OISD-RP-205

Prepared by

COMMITTEE ON RECOMMENDED PRACTICE
FOR
CRANE OPERATION,MAINTENANCE AND TESTING
(For Upstream )




























OIL INDUSTRY SAFETY DIRECTORATE
7
th
FLOOR,"NEW DELHI HOUSE"
27, BARAKHAMBA ROAD
NEW DELHI-110 001

NOTE




OISD (Oil Industry Safety Directorate) publications are prepared for use in the Oil and Gas Industry
under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and
shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.


Though every effort has been made to assure the accuracy and reliability of the data contained in the
document, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their
use.

The document is intended to supplement rather than replace the prevailing statutory requirements.




































FOREWORD


The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a
variety of international codes, standards and practices have been in vogue. Standardisation in design
philosophies and operation and maintenance practices at a national level was hardly in existence. This coupled
with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised
the need for the industry to review the existing state- of- the-art in designing, operating and maintaining oil and
gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council
assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and
implementing a series of self regulatory measures aimed at removing obsolescence, standardising and
upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of
functional committees of experts nominated from the industry to draw up standards and guidelines on various
subjects.

The present standard was prepared by the Functional Committee on Recommended Practice for Crane
Operation, Maintenance And Testing . The document is based on the accumulated knowledge and experience
of industry members and the various national and international codes and practices.

This standard is meant to be used as supplement and not as a replacement for existing codes and
practices.

It is hoped that provisions of this standard, if implemented objectively, may go a long way to improve the
safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no standard can be substitute for
the judgement of responsible and experienced Engineers/Geo-scientists..

Suggestions are invited from the users after it is put into practice to improve the document further.
Suggestions for amendments to this document should be addressed to the Coordinator, Committee on
Recommended Practice for Crane Operation, Maintenance and Testing , Oil Industry Safety Directorate, 7
th

Floor, New Delhi House, 27, Barakhamba Road, New Delhi 110 001.

This standard in no way supercedes the statutory requirements like Factories Act, OMR, CCE etc.

1



COMMITTEE
ON
RECOMMENDED PRACTICE FOR
CRANE OPERATION,MAINTENANCE AND TESTING ''



NAME ORGANISATION POSITION IN
THE COMMITTEE

S/SHRI

1. H.N. BHAKTA ONGC LEADER


2. ROY J OHN ONGC MEMBER


3. SUNIL SOHANI SCHLUMBERGER INVITEE


4. GIRISH KAMAL EIL MEMBER


5. PRADEEP KUMAR OISD MEMBER -
COORDINATOR






































CONTENTS


Sl .No. Descri pti on Page
No.
---------- ---------------------- ------------
---

1.0 Introduction 1

2.0 Scope 1

3.0 Definitions 1

4.0 Equipment 3

5.0 Control 4

6.0 Safety Equipment 5

7.0 Operation 5

8.0 Inspection 13

9.0 Maintenance 13

10.0 Load Testing And Certification 14

11.0 Incidence/Accident Reporting System 14

12.0 Contract Management 14

13.0 Personnel Protective Equipment 14

14.0 References 14

15.0 Annexures
A Identification Of Actions On Use Of Hand Signals 15
B Maintenance guidelines 17
C - Inspection guidelines 21
















1





Recommended Practi ces
for

CRANE OPERATION, MAINTENANCE AND TESTING


1.0 INTRODUCTION

In oil industry, material handling using
cranes is one of the most important
operations requiring utmost care.

The primary purpose of this standard is to
outline recommended practices for crane
operations, maintenance, inspection and
testing to crane owners, users and
operators in upstream sector of oil industry
both offshore and onshore. This
recommended practice focuses on safe
operation of cranes in order to establish,
maintain and further develop an adequate
level of safety for personnel, property and
environment during planning and execution
of lifting operations.

2.0 SCOPE

These Recommended Practices cover
various aspects related to operating and
maintenance practices and procedures for
use in the safe operation including the
requirement of competent crane operator of
various types of revolving cranes on
offshore platforms, rigs, floating units. It
also covers fixed, mobile (except crawler
cranes) and hydraulic telescoping cranes
used at onshore installations of upstream
operations.

These recommended practices are to
provide and assist in the proper operation
and maintenance of crane, as a
supplement to the Manufacturer's
instructions, which should be carefully
read, retained and followed.

3.0 DEFINITIONS

Anti -two bl ock : A limiting device that
prevents the load block
sheaves, auxiliary or fast
line ball from contacting the
boom tip sheaves.

Boom angl e : The angle above or below
horizontal of the longitudinal
axis of the base boom
section.

Boom l ength : The straight line distance
from the centerline of boom
foot pin to centerline of boom
point load hoist sheave pin,
measured along the
longitudinal axis of the boom.

Boom l ift Cyl i nder : Means for supporting the
boom and controlling the
boom angle.

Certi fi ed : To formally attest as being
true or meeting a
standard.

Choke : Block used to stop the
wheels of a truck.
Counterwei ght : Weight used to
(BALLAST) supplement the weight of the
machine in providing stability
for lifting working loads and
usually attached to the rear
of revolving upper
structure.

Crane : A lifting device that is
capable of being
dynamically loaded when
lifting, lowering, or shifting
loads by means of a
projecting arm.
Drum rope : A rotating cylinder with side
flanges on which wire rope
used in machine operation is
wrapped.

Dynami c : Loads introduced into the
l oadi ng machine or it's components
due to accelerating or
decelerating forces.

Gantry(A-Frame) : A structure mounted on the
revolving super-structure of
the machine to which the
boom support ropes are
reeved.

Heavy l i ft : A non-routine lift which is
equal to or greater than 75%
of the rated capacity of the
crane, at either a dynamic or
static condition.

Heavy usage : Heavy usage applies to
Category those cranes that are used for
50 hours or more per
month. These cranes will be
2



subject to Pre-use, Monthly,
Quarterly, and
Annual Inspections. Cranes
assigned category of heavy
usage need not be reviewed
to determine the number of
hours used each month.

Hoi st : The device for lifting or
lowering of the load in
vertical direction. Also called
winch.

Hook Load : The load being lifted plus the
weight of slings and rigging.
Hook load may or may not
include the weight of the hook
block and wire rope. This can
be determined from the cranes
load rating chart.

Hydraul i c crane : A crane whose movements
are directed by fluid pressure
applied to the pumps/gears,
hydraulic cylinder, and
hoists.

Infrequent usage : Infrequent usage applies
category to those cranes that are
used for 10 hours or less
per month, based on the
averaged use over a quarter.
These cranes will be
subjected to a Pre-use
Inspection and an Annual
Inspection. Crane usage
categories will be reviewed
on a periodic basis by the
owner to ensure proper
inspection intervals.

Ji b(Ti p Extensi on) : An extension attached to the
boom point to provide added
boom length for lifting
specified loads.

Latti ce boom : Boom of open construction
with angular or tubular lacing
between main corner
members (chords) in form of
truss.

Li mi t devi ce : A safety feature used to stop
the movement of a crane or
its components beyond a
predetermined point that
could cause damage to
components or the crane to
fail.
Load test : The test undertaken to
validate load rating of the
crane.

Load -worki ng : External load in pounds
(Kilogram) apply to the crane
including the weight of load
attaching equipment such
load block, shackles and
slings

Luffi ng : Same as derricking. The
operation of changing boom
angle in a vertical plane.

Moderate usage : Moderate usage applies
category to those cranes that are used
for more than 10 hours but
for less that 50 hours per
month, based on the
averaged use over a quarter.
These cranes will be
subjected to Pre-use,
Quarterly, and Annual
Inspections. Crane usage
categories will be reviewed on
a periodic basis by the owner
to ensure proper inspection
intervals.

Out-Ri ggers : Members attached to the
carriers frame which may be
blocked up to increase
stability. These may be fixed
or extendible.

Pawl (Dog) : A device for positively holding
a member against motion in
one or more directions.

Pedestal ( BASE) : The supporting sub-structure
upon which the revolving
upper structure is mounted.

Pul l test : A test, using a suspended
weight or a dynamometer, to
verify crane capability for the
expected lift, not to exceed
100% of the rated crane load
chart capacity. Thi s i s not a
LOAD TEST.

Qual i fi ed crane : A person with training and
i nspector experience who has
demonstrated proficiency in
the skills and abilities
necessary to inspect,
maintain, and repair cranes.

Qual i fi ed crane : A person with training and
operator experience who has
successfully completed a
crane operator training
course.

Rated Capaci ty : The rated load at specified
radii as established by the
manufacturer and are the
3



maximum loads at those radii
covered by the
manufacturers warranty.

Ri gger : A rigger is anyone who
attaches or detaches lifting
equipment to loads or lifting
devices.

Si gnal man : A qual i fi ed ri gger who is
designated by a qual i fied
crane operator to give hand
signals.

Sl ewi ng : Same as swing. Rotation of
the upper structure for
movement of loads in a
horizontal direction about
axis of rotation.

Sl i ng : A device used to connect
loads to be lifted by a crane
or a hoist.

Stati c loadi ng : Loads introduced into the
machine or its components
with no accelerating or
decelerating forces.
Sti nger : A single length of wire rope
equipped with a hook and
safety latch, which is capable
of handling the maximum
capacity of the load. Its use
is intended to keep the main
hoist load block or auxiliary
hoist headache ball from
coming in contact with
personnel rigging loads.

Swi ng Circl e : The swing circle
assembl y assembly is the connecting
component between the
crane revolving
upper structure and pedestal.
This component allows crane
rotation and sustains the
movement ,radial and axial
loads imposed by
crane operation.
Tag l i ne : A length of rope/ropes
attached at a point to the
load and used by riggers to
help control its movement.
Tel escopi ng : Consists of a base boom
boom from which one or more boom
sections are
telescoped for additional
length.

Temporary crane : Any crane that is attached to
or connected via a
substructure to a platform
and not a permanent part of
the structure).

Whi p line : A secondary rope system
usually of lighter load
capacity than provided by the
main rope system. Also
known as AUXILIARY.


4.0 EQUIPMENT


4.1 Pri me Mover:

Prime mover may be Electric or Diesel
engine. Starting system may be
pneumatic, manual, hydraulic, electrical or
combination of any two. Engine driven
generator for power supply in cabin and
accessories . Air compressor, receiver and
auxiliaries for air starting system and
engine shaft driven Hydraulic pump for
engine starting system. Air is also required
for signal horn, load indicator mechanism
and wind screen wiper .Prime mover
should be suitably selected for carrying out
the main hoisting, Luffing and slewing
operations simultaneously at rated capacity
and specified radii.

The engine should be fitted with a suitably
calibrated running hours recorder which is
to be positioned so that it can be easily
read by the operator.

The engine exhaust shall be equipped with
spark arrestor and exhaust pipe shall be
insulated to protect operator from burn
injury. The exhaust should be directed
away from the operator.

4.2 Cabi n :

The cabin should be mounted on the crane
with fully enclosed sturdy door with Lock,
shatter proof glass windows on all sides,
wind shield wipers and sun visor, horn,
lights, fan and adjustable seat. Controls,
indicators, alarms, load charts (one
dynamic and other static for offshore
cranes and static load chart for onshore
crane) and boom angle indicator should
also be provided in the cabin.

Service walkways all around the cabin with
handrail should be provided.

As far as possible , cabin should be
constructed to protect the upper structure
machinery , brakes ,clutches and the
operators station from the weather.

4



Unless and otherwise specified, the sound
levels at operators station shall not
exceed:
a. 90dB(A) (Slow response) measured
with the prime mover at low idle and
crane controls in neutral position
b. 95dB(A) (Slow response) measured
with the crane operating at full throttle
and full rated load of the rotating
machinery.

4.3 Hydraul i c System

A separate hydraulic pumps with motor and
automatic braking system should be
provided for main hoist, auxiliary hoist, and
Boom Hoist for hydraulically operated
cranes. A separate hydraulic motor should
be provided for swing drive. The swing
drive should be provided with Mechanical
positive lock arrangement, controllable by
operator.

Means should be provided for checking
manufacturers specified pressure settings
in each hydraulic circuit. Each loop shall be
fitted with pre-set safety relief valves.

4.4 El ectri cal System

The supply of electrical power for lighting
for cabin, Housing, Flood light , Air craft
warning and other auxiliaries on the crane
through alternator/dynamo which is a part
of crane shall be provided.

Some of the offshore/ fixed cranes are
electrical driven for which electrical power
is supplied by available installed electrical
power.

4.6 Mounti ng

4.6.1 Fi xed Cranes

Fixed type of cranes are mounted on
suitably designed pedestal. The pedestal
construction should be conforming to API-
2H or other national/international standard.

4.6.2 Mobi l e Cranes:

a. The mobile crane shall be mounted
on atleast four pneumatic tyred
wheels and shall be provided with air
or hydraulic braking on all wheels. An
entirely independent hand brake shall
be fitted for parking .
b. Emergency towing eyes of approved
design shall be fitted at the front and
rear of the crane.

Wheel and axle arrangements should be
designated as per standard automotive
practice. Any one wheel may have one or
more tyres.

4.7 Out Ri ggers

The manufacturer should specify whether
out-riggers are fixed or extendible, whether
telescopic or hinged , whether front or rear
outriggers or both are supplied and if jacks
or supporting floats are available.

5.0 CONTROLS

5.1 General

Controls should be in accordance with the
following requirement :
a. The control should be installed in
such a way that one operator can
easily perform all maneuvers and
speed control.
b. Control levers for boom hoist, load
hoist , swing and boom
telescope(when applicable) should
return automatically to their
centre(neutral) positions on
release.
c. Foot operated pedals, where
provided should be constructed so
as the operators feet will not
readily slip off.
d. Brakes engage automatically
when a control is placed in the
neutral position in the event of
engine power failure, loss of
hydraulic pressure or control
failure.
e. Main hoist line and auxiliary line
each should be equipped with anti-
two blocking devices with audible
and visual warning and is
hydraulically operated.
f. The crane should be fitted with a
load, boom angle & radius
indicating and sensing device
which automatically weigh load
continuously and is being carried
with a particular radius. The crane
has visual lighting indications
inside crane cabin for indicating
static and dynamic mode of
operations. The normal re-setting
of the controls for static lifting
should also be provided.
g. An emergency stop, to stop all
functions of crane instantaneously
in case of emergency is provided
without stopping the engine.
h. The mobile crane should be
capable of being steered either
right or left in either directions of
travel and the control shall be from
operators position on the revolving
superstructure.
5



5.2 Forces and movement of control l evers

When control levers /pedals are properly
maintained as per manufacturers
recommendations the forces and
movement to operate the crane within its
rated limits should not exceed the
following:
a. Hand levers 20 lbf and 28 inches
total travel
b. Foot pedal 25lbf and 10inches total
travel

6.0 SAFETY EQUIPMENT

Following minimum Safety equipment
should be installed/made available on the
crane : -

Weight load indicator
Overload (not less than 97.5% of SWL
at that radius) alarm & shutdown ,
visual warning at 90% of SWL.
Boom Angle indicator
Swing lock device
Horn
Boom hoist stop
Aircraft warning light
Latch for main & auxiliary hook
Limit switches
Walkie-talkie/telephone/pager/any
communication device
Audio warning Horn / Hooter for alarms
Fire extinguisher
Anti two block
Emergency shutdown valve
Guards on moving parts wherever
possible to fit
Pressure & oil Gauges
Spark Arrestor with engine
First Aid kit
Following shall be displayed in the
cabin:
-Hand Signals
-Load & range charts

Safety equipment specific to Mobile Cranes
shall be fitted
Reverse alarm
Level Gauge
Out-rigger controls functions
Chokes
A brake or alternative device to lock the
superstructure in any position when the
crane is travelling or working on slopes.
In addition a positive locking device to
locate the superstructure in its normal
travelling position.

7.0 OPERATION

7.1 Operator's Qual i fi cati on

1. A crane operator must have valid
certificate for operation of crane
from authorised agency. The
operator must be physically and
mentally fit. (vision, hearing, colour
identification & no history of any
disabling medical condition)

2. A crane operator must have valid
Heavy duty driving license (for
mobile cranes)

3. Operator should have undergone
operators training (classroom and
practical). Operator should be
conversant with load chart and
stability (available on the crane),
use of correct slinging practice,
Operator should have clear
understanding of standard signals,
and safe operating practices

7.2 Ri ggers Qual i fi cati on

A person with training and experience who
has knowledge of rigging hardware, slings ,
safety issues related to rigging, use and
selection of proper slings, hitches,
shackles, hooks etc..

7.3 Safe Operati ng Procedure

i. Before starting the operations, operator
shall verify that all pre-use inspections as
per standard Practices or manufacturers
guidelines have been completed.
ii. Operator shall be responsible for
operations under his direct control.
iii. While lifting/placing of the load, no
unauthorised person shall remain within the
radius of the boom and underneath the
load
iv. For any safety reason , the crane operator
shall stop handling loads / operations and
report the matter to the installation
Manager for further instructions.
v. Always follow the operating practices
supplied by the manufacturer for each type
of crane.
vi. The operator shall be familiar with the use
of equipment and its care.
vii. The operator will respond to signals given
by authorised signal person.
viii. Before leaving the crane for a long period
the operator shall land any attached loads,
disengage master clutch, set all locking
devices, put controls in off or neutral
position and stop the prime mover. Crane
will be secured against swinging when not
in use.
ix. During operations, if power or a necessary
control function fails, set all the brakes and
locking devices and move all clutches or
6



other power controls to off position or
neutral position.
x. Relief valves on hydraulic cranes should
not be adjusted above manufacturers
recommended pressures and current
limiting devices on electric cranes should
not be bypassed to increase available hoist
line pull.
xi. During high wind conditions and nights, lift
of heavy equipment should be avoided. If
unavoidable, the operator shall ensure that
there is proper illumination in the night.

For mobi l e cranes (except crawl er cranes)
fol l owi ng addi ti onal procedures to be fol l owed:

xii. Crane to move on reasonably hard leveled
surface. Crane placement programme to
be prepared for lifting heavy equipment.
xiii. Make sure wheels have chokes installed
before commencing the job.
xiv. Out rigger beam should be fully extended
before operation.
xv. While working on a slope , the crane
should be parked with front wheels towards
downhill. the load lifted from the rear of the
truck.
xvi. The crane shall not be driven with out-
riggers extended.
xvii. The crane level should be checked for
stability.
xviii. A trained rigger/ signalman shall always
accompany the crane when it is being
moved.
xix. The crane hook shall be secured to prevent
it from swinging while the crane is traveling.
xx. The crane shall not be placed for working
in Hazardous area classified by existing
DGMS/Statutory notification . The
components like light etc. shall be of flame
proof type as boom can be used for
handling loads in hazardous area.

7.4 Crane Danger Si gns to watch For :
While working around crane, the operator
should be careful about following eight
danger signs of improper operation. If any
of the following occurrences are noticed at
jobsite, immediately inform to
supervisor/competent person before a
catastrophe takes place.
a Outri ggers, crawl er tracks, or
tires rai sed off the ground while
operati ng. This is an extremely
dangerous condition which
indicates the crane is being
overloaded and may tip over or
collapse. The wrong move in this
situation can cause a catastrophe.
b Operati ng cl ose to power l i nes
or other dangerous objects.
Electrocution due to contact with
power lines is the leading cause of
crane related fatalities. Detailed
regulations for proximity to high
voltage sources must be strictly
enforced. Any potential danger
should be pointed out to the crane
operator or a supervisor-but never
touch the crane at this time.
c Ri di ng the l oad or crane hook.
This is a serious violation of safety
regulations. Crane structures and
cables have far lower strength
margins for handling material than
what is required for lifting
personnel. Workers must never be
suspended from a crane boom
unless an approved personnel
basket with mandatory safety
equipment is used, and lifting
procedures are strictly followed.
d Vi si bl e structural damage on the
crane . There is little or no back up
system in the load-supporting
components of most cranes. A
damaged component can fail
completely and without warning,
causing the boom or load to fall.
e Modi fi cati ons made by addi ng
extra counterwei ght or hol di ng
down the rear of the crane. All
job initiated modifications are
illegal and may permit overloading
the crane. If not approved by the
crane manufacturer in writing,
these modifications can over stress
critical structural components,
which could cause failure of the
crane.
f A crane operati ng near a trench
or excavati on. Cranes exert
extremely high loads on the soil
near the tracks, outriggers, or tires.
A crane set up in close proximity to
an excavation can cause soil
failure, crane turnover, and
possible disaster.
g The crane i s noti ceabl y out of
l evel while operati ng. There is no
faster way to collapse a crane
boom than to impose a side force
on the boom. Working out of level
creates a dynamic side force which
means a crane collapse may be
imminent.
h The crane's hoi st l i ne i s not
verti cal at all ti mes duri ng
operati on. This indicates improper
operation. A hoist line which is not
vertical obviously indicates that the
7



load is not hanging straight down.
Out of plumb loads can cause
crane collapse by generating side
forces on the boom. In some
instances, the crane may tip over if
the load swings.
7.5 Precauti ons from live power li nes
Everyone in proximity to a crane, when
energized lines are near, must stay alert. It
takes employee teamwork to successfully
and safely operate under this combination
of conditions.
Power lines can be hard for the crane
operator to see. They sometimes appear to
be either further away or much closer than
they really are. It is difficult for the human
eye to accurately judge the clearance
between the crane's boom or line, and a
power line. Fellow workers can help assure
that safe clearances are being maintained
between the crane, the line, the load and
the overhead power line. The table below
shows basic clearance minimums, which
apply to all areas around the power line-
above, below or to either side:
Power Li ne Vol tage Mi ni mum Cl earance
up to 50k 10 feet
50k to 75k 11 feet
75k to 125k 13 feet
125k to 175k 15 feet
175k to 250k 17 feet
250k to 370k 21 feet
370k to 550k 27 feet
550k to 1,000k 42 feet
The following guidelines are intended to
prevent crane accident due to electrocution
:
Avoid storing materials around and
especially underneath overhead power
lines.
Locate all power lines on the job and
make a drawing of where you will set
up the crane.
Consider any overhead line "hot" until
the owner or utility company verifies
that it is not energized and is visibly
grounded. The line must be "cold" if
minimum clearance cannot be met.
Look carefully before the boom is
moved, particularly in congested areas
of poor visibility. Get additional workers
to help with the move if a clear view of
all areas is not possible.
Place a visual marker, such as a
florescent line or flagging to mark off
the danger zone.
Communicate the lifting plan to all
crewmembers every time you set up
(after breaks and lunch).
Use proper hand signals for directing
crane operations. Make sure all crew
members understand the signals.
Appoint a watch person who does
nothing but watch the load every time
you work in the proximity of power
lines.
Never work closer to power lines than
the code allows. Power lines are not
insulated and they can arc across
several feet.
If working near power lines can not be
avoided, contact the utility who owns
them, have them de-energized and
visibly grounded. This takes pre-
planning; most utilities require a
minimum notice.
If lines can not be de-energized, the
utility must approve your work plan and
install protective barriers. Again, a full
time watch person is required.
If one cannot move the crane away
from the lines, stay in the cabin until
the utility company arrives and makes
sure the lines are de-energized.
If a dangerous situation demands that
you must exit the crane, " DON'T
CLIMB DOWN" . J ump away from the
crane ( a distance of 2 to 4 feet is
usually far enough) and land with both
feet together as there may be areas in
the ground with differing voltage. This
will avoid having one foot in an area of
higher voltage than the other, which
can be lethal. Avoid contacting the
load, load line or the crane. Ground
crew should follow this same advice.


8



7.6 Load Handl i ng

7.6.1 The Load

Crane lifting capacities are based on
relative motion conditions between the
crane and the load to be handled. All
cranes will have one static and at least one
dynamic load rating chart. These charts
must show the Rated Lift Capacity for
boom lengths and angles.

a) The appropriate load rating charts for
the configuration in use must be in a
position where they are visible to the
operator while operating the crane. The
Operator should know that the hook
load is within the cranes applicable
Static or Dynamic Rated Load at the
radius at which the load is to be lifted.
b) The safe working load on the crane at
each radius should not be more than
90% of the test load, but in no case
should the rated capacity loads be
exceeded. The safe working load of the
crane should be legibly marked on it. A
scale or weight indicator should be
available which can be used to
determine weight of unknown load to
be lifted.
c) Never attempt to operate a crane
where the load capacity chart shows no
load capacity or where there are no
values shown on the charts. This load
is more than the safe operating
conditions for the crane. The crane can
turn over when the boom is extended
too far, even with no load.
d) To make a safe lift, the operator must
know the exact weight of the load, the
length of the crane boom, the load
radius and the boom angle.
e) For lifting heavy equipment ,
shackles/hooks shall be engaged on
lugs/eyes provided for lifting.
f) General load moment indicators do not
sense extension of outrigger beams
.As such, while operating a crane , it
should be ensured that the outrigger
beams are fully extended.
g) Cranes should always be placed
horizontally , as load moment indicator
parameters are fixed, assuming the
crane in horizontal position. Any
horizontal imbalance of the crane will
result in decrease of the balancing
moment not accounted for by the load
moment indicator, which may lead to
serious over-loading.
7.6.2 Attachi ng The Load

a) The load should be attached to the
hook by means of slings or other
suitable devices. The latch shall be
closed to secure loose slings. Hooks
should be self-closing.
b) The hoist rope shall not be wrapped
around the load.
c) Discard defective slings. Each slings
metal connector shall be stenciled with
the date the sling is placed in service.
d) Longer objects should be lifted from
both ends to maintain its balance.
e) Care and use of wire ropes shall be in
accordance with OISD Standard-187.

7.6.3 Movi ng The Load

Guidelines for moving the load are as
under:

I. The Qualified crane operator and
the designated signal person
directing the lift should determine
that:

a) The crane is placed on a
firm level foundation and
properly secured in place.
b) The load is secured and
properly balanced in the
sling or lifting device before
it is lifted.
c) The lift and swing paths
are clear of obstructions
and personnel.
d) An appropriate fire
extinguisher is kept in the
crane cabin or vicinity of
the crane.

II. Before starting to lift, the following
conditions should be verified:

a. Refer to crane load chart
for proper boom angle
before lifting any static or
dynamic load.
b. Never attempt to lift a load
that exceeds the crane
lifting capacity for a
specific boom angle.
c. Multiple part lines are not
twisted around each other
in such a manner that all of
the lines will not separate
upon application of load.
d. The hook is brought over
the load in such a manner
as to minimize swinging.
e. If there is a slack rope
conditions, the rope is
properly seated on the
drum and in the sheaves.
f. The correct slings have
been selected for the
weight to be lifted.
9



g. Stops have been provided
on crane booms to prevent
the possibility of
overtopping the boom.

III During lifting, care should be taken
that:

a) Acceleration or
deceleration of the moving
load is accomplished in a
smooth manner.
b) Load, boom or other parts
of the machine do not
contact any obstruction.

IV The Operator should engage the
controls smoothly to avoid
excessive stress on crane
machinery.

V When rotating the crane, sudden
starts and stops should be
avoided. Rotational speed shall be
such that the load does not swing
out beyond the radius at which it
can be controlled.

VI No external forces should be
applied to suspended loads which
will create side loading of the
boom. Care should be taken when
swinging the crane so as to
minimize the pendulum action of
the hook and suspended load.

VII Cranes will not be used for
dragging loads unless properly
rigged for a vertical pull not
exceeding the rated capacity.

VIII The operator will not hoist, lower or
swing while any personnel are on
the load or hook (other than in a
personnel basket).

IX While the crane is in operation, no
other work shall be performed on
the crane.

X The operator should test the
brakes each time a load
approaching the rated load is
handled.

XI The operator should avoid moving
loads over personnel. Loads which
are suspended by use of slings or
hoists should be blocked or cribbed
before personnel are permitted to
work beneath or between them.
Blow horn before moving loads
over the area where people are
working.

XII Riding on loads and hooks is
strictly prohibited.

XIII No fewer than five (5) full wraps of
rope will remain on the drum(s) in
any operating condition. Due
consideration should be given to
hoist manufacturers recommended
practices, especially for break
away anchor type hoists.

XIV All the cranes must be equipped
with safety cutouts and the weight
indicators . Safety cutouts must
always be in good working
condition.

XV When two or more cranes are used
to lift a load, one qualified operator
will be responsible for the
operation. The responsible
operator should analyze the
operations and instruct all
personnel involved in the proper
positioning, rigging of the load and
the movements to be made. The
positioning of cranes and
distribution of load should be
ascertained .

XVI Appropriate non-electrical
conducting tag or restraining lines
should be used where necessary
to guide and control the load.

XVII The Operator should not leave the
crane controls until the load has
been safely landed. He must
properly secure the crane and
boom before going off duty when
shutting down operations.


7.7 Sl i ngs

Sling, their fittings and fasteners, when not
in use, should be inspected and retired in
accordance with the following guidelines:
a) Suitable protection should be provided
between the sling and sharp surfaces of
the load to be lifted.
b) Proper storage should be provided for
slings while not in use.
c) Slings should never be choked in the
splice.
d) Sharp kinks or knots should not be
permitted in wire rope slings.
e) Loads should not be lifted with one leg of a
multi-leg sling until the unused legs are
secured.
f) The sling should show the trademark or
name of the manufacturer, the stock
number and most importantly the load
10



rating and types of hitches to be used. Do
not use it ,if it is not rated for the capacity
g) Slings, which are damaged or defective,
shall not be used.
h) Slings shall not be shortened with knots,
bolts or other makeshift devices.
i) Sling legs shall not be kinked.
j) Slings shall not be loaded in excess of their
rated capacities.
k) Slings used in a basket hitch shall have the
load balanced to prevent slippage.
l) Slings shall be securely attached to their
loads.
m) Slings shall be padded or protected from all
sharp edges of their loads.
n) Suspended loads shall be kept clear of all
obstructions.
o) All persons shall be kept clear of
suspended loads or those about to be
lifted.
p) Hands or fingers shall not be placed
between the sling and its load while the
sling is being tightened around the load.
q) Shock loading is prohibited.
r) A sling shall not be pulled from under a
load when the load is resting on the sling.
s) Any angle other than vertical at which a
sling is rigged increases the loading on the
sling.
t) Whenever a sling is found to be deficient,
the eyes must be cut or other end
attachments or fittings removed to prevent
further use and the sling body discarded.
u) A sling eye should never be used over a
hook or pin with a body diameter larger
than the natural width of the eye. Never
force an eye on a hook. The eye should
always be used on a hook or pin with at
least the diameter of the rope.
v) A sling shall be visually inspected before
use to determine if it is capable of safely
making the intended lift.
Rated loads of a sling is different for each of
the three basic method of rigging (vertical,
choker, basket etc.) and the rated loads of a
sling is different for each of the methods of
rigging based on construction of the wire rope,
web material and width etc. These rated loads
are available from the manufacturers. These
rated loads will be indicated on the heavy duty
tags attached to each type of sling at the time it
is fabricated.

Care and use of proper slings and handling
procedure should be in accordance with OISD
std.-187.

7.8 Personnel Transfer

Off loading materials and men from supply
vessels to offshore installations and vice-
versa in a heavy swell, is always
hazardous. Of all lifting operations, lifting of
personnel presents the greatest risk and
shall only be considered if no alternative
method can be found. It requires quite an
exceptional level of coordination between
the captain of the supply vessel and the
platform crane operator. The latter only has
a small time window in which to start
hoisting the load to avoid it being hit by the
heaving deck of the vessel. Personnel
transfer shall only be performed after
assessing the risk, defining associated
prevention and mitigation measures and
obtaining approval from the person in
charge of the installation.
7.8.1 Transfer of personnel by baskets
If sea is rough or wind does not permit
vessel drawing alongside or if there is no
landing platform, personnel shall be
transferred by using unsinkable basket.
The personnel basket should be so
constructed, that it is capable of serving as
a temporary life raft for the maximum
number of persons that it is designed to
carry.
7.8.2 Baskets
Manufacturer's certificate, certificate of
application and declaration of conformity,
shall be issued prior to operation.
7.8.3 Use of personnel Basket
When transferring personnel between an
installation and a vessel by means of an
offshore crane and a personnel basket, the
following precautions are recommended as
basis for setting up a procedure.
a) General precauti ons
1. The installation manager may after
careful consideration allow transfer
by means of personnel basket in
each specific case where this for
special reasons is necessary or
reasonable. Transfer shall take
place on a voluntary basis .
2. Transfer of personnel between
installation and vessel shall only
take place when there is good
visibility and adequate illumination
and only when the weather
conditions permit a safe transfer,
unless transfer is necessary with
regard to the safety of the
personnel or the installation.
3. Suitability of the vessel to which
personnel are to be transferred
must be ascertained. The type of
vessel considered suitable to carry
out a transfer should be
11



determined by its ability to maintain
station alongside the installation
and have sufficient clear deck
space to safely receive the basket.
4. Instructions shall be drawn up for
transfer operations, including
rescue instructions in the event of
accident during transfer.
5. Personnel basket shall be
designed for a maximum of 4
persons, and shall be clearly
marked accordingly. Further, it
shall be designed so that it can
serve as a temporary raft for the
number of persons it is designed to
accommodate.
6. The personnel basket shall be kept
in good condition. It should be
tested with a test load twice the
maximum workload . The result of
the test shall be entered in the
records.
7. The basket shall be safely stored
when not in use.
8. The basket shall be inspected at
least once a week.
9. The personnel basket shall be
stowed together with the life
jackets in a separate storage room
where it will not be subjected to
damage of a mechanical or
chemical nature.
10. All persons riding on the basket
should wear life jackets.
11. Any person unfamiliar with the
basket shall be given a short
briefing prior to riding the basket
and shall be accompanied by an
experienced person. Any person
sick, suffering vertigo or injured
should not be allowed to ride the
basket, except if placed inside and
escorted by an experienced
person.
12. Personnel basket shall not be used
for transfer of cargo, except for
light personnel hand luggage.
Luggage shall not be held by hand
but positioned in the middle of the
basket.
13. The crane to be used shall have
valid certificate of application and
shall be in good technical
condition.
14. The crane intended to be used for
personnel transfer shall be fitted
with an emergency release and
anti-two-block device.
15. To ensure that the crane hook
does not damage anyone using the
personnel basket, a suitable
loop/sling shall be used.
16. The crane operator should have
valid certificate of the crane
operation.
17. Transfer during the night shall only
be allowed in case of emergencies.
b) Operati onal precauti ons
1. When transfer of personnel must
be carried out, there must be
consensus between the installation
manager, the crane operator and
the safety manager to the effect
that the operation can be carried
out safely.
2. Prior to use basket shall be
thoroughly examined by the
responsible person.
3. The basket shall be fastened to the
crane hook with a long sling. The
crane hook shall have a positive
locking throatlatch. In addition to
this, the personal basket must
have a designated safety sling for
additional safety back-up.
4. The personnel basket shall be
equipped with life jackets for the
number of persons it is used for.
5. The safety harness should be used
during work from a personnel
basket.
6. The installation manager or a
person appointed by the
installation manager shall be in
charge of the transfer.
7. Before starting the transfer
operation, the starting and landing
area for the personnel basket shall
be clear to ensure that there is
sufficient space for a safe
operation. The basket shall not be
landed onto other equipment.
8. During transfer of personnel, all
unnecessary noise in the crane
operator's cabin should be
avoided, and the crane operator's
complete attention shall be
concentrated on the operation.
12



9. A designated signalman shall give
the hand signals to the crane
operator. The crane operator shall
have eye contact with the
signalman, who in turn shall have
eye contact with the personnel
basket.
10. The master of the vessel, the crane
operator and the person in charge
of the transfer operation shall be in
direct radio contact with each other
from a time before the personnel
basket is hoisted until the transfer-
operation is completed.
11. If major job is carried over-sea on
an offshore installation , a stand by
vessel shall be located in the
vicinity of the installation. The
presence or assistance of catchers,
signalmen, spotters and helpers
shall be ensured.
12. During transfer the persons
transferred shall stand on the ring
outside the ropes on the personnel
basket, and both hands shall be
free to grip on to the ropes. Life
jacket or lifesaving suit shall be
used during the transfer.
13. Personnel should position
themselves so that there is even
distribution of load around the rim
of the basket.
14. Lifting and lowering of the
personnel basket shall take place
over open water, and the vessel
shall be prepared to stop the
propellers during the transfer.
15. The crane operator should raise
the basket only high enough above
the deck of vessel to clear
obstructions, swing it over the
water, raise it to a position slightly
above landing deck level, swing
the basket over the landing area
and gently lower it to the deck. The
same method should be followed
while transferring personnel from
the installations to the vessel.
Personnel should not get off the
basket until it is settled on the deck
of the boat or platform.
16. Tag lines shall be used on the
basket and a person shall be
present to control the direction of
the basket on the deck.
17. Use of personnel basket shall be
entered into the records.
18. Free-fall or non powered lowering
should not be adopted when
personnel are carried in the basket.
7.9 Si gnal s

7.9.1 Standard Si gnal s
Signals between the crane operator and
the designated signal person will be
discernible audibly or visually, at all times.
The crane operator will work with a
designated signal person who uses
standard hand signals and will not respond
unless signals are clearly understood.
7.9.2 Use of Hand Si gnal s
It is frequently necessary during crane
operation for the operator to depend on a
signal man for instructions, when moving
an equipment into a position where there is
very limited clearance or when handling
loads that are out-of sight of the operator.
The hand signals illustrated are those
generally accepted throughout the industry.
Ensure both the operator and the signal
man are thoroughly familiar with standard
hand signals to enable co-operation and
teak work The details of use of hand
signals are attached at Annexure-A.
7.9.3 Si gnal man
The signalman shall be responsible for
relaying signals from the slinger to the
crane operator and for initiating and
directing safe movement of the crane and
hook load. Recommended standard hand
and radio signals are identified as
mentioned overleaf.
Hand si gnal s:
Fully conversant with the use of signals.
Be placed in the right position.
Check that the load is hooked correctly.
Give the signals clearly
Radi o Si gnal s :
correct use of radio.
Test the radio communication before
starting a lifting operation.
Speak clear and slowly.
Use continuous radio connection during the
lifting operation when the load is out of
sight of the crane operator.
Avoid unnecessary use of the radio
13



Prior to commencement of a lifting
operation the signalman shall satisfy
himself that loads may be safely handled.
The signalman shall remain in visual or
radio contact with the crane operator at all
times and with the slinger at initial and at
the final phases of the lift as appropriate.
If the signalman changes during a lifting
operation, both the crane operator and the
slinger shall be duly notified of the identity
of the new person in charge of signaling.
The designated signal person should:
a) Be qualified by experience with the
operation and knowledge of the
standard hand and radio signals as
shown in the table .
b) Be in clear view of the Operator to
ensure that his signals can be
seen. His position should give him
a clear view of the load, crane,
personnel and area of operation. If
the Operators view of the primary
signal person is obstructed, an
additional signal person will be
provided.
7.9.4 Speci al Si gnal s
For operations not covered in section
7.9.2/7.9.3 or for special conditions,
additions or modifications to the
recommended standard signals may be
required. In such cases, these special
signals will be agreed upon in advance by
the Operator and the designated signal
person and should not be in conflict with, or
have the potential to be confused with
standard signals.
7.10 Si multaneous Operati ons

i. When logging operation is in
progress crane operation should
not be conducted around the area
where the cable is under tension,
due to the risk associated with
simultaneous operation.
ii. During the arming of an explosive
device, crane operation should not
be conducted around the
designated arming area.
iii. During helicopter landing/take off
crane operation should be stopped
and crane boom must be away
from the landing/take off area.

8.0 INSPECTION


8.1 Pre-Use and After

Before starting of the crane the basic
checks are to be carried out by the
operator as per the manufacturers check
list requirement or guidelines given in
Annexure-B ,

8.2 Regul ar Inspecti on

Regular inspection needs to be done based
upon usage of the crane in addition to OEM
Manual requirement or as per the
inspection details indicated in of
Annexure- C.

9.0 MAINTENANCE

The maintenance of the crane shall be
made on the recommendation of the crane
manufacturers standard practices,
However, maintenance practices shall be
followed based upon utilisation of the
crane. The recommended practices for the
maintenance has been indicated in
Annexure- B

9.1 Preventi ve Mai ntenance

Periodic/ preventive maintenance schedule
shall be followed as per standard
manufacturer's practices/operator's
recommended practices.

9.2 Repai rs & repl acement

The Repairs & replacement of items shall
be followed based upon the
recommendation of inspection agency.
However, if any major item / part is
obsolete / not available the same shall be
replaced with compatible parts which has
to be approved by competent
person/agency.

No welding repair can be made to critical
components such as booms and swing
circle assemblies unless a repair procedure
and recommendations are approved .

If any critical component such as section of
the boom etc. are required to be repaired,
a qualified welder shall be deployed for
welding jobs.

9.3 Precauti ons duri ng major repai r &
mai ntenance

a. Any job will be started only after
obtaining the hot / cold work permit at
any site as per OISD Std.- 105 .
b. Care should be taken to ensure that
arcing does not occur across the
bearings.
c. Hooks should not be exposed to
excessive heat.
14




9.4 Mai ntenance of Wire rope

Maintenance and inspection of wire ropes
used in crane shall be done in accordance
with OISD Std. 187(Use and care of wire
rope)

10.0 LOAD TESTING & CERTIFICATION

10.1 A copy of the original load test carried out
by the manufacturer/contractor during the
supply/sale of crane certified by
International/National reputed certifying
agency shall be made available to the
operator/user.

10.2 In general two types of load testing
certifications are required

1) The load testing & certification
shall be done after major repair/
replacement of parts of the crane
based upon the recommendations
of third party certifying agency.

2) Periodic load test and certification :

Based on the usage rate of the
cranes all those cranes used
frequently shall be load tested and
certified annually, however for less
used cranes the load testing shall
be done based upon the
recommendation of the certifying
agency.

11.0 INCIDENT / ACCIDENT REPORTING
SYSTEM

Incident/accident reporting shall be done in
OISD proforma-107.

12.0 CONTRACT MANAGEMENT

If outside contractors are used for crane
operations, the contract management
section should ensure that minimum
qualification for operator is followed, as per
recommended practices.

13.0 PERSONNEL PROTECTIVE EQUIPMENT

All personnel working with and around
the crane shall wear safety shoes,
Hard hat, Hand gloves & overalls.
Additionally while checking the
pressure & oil gauges or working near
air source or moving parts, safety
glasses should be used.
While working at height (above ten
feet), safety harness shall be used.
Life vests shall be worn by all
personnel being transferred offshore by
Personnel basket.


14.0 REFERENCES

The following codes and standards (latest
edition) are referenced to and made a part
of this specifications :

API spec - 2C : Specification for Offshore
Cranes

API-RP-2D : Recommended Practice for
Maintenance and
Operation of Offshore
Cranes.

OISD Std.- GDN-192 : Safety practices
during construction.

OISD Std. 187: Care and use of wire
ropes.

OISD Std.-105 : Work Permit System

IS:807-1976(FirstEdition): Code Of Practice
For Design, Manufacture,
Erection
and Testing(Structural
Portion) Of Cranes And
Hoists

IS : 6717: Specification for Mobile Road
Cranes, Fully Slewing.














15




ANNEXURE :A

IDENTIFICATION OF ACTIONS ON USE OF HAND SIGNALS
1. Emergency stop : with arms extended, palm down, move hands rapidly right and left.
2. Stop : With arms extended, palm down hold position rigidly.
3. Dog Everythi ng : Clasp hands in front of body.
4. Move sl owl y : use one hand to give any motion signal and place other hand motionless in front
of hand giving the motion signal.
5. Raise the Boom : with arm extended fingers closed thumb pointing upward and a jerky upward
motion.
6. Lower the Boom : with arm extend, fingers closed thumb pointing down-ward and a jerky down-
ward motion.
7. Use Mai n Hoi st : Tap first on head then use regular signals.
8. Use whi p Li ne : (Auxiliary Hook Line)Tap elbow with one hand, then use regular signal
9. Swi ng : Arm extended point with finger in direction of swing of boom.
10. Travel : Arm extended forward, hand open and slightly raised, make pushing motion in direction of
travel
11. Hoi st : With forearm vertical, fore-finger pointing up, move hand in small horizontal circle
12. Lower: With arm extended downward, fore-finger pointing down, move hand in mall horizontal
circle.
13. Raise the Boom and Lower the Load : with one arm extended fingers closed thumb pointing
upward and a jerky upward motion and the other arm extended in a down-ward position palm
horizontal with an up-down motion of this palm.
14. Lower the Boom & Raise the Load : With the arm extended finger closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended finger pointing up move hand in
small horizontal circle.
15. Raise the l oad sl owl y : with both hands placed in front of the body, palm open and an up-down
motion with the lower palm.
16. Lower the Load : With arm extended outwards, palm down and an up-down motion towards the
downward direction.
17. Lower the Load Sl owl y : With both hands placed in front of the body palm open and an up-own
motion with the upper palm.
18. Raise the Boom sl owl y : with arms placed in front of the body and the lower hand with fingers
closed thumb pointing upward and a jerky upward motion with the upper hand palm down.
19. Lower the Boom sl owl y : with arms placed in front of the body and the upper hand with fingers
closed thumb pointing down-wards and a jerky down-ward motion with the lower hand palm up.
20. Raise the Boom & Hol d the Load : With one arm extended fingers closed thumb pointing upward
and a jerky upward motion and the other arm extended in a down-ward position closed first and
held firmly.
21. Lower the Boom & Hol d the Load : With the arm extended fingers closed thumb pointing down-
ward and a jerky down-ward motion and the other arm extended in a down-ward position closed
thumb pointing down-ward and a jerky down-ward motion and the other arm extended in a down-
ward position closed first and held firmly.

16



































































17



ANNEXURE-B


1. Di esel Engi nes

Refer secti on 5.0 of OISD STD.121 for engi ne mai ntenance.


No. Maintenance Activity Dail y Monthl
y
Qtrl y Yearl y Condi ti on
based
1 Check lubricating oil level and top-up as required . *
2 Check cooling water level and top up as required . *
3 Check fuel tank level and top-up as required . *
4 Check for any loose bolts , nuts , pipe/line
connection of foundation and tighten if required .
*
5 Start the unit and record following immediately
after start and again after 1/2 to 1 hour of running
in the log look .

a) Operating oil temperature . *
b) Operating oil pressure *
c) Engine speed ,. *
d) Water temperature . *
e) Hour meter reading *
f) Any other meter provided on the engine / panel . *
6 Rectification of fuel/lubricating oil leakage including
repair/replacement of pipes.
*
7 Cleaning of radiator with air/water . *
8 Cleaning/changing of air intake filter and pre-
cleaner dust pan including associated works.
*
9 Changing / cleaning oil /fuel / air filter/water /
hydraulic filters .
*
10 Lubricate governor , all linkage etc. *
11 Servicing and testing of injectors including allied
works.
*
12 Checking / setting of rocker and tappet clearance. *
13 Checking/tightening of belt drives . *
14 Replacement of radiator with associated works . *
15 Replacement of hydraulic and pneumatic starter. *
16 Replacement of hydraulic hand pump for starting . *
17 Replacement of starting air compressor . *
18 Replacement of cooling water pump . *
19 Replacement of turbo charger . *
20 Servicing / repair of radiator . *
21 Servicing of hydraulic and pneumatic starter. *
22 Servicing of hydraulic starting pump . *
23 Servicing of starting air compressor . *
24 Servicing of cooling water pump . *
25 Replacement of fuel pumps. *
26 Replacement of governor. *
27 Changing of acceleration cable . *
28 Removal , cleaning and fixing of flame arrestor.

*
29 Removal , repair and fixing of air receiver tank .

*
30 Removal , cleaning and fixing of exhaust muffler . *
31 Removal , cleaning and fixing of exhaust pipe . *
32 Cleaning , flushing and changing of lubricating oil
including cleaning , / changing of lubricating oil filter
and breather
*
18



33 Cleaning , flushing and changing of fuel in fuel tank
including cleaning , / changing of fuel filter .
*
34 Replacement of belts for cooling fans or water
pump of compressor or generator .
*
35 Removal of cylinder head including allied jobs
connected with its removal .
*
36 Assembling of cylinder head in the engine with
associated work for total completion of the job and
satisfactory testing .
*
37 Replacement of piston ring , connecting rod , piston
ring set etc. Including associated work necessary
for completion of the job .
*
38 Replacement of crankshaft including associated
work for total completion of the job.
*
39 Removal and getting repaired / serviced including
calibration of fuel injection pump from authorised
agencies and checking for satisfactory
performance of the engine with calibrated fuel
injection pump .
*
40 Removal and getting repaired / serviced including
calibration of governor from authorised agencies
and checking for satisfactory performance of the
engine with calibrated governor .
*
41 Painting of engine including supply of primer and
marine epoxy paint as required .
*

2. CRANES

No. Mai ntenance Acti vi t y Dail y Monthl y Qtrl y Yearl y Condi ti on/
Use based
1 Brake System :--Aux./main crane hoist , boom
And swing for proper functioning .
*
2

Safety System :-- Like limit of travels and movements ,
limits of safe operating load etc for proper functioning .
*
3

Condition of the hoses & hose connectors , grease to be
applied for corrosion prevention at the hose
connections ( as required )
*
4 Function of control levers and pedals and lubricate as
required .
*
5 Operation of cabin doors , wipers , horns ,fan etc
And lubricate / clean as required .
*
6 Check and top up of oil in following ( as required )
a) Aux. Hoist gear box ,
b) Swing drive unit gear box ,
c) Boom hoist gear box .
d) Load hoist gear box ,
e) Hydraulic oil tank .
*
7 Lubricate / grease Boom tip extention sheaves . *
8 Lubricate / grease Boom point sheaves . *
9 Lubricate / grease Outer boom extension sheaves . *
10 Lubricate / grease Gauntry Sheaves. *
11 Lubricate / grease of all pivot pins of boom ,derrick and
sheaves including that of telescopic cylinders/chains/wire
ropes inside the boom.
*
12 Lubricate / grease Radius Indicator bearings. *
13 Lubricate / grease Boom hoist pawl bearings . *
14 Lubricate / grease Upper & lower boom hoist kick-out . *
15 Lubricate / grease Front and rear bogie roller / gears . *
Lubricate slew ring gear *
16 Lubricate / grease Position lock/Slew lock . *
19



17 Lubricate / grease Swing chain & lock . *
18 Lubricate / grease Main & aux. Block, swivel hook
bearings and locking latch on hook/swivel.
*
19 Lubricate / grease Cross head bearing/main thrust
washers.
*
20 Main aux. Hooks for deformations , cracks and safety
latch .
*
21 Boom for any structural abnormalities , cracks of
deformation .
*
22 Winch mounting -- tighten if required . *
23 Checking /lubrication of boom hook anchoring latch on
chassis. Swing chain / pinion for proper fitting and
functioning .
*
24 Checking for missing and tightening of slew ring gear
mounting nuts and bolts
*
25 Checking and tightening of counter-weight pins/nuts &
bolts.
*
26 Checking for creeping of derrick(luffing), boom telescopic
and outrigger jack cylinders
*
27 Checking for leakage for hydraulic cylinders *
24
28
Pedestal and other structural mountings - tightened as
required
*
29 Checking for full extension of outrigger beams *
30 Checking of cracks/deformation of out-rigger jack plates *
31 Checking of boom pad condition and their lubrication(in
case of telescopic boom) and missing of members
members for lattice boom.
*
32 Hydraulic pumps and motors mounting - tighten as
required .
*
33 Clean the wire ropes with wire brush,record dimensions
and check for any kink ( if any ) . Also check end
connections for proper fitting .Lubricate with grease
.Boom Rope,main hoist rope and auxiliary hoist rope to
be checked.
*
34 Replacement of wire rope and greasing including
all allied job for the same .Boom rope
*
35 Replacement of wire rope and greasing including
all allied job for the same .Main hoist rope
*
36 Replacement of wire rope and greasing including
all allied job for the same .Aux hoist rope
*
37 Cutting , splicing and connection on hook/drum end of
wire rope.
*
38 Replacement of swing drive motor ( hydraulic) including
all associated works for completion of the job and
checking for proper operation after fittings.
*
39 Replacement of winch drive motor ( hydraulic) including
all associated works for completion of the job and
checking for proper operation after fittings.
*
40 Replacement of auxiliary hook drive motor ( hydraulic)
including all associated works for completion of the job
and checking for proper operation after fittings.
*
41 Replacement of Main hydraulic pump including all
associated works for completion of the job and checking
for proper operation after fittings.
*
42 Replacement of swing drive motor ( hydraulic) including
all associated works for completion of the job and
checking for proper operation after fittings.
*
43 Replacement of Swivel hook bearing and checking for
proper operation after replacement .
*
44 Replacement of Boom hoist pawl bearing and
checking
for proper operation after replacement .
*
20



45 Replacement of Cross head bearing and checking for
proper operation after replacement .
*
46 Replacement of Main thrust washer and checking for
proper operation after replacement .
*
47 Replacement of Swing chain and checking for proper
operation after replacement .
*
48 Replacement of Swing pinion checking for proper
operation after replacement .
*
49 Replacement of Pulley and checking for proper
operation after replacement .
*
50 Servicing of hydraulic pump of motor . *
51 Drain , flush and refilling of Aux hoist gear box .- *
52 Drain , flush and refilling of Swing drive unit. *
53 Drain , flush and refilling of Boom hoist gear box . *
54 Drain , flush and refilling of Load hoist gear box. *
55 Drain , flush and refilling of Hydraulic oil tank *
56 Drain , flush and refilling of Fuel oil tank . *
57 Servicing of slip ring and brushes of collector column ,if
provided
*
58 Cleaning of battery terminals and applying of petroleum
jelly and topping up of distilled water . Petroleum jelly
to be supplied by the contractor .
*
59 Servicing of Aviation light on boom including change of
bulb etc .
*
60 Replacement of aviation light including making
Servicing of search light on boom/operators cab for
illuminating working area and audio/visual warning
system for reversing.
*



Note: The above list of items for maintenance and its frequency is only recommended practice. As far as
practical manufacturers guidelines should be followed.





























21





ANNEXURE-C

Inspecti on of Components of crane

S.NO. COMPONENT TYPE OF CHECK REMARKS
1 Boom Hoist Assembly Visual
2 Boom Point Sheave Assembly Visual
3 Boom Section
A. Base Visual
B Middle Thickness
C. Upper NDT
D Tip MPI

4. Boom Hoist Wire / Rope Visual
5 J oy Stick Visual
6 Hook Block A) Visual
B) MPI
7 Main Hoist Rope Visual
8 Cabin Visual
9 Overhaul Ball Visual
10 Swing Circle Assembly Visual
11 Whip-line Visual
12 Pedestal Visual
Fasteners
NDT of welds
13 Brake Assembly Operational
14 Great Assembly Visual
15 Hydraulic Assembly Operational
16 Control Assembly Operational
Boom Control Limit Switch
Hoist Control Operational
Swing Control Main Aux Luff & Slew.
17. Manual & Control Lowering Operational By Failing
Engine Power.

18. Electrical Such As Lights Operational
Switches, Voltmeter,
Ammeter, Wiper , Fan, Horn.

19. Structural Such As Visual
Ladder, Catwalk And
Rails.

20 Engine Visual
Noise Level/Vibration

Air Pr, Oil level, Air filter,
Starter
Governor

21. Static Load Test Performance

22. Dynamic Load Test Operational
For Main. Aux.
Luff & Slew.




Detailed inspection report of various items to be inspected are placed in table below. The report
i ndi cates whether the i nspected i tem i s to be re-used, to be provided as new, to be repaired or
replaced .
22





1. CABIN ITEMS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
1.1 Operator Chair
1.2 Rubber beading
1.3 Cabin Door
1.4 Roller assembly for doors
1.5 Aluminium sliding window
1.6 Wiper with wiper motor, blade &
switch

1.7 Cabin light fitting
1.8 Cabin fan
1.9 Cabin body
2.0 Boom angle indicator
2.1 Lubro set
2.2 Load cell

2. CONTROL AND SAFETY SYSTEMS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
2.1 Weight load Indicator
2.2 Hyd. Main Pressure gauge
2.3 Hyd. Pilot Pressure gauge
2.4 Air Pressure gauge
2.5 Lube oil pressure gauge
2.6 Lube oil temperature gauge
2.7 Techo hour meter
2.8 Techo Hour Meter Chord
2.9 Chord Control Mechanism
2.10 Chords for Control Mechanism.
2.11 Diesel level gauge
2.12 Hyd. Oil level gauge
2.13 Emergency shutdown valve
2.14 Water temperature gauge

3. ELECTRICAL MECHANICAL AND OTHER HARDWARE ITEMS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
3.1 Horn & Horn switch
3.2 Main switch
3.3 Voltmeter
3.4 Ammeter
3.5 Engine Room light
3.6 Air craft warning lights
3.7 Flood lights with fittings
3.8 Electric cables
3.9 Nuts & Bolts (Assorted)
3.10 Wedge & Sockets
3.11 Latches for Main and Aux. Hook
Blocks

3.12 Brake liners / Brake Shoes
3.13 Plumber Block Bearing
3.14 "V" Belts
3.15 Exhaust Bend
3.16 Engine cooling fan guard
3.17 Exhaust Manifold
3.18 Exhaust Bellow
3.19 Injector overflow pipe
3.20 Diesel Filter
23



3.21 Lube Oil Filter
3.22 Anti vibration Pads
3.23 Grease Nipples(Assorted)
3.24 Spark Arrestor
3.25 Air Inlet valve
3.26 Roller Assemblies for Engine Room
Doors

3.27 J unction boxes

4.EQUIPMENT AND COMPONENTS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
4.1 Luff Pawl Cylinder
4.2 Hyd. Starter with dog &pinion
4.3 Transmission Belts
4.4 Mechanical Engine Protection unit
for hazardous area

4.5 Oil cooler

5. PNEUMATIC & HYDRAULIC SYSTEMS

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
5.1 Hydraulic Hose pipe
5.2 Hydraulic pipes for all sizes
5.3 Hydraulic fittings
5.4 Suction Hose
5.5 Pneumatic hoses
5.6 Drain valve for Diesel tank
5.7 Drain valve for Air tank
5.8 NRV-1/2
5.9 Hyd. Filter
5.10 Hyd. Tank Breather
5.11 Suction Valve
5.12 Hyd. Tank drain valve
5.13 Pneumatic switches
5.14 Hyd. Tank Gasket
5.15 Hydraulic oil filter
5.16 Hydraulic Float
5.17 Pneumatic FITTINGS
5.18 Main Hydraulic Pump Assy

6. WIRE ROPES

S.NO. ITEM REUSE PROVIDE REPLACE SERVICE
6.1 Wire rope for Main Hoist, Aux.
Hoist & luff winch


7. STRUCTURAL DAMAGES

NO. ITEM REUSE PROVIDE REPLACE SERVICE
7.1 Top Catwalk
7.2 Top covers
7.3 Cabin Top
7.4 Diesel Tank with Fittings
7.5 Engine Room Doors
7.6 All panels
7.7 Hand rail
7.8 Ladder