LE Inspection Procedure-02

INSPECTA INTERNATIONAL CO.
PAGE 1 of 156
THOROUGH EXAMINATION AND
DATE 05/01/2014
TEST OF LIFTING APPLIANCES AND ACCESSORIES
DOC REF INSP/LEI/01 REVISION 02
INSPECTA INTERNATIONAL CO.

TEST OF LIFTING APPLIANCES AND
ACCESSORIES
DOC.NO. INSP/LEI/01
Rev no: Date Prepared By Reviewed By Approved By
Lifting Engineer/
UK General QHSE Manager Managing Director
Manager
02 05/01/2014
William Pike Shajahan Nawabjan Mahmoud Al Shehry
Inspecta International Co. Global Assets Integrity Services

INSPECTA INTERNATIONAL CO. PAGE 2 of 156
DATE 05/01/2014
1.0 Introduction
The procedures contained within this document are designed to be used by a competent and
experienced person knowledgeable in the field of Lifting and Handling Equipment. These
procedures are intended to guide the technician through the various pre-determined tasks to
carry out a Thorough Examination. The procedures also contain guidance on testing for the
equipment listed below so far as the conditions for testing are deemed to be safe and suitable
for the purpose.
1.0 CRANES
 Offshore Pedestal Crane
 Overhead Travelling Crane & Rails- (Pneumatic and Electrical)
2.0 WINCHES
 Utility, Pneumatic, Hydraulic, Manual Winches and Man Riding Winches
3.0. MAN RIDING EQUIPMENT.
 Passenger & Goods Lifts

 Work Basket, Billy Pugh, Frog Types Carriers
 Harness, Fall Arrestor Devices, Karabiner Ropes
 Medical Stretchers
 Casing Stabbing Board
4.0 LIFE BOATS AND LIFE RAFTS
 Life Boats and Davits

 Life Raft Davits

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5.0 LIFTING ACCESSORIES
 Open Wedge Sockets

 Wire Rope Slings
 Webbing and Round Slings
 Sheave Blocks
 Shackles
 Shackles (Dee, Bow, Safety Dee/Bow)
 Vertical, Horizontal, Universal Plate Clamps
 Rigging Screws / Turn Buckles
 Pad Eyes
 Overhaul/Headache Ball
 Master Link
 Hooks (General and Self Locking)
 Adjustable Beam Clamp
 Eye Bolts (Collared) and Swivel Hoist Rings
 Adjustable Beam Trolley
 Chain Slings and Chain
 Fiber Rope Sling and Fiber Nets
 Bunker Hose Saddle/Lifting Brackets/Clamps/Flanges and Plates
 Barrel Lifting Clamp
6.0 LIFTING APPLIANCES
 Wire Rope
 Wire Rope Pulling Machine (Tirfor)
 Electric Chain / Wire Rope Hoist
 Chain Hoist (Pneumatic)
 Chain Block (Hand Operated)
 Pull Lift (Lever Hoist)
 Hydraulic Jack, Pump/Cylinder
 Hydraulic Trolley Jack

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 Lifting Beam/Frame
 Runway Beam
 Swing Jib
 "A" Frame Gantry (Portable)
 Cargo Carrying Containers
 Cargo Carrying Units
 Fork Lift Truck
 Switch Gear Lifter/Pallet Truck/Hydraulic Floor Crane
 Mobile (Access) Platform
7.0 TEST EQUIPMENT
 Test Weight (Lifting Points)

 Load Cell Shackles - Dynamometers (Test Clocks) Strain Gauges
 Hooks (General And Self Locking)
 Adjustable Beam Clamp
 Eye Bolts (Collared) And Swivel Hoist Rings
 Adjustable Beam Trolley
 Chain Slings And Chain
 Fibre Rope Sling And Fibre Nets
 Bunker Hose Saddle/Lifting Brackets/Clamps/Flange sand Plates
 Barrel Lifting Clamp
 Wire Rope
 Wire Rope Pulling Machine (Tirfor)
 Electric Chain / Wire Rope Hoist
 Chain Hoist (Pneumatic)
 Chain Block (Hand Operated)
 Pull Lift (Lever Hoist)
 Hydraulic Jack, Pump/Cylinder
 Hydraulic Trolley Jack
 Lifting beam/frame

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 Runway beam
 Swing jib
 "a" frame gantry (portable)
 Cargo carrying containers
 Fork lift truck
 Switch gear lifter/pallet truck/hydraulic floor crane
 Mobile (access) platform
 Test weight (lifting points)
 Load cell shackles - dynamometers (test clocks)

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Category Cranes
Equipment Description Offshore Pedestal Crane
Specification/Legislation BS 7121 Parts1, 2 & 11, HSG 221 BS 2573 Parts 1 & 2,
BS 1290, BS 302, BS 463, ISO 4309, BS4536, PM46,
API 2D/2C, BS7262,
Servlet NDT Inspection Procedure
Applicable Test New, Primary Load Path Repairs, Modification, Boom,
Change Out, Quadrennial Test (Check Company
Procedure)
Proof Loads Under 20 tons : SWL + 25%
20 tons to 50 tons : SWL + 5 tones
Over 50 tons : SWL + 10%
Examination Requirement 6 Monthly As Per SI2307 1998
Internal Examination Clients Planned Maintenance System
Identification Manufacturer Date Manufactured, Serial No., Clients,
ID
No., Slew bearing, ID No, Wire Ropes ID No., Test
Date of Crane, SWL,
Certification Crane Test Certificate
Slew bearing Certificate
Wire Rope & Hook Block Certificate
Wire Termination Certificates
NDT Examination Report\
The thorough examination will comprise of but not be limited to the following main areas,
further comprehensive breakdown of component parts that will be examined during crane
examination are to be found in Appendix "A" of this procedural section.
1.1 Access Egress
1.2 Pedestal
1.3 "A" Frame
1.4 Boom
1.5 Control Cab
1.6 Machinery House
1.7 Wire Ropes (Running)

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1.8Wire Ropes (Support)

1.9 Hook Blocks
1.10 Slew bearing

1.11The condition of component parts will be recorded and any defects/structural damage will
be reported on the daily defect listing and handed to the Area Supervisor.
2.1. Due to the wide range of items and functions to be checked such a formal examination
must be accompanied by an examination CHECK LIST, this must be submitted along with
routine inspection reports. These check lists ensure that all vital areas of the crane receives the
necessary inspection.
2.2Whenever considered necessary, the visual examination may be supplemented by methods

of non-destructive testing that will determine the condition of any part of the crane. In order to
facilitate visual examination and ascertain extent of damage it may be considered necessary to
have parts of the crane dismantled. This work must only be carried out by skilled personnel.
The examination shall cover, but not be restricted to, the following areas
3.0 Checks on Boom

3.1Inspect the entire boom for straightness and for any evidence of mechanical damage, such
as cracking, bending or deformation. Pay particular attention for signs of cracking or flaking
paint as this may indicate yielding of the metal which may precede failure.
3.2 Check all cords and lattices for damage, cracking, bending or excessive corrosion. No
damage to the main cords is permissible, although a small amount of damage to the lattice
work is allowed (max 3 lattices in any one section) as long as the damage to the lattice and
lattice roots is not in the "Picture Frame" area which is regarded as critical.
3.3 Check boom tip for any signs of damage caused by main block.
3.4 Check all connecting pins for wear, damage and distortion, also ensure that cotter pins are
installed.
3.5 Check boom foot pins for wear, this can be done by putting the boom into the rest and
using the slew in a back and fore motion to detect excess movement if this is observed then
pins may be worn, also boom foot and housing should be checked for signs of cracking.
3.7 Boom Corrosion Boom corrosion, this part of the procedure covers the examination
elements of corrosion and coating breakdown. To ensure the client is given a detailed survey
report on the extent and severity of any corrosion identified, the following guidelines should
3.8 Main Chords using the diagrammatic drawings of the boom sections, i.e. Boom Foot,
Intermediate or Head Section. Indicate precisely the position of the corrosion, approximate

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area covered and the depth of the corrosion. These can also be used for dents and wear on the
chords Recommend boom section change outs for any major chord and picture frame defect.
Checks should be made through the clients maintenance departments for clarification on the
subject.
Note: Leibherr Cranes have an insitu repair policy. Any severe dents or mechanical
damage to the chord should be NDT/MPI inspected and the area closely monitored by
installation staff.
3.9 Boom Lacings using the diagrammatic drawings indicate the severity of the corrosion or
mechanical damage to the lacings. Some crane manufacturers will not allow more than one
bent lacing per section, i.e. National Cranes. The recognized industry criteria are 3 bent lacings
per section before repairing. This can be carried out in two ways, either sleeping or complete
replacement. To monitor bent lacings check the severity of the damage checking if the welds to
the boom chord is pulled/torn or cracked. If this has occurred carry out an NDT/MPI inspection
to ascertain if cracking has penetrated the chord, if this has not occurred, indicate in your report
(defect) this area has to be monitored regularly. Ensure your drawings have accurate
measurements and descriptions of the damage. Copies should be signed by the area supervisor
and the Inspecta inspector, copies to be left on the platform with defect report.
3.10 Crane General Area Using the appropriate drawing for the area causing concern, make
precise measurements and sketches. All fixings and fastenings should be inspected and
reported in exactly the method as for lacing and chords.
3.11 Tools Required Engineers foot rule/straight edge Engineers 6" rule and vernier gauge
Spring calipers (outside/inside) Box of plasticize NDT/MPI Equipment UT Equipment
4.0 Checks on Machinery
4.1 Check all fixings and fastenings for corrosion, wear, damage and security. Any loose or
missing bolts should be replaced, not re-tightened as there is a good chance that they have been
stretched.
4.2 Inspect for excessive wear on brake and clutch system, parts, linings, pawls and ratchets.
Ensure that all safety pawls operate correctly and are in good condition, free to move and
sufficiently lubricated.
4.3 Hydraulic and pneumatic systems should be inspected for deterioration. If any of the
following faults are noted then the faulty part should be replaced.
(a) Oil or air leaks on the surface of flexible hoses at the points at which the hose joins the
metal end couplings.
(b) Abnormal deformation of the outer covering of hydraulic hose, including any enlargement,
local or otherwise.
(c) Any leakage at connections which cannot be remedied by normal tightening.
(d) Signs of abrasion on the wall of any hose or tube which could reduce their pressure
retaining capabilities. It is also important to eliminate the cause of the abrasion.

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4.4 Check all rope drum assemblies for wear and/or damaged by in scoring, damaged or worn
bearings and journals. Ensure that at least three full wraps of rope remain on the drum and all
in good condition.
4.5 Ensure that the drum end of the rope is securely anchored to the drum by a means approved
by either the crane or rope manufacturer, and also that it is clear of the rope windings.
4.6 Inspect all indicators, including those for load and jib angle, and automatic safe load
indicators, for any significant in accuracies.
5.0 Wire Rope Checks
5.1 All wire ropes used on the crane shall be inspected in accordance with ISO4309 over their
entire length for the following defects; paying particular attention to the sections that pass
through the block or over pulleys, or is continually exposed to the elements of may be subject
to regular abrasion.
5.2 Check for corrosion, kinks, broken wires, changes in rope diameter, wear, heat damage and
lack or lubrication.
5.3 Check terminal fittings for wear, damage and distortion. Also for signs of overloading (i.e.
collapsed thimbles). Ensure all wedge and socket terminations are as per
BS7166:1989.
5.4 Examine wire rope test certificate to ensure rope is the correct size, capacity and
construction for the crane.
5.5 Deterioration normally results from a combinations of several defects occurring

simultaneously giving a cumulative effect. The overall effect should be taken into
consideration when deciding if a wire rope should continue in service. However the following
defects would result in the rejection of the rope.
5.6 Total number of broken wires in one lay length must not exceed six.
5.7 Total number of broken wires in one strand in one lay length must not exceed three.
5.8 Total number of broken wires in a measured length of ten rope diameters must not exceed
5% of the number of wires in the rope.
5.9 No broken wires are permitted where the rope enters the termination.
5.10 Wear must not exceed 10% of the original diameter for a six strand rope and 3% of a
multi strand rope

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NOTE: Any broken wire found in the course of the examination which do not constitute
rejection shall be broken off in the lay of the rope and their location noted for future reference.
5.11 The reeving configuration of the crane must be checked against the manufacturers
schematic which shall be provided by the operator prior to the inspection. Particular attention
should be paid to any area where rope could come into contact with the crane structure during
the travel of the jib.
6.0 Checks on Main & Aux Hoist Blocks and Sheaves
6.1 The blocks and all sheaves shall be checked for the following defects:
6.2 The Safe Working Load and Identification marking is legible and corresponds with the Test
Certificates.
6.3 Wear/fracture in eye of block.
6.4 Wear/fracture in shank of head fitting. Where the shank of the head fitting has been welded
to the collar or nut, then the wear on the shank shall be determined by rotating the head fitting,
the wear shall not exceed a maximum of 1.5mm per 25mm shank diameter, or the shank bent.
6.5 Side plates distorted or chaffed.
6.6 Fracture leading from center pin holes.
6.7 Side straps distorted or torn.
6.8 Bush worn, distorted or fracture.
6.9 Sheaves chipped, fractured and worn in score or at sheave edge.
6.10 Check that all oil and grease ways in pin and bush, sheaves and shell are clear.
6.11 Becket worn, distorted or fractured (also ensure it is the correct size for load to be applied
to it). If any faults are found at the time of examination which would affect the safe use of the
item, then it must be withdrawn from service and details recorded on the Inspection Report.

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Category Cranes
Equipment Description Offshore Pedestal Crane
Examination Thorough Examination (Visual)
Test New, Modified, Repairs to Primary Load
Path
Safety: Cordon of test area and carry out work permit requirements, obey installation/site
safety rules at all times. Should the test require water bags inform Control Room if fire main
system is required to fill water bags.
1.0 Preparation of Test Equipment

Ensure that test equipment is available on the installation prior to commencement of testing,
and is placed in a convenient "pick up" position within the crane's working radius.
Ensure that each test weight is clearly identified and the exact weight is marked thereon.
Ensure each weight is fitted with a suitable certified lifting set secured in such a manner that it
cannot be inadvertently dislodged.
Ensure the lifting cradle complete with slings and shackles have current certification and are
capable of carrying the total test load.
If water bags are being used ensure they are free from any defects and a suitable water supply
is available
(NOTE: Special permission is required to connect into the firewater mains).
The certified and calibrated test clock/dynamometer or load cell to be used in conjunction with
the water bags should be stored safety until the test commences. Where possible ensure any
obstructions on the deck of the platform which are within the working radius of the crane
(during testing) are cleared. Prior to any testing a thorough visual examination of the crane
must be carried out. This and all subsequent actions required for the test must be performed by
a test technician who is:
(I) Trained, qualified and fully experienced with the type of crane to be tested
(ii) Fully conversant with all related operating requirements and safety rules/regulations.
NOTE:
1 As part of the visual examination all exposed clutch and brake linings must be
examined for signs of wear and checked for ingress of oil or grease on the linings and
drums.

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2 Wire ropes are to be inspected in accordance with manufacturer's laid down

specification and procedures.
Function Tests
A thorough function test of the crane must be carried out without load, and any defects or
adjustments found should be repaired in accordance with the manufacturer’s recommendations.
When all defects have been rectified proceed with the safe working load and proof load tests.
Function Test as follows:

Boom Hoist System
Raising the Boom - prior to raising the boom where applicable, engage the pawl.
Raise the boom and test the efficiency of hoisting mechanism, brake and pawl.
Lowering the Boom - Prior to lowering the boom where applicable, disengage the pawl.
Lower the boom and test the efficiency of lowering mechanism and brake.
Ensure the boom angle indicator is functioning correctly (if fitted).
Check maximum and minimum radius limits are functioning and are correctly set.
Main Hoist Line
· Raise and test the efficiency of hoisting mechanism and brake.

· Lower and test the efficiency of hoisting/lowering mechanism and brake.
· Check the over hoist limit.
· Check lower limit.
Aux Hoist (if fitted)
· Raise and test the efficiency of hoisting/lowering mechanism and brake.

· Check over hoist limit.
· Check lower limit.
Slewing
· Slew left and tests the efficiency of the brake (and clutch where applicable).
· Slew right and test the efficiency of the brake (and clutch where applicable).
· If fitted, ensure any slew limits function correctly.
Testing Procedures
Safe Working Load Test

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Position and stack test weights at approximately "measured" radius. (All radius measurements
must be taken from the center of the pedestal to the hoist line).
Raise the approximate test load weights just clear of the deck; operate the crane in all modes
and slew (as far as possible) through 360 degrees.
Check the accuracy of the safe load and radius indicators.

Proof Load Test
The proof load applied will vary with the crane radius but shall not exceed the percentage
overload as indicated below. Up to 20 tones: Capacity + 25%
Between 20 tones and 50 tones Capacity + 5 tones
Above 50 tones Capacity + 10%
The proof load is to be applied at minimum radius, maximum radius and at least one radius in
between. The proof load shall include the weight of the test cradle and rigging.
Raise the appropriate proof load test weights just clear of the deck, slew the crane through 360
degrees (or as far as possible).
At the commencement of overload testing, correct function of the safe load alarm systems
should be verified.
Automatic safe load indicators may then be disconnected for the duration of the overload tests
but they must re-connect immediately afterwards.
After re-connection, the safe load indicators must be tested to establish that they are
functioning.
Warning: operators are reminded that it is absolutely forbidden for any alarm, warning
or safety device to be disconnected unless specifically authorized by a suitably qualified
person and only then under strictly controlled conditions. Action upon completion of tests
Carry out thorough examination of the crane to establish that all parts have withstood the test
programme without defect.
All test weights, water bags, test clocks, load cells and associated equipment must be returned
to a suitable storage position until it can be back loaded.
The Company must be informed immediately of any defects found which would prevent the
crane becoming certified. A copy of the certification and/or report form is to be left onboard
the installation and official typed copy is to be sent to the relevant onshore, company
representative.

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Equipment Description Overhead Travelling Crane & Rails

(Pneumatic and Electrical)
Specification/Legislation BS 7121 Part 2, BS 5744, BS 449, BS1290,
BS 466, BS 456, BS 2453, ISO4309
BS 2573 Part 1 & 2, BS 302 Inspecta NDT
Inspection Procedures
Applicable Test New, Modified, Repaired/Re-sited Cranes
Proof Loads SWL + 25%
Examination Requirement Every 6 Months SI2307
Internal Exanimation Clients Planned Maintenance System
Identification Serial No, ID No., Manufacturer, SWL, Last
Examination, Test Date.
Certification Load Test Certificate.
Wire Rope Certificate.
Hook Block Certificate.
EC Declaration of Conformity.
Declaration of Incorporation
NDT Examination Report
Thorough examination will comprise of but not limited to the following:
1.0 Examination of Bridge and Crab Unit
1.1 Prior to carrying out the examination, isolate the crane and remove the fuses/lock or air
valve.
1.2 Examine the hoist unit, ensure that all fixing bolts are properly fitted and secure, all welds
are intact and free from cracks.
1.3 Examine runner wheels for wear and correct fitment.
1.4 Ensure that all wheels are not contaminated with oil and grease which could cause slippage.
1.5 Examine rope drum for wear on grooves, cracks and sharp edges, ensure that load rope is
reeved correctly, that there is at least 3 turns of wire rope left on the drum when the bottom
hook is at its lowest position and that the load rope is anchored correctly.
1.6 Examine the rope bands and guides for wear and damage.
1.7 Examine the bridge girder for wear, impact damage, bending and deformation, ensure that
all fixing bolts are secure.
1.8 Examine the end carriages and long travel wheels for wear, impact damage and
deformation, ensure that all fixing bolts are correctly fitted and secure and that all welds are
intact and free from cracks.

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1.9 Ensure that buffer ends stops are fitted.
1.10 Examine all motors and gearboxes, ensure that all fixing bolts are properly fitted and
secure, all seals are intact and free from leaks.
1.11 Examine brake units for wear and if necessary reset to correct tolerance, check that all oil
levels are correct, lubrication points are clean and unblocked and that the crane is adequately
lubricated.
1.12 Examine the cross travel festoon system, ensure that all track, support brackets,
connection joints, trolleys and fixing bolts are properly fitted and secure, examine cables for
cracks, breaks and damage to insulation.
1.13 Examine down shop lead system, ensure that all track, support brackets, connection joints
and fixing bolts are properly fitted and secure, ensure that expansion joints are fitted, examine
collector arms and contact shoes for wear and misalignment.
1.14 Examine the bottom block load sheaves for wear in grooves, cracks and sharp edges,
examine the cross head\ fitting for wear and impact damage, ensure that top nut is properly
fitted and securely locked, ensure that side plates are free from cracks and correctly aligned.
1.15 Examine the pendant cable for cracks, breaks and damage to insulation, ensure that
strainer wire is fitted to take weight of pendant control box and of the cable.
1.16 Examine the pendant control box for damage to casing; ensure that push buttons make
good contact and that the directional controls are clearly marked and that they function
correctly.
1.17 Examine the load rope in accordance with the relevant examination procedure.
1.18 Refit fuses, reconnect air supply and function test crane through all motions, check for
correct adjustments of overload devices (if fitted) and that the over hoist and over lower limit
switches function correctly.
NOTE: An emergency stop button should be fitted to the pendant control box, activation
of the emergency stop should arrest all motions of the crane and shut down the crane
power supply.
2.0 Examination Rail Gantry & Rails
2.1 Check the condition of travel rails checking for distortion, loose fixings and fastenings.
2.2 Examine the support structure for mechanical damage cracked welds etc.

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2.3 Travel the crane the full working length of the gantry checking for ease of movement and
no apparent declivity of the rails.
2.4 Check the rail alignment and record any variances.
2.5 Some overhead crane rails may have a rack and pinion drive.
2.6 Check the meshing of rack and pinion teeth and security of the rails.
Examination Procedure (Cont’d)
2.7 Check rail end stops for security and correct fitment, on completion of the crane bridge and
gantry rail examinations. Carry out a full function test of the crane checking all safety cutouts
any anti-collision devices fitted, function correctly, and record findings.

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Category Cranes
Equipment Description Overhead Travelling Crane & Rails (Pneumatic
and Electrical)
Test New, Modified, Repaired Cranes
1.0 Testing Overhead Crane & Gantry Rails
1.1 Prior to carrying out crane test, function test the crane to check, brake systems, and safety
cut out devices are functioning correctly.
1.2 Prepare the test equipment and check the deck loading will sustain the test load.
1.3 Check if test weights and test clock are calibrated and certified, lifting accessories and
weights cradles are certified.
1.4 Assemble weights to SWL designations and attach to crane.
1.5 Carry out deflection test, crane beam deflection 1/750 of span and gantry deflection is
1/600 of span and record reading.
1.6 If satisfactory load system to SWL + 25% and carry out proof load test.
1.7 On completion of test carry out a full visual examination of the crane and gantry rails.
1.8 On completion of test and examination, clear area and return crane to operation.
1.9 Issue Test Certificate and report.

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Category Winches
Equipment Description Utility, Pneumatic, Hydraulic, Manual Winches

and
Man Riding Winches
Specification/Legislation BS 302, ISO 4309, BS 463, BS 5281, BS 7166, BS
4018
BS 6570, Servlet NDT Inspection Procedure,
HSG221
Applicable Test First Installation and After Modification /
Repair / Resisting
Proof Loads SWL x 50% for Both Brakes
SWL x 25% for Individual Brakes
SWL x 10% of Dynamic Test on Both Brakes
NOTE : These figures are for pre 2001 man riding adapted Winches
Examination Requirement At Least Once Every 6 Months SI 2307
Internal Examination Clients Planned Maintenance System
Identification Record Serial No., Unique ID No., SWL, Winch Type,
Examination / Test Date, Manufacturer, Current
Color
Code, Wire Rope Installed Date.
Certification EC Declaration of Conformity
Installation Test Certificate, Wire Rope
Certificate
Wire Rope Termination Certificate
1.0 Utility Winch
1.1 Clarity of markings of serial number, safe working load and plant number (if applicable)
and those details correspond with Test Certificate.
1.2 Examine all mounting bolts and fixings for security and correct tensile grade.
1.3 Examine all welded mounting structures and tie down plates.
NOTE: A Suitable NDT Inspection should be carried out if deemed necessary by the
competent person.
1.4 Examine all air connections and fittings for condition and integrity. Pay particular attention
to brake control lines (if fitted) nipping or cuts.
1.5 Visually examine brake band linings for wear and thickness. If worn down to the head of
fixing rivets they should be replaced. Check that brake bands are also free from dirt, grease of

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grit. In the case of winches with integral braking system check last maintenance report for
condition of drum and brake.
1.6 Examine winch brake drum for scoring, wear, fitting or build up scale on surface (glazing)
check for trueness of drum.
1.7 Examine all brake mounting brackets and pin for bending and wear. Check for seizing of
pins in bores and all locking pins/split pins are present.
1.8 Examine winch structure for deformation of twisting. Check oil levels and operation of
drum locks if fitted.
1.9 Examine break operating linkages for wear and distortion. Examine all parts can move
freely and are not corroded.
1.10 Examine control lever/system for freedom of movement and that lever returns to neutral
position on release and that the direction of operation is clearly marked.
1.11 Ensure rope is spooled in the right direction in relation to brake operation and is correctly
mounted to the drum. Examine in accordance with relevant procedure.
1.12 If air supply is fitted, run winch to check operation of all functions. Check lubricators for
oil level and drain dehumidify traps.
1.13 If air winch is for man riding purposes ensure that it is of an approved design and clearly
marked for man riding purpose, proof load applied. Examine winch wire for correct factor of
safety for man riding purposes.
1.14 If winch is fitted with limit switches a full check should be carried out to verify
satisfactory operation and settings are correct. This should be done by actual operation of
winch through all functions both hoisting and lowering.
1.15 If any faults are found at the time of examination which would affect the safe use of item
then it must be withdrawn from service and details recorded on inspection report.
Note: Winch wire rope anchorages are not designated for lifting.
2.0 Pneumatic Winch
2.1 Examine the winch base for cracked welds, cracks around bolt holes, impact damage,
distortion and elongation, ensure that all fixing bolts are properly fitted and secure and of
sufficient grade/strength, that all welds are intact and free from cracks and that supporting
steelwork is capable of withstanding winch loads.
2.2 Examine winch structure for deformation and twisting.

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2.3 Examine rope guard for wear, distortion and damage that could obstruct or damage wire
rope – ensure it is secure.
2.4 Examine the brake bands and drum for wear, ensure that they are clean and free from
contamination.
2.5 Examine the brake mounting brackets, linkages and pins for wear and distortion, ensure
that linkages and pins are not seized and that locking/cotter pins are fitted.
2.6 Examine the winch drum for wear, distortion, scoring and cracks, ensure that drum runs
true and that the rope is anchored correctly.
2.7 Examine automatic brake, springs, link arms and pins for wear, distortion and stretch.
2.8 Examine automatic brake cylinder and pipe work for leaks.
2.9 Examine chromed piston rod for wear, scoring and corrosion.
2.10 Examine operating lever for freedom of movement, ensure that it returns to neutral
position when released.
2.11 Ensure that all operating levers are clearly marked with direction of operation.
2.12 Check that oil level is correct.
2.13 Ensure that power supply is sufficient for the safe working load of the winch, if air supply
is fitted operate winch to ensure that it functions correctly.
2.14 If winch is for man-riding purposes, ensure that it is an approved design, fitted with two
independent brake systems and clearly marked suitable for lifting personnel.
2.15 Limit switches (if fitted) to prevent over-riding, under-riding and over-speeding should be
function tested to verify satisfactory operation.
NOTE : Wire rope (if fitted) should be spooled correctly onto winch drum, and there
should be at least 3 turns of wire rope on the drum at all times, wire rope and associated
fittings should be examined in accordance with the relevant examination procedures.
Wire rope anchorage is not designated for lifting.
3.0 Hydraulic Winches
3.1 Check clarity of markings of SWL, identification number, plant number and operational
instructions and that is corresponds with the test certificate.
3.2 Check all mounting bolts and fixings for security and correct tensile grade.

DATE 05/01/2014
3.3 Check all welded mounts and tie downs for security (NDT may be required if deemed
necessary by the competent person). Ensure that the supporting structure is of adequate
strength.
3.4 Check all hydraulic couplings, hoses and fittings for condition and leakage.
3.5 Examine brakes and linings for security, wear and contamination. Ensure free movement in
hinge pins and security of fittings ensure parts are not corroded.
3.6 Check brake actuator for leakage, corrosion, damage, and ensure that it is secure. Check
mounting pins are secure and not corroded examining hydraulic lines for damage, corrosion
and leakage. Function test system.
3.7 Check control lever for free movement. Ensure that the lever returns to the neutral position
when released.
3.8 Check the rope is spooled correctly on to the drum and that the "dead-end" is correctly
terminated.
3.9 If the winch is of a man-riding purpose, ensure that the winch is correctly marked and
ensure that the correct factors of safety are applied.
3.10 If limit switches are fitted ensure correct operations and fully functional. Examine all
cables and/or hydraulic lines for damage corrosion or leakage.
4.0 Manual Winch DIRECT DRIVE/WORM GEAR WINCHES
4.1 Examine the winch structure for wear, cracks, distortion and corrosion.
4.2 Ensure that all fixings bolts are correctly fitted and secure, all welds are intact and free
from cracks, and that all supporting steelwork is capable of withstanding winch loads.
4.3 Examine the winding handle for freedom of movement, ensure that it is not seized or
distorted.
4.4 Examine the winch drum for wear, distortion, scoring and cracks, ensure that drum runs
true and that rope is anchored correctly.
4.5 Where applicable examine ratchet or worm gear (mounted on side of drum) for wear,
broken teeth and misalignment.
4.6 Examine the pawl and pawl spring/worm for wear and distortion, ensure that pawl
functions correctly, and that the worm drive meshes correctly with the worm wheel.
4.7Function test the winch through one complete revolution of the gears to ensure that winch
functions correctly and that gears mesh correctly.

DATE 05/01/2014
4.8 Ensure that unit sustains load.
4.9 Examine the brake assembly and operate the winch handle to ensure that it functions
correctly.
4.10 Examine all spur gears for alignment, wear and chipping on gear teeth, truth of gear shafts
and smooth running of bearing (if fitted).
NOTE : Wire rope (if fitted) should be spooled correctly onto winch drum and there
should be at least 3 turns of wire rope on the drum at all times, wire rope and associated
fittings should be examined in accordance with the relevant examination procedure,wire
rope anchorage is not designated for lifting.
5.0 If any faults are found at the time of examination which would affect the safe use of the
item, then it must be withdrawn from service and details recorded on the
Inspection

DATE 05/01/2014
Category Winches
Equipment Description Utility, Pneumatic, Hydraulic,
Examination Thorough Examination (Visual) and Test
Procedure for Man Riding Winches
1.0 Procedure:
1.0 The new style and types of man-riding winches only require SWL function test, to check
the base welds and the safety cut outs.
1.2 The winches are all preset and tested by the manufacture, and as such we are not allowed to
touch or adjust these settings.
1.3 Visual examination should be carried using the appropriate examination procedure for
winches.

DATE 05/01/2014
Category Winches
Equipment Description Utility, Pneumatic, Hydraulic, Manual Winches and
Man Riding Winches
Test New, Repaired, Modified, Resisted.
Utility Winches
1.1 If during the course of the examination, no faults are found which would affect the safe
working load of the equipment then a proof load test may be carried out as follows:
1.2 A proof load equal to the working load limit of the equipment plus 25% shall be applied
and a check made of the load bearing parts. This test may be applied by a static pull or by live
weights.
1.3 If no defects are apparent then the load shall be raised (where practical) through a height of
lift which will ensure that every part of the winch mechanism comes under load.
This load shall be held for a period of five minutes. The brake shall show no signs of slippage
or creep.
Repeat operations 1.2 to 1.3 for each brake if winch fitted with dual brakes.
2.0 Reporting
2.1 A written report shall contain the following information:

a) Unique identification number
b) A full description of the equipment
c) Safe working load
d) Proof load applied
e) Date of test and thorough examination
f) A statement of type of use, e.g. "Approved for
Man-Riding" or "Utility Winch"
g) Any limitations or restriction to use
h) Name and address of company performing the test and examination
i) Act or regulation under which the test and examination was carried out
j) Position and location of the equipment
3.0 Defective Equipment
3.1 Where the test is not satisfactory, a responsible representative of the user shall be informed
by means of a defect report. If the test engineer considers the defect to be of a dangerous nature
then arrangements must be made for its immediate withdrawal from service.
1.0 Winches Converted for the Purpose of Raising/Lowering Personnel

DATE 05/01/2014
1.1 Winches used for the raising and lowering of personnel will have a dual braking system
usually consisting of one manual brake and one automatic brake (which will activate should
there be a loss of power). These brakes are to be overhauled to manufacturers specification.
1.2 Where limit switches are fitted to prevent over-travel in both hoisting and lowering,
function test to ensure their operation.
1.3 Ensure the winch does not have a disengaging clutch pawl or ratchet mechanism.
1.4 Ensure that the winch has been adequately de-rated to reflect a factor of safety of no less
than 10-1.
1.5 Ensure the winch is clearly marked that it is to be issued solely for raising and lowering
personnel.
2.0 Testing
2.1 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.
a) Test 1 (Dynamic) Raise a proof load 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.
b) Test 2 (Static) Disconnect power source to winch and apply brake. Using an alternative
pulling source i.e. pull lift/chain block on the winch rope, apply a proof load of SWL + 50% to
check the braking efficiency (the brake may require adjusting to achieve this). Sustain the load
for a short time and check winch drum for creep. Re-connect automatic brake and with the
manual brake in the off position, repeat test 2 so full load is taken on automatic brake.
NOTE : Should any of the brake drums be exposed to the elements, the aforementioned
tests should be carried out with the drum wet, to simulate operating conditions. Make
any brake adjustments as required.
c) Test 3 (Function) 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 winch's performance).
NOTE: Ensure all levers/controls return to neutral\ on release.
2.2 Re-examine winch to ensure that proof load testing has not exposed any defects. The above
tests are to be witnessed.
2.3 Fit winch drum guard where applicable.

DATE 05/01/2014
2.4 Examiner to do final plating.
NOTE: Ensure SWL and all directional arrows are clearly visible.
3.0 Reporting
3.1 This shall be carried as per utility winch test procedure, Section 2.0.

DATE 05/01/2014
Category Man Riding Equipment.

Equipment Description Passenger & Goods Lifts.
Specification/Legislation LRS, Code for Lifting Appliances, Modu Code.
IS0 4309, BS 302, BS 5655 PTI-10, BS 7255.
HSE Documents PM7 - PM24 - PM26.
Inspecta NDT Inspection Procedures.
Applicable Test First Installation, Modification, Substantial Repairs.
ALIMAK Drop Test Every 6 Months
Proof Loads SWL x 25%.
Examination Requirement At Least Once Every 6 Months (SI 2307).
Internal Exanimation Clients Planned Maintenance System.
Identification Serial No. Owners Unique Plant ID No,
SWL, Type of
Equipment, Examination/Test Date, Manufacturer
Wire Rope, Installation Date, Current Colour Code.
Certification EC Declaration of Conformity.
Declaration of Incorporation.
Installation Test Certificate, Wire Rope Certificate.
Wire Rope Termination Certificate.
1.0 Machinery Room / Area
1.1 Check the condition and security of the hoisting machinery holding down bolting
arrangement.
1.2 Check external braking system for wear, mechanical damage, oil and grease ingress on
brake drum.
1.3 Check actuation of braking system mechanism for freedom of movement.
1.4 Check condition of any visible drive belt, drive chain or direct drive from motor/gear
box/winch unit for mechanical damage, wear, incorrect adjustment etc.
1.5 Check wire rope condition along its full length.
1.6 Check terminations, drum anchorages, and spooling.
1.7 Check condition of winch drum and flanges.
1.8 Check condition of any sheave arrangements for cracking, wear, sheave rope groove wear
etc.
1.9 Check condition of any runway beams or support frames for the lift hoisting/lowering
mechanism.

DATE 05/01/2014
1.10 Check condition of electrical fittings, cables, junction boxes and lighting.
2.0 Lifting Cage and Shaft
2.1 Carry out examination of the cage, external and internal structure, lifting points, and any
lifting accessories attached.
2.2 Check all bolting is secure and correctly installed.
2.3 Check all welded areas are free from cracking and mechanical damage.
2.4 Carry out examination of the internal structure of the lift shaft for cracking of welds and
mechanical damage.
2.5 Carry out examination of cage guide/drive rails for distortion/mechanical damage.
2.6 Check condition of any mechanical safety devices for mechanical damage and freedom of
movement record any problems.
2.7 Carry out examination of cage gates for damage and locking mechanism function, check
condition of landing area gates and landing entrance sill for correct stopping distance and
safety locks.
2.8 Carry out function checks on all safety devices fitted and record results.
NOTE: Free fall braking system should be checked annually by the clients planned
maintenance system and results recorded, review results and record this has been
reviewed.
3.0 Alimak Type Lifts
3.1 Additional areas for examination for this type of lift are as follows.
3.2 Examine the mast structure for deformation, corrosion, mechanical damage, and security of
all fixings and fastenings record finding.
3.3 Examine the rack and pinion for wear, cracking, and misalignment, check rack to pinion
meshing.
3.4 Check guide rollers for wear and alignment.
3.5 Check the condition of structural tie-ins between the lift structure and derrick/column
structure for corrosion, mechanical damage, and security and weld cracking.

DATE 05/01/2014
3.6 Check the drive motors fixing and fastening for security, check condition of drive pinion
and shaft.
NOTE: Additional information is given in HSE Documents Guidance Note PM7 and
PM24.
NOTE: Alimak recommend centrifugal braking system should be changed out 4 yearly.
Safety During the testing of this equipment safety harness will be worn and fixed to a
suitable anchor point.
NOTE: No safety harness anchorages to be fitted on the lift cage. Barrier of all entrances
to the lift cage and shaft. Tannoy to inform rig staff loads testing is being carried out.
Obey work permit requirements. Work to installation/site safety rules at all times.
Equipment Test weights (portable 56 lbs weights). Check certificates and calibration
documents. SWL/Proof Cage and System Test Load the cage to SWL, spread the load evenly
across floor of lift cage, Operate the lift from remote or machinery floor. Raise and lower the
lift cage to check if the cage moves freely and smoothly during the operation. Check all safety
functions. Proof load and 25% off SWL and Proof load add 25% of SWL and carry out full
travel of the hoist way (up and down). Check all clearances are correct. Remove test weights
and return to service.
Safety Test and Braking Systems Carry out manufacturers requirements and record all
checks carried out.
NOTE: Alimak recommend drop test for braking system be checked and tested on 6
monthly examinations.
Completion Checks On completion of test carry out a full thorough examination if all
satisfactory sign of all permits, clean up area and return all equipment to base.

DATE 05/01/2014
Category Man Riding (Personnel Carriers)

Equipment Description Work Basket, Billy Pugh, Frog Types Carriers
Specification/Legislation BS 2052, BS 4128, BS 4928, BS 2830, HSG 221
Inspecta NDT Inspection Procedures.
Applicable Test New, Repaired, Modified
Guard Rail Test 50kgs Fixed on Centre Rail at
30 Degrees Tilt.
Impact Test 4.5kgs Dropped on 25mm Square Area From
1.2 Mtrs
25kgs Sand Bag, Dropped From 1.2Mtrs
Examination Requirement 6 Monthly SI2307 (LOLER)
Internal Exanimation Not Applicable.
Identification Serial Nos, Clients Unique No., SWL, Test Date,
Color Code.
Certification EC Declaration on Conformity
Test Certificate
1.0 Personnel Work Basket
1.1 Prior to commencing the examination, remove the lifting attachments and examine in
accordance with the relevant examination procedures.
1.2 Examine the structure, guard rails and toe board for security, dents distortion, cracked
welds and corrosion, ensure that hinged gate opens inwards, is automatically locked in the
closed position and that the locking device cannot be disengaged accidentally.
1.3 Examine the floor inside and underneath for dents, distortion, cracked welds and corrosion,
the floor surface should be non-slip and have adequate drainage to prevent
Build up of water inside the basket.
1.4 Examine the lifting points for distortion, cracked welds and corrosion, ensure that pin holes
are not worn or elongated.
1.5 There should be adequate anchor points or rails for attachments of safety harnesses, these
should be examined for security, dents, distortion, cracked welds and corrosion, pin holes
should not be worn or elongated.
1.6 There should be an effective method of securing tools and loose equipment inside the
basket in order that items remain captive in the event of the basket being inadvertently spilled.

DATE 05/01/2014
1.7 Ensure that all markings comply with Regulation 7 of LOLER SI2307 for lifting equipment
and man riding.
1.8 Ensure safety coefficient of all lifting factors of safety is twice that for general use.
2.0 Billy Pugh Type Carriers
2.1 Prior to commencing the examination, remove the lifting attachments and examine in
2.2 Examine the top and bottom rings for dents and impact damage, ensure that the canvas
covers are not worn, torn or damaged, especially around the eyelets and that the covers are
completely secured in position.
2.3 Examine the fiber ropes for wear, cuts, abrasions, mechanical damage, fraying, heat
damage, water damage, chemical damage and solar degradation.
2.4 Examine the hand splices, ensure that they are intact, properly served and protected.
2.5 Ensure that thimbles (if fitted) are properly fitted and secure and are not worn, cracked,
distorted elongated or corroded.
2.6 Ensure that shock absorber lanyard is correctly fitted and secure; ensure end terminations
are not corroded.
2.7 Ensure that all markings comply with Regulation 7 of LOLER SI2307 for lifting equipment
and man riding.
2.8 Ensure safety coefficient of all lifting factors of safety is twice that for general use.
3.0 Frog Type Carrier
3.1 Check the overall condition of the carrier for mechanical damage; weld cracking, security
of all fixings and fastenings, condition of the tripod feet.
3.2 Check the condition of the seating and the seat safety harness, ensuring that they are secure
and free from defect.
3.3 Check the spring in the seating arrangement for mechanical damage, loss of compression,
and that it is secure.
3.4 Check the lifting point for wear and elongation of the pin holes and mechanical damage.
3.6 Check SWL is displayed also number of persons, to be carried.

DATE 05/01/2014
Test New, Repaired, Modified

DATE 05/01/2014
Category Man Riding (Personnel Carriers)

Equipment Description Work Basket, Billy Pugh, Frog Type Carriers
1.0 Test Procedure
1.1 The carrier should be subjected to an evenly distributed proof load of SWL + 25%.
1.2 On removal of the load, the carrier should be free from permanent deformation, cracks,
flaws and other defects.
2.0 Impact Tests (These tests may be required by DNV Certifying Authority)
The design of the carrier shall be such that when the following weights are dropped on any part
of the platform, it shall not fracture.
2.1 A 4.5kg weight dropped on to an area 25mm square from the height of 1.2 m.
2.2 A 25kg weight of sand in a bag dropped from a height of 1.2m.
3.0 Guard Rail Tests
3.1 No guard rail shall fracture or show any permanent deformation when a 50kg weight is
hung on its center point and the platform of the carrier is tilted at an angle of 30 degrees from
the horizontal.
NOTE: Fabricated carriers may be subjected to a higher proof load test depending on
construction.
3.2 If all satisfactory, record relevant details and issue test certificate.

DATE 05/01/2014
Category Man Riding Equipment

Equipment Description Harness, Fall Arrestor Devices, Karabiner Ropes
etc.
Specification/Legislation BS-EN-360, BS-EN-361, BS-EN-358, BS-EN-831
BS-EN-1497
Applicable Test Manufacturing Only.
Proof Loads Not Applicable.
Examination Requirement Once Every 6 Months and Pre Use (SI2307
LOLER).
Internal Exanimation Fall Arrest Device Annual Service.
Identification Serial No., Unique ID No., SWL, Test Date, Colour
Code,
Last Inspection Date.
Through examination will comprise of but not limited to the following:
Examination Procedure
INSPECTION PROCEDURE FOR RETRACTABLE TYPE FALL ARRESTORS TO
BS-EN- 360: 1993
NOTES:
a) Remember that someone's life could depend on the equipment you are examining, if in
doubt discard the equipment or pass to a qualified approved service center for a thorough
examination.
b) Inspection of this equipment should only be carried out by a competent person. A record of
the inspection should be kept by the person carrying out the examination.
c) If the opinion of the person carrying out the inspection continued use of the equipment could
constitute a risk to personnel then a written report to this affect should be given to the
appropriate person and a copy of this report sent to the local Health & Safety Executive, Safety
Division/Department.
1.0 Fall Arrest Device (FAD): Inertia Reel
1.1 Lay the FAD on a suitable surface and ensure that adequate illumination exists around the
inspection area. Record the FAD's serial number, manufacturer, type and date of last service.
Should the last date of service be 12 months, or over, the FAD must be immediately withdrawn
from use and returned to an authorized service center for further examination, a report detailing
the reasons for this action should be sent to the appropriate person. If a Fall
Occurrence Mechanism is fitted; firstly check for signs of its activation, further reference to
this is detailed in Section 6.

DATE 05/01/2014
1.2 Check the overall integrity of the FAD, for distortion, corrosion, and cracks, ensuring no
component part are missing or loose.
1.3 Starting at the top of the FAD, ensure the shackle/handle is secure and free of cracks, nicks
or burrs. Where a shackle is fitted check the holding nut(s) and bolt(s) are secure and moving
freely.
1.4 Check labels are secure and legible.
1.5 Hang the device at a suitable location, ensuring it is in a vertical position. Pull the
retractable lanyard from FAD and allow it to return smoothly. During this operation always
listen for audible indications of internal abnormalities, such as a grinding noise or rattling. Flex
the lanyard approximately every 5cm and check along its entire length for any signs of
damage, examples of such have been listed below. While allowing the lanyard to retract,
occasionally give it a sharp downward tug to ensure the locking mechanism functions
correctly.
NOTE: Pass lanyard slowly through hands as damaged parts may cause injury or wear a
pair of suitable gloves; also, allowing unhindered reaction may result in the lanyard
jamming.
1.6 Webbing Lanyard The following information details the principle causes of deterioration in
webbing lanyards, and the FAD is to be immediately withdrawn from use should they be
evident and report sent to the appropriate person.
1.7 Signs of excessive wear, cuts, abrasion or chemical attack are not acceptable. Indications of
prolonged exposure to extreme conditions, such as strong sunlight, heat, damp and chemicals
are also not acceptable. Evidence of this type of deterioration could be could be brittle
materials, discoloration or rotting.
1.8 Check the condition of the stitch pattern; broken or worn stitches are not allowed. Where
possible pull webbing apart to check stitches.
1.9 Ensure that all stitching is visible and free of contamination; stitches that cannot be cleaned
for inspection is unacceptable.
1.10 Ensure the bottom hook, if fitted, is free of excess wear, distortion, cracks, burrs, dents
and sharp edges. The gate on the hook must open and close smoothly, and the gate must fully
engage the nose of the hook.
2.0 Wire Rope Lanyard
The following information details the principal causes of deterioration in wire rope lanyards,
and the FAD is to be immediately withdrawn from use should they be evident and a report sent
to the appropriate person.

DATE 05/01/2014
2.1 Crushing - Often results in flattened or bent section of cable.
2.2 Cutting - Damaged strands and broken wire are evident of this.
2.3 Abrasion - Results in localized wear, whereby outer strands appear flattened and appear
brighter in appearance.
2.4 Strand Core Protrusion or "Bird caging" - The central core will be showing with the outer
strands swelling out. This is usually the result of the cable being subject to a shock load.
2.5 Kinking - Typically the cable shows signs of deformation.
2.6 Corrosion - This is recognized as roughness and pitting and wire breaks will propagate
from cracks and pitting.
2.7 Electric Arcing or Heat Damage - Bluing of the wire surface should be evident or fusion of
the wire surfaces and weld splatters will be present.
2.8 Check thimble and ferrules are secure and free from damage, ensuring other components,
e.g. springs, stoppers, balls, are secure and undamaged.
2.9 Ensure the bottom hook, if fitted, is free of excess wear, distortion, cracks, burrs, dents and
sharp edges. The gate on the hook must open and close smoothly, and the gate must fully
engage the nose of the hook.
3.0 Fall Occurrence/Service Indicator Mechanisms

NOTE: Some FAD's will not contain an indicator mechanism
There are several mechanisms used to indicate a fall has occurred in an inertia reel, activation
of which must result in the FAD's immediate withdrawal from use and its return to an
authorized service center, and a report sent to the appropriate person:-
3.1 Stitching - Sewn into the hook end of a webbing lanyard, usually. To indicate a fall the
thread usually red, will tear apart.
3.2 Dial - Typically, this has two visible zones, and is located in a small window on the FAD:-
Safe Zone allows continuation of use, but if it has moved into this zone it is recommended the
FAD be returned for service as soon as possible. This mechanism also gives an indication as to
when the FAD is required to be serviced. Danger Zone immediately remove from use and
return for service.
NOTE: The dial should be stable and not move, if this is not evident remove from use and
return for service.
3.3 Button - these are usually red in color and can be flush with body of FAD or slightly
recessed. With the occurrence of a fall they will protrude from the body of the FAD.

DATE 05/01/2014
3.4 Indicator Hook - at the top of the hook a colored band will be visible should a fall or shock
load occur.
3.5 Colored Indicator - again, typically located in a window on the FAD. Should a fall or shock
load occur the indicator will change color, for example:-Blue - safe to continue use.
Red - immediately withdraw from use and return for service.
4.0 Winch Mechanism (Where Applicable)
NOTE: It is advisable to seek information from the operator prior to conducting the following
checks.
4.1 Ensure all components are located correctly and free from damage and/or excess wear.
4.2 Pull out cable and attach a 5kg mass/weight to the hook, allow FAD to lock and hold the
mass/weight.
4.3 Activate the winch mechanism and check its operation is smooth, without binding. Do not
fully winch all of the cable back into the FAD, leave a minimum of 10cm extended and remove
mass/weight.
4.4 Relocate all the winch mechanism components, and the remaining cable will retract
unaided into the FAD. Ensure the FAD is now in its normal functioning mode.
4.5 Should the winch fail to operate the FAD must be returned to an authorized service center
for further examination and a report sent to the appropriate person.
4.6 Check the winch mechanism is labeled/tagged/marked with the instruction "Suitable For
Personnel Retrieval Only".
5.0 Inspection of Harness and Belts, Manufactured to the

Following Standards
EN361: Fall Arrest
EN358: Work Positioning
EN813: Suspension
EN1497: Rescue
5.1 Lay the harness out on a suitable work surface and ensure that adequate illumination exists
around the inspection area.
5.2 Ensure the details on the label are clear and legible, if they are not, reject the harness and
report this to the appropriate person.
5.3 Connect up all the fittings and buckles and check the overall appearance of the harness;
record any obvious defects however minor.

DATE 05/01/2014
5.4 Starting at the back of the harness, check the condition of the rear "D" for signs such as
metal fatigue, cracking, distortion, corrosion, burrs, nicks and excessive wear.
Always check under the webbing.
NOTE: other "D" attachments may be fitted, apply the same checks to these.
5.5 Ensure the back plate is free of excessive wear, damage or cracking. Some back plates will
alter color if subject to stress.
5.6 Check all links, fasteners and adjusters operate correctly and are not excessively worn,
damaged, distorted, corroded or fatigued. Always check under the webbing.
5.7 Check the webbing has not been detrimentally affected by extreme environmental
conditions, such as strong sunlight, heat or damp. Evidence of this type of deterioration could
be brittle materials, discoloration or rotting.
6.0 Inspection of Connecting Hooks, Manufactured in Accordance with EN362 : 1993
6.1 Prior to conducting the inspection, ensure that adequate illumination exists around the
inspection area.
6.2 Check the overall condition of the hook, ensuring it is free of corrosion, burrs, nicks, cracks
and indentations. Also check the hook is not distorted or excessively worn. Any indication of
the aforementioned and the hook should be discarded and a report submitted to the appropriate
person.
6.3 If a securing pin is fitted ensure it is located correctly.

6.4 Generally, hooks contain three types of gate, and the following checks should be applied.
Should the gate fail to operate correctly the hook is to be rejected.
a) Automatic Locking
Check the gate opens fully and returns, unaided, to its locking position.
b) Snap
Check the snap action is functional, and ensure the gate fully engages the nose of the hook
when closed.
c) Screw gate
Check the screw ferrule fully opens and closes, and ensure the snap action is functional.
NOTE: Should the snap action or gate on a hook fail to operate smoothly a spray
lubricant may be used to free it up, ensuring any webbing or rope product attached does
not get the lubricant on it.
EN354: Lanyards
EN355: Shock Absorbers Shock Absorber Inspection

DATE 05/01/2014
7.1 Lay the lanyard/shock absorber pack out on a suitable work surface and ensure that
adequate illumination exists around the inspection area.
7.2 Beginning with the shock absorber pack, check the webbing for signs of damage, wear or
contamination. Always check the areas near the fittings and links.
7.4 Check all links, fasteners and adjusters operate correctly and are not excessively worn,
damaged, distorted, corroded or fatigue.
7.5 Check the sleeve covering the shock absorber for damage such as holes and tears.
7.6 Ensure the webbing has not started to tear or pull out the sleeve, any indication of this is to
result in the lanyard being discarded and reported to the appropriate person.
7.7 Next, inspect the lanyard, of which there are two basic types
8:0
8.1 Ensure the details on the label are clear and legible, if they are not, discard the lanyard and
report to the appropriate person.
8.3 The stitching is to be subject to the following checks.
8.4 The stitch pattern is correct and there are no broken or worn stitches, where possible pull
the webbing apart to ensure the stitches are secure.
8.5 All the stitches should be visible, and, if they cannot be cleaned the lanyard is to be
discarded and a report sends to the appropriate person.
9.1 Ensure the detail on the label is clear and legible, if they are not, discard the lanyard.
9.3 Ensure the rope is free of cuts or damage, if this is evident the lanyard and send a report to
the appropriate person.
9.4 Check the splicing and ensure the rope is free of knots. If the splice is damaged or the
lanyard is knotted discard the lanyard and send a report to the appropriate person.
9.5 Ensure that, where fitted, the thimble(s) are securely fitted.

DATE 05/01/2014
Category Man Riding

Equipment Description Medical Stretchers
Specification/Legislation BS 7497, BS 896
NOTE : Lifting Bridle Should be Inspected and Tested as per the Applicable Inspecta
Procedure
Applicable Test Manufacture ring Test
Lifting Bridle (Proof Test)
Proof Loads Lifting Bridle Only.
Examination Requirement 6 Monthly SI2307 LOLER
Internal Exanimation Not Applicable
Identification Serial No., Clients Unique No., Color Code
Test Certificate For Lifting Bridle And
Accessories
1.0 Stretchers (Rigid)

1.1 Examine the main body for wear, cracking, distortion, or corrosion on the main hand lifting
points.
1.2 Examine the lifting bridle and accessories as per the applicable Inspecta Examination
Procedures. Examine the lifting points on the stretcher for cracking, distortion, corrosion and
wear or elongation of the lifting pin holes.
1.3 Ensure weather cover fits correctly and all latches are correct and lock correctly.

DATE 05/01/2014
Category Man Riding

Equipment Description Casing Stabbing Board
Specification/Legislation HSG 221, Inspecta NDT Inspection Procedures
Proof Loads SWL + 25% and Regular Testing with
Maximum Rated Load
Examination Requirement 6 Monthly SI2307 LOLER
Internal Exanimation Clients Planned Maintenance System
Identification Clients Unique ID No., SWL, Test Date,
Color Code, (Man Riding Only)
Test Certificate
1.0 The stabbing board shall be examined for the following defect:-
1.1 Examine winch/hoist in accordance with the relevant examination procedure and ensure it
is suitable to take both pay load and the weight of the stabbing board itself.
1.2 Ensure running track is parallel, free of obstruction and securely attached to derrick. All
fasteners shall be examined for wear, corrosion and security (NDT if required).
1.3 Examine running wheels for correct fit into track also for signs of mechanical damage and
wear.
1.4 Examine fall arrestor dogs, check for correct operation also signs of mechanical damage
and cracking.
1.5 Examine platform suspension point for wear, damage, whole elongation and cracking
(NDT if required).
1.6 Examine condition of platform and integrity of hand rails, also examine all actuating levers.
Check they function correctly and are free from mechanical damage and direction of operation
is clearly marked.
1.7 Examine all safety lines and arrestors for correct operation, also anchor points for signs of
damage, distortion and cracking.
1.8 A function test shall be carried out, operating the board through its full range of travel
ensuring that limit switches operate correctly, and correct functioning of control and braking
system, condition of ropes and safety systems.
1.9 If during the course of the examination the inspector has reason to doubt the integrity of
any part of the equipment then an NDT examination will be carried out to ensure that it is free
from defects.

DATE 05/01/2014
1.10 Check platform floor for anti-slip and toe boards.
2.0 Rack & Pinion/Hydraulic Stabbing Boards
2.1 These types of boards should be inspected under the appropriate Inspecta Examination
Procedures for Rack &Pinion/Hydraulic Equipment.

DATE 05/01/2014
Category Man Riding

Equipment Description Casing Stabbing Board
Test Procedure
1.0 Prepare the area around the stabbing board for the test, barrier off the area, display
warning notices.
1.1 Inform tool pusher testing is about to commence.
1.2 Prepare test weights SWL + 25%.
1.3 Place test weights on stabbing board platform spread evenly around the work platform.
1.4 Raise and lower the platform through its full travel check its movement is smooth and
graduated.
1.5 Activate the locking device and hold the load for a minimum of 3 minutes.
1.6 Check that both braking systems hold the load independently.
1.7 On completion of these tests remove the test weights.
1.8 Carry out a full function check of the stabbing board and its controls, then carry out a full
thorough visual examination.
1.9 If all correct mark the stabbing board suitable for carrying persons.
1.10 Remove all barriers, safety notices and test weights, cleanup work area, sign of permit and
return unit to operations.

DATE 05/01/2014
Category Life Boats and Life Rafts

Equipment Description Life Boats and Davits
Specification/Legislation MSN No M1546, SOLAS2000, LRS Code for
Lifting
Appliances in a Marine Environment, Modu
Code 1989,
ISO 4309, BS 302, BS MA 55.
Inspecta NDT Inspection Procedures
Applicable Test First Installation,
Modification/Repair/Updating.
NOTE : Life Boat Falls, shall be end for ended every 30 Months and changed out every
5 Years.
Proof Loads Davit Test SWL x 2.2
Winch Brake Test Static SWL x 1.5
Winch Brake Test Dynamic SWL x 1.1
Examination Requirement At Least Once Every 6 Months SI2307
Internal Exanimation Client Planned Maintenance System
Identification Serial No., Owners Unique IN No., SWL, And
All
Ancillary Equipment No's, etc.
Davit Certification, Life Boat Certification
Wire Rope Certification and all Ancillary
Certificates
Wire Termination Certificates
1.0 Safety
1.1 During any work being carried out on life boats and davits, safety harness will be worn and
attached to a secure anchorage.
2.0 Davits
2.1 Check the main davit structure for mechanical damage, weld cracking, and bolt security.
2.2 Check the condition of all sheaves, for sheave groove wear, cracking, loose/worn sheaves,
and bearings.
2.3 Check all lifting accessories, maintenance pennants, shackles, "D" ring/master links, etc.

DATE 05/01/2014
2.4 Check the wire rope falls for broken wires lubrication etc., also check terminations i.e.
Resin socket / open wedge sockets, inspect using Servlet Examination and Test Procedure for
wire rope and terminations.
2.5 Check davit specification plate for details and check against actual specification i.e does
the plate information match the actual boat and davit details.
3.0 Winches
3.1 Check winch details.
3.2 Check wire rope spooling on winch drum, and wire rope anchorage is correct.
3.3 Check hand operation of winch.
3.4 Check overall condition of winch.
3.5 Check winch securing bolts etc.
4.0 Life Boat Release Gear
4.1 NOTE: Attention is drawn to HSE Guidelines and recommendation for inspection of
release equipment and safe procedures for lowering boat onto falls. Ensure that the boat is
correctly fitted to certified hang off pad eyes and pennants.
5.0 Pad Eyes (Hang Off Pennants)
5.1 Check condition of pad eyes for distortion mechanical damage and weld cracking (NDT
Inspection if required.
5.2 Check SWL and color code.
6.0 Safety Limit Switches
6.1 Manually check safety limit switches and record condition.
7.0 General
7.1 List all defects and ensure the color code is correct on all lifting equipment associated with
the life boat and davits.

DATE 05/01/2014
Category Life Boats And Life Rafts

Equipment Description Life Boats And Davits
Test Procedure:
1.0 Certificates
1.1 Prior to commencing testing ensure all certificates are available and have been reviewed for
all individual accessories, pad eyes, davits, life boat, wire rope falls, and terminations.
2.0 Testing
2.1 Prior to test carry out a thorough examination of the life boat and launching appliances.
Have all defects rectified prior to testing.
NOTE: Check manufactures instruction regarding retrieval of life boat under load
Conditions. Also check the client’s safety policy regarding loading and working onboard
life boats in davits.
2.2 Life Boat Testing to MSN No. M1446, 5 yearly Test. Life boat and launching appliances
test to SOLAS. Chapter III part C Regulation 48 Section V1.
NOTE: 75kilo's Represents Weight Of One Person.
3.0 Safety
3.1 All personnel working on life boat test will wear a safety harness at all times, which should
attached to a suitable anchorage. The area should be suitably cordoned off and safety notices
displayed, obey clients safety policies.
4.0 Test Equipment
4.1 Test Weights Steel Weights - Certified and Calibrated Water Bag/Pillow - Certified and
Calibrated Gravel/Sand Bags - Known Weights
4.2 Load Cell Certified and Calibrated
4.3Wire Rope/Web/Round Slings Certified, Color Coded
4.4 NDT Equipment Certified and COSHH Documents
NOTE: Permission from control room to fill water bags using fire main system.

DATE 05/01/2014
5.0 Brake Test
5.1 Dynamic Test using a proof load of 1.1 x SWL apply brakes at maximum lowering speed
hold for 2 minutes.
5.2 Static Test with a proof load of 1.5 x SWL theses brake tests should hold with no
movement for 2 minutes.
6.0 LAUNCHING APPLIANCES (DAVIT)
6.1 Static Proof load test of 2.2 x SWL hold for 2 minutes.
6.2 On completion of tests carry out a full thorough examination of life boat and davit, carry
out NDT Inspection as per clients requirements.
6.3 On completion clear up work area, remove all test equipment to shipment area. Complete
all documentation and return equipment to service

DATE 05/01/2014
Category Life Boats and Life Rafts

Equipment Description Life Raft Davits
Specification/Legislation MSN No M1546, SOLAS 2000, LRS Code For
Lifting
Appliances in a Marine Environment, Modu
Code 1989,
ISO 4309, BS 302, BS MA 55
Applicable Test First Installation, Modification/Repair/Up

rating.
NOTE : Life Boat Falls, shall be end for ended
every 30
Months and changed out every 5 years.
Proof Loads Davit Test SWL x 2.2

Winch Brake Test Static SWL x 1.5
Winch Brake Test Dynamic SWL x 1.1
Examination Requirement At Least Once Every 6 Months SI2307

Internal Exanimation Client Planned Maintenance System
Identification Client Serial No., Owners Unique IN No., SWL, And
All
Ancillary Equipment No's, etc.
Davit Certification
Wire Rope Certificate
NDT Examination Report, Ancillary
Certificates.
The thorough examination will comprise of but not be limited to the following :
1.0 Safety
1.1 During any work being carried out on life rafts and davits, safety harness will be worn and
attached to a secure anchorage.
2.0 Davits
2.2 Check the main davit structure for mechanical damage, weld cracking, and bolt security.

DATE 05/01/2014
2.2 Check the condition of all sheaves, for sheave groove wear, cracking, loose/worn sheaves,
and bearings.
2.3 Check all lifting accessories, shackles, master links, etc.
2.4 Check the wire rope for broken wires, lubrication etc, also check terminations i.e. Resin
socket / open wedge sockets; inspect using Inspecta Examination and Test Procedure for wire
rope and terminations.
2.5 Check davit specification plate for details and check against actual specification i.e does
the plate information match the actual boat and davit details.
2.6 Check the davit slewing mechanism for smooth and full operation.
3.0 Winches
3.1 Check winch details.
3.2 Check wire rope spooling on winch drum, wire rope anchorage is correct.
3.3 Check hand operation of winch.
3.4 Check overall condition of winch.
3.5 Check winch securing bolts etc.

DATE 05/01/2014
Category Life Boats And Life Rafts

Equipment Description Life Raft Davits
Test Procedure
1.0 DAVIT STRUCTURAL LOAD TEST (STATIC LOAD OF SWL X 2.2)
1.1 Carry out a thorough visual examination.
1.2 Disconnect and remove auto-release hook and attached a suitable weight (25-50kgs) to
winch wire, slew out board and lower to sea level (to check correct length of rope has been
fitted) at slack water.
1.3 Ensure that there is at least 5 turns of wire remaining on drum. Re-spool the wire.
1.4 With davit slewed inboard, remove the davit winch wire from the top sheave and fit a wire
rope sling around the sheave. Connect suitable calibrated load cell/test clock and appropriate
capacity water bag to wire rope sling.
1.5 Insert supply hose in water bag and slew outboard.
1.6 Fill water bag to SWL. Of all correct then continue to fill to required proof load and leave
suspended for approximately five minutes.
1.7 Discharge contents of water bag and slew inboard
1.8 Carry out visual examination to ensure that testing has not exposed any defects.
2.0 WINCH TEST (STATIC LOAD OF SWL X 1.5)
2.1 Remove wire rope sling from sheave at top of davit and refit winch wire.
2.2 Connect calibrated load cell/test clock and water bag to winch wire.
2.3 Insert supply hose in water bag and slew outboard.
2.4 Mark the winch drum position in relation to the davit structure (I.e. two chalk marks) to
enable detection of any creep.
2.5 Fill water bag until a weight of SWL x 1.5 is indicated and leave suspended for
approximately 5 minutes. Check the position of chalk marks mentioned above.
2.0 WINCH TEST (STATIC LOAD OF SWL X 1.5) In The event of any creep/slippage:

DATE 05/01/2014
a) Immediately discharge content of water bag.

b) Make brake adjustments as necessary.
c) Repeat testing procedure until satisfactory.
2.6 Lower the load for at least 1 complete revolution of the winch drum and check the winch
brake efficiency.
2.7 Discharge contents of water bag and slew inboard.
2.8 Carry out visual examination to ensure that testing has not exposed any defects.
2.9 Carry out post-load test NDT.
3.0 DYNAMIC LOAD TEST (SWL X 1.1)
3.1 Slew davit outboard and proceed to fill water bag until a load of SWL x 1.1 is obtained.
3.2 Withdraw supply hose and if using a load cell with remote readout, disconnect cable or
ensure it is long enough for the descent rate test (approx. 10M).
3.3 Mark with winch drum with a corresponding mark on the davit structure to enable the
counting of drum revolutions during drop test.
I.e. No. of revs x circumference of spooled drum = amount of wire played out.Or mark
the winch wire with a corresponding mark on the davit structure. on completion of the
drop test, a second mark will be made on the wire corresponding to the original mark on
the davit structure and the distance between these measures as the rope is wounded back
on the drum.
3.4 Release brake/start stops watch simultaneously and allow to free fall for six seconds.
3.5 By whatever method used in (3), obtain the rope measurement and ensure the descent rate
falls between 90 - 180ft/min. (27.4M - 54.8M).
NOTE: This test may have to be repeated for confirmation if the results are border line.
3.6 If all satisfactory, discharge contents of water bag, spool in winch wire with testing
equipment and slew inboard.
3.7 Re-examine to ensure that testing has not exposed any defects and where appropriate
employ NDT techniques.
4.0 If all satisfactory, record relevant details and issue certificate.

DATE 05/01/2014
Category Lifting Accessories

Equipment Description Open Wedge Sockets
Specification/Legislation BS 7166, Inspecta NDT Procedures
Applicable Test New
Examination Requirement As SI2307 (LOLER)
6 Monthly Internal Exanimation Not Applicable
Identification Client Unique ID No, SWL, Color Code, CE Marking
Certification EC Declaration Of Conformity
Test Certificate
The thorough examination will comprise of but not limited to the following:
1.0 Examine the main body for wear, cracks, distortion, and corrosion, ensures that pin holes
are not worn or elongated and that they are aligned. Examine the pin for wear, distortion and
corrosion, if fitted ensure that nut and cotter pin are properly fitted and secure. Examine the
wedge for wear, cracks, distortion, scoring and corrosion. Carry out MPI on body of socket.
NOTE: Ensure that the wedge socket is being used so that the SWL of the system does
not exceed the WLL of the socket i.e. 80% of the wire WWL.
3.0 Re-assembled wedge socket using correct size of wire for socket and carry out proof test to
SWL + 100%.
4.0 Dismantle and carry out post MPI examination and visually examine for defect which may
have been exposed by proof test.
5.0 If all satisfactory hard stamp test date/SWL/ID No. on unit and issue certification.

DATE 05/01/2014

Equipment Description Wire Rope Slings
Specification/Legislation BS 302, BS 464, BS 1290, BS 5281, BS 6166,
BS 6210, BS 6570, IS 4309
Applicable Test New, Repaired Equipment
Examination Requirement 6 Monthly, Pre Use Visual, SI 2307
Identification Client Unique ID No, SWL, Colour Code, Test
Date,
CE Marking
Test Certificate
1.0 Examination Procedure
1.1 Lay out the wire rope sling and measure the bearing to bearing length to check for stretch.
1.2 Examine each leg along its entire length for wear, kinks, abrasion, broken wires, core
protrusion, insufficient lubrication, crushed, flattened or jammed strands and corrosion.
1.3 Measure the rope diameter at regular intervals for any reduction in the nominal diameter,
this could be due to wear on outer wires, stretch due to overloading and collapse of the internal
core.
1.4 Examine the ferrule for wear and cracks, ensure that the correct size of ferrule has been
fitted and that the rope does not terminate inside the ferrule, it should be slightly protruding,
but not more than 1/3rd of the diameter of the wire rope.
1.5 Examine the thimbles for wear, cracks, elongation, and distortion, ensure that they have
been properly fitted.
1.6 Ensure master links/master link assemblies are the correct dimensions for fitting onto the
pedestal deck crane hook.
1.7 Shackles (if fitted) must be compatible with the safe working load of the individual sling
legs.
1.8 Where slings are fitted onto cargo carrying units, ensure that their safe working load is 1.3
times greater than the gross weight of unit it is fitted to.
1.9 Where end terminations are other than ferrule secured thimble eyes, examine for wear,
distortion, cracks corrosion, poor fitment and incorrect application.

DATE 05/01/2014
1.10 The number of broken wires in a length of 10 diameters must not exceeds 5% of the total
number of wires in the rope.
NOTE:
a) No broken wires are permitted in the area near to an end termination.
b) Master links, shackles and hooks fitted to wire rope slings should be examined in
2.1 If during the course of examination, no faults are found which would affect the safe
working load of the equipment then a proof load as listed below may be applied as follows:
2.2 A proof load equal to the working load limit of the piece of single sling leg or wire rope
termination plus 100% shall be applied.
2.3 The proof load shall be slowly applied and checks made to ensure correct alignment and
orientation of sling eyes to prevent damage or distortion. Correct diameter pins must be used to
prevent over stretching of the sling eye or deformation of the thimble.
2.4 On release of the proof load, the piece of equipment shall be examined as per Section 1.0.
3.0 Marking
3.1 If the item is not already marked, it shall be clearly stamp marked with an identification
number, safe working load and date of test.
4.0 Reporting
4.1 The written report shall contain the following information:

a) Unique identification number.
b) A full description of the piece of equipment.
c) Number of legs and angle of use.
d) Proof load applied.
e) Date of test and examination.
f) Name and address of company performing the test and examination.
g) Act of Regulations under which the test and examination was carried out.

DATE 05/01/2014
by means of defect report. If the test engineer considers the defect of a dangerous nature then
arrangements must be made for its immediate withdrawal from service.

DATE 05/01/2014

Equipment Description Webbing and Round Slings
Specification/Legislation BS-EN-1492-1
Applicable Test Not Applicable
Proof Loads Not Applicable
Identification Clients Unique ID No., SWL, CE Marking
1.1 Overheating due to wrong positioning of sling, surface of sling will be polished and easily
reflect light.
1.2 Cutting, wear, broken load bearing threads and pulled load bearing threads. The latter must
be repaired as the threads can easily catch and break if left unattended.
1.3 Damaged stitching particularly in the eye and where the webbing overlaps.
1.4 Check entire length of endless slings for seam damage.
1.5 The load bearing point in the eye of the sling shall be checked for cutting, wear, scuffing
and damaged leather protection.
1.6 In the case of Round slings the outer sleeve shall be checked for cuts and general
deterioration.
1.7 Chemical attack is very difficult to detect until in an advanced state. Signs are surface
powdering and possible loss of coloring.

DATE 05/01/2014

Equipment Description Sheave Blocks
Specification/Legislation BS 4018, BS 4536, Inspecta NDT Procedures
Applicable Test New, Modified, Repaired
Proof Loads Single sheave block and multi sheave up to 20
Ton.
Working load limit on head fitting or hook +
100%.
Multi sheave blocks 20 Ton, up to 40 Ton.
Working load limit + 20 Ton.
Multi sheave blocks over 40 Ton. Working load
limit +50%.
Proof loads to be applied to the Becket are as
listed below.
Single sheave = 1/3 of the proof load applied to
the block.
Double sheave = 1/4 of the proof load applied to
the block.
Triple sheave = 1/6 of the proof load applied to
the block.
Four sheave = 1/8 of the proof load applied to
the block.
Internal Exanimation Clients Planned Maintenance Schedule
Identification Clients Unique ID No., SWL and Head Fitting, Rating
and Color Code
Test Certificates
1.1 Examine the head fitting, eye, hook or shackle for wear, cracks, stretch and corrosion;
ensure that head fittings swivels 360 degrees.
NOTE: If head fittings are shank type, examine shank and cross head fitting for wear,
stretch and distortion ensure that nut is properly fitted and secure.
1.2 Examine side plates for wear, distortion, sharp edges, misalignment and corrosion; examine
holes for wear and elongation.
1.3 Examine sheaves for wear in rope groove, cracks, and distortion and sharp edges, ensure
sheaves rotate freely.

DATE 05/01/2014
1.4 Try to lift sheaves or ascertain level of wear in bushes or bearings.
1.5 Ensure that all lubrication points are clean and unblocked and that the block is adequately
lubricated.
1.6 Examine thrust bearing/washer for smoothness of operation.
1.7 Examine side spacers/straps for wear, distortion and corrosion.
1.8 Examine becket (if fitted) for wear, cracks, misalignment and corrosion.
1.9 Examine cheek plates (if fitted) for wear, cracks, misalignment and corrosion.
1.10 If snatch block type, unscrew retaining block and check operation of drop down side
plate, ensure that retaining bolt and head fitting cannot become completely detached, refit
"R" clip when side plate and retaining bolt are returned to their original position.
2.1 If during the course of examination, no faults are found which would affect the safe
working load of the equipment then a proof load test may be carried out as follows:
2.2 Single sheave block and multi sheave up to 20 Ton. Working load limited on head fitting or
hook 100%.
2.3 Multi sheave blocks 20 Ton, up to 40 Ton. Working load limit + 20 Ton.
2.4 Multi sheave blocks over 40 Ton. Working load limit + 50%.
2.2 Proof loads to be applied to the becket are as listed below.
2.1 Single sheave = 1/3 of the proof load applied to the block.
2.2 Double sheave = 1/4 of the proof load applied to the block.
2.3 Triple Sheave = 1/6 of the proof load applied to the block.
2.4 Four sheave = 1/8 of the proof load applied to the block.
2.5 The proof load shall be applied using a suitable wire rope of the correct diameter for the
sheave groove.
2.6 The proof load shall be slowly applied and checks made to ensure that the wire rope has
engaged correctly in sheave groove. The proof load shall be maintained for five minutes.
2.7 On releasing the proof load, the piece of equipment shall be examined as per Section 1.0.

DATE 05/01/2014
3.0 Marking
3.1 If the item is not already marked, it shall be clearly stamped or marked with an
identification number and if the test is satisfactory, the working load on head fitting and line
pull. The factor of safety and date of test should also be stamped.
4.0 Reporting

b) A full description of the piece of equipment Including make, model and height of lift.
c) Safe working load on head fitting and line pull.
g) Act of Regulations under which the test and examination was carried out.
h) Factor of safety.
by means of a defect report. If the test engineer considers the defect of a dangerous nature then

DATE 05/01/2014

Equipment Description Shackles
(Dee, Bow, Safety Dee/Bow)
Specification/Legislation BS 3032, BS 3551, BS 6994, ISO 2415, ISO 2791
ISO 2731, US Fed Spec RR-C-271D
Applicable Test New
Proof Loads 2 x SWL up to 35 Tonne
1.22 x SWL Above 35 Tonne
Identification Client Unique ID No., SWL, CE Marking, Colour
Code
Test Certificate
The thorough examination will comprise of but not limited to the following :
1.1 Remove the shackle pin and examine for wear, cracks, deformation, flats on threads and
corrosion.
1.2 Ensure that the pin is the correct type for the shackle in which it is fitted.
1.3 Examine the body for wear, cracks, nicks, gouges and corrosion; ensure that shackle pin
holes are not worn or elongated, that they are in alignment and that threads in shackle pin hole
are not damaged. Screw the pin back into the body and ensure that it fits correctly.
1.4 In the case of safety shackles, the nut must close on the last thread of the pin and not on the
body of the shackle, ensure that the nut and cotter pin are correctly fitted and secure.
1.5 Wear on the pin and body of the shackle must not exceed 8% of the original diameter.
2.0 If any faults are found at the examination which would affect the safe use of the item, then
it must be withdrawn from service and details recorded of the Inspection Report.
2.1 Carry out proof load test 2 x SWL up to 35 tones and 1.22 x SWL for shackles with a SWL
above 35 tones.
2.2 Carry out post inspection if all correct hard stamp ID No. and SWL (if not marked). Hard
stamp only on shackle side and not crown.
2.3 In the case of safety pin shackles replace the split pin.
3.0 Reporting

DATE 05/01/2014

b) A full description of the piece of equipment including make, model and height of lift.
c) Safety working load on head fitting and line pull.
g) Act or Regulations under which the test and examination was carried out.

DATE 05/01/2014

Equipment Description Vertical, Horizontal, Universal Plate Clamps
Specification/Legislation None Applicable
Applicable Test New, Repaired Equipment
Identification Client Unique ID No., SWL, CE Marking
Test Certificate
1.0 Examination Procedure (Horizontal)
1.1 Examine the hook ring for wear, distortion, stretch and corrosion.
1.2 Check for lateral movement on hook ring and on load bolt connection to serrated
jaws/rocker arms. Excessive movement could indicate wear or distortion.
1.3 Examine the serrations on the jaws or swivel toes for wear, deformation and corrosion.
1.4 If a toe is fitted, check for lateral movement of swivel toe on load bolt connection to rocker
arms. Excessive movement could indicate wear or distortion.
1.5 Ensure that horizontal plate clamps are a matched pair.
NOTE: Do not sharpen or re-cut teeth on jaws.
2.0 (Vertical)
2.1 Examine the hook ring for wear, distortion, stretch, corrosion and internal movement.
Excessive lateral movement could indicate internal wear.
2.2 Examine jaw pin and nut for wear and deformation, ensure that they are properly fitted and
secure.
2.3 Check the operation of the cam assembly locking lever/jaw spring, ensure that spring has
correct tension and is not stretched or broken.
2.4 Examine serrated jaw and pad for wear, deformation and corrosion.
2.5 Examine the main body for wear, cracks and deformation.

DATE 05/01/2014
NOTE: Do not sharpen or re-cut teeth on jaws.
item, then it must be withdrawn from service and details recorded on Inspection Report.
3.1 If, during the course of examination, no faults are found which would affect the safe
working load of the clamp then a proof load as listed below may be applied as follows :-
3.2 All proof loads equal to the working load limit of the piece of equipment plus 100% shall
be applied and a check made of the load bearing points.
3.3 The proof load shall be gradually applied, checking at all times for alignment. It is also
important to use the correct width test beam or plate thickness to prevent damage or distortion
to the clamp jaws.
3.4 On releasing the proof load the piece of equipment shall be examined as per Section 1.0.
4.0 Marking
5.0 Reporting
5.1 The written report shall contain the following information :-

b) A full description of the piece of equipment including make, model and range plate
thickness capacity.
c) Safe working load.
arrangements must be made of its immediate withdrawal from service.

DATE 05/01/2014

Equipment Description Rigging Screws / Turn Buckles
Specification/Legislation BS 4429
Applicable Test New
Proof Loads 2 x SWL
Examination Requirement 6 Monthly SI2307 (LOLER
Identification Client Unique ID No., SWL, Colour Code, Test Date
Test Certificate
1.1 Unscrew both ends of the rigging screw to separate the unit into three main components.
1.2 Examine the body for wear, cracks and corrosion.
1.3 Examine the threads for wear, impact damage, stretch and corrosion.
1.4 Examine eye (if fitted) for wear, impact damage, distortion, stretch and corrosion.
1.5 Examine hooks (if fitted) for wear, impact damage, distortion, stretch and corrosion.
1.6 Examine jaws (if fitted) for wear, splaying, distortion and corrosion, examine pin holes for
wear and elongation, examine pin for wear, distortion and corrosion. Ensure retaining pin or
clip is fitted correctly.
1.7 Reassemble and ensure that both ends close correctly.
2.0 If any faults are found at the time of examination which would affect the safe use of item,
then it must be withdrawn from service and details recorded on the Inspection Report.
Test New 1.0 Carry out a fully visual examination prior to load testing rigging
screws/turnbuckles checking for mechanical/corrosion damage to the body and threads.
2.0 Prior to testing ensure the male threads are fully through the female threads.
3.0 Load test to SWL + 100% proof load. On completion of test examine the threads and body
for defect or distortion.
4.0 If all satisfactory hard stamp with test date/SWL/ID No and issue test certificate.

DATE 05/01/2014

Equipment Description Pad Eyes
Specification/Legislation BS 2573 Pt 1, Inspecta NDT Inspection
Procedure
NOTE: Pad eyes NDT Inspected during a SI2307 Thorough Examinations shall have a
copy of the Inspection Report appended to the SI2307 Report.
Applicable Test Installed
Proof Loads 2 x SWL up to 10 Tones SWL
For pad eyes in excess of 10 Tones SWL is the
following SWL x 1.04+9.6 = Proof Load Derived
from Lloyds Register Code for Lifting
Appliances in Marine Equipment Table 9.1.1
Examination Requirement Examination Based on Usage SI2307
Identification Client Unique ID No., SWL, Color Code, Test Date
NDT Report (Pre & Post Test)
Test Certificate
1.1 Examine the profile of the pad eye, ensure that all flame cutting marks have been ground
smooth to avoid creating possible stress areas and injury to operators hands.
1.2 Examine the pad eye for soundness of structure, wear and deformation.
1.3 Ensure the lifting/suspension hole has been either drilled or machined (flame cut holes are
not acceptable), examine for elongation.
1.4 Ensure that hole diameter and pad eye width are compatible with the appropriate safe
working load shackle, hole should be pin diameter + 10%, width should be jaw gap + 10%.
1.5 Examine welded and surrounding areas for cracks, deformation and distortion and
surrounding structure is satisfactory for purpose.
1.6 In the case of bolt on pad eyes, examine the attached steelwork for any local distortion,
ensure that bolts or fasteners are properly fitted, secure and are not stretched, deformed or
corroded.
1.7 Pad eyes designed for angular pulls often have torque values for bolting to prevent
slippage, ensure that these are tightened to the correct torque values.
NOTE:
a) If the pad eye hole diameter is to large, the shackle pin could possible over stress the pad eye
due to point loading.

DATE 05/01/2014
b) If the pad eye is too narrow, the shackle could sit askew and consequently be subjected to
stress other than which is designed.
2.1 If during the course of the examination, no faults are found which would affect the safe
working load of the pad eye then a proof load as detailed below may be applied.
2.1.1 For pad eyes with a safe working load up to 10 tone, a proof load of 2 x SWL shall be
applied.
2.1.2 For pad eyes in excess of 10 tons safe working load, the following formula shall be used.
SWL x 1.04 + 9.6 = Proof Load
Derived from Lloyd’s code for Lifting Appliances in an Marine Environment Table 9.1.1.
NOTE: Other certifying authorities (e.g. DNV) and individual clients may have their own
specifications on the proof load on pad eyes. These should be referred to where possible.
2.1.3 The proof load may be applied by direct pull using a chain block and load cell, calibrated
hydraulic jack set, test weights, water bags or a method that shall suitably apply the proof load.
2.1.4 The proof load shall be applied in a similar direction to which the pad eye will be loaded
in service.
2.1.5 The proof load shall be maintained for a period of five minutes.
2.1.6 On release of the proof load, the piece of equipment shall be examined as per Section 1.0.
3.0 Marking
3.1 If the item is not already marked, it shall be clearly stamped/marked with an identification
4.1 The written report shall contain the following information.

e) Name and address of company performing test and examination.
f) Position and location of piece of equipment.
g) Act or Regulation under which the test and examination was carried out.

DATE 05/01/2014
NOTE: All pad eyes NDT inspected during SI2307 examinations will have NDT report
attached to the final report document.

DATE 05/01/2014

Equipment Description Overhaul/Headache Ball
Specification/Legislation Manufacturers Specification
Applicable Test New, Modified, Repaired
Proof Loads Working Load Limit + 100%
Internal Exanimation Clients Planned Maintenance Schedule
Identification Clients Unique No., Serial No., SWL, Date of Test
Test Certificate
1.1 Examine the swivel for excessive play; ensure that the swivel turns freely on the bearing.
1.2 Examine the eye or clevis/pin for wear and deformation. Ensure correct retaining pin is
fitted and secure.
1.3 Examine the body of the overhaul ball for wear, deformation, cracks and corrosion.
1.4 Ensure lubrication point is clean and unblocked and that the overhaul ball is adequately
lubricated.
1.5 Ensure that all fixing bolts are properly fitted and secure and not corroded.
1.6 Examine safety hook for wear, distortion, stretch, nicks, gouges, scoring and excessive
movement, ensure that safety catch is fitted, functions correctly and that the hook swivels 360
degrees.
item, then it must be withdrawn from service and details recorded in the Inspection Report.
working load of the unit then a proof load as listed below may be applied as follows.
2.2 A proof load equal to the working load limit of the piece of equipment plus 100% shall be
applied to the item to be tested.

DATE 05/01/2014
2.3 The proof load shall be gradually applied, checking all times for alignment to prevent any
damage or deformation. The proof load shall be held for five minutes.
2.4 If the overhaul ball or swivel has an integral wedge socket as a top termination it is critical
that the correct diameter wire rope is used to prevent damage and jamming of the wedge in the
socket body.
2.6 A magnetic particle inspection as per Servlet Procedure should be carried out on the wedge
and socket if applicable after load testing.
3.0 Marking
number, safe working load and date of test. If the swivel has an integral wedge socket, the
wedge shall be stamped with the unit identification number to match it to the socket.
4.0 Reporting


DATE 05/01/2014

Equipment Description Master Link
Applicable Test New
Proof Loads 2 x SWL
Identification Client Unique ID No., SWL, CE Marking, Test Date
Test Certificate
1.1 Examine the master link for wear, distortion, elongation, cracks and corrosion.
1.2 Wear on the master link must not exceed 8% of the original diameter.
working load of the equipment then a proof load as listed below may be applied as follows
2.2 A proof load equal to the working load limit x 2 shall be applied to the item to be tested.
2.3 The proof load shall be slowly applied and checks made to ensure satisfactory alignment
for each component being tested to prevent damage or distortion. The proof load shall be held
of five minutes.
3.0 Marking
identification number and if the test is satisfactory, the safe working load and date of test.
4.0 Reporting


DATE 05/01/2014



DATE 05/01/2014

Equipment Description Hooks (General and Self Locking)
Specification/Legislation BS 2903, BS 3017, Inspecta NDT Inspection
Procedures
Applicable Test New, Repaired
Proof Loads 2 x SWL
Identification Client Unique ID No., SWL, Color Code
Test Certificate
1.1 Distortion, ensure that the hook is not bent, and check opening against manufacturers tables
to ensure that there has been no overloading of hook, ensure the safety latch is correct and
function.
1.2 Check with manufacturer’s tables to ensure correct size of hook is being used for Safe
Working Load.
1.3 Nicks, gouges, scores, etc. Some of these defects may be rectified by filing out so as to
remove the defect. If the amount of metal removed is more than 1/64 inch per 1 inch
of section, then the hook must be removed from service.
1.4 The eye of the hook must be checked for wear if this exceeds 8% of the original diameter
then the hook must be removed from service.
1.5 The following extra checks shall be carried out on shank hooks.
a) Shank is true with center line of hook.

b) Swivel hook turns freely.
c) Soundness of shank thread fit of thread in nut and completeness of thread.
d) Signs of cracks particularly where there are changes of section at bottom of threads and at
cotter pin holes.
1.6 For BK type hooks, ensure that the trigger mechanism operates freely to open and returns
to its original position when closed; ensure that safety catch opening is within manufacturer’s
tolerances.
1.7 For BKL type hooks ensure that the swivel rotates freely and that the securing nut and
dowel pin are properly fitted and secure.

DATE 05/01/2014
Side Play
The total machined face of the latch must not pass beyond the center line of the machined face
of the hook body tip.
Vertical Play
The limit for wear measured between the machined face of the latch tip and the machined face
of the hook body tip is as follows.
Gun Nebo Self Locking Safety Hooks
Applies to types BK, BKG, BKH, BKL, BKT.
CROSBY SELF LOCKING SAFETY HOOKS

Applies to types 316A, 317A, 318A, 326A.

DATE 05/01/2014
2.0 Testing
working of equipment then a proof load as listed below may be applied as follows:-
2.1.1 A proof load equal to the working load limit of the piece of equipment plus 100% shall
be applied to the items to be tested.
2.1.2 The proof load shall be slowly applied and checks made to ensure satisfactory alignment
of each component being tested to prevent damage or distortion. The proof load shall be held
for five minutes.
2.1.3 On releasing the proof load, the piece of equipment shall be examined as per Section 1.0.
3.0 Marking
4.0 Reporting


DATE 05/01/2014

Equipment Description Adjustable Beam Clamp
Proof Loads 2 x SWL
Identification Client Unique ID No., SWL, Color Code, Test Date
Test Certificate
1.1 Examine the suspension shackle or eye for wear, cracks, stretch, gouges and corrosion.
1.2 Examine the suspension load bar for wear, bending, distortion and corrosion, ensure the
locking nut is properly fitted and secure.
1.3 Examine the outer and inner clamp halves for wear cracks, distortion and corrosion; ensure
that there is no deformation of the jaw.
NOTE: Where swivel jaws are fitted, ensure that they rotate freely.
1.4 Operate adjusting bar and examine the threads for wear, damage and corrosion, bar
distortion and that the clamp opens to its maximum and minimum beam sizes.
1.5 Ensure that the tommy bar handle is not distorted or damaged to an extent that could injure
the operator’s hands.
1.6 Examine screw spigots (in each half of clamp) and ensure that they are not deformed.
Test Procedure:
2.0 Testing
2.1 If, during the course of the examination, no faults which would affect the safe working load
of the clamp then a proof load as listed below may be applied as follows :-
2.2 All proof loads equals to the working load limit of the piece of equipment plus 100% shall
be applied and a check made of the load.

DATE 05/01/2014
2.3 The proof load shall be gradually applied, checking at all times for alignment. It is also
important to use the correct width test beam or plate thickness to prevent damage or distortion
to the clamp jaws.
3.0 Marking
4.0 Reporting


DATE 05/01/2014

Equipment Description Eye Bolts (Collared) and Swivel Hoist Rings
Applicable Test New
Proof Loads 2 x SWL
Examination Requirement 6 Monthly Pre Use SI2307 (LOLER)
Identification Client Unique ID No., SWL, Test Date
Test Certificate
1.1 Clean threads to remove debris, examine for flats, wear ,impact damage, stretch and
corrosion, threads must be complete (no broken threads) and full (no flats on top).
1.2 The threads should be concentric and fit neatly into a standard nut, if stretch is suspected, a
thread gauge should be used to confirm condition.
1.3 Examine the eye for wear, cracks, distortion, elongation and corrosion.
1.4 Examine the shank for distortion, reduced diameter and undercut threads.
1.5 For eyebolts with links, examine the link for wear, cracks, distortion and elongation.
1.6 Where eyebolts have links fitted the link should be large enough to allow a hook to be
directly fitted into the link.
1.7 Wear on eyebolt must not exceed 8% of the original diameter.
NOTE: Under no circumstances should distorted shanks be straightened.
1.8 For swivel hoist rings also ensures full rotation of bail turn-on and bail arm.
1.9 Ensure torque values are available. Ensure torque bolt is secured with correct retaining
ring.

DATE 05/01/2014

Equipment Description Eye Bolts (Collared) and Swivel Hoist Rings
Test New
1.0 Test Procedure
1.1 If, during the course of the examination, no faults are found which would affect the safe
working load of the equipment then a proof load as listed below may be applied as follows:-
1.3 The proof load shall be slowly applied and checks made to ensure satisfactory alignment of
each component being tested to prevent damage or distortion. The proof load shall be held for
five minutes.
2.0 Marking
3.0 Reporting
3.1 The written report shall contain the following information:-


DATE 05/01/2014

Equipment Description Adjustable Beam Trolley
Proof Loads 2 x SWL
Identification Client Unique ID No., SWL, Test Date, Color Code
Test Certificate
1.1 Examine the side plates for wear, cracks, distortion, misalignment and corrosion.
1.2 Ensure that all bolts and spacers are properly fitted and secure.
1.3 Examine the wheels, axels, nuts and bearings for wear, cracks, distortion and corrosion,
ensure that nuts are properly fitted and secure.
1.4 Ensure that the wheels are not contaminated with oil and grease that could cause slippage.
1.5 Examine load bar, suspension points/shackles for wear, cracks, stretch, distortion, gouges
and corrosion, ensure that locking nuts are properly fitted and secure.
1.6 Where an adjusting bar is fitted, operate the bar and examine the threads for wear, damage
and corrosion, bar distorted and that the clamp opens to its maximum and minimum beam
sizes.
1.7 Ensure that the tommy bar handle is not distorted or damaged to an extent that could cause
injury to the operator’s hands, ensure that the locking device functions correctly.
1.8 If geared travel, examine gear teeth on wheel flanges and drive sprockets of hand chain
drive shaft for wear, cracks, broken teeth, misalignment and corrosion.
1.9 Ensure the anti-tilt device is fitted, correctly and secure.
1.10 Examine the hand chain and hand chain wheel for wear, stretch, impact damage and
corrosion, ensure that the chain seats correctly in the chain pockets and that the chain is not
damaged to an extent which would cause injury to the operators hands.
1.11 Examine the chain guides for wear and deformation, ensure that they are correctly
positioned to feed chain smoothly onto hand chain wheel.

DATE 05/01/2014
1.12 Ensure that the trolley is correctly installed, that it is centrally aligned and that the side
clearance between the wheel flange and the beam flange is correct (usually 3mmto 4mm total
clearance).
item, then it must be withdrawn from service and detailed on the Inspection Report.

DATE 05/01/2014

Equipment Description Adjustable Beam Trolley
Test New, Repaired
1.0 Test Procedure
1.1 Fix to an appropriate sized beam and commence proof testing as follows:-
1.2 A proof load equal to the working load limit + 100% shall be applied to the trolley.
1.3 A steady application of the load is required to ensure that the trolley wheels keep true
alignment of the test beam to ensure equal loading. The proof load shall be held for five
minutes.
1.4 Release the proof load and re-examine the equipment as per Section 1.0.
2.0 Marking
2.1 Ensure the equipment is clearly stamped with an identification number, safe working load
and date of test.
3.0 Reporting


DATE 05/01/2014

Equipment Description Chain Slings and Chain
Specification/Legislation BS EN 818-4, BS 3458, BS 4942, BS 6166, BS
6304
Proof Loads See Next Page
Chain Tag
Test Certificates
Proof Load Information

CHAIN SLINGS RATED USING THE UNIFORM LOAD METHOD
3.1 Single Leg 2 x W.L.L of chain

3.2 Two Leg Each leg 2 x W.L.L of chain Master Link 2.8 x W.L.L of chain
3.3 Three / Four Leg Each leg 2 x W.L.L of chain Master link 4.2 x W.L.L of chain
Sub links 3.2 x W.L.L of chain
3.4 Endless (rated at 1.5 x W.L.L of chain) 4 x W.L.L of chain (=8/3 W.L.L of sling)
CHAIN SLINGS RATED USING THE TRIGONOMETRICAL METHOD

4.2 Two Leg Each leg 2 x W.L.L of chain Master link 4 x W.L.L of chain
4.3 Three Leg Each leg 2 x W.L.L Master link 6 x W.L.L of chain Sub links 4 x W.L.L of
chain
4.4 Four Leg Each leg 2 x W.L.L of chain Master link 8 x W.L.L of chain Sub links 4 x
W.L.L of chain
4.5 Endless (rated at 1.5 x W.L.L of chain) 4 x W.L.L of chain (= 8/3 W.L.L of chain)

DATE 05/01/2014

Examination Thorough Examination
Thorough examination will comprise of but not limited to the following:-
1.1 Lay out the chain sling, remove all twists from the leg and measure bearing length to check
for stretch.
1.2 Check for the quality mark on the chain to establish grade of chain, mark should be every
20th link or 1 meter, whichever is the lesser distance.
1.3 Examine all components to ensure that they are compatible.
1.4 Examine each leg of the sling along its entire length for wear, distortion, elongation,
stretch, pitting, heat damage, chemical damage and corrosion.
1.5 Examine hook safety catches (if fitted) for correct function.
1.6 Ensure security of load and retaining pins.
1.7 Examine connectors for wear and deformation, ensure that they are not seized and can
move freely.
1.8 Examine shortening clutches (if fitted) for wear and deformation, ensure that chain seats
properly in the chain pockets.
1.9 Examine all hooks, master links and shackles in accordance with the relevant examination
procedures.
1.10 Wear on chain and components should not exceed 8% of the original diameter.
1.11 Stretch on chain must not exceed 5% of the original length.
2.0 Examination Procedure (Chain)
2.1 Check quality mark on chain to establish grade of chain, mark should be every 30th link or
1m whichever if the lesser distance.
2.2 Check manufacturer’s tables to ensure the Safe Working Load is correct for the diameter of
chain.

DATE 05/01/2014
2.3 Check all components used are compatible with the Safe Working Load of the chain.
2.4 Wear on the links of the chain must not exceed 8% of the original diameter.
2.5 Check for bent or twisted links.
2.6 Stretch in the chain shall not exceed 5% of the original length of the chain sling and 2%
over 5 links of calibrated chain.
2.7 Examine for nicks, cracks, corroded and pitted links.
Table A

DATE 05/01/2014

DATE 05/01/2014

Test New, Repaired
Test Procedure
1.0 When assembling chain slings from pre-tested components it is not a requirement to
test the completed sling or sling legs unless requested by the customer.
1.1 When introducing new components into a chain sling in order to affect a repair, the sling
should be proof tested in accordance with the following values.
2.0 CHAIN SLINGS RATED USING THE UNIFORM LOADMETHOD

2.2 Two Leg Each leg 2 x W.L.L of chain Master Link 2.8 x W.L.L of chain
2.3 Three / Four Leg Each leg 2 x W.L.L of chain Master link 4.2 x W.L.L of chain
Sub links 3.2 x W.L.L of chain
3.0 CHAIN SLINGS RATED USING THETRIGONOMETRICAL METHOD

3.2 Two Leg Each leg 2 x W.L.L of chain Master link 4 x W.L.L of chain
3.3 Three Leg Each leg 2 x W.L.L Master link 6 x W.L.L of chain Sub links 4 x W.L.L of
chain
3.4 Four Leg Each leg 2 x W.L.L of chain Master link 8 x W.L.L of chain Sub links 4 x
W.L.L of chain
3.0 CHAIN SLINGS RATED USING THETRIGONOMETRICAL METHOD (Con't)
3.6 Having proof loaded the sling re-examine the sling to ensure that proof loading has not
exposed any defects.
3.7 If, during the course of the examination no faults are found which would affect the safe
3.8 A proof load equal to the working load limit plus 100% shall be applied to the chain to be
tested.
3.9 The proof load shall be slowly applied and checks made to ensure correct alignment and
orientation of chain links. If the length of the chain exceeds the length of the test facility, then

DATE 05/01/2014
the chain must be repositioned and the proof load reapplied to ensure that all sections of the
chain are tested. The proof load shall be held for five minutes.
4.0 Marking
4.10 If the item is not already marked, a chain tab or similar shall be clearly stamped or marked
with an identification number, safe working load and date of test and attached securely to the
chain.
5.0 Reporting
5.1 The written report shall contain the following information ;-

6.10 Where the test is not satisfactory, a responsible representative of the user shall be
informed by means of a defect report. If the test engineer considers the defect of a dangerous
nature then arrangements must be made for its immediate withdrawal from service.

DATE 05/01/2014
Equipment Description Fiber Rope Sling and Fiber Nets

Specification/Legislation BS 2052, BS 3226, BS 4128, BS 29828, BS 6033
BS 6668, BS 6756
Applicable Test Not Applicable
Proof Loads Not Applicable
Identification Client Unique ID No., SWL, CE Mark, Color Code
1.0 Lay out the fiber rope sling and measure bearing to bearing length to check for stretch.
1.2 Examine the sling along its entire length for wear, cuts, abrasions, mechanical damage,
fraying, heat damage, water damage, chemical damage and solar degradation.
1.3 Examine hand splice (if fitted), ensure that they are intact. Properly served and protected.
1.4 Ensure that thimbles (if fitted) are properly fitted and secure and that they are not worn,
cracked, distorted, elongated or corroded.
1.5 Examine the ferrule (if fitted), for wear and cracks, ensure that the correct size of ferrule
has been fitted and that the report does not terminate inside the ferrule, it should be slightly
protruding, but not more than 1/3rd of the diameter of the rope.
2.0 Examination Procedure (Fiber Net)
2.1 Lay out the net and measure length and width to ensure that there has been no stretch.
2.2 Examine the rope for wear, cuts and abrasions, mechanical damage, fraying, heat damage,
water damage, chemical damage and solar degradation; ensure that knots are properly formed
and that they are equidistant in all directions.
2.3 Examine the lifting eyes for wear and stretch.
2.4 Ensure that thimbles (if fitted) are properly fitted and secure and are not worn, cracked,
distorted, elongated or corroded.
2.5 Examined hand splices (if fitted) ensure they are intact, properly served and protected.

DATE 05/01/2014

Equipment Description Bunker Hose Saddle/Lifting
Brackets/Clamps/Flanges
and Plates
Specification/Legislation Approved Manufacturers Specification
Proof Loads 2 x SWL
Examination Requirement 6/12 Monthly Dependent on Use
Test Certificate
1.1 Examine the profile of the lifting points; ensure that all flame cutting marks have been
ground smooth to avoid creating possible stress areas and injury to operators hands.
1.2 Examine the lifting points for soundness of structure, wear and deformation.
not acceptable), examine for wear and elongation.
1.4 Ensure the hole diameter and lifting points width are compatible with the appropriate safe
working load shackle, hole should be pin diameter + 10% width should be jaw gap- 10%.
1.5 Examine welded and surrounding areas for cracks, deformation and distortion. NDT lifting
point well-meant as required.
1.6 In the case of bolt on lifting points, examine the attachment steelwork for any local
distortion, ensure that bolts or fasteners are correctly fitted and secure and are not stretched,
deformed, corroded or worn and are of suitable grade.
1.7 Lifting points designed for angular pulls often have torque values for bolting to prevent
slippage, ensure that these are tightened to the correct torque values.
1.8 Associated lifting equipment is to be examined in accordance with relevant procedure.
NOTE:
a) If the lifting points are too large, the shackle could possibly overstress the pad eye due to
point loading.

DATE 05/01/2014
b) If the lifting point is too narrow the shackle could sit askew and consequently be subjected
to stress other than which is was designed. If this is the case packer pieces are to be used.

DATE 05/01/2014

Equipment Description Bunker Hose Saddle/Lifting
Brackets/Clamps/Flanges
and Plates
Test New, Repaired
1.0 Test Procedure
1.3 The proof load shall be slowly applied and checks made to ensure satisfactory alignment of
each component being tested to prevent damage or distortion. The proof load shall be held for
five minutes.
2.0 Marking
3.0 Reporting

4.1 Where the test is not satisfactory, a responsible representative of the users shall be

DATE 05/01/2014

Equipment Description Barrel Lifting Clamp
Inspecta NDT Inspection Procedure
Proof Loads 2 x SWL
Test Certificate
1.1 Prior to commencing the examination, remove all lifting attachments and examine in
1.2 Examine the structure, ensure that it is not distorted and that all welds are intact and free
from cracks.
1.3 Examine the adjusting screw; ensure that the threads are not damaged and that the screw
operates correctly throughout its complete range.
1.4 Examine the locking mechanism and ensure it functions correctly.

DATE 05/01/2014

Equipment Description Barrel Lifting Clamp
1.0 Test Procedure
1.1 Attach clamp to barrel
1.2 Attach a uniformly distributed load over the barrel in such a way that the combined weight
of the barrel and test load is equal to two times the maximum safe working load of the drum
lifting clamp.
1.3 Maintain the proof load on the clamp for five minutes.
1.4 Having proof loaded the clamp re-examine the clamp and sling set to ensure that proof
loading has not exposed any defects.
2.0 Reporting

b) A full description of the piece of equipment including make and model.

DATE 05/01/2014
Category Lifting Appliances

Equipment Description Wire Rope
Specification/Legislation BS 302, BS 6570, ISO 4309
Applicable Test New, In-service, Destruction
Proof Loads MBL of the Rope divided by 5 for Factor of
Safety
Internal Exanimation During Visual Examination
Test Certificate
1.1 Examine the wire rope along its entire length for wear, kinks, abrasions, broken wires, core
protrusions, insufficient lubrication, crushed, flattened or jammed strands and corrosion.
1.2 Measure the rope diameter at regular intervals for any reduction in the nominal diameters,
this could be due to wear on outer wires, stretch due to overloading and collapse of the internal
core, should reduce diameters be discovered, the position should be clearly marked to allow for
further investigation to be carried out.
1.3 Using two specially designed clamps open up the lay of the rope at regular intervals along
the entire length and examine internally for fretting, broken wires, damaged core, lack of
lubrication and corrosion.
1.4 Examine end termination for wear, distortion, cracks, corrosion, poor fitments and incorrect
application.
1.5 The number of broken wires in a length of 10 diameters must not exceed 5% of the total
number of wires in the rope.
NOTE:
a) No broken wires are permitted in the area near to an end termination.
item, then it must withdraw from service and details recorded on the Inspection Report.

DATE 05/01/2014

Equipment Description Wire Rope
Test Destruction Test
1.0 Test Procedure
1.1 This procedure defines the method used to carry out destruction testing on wire rope using
poured resin sockets and telluric splice.
2.0 Pre-Testing
2.1 When cutting sample from wire rope ensure that sufficient length is removed to allow for
two samples. This is in case the first test result is below the minimum break load and a second
test is required to verify load.
2.2 Samples should be clearly labeled and identified and original certificate number quoted.
NOTE: Use more than one label and permanent marker.
2.3 Identify construction, diameter, lay, condition and lubricant status and record findings.
2.4 Make up sample into destruction test piece by termination with resin poured sockets or by
talruit mechanical splice. If by tarot soft eyes to be in accordance with BS1290dimensions.
2.5 Finished samples must have a minimum length of 600mmbetween the terminations for
ropes up to 20mm diameter and a minimum of 30 x diameter for ropes over 20mmdiameter.
3.1 Fit the prepared test piece into the load points of the 200tone test bed. When piece is by
talruit soft eyes ensure adequate pin diameter is used.
3.2 Apply 80% of minimum breaking load quickly then apply the remainder slowly and
steadily until the actual breaking load is achieved.
3.3 The actual break load is then recorded. If the break load is below the expected minimum,
carry out a second test to verify.
NOTE: A percentage reduction is allowable for ropes that have been in service. Check
the appropriate standard or regulation as applicable for figures.
3.4 If the second sample fails below the minimum break load the wire should be rejected. It
may be desirable to cut back the rope until the non-worked section is reached and carry out
further destruction test, however consideration must be given to the final finished length.

DATE 05/01/2014
4.0 Reporting
4.1 Issue destruction test report detailing actual break load, construction, lay, condition and
lubrication status. Where possible attach copy of original wire rope test certificate.

DATE 05/01/2014

Equipment Description Wire Rope Pulling Machine (Tirfor)
Specification/Legislation Manufacturers Specification (No BSI Standard)
Proof Loads W.L.L + 50%
Examination Requirement Requirement 6 Monthly SI2307 (LOLER)
Internal Exanimation Clients Planned Maintenance Scheme
Pulling SWL, Lifting SWL
Test Certificate
Wire Rope Certificates
1.1 Examine the side casings for wear, impact damage and cracks, ensure that all casing bolts
are properly fitted and secure.
1.2 Examine the load pin for wear and distortion.
1.3 Examine hooks (if fitted) of wear, distortion and stretch, ensure that the safety catch is
fitted, that it functions correctly and that the hook is properly fitted, secure and swivels 360
degrees.
1.4 Operate both the forward and reverse operating levers, ensure that shear pins are intact
(sheared or cracked pins would indicate overloading) replacement pins are available in the unit.
1.5 Check the operation of the release lever.1.6 Ensure that the telescopic handle is not
distorted and is correct type for the model.
1.7 Using a torch, examine the internals of the machine through the opening at the top of the
hoist ensure that is adequately lubricated.
1.8 Ensure that the wire rope being used with the wire rope hoist is the correct diameter.
NOTE: Wire rope and fittings should be examined in accordance with the relevant
procedures.
1.9 Model SWL Rope Diameter

TU8/T508 800Kgs 8.2mm
TU16/TU15 1600Kgs 11.3mm
T30/T35/T532 2100Kgs 16.3mm
3.0 If any faults are found at the time of inspection which would affect the safe use of the item,
then it must be withdrawn from service and details recorded on the Inspection Report.

DATE 05/01/2014

Equipment Description Wire Rope Pulling Machine (Tirfor)
Test New and Repaired
1.0 Test Procedure
1.3 If no defects are apparent then the load shall be raised through a height of lift which will
ensure that every part of the uplift mechanism and each tooth of the gears comes under load.
This load shall be maintained for a period of five minutes.
2.0 Marking
3.0 Reporting


DATE 05/01/2014

Equipment Description Electric Chain / Wire Rope Hoist
Specification/Legislation DIN-FEM 1001 Section 9
BS 466
Applicable Test New, Repaired, Resisted
Examination Requirement Clients Written Scheme of Examination
Identification Clients Unique ID No., SWL, Test Date, Color Code
Test Certificate
1.1 Prior to carrying out the examination isolate the hoist and remove the fuses.
1.2 Examine the top and bottom hooks for wear, distortion and stretch ensure that safety
catches are fitted and function correctly and that hooks swivel freely and that their mountings
are secure.
1.3 Examine the load and anchor pins for wear and distortion, ensure that they are securely
fitted.
1.4 For chain hoists examine the bottom hook load sprocket for wear and debris in pockets,
ensure that that load chain seats correctly in the chain pockets.
1.5 For wire rope hoists examine the bottom hook load sheaves for wear in grooves, cracks,
breaks and sharp edges, examine the cross head fitting for wear and impact damage, ensure that
the top nut is properly fitted and secure and the side plates are free from cracks and are aligned.
1.6 For chain hoists, examine the load sheave for wear and debris in pockets, ensure that the
load chain seats correctly in chain pockets.
1.7 For wire rope hoists, examine the rope drum wear in grooves, cracks and sharp edges,
ensure that the load rope is reeved correctly and that there is at least three turns of wire rope
left on the drum when the bottom block is at its lowest position.
1.8 Ensure that load chain or load rope is anchored correctly.
1.9 For chain hoists examine that the chain guide rollers and chain stripper are in position and
functioning correctly.
1.10 For wire rope hoists examine the rope bands and guides for wear and damage.

DATE 05/01/2014
1.11 Examine the body casing for wear and cracks ensure that all covers are aligned, that there
are no missing bolts and that they are correctly fitted and secure and that there are no oil leaks
from the gear box.
1.12 Ensure that oil levels are correct, lubrication points are clean and unblocked and that the
hoist is adequately lubricated.
1.0 Examination Procedure (Cont’d)
1.13 Examine the cross travel feed system ensure that all centenary cables, straining screws
and trolleys are properly fitted and secure, examine cables for cracks, breaks and damage to
insulation.
1.14 Examine the pendant cable for cracks, breaks and damage to insulation, ensure that
strainer wire is fitted to take weight of pendant control box off of cable.
1.15 Examine the pendant control box for damage to casing; ensure that push buttons make
good contact and that directional controls are clearly marked and they function correctly.
1.16 Examine the load chain, load rope or trolley (if fitted) in accordance with the relevant
examination procedures.
1.17 Refit fuses and function test hoist though all motions, check for correct adjustments of
overload devices (if fitted) and that the over hoist and over lower limit switches function
correctly.

DATE 05/01/2014

Equipment Description Electric Chain / Wire Rope Hoist
Test New and Repaired
1.0 Test Procedure
working load of the chain hoist then a proof load as listed below may be applied as follows:-
raised just clear of the ground and a check made of the load bearing parts.
ensure that every part of the block mechanism and each tooth of the gear train come under
load. This load shall be maintained for a period of five minutes.
1.4 On releasing the proof load, the piece of equipment shall be examined as per Section 1.0
1.5 Reset any regulators/load limits which may have been adjusted to achieve raising of proof
load.
4.0 Marking
2.1If the item is not already marked, it shall be clearly stamp marked with an identification
3.0 Reporting

b) A full description of the piece of equipment including make, mode and height of lift.

DATE 05/01/2014

Equipment Description Chain Hoist (Pneumatic)
Specification/Legislation DIN-FEM 1001 Section 9
Applicable Test New, Repaired, Resisted
Examination Requirement Clients Examination Scheme SI2307
Test Certificate
1.1 Prior to carrying out the examination, isolate the hoist and lock off the air supply.
1.2 Examine the top and bottom hooks for wear, distortion and stretch, ensure that safety
catches are fitted and function correctly and that the hooks swivel freely and that their
mountings are secure.
1.3 Examine the load and anchor pins for wear and distortion ensure that they are securely
fitted.
1.4 Examine the load chain sheaves for wear and debris in pockets, ensure that the load chain
seats correctly in the chain pockets.
1.5 Examine the load chain along its entire length and check for wear, deformation, stretch,
nicks, corrosion and twists.
1.6 Ensure that chain guide rollers and chain stripper are in position and functioning correctly.
1.7 Examine the body casing for wear and cracks, ensure that all covers are aligned, that there
are no missing bolts and that they are correctly fitted and secure.
1.8 Examine the pendant hose for cracks, perishing and leaks, that they are correctly fitted into
their connections and are secure and that strainer wire is fitted to take the weight of
the pendant control box off hoses.
1.9 Examine the pendant control box for damage to casing, ensure that push buttons make good
contact and that directional controls are clearly marked and function correctly.
1.10 Examine trolley (if fitted) in accordance with relevant examination procedure.

DATE 05/01/2014
1.11 Reconnect air supply and function test hoist through all motions, check for correct
adjustment of overload devices (if fitted) and that the over hoist and over lower limit switches
function correctly.
NOTE: Would suggest fitting filter lubricator to prevent ingress of contamination into
hoist.
2.0. If any faults are found at the time of examination which would affect the safe use of the

DATE 05/01/2014

Equipment Description Chain Hoist (Pneumatic)
Test New, Repaired, Re sited
1.0 Test Procedure
working of the chain hoist then a proof load as listed below may be applied as follows :-
raised just clear of the ground and a check made of the load bearing parts.
ensure that every part of the block mechanism and each tooth of the gear train comes under
1.5 Reset any regulators/load limits which may have been adjusted to achieve rising of proof
load.
2.0 Marking
3.0 Reporting


DATE 05/01/2014

Equipment Description Chain Block (Hand Operated)
2%-5% of W.L.L for Light Load Test

Test Certificate
fitted.
1.3 Examine the load chain sheaves for wear and debris in pockets, ensure that the load chain
1.4 Examine the load chain along its entire length and check for wear, deformation, stretch,
nicks, corrosion and twists.
1.5 Ensure that the load chain is anchored correctly.
1.7 Examine the body casing for cracks and distortion; ensure that casing is aligned and that
there are no missing bolts/nuts, and that they are secure.
1.8 Examine the load chain collection box (if fitted) to ensure that it is correctly fitted and
secure, that it adequate capacity for the chain fitted to the hoist and that a draining hole is
provided to prevent buildup of water in the box.
1.9 Suspend the hoist and spin the hand chain wheel in hoist motion to check function of
ratchet pawl, there should be healthy clicking sound, if this is not the case the pawl may be
seized, dislodged or the pawl spring broken.

DATE 05/01/2014
1.10 Examine the hand chain wheel for wear and impact damage and the hand chain for wear,
damage. Stretch and corrosion, ensure that the hand chain seats correctly in the chain pockets
and that the chains is not damaged to an extent that could injure operators hands.
1.11 Visually examine load limiter device (if fitted) for security of nuts, bolts etc. for check for
corrosion, distortion, wear or debris.

DATE 05/01/2014

Equipment Description Chain Block (Hand Operated)
Test New, Repaired
1.0 Test Procedure
working of the equipment then a proof load test may be carried out as follows :-
raised just clear of the ground and a check made of the load bearing points.
ensure that every part of the block mechanism and each tooth of the gear train comes under
1.5 A light load test of between 2% and 5% of the working load limit shall be raised and
lowered through a height of between 250mm and 500mm. When the hand chain is released
during the raising or lowering operation the brake shall hold the weight.
2.0 Marking
If the item is not already marked, it shall be clearly stamped or marked with an identification
number, and if the test is satisfactory, the safe working load and date of test.
3.0 Reporting


DATE 05/01/2014

Equipment Description Pull Lift (Lever Hoist)
Test Certificate
fitted.
1.3 Examine the chain end stop for security and effectiveness ensure that the end stop cannot
be pulled through the machine.
1.4 Examine the load chain sheaves for wear or debris in pockets, ensure that the load chain
1.5 Ensure the load chain is anchored correctly.
1.7 Examine the body casing for cracks and distortion, ensure that casing is aligned and that
there are no missing bolts or nuts and that they are secure.
1.8 Examine the operating lever assembly, ensure that it is not deformed (a deformed lever
could indicate possible overload of the machine). Operate the lever in hoist, lower and free
wheel motions to check the operation of the pawl(there should be a healthy clicking sound, but
if this is not the case the pawl may be seized, dislodged or pawl spring broken).
2.0 If any faults are found at the time of examination which would affect the safe use of
the item, then it must be withdrawn from service and details recorded on the
Inspection Report.

DATE 05/01/2014

Equipment Description Pull Lift (Lever Hoist)
Test New, Repaired
1.0 Test Procedure
working load of the equipment then a proof load test may be carried out as follows :-
raised just clear of the ground and a check made of the load bearing points.
ensure that every part of the pull lift mechanism and each tooth of the gear train comes under
2.0 Marking
5.0 Reporting

b) A full description of the piece of equipment including, make, model and height of lift.

DATE 05/01/2014

Equipment Description Hydraulic Jack, Pump/Cylinder
Applicable Test New, Repair, Modification
Proof Loads Hydraulic Jack - SWL + 25%
Pump Unit - Working Pressure + 25%
Identification Client Unique ID No., SWL, Test Date,
Calibration Date, Color Code
Test Certificate, Calibration Certificate
1.1 Examine the cylinders/jacks/pumps for impact damage, cracks, scores, corrosion and oil
leaks.
1.2 Examine the hoses and fittings for mechanical damage, leaks and corrosion, ensure that
they are properly fitted and secure.
1.3 Operate the pump to extend the cylinder/jacks to its full working height, check the pump
for smoothness of operation, that the pressure gauge functions correctly and there are no leaks,
and examine the ram for belling, scoring, corrosion and leaks at the seal.
1.4 Operate the release value ensure that the ram runs smoothly to its closed position, that there
are no leaks and that the pressure gauge needle returns to zero.
1.5 Ensure that all oil levels are correct.
1.6 If the ram is threaded externally and fitted with a locking collar, examine the threads for
wear and stretch the collar for free movement.
1.7 If the claw attachments are fitted, examine for cracks and distortion, ensure that jack is de-
rated by 60% of the safe working load.

DATE 05/01/2014

Equipment Description Hydraulic Jack, Pump/Cylinder
Test New, Repair, Modification
1.0 Test Procedure
2.0 Hydraulic Jack
a) Function tests the jack by pumping up to full stroke with no load checking for free
movement and leaks. Release jack pressure.
b) Using calibrated test rig, set jack against a proof load of SWL + 25%. Hold for
approximately 10 minutes checking for leakage and creep.
c) Re-examine the jack for any defects after load test.
NOTE: Should the jack be fitted with a relief value which is normally set at between
105% and 110% of the rate load. In these cases pump up the jack to the rated load and
hold for 10 minutes and release pressure.
d) Hard stamp ID No, SWL and issue certificate.
3.0 Cylinders (Hydraulic)
A) Function test cylinder by pumping up to full stroke, check leakage and creep.
b) Load the cylinder to SWL + 25% and pump up to full stroke hold for approximately 10
minutes checking for leaks and creep.
c) Re-examine after proof load test for defects.
3.0 Pump Unit
a)Function test the pump unit ensuring no air in pump and full pump stroke is obtained and
relief valve functions.
b) Pressure test against calibrates master gauge to working pressure + 25% proof pressure.
Check relief valve function correctly.
c) Re-examine after test for defects. If correct hard stamp ID No and working pressure.
5.0 Hydraulic Jack Claws
a) Carry out visual examination for cracks and deformation.(Possible MPI Inspection).
b) Fit claw to mating hydraulic jack and proof load claw toe to manufacturers instructions.
c) Inspect claw for defect on completion of proof test, using NDT Examination.
d) If all correct hard stamp ID No and SWL and issue certificate.

DATE 05/01/2014

Equipment Description Hydraulic Trolley Jack
Specification/Legislation BS AU 154A
Examination Requirement Client Written Scheme of Examination
Identification Client Unique ID No., SWL, Test Date, Colour Code
Test Certificate
1.1 Examine the structure for wear, impact damage and corrosion, ensure that all fixing bolts
are properly fitted and secure, that all welds are intact and free from cracks.
1.2 Examine the operating handle for wear and distortion, ensure that it is properly fitted and
secure and that the hoist and lower mechanism functions correctly.
1.3 Examine the hydraulic pump unit for mechanical damage, scoring and oil leaks at seals,
ensure that oil levels are correct.
1.4 Examine the wheels for wear, ensure that they are fitted properly and secure and swivel and
rotate freely.
1.5 Examine the lifting saddle/turntable for wear, distortion and cracks, ensure that it swivels
360 degrees (if applicable).

DATE 05/01/2014

Equipment Description Hydraulic Trolley Jack
1.0 Test Procedure

2.0 Hydraulic Jack
a) Function tests the jack by pumping up to full stroke with no load checking for free
movement and leaks. Release jack pressure.
b) Using calibrated test rig, set jack against a proof load of SWL + 25%. Hold for
approximately 10 minutes checking for hydleaks and creep age.
c) Re-examine the jack for any defects after load test.
NOTE: Should the jack be fitted with a relief value which is normally set at between
105% and 110% of the rate load. In these cases pump up the jack to the rated load and
hold for 10 minutes and release pressure.
3.0 Cylinders (Hydraulic)
A) Function test cylinder by pumping up to full stroke, check leakage and creep.
b) Load the cylinder to SWL + 25% and pump up to full stroke hold for approximately 10
minutes checking for leaks and creep.
c) Re-examine after proof load test for defects.
4.0 Pump Unit
a) Function test the pump unit ensuring no air in pump and full pump stroke is obtained and
relief valve functions.
b) Pressure test against calibrates master gauge to working pressure + 25% proof pressure.
Check relief valve function correctly.
c) Re-examine after test for defects. If correct hard stamp ID No and working pressure.

DATE 05/01/2014

Equipment Description Lifting Beam/Frame
Specification/Legislation BS 449, BS 970, BS 2573, BS 4360
Proof Loads Up to and Including 4 Tone - SWL + 100%
Over 3 tone up to and Including 6 tone + 3 tone
Over 6 tone up to and Including 20 tone - SWL
+ 50%
Over 20 tone up to and Including 40 tone + 10
tone
Over 40 tone - SWL + 25%
Internal Examination Not Applicable
Identification Client Unique ID No., SWL, Test Date, Color
Code
Test Certificate
1.1 Prior to commencing the examination removes all lifting attachments and examine in
1.2 Examine the lifting beam for wear, impact damage bending, distortion and corrosion,
ensure that all fixing bolts are correctly fitted and secure, that all welds are intact and free from
cracks.
1.3 Examine lifting points for wear, distortions, elongation and cracks.
1.4 Ensure that holes in lifting points are not too large for the shackle pins as this could cause
stress due to point loading.
1.5 Ensure that the lifting points are in the same plane as the load being lifted.
item, then it must be with drawn from service and details recorded on the Inspection
Report.

DATE 05/01/2014

Equipment Description Lifting Beam/Frame
1.0 Test Procedure
1.1 Carry out Pre and Post NDT Examination of the lifting points are any other load bearing
elements.
1.2 Apply the proof loads are per Table One according to the frame/beam SWL.
1.3 Examine the beam for any defects after the proof load test.
1.4 When all completed hard stamp ID No, SWL, Test Date on unit and issue certification and
NDT Report.
Table One Proof Loads
Up to an including 3 tone - SWL + 100%

Over 3 tone up to and including 6 tone + 3 tone
Over 6 tone up to and including 20 tone - SWL + 50%
Over 20 tone up to and including 40 tone + 10 tone
Over 40 tone - SWL + 25%.

DATE 05/01/2014

Equipment Description Runway Beam
Applicable Test New, Repair, Modified, Resisted
Proof Loads Test Load : SWL + Heaviest Lifting Appliance
Proof Load : SWL + Heaviest Lifting Appliance
25% of
SWL
Identification Client Unique ID No., SWL, Test Date, Colour
Code
Test Certificate
1.1 Examine the running surface for dents, bending, distortion and corrosion, all stools, joints,
connection, supports, bolts and locking devices must be properly fitted and secure, all welds
must be intact and free from cracks. Bolts must not be over tightened as to over stress the bolts,
should doubts exist concerning wear, corrosion for over stressing, then a sample bolt should be
removed for further investigation and replaced with a bolt of the same size and grade.
1.2 Ensure that the surface on which the trolley runs is clean and lubricated to prevent slippage.
1.3 Examine the supporting steelwork for dents, bending, distortion and corrosion.
1.4 Ensure that packers used to level the steelwork are properly fitted and secure.
1.5 Examine the walls/steelwork surrounding and adjacent to the fastenings of the runway
beams for cracks, crumbling, distortion and loose connections.
1.6 End stops must be fitted and secured to both ends of the runway beam to prevent the lifting
appliance running off the ends of the beam or colliding with the support structure and walls.
1.7 These end strops must be so positioned as to prevent the load being imposed within a
flange width from the beam end and do not operate on the trolley wheels.

DATE 05/01/2014
1.8 Ensure that the lifting appliance (if fitted) is compatible with the safe working load of the
runway beam.
NOTE: Lifting appliances (if fitted) should be examined in accordance with the relevant
procedures.
1.9 Ensure that the beam is marked with the SWL clearly visible.

DATE 05/01/2014

Equipment Description Runway Beam
Test New, Repair/Modified, Resisted
1.0 Test Procedure
1.1 Once the preliminary inspection has been carried out and the test engineer is satisfied that
the runway and its supporting structure is free from defects, complies with BS
2853:1957 and is capable of sustaining the loads, only then can the test loads be applied.
1.2 A test load equivalent to the maximum safe working load, together with the weight of the
heaviest lifting appliance supported by the runway shall be applied and traversed along the
whole length of the runway. The load shall be halted during its passage along the runway and
kept at rest at suitable positions, in order that stable deflection readings may be taken and
recorded. Sufficient readings shall betaken to ensure that the maximum reading is obtained.
1.3 A proof load equivalent to the weight of the heaviest lifting appliance supported by the
runway plus 25% in excess of the safe working load lifted by this appliance shall now be
applied and traversed along the whole length of the runway. A stable deflection reading shall
be taken and recorded only at the position where the maximum reading was obtained during
the application of the load referred to in 1.2.
1.4 During the application of both the test load referred to in 1.2and the proof load in 1.3, the
runway shall be kept under strict observation, to ensure the ready detection of any deformation
or signs of premature failure.
1.5 After application of the test loads the runway and its supporting structures shall be visually
examined for any signs of deformation or damage. If necessary parts may be dismantled for
further examination in order to ascertain the suitability of the runway for the purpose it is
intended.
2.0 Deflection
2.1 BS 2853 Clause K4 states "The maximum measured deflection of runway beam under the
safe working load shall not exceed 1/500 of the span. For cantilever beams the maximum
measured deflection under the safe working load shall not exceed 1/250 of the span".
2.2 It is important to note that the allowable deflection of a runway beam refers to the beam
itself and does not include any additional deflections attributed to the supporting structure.
NOTE: Most structural engineers ignore fixing moments when designing runway beams
,for this reason it is very rare to find a runway beam deflect the permissible 1/500of span.
If it does then the installation should be "suspect".
3.0 Marking

DATE 05/01/2014
3.1 The safe working load, identification number and any lifting conditions shall be plainly and
permanently marked on the runway in a manner that makes them clearly visible to the operator.
3.2 If the beam is made from H.Y.S Steel BS 4360 Grade 50but this is not marked on the beam
then the manufacturer of the runway shall stamp G50 on the beam next to the identification
mark.
4.0 Reporting
4.1 Once the final inspection has been performed and the runway found to be satisfactory a
certificate of Test and Examination can now be issued containing the following information:
a) Identification number or mark also grade of steel used.

b) A complete description of the runway detailing the size and length of the beam and its
precise location.
c) Date when the proof load was applied and the thorough examination carried out.
e) Maximum deflection recorded during application of the safe working load and the ratio of
f) Maximum deflection recorded during application of proof load.
g) Maximum safe working load any limiting conditions.
h) A statement that the runway complies with the requirement of BS 2853 and the certificate
only applied to the runway beam.
i) Name and address of maker or supplier of the runway beam.
j) Name of company or persons who carried out the test and examination.
k) Signature of test engineer.
arrangements must be made to ensure that runway beam cannot be used until remedial work
has been carried out and the beam retested.

DATE 05/01/2014

Equipment Description Swing Jib
Applicable Test New, Repair, Modified, Resisted
Proof Loads Test Load : SWL
Proof Load : SWL + 25%
Code
Test Certificate
1.1 Examine the main beam for dents, bending and distortion, ensure that it is level, the joint
connections, bolt and locking devices are properly fitted and secure, that welds are intact and
free from cracks.
1.2 Ensure that the surface on which the trolley runs clean and lubricated to prevent slippage.
1.3 Ensure that end stops are fitted to prevent lifting appliance running off end of beam or
striking the pillar, wall or bracing.
1.4 For wall mounted units, examine the wall beams for distortion and the surrounding and
adjacent walls for cracks and crumbling, ensure that wall beams are similar dimensions to the
main beam and that fixing bolts are correctly fitted and secure.
1.5 For pillar mounted units, examine pillar for impact damage and corrosion, ensure the pillar
is perpendicular and level that all floor bolts are correctly fitted and secure. All shims are in
place and secure.
1.6 Examine rotation bush/bearing for smoothness of operation; ensure jib slews through full
radius.
1.7 Ensure that jib does not slew of its own accord whether loaded or unloaded.
1.8 Ensure that the load does not run along the jib of its own accord.

DATE 05/01/2014
1.9 Examine over/under bracing's for wear and distortion ensure that they are securely fitted
into position, that bolts are correctly fitted and secure, that welds are intact and free from
cracks.
1.10 Ensure that lifting appliances (if fitted) are compatible with the safe working load of the
jib.
NOTE: The lifting appliances (if fitted) should be examined in accordance with the
relevant examination procedures.

DATE 05/01/2014

Equipment Description Swing Jib
Test New, Repair/Modified, Resisted
1.0 Test Procedure
1.1 TESTING OF OVER STRUTTED JIBS
1.1.1 Prior to application of loads, the structural engineers or other competent authority shall
have satisfied the test engineers that all supporting structures, for wall and column mounted
swing jibs, are suitable for the loadings to be applied.
1.1.2 Once the test engineer has satisfied himself that the structure is capable of supporting the
load, a test load equivalent to the safe working load shall be applied at minimum radius and the
deflection measured at the end of the jib (A),
1.1.3 Move the load along the jib to the end stops and measure deflection at the end of the jib
(B). This will give the actual deflection of the cantilever section, which should not exceed
1/250 of cantilever span.
1.2 ACTUAL DEFLECTION = DEFLECTION @ B -DEFLECTION @ A
1.2.1 The load shall be moved back to the central position of the simply supported section of
the jib and deflection readings taken at that point (C) and at the point where the tie rod is
attached to the jib (D). This will give the actual deflection of the simply supported section of
the beam, which should not exceed 1/500 of simply supported span.
1.3 ACTUAL DEFLECTION = DEFLECTION @ C -DEFLECTION @ D
1.3.1 With the safe working load at the maximum radius the maximum total measured
deflection shall not exceed 1/250of maximum radius.
NOTE: Certain manufacturers of proprietary brands work to a higher deflection for

their light weight installations, it is therefore very important that the test engineer is
made aware of this information.
1.3.2 With the safe working load at minimum radius the jib arm should be rotated through 90o
and deflection reading taken at the end of the jib position (A).
1.3.3 The load shall be carefully run out to the maximum radius and deflection reading taken at
position (A).
1.3.4 Any deflections measured in excess of those recorded in1.1.2 and 1.1.3 would indicate
excessive deflection of supporting steel work and should be investigated.

DATE 05/01/2014
1.3.5 If no excessive deflection occurs then the jib shall be checked with the load at maximum
radius through the full range of slew.
1.3.6 An overload of the safe working load plus 25% shall be applied and the test procedure
repeated. Deflection readings should be taken at 0 degrees and 90 degrees and all motions
checked to ensure satisfactory braking, slewing and no tendency for the trolley to run away.
1.4 TESTING OF UNDER STRUTTED JIB
1.4.1 Testing of under strutted jib cranes shall be carried out as per Section 1.1. The only
exception being checking of the jib deflection criteria which will be as follows.
1.4.2 with the safe working load at minimum radius measure deflection at the end of the jib
(A).
1.4.3 Move the load to the end stops, maximum radius, and measure deflection at the end of the
jib (B).
1.4.4 The actual deflection of the beam shall not exceed 1/250 of the maximum radius minus
the minimum radius.
1.5 MARKING
1.5.1 The safe working load, identification number and any limiting conditions shall be plainly
and permanently marked on the runway in a manner that makes them clearly visible
to the operator.
1.6 REPORTING
1.6.1 Once the final inspection has been performed and the runway found to be satisfactory a
certificate of Test and Examination can now be issued containing the following information.
a) Identification number or mark and grade of steel used.

b) A complete description of the runway detailing the size and length of the beam and its
precise location.
deflection to span.
g) Maximum safe working load and any limiting conditions.
h) Name and address of maker or supplier of the runway beam.
i) Name of company or person who carried out the test and examination.
j) Signature of test engineer.

DATE 05/01/2014

1.7.1 Where the test is not satisfactory, a responsible representative of the users shall be
informed by means of a defect report. If the test engineer considers the defect to be of a
dangerous nature then arrangements must be made to ensure the runway beam cannot be used
until remedial work has been carried out and the beam retested.

DATE 05/01/2014

Equipment Description "A" Frame Gantry (Portable)
Specification/Legislation BS466, BS 2573, BS2853, BS 5744, BS 7121
Applicable Test New, Repair, Modified
Code
Test Certificate
1.1 Examine the main lifting beam for dents, bending, distortion and corrosion, ensure that all
connection plates and bolts are correctly fitted and secure, examine bolt holes for wear and
elongation.
1.2 Ensure that the surface on which the trolley runs is clean and lubricated to prevent slippage.
1.3 End stops must be fitted and secure, to prevent the lifting appliance running off the ends of
the beam.
1.4 Examine the legs for dents, bending and distortion, ensure that all welds are free from
cracks and that bolt holes are not worn or elongated.
1.5 Examine bracings for wear and distortion; ensure that they are securely fitted into position,
that bolts are correctly fitted and secure, that welds are intact and free from cracks.
1.6 Examine all wheels and bearing for smoothness of operation, wear deformation and cracks.
1.7 If fitted, ensure that parking brakes work correctly, screw down of ground level and lock in
position.
1.8 Ensure that gantry is level (imbalance however slight is not allowed).
1.9 Ensure that the lifting appliance (if fitted) is compatible with the safe working load of the
gantry.

DATE 05/01/2014
NOTE: Lifting appliances (if fitted) should be examined in accordance with the relevant
examination procedures.
1.10 Ensure SWL is clearly marked on the beam.
the item, then it must be withdrawn from service and details recorded on he
Inspection Report.

DATE 05/01/2014

Equipment Description "A" Frame Gantry (Portable)
Examination
Test New, Repair, Modified
1.0 Test Procedure
1.1 Once the preliminary inspection has been carried out and the test engineer is satisfied that
the runway and its supporting structure is free from defects, complies with BS2853:1957 and is
capable of sustaining the loads, only then can the test loads be applied.
1.2 A test load equivalent to the maximum safe working load, together with the weight of the
heaviest lifting appliance supported by the runway shall be applied and traversed along the
whole length of the runway. The load shall be halted during its passage along the runway and
kept at restat suitable positions, in order that stable deflection readings may be taken and
recorded. Sufficient readings shall be taken to ensure that the maximum reading is obtained.
1.3 A proof load equivalent to the weight of the heaviest lifting appliance supported by the
runway plus 25% in excess of the safe working load lifted by this appliance shall now be
applied and traversed along the whole length of the runway. A stable deflection reading shall
be taken and recorded only at the position where the maximum reading was obtained during
the application of the load referred to in 1.2.
1.4 During the application of both the test load referred to in 1.2and the proof load in 1.3, the
runway shall be kept under strict observation, to ensure the early detection of any deformation
of signs of premature failure.
1.5 After application of the test loads the runway and its supporting structures shall be visually
examined for any signs of deformation or damage. If necessary parts may be dismantled for
further examination in order to ascertain the suitability of the runway for the purpose it is
intended.
2.0 Deflection
2.1 BS 2853 Clause K4 states "The maximum measured deflection of runway beams under the
safe working load shall not exceed 1/500 of the span. For cantilever beams the maximum
measured deflection under the safe working load shall not exceed 1/250 of the span".
2.2 It is important to note that the allowable deflection of a runway beam refers to the beam
itself and does not include any additional deflections attributed to the supporting structure.
NOTE: Most structural engineers ignore fixing moments when designing runway beams,
for this reason it is very rare to find a runway beam deflect the permissible 1/500of span.
If it does then the installation should be "suspect".

DATE 05/01/2014
3.0 Marking
3.1 The safe working load, identification number and any limiting conditions shall be plainly
and permanently marked on the runway in a manner that makes them clearly visible to the
operator.
3.2 If the beam is made from H.Y.S Steel BS 4360 Grade 50but this is not marked on the beam
then the manufacturer of the runway shall stamp G50 on the beam next to the identification
mark.
4.0 Reporting
4.1 Once the final inspection has been performed and the runway found to be satisfactory a
certificate of Test and Examination can now be issued containing the following information :
a) Identification number or mark also grade of steel used.

b) A complete description of the runway detailing he size and length of the beam and its
precise location.
g) Maximum safe working load any limiting conditions.
h) A statement that the runway complies with the requirement of BS 2853 and the certificate
only applied to the runway beam.
I) Name and address of maker or supplier of the runway beam.
j) Name of company or persons who carried out the test and examination.
k) Signature of test engineer.
informed by means of a defect report. If the test engineer considers the defect to be of a
dangerous nature then arrangements must be made to ensure the runway beam cannot be used
until remedial work has been carried out and the beam retested.

DATE 05/01/2014

Equipment Description Cargo Carrying Containers
Specification/Legislation BS 7072, BS-EN 12079
Applicable Test New, Bi Annual, Repair
Proof Loads Equal to Twice the Gross Weight of the

Container Less the Tare Weight
NOTE : The Tare Weight Includes the Weight of
the Lifting Attachments
Examination Requirement As Required by the Current Legislation
Internal Examination As Above
Identification Client Unique ID No, Container No, SWL, Test
Date
Test Certification for Container & Lifting
Assembly
1.1 Prior to commencing the examination, remove all lifting attachments and examine in
accordance with the relevant procedures.
1.2 Examine the structure for cracked welds, dents, tears, holes and corrosion.
1.3 Examine the floor inside and underneath for cracked welds, dents, tears, holes and
corrosion, ensure drainage holes are free from debris, examine floor bearers for corrosion.
1.4 Examine door frames, seals, hinges and locks for wear, impact damage, distortion and
corrosion, function test doors to ensure that they operate in a satisfactory manner without
undue force being applied.
1.5 Examine lifting points for cracked welds, distortion and corrosion, ensure that eyes are not
worn or elongated and the lifting points are aligned to the center of the unit.
1.6 Examine forklift pockets for impact damage, tears and corrosion.
1.7 Ensure that the identification number has been stenciled on both sides and the roof of the
unit in accordance with BS7072:1989/BS-EN 12079:1999 where applicable.

DATE 05/01/2014
1.8 Ensure that hatching and contrasting colors are marked on the top of the unit.
1.9 Ensure that hazard labels (if fitted) are correct for the goods being carried in the unit.

DATE 05/01/2014

Equipment Description Cargo Carrying Units
Test New and Current Legislative Requirements
1.0 Test Procedure
working load of the container or basket then a proof load as listed below may be applied as
follows :-
1.2 All containers and baskets shall be tested in accordance with BS 7072, BS-EN 12079.
1.3 The proof load shall be equal to twice the gross weight of the piece of equipment less the
tare weight (the tare weight shall include any items permanently attached to the unit).
1.4 The unit shall be weighed using a calibrated load cell and the proof load to be applied will
be calculated.
1.5 The proof load shall be applied using steel test weights, the preferred method shall be to
place the weights inside the unit. In the event of this being impractical then they may be
suspended from or placed on the unit, Extreme care must be taken when using this method to
ensure that the structure supporting the test weight is strong enough.
NOTE: It is imperative that consideration is given to the effects of a particular method of

applying test weights to a unit by slinging .All slings must be equally spaced to prevent
point loading. Suitable spreader plates, packets or battens should be used to distribute
the load evenly over the structural members. Care should be taken when a sling passes
over a beam flange. Ensure that proper protection/ packers are used to prevent the sling
cutting and/or flange distorting. All test loads should be applied slowly and the test
monitored continually to allow for any repositioning or adjustment that may be required
to the slings or test weights.
1.6 The unit is then raised clear of the ground and suspended for five minutes.
1.7 The accuracy of the Proof Load can now be verified. The Hook Load (the load shown on
the calibrated load cell) should be 2 x Gross Weight of the unit.
2.0 Marking
number, safe working load and date of test as per BS 7072, BS-EN 12079.

DATE 05/01/2014
3.0 Reporting

b) A full description of the container or basket.
d) Tare weight.
e) Proof load applied.
f) Date of test and examination.
g) Name and address of company performing the test and examination.
h) Act or Regulations under which the test and examination was carried out.
4.1 Where the test is not satisfactory, a responsible representative of the user shall be
information by means of a defect report. If the test engineer considers the defect of
a dangerous nature then arrangements must be made for its immediate withdrawal from
service.

DATE 05/01/2014

DATE 05/01/2014

Equipment Description Fork Lift Truck
Specification/Legislation BS 5639, BS 5778, BS 3726, ISO 2330, ISO 2328
Applicable Test New, Repair. Modified, Quadrennial
Proof Loads SWL + 25% - Lifting Chains
SWL + 5 % - Proof Load
Examination Requirement 6 Monthly SI 2307 Pre User (LOLER)
6 Monthly Statutory for Lifting Chains
Internal Examination Clients Planned Maintenance Scheme
Identification Road No. Plates, Clients Unique ID No., SWL,
Test Date,
Color Code
Certification Road Tax Disc
EC Declaration Of Conformity
Test Certificates for Chains
Test Certificates for Forks and Truck
1.1 Examine the cab structure for impact damage, deformation or cracks; ensure that the
driver’s window is not cracked or broken and that the wipers function correctly and that the
driver has all round visibility. Audible warnings are operational where fitted.
1.2 Examine the driver’s seat for damage and correct adjustment. Check seat belts if installed.
1.3 Ensure the door opens and closes correctly.
1.4 Ensure that the horn functions correctly.
1.5 Examine the steering wheel and column for end float and side play.
1.6 Examine the control pedals for wear, ensure that there is no oil or grease on the pedals or
floor.
1.7Function test the foot brake, hand brake, and parking brake to ensure that they function
correctly.
1.8 Function tests the headlights, brake lights and indicators to ensure that they function
correctly.

DATE 05/01/2014
1.9 Ensure that there are no leaks (diesel fuel, gas, coolant or water).
1.10 Examine the hoist mast for wear and deformation, examine the hydraulic rams for
mechanical damage, scoring and leaks at the seals, ensure that slide way stops are fitted
correctly and secure.
1.11 Examine the hoist chain for worn, cracked or broken links, ensure that pins are not worn
or elongated and that the chain is not stretched, examine the chain guide rollers and
anchorage's for wear and ensure that they fitted correctly and secure.
Note: If the load chain has over 2% extensions it should be replaced.
1.12 Examine the forks for wear and alignment the support frame and locking pins for wear
and deformation. Ensure carriage end stops are secure.
1.13 Examine the types for wear and damage to treads and walls.
1.14 Examine hydraulic hoses and fittings for mechanical damage, leaks and corrosion, ensure
that they are correctly fitted and secure.
1.15 Examine all battery terminals for corrosion; ensure that cables and plugs are not worn or
corroded.
1.16 Ensure that spark arrestor is fitted to the exhaust system if diesel or gas is the power
source.
1.17 Examine wheels for security and operation of steering mechanism. Ensure lubrication
points are serviceable.
1.18 Examine fork extensions (if fitted) for wear, deformation and cracks; ensure that they fit
smoothly onto forklift truck forks.
1.19 Examine forklift attachment (if fitted) for wear, deformation and cracks, ensure that they
fit smoothly onto forklift truck forks and are secure.
NOTE: Diesel/Gas powered forklift trucks should minimum requirements of EEMU standard
and electric forklifts should meet the minimum requirements of BASEEFA standards if they
are to work in hazardous areas.
1.20 Ensure all controls are clearly marked.
the item, then it must withdraw from service and details recorded on the Inspection
Report.

DATE 05/01/2014

Equipment Description Description Fork Lift Truck
Test New, Repair, Modified, Quadrennial
Test Procedure
1.0 STATUTORY REQUIREMENTS
Prior to entering service the forklift truck should be fully proof load tested by the manufacturer
and a certificate of test and thorough examination issued. Proof load test applied shall be1.25 x
SWL.
1.1 Subsequent load tests carried out at statutory 4 year intervals shall have a proof load of
SWL + 5%.
1.2 Lifting chains only shall be subject to a 6 monthly inspection.
2.0 EXAMINATION OF FORKS PRIOR TO LOAD TESTING
2.1 METHOD OF MANUFACTURE
Forklift trucks are manufactured from a variety of steels but generally from a specification
which requires specialized heat treatment after forging. Forks are accurately matched
as a pair and should not be changed individually. The included angle at the fork heel when new
is 90 degrees.+ 0.5 degrees and the matched surface for each pair of forks 3mm.
2.2 Forks shall be inspected for cracking by means of MPI inspection over 100% of their
surface. This shall also apply to any welded attachments. Any indication of cracking in either
case shall be cause for rejection.
2.3 Check for permanent deformation using a steel straightedge along the lifting surfaces.
2.3.1 Place the forks in an upright position on a level surface and adjacent to each other, and
check right angle using a setsquare.
2.4 If there is any evidence of flaw or defect signs of permanent set of disparity between the
two forks they should be removed from services for replacements or to be repaired by an
approved repairer.
2.5 EXAMINATION OF FORK EXTENSIONS
Ensure that the extensions are the correct type for the truck and such that the truck cannot be
overloaded and are in accordance with the rating plate and manufacture date.

DATE 05/01/2014
2.6 Examine fork extensions as for forks paying particular attention to welds and the underside
of the extension. Ensure that the extensions locate correctly onto the forks.
2.7 Any flaw defect or permanent deformation should be recorded and the extensions removed
from service pending repair or replacement.
3.0 OPERATIONAL TESTS
With the mast vertical and a load equivalent to the rated capacity of the truck should be lifted
slowly. During this operation observe the forks for any signs of excessive bending or erratic
behavior of operation.
4.0 EXAMINATION OF MASTS PRIOR TO LOAD TESTING
Check the surface of the mast for corrosion, mechanical damage, defective welds, loose bolts
and any other defect.
5.0 LOAD AND CREEP TESTS
5.1 Place a uniformly distributed load at the truck rating load Centre of SWL + 5%.
5.2 Raise the load and check the lifting speed against the design speed. If this is radically
different. The hydraulic pump or valves should be examined for wear.
5.3 With the mast vertical, lift the load to its maximum height. Mark a datum point on the mast
below the forks against a plumb' line attached to the forks. Observe the creep rate
over a period of 10 minutes. The creep rate should not exceed 40mm in 5 minutes.
5.4 Where mast tilting is provided the forks should be lowered to minimum height and tilted
backwards to they're maximum extent. Under normal tilt conditions for 10 minutes. Any
tendency to creep forward should be noted and reported.
6.0 HYDRAULIC RELIEF VALVE
The hydraulic relief valve on some trucks may restrict the amount of pressure required to lift
an overload. In this case the test shall be carried out at the greatest load that can be lifted
providing this exceeds the SWL rating. If in doubt as to the setting of the valve, check the
manufacturers Data Manual. Usually valves are set at SWL + 5%.

DATE 05/01/2014

Equipment Description Switch Gear Lifter/Pallet Truck/Hydraulic Floor
Crane
Specification/Legislation Manufacturers Specification Servlet NDT
Inspection
Hand Winch - SWL + 50%
Pallet Truck - SWL Only
Examination Requirement Client Written Scheme of Examination
Identification Clients Unique ID No., SWL, Test Date, Color
Code
Test Certificate for Unit
Test Certificate for Forks and Wire Rope
1.0 Examination Procedure (Switch Gear Lifter)
1.1 Examine the general condition of the machine structure, ensuring that it is free from
contamination and that is not deformed or twisted in any way which could affect the safe
operation of the machine.
1.2 Examine all wheels and bearings for smoothness of operation, wear, deformation and
cracks. Examine brake for operation.
1.3 Examine forks for deformation and twists, ensure that forks are level.
1.4 Examine the fork support frame, mast and base steel work for impact damage and
distortion.
1.5 Ensure that mast roller guides rotate freely.
1.6 Examine all hydraulic pipe work and fittings for mechanical damage, scoring and leaks at
seals, ensure that they are correctly fitted and secure.
1.7 Examine hydraulic pump for mechanical damage, check oil level is correct.
1.8 Function test to check operation of non-return valve.

DATE 05/01/2014
1.9 Examine pump piston for leaks at seals.
1.10 Examine hydraulic cylinder for wear, mechanical damage and corrosion.
1.11 Pump rams up to its full stroke and examine for mechanical damage, scoring and
corrosion.
1.12 Function test machine through its complete range of operations.
NOTE:
a) Examine the wire rope, chain and sheaves in accordance with the relevant examination
Procedures.
b) Should the machine be manual in operation, it will be fitted with a winch unit, the winch
should be examined in accordance with the relevant examination procedure.
2.0 Examination Procedure (Pallet Truck)
2.1 Examine the general condition of the truck structure, ensure that it is free from
contamination and that it is not distorted, deformed or twisted in any way which would affect
the safe operation of the
2.2 Examine all wheels and bearings for smoothness of operation, wear, deformation and
cracks.
2.3 Examine forks; ensure that they are not deformed or twisted and that they are in the same
plane and level.
2.4 Raise the truck and examine the cylinder for mechanical damage, scoring and leaks at seal,
there should be a thin film of oil that lubricates the piston. If leakage occurs, a new seal kit for
the pump and lift piston should be fitted and the pallet truck tested.
2.5 Ensure that the controls are clearly marked with direction of operation. Function test to
ensure truck raises and lowers correctly.
3.0 Examination Procedure (Hydraulic Floor Crane)
3.1 Examine the structure for wear, impact damage and corrosion, ensure that all fixing bolts
are correctly fitted and secure, all welds are intact and free from cracks.
3.2 Examine the jib and extensions for wear, impact damage and corrosion, ensure freedom of
movement and that the locating holes line up properly and are not elongated.
3.3 Examine the hook for wear, distortion, stretch, nicks, gouges and scores, ensure that it
rotates 360 degrees that the safety catch is fitted and functions correctly.

DATE 05/01/2014
3.4 Examine the hydraulic pump unit for mechanical damage, scoring and leaks at seals, ensure
that it has been correctly fitted and is secure and that the operating handle is not
worn or distorted.
3.5 Examine the wheels for wear and ensure that they are properly fitted, secure and swivel and
rotate correctly.
3.6 Examine hoses and fittings for nicks, gouges, corrosion or leakage.
3.7 Ensure oil levels are satisfactory.
item, then it must be withdrawn from service and details recorded on the Inspection
Report.

DATE 05/01/2014

Equipment Description Switch Gear Lifter/Pallet Truck/Hydraulic
Floor Crane
Test New, Repair, Modified New, Repair, Modified
1.0 Test Procedure
1.1 PALLET STACKERS/SWITCH GEAR LIFTERS/HYDFLOOR CRANE
1.2 MANUAL PALLET STACKERS/SWITCH GEAR LIFTERS
1.3 The winch unit should load tested to SWL + 50% prior to installation. It should also be
operated so that one complete revolution of all working parts is attained. Re-inspect ensuring
load test has shown any defects.
1.4 Should the unit have hydraulic rams function test these to ensure no defects of leaks are
apparent.
1.5 When re-assembly is completed set up the units for proof testing. Lock castor/wheels, load
the units to SWL + 25%and raise to maximum lift heights to prove stability. (The client may
wish to witness tests).
1.6 Re-examine unit after test to ensure all is secure (NDT/MPI examination may be
requested).
1.7 If all correct hard stamp ID No., SWL and test date. Issue certificate.
1.8 Ensure the security of holding down bolts, check the welding/clamping is adequate and free
from corrosion/distortion.
2.0 PALLET TRUCK (MANUAL)
2.1 Function test the pallet through all motions, if all correct proceed with prove test.
2.2 Load the truck evenly across the fork to its full SWL. Carryout function through all
motions.
2.3 If all is correct hard stamp ID No., SWL and test date. Issue certificate.

DATE 05/01/2014

Equipment Description Mobile (Access) Platform
Servlet NDT Inspection Procedure
Examination Requirement 6 Monthly (Man Riding Equipment) SI 2307
(LOLER)
Identification Clients Unique ID No., SWL, Test Date, Color
Code
Test Certificate
1.1 Examine the main structure and chassis for wear, impact damage and corrosion; ensure that
all fixing bolts are properly fitted and secure, that all welds are intact and free from cracks.
1.2 Examine the power unit pneumatic, electric or battery for loose connections and
contamination and ensure that it is securely fitted.
1.3 Examine the hydraulic ram and cylinder for mechanical damage, scoring and leaks at seals.
1.4 Examine the hydraulic hoses and reservoir and fittings for mechanical damage, leaks and
corrosion, ensure that are fitted properly and secure.
1.5 Examine the brake system, out riggers, leveling jacks and indicators, parking jacks and foot
pads for wear and distortion, ensure that they function correctly and that the locking
mechanisms work correctly.
1.6 Examine the work platform for cracked welds, dents, distortion and corrosion, ensure that it
is securely fitted to the main structure.
1.7 Ensure that hand rails and anchor points are securely fitted; the hinged locking device
cannot be disengaged accidentally.
1.8 Examine the wheels and tyres for tread wear, ensure that they run smoothly, that the tyre
pressures are correct and wheel nuts are correctly fitted and secure.

DATE 05/01/2014
1.9 Ensure that all control levers are correctly marked with direction of operations.
1.10 Function test to ensure all components work correctly.

DATE 05/01/2014

Equipment Description Mobile (Access) Platform
Test New, Repair, Modified
1.0 Test Procedure
1.1 With our riggers in the operating position, carry out a full function test to all work
parameters.
1.2 If function is satisfactory, load the platform to the SWL +25%. Proof load, and operate unit
to its full work parameters. This will also verify the stability of the unit.
This test should be witnessed by the client, or his representative.
1.3 Visually examine the unit after the proof load test for any defects which may have been
exposed. Post load test NDT may also be advisable.
1.4 If all satisfactory affix test plate and issue certification to client.

DATE 05/01/2014
Category Test Equipment

Equipment Description Test Weight (Lifting Points)
Proof Loads Loads 2 x SWL up to 10 tone
SWL x 1.04 + 9.6 = Proof Load
Examination Requirement Annual and Pre Use
Identification Owners Unique ID No., SWL, Test Date,
Calibration Date
Test Certificate
Calibration Certificate
1.0 Examination Procedure:
1.1 Examine the main body for wear, cracks, distortion and corrosion.
1.2 Examine the profile of the lifting point; ensure that all flame cutting marks have been
ground smooth to avoid creating possible stress area and injury to operators hands.
1.3 Examine the lifting point for soundness of structure, wear and deformation.
not acceptable). Examine for wear and elongation.
1.5 Ensure the hole diameter and lifting points width are compatible with the appropriate safe
working load shackle, hole should be pin diameter + 10% width should be jaw gap
+ 10%.
1.6 Examine welded and surrounding areas for cracks, deformation and distortion by
appropriate method of NDT if required.
1.7 In case of bolt on lifting points, examine the attachment steelwork for any local distortion,
ensure that bolts or fasteners are correctly fitted and secure and are not stretched, deformed,
corroded or worn.
1.8 Ensure that tare weights/SWL is clearly marked on the weight.

DATE 05/01/2014
1.9 Ensure that associated lifting equipment is examined in accordance with relevant
procedures.
2.0 Testing
working load of the pad eye then a proof load as detailed below may be applied.
2.1.1 For pad eyes with a safe working load up to 10 tone, a proof load of 2 x SWL shall be
applied.
2.1.2 For pad eyes in excess of 10 tone safe working load, the following formula shall be
used.SWL x 1.04 + 9.6 = Proof Load Derived from Lloyds code for Lifting Appliances in a
Marine Environment
NOTE other certifying authorities (e.g. D.N.V) and individual clients may have their own
specifications on the proof load of pad eyes. These should be referred to where possible.
2.1.3 The proof load may be applied by direct pull using wither a chain block and a load cell,
calibrated hydraulic jack set, test weights, water bags or a method that shall suitably apply the
proof load.
2.1.4 The proof load shall be applied in a similar direction to which the pad eye will be loaded
in service.
2.1.5 The proof load shall be maintained for a period of five minutes.
2.1.6 On release of the proof load, the piece of equipment shall be examined as per Section 1.0.
3.0 Marking
3.1 If the item is not already marked, it shall be clearly stamped/marked with an identification
4.0 Reporting


DATE 05/01/2014
g) Position and location of piece of equipment.

h) Act or Regulation under which the test and examination was carried out.
6.0 Test weights shall be calibrated on a 12 monthly cycle.

DATE 05/01/2014
Category Test Equipment

Equipment Description Load Cell Shackles - Dynamometers (Test
Clocks)
Strain Gauges
Applicable Test Annual Calibration
Proof Loads Manufacturers Specification
Examination Requirement 6 Monthly SI 2307 (LOLER)
Internal Examination Manufacturers Specification
Identification Serial No., Unique ID No.
Certification Calibration Certificate
Test Certificate
EC Declaration of Conformity
1.0 Examination Procedure:
LOAD CELL SHACKLES

1.1 Examine the body for wear and deformation, ensure that the pin holes are not worn or
elongated and are in alignment.
1.2 Examine the pin and bobbin for wear and distortion.
1.3 Examine the electrical plugs and sockets are clean, free from contamination and dry.
1.4 Examine the supply cable for cuts and breaks, ensure that sockets are fitted correctly, clean,
free from contamination and dry.
1.5 Examine readout box for wear and impact damage.
1.6 Connect shackle, cable and readout box, function test and ensure that unit tares to zero.
DYNAMOMETERS (TEST CLOCKS)
1.7 Remove shackles (if fitted) and examine in accordance with their relevant examination
procedure.
1.8 Examine upper and lower lifting eyes (if fitted) for wear and distortion.
1.9 Ensure swivel and thrust bearings function correctly.
1.10 Examine the body of the dynamometer for wear, impact damage and cracks, ensure that
shackle pin holes are not worn or elongated.

DATE 05/01/2014
1.11 Examine all seals and ensure that they are not worn, damages or perished.
1.12 Examine clock face, ensure that needle is at zero and that no water or foreign objects are
trapped in clock face.
1.13 Remove shackles (if fitted) and examine in accordance with their relevant examination
procedure.
1.14 Examine the body for wear, impact damage, deformation, gouges and cracks, shackle pin
holes for wear and elongation, and ensure that electrical plugs and sockets are clean, free from
contamination and dry.
1.15 Examine the supply cable for cuts and breaks, ensure that sockets are fitted correctly,
clean, free from contamination and dry.
1.16 Examine the readout box for wear and impact damage.
1.17 Connect the strain gauge, cable and readout box, function test and ensure that both the
strain gauge and readout box tares to zero.
NOTE: Calibration certificates should be no more than12 months old.
the item, then it must be withdrawn from service and

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INSPECTA INTERNATIONAL CO.

INSPECTA INTERNATIONAL CO.

THOROUGH EXAMINATION AND

Rev no: Date Prepared By Reviewed By Approved By

Inspecta International Co. Global Assets Integrity Services

 Offshore Pedestal Crane

 Overhead Travelling Crane & Rails- (Pneumatic and Electrical)

 Utility, Pneumatic, Hydraulic, Manual Winches and Man Riding Winches

3.0. MAN RIDING EQUIPMENT.

 Passenger & Goods Lifts

4.0 LIFE BOATS AND LIFE RAFTS

 Life Boats and Davits

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5.0 LIFTING ACCESSORIES

 Open Wedge Sockets

6.0 LIFTING APPLIANCES

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7.0 TEST EQUIPMENT

 Test Weight (Lifting Points)

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1.1 Access Egress

1.3 "A" Frame

1.5 Control Cab

1.6 Machinery House

1.7 Wire Ropes (Running)

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1.8Wire Ropes (Support)

1.10 Slew bearing

2.2Whenever considered necessary, the visual examination may be supplemented by methods

3.0 Checks on Boom

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4.0 Checks on Machinery

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5.0 Wire Rope Checks

5.5 Deterioration normally results from a combinations of several defects occurring

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6.0 Checks on Main & Aux Hoist Blocks and Sheaves

6.3 Wear/fracture in eye of block.

6.5 Side plates distorted or chaffed.

6.6 Fracture leading from center pin holes.

6.7 Side straps distorted or torn.

6.8 Bush worn, distorted or fracture.

6.9 Sheaves chipped, fractured and worn in score or at sheave edge.

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1.0 Preparation of Test Equipment

(NOTE: Special permission is required to connect into the firewater mains).

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2 Wire ropes are to be inspected in accordance with manufacturer's laid down

Function Test as follows:

Ensure the boom angle indicator is functioning correctly (if fitted).

· Raise and test the efficiency of hoisting mechanism and brake.

Aux Hoist (if fitted)

· Raise and test the efficiency of hoisting/lowering mechanism and brake.

Safe Working Load Test

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Check the accuracy of the safe load and radius indicators.

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Inspecta International Co. Global Assets Integrity Services

Inspecta International Co. Global Assets Integrity Services

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