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CERTIFICATION PROCEDURES
MODULE 2 : WINCHES & POWERED HOISTS
NSL LTD
2
NSL 2004
NSL LTD :
42 Queens Road,
Aberdeen AB15 4YE UK
tel +44 (0) 1224 208988
www . nsl-uk.com
INDEX
Introduction
2.1 Manual Winches
2.2 Utility Winches
2.3 Man-riding Winches
2.4 Powered Hoists
2.5 Lifeboat / Liferaft Davit Winches
2.6 Report Examples
2.7 Blank Reports
2.8 Appendix
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INTRODUCTION
The testing and inspection of lifting equipment shall only be carried out by a competent person. It is essential
that a competent person engaged in this work must be aware of current regulations, standards, best industry
practices and relevant company procedures.
Competence can only be achieved and recorded through training, experience and assessment in the workplace.
The inspector must act with the necessary degree of impartiality, be free from any external pressures or
influences, make decisions regarding the extent of testing requirements and issue certificates stating that the
lifting equipment is suitable, and if used correctly, safe to use during a specific period of time.
For the most part, it is unlikely that any one person or even company, will be able to provide the knowledge
and expertise required to test and inspect, the vast range of lifting equipment used in todays industries. The
inspector will need to utilise information from standards, regulations and manufacturers guidelines to ensure an
informed decision is made.
The inspection of lifting equipment by the competent person, will determine if it is fit for purpose. The criteria
used to determine this, must be applied to new and used equipment alike, the inspector must never assume new
equipment is free of patent defects.
The purpose of an overload or proof load test is to prove the design, materials used, and the workmanship during
assembly of the equipment. The sole use of calculations to prove the integrity of equipment may not accomplish
this. It should be borne in mind that lifting equipment undergoing an overload test, might not withstand the
applied loadings.
All personnel not essential to the test must be kept clear of the area, with the inspector also positioned, where he
is unlikely to be injured if equipment fails.
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MANUAL WINCHES
Bolts
Drum
Worm Gear
Handle
Frame
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MANUAL WINCHES
Ensure Safe Working Load and Identification numbers are legible and correspond with the test certificate
Examine winch drum and check for distortion, wear or cracking (if accessible, examine rope anchorage
and ensure it is secure)
Where applicable, examine ratchet or worm gear and check for wear / broken teeth
Examine pawl and pawl spring / worm and check for wear / distortion
Ensure the pawl functions correctly and ensure the worm meshes correctly with the worm wheel
Examine winch frame and check for distortion, wear and cracking
Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy yourself that
the support steel work is capable of sustaining the winch under load
Visually examine the brake assembly and operate the winch handle to ensure it functions correctly
Examine all spur gears checking for alignment, wear on gear teeth, truing of gear shafts and smooth
running of bearings (where fitted)
Function check the winch through one complete revolution of the drum
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MANUAL WINCHES
If satisfactory, use test weights or a test clock with suitable anchor point, apply a proof load of SWL + 50%
Release load and re-examine to ensure proof loading has not exposed any defects
Re-examine after proof load testing to ensure this has not exposed any defects.
If all satisfactory, hard stamp with ID number, SWL and issue certificate.
This procedure is to be followed as a guideline to NSLs minimum requirements for a proof load test.
Live test weights should be weight-checked annually and be accurate to better than 1% of the nominal weight.
The accuracy of testing machines shall be in accordance with BS 1610 and BS EN 10002.
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MANUAL WINCHES
MANUAL WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Handle
2 Drum
6 Winch frame
7 Friction discs
8 Spur Gears
10 Bearing
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REQUIRES REPAIR
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UTILITY WINCHES
Controls
Brake
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Base
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UTILITY WINCHES
Ensure Safe Working Load and Identification numbers are legible and correspond with the test certificate
Examine rope guard and ensure there is no damage / distortion which may obstruct and / or abrade the
winch rope
Ensure the brake bands / brake drums are clean and free from contamination
Where fitted, examine the automatic brake checking springs, link arms and pins
With power disconnected, check that all operating levers return to neutral when released
Examine winch base and check for cracked welds, cracks around bolt holes, distortion or impact damage
Anchorage: Ensure the hold down bolts / welding / clamping is adequate and as far as possible, satisfy
yourself that the support steel work is capable of sustaining the winch under load
Check that the power supply is adequate for that particular model of winch
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UTILITY WINCHES
Bolt down winch to suitable test bed and fit a wire of such length that no fewer than five turns remain on
drum during any part of the test
TEST 1
If satisfacory, raise a proof load of the SWL + 25% to the required height to allow one full rotation of drum
under load
This test can be simulated on a hydraulic test bed where a variable pressure relief valve has been fitted
Apply manual brake to sustain load and check winch drum for creep
NOTE
When testing winches with an automatic brake on a hydraulic test bed, there will be a slight drop in load
due to the time it takes for the brake to activate
TEST 2
Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL
+ 50% to check the braking efficiency. (The brakes may require adjusting to achieve this)
Sustain the load for a short time and check winch drum for creep
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UTILITY WINCHES
TEST 3
Ensure the brake has not been over tightened to such an extent as to affect the winchs performance
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UTILITY WINCHES
UTILITY WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Rope Guard
2 Winch drum
9 Oil level
10 Winch base
11 Winch anchorage
12 Power supply
13 Function test
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Controls
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Winches of this type will be fitted with a dual braking system usually consisting of one manual brake and
one automatic brake
Examine the winch and ensure the winch does not have a disengaging clutch or pawl and ratchet
mechanism
Check that the winch has been adequately de-rated to reflect the appropriate factor of safety
(Note: Man-riding winch rope to have F.O.S. of 10:1)
NOTE
It is recommended that this type of winch is not used for general duties.
STANDARD MAN-RIDING WINCHES
Where limit switches are fitted to prevent over travel in both hoisting and lowering, function test to ensure
their operation
Function test slack wire device and emergency lowering system if fitted
Ensure the winch is clearly marked stating it can be used for raising and lowering personnel
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If satisfactory, raise a proof load of SWL + 25% to the required height to allow one full rotation of drum
under load. (This test can be simulated on a hydraulic test bed where a variable pressure relief valve has
been fitted)
Apply manual brake to sustain load and check winch drum for creep
Re-connect automatic brake and with the manual brake in the off position, repeat test 1 so full load is
taken on automatic brake
TEST 2
Using an alternative pulling source i.e. pull lift / chain hoist on the winch rope, apply a proof load of SWL +
50% to check the braking efficiency. (The brakes may require adjusting to achieve this)
Sustain the load for a short time and check winch drum for creep
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NOTE
Should any of the brake drums be exposed to the elements, the aforementioned tests should be carried out with
the drums wet, to simulate operating conditions. Make any brake adjustments as required.
TEST 3
If tests 1 & 2 are acceptable raise a load of SWL + 10%, stop load during test to ensure the brake sustains the
load without any drum creep.
TEST 4
Re-connect power supply to winch and pull up to SWL (To ensure the brake has not been over tightened to
such an extent as to affect the winchs performance)
Ensure the manual brake has not been over tightened to such an extent as to affect the winchs
performance
Function test slack wire device and emergency lowering system if fitted
Ensure all levers / controls return to neutral on release
The above tests are to be witnessed.
Re-examine winch to ensure that proof load testing has not exposed any defects.
If all satisfactory, hard stamp with ID number, SWL and issue certificate.
This procedure is to be followed as a guideline to NSLs minimum requirements for a proof load test.
Live test weights should be weight-checked annually and be accurate to better than 1% of the nominal weight.
The accuracy of testing machines shall be in accordance with BS 1610 and BS EN 10002.
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MAN-RIDING WINCHES
JOB NO :
CONDITIONS
MODEL :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
PLANT NO :
D = REPLACED
E = N.D.T.D
DESCRIPTION
CONDITION
COMMENTS
1 Rope Guard
2 Winch Drum
9 Oil level
10 Winch base
11 Winch anchorage
12 Power supply
13 Function test
14 Upper limit
15 Lower limit
17 Overload protection
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REQUIRES REPAIR
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POWERED HOISTS
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POWERED HOISTS
PENDANT CONTROL
Directional decals
LIMIT SWITCH
BRAKES
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POWERED HOISTS
GEARS / SHAFTS
If gears sound unduly noisy, send ashore for checking and examination
LOAD CHAIN
LOAD ROPE
Ropes should be considered unusable when broken wires exceed 10% over a length of eight times the diameter
of the rope or any sign of necking indicating internal damage or excessive wear.
TROLLEY UNIT (if fitted)
Security of fittings
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POWERED HOISTS
TOP HOOK
SUPPLY / CONNECTIONS
Security of connections
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POWERED HOISTS
In such a fashion that all the gearing makes one full revolution under load
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POWERED HOISTS
CONDITIONS
PLANT NO. :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
DESCRIPTION
CONDITION
A
1 Top hook
2 Safety catch
3 Bottom hook
4 Safety catch
7 Body casing
9 Function test
14 Direction decals
19 Limit switches
21 Security of fittings
22 Lubrication
24 Chain bucket
25 Drum
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POWERED HOISTS
Rope Hoists
EXAMINATION PROCEDURE
Ensure drum flange height projects at least 1.5 times the rope diameter above upper most layer
Examine brake release device for distortion and is located in the on position
Crank handle is located close to the winch, is undamaged and locates correctly onto winch
Examine push button controls and casing (if fitted) for damage and are (with power shut off) free to move
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POWERED HOISTS
Load boat with weights that together with the weight of the boat, represents 1.1 times the full load of
personnel and the boat equipment
The method of loading weights must be such that no one enters the boat once 90% of the total load is reached.
If this cannot be achieved then the weight of the boat must not be taken by the falls during loading, but by a
crane (the capacity of the crane shall be at least 2.2 times the loaded weight of the boat) and a spreader bar.
If a crane and spreader bar are used, this should then be lowered so the weight of the boat is taken on the falls.
Under no circumstances should anyone enter the boat at this time.
The area under and around the boat must now be checked to ensure it is clear of personnel and obstructions
The boat is now lowered by lifting the brake fully to enable the boat to reach maximum speed on the
centrifugal brake
The mechanical brake is then applied suddenly, before the boat enters the water, and the test paused to
ensure that the position of the boat is held
The winch shall be capable of lowering the lifeboat under gravity conditions at speeds not less than 0.30
m/s nor greater than 0.60 m/s
The results of the test should be recorded on a test certificate produced by the competent person and signed by
the witnessing authorised person.
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POWERED HOISTS
UK Regulation and SOLAS requires that at least once every five years rescue boats and lifeboats shall be turned
out and lowered when loaded with weights to simulate 1.1 times the total mass of the lifeboat or rescue boat
when loaded with its full complement of persons and equipment.
If liferaft davits and winches are to be tested, weights are to be suspended directly from the davit rather than
using a liferaft.
TESTS CARRIED OUT AT MANUFACTURERS WORKS FOR THE ACCEPTANCE OF THE WINCH BY THE
PURCHASER
TEST WITHOUT LOAD
The winch shall be run at light line speed for a period of 10 min, 5 min in each direction
HOISTING TEST
The winch shall hoist a load related to the weight of the lifeboat and its required equipment
At the speed of 0.05 m/s for lifeboats and with a speed not less than 0.3 m/s for emergency boats
BRAKE TEST
The brake shall be applied and a static test load equivalent to the working load times 1.5 shall be applied
to a rope secured to and wound on the drum fully and evenly reeled to the specified two or three layers
The drum shall not rotate and it shall be demonstrated that it is possible to release the brake
It shall also be demonstrated that the winch can slowly lower the static test load, under control of the
brake, for at least one complete revolution of the drum and then hold the load
LOWERING TEST
A load equivalent to the working load shall be applied to a rope secured to and wound on the drum fully
and evenly reeled to the specified two or three layers
The drum shall be declutched from the prime mover and the drum brake released
The governing brake shall govern the speed of descent to comply with not less than 0.30 m/s nor greater
than 0.60 m/s
The total lowering height for this test shall not be less than 15 m
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POWERED HOISTS
The results of the test should be recorded on a test certificate produced by the competent person and signed by
the witnessing authorised person.
Re-examine winch to ensure that proof load testing has not exposed any defects.
If all satisfactory, hard stamp with ID number, SWL and issue certificate.
This procedure is to be followed as a guideline to NSLs minimum requirements for a proof load test.
Live test weights should be weight-checked annually and be accurate to better than 1% of the nominal weight.
The accuracy of testing machines shall be in accordance with BS 1610 and BS EN 10002.
LIFEBOAT / LIFERAFT DAVIT WINCHES
EQUIPMENT TYPE :
CONDITIONS
PLANT NO. :
A = SATISFACTORY
SERIAL NO. :
SWL :
C = CONDEMNED
DESCRIPTION
CONDITION
A
1 Drum
2 Drum flange
4 Crank handle
9 Lubrication
11 Winch wire
12 Winch base
13 ID / SWL markings
14 Oil levels
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54321/001
J. Bloggs
CERTIFICATION NO : ..............................................................................................
TESTER / EXAMINER:............................................................
EAL Module 2
19.08.07
QUALIFICATION : ...................................................................................................
DATE OF TEST / EXAMINATION : ..........................................
IDENTIFICATION
NO.
QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
ABC 0001
150kg
N/A
18.02.08
12345/001
21.08.06
NSL
20.02.07
NONE
NONE
Platform Alpha
19.08.07
We hereby certify that on ............................
(date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
J. Bloggs
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
19.08.07
DATE ..................................................................................................................DOC
REF NO : NSL C 001
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12345/001
J. Bloggs
CERTIFICATION NO : ..............................................................................................
TESTER / EXAMINER:............................................................
EAL Module 2
20.02.07
QUALIFICATION : ...................................................................................................
DATE OF TEST / EXAMINATION : ..........................................
IDENTIFICATION
NO.
QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
ABC 0001
150 kg
19.08.07
Serial No:0100010
Winch fitted with main air emergency stop device
Satisfactory
emergency
nitrogen source
N/A
N/A
N/A
20.08.06
NONE
NONE
Platform Alpha
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LOCATION
INSPECTION DATE
Platform Alpha
20.02.07
NSL JOB NO
REPORT NO
AD12 1AD
G12345
G12345 /001
CLIENT ORDER NO
SHEET
ABCD00001
one
of
one
SURFACE CONDITION
Carbon Steel
Acceptable
ACCEPTANCE STANDARD
BS 6072
EQUIPMENT
POWER / CURRENT
MATERIAL THICKNESS
Permanent magnet
20mm
METHOD
MEDIUM
BACKGROUND
RESULT
100% magnetic particle inspection was carried out on winch No ABC00001 base welds pre & post load test
No defect was found at time of inspection and is acceptable to specifications
This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of the
inspection body and the client.
NSL INSPECTOR
ISSUING AUTHORITY
CLIENT
Sign
Sign
Sign
Name
Joe Bloggs
Name
Name
Quals
Module 2
Quals
Quals
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DEFECTIVE ITEM
(DESCRIPTION ,
LOCATION, SERIAL
NO.)
PARTICULARS
REPAIR BY
OF DEFECT
(INCLUDING RETEST
IF APPLICABLE
TO BE REPORTED
TO ENFORCING
AUTHORITY
REMARKS
(MANIFEST NO.
ETC.)
123/001
Safety pin
Deformed body
N/A
00010/001
Removed from
Bow shackle
Remove from
service
service 18.02.08
1 tonne,
missing from
before use
HOL 3m,
bottom hook
N/A
66616/002
New safety
catch fitted
18.02.05
welders Swing
arm jib
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QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
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QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
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QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
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QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
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QTY
DESCRIPTION OF EQUIPMENT
SWL
PROOF LOAD
APPLIED
DATE OF NEXT
EXAMINATION
We hereby certify that on ............................ (date) the item/s described in this report was/were thoroughly examined, so far
as accessible, and the above particulars are correct. If installation is relevant, the equipment checked and examined is safe
to operate.
SIGNATURE OF PERSON : ................................................................................. NAME OF PERSON...................................................................
CONDUCTING EXAMINATION
CONDUCTING TEST / EXAMINATION (delete as nessassary)
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LOCATION
INSPECTION DATE
NSL JOB NO
REPORT NO
CLIENT ORDER NO
SHEET
of
MATERIAL
SURFACE CONDITION
ACCEPTANCE STANDARD
EQUIPMENT
POWER / CURRENT
MATERIAL THICKNESS
METHOD
MEDIUM
BACKGROUND
RESULT
This report relates exclusively to the work ordered and / or the item(s) inspected. It shall not be reproduced except in full, without the approval of the
inspection body and the client.
NSL INSPECTOR
ISSUING AUTHORITY
CLIENT
Sign
Sign
Sign
Name
Name
Name
Quals
Quals
Quals
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CLIENT :.................................................................................................................................................................................................................
INSPECTION ENGINEER:........................................................................................................................................................................................
INSTALLATION :.....................................................................................................................................................................................................
DATE : ...................................................................................................................................................................................................................
CD09
NSL LTD
DEFECTIVE ITEM
(DESCRIPTION ,
LOCATION, SERIAL
NO.)
PARTICULARS
REPAIR BY
OF DEFECT
(INCLUDING RETEST
IF APPLICABLE
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TO BE REPORTED
TO ENFORCING
AUTHORITY
REMARKS
(MANIFEST NO.
ETC.)
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APPENDICES
2.8 : APPENDIX
WINCH DRUM CAPACITY
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APPENDICES
2.8 : APPENDICES
WINCH DRUM CAPACITY
L = Length of rope (metres)
A = Desired depth of winding (mm). The depth of the
flange is normally reduced by 40 to 50 mm to allow
ground clearance for the rope.
1274
24
183300
2865
26
215200
5093
28
249600
7958
32
326000
11470
35
389900
15600
38
459700
20370
40
509300
25780
44
616300
11
38520
48
733300
13
53800
51
828100
14
62400
52
860800
16
81490
54
928300
18
103100
56
998200
19
114900
60
1147000
20
127400
64
1304000
22
154100
67
1429000
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APPENDICES
2.8 : APPENDIX
WINCH DRUM CAPACITY
FORMULA
L = (A+B) x A x C
K
EXAMPLE
Drum dimensions :
A = 400mm
B = 600mm
C = 700mm
K : Rope diameter 16mm = 81490
= 280,000,000
81490
= 3437m
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