Procedure annexure / formats

MOBILE CRANE SAFETY

Sr no Procedure Description
1 MOBILE Request for Heavy Equipment requirement Annexure -1
2 CRANE Operator’s Daily check list Annexure -2
3 SAFETY Equipment Handling Checklist/Permit Annexure -3
4 PREVENTIVE MAINTENANCE CHECK LIST Annexure -4

CRANE
5 Annexure -5
Annual crane check list by third party

6 Annexure -6
Checklist For Hired Crane
7 Annexure -7
Load charts of RIL Cranes

8 Annexure -8
Check list for maintenance for lifting tools for

crane viz hook, slings

9 Annexure -9
Guidance for use of “Site Inspection before

lift”

ANNEXURE 1
Reliance
Industries Limited
Hazira Manufacturing Division
 Request for Heavy Equipment requirement

Plant: Department:
Priority: Engg in-charge:

Job Description : Mobile

Equipment reqd: Phone no:
Weight of job: Boom angle:
Radius of load : Boom length:
Date of job:
Time from : Time to :
 ANNEXURE - 2
Reliance
Industries Limited
Hazira Manufacturing Division

Operator’s Daily check

 ANNEXURE - 3

Reliance
Industries Limited
Hazira Manufacturing Division

Equipment Handling Checklist/Permit

(Loading/Unloading/Dismantling & Erection of equipment weighing more than 2MT or % loading
of crane > than 85% irrespective of load)

Equipment Detail Tools & Tackles

Plant D-Shackles size & capacity
Tag No Sling size & capacity
Net Weight to be lifted(MT) Chain Block size & capacity
Height of Eqpt (m) Test Certificate of tools &
Dia (m) tackles
Horizontal/Vertical (H/V)
Elevation(m)
Lifting Lug

Crane Detail Ground Preparation

Make & Model of Crane Ground preparation with
Operating radius (m)  MS Plate
Max Operating Boom Length (m)  Wooden Sleepers
Load Capacity at operating radius & boom As per calculation
%age Loading Of Crane

Piping & Structure Fouling Rigging Plan

What will be the minimum clearance from Attach the schematic rigging
piping & structure & other adjoining plan
equipment? (See the equipment layout
drawing)

Date

(Plant Engineer) (Contractor Supervisor)

(Plant Mechanical Head) (Plant HOD)

(Head CES fabrication & Rigging Cell) (CES HOD)

(if weight >30MT) ( if weight > 50MT)
---------------------------------------------------------------------------------------------------------
 To be filled before starting the job & should be available at site
 Format to be filled/signed preferably at site or after visit to site.
 This form will not overrule any other permit or safe working practices.
 To be filled in duplicate (original for display at site & duplicate for record).
 ANNEXURE - 4
Reliance
Industries Limited
Hazira Manufacturing Division
PREVENTIVE MAINTENANCE CHECK LIST CRANE
Equip. Tag No._________ Date: _________
Frequency: Every Four Month (as per schedule)
SR Check Points Observations Compliance Yes / No
1 Check engine oil & Change oil & filter
element if reqd.
2 Clean air filter element .

3 Change & refill F.I.P.lube oil.

4 Drain filter bowl until clean fuel

appears.
5 Check fan belt /water pump belt
tension, reset if required.
6 Flush out radiator water & refill with
soft water.
7 Check Winch oil & hydraulic oil level
in tank .
8 Adjust clutch, brake system for free
play, check brake fluid, clutch fluid
level top up if required.

9 Check oil in Gear box & wheel

axle. Replace if necessary
10 Check for any hydraulic oil leakage

11 Check u.j. cross for normal operation

12 Check air system for any leak.

13 Wire rope cardium compound to be

applied / Grease all pivot points
14 Check all operations for normal
working.
ELECTRICAL

1 Check battary electrolyte level

,Charge battery
2 Service starter

3 Service alternator

4 Check all V.F.C. related items

5 Check KRUGER, PTO switch for

proper functioning.
6 Check oil cooler fan functioning.
Remark for abnormalities :

Spare Required to rectify :

Signature : Signature : Signature :

Name of Technician Name of Supervisor Name of RIL Engineer

 ANNEXURE - 5

Reliance
Industries Limited
Hazira Manufacturing Division

Annual crane check list by third party

 ANNEXURE 6
Reliance
Industries Limited
Hazira Manufacturing Division

Checklist For Hired Crane

HEAVY EQUIPMENT
INSPECTION & LOAD TESTING REPORT OF HIRED EQUIPMENT [ HYD.CRANE/CRAWLER/HYDRA]
Date:
Basic details:
Name of the Party: Contact Person: Tel.:
Sr.No.: Regn.No: Eqpt.:Crawler / Hyd.Crane/ Hydra
Make : Model: Cap:
Insurance validity: Vehicle Fitness : RTO Permit:
Other Remarks:

Operating crew:
Name of the Operator: Driving License No: Optr.'s Fitness:
Work Experience: Equipment Operated:
Name of the Operator: Driving License No: Optr.'s Fitness:
Work Experience: yrs. Equipment Operated:

Name of the helpers : Fitness of the Helpers:

Boom
Type: Telescopic / Fixed / Lattice: Telescopic
Boom Length: Basic: Full Extension: Intermediate Sections:
Jib: Type : Length:
General Condition of Boom:
Condition of Sheaves: Boom tip: Condition of Guides/Pins etc. :
Hook block: Standard / Local Safety Latch: Cap.:
Condition of Main Hoist Winch: Condition of Aux. Winch:
Brakes: Hoist: Slew: Vehicle brake: Hand brake:

Wire rope:
Main hoist Boom Suspension

Dia as per Dia at Length as Length at Dia as per Dia at Length as

design present per design present design present per design Length at present
mm mm mm mm mm mm mm mm

Condition of Wire ropes / Guy Rope : Rope termination(dead end):

General Condition of Hydraulic Cylinders:

Derrick: Hoist:
Steering: Suspension:
Outriggers : Front Right Lift: Front Left: Lift:
Rear Right Lift: Rear Left : Lift:

LOAD TEST
Rated load ………... Kg, Boom Length ………….Ft / Mtr, Angle…..*, Radius…...Ft / Mtr, (AS PER LOAD CHART)
Actual Load (including Hook+ Lifting tackles) ……….Kg, % of Loading ………….,
Creeping Rate @ ………..mm/15 min
Signature of Hiring agency representative for carrying load test on over load:
Overload test: Tonnes Creeping Rate in mm/hr: Radius: Angle:
Weight(in SLI ) Radius(in SLI) Boom Length(in SLI) Angle(in SLI):
Limit Switch: Boom Hoist Upper Limit Lower Limit Anti two block:
Single fall Test: Load in tonnes: Boom Length in M Angle Creeping rate:
Statutory Test Requirement: TESTED BY: Dtd.:
Availability of Load Chart:

SPARK ARRESTER : Available / Not Available

Other Statutory requirements:

LIGHTS : Vehicle Lights Indicators: Front : OK Rear: Boom Lights: Not Available
BATTERY TERMINALS: Cond. of Alternators: Cond. Self Starters:
CONDITION OF CABIN:
HORN Front (Main): Reverse: Overload Alarm:
Condition of ENGINE: Blow Bye Oil Leak(External): Oil Pr. Water Temp
Tyres:
 ANNEXURE - 7
Reliance
Industries Limited
Hazira Manufacturing Division

Load charts of RIL Cranes

 AMK-125 Gottwald crane ( Hired for RIL Hazira)

3 4 5 6 7 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
BOOM OPERATING
LENTH RADIUS
Deg. 72 68 63 58 53 47 32
13.7 Cap. 125 100 80 68 61 55 39
Hyd. Press. 319 302 280 270 270 266 227
Deg. 80.5 78.5 76.5 74 69 66 60 54 47 39 29
22.4 Cap. 55 55 52 49 44 39 33 27.5 20 15.8 12
Hyd. Press. 165 193 210 222 224 217 226 206 187 180 177
Deg. 82.5 81 79 77 76 70 65 61 56 52 47 42 36 28 18
31.1 Cap. 35 35 33 31.5 30 25 20.5 16.5 13.4 11 8.8 7 5.4 4.1 3
Hyd. Press. 140 161 173 185 195 199 197 194 184 176 168 165 163 165 177
Deg. 85 81.5 80.5 78.5 75 70 68 65 62 58 55 51 47 43 39 36
39.8 Cap. 18 18 18 18 18 15.4 13.2 11 9.6 8.2 6.6 6 5.2 4.2 3.3 2.5 1.7
Hyd. Press. 121 122 123 125 152 164 167 168 168 168 170 166 163 162 159 159
Deg. 82 81 80 79 78 76 72 70 68 64 62 59 57 55 52 47 44 40
48.5 Cap. 14 14 13.5 12 11 9.6 8.6 7.8 7 6.6 5.7 4.8 4.1 3.5 3 2.3 1.8
Hyd. Press. 121 122 124 125 128 136 138 149 151 158 161 168 165 160 160 160 158 150
 ANNEXURE - 8
Reliance
Industries Limited
Hazira Manufacturing Division
 ANNEXURE - 9

Reliance
Industries Limited
Hazira Manufacturing Division

Guidance for use of “Site Inspection before lift”

This is the second set of checks and shall be done before the lift is started with the crane set up
at the place for the lift. These checks must be done for each new set up even if the same crane
is deployed in different set ups.
 Does lift radius and boom length check with the planned: With the crane set up
measure the lift radius and check the boom length required. For hydraulic cranes the
boom length can be read on the SLI and the lift radius measured checked against the
SLI reading for lift radius. For crawler cranes boom length is fixed and can be taken from
the load chart using the relevant configuration. If lift radius or/and boom length is bigger
than planned, the capacity loading must be recalculated to check that the loading still is
within prescribed limit; 85% for cranes with SLI, 60% for cranes without SLI or for crane
used for lifting personnel.
 Are outriggers fully extended, placed on load spreaders and crane leveled: Check
that all 4 outriggers are fully extended to the marking on each of the outriggers. It is not
allowed to proceed with the lift if any of the outriggers cannot fully be extended. If
possible always use the spreaders provided with the crane under the outriggers. Is the
crane leveled as per spirit level installed in the crane? If the crane will move free on
wheels (hydras) or on crawler with the load suspended ensure it will stay leveled.
 Are out riggers set on solid ground free from water logging/soaking and on safe
distance from any excavation, storm-water channel, pit, trench etc.: Do not allow
the crane setting on ground with water logging or soil soaked with water as the ground
loading capability might be much lower than expected. The distance of any outrigger to
an excavation, storm-water channel, pit (not RCC pit), trench must at least be equal to
the depth of the cavity. Outriggers should not be placed above storm-water culverts
without spreading the load.
 Is electrical overhead line at least 6 meters away from the tip of crane boom: When
crane boom, fully extended, is pointed towards the overhead line the distance must be at
least 6 meters away from the vertical projection of the line on the ground. Never use a
crane to lift any load under a charged line. If required the line must be isolated and
permit given by authorized electrical person.
 Is crane slewing/movement free from any obstruction with at least 0.6 m: Check
that the crane can slew with the prescribed safety margin of 0.6 m, if not possible
barricade the area to stop personnel access.
 Is the crane free of any oil leakage: When walking around the crane check for any oil
leakage from the hydraulic system especially on the outriggers.
 Is weather condition safe for lift: High wind speed will have a significant impact on
loads with high wind areas, say above 25 m2. The wind might cause the lift line to get
out of plumb and cause the crane to topple. If wind speed is above 35 km/hr or 19.4
knots the lift shall be stopped. For lift of personnel the wind speed limit is 14 knots . Call
MFS, ext. 11191, to get actual wind speed. Do not permit the lift if visibility is limited by
e.g. heavy rain or fog. Avoid lift during not daylight hours. Do not lift during thunderstorm.
 Are slings marked with safe load, valid color-coding and without any visual
damage. Is capacity loading below 50%: All slings, belts, shackles shall be visual
inspected for wear and tear, cuts before any lift. No damage shall be accepted. The
load on slings/belts shackles should not exceed 50% of the marked safe load. When
lifting plan available higher sling loading is acceptable. Account for sling angles when
 more than one sling is used. A sling angle of 60 degree towards the load will increase the
load in the sling with 15%, 45 degree with 41% and 30 degree with 100%. Slings used
for lifting personnel shall only be loaded to 20%.
 Are slings protected from sharp edges on the load: A couple of incidences at site
have happened when sharp edges have cut through the belts and caused the load to
drop. Ensure that the slings are protected by e.g. fitting wooden beams between load
and slings.
 Is angle between sling and load more than 60 degree: A small angle will cause high
load on the sling and load, see above. If possible keep the angle above 60 degree and
the extra load will be limited to 15%.
 Are shackles used if more than 2 slings are attached to the hook: To avoid undue
load on the slings from each other, the slings shall be connected to the hook by help of
shackles if more than 2 slings are used.
 Is the load free from adhesion: Ensure that the load is free from adhesion by e.g. use
of a jack. If it is not possible to conclude that the load is free, e.g. during dismantling
operation, add 100% to the load and check capacity loading.
 Are lifting lugs free from visual defects: Visual inspect lifting lugs for any defects.
 Is load center of gravity known: For eccentric load with unknown center of gravity
always determine center of gravity by trial and error without lifting the load completely off
the ground.
 Is lift line plumb: It is not allowed to use the crane for dragging the load as this could
cause the crane to topple. The lift line shall hang vertical free from any obstruction above
the center of gravity of the load.
 Is the lift area free from any other conflicting activities: During the lift other activities
in the direct vicinity and especially under the load must temporarily be stopped. A crane
operation is a hot job and no draining of hydrocarbon shall be allowed in the vicinity as
long as the crane engine is running.
 Is signaler in high visibility vest: Ensure that the person signaling to the crane
operator is in high visibility vest. Vest will be provided by MFS
 Is lift area barricaded? Are the slinger and signaler clear of the lifted load by use of
guide ropes: This is the ultimate precaution for all lifts. No person shall be allowed
under suspended load. If it is not practical to barricade the area other means to keep
people away must be used.