit of travel of all powered hoisting mechanism.

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2. The upper over travel device shall not be used for positioning of the hoist. It is used only as a safety device in the event of emergency. Employee must work in a safe manner so as to ensuring safety of himself, his co-workers and other employees. Damage to company property is a penal offense.

3. It is preferred to implement only a weight actuated power circuit limit switch that interrupts the power to the hoist motor. It should be electrically or pneumatically positioned so that it is the last device before the motor power input. It should be on the output( load) side of the power source.

4. On all AC.3 phase control circuits, where a double pole power limit switch is employed, a contact or similar device shall be installed in the control circuit to de-energize the third phase of the motor power connection.

5. Lower travel limit device should be provided where the load block enters a pit ot hatchway during normal operation.

6. The device shall be designed to be checked for proper operation once every twenty –four hours for automatic material handling hoists once per shift, prior to use for material handling hoists manually controlled.

5.2 Hoist brake system

1. Each hoist system shall have a braking system to control load lowering.2. The hoist brake shall not be changed to a different specification from that

furnished for the application without written approval of the hoist manufacturer or qualified person.

3. Any change shall be documented and the documentation retained including the written approval of the change.

4. Brakes using standard couplings as brakes wheels are prohibited. A mechanical load brake is preferred on underhung hoists of 5 brakes does not need to be replaced.

5. The trip setting of each upper over travel device shall be determined by tests with an empty hook or reeve in device traveling in increasing speeds up to the maximum speed.

6. The actuating mechanism of the upper over travel device shall be located so that it will trip under all conditions in sufficient time to prevent any strain on the crane rope.

7. If below – the hook lifting device or hook attached device is used, then the tests should also be conducted with the device in place or determined by a qualified person.

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8. The hoist rope or chain shall not be changed to different specifications from that furnished for the application without written approval of the hoist manufacturer or qualified person. Any such change should be documented and the documentation retained, including the written approval of change.

5.3 means of interruption of hoist power by the operator:

1. Except for under hung hoists, each hoist shall be equipped with a clearly identifiable on/ off switch, emergency stop pushbutton or power safety switch that the operator can easily reach to interrupt power to the hoist and set the hoist brake in any event.

2. it is not required to have a separate on / off switch or hoist emergency stop pushbutton or power safety switch for a hoist if there is such a device for the entire crane brakes regardless of where the operator hoist control is positioned.

4.4 Hoist brake system

9. Each hoist system shall have a braking system to control load lowering.10. The hoist brake shall not be changed to a different specification from that

furnished for the application without written approval of the hoist manufacturer or qualified person.

11. Any change shall be documented and the documentation retained including the written approval of the change.

12. Brakes using standard couplings as brakes wheels are prohibited. A mechanical load brake is preferred on underhung hoists of 5 brakes does not need to be replaced.

6.0.1 inspection requirements for mobile crane:

1. Prior to the initial use of any crane during each lift, the crane operator shall verify the operation of the primary device. The primary device is defined as the first device intended to stop the upward direction of hoist travel that the hoist actuates in the raising direction. If the primary device shall is used as a positioning device, both devices shall be checked prior to the individual use of the hoist during each lift.

2. The device shall e checked by raising the crane in the slowest possible speed as the lower block approaches the device trip point.

3. Additional pre- operation visual checks may be required as determined by each location such as hoist rope/chain, hoist/chain brakes.

7. basic requirement for the inspection :

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To do the effective and standard inspection for all mobile cranes, the following requirements are required to perform such inspection:• inspection standards requirements according to OSHA• crane inspection• inspection records• how to conduct a mobile crane inspection• Basic crane inspection list.

7.1 Standard requirements:

1. Competent person need to do the inspection.

2. Any deficiencies should be corrected immediately.

3. Maintain inspection record. All plug and sockets shall be industrial type.

7.2 crane inspection types: There are two distinct types of inspection which are frequent inspection and periodic inspection.1. Frequent inspection

• Daily to monthly intervals• Performed at the start of each process where the operator walks around the

crane looking for defects or problem areas.• Components that may change from day to day must be inspected daily, and

when possible observed during operation for any defects that could affect the operation.

• Frequent inspections should include but are not limited to the following:

o Check that all exposed moving parts are guarded. A removed guard may indicate that a mechanic is still working on part of the crane.

o Visually inspect each component of the crane used in lifting, swinging, or lowering the load or boom for any defects that might result in unsafe operation.

o Inspect all wire rope (including standing ropes), sheaves, drums rigging, hardware, and attachments. Remember, any hook that is deformed or cracked must be removed from service. Hooks with cracks, excessive throat openings of 15%, or hook twists of 10 degrees or more, must be removed from service.

o Check for freedom of rotation of all swivels. o Visually inspect the boom and jib for straightness and any evidence of physical damage,

such as cracking, bending, or any other deformation of the welds. Look for corrosion under any attachments that are connected to the chords and lacing. Watch carefully for cracking or flaking of paint. This may indicate fatigue of the metal which often precedes

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a failure. On lattice booms, look for bent lacing. If they are kinked or bent, the main chord can lose substantial support in that area. When lacing is bent, the ends also tend to draw together which pulls the main chords out of shape. This precaution is especially important on tubular booms where every component must be straight and free from any dents. Do not attempt to straighten these members by hammering or heating them and drawing them out. They must be cut out and replaced with lacing to the manufacturer's specifications, procedures, and approval.

o Inspect tires for cuts, tears, breaks, and proper inflation. o Visually inspect the crane for fluid leaks, both air and hydraulic.

o Visually check that the crane is properly lubricated. The fuel, lubricating oil, coolant and hydraulic oil reservoirs should be filled to proper levels.

o Check that the crane is equipped with a fully charged fire extinguisher and that the operator knows how to use it.

o Check all functional operating mechanisms such as: sheaves, drums, brakes, locking mechanisms, hooks, the boom, jib, hook rollers brackets, outrigger components, limit switches, safety devices, hydraulic cylinders, instruments, and lights.

o Check the turntable connections for weld cracks and loose or missing bolts. If they are loose, there is a good chance that they have been stretched.

o When checking the outriggers be sure that neither the beams nor the cylinders are distorted. Check that the welds are not cracked and that both the beams and cylinders extend and retract smoothly and hold the load. Check the condition of the floats, and check that they are securely attached.

o Inspect and test all brakes and clutches for proper adjustment and operation. o Always inspect boom hoist lockout and other operator aids, such as anti-two-block

devices (ATB) and load moment indicators (LMI), for proper operation and calibration. o While the engine is running, check all gauges and warning lights for proper readings and

operate all controls to see that they are functioning properly. o Check for any broken or cracked glass that may affect the view of the operator

2. Periodic inspection:This is not a task performed by Lufkin supervisor or Lufkin inspector in the present time, since all cranes are leased, but it needs to be mentioned here for the future usage and to be useful for inspecting the crane of the supplier.

• From 1 : 12 month • Includes items listed in daily inspection as well as structural defects, excessive

wear, hydraulic or air leak.• From 1 : 12 month • Includes items listed in daily inspection as well as structural defects,

excessive wear, hydraulic or air leak it may be summarized as follows:

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• Inspect the entire crane for structural damage. Be careful to check for distortion or cracks in main frame, outrigger assemblies, and structural attachments of the upper works to the carrier.

• Inspect all welded connections for cracks. Inspect the main chords and lacings and other structural items for paint flaking and cracking which may indicate potential failure, as well as for dents, bends, abrasions, and corrosion. Check hydraulic booms for bending, side sway, or droop.

• Check for deformed, cracked, or corroded members in the load/stress bearing structure. Magnetic particle or other suitable crack detecting inspection should be performed at least once each year by an inspection agency retained by the owner. Inspection reports should be requested and retained in the crane file.

• Inspect cracked or worn sheaves and drums. • Inspect for worn, cracked, or distorted parts such as: pins, bearings, shafts, gears, rollers,

locking devices, hook roller brackets, removable outrigger attachments lugs, and welds. • Inspect for excessive wear on brake and clutch system parts, linings, pawls, and ratchets. • Inspect all indicators, including load and boom angle indicators, for proper operation and

calibration. • Inspect all power plants for proper operation. • Inspect for excessive wear on drive sprockets and/or chain stretch. • Inspect for correct action of steering, braking, and locking devices. • Check that the counterweight is secure. • Check that the identification number is permanently and legibly marked on jibs, blocks,

equalizer beams, and all other accessories. • Inspect all hydraulic and pneumatic hoses, fittings, and tubing. Any deterioration of any system

component should cause the inspector to question whether further use would constitute a safety hazard. Conditions, such as the following, require replacement of the part in question.

• Any evidence of oil leaks on the surface of flexible hoses or at the point at which the hose in question joins the metal and the couplings.

• Any abnormal deformation of the outer covering of hydraulic hose, including any enlargement, local or otherwise.

• Any leak at connections which cannot be eliminated by normal tightening.• Any evidence of abrasive wear that could have reduced the pressure retaining capabilities of the

hose or tube effected. The cause of the rubbing or abrasion must immediately eliminated.

7.3 crane inspection records :

1. date of inspection2. signature of person conducting inspection3. serial number of inspection

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8.0 Sling properties and Inspection

Slings should be visually inspected before each use to ensure their effectiveness. Improper use of hoisting equipments – including slings may result in overloading, excessive speed or sudden acceleration or deceleration of equipment.There are generally six types of slings: chain, wire rope, metal mesh, natural fiber rope, or synthetic webs.

When selecting a wire rope sling to give the best services. There are four characteristics to consider; strength, ability to withstand, fatigue (to bend without distortion, ability to withstand abuse.

1. Strength: is a function of its size,grade,and construction and must be sufficient to accommodate the maximum applied load.

2. Fatigue: Fatigue failure of wire rope is caused by the development of small cracks during small radius bends. The best means for preventing fatigue failure of wire rope slings is to use blocking or padding to increase the bend radius.

3. Abrasive to wear: The ability of wire rope to withstand abrasion is determined by the size and number of the individual wires used to make up the rope. Smaller wires bend more readily and offer greater flexibility, but are less able to withstand abrasion. Larger wires are less flexible, but withstand abrasion better

4. Abuse: Misuse or abuse of wire rope slings will result in their failure long before any other factor. Abuse can lead to serious structural damage, resulting in kinks or bird caging. (In bird caging, the wire rope strands are forcibly untwisted and become spread outwards.) To prevent injuries to workers and prolong the life of the sling, strictly adhered to safe and proper use of wire rope slings.

9.0 Safe lifting practices: Selection of the sling is only the first step in the rigging process. The next step is learning how to safely use it to hold and move a suspended load. There are four primary factors to consider when lifting a load safely. These are:

a. Load Size, Weight, and Center of Gravity

The center of gravity of an object is that point at which the entire weight may be considered to be concentrated. To make a level lift, the hoist hook must be located directly above this point. If the hook is too far to either side of the center of gravity, dangerous tilting will result, causing unequal stress in the sling legs. Load imbalances must be corrected immediately.

b. Number of Legs and Angle with the Horizontal

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The smaller the angle between the sling legs and the horizontal, the greater the stress on the individual sling legs. This increased stress effectively decreases the weight that can be safely lifted with any given sling size. Large (heavy) loads can be safely moved by keeping this angle as large as possible and, when necessary, distributing the weight of the load among more sling legs.

c. Rated Capacity of the Sling The rated capacity of a sling varies depending upon the type of material the sling is made of, the size of the sling, and the type of hitch. Workers must know the capacity of the sling, and can obtain this information through charts or tables available through the manufacturer. The rated capacity of a sling must not be exceeded, under any circumstances.

d. History of Care and Use Mishandling and misuse of slings are the leading causes of sling failure. Following the manufacturer’s recommendations for proper care and use are essential for maximum sling service life and safety

10.0 training

People involved in hoisting and rigging operation should have training in the following: 1. Sling and hitch types 2. Sling capacity determination 3. Equipment inspection, care, and maintenance 4. Load weight and center of gravity determination 5. Safe lifting techniques.

Appendix 1. OSHA inspection items

Inspection Items and Description

ITEM DESCRIPTION / PURPOSE

(1) Manufacturer's operating and Maintenance Manuals Manufacturer's operating and maintenance manuals shall accompany all mobile hoisting equipment. These manuals set forth specific inspection, operation and maintenance criteria for each mobile crane and lifting capacity.

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(2) Guarding All exposed moving parts such as gears, chains, reciprocating or rotating parts are guarded or isolated.

(3) Swing Clearance Protection Materials for guarding rear swing area.

(4) High-Voltage Warning Sign High-voltage warning signs displaying restrictions and requirements should be installed at the operator's station and at strategic locations on the crane.

(5) Boom Stops Shock absorbing or hydraulic type boom stops are installed in a manner to resist boom overturning.

(6) Jib Boom Stops Jib stops are restraints to resist overturning.

(7) Boom Angle Indicator A boom angle indicator readable for the operator station is installed accurately to indicate boom angle.

(8) Boom Hoist Disconnect, Automatic Boom Hoist Shutoff

A boom hoist disconnect safety shutoff or hydraulic relief automatically stops the boom hoist when the boom reaches a predetermined high angle.

(9) Two-Blocking Device Cranes with telescoping booms should be equipped with a two-blocking damage prevention feature that has been tested on-site in accordance with manufacturer’s requirements. All cranes hydraulic and fixed boom used to hoist personnel must be equipped with two-blocking devices on all hoistlines intended to be used in the operation. The anti-two blocking device has automatic capabilities for controlling functions that may cause a two-blocking condition.

(10) Power Controlled Lowering Cranes for use to hoist personnel must be equipped for power controlled lowering operation on all hoistlines. Check clutch, chains, and sprockets for wear.

(11) Leveling Indicating Device A device or procedure for leveling the crane must be provided.

(12) Sheaves Sheave grooves shall be smooth and free

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from surface defects, cracks, or worn places that could cause rope damage. Flanges must not be broken, cracked, or chipped. The bottom of the sheave groove must form a close fitting saddle for the rope being used. Lower load blocks must be equipped with close fitting guards. Almost every wire rope installation has one or more sheaves – ranging from traveling blocks with complicated reeving patterns to equalizing sheaves where only minimum rope movement is noticed.

(13) Main Hoist and Auxiliary Drums System Drum crushing is a rope condition sometimes observed which indicates deterioration of the rope. Spooling is that characteristic of a rope which affects how it wraps onto and off a drum. Spoiling is affected by the care and skill with which the first larger of wraps is applied on the drum. Manufacturer's criteria during inspection usually specify:

• Minimum number of wraps to remain on the drum.

• Condition of drum grooves • Condition of flanges at the end of

drum. • Rope end attachment. • Spooling characteristics of rope.

• Rope condition.

(14) Main Boom, Jib Boom, Boom Extension Boom jibs, or extensions, must not be cracked or corroded. Bolts and rivets must be tight. Certification that repaired boom members meet manufacturers original design standard shall be documented. Non-certified repaired members shall not be used until recertified.

(15) Load Hooks and Hook Blocks Hooks and blocks must be permanently labeled with rated capacity. Hooks and blocks are counterweighted to the weight of

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the overhaul line from highest hook position. Hooks must not have cracks or throat openings more than 15% of normal or twisted off center more than 10o from the longitudinal axis. All hooks used to hoist personnel must be equipped with effective positive safety catches especially on hydraulic cranes.

(16) Hydraulic Hoses Fittings and Tubing Flexible hoses must be sound and show no signs of leaking at the surface or its junction with the metal and couplings. Hoses must not show blistering or abnormal deformation to the outer covering and no leaks at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures. There should be no evidence of excessive abrasion or scrubbing on the outer surfaces of hoses, rigid tubing, or hydraulic fittings.

(17) Outriggers Outrigger number, locations, types and type of control are in accordance with manufacturer's specifications. Outriggers are designed and operated to relieve all weight from wheels or tracks within the boundaries of the outriggers. If not, the manufacturer's specifications and operating procedures must be clearly defined. Outriggers must be visible to the operator or a signal person during extension or setting.

(18) Load Rating Chart A durable rating chart(s) with legible letters and figures must be attached to the crane in a location accessible to the operator while at the controls. The rating charts shall contain the following:

• A full and complete range of manufacturer's crane loading ratings at all stated operating radii.

• Optional equipment on the crane such as outriggers and extra counterweight which effect ratings.

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• A work area chart for which capacities are listed in the load rating chart, i.e. over side, over rear, over front.

• Weights of auxiliary equipment, i.e. load block, jibs, boom extensions.

• A clearly distinguishable list of ratings based on structural, hydraulic or other factors rather than stability.

• A list of no-load work areas.

• A description of hoist line reeving requirements on the chart or in operator's manual.

(19) Wire Rope Main hoist and auxiliary wire rope inspection should include examining for

• Broken wires. • Excess wear.

• External damage from crushing, kinking, cutting or corrosion.

(20) Cab Contains all crane function controls in addition to mechanical boom angle indicators, electric wipers, dash lights, warning lights and buzzers, fire extinguishers, seat belts, horn, and clear unbroken glass.

(21) Braking Systems Truck cranes and self-propelled cranes mounted on rubber-tired chassis or frames must be equipped with a service brake system, secondary stopping emergency brake system and a parking brake system. Unless the owner/operator can show written evidence that such systems were not required by the standards or regulations in force at the date of manufacture and are not available from the manufacturer. The braking systems must have been inspected and tested and found to be in conformance with applicable requirements.

Tlaat 11/10/2008

Lufkin Middle East



Crawler cranes are provided with brakes or other locking devices that effectively hold the machine stationary on level grade during the working cycle. The braking system must be capable of stopping and holding the machine on the maximum grade recommended for travel. The brakes or locks are arranged to engage or remain engaged in the event of loss of operating pressure or power.

(22) Turntable/Crane Body Make sure that the rotation point of a crane gears and rollers are free of damage, wear and properly adjusted and the components are securely locked and free of cracks or damage. The swing locking mechanism must be functional (pawl, pin) and operated in the cab.

(23) Counterweight The counterweight must be approved and installed according to manufacturer's specifications with attachment points secured.

Tlaat 11/10/2008

7856126 Lifting and Rigging Written Program (1)

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Transcript of 7856126 Lifting and Rigging Written Program (1)