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TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCES

3.0 DEFINITIONS

4.0 RESPONSIBILITIES

5.0 LIFTS

6.0 CRANE MAINTENANCE INSPECTION,

TESTING & CERTIFICATION

7.0 LIST OF ATTACHMENTS

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1.0 SCOPE
1.1 This procedure outlines the system and responsibilities for operating, inspection,
testing and certification of all cranes and other lifting equipments in Batam
Fabrication Yard to ensure its compliance with the reference standards and the
local government regulation.
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2.0 REFERENCES
This procedure shall be read in conjunction with the following referenced
documents:
• JRM 2204-001 – Corporate Equipment & Machinery Department
Guidelines Manual
• ASME B30.2 - 2005, Overhead and Gantry Crane (Top Running Bridge,
Single or Multiple Girder, Top Running Trolley Hoist)
• ASME B30.4 - 2003, Portal, Tower and Pedestal Crane
• ASME B30.5 - 2004, Mobile and Locomotive Crane
• ASME B30.23 - 2005, Personnel Lifting System
• QP-036/002 – Lifting Equipment, Wire Rope & Below the Hook Lifting
Devices – Volume 2: Wire Rope
• QP-036/003 – Lifting Equipment, Wire Rope & Below the Hook Lifting
Devices – Volume 3: Below the Hook Lifting Devices and Hand Operated
Lifting Devices
• QP-041 – Critical Lifts
• Regulation of Manpower Minister of Republic Indonesia No. PER-
05/MEN/1985: Hoist and Transport Instruments
• Regulation of Manpower Minister of Republic Indonesia No. PER-
01/MEN/1989: The Qualification and Requirements for Crane Operators
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3.0 DEFINITIONS
3.1 LIFTING AND TRANSPORT EQUIPMENTS
Lifting and Transport Equipments means the equipments which are used for
moving, hoisting load, either materials or goods or people vertically and or
horizontally within a certain distance.
Including in Lifting and Transport Equipments are:
• Crawler Cranes • Hydraulic Cranes
• Overhead Cranes • Forklift
• Tower Cranes • Tractor

3.2 APPOINTED PERSONS

• An appointed person is a person deemed by the Batam Fabrication Yard to
be suitably qualified and to have the necessary experience to perform all
related duties associated with the safe operation, testing, inspection and
certification of lifting equipment within the fabrication yard.
• All appointed persons involved in wire rope monthly and annual inspections
shall be appointed in written by the Rigging Superintendent. The list of
appointed wire rope inspectors will be updated and issued within the Batam
Fabrication Yard to the JRM Group E&M Department in a six (6) month
frequency.
• All appointed persons involved in crane monthly and annual inspections
shall be appointed in written by the Maintenance Manager.
• An appointed wire rope inspector will have undergone instruction by a third
(3rd) party organization, and will have passed written and practical
examinations based on ASME/ANSI B30 standards, Section 3.
• An appointed crane inspector will have undergone instruction by a third
(3rd) party organization, and will have passed written and practical
examinations based on ASME/ANSI B30 standards and the Regulation of
Manpower Minister of Republic Indonesia No. PER-05/MEN/1985.
• An appointed crane operator will have undergone instruction by a third (3rd)
party organization, and will have passed written and practical examinations
based on ASME/ANSI B30 standards and the Regulation of Manpower
Minister of Republic Indonesia No. PER-01/MEN/1989.
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4.0 RESPONSIBILITIES
4.1 OPERATION MANAGER
• The Operation Manager is responsible for submitting the proposed training
details, list of appointed person & provider to the JRM Group E&M
Department.

4.2 YARD GENERAL SUPERINTENDENT

• The Yard General Superintendent shall ensure that the yard lift schedule
allows sufficient time for the appointed persons to perform the necessary
crane & wire ropes inspections.

4.3 DESIGN ENGINEER ONSHORE

• The Design Engineer Onshore shall attend to witness all tests and to record
the results and observations made during the test.
• The Design Engineer Onshore shall maintain the backup files of personnel
basket design calculation, drawing and register.

4.4 RIGGING SUPERINTENDENT

• The Rigging Superintendent shall appoint in written all appointed persons
involved in wire rope monthly and annual inspections.
• The Rigging Superintendent shall ensure that all activities related to the
crane operation identify within this procedure are complied with.

4.5 MAINTENANCE MANAGER

• The Maintenance Manager shall appoint in written all appointed persons
involved in crane monthly and annual inspections.
• As a nominated coordinator with Manpower Ministry, the Maintenance
Manager will be responsible for the certification process.
• Shall ensure the record of crane monthly inspections are maintained and
updated.

4.6 TRAINING MANAGER

• Shall ensure the training providers and syllabus are approved by the
Corporate E&M Group.
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5.0 LIFTS
5.1 CRANE OPERATORS
5.1.1 Crane Operator will be qualified in accordance with the requirement of ASME
B30.5, Section 3 and Regulation of Manpower Minister of Republic Indonesia
No. PER-01/MEN/1989
5.1.2 Only qualified crane operators will be allowed to operate cranes and they will
follow the recommendations outlined ASME B30.5 Section 3, Regulation of
Manpower Minister of Republic Indonesia No. PER-01/MEN/1989 and the
Operation & Maintenance Manuals issued for the crane.

5.2 CRANE OPERATIONS

5.2.1 Crane operators will be instructed to respond to signals only from the appointed
person who is directing the lift or from an appointed signal person, (see
Attachment – 8).
5.2.2 The person directing the lift shall see that the load is secured and balanced in
the sling or lifting device before it is lifted more than a few inches.
5.2.3 When a signal person is not required as part of the crane operation, the crane
operator will directly be responsible for the lift. The operator will obey a STOP
signal at all times, no matter who gives the signal, (see Attachment – 8).
5.2.4 During lifting operations, care shall be taken that there is no sudden acceleration
and deceleration of the moving load.
5.2.5 No crane will be loaded beyond the crane manufacturer’s load rating chart
except in the case of crane rated load tests as defined in this procedure.
5.2.6 A simplified crane load chart (see Attachment – 9) will be provided for each
crane. If there is a change of crane configuration (e.g. boom change, fly jib
installed etc.) the correct simplified load chart will be re-issued to the crane.
5.2.7 The Rigging Superintendent will ensure that the correct simplified load chart is
available in each crane at all times.
5.2.8 When loads are to be lifted and the weight is not accurately known, the
appointed person responsible for the job will assess the lift and confirm the
suitability of the equipment used for the operation.
If the appointed person is in any doubt whatsoever, he shall involve his
immediate supervisor and/or engineering assistance to evaluate the lifting
operation.
5.2.9 The operator shall not leave the controls while the load is suspended, unless
under the direction of the Rigging Superintendent & special conditions prevail.
5.2.10 Neither the load nor the boom shall be lowered below the point where no less
than two full wraps of rope remain on their respective drums.
5.2.11 If there is “Warning” or “Out of Service” sign on the switch or engine starting
controls, the operator shall not switch the engine until the warning sign has been
removed by the person who installed it.
5.2.12 When more than one crane is to be used to lift a load (multi-crane lifting); one
appointed person will be responsible for the lifting operation. It is the
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responsibility of the appointed person to ensure that the cranes involved in the
operation work according to the lift procedure.
If at any time during the operation the cranes encounter unexpected loading the
appointed person is responsible to stopping the lift and re-evaluating with the
Engineering, prior to proceeding further with the lift.

5.3 PERSONNEL LIFTS

5.3.1 GENERAL
5.3.1.1 All personnel lifting requirements will be identified by the appropriate craft
Supervisor, prior to the start of the work shift. These will be addressed at the
daily morning meeting where the Yard General Superintendent or his designee
will authorize the operation. No personnel lifting will be performed without the
prior approval of the Yard General Superintendent or his designee.
5.3.1.2 The lifting equipment shall have an anti two block device fitted, and wherever
practicable, the lifting equipment shall have positive drive hoist and lower
functions. Under no circumstances shall a work basket be lowered through the
“free fall” mechanism.

5.3.2 LIFTING OPERATIONS

5.3.2.1 A pre-lift meeting attended by the Crane Operator, Signal Person and the
responsible Yard Supervisor will be held to discuss the lift which is to be
undertaken, and the work tasks required. A Personal Basket and Lift
Authorization form shall be completed and the personnel fully briefed prior to
commencing the operation. A copy of the form shall be held by the crane
operator.
5.3.2.2 A full crane function test without personnel in the work basket shall be performed
prior to commencing the operation. Where the operation extends beyond one
shift or several days, the function test shall be performed at the beginning of
each shift. This test shall also be performed immediately following inclement
(wet bad) weather.
5.3.2.3 Once the personnel being lifted are supported in the personnel platform, and just
prior to hoisting, the platform shall be raised a few inches clear of the ground,
and inspected to ensure that it is secure and properly balanced.
5.3.2.4 The total weight of the lifted load (including personnel) will not exceed 50% of
the crane rating under the planned lift radius during personnel handling
operations.
5.3.2.5 The lift plan shall be such that a minimum number of crane functions need to be
performed whilst personnel are suspended from the hoist rope. Particularly any
travel function.

5.3.3 CONSTRUCTION AND TESTING OF PERSONNEL PLATFORMS/

BASKETS
5.3.4 All personnel baskets will have the back-up design calculations and drawings
prepared. The Design Engineer Onshore will maintain these files.
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5.3.5 Personnel baskets will be designed in accordance with the following rules:
• In the case of a Pettibone crane, the personnel platform will be limited to a
maximum capacity of two (2) persons.
• In the case of crawler cranes, the personnel platform will be limited to a
maximum capacity of four (4) persons.
• The personnel platform and attaching devices will have a minimum design
factor of 5.0
• The personnel platform will have a plate attached specifying:
- the weight of the empty personnel platform
- an identifying number
- the maximum number of persons and the SWL for which the
platform is rated
• All welding procedures and welder operator qualifications will be in
accordance with AWS D1.1, and all welding shall be performed by qualified
welders.
5.3.6 Every personnel platform and basket will be proof tested annually to twice its
rated SWL. A register of the proof tests will be maintained by the Rigging Store-
man, in the Rigging Department.
The platform will be held in a suspended position for five (5) minutes. An
inspection will be made by the appointed person and any deficiencies noted will
be corrected and another proof test conducted. Any modifications will require re-
testing.
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6.0 MAINTENANCE, INSPECTION, TESTING AND CERTIFICATION

6.1 GENERAL
This section sets out the requirements for the maintenance, inspection, testing
and certification of lifting equipment.

6.2 MAINTENANCE
6.2.1 A preventative maintenance program will be established and maintained based
on the manufacturer’s recommendations. The preventive maintenance will be
outlined specifically in the QP-072.
6.2.2 A record will be maintained for each crane showing the maintenance history,
(see Attachment – 10).
6.2.3 All crane replacement parts will be obtained from the original manufacturer of
the equipment unless the approval for material substitutions is received in
written from the Yard General Superintendent.
6.2.4 Any hazardous conditions disclosed by inspections will be corrected prior to
resuming crane operations. All adjustments and repairs will be documented by
means of Repair Maintenance Requests which will be maintained in file for each
crane.

6.3 INSPECTION
6.3.1 At the beginning of each shift, the equipment operator will complete a crane
daily checklist, (see Attachment – 1 and Attachment – 11 for Lampson Translift).
The daily check sheets will be forwarded to the Maintenance Department and
they will take remedial action that may be required. The crane operator will be
familiar with the equipment and its proper care. If the adjustments are required,
the operator will report the details promptly to their supervisor and notify the next
operator. All controls will be tested at the start of each new shift. If any control
fails to operate correctly, they will be adjusted prior to any operations
commencing.
6.3.2 On a monthly basis, the crane shall be visually inspected by the appointed
person, (see Attachment – 2). Any damage or concern will be brought to the
attention of the Yard General Superintendent. The monthly inspections will be
recorded and the record held on file by the Maintenance Department.
6.3.3 A thorough annual inspection will be performed for all cranes. The appointed
person undertaking the examination will complete an inspection report, which
will be held in file by the Maintenance Department. Cranes without a valid
inspection certificate will not be used on any critical lifts (see QP-041 Critical
Lifts)
6.3.4 Cranes that are not in regular use and have been idle for a period exceeding six
(6) months will be given a thorough inspection to match the annual inspection
before being placed in service.
6.3.5 Additional checks may be called for at any time when new equipment is
received, prior to critical lifts or when equipment is believed to be suspect.
All inspections will include an inspection of the wire rope condition.
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6.4 TESTING
6.4.1 As part of the thorough annual inspection or when load sustaining parts have
been altered, replaced or repaired, a load test shall be performed.
6.4.2 Load test will be done in steps progressively from 25%, 50%, 75% and 100% of
the manufacturers load rating.
6.4.3 For all rated over-load tests, the test loads will not exceed 110% of the
manufacturers load rating for crawler cranes and will not exceed 125% of the
safe working load for gantry and overhead cranes. The Design Engineer
Onshore will be in attendance to witness all tests and to record the results and
observations made during the test.

6.5 CERTIFICATION
6.5.1 The Operation Manager will send the application letter to the Manpower Ministry
by using form 52 (attachment – 14).
6.5.2 The Maintenance Manager is responsible to develop the certification schedule
which is in-line with the annual inspection schedule.
6.5.3 The Maintenance Manager will assign in written the appointed persons who will
perform the inspection during the certification process.
6.5.4 All lifting and transport equipments shall be re-certified annually. For the new
build of lifting and transport equipments then the second certification will be
executed two years after the first certification and the following certification shall
be done once a year.
6.5.5 All inspection and testing during certification process will be done using standard
forms (form 51) required by Manpower Ministry. The annual thorough crane
examination report will be attached to the form 51 (attachments – 15, 16, 17, 18).
6.5.6 Maintenance Department will update list of the Certifying Authority in a 6 (six)
month frequency.

6.6 RECORDS
6.6.1 The Maintenance Department through Maintenance Manager will maintain
records for all cranes. Each crane will have a file in a standard format.
Attachment – 10 outlines the filing system adopted by the Maintenance
Department for crane records.
6.6.2 All test and inspection reports will be referenced to the specific crane
identification number.
6.6.3 A register will be maintained by Maintenance Manager to monitor the frequency
of inspection for each crane. The Operation Manager will ensure that sufficient
resources are made available to perform the required inspections.
6.6.4 Crane Certification records will be kept and maintained by Maintenance
Department.
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7.0 LIST OF ATTACHMENTS

Attachment – 1 : Crawler Crane Operator Daily Check List
Attachment – 2 : Monthly Crane Local Inspection Report
Attachment – 3 (a - f) : Annual Thorough Crawler Crane Examination Report
Attachment – 4 (a - g) : Annual Thorough Hydraulic Crane Examination Report
Attachment – 5 (a - f) : Annual Thorough Overhead Crane Examination Report
Attachment – 6 (a - e) : Annual Thorough Tower Crane Examination Report
Attachment – 7 (a - d) : Annual Thorough Forklift Examination Report
Attachment – 8 (a - c) : Standard Hand Signals for Controlling Crane Operations
Attachment – 9 (a - b) : Simplified Crane Load Chart
Attachment – 10 : Crane Inspection History - Filling Format
Attachment – 11 (a - b) : Lampson Translift Operator Daily Check List
Attachment – 12 : Request for Inspection Form
Attachment – 13 : Personal Basket Inspection Report Form
Attachment – 14 : Application Letter for Certification (Form 52)
Attachment – 15 (a - r) : Form 51A: Tower Crane
Attachment – 16 (a - q) : Form 51B: Overhead Crane
Attachment – 17 (a - v) : Form 51C: Mobile Crane
Attachment – 18 (a - j) : Form 51E: Forklift
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Attachment – 1: Crawler Crane Operator Daily Check List

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Attachment – 2: Monthly Crane Local Inspection Report

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Attachment – 3a: Annual Thorough Crawler Crane Examination Report

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Attachment – 3b: Annual Thorough Crawler Crane Examination Report

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Attachment – 3c: Annual Thorough Crawler Crane Examination Report

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Attachment – 3d: Annual Thorough Crawler Crane Examination Report

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Attachment – 3e: Annual Thorough Crawler Crane Examination Report

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Attachment – 3f: Annual Thorough Crawler Crane Examination Report

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Attachment – 4a: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4b: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4c: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4d: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4e: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4f: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 4g: Annual Thorough Hydraulic Crane Examination Report

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Attachment – 5a: Annual Thorough Overhead Crane Examination Report

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Attachment – 5b: Annual Thorough Overhead Crane Examination Report

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Attachment – 5c: Annual Thorough Overhead Crane Examination Report

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Attachment – 5d: Annual Thorough Overhead Crane Examination Report

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Attachment – 5e: Annual Thorough Overhead Crane Examination Report

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Attachment – 5f: Annual Thorough Overhead Crane Examination Report

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Attachment – 6a: Annual Thorough Tower Crane Examination Report

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Attachment – 6b: Annual Thorough Tower Crane Examination Report

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Attachment – 6c: Annual Thorough Tower Crane Examination Report

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Attachment – 6d: Annual Thorough Tower Crane Examination Report

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Attachment – 6e: Annual Thorough Tower Crane Examination Report

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Attachment – 7a: Annual Thorough Forklift Examination Report

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Attachment – 7b: Annual Thorough Forklift Examination Report

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Attachment – 7c: Annual Thorough Forklift Examination Report

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Attachment – 7d: Annual Thorough Forklift Examination Report

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Attachment – 8a: Standard Hand Signals for Controlling Crane Operations

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Attachment – 8b: Standard Hand Signals for Controlling Crane Operations

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Attachment – 8c: Standard Hand Signals for Controlling Crane Operations

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Attachment – 9a: Simplified Crane Load Chart

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Attachment - 9b: Simplified Crane Load Chart

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Attachment – 10: Crane Inspection History – Filling Format

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Attachment - 11a: Lampson Translift Operator Daily Check List

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Attachment - 11b: Lampson Translift Operator Daily Check List

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Attachment - 12: Request for Inspection Form

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Attachment - 13: Personnel Basket Inspection Report

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Attachment - 14: Application Letter for Certification (Form 52)

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Attachment – 15a: Form 51A: Tower Crane

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Attachment – 15b: Form 51A: Tower Crane

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Attachment – 15c: Form 51A: Tower Crane

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Attachment – 15d: Form 51A: Tower Crane

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Attachment – 15e: Form 51A: Tower Crane

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Attachment – 15f: Form 51A: Tower Crane

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Attachment – 15g: Form 51A: Tower Crane

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Attachment – 15h: Form 51A: Tower Crane

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Attachment – 15i: Form 51A: Tower Crane

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Attachment – 15j: Form 51A: Tower Crane

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Attachment – 15k: Form 51A: Tower Crane

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Attachment – 15l: Form 51A: Tower Crane

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Attachment – 15m: Form 51A: Tower Crane

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Attachment – 15n: Form 51A: Tower Crane

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Attachment – 15o: Form 51A: Tower Crane

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Attachment – 15p: Form 51A: Tower Crane

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Attachment – 15q: Form 51A: Tower Crane

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Attachment – 15r: Form 51A: Tower Crane

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Attachment – 16a: Form 51B: Overhead Crane

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Attachment – 16b: Form 51B: Overhead Crane

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Attachment – 16c: Form 51B: Overhead Crane

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Attachment – 16d: Form 51B: Overhead Crane

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Attachment – 16e: Form 51B: Overhead Crane

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Attachment – 16f: Form 51B: Overhead Crane

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Attachment – 16g: Form 51B: Overhead Crane

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Attachment – 16h: Form 51B: Overhead Crane

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Attachment – 16i: Form 51B: Overhead Crane

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Attachment – 16j: Form 51B: Overhead Crane

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Attachment – 16k: Form 51B: Overhead Crane

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Attachment – 16l: Form 51B: Overhead Crane

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Attachment – 16m: Form 51B: Overhead Crane

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Attachment – 16n: Form 51B: Overhead Crane

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Attachment – 16o: Form 51B: Overhead Crane

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Attachment – 16p: Form 51B: Overhead Crane

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Attachment – 16q: Form 51B: Overhead Crane

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Attachment – 17a: Form 51C: Mobile Crane

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Attachment – 17b: Form 51C: Mobile Crane

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Attachment – 17c: Form 51C: Mobile Crane

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Attachment – 17d: Form 51C: Mobile Crane

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Attachment – 17e: Form 51C: Mobile Crane

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Attachment – 17f: Form 51C: Mobile Crane

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Attachment – 17g: Form 51C: Mobile Crane

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Attachment – 17h: Form 51C: Mobile Crane

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Attachment – 17i: Form 51C: Mobile Crane

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Attachment – 17j: Form 51C: Mobile Crane

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Attachment – 17k: Form 51C: Mobile Crane

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Attachment – 17l: Form 51C: Mobile Crane

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Attachment – 17m: Form 51C: Mobile Crane

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Attachment – 17n: Form 51C: Mobile Crane

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Attachment – 17o: Form 51C: Mobile Crane

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Attachment – 17p: Form 51C: Mobile Crane

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Attachment – 17q: Form 51C: Mobile Crane

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Attachment – 17r: Form 51C: Mobile Crane

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Attachment – 17s: Form 51C: Mobile Crane

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Attachment – 17t: Form 51C: Mobile Crane

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Attachment – 17u: Form 51C: Mobile Crane

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Attachment – 17v: Form 51C: Mobile Crane

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Attachment – 18a: Form 51E: Forklift

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Attachment – 18b: Form 51E: Forklift

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Attachment – 18c: Form 51E: Forklift

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Attachment – 18d: Form 51E: Forklift

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Attachment – 18e: Form 51E: Forklift

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Attachment – 18f: Form 51E: Forklift

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Attachment – 18g: Form 51E: Forklift

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Attachment – 18h: Form 51E: Forklift

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Attachment – 18i: Form 51E: Forklift

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Attachment – 18j: Form 51E: Forklift